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[0001] This is a continuation of and claim priority to PCT/EP2016/067703 filed on Jul. 25, 2016, and further claims priority to EP 15180205.5 filed on Aug. 7, 2015; both of which are hereby incorporated by reference in their entirety.
BACKGROUND
[0002] Some embodiments relate to aerosol-generating systems that comprise a heater assembly suitable for vaporising a liquid soaked from a capillary medium. In particular, the some embodiments relate to handheld aerosol-generating systems, such as electrically operated vaping systems.
[0003] One type of aerosol-generating system is an electrically operated vaping system. Handheld electrically operated vaping systems consisting of a device portion comprising a battery and control electronics, a cartridge portion comprising a supply of aerosol-forming substrate, and an electrically operated vaporiser, are known. A cartridge comprising both a supply of aerosol-forming substrate and a vaporiser is sometimes referred to as a “cartomizer”. The vaporiser typically comprises a coil of heater wire wound around an elongate wick soaked in liquid aerosol-forming substrate. The cartridge portion typically comprises not only the supply of aerosol-forming substrate and an electrically operated vaporiser, but also a mouthpiece, which the adult vaper sucks on in use to draw aerosol into their mouth.
SUMMARY
[0004] At least one embodiment is directed to an aerosol-generating system which offers improved aerosolization and better aerosol droplet growth and which avoids occurrence of hot spots especially in the middle part of the heater assembly.
[0005] It would be desirable to provide an aerosol-generating system that improves the airflow on the surface of the heater assembly to encourage the mixing of the volatized vapors.
[0006] It would be further desirable to provide an aerosol-generating system that accelerates the airflow of the aerosol from the heater assembly towards the mouthpiece, thereby further improving the aerosolization through faster cooling of the volatized vapors. In some embodiments, enhanced mixing and acceleration of airflow is achieved by the introduction of turbulence and vortices.
[0007] In one embodiment, an aerosol-generating system comprises a liquid storage portion comprising a housing holding a liquid aerosol-forming substrate and a capillary material. The housing has an opening. The fluid permeable heater assembly comprises an arrangement of electrically conductive filaments arranged to define a non-planar air impingement surface, wherein the fluid permeable heater assembly is aligned with the opening of the housing such that the heater assembly extends across the opening of the housing. The capillary medium is provided in the liquid storage portion in such a way that, the capillary medium is in direct contact with the heater assembly. The capillary medium draws the liquid aerosol-forming substrate to the electrically conductive filament arrangement. The capillary medium defines an opening for allowing airflow to pass through the capillary medium.
[0008] At least one embodiment is further directed to a method of manufacture of a cartridge for use in an electrically operated aerosol-generating system. In one embodiment, the method comprises providing a liquid storage portion comprising a housing having an opening, providing a capillary material within the liquid storage portion, filling the liquid storage portion with liquid aerosol-forming substrate and providing a fluid permeable heater assembly comprising an arrangement of electrically conductive filaments arranged to define a substantially non-planar air impingement surface, wherein the fluid permeable heater assembly extends across the opening of the housing, wherein the capillary medium is provided in contact with the heater assembly and wherein the capillary medium comprises a capillary medium opening allowing airflow to pass through the capillary medium.
[0009] The provision of a heater assembly that extends across an opening of a liquid storage portion allows for a robust construction that is relatively simple to manufacture. This arrangement allows for a large contact area between the heater assembly and liquid aerosol-forming substrate. The housing may be a rigid housing. As used herein “rigid housing” means a housing that is self-supporting. The rigid housing of the liquid storage portion preferably provides mechanical support to the heater assembly.
[0010] The heater assembly may be formed from a substantially flat configuration allowing for simple manufacture. As used herein, “substantially flat” means formed initially in a single plane and not wrapped around or other conformed to fit a curved or other non-planar shape. Geometrically, the term “substantially flat” electrically conductive filament arrangement is used to refer to an electrically conductive filament arrangement that is in the form of a substantially two dimensional topological contour or profile. Thus, the substantially flat electrically conductive filament arrangement extends in two dimensions along a surface substantially more than in a third dimension. In particular, the dimensions of the substantially flat filament arrangement in the two dimensions within the surface is at least 5 times larger than in the third dimension, normal to the surface. An example of a substantially flat filament arrangement is a structure between two substantially imaginary parallel surfaces, wherein the distance between these two imaginary surfaces is substantially smaller than the extension within the surfaces.
[0011] The initially substantially flat arrangement of filaments is deformed, shaped or otherwise modified to define an arrangement of filaments which define a non-planar air impingement surface. In an embodiment, an initially substantially flat filament arrangement is formed so that it is curved along one or more dimensions, for example forming a convex or “dome” shape, a concave shape, a bridge shape, or a cyclone or “funnel” shape. In an embodiment, the filament arrangement defines a concave surface which faces the airflow that arrives at and impinges upon the filament arrangement. The non-planar-shape of the filament arrangement accounts for the introduction of turbulences and vortexes onto the airflow arriving at the filament arrangement. Position and shape of the filament arrangement are arranged such that an airflow guided to the air impingement surface of the filament arrangement is whirled around the air impingement surface.
[0012] The term “filament” is used throughout the specification to refer to an electrical path arranged between two electrical contacts. A filament may arbitrarily branch off and diverge into several paths or filaments, respectively, or may converge from several electrical paths into one path. A filament may have a round, square, flat or any other form of cross-section. A filament may be arranged in a straight or curved manner.
[0013] The phrases “filament arrangement” or “arrangement of filaments” are used interchangeably throughout the specification to refer to an arrangement of a plurality of filaments. The filament arrangement may be an array of filaments, for example arranged parallel to each other. The filaments may form a mesh. The mesh may be woven or non-woven. Throughout the specification, the surface of the filament arrangement that is in contact with the air flow is also referred to as “air impingement surface” of the filament arrangement.
[0014] The electrically conductive filaments may define interstices between the filaments and the interstices may have a width of between 10 micrometer and 100 micrometer. The filaments may give rise to capillary action in the interstices, so that in use, liquid to be vaporised is drawn into the interstices, increasing the contact area between the heater assembly and the liquid.
[0015] By providing the filament arrangement with a plurality of interstices for allowing fluid to pass through the filament arrangement, the filament arrangement is fluid permeable. This means that the aerosol-forming substrate, in a gaseous phase and possibly in a liquid phase, can readily pass through the filament arrangement and, thus, the heater assembly.
[0016] The filament arrangement is configured for customizing the airflow around the air impingement surface. This is done by introducing turbulences and vortexes which encourage the mixing of volatized vapors and leading to enhanced aerosolization.
[0017] In some embodiments, the filament arrangement defines a filament opening allowing airflow to pass through, and wherein the capillary medium opening extends the filament opening to form an air duct through the capillary medium. Position and shape of the filament arrangement, of the filament opening, and of the capillary medium opening are dimensioned and arranged such that an airflow guided to the air impingement surface of the filament arrangement is whirled around the air impingement surface.
[0018] The filament opening of the filament arrangement is substantially larger than the interstices between the filaments of the filament arrangement. Substantially larger means that the filament opening covers an area that is at least 5 times larger, or at least 10 times larger, or at least 50 times larger, or at least 100 times larger than the area of an interstice between two filaments. The relation of the area of the filament opening and the cross-section area of the filament arrangement including the filament opening may be at least 1 percent, or at least 2 percent, or at least 3 percent, or at least 4 percent, or at least 5 percent, or at least 10 percent, or at least 25 percent.
[0019] The position of the filament opening substantially may match the position of the capillary medium opening. Shape and size of the cross section of the filament opening may be the shape and size of the cross section of the capillary medium opening.
[0020] The heater assembly and the capillary medium may be arranged in an aerosol-generating system in such a way that at least a portion of the airflow that arrives at the air impingement surface of the filament arrangement is guided through an air duct defined by the capillary medium opening through the capillary medium. The airflow through the air duct is accelerated by the suction or draw of the air duct, thereby improving aerosolization through faster cooling of the volatized vapors.
[0021] Alternatively, the heater assembly and the capillary medium may be arranged such in an aerosol-generating system that the airflow arriving at the air impingement surface of the filament arrangement is guided through the air duct defined by the capillary medium opening through the capillary medium.
[0022] The electrically conductive filaments may form a mesh of size between 160 and 600 Mesh US (+/−10 percent) (i.e. between 160 and 600 filaments per inch (+/−10 percent)). The width of the interstices is preferably between 75 micrometer and 25 micrometer. The percentage of open area of the mesh, which is the ratio of the area of the interstices to the total area of the mesh is preferably between 25 percent and 56 percent. The mesh may be formed using different types of weave or lattice structures. Alternatively, the electrically conductive filaments include an array of filaments arranged parallel to one another. The mesh, array or fabric of electrically conductive filaments may also be characterised by its ability to retain liquid, as is well understood in the art.
[0023] The electrically conductive filaments may have a diameter of between 10 micrometer and 100 micrometer, preferably between 8 micrometer and 50 micrometer, and more preferably between 8 micrometer and 39 micrometer. The filaments may have a round cross section or may have a flattened cross-section.
[0024] The area of the mesh, array or fabric of electrically conductive filaments may be small, preferably less than or equal to 25 square millimeter, allowing it to be incorporated in to a handheld system. The mesh, array or fabric of electrically conductive filaments may, for example, be circular with a diameter of 3 millimeter to 10 millimeter, preferably 5 millimeter. The mesh may also be rectangular and, for example, have dimensions of 5 millimeter by 2 millimeter. Preferably, the mesh or array of electrically conductive filaments covers an area of between 10 percent and 50 percent of the area of the heater assembly. More preferably, the mesh or array of electrically conductive filaments covers an area of between 15 percent and 25 percent of the area of the heater assembly. Sizing of the mesh, array or fabric of electrically conductive filaments 10 percent and 50 percent of the area, or less or equal than 25 millimeter2, reduces the amount of total power required to heat the mesh, array or fabric of electrically conductive filaments while still ensuring sufficient contact of the mesh, array or fabric of electrically conductive filaments to the liquid provided one or more capillary mediums to be volatilized.
[0025] The heater filaments may be formed by etching a sheet material, such as a foil. This may be particularly advantageous when the heater assembly comprises an array of parallel filaments. If the heater assembly comprises a mesh or fabric of filaments, the filaments may be individually formed and knitted together. Alternatively, the heater filaments may be stamped from electrically conductive foil, as for example stainless steel.
[0026] The filaments of the heater assembly may be formed from any material with suitable electrical properties. Suitable materials include but are not limited to: semiconductors such as doped ceramics, electrically “conductive” ceramics (such as, for example, molybdenum disilicide), carbon, graphite, metals, metal alloys and composite materials made of a ceramic material and a metallic material. Such composite materials may comprise doped or undoped ceramics. Examples of suitable doped ceramics include doped silicon carbides. Examples of suitable metals include titanium, zirconium, tantalum and metals from the platinum group. Examples of suitable metal alloys include stainless steel, constantan, nickel-, cobalt-, chromium-, aluminium- titanium- zirconium-, hafnium-, niobium-, molybdenum-, tantalum-, tungsten-, tin-, gallium-, manganese- and iron-containing alloys, and super-alloys based on nickel, iron, cobalt, stainless steel, Timetal®, iron-aluminium based alloys and iron-manganese-aluminium based alloys. Timetal® is a registered trade mark of Titanium Metals Corporation. The filaments may be coated with one or more insulators. Preferred materials for the electrically conductive filaments are 304, 316, 304L, 316L stainless steel, and graphite. Additionally, the electrically conductive filament arrangement may comprise combinations of the above materials, A combination of materials may be used to improve the control of the resistance of the substantially flat filament arrangement. For example, materials with a high intrinsic resistance may be combined with materials with a low intrinsic resistance. This may be advantageous if one of the materials is more beneficial from other perspectives, for example price, machinability or other physical and chemical parameters. Advantageously, a substantially flat filament arrangement with increased resistance reduces parasitic losses. Advantageously, high resistivity heaters allow more efficient use of battery energy. The battery energy is proportionally divided between the energy lost on the printed circuit board and the contacts and energy delivered to the electrically conductive filament arrangement. Thus the energy available for the electrically conductive filament arrangement in the heater is higher the higher the resistance of the electrically conductive filament arrangement.
[0027] Alternatively, the electrically conductive filament arrangement may be formed of carbon thread textile, Carbon thread textile has the advantage that it is typically more cost efficient than metallic heaters with high resistivity. Further, a carbon thread textile is typically more flexible than a metallic mesh. Another advantage is that the contact between a carbon thread textile and a transport medium like a high release material can be well preserved during construction of the fluid permeable heater assembly.
[0028] A reliable contact between the fluid permeable heater assembly and a transport medium, like for example a capillary transport medium such as a wick made from fibres or a porous ceramic material, improves the constant wetting of the fluid permeable heater assembly. This advantageously reduces the risk of overheating of the electrically conductive filament arrangement and inadvertent thermal decomposition of the liquid.
[0029] The heater assembly may comprise an electrically insulating substrate on which the filaments are supported. The electrically insulating substrate may comprise any suitable material, and may be a material that is able to tolerate high temperatures (in excess of 300 degrees Celsius) and rapid temperature changes. An example of a suitable material is a polyimide film, such as Kapton®. The electrically insulating substrate may have an aperture formed in it, with the electrically conductive filaments extending across the aperture. The heater assembly may comprise electrical contacts connected to the electrically conductive filaments. For example, the electrical contacts may be glued, welded or mechanically clamped to the electrically conductive filament arrangement. Alternatively the electrically conductive filament arrangement may be printed on the electrically insulating substrate, for example using metallic inks. In such an arrangement, preferably, the electrically insulating substrate may be a porous material, such that the electrically conductive filament arrangement can be directly applied to the surface of the porous material. Preferably, in such an embodiment the porosity of the substrate functions as the “opening” of the electrically insulating substrate through which a liquid may be drawn towards the electrically conductive filament arrangement.
[0030] The electrical resistance of the mesh, array or fabric of electrically conductive filaments of the filament arrangement is between 0.3 Ohms and 4 Ohms. Preferably, the electrical resistance of the mesh, array or fabric of electrically conductive filaments is between 0.5 Ohms and 3 Ohms, and more preferably about 1 Ohm. In one embodiment, the electrical resistance of the mesh, array or fabric of electrically conductive filaments is preferably at least an order of magnitude, and more preferably at least two orders of magnitude, greater than the electrical resistance of the contact portions. This ensures that the heat generated by passing current through the filament arrangement is localised to the mesh or array of electrically conductive filaments. It is advantageous to have a low overall resistance for the filament arrangement if the system is powered by a battery. A low resistance, high current system allows for the delivery of high power to the filament arrangement. This allows the filament arrangement to heat the electrically conductive filaments to a desired temperature quickly.
[0031] The first and second electrically conductive contact portions may be fixed directly to the electrically conductive filaments. The contact portions may be positioned between the electrically conductive filaments and the electrically insulating substrate. For example, the contact portions may be formed from a copper foil that is plated onto the insulating substrate. The contact portions may also bond more readily with the filaments than the insulating substrate would.
[0032] In embodiments of filament arrangement with a filament opening, a first electrically conductive contact portion may be located at an interior boundary line of the filament arrangement to the filament opening. The first electrically conductive contact portion may be guided through the capillary medium opening. A second electrically conductive contact portion may be located at an exterior boundary line of the filament arrangement.
[0033] Alternatively or additionally, the first and second electrically conductive contact portions may be integral with the electrically conductive filaments. For example, the filament arrangement may be formed by etching a conductive sheet to provide a plurality of filaments between two contact portions.
[0034] The housing of the liquid storage portion contains a capillary medium. A capillary medium is a material that actively conveys liquid from one end of the material to another. The capillary medium is advantageously oriented in the housing to convey liquid to the heater assembly.
[0035] The capillary medium may have a fibrous or spongy structure, The capillary medium may comprise a bundle of capillaries. For example, the capillary medium may comprise a plurality of fibres or threads or other fine bore tubes. The fibres or threads may be generally aligned to convey liquid to the heater. Alternatively, the capillary medium may comprise sponge-like or foam-like material. The structure of the capillary medium forms a plurality of small bores or tubes, through which the liquid can be transported by capillary action. The capillary medium may comprise any suitable material or combination of materials. Examples of suitable materials are a sponge or foam material, ceramic- or graphite-based materials in the form of fibres or sintered powders, foamed metal or plastics material, a fibrous material, for example made of spun or extruded fibres, such as cellulose acetate, polyester, or bonded polyolefin, polyethylene, terylene or polypropylene fibres, nylon fibres or ceramic. The capillary medium may have any suitable capillarity and porosity so as to be used with different liquid physical properties. The liquid has physical properties, including but not limited to viscosity, surface tension, density, thermal conductivity, boiling point and vapour pressure, which allow the liquid to be transported through the capillary device by capillary action.
[0036] The capillary medium is in contact with the electrically conductive filaments. The capillary medium may extend into interstices between the filaments. The heater assembly may draw liquid aerosol-forming substrate into the interstices by capillary action. The capillary medium may be in contact with the electrically conductive filaments over substantially the entire extent of the aperture. In one embodiment the capillary medium in contact with the electrically conductive filament arrangement may be a filamentary wick.
[0037] Advantageously, the heater assembly and the capillary medium may be sized to have approximately the same area. As used here, approximately means between that the heater assembly may be between 0-15 percent larger than the capillary medium. The shape of the heater assembly may also be similar to the shape of the capillary medium such that the assembly and the material substantially overlap. When the assembly and the material are substantially similar in size and shape, manufacturing can be simplified and the robustness of the manufacturing process improved. As discussed below, the capillary medium may include two or more capillary mediums including one or more layers of the capillary medium directly in contact with the mesh, array or fabric of electrically conductive filaments of the heater assembly in order to promote aerosol generation. The capillary mediums may include materials described herein.
[0038] At least one of the capillary mediums may be of sufficient volume in order to ensure that a minimal amount of liquid is present in said capillary medium to prevent “dry heating”, which occurs if insufficient liquid is provided to the capillary medium in contact with the mesh, array or fabric of electrically conductive filaments. A minimum volume of said capillary medium may be provided in order to allow for between 20-40 puffs by the adult vaper. An average volume of liquid volatilized during a puff of a length between 1-4 seconds is typically between 1-4 milligrams of liquid. Thus, providing at least one capillary medium having a volume to retain between 20-160 milligrams of the liquid comprising the liquid-forming substrate may prevent the dry heating.
[0039] The housing may contain two or more different materials as capillary medium, wherein a first capillary medium, in contact with the filament arrangement, has a higher thermal decomposition temperature and a second capillary medium, in contact with the first capillary medium but not in contact with the filament arrangement has a lower thermal decomposition temperature. The first capillary medium effectively acts as a spacer separating the filament arrangement from the second capillary medium so that the second capillary medium is not exposed to temperatures above its thermal decomposition temperature. As used herein, “thermal decomposition temperature” means the temperature at which a material begins to decompose and lose mass by generation of gaseous by-products. The second capillary medium may advantageously occupy a greater volume than the first capillary medium and may hold more aerosol-forming substrate that the first capillary medium. The second capillary medium may have superior wicking performance to the first capillary medium. The second capillary medium may be cheaper than the first capillary medium. The second capillary medium may be polypropylene.
[0040] The first capillary medium may separate the heater assembly from the second capillary medium by a distance of at least 1.5 millimeter, and preferably between 1.5 millimeter and 2 millimeter in order to provide a sufficient temperature drop across the first capillary medium.
[0041] The size and position of the capillary medium opening can be selected based on the airflow characteristics of the aerosol-generating system, or on the temperature profile of the heater assembly, or both. Position and shape of the capillary medium opening are arranged such that an airflow guided to the air impingement surface of the filament arrangement is whirled around the air impingement surface. In some embodiments, the capillary medium opening may be positioned towards the center of the cross section of the capillary medium. In one embodiment, the capillary medium opening is positioned in the center of the cross section of the capillary medium. In one embodiment, the capillary medium is of cylindrical shape. In one embodiment, the air duct through the capillary medium opening is of cylindrical shape.
[0042] The term “towards the center of the cross section of capillary medium” refers to a center portion of the cross section of the capillary medium that is away from the periphery of the capillary medium and has an area which is less than the total area of the cross section of the capillary medium. For example, the center portion may have an area of less than about 80 percent, less than about 60 percent, less than about 40 percent, or less than about 20 percent of the total area of the cross section of the capillary medium.
[0043] In embodiments with a filament opening, the filament opening may be positioned in a center portion of the filament arrangement, wherein the filament opening is extended by the capillary medium opening to form an air duct through the capillary medium. In this case, more aerosol passes through the filament arrangement in the center of the filament arrangement. This is advantageous in aerosol-generating systems in which the center of the filament arrangement is the most important vaporization area, for example in aerosol-generating systems in which the temperature of the heater assembly is higher in the center of the filament arrangement. Position and shape of the filament arrangement, of the filament opening, and of the capillary medium opening are arranged such that an airflow guided to the air impingement surface of the filament arrangement is whirled around the air impingement surface.
[0044] As used herein, the term “center portion” of the filament arrangement refers to a part of the filament arrangement that is away from the periphery of the filament arrangement and has an area which is less than the total area of the filament arrangement. For example, the center portion may have an area of less than about 80 percent, less than about 60 percent, less than about 40 percent, or less than about 20 percent of the total area of the filament arrangement.
[0045] An air inlet of the aerosol-generating system may be arranged in a main housing of the system. Ambient air is directed into the system and is guided to the air impingement surface of the heating assembly. The air stream arriving at the air impingement surface of the heater assembly is guided through the air duct defined by the capillary medium opening. The airflow entrains aerosols caused by heating the aerosol-forming substrate on the surface of the heater assembly. The aerosol containing air may then be guided along the cartridge between a cartridge housing and a main housing to the downstream end of the system, where it is mixed with ambient air from the further flow route (either before or upon reaching the downstream end). Guiding the aerosol through the air duct accelerates the airflow, thereby improving aerosolization through faster cooling.
[0046] The air inlets may be provided at the sidewalls of the main housing of the system, such that ambient air may be drawn towards the heating element at an angle of approximately or up to 90° with respect to the air duct defined by the capillary medium opening. Thus, at least a large part of air flow is guided substantially parallel along the air impingement surface of the heater assembly and is then redirected into the air duct defined by the capillary medium. By the specific air flow routing, turbulences and vortices are created in the airflow, which efficiently carries the aerosol vapours. Further, the cooling rate may be increased which may also enhance aerosol formation. The ambient air may also be guided through the air duct to the surface of the heater assembly, e.g., the direction of airflow may be inverted as compared to the preferred direction of airflow. Also in this embodiment, guiding the ambient air through the air duct accelerates the airflow, thereby improving aerosolization.
[0047] An inlet opening of the second channel arranged in a region of a distal end of a cartridge housing may also be provided in an alternative system where a heating element is arranged at a proximal end of the cartridge. The second flow route may not only pass outside of the cartridge but also through the cartridge. Ambient air then enters the cartridge at a semi-open wall of the cartridge, passes through the cartridge and leaves the cartridge by passing though the heating element arranged at the proximal end of the cartridge. Thereby, ambient air may pass through the aerosol-forming substrate or through one or several channels arranged in a solid aerosol-forming substrate such that ambient air does not pass through the substrate itself but in the channels next to the substrate.
[0048] For allowing ambient air to enter a cartridge, a wall of the cartridge housing, for example, a wall opposite the heating element, for example a bottom wall, is provided with at least one semi-open inlet. The semi-open inlet allows air to enter the cartridge but no air or liquid to leave the cartridge through the semi-open inlet. A semi-open inlet may for example be a semi-permeable membrane, permeable in one direction only for air but is air- and liquid-tight in the opposite direction. A semi-open inlet may for example also be a one-way valve. Preferably the semi-open inlets allow air to pass through the inlet only if specific conditions are met, for example a minimum depression in the cartridge or a volume of air passing through the valve or membrane.
[0049] Such one-way valves may, for example, be commercially available valves, such as for example used in medical devices, for example LMS Mediflow One-Way, LMS SureFlow One-Way or LMS Check Valves (crosses membranes). Suitable membranes to be used for a cartridge having an airflow passing through the cartridge, are for example vented membranes as used in medical devices, for example Qosina Ref. 11066, vented cap with hydrophobic filter or valves as used in baby bottles. Such valves and membranes may be made of any material suitable for applications in electrically heated vaping systems. Materials suitable for medical devices and FDA approved materials may be used; for example Graphene having very high mechanical resistance and thermal stability within a large range of temperatures. Preferably, valves are made of soft resilient material for supporting a liquid-tight incorporation of the one or several valves into a wall of the container housing.
[0050] Letting ambient air pass through the substrate supports an aerosolization of the aerosol-forming substrate. During puffing, a depression occurs in the cartridge, which may activate the semi-open inlets. Ambient air then passes the cartridge, preferably a high retention or high release material (HRM) or a liquid, for example, and crosses the heating element, thereby creating and sustaining aerosolization of the liquid, when the heating element sufficiently heats the liquid. In addition, due to the depression caused during puffing, a supply of liquid in a transport material such as a capillary medium to the heating element may be limited. An ambient airflow through the cartridge may equalize pressure differences within the cartridge and thereby support an unhindered capillary action towards the heating element.
[0051] A semi-open inlet may, in addition, or alternatively also be provided in one or several side walls of the cartridge housing. Semi-open inlets in side walls provide a lateral airflow into the cartridge towards the open top end of the cartridge housing, where the heating element is arranged. In one embodiment, lateral airflows pass through the aerosol-forming substrate.
[0052] The system may further comprise electric circuitry connected to the heater assembly and to an electrical power source, the electric circuitry is configured to monitor the electrical resistance of the heater assembly or of one or more filaments of the heater assembly, and to control the supply of power to the heater assembly dependent on the electrical resistance of the heater assembly or the one or more filaments.
[0053] The electric circuitry may comprise a microprocessor, which may be a programmable microprocessor. The electric circuitry may comprise further electronic components. The electric circuitry may be configured to regulate a supply of power to the heater assembly. Power may be supplied to the heater assembly continuously following activation of the system or may be supplied intermittently, such as on a puff-by-puff basis. The power may be supplied to the heater assembly in the form of pulses of electrical current.
[0054] The system advantageously comprises a power supply, typically a battery, within the main body of the housing. As an alternative, the power supply may be another form of charge storage device such as a capacitor. The power supply may require recharging and may have a capacity that allows for the storage of enough energy for one or more vaping experiences; for example, the power supply may have sufficient capacity to allow for the continuous generation of aerosol for a period of around six minutes or for a period that is a multiple of six minutes. In another example, the power supply may have sufficient capacity to allow for a desired (or, alternatively predetermined) number of puffs or discrete activations of the heater assembly.
[0055] In one embodiment, the aerosol generating system comprises a housing. In one embodiment, the housing may be elongate. The housing may comprise any suitable material or combination of materials. Examples of suitable materials include metals, alloys, plastics or composite materials containing one or more of those materials, or thermoplastics that are suitable for food or pharmaceutical applications, for example polypropylene, polyetheretherketone (PEEK) and polyethylene. In one embodiment, the material is light and non-brittle.
[0056] The aerosol-forming substrate is a substrate capable of releasing volatile compounds that can form an aerosol. The volatile compounds may be released by heating the aerosol-forming substrate. The aerosol-forming substrate may comprise plant-based material. The aerosol-forming substrate may comprise tobacco. The aerosol-forming substrate may comprise a tobacco-containing material containing volatile tobacco flavour compounds, which are released from the aerosol-forming substrate upon heating. The aerosol-forming substrate may alternatively comprise a non-tobacco-containing material. The aerosol-forming substrate may comprise homogenised plant-based material. The aerosol-forming substrate may comprise homogenised tobacco material. The aerosol-forming substrate may comprise at least one aerosol-former. The aerosol-forming substrate may comprise other additives and ingredients, such as flavourants.
[0057] The aerosol-generating system may comprise a main unit and a cartridge that is removably coupled to the main unit, wherein the liquid storage portion and heater assembly are provided in the cartridge and the main unit comprises a power supply.
[0058] The aerosol-generating system may be an electrically operated vaping system. In one embodiment, the aerosol-generating system is portable. The aerosol-generating system may have a size comparable to a conventional cigar or cigarette. The vaping system may have a total length between approximately 30 millimeter and approximately 150 millimeter. The vaping system may have an external diameter between approximately 5 millimeter and approximately 30 millimeter.
[0059] In the method of manufacture of a cartridge for use in an electrically operated aerosol-generating system, the filling of the liquid storage portion may be performed before or after providing the heater assembly. The heater assembly may be fixed to the housing of the liquid storage portion. The fixing may, for example, comprise heat sealing, gluing or welding the heater assembly to the housing of the liquid storage portion.
[0060] Features described in relation to one aspect may equally be applied to other aspects of the embodiments.
[0061] As used herein, “electrically conductive” means formed from a material having a resistivity of 1×10-4 Ohm meters, or less.
[0062] As used herein, “electrically insulating” means formed from a material having a resistivity of 1×10 4 Ohm meters or more.
[0063] As used herein “fluid permeable” in relation to a heater assembly means that the aerosol-forming substrate, in a gaseous phase and possibly in a liquid phase, can readily pass through the heater assembly.
BRIEF DESCRIPTION OF THE DRAWINGS
[0064] Embodiments will now be described, by way of example only, with reference to the accompanying drawings, in which:
[0065] FIG. 1 is a perspective topside view of an arrangement comprising a heater assembly and a capillary medium, in accordance with an embodiment;
[0066] FIG. 2A is a perspective topside view of a heater assembly comprising a filament arrangement of curved shape with a central opening;
[0067] FIG. 2B is a perspective topside view of a heater assembly comprising a filament arrangement of funnel shape with a central opening;
[0068] FIG. 3 is a perspective topside view of a capillary medium comprising a first capillary medium and a second capillary medium with both having a central opening;
[0069] FIG. 4A is a perspective topside view of an arrangement comprising a heater assembly and a capillary medium, in accordance with an embodiment;
[0070] FIG. 4B is a perspective topside view of an arrangement comprising a heater assembly and a capillary medium, in accordance with an embodiment;
[0071] FIG. 4C is a perspective topside view of an arrangement comprising a heater assembly and a capillary medium, in accordance with an embodiment; and
[0072] FIG. 5 is a schematic illustration of a system, incorporating a cartridge comprising a heater assembly and a capillary medium, in accordance with an embodiment.
DETAILED DESCRIPTION
[0073] Various example embodiments will now be described more fully with reference to the accompanying drawings in which some example embodiments are shown. However, specific structural and functional details disclosed herein are merely representative for purposes of describing example embodiments. Thus, the embodiments may be embodied in many alternate forms and should not be construed as limited to only example embodiments set forth herein. Therefore, it should be understood that there is no intent to limit example embodiments to the particular forms disclosed, but on the contrary, example embodiments are to cover all modifications, equivalents, and alternatives falling within the scope.
[0074] In the drawings, the thicknesses of layers and regions may be exaggerated for clarity, and like numbers refer to like elements throughout the description of the figures.
[0075] Although the terms first, second, etc. may be used herein to describe various elements, these elements should not be limited by these terms. These terms are only used to distinguish one element from another. For example, a first element could be termed a second element, and, similarly, a second element could be termed a first element, without departing from the scope of example embodiments. As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items.
[0076] It will be understood that, if an element is referred to as being “connected” or “coupled” to another element, it can be directly connected, or coupled, to the other element or intervening elements may be present. In contrast, if an element is referred to as being ‘directly connected’ or “directly coupled” to another element, there are no intervening elements present. Other words used to describe the relationship between elements should be interpreted in a like fashion (e.g., “between” versus “directly between,” “adjacent” versus “directly adjacent,” etc.).
[0077] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of example embodiments. As used herein, the singular forms “a,” “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises,” “comprising,” “includes” and/or “including,” if used herein, specify the presence of stated features, integers, steps, operations, elements and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components and/or groups thereof.
[0078] Spatially relative terms (e.g., “beneath,” “below,” “lower,” “above,” “upper” and the like) may be used herein for ease of description to describe one element or a relationship between a feature and another element or feature as illustrated in the figures. It will be understood that the spatially relative terms are intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as “below” or “beneath” other elements or features would then be oriented “above” the other elements or features. Thus, for example, the term “below” can encompass both an orientation that is above, as well as, below. The device may be otherwise oriented (rotated 90 degrees or viewed or referenced at other orientations) and the spatially relative descriptors used herein should be interpreted accordingly.
[0079] Example embodiments are described herein with reference to cross-sectional illustrations that are schematic illustrations of idealized embodiments (and intermediate structures). As such, variations from the shapes of the illustrations as a result, for example, of manufacturing techniques and/or tolerances, may be expected. Thus, example embodiments should not be construed as limited to the particular shapes of regions illustrated herein but may include deviations in shapes that result, for example, from manufacturing. For example, an implanted region illustrated as a rectangle may have rounded or curved features and/or a gradient (e.g., of implant concentration) at its edges rather than an abrupt change from an implanted region to a non-implanted region. Likewise, a buried region formed by implantation may result in some implantation in the region between the buried region and the surface through which the implantation may take place. Thus, the regions illustrated in the figures are schematic in nature and their shapes do not necessarily illustrate the actual shape of a region of a device and do not limit the scope.
[0080] It should also be noted that in some alternative implementations, the functions/acts noted may occur out of the order noted in the figures. For example, two figures shown in succession may in fact be executed substantially concurrently or may sometimes be executed in the reverse order, depending upon the functionality/acts involved.
[0081] Although corresponding plan views and/or perspective views of some cross-sectional view(s) may not be shown, the cross-sectional view(s) of device structures illustrated herein provide support for a plurality of device structures that extend along two different directions as would be illustrated in a plan view, and/or in three different directions as would be illustrated in a perspective view. The two different directions may or may not be orthogonal to each other. The three different directions may include a third direction that may be orthogonal to the two different directions. The plurality of device structures may be integrated in a same electronic device. For example, when a device structure (e.g., a memory cell structure or a transistor structure) is illustrated in a cross-sectional view, an electronic device may include a plurality of the device structures (e.g., memory cell structures or transistor structures), as would be illustrated by a plan view of the electronic device. The plurality of device structures may be arranged in an array and/or in a two-dimensional pattern.
[0082] Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which example embodiments belong. It will be further understood that terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.
[0083] In order to more specifically describe example embodiments, various features will be described in detail with reference to the attached drawings. However, example embodiments described are not limited thereto.
[0084] FIG. 1 shows a filament arrangement 30 according to one of the embodiments of the present disclosure. The filament arrangement 30 has a filament opening 32 . A capillary medium 22 is in contact with the filament arrangement 30 . The capillary medium has a capillary medium opening 28 that acts as an air duct through the capillary medium 22 . Ambient air is guided in airflow 40 to the air impingement surface of the filament arrangement 30 . The suction of the air duct through the capillary medium 22 causes an acceleration of the airflow so that the volatized vapors are drawn in an airflow 42 through the air duct.
[0085] FIGS. 2A and 2B illustrate various shapes of filament arrangements 30 , each having a filament opening 32 in a center portion of the filament arrangement 30 .
[0086] FIG. 2A shows a non-planar filament arrangement 30 that is curved along one dimension. The curved shape causes a whirling of the airflow 40 on the air impingement surface. This effect is further increased by the optional filament opening 32 .
[0087] FIG. 2B shows a non-planar filament arrangement 30 having a funnel shape with an optional filament opening 32 at the bottom of the funnel shaped filament arrangement 30 . The funnel shape causes a whirling of the airflow 40 on the air impingement surface. This effect is further increased by the optional filament opening 32 .
[0088] FIG. 3 shows a capillary medium 22 to be used in an aerosol-generating system. There are two separate capillary mediums 44 , 46 in use. A larger body of a second capillary medium 46 is provided on an opposite side of the first capillary medium 44 that is in contact with the filament arrangement 30 of the heater assembly. Both the first capillary medium 44 and the second capillary medium 46 retain liquid aerosol-forming substrate. The first capillary medium 44 , which contacts the filament arrangement, has a higher thermal decomposition temperature (at least 160 degrees Celsius or higher such as approximately 250 degrees Celsius) than the second capillary medium 46 . The first capillary medium 44 effectively acts as a spacer separating the filament arrangement 30 from the second capillary medium 46 so that the second capillary medium is not exposed to temperatures above its thermal decomposition temperature. The first capillary medium 44 is flexible and may accommodate the non-planar shape of the heater assembly, such that the contact surface between the capillary medium and the heater assembly is increased or maximized.
[0089] The thermal gradient across the first capillary medium is such that the second capillary medium is exposed to temperatures below its thermal decomposition temperature. The second capillary medium 46 may be chosen to have superior wicking performance to the first capillary medium 44 , may retain more liquid per unit volume than the first capillary medium and may be less expensive than the first capillary medium. The capillary medium 22 comprises a capillary medium opening 28 acting as an air duct through the capillary medium 22 .
[0090] FIGS. 4A to 4C illustrate the combination of a filament arrangement 30 with two separate capillary mediums 44 , 46 that guide the airflow 42 through an air duct defined by the capillary medium opening 28 after being mixed with volatized vapors on the surface of the filament arrangement 30 . Alternatively, the airflow may be guided in the reverse direction, e.g., the ambient air may be guided as airflow 40 through the air duct to the surface of the filament arrangement 30 .
[0091] FIG. 4A shows a non-planar filament arrangement 30 of a funnel shape with a filament opening 32 at the bottom end of the filament arrangement 30 , the filament opening 32 extending the capillary medium opening 28 . The funnel shape creates turbulences and vortexes that encourage the mixing of the volatized vapors with the ambient air.
[0092] FIG. 4B shows a non-planar filament arrangement 30 of a curved shape. The curved shape creates turbulences and vortexes that enhance mixing of the volatized vapors with the ambient air. The filament arrangement 30 of FIG. 4C largely corresponds to the filament arrangement 30 depicted in FIG. 2A , with the exception that the filament arrangement 30 of FIG. 4B does not exhibit a dedicated filament opening 32 . Due to the interstices in the filament arrangement 30 , the filament arrangement 30 is fluid and air permeable even without a dedicated filament opening 32 . Therefore, the effect of suction or draw through the air duct of the capillary mediums 44 , 46 is also given in the case where the capillary opening 28 is not extended by a filament opening 32 .
[0093] FIG. 4C corresponds to FIG. 4B with a filament arrangement 30 of a funnel shape without a dedicated filament opening 32 . The funnel shape of the filament arrangement 30 accounts for whirling the air that arrives at the air impingement surface of the filament arrangement 30 , thereby creating turbulences and vortexes that encourage the mixing of the volatized vapors with the ambient air. Due to the interstices in the filament arrangement 30 , the filament arrangement 30 is fluid and air permeable even without a dedicated filament opening 32 .
[0094] In the embodiments depicted in FIGS. 4A and 4C , the lower portion of the filament arrangement 30 is in direct contact with the second capillary medium 46 . Of course the size of capillary medium 44 can also be increased, such that it covers the complete filament arrangement 30 , and such that direct contact between the filament arrangement 30 and the second capillary medium 46 is prevented.
[0095] FIG. 5 is a schematic illustration of an aerosol-generating system, including a cartridge 20 with a heater assembly comprising a filament arrangement 30 according to one of the embodiments of the present disclosure and with a capillary medium 22 according to one of the embodiments of the present disclosure. The aerosol-generating system comprises an aerosol-generating device 10 and a separate cartridge 20 . In this example, the aerosol-generating system is an electrically operated vaping system.
[0096] The cartridge 20 contains an aerosol-forming substrate and is configured to be received in a cavity 18 within the device. Cartridge 20 should be replaceable by an adult vaper when the aerosol-forming substrate provided in the cartridge 20 is depleted. FIG. 5 shows the cartridge 20 just prior to insertion into the device, with the arrow 1 in FIG. 5 indicating the direction of insertion of the cartridge 20 . The heater assembly with the filament arrangement 30 and the capillary medium 22 is located in the cartridge 20 behind a cover 26 . The aerosol-generating device 10 is portable and has a size comparable to a conventional cigar or cigarette. The device 10 comprises a main body 11 and a mouthpiece portion 12 . The main body 11 contains a power supply 14 , for example a battery such as a lithium iron phosphate battery, control electronics 16 and a cavity 18 . The mouthpiece portion 12 is connected to the main body 11 by a hinged connection 21 and can move between an open position as shown in FIG. 5 and a closed position. The mouthpiece portion 12 is placed in the open position to allow for insertion and removal of cartridges 20 and is placed in the closed position when the system is to be used to generate aerosol. The mouthpiece portion comprises a plurality of air inlets 13 and an outlet 15 . In use, an adult vaper draws or puffs on the outlet to draw air from the air inlets 13 , through the mouthpiece portion and the cartridge 20 to the outlet 15 . Internal baffles 17 are provided to force the air flowing through the mouthpiece portion 12 past the cartridge.
[0097] The cavity 18 has a circular cross-section and is sized to receive a housing 24 of the cartridge 20 . Electrical connectors 19 are provided at the sides of the cavity 18 to provide an electrical connection between the control electronics 16 and battery 14 and corresponding electrical contacts on the cartridge 20 .
[0098] Other cartridge designs incorporating a heater assembly with a filament arrangement 30 in accordance with this disclosure and a capillary medium 22 in accordance with this disclosure can now be conceived by one of ordinary skill in the art. For example, the cartridge 20 may include a mouthpiece portion 12 , may include more than one heater assembly and may have any desired shape. Furthermore, a heater assembly in accordance with the disclosure may be used in systems of other types to those already described, such as humidifiers, air fresheners, and other aerosol-generating systems.
[0099] The exemplary embodiments described above illustrate but are not limiting. In view of the above discussed exemplary embodiments, other embodiments consistent with the above exemplary embodiments will now be apparent to one of ordinary skill in the art.
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An aerosol-generating system includes a liquid storage portion having a housing holding a liquid aerosol-forming substrate and a capillary medium. The housing has an opening. A fluid permeable heater assembly includes an arrangement of electrically conductive filaments arranged to define a substantially non-planar air impingement surface. The fluid permeable heater assembly extends across the opening of the housing. The capillary medium is provided in contact with the heater assembly. The capillary medium draws the liquid aerosol-forming substrate to the electrically conductive filament arrangement. The capillary medium includes a capillary medium opening allowing airflow to pass through the capillary medium.
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FIELD OF THE INVENTION
The invention describes a process and an apparatus for the production of textured filament strips for artificial grass, wherein these strips are stretched or shrunken between two heating godets and then textured, and the textured filament strips are drawn off over a cooling godet and then spooled.
BACKGROUND OF THE INVENTION
The knit-deknit process is mostly used for the texturing of thermoplastic polymer fibres. In addition, gear crimping is also customary for the production of fibres for artificial grass.
A draw texturing process in which a stuffer box is used in which a cooling zone is provided is known from the textbook “Synthetische Fasern” by Franz Fourné (see page 433, FIG. 4.255, right-hand side of the figure).
The texturing of threads by means of a stuffer box is also known from DE 21 42 652 and DD 221 214.
The knit-deknit process is used for the production of crimped fibres. EP 0 263 566 describes the production of crimped polypropylene fibres for artificial turf with the knit-deknit process. However, the degree of texturing is limited in these processes.
A process for the crimp texturing of an extruded yarn in which the extruded yarn is first stretched through two heating rollers, then crimped in a texturing unit and subsequently cooled via a cooling drum with a certain number of turns is known from DE 38 00 773. The texturing unit is a plug former. To cool the textured yarn, cooling air is sucked through holes located on the outside of the cooling drum.
A cooling godet or roller for the treatment of synthetic thread- or web-shaped goods is also known from DE 28 44 207.
An apparatus for the continuous crimping of thermoplastic yarns with which the crimping (texturing) is carried out with a stuffer box mounted tangentially on a rotary cylinder and the rotary cylinder is used for cooling is known from DE 21 10 670. For this, openings through which cooling air is passed over the cylinder and a cover plate are mounted on the outside of the rotary cylinder next to the stuffer box.
A process for the production of low-shrinkage strips in which flat strips, strands or monofilaments made of plastic are stretched in a stretching station and fixed in a fixing station is known from DE 43 18 689.
The cooling of threads is known from EP 0 003 952, wherein these threads are formed from thread plugs formed in stuffer boxes and then spooled on an air-permeable drum and cooled. There is a substantial distance between the stuffer box and the cooling godet.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a process and an apparatus for the production of highly crimped polymer strips which are suitable for use in artificial turf surfaces, for example for football pitches, hockey pitches, tennis courts or golf courses, and are characterized by a high degree of strength, a large volume and a high elasticity.
It is a further object of the present invention to provide a process for the production of textured filament strips for artificial grass, comprising the steps of stretching filament strips between two heating godets; texturing the filament strips in a stuffer box; and drawing off the textured filament strips over a cooling godet and laying the textured filament strips on the cooling godet immediately after the texturing.
Preferably, up to ten strips are processed simultaneously and the strips are 0.5-1.5 mm wide and have a linear density of 250-1200 dtex.
The filament strip can also be a monofilament tape which is 1.5-8 mm wide and has a linear density of 500-8000 dtex.
The filament strip leaving the stuffer box is preferably fed approximately radially to the cooling godet.
An additional air nozzle is preferably mounted above the cooling godet and laterally beside the stuffer box. The additional air nozzle supports the laying of the material on the cooling godet.
The stuffer box is to be mounted at as small as possible a distance above the cooling godet. The laying on the cooling godet takes place without the use of feeder rolls, as the texturing would be destroyed again as a result of using feeder rolls.
A guide groove is located on the outside of the cooling godet. The guide groove is provided with small openings. The radius of the guide groove is matched to the texturing of the textured materials in order to avoid deformations of the texturing. The cooling godet is provided with a suction device which sucks air through the openings in the guide groove in order to cool the filament strip laid in the groove and keep it in the groove. A rapid cooling of the material is thereby achieved and the texturing is fixed by the onset of crystallization. In addition, an upright cover is incorporated into the cooling godet in order that the suction action is confined to the section of the periphery of the cooling godet in which the thread lies in the guide groove. The filament is drawn off from the cooling godet by a draw-off godet.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows diagrammatically the device for carrying out the process.
FIG. 2 shows in section along A-A of FIG. 1 the stuffer box and the cooling godet with a suction device.
DETAILED DESCRIPTION OF THE EMBODIMENTS
In the present process, a polymer material in the form of strips 10 , 0.5 to 1.5 mm wide and with a linear density of 250-1200 dtex, is processed. PA (polyamide), PP (polypropylene) HDPE (high density polyethylene) or LLDPE (linear low density polyethylene) are used for example as polymeric materials. The strips 10 are further processed either fed from a creel or direct on leaving the extruder.
For further processing, four to ten strips 10 are bundled into a multifilament and thermally stretched or shrunken by up to 20% over two heating godets 11 and 12 .
The strips 10 are then subjected to a hot-air texturing process in a stuffer box 13 , wherein the strips 10 are pressed into a box and knocked against the fibre plug forming there. The filaments buckle up against one another. The stuffer box has a lateral inlet for a hot-air texturing nozzle 21 and an air outlet zone 23 . The resulting structure is thermoset while still in the box with hot air from the texturing nozzle 21 . A three-dimensional, sawtooth-shaped crimp structure forms. Stuffer boxes customary in the trade can be used in the process.
To stabilize the texturing, the compressed and crimped strips 10 are taken up by a cooling godet 14 immediately after the texturing. The cooled strips 10 are drawn off from the cooling godet 14 by a draw-off godet 16 and fed to a spooling machine. The degree of texturing is limited by the speed ratio of the cooling godet 14 to the draw-off godet 16 , the speed ratio of the draw-off godet 16 to the second heating godet 12 , and the air pressure in the stuffer box 13 .
The discharge end of the stuffer box is arranged as near as possible to the surface of the cooling godet 14 , and the stuffer box 13 ends just a few millimeters above the cooling godet 14 . The filament strip 10 leaving the stuffer box 13 is conducted radially onto the cooling godet 14 . In addition, there is mounted laterally on the stuffer box 13 an air nozzle 18 which directs an air jet at an angle of approximately 45° to the longitudinal axis of the discharge end of the stuffer box 13 and the surface of the cooling godet 14 onto the point at which the filament strip 10 leaves the stuffer box 13 and is laid on the cooling godet 14 . The laying of the filament strip 10 on the cooling godet 14 is thereby supported.
As shown in FIG. 2 , the cooling godet 14 has a suction device 15 . Arranged on the outside of the cooling godet 14 is a radial guide groove 25 with small openings 26 through which air is sucked in from the outside and which ensure an air throughput sufficient for cooling. The radius of the guide groove 25 is matched to the textured material. The filament strips 10 generally rest against the cooling godet 14 on a circular arc of less than 360°, e.g. approximately 180°. Incorporated into the cooling godet 14 is an upright cover 19 which shields from the inside the part of the guide groove 25 on which no filament strips lie. Unnecessary consumption of suction air and an unnecessary reduction of the negative pressure in the cooling godet 14 are thereby avoided. Wrapping of the filament strips 10 around the cooling godet 14 is also avoided thereby because the textured filament strips drop down from the cooling godet 14 as from the beginning of the cover 19 due to their own weight and the absence of the suction.
The textured strips 10 are held and cooled by the suction air at the cooling godet 14 in their guide groove 25 in the desired segment of e.g. approximately 180° on the periphery of the cooling godet 14 . The cooling quickly reduces the temperature to below the glass-transition temperature with the result that the texture of the fibres is fixed by the onset of crystallization.
The speed ratios of the godets are variable and can be adjusted according to the desired degree of texturing. Particularly important here is the speed ratio between the second heating godet 12 , the cooling godet 14 and the draw-off godet 16 , as this determines the degree of texturing. The cooling godet 14 travels by the factor 5 to 20 slower than the second heating godet 12 and the draw-off godet 16 travels by the factor 2 to 4 slower than the second heating godet 12 .
The speed difference between extrusion and spooling is 5-35%, wherein the extrusion speed is 1.05 to 1.35 times greater than the spooling speed. Production speeds of 100-500 m/min. can thus be reached.
The thus-obtained fibres can then be bundled as fibre groups and anchored on dimensionally stable backing fabric, whereby an artificial turf surface with high elasticity, an optimum recovery capacity and high wear resistance is obtained.
EXAMPLE
Six extruded polyamide strips 10 are stretched by 10% at 160° C. over the two heating godets 11 and 12 with a thread tension of 4000 g. The stretched strips 10 are then compressed and crimped in the stuffer box 13 with a texturing pressure of 5 bar and thermoset at 120° C. texturing nozzle temperature. There is a back shrinkage of 35%. The textured strips 10 , supported by an air jet from the lateral air nozzle 18 , are laid tensionless on the cooling godet 14 and held, cooled and transported further in the guide groove of the cooling godet 14 by the air jet from the suction device 15 . The temperature at the cooling godet 14 corresponds to the ambient temperature. The cooled strips 10 are taken up by the draw-off godet 16 and fed to the spooling machine, wherein the spooling tension is 300 g. The speed difference between extrusion and spooling is 25% and thus compensates for the back shrinkage. A production speed of 400 m/min. is reached.
LIST OF REFERENCE NUMBERS
10 strip
11 first heating godet
12 second heating godet
13 stuffer box
14 cooling godet
15 suction device
16 draw-off godet
18 air nozzle
19 upright cover
21 texturing nozzle
23 air outlet zone
25 guide groove
26 openings
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The invention describes a process and an apparatus for the production of highly crimped polymer strips which are suitable for use in artificial turf surfaces, for example for football pitches, hockey pitches, tennis courts or golf courses, and are characterized by a high degree of strength, a large volume and a high elasticity. The texturing of the polymer strips is carried out by means of a stuffer box, wherein the polymer strips are laid on a cooling godet immediately after the stuffer box.
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FIELD OF THE INVENTION
[0001] The present invention relates to a method and system for improvements in or relating to off-line virtual environments, particularly in respect of compliance management of off-line virtual environments.
BACKGROUND ART
[0002] Many software virtualization products exist in the market today. The software virtualization products typically provide host software (for example, a control program) which creates a simulated computer environment, often referred to as a virtual machine, for so-called “guest software”. Guest software is often a complete operating system running as if it were installed on a stand alone hardware platform. Many different virtual guest machines may be simulated on a single physical host machine and each virtual machine can be activated, suspended, shutdown, cloned or moved as required. The effect of some of these activities can have a detrimental effect on the IT infrastructure of an organization. For example, if a virtual machine image is either suspended or shut down, the in-memory representation of the virtual machine is unloaded from the host machine. The content of the virtual machine is stored in a set of files on the filesystem of the host computer. This content may include vital resources and settings, such as the CPU, memory settings, devices, hard disk content etc.
[0003] In the example of a virtual machine image implemented by a virtual machine software provider, such as VMWare, the following are typically found:
[0004] a .nvram file which includes resource settings such as CPU, memory, Virtual devices etc.;
[0005] one or more .vmdk files each for simulated hard drive settings, for example the settings of a filesystem; and
[0006] a .vmx file with virtual machine customization settings.
[0007] Accordingly, once the virtual machine image is completely shut down, it can be managed as appropriate by managing the above mentioned set of files. The management may include versioning, archiving, cloning, provisioning, etc. The files include all information relating to the operating system, all the installed software and related settings and any other appropriate information or data relating to the virtual machine.
[0008] Subsequently, if the virtual machine is restored and reconnected with the other physical and virtual machines on the network it is possible that they may include potentially harmful content. For example, security exposures, viruses, unlicensed software, events which have changed the files such that they are not in compliance with the current IT requirements for the network, etc. As a consequence, it is important to determine if the virtual machine image is “good” or “bad”. In addition, it is important to determine whether the virtual machine image includes the appropriate levels of anti-virus software, firewalls and security setting, license compliance tools and any other appropriate elements that indicates that the virtual machine will comply with the network. In order for this to be carried out, the virtual machine can consume significant resources from the virtual machine environment; and, if found to be non-compliant while being tested or verified, can trigger undesirable noncompliance events or security issues.
[0009] In the past, the typical scenario has been to restore and test a virtual machine in a closed virtual environment. This is time-consuming and requires effort before it is even decided whether it is worth repairing or updating the virtual machine rather than creating a new virtual machine image. The fact that the virtual machine is being restored and tested in a network environment can have negative impacts on the level of security and compliance especially during any security audits in respect of the network. In addition, in certain cases virtual machines to be used for demo purposes or commercial virtual applications can also be found and downloaded from the Internet. These machines are already configured and may not comply with the network concerned and the company security rules. Since more and more of these types of applications are occurring the above issues relating to security and compliance are being encountered more and more frequently.
[0010] US 2006/0136720 discloses a virtual machine scanning system that works on an active virtual machine created with a cloning operation from the original virtual machine or taking a snapshot of the running virtual machine. As the virtual machine is active the system does not solve the problem associated with compliance and security issues that arise when bringing a virtual machine back on-line after it has been dormant.
[0011] A web page associated with an off-line virtual machine servicing tool executive overview http://technet.microsoft.com/en-us/library/cc501231.aspx discloses an off-line virtual machine servicing tool and how it may be used in various business scenarios. Whilst this discloses some solutions to some problems mainly related to provide a way to automate the process of updating the virtual machines, it does not address all the issues associated with “reinstating” a dormant virtual machine back into a network.
[0012] Similarly, McAfee discloses the feature of security management of virtual machines in an off-line state http://www.mcafee.com/us/about/press/corporate/2008/20080227 — 181010_q.html. Again, this document solve certain problems that does not address all the issues associated with “reinstating” a dormant virtual machine back into a network.
SUMMARY OF THE INVENTION
[0013] The present invention is directed to a method, computer product and system for determining the compliance of a virtual machine image during a process to potentially introduce the virtual machine image into a network. One or more virtual machine images are identified. During compliance testing, the identified virtual machine image is controlled such that it cannot connect to the network. One or more tests are carried out to determine if the virtual machine image is compliant with one or more predetermined requirements. If a virtual machine is compliant with said one or more predetermined requirements, the virtual machine image is connected to the network.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] Reference will now be made by way of example to the accompanying drawings, in which:
[0015] FIG. 1 is a block diagram of a system in accordance with an embodiment of the invention, by way of example.
[0016] FIG. 2 is a block diagram showing the first set of method steps, in accordance with an embodiment of the invention, by way of example.
[0017] FIG. 3 is a block diagram showing a second set of method steps, in accordance with an embodiment of the invention, by way of example.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0018] Referring initially to FIG. 1 a system according to the present invention will now be described. The system comprises, in a first embodiment, a host 100 . The host supports a virtual machine layer 102 which includes a module 104 for analyzing and attempting to fix virtual machines before they are put on-line. In addition, a virtual machine repository 106 is connected to the host by means of the Internet 108 (or any other appropriate connection). The virtual machine repository downloads virtual machines onto the virtual machine layer 102 situated on the host 100 . The virtual machines shown are VM 1 , VM 2 , and VM 3 : 110 , 112 and 114 respectively. The manner in which the virtual machines are downloaded will now be described.
[0019] In order to implement the method and system to perform efficient compliance assessment for an off-line virtual image the method relies on a particular sequencing and use of APIs and commands that a specific virtualization provider can facilitate. This is achieved by quickly filtering out non-compliant virtual machine images and where possible preventing them coming on-line.
[0020] The method depends on the ability of the virtualization technology to provide APIs or commands for inspecting the virtual filesystems off-line. Step one is a preliminary step which is optional and depends on the virtualization provider inspection capabilities for the filesystem (e.g. VMWare vmdk files) of any un-powered virtual machines. As shown in FIG. 2 , this includes the following sub steps:
[0021] connect to the local host, 200 ;
[0022] locate all registered virtual machine images, 202 (for example, by finding folders with .vmx validated files);
[0023] conduct for each virtual machine, an off-line scan of the virtual filesystem step 204 . In other words, identify and scan all the .vmdk files contained in each of the above-mentioned folders.
[0024] If no problems are encountered in the off-line scan ( 206 ) the method progresses to step 2 , 208 , which will be described in greater detail below. If problems are encountered 210 , the virtual machine image is prevented from going on-line ( 212 ). The virtual machine may then be fixed if necessary at step 214 and the process stops at step 216 .
[0025] The above described step 1 may be sufficient to detect if there is any undesirable software inside any of the virtual machines. For example, if a virus signature is detected, the option of bringing the virtual machine on-line can be stopped. In addition, if undesirable software is identified at this stage it may avoid the necessity to carry out any further analysis and thereby reduce further investigation efforts.
[0026] If there are no problems identified during step 1 , step 2 is carried out. The step 2 will now be described with reference to FIG. 3 . In this step, the virtual machine image is more deeply analyzed, although it is still not exposed to the production environment. The second step does not give rise to complex or expensive certification network requirements. Instead, the analysis is carried out by pre-configuring the virtual machine image so that it cannot access the external network and is not persistently attempting to modify its virtual filesystem (FS).
[0027] In general, the method requires the virtual machine to be powered up and for virtualization APIs to be leveraged to carry out inspections as required, with no formal inventory; or license management agent or infrastructure being required. The specific steps shown in FIG. 3 will now be described. The first step 300 locates all registered virtual machine images on the host. The subsequent steps are then carried out for each virtual machine image identified in this first step 300 . Subsequent step 302 requires that the vmx configuration is set so as to prevent network connectivity. This can be represented in the following manner:
[0000]
>
> ethernet0.startConnected = “FALSE”
> ethernet0.present = “FALSE”
> ..
[0028] In step 304 the vmx configuration is set so that the FS changes will not persist. This can be represented in the following manner:
[0000]
>
> ide0:0.mode = “independent-nonpersistent”
> ide0:1.mode = “independent-nonpersistent”
> ..
[0029] In step 306 the automation APIs are activated and include the following sub-steps:
[0000]
a. power on the VM
> VixVM_Open(localhost, “myVM.vmx”, ..)
b. wait for VM tools to be ready
> VixVM_WaitForToolsInGuest( )
c. log into the VM
> VixVM_LoginInGuest( )
d. copy compliance sensors in the VM (e.g. sw/fs/registry
scanners)
> VixVM_CopyFileInGuest( )
e. execute sensors inside VM and extract results
> VixVM_RunProgramInGuest( )
> VixVM_CopyFileFromGuest( )
f. power off the VM
> VixVM_PowerOff( )
[0030] By carrying out the above-mentioned sub steps, the virtual machine image has been powered up, populated with appropriate sensors or tests and scanned or tested for a series of compliances. In this way, the virtual machine image has remained shielded from the rest of the network environments. The appropriate sensors, tests and compliances will depend on the exact nature of the virtual machine image and the system and method used to produce the virtualization.
[0031] As a result of carrying out steps 302 and 304 , no network activity originates from the virtual machine during the scan. This prevents adverse effects from occurring, for example: possible network worms, unnecessary license compliance broadcasts, unnecessary virus warning broadcasts, etc. In addition, if the virtual machine image passes the compliance check after shut down, no changes to the virtual filesystem of the virtual machine will have been effected. As such, the virtual machine remains intact and is not altered by the injected probes and the execution side-effects that they may produce.
[0032] In summary, the execution of the above-mentioned steps provides a compliance analysis and scanning methodology for off-line virtual machines. The virtual machines are unaffected by the process and are also prevented from causing any major problems in a production environment before becoming fully activated. Examples of compliance checks which may be carried out “on the fly” include, but are not limited to the following: virus detection: software and mandatory patch installation; detection and software compliance based on the software installed. This may also include the license entitlements and guarantees, and the fact that all virtual machines hosted on the same system are similar.
[0033] Returning now to FIG. 3 after automation in the APIs has been activated, if appropriate the virtual machine is prevented from going on-line at step 308 . At step 310 , a decision is made as to whether or not to fix the virtual machine if there are errors or problems associated therewith. If the virtual machine is fixed (yes, step 312 ) the virtual machine may subsequently be loaded into the network at step 314 . This may occur after a further re-run of the earlier steps in FIG. 3 in order to guarantee that the virtual machine is now “good”. If a decision is made not to fix the virtual machine or indeed the virtual machine cannot be fixed (no, step 316 ) then the process is stopped at step 318 and the virtual machine image is isolated.
[0034] Returning now to FIG. 1 , where major problems are identified for a particular virtual machine, this can either be destroyed or isolated as above-mentioned. The isolation can take place in a specific quarantine area which is separated from the host by means of an appropriate firewall 116 or other security means. The specific quarantine area can include a secure host which is similar to hostA. The secure host 118 includes a virtual machine layer 120 and repair and scanning capabilities 122 . As is shown in FIG. 1 , VM 3 has been transferred to the secure host from hostA in order to ensure that VM 3 does not have any adverse effects on the whole network. The secure host may include its own logical storage, VPN, etc. Later, the virtual machine image can be safely networked and updated after all the security issues and software compliancy problems have been fixed.
[0035] It will be appreciated that there will be included in the system modules which carry out each of the functional steps of the method: for example, a testing module which carries out the various compliance or security checks or tests. Other modules will be apparent from the functions they carry out.
[0036] The present invention provides a number of advantages. One of the advantages is that the virtual machine image is prevented from going on-line in the network until all security and compliance of the concerns have been met. The automation APIs can be adapted to suit the circumstances of the virtual machine images and the virtualization system process being used. There is no requirement to use time-consuming and expensive on-line resources in order to validate the virtual machine image. By isolating “bad” virtual machine images, time can be taken in an off-line environment to repair or fix the virtual machine image to avoid risks to the network.
[0037] It will be appreciated that examples other than those described above may exist, which fall within the scope of the present invention. For example, the steps may take place in different orders and by different modules.
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The compliance of a virtual machine image to a set of requirements is determined during a process to potentially introduce the virtual machine image into a network. One or more virtual machine images are identified. During compliance testing, the identified virtual machine image is controlled such that it cannot connect to the network. One or more tests are carried out to determine if the virtual machine image is compliant with one or more predetermined requirements. If a virtual machine is compliant with said one or more predetermined requirements, the virtual machine image is connected to the network.
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CROSS REFERENCE TO RELATED APPLICATION
This application is a divisional of co-pending application Ser. No. 10/932,325, now U.S. Pat. No. 7,334,394, filed Sep. 1, 2004.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
This invention was made with Government support under NAS3-02116 awarded by NASA. The government has certain rights in the invention.
BACKGROUND OF THE INVENTION
The present invention relates to the control of high-velocity fluid streams, such as those present in core and fan streams exhausting a gas turbine engine, and more particularly to the manipulation of such fluid streams through localized arc filament plasmas to affect noise radiation from and mixing rate in the mixing layers of these streams.
Noise radiation from an aircraft gas turbine engine is the dominant component of noise during takeoff and a major component during landing. As such, it is becoming an important issue for both commercial and military aircraft that are operating at considerably closer proximity to population centers, as there is mounting pressure to reduce noise propagated to adjacent communities. Commercial subsonic aircraft engine manufacturers have been able to satisfy increasingly stringent environmental noise regulations by using larger by-pass ratio engines. Unfortunately, the sheer physical size of current commercial subsonic aircraft engines is such that even larger bypass ratio engines are not practical. Additionally, in future supersonic commercial aircraft and also in high-performance military aircraft, large bypass ratio engines are not a viable option because of the performance penalties that such a design would incur.
It has been known for quite some time that large-scale coherent structures in jets are responsible for the entrainment and mixing of exhaust systems, and that their dynamical processes are responsible for a major portion of far field noise radiation. Research has indicated that these large-scale spanwise coherent structures in two-dimensional or ring-like coherent structures in axisymmetric jets or mixing layers, become more three-dimensional and less coherent as the compressibility level (which is generally proportional the ratio of velocity difference across the mixing layer to the average speed of sound in the two streams) is increased. This phenomenon renders these structures less amenable to control strategies similar to those traditionally used in incompressible and low Reynolds number flows. In contrast to these large-scale structures, longitudinal (streamwise) large-scale vortices do not seem to be much affected by compressibility. Thus, the use of streamwise vortices appears to be a logical approach in controlling mixing and consequently controlling the far field acoustic radiation in highly compressible jets.
In the past, several techniques have been explored in generating streamwise vortices. For example, small tabs or chevrons attached to the nozzle exit and used as streamwise vortex generators were found to be an effective device in enhancing mixing and altering noise characteristics in both incompressible and compressible jets, due to the presence of a spanwise pressure gradient set up in front of a tab, which since it protrudes into the flow, generates a spanwise pressure gradient regardless of whether the flow is subsonic or supersonic. In addition to streamwise vortices generated due to the spanwise pressure gradient, the streamwise pressure gradient generated by a tab promotes the development of robust spanwise vortices. Although the use of tabs and related protrusions to enhance mixing is effective in both incompressible and compressible flows, such use results in thrust losses due to the blockage effects. Gentler tabs, such as chevrons, can be used to reduce this thrust loss; however, their smaller profile necessitates weaker streamwise vortices and thus less mixing enhancement or noise alteration. Moreover, it is also beneficial to minimize the performance penalties associated with flowstream protrusions by having them deploy only during certain operational conditions (for example, during takeoff and landing in aircraft applications). Such an on-demand system requires complex tabs/chevrons geometries, ancillary actuation hardware and controllers, thereby exacerbating system complexity, weight and cost.
An alternative technique for generating streamwise vortices is the use of simple nozzle trailing edge modifications or cutouts. These cutouts are similar to chevrons, except that they do not protrude into the flow. Prior research has shown that such modifications have been effective in producing streamwise vortices that in turn generate enhanced mixing in incompressible axisymmetric jets, although the effectiveness of trailing edge modifications heavily depend on the flow regime. It was found that the use of trailing edge modifications enhanced mixing significantly in the underexpanded cases and moderately in the overexpanded cases. It was also found that the trailing edge modified nozzles substantially reduced the broadband shock associated noise radiation for both the underexpanded and overexpanded flow regimes, but did not significantly alter the noise field for the ideally expanded flow condition. While it is believed that the mechanism employed by nozzle trailing edge modifications to produce streamwise vortices is still a spanwise pressure gradient, it appears that such effects are relatively small in subsonic jets and heavily flow regime-dependent in supersonic jets. There is also evidence that trailing edge modifications exhibit a strong effect on the rate of jet mixing and thus noise radiation.
Another technique involves the use of fluidics, where pressurized fluid (typically air) is introduced into the flowpath to force an instability therein. Fluidic injection has not been entirely successful for use in high-speed flows for two main reasons. First, instability frequencies in high-speed flows are quite high, which necessitates that any actuation mechanism must possess high bandwidth capability. Second, fluid flows with high Reynolds numbers (such as those found in high subsonic and supersonic flow velocities) possess large dynamic loading within a noisy environment, which require high amplitude forcing. The lack of the availability of actuators with high bandwidth and high amplitude has been one of the main obstacles in fluidic control of high-speed flows. Efforts have been made to force shear layers in high Reynolds number at the jet column frequency; however, the required forcing amplitude is much higher than that used traditionally. Similarly, efforts have been made to develop high bandwidth and amplitude fluidic actuators. The main drawback of such fluidic actuators is the difficulty of establishing a reference time (or phase), for without such a reference time, the actuators cannot be used to force various azimuthal modes in axisymmetric jets. Since it is believed that certain of these azimuthal modes are instrumental in achieving noise reduction, the presence of an actuator that can excite such instabilities is highly desirable.
Still another technique that has been used in recent years exploits electric discharge plasmas for flow control. In a typical plasma-based approach, intense, localized and rapid heating is produced in the high-current pulsed electric discharges and pulsed optical discharges. This rapid near-adiabatic heating results in an abrupt pressure jump in the vicinity of the current-carrying filament. These pressure jumps in turn produce shock waves in supersonic flows, which can considerably modify the supersonic flow over blunt bodies and in supersonic inlets. Therefore, the rapidly heated regions act similar to physical geometry alterations (such as the tabs and trailing edge cutouts discussed earlier) in the flow but do so for short time durations. Various methods of plasma generation, including direct current (DC), alternating current (AC), radio frequency (RF), microwave, arc, corona, and spark electric discharges, as well as laser-induced breakdown, have been used to initiate plasma-based fields for flow control.
Previous investigations into plasma-based flow control have mainly focused on viscous drag reduction and control of boundary layer separation in low-speed flows, as well as shock wave modification and wave drag reduction in supersonic and hypersonic flows. In the previous high-speed research, spatially distributed heating induced by AC or RF glow discharges has been used to produce weak disturbances in the supersonic shear layer or to weaken the oblique shock in the supersonic inviscid core flow. These experiments have been conducted at fairly low static pressures, for example, at stagnation pressures of between 0.3 and 1.0 atmosphere with Mach numbers between two and four. This allowed initiating and sustaining diffuse glow discharges, which weakly affected relatively large areas of the flow. The main mechanism of the plasma flow control in these previous studies is heating of the flow by the plasma. In low-speed flows, the dominant plasma flow control mechanism is flow entrainment due to momentum transfer from high-speed directed motion of ions (i.e. electrical current) to neutral species (i.e. bulk flow) in the presence of a strong electric field. At these conditions, the ion velocity can be very high (for example, approximately 1000 meters per second for typical electric fields of 10 kilovolts per centimeter at one atmosphere). Although this approach was demonstrated to significantly vary the skin friction coefficient and to control the boundary layer separation in low-speed flows (at flow velocities up to a few meters per second), its applicability to high-speed flows is unlikely. The main disadvantage of this technique is that the ion number density in non-equilibrium plasmas is very low (for example, typical ionization fractions n i /N are between approximately 10 −8 and 10 −6 ), which limits the momentum transfer to the neutral species flow; such limited momentum transfer is not conducive for high flow velocities. Another disadvantage of this approach is the high power consumption of non-equilibrium plasmas (typically between approximately 10 to 100 watts per cubic centimeter), due to the fact that only a very small fraction of the total input power (often well below 1%) goes to direct momentum transfer from the charged species to the neutral species. The rest of the power (more than 90%) is spent on excitation of vibrational and electronic levels of molecules by electron impact, followed by flow heating during relaxation processes. This makes affecting large areas of the flow by such plasmas prohibitively expensive.
What is needed are actuators that can exploit streamwise vorticity generation, manipulation of jet instabilities, or a combination of the two techniques to facilitate noise reduction and flow mixing in high speed fluid flow environments. What is also needed are such actuators that can provide high amplitude, high bandwidth forcing while simultaneously being capable of withstanding harsh environments, such as those found in air-breathing turbomachinery and related power-generating equipment. What is additionally needed are actuators that do not interfere with fluid flow in the jet by protruding into the jet stream.
SUMMARY OF THE INVENTION
These needs are met by the present invention, where one or more localized arc filament plasma actuators (in the form of paired electrodes) include both high amplitude and high bandwidth without requiring the use of high-power pulsed lasers, focused microwave beams, or electrodes protruding into the flow. The present inventors have discovered that the use of repetitively pulsed high-energy discharges emanating from electrodes spatially distributed on a conduit surface can produce streamwise vortices of desired distribution and kind. As previously mentioned, flow perturbations can produce spanwise vortices where, due to the nature of jet flow, they are generated naturally by jet instabilities. Thus, while the inventors' intent focuses on the generation and use of streamwise vorticity, it will be appreciated by those skilled in the art that the production of spanwise vorticity could also have utility, and that the present invention could be adapted to enhance or weaken such spanwise vorticity, depending upon the application. The present invention can be configured to distribute electrodes and energize them with proper excitation frequencies in such a way as to influence shear layer instabilities.
The present inventors have discovered that the use of repetitively pulsed high-energy discharges can produce strong localized pressure perturbations in subsonic and supersonic flows, at static pressures of 1.0 atmosphere, with no fundamental limitations at higher or lower pressures. These localized pressure perturbations are hefty enough to effectively act like a physical obstacle (such as a flap, tab or the like) suddenly placed in the flowpath. In the present context, the term “localized” and its variants represent changes made in the area of the duct, conduit or related flowpath that is immediately adjacent the electrodes or related plasma-producing terminals. The proximity of the plasma to the solid surface (i.e., the nozzle wall) greatly improves plasma stability, reducing the chance of plasma being blown off by the incident high-speed gas (such as air or exhaust gas) flow. Repetitive pulsing of the discharge would enable control over these pressure perturbation obstacles by having an arc filament initiated in the flow generate rapid (on the time scale of down to a few microseconds) localized heating up to high temperatures, which produces a concomitant localized pressure rise in the flow near the electrodes. Consequently, when the arc filament is on, the electrode functions as the aforementioned physical obstacle, similar to a small tab inserted into the flow. Advantages associated with the present invention include: the ability of the electrodes to modify the flow field on-demand, thereby allowing the electrodes to be turned on and off to minimize power consumption and potential losses when actuation is not necessary; avoidance of changing the geometry of the flowpath; avoidance of using moving parts that can wear out; and the controlling of mixing and noise in the jet by either excitation of flow instabilities, generating streamwise vorticity of desired frequency and strength, or by a combination of the two techniques.
Regarding the excitation of flow instabilities (such as the aforementioned shear layer instabilities), the present inventors have determined that the electrodes of the present invention can excite axisymmetric and azimuthal instabilities in high-speed jets for noise mitigation and mixing control, as well as demonstrating that streamwise vortices can be generated in non-axisymmetric (for example, rectangular) exhaust nozzles in subsonic or supersonic flow conditions. While the present inventors have tested the technique in limited geometries and flow conditions, there is no physical limitation imposed on the technique in terms of Mach number or the nozzle geometry.
According to a first aspect of the invention, a fluid stream flow modification system is disclosed. The system includes a fluid stream conduit configured to receive flowing fluid from a fluid source, and an arc generator cooperative with the conduit such that upon system operation, an arc filament plasma is formed that produces a localized perturbation in a portion of the fluid stream. The arc generator includes numerous electrodes disposed adjacent the fluid stream. The arrangement of the electrodes is such that they do not substantially protrude into the fluid stream, thereby by avoiding unnecessary flow disturbances. This unobtrusive profile, coupled with the on-demand nature of the flow perturbations, results in overall improvements in the flow of fluid in the stream. The electrodes produce localized (rather than global) perturbation that generates streamwise vorticity in the localized portion of the fluid stream. As previously mentioned, spanwise vortices are generated naturally by jet instabilities, and the present invention can be configured to enhance or weaken these spanwise vortices as needed. In addition to the electrodes, the system includes an energy source that can impart enough energy to the electrodes such that an arc filament plasma capable of generating the localized perturbation is formed.
In one optional embodiment, the energy source is an electric current source capable of high voltage operation. In one form, the electrodes are placed substantially flush with the surface of the conduit adjacent the fluid stream. Thus, for example, where the conduit is a duct, the electrodes form a substantially flush fit with the inner duct wall. The electrodes can be configured as an array of one or more rows, where configurations employing a plurality of rows can be arranged such that each successive row is axially downstream in the conduit relative to its immediately preceding row. In another form, the electrodes can be disposed adjacent a trailing edge of the conduit, as well as about the conduit's periphery. In configurations where the conduit is a duct, both substantially axisymmetric and non-axisymmetric constructions are possible, where in the latter, the duct could be, among other shapes, rectangular. In the present context, the term “substantially” is utilized to represent the inherent degree of uncertainty that may be attributed to any quantitative comparison, value, measurement, or other representation. As such, it refers to an arrangement of elements or features that, while in theory would be expected to exhibit exact correspondence or behavior, may in practice embody something slightly less than exact. The term also represents the degree by which a quantitative representation may vary from a stated reference without resulting in a change in the basic function of the subject matter at issue.
In another option, a controller can be coupled to the generator such that the generation of the localized perturbations at the electrodes occurs at predetermined times. For example, the electrodes can be energized either simultaneously or at staggered time intervals. Such staggering can promote the excitation of a desired instability or related perturbation pattern. The resistance of the conduit to the excess heat generated by the arc filaments can be made enhanced by various approaches. In one, the conduit can be made from a refractory material, such as a ceramic or ceramic composite. In another, a coolant supply can be placed in heat exchange relationship with the conduit to avoid excessive temperatures.
A significant difference of the localized arc filament plasma electrodes of the present invention over plasma electrodes developed previously (such as surface glow discharge-based devices) is that the present electrodes are designed to generate localized, high-temperature arc filaments rather than large surface area, low-temperature, non-equilibrium plasmas. Applying high voltage of select frequency to the electrode would generate a periodic arc and corresponding Joule heat release, resulting in high-frequency excitation of the flow. In addition, using two or more properly phased electrodes at the same time would allow excitation of specific flow instabilities (for example, azimuthal modes) by varying both the excitation frequency and the phase shift between individual electrodes. This effect, together with the small size of the filaments would make it possible to produce significant changes in the flow without a concomitant level of power consumption. Thus, two of the electrodes can be configured to cooperate with each other to define an actuator that produces the arc filament that in turn produces the localized perturbation. In a similar way, two (or more) electrodes could each be coupled to a ground electrode to define the actuator.
According to another aspect of the invention, an exhaust system is disclosed. The system includes an exhaust duct defining an exhaust stream flowpath surface, and an arc generator cooperative with the exhaust duct. Activation of the arc generator during the flow of the exhaust stream causes an arc filament plasma to be formed, which in turn produces a localized perturbation in a portion of the exhaust stream that is adjacent the arc filament formed around the electrodes. The arc generator is made up of a plurality of electrodes disposed adjacent the portion of the exhaust stream. As before, the electrodes do not substantially protrude into a flowpath defined by the exhaust stream. The electrodes are arranged such that when energized, the localized perturbation generates streamwise vorticity in the portion of the exhaust stream nearest the electrodes. In addition to the electrodes, the arc generator includes an energy source coupled to the electrodes and configured to impart enough energy to them such that an arc filament plasma capable of generating the localized perturbation is formed.
Optionally, the electrodes are disposed in the exhaust duct to define a substantially flush fit with the inner (exhaust stream flowpath) surface. As with the previous aspect, the exhaust duct can be substantially axisymmetric or substantially non-axisymmetric. Also as before, the electrodes are arranged around a substantial periphery of the exhaust stream flowpath surface. A controller can be coupled to the arc generator to energize the electrodes according to a predetermined sequence; such an arrangement is beneficial in exciting certain flow instabilities in the exhaust stream. In one form, the energy source is an electric current source capable of delivering high current between adjacent electrodes. At least a portion of the electrodes can be grouped such that a pair (or more) within the group defines an actuator. In a preferred embodiment, the groups of electrodes are formed in pairs. The aforementioned actuators, which can be placed in many duct configurations (including axisymmetric and non-axisymmetric ones) are configured to produce the arc filament plasma that produces the localized perturbation.
According to yet another aspect of the invention, a propulsion system is disclosed. The propulsion system includes a gas generator and an exhaust system in fluid communication with the gas generator. The exhaust system includes an exhaust duct defining an exhaust stream flowpath surface, and an arc generator cooperative with the exhaust duct. When the arc generator is activated while exhaust gas is flowing through the duct, an arc filament plasma is formed that produces a localized perturbation in the exhaust stream. The arc generator includes numerous electrodes disposed adjacent the exhaust duct. As before, the electrodes are placed such that they do not substantially protrude into the exhaust stream. The arrangement of the electrodes permits the localized perturbation to generate streamwise vorticity in the effected portion of the exhaust stream. As previously discussed, an energy source coupled to the electrodes is configured to impart enough energy to them so that an arc filament plasma capable of generating the localized perturbation is formed. Optionally, the gas generator is a gas turbine engine comprising a compressor, a combustor and turbine. In addition, at least a portion of the electrodes can be arranged in groups (such as the aforementioned pairs) such that each group or pair defines an actuator. Two or more of the electrodes can be arranged to be electrically coupled to a common ground electrode. It will be appreciated by those skilled in the art that such a common ground electrode arrangement is equally applicable to the other aspects of the invention disclosed herein.
According to still another aspect of the invention, a method of reducing noise emanating form a flowpath is disclosed. The method includes flowing a fluid along the flowpath and generating an arc filament plasma at one or more locations along the flowpath to produce at least one localized perturbation in a portion of the flowpath, the localized perturbation configured such that upon its production, streamwise vorticity is formed in the portion of the flowpath.
Optionally, the flowpath is defined by a conduit (such as an enclosed duct). To generate an arc filament plasma, the method includes operating an arc generator such that upon activation of the generator, an arc filament is formed that produces the localized perturbation in fluid flowing through the flowpath. In a more specific option, the arc generator includes a plurality of electrodes disposed adjacent the flowpath in an unobtrusive way. In addition, the arc generator includes an energy source coupled to the electrodes and configured to impart enough energy to them such that the arc filament plasma capable of generating the localized perturbation is formed. The method may further comprise arranging the electrodes in the conduit to define a substantially flush fit with the surface of the conduit adjacent the flowpath, as well as arranging them around a substantial periphery of the flowpath. As before, the conduit can be a substantially axisymmetric exhaust duct or a substantially non-axisymmetric exhaust duct. In addition, the arc generator can be operated to energize the electrodes according to a predetermined sequence, frequency or both in order to excite flow instabilities in the flowpath. In one example, the electrodes can be operated to be in phase (simultaneously on or off) with each other, or out of phase with each other. In one form, the energy source is an electric current source. In addition, the electric current source can operate at alternating current frequencies of up to hundreds of kHz, and voltages of up to tens of thousand volts. Moreover, the arc filament plasmas can be used to generate the localized flow perturbations via very rapid heating. For example, by taking as low as a few microseconds to cause the heating of the adjacent fluid, a highly desirable localized accompanying pressure jump is formed to effect the requisite flow perturbation that is otherwise not possible with large surface area, low-temperature, non-equilibrium plasmas. The method of reducing noise may further include exciting jet instabilities within the flowpath by generating the arc filament plasma with predetermined forcing frequencies that match the initial shear layer instabilities or as high as frequencies associated with the flow structures in inertial subrange. For example, the forcing frequency can be from tens of kilohertz (kHz) to hundreds of kHz in a laboratory environment.
According to another aspect of the invention, a method of mixing fluid within a flowpath is disclosed. The method includes flowing fluid through a conduit and operating an arc generator to cooperate with the conduit such that upon activation of the generator during the flow of the fluid through the conduit, an arc filament plasma is formed that produces a localized perturbation in a portion of the fluid stream. The arc generator includes a plurality of electrodes disposed adjacent the portion of the fluid stream being perturbed. As before, the electrodes do not substantially protrude into the fluid stream, and are arranged such that the localized perturbation generates at least one of streamwise vorticity or excitation of flow instabilities in the portion of the adjacent fluid stream. Also as before, an energy source is coupled to the electrodes to impart the energy needed to form the localized perturbation. Optionally, the arc generator can be operated to energize the electrodes according to a predetermined sequence in order to introduce streamwise vorticity and excite flow instabilities in the flowpath.
According to another aspect of the invention, a method of using an arc filament plasma discharge to control the flow of exhaust gas in a propulsion system is disclosed. The method includes flowing fluid through an exhaust duct and operating an arc generator to cooperate with the exhaust duct such that upon activation of the generator during the flow of the exhaust gas through the exhaust duct, an arc filament plasma is formed that produces a localized perturbation in the exhaust gas. The arc generator includes a plurality of electrodes disposed adjacent the portion of the exhaust gas such that the electrodes do not substantially protrude therein, the electrodes arranged such that the localized perturbation can impart substantial streamwise vorticity in the portion of the exhaust gas; and an electric current source coupled to the electrodes and configured to impart enough energy thereto such that an arc filament plasma capable of generating the localized perturbation is formed. As previously discussed, the exhaust duct can be substantially axisymmetric or substantially non-axisymmetric. In addition, the electrodes can be arranged in groups such that each group defines an actuator. In a more particular form of this arrangement, two or more of these electrodes can be electrically coupled to a common ground electrode. In another configuration, each actuator may be made up of a pair of electrodes.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
The following detailed description of the preferred embodiments of the present invention can be best understood when read in conjunction with the following drawings, where like structure is indicated with like reference numerals and in which:
FIG. 1A illustrates a schematic arrangement of a pair of plasma actuators with a common ground electrode according to an aspect of the present invention as placed in a rectangular exhaust nozzle;
FIG. 1B illustrates a perspective view of an electrode array placed in a rectangular exhaust nozzle;
FIG. 2A illustrates an axial view of the formation of streamwise vortices produced by the operation of the electrode arrangement of FIG. 1A ;
FIG. 2B illustrates an axial view of the formation of a spanwise pressure rise produced by the operation of the electrode arrangement of FIG. 2A ;
FIG. 3 illustrates current traces of two actuators from the array of FIG. 1B operating out of phase from one another;
FIG. 4A illustrates a cross section of a jet deformed by the plasma actuators configuration of FIG. 1A ;
FIG. 4B illustrates a cross section of a jet deformed by a large tab according to the prior art;
FIG. 5A illustrates four electrode pairs, two on the top and two on the bottom of an axisymmetric exhaust nozzle extension;
FIG. 5B illustrates a simplified perspective view of the nozzle extension of FIG. 5A ;
FIGS. 6A and 6B illustrate how the actuators of the present invention can be used to excite jet instabilities in the axisymmetric exhaust nozzle of FIGS. 5A and 5B to organize structures and to increase entrainment and mixing;
FIGS. 7A and 7B illustrate how the actuators of the present invention can be used to excite jet instabilities in the axisymmetric exhaust nozzle of FIGS. 5A and 5B to reduce entrainment, mixing, and noise;
FIG. 8 illustrates spatial correlation of images similar to those of FIGS. 6A , 6 B, 7 A and 7 B, and how excitation of the instabilities via the actuators is coupled into the flow; and
FIG. 9 illustrates a turbofan engine into which electrodes according to the present invention are notionally placed.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring first to FIGS. 1A and 1B , a schematic of a localized arc filament flow control system 1 is shown. The system 1 includes a conduit (shown in the form of a rectangular exhaust nozzle extension 10 ) configured as a fluid flowpath 15 , and an arc generator 20 . The system 1 includes copper or steel pin electrodes 60 shown embedded into the flowpath surface 12 of exhaust nozzle 10 . Electrodes 60 are substantially flush mounted into surface 12 in order to avoid protruding into the flowpath 15 . In one embodiment, each electrode 60 is two millimeters in diameter, connected to arc generator 20 through appropriate wiring 25 . In a preferred form, each pair of electrodes that are used together to complete a circuit cooperate as an actuator. The actuator can be placed in numerous locations within the exhaust nozzle 10 , thus permitting tailoring of the position of the generated arc filament plasma. Additional equipment making up the arc generator 20 include amplifiers 30 , transformers 40 and ballast resistors 50 . In the embodiment shown, two electrodes 60 share a ground electrode that is electrically coupled to ground 80 to complete the electric circuit that passes through either or both electrodes 60 . In a preferred embodiment, the exhaust nozzle 10 is made from a non-conducting refractory material (such as a ceramic or ceramic composite) to best resist the localized high temperature regime produced by the electrodes 60 . A cooling system (not shown) can be placed in heat exchange relationship with the exhaust nozzle 10 to keep local surface temperatures below the maximum nozzle operating temperature. The use of cooling air from a compressor bypass or a fan duct to cool exhaust duct liners and nozzle flaps, as used in conventional gas turbine engine exhaust systems, could be employed. The electrodes 60 can be configured as an array of pairs, forming an actuator. Each actuator then can be powered with variable frequency (up to hundreds of kHz) and amplitude. The array could then be tailored to the needs of specific flow regimes, including those for aircraft exhaust systems designed to fly with subsonic and supersonic Mach numbers, including both current civil subsonic and future supersonic aircraft, as well as military aircraft. An additional benefit of the electrodes 60 is that they are equally applicable whether the fluid environment is hot (such as encountered in the exhaust duct of a typical aircraft) or cold.
Referring with particularity to FIG. 1B , the dimensions of the exhaust nozzle 10 of the experimental setup is described as follows. The exit dimensions are one-half inch high by one and one-half inches across, producing an aspect ratio of three. It will be appreciated by those skilled in the art that while the present inventors incorporated an experimental setup with exhaust nozzle 10 that were configured to operate at three discreet Mach numbers, specifically Mach 0.9, 1.3 and 2, that other Mach numbers, nozzle dimensions, aspect ratios and shapes are within the scope of the present invention. The electrodes 60 are formed in rows, where each of the electrodes are four millimeters apart in the spanwise direction, while adjacent rows are spaced six millimeters apart in the streamwise direction. The downstream row of electrodes are spaced four millimeters from the trailing edge of the exhaust nozzle 10 . Referring with particularity to FIG. 1A , the configuration of the remainder of the experimental setup is described as follows. The electrodes were powered by a Powertron 3 kilowatt, high-voltage (up to 15 kV root mean square (rms)), variable frequency (2 to 60 kHz) AC power supply, which included the two individually excited amplifiers 30 and two-arm step-up transformer 40 . The power supply generated two high-voltage output signals used to generate a pair of either streamwise or spanwise arc filaments in the flowpath of the exhaust nozzle 10 . The power supply frequency and the phase shift between the two AC excitation signals could be independently varied. Experiments were conducted in ideally expanded Mach 0.9, 1.3 and 2.0 flows with exhaust nozzle 10 exit static pressure of one atmosphere. Two spanwise arc filaments, lined up in the spanwise direction shown, were generated at the AC voltage frequency of 10 kHz, in phase with each other. Since the arc is initiated twice during each period, in both positive and negative peak voltages, the forcing frequency at these conditions in this specific embodiment is 20 kHz. At all experimental conditions, the arcs were stable and were not blown off by fluid in the flowpath 15 exiting the exhaust nozzle 10 . Flow visualization was used to assess the effects of forcing on the fluid (air) flowing through exhaust nozzle 10 . While these experiments were carried out using the rectangular nozzle shown at airflow Mach numbers of 0.9, 1.3 and 2.0 under ideally expanded conditions, the electrodes 60 are equally applicable to an axisymmetric exhaust structure, as well as to other flow velocities, as will be shown and discussed later.
Referring next to FIGS. 2A and 2B , the effects of the localized perturbations on the formation of streamwise vortices and the induced pressure patterns are shown. When electrodes 60 are energized, the arc filament plasma 90 formed in the region between the electrodes 60 mimics the presence of a physically rigid body placed in the flowpath. This causes a pressure profile P to form upstream of the arc filament plasma 90 . This profile P promotes the formation of the pair of localized streamwise vortices 95 . Although not shown for an axisymmetric nozzle configuration, it will be appreciated by those skilled in the art that the general principles behind pressure profile buildup and consequent streamwise vorticity formation are similar. The same holds true also for any flow Mach number.
Control of excitation frequency, amplitude and duty cycle of the electrode pairs 60 , as well as phase shift between adjacent electrode pairs 60 using the variable frequency AC power supply is fairly straightforward. FIG. 3 shows the time-dependent current traces in two arc filaments generated in a Mach 1.3 jet flow when they are operated at the AC voltage frequency of 10 kHz and out of phase with one another. Indeed, it can be seen that the current in filament A reaches maximum (about 0.4 A) when the current in filament B approaches zero (i.e. when the arc is extinguished). This shows that by varying the phase shift between the two AC excitation signals, periodic Joule heat release patterns in multiple filaments can be accurately controlled. It can likewise be seen that the heat release pattern is indeed periodic at a frequency equal to double the input AC voltage frequency in this specific embodiment. Most importantly, the time-averaged power at these conditions is only about 180 Watts, with a substantial fraction of that being dissipated in a 500 ohm ballast resistor connected in series with the electrode gap to stabilize the discharge. The time-averaged power generated in the discharge gap and actually coupled to the flow is only about 50 W per pair of electrodes 60 . Comparing this to a kinetic energy flux of the jet of about 22 kW in this laboratory experiment (based on a mass flow rate of 0.3 kilograms per second and flow velocity 380 meters per second) at these conditions reveals that the total plasma power requirement per electrode 60 pair is about 0.8% of the flow power, while the power coupled to the flow by every electrode 60 pair is only about 0.2% of the flow power, thus demonstrating the highly energy efficient nature of the present process. Moreover, this is scalable to high mass flow rate flows. Also, unlike non-equilibrium plasmas, small high-temperature arcs are not subjected to various instabilities, which make possible their use at pressures exceeding one atmosphere.
FIG. 4A shows an average image of an ideally expanded Mach 1.3 rectangular exhaust nozzle with the two plasma actuators of FIG. 1A turned on at forcing frequency of 20 kHz. The image is an average of 25 instantaneous (9 nanosecond exposure time) images obtained using a pulsed Neodymium Yttrium Aluminum Garnet (Nd:YAG) laser operating at a frequency of 10 Hz (the total run time of about 2.5 sec). The laser pulses were not phase-locked with the AC voltage and thus the average is obtained from 25 consecutive instantaneous images. A sheet of spanwise light was passed orthogonal to the exhaust jet centerline along the Y-axis at eight jet heights along the X-axis (where the jet height is one half inch) downstream of the exit. The bright region in the images is the jet mixing layer, where line 90 is shown to track the general shape of the flow deformation induced by the energized electrodes. The bright region in the figure is illuminated via scattering of the laser light by the order of 50 nanometer water particles in the mixing layer. These particles are generated by condensation of moisture in the entrained ambient air when it mixes with the cold and dry jet air. The shape of a nearly rectangular mixing layer is deformed due to the presence of the pair of streamwise vortices (previously shown schematically in FIG. 2A ). In addition to the deformation, it can be seen that the scattered light intensity in the lower part of the mixing layer dramatically increases. This implies significant increase of the entrained ambient air into the mixing layer due to streamwise vortices generated by the electrodes. The plasma actuators turn on and off, thereby generating streamwise vortices and causing intermittent deformation in the jet cross section. FIG. 4B shows a similar behavior of an axisymmetric Mach 1.3 jet cross section when a large tab is placed in the jet flowpath. In contrast to the intermittent vortices formed by the plasma actuators of FIG. 4A , the large tab generates a pair of streamwise vortices continuously, causing concomitant continuous deformation in the jet cross section. The size of the tab is a big factor in the strength of the streamwise vortices and jet deformation.
Referring next to FIGS. 5A and 5B , in addition to being used for the generation of streamwise vortices, the present electrodes 160 could be used in an axisymmetric exhaust nozzle 110 for excitation of jet instabilities, where four pairs of electrodes 160 are located around portions of the nozzle flowpath. It will be appreciated by those skilled in the art that any jet flow, whether through an axisymmetric or rectangular conduit (or any other shape), has certain inherent instabilities. By providing disturbances with a frequency associated with one of the instabilities in the flow, the disturbances will grow and affect the flow. By keeping the distance between two electrodes very small, or by lining them up in streamwise direction, the generated streamwise vortices can be made very small or virtually eliminated. Turning the electrodes on and off with a preferred frequency will have the effect of exciting a particular jet instability. In the present example, the exit diameter D of the experimental exhaust nozzle 110 (also designed for Mach 0.9, 1.3 or 2.0 flow speeds) was set at one inch. As previously mentioned, the electrodes 160 can be operated either in phase or out of phase with respect to one another. Time resolved pressure measurements with the present configuration revealed an initial jet shear layer instability frequency of about 60 kHz for the baseline jet.
FIGS. 6A and 6B show instantaneous jet streamwise images (approximately 9 nanosecond exposure time) of Mach 1.3 ideally expanded jet for the baseline case of FIG. 6A (where the electrodes are turned off) and for the operating case of FIG. 6B (where all four electrode pairs are energized and operating in-phase and forcing the jet at 10 kHz). The tic marks are one nozzle exit diameter (D) apart, with the first one located at ID. As can be seen in FIG. 6A , the baseline case has large scale structures that are not organized and are distributed randomly in space. Contrarily, in FIG. 6B exciting the jet instabilities with plasma actuators regulates the structures into spatially quasi-periodic structures, where the wavelength (spacing) of large scale structures is commensurate with the 10 kHz forcing frequency. This forcing frequency is twice the jet column instability frequency, but still within the jet column excitation frequency range. In such an excited state, the entrainment and mixing will increase. As before, only the mixing region is visualized and the intensity of light in the mixing region is directly related to entrainment of the moist ambient air into the jet.
FIGS. 7A and 7B show instantaneous jet streamwise images (approximately 9 nanosecond exposure time) of Mach 1.3 ideally expanded jet for the baseline case of FIG. 7A (where the electrodes are turned off) and for the operating case of FIG. 7B (where all four electrode pairs are energized and operating in-phase and forcing the jet at 60 kHz). As with FIGS. 6A and 6B , the tic marks are one nozzle exit diameter (D) apart, with the first one located at 1 D. While FIG. 7A is the same as the image in FIG. 6A , showing the baseline case, FIG. 7B shows an image of the same jet but with much smaller structures and much less entrainment and mixing, due to the higher excitation frequency that is coupled to the flow. This forcing frequency is close to jet initial shear layer instability frequency and would find many applications, especially in relation to jet noise reduction. Since the presence of large scale structures are responsible for a major portion of jet noise, any reduction in the dynamics associated with such structures would produce a concomitant reduction in jet noise.
If the convective velocity and the spacing (or the wavelength) of large-scale structures shown in the images of FIGS. 6A , 6 B, 7 A and 7 B are determined, one can then obtain approximate shedding frequencies of these structures and thus the response of the jet to forcing. The spacing between the structures can be determined manually from the images, or could be obtained using spatial-correlation of the images. Referring next to FIG. 8 , the average spatial correlation over 50 instantaneous streamwise images similar to those in FIGS. 6 and 7 is shown. Spatial correlation is a statistical technique which shows quantitatively how well organized or how random the large scale turbulence structures in a given flow is. If there is no organization of structures, then the peak correlation level of 1 at zero x/D separation in FIG. 8 will continuously drop as the separation is increased. This is typical of the baseline case with actuators off. If structures are well organized, then following 1 at zero x/D, the correlation will decrease with x/D, but will go through local peaks and valleys, as is the case for example for actuators operating at 9 kHz. The distance between two peaks or valleys is directly related to the forcing frequency. These results are consistent with the flow visualization results shown in FIGS. 7A and 7B .
The distance between the local maxima in FIG. 8 is equivalent to the spatial wavelength (or the spacing) of the periodic structures. This wavelength can be used along with the convective velocity of the structures to determine the shedding frequency of the structures. The average convective velocity for this jet was measured at 266 meters per second. The measured average convective velocity was used along with the spatial wavelength determined from FIG. 8 to estimate the shedding frequency of the structures in the forced jet. It is clear from the results that the jet responds to the plasma actuator forcing, where robust quasi-periodic structures develop with strong spatial correlations at lower forcing frequencies, and much smaller and less robust structures at higher forcing frequencies. Accordingly, the actuators have wide bandwidth and strong authority to force the jet at any of its instabilities and affect the jet in any desired fashion.
Referring next to FIG. 9 , a simplified schematic of a turbofan engine used to power an aircraft is shown. The engine 1000 includes an inlet 1100 , fan 1200 , compressor 1300 , combustor 1400 , turbine 1500 (typically including a high pressure turbine 1510 and a low pressure turbine 1520 ) and exhaust nozzle 1600 . Cowling 1700 is used to shroud most of the engine 1000 , while the fraction of the air passes through the core (the latter of which is made up of the aforementioned compressor 1300 , combustor 1400 , turbine 1500 and exhaust nozzle 1600 ) with the remainder bypassed through the fan 1200 between the core and the cowling 1700 . The air exiting the exhaust nozzle 1600 generate two mixing regions, where noise is generated, one between the core flow and the fan flow and another between the fan flow and the ambient air. Electrodes 1060 according of the present invention would be placed in the ducting that makes up the exhaust nozzle 1600 . A representative placement of the electrodes 1060 in the core and fan flow (without the remainder of the flow control system) is shown along the outer wall of the flowpath of the core nozzle and the fan nozzle, respectively, of the exhaust nozzle 1600 . Cooling air for portions of exhaust nozzle 1600 situated adjacent electrodes 1060 could be provided by bleeding off portions of air produced by compressor 1300 or bypass air produced by fan 1200 .
Having described the invention in detail and by reference to preferred embodiments thereof, it will be apparent that modifications and variations are possible without departing from the scope of the invention defined in the appended claims. More specifically, although some aspects of the present invention are identified herein as preferred or particularly advantageous, it is contemplated that the present invention is not necessarily limited to these preferred aspects of the invention.
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A device for controlling fluid flow. The device includes an arc generator coupled to electrodes. The electrodes are placed adjacent a fluid flowpath such that upon being energized by the arc generator, an arc filament plasma adjacent the electrodes is formed. In turn, this plasma forms a localized high temperature, high pressure perturbation in the adjacent fluid flowpath. The perturbations can be arranged to produce vortices, such as streamwise vortices, in the flowing fluid to control mixing and noise in such flows. The electrodes can further be arranged within a conduit configured to contain the flowing fluid such that when energized in a particular frequency and sequence, can excite flow instabilities in the flowing fluid. The placement of the electrodes is such that they are unobtrusive relative to the fluid flowpath being controlled.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention relates to a water repellant and more particularly to a novel water repellant which forces no fastidious choice of a substrate (base material) and retains the properties of durability and weatherability for a long time.
[0003] 2. Description of the Related Art
[0004] The water repellant which confers water repellency on the coating film applied to the surface of a substrate of concrete or wood and improves the substrate in weatherability has been finding extensive utility mainly in the fields of building construction and building materials. It is mainly known in the form of a fluorine type coating material. “Patent Document 1,” for example, suggests a method which effects prime coating as with an epoxy resin coating material or a phenol/alkyd resin coating material and finish coating as with a coating material having as a main component thereof a fluorine type copolymer possessing such a hardening reaction site as hydroxybutyl vinyl ether or glycin vinyl ether.
[0005] “Patent Document 2” discloses a water- and oil-repellent coating material for use on a cement type concrete composed with a specific fluorine-containing silane compound.
[0006] Further, “Patent Document 3” discloses a technique for applying to a cement type substrate a coating material having as main components thereof a fluoro-olefin copolymer possessing a hydroxyl group or a carboxyl group and a specific silane compound.
“Patent Document 1”: JP-B-SHO 62-16141 “Patent Document 2”: JP-A-HEI 2-107583 “Patent Document”: JP-A-HEI 5-200353
[0010] According to the method of the invention of “Patent Document 1,” though the fluorine type copolymer is endowed with durability proper for a coating material grade resin, this durability has only a short life and does not deserve the modifier “satisfactory” in terms of the long-term durability.
[0011] Even the coating material of “Patent Document 1” is such that it cannot retain high water repellency for a long time and cannot help imposing a limit on durability.
[0012] Further, the technique of “Patent Document 3,” which is capable of conferring high durability on the cement type substrate, has never been awarded any contrivance regarding retention and enhancement of water repellency.
SUMMARY OF THE INVENTION
[0013] This invention has for a task thereof the provision of a novel water repellant which forces no fastidious selection of a substrate to be used, possesses lasting water repellency and weatherability, avoids emitting a harmful substance, and promises an effective measure to cope with the acid precipitation caused by the recent years' aggravation of the terrestrial environment.
[0014] The present inventor, after pursuing a study in search of a way of formulating a water-repelling agent with a substance capable of taking the place of the water-repellant using the fluorine type resin observed in the prior art mentioned above, has come to take notice of zirconium oxide possessing high durability as a solid state property and arresting attention as an ultraviolet absorbent and a polyvinyl acetate resin used as an emulsion in a water paint and adhesive agent and has consequently acquired a knowledge that by mixing these compounds with paraffin, it is made possible to obtain a water repellant which is endowed with excellent water repellency in combination with long-term durability and resistance to acids. This invention has been perfected on the basis of this knowledge.
[0015] This invention which has achieved the task is directed toward a long-term general-purpose water repellant characterized by mixing three ingredients, ie an emulsion of zirconium oxide, liquid paraffin, and an emulsion of polyvinyl acetate resin sequentially at a ratio of 1:4:1 or at a ratio approximating it.
[0016] The water repellant of this invention forces no fastidious selection of a substrate to be used and enables a selected substrate to acquire water repellency, lasting weatherability, and resistance to acids. When it is applied to wood, it enables the wood to retain water repellency at no sacrifice of its inherent ability to absorb and release moisture. Further, since it emits no harmful substance, it can provide a water repellant which is safe to the human body.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] FIG. 1 is a table showing the results of a qualitative analysis performed on the water repellant of this invention.
[0018] FIG. 2 is a diagram showing a fluorescent X-ray spectrum obtained as a result of the qualitative analysis of the water repellant of this invention.
[0019] FIG. 3 is a table showing the results of an analytical test performed on the water repellant of this invention to determine the presence or absence of a harmful substance therein.
[0020] FIG. 4 is a table showing the properties of weatherability and angle of contact with water exhibited by the water repellant of this invention after an exposure test.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0021] For the purpose of enabling a substrate to derive the properties of water repellency and durability most efficiently from the use of the water repellant of this invention, it is most appropriate to fix the mixing ratio of the three ingredients, ie an emulsion of zirconium oxide, liquid parafin, and an emulsion of polyvinyl acetate resin, at 1:4:1. This ratio has been singled out empirically.
[0022] Even at a ratio which approximates the mixing ratio mentioned above, the effect of this invention can be materialized satisfactorily. To be specific, the approximation contemplated herein relative to the mixing ratio whose optimum standard value is fixed at 1:4:1 is such that the numerical values of the individual proportions of the mixing ratio of the three ingredients are each allowed to increase or decrease within the limit of 20 percents.
[0023] When the water repellant of this invention is dried at 105° C. for five hours and further ignited and incinerated at 700° C. for two hours and the produced ash is subjected to fluorescent X-ray analysis, it is found to contain at least 0.005-0.03;% of sodium (Na), 0.003-0.015% of aluminum (Al), 0.001-0.010% of phosphorus (P), 0.01-0.10% of sulfur (S), and 0.20-0.80% of potassium (K). In these element contents, the water repellant of this invention is preferred to contain Na in the range of 0.015-0.025%, Al in the range of 0.006-0.012%, P in the range of 0.003-0.007%, S in the range of 0.02-0.06%, and K in the range of 0.45-0.55%.
[0024] Further, the water repellant of this invention contains magnesium (Mg), silicon (Si), chlorine (Cl), calcium (Ca), iron (F), zinc (Zn), and rubidium (Rb) in a minute amount besides the elements mentioned above. The term “minute amount” as used herein means a numerical value very close to the limit of detection, specifically falling in the range of 0.001%-0.002%.
[0025] Incidentally, these numerical values have been obtained by qualitatively analyzing relevant elements having atomic numbers of not less than 6 (carbon) by using the fundamental parameter method (FP). The “FP” method is a means to calculate contents aimed at by effecting comparison of analyses obtained with pertinent fluorescent X-ray intensities and then performing convergence of the results of this comparison by using such physical constants as mass absorption coefficients and spectral distribution curves of an X-ray source. Table I shows in a tabulated form the typical numerical values found of the water repellant of this invention, with the mixing ratio of the component ingredients fixed at the optimum value of 1:4:1. In this case, the calculation was carried out by assuming the hydrogen content to be 0% because the fluorescent X-ray analysis was unable to analyze hydrogen and the quantitative analyses of carbon and oxygen were left unindicated because a liquid sample used for the analysis had undergone a treatment of calcination. FIG. 2 illustrates the fluorescent X-ray spectrum involved in the calculation.
[0026] Next, one example of the method for the production of the water repellant contemplated by this invention will be described below. First, in a room of normal temperature, 1 kg of liquid zirconium oxide (made by Goou Kagaku Kogyo K.K. and sold under the trademark designation of “Digest T90”) and 4 kg of liquid paraffin (made by Toho Kagaku K.K. and sold under the trademark designation of “Parax 40K”) are placed in a reaction column and stirred therein with a propeller stirrer for a period in the approximate range of 5 minutes-15 minutes. Subsequently, the resultant mixture and 1 kg of liquid polyvinyl acetate resin (made by Showa Kobunshi Resol K.K. and sold under the product code of “AP50”) are added together and stirred for a period similarly in the approximate range of 5 minutes-15 minutes till they are thoroughly mixed. Consequently, the water repellant contemplated by this invention is easily obtained.
[0027] The water repellant of this invention is applicable to a wide variety of substrates. When the substrate is concrete, mortar, or stone, for example, when the water repellant is applied to the surface of such a substrate, it is capable of exalting the durability of a building structure made of the substrate as by preventing water from permeating the substrate and precluding the reinforcing steel used in the substrate from gathering rust. When the substrate happens to be a plywood, the water repellant is capable of preventing the plywood from succumbing to separation into component layers and yielding to deterioration of quality as a wood material. It is also appropriate for building materials. Particularly when it is applied to sashes, panes of window glass, and rain water gutters in the district experiencing heavy snowfalls and effects of cold latitudes, it prevents the windows from freezing and gathering piles of snow and precludes occurrence of icicles hanging from the gutters. It is further applicable to telephone lines and power transmission lines. When it is applied to these lines, it prevents them from being burdened with piling snow, being frozen with very cold air, or aiding growth of icicles and consequently prevents them from breaking. It is also applicable to packaging materials. When it is applied to the inner sides of a corrugated cardboard box, for example, it can prevent a commodity held in the box from being damaged by frozen dew. Further, this water repellant, on account of its freedom from odor, is applicable to packing materials and transporting materials used for such foodstuffs as vegetables which abhor odor.
[0028] The water repellant of this invention greatly excels in workability because it has only to be applied in its unmodified form to a substrate without requiring addition of a solvent. When the substrate is made of a porous substance, this water repellant permeates this substrate to the core because it is soluble in water. Even if the coating film covering the surface of the substrate happens to be damaged, the water repellant applied thereto will not have the effect thereof seriously impaired. The water repellant permits free selection of the color of the coating film owing to its another advantage of allowing incorporation of a coloring agent therein. Further, the coating film formed of the water repellant of this invention may be overcoated with another coating material.
[0029] The formation of the coating film with the water repellant of this invention can be effected by any of the ordinary techniques in popular use such as brushing, gun blowing, spraying, and roller coating. The drying time of the applied coating film is so short as to fall in the range of 15 minutes-30 minutes in the environment of 20° C. The thickness of the coating film to be formed on the substrate is proper in the approximate range of 10μ-50μ, though variable with the kind of the substrate to be used. If this thickness falls short of 10μ, the shortage will result in preventing the formed coating layer from acquiring sufficient water repellency and durability. If the thickness exceeds 50μ, the excess will possibly induce the applied coating film to gather wrinkles and suffer from impaired durability.
EXAMPLES
Example 1
[0000] [Evaluation of Retention of Water Drops]
[0030] The water repellant of this invention was applied in a thickness of 30μ to a glass plate and dried to obtain a sample. This sample was erected at right angles and sprayed for one hour on the entire surface thereof with the water from a nozzle held at a distance of 20 cm. Then, the water drops remaining on the sample surface were visually observed and rated. The rating was made on a four-point scale, wherein A stands for total absence of water drop from the sample surface, B for slight presence of water drops on the sample surface, C for notable persistence of water drops on the sample surface, and D for full spread of water drops on the sample surface. The sample coated with the water repellant of this invention was rated as B.
Example 2
[0000] [Evaluation of Water Contact]
[0031] The water repellant of this invention was applied in a thickness of 30μ on glass plates and cardboards each measuring 4 cm×4 cm and the applied layers of the water repellant were dried for 24 hours to prepare three samples each of the two kinds of substrate. Water was dropped onto the coated surfaces of the samples. The angles of contact of the water drops to the surfaces were measured with a contact angle meter. Consequently, the angles of contact on the glass plate samples averaged 102.3 and that on the cardboard samples averaged 102.7.
Example 3
[0000] [Evaluation of Resistance to Acid]
[0032] The water repellant of this invention was applied in a thickness of 30μ to both sides of a steel sheet measuring 150 mm×70 mm×0.8 mm in surface area to obtain a sample. The sample was kept immersed in a deionized aqueous 5% sulfuric acid solution for 24 hours in an atmosphere kept at a room temperature of 22° C. and then dried. When the surface appearance of the sample was visually observed, no change was detected.
Example 4
[0000] [Evaluation of Weatherability in Natural State]
[0033] The water repellant of this invention was applied in a thickness of 30μ to one side of a plywood measuring 9 mm in thickness to prepare a sample. The sample was pasted, with the coated surface thereof kept on the outer side, to the front side and the opposite lateral sides of the upright wall of a sink installed outdoors and exposed to the ambient air on rainy days and sunny days alike for three years. When the sample was visually observed, no change was found in the surface appearance. When it was sprayed with water, the coated surface of the sample showed only slight retention of water drops, indicating that the sample was still retaining a water-repelling property. Ordinarily, if the cardboard itself was kept exposed to rain, it would suffer partial loss of power of adhesion and partial separation of component sheets. The sample showed absolutely no discernible sign of separation on the coated side, indicating that the state of good adhesion obtained at first was still retained.
Example 5
[0000] [Evaluation of Ability to Absorb and Release Moisture]
[0034] The water repellant of this invention was spread on a board of Japanese cedar measuring 251 mm×251 mm×27.2 mm to prepare a sample. This sample was tested for ability to absorb and release moisture. The test was based on JIS (Japanese Industrial Standards) A 1470-1 (Method for testing moisture-conditioned building material for ability to absorb and release moisture—Part 1: Temperature-responding method—Test for absorption and release of moisture due to change of temperature). As regards the testing conditions, the sample was cured for 24 hours in an atmosphere of intermediate humidity region at a temperature of 23° C. and a humidity of 53%, then placed in a hygroscopic process at a temperature of 23° C. and a humidity of 75% for 24 hours as the first step, and placed in a humidity-releasing process at a temperature of 23° C. and a humidity of 53% at the second step. The results show that the amount of moisture absorbed was 24.1 g/m 2 , the amount of moisture released was 9.0 g/m 2 , and the difference between the amounts of moisture absorbed and released was 15.1 g/m 2 . Ordinarily, when a water repellant or a coating material is applied to a wood board, the ability to absorb and release moisture which is proper to wood is obstructed. The results of the test, however, show that when the water repellant of this invention is applied, the ability of wood to absorb and release moisture is sufficiently retained.
Example 6
[0000] [Evaluation of Presence and Absence of Harmful Substance]
[0035] Japan Food Analysis Center, a foundation, was entrusted with the task of testing the water repellant of this invention with respect to the items of analytical test indicated in the lefthand column of the table of FIG. 3 . The results indicate as shown in the table that such harmful substances as PCB, formaldehyde, cadmium, and arsenic were not detected at all. The contents of the remarks given in the table were as shown below.
[0036] Note 1: The test was performed on a specimen which was spread in a thickness of about 0.1 mm on a glass plate and then left standing at rest for three days at normal room temperature.
[0037] Note 2: The specimen deposited on the glass plate was eluted at 60° C. for 30 minutes with 2 ml of a solvent per 1 cm 2 of the coated surface. The eluate consequently obtained was filtered through a membrane filter (0.5μ) and then put to test.
[0038] Note 3: The elution was carried out by using 2 ml of the solvent per 1 cm 2 of the coated surface at 25° C. for one hour.
[0039] Note 4: As regards the method for the inspection of devices or containers and packages which had used a fluorescent substance, the test was performed by following the process indicated in “Environment and Foodstuff No. 244, 1971” with necessary modifications. The test was carried out on the specimen which had been spread in a thickness of 0.1 mm on a glass plate and then left standing at rest at normal room temperature for three days.
Example 7
[0000] [Evaluation of Weatherability and Angle of Contact of Water after Exposure Test]
[0040] The test piece obtained by spreading the water repellant of this invention in a thickness of 30μ on one side of a varying test piece indicated in the table of FIG. 4 (obtained by cutting from a board made by a proper forming method) and then drying the applied layer of the water repellant was tested for 850 hours based on the WS-A specified in Paragraph 6.3 of JIS (Japanese Industrial Standards) A 1415 (Method for exposure test with the light source for a laboratory on polymer type building material). Then, the surface of the test piece was evaluated to determine the weatherability and the angle of contact of water. The radiant flux density to one side of the test piece was 255±(10%) W/m 2 and the cycle of water spray was 102 minutes of radiation and 18 minutes of radiation and water spray. The results are shown in the table of FIG. 4 . The results of the visual observation of the test piece after the test for weatherability were rated on the five point scale, wherein A stands for no sign of a crack but a discernible sign of only slight blushing, B for no sign of a crack but a discernible sign of partial blushing, C for no sign of a crack but a discernible sign of a partial change of color to brown, D for no sign of a crack but a discernible sign of a marked change of color, and E for no sign of a crack but a discernible sign of a partial blushing. The rating of the angle of contact of water was performed at five sites of a given test piece and the average of the five marks obtained was compared with the result of the measurement performed immediately after the application.
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This invention is aimed at conferring a lasting water-repelling property, durability, and weatherability on a substrate without forcing fastidious selection of a substrate to be used. The object is accomplished by providing a long-term general-purpose water repellant, having the three ingredients thereof, ie an emulsion of zirconium oxide, a liquid paraffin, and an emulsion of polyvinyl acetate resin, mixed sequentially at a ratio of 1:4:1 or a ratio approximating it.
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FIELD OF THE INVENTION
The present circuit relates generally to telecommunication line circuitry and more specifically to circuitry for reducing the power dissipation in telephone subscriber line circuits with a consequent reduction in the total amount of power consumed by a central office.
BACKGROUND OF THE INVENTION
Before electronic battery feed circuits existed, a hybrid transformer was used to convert a balanced two wire signal from an unbalanced four wire signal. In the last few years there has been a considerable amount of effort, however, to replace the hybrid transformer due to its size, weight and cost. With the advent of electronic battery feed circuits, there is a further need to reconfigure the hybrid circuit so that it will be suitable for newer electronic battery feed circuit designs. Present state-of-the-art does not permit an inexpensive solution to this problem, primarily due to the high voltages involved. The -50 volt office battery, which is used to provide power, exceeds the voltage rating of most semiconductor devices on the market today.
The problem of designing a circuit to withstand the higher voltages of an office battery has generally been approached in one of three ways. First, a semiconductor integrated circuit which uses a manufacturing process that can operate at higher voltages can be designed. This is an expensive solution, however. Second, an intermediate power supply, with a voltage of about half of the office battery, can be added to the office power supply. This, however, necessitates additional equipment, power buses, wire routing and connectors. Third, one can derive an intermediate, secondary voltage from the -50 v battery by using Zener diodes, or some other voltage regulating device. Higher power consumption will result from this technique, however.
The present invention falls into the third category of deriving a secondary voltage from the -50 volt battery. Since operational amplifiers are not normally capable of handling the battery voltages found in a central office, the two operational amplifiers are placed in series, and two Zener diodes are used to provide a lower stable supply voltage which the operational amplifiers can safely use. Using a -50 volt battery, such a circuit configuration will consume about 170 milliwatts of power.
SUMMARY OF THE INVENTION
The object of the present invention is to provide a low cost, novel, reliable and maintenance free technique to efficiently provide power to a line using the relatively high voltage of the central office battery. This novel circuit technique uses three components: a standard operational amplifier, a low power operational amplifier, and a Zener diode. The voltage rating of the operational amplifiers may be only 30 volts, and the breakdown voltage rating of the Zener diode in the range from 26 to 29 volts.
Power is provided to the two operational amplifiers in a manner where one operational amplifier is powered near ground, and the other near the office battery voltage of -50 volts. This invention uses an arrangement where the two operational amplifiers are wired together so that their power leads are connected in series with the central office battery. That is, the positive power lead of the tip driver operational amplifier is connected to ground. Similarly, the negative power lead of the ring driver operational amplifier is connected to the central office battery. Then, the positive power lead of the ring driver operational amplifier and the negative power lead of the tip driver operational amplifier are tied together. This point, where the power leads of the two operational amplifiers are tied together, has a shifting voltage, and this voltage can vary tremendously. In order to prevent this floating voltage from destroying either of the operational amplifiers, a voltage regulator, a Zener diode, for example, must be applied between this floating voltage point and a stable reference voltage. The reference voltage can be ground, a battery voltage, or some other reference voltage. The voltage regulator, therefore, will provide a stable voltage for the operation of the operational amplifiers.
Unfortunately, any voltage regulator takes power to operate. The regulator power, in fact, can almost double the total power consumption of a battery feed circuit that were to use this type of approach. The proposed solution to this problem is to use one low power operational amplifier, and one standard operational amplifier. The difference between these two operational amplifiers is the standard operational amplifier draws more current than the low power one. Because the supply current flows through both operational amplifiers in series, the standard operational amplifier will try to force the low power operational amplifier to draw more current. If one puts a Zener diode in parallel with the low power operational amplifier, the excess current will flow through the Zener diode. Since a Zener diode will drop a constant voltage regardless of the current (as long as a minimum current is present), this method provides an effective means of regulating the floating voltage. Thus, this invention can reduce the amount of power consumed without the penalties of using an expensive manufacturing process or using additional power supplies.
BRIEF DESCRIPTION OF THE DRAWING
The drawing FIGURE is a simplified blockdiagram of a single power supply battery feed circuit according to the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, there are three major components in describing the invention. These three components are: a low power analog amplifier A1, a standard analog amplifier A2 and a Zener diode Z1. The two analog amplifiers provide DC loop current as well as an AC signal to the telephone line. The Zener diode is used to clamp the intermediate voltage between the two analog amplifiers to a fixed value.
FIG. 1 has other components besides those mentioned above. The resistors R5 and R6 at the signal output terminations of each analog amplifier are line impedance matching resistors, and are used to match the interface circuit with the telephone line impedance. The combination of the two resistors and one capacitor at the signal input termination of each analog amplifier serves to set the proper DC bias to the amplifier and to pass the receive signal to the amplifier from the four wire receive port. These resistors are large in value. The capacitors C1 and C2 are also large in value, so that the AC signal can pass through to the input of the analog amplifier unattenuated. The last component to be mentioned in FIG. 1 is the inverter amplifier A3. The input of the inverter is connected to the four wire receive port. The output of the inverter feeds an inverted version of the receive signal to the input of the analog amplifier A2. The purpose of the inverter is to provide an inverted signal to the analog amplifier A2 so that a differential AC signal is sent down the telephone line. The subscriber will then receive this differential AC signal in the form of a voice or digital communication.
Returning to a discussion of the two analog amplifiers, these two components are responsible for driving the telephone line by using the four wire receive signal. In FIG. 1, these analog amplifiers are shown as unity gain buffer amplifiers. They don't have to be set at unity gain, however. A positive or negative feedback approach using operational amplifiers could be implemented. It is important that the analog amplifiers have a DC bias reference, so that the DC current draw will flow through the top lead to the subscriber termination and back through the ring lead, regardless of the presence or absence of an AC signal on the telephone line. In FIG. 1, the tip analog amplifier A1 has its positive current supply terminal biased at ground from a positive current supply terminal, and the ring analog amplifier A2 has its negative current supply terminal biased near the battery voltage of 50 volts.
The low power analog amplifier A1 and the Zener diode Z1 are at the heart of this invention. By connecting these two components in parallel, one can establish a fixed supply voltage for the low power analog amplifier, and, at the same time, one can establish a minimum current for the Zener diode Z1. Thus the Zener diode Z1 has the anode terminal connected from between the amplifier A1 and A2 respective negative and positive current supply terminals, and the cathode terminal to ground. The standard analog amplifier A2 connected to these two components must sink the current of the low power analog amplifier A1 and the Zener diode Z1 under all loads. Generally, this is not a problem, because whatever current is sent out to the subscriber loop must pass through both analog amplifiers as well. If no current is sent through the loop, which would happen if the phone was on-hook, then the standard analog amplifier would still sink the current of the low power analog amplifier and the Zener diode. The basis for this type of operation is the fact that the low power analog amplifier runs on less current under all loads. If, for some reason, the standard analog amplifier was not sinking enough current to keep the Zener diode in regulation, then a small dummy load could be connected to the analog amplifier to prevent such an occurrence.
A typical arrangement of the invention found to be operative uses the following values of components.
______________________________________Reference Value______________________________________Cl .15 of capacitorA1 TL062 amplifier (low power)A2 741 amplifierA3 741 inverterZ1 27V Zener diodeR1, R2, R3, R4 120K ohms resistorR5, R6 300 ohms resistor______________________________________
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A two amplifier subscriber line interface circuit that uses a novel voltage divider technique for providing power to the two lower voltage amplifiers from a 50 volt central office battery. This is achieved by using one lower power amplifier with a Zener regulator diode in shunt thereof to regulate its current.
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BACKGROUND OF THE INVENTION
In general, the move to Web 2.0 has focused much more on user-centric computing and has both enabled and highlighted the need for contextual collaboration and the social aspects of collaboration. The common methods for collaboration include email and bulletin boards. However, the current email agents focus on the management of individual messages rather than focusing on the collaboration between parties. For example, email agents tend to order the messages based on the time of arrival or sort them by subject line, but they do not provide for a visualization of conversations in electronic form such that the collaboration between parties becomes the focus of the user.
SUMMARY OF THE INVENTION
One embodiment of the invention described here pertains to the visualization of threaded electronic conversations (email) such that a client application can present various information about a particular conversation (or the conjunction of separate conversations) allowing the user to easily see message sequences, conversation participants, time in transit, time in process and other information.
One embodiment is equally applicable to electronic mail, bulletin boards, instant messaging or other forms of conversation and is equally applicable both to traditional desktop based mail agents as well as web 2.0 browser-based applications (such as social networking sites). This disclosure will use the example of email consistently throughout but the invention is applicable to other forms of conversation.
The visualization, with appropriate actions available on the visual elements, allows for even traditional email to become more of a social and collaborative tool than simply a message-oriented and reactive one. One embodiment uses the industry standard Message Sequence Chart (MSC) notation common in software and systems design languages such as the Unified Modeling Language (UML) or Specification and Description Language (SDL).
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic diagram of a visualization of an email thread.
FIG. 2 is a data flow diagram showing an example of message processing steps
FIG. 3 is a schematic diagram of the incomplete view of visualization email thread.
FIG. 4 is a schematic diagram of the visualization email threads with an out of sequence participant.
FIG. 5 is a schematic diagram of an example of the visual cue reference sample.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
One embodiment uses the industry standard MSC notation common in software and systems design languages such as the ML or SDL. The following example demonstrates the visualization of a simple email exchange in one embodiment.
The simple exchange depicted in FIG. 1 corresponds to the first author Simon ( 110 ) sending a message to Kevin ( 112 ). After some time, Kevin forwards the message to Steve ( 114 ) who after reading it replies to Kevin. Finally, Kevin forwards the response back to Simon. The visualization allows any participant to view that part of the exchange they have available to them and see the participants in the exchange (denotes by the icons along the top) and the visual cues such as the slant of the arrows (e.g., 120 ) indicating the time taken to deliver the message, the length of the thick vertical bar (e.g., 116 ) indicating the time the message sat in the users inbox, and a time bar ( 118 ) indicating when various events occurred.
One embodiment presents visual cues such as the use of hover-over tool tips to display the actual time taken for a message or the email address of a user. In one embodiment, each message transit arrow (e.g., 120 ) responds to common email operations such as reply-to or forward to allow the user to respond to a particular message.
The flowchart in FIG. 2 indicates the steps taken in one embodiment of the invention from the user selecting a message that is included in a thread of interest to the presentation of the visualization. Here, a user selects one or more messages to use as a context ( 210 ). The mail agent searches ( 212 ) the mail store ( 226 ) for related messages, using message IDs, subject text and other heuristics. Messages may be found which are related but which appear to be in different threads ( 214 ). The user is prompted to include (or not) related threads ( 216 ). If user selects to include related threads, the mail agent searches the mail store for messages related to the new threads ( 218 ). Next, the messages are parsed to find embedded responses ( 222 ). One embodiment presents the visualization ( 224 ) in the display using user information (e.g. icons/images representing each thread participant) extracted from a user store ( 228 ) such as a directory server. In case of no image, one embodiment uses default icons.
In particular, the parsing of messages is important, as those messages that are in user's inbox only represent those sent to the user; however, more messages may include embedded responses as shown in listing 1. In Bulletin Board systems where all messages are public, an embodiment processes all messages discretely to present visualization. In an email systems where an email agent only has access to those messages sent to the particular user, an embodiment parses out these responses to allow for the presentation of more of the conversation even when the entire store of messages is not available to the mail agent. Below is an example listing of an e-mail message:
Listing 1.
From: Kevin [mailto:kevin@.com]
Sent: Mon 8/6/2007 4:01 PM
To: simon@.com
Subject: Fw: the project
This project is now finished.
> From: Steve [mailto:steve@.com]
> Sent: Mon 8/6/2007 2:30 PM
> To: kevin@.com
> Subject: Re: the project
>
> All done now
>
>> From: Kevin [mailto:kevin@.com]
>> Sent: Mon 8/6/2007 11:00 AM
>> To: steve@.com
>> Subject: Fw: the project
>>
>> Can you deal with this please?
>>
>>> From: Simon [mailto:simon@.com]
>>> Sent: Mon 8/6/2007 9:01 AM
>>> To: kevin@.com
>>> Subject: the project
>>>
>>> We need to finish this project
While a user may send a message to a group of people (either by selecting multiple To: or Cc: addresses) or by selecting a mailing list, the actual conversations are point-to-point. In one embodiment, upon the user hovering the mouse over individual arrow line within the visualizations, To: or Cc: list are displayed for the message represented by the arrow. One embodiment navigates directly to the corresponding message to display the precise details when the user clicks on the arrow.
FIG. 1 demonstrates an embodiment with a scenario where a visualization of the message involves three users sending messages back and forth. In another scenario ( FIG. 3 ), Steve ( 314 ) (and not Simon ( 310 )) requests the visualization of the same thread. In this scenario, the user (Steve) has replied to the message from Kevin ( 312 ), but he may not know where the messages go from there; so the user sees an incomplete view of the thread ( FIG. 3 ). In particular, the arrow corresponding to the user's reply does not indicate any transmit time (as the user would not necessarily know when it was delivered). Also, there is no indicator on the vertical line for Kevin, as to the time taken for that user to process the message is unknown in this scenario. One embodiment uses a flat line ( 316 ) for the message representation from Steve to Kevin to indicate no or unknown transit time.
An embodiment deals with a scenario depicted in FIG. 4 where one or more users appear “out of sequence” in a thread because someone sent them a message but that information is not reflected in their reply and they appear to enter a conversation at some point. One embodiment displays this occurrence in the visualization by showing the message arrive into the thread by a person or entity ( 416 ) without showing the message sent to that person or entity (e.g., by any other participants 410 , 412 , or 414 ). In one embodiment, the corresponding message arrow is displayed as a flat arrow ( 418 ).
One embodiment deals with visualization of multiple related threads as well as related messages in a single thread. For example, the user, Steve, before replying to the message from Kevin forwards the message to Jan; however, Steve changes the subject to something more appropriate before sending. This thread goes to Bob (a fifth person in the e-mail thread) who also sends a copy back to Simon. Therefore, an embodiment determines this message as part of a new thread but it also determines that some of the message content is shared and therefore it marks the thread as related. One embodiment superimposes these threads in one visualization by using different colors or other visual cues for messages belonging to different threads.
One embodiment indicates certain message actions such as send, reply, and forward with different visual cues allowing the user to quickly see the dynamic nature of the conversation. For example, as shown in FIG. 5 , filled arrow heads indicate a message sent; empty arrow heads indicate a message forwarded; a double arrow head indicate a message being replied to; a double empty arrow head on a dashed line indicates a system message (e.g., the user requested a delivery-receipt message which has been delivered to the user). One embodiment categorizes and treats read-receipt and message cancellation as system messages.
One embodiment uses additional cues to denote properties of messages such as their being marked as urgent, having attachments, being signed or encrypted. An embodiment visually identifies additional system messages such as “out of office”, or “mail delivery” reports with separate visual cues.
In one embodiment, a mail agent provides additional semantics for messages such as “this message is an addendum to/continuation of the conversation” or “this message contains a new assertion that could serve as a focal point for new replies”. In one embodiment, such tags enable email agents to efficiently identify and process related messages.
One embodiment of the invention turns on or off visual cues per user's setting and specification in order to reduce “clutter” in the visualization. One embodiment filters the messages by type per user's setting or specification. E.g., the embodiment removes all system messages from the display.
One embodiment of the invention is a method for visualization of threaded emails, the method comprising:
receiving email threads from a sequence of emails between multiple users; using a message sequence chart notation to represent the email threads; representing time on a first axis; representing the email threads on a second axis; wherein the first axis and the second axis are orthogonal with respect to each other; using an arrow to indicate the direction of an email; representing each of reply, send, forward, system, urgent, and attachment messages using different unique shapes, thickness, and symbols; using slope of the arrow to indicate passage of time corresponding to the first axis; one of the multiple users selecting one or more emails from the sequence of emails, to use as a context; a mail agent searching a mail storage for a related message, with respect to the selected one or more emails from the sequence of emails; in case the related message is found, prompting the one of the multiple users to decide to include or not include the related message; parsing messages to find embedded responses; providing icons for visualization purpose from a user store or a directory server; hovering over the arrow to display TO-list, CC-list, and other information from its corresponding message; displaying an incomplete view; displaying an out-of-sequence view; displaying related messages and threads; using colors, shadings, symbols, dotted lines, arrows, different sizes, and different thicknesses, to indicate relationships between the related messages and threads, context, topic, or subject; displaying delivery-receipt, read-receipt, out-of-office, addendum, continuation, approval, counter-argument, and message cancellation; tagging the messages; filtering the messages; hiding the messages; removing the messages; and aggregating, tabulating, and summarizing details of the messages.
A system, apparatus, or device comprising one of the following items is an example of the invention: email, thread, message, user, sequence chart, time, line or arrow representing a message, visual cues, message attributes, context, mail storage, mail agent, mail server, bulletin board, social network, response, embedded response, icon, image, user information, user information store, directory server, any display screen, computer display, views, topic or subject, tag, filter, query result, or any software, applying the method mentioned above, for purpose of invitation or visualization of threaded emails.
Any variations of the above teaching are also intended to be covered by this patent application.
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An embodiment of the invention uses the message sequence chart (MSC) and various visual cues to provide an interactive visualization of threaded electronic conversations (e.g., in email, bulletin board, instant message, or social network) by presenting to users various information about a particular conversation or the conjunction of separate conversations, such as sequences of messages, conversation participants, time in transit, time send/received, and other message attributes.
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CROSS-REFERENCE TO RELATED APPLICATION
This application is a continuation of copending International Application No. PCT/DE01/03234, filed Aug. 22, 2001, which designated the United States and was not published in English.
BACKGROUND OF THE INVENTION
Field of the Invention
The invention relates to an optoelectronic assembly for multiplexing and/or demultiplexing optical signals. More specifically, the invention pertains to an optoelectronic assembly for multiplexing and/or demultiplexing optical signals, having:
a monolithic multiplexing member for multiplexing and/or demultiplexing optical signals; a first optical imaging system that couples light beams of an optical channel with a multiplicity of wavelengths into and out of the multiplexing member; and a second optical imaging system, that couples light beams of a plurality of optical channels each having one wavelength into and/or out of the multiplexing member; the first optical imaging system is integrated into a single-channel interface member and/or the second optical imaging system is integrated into a multichannel interface member, and at least one interface member is connected directly to the multiplexing member.
It is known in optical telecommunications engineering to multiplex the data to be transmitted in order to transmit as large a data volume as possible via one optical waveguide. One possibility for this includes transmitting information with the aid of a plurality of wavelengths independently and simultaneously via one waveguide. It is necessary in this case for the signals from the various light sources to be combined at the transmitting end in one optical waveguide by using an optical multiplexer, and for the signals of various wavelengths from the incoming waveguide to be distributed at the receiving end into individual channels by using an optical demultiplexer for the purpose of separate detection.
In order to implement multiplexing or demultiplexing, it is known from European Patent Application No. EP 0 877 264, which corresponds to U.S. Pat. No. 5,894,535, to separate the individual wavelengths with interference filters. The high number of interference layers of the interference filters produce very steep spectral edges between transmission and reflection of different wavelengths. Only one specific wavelength is passed in this case by the interference filters, while the other wavelengths are reflected. A multiplicity of wavelength channels can be selected and/or combined by cascading such filters with individually distinguishable spectral transmission positions. The use of interference filters is extremely effective, particularly in the case of large wavelength spaces of 10 nm more between the individual channels.
Coupling light signals into and out of an assembly for the purpose of multiplexing and/or demultiplexing optical signals requires optical imaging systems that couple light beams of an optical channel with a plurality of wavelengths, or light beams of a plurality of optical channels with in each case only one wavelength into and out of multiplexing members.
SUMMARY OF THE INVENTION
It is accordingly an object of the invention to provide an optoelectronic assembly for multiplexing and/or demultiplexing optical signals that overcomes the hereinafore-mentioned disadvantages of the heretofore-known devices of this general type and that provides a compact, space-saving and stable configuration of the optical image systems for a multiplexing member.
With the foregoing and other objects in view, there is provided, in accordance with the invention, an optoelectronic assembly for multiplexing and demultiplexing optical signals. The optoelectronic assembly includes a monolithic multiplexing member, two optical imaging systems, an optical element, and an optically transparent sealing compound. The monolithic multiplexing member multiplexes and demultiplexes optical signals. The first optical imaging system couples light beams of an optical channel into and out of the multiplexing member. The second optical imaging system couples light beams of a plurality of optical channels into and out of the multiplexing member. At least one of the first optical imaging system and the second optical imaging system is integrated into an interface member. The interface member is a single-channel interface member when integrating the first optical imaging system, and the interference member is a multichannel interface member when integrating the second optical imaging system. The interface member is connected directly to the multiplexing member. The optically transparent sealing compound optically couples directly the interface member to the optical element and contains an optical path between the interface member and the optical element.
In accordance with a further object of the invention, the solution according to the invention is distinguished in that, in the case of an optoelectronic assembly having a first and a second optical imaging system and a monolithic multiplexing member, the first and/or the second optical imaging system is integrated into an interface member, and at least one interface member is connected directly to the multiplexing member.
Depending on whether the optical imaging system images light beams of an optical channel with signals of various wavelengths or light beams of a plurality of optical channels with in each case only one wavelength, the interface members are in this case a single-channel interface member or a multichannel interface member. Of course, both a single-channel interface member and a multichannel interface member are present.
The interface members are preferably configured as unipartite shaped pieces by precise molding methods such as injection molding from materials such as plastic or glass. The interface members preferably are formed from plastic, while the multiplexing members include glass or a vitreous material. The construction of the multiplexing member from glass has the advantage that the light to be separated in its individual wavelength or to be combined from individual wavelengths runs in an exceptionally homogeneous medium of low attenuation.
The construction of the interface members from plastic has the advantage that these members can be produced easily and, in particular, optical imaging elements can easily be implemented in or on these and/or optical imaging elements can be indicated in these.
The connection of an interface member to the multiplexing member is performed in a simple way by mounting it directly onto a flat surface of the multiplexing member. The two interface members are preferably mounted directly onto the multiplexing member, the interface members being advantageously disposed on opposite, parallel surfaces of the multiplexing member.
In a preferred refinement of the invention, the optical imaging systems of the two interface members are configured in such a way that the optical path through the multiplexing member occurs in a substantially parallel fashion. The traversing of the multiplexing member with parallel light has the advantage that wavelength-selective reflecting layers disposed on the multiplexing body. That is, the interference filters have particularly good properties in the case of transirradiation with virtually parallel light. That is, with high spatial resolution in each case, only one specific wavelength passes through, while the other wavelengths are reflected.
The optical paths through the interface members bordering the multiplexing member preferably run at an acute angle to the perpendicular to the parallel faces of the multiplexing member. This ensures that light coupled into the multiplexing member is multiply reflected to and fro in the latter such that the light coupled in or out can traverse a plurality of interference filters for the purpose of separating or combining the individual wavelengths (channels).
The multiplexing body preferably has two opposite, parallel surfaces. On at least one of the surfaces, wavelength-selective reflective surfaces are provided. The wavelength-selective reflective surfaces serve as interference filters and are respectively assigned to an optical path. The wavelength-selective reflective surfaces can in this case be applied directly to the surface. Alternatively, the wavelength-selective reflective surfaces are implemented on separate carrier parts that are disposed on the surface of the multiplexing member.
Furthermore, the multiplexing member preferably has, on at least one surface, reflective surfaces that are not wavelength selective. Consequently, a light beam coupled into the multiplexing member at an angle to the perpendicular is reflected to and fro multiply between the two parallel surfaces, the light beam being respectively coupled out with a wavelength component at the wavelength-selective reflective surfaces. The actual multiplexing and/or demultiplexing of the signals of various wavelengths is performed thereby. By contrast, the interface members ensure the optical coupling of respective optical paths to further optical elements such as optoelectronic transducers or waveguides.
One or more optical imaging elements or groups of optical imaging elements (lens and mirror, for example) are provided in the interface members, depending on whether only one channel or a plurality of channels are coupled into or out of the multiplexing member. The imaging elements can be implemented in various ways in the interface members. The optical imaging elements are preferably formed in the interface members by curved, lenticular surfaces that form, for example, the boundary surfaces with at least one cavity, which is constructed in the interface member. This has the advantage that there is no need to integrate additional lenses in the interface member.
Alternatively, the optical imaging elements are formed in the interface members by curved mirrors that are constructed, in particular, on subregions of an outer surface of the interface member. In order to be constructed as a reflecting mirror, the outer surfaces are preferably provided in this case with a reflecting layer.
It is likewise within the scope of the invention when the optical imaging elements are formed in the interface members by lenses and/or reflective surfaces that are integrated in the interface members.
In a preferred development of the invention, optical elements to be coupled to the optoelectronic assembly are optically coupled directly to the single-channel or multichannel interface member. The optical elements to be coupled are preferably optoelectronic transducers, each optoelectronic transducer being assigned an optical path of the multichannel interface member.
The optoelectronic transducers are configured in an array chip, for example. This configuration is advantageous, in particular, for the case when the optoelectronic transducers serve as receivers. In the case of transmitting elements, it will be sensible as a rule to provide separate transmitting element chips for the individual wavelengths.
The optoelectronic transducers ensure in a way known per se the conversion of optical into electric signals and/or the conversion of electric into optical signals.
In a preferred refinement, the invention provides that at least one interface member and the associated optical elements are at least partially jointly sheathed by an optically transparent sealing compound. As a result, the optoelectronic assembly and the optical elements to be coupled are encapsulated from the environment and thus protected from moisture, dirt, etc. This ensures that the optical path between the optoelectronic assembly and the optical elements to be coupled, which runs within the sealing compound, is not impaired.
An optoelectronic assembly in the case of which two interface elements with optical imaging elements are mounted directly onto a plane-parallel monolithic multiplexing member, and one and/or another of the interface members is connected to optical elements to be coupled by an optically transparent sealing compound for protection of the optical path makes available a high-quality, compact, space-saving configuration that is easy to produce and shielded against environmental influences.
It may be pointed out, moreover, that light can be coupled into and out of the optoelectronic assembly in the same planes, but also in planes disposed differently relative to one another. For example, light coupled into the assembly in a specific direction is coupled out at an angle of 90° to the coupling-in direction.
In an advantageous development of the invention, the single-channel and/or multichannel interface member is formed in such a way that it fashions receptacles or other mechanical mounts for coupling optical elements. In particular, the interface member forms a receptacle for an optical plug, thus permitting an optical waveguide that is to be coupled to be aligned without adjustment.
In an alternative refinement of the invention, the two interface members are disposed on one side of the multiplexing member. Light is thus coupled into and out of the multiplexing member on the same side. The two interface members are disposed next to one another in this case. In a development of this alternative of the invention, the two interface members are additionally configured in a unipartite fashion; that is, the respective optical imaging systems of the two interface members are integrated into one part.
Other features that are considered as characteristic for the invention are set forth in the appended claims.
Although the invention is illustrated and described herein as embodied in a optoelectronic assembly for multiplexing and/or demultiplexing optical signals, it is nevertheless not intended to be limited to the details shown, since various modifications and structural changes may be made therein without departing from the spirit of the invention and within the scope and range of equivalents of the claims.
The construction and method of operation of the invention, however, together with additional objects and advantages thereof will be best understood from the following description of specific embodiments when read in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagrammatic side view showing a first exemplary embodiment according to the invention of an optoelectronic assembly for multiplexing and/or demultiplexing optical signals, optical signals in the same plane being coupled into and out of the optoelectronic assembly;
FIG. 2 is a diagrammatic plan view showing a second exemplary embodiment of an optoelectronic assembly, in the case of which optical signals are coupled in and out in different planes; and
FIG. 3 is a sectional view of the optoelectronic assembly of FIG. 2 taken along the section line III-III.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the figures of the drawings in detail and first, particularly to FIG. 1 thereof, there is shown an optoelectronic assembly having a first interface member 1 , a second interface member 2 , and a multiplexing member 3 that is disposed between the first and the second interface members 1 , 2 .
On its side opposing the multiplexing member 3 , the interface member 1 has a receptacle 11 for a support member 4 , in which there is constructed an optical channel or optical path 5 that is formed by an optical waveguide.
The first interface member 1 has two curved surfaces 12 , 13 that together fashion a lens 14 . The lens surfaces in this case respectively border a cavity 15 , 16 that is constructed between the lens 14 and the support member 4 or the lens 14 and the multiplexing member 3 .
The effect of the lens 14 is that divergent light emerging from the optical channel or optical waveguide 5 at the plane end face 41 of the support member 4 is projected to form a parallel light beam that is then coupled into the multiplexing member 3 at an acute angle to the perpendicular to the bordering surface 31 of the multiplexing member 3 .
Just like the second interface 2 , the first interface 1 is formed from a plastic, in particular a polymer material such as polycarbonate, for example. It is produced, for example, using an injection molding method.
The multiplexing member 3 has two plane-parallel surfaces 31 , 32 , and is formed by a monolithic glass body. On its surface 31 next to the entrance face of the parallel light beam, the multiplexing member 3 has a silvering 34 that reflects light beams of all wavelengths.
By contrast, at regular spacings the opposite surface 32 of the multiplexing member 3 has interference filters 33 that are transparent to light of a specific, in each case different wavelength, but reflect all other wavelengths.
The result of this is that light coupled into the multiplexing member 3 via the interface member 1 is reflected to and fro between the two faces 31 , 32 , one wavelength component being coupled out in each case at the interference filters 33 . Consequently, a multiplicity of optical paths or channels that in each case have light signals of a specific wavelength emerge from the multiplexing member 3 .
Light emerging from the multiplexing member 3 is coupled directly into the second interface member 2 . The latter has in the sectional view of FIG. 1 two U-shaped limbs 21 , 22 between which a baseplate 23 extends. A cavity 25 is formed between the baseplate 23 , the lateral limbs 21 , 22 and the surface 32 of the multiplexing member 3 . Material projections with curved, lenticular surfaces 26 that respectively fashion a lens 24 extend on the baseplate 23 in the direction of the multiplexing member 3 at regular spacings. In this configuration, the individual lenses 24 are assigned in each case to an optical channel emerging from the multiplexing member 3 .
In an alternative refinement, the interference filters are not implemented directly on the surface 32 of the multiplexing member 3 , but on separate support parts 35 (illustrated schematically by dashed lines FIG. 1 ) that are disposed on the surface 32 of the multiplexing member 3 and project slightly into the cavity 25 . The interference filters can be produced more simply and cost-effectively in this way.
Of course, the optoelectronic assembly described can be disposed both at the transmitting end and at the receiving end of a light transmission link. Depending on the direction of the light signals, light of a plurality of wavelengths of the optical channel 5 is separated into a multiplicity of optical channels each having only one wavelength (that is to say the light transverses the assembly in the illustration of FIG. 1 from top to bottom and serves in the process as a demultiplexer or receiver), or light of a multiplicity of channels of different wavelength is combined by the multiplexing member 3 to form the optical channel 5 (that is to say the light transverses the assembly of FIG. 1 from bottom to top, the assembly serving as a multiplexer or transmitter).
An array chip with a plurality of optoelectronic transducers is assigned to the second interface member 2 . In each case, one optoelectronic transducer is assigned to an optical channel emerging from the second interface member or entering into the latter. This array chip 6 is disposed on a substrate 7 in a way known per se. The optoelectronic transducers are, for example, light-emitting diodes or semiconductor lasers. Light emerging vertically upward is guided via the interface member 2 into the multiplexing member 3 and further into the interface member 4 and the optical channel 5 . Alternatively, receiving elements such as photodiodes are involved, which convert the light of the individual optical channels into electric signals.
Alternatively, the optoelectronic transducers are not disposed on an array chip, but on separate chips.
The array chip 6 , the substrate 7 , and the second interface member 2 are transparently sealed by an optical sealing compound 8 and thereby protected against environmental influences such as moisture and dust. The optical path between the array chip 6 and the second interface member 2 runs in this case in the sealing compound 8 . It is therefore optimally shielded against the outside.
If the optoelectronic transducers are transmitting elements such as light-emitting diodes or semiconductor lasers, it is to be ensured that the light they emit is coupled into the multiplexing member 3 in an angular fashion. This is possible, for example, by illuminating the lenses 24 of the second interface member 2 obliquely or angularly with light. A further possibility includes providing a sawtooth construction of the underside of the baseplate 23 or the boundary surface between the sealing compound 8 and the second interface member 2 in order to create boundary surfaces that refract the light in an angular fashion into the interface member 2 and onto the lenses 24 (not illustrated). The sealing compound 8 and the second interface member 2 would have to exhibit a different refractive index for this case.
An alternative exemplary embodiment of the optoelectronic assembly according to the invention is illustrated in FIGS. 2 and 3 . The basic structure of a multiplexing member 3 having two plane-parallel surfaces 31 , 32 to which in each case a first interface member 100 and a second interface member 200 are directly coupled corresponds to the structure of FIG. 1 . The difference between the exemplary embodiment of FIG. 2 and the exemplary embodiment of FIG. 1 lies in that the light is coupled into or out of the second interface member 200 in a plane perpendicular to the plane of the drawing of FIG. 2 , and the optical imaging elements of the interface members 100 , 200 have curved mirrors.
The first interface element 100 has, again, a receptacle 111 for coupling a support member 4 . The support member 4 is, for example, an optical plug.
A cambered surface 112 of the interface member 100 , which borders a cavity 118 , serves as a positive lens that reduces the degree of divergence of the emerging light. The interface member 100 also has a curved mirror 117 that is constructed on an outer face of the interface member 100 . The outer face is provided in this case with a reflecting layer (not illustrated separately), and so a light beam penetrating into the interface member 100 is reflected at the curved mirror 117 .
The effect of the configuration illustrated is that a divergent light beam emerging from the optical waveguide 5 of the support member is reflected at the mirror 117 in such a way that a parallel light beam is coupled into the multiplexing member 3 .
In accordance with FIG. 3 , an optical configuration similar to FIG. 2 is shown except the optical configuration of the interface member 100 is constructed in the interface member 200 . Thus, light emerging from the multiplexing member 3 is reflected downward in the direction of the optoelectronic array chip 7 via a curved mirror 217 that is fashioned on the outer surface of the interface member 200 . In this case, the reflective surface 217 concentrates light incident from the multiplexing member 3 in the direction of the array chip with the optoelectronic transducer.
The array chip 7 , the substrate 6 , and the second interface element 200 are, in turn, sheathed by an optically transparent sealing compound 8 such that the complete optical path is shielded from the environment. The beam path between the interface member 200 and array chip 7 lies within the sealing compound. No further protection of the configuration from the outside is therefore required.
The invention is not limited in its construction to the exemplary embodiments illustrated above. All that is essential for the invention is that at least one of the two optical imaging systems responsible for coupling light into and out of the multiplexing member is integrated into an interface member, and that this interface member is directly connected to the multiplexing member.
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An optoelectronic assembly multiplexes and/or demultiplexes optical signals. The assembly includes a monolithic multiplexer for multiplexing and demultiplexing optical signals, and two optical imaging systems for coupling light beams in or coupling them out of the multiplexer. The first optical imaging system is integrated in a single-channel interface and/or the second optical imaging system is integrated in a multi-channel interface, and at least one interface is directly linked with the multiplexer.
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BACKGROUND OF THE INVENTION
This application is related to the subject matter of copending U.S. application Ser. No. 813,191 which was filed on July 5, 1977 and assigned to the same assignee as the assignee of the present application.
This invention relates to an apparatus and method for accurately controlling the velocity of a moving member, like a print head carrier, for example, which moves along the platen of a printer, and for providing timing signals for printing uniformly spaced dots when using a wire matrix printer as the printing element, even with some variation in the velocity of the print head carrier.
Most systems of the prior art utilize a tachometer which is coupled to the drive shaft of the motor driving the print head carrier, and the tachometer is used to feed back an analog signal which is proportional to the speed of the motor. The analog signal is then compared with a reference signal in a comparator means which controls the operating speed of the motor by a variety of techniques disclosed in the prior art. One system disclosing an electronic tachometer is shown in U.S. Pat. No. 3,986,091.
The preferred embodiment of the present invention utilizes a completely digital-to-digital circuit including a processor for controlling the speed of a moving member such as a print head carrier, thereby making the control of the speed more accurate than prior art systems which employ analog circuitry.
SUMMARY OF THE INVENTION
This invention relates to an apparatus and method for controlling the velocity of a moving member as, for example, a print head carrier in a printer. The apparatus includes a motor drive means which is operatively coupled to the moveable member to move it along the platen of the printer in the example given. The motor of the motor drive means is driven by alternately energizing it during an "on" period and de-energizing it during an "off" period. Velocity detection means are utilized to produce signals which are indicative of the actual velocity of the moveable member whose velocity is to be controlled with respect to a desired velocity, and circuit means operatively couple the velocity detection means with the motor drive means to enable the motor to drive the moveable member at the desired constant velocity.
The circuit means includes means for establishing predetermined on and off periods for the motor when the moveable member is moving at the desired velocity, and means for continually inversely varying the duration of the "on" period energizing the motor in accordance with a time period measured between predetermined signals from said velocity detection means whenever the actual velocity of the moving member deviates from the desired velocity. The circuit means is completely digital and includes a processor, making the control of the velocity of the moveable member more accurate when compared to prior art systems employing digital-to-analog and analog-to-digital converters in the speed control system.
When this invention is used in a wire matrix printer environment, for example, it can provide accurate timing signals for printing uniformly spaced dots comprising a character even with some variation in the velocity of the moveable member or carriage supporting the wire matrix print head.
An added feature of this invention is that standard, medium-scale, integrated devices and standard processors can be used for minimum cost and maximum flexibility of design. Because the circuit of this invention is functionally modular, it is suitable for large scale integration.
Another feature of this invention is that it produces a first waveform comprising first pulses and portions interconnecting said first pulses, with said first pulses having widths which vary inversely according to the time intervals between successive predetermined pulses of a second waveform.
Still another feature of this invention is that it uses a single digital counter for generating recurrent pulses having controlled different on and off intervals.
These advantages and others will become more apparent from the following specification, claims and drawing.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a general diagrammatic view of the apparatus of this invention as used in a typical embodiment such as a wire matrix printer, showing a carriage means having a wire matrix printer thereon, a motor which is operatively connected to the carriage means to drive it, a motor drive means for driving the motor, velocity sensing means located on the moveable member or carriage means, a printer control means for controlling a wire matrix printer located on the carriage means, and speed control means including a processor and speed control circuitry for controlling the velocity of the carriage means;
FIG. 2 is a general schematic diagram in block form, showing more details of the speed control circuitry shown in FIG. 1;
FIGS. 3A and 3B taken together represent a detailed schematic showing of a portion of the speed control circuitry shown in FIG. 2 and specifically relate to the multiplexer means, counter means H3-J3, and control means K3 shown in FIG. 2;
FIG. 4 is a detailed schematic showing of a portion of the timing pulse generation means shown in FIG. 2;
FIG. 5 shows several waveforms associated with the timing pulse generation means shown in FIG. 2;
FIG. 6 is a detailed schematic of a portion of the speed control circuitry shown in FIG. 2 and specifically relates to the counter means C2-D2 shown in FIG. 2;
FIG. 7 shows a manually settable switch upon which is entered a binary count related to the nominal desired speed of the print head and carriage shown in FIG. 1;
FIG. 8 is a graph showing the relationship between the nominal desired speed and the actual velocity, and the PCO count which is a count used by the control means to adjust the actual velocity to make it approach the nominal desired speed;
FIG. 9 shows a manually settable switch upon which is entered a binary count which is related to the up-ramp circuitry for accelerating the print head from a rest position to a velocity which is close to the nominal desired speed, and also shows input ports associated with the processor shown in FIG. 1;
FIG. 10 shows an input port associated with the processor shown in FIG. 1;
FIG. 11 shows circuitry for interrupting the processor shown in FIG. 1 to effect the speed control of this invention;
FIG. 12 is a truth table associated with the circuitry shown in FIG. 11;
FIG. 13 shows a group of timing diagrams associated with the circuitry of FIG. 11;
FIGS. 14 (A through D) show flow charts for the speed control program associated with the processor shown in FIG. 1;
FIG. 14E shows a flow chart for a program associated with firing the print hammers of the wire matrix printer;
FIG. 14F is a diagram showing the firing of print column images as they relate to control pulses;
FIGS. 15 (A and B) show a detail program listing of the speed control program; and
FIG. 15C shows a detail program listing for the flow chart shown in FIG. 14E.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 is a general diagrammatic view of a preferred embodiment of the apparatus of this invention as used in a typical application such as a wire matrix printer. The printer may be conventional and includes a platen 10, a carriage means 12, and a wire matrix printer 14 mounted on the carriage means 12. The carriage means 12 is moveably supported on fixed guide rods 16 and 18 to enable the carriage means to be reciprocated relative to platen 10. The output shaft 20 of motor 22 is conventionally coupled to the carriage means 12 by suitable connecting means 24 to reciprocate it along the platen 10. Because the connecting means 24 may be conventional, such as a traversing lead screw or a belt and pulley system, it is shown only as a dashed line in FIG 1. The motor 22 is preferably a conventional DC motor, and it is selectively energized by a conventional motor drive means shown only as a block 26. The printer control means 28 includes a processor 30 and a general program 32 for controlling the usual start up procedures and functions such as interfacing with associated peripherals and for performing the usual functions such as paper feeding, etc. associated with a printing operation. Additionally, the processor 30, the speed control program 34, and the speed control circuitry 36 combine to form the apparatus of this invention for controlling the speed of the carriage means 12 (moveable member) and for controlling the firing of the individual solenoids 38 in the wire matrix printer 14.
The speed control circuitry 36 receives the output from a velocity sensing means 40, and uses this information in conjunction with the processor 30 and the speed control program 34 to control the speed of motor 22 so as to maintain the velocity of the carriage means 12 constant relative to a nominal desired velocity. The velocity sensing means 40 includes a light source 42 and a detector such as a photoelectric cell 44 which are positioned on opposed sides of a timing strip 46. The timing strip 46 is stationary relative to the velocity sensing means 40 which is secured to the carriage means 12 to travel therewith. The timing strip 40 is made of opaque material and has a plurality of equally spaced slots therein which enable light from the light source 42 to pass therethrough to the photoelectric cell 44, and the time period between successive pulses from photoelectric cell 44 gives an indication of the actual velocity of the carriage means 12 as it is traversed along the platen 10. A conventional power source 50 is utilized to provide the necessary voltage levels to the motor drive means 26, the speed control circuitry 36, and the printer control means 28.
FIG. 2 is a general schematic diagram, in block form, showing additional details of the speed control circuitry 36 shown in FIG. 1, and is used to provide a general description thereof. In the previous description it was noted that the velocity of the carriage means 12 is controlled by alternately energizing the motor 22 during a so-called "on" period and de-energizing the motor 22 during a so-called "off" period. The output of speed control means circuitry 36 includes a pulse marked PLSWDON/ which is fed into the motor drive means 26 (FIG. 1) for conventionally controlling the energization of motor 22. When pulse PLSWDON/ is a binary 0 or active low for example, the motor 22 is conventionally energized via the motor drive means 26, and when the pulse PLSWDON/ is a binary 1 or active high, the motor 22 is de-energized. The pulse PLSWDON/ comes from the control means K3 shown in FIG. 2. In general, the on period for energizing motor 22 and the off period for deenergizing it are designed so that the on period will represent about 25 to 33 percent of the total duty cycle time for the motor 22.
Assume for the moment, that the motor 22 (FIG. 1) is at rest and it is desired to move the carriage means 12 in a forward direction to the desired operating velocity so as to begin printing. To initiate the control, a MOTOREN pulse coming from the printer control means 28 of FIG. 1, is used to reset the counter means H3-J3, and the control means K3 shown in FIG. 2, and a FORWARD (FWD) pulse is used to condition the motor drive means 26 to drive the motor 22 in a forward direction. An up-ramp routine under the control of the speed control program 34 of FIG. 1 is used to provide a gradual starting up to approximately the desired nominal velocity. The processor 30, via its speed control program 34, outputs a first count over the processor's data bus DB0/-DB7/ to the latch F5 in FIG. 2 and this first count is gated into the counter means H3-J3 by the multiplexer means H2-J2 which was conditioned by the control means K3 to initiate the start of an energizing "on" period to the motor 22. The first count is preset upon the counter means H3-J3, and the φ1/ clock coming from the timing pulse generation means 52 is used to increment the counter means from the preset count thereon to the terminal count (TC) thereof. The terminal count signal from counter means H3-J3 is then fed into the control means K3 causing it to change state to thereby terminate the "on" period and initiate the start of the de-energizing "off" period by enabling the multiplexer means H2-J2 to accept an "off" count which is a binary count which is hardwired on to the multiplexer means H2-J2 and represented by the "off period data" rectangle designated as 50 in FIG. 2. This off count is then preset upon the counter means H3-J3 via the multiplexer means H2-J2, and the counter means H3-J3 is incremented by the φ1/ clock until the terminal count thereof is reached and this terminal count causes the control means K3 to change state, thereby terminating the "off" period, and initiating the start of another energizing on period. The two states of the control means K3 are used to alternately energize and de-energize the motor through the use of the PLSWDON/ pulse from the control means K3 via the motor drive means 26.
It should be noted at this time, that if the motor 22 is started from rest, the velocity sensing means 40 will not produce any signal until such time as motor 22 causes sensing means 40 to move past one of the timing slots on the timing strip 46 shown in FIG. 1. The predetermined binary count which was hardwired on the multiplexer means H2-J2 and the first count from the processor 30 are alternately multiplexed into the counter means H3-J3 for several such cycles until the carriage means 12 moves sufficiently far to enable the sensing means 40 to coact with the timing strip 46 to produce a first pulse which is called CHAR and is shown on FIGS. 1 and 2.
The first CHAR pulse coming from the sensing means 40 is fed into the timing pulse generation means 52 (FIG. 2) which will be described in detail hereinafter. For the moment, it is sufficient to state the timing pulse generation means 52 produces a CHP/ pulse (derived from the CHAR pulse) which is utilized by the speed control circuitry 36 (FIG. 1) to provide an interrupt to the processor 30, and the speed control program 34 causes a second binary count for the up ramp routine to be output over the data bus DB0-DB7 to the latch F5 (FIG. 2). The second binary count is then preset upon the counter means H3-J3 via the multiplexing means H2-J2 to control the next group of energizing on periods for the motor 22. The counter means H3-J3 is then incremented to its terminal count via the φ1/ clock, whereupon, the control means K3 changes state, causing the multiplexing means H2-J2 to multiplex the off period data (from rectangle 50) into the counter means H3-J3. The φ1/ clock then increments the counter means H3-J3 until its terminal count is reached, whereupon, the control means K3 changes state to condition the multiplexing means H2-J2 to again multiplex the second binary count into the counter means H3-J3. This process of alternately loading the second binary count and the binary count for the off period data from rectangle 50 into the counter means H3-J3 continues until the motor 22 moves the carriage means 12 sufficiently far to enable the velocity sensing means 40 to produce a second CHAR pulse as the motor 22 gains speed.
The second CHAR pulse coming from the velocity sensing means 40 is then utilized by the timing pulse generation means 52 (FIG. 2) to produce a second CHPA/ pulse which completes the up ramp routine and initiates the speed control routine when the carriage means 12 is moving at approximately the desired nominal velocity. The second binary count is retained in a memory location by the speed control program 34 and becomes a present count output (PCO) which is continually adjusted (as necessary) as the velocity of the carriage means 12 deviates from the desired nominal velocity, and this adjusted PCO count is output to the latch F5 (FIG. 2) to be multiplexed into the counter means H3-J3 as previously described.
The second CHPA/ pulse causes the speed control program 34 to input to the processor 30 a current speed count (CSC) which is accumulated in the counter means C2-D2 shown in FIG. 2. The current speed count represents a binary count which corresponds to the actual velocity of the carriage means 12 as measured between successive CHAR pulses coming from the velocity sensing means 40. The CHPB/ pulse (derived from the CHAR pulse) clears the counter means C2-D2, and the HCKB clock (which is 96 times slower than the clock used to increment the counter means H3-J3) increments the counter means C2-D2 until a CHPA/ pulse conditions the latch C5-D5 to record therein the binary count which has accrued upon the counter means C2-D2. As the count in the counter means C2-D2 gets higher (between successive CHAR pulses) it indicates that the velocity of the carriage means 12 is decreasing, and conversely, as the count gets lower, a higher velocity is indicated. The CHPA/ pulse also causes the processor 30 to enter the speed control program 34 (FIG. 1) and the SELPRT (Select Port) pulse 101 coming from this program 34 is used to transfer the CSC count which is latched in latch C5-D5 to the processor 30 via the inport port 10 and the data bus DB0/-DB7/. The processor 30 under the control of the speed control program 34 (to be discussed in detail hereinafter) receives the CSC count and compares it with a desired nominal speed count (NSC) which was input to the processor 30 from an entry means such as manually settable switches S1 shown in FIG. 7. The NSC count is a binary count which represents or corresponds to the desired nominal velocity or speed at which the carriage means 12 is to be moved. After the comparison between the NSC and the CSC counts is made, the PCO is adjusted if necessary, and is utilized to control the duty cycle of the motor 22 as follows:
(1) If the NSC count is less than the CSC count, then the PCO count which is located in memory is adjusted by increasing it by a count of 1 (in the embodiment described) to become an adjusted PCO count. This indicates that the carriage means 12 moved slower than the desired nominal velocity, and accordingly, the energizing on period for the motor 22 must be increased to make it speed up.
(2) If the NSC count is greater than the CSC count, then the PCO count which is located in memory is adjusted by decreasing it by a count of 1 to become an adjusted PCO count. This indicates that the carriage means 12 moved faster than the desired nominal velocity and accordingly, the energizing on period for the motor must be decreased to slow it down.
(3) If the NSC count is equal to the CSC count, then the PCO count which is located in memory is not adjusted, as the motor 22 is moving the carriage means 12 at the desired nominal velocity.
In the embodiment described, the PCO count is adjusted, if necessary, after each CHAR signal coming from the velocity sensing means 40 (FIG. 1). The wire matrix printer 14 prints in a "7 by 9" matrix with the characters being 7 "dots" high and 7 "dots" wide, with 2 "dot" positions being used for spacing between adjacent characters being printed, and with two CHAR signals being needed to complete a character being printed. From this, it is apparent that the PCO count is adjusted, if necessary, for each 1/2 character position. Thus, the speed of the carriage means 12 is controlled by the CSC count received for the preceding 1/2 character position. This close control of the velocity of the carriage means 12 enables the spacing of the "dots" of each 1/2 character to be uniformly printed within that 1/2 character spacing; this aspect will be described in detail hereinafter.
During the speed control routine, the PCO count is continually adjusted (as necessary) and the adjusted PCO count which is stored in memory is continually adjusted upwardly or downwardly depending upon the most recent CSC count derived from the counter means C2-D2 shown in FIG. 2. This adjusted PCO count (representing the adjustments to the energizing on period) is then alternately multiplexed into the counter means H3-J3 with the off period data 50 as previously described to maintain the velocity of the carriage means 12 at the desired nominal velocity. The off period remains fixed and it is the energizing on period to the motor 22 which is varied or modulated to obtain the desired nominal velocity. The frequency of the energizing on pulse PLSWDON/ (for energizing motor 22) coming from the control means K3 in FIG. 2 is about 10 KHz in the embodiment illustrated. Naturally, the energizing frequency is dependent upon the specific parameters chosen for the various elements included in the apparatus of this invention and the response times, etc. of the particular conventional motor drive means 26 selected to drive the motor 22 and the particular motor 22.
FIGS. 3A and 3B taken together show a portion of the speed control circuitry 36 shown in FIGS. 1 and 2. The data bus DB0/-DB7/ is a bi-directional data bus which communicates with the processor 30, which in the embodiment chosen to describe the invention, is an eight bit Intel 8080 microprocessor; naturally, the principles of this invention may be extended to other processors. The data bus DB0/-DB7/ is input into the latch F5 which is a conventional dual four bit latch, as for example, a Fairchild 9308 latch, and the 8 bit output therefrom is fed into the multiplexers H2 and J2 with output lines I1-I4 from latch F5 going to one set of input lines of multiplexer H2 and with output lines I5-I8 going to one set of the input lines of multiplexer J2. The multiplexer H2 and J2 are conventional quad, two-input multiplexers, as for example, Fairchild 9322 multiplexers. The multiplexers H2 and J2 shown in FIG. 3A comprise the multiplexer means H2-J2 shown in FIG. 2. The off period data 50 shown in FIG. 2, which relates to the de-energizing off period of motor 22, is hardwired on to the multiplexers H2 and J2 by wiring the low four bit byte of data into the second set of inputs to multiplexer H2, and by wiring the high four bit byte of data into the second set of inputs to multiplexer J2. The particular count which is collectively wired on to the multiplexers H2 and J2 is a binary count of 128; this is accomplished by wiring pin 11 of multiplexer J2 to a source of +5 volts potential via a pull up resistor R1, with all the remaining inputs of the second sets of inputs of the multiplexers H2 and J2 being connected to system ground.
The four bit output of multiplexer H2 (FIG. 3A) is connected to the input of the four bit counter H3 (FIG. 3B) and the output of multiplexer J2 is similarly connected to the input of the four bit counter J3. The counters H3 and J3 are conventional 4 bit counters such as Fairchild 9316 counters, with these counters being conventionally combined as shown to provide the 8 bit counter means H3-J3 shown in FIG. 2, and with counter H3 handling the low byte data and counter J3 handling the high byte data. The terminal count output (pin 15) of the high byte counter J3 is fed into a conventional inverter E3 whose output is fed into the K input (pin 3) of a conventional Fairchild 9024 flip-flop, and this terminal count output is also fed directly into the J input (pin 2) of flip-flop K3 which comprises the control means K3 shown in FIG. 2. The Q/ output of flip-flop K3 (pin 7) represents the pulse width on signal (PLSWDON/), and this signal is fed into a conventional inverter H4 whose output is connected to the motor drive means 26 (FIG. 1) and the pull up resistor R2 to control the energization and de-energization of motor 22 as previously explained.
Each of the modules such as latch F5, multiplexers H2, J2, counters H3, J3 and flip-flop K3 have the usual VCC and ground connections connected thereto as shown and the various numbered pin connections for the modules are shown in FIGS. 3A and 3B. The MOTOREN pulse resets the counters H3 and J3 and the control means K3, and the φ1/ clock pulse, which is derived from the timing pulse generation means 52 shown in FIGS. 2 and 4, is fed into the clock inputs of counters H3 and J3 and the control means K3. The PLSWDON/ coming from the control means K3 is fed into the inputs (pins 1) of multiplexers H2 and J2 as shown in FIG. 3A. When the control means K3 is reset or in one state, the multiplexers H2 and J2 are conditioned to accept data from latch F5 (relative to the energizing on period for motor 22), and when the control means K3 changes state, the multiplexers H2 and J2 are conditioned to accept the off period data 50 which is hardwired on the multiplexers as previously explained. The various counts which are related to the energizing on period and de-energizing off period are alternately preset upon the counter means H3-J3, and the φ1/ clock is utilized to increment it until the terminal count thereof is reached. The terminal count, after inversion by inverter E3, is used to parallel enable the counters H3 and J3 (via pins 9) to accept the next binary count to be preset thereupon. The various binary counts which are ouput over the data bus DB0/-DB7/ of the processor 30 are held in the latch F5 through the use of select port signal SELPRT 11/ which is under the control of the speed control program 34 (FIG. 1). The input WR.G/ going to the AND enable pins 2 and 14 of latch F5 is a strobing pulse which comes from the processor 30.
A portion of the timing pulse generation means 52 shown in FIG. 2 is shown in FIG. 4 and has the basic 01.F fed into the inverter 3E1. The basic clock 01.F has a period of 0.7 microseconds, and after inversion by inverter 3E1, becomes the 01/ clock. The output of the inverter 3E1 is also fed into the CP intput terminal (pin 2) of the divide by 16 counter F2 which is a conventional Fairchild 9316, 4 bit, binary counter which is conventionally wired as shown to provide a divide by 16 function on the TC output (pin 15) thereof. The TC output of counter F2 provides an HCKA pulse (having a period of 11.2 microseconds) which is fed into a conventional inverter 3E2 whose output is fed into another conventional inverter 3E3 whose output is fed into the CP (pin 4) input of a conventional Fairchild 9024 flip-flop F3. The output of inverter 3E2 produces an HCKAB/ pulse which is also fed back into the PE input (pin 9) of the counter F2, and the output of the inverter 3E3 produces an HCKAB clock pulse which is fed into the counter F4 shown in FIG. 6. The CHAR pulse coming from the velocity sensing means 40 of FIG. 1 is fed into a conventional non-inverter 3B such as a Motorola 4050 circuit chip which improves the signal by minimizing noise, and the output of non-inverter 3B is fed to the J and K inputs (pins 2 and 3) of flip-flop F3. The Q output (pin 6) of flip-flop F3 represents the CHARB signal which is shown in FIG. 5 and is fed into the CP input (pin 12) of flip-flop F3-1 which is the same type of flip-flop as is F3. The K input (pin 13) of flip-flop F3-1 is connected to system ground. The Q output (pin 10) of flip-flop F3-1 is fed into the J input (pin 2) of flip-flop G3 and the Q/ output (pin 9) of flip-flop F3-1 is fed back to the J input (pin 14) thereof. The CD (pin 15) of flip-flop F3-1 is connected to the Q/ output (pin 7) of flip-flop G3 which produces the CHPB/ pulse also shown in the timing diagram of FIG. 5. The CP inputs (pins 4) of flip-flops F3 and G3 are connected together as shown. Each of the flip-flops F3, F3-1, and G3 has the usual VCC and ground connections made thereto as shown, and the flip-flops F3 and G3 have the SD and CD (pins 5 and 1 respectively) and the flip-flop F3-1 has the SD input (pin 11) connected to a +5 volt source of potential via the resistor R6 which is 2K ohms. The various relationships among the various signals described in connection with FIG. 4 are shown in the timing diagram of FIG. 5.
The HCKAB pulse coming from the output of inverter 3E3 shown in FIG. 4 is fed into the CP input (pin 2) of the counter F4 (FIG. 6) which is a conventional Fairchild 9316, 4-bit binary counter which is conventionally wired to produce a divide by six function on the TC output (pin 15) thereof, which TC output provides an HCKB clocking pulse having a period of 67.2 microseconds and a pulse width of 11.2 microseconds. The CHPA/ output from flip-flop F3-1 (FIG. 4) is fed into the MR input (pin 1) of counter F4 which has the usual VCC and ground connections thereto as shown.
The TC output (pin 15) of counter F4 (FIG. 6) is fed into the CP inputs (pins 2) of counters C2 and D2, each of which is a conventional Fairchild 9316, 4-bit counter. The counters C2 and D2 are conventionally wired together to produce the 8 bit counter means C2-D2 shown in FIG. 2. The CHPB/ output from flip-flop G3 shown in FIG. 4 is fed into the MR inputs (pins 1) of counters C2 and D2 and the TC or terminal count output (pin 15) of counter C2 is fed into the CET input (pin 10) of counter D2. The TC output (pin 15) of counter D2 is fed into a conventional inverter 3E4 whose output is fed back to the CEP inputs (pins 7) of the counters C2 and D2. The PE input (pin 9) and the CET input (pin 10) of counter C2 are connected to a +5 volt source of potential via the pull up resistor R5 which is 2K ohms, and the PE input (pin 9) of counter D2 is similarly connected to resistor R5. The four Q outputs (pins 11-14) of counter C2 are fed into the D inputs (pins 8, 4, 6, and 10) of latch 5C, and similarly, the Q outputs (pins 11-14 of counter D2 are fed into the D inputs (pins 16, 18, 20, 22) of latch D5. The latches C5 and D5 comprise the 8 bit latch C5-D5 shown in FIG. 2 with latch C5 handling the 4 bit low byte and latch D5 handling the 4 bit high byte of data from the counters C2 and D2. The CHPA/ pulse coming from the Q/ output (pin 9) of flip-flop F3-1 (FIG. 4) is fed into the AND enable input (pin 2) of latch C5, and the similar input (pin 15) of latch D5. The other AND enable inputs (pin 3 of latch C5 and pin 14 of latch D5) are connected to system ground as shown. The MR input (pin 1) of latch C5 and the MR input (pin 13) of latch D5 are connected to the pull up resistor R5. The Q outputs (pins 5, 7, 9 and 11) of latch C5 and the Q outputs (pins 17, 19, 21, and 23 of latch D5) are connected to the input port #10 (FIG. 2) which is a latch which transfers the output of counter means C2-D2 to the processor 30 over the data bus DB0/-DB7/. The output of latch C5 is marked VEL 1-4 in FIG. 6, and the output of latch D5 is marked VEL 5-8. As previously stated, the count which is accrued on the counter means C2-D2 is a count which corresponds to the actual velocity of the carriage means 12 as derived from successive CHAR pulses from the velocity sensing means 40 shown in FIG. 1.
The buffer 4C (FIG. 10) and a portion of the buffer F1 (FIG. 9) comprise the input port #10 shown in FIG. 2. The buffers 4C and F1 are conventional tri-state interface elements such as tri-state 8T97 buffers manufactured by Signetics. The buffers 4C and F1 are six bit buffers, and because the data from the counter means C2-D2 comprises 8 bits, two such buffers are required with buffer 4C handling bits VEL (1-6) shown in FIG. 6, and buffer F1 handling the bits VEL (7 and 8). Bits VEL (1-6) are fed into the input terminals (pins 2, 4, 6, 10, 12 and 14) of buffer 4C and bits VEL (7 and 8) are fed into the input terminals (pins 12 and 14) of buffer F1. The output terminals (pins 3, 5, 7, 9, 11 and 13) of buffer 4C are connected to the data bus DB(0/-5/) and the output terminals (pins 11 and 13) of buffer F1 are connected to the data bus DB6/ and DB7/. A SELPRT 10/ signal from the speed control program 30 (FIG. 1) conditions the buffer 4C to transfer its input to the data bus, and similarly, the SELPRT 10/ signal also fed into the DIS 2 (pin 15) of buffer F1 conditions the buffer F1 to transfer its inputs VEL 7 and VEL 8 to the data bus DB6/ and DB7/ at pins 11 and 13 respectively. The buffers 4C and F1 have the usual VCC and ground connections made thereto as shown.
Earlier herein, it was stated that the up ramp data was supplied from the manually settable switches shown as S2 in FIG. 9. The data which is entered upon the switches S2 is placed upon the data bus DB(0/-7/) via the buffers F1 and E1 shown in FIG. 9. There are 8 manually settable switches shown as S2 with one pole of each switch being connected to system ground. The remaining pole of each switch is connected to the inputs of buffers E1 and F1. For example, lines S(20-23) comprising the low byte of data are connected to the inputs (pins 2, 4, 6, and 10) of buffer E1, and lines S(24-27) comprising the high byte of data are connected to the inputs (pins 2, 4, 6, and 10) of buffer F1. Each of the lines S(20-27) is connected through a pull-up resistor R42 (2K ohms) to a source of +5 volts potential. When the switches S2 are open, a high or binary 1 is transferred over the lines S(20-27) and when the switches are closed, these lines are placed at system ground for a low or binary zero. The data which is entered upon the manually settable switches S2 is transferred to the data bus DB(0/-7/) whenever the buffers E1 and F1 are conditioned by the SELPRT 12/ signal coming from the speed control program 34 (FIG. 1), which said signal is fed into the DIS 4 input (pin 1) of buffers E1 and F1. With the SELPRT 121 signal, the S24-S27 lines are output from pins 3, 5, 7 and 9 of buffer F1.
The data relating to the nominal speed count (NSC) which corresponds to the desired nominal speed or velocity at which the carriage means 12 is to be driven is entered upon the manually settable switches S1 shown in FIG. 7. The switches S1 are identical to the switches S2 already described and therefore need not be described in any further detail. Lines S (10-17) from the switches S1 comprise the 8 bits of data which are placed on the data bus DB(0/-7) via the buffers A1 and C1 (which are identical to the buffers E1 and F1) upon the occurrence of a SELPRT 13/ signal coming from the speed control program 34 (FIG. 1). The two lowest order bits S10 and S11 are fed into the inputs (pins 12 and 14) of buffer A1, and the next six bits from switches S1 are fed into the inputs (pins 14, 6, 4, 2, 10, and 12) of buffer C1. The corresponding outputs from buffer A1 (pins 13 and 11) are connected to the data bus DB0/ and DB1/, and the corresponding outputs from buffer C1 (pins 13, 7, 5, 3, 9, and 11) are connected to the data bus DB(2/-7/).
FIG. 11 shows a part of the speed control circuitry 36 (FIG. 1) which is used to provide a conventional interrupt to the processor 30. The processor 30 is able to handle the usual functions such as paper feed, etc. associated with the printing function shown in FIG. 1, and it is interrupted to also handle the adjustments to the velocity of the carriage means 12. An INTE.G/ (interrupt enable) signal coming from processor 30 is inverted by inverter 3E5 and is fed into the CP input (pin 12) of the flip-flop G3 which is a convention Fairchild 9024 flip-flop. The reset/ signal is fed into the CD input (pin 15) of flip-flop G3 and the J and K inputs (pins 14, 13) thereof are connected to system ground. The CHPA/ signal coming from the Q/ output of flip-flop F3-1 (FIG. 4) is fed into the SD input (pin 11) of flip-flop G3 and the Q output (pin 10) is inverted by a conventional inverter 4H to provide the ISL1/ signal which interrupts the processor 30 to enter the routine controlled by the speed control program 34 shown in FIG. 1. The flip-flop G3 has the usual VCC and ground connections made thereto as shown. FIG. 12 is a truth table showing the mode of operation of the flip-flop G3 shown in FIG. 11.
FIG. 13 shows the relationship among the various pulses associated with the flip-flop G3 shown in FIG. 11.
The RESET/ term shown in FIGS. 11 and 13 is a general power up reset which resets the flip flop G3 to ISL1/ true. ISL1 is set by CHPA, i.e., CHPA/ to ISL1/ false if INTE is true. The interrupt signal INTE.G/ comes from the processor 30 and when ISL1/ is false, i.e.; ISL1 true, the processor 30 is interrupted and the INTE signal is turned off. The next time INTE goes true, ISL1 is set (ISL1 resets) at the rise of CHPA, i.e., the fall of CHPA/.
FIGS. 14 (A-D) comprise a part of the speed control program 34 shown in FIG. 1. The general program 32 is utilized to provide the usual initialization procedures for the printer shown in FIG. 1 and to indicate when the carriage means 12 is to be moved and to effect printing. Assume that the carriage means 12 is in a home position and it is desired to move the carriage means 12 in a forward direction. The forward step 54 in FIG. 14A initiates the start of the speed control program 34 known as the up ramp routine. The first step 56 loads the NSC count from the manually settable switches S1 (FIG. 7) into a portion of memory associated with the program 34 by the SELPRT 13/ signal mentioned earlier herein. The next step 58 is to store an experimentally derived count into a PCO (Present Count Output) counter also located in a portion of memory associated with the program 34. The experimentally derived count is simply a count to get the motor going prior to the binary count from the manually settable switches S2 being introduced into the counter means H3-J3, and it is a count which provides a suitable duty cycle for the motor 22 during acceleration from rest towards the desired nominal velocity. In the embodiment described, the experimentally derived count is a binary count of 64, and this count which was loaded into the PCO counter in step 58 is output therefrom to the latch F5 by the SELPRT 11/ signal in step 60. The forward and MOTOREN bits are set in step 62 (to set the motor drive means 26 to drive the motor 22 forward and to reset the counter means H3-J3), and these bits are output to conventional port #1 (not shown) by a SELPRT 1/ signal in step 64. The motor 22 then starts to move the carriage means 12 at start step 66. During this time, the experimentally derived count from step 58 and the off period data 50 (FIG. 2) are alternately multiplexed into the counter means H3-J3 as previously explained. An upramp flag associated with the upramp routine (FIG. 14A) is cleared in step 68 (meaning that it is in an upramp mode) and the interrupt is enabled in step 70 by the first CHAR pulse coming from the velocity sensing means 40 (FIG. 1) via the CHPA/ pulse (derived from CHAR) shown in FIG. 11. After the interrupt is enabled, the binary count for the up ramp setting entered upon the manually settable switches S2 (FIG. 9) is fed into the PCO counter in memory in step 72 and this count is alternately multiplexed with the off period data 50 (FIG. 2) into the counter means H2-J2 as previously explained to accelerate the motor 22 to approximately the desired nominal velocity. The second CHPA/ pulse (derived from the second CHAR pulse coming from the velocity sensing means 40) is used to indicate in step 74 whether or not the carriage means 12 is out of the home position, and/or additionally, a home position switch (not shown) may be used to conventionally sense when the carriage means 12 leaves the home position. If the carriage means 12 is not out of the home position, the binary count from switch S2 (step 72) is alternately multiplexed into the counter means H2-J2 with the off period data 50 until the second CHPA/ pulse is received to cause the upramp flag to be reset in step 76, meaning that the upramp routine is completed. The next step in the program is a return step 78 causing the control to be shifted to the general program 32 to perform other operations not pertinent to this invention; it should be recalled that the processor 30 performs other functions in addition to the speed control being described herein and that it handles the speed control function on an interrupt basis.
The next CHPA/ pulse causes an interrupt (FIG. 11) to the processor 30 causing the speed control program 34 to be initiated at step 80 (also marked A) in FIG. 14B. If the carriage means 12 is still in the up ramp routine as indicated by step 81, the program control shifts to step 82 (also marked B) in FIG. 14C. At this step, the count which was stored in the PCO counter from step 72 will be output in step 84 to the counter means H3-J3 and multiplexed with the off period data 50 as previously described. The PCO count is saved in step 86 for use in subsequent routines, and the control is shifted back to the general program 32 by the return step 88.
Upon the next CHPA/ (derived from the CHAR pulse) the general program 32 is interrupted, and the speed control program 34 shifts to steps 80 and 81 already described in relation to FIG. 14B. If the carriage means 12 is not upramping, the last PCO count is loaded and saved in step 90. Because the up ramping is usually completed at this time, the CSC count which has been accruing on the counter means C2-D2 (FIG. 2) is input to the processor via input port 10 by SELPRT 10/ in step 92. The CSC count is complemented in step 94, and it is examined in step 96 to determine whether or not the counter means C2-D2 turned over i.e. whether or not the count therein was greater or equal to 256, as an 8 bit binary counter means C2-D2 was used herein. If the answer to the examination step 96 is yes, the program shifts to step 82 on FIG. 14C to complete the steps 84, 86, and 88 as previously described. If the answer to examination step 96 is no, the CSC count is saved in step 98. The NSC count from step 56 in FIG. 14A is then loaded into a register in step 100 in FIG. 14B, and the NSC and CSC counts are compared in step 102 with regard to the question stated in step 104, namely, "Is the NSC count less than the CSC count?" If the answer is "yes", (thereby indicating that the carriage means 12 is moving slower than the desired nominal velocity) the PCO count which was stored in step 90 is increased by 1 in step 106 and from step 82 (B in FIG. 14C) this adjusted PCO count is then output in step 84 and saved for the next cycle in step 86. If the answer to the question from step 104 is "no", the program shifts to step 108 also marked "C" on FIGS. 14B and 14C where a second comparison follows in step 110 with the question of step 112 being, "Does the NSC count equal the CSC count?" If the answer is "yes", indicating that the carriage means 12 is moving at the desired nominal velocity, no adjustment is necessary to the PCO count, and steps 82, 84 and 86 are repeated. If the answer to the question of step 112 is "no", indicating that the carriage means 12 is moving faster than the desired nominal velocity, then the last PCO count is decreased by 1 in step 114 and steps 84, 86 and 88 are completed as previously described. When the PCO count is increased, the increased count has the effect of increasing the energizing on period to the motor 22, and correspondingly, a decreased PCO count has the effect of decreasing the energizing on period. Thus, the last PCO count after adjustment (if necessary) is saved and used for the next interrupt cycle starting at step 80 in FIG. 14B so that the change (if any) between successive PCO counts is always limited to 1 in the embodiment described (although other constants may be used), thereby making the adjustments to the velocity of the carriage means 12 very gradual. This minimizes "overshoot" and "undershoot" conditions which occur in some prior art systems of motor speed control.
The reverse up ramp routine shown in FIG. 14D is generally similar to the forward up ramp routine described in relation to FIG. 14A; however there are some differences. Whenever the general program 32 indicates that a reverse routine is required, the reverse routine at 110 is initiated at step 112 by setting or loading an experimentally derived NSC count (for fast return) from memory into the PCO counter in step 114. The NSC count for reverse represents a speed which is faster than the nominal desired speed in a forward direction. This NSC count for reverse is then output into the latch F5 in step 116 as previously described to control the energizing on period. The reverse and MOTOREN bits are set in step 118 (to set the motor drive means 26 to drive the motor 22 in a reverse direction and to reset the counter means H3-J3) and this data is output in step 120 over the port #1 as previously described. The motor 22 then starts to move the carriage means 12 in a reverse direction at start step 124 in FIG. 14D. During this time, the experimentally derived NSC count for reverse for fast return and the off period data 50 (FIG. 2) are alternately multiplexed into the counter means H3-J3 as previously described until a first CHPA/ pulse (derived from the CHAR pulse) is received. This CHPA/ pulse provides the interrupt necessary to shift the control of the motor 22 to the nominal speed control routine shown in FIGS. 14B and 14C, starting at step 80. There is no separate up ramp routine (paralleling switches S2 of FIG. 9) for moving the motor 22 in a reverse direction, consequently, no up ramp flags embodied in steps 68-76 of FIG. 14A need be set. Consequently, since no such flag is set, the speed of motor 22 is controlled by the steps beginning with step 90 on FIG. 14B and ending with step 88 on FIG. 14C. Each CHPA/ pulse will interrupt the processor 30 to repeat the nominal constant speed routine shown in FIGS. 14B and 14C, and thereby adjust the PCO count to the counter means H3-J3 by comparing the CSC count with the NSC count for the reverse direction.
The following illustrates the various counts used in an embodiment of this invention; however, the techniques of this invention may be used with other counts depending upon the specific application used. The experimentally derived count which is used in step 58 of FIG. 14A is an eight bit binary count which is equal to 64. This count is output to latch F5 (FIG. 2) as an inverted count of 191, and multiplexed into the counter means H3-J3 where the count of 191 is preset thereupon. After 65 pulses from clock φ1/, the TC count from counter means H3-J3 causes the control means K3 to change state, ending the energizing on period to motor 22 and causing the off period data 50 which is a binary count of 128 (to establish the duty cycle mentioned earlier herein) to be preset upon the counter means H3-J3 to begin the deenergizing off period to the motor 22. After 128 φ1/ clock pulses, the TC count of counter means H3-J3 is reached, causing the control means K3 to change state ending the deenergizing off period and starting the next energizing on period to motor 22. Several such cycles are alternated until the motor 22 has moved the carriage means 12 sufficiently far to enable the first CHAR pulse (from velocity sensing means 40) to be produced. At this point the binary count which is entered upon the switches S2 (FIG. 9) is stored in the PCO counter as indicated in program step 72 of FIG. 14A. At this point it should be stated that the binary counts which are entered upon the switches S1 and S2 and the counter means C2-D2 (FIG. 2) are inverted by conventional interface logic (not shown) prior to being processed by the processor 30 as is customarily done in programming when it is desireable to adapt to positive or negative logic in programming or to minimize the hardware used, and these binary counts are also inverted back by the interface logic when placed on the data bus of the processor 30 to be output therefrom. A binary NSC count of 56 which represents or corresponds to the desired nominal velocity of the carriage means 12; however, due to the inversion mentioned, a binary count of 199 is actually entered on the switches S1 (FIG. 7).
After the motor 22 has accelerated the carriage means 12 as described in relation to the speed control program 34 shown in FIGS. 14A-14C, an input from counter means C2-D2 (FIG. 2) is inputted to the processor 30 as shown in step 92 in FIG. 14B. Typically, when the motor 22 is driving the carriage means 12 at approximately the desired nominal velocity, a CSC count of approximately 56 will be recorded on the counter means C2-D2. Assume for the moment that a count of 57 is recorded on the counter means C2-D2. This CSC count of 57 is inverted by the interface logic previously mentioned to become a binary count of 198 as received by the processor 30 in step 92 of FIG. 14B. This binary count of 198 is complemented in step 94, to become a binary count of 57, and is compared in step 104 as previously described. The NSC count of 56 which was recorded as a binary 199 on switches S1 and inverted by the interface logic mentioned, becomes a binary count of 56 when handled by the processor 30. According to the logic equations presented earlier herein, because the NSC count (56) is less than the CSC count (57) as examined in step 104, the PCO count is increased by 1 as indicated in step 106. This has the effect of modifying (increasing) the energizing on time to motor 22 to make the motor 22 drive the carriage means 12 faster. While the energizing on time to motor 22 is modulated by this invention, it is conceivable that other parameters such as current etc. of a motor can be modulated to obtain the benefits of this invention. If the actual velocity of the carriage means 12 had been greater than the desired nominal velocity, a CSC count of perhaps 55 might be recorded on the counter means C2-D2 between two consecutive CHAR pulses. A CSC count of 55, after inversion by the interface logic, becomes a CSC count of 200 at step 92 of FIG. 14 and a CSC count of 190 at step 94 as previously mentioned. At step 104, the NSC count (56) in the example given in this paragraph is greater than the CSC count of 55; therefore, the program would continue from step 108 on FIG. 14B through step 114 on FIG. 14C. Consequently, from step 114 the last PCO count recorded in memory would be decremented by 1 to produce a new PCO count which is output in step 84 of FIG. 14C. The reduced PCO count has the effect of shortening the energizing on time for the motor 22, and accordingly, the velocity of the carriage means 12 will be reduced. For example, if the PCO count is a binary count of 56, it is inverted by the interface logic mentioned to become a binary count of 199 on the data bus D0/-D7/, which is fed into the latch F5 in FIGS. 2 and 3A. The count of 199 is then multiplexed into the counter means H3-J3 by the multiplexer means H2-J2 to preset the counter to a binary count of 199 for the start of an energizing on period. The φ1/ clocking pulses then increment the counter means H3-J3, and on the 57th clock pulse, the TC output therefrom will cause the control means K3 to change state, thereby terminating the energizing on period and initiating the start of a de-energizing off period. In the example being given, a PCO count of 56 minus 1 would equal a reduced PCO count of 55 which after inversion by the interface logic would present a binary count of 200 to latch F5 which is multiplexed to the counter means H3-J3; only 56 φ1/ clocking pulses would be needed to cause the control means K3 to change state thereby shortening the energizing on period. Thus reducing the PCO count in step 114 (FIG. 14C) has the effect of reducing the velocity of the carriage means 12, and increasing the PCO count in step 106 (FIG. 14B) has the effect of increasing the velocity of the carriage means 12 and the wire matrix printer 14 thereon, as is apparent from the graph shown in FIG. 8. The PCO counts are arranged to start high (a binary count of 64 from step 58 of FIG. 14B) as shown in FIG. 8 to get the motor started with a long energizing on period; however, the control thereof is arranged to permit the constant speed control routine shown in FIGS. 14B and 14C to take over before the velocity of the carriage means 12 and wire matrix printer 14 thereon have reached the desired nominal velocity. This is apparent from step 72 of FIG. 14A in which a binary count of 51 is fed into the PCO counter, although the count which is actually recorded on the 8 bit switches S2 is its complement or a binary count of 204. This prevents excessive "overshoot" when accelerating the moveable member or carriage means 12 to the desired nominal velocity shown. As is apparent from the graph of FIG. 8, the PCO counts are adjusted in step fashion or increments of 1 for each CHAR pulse when in the constant speed control routine (FIGS. 14B and 14C) to provide gradual acceleration and deceleration as needed.
The off period data 50 (FIG. 2), which is a binary count of 128 recorded on the multiplexers H2 and J2, is preset upon the counter means C2-D2 and incremented to the terminal count thereof to cause the control means K3 to change state as previously described.
The reverse upramp routine (FIG. 14D) utilizes a NSC count of 31 in step 112. This NSC count of 31 for reverse is utilized for the upramp routine and is also used in the nominal constant speed control routine shown in FIGS. 14B and 14C when the motor 22 is driving the carriage means 12 in reverse.
The detail program listing for the program shown in the flow charts in FIGS. 14(A-D) is shown in FIGS. 15A and 15B. The various instructions and codes used are the standard ones defined in the "Intel 8080 Microcomputer Systems Manual" which was published in Sept. 1975, for example. Page 4-15 of this manual provides a summary of the processor instructions, and pages 4-1 through 4-14 provide detailed explanations of the 8080 instruction set.
FIG. 14E shows the fire hammers routine associated with the speed control program 34. The general program 32 conventionally performs the usual printing functions such as checking on paper indexing, and collating the information to be printed. A CHPA/ is utilized to initiate the actual printing or firing of the hammers via the associated solenoids 38 (FIG. 1) of the wire matrix printer 14. Upon receiving a CHPA/ pulse (shown also in FIG. 14F), the print column image for the first column image is output to latch H5 in step 126 over the data bus DB0/-DB6/ by the SELPRT 5 signal and the associated timing strobe signal WR.G/ shown in FIG. 2. In the embodiment described, a 7 × 9 matrix format was utilized, with the height of the characters being printed being 7 "dots" high and 7 "dots" wide and with two "dot" columns being provided for spacing between adjacent characters. The hammer fire pulses HMR1A-HMR7A (FIG. 2) are utilized by conventional drivers (not shown) to activate the solenoids 38 to print the first print column images numbered 1 in FIG. 14F.
At this point, it should be stated that the fire hammers routine in FIG. 14E will determine the interval to be set between the print column image 1 and the next print column image (as for example 2 in FIG. 14F) to effect an even spacing of the print image columns in accordance with the actual velocity of the carriage means 12. In this regard, step 128 of FIG. 14E is utilized to determine whether or not the CSC count for the previous half character, i.e., the period between two successive CHAR pulses from the velocity sensing means 40, was within 10% of the NSC count, the acceptable spread being within 10% above and within 10% below the NSC count. If the previous CSC count is within this acceptable spread, the program shifts to step 140 in which a timer is set for normal, meaning that the carriage means 12 was moving at the nominal desired velocity. In the embodiment being described, the timer may be the "A" Register associated with the processor 30 on which particular values are set, and then decremented to zero to obtain the desired elapsed time between successive print hammer firings. For example, a count of 7 sets the timer (A register) for obtaining a normal elapsed time between the print column images. From the point A at location 134 in FIG. 14E, the A register is decremented in step 142 and step 144 returns the control from the routine of FIG. 14E to the general program 32 where the data for the next print column image (for column 2) is obtained to repeat the process at step 126.
If the previous CSC count is not within 10% of the NSC count as compared in step 128 of FIG. 14E, the program shifts to comparison step 130 where the CSC count is compared with the NSC count to determine whether or not the CSC count is lower than the NSC count by more than 10%. If the answer is "Yes", the timer (A register) is set in step 132 for a short period, meaning that the carriage means 12 was moving at a rate faster than the desired nominal velocity. The control then shifts to A at point 134 from which steps 142 and 144 are repeated. If the answer to step 130 is "No", the control shifts to step 136 where the CSC count is compared with the NSC count to determine whether or not the CSC count is higher than the NSC count by more than 10%. If the answer is "Yes", the timer (A register) is set in step 138 for a long period, meaning that the carriage means 12 was moving at a rate slower than the desired nominal velocity. The program then shifts to A at point 134 from which steps 142 and 144 are repeated. If the answer to step 136 is "No", the control shifts to step 140 which was previously described. The timer ("A" register) in step 142 has a count of 7 set thereon for a normal elapsed time between print column images, a count of 5 for a short period, and a count of 8 for a long period. After the timer in step 142 is decremented to zero from one of the preset values (5, 7, or 8) set upon the "A" register in the example being given, the general program 32 collates the data required for the printing of the second print column image numbered 2 in FIG. 14F. The elapsed time (T) obtained by decrementing the "A" register is shown between the firing of the first and second print column images shown in FIG. 14F. The firing of the first four print column images is controlled by the time interval between the prior CHPA/ pulse and the CHPA/ pulse 146 shown in FIG. 14F., while the print column images 5-9 are controlled by the period between the CHPA/ pulses marked 146 and 148. There are two CHPA/ pulses (derived from CHAR pulses) required for the printing of a complete character with the second CHPA/ pulse (like 148) occurring between the printing of the 4th and 5th print column images. In the embodiment described, the wire matrix printer 14 prints at a rate of 72 characters per second.
The detail program listing for the program shown in the flow chart of FIG. 14E is shown in FIG. 15C.
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An apparatus and method for controlling the velocity of a moving member like, for example, a print head carrier. The apparatus includes motor means which drives the carrier along the platen of a printer. The motor is driven by alternately energizng it during an "on" period and deenergizing it during an "off" period. A velocity detector detects the actual velocity of the carrier and a processor determines whether an overspeed or an underspeed condition exists relative to a desired velocity. A counter capable of counting pulses relative to the on and off periods receives the output of the processor and is utilized to effectively shorten or lengthen the "on" period, respectively, whenever an overspeed or underspeed condition exists.
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This application is a continuation-in-part of U.S. patent application Ser. No. 07/215,521, filed Jul. 6, 1988, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to the field of incubation of viable eggs and larvae of fish, crustaceans and similar organisms.
2. DESCRIPTION OF RELATED ART
When traditional incubation methods are used, the fatality rate among eggs and larvae is high due to impact and other mechanical forces. This is a problem for both pelagic (freely-suspended)and demersal (seal bottom resident) fish eggs.
Certain types of larvae are extremely sensitive to mechanical forces. This is particularly the case for halibut, where the incubation of the larvae prior to the start of feeding seems to be a problem for the production of fry.
In some situations, traditional approaches necessitate keeping the salinity of the water at a high level to prevent the eggs and larvae from sinking to the bottom. From an energy perspective, it would have been more rational to incubate eggs or larvae at lower salinity levels, since these organisms will then use less energy for ion-control.
Another substantial problem with traditional incubation systems is that eggs/larvae are very exposed to fungal and bacterial infection.
A further difficulty with present systems is the maintenance of eggs/larvae during vaccination and gene transfer. This is a factor which makes such treatment difficult to implement on a commercial scale.
SUMMARY OF THE INVENTION
The primary object of the invention is the incubation of eggs/larvae of fish and crustaceans, where the eggs/larvae are protected as much as possible from physical forces such as impact and blows.
A further object of the invention is to prevent the organisms in question from coming into contact with fungi, viruses, and bacteria, and to immobilize the organisms so as to allow injection and vaccination.
It is another object of the invention to provide a method and apparatus allowing eggs or larvae to be transported for longer distances, without liberating the eggs/larvae from their safe incubation environment.
These objects are achieved by encapsulating and thereby immobilizing the eggs in a gel material, in which the gel material protects the eggs/larvae from external mechanical influence. Further, the nature of the gel ensures sufficient oxygen supply, and transport of excretory material including CO 2 and NH 3 away from the egg/larvae.
One method for incubating eggs comprises locating the eggs into cavities (gel chambers) in a gel plate (similar to an egg tray), whereupon a membrane is laid upon the plate, covering the entire plate and all gel chambers containing the eggs and establishing a tight seal. The seal should be so tight that there is no possibility for either air or liquid to flow between the gel chambers, or through the sides between the membrane and gel plate, thereby providing sterile surroundings during the incubation. Moreover, the eggs should be disinfected before being transferred to the respective gel chambers.
The plates may comprise a dissolvable gel material, whereupon the eggs are cast into the plate in one step. When the incubation is complete, the gel material may be dissolved by, for example, flushing away the components interconnecting the gel with, for example, water, NaH 2 PO 4 or monovalent ions, this dissolving process requiring a relatively long period of time. Some gels can also be removed by temperature change.
The plates can alternatively be made of a relatively rigid material, such as polyacrylamide gel (hereinafter referred to as PAAm gel). The plates are then cast in advance with the desired shape, dimensions and number of gel chambers by using a mold having an inverse geometry to the plate. In case of a PAAm gel, the resulting plate is thereafter washed in order to remove any unreacted monomer remaining in the gel. Then, the eggs are located into their respective gel chambers, and finally the gel chambers are completely covered and closed by applying a membrane on the plate. It is important that the plates be cast with smooth and planar surfaces in order to ensure a sufficient seal between the plate and the membrane.
The membrane may be composed of the same material as the plate itself, but in which the thickness of the membrane is small enough to ensure a sufficient flow of oxygen from the surroundings into the gel chambers and excretory material (CO 2 , NH 3 ) away from the gel chambers. In order to provide a tight seal between the respective gel chambers and the surroundings, fixing plates are applied to both sides of the incubation plate. The plate, now conforming to the membrane, has in advance been perforated in such a way that the respective gel chambers are allowed to communicate with the surroundings through the membrane. The oppositely disposed fixing plates are held together by means of clamps, screws, bolts or the like. When the incubation is complete, the larvae are uncovered and released by simply mechanically separating the membrane from the plate.
In case of a PAAm gel, it is not possible to cast the plate with the eggs in one step, because the poisonous raw materials present in the mixture before polymerization will kill the eggs. However, one step processes are possible with certain dissolvable gel formers.
Thus a further method for incubating eggs comprises encapsulating the eggs in spherical capsules comprising a dissolvable gel material. If an alginate is used as a gel material, the eggs are first stirred into an alginate solution having a predetermined consistency, in which the resulting mixture then is dripped through a pipe, hose or the like, into a bath containing CaCl 2 in order to harden the gel material. This method results in nearly spherical capsules, although the term "spheres" as used herein also applies to capsules having other geometries, such as elliptical. When the larvae are evolved, the larvae may under certain circumstances escape from the gel independently, or the gel may be dissolved by exchanging the ions interconnecting the gel.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows in cross-section a plate for incubating eggs and larvae in accordance with the invention;
FIG. 2 shows a case including several plates according to FIG. 1 for incubating eggs and larvae in accordance with the invention;
FIG. 3 illustrates one method for encapsulating eggs in a dissolvable gel material; and
FIG. 4 shows a plan view of a gel chamber in accordance with FIG. 1, illustrating the principles of mass transfer via a membrane.
DETAILED DESCRIPTION OF THE INVENTION
Two different gel forming materials are preferred for the invention, polyacrylamide and alginate. However, other gel forming materials may also be utilized, such as kappacarrageenan, and Instacryl-L® and Instacryl H® (registered Trademarks of Kodak International Biotechnologies, Inc. Conn.).
In the following methods for production of the gel materials, physical properties of the materials, and methods for incubating eggs in accordance with the present invention as described.
PAAm Gel, Production and Properties
This gel is made up of four different components, acrylamide (hereinafter referred to as AAm), methylene bis-acrylamide (hereinafter referred to as bis-AAm), ammonium persulphate and tetramethylethylenediamine (the latter hereinafter referred to as TEMED). Methylene bis-acrylamide acts as a cross-linking agent for the polymer, and accordingly affects strength and pore size of the final gel. The desired concentration of AAm may for example be provided by diluting a parent solution with distilled water. This parent solution comprising AAm and bis-AAm should be stored in dark surroundings. Then, TEMED is added to the solution, whereupon an inert gas such as nitrogen is bubbled through the solution for about 5 minutes. Ammonium sulphate is then added to the solution, and the gel polymerizes and hardens over a period of a few minutes, depending on various factors such as concentration, temperature, and oxygen level. Moreover, the solution may be sterilized by autoclaving before hardening.
The concentration of AAm in the starting solution is from about 5 to about 10% by weight, based upon the weight of the water; the concentration of bis-AAm is about 5% by weight of the total amount of AAm; and the concentration of TEMED constitutes about 0.5 ml/liter based upon the starting solution comprising all four components. In order to allow gel formation to occur, the minimal amount of monomer in such a mixture is about 2.5% by weight. If the concentration of AAm is less than 5%, the resulting gel will exhibit a consistency which is too loose to be regarded as practically usable, and if the concentration of AAm is more than 10%, the resulting gel will exhibit a too rigid and brittle consistency resulting in a reduction of the water permeability of the gel.
The average pore radius in gels containing a 5-10% AAm by weight with respect to water, is 1.2-1.8 nm. Accordingly, the pore diameter is 2.4-3.6 nm. The diameter of the water molecule is only 0.3 nm, while the smallest bacteria have a diameter of about 1×10 -6 m. Accordingly, water and other relatively small molecules can diffuse unhindered through the gel, whereas relatively large molecules and bacteria are prevented from entering the gel.
Alginate Gel
Gel materials for use with the present application may be produced by using a dissolvable alginate gel with an alginate content about 1 to 4% by weight. The gel is formed by simply dripping aqueous alginate solution into an aqueous solution containing nontoxic, stabilizing, divalent ions, e.g. Ca 2+ , Sr 2+ , Ba 2+ , generally having a concentration between 0.1 and 1.0 moles/liter (Mg 2+ ions destablize the gel). The alginate may, before being added to this solution, be sterilized by autoclaving and intermixed with eggs for incubation, so that the eggs are completely surrounded by the alginate solution, whereupon the alginate gel including the encapsulated eggs hardens contacting a solution such as CaCl 2 . The mechanism for this hardening is diffusion of Ca 2+ ions into the gel structure resulting in bonding the alginate chains together. Thus, the strength, pore size and the consistency of the resulting gel may be tailored by altering the concentration of Ca 2+ in the solution. Divalent ions may also be added to the surrounding medium during incubation to stabilize the gel.
Dissolution of the gel may be carried out by flushing/washing the ions interconnecting the gel away. If the surrounding medium has a low concentration of stabilizing ions, these interconnecting ions will diffuse out from the gel and into the surrounding medium, resulting in a decrease of the gel strength. If the surrounding medium for example is sea water, the Na + ions will replace the Ca 2+ ions in the gel, whereupon the gel strength gradually decreases because the Na-alginate is soluble in water, as opposed to Ca-alginate. Moreover, the addition of Na + and PO 4 -3 ions to the surrounding medium, such as with NaH 2 PO 4 , will dissolve the gel structure and release the eggs/larvae.
Some gel materials, such as agar, often require gel forming temperatures which would kill the eggs/larvae, and are accordingly not intended to be included in the term "dissolvable gel" as used herein.
The alginate gels can, like PAAm-gels, be utilized for casting of plates for incubation including membranes, although it is preferred to form gel capsules when alginate is used.
Kappa-carrageenan Gels
As mentioned above, kappa-carrageenan can also be utilized for incubation, both with respect to capsules and to plates. This type of gel is in principle produced by adding kappa-carrageenan, typically in a concentration of 1-3% by weight in distilled water, to the eggs for incubation, whereupon the resulting mixture is dripped or poured into an aqueous solution of gel stabilizing ions, typically K + in the form of KCl, in which the concentration of KCl is less than 0.2 moles/liter, depending on the desired gelling temperature. This procedure may be carried out at room temperature, or alternatively at lower temperatures. The gelling temperature is dependent on the concentration of KCl; the lower the concentration of KCl, the lower gelling temperature. However, this gel material requires a certain concentration of K + ions present during the incubation of the eggs, in order to stabilize the gel. Other gel stabilizing ions are Cs + , Rb + and NH 4 + .
Carrageenan gels show marked hysteresis, dissolving at a temperature in the range of 5°-30° C., typically about 10° C., above the gelling temperature, a property not observed for alginate. However, the gel can also be dissolved without utilizing heat in the presence of I - ions, for example from LiI.
Thus, carrageenan gels are thermoreversible in the sense that they "melt" upon heating and reform in cooling. This is in contrast to gels made from alginate with divalent metal ions, which are stable up to the boiling point of water. Whether this is a qualitative difference between the two gelling systems or merely a quantitative difference within the temperature range accessible for investigation (0°-100° C.) is not clear. It is well known that gels of carrageenan become increasingly stronger as the temperature is lowered below their melting point. Temperature dependence of the modulus of rigidity is also a property of alginate gels, i.e. the modulus remains approximately constant until the temperature of rupture or dissolution is reached. Such temperature dependence is most easily explained by assuming that junctions are ruptured during compression, and that their strength decreases when the temperature is increased. A transition temperature for alginate above the boiling point of water may therefore exist, and it is interesting that in certain mixed gelling systems (pectin and gelatin) thermoreversible gels can be formed.
Membranes
When incubating eggs/larvae with the plate method in accordance with the invention, the membrane provides the substantial part of the mass transfer between the eggs/larvae and the surrounding medium outside the gel.
Gel membranes are produced by casting a reinforcing structure into the gel, for example in the shape of a net-like structure. In the gel forming process, the net-like structure and the gel formers (solution of monomers/polymers) are compressed in a mold including a lid positioned thereabove. The reinforcement is strongly preferred in order to ensure sufficient mechanical strength of the membrane. If the reinforcement is omitted, the resulting membrane will easily break apart in handling. When using a reinforcement the gel membranes can be constructed very thin, typically 1 mm, but the thickness may be greater. It is preferred that the thickness of the membrane should be as small as possible, but a practical range of thickness is from 1 to 3 mm. The thickness of the gel membrane should be small enough to provide a sufficient transport of excretory matter away from the eggs/larvae and of oxygen to the eggs/larvae. Accordingly, the lower limit of thickness is restricted by practical handling, i.e. the membrane should be thick enough simply to prevent the membrane from disintegrating or breaking apart.
The membranes can comprise the same gel material as the plates, i.e. for example PAAm gel, alginate gel, kappa carrageenan, or Instacryl-H or Instacryl-L.
Experiments utilizing different types of membrane filters available on the market have been carried out. Membranes from Schleiner & Schull comprise cellulosic nitrate or nylon having a pore diameter of 0.2×10 -6 and 0.45×10 -6 m, respectively. Moreover, experiments utilizing Nucleopore filters having a pore diameter of 8×10 m have been carried out. As explained in further detail below, the membranes available on the market do not seem to provide any benefits with respect to membranes comprising gel material. One advantage of gel material is the transparency, resulting in a convenient surveillance of the development of the eggs/larvae from outside the gel chamber. Moreover, production of the gel membranes is less expensive than use of the commercially available membranes.
Physical Properties of the Gels
The water permeability of the gel is a property which is assumed, to a certain extent, to constitute an important property since in the absence of water, the eggs will dry out and die. The water permeability of the gel can be evaluated by casting gel plates (a diameter of 63 mm) having a thickness of 1 to 7 mm. These plates are located upon a grating at the bottom of a water filled cylinder. The measurements are carried out at a constant liquid head of 1962 Pa.
Generally, the water flux through the gel is small at the actual experimental conditions. Depending on the type of the alginate gels examined, the water flux have been determined to be within the range of 0.06-1.32 1/(m 2 hour). The water flux in 4% PAAm gel is determined to be 0.02 1/(m 2 . hour). However, the uncertainty connected with those measurements is relatively high, because the volume changes measured are small and occur over a long period of time.
The water permeability of the membrane filters is substantially higher. Membranes from Schleiner & Schull have been tested in the same manner as those mentioned above, with the following results:
______________________________________BAS 83 (0.2 um): 376 l/(m.sup.2 · hour)Nytran NY 13N (0.45 um): 405 l/(m.sup.2 · hour)______________________________________
Considering the great difference of water permeability between gel membranes and membrane filters available on the market, one might have concluded that membrane filters were totally superior to gel membranes with respect to incubation. However, this is not the case when considering mortality rates from hatching and incubation. There are no clear tendencies suggesting that one type of membrane is better than the other, but gel membranes are preferred because of their transparency and low cost.
The elasticity of the gel materials is measured by compressing gel cylinders with constant cross-section (a diameter of 14 mm and length of 20 mm) at a constant rate of 0.2 mm/sec. The relationship between force and length of deformation is recorded on a printer, and modulus of elasticity (the so-called G modulus) may be calculated from the initial angle of declination of the curve. The force required to compress the gel 1 mm (P 1 mm) is also recorded. The measurements are carried out by means of an instrument of the type "Stevens L.F.R.A. Texture Analyser". The results from three different types of gels are set forth in Table 1 below.
TABLE 1______________________________________Gel Type F.sub.1mm (gram) G (kN/m.sup.2)______________________________________0.5% alginate*.sup.) 5 124% alginate **.sup.) 392 1314% PAAm 3 3______________________________________ *.sup.) Protan LF 10/60 **.sup.) Protan LF 20/40 RB
The results from Table 1 show that a 4% alginate gel is substantially more rigid than a 0.5% alginate gel, whereas a 4% PAAm gel to some extent is more elastic than a 0.5% alginate gel.
One of the advantages of the PAAm gel compared with alginate gel is clearly apparent from Table 1.1. The table shows the results with respect to force required to compress the gel 1 mm, comparing fresh gels with gels stored in sea water in 190 days at 5° C.
TABLE 1.1______________________________________ P.sub.1mm (grams) P.sub.1mm (grams)Gel Type Fresh Gel Stored 190 Days______________________________________1% alginate*.sup.) 26 72% alginate*.sup.) 82 274% alginate*.sup.) 374 1064% PAAm 3 47.5% PAAm 18 1915% PAAm 68 73______________________________________ *.sup.) Protan LF 10/60
From Table 1.1 it is apparent that the strength of the alginate gels is dramatically reduced after being stored in
sea water, whereas the PAAm gels are not affected at all.
Moreover, the alginate gels were covered by a slime layer after storage, thereby indicating microbial activity. No such activity was observed for the PAAm gels.
The reason for the resulting decrease in strength for the alginate gels may be that the gel is destabilized as a result of a deficiency of calcium ions in the sea water resulting in removal of the calcium ions by diffusion in favor of sodium ions. The gel structure is interconnected by calcium ions, whereas sodium alginate is soluble in water. Another possible explanation for the decrease in gel strength may be enzymatic cutting of the alginate chains due to microbial activity. However, both of these disadvantages may be avoided by adding CaCl 2 to the water surrounding the gel, and by preventing microbial activity, such as by adding disinfecting agents. Such circumstances impose additional requirements for alginate gels, and accordingly, PAAm gels are preferred.
Incubation Techniques
Most of the experiments have been carried out with salmon and rainbow trout by means of the techniques involving plate incubation according to the invention.
a) Plate Incubation
For plate incubation both alginate gels and PAAm gels can be utilized, as stated above. Since PAAm gels are preferred for production of incubation plates, this gel material will primarily be described.
When the reaction mixture for production of PAAm gels is prepared (as described hereinabove), the mixture will polymerize and harden during a short period of time, i.e. a few minutes. Therefore, the reaction mixture should be poured into a suitable mold for casting incubation plates immediately. This mold should exhibit an inverse geometry to the desired plates. After the gel forming is complete, the cast plate should rest for a few hours before use, in order to ensure a complete polymerization, preferably in water in order to prevent the gel material from drying out. The final cast gel plate should be removed from the mold submerged in water, since this arrangement reduces the risk of breaking the plate in pieces. Thereafter, the gel plate should be stored in water, to which may be added components for preventing growth of microbes.
The plates can be produced with any dimension and arrangement of gel chambers, depending on the combination desired. The shape of the gel chambers can also be chosen freely, but semi-spherical shapes are preferred. Typical plates which often have been utilized for the experiments have a length of 14 cm and a width of 16 cm. The thickness of the plates can be varied, depending on the size and type of the eggs/larvae, typically from 1 to 1.5 cm. Moreover, the typical plates are provided with 54 gel chambers. The incubation plates can also be provided with gel chambers in opposite surfaces of the plates with membranes covering both surfaces. In order to increase the area available for mass transfer, i.e. transportation of excretory matter away from the gel chamber and oxygen into the gel chamber, it is possible to provide the plates with one or more gel chambers extending through the whole plate; the gel chamber then communicates with the surroundings from both sides of the incubation plate. In this case, membranes must be again applied to both sides of the plate. However, it is not necessary to extend the depression through the entire thickness of the plate, since the same effect can be achieved by extending the depression through most of the thickness, leaving only a thin gel portion, substantially of membrane thickness, between the depression and the opposite surfaces of the plate. Reinforcement of this portion of the plate may be necessary.
Casting the eggs directly into a PAAm gel before gel formation in one step is not possible because the reaction components are poisonous. After the polymerization reaction is completed, the gel is no longer poisonous, but the resulting gel should be thoroughly flushed in order to remove any remaining poisonous monomers.
The gel membranes are produced in the same manner and can comprise the same materials as the gel plate, as described hereinabove.
One of the advantages of the PAAm gel is that the PAAm gel may easily be cast into different shapes, and it is easy to achieve planar and smooth surfaces. This is an important aspect with respect to providing a sufficient seal between the membrane and the gel plate. Further, the resulting gel plates are homogenous and do not shrink during the gelling process.
In the method of incubation, gel plates and membranes are washed with water, preferably sterilized water, and may be by disinfected prior to the washing by means of a chlorine bleach. Then, the gel plates are cooled and located upon ice during the whole procedure until the plate arrangement has been mounted. In most cases, the gel and the membrane are irradiated with ultraviolet radiation for about 15 to 30 minutes before supplying the eggs into the gel chambers. Immediately before the sterilized eggs are supplied, the gel is preferably washed with sterilized water. The resulting water film located on the plate surface will simplify the "rolling" of eggs into their respective gel chambers. Moreover, the eggs should be entered in an environment as dark as possible When all eggs have been located in their respective gel chambers, one in each chamber (e.g. 54 eggs), the membrane(s) is applied onto the plate. In order to maintain a tight seal, the gel plate and the membrane or membranes are fixed together by means of a frame, a perforated plate or the like, for example, constructed of polyvinyl chloride, plexiglass or polycarbonate. However, transparent plates comprising polyvinyl chloride or plexiglass are the preferred materials, wherein a plate conforming to the membrane is perforated in such a way that the respective gel chambers are allowed to communicate with the surroundings through the membrane. The oppositely located fixing plates are held together by means of clamps, screws, bolts or the like. The plates should preferably be constructed of a plexiglass This arrangement is illustrated in FIG. 1.
Referring to FIG. 1, gel plate 6 comprises depressions forming gel chambers 4 containing the eggs, where the gel chambers communicate with the surroundings. A membrane 3 is applied to the gel plate 6, covering all gel chambers, and thereby providing a proper seal between the respective gel chambers and between the chambers and the surroundings, after fixing the plate/membrane with fixing plates 15 and bolts 16.
Then, the complete incubation plates including the eggs are immediately transferred to incubating cases located in a dark cool room at a temperature generally between about 1°-10° C., depending on the species. An example of such a case is illustrated in FIG. 2. Each of the incubation cases 12, which in this example have outer dimensions 35×19×21 cm, can contain six incubation plates 13 as described above. The individual plates 13 are placed into the case in grooves or the like (not shown). The plates 13 can also be mounted in a horizontal manner, but a vertical arrangement of the layered plates is preferred. Below this plate arrangement, pipes, hoses, or the like 14 are located for distributing oxygen rich water into the case 12, preferably in an upwards direction in front of each plate 13. After a certain period of time, the supplied water exits the case 12 via an overflow pipe 15. If the plates were arranged in a horizontal manner, the distributor pipes 14 would have to be positioned in a substantially vertical direction, thereby distributing water in a horizontal direction between the individual plates 13.
One mode of carrying out this water distribution is to completely submerge the plates 13 in water, as shown in FIG. 4, where oxygen dissolved in the water passes to the eggs through membrane 3 and waste products NH 3 and CO 2 pass out through the membrane. However, it is also possible to spray/shower the individual plates with water, thereby providing a downwards flowing water film for allowing mass transfer to occur. When using spray/shower water distribution, the plates should be arranged in a vertical manner.
The typical flow of water through such a case is from about 0.5 to about 1.0 liters/minute with the water having a temperature between about 5 and about 9° C., depending on the species. Sporadic measurements of dissolved oxygen in the water should indicate that water saturated with oxygen prevails.
The incubation procedure is continued for a certain period of time until the eggs are hatched, and the larvae have become viable, e.g. from 6 to 10 weeks in the case of salmon eggs. Then the hatched larvae are simply liberated from the incubation plates by removing the fixing arrangement (e.g. screws) and removing the gel membrane. The larvae may then be transferred to, for example, rearing tanks for start-feeding.
In certain instances, the gel plates will be incubated in a water saturated air atmosphere in the cases described or in larger cases, with or without spraying the plates with water. This spraying can be carried out continuously or periodically. The advantage of this method of incubation is that the water consumption is decreased. Moreover, one has the opportunity to increase the supply of oxygen to the eggs/larvae by increasing the partial pressure of oxygen in the atmosphere surrounding the incubation plate.
The principle of showering/spraying the plates with water simplifies long distance transport of the eggs/larvae during incubation. For such purposes the water should be recirculated in order to decrease the volume of water necessary.
Incubating with plates and membranes comprising a dissolvable gel material is carried out in the same manner as with the PAAm gel described above, except for the different methods for production of the gels. Moreover, the Instacryl-L/-H may also be used for production of dissolvable plates and membranes in accordance with the present invention.
Incubating with Spheres
In the following, an example illustrating production of alginate gel spheres for incubating eggs according to the invention is provided.
The alginate raw material may be provided in powder form. Alginate, e.g. Protan LF 10/60 or LF 20/40, is carefully sprinkled little by little into distilled water under continuous agitation. The concentration of alginate is raised to between 1 and 4%, based upon the weight of water. When adding the powdered alginate, it is important to avoid formation of lumps. The water may, if desired, be heated, for example, to a temperature of up to 100° C. The agitation of the mixture is continued until all alginate is dissolved. If NaCl (0.2 moles/liter) is present in the mixture, the resulting gel will achieve a more homogenous structure, but this is not required. Then the homogenous solution of alginate is cooled, typically to a temperature of 5° C., whereupon the eggs for incubation are added to the mixture. The resulting mixture comprising eggs and alginate solution is added dropwise into an aqueous solution of CaCl 2 having a concentration of from about 0.1 to about 1.0 moles/liter. This solution of CaCl 2 will typically also have a temperature of about 5° C. The gel formation occurs immediately, but the resulting spheres, each containing completely embedded eggs should harden in the solution for a certain period of time depending on the type of alginate and the concentration of CaCl 2 . The resulting alginate gel spheres containing the eggs are thereafter transferred to a sufficiently sterilized system for incubation, preferably comprising 0.05-0.2 moles Ca 2+ /mole K + .
In FIG. 3, illustrating one method for formation of the spheres, the eggs 21 are supplied to a mixing pipe, hose or the like 25, from a container 22 via a supply pipe 23 and are intermixed with the alginate solution 27 from a second container 26, supplied via a supply pipe 24 or the like. The resulting mixture of eggs and alginate solution is thereafter transferred to a mixing chamber 28, and dropped through a relatively thin tube or the like 29 into a third container 30 containing the solution of CaCl 2 31. Mixing chamber 28 is optional and is not necessary to achieve sufficient mixing.
c) Vaccinating
A customary method for vaccinating fish fry is so-called "dipping or bath vaccination", i.e., the vaccine is not injected, but dissolved in the surrounding water. According to the invention, experiments comprising injection of a vaccine solution into the gel chamber in which the larvae resides, have been carried out. This mode of vaccination has been carried out successfully and the method shows great advantages in that loss of vaccine is negligible. Further, it is possible to carry out an automatic injection of a vaccine solution into the separate chambers, e.g. by using a simple industrial robot. It is also possible to inject the solution directly into the egg yolk in a corresponding manner.
d) Disinfection of Eggs
All the eggs that were utilized in the experiments were disinfected by the supplier by means of Buffodine (100 ppm in 10 minutes). In addition to this treatment, some of the eggs were disinfected in advance of the incubation experiments. However, the results from those experiments do not show any effect on mortality rate of either eggs or larvae from this additional disinfection; since the disinfection by the supplier seems to have been sufficient. On the other hand, those experiments show that the following preparation may be utilized for eggs without any detrimental effects on the eggs:
______________________________________lysozyme (1 g/liter and 100 ppm, 10-40 min), withthe eggs brought into a lysozyme solution beforeincubation, and in some instances the lysozymesolution poured over the gel plate and down into theindividual gel chambers at the same time as supplyingthe eggs.Also useful are:lysozyme (80 ppm) + glycine (1%) for 105 min;Utilized for rainbow trout only.glutaric aldehyde (Glu) (400 and 800 ppm, 10 min);Buffodine (100 ppm, 10 min).Utilized for salmon only.______________________________________
EXAMPLE 1
This example describes incubation of salmon eggs by means of incubation plates in accordance with the invention, utilizing a continuous flow of water through the incubation system. A total of 30 plates were incubated in the incubation cases. The incubation plates were constructed of PAAm gel or of alginate gel having a width of 14 cm and length of 16 cm, and having a thickness of 1 to 1.5 cm. The plates were rinsed, provided with eggs, and mounted as described above. The complete incubation plates were brought into the incubation cases (each having outer dimensions of 35×19×21 cm), resulting in a total of 6 incubation plates in each case. The incubation lasted from 6 to 10 weeks. The yolk sack larvae remained in the gel for different periods of time after hatching, with a maximum of 3 weeks.
Typical percentage of hatching for the most of the plates was between 88 and 100%. Details concerning the composition of the gels, their dimensions, and the incubation described in Table 2.
TABLE 2__________________________________________________________________________ Days of incubation Membrane*.sup.) Percent PercentPlate incubation after Gel thickness/ of ofno. (Total) hatching (% PAAm) Membrane pore size Disinfection Sterilisation hatching survival__________________________________________________________________________ 1-1.sup.#) 41 22 15 Nytran NY 13N 0.45 μm 93 93 1-6.sup.#) 41 22 5 Nytran NY 13N 0.45 μm 88 86control 57 18 92 98 4 A 54 15 7.5.sup.1) Nytran NY 13N 0.45 μm autoclaving 91 50 4 B 56 17 5 5% PAAm 1 mm lysozym autoclaving 92 14 4 C 90 50 10 None (ty11.sup.2)) 91 71 4 D 55 18 7.5 Nytran NY 13N 0.45 μm lysozym autoclaving 83 45 4 E 51 18 2.sup.3) Two.sup.4) Nytran 0.45 μm UV-light 87 55 4 F 51 18 7.5.sup.5) Nytran NY 13N 0.45 μm autoclaving 94 98control 65 16 95 100 6 A 64 15 10 BAS 83.sup.6) 0.2 μm 24 15 6 B 64 15 10 BAS 83 0.2 μm Glu 39 100.sup.7) 6 C 65 16 5 BAS 83 0.2 μm Glu 48 77.sup.8) 6 D 63 15 5 Nytran.sup.9) 0.45 μm autoclaving 94 93 6 E 64 16 7.5 15% PAAm 0.8 μm Buff 78 2 6 F 64 15 5 5% PAAm 1 mm Buff autoclaving 74 3control 73 21 79 100 7 A 70 18 10 Nytran NY 13N 0.45 μm 80 49 7 B 70 18 10 7.5% PAAm 1.1 mm 83 22 7 C 70 18 5 Nytran NY 13 N 0.45 μm Glu autoclaving 80 100 7 D 70 18 5 5% PAAm 1.5 mm Glu autoclaving 87 13 7 E 73 21 7.5 Nytran NY 13N 0.45 μm Buff autoclaving 72 76 7 F 55 3 7.5 5% PAAm 1 mm Buff autoclaving 78 88control 36 10 93 9910 A 36 10 7.5 BAS 83 0.2 μm autoclaving 91 9210 B 76 47 10 None (PVC.sup.2)) 85 5410 C 30 6 7.5 Nucleopore 8 μm autoclaving 89 9810 D 44 21 7.5 5% PAAm 0.7 mm autoclaving 87 1310 E 34 9 10 Two.sup.4) Nytran 0.45 μm 91 8610 F 44 22 10 Two.sup.4) 7.5% PAAm 0.8 mm 98 30control 75 22 78 9911 A 70 17 7.5 Nytran NY 13N 0.45 μm 86 6111 B 70 20 10 5% PAAm 1 mm 79 011 C 74 21 7.5 BA 85 0.45 μm Buff autoclaving 91 9011 D 74 21 10 Nytran NY 13N 0.45 μm Buff autoclaving 89 3611 E 75 22 10 Nytran NY 13N 0.45 μm Glu autoclaving 85 2211 F 70 17 7.5 7.5% PAAm 1 mm Glu autoclaving 80 16__________________________________________________________________________ Key to Table 2 Buff = Buffodine Glu = Glutaraldehyde CB = Chlorine bleach *.sup.) thickness of membrane refers to gel thickness, whereas pore size refers to the membrane filters .sup.# incubated in oxygen/air atmosphere .sup.1) Buffodine added to the gel by production of the plate .sup.2) net comprising polyvinyl chloride or tyll (nylon) covering the ge chambers in the gel plate .sup.3) alginate gel plate .sup.4) the chambers made as holes extending through the gel plate, one membrane on each side of the plate .sup.5) open bottom of the gel plate, covered by tyll (nylon) .sup.6) the membrane wetted by sandalwood oil (makes the membrane transparent) .sup.7) 18% malformed larvae .sup.8) 30% malformed larvae .sup.9) cracks in the membrane
EXAMPLE 2
This example illustrates incubation of eggs from rainbow trout by means of the plates in accordance with the invention, in which, contrary to Example 1, the plates in one incubation case were periodically showered/sprayed, and where one incubation case was provided comprising a water saturated atmosphere without utilizing showering/spraying with water. A total of 41 plates were incubated in the cases spread over a total of 7 cases. The thickness of the gel membranes varied from 1.0 to 1.7 mm.
The incubation lasted for the major part of the plates for 8 to 12 days and the larvae remained in the gel for 0 to 10 days after hatching. Typical percentage of hatching for plates incubated in a continuous flow of water was 80-100%, in which the mortality rate for the larvae after hatching varied from 0-100%. With respect to the plates incubated with periodically spraying/showering with water, the percentage rate of hatching varied from 55 to 90% and the mortality rates from 100-8%. The plate which was sprayed directly exhibited best results. The remaining plates were positioned therebelow, and were wetted with the water from the uppermost positioned plate. This indicates that directly spraying of the plates will stabilize the percentage of hatching and survival at a high level, also in an atmosphere containing air/oxygen.
The advantage of the spraying method is that eggs may be transported in a sealed, sterile system, simplifying control of epidemic diseases and separation of different groups of eggs from each other. Moreover, marine eggs may be transported by airplane with a minimal amount of sea water present.
The plates incubated in a water saturated atmosphere without spraying with water showed, except for one, substantially inferior results with respect to hatching and survival rates than the average for the other series. One plate showed a percentage of hatching of 96% and a survival rate of 91%, and for the remaining five plates, the respective values were 11-71% and zero % (five plates)-11% (one plate), respectively.
This indicates that if it is desired to incubate plates in air/oxygen, the plates should be sprayed periodically or continuously. The reason for this is possibly that spraying/showering is required in order to remove excretory matter.
Further details with respect to this is given in Table 3.
TABLE 3__________________________________________________________________________Days of incubation Membrane*.sup.) Percent PercentPlateincubation after Gel thickness/ of ofno. (Total) hatching (% PAAm) Membrane pore size Disinfection Sterilisation hatching survival__________________________________________________________________________#)control10 6 92 27 1 A 10 6 7.5 Nytran NY 13N 0.45 μm CB 98 92 1 B 10 6 7.5 7.5% PAAm 1.6 mm CB 70 5 1 C 8 4 5 Nytran NY 13N 0.45 μm CB 83 97 1 D 10 6 5 5% PAAm 0.8 mm 55 0 1 E 10 6 7.5 BAS 83 0.2 μm 54 0 1 F 10 6 7.5 BAS 83 0.2 μm CB 74 5##)control13 3 87 95 3 A 13 3 5 BAS 83 0.2 μm 93 94 3 B 13 3 10 Nytran NY 13N 0.45 μm CB 96 98 3 C 13 3 7.5 7.5% PAAm 1.0 mm CB 87 100 3 D 13 3 7.5 BAS 83 0.2 μm CB 94 96 3 E 13 3 10 Nytran NY 13N 0.45 μm CB 89 100 3 F 13 3 10 7.5% PAAm 0.9 mm CB 94 98###)control10 2 41 11 8 A 10 2 7.5 BA 85 0.45 μm 19 0 8 B 10 2 10 BAS 83 0.2 μm CB 71 0 8 C 10 2 10 15% PAAm 1.5 mm CB 96 91 8 D.sup.3) 9 2 10 7.5% PAAm 2.7 mm UV 35 0 8 E 10 2 5 BAS 83 0.2 μm CB 22 0 8 F 10 2 5 None (PVC.sup.2)) CB 11 0####)control12 3 lysozym 94 96 9 A 12 8 7.5 7.5% PAAm 2.9 mm lysozym.sup.4) UV 76 0 9 B 12 8 5 Nucleopore 8 μm lysozym.sup.4) 94 59 9 C 12 10 5 7.5% PAAm ? lysozym.sup.4) UV 91 50 9 D 12 7 5 7.5% PAAm 1.5 mm UV 87 23 9 E 11 9.sup.5) 5 7.5% PAAm 0.5 mm 93 66 9 F 12 8.sup.5) 7.5 Nucleopore 8 μm UV 100 95####)control12 2 Glu.sup.6) 0.sup.7) 010 A 12 2 7.5 BA 85 0.45 μm CB 100 10010 B 8 2 7.5 BAS 83 0.2 μm CB 66 9110 C 2 -- 7.5 7.5% PAAm 1.7 mm Glu.sup.8) CB 0 010 E 12 2 10 BA 85 0.45 μm Glu.sup.6) CB 98 9810 F 12 2 7.5 BAS 83 0.2 μm Glu.sup.6) CB 69 87####)control12 8 lysozym + 87 96 glycin11 A 12 10 10 10% PAAm 1.2 mm lysozym.sup.4) 94 611 B 12 8 7.5 7.5% PAAm 1.7 mm UV 96 7811 C 12 7 7.5 7.5% PAAm 0.6 mm lysozym + UV 93 82 glycin11 D 11 8 5 7.5% PAAm 0.7 mm UV 74 811 E 12 9 7.5 10% PAAm 0.8 mm lysozym.sup.4) 96 3311 F 12 9 7.5 5% PAAm 2.2 mm lyso. + 96 20 glycin.sup.4)__________________________________________________________________________ Key to Table 3 Glu = Glutaraldehye CB = Chlorine bleach x) maximum number of days listed: most of the hatching occurred during 2- days &) maximum number of days listed: may vary to some extent within the respective plate (relevant for several plates) *.sup.) thickness of membrane refers to gel thickness, whereas pore size refers to the membrane filters #) case for transportation; incubation in air atmosphere with periodic showering/spraying of the uppermost plate with water. The lowermost plate (in the bottom of the case) was partially submerged in water ##) membrane test ###) incubated in air saturated with water, without spraying with water ####) effect of disinfection .sup.1) the chambers made as holes extending through the gel plate, one membrane on each side of the plate .sup.2) net comprising polyvinyl chloride covering the gel chambers in th gel plate .sup.3) the eggs reincubated in a new gel plate after four days .sup.4) lysozyme (+ alternatively glycine) added directly into the gel chambers immediately prior to (and after) formation of the incubation plate system .sup.5) the plate partly open (damaged) at the bottom, but the chambers covered by tyll (nylon) .sup.6) glutaric aldehyde (800 ppm, 10 minutes) .sup.7) the yolk liquid "expanded" out from the eggs after disinfection .sup.8) glutaric aldehyde (400 ppm, 10 minutes)
EXAMPLE 3
This example illustrates separation of incubated eggs from a stable gel by increasing the gel temperature.
A suspension of marine eggs in a 2% by weight aqueous solution of kappa-carrageenan is maintained at a temperature of 2°-4° C., and added dropwise to a 0.1 molar aqueous KCl solution, also at 2°-4° C. to avoid a temperature shock to the eggs. After a period of a few minutes, the eggs are transferred to a seawater incubation medium at 8° C. containing 0.008 molar K + which was sufficient to stabilize the gel for a long incubation period at this temperature.
The gel beads were dissolved after incubation by reducing the salinity of the water and carefully raising the temperature to 4°-5° C.
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A method for incubating eggs or larvae of fish, crustaceans, or related organisms. The eggs or larvae are located in depressions in the surface of a plate formed of an aqueous polymeric gel, and the surface is sealingly covered with a porous membrane capable of gas transport therethrough. The plate sealed with the membrane is placed in at least intermittent contact with water during the incubation period, and the eggs or larvae are separated from the plate and membrane after incubation is complete.
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BACKGROUND OF THE INVENTION
In the present era of environmental awareness, the gas turbine engine designer, and particularly the designer of such engines for aircraft propulsion, is faced with the dilemma of reducing engine pollutants while sacrificing the minimum engine performance. One type of pollution which recently has received considerable attention is noise.
Gas turbine engine noise is generated from two primary sources. First, there is that associated with the viscous shearing of rapidly moving gases exhausted into the relatively quiescent surrounding atmosphere. In turbofan aircraft engines, such gases are emitted from the fan and core nozzles at the rear of the engine. Various approaches have been utilized to reduce this "shear" noise, most approaches incorporating mixers to comingle fan and exhaust gases with each other and with the surrounding environment.
The second source of noise, and the one to which the present invention is directed, is generated by the rotating turbomachinery itself. This results from the relative motion between the rapidly rotating blade rows and the interflowing gas stream. The noise is affected by such parameters as blade rotational speed, blade-to-blade spacing, blade geometry, and by the proximity of stationary hardware to such rotating blade rows, as in the case of an outlet guide vane arrangement. Another example of the latter condition occurs in typical multistage axial compressors where stationary blade rows are alternated with rotating blade rows. Some of the noise generated in this manner can be absorbed and suppressed by means of acoustic or sound absorbing paneling disposed about the periphery of the nacelle enclosing the rotating turbomachinery. Such sound absorbing material is well known in the art. However, because of the close proximity of the fan or compressor to the inlet frontal plane, and the lack of acoustic shielding in the forward direction, a significant percentage of noise propagates forward from the gas turbine inlet duct.
Prior attempts to solve this problem have concentrated on the application of sound absorbing material to the inlet duct inner wall. This does little to attenuate unreflected noise propagating in the axially forward direction. Additional benefits have been obtained by providing coaxial, circumferential rings of sound absorbent material within the inlet. However, such rings produce a loss of inlet total pressure and, therefore, bring about performance losses which remain throughout the engine operating envelope even when noise propagation presents no hazard or nuisance to inhabitants below.
Another concept incorporates an axially translating wedge-shaped scoop on the bottom of the inlet duct to selectively reduce the downward transmission of noise from the inlet. However, this configuration is inadequate for two reasons. First, it has been shown that an inlet incorporating such a scoop has a poor pressure recovery characteristic (i.e., it is inherently a high loss system). Secondly, and somewhat related to the foregoing problem is that the total pressure pattern is highly distorted, as for example in the plane of a gas turbine fan stage disposed within the duct. While the former characteristic results in degraded engine performance, the latter may, under certain conditions, cause excessive fan blade stresses and possible destruction of the rotating turbomachinery.
Yet another approach has been to extend axially forward the lower cylindrical half of the inlet duct. In side profile, this results in a stepped duct wall contour. Although the configuration tends to reduce noise level, it is aerodynamically undesirable from the inlet recovery and distortion aspects discussed hereinbefore.
The problem facing the gas turbine designer is, therefore, to provide a means for attenuating noise emanating from the duct without incurring overall performance penalties.
SUMMARY OF THE INVENTION
Accordingly, it is the primary object of this invention to reduce noise emanating from within a duct without sacrificing overall performance.
This, and other objects and advantages, will be more clearly understood from the following detailed description, the drawings and specific examples, all of which are intended to be typical of rather than in any way limiting the present invention.
Briefly stated, the above objective is attained by providing within a predetermined sector of the duct inlet an axially upstream protruding deflector. The profile of the transition between the extended deflector and the downstream inlet duct sector opposite the deflector is arcuate, having no sharp corners at the inlet lip. Further, the curvature thus imposed upon the inlet lip has a point of inflection, thereby causing the radius of curvature to change in sense during the transition.
While this invention will aid in inlet noise suppression, most significant is that it will accomplish this suppression without substantial performance degradation from that of an ideal inlet wherein the plane of the inlet is essentially normal to the inlet longitudinal axis.
Further, limits have been established for the length of the deflector and the radius of curvature of the transition within which maximum noise attenuation will result, and beyond which noise attenuation improvement is offset by increased duct length and weight.
DESCRIPTION OF THE DRAWINGS
While the specification concludes with claims particularly pointing out and distinctly claiming the subject matter which is regarded as part of the present invention, it is believed that the invention will be more fully understood from the following description of the preferred embodiment which is given in connection with the accompanying drawings, in which:
FIG. 1 is a schematic representation of a gas turbine engine incorporating the subject invention;
FIG. 2 is an enlarged view of the inlet portion of FIG. 1 incorporating the subject invention;
FIG. 3 depicts schematically a plurality of prior art gas turbine inlets;
FIG. 4 is a plot depicting the reduction in perceived noise level of the present invention over that of prior state-of-the-art inlets as a function of angular position from the inlet; and
FIG. 5 is a plot depicting the reduction in perceived noise level of the present invention as a function of length of the deflector and depicting optimum deflector length.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the drawings wherein like numerals correspond to like elements throughout, reference is initially directed to FIG. 1 wherein an engine depicted generally at 10 embodying the present invention is diagrammatically shown. This engine may be considered as comprising generally a core engine 11, a fan assembly 12 and a fan turbine 14 which is interconnected to the fan assembly 12 by shaft 16. The core engine 11 includes an axial flow compressor 18 having a rotor 20. Air enters inlet assembly 22 and is initially compressed by fan assembly 12. A first portion of this compressed air enters the fan bypass duct 24 and subsequently discharges through a fan nozzle 25. A second portion of the compressed air enters inlet 26, is further compressed by the axial flow compressor 18 and then is discharged to a combustor 28 where fuel is burned to provide high energy combustion gases which drive a turbine 30. The turbine 30, in turn, drives the rotor 20 through a shaft 32 in the usual manner of a gas turbine engine. The hot gases of combustion then pass to and drive the fan turbine 14 which, in turn, drives the fan assembly 12. A propulsive force is thus obtained by the action of the fan assembly 12, discharging air from the fan bypass duct 24 through the fan nozzle 25 and by the discharge of combustion gases from a core engine nozzle 36 defined, in part, by plug 38.
The above description is typical of many present-day engines and is not meant to be limiting, as it will become readily apparent from the following description that the present invention is capable of application to any duct having noise emanating from within. It is not intended to be restricted to application in gas turbine engines. The above description of the engine depicted in FIG. 1 is, therefore, merely meant to be illustrative of one type of application.
Referring now to FIG. 2, the inlet assembly of FIG. 1 is shown to include an essentially cylindrical duct wall 39 having a lip 41. A deflector member 40 is disposed about a predetermined sector of the duct assembly and comprises an extension of lip 41 in the axially upstream direction. The rearward-most sector of the inlet lip is depicted at 42 and, although shown in FIG. 2 to be diametrically opposite the forward-most extension of deflector 40, it is contemplated that sector 42 and deflector 40 could be disposed in a variety of circumferential relationships with respect to each other. The lip of the deflector 40 is shown to be contoured as at 44 in the axial direction, having a generally double arcuate profile (i.e., a smooth curve having a point of inflection 46). The diameter of the inlet duct 22 is represented as D and the length of the deflector member 40 as L. A rotating stage of gas turbine fan blades 48 is disposed within the duct to pressurize the flow of air therethrough. Acoustic paneling 49 of the honey-comb type known in the art may be disposed upon the walls to enhance acoustic suppression.
FIGS. 3a, 3b, and 3c represent prior art inlets which have been adapted for gas turbine application. FIG. 3a depicts a typical ideal axisymmetric fixed lip inlet (hereinafter referred to as a conventional inlet) wherein the inlet frontal plane is essentially perpendicular to the duct longitudinal axis. FIGS. 3b and 3c depict attempts to extend the lower lip axially forward to shield noise in the downward direction. While the inlet of FIG. 3a could be extended forward to provide improved sound suppression, an extended 360° structure results in significant weight increases which are undesirable in aircraft applications. In such applications, it is most desirable to shield noise in the essentially downward 180° sector during aircraft approach or landing. It is desirable to maximize the shield area in the lower inlet quadrant to maximize noise attenuation in that direction since the human observer is on the ground.
Previously, the configuration of FIG. 3b was considered optimum for noise attenuation since for a given axially forward extension L of the lower half of the essentially cylindrical inlet duct 50, this would yield the maximum shielded area. Configuration 3b is inherently better than that of FIG. 3c with wedge-shaped deflector member 52 since the shielded area in the lower quadrant is substantially increased, the shaded area 54 of FIG. 3c representing the increased shielded area of inlet 3b over inlet 3c when superimposed. Each of the prior art configurations of FIG. 3, however, have been found to be deficient in either inlet total pressure recovery (the ratio of total pressure at the plane of the fan blades 48 to that of the free stream ahead of the fan) or to produce less sound attenuation than the present invention, or both. Unexpectedly, the duct inlet of FIG. 2 produces better sound attenuation than the inlet of FIG. 3b, heretofore thought to constitute an optimum deflector from acoustic considerations.
FIG. 4 depicts a graph showing reduction in perceived noise level of the inlet of the present invention and that of FIG. 3b with respect to a conventional inlet as a function of the angular position from the inlet. The characteristic of the deflector of FIG. 3b is denominated as curve A and that of the present invention as curve B. The angle θ is defined as that measured between the inlet duct longitudinal axis and a line constructed from the observer to the inlet duct noise source in a plane defined by the inlet duct longitudinal axis and the centerline of the deflector as shown in FIG. 3b. As is readily apparent, the present invention has superior sound suppression over the prior art inlet throughout the angular range of interest. This is attributed to the fact that the corner 56 of the deflector 50 (FIG. 3b) has been eliminated. This prior art corner is suspected of shedding a vortex of swirling air which impinges upon the fan and creates its own noise source. In essence, though the deflector of the present invention has a smaller projected area than the prior art deflector, it has improved sound suppression through elimination of vortices. This also results in a lighter inlet, which is of critical importance in aircraft gas turbine applications. Further, it has been found that due to the elimination of the sharp corners, the inlet pressure recovery of the present invention is superior to that of the prior art devices.
The subject invention, as tested, comprises a structure wherein the arcuate transition 44 of the axially forward deflector 40 consists of two tangent, essentially circular arcs of opposite senses, with radii of curvature of R 1 and R 2 , FIG. 2. Though the value of the ratios R 1 /D and R 2 /D were essentially 0.4 and 0.6, respectively, it is contemplated that values of R 1 /D between essentially 0.3 and 0.5, and values of R 2 /D between 0.5 and 0.7 would yield acceptable performance. Similarly, a sinusoidal curvature could be employed.
Further, through parametric studies, Applicant discovered that for an L/D ratio greater than 0.4, no noise reduction occurred even though the deflector length was increased substantially. This is graphically depicted in FIG. 5 wherein reduction in perceived noise level is plotted as a function of the ratio of L/D. It is clear that the improvement starts to attenuate rapidly between an L/D of 0.3 and 0.4, and beyond a value of 0.5 the curve is essentially flat. Therefore, the weight-conscious inlet designer would choose a ratio of L/D between essentially 0.3 and 0.5 for optimum noise reduction with minimum duct length and weight.
It should be obvious to one skilled in the art that certain changes can be made to the above-described invention without departing from the broad inventive concepts thereof. For example, as previously mentioned, the subject deflector may be employed on any duct having noise emanating within and not necessarily restricted to gas turbine engine applications. Further, it is contemplated that the subject deflector could be disposed at other than the bottom of the inlet duct and that it could be made axially and circumferentially translatable. It is intended that the appended claims cover these and all similar variations of the present invention's broader inventive concepts.
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An inlet duct for use with gas turbine engines or the like is provided with an axially upstream projecting deflector means to reduce noise propagation emanating within said duct. The deflector member has an essentially double arcuate contour of the lip in the axial direction which improves noise attenuation and inlet total pressure recovery. The contour is provided with at least one point of curvature inflection.
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BACKGROUND OF THE INVENTION
The present invention is directed to cassette loaders. More specifically, the present invention is directed to a mechanism for threading cassette leader onto an automatic cassette splicer and loader.
With the ever increasing availability to and use by the consumer public of sophisticated electronic devices, pre-recorded audio magnetic tape has become more and more popular. One form in which this tape is commonly supplied is in what has come to be known as an audio cassette. Such audio cassettes are supplied by the manufacturers of same with leader permanently threaded to each reel of the cassette. This leader is continuous and requires cutting at a mid-point thereof and splicing in of either a blank or pre-recorded length of magnetic tape. The cost of manually splicing in a length of magnetic tape is prohibitive from a commercial standpoint. Consequently, machines have been developed to automatically splice and load magnetic tape into such cassettes.
The automatic splicing and loading mechanisms have heretofore required threading by an operator. This is accomplished by the operator placing the cassette on the machine and drawing a loop of the leader from the cassette onto a vacuum track. Once this loop is placed on the track, the machine will automatically complete the splicing and loading operations. Consequently, it has been found economical to have one operator thread and oversee several machines at one time. In this way, the operator may be threading one machine while the remaining machines are continuing through the cycle of splicing and loading tape onto the cassette. Naturally, the more machines the operator can control, the greater the productivity of the operator.
A number of mechanisms are available for such splicing and loading. One example is illustrated in U.S. Pat. No. 3,848,825. As can be seen from FIG. 10, a loop of leader is drawn across a vacuum track to initiate operation. The sequence of splicing and loading of tape once threaded onto such a mechanism is not part of the present invention and disclosure of U.S. Pat. No. 3,848,825 is incorporated herein by reference to illustrate one such sequence of operation.
SUMMARY OF THE INVENTION
The present invention is directed to a mechanism for further automating automatic splicing and loading devices by providing automatic threading. By the present invention, an operator is able to service a larger number of machines because it is only necessary to place the unloaded cassette on the machine and press the start button.
To accomplish the foregoing, the present invention includes a mechanism for drawing a loop of leader from an unloaded cassette. Once such a loop of leader has been drawn from the cassette, a leader placement assembly engages the loop and draws leader up over a vacuum track. An additional mechanism holds one side of the loop drawn from the cassette outwardly away from the mechanism to prevent interference by that part of the tape with the splicing and loading operation. Guides are also provided to insure proper placement and retraction of the leader and magnetic tape during the complete operation. The several functions are carried out by means of a system including a cam mechanism to operate pneumatic cylinders.
Accordingly, it is an object of the present invention to provide an automatic threading mechanism for a cassette loader.
It is another object of the present invention to provide an improved mechanism for drawing a loop of leader from a cassette.
It is yet another object of the present invention to provide a mechanism for drawing leader of a cassette onto a conventional vacuum track.
It is a further object of the present invention to provide a threading mechanism which so guides the leader and magnetic tape that high reliability is achieved.
Other objects and advantages will appear hereinafter.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front view of an automatic cassette loader illustrating the present invention in its rest position.
FIG. 2 is a front detail of the leader pickup mechanism of the present invention shown inserted into a cassette.
FIG. 3 is a cross-sectional view taken along line 3--3 of FIG. 2.
FIG. 4 is a cross-sectional view taken along line 4--4 of FIG. 2.
FIG. 5 is a front view of the threading mechanism with a loop of leader drawn from a cassette.
FIG. 6 is a detailed plan of a leader placement head of the present invention shown ready to engage a loop of leader.
FIG. 7 is a the plan view of FIG. 6 with a leader placement head of the present invention shown engaging a loop of leader.
FIG. 8 is a front view of the automatic threading mechanism showing a leader placement head in its retracted position with a loop of leader.
FIG. 9 is a plan view of the threading mechanism shown in the position illustrated in FIG. 8.
FIG. 10 is a front view of the threading mechanism with a leader placement head shown ready to extend, as illustrated in phantom, in placement of a leader.
FIG. 11 is a plan view of a tape guide assembly with one side of the loop of leader drawn away from the mechanism.
FIG. 12 is a front view of the automatic threading mechanism showing the leader in its placement position for splicing.
FIG. 13 is a plan view taken along line 13--13 of FIG. 12.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Turning in detail to the drawings, FIG. 1 provides an overview of the present mechanism in the environment of a cassette loader. The cassette loader generally designated 10, includes a box-like frame having a source of magnetic tape 12, a cutting and splicing mechanism 14 having its own supply of splicing tape 16, and a tape splicing guide 18.
The tape splicing guide 18 can be seen in greater detail in FIG. 13 as including a first guide block 20 having a vacuum track 22. The guide block 20 is fixed relative to the front of the cassette loader 10 and employs vacuum ports (not shown) in the vacuum track 22 to hold leader from a cassette mounted on the mechanism. A splicing block 24 includes two vacuum tracks 26 and 28. The first vacuum track 26 is initially aligned with the vacuum track 22 of the first guide block 20. Thus, leader may be extended across the first guide block 20 in the vacuum track 22 and the splicing block 24 in the vacuum track 26. When the leader has been placed in such a position, it is considered to have been threaded onto the mechanism.
The cutting and splicing mechanism 14 includes a cutter 29 which then acts to cut the leader. The splicing block 24 then moves outwardly from the cassette loader 10 to align the vacuum track 28 with the vacuum track 22. One end of the magnetic tape 30 to be threaded onto the cassette is located in the vacuum track 28 which becomes aligned with the portion of the leader remaining in vacuum track 22. The cutting and splicing mechanism 14 then splices this tape 30 to the leader and the appropriate length of magnetic tape 30 is wound into the cassette. At the end of the selected length of magnetic tape 30, the cutting and splicing mechanism 14 cuts the tape 30 and the splicing block 24 returns to its original position. At this point the other half of the leader located in vacuum track 26 is aligned with the end of the magnetic tape 30 which has been drawn into the vacuum track 22. The cutting and splicing mechanism 14 then splices these tapes together. The cassette then is caused to receive the last loop of magnetic tape and leader and pops from the machine. The cassette loader 10 may then be loaded with another cassette.
The cassette 32 is mounted on the face of the cassette loader 10 in conventional brackets 34. Only one reel 36 need be driven. A mechanism located behind the cassette 32 is employed to pop the cassette 32 from the cassette loader 10 when the loading has been completed. The basic cassette loader 10, the cutting and splicing mechanism 14, the tape splicing guide 18 and the cassette and cassette mounting brackets 34 and all of the immediately attendant mechanisms are of conventional design.
Turning then to the novel mechanisms of the present invention, a leader pickup assembly, generally designated 38 is illustrated for drawing a small loop of leader from the cassette 32. The leader pickup assembly 38 includes an arm 40 pivotally mounted on a pin 42 to the face of the cassette loader 10. A means for pivotally moving the arm 40 is provided by pneumatic cylinder 44. The pneumatic cylinder 44 is pinned at one end to the cassette loader 10; and the rod end of the cylinder is pinned by pin 46 to the arm 40 at a point spaced from the pivotal mounting of the arm 40. The cylinder 44 is preferably double acting to extend and retract the arm 40. Consequently, addition of pressurized air through air inlet 48 causes the arm 40 to rotate in a clockwise direction as viewed in FIG. 1.
FIGS. 2 through 5 best illustrate the leader pickup assembly 38.
At the distal end of the arm 40, a shaft 50 is slidably mounted. The shaft is oriented substantially tangentially to the movement of the arm 40 at the shaft 50. Thus, the shaft 50 moves with the arm 40 substantially along the axis of the shaft, albeit in an arc. The shaft 50 includes a helical groove 52 along a portion of its length. A pin 54 is located adjacent one end of the shaft and extends perpendicularly from the axis of the shaft. Near the opposite end of the shaft 50, there is a spring clip 56 to limit movement of the shaft 50.
Located in the arm 40 is a follower consisting of a pin 58 which extends to fit into the helical groove 52. The pin 58 is located in a bore 60 which has been partially tapped to receive a set screw 62. A spring 64 retains the pin 58 in the helical groove 52.
The orientation of the helical groove 52, the pin 54 and the pin 58 are such that the shaft rotates approximately 90° as it moves between the spring clip 56 and the far extent of the helical groove 52. With the spring clip 56 against the arm 40, the pin 54 extends parallel to the cassette 32 and the leader therein. An adjustable set screw 59 is employed to stop the arm 40 such that the pin 54 extends perpendicularly to the cassette and to the leader therein. This orientation enables the leader pickup assembly to engage the leader and draw a loop of same from the cassette.
The shaft 50 works in combination with a stop 66 to orient the pin 54 parallel to the leader. This is accomplished by movement of the arm 40 in a counter-clockwise direction away from the cassette. The end of the shaft 50 is forced through the arm 40 by the stop 66 until the spring clip 56 prevents further movement. Upon actuation of the pneumatic cylinder 44, the arm 40 rotates to the cassette 32 with the pin 54 parallel to the leader in the cassette. This enables the end of the shaft 50 to extend down past the leader to come to rest against the body of the cassette 32. The arm 40 continues to advance with the shaft 50 against the body of the cassette 32. This movement of the arm 40 rotates the pin 54 into a position beneath the leader. This may be best seen in FIGS. 3 and 4 where the pin 54 is shown beneath a leader 68. Once pressure is released from the pneumatic cylinder 44, the arm returns to its rest position and draws a loop of leader from the cassette. Upon encountering the stop 66, the pin 54 is rotated out of the way of the loop for the next process. This final position is illustrated in FIG. 5 where a loop 70 of leader is shown as it is drawn out by the arm 40 and is shown in phantom after being released by the leader pickup assembly.
Once the loop 70 has been formed, a leader placement assembly 72 draws this loop into a threaded position on the vacuum track 22 and vacuum track 26 of the first guide block 20 and the splicing block 24 respectively. The initial, at rest position of the leader placement assembly 72 is shown in FIG. 1. FIG. 5 illustrates the leader placement assembly 72 in its extended position in preparation for receiving the loop 70. FIGS. 8, 9, 10, 12 and 13 demonstrate the leader placement assembly 72 in its successive locations after having received the loop 70.
The leader placement assembly 72 includes a mounting block 74 having a bushing 76 therein. The bushing 76 cooperates with a shoulder bolt extending from the face of the cassette loader 10 for pivotal mounting of the leader placement assembly 72. The block is retained on the bolt by means of the head 78 of the bolt. The block 74 is pivotally controlled by means of a pneumatic cylinder 80 which is pinned at a first end to the face of the cassette loader 10 at bracket 82 and is pinned to an extension 84 of the mounting block 74 at the piston end of the cylinder 80. The pneumatic cylinder 80 is of the double acting type such that the leader placement assembly 72 may be driven to either of two pivotal extremes as can be seen in FIG. 1 and FIG. 10.
Mounted within the mounting block 74 is a pneumatic cylinder 86. Attached to the piston rod thereof is a leader placement head 88 which can be extended or retracted by the pneumatic cylinder 86. A second rod 90 extends parallel to the piston shaft of the pneumatic cylinder 86. A guide bracket 92 retains the rod 90 parallel to the pneumatic cylinder 86 and in a fixed angular orientation with respect to the mounting block 74. The rod 90 also extends through a hole provided for in the mounting block 74 for further guidance.
The leader placement head 88 includes a jaw assembly having a first jaw 94 fixed relative to the leader placement head 88. In this embodiment, the first jaw 94 is an integral part of the leader placement head 88. The first jaw 94 has a smooth inner surface 96 without protrusions. Thus, this jaw does not provide any means by which leader could be caught. The end of this first jaw 94 is beveled to further promote facile acceptance and release of the leader.
Pivotally mounted on the reader placement head 88 is a second jaw 98. This second jaw extends rearwardly as to clevis lugs 100 and 102 to accept a clevis pin 104 about which the second jaw 98 pivots. The second jaw further includes a cylindrical protrusion in the form of a pin 106 extending inwardly toward the first jaw 94. This pin 106 is of sufficient width to accept the leader such that the leader may slide over the pin 106 during placement thereof.
Control of the second jaw 98 is provided by a number of means. First, a spring 108 biases the second jaw toward the open position as can best be seen in FIG. 6. An upstanding surface 110 on the leader placement head 88 prevents further opening of the second jaw 98. In the closed position, a lock is provided to hold the second jaw 98 against the bias of the spring 108. Located on the clevis lug 100 is a notch 112 which receives a pawl 114. The pawl 114 is pivotally mounted to the leader placement head 88 by pin 116. A spring 118 holds the pawl in the notch 112 when the second jaw 98 is closed. This can best be seen in FIG. 7.
A release is provided by means of a pin 120 extending through the first jaw 94. The pin is capable of moving longitudinally therein to force the pawl 114 away from the notch 112. With the lock release, the spring 108 will sharply open the second jaw 98 to release a leader contained therein.
To close the jaw assembly, the clevis lug 102 includes an extending lever 122 which extends laterally beyond the body of the leader placement head 88. When this lever 122 is forced rearwardly relative to the leader placement head 88, the second jaw 98 is closed.
The configuration of the jaw mechanism is designed to insure fascile grasping and release of a leader loop. By locating the pin 106 on the second jaw 98 which is able to pivot open, the pin 106 becomes oriented to insure release of the leader loop when desired. The rigid first jaw 94 retains its orientation to insure proper guidance of the loop into the jaw assembly. To further insure this engagement of the leader loop when desired, the rod 90 is hollow and is supplied with a source of compressed air at the back end thereof. A hole is provided through the body of the leader placement head 88 to a position between the two jaws 94 and 98. During release of the leader from the jaws, a stream of compressed air is directed to the leader to force it from the jaws and onto the vacuum tracks 22 and 26.
In its operation, the leader placement assembly 72 first is pivoted to the lower position as can be seen in FIG. 1. The leader placement head 88 is then extended to the loop 70 of leader extending from the cassette 32. As the leader placement head 88 comes into a position for receiving the loop 70, a stop 124 is encountered by the lever 122. As the leader placement head 88 continues forward, the lever 122 is forced to pivot and close the second jaw 98 about the loop 70.
The leader placement head 88 is then retracted with the loop 70 as can best been seen in FIG. 8. Once in this retracted position, the leader placement head 88 is raised by means of the pneumatic cylinder 80 to the position illustrated in FIG. 10. At this point, one side of the loop 70 comes into contact with a guide roller 126. The guide roller 126 includes a groove aligned with the vacuum track 22 of the first guide block 20. The leader placement head 88 is then extended again, as can be seen in phantom in FIG. 10. The vacuum track 22 attracts the leader and it becomes positioned thereon as can best been seen in FIG. 12.
At the end of the path of travel of the leader placement head 88 as it moves across the vacuum track 22 there is a stop 128. This stop is designed to interfere with the protruding end of the release pin 120 which in turn disengages the pawl 114 to allow the second jaw 98 to open. This condition is best seen in FIG. 12. At this time, the jet of air provided through the rod 90 insures that the leader is disengaged from the leader placement head 88 and is drawn over the vacuum track 26 in proper position for splicing. The leader placement head 88 is then retracted and returned to its lower most position in preparation for the next cycle.
In placing the loop of leader on the vacuum track, it is necessary that only one side of the loop is so positioned. The other side of the loop must avoid the cutting and splicing area of the cassette loader 10. To accomplish this, several mechanisms have been devised. A tape guide assembly is employed to draw one side of the leader loop outwardly away from the mechanism. This guide mechanism includes an arm 130 pivotally mounted to the face of the cassette loader 10 such that the axis of pivotal movement of the arm 30 is parallel to the plane of the front surface of the cassette loader 10. To this end, a mounting block 132 is fixed to the face of the cassette loader 10. This mounting block forms a bearing for the pivotal mount of the arm 130 with an axis parallel to the face of the cassette loader 10.
To cause the arm 130 to pivot, the arm is attached to a drive block 134 through an axis parallel to and spaced from the axis through the mounting block 132. The drive block is fixed to a pneumatic cylinder 136. The other end of the pneumatic cylinder 136 is fixed by means of a bracket 138 to the face of the cassette loader 10. The pneumatic cylinder 136 is spring loaded to a retracted position such that the addition of air elongates the cylinder. In this way, the arm 130 may be forced outwardly away from the face of the cassette loader 10.
The arm 130 includes a notch 140 defined by a finger 142 which extends upwardly and then outwardly from the arm 130 as can be seen, for example, in FIGS. 8 and 11. As also can be seen in FIG. 8, the leader placement head 88 retracts to a position during its movement where one side of the leader loop being drawn by the leader placement head 88 lies in the path of the finger 142. At this point, the arm 130 is pivoted outwardly from the face of the cassette loader 10 as can be seen in the sequence drawings of FIGS. 9 and 11. As best seen in FIG. 10, the leader placement head 88 then continues its path with one side of the leader falling into the guide roller 126 and the other side of the loop being held away from this area. The finger 142 is capable of retaining the second side of the loop until the leader placement head 88 has advanced sufficiently to draw this second side of the loop from the finger 142 past the outside of the assembly including the vacuum track 22. At this point, the tape cannot become entangled or drawn over onto the vacuum tracks.
Eventually, the leader is released by the arm 130 and assumes a position as illustrated in FIGS. 12 and 13. To insure proper placement of the leader once released by the arm 130, a guide 144 has been fixed to the splicing block 24. This guide includes a first bottom plate 146 which is juxtaposed with the bottom of the splicing block 24. The plate 146 extends to an edge outwardly of the splicing block 24 and is cut at an angle such that it intersects and extends beneath the first guide block 20. This bottom plate 146 is thus able to keep the loose portion of the leader away from the splicing block 24 and away from the joint between the splicing block and the first guide block 20. The guide 144 also includes an upwardly and outwardly extending plate 148 which helps define a notch between the plate 148 and the plate 146. The plate 148 extends outwardly such that the leader will not loop over the top of the plate and become entangled. The notch defined by the two plates prevents the leader from moving back over the rear portion of the splicing block 24 and thus become unable to be retracted later into the cassette.
A guide 150 is fixed to the side of the first guide block 20 parallel to the vacuum track 22. This guide 150 extends upwardly above the first guide block 20 as can be seen by the hidden lines outlining the first guide block 20 behind the guide 150 in FIG. 12. The guide 150 extends in a smooth curve about its upper edge and beyond the end of the first guide block 20. This allows the leader to slide smoothly over this surface as it is being retracted into the cassette 32.
The guide 150 is configured such that it defines a large hook which, under certain conditions, would engage the loop of tape and prevent it from being drawn into the cassette. However, it has been found that the configuration provided is successful in guiding the tape back into the cassette following splicing because tape is drawn into the cassette only onto the reel 36. Thus, the tape is drawn over the guide roller 126 and the portion of the leader hanging free over the side of the guide 150 naturally follows the tape around the end of the guide 150. A bevel 152 is provided on the end of the guide 150 to further insure proper retraction of the tape. The bevel adds to the tendency of the tape to fall down past the end of the guide 150 such that it can be drawn into the cassette 32 to complete the loading process.
In drawing the tape back into the cassette 32, the tape has a tendency to drag across itself where the two sides of the loop cross right near the cassette 32 where the tape enters. To avoid this, the guide 144 includes a depending plate 154 having at its distal end an outwardly extending flange 156. The flange 156 extends to a point near the cassette and back of the intersection of the two sides of the loop of tape which is to return to the cassette. When the splicing block 24 moves outwardly, the flange 156 forces the side of the loop depending down from the splice block 24 away from the portion extending up and around the guide roller 126. In this way, cutting of one portion of the tape by the other can be avoided.
The several pneumatic cylinders employed in the guide means as well as the puff of air directed through rod 90 are controlled by means of a cam mechanism 158 as best seen in FIG. 1. The cam mechanism 158 includes a series of cams 160 mounted on and fixed to rotate with a shaft 162 which is driven by a timed power source. Followers 164 are associated with air valves 166 which gate the air to the pneumatic cylinders. In this way, the threading mechanism is properly sequenced.
Thus, an automatic threading mechanism for a cassette splicer and motor has been described. While embodiments and applications of this invention have been shown and described, it would be apparent to those skilled in the art that many more modifications are possible without departing from the inventive concepts herein described. The invention, therefore, is not to be restricted except by the spirit of the appended claims.
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A mechanism for threading cassette leader onto an automatic cassette splicer and loader. The threader with the automatic splicer and loader requires no manual intervention once the cassette is placed thereon and the cycle is initiated. The threader includes a leader pickup mechanism for drawing a loop of leader from a cassette, a leader placement assembly which engages the loop and extends the leader over a vacuum track, and a tape guide assembly including an arm to pivotally move one side of the loop away from the vacuum track of the splicer and loader and a guide plate adjacent the vacuum track to prevent tape from catching on the vacuum track. These various devices are driven pneumatically by means of a cam and pneumatic switch assembly.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This is a continuation-in-part application of U.S. Ser. No. 09/411,686, which claims the benefit of an earlier filing date from U.S. Provisional Application No. 60/107,266.
BACKGROUND
[0002] Horizontally disposed wellbores have been employed in growing numbers in recent years to access oil reservoirs not previously realistically producible. Where the formation is consolidated, relatively little is different from a vertical wellbore. Where the formation is unconsolidated however, and especially where there is water closely below the oil layer or gas closely above, horizontal wells are much more difficult to produce.
[0003] Pressure drop produced at the surface to pull oil out of the formation is at its highest at the heel of the horizontal well. In an unconsolidated well, this causes water coning and early breakthrough at the heel of the horizontal well. Such a breakthrough is a serious impediment to hydrocarbon recovery because once water has broken through at the heel, all production from the horizontal is contaminated in prior art systems. Contaminated oil is either forsaken or separated at the surface. Although separation methods and apparatuses have become very effective they still add expense to the production operation. Contamination always was and still remains undesirable. Zonal isolation has been attempted using external casing packers and open hole packers in conjunction with gravel packing techniques but the isolation of individual zones was not complete using this method and the difficulties inherent in horizontal unconsolidated formation wells have persisted.
[0004] Another inherent drawback to unconsolidated horizontal wells is that if there is no mechanism to filter the sand prior to being swept up the production tubing, a large amount of sand is conveyed through the production equipment effectively sand blasting and damaging the same. A consequent problem is that the borehole will continue to become larger as sand is pumped out. Cave-ins are common and over time the sand immediately surrounding the production tubing will plug off and necessitate some kind of remediation. This generally occurs before the well has been significantly depleted.
[0005] To overcome this latter problem the art has known to gravel pack the horizontal unconsolidated wells to filter out the sand and support the bore hole. As will be recognized by one of skill in the art, a gravel packing operation generally comprises running a screen in the hole and then pumping gravel therearound in known ways. While the gravel effectively alleviates the latter identified drawbacks, water coning and breakthrough are not alleviated and the horizontal well may still be effectively occluded by a water breakthrough.
[0006] Since prior attempts at enhancing productivity in horizontal wellbores have not been entirely successful, the art is still in need of a system capable of reliably and substantially controlling, monitoring and enhancing production from unconsolidated horizontal wellbores.
SUMMARY
[0007] The above-identified drawbacks of the prior art are overcome or alleviated by the unconsolidated horizontal zonal isolation and control system disclosed herein.
[0008] The invention teaches a zonally isolated horizontal unconsolidated wellbore where packers are not employed on the outside of the basepipe but a reliable zonal isolation is still created. Zones are created by interspersing blank basepipe with slotted or otherwise “holed” basepipe. The blank pipe is not completely blank but rather includes closeable ports therein at preselected intervals. Screens are employed over these ports and (as conventional) over the slotted basepipe. Upon gravel packing, a near 100% of pack is achieved over the blank pipe section because of the closeable ports. Only about 60% is achievable without the ports. With a full gravel pack of a preselected distance, i.e., the distance of the blank pipe, and the ports closed, isolation is assured with fluid produced for a bad zone being virtually completely prevented from migrating to the next zone. By shutting off production from the undesirable zone, then, through production string seals, only the desired fluid is produced.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] [0009]FIG. 1 is a schematic cross section view of an unconsolidated zonal isolation and control system of the invention;
[0010] [0010]FIG. 1A is a schematic cross section as in FIG. 1, illustrating the washpipe;
[0011] [0011]FIG. 2 is a schematic cross section view of a horizontal gravel packed zonal isolation system with dehydration ports in a blank pipe section;
[0012] [0012]FIG. 3 is an enlarged schematic cross section view of a dehydration section from the invention of FIG. 2; and
[0013] [0013]FIG. 4 is a cross section view of FIG. 3 taken along section line 4 - 4 .
DETAILED DESCRIPTION
[0014] In order to most effectively produce from a hydrocarbon reservoir where a horizontal wellbore in an unconsolidated formation is indicated, a gravel pack is ideally constructed. Moreover, the gravel packed area is most desirably zonally isolatable for reasons discussed above. Such zonal isolation preferably is effected by creating unfavorable flow conditions in the gravel pack at selected areas. To complete the system, a number of alternatives are possible: a production string including flow control devices may be run into the hole, each zone being isolated by a locator and a seal; production may commence directly from the base pipe and bridge plugs may be added later to seal certain offending zones; or a straddle packer which extends from blank pipe to blank pipe may be installed on an offending zone. The latter two alternatives are installed conventionally. The various components of the system are illustrated in FIGS. 1 and 1A wherein those of skill in the art will recognize a liner hanger or sand control packer 10 near heel 12 of horizontal wellbore 14 . From liner hanger or packer 10 hangs a production string including flow control device 16 which may be hydraulic, mechanical, electrical, electromechanical, electromagnetic, etc. operated devices such as sliding sleeves and seal assemblies 18 . Seal assembly 18 operates to create selectively controllable zones within the base pipe of a horizontal wellbore 14 . Seal assemblies 18 (in most cases there will be more than one though only one is depicted in FIG. 1) preferably seal against a polished bore in the original gravel packing basepipe 22 which remains in the hole from the previous gravel packing operation. Not visible in FIG. 1 but shown in FIG. 1A for clarity is washpipe 20 which is conventional and known to the art for many years. Additionally, a shifting profile 21 is illustrated in FIG. 1A depending from washpipe 20 . The shifting profile may be of any conventional or unconventional type. Shifting profiles in general are known in the art. Still referring to FIGS. 1 and 1A, one of skill in the art will recognize conventional holes 23 in the base pipe and production string 25 . Although the seal assemblies on the inside of the basepipe are effective and controllable, the gravel pack is generally a source of leakage zone to zone as hereinbefore noted.
[0015] In a preferred zonal isolation embodiment of the invention, referring to FIG. 2, one will recognize the open hole wall 50 and the gravel pack 52 . Centered within the packed gravel 52 are several sections of attached pipe. On the left and right sides of the drawing are standard gravel pack zones 54 and 55 which include a slotted or otherwise “holed” base pipe with screen thereover. Between these zones 54 is an elongated section of essentially blank pipe 56 . The blank pipe does, however, have what is referred to herein as a dehydration zone which comprises short sections of screen 58 over at least one, preferably several, closeable port(s). The ports enable full packing of gravel around the blank pipe 56 . Without the dehydration ports, only about 60% of the annular region surrounding a blank pipe will be packed. Since this provides a 40% open annulus, zonal isolation would be impossible. With a full pack (about 100%), very good zonal isolation is achieved. The isolation between zones is created by the length of blank pipe. Whatever that length be, undesired fluid would have to travel through the gravel pack in the annulus in order to get to a producing zone once the production pipe has shut off the offending zone. For example, if water had been produced from zone 55 but not from zone 54 the answer would be to shut off zone 55 from production in some conventional way and continue to produce from zone 54 . Although it is possible to move fluids from zone 55 to zone 54 through the pack 52 , it requires a tremendous pressure differential to move any significant volume of fluid. Tests have indicated that at 1500 psi of differential pressure and 40 feet of gravel packed annulus, only 0.6 barrels of the unwanted fluid will migrate to the producing zone through the gravel pack per day. Since in reality it is unlikely that more than 200-300 psi of differential pressure could exist between the zones, the leakage is so small as to be negligible.
[0016] As stated above, gravel packing blank pipe is generally an unsuccessful venture. This is because there is no leak-off of the gravel carrier fluid. When there is no leak-off, the velocity of the fluid stays high and the gravel is carried along rather than deposited. Thus, with respect at least to the β wave of the gravel packing operation, very little sand or gravel is deposited in the annulus of the blank pipe. To slow the gravel carrier fluid down, leak-off must occur. With slower fluid, gravel deposition occurs and the desired result is obtained.
[0017] The purpose of the blank pipe is zonal isolation. If there can be leak-off in the blank pipe, the zones will be not be isolated. The inventor of the present invention solved the problem by supplying the temporary leak-off paths introduced above as dehydration zones. Referring to FIG. 3, one of the dehydration zones is illustrated in an enlarged format to provide an understanding thereof to one of ordinary skill in the art. The screen 58 is an ordinary gravel pack screen employed as they are conventionally i.e. wrapped around a length of pipe to screen out particles. Under the screen is the essentially blank pipe 56 but which includes one of preferably several ports 60 which operate identically to a selected base pipe in a conventional gravel pack assembly while the ports 60 are open. Ports 60 allow for leak-off and therefore cause gravel to deposit.
[0018] When the gravel packing operation is complete and the otherwise conventional washpipe is withdrawn, a profile on the end thereof (not shown but any type of shifting profile is acceptable) is pulled past closing sleeve 62 to close the same. The sleeve 62 completely shuts off port 60 with the sleeve and it seals 64 and is not permitted to open again because of any number of conventional locking mechanisms such as dogs, collet, lock ring, etc. existing preferably at 66 . The locking arrangement is needed only to prevent accidental opening of the closing sleeve 62 after it has been closed. Once the closing sleeve 62 is closed, the pipe 56 is indeed completely blank pipe and is a zonal isolator.
[0019] Preferably the screen 58 is about one foot in length. Ports 60 may be distributed in many different patterns thereunder with as many ports as desired. One preferred embodiment employs four one quarter inch holes radially arranged about the circumference of the pipe. With respect to the blank pipe section length between the dehydration zones, a range of about five feet to about ten feet is preferred.
[0020] Since the provision of different zones and flow control devices in the invention allow the metering of the pressure drop in the individual zones, the operator can control the zones to both uniformly distribute the pressure drop available to avoid premature breakthrough while producing at a high rate. Moreover, the operator can shut down particular zones where there is a breakthrough while preserving the other zones' production.
[0021] After construction of one of the assemblies above described, and the washpipe has been removed, a production string is installed having preferably a plurality of the seal assemblies with at least one tool stop mechanism to locate the seal assemblies at points where the basepipe is smooth and the inner diameter is not reduced. Location may also be assured based upon the liner hanger. The seal assemblies allow different zones to be created and maintained so that selective conditions may be generated in discrete zones.
[0022] In an alternative embodiment of the dehydration ports, the closing sleeve 62 is not locked and remains operable so that if needed, individual closing sleeves may be opened. This alternative embodiment provides the invention with even more utility in that it allows the well operator to contaminate selected sections of the gravel pack to even more strongly hamper the ability of fluid to move longitudinally through the gravel pack. More specifically, the sleeve 62 would be opened by a shifting tool and an injection tool (one of many known to the art) would be used to apply a contamination fluid through the open port 60 . The contamination fluid could be cement, drilling mud, epoxy, etc. and once injected into the gravel pack through the port it would fill all interstitial spaces in the pack making it even more impermeable.
[0023] Referring back to FIG. 1, particularly valuable with respect to achieving maximum benefits of the zonally isolated gravel pack taught herein is an intelligent completion string 25 having one or more intelligent control devices 70 and one or more sensors 72 for temperature, pressure, flow rate, chemical composition, etc. which when installed operates in concert with the construction of the zonally isolated pack to further enhance controllability of different zones and isolation therebetween. Controllability includes the ability to control fluid movement both into or out of a particular zone for purposes such as production of fluids, remediation or even modification of the gravel pack or the formation by various methods. More specifically, an intelligent completion string 25 provided with one or more relevant sensors as elucidated above will query incoming fluid for chemical composition and if not acceptable may execute a program in a downhole processor which is part of string 25 to determine an appropriate action and then take action. Actions taken may be such as closing a flow control device, calling for or carrying out injection of a substance into the gravel pack and or into the formation or simply modifying the flow rate for such reasons as controlling the advance of a steam front from an associated injection well, for example. Moreover, the string may include a communication capability for communication with a remote location including but not limited to a surface location. It will be understood that both communication and control may be carried out by wire conductor, optic fiber conductor, acoustically, hydraulic line or wirelessly.
[0024] The combination of the disclosed gravel pack and method for forming the same and advanced completion strings such as the above discussed intelligent completion string provides a synergistic effect relative to the enhancement of hydrocarbon well systems in vertical, deviated and even horizontal configurations. The combined disclosed elements create a versatile, function changeable system having significant benefit to the hydrocarbon recovery industry in both economy and efficiency.
[0025] While preferred embodiments have been shown and described, various modifications and substitutions may be made thereto without departing from the spirit and scope of the invention. Accordingly, it is to be understood that the present invention has been described by way of illustration and not limitation.
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A system for enhancing oil production and reducing contamination thereof by such things as water breakthrough in unconsolidated horizontal wells comprises gravel packing, zonal isolation and selective flow control in combination. The significant control provided by the system enables the well operator to create a uniform pressure drop form heel to toe of the horizontal well and avoid commonly experienced water coning and early breakthrough of the horizontal borehole. An intelligent completion string including one or more flow control devices and one or more sensors is installable to enhance zonal isolation and control.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application is a continuation in part of application Ser. No. 09/311,043 titled “Method and Apparatus for Converting a DC Voltage to an AC Voltage,” filed on May 13, 1999, now U.S. Pat. No. 6,404,658 which is incorporated herein by reference.
This application is related to an application titled “Method and Apparatus for Converting a DC Voltage to an AC Voltage,” filed on Mar. 19, 2001, which is incorporated herein by reference.
FIELD OF THE INVENTION
Embodiments of the present invention are directed generally to a method and an apparatus for converting a DC voltage to an AC voltage. More specifically, embodiments of the present invention are directed to methods and apparatus for detecting excessive capacitance in a load when converting DC voltages to AC voltages using inverter circuits in devices such as uninterruptible power supplies (UPS).
BACKGROUND OF THE INVENTION
The use of uninterruptible power supplies (UPSs) having battery back-up systems to provide regulated, uninterrupted power for sensitive and/or critical loads, such as computer systems, and other data processing systems is well known. FIG. 1 shows a typical prior art UPS 10 used to provide regulated uninterrupted power. The UPS 10 includes an input filter/surge protector 12 , a transfer switch 14 , a controller 16 , a battery 18 , a battery charger 19 , an inverter 20 , and a DC—DC converter 23 . The UPS also includes an input 24 for coupling to an AC power source and an outlet 26 for coupling to a load.
The UPS 10 operates as follows. The filter/surge protector 12 receives input AC power from the AC power source through the input 24 , filters the input AC power and provides filtered AC power to the transfer switch and the battery charger. The transfer switch 14 receives the AC power from the filter/surge protector 12 and also receives AC power from the inverter 20 . The controller 16 determines whether the AC power available from the filter/surge protector is within predetermined tolerances, and if so, controls the transfer switch to provide the AC power from the filter/surge protector to the outlet 26 . If the input AC power to the UPS is not within the predetermined tolerances, which may occur because of “brown out,” “high line,” or “black out” conditions, or due to power surges, then the controller controls the transfer switch to provide the AC power from the inverter 20 . The DC—DC converter 23 is an optional component that converts the output of the battery to a voltage that is compatible with the inverter. Depending on the particular inverter and battery used the inverter may be operatively coupled to the battery either directly or through a DC—DC converter.
The inverter 20 of the prior art UPS 10 receives DC power from the DC—DC converter 23 , converts the DC voltage to AC voltage, and regulates the AC voltage to predetermined specifications. The inverter 20 provides the regulated AC voltage to the transfer switch. Depending on the capacity of the battery and the power requirements of the load, the UPS 10 can provide power to the load during brief power source “dropouts” or for extended power outages.
In typical medium power, low cost inverters, such as inverter 20 of UPS 10 , the waveform of the AC voltage has a rectangular shape rather than a sinusoidal shape. A typical prior art inverter circuit 100 is shown in FIG. 2 coupled to a DC voltage source 18 a and coupled to a typical load 126 comprising a load resistor 128 and a load capacitor 130 . The DC voltage source 18 a may be a battery, or may include a battery 18 coupled to a DC—DC converter 23 and a capacitor 25 as shown in FIG. 2 A. Typical loads have a capacitive component due to the presence of an EMI filter in the load. The inverter circuit 100 includes four switches S 1 , S 2 , S 3 and S 4 . Each of the switches is implemented using power MOSFET devices which consist of a transistor 106 , 112 , 118 , 124 having an intrinsic diode 104 , 110 , 116 , and 122 . Each of the transistors 106 , 112 , 118 and 124 has a gate, respectively 107 , 109 , 111 and 113 . As understood by those skilled in the art, each of the switches S 1 -S 4 can be controlled using a control signal input to its gate. FIG. 3 provides timing waveforms for the switches to generate an output AC voltage waveform Vout (also shown in FIG. 3) across the capacitor 130 and the resistor 128 .
A major drawback for various inverter circuits is that for loads having a capacitive component, a significant amount of power is dissipated as the load capacitance is charged and discharged during each half-cycle of the AC waveform. Part of this power is absorbed by the inverter circuit switches, which generates heat and causes temperature rises in those switches. To dissipate the heat, the switches are mounted on relatively large heat sinks. According to a known method, to better manage the heat dissipation, the inverter circuit is designed around a safe operating maximum capacitive load. However, in the event that a capacitive load greater than the specified load is applied to the inverter circuit, the heat generated by the switches may be greater than the heat dissipated. As a result, excessive heat causes components in the inverter circuit and in particular the switches to get hotter and hotter and eventually, the switches fail. Accordingly, a method and apparatus is required to overcome the shortcomings of above and other shortcomings.
SUMMARY OF THE INVENTION
One aspect of the invention is directed to an uninterruptible power supply for providing AC power to a load having a first capacitive element. The uninterruptible power supply includes an input to receive AC power from an AC power source, an output that provides AC power, a DC voltage source that provides DC power, the DC voltage source having an energy storage device, and an inverter operatively coupled to file DC voltage source to receive DC power and to provide AC power. The inverter includes first and second output nodes to provide AC power to the load having the first capacitive element, first and second input nodes to receive DC power from the DC voltage source, a circuit operatively coupled to the first output node of the inverter, the circuit being configured to compare a value representative of load capacitance of the first capacitive element with a reference value to determine excessive load capacitance, a set of switches operatively coupled between the first and second output nodes and the first and second input nodes and controlled to generate AC power from the DC power. The power supply further includes a transfer switch constructed and arranged to select one of the AC power source and the DC voltage source as an output power source for the uninterruptible power supply.
A second aspect of the invention is directed to an uninterruptible power supply for providing AC power to a load having a first capacitive element. The uninterruptible power supply includes an input to receive AC power from an AC power source, an output that provides AC power, a DC voltage source that provides DC power, the DC voltage source having an energy storage device, and an inverter operatively coupled to the DC voltage source to receive DC power and to provide AC power. The inverter includes first and second output nodes to provide AC power to the load having the first capacitive element, first and second input nodes to receive DC power from the DC voltage source, means for comparing a value representative of load capacitance of the first capacitive element with a reference value to determine excessive load capacitance, a set of switches operatively coupled between the first and second output nodes and the first and second input nodes and controlled to generate AC power from the DC power. The power supply further includes a transfer switch constructed and arranged to select one of the AC power source and the DC voltage source as an output power source for the uninterruptible power supply.
BRIEF DESCRIPTION OF THE DRAWINGS
For a better understanding of the present invention, reference is made to the drawings which are incorporated herein by reference and in which:
FIG. 1 is a block diagram of a typical uninterruptible power supply;
FIG. 2 shows a schematic diagram of a typical prior art inverter circuit;
FIG. 2A shows a block diagram of a voltage source used with the inverter circuit of FIG. 2 .
FIG. 3 shows timing waveforms for the inverter circuit shown in FIG. 2;
FIG. 4 shows a schematic diagram of an inverter circuit in accordance with one embodiment of the present invention;
FIG. 5 shows timing waveforms for the inverter circuit shown in FIG. 4;
FIG. 6 illustrates a current path through the inverter of FIG. 4 during a charging mode of the inverter corresponding to a starting point of the positive half cycle of the output voltage waveform;
FIG. 7 illustrates a current path through the inverter of FIG. 4 during a positive half cycle of the output voltage waveform;
FIG. 8 illustrates a current path through the inverter of FIG. 4 during a discharging mode of the inverter at the end of the positive half cycle of the output voltage waveform;
FIG. 9 illustrates a current path through the inverter during an energy recovery mode of the inverter;
FIG. 10 illustrates an exemplary excessive load capacitance detector circuit according to an embodiment of the invention;
FIG. 11 is a flow diagram of an operation of an exemplary excessive load capacitance detector circuit;
FIG. 12 illustrates alternative timing waveforms for the inverter circuit in FIG. 4; and
FIG. 13 illustrates another exemplary excessive load capacitance detector circuit according to an embodiment of the invention.
DETAILED DESCRIPTION
One embodiment of an inverter 200 in accordance with the present invention that may be used in the UPS of FIG. 1 will now be described with reference to FIG. 4 which shows a schematic diagram of the inverter 200 coupled to the voltage source 18 a and the load 126 . The inverter 200 includes MOSFET switches S 1 , S 2 , S 3 and S 4 of the prior art inverter 100 and includes two additional MOSFET switches S 5 and S 6 and an inductor 140 . In one embodiment, the switches S 5 and S 6 are similar to switches S 1 -S 4 and include a transistor 134 , 138 having an intrinsic diode 132 , 136 . Each of the transistors 134 and 138 has a gate 115 and 117 that is used to control the state of the transistor.
In one embodiment that provides an output of 120 VAC, 400 VA, 25 amps peak current to the load from an input to the inverter of approximately 170 VDC, the switches S 1 -S 6 are implemented using part no. IRF640 available from International Rectifier of E1 Segundo, Calif. For 220 VAC applications, the switches may be implemented using part no. IRF730 also available from International Rectifier. The inductor 140 , in the 120 VAC embodiment, is implemented using a 1.8 mH inductor having a very high Bsat value to be able to withstand high peak currents without saturating. In one embodiment, the inductor is made from an E1 lamination structure of M-19, 18.5 mil steel having a large air gap between the E and I laminations. Other values of inductors may be used with embodiments of the present invention depending upon the peak switch current and physical size of the inductor desired. In selecting an inductor for use, the transition time, or time required to charge or discharge the load capacitance, should also be considered to prevent the transition time from becoming either too short or too long. If the transition time is too long, then the pulse width of the output waveform may become too long. If the transition time is too short, the peak switch currents become greater.
The operation of the inverter 200 to provide AC power to the load will now be described with reference to FIGS. 5-9. FIG. 5 provides a timing diagram of the operation of the switches S 1 -S 6 of the inverter 200 and also provides the output voltage waveform across the load 126 . In the timing diagram of FIG. 5, for each of the switches S 1 -S 6 , when the corresponding waveform is in the high state, the switch is turned on (conducting state) and when the corresponding waveform is in the low state the switch is turned off (non-conducting state).
In the inverter 200 , the switches are shown as being implemented using NMOS devices. As known by those skilled in the art, for an NMOS device, a control signal having a high state is supplied to the gate of the device to turn the device on (conducting), while a control signal having a low state is supplied to the gate to turn the device off (non-conducting). Accordingly, the timing diagram of each of the switches also represents the state of the control signal provided to the gate of the corresponding transistor. In embodiments of the present invention, the control signals may be provided from, for example, controller 16 of the UPS of FIG. 1 when the inverter is used in a UPS. Alternatively, the control signals may be supplied using timing logic circuits residing within the inverter itself as is known in the art.
During a first time period from t 0 to t 1 in FIG. 5, switches S 4 and S 5 are turned on and switches S 1 , S 2 , S 3 and S 6 are turned off creating a current path through the inverter 200 in the direction of arrows 150 as shown in FIG. 6 . Only the components of the inverter 200 in the current path created during the first time period are shown in FIG. 6 . As shown in FIG. 6, with switches S 4 and S 5 turned on, the inductor 140 and the load 126 are connected in series across the voltage source 18 a . During the first period, the output voltage across the load Vout rises in a resonant manner from zero volts to the voltage of the voltage source 18 a . The output voltage Vout is prevented from rising beyond the voltage of the voltage source by the diode 104 (FIG. 7) of switch S 1 . The diode 104 will conduct current to limit the output voltage Vout to the voltage of the voltage source.
Once the output voltage Vout reaches the voltage of the voltage source (or shortly thereafter), at time t 1 , switch S 1 is turned on and switch S 5 is turned off. Switches S 1 and S 4 remain on for a second period from time t 1 to time t 2 , during which time, the load is coupled across the voltage source 18 a . FIG. 7 shows the current path through the inverter during the second time period. As shown in FIG. 7, load current during the second period follows arrows 154 . Also during the second time period, the energy that was stored in the inductor during the first time period causes the voltage across the inductor to reverse and energy in the inductor is released to a storage device in the voltage source, such as a battery or a capacitor, through a current that follows a path along arrow 156 through diode 104 of switch 1 and diode 136 of switch 6 . In addition, depending upon the load impedance, current from the energy stored in the inductor may also follow a path through the load.
During a third time period from time t 2 to time t 3 , the voltage across the load is returned to zero. At time t 2 , switches S 1 and S 4 are turned off to disconnect the load from the voltage source and switch S 6 is turned on to place the inductor effectively across the load as shown in FIG. 8 . During the third time period, energy stored in the load capacitor 130 is transferred to the inductor 140 , and the voltage across the load decreases to zero. The output voltage Vout is prevented from going negative by diode 110 (FIG. 9) of switch S 2 . The diode 110 will conduct current to limit the output voltage to zero.
At time t 3 switch S 6 is turned off, and all switches remain off during a fourth time period from t 3 until t 4 . The current path through the inverter 200 during the fourth time period follows arrows 160 shown in FIG. 9 . During the fourth time period, the energy in the inductor 140 freewheels into the voltage source 18 a through diodes 110 and 132 of S 2 and S 5 , and the voltage across the load typically remains at zero. The time from t 3 until t 4 is normally chosen to be long enough to permit all of the inductor energy to be transferred to the voltage source 18 a.
During a fifth time period from t 4 to t 5 , switches S 2 and S 4 are turned on to maintain a low impedance across the load to prevent any external energy from charging the output to a non-zero voltage. This is referred to as the “clamp” period. At time t 5 , all switches are again turned off and remain off for a sixth time period until time t 6 .
Beginning at time t 6 , and continuing until time t 9 the negative half cycle of the AC waveform is created. The negative half cycle is created in substantially the same manner as the positive half cycle described above, except that switch S 3 is substituted for switch S 4 , switch S 6 is substituted for S 5 and switch S 2 is substituted for S 1 . The positive and negative half cycles then continue to be generated in an alternating manner to create an AC output voltage waveform.
As described above, excessive heating may occur when the load capacitor 130 is greater than the design specification. This may occur as follows. Using a positive half cycle as an example, prior to the clamp period that occurs during the fifth time period from t 4 to t 5 , switch S 6 is turned on at the third time period from t 2 to t 3 to place the inductor effectively across the load (see FIG. 8 ). The load capacitor 130 transfers its energy to the inductor 140 including switch S 6 and the drain diode of S 4 . If the third time period is greater than the time needed for the resonant discharge, then the voltage at the drain of S 2 will be at a diode drop below ground when the clamp period begins. The time it takes to discharge the load capacitor and for S 2 drain to reach 0 V is ideally ¼ of the resonant period formed by the load capacitor 130 and inductor 140 . This equals to (¼)*2*□*SQRT(L*C). For a third time period of 120 us and inductor 140 of nominal 2 mH, the max value of load capacitor 130 that results in a S 2 drain of 0 volts is 2.9 uF. If the load capacitor 130 exceeds the maximum design value then the load capacitor 130 remains partially charged when the clamp period occurs. A surge of discharge current at the start of the clamp period results and the clamping switches S 2 and S 4 absorb the excessive capacitor energy resulting in heat being generated. Should the switches S 2 and S 4 continuously absorb the capacitor energy over many cycles, the resulting temperature rise may destroy switches S 2 and S 4 .
FIG. 10 illustrates an excessive load capacitance (x-cap) detector circuit 1000 that is used in one embodiment of the present invention to detect excessive load capacitance in an inverter circuit implementing the timing sequences illustrated in FIG. 5 . The circuit functions as a peak detector that looks at the drain voltage of switch S 2 when switches S 2 and S 4 are turned on during the clamp period. The circuit detects when the load capacitor 130 exceeds a maximum design value that leads to excessive heating of switches S 1 -S 4 . The x-cap detector circuit produces an analog value that is proportional to the excessive load capacitance, which is conveyed to an analog/digital (A/D) input of a microprocessor (uP) 1200 . The uP 1200 determines if the load capacitance is too high and if so, the uP 1200 causes the UPS to be shut down to protect it from damage. Because the heating of the switches S 1 -S 4 and their failure may not be immediate, the uP 1200 may be programmed to ride through several cycles of excessive load capacitance readings before a shutdown is initiated. As an alternative embodiment to an A/D input, the output of the detection circuit may be connected to other hardware that effectuates a shutdown.
The x-cap detector circuit comprises a resistor RX 1 that has one end coupled to the drain of the switch S 2 of the UPS 10 (see FIG. 1 ). The other end of the resistor RX 1 is coupled to two diodes DX 3 and DX 4 coupled in series in which the output of diode DX 4 is coupled to the switch S 2 driver IC 19 . The resistor RX 1 is also coupled to two clamping diodes DX 1 and DX 2 . A resistor RX 2 has one end coupled to the output of diode DX 3 and the other end coupled to a capacitor CX 1 . The x-cap detector circuit operates as follows. During the third time period the control signal to drive switch S 2 is off, therefore the S 2 driver IC 19 is low and the detection voltage on capacitor CX 1 is held low through diode DX 4 and resistor RX 2 . When the third time period ends, and the clamping period starts, the S 2 driver IC 19 goes high (e.g., 12 V), which back biases diode DX 4 . At that time a voltage, if any, on the drain of switch S 2 is captured by capacitor CX 1 via resistor RX 1 , diode DX 3 and resistor RX 2 . Thus, at the time t 4 of clamping period, if there is a discharge current, switch Q 2 comes out of saturation and the resulting drain voltage at switch S 2 is captured on capacitor CX 1 . When the discharge is complete the drain voltage will be zero, however diode DX 3 prevents capacitor CX 1 from discharging. The uP samples the capacitor CX 1 voltage and a decision is made on whether the inverter circuit should be shutdown to protect against excessive load capacitance. Diode DX 1 and diode DX 2 , for example, clamp the voltage between 5 volts and ground. Until these clamp diodes conduct the response of the detection circuit is governed by the time constant (RX 1 +RX 2 )*CX 1 . IF RX 1 is 100 Kohms, RX 2 is 10 Kohms and capacitor CX 1 is 470 pF, the time constant is 52 us. However once the 5 V clamp conducts the effective time constant is 4.7 us. The net effect is that low amplitude short duration drain voltage transients are rejected while high amplitude drain transients indicative of high capacitive loads are captured.
FIG. 11 is a flow diagram that illustrates an operation of the exemplary x-cap detector circuit. In stage 1102 , a drain of a clamping switch is monitored to determine if there is presence of a voltage (stage 1104 ). In stage 1106 , if there is a voltage present, it is captured to be evaluated against a reference to determine if the voltage is excessive. In stage 1108 , if the voltage is excessive in comparison with a reference, this indicates that there is excessive load capacitance driven by the UPS and the UPS is shut down to prevent damage to the UPS (stage 1112 ).
The inverter circuit of FIG. 4 may use alternative timing sequences such as that illustrated in FIG. 12 . With reference to FIG. 12, during a first time period from t′ 0 to t′ 1 , switches S 4 and S 5 are turned on and switches S 1 , S 2 , S 3 and S 6 are turned off creating a current path through the inverter 200 in the direction of arrows 150 similar to that shown in FIG. 6 . With switches S 4 and S 5 turned on, the inductor 140 and the load 126 are connected in series across the voltage source 18 a . During the first time period, the load voltage Vout rises in a resonant manner from zero volts to a portion of the voltage of the voltage source 18 a , preferably, approximately half of the voltage of the voltage source 18 a . At time t′ 1 , switch S 5 turns off blocking the current path from the voltage source 18 a to the inductor 140 . During the second time period from t′ 1 to t′ 2 , the current in inductor 140 freewheels through diode 136 and the energy stored in the inductor continues to charge the capacitor and increase the load voltage Vout to the voltage of the source voltage 18 a . Accordingly, the power loss due to the inductor's stored energy being freewheeled into the bus capacitance is minimized. According to one embodiment, the controller 16 controls appropriate switches such that freewheeling or “swing” time is made approximately equal to the inductor charge time. For example, if the inductor charge time is 100 us the inductor freewheeling time is set at about 100 us. The output voltage Vout is prevented from rising beyond the voltage of the voltage source by the diode 104 (FIG. 7) of switch S 1 .
Once the load voltage Vout reaches the voltage of the source voltage (or shortly thereafter), at time t′ 2 , switch S 1 turns on and switches S 1 and S 4 remain on for a third time period from t′ 2 to t′ 3 , during which time, the load is coupled across the source voltage 18 a similar to that shown in FIG. 7 . At time t′ 3 , switch S 1 turns off to disconnect the load from the voltage source 18 a and switch S 6 turns on to place the inductor effectively across the load similar to that shown in FIG. 8 . During a fourth time period from t′ 3 to t′ 4 , some of the energy stored in the load capacitor 130 is transferred to the inductor 140 and the voltage across the load decreases to approximately half the voltage source 18 a , at which time t′ 4 , the switch S 6 is turned off. During the fifth time period from t′ 4 to t′ 5 , with the switch S 6 turned off, the inductor 140 freewheels its stored energy through diode 132 and is returned to the voltage source 18 a in a manner similar to that shown in FIG. 9 and finishes discharging the load capacitor to zero volts. The output voltage Vout is prevented from going negative by diode 110 (FIG. 9) of switch S 2 . The diode 110 will conduct current to limit the output voltage to zero.
During a sixth time period from t′ 5 to t′ 6 , switch S 2 turns on and switches S 2 and S 4 maintain a low impedance across the load to prevent any external energy from charging the output to a non-zero voltage. This is referred to as the “clamp” period. At time t′ 6 , all switches are turned off.
Beginning at time t′ 6 and continuing until time t′ 12 , the negative half cycle of the AC waveform is created. The negative half cycle is created in substantially the same manner as the positive half cycle described above, except that switch S 3 is substituted for switch S 4 , switch S 6 is substituted for S 5 and switch S 2 is substituted for S 1 . The positive and negative half cycles then continue to be generated in an alternating manner to create an AC output voltage waveform. In this embodiment, the negative half cycle of the waveform is symmetric with the positive half cycle, and accordingly, the rise time, fall time and duration of the negative half cycle are approximately equal to those of the positive half cycle.
FIG. 13 shows a x-cap detector circuit 1300 in accordance with another embodiment of the present invention that may be used to detect excessive load capacitance in the alternative timing sequence described immediately above. The x-cap detector circuit 1300 provides an output signal having a pulse width that is proportional to the load capacitance. The length of the pulse, for example, can be measured by a microprocessor (uP) as is described. If the duration of the pulse exceeds a determined value then the amount of capacitance loading is deemed excessive and protective measures are taken by the uP, such as shutting down the UPS.
The principle of detecting excessive load capacitance in the alternative timing sequence is as follows. In one embodiment, detection of excessive load capacitance begins at each beginning of an end of a positive half cycle (i.e., fourth time period from t′ 3 to t′ 4 ). At time t′ 3 switch S 1 turns off to disconnect the load from the voltage source 18 a and switch S 6 turns on to place the inductor 130 across the load. This causes a resonant transition of load capacitor 130 that discharges into the inductor 140 , which defines a voltage waveform S 2 _Drain at the drain of switch S 2 . In essence, the discharge of the load capacitor 130 may be detected at the drain of switch S 2 . The timing of the waveform is defined by the resonant inductor value and the load capacitor value. At the maximum load capacitor design value, the voltage S 2 -Drain reaches a predetermined value (such as half of the voltage of the voltage source 18 a ) at which time switch S 6 is turned off. The load capacitor 130 further discharges into inductor 140 that in turn freewheels its energy to the voltage source via the drain diode of switch S 5 (current path similar to FIG. 9 ). If the load capacitor is smaller than the design value then the voltage S 2 -Drain transitions through greater than the half of the voltage rail at the time the switch S 6 is turned off. Conversely, if the load capacitor is greater than design value, then the voltage S 2 -Drain transitions through less than half the voltage rail at the time the switch S 6 is turned off. In embodiments of the present invention the time it takes for voltage S 2 -Drain to transition through a defined fraction of the voltage rail, in this example half the voltage rail is used to determine whether the load capacitor is excessive.
With that principle in mind, the x-cap detector circuit 1300 includes a comparator 1302 . Inputs to the comparator 1302 are voltage V_Rail, the voltage across the voltage rail, and voltage S 2 Drain, the voltage on the drain of switch S 2 . The circuit 1300 outputs a voltage xcap_sense. The voltage V Rail and voltage S 2 Drain are scaled by resistors R 37 , R 12 , R 61 and R 135 . The voltage V_Rail to voltage S 2 _Drain ratio for detection is set by the ratios of these resistor dividers, which in one embodiment is 13/20 (for example, R 37 =996 Kohms, R 12 =13 Kohms, R 61 =996 Kohms and R 135 =20 Kohms). When the voltage S 2 _Drain falls to or beyond 13/20ths of the voltage V_Rail the comparator 1302 output changes state from logic high to logic low. The signal S 6 _Drive, which is the control signal for switch S 6 , is diode Ored in with the comparator 1302 output. The signal S 6 _Drive remains low until driven high by a control logic which starts the falling resonant transition defined by fourth time period from t′ 3 to t′ 4 . This turns on switch S 6 . This also causes the rising edge of xcap-sense which indicates to a uP 1304 to start a timer used to detect an overload. When the voltage S 2 _Drain falls to or beyond 13/20ths of the voltage V_Rail the comparator 1302 output pulls xcap_sense low which indicates to the uP 1304 to stop the timer. If the duration of the timer exceeds a predetermined threshold then there is excessive load capacitance and appropriate action is taken such as causing the uP 1304 to shut down the UPS. Usually the uP 1304 allows several excessive load capacitance readings to occur before it causes the shutdown of the UPS. Because the output of the comparator 1302 is an open collector, resistor R 134 is provided as a pull-up resistor.
In embodiments of the present invention described above, inverters are described as being used with uninterruptible power supplies, for example, in place of the inverter 20 in the UPS 10 of FIG. 1 . As understood by those skilled in the art, inverters of the present invention may also be used with other types of uninterruptible power supplies. For example, the inverters may be used with UPSs in which an input AC voltage is converted to a DC voltage and one of the converted DC voltage and a DC voltage provided from a battery-powered DC voltage source is provided to an input of the inverter to create the AC output voltage of the UPS. In addition, as understood by those skilled in the art, inverters in accordance with embodiments of the present invention may also be used in systems and devices other than uninterruptible power supplies.
In the inverter 200 described above, MOSFET devices are used as the switches S 1 -S 6 . As understood by those skilled in the art, a number of other electrical or mechanical switches, such as IGBT's with integral rectifiers, or bipolar transistors having a diode across the C-E junction, may be used to provide the functionality of the switches. Further, in embodiments of the present invention, each of the switches S 1 -S 6 need not be implemented using the same type of switch.
In embodiments of the invention discussed above, an inductor is used as a resonant element in inverter circuits. As understood by one skilled in the art, other devices having a complex impedance may be used in place of the inductor, however, it is desirable that any such device be primarily inductive in nature.
In the embodiments of the present invention described above, energy is returned from the inductor to the voltage source after the load capacitance has been discharged. As understood by those skilled in the art, the voltage source may include a battery that receives the energy from the inductor, or the voltage source may include a storage device other than a battery, such as a capacitor that receives the energy.
In embodiments described, the x-cap detector circuits may be modified to detect excessive load capacitor using any of the time periods when the output voltage transitions from zero to positive or negative output, or from positive or negative output to zero. For the embodiments of FIG. 5 the periods are t 0 to t 1 , t 2 to t 3 , t 6 to t 7 and t 8 to t 9 . For the embodiment of FIG. 12 the time periods are t 0 to t 1 , t 3 to t 4 , t 6 to t 7 and t 9 to t 10 . When using other time periods the voltage across S 1 , S 3 or S 4 is measured instead of S 2 .
In embodiments described above, inverter circuits using a resonant element have been used to aid in the understanding of the invention. However, the invention may be practiced in inverter circuits that do not have a resonant element in their circuit. In particular, it is noted that the invention pertains to circuits that detect excessive load capacitance in a load coupled to an inverter circuit. Thus, for example, in embodiments using x-cap circuit described above, inverter circuits are not restricted to resonant bridge inverter circuits but also include conventional four-switch H-bridge inverter circuits, among others.
Having thus described at least one illustrative embodiment of the invention, various alterations, modifications and improvements will readily occur to those skilled in the art. Such alterations, modifications and improvements are intended to be within the scope and spirit of the invention. Accordingly, the foregoing description is by way of example only and is not intended as limiting. The invention's limit is defined only in the following claims and the equivalents thereto.
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Embodiments of the present invention are directed to an uninterruptible power supply for providing AC power to a load having a capacitive element. In embodiments of the present invention the uninterruptible power supply includes an input to receive AC power from an AC power source, an output that provides AC power, a DC voltage source that provides DC power, the DC voltage source having an energy storage device, an inverter operatively coupled to the DC voltage source to receive DC power and to provide AC power, the inverter including: first and second output nodes to provide AC power to the load having the first capacitive element, first and second input nodes to receive DC power from the DC voltage source, a circuit operatively coupled to the first output node of the inverter, the circuit being configured to compare a value representative of load capacitance of the first capacitive element with a reference value to determine excessive load capacitance, a set of switches operatively coupled between the first and second output nodes and the first and second input nodes and controlled to generate AC power from the DC power, and a transfer switch constructed and arranged to select one of the AC power source and the DC voltage source as an output power source for the uninterruptible power supply.
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CROSS REFERENCE TO RELATED APPLICATION
This application is a continuation-in-part of application Ser. No. 559,806, filed Mar. 19, 1975, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a process for the N,N-alkylation of unsubstituted acid hydrazides.
2. Description of the Prior Art
The N,N-dialkyl acid hydrazides afford a potentially attractive way for preparing aminimides; i.e., those compounds characterized in having one or more ##STR1## groups. The aminimides have recognized utility as surface active compounds, antimicrobial agents, polymerization catalysts, etc., as well as being precursors for deriving corresponding isocyanates in accordance with a known thermolytic rearrangement mechanism. The methods heretofore available for preparing aminimides, however, all involve the use of unsymmetrical disubstituted hydrazine as a reactant. On the other hand, the only commercially feasible method for preparing the latter hydrazines involves the hydrogenation of a nitroso secondary amine in turn obtained by nitrosating the 2° amine. These nitroso compounds have proven to be very potent carcinogens and consequently this method for the production of the indicated hydrazines stands currently abandoned. Accordingly, there presently exists an important need for a method of preparing aminimides which obviates the requirement for using an N,N-dialkyl hydrazine as a basic raw material.
SUMMARY OF THE INVENTION
In accordance with the present invention a method is provided for the preparation of an N,N-dialkyl acid hydrazide of the formula: ##STR2## WHEREIN N IS THE INTEGER 1 OR 2; R is alkylene, m-phenylene or p-phenylene when n is 2; R is alkyl or aryl when n is 1; and R 1 is C 1 -C 6 alkyl.
The method comprises first reacting hydrazine and a lower alkyl ester of a mono- or dicarboxylic acid having the formula R(COOH) n wherein R and n are as defined above, to form the corresponding acyl or diacyl hydrazine. The aforesaid mixture is thereupon reductively alkylated with a C 1 -C 6 saturated aliphatic aldehyde to result in the formation of the N,N-dialkyl acid hydrazide.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The first step contemplated in the practice of the present invention involves the reaction of a lower alkyl ester of a mono- or dicarboxylic acid with hydrazine to form the corresponding acyl hydrazine. While this reaction is not new, in overall context of this invention the step represents an important integral aspect thereof inasmuch as it has been found that the acyl hydrazine as produced in the crude form can be reductively alkylated if the latter reaction is carried out in a particular manner, details concerning which will be given later. The reductive alkylation has been found to be a highly sensitive reaction mechanism and consequently it was surprising to find that crude acyl hydrazine could be employed as such without resorting to recrystallization procedures in order to obtain a pure form thereof.
The preparation of the acyl hydrazine consists of reacting the lower alkyl ester of the starting acid, preferably the ethyl ester, with hydrazine on an essentially equivalent basis. Preferably an excess of the ester is used ranging up to about 15% over the equivalent requirement. The reaction can be carried out in a lower alkanol of which methanol is most suitable. However, solvents are not necessary for effecting this reaction since the generated alcohol in combination with the associated water of the preferred form of the hydrazine serves to solubilize the reaction system in most instances. The hydrazine can be anhydrous but for economic reasons the conventional 85% hydrazine hydrate of commerce is preferred. An applicable reaction temperature range is from about 50° to 120° C. at atmospheric or moderately elevated pressure conditions. An alcohol solvent when employed is ordinarily used on the basis of about 1 mole per mole of the ester. The reaction mixture is maintained under the conditions indicated until there has been an almost quantitative utilization of the hydrazine.
A variety of saturated mono- and dicarboxylic acids can be utilized for deriving the substituted acid hydrazides contemplated herein. An enumeration of suitable monobasic acids include: acetic, propionic, caproic, caprylic, capric, lauric, myristic, palmitic, stearic, eicosanoic, behemic, carnaubic, etc. Representative of applicable saturated aliphatic dibasic acids are such as adipic, suberic, azelaic and sebacic. Of the aromatic acids, benzoic, meta- and terphthalic are representative.
Before proceeding with the reductive alkylation phase of the process, it is important that the crude acyl hydrazine be adjusted so as to exhibit a pH not in excess of 7.5. The preferred pH range is in the order of from 6 to 7. Maintaining the pH as indicated is one factor which allows the use of the crude acyl hydrazine. Additionally, pH control in this manner importantly contributes to extended catalyst life. The pH of the system can be regulated by the addition of an appropriate amount of a lower carboxylic acid such as, for example, formic, acetic acid or the anhydride thereof. Still another suitable acid for this purpose is phoshoric which can be most advantageously used under those circumstances where corrosion problems associated with the use of the indicated carboxylic acids are presented.
The next step in sequence consists of reductively alkylating the acidified crude acyl hydrazine with a C 1 -C 6 saturated aliphatic aldehyde. This reaction is carried out by first adding the hydrogenation catalyst, pressuring with hydrogen, heating to the contemplated temperature and thereupon adding the aldehyde. The manner required for introducing the aldehyde is critical from the standpoint of obtaining optimum yield and for avoiding premature inactivation of the catalyst. The aldehyde is to be added slowly and continuously during this phase of the process. The time required for introducing the aldehyde can not be stated in absolute terms inasmuch as such depends on batch size and also on the reactor's design; e.g., agitation rate and ability to dissipate the rather considerable heat of reaction. In a large scale operation the addition rate of the aldehyde can be suitably arrived at simply by introducing this reactant at a rate which permits control of the temperature within the range specified. Normally in a plant or pilot plant type run the addition of the aldehyde can be accomplished within from 4 to 6 hours. The important factor to observe is that the aldehyde addition be continuous with continuous flow of the hydrogen throughout the reductive alkylation reaction. Any stoppage of the aldehyde addition can have a pronounced adverse effect upon catalyst activity resulting in a lower yield of the desired product.
As indicated, the applicable aldehydes include the C 1 -C 6 saturated aliphatic type which is desirably employed as a solution in a lower alkanol. When formaldehyde is used as the aldehyde such can take the form of an aqueous or methanolic solution thereof. The preferred form of formaldehyde is Methyl Formcel (formaldehyde methyl hemiacetal). Irrespective of the specific aldehyde employed or the particular form thereof, it is desirably modified by the addition of acetic acid. The presence of the added acid serves to keep the reductive alkylation mixture within the proper pH range during the course of reaction. An amount of acetic acid in the order of about 4-6 wt. percent based on the aldehyde is adequate for this purpose. As indicated previously, other acids can be used; however, acetic acid is preferred. The amount of aldehyde suitable for conducting the reductive alkylation reaction is from 2 to 3 moles thereof per equivalent of the acyl hydrazine sought to be alkylated. The preferred combining ratio of the aforesaid reactants is about 2.1 moles of the aldehyde per equivalent of acyl hydrazine.
A suitable temperature range for carrying out the reductive alkylation reaction is from about 40° C. to 100° C. More preferably, the reaction temperature is maintained within the range of from about 60° to 85° C. During the reaction hydrogen pressures between about 7 and 17 atmospheres are generally applicable. Preferred pressure conditions are in the range of 8 to 10 atmospheres. Following the completion of the reaction, recovery of the resultant 1,1-dimethyl-2-acyl hydrazine can be accomplished by stripping the reaction mixture to remove volatiles. By carrying out the reaction under the preferred conditions noted above and employing the preferred catalyst yields in the order of from 80 to 86% can be readily realized.
The catalysts useful for effecting reductive alkylation can be a particulate catalytic material in the form of a Group VIII metal such as palladium, platinum, rhodium, nickel, etc. The usual supports for such catalytic materials can be used representative of which include carbon, alumina, silica, etc. The most effective catalyst is 5% palladium on a carbon support. The preferred catalyst as a 50% water wet mixture is employed in the amount of about 1 wt. % based on the total reactor charge.
In order to illustrate to those skilled in the art the best mode contemplated for carrying out the invention, the following working examples are set forth. It is to be understood that these examples are given solely by way of illustration and accordingly, any enumeration of details set forth therein is not to be interpreted as limiting the invention except as such limitations appear in the appended claims. All parts and percentages are by weight unless otherwise noted.
EXAMPLE I
Into a pressure reactor having a capacity of 113.5 liters were charged 23.8 Kg. of ethyl acetate. Hydrazone hydrate (85%) in the amount of 13.9 Kg. was added to the reactor with stirring during a 30 minute period. The reactor was then sealed and heated to 120° C. at 2 atmospheres of pressure. Holding for 5 hours at the indicated temperature resulted in a residual hydrazine content of 0.64%.
To the acetylhydrazide solution were added 0.68 Kg. glacial acetic acid and 0.64 Kg. of catalyst consisting of 5% palladium on carbon support in the form of a 50% water wet mixture. The reaction mixture was pressurized to 10 atmospheres with hydrogen and heated to 90° C. with stirring. Methyl Formcel (54%) in the amount of 28.4 Kg. was continuously pumped into the reactor over a 5 hour period while providing a hydrogen flow rate such as to maintain the pressure at 10 atmospheres. The Methyl Formcel contained 2.5% added glacial acetic acid.
Following the completion of the addition of the formaldehyde, the reaction mixture was cooled and filtered to recover the catalyst. The filtered product was thereupon returned to the reaction vessel and 27.5 Kg. of solvent were removed at 55° C. under reduced pressure to provide 39.3 Kg. of 1,1-dimethyl acetylhydrazide representing about 85% yield of product based on the hydrazine charged.
EXAMPLE II
Into a 2-liter, high-pressure reactor were charged 235.4 g. of methyl laurate, 40 g. of methanol and 59 g. of 85% hydrazine hydrate. The reactor was sealed and with stirring heated to 80° C. and held for 18.5 hours. The reaction was cooled and half of the reactor contents removed, filtered and vacuum dried. The overall yield of lauroyl hydrazide was 93%.
To the remaining portion of lauroyl hydrazide were charged 10 g. of acetic acid, 20 g. of methanol and 5 g. of 5% Pd/C catalyst (50% wet). The reactor was sealed, heated to 95° C. and pressurized to 9 atmospheres of hydrogen. Methyl Formcel (100 g.) was pumped into the reactor over a 0.5 hour period. The reaction was heated for an additional 3.5 hours. The reaction was cooled to ˜40° C. and the catalyst removed by filtration. The orange solution was stripped of solvents on a rotoevaporator to yield 138 g. (101%) of crude 1,1-dimethyl lauroylhydrazide. The TLC R f values of the product agreed with an authentic sample of 1,1-dimethyl lauroyl hydrazide.
EXAMPLE III
Into a 2-liter, high-pressure reactor was charged 243 g. of a benzoyl hydrazide stock solution. The stock solution was prepared by reacting 680.1 g. of methyl benzoate, 288.6 g. of 85% hydrazine hydrate and 100 g. of absolute ethanol and heated for 18 hours at 50° C. Methanol (1235 g) was added to the pale yellow solution to prevent precipitation of benzoyl hydrazide.
A 5% Pd/C catalyst (3 g. 50% wet) and 5.4 g. of acetic acid were added to the reactor. The reactor was sealed, heated to 82° C. and pressurized with hydrogen to 8.5 atmospheres. Methyl Formcel (65 g.) was pumped into the reactor during a 0.25 hour period. The reaction was heated for an additional 2 hours. The reactor was cooled and vented and the catalyst removed by filtration through Hyflow filter aid. The solvents were stripped on a rotoevaporator and the residue oil was distilled at 118° C. at 0.03 mm. A yield of 56 g. (68% based on hydrazine) of 1,1-dimethylbenzoyl hydrazide was recovered.
EXAMPLE IV
Into a 2-liter Parr reactor were charged 234 g. of a 47.5% solution of acetylhydrazine in methanol, 18 g. of 5% palladium on carbon (50% wet) and 11 g. of glacial acetic acid. The reactor was sealed and heated to 75° C. with stirring. The reactor was purged three times with hydrogen and then pressurized with the hydrogen to 10 atmospheres. A solution of 139 g. of acetaldehyde and 140 g. of isopropanol was pumped into the reactor at a rate of 192 ml/hour. A change in pressure was noted after 10 minutes of the addition. A constant flow of hydrogen was provided to maintain the pressure at 10 atmospheres. After 6 hours total reaction time the reactor was cooled and vented. The product was filtered and vacuum stripped to 130 g. of a light viscosity liquid. TLC and IR analysis indicated that approximately 50% of the acetylhydrazine was converted into diethylacetylhydrazide.
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A method for the preparation of N,N-dialkyl derivatives of mono- and diacyl hydrazines wherein the corresponding unsubstituted acid hydrazide is reductively alkylated with an aldehyde.
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BACKGROUND OF THE DISCLOSURE
1. Field of the Invention
The invention relates to semiconductor substrate processing, and more particularly, to a method for improved handling and processing of a semiconductor wafer in a sputter etch process system.
2. Description of the Background Art
Semiconductor processing typically is carried out in specialized apparatus comprised of multiple chambers wherein wafers are processed by the deposition and various treatments of multiple layers of semiconductor material in a single environment. The plurality of processing chambers and preparatory chambers are strategically arranged to process substrates (i.e., semiconductor wafers) through a plurality of sequential steps to produce integrated circuits.
Plasma-based reaction chambers have become increasingly utilized in such specialized apparatus, providing for precisely controlled thin-film etchings and depositions. For example, in an inductively coupled plasma source (IPS) sputter etch chamber, a plasma is used to initiate wafer processing conditions. In such a chamber, a pedestal supports an electrostatic chuck and also functions as an RF powered cathode. The chamber walls typically form an RF anode. The electrostatic chuck (e.g., a ceramic electrostatic chuck) creates an electrostatic attractive force to retain the wafer in a stationary position during processing. A voltage is applied to one or more electrodes imbedded within a ceramic chuck body so as to induce opposite polarity charges in the wafer and electrodes, respectively. The opposite charges pull the wafer against the chuck support surface, thereby electrostatically clamping the wafer.
An additional coil on the outside surface of the IPS chamber lid is energized with RF power that inductively couples through the lid and into the chamber. The electric field generated between the anode and cathode along with the inductively coupled power from coil ionizes a reactant gas introduced into the chamber to produce the plasma. Ions from the plasma bombard the wafer to create (etch) a desired pattern.
Electrically biasing the pedestal and wafer as a cathode enhances the wafer process; however, it also creates certain undesirable conditions afterwards. Particularly, wafers with relatively thick (e.g., 1 μm) oxide coatings will tend to accumulate charges during processing. The charges are primarily RF induced, and it is believed that they are trapped by the electrostatic chucking forces that retain the wafer. As such, the wafer is retained by the chuck to some degree even after the chucking voltage is removed. The wafer must then be mechanically forced from the pedestal which leads to breakage or particle formation; neither of which is desirable.
A second problem are the electrical transients that travel through the wafer (again as a result of the RF power). These transients cause the wafer to locally alter its bias thereby weakening or totally repelling the chucking force. Accumulated charges are detrimental because they reduce the available chucking force for retaining a wafer. This condition, in turn, results in poor process conditions. For example, a reduced chucking force can contribute to a non-uniform backside gas pressure under the wafer. Such unequal forces cause wafer shifting or pop-off and compromises temperature control which results in poor etch process conditions or particle contamination.
Therefore, a need exists in the art for a method of properly controlling the process parameters of a sputter etch wafer process to reduce the likelihood of residual charge retention in the substrate and allow for improved dechucking of same.
SUMMARY OF THE INVENTION
The disadvantages associated with the prior art are overcome with the present invention of a method for processing a semiconductor substrate in a chamber comprising the steps of establishing preprocess conditions in the chamber, executing a two-step plasma ignition, processing the substrate, executing a two-step plasma power down and executing a two-step substrate dechuck. Establishing the preprocess conditions consists of applying a chucking voltage to the substrate, flowing a backside gas at a flow rate of approximately 4 sccm for approximately 10 seconds to the substrate to establish a backside gas pressure, introducing a first flow of process gas at a flow rate of approximately 100 sccm, introducing a second flow of process gas at a flow rate of approximately 5 sccm and reducing the backside gas flow to approximately 1 sccm for approximately 5 seconds.
The two step plasma ignition consists of applying an RF bias power of approximately 200 Watts at a frequency of approximately 13.56 Mhz to the chamber and approximately 0.5 seconds later applying an RF coil power of approximately 300 Watts at a frequency of approximately 400 Khz to the chamber.
The RF bias power is then increased to approximately 300 Watts and the first flow of process gas is reduced to 0 sccm for approximately 60 seconds or other sufficent time to process the substrate (i.e., to achieve the desired oxide removal).
The two step plasma power down consists of increasing the RF coil power to approximately 500 Watts and reducing the backside gas flow to approximately 0 sccm for approximately 2 seconds. Then, the RF bias power is decreased to approximately 150 Watts for approximately 2 seconds. The two step substrate dechuck consists of decreasing the RF bias power to approximately 1 Watt for approximately 6 seconds and then reducing the chucking voltage to approximately 1 volt for approximately 5 seconds. The chamber can then be purged and byproducts pumped out so as to render the chamber environment suitable for another process run.
The benefits realized by this improved method are a "softer" ignition of a plasma which reduces the DC bias spikes on the substrate. Reducing DC bias spikes reduces processing anomolies such as excess charge retention in the wafer after removing the chucking voltage and wafer repulsion and plasma discontinuity during processing. Additionally, the plasma ramp down after processing allows adequate time for discharging of residual charges in the wafer which allows for more reliable removal of the substrate from the chamber (dechucking).
BRIEF DESCRIPTION OF THE DRAWINGS
The teachings of the present invention can be readily understood by considering the following detailed description in conjunction with the accompanying drawings, in which:
FIG. 1 depicts a process chamber within which the method of the present invention can be executed; and
FIG. 2 is a flow chart of the method of the present invention.
To facilitate understanding, identical reference numerals have been used, where possible, to designate identical elements that are common to the figures.
DETAILED DESCRIPTION
An improved method for processing of semiconductor wafer in a semiconductor wafer processing system is described. The method may be practiced, for example, in a sputter etch process chamber such as the Preclean II/e process chamber manufactured and sold by Applied Materials, Inc. of Santa Clara, Calif. Specifically, FIG. 1 depicts a schematic of a sputter etch process chamber 100 mentioned above. The chamber 100 comprises a plurality of walls 102 extending upwards from a base 104. A dome-shaped lid 106 encloses a process cavity 108 of the chamber 100. Within the cavity 108, a substrate support 110 is disposed for supporting and retaining a workpiece 118 such as semiconductor wafer. The substrate support 110 further comprises a pedestal 112 sheathed in a bellows assembly 114. The bellows assembly 114 allows for movement of the substrate support 110 within the process cavity 108 while maintaining a vacuum condition within the enclosure 108. An electrostatic chuck 116 is disposed on top of the pedestal 112 for retaining a workpiece 118 thereupon. The workpiece 118 is electrostatically retained by the electrostatic chuck by the one or more electrodes 120 connected to a chucking power supply 122 (e.g., a high-powered DC source). Additionally, the substrate support 110 functions as an RF cathode via connection to an RF power supply 124. The chamber comprises one or more deposition shields, cover rings or the like 126 circumscribing various chamber components to prevent unwanted reaction between such components and ionized process material.
To create the desired plasma for processing the substrate 118 an RF coil 128 is provided in the chamber 100. Specifically, the coil 128 is disposed within a resonator housing 130 disposed above the lid 106. The coil 128 is vertically aligned with the walls 102 of the chamber 100 and is powered by an RF coil power source 132. Process gas (e.g., argon) is introduced into the chamber 100 from a process gas source 134. A plasma 136 is created in the process cavity 108 when the RF coil inductively couples power from source 132 into the process gas in the chamber. A backside gas is also provided through the substrate support 110 to a backside of the wafer 118 via a backside gas source 136. The backside gas acts as a thermal conduction medium between the substrate support 110 and the wafer 118. To establish and maintain the necessary environmental conditions in the chamber 100, a pressure control device 138 is connected to the chamber 100. The pressure control device is for example a turbo pump or other similar pump capable of establishing near vacuum conditions (i.e., chamber pressure in the mTorr range).
FIG. 2 depicts a series of method steps 200 for controlling process conditions within the chamber 100. This method reduces the residual charges and hence the time required to dechuck a wafer as well as enhancing defect performance. Specifically, the method 200 starts at step 202 and proceeds to the next step, step 204 wherein a substrate (i.e., a semiconductor wafer) is chucked to a substrate support. The substrate support is, for example a ceramic electrostatic chuck which comprises one or more electrodes buried within a ceramic chuck body. The electrodes are energized by a power source which in turn creates a strong attractive force between the chuck and the substrate. In a preferred embodiment of the invention, a high voltage DC power source is used to create the appropriate chucking voltage and electrostatic force to retain the substrate on the chuck. Preferably the chucking voltage is approximately 250 volts DC.
After the substrate is properly retained upon the chuck in step 204, a backside gas is applied behind the substrate at step 206. The flow of gas to the backside of the substrate ensures a sufficient thermal energy transfer from the substrate to the chuck which is cooled by a variety of methods (i.e. water passing through conduits below the chuck surface). Preferably, the backside gas is an inert gas such as Argon applied to the backside of the wafer at a flow rate of approximately 4 sccm for approximately 10 seconds. Experimentation has revealed that the 10 second interval of backside gas results in a backside pressure of approximately 5 Torr. This value is considered sufficient for cooling of the substrate during process conditions while allowing for leakage.
After the pressurization step 206 the chamber environment is stabilized in step 208. Specifically, the stabilization step comprises introducing a first flow of a process gas for approximately 5 seconds to the chamber at a flow rate of approximately 100 sccm and a second flow of a process gas into the chamber at a rate of approximately 5 sccm for approximately 5 seconds. The first flow of process gas is used primarily for creating a high pressure condition necessary for plasma ignition and the second flow of process gas is used primarily for sustaining process conditions within the chamber as described in greater detail below. Additionally, the flow rate of the backside gas is reduced to approximately 1 sccm to maintain the backside gas pressure conditions discussed above. That is, once the substrate has been adequately chucked the backside gas pressure is sufficient for thermal transfer yet not enough to cause the wafer to shift, move or pop off the electrostatic chuck. However, some leakage may occur which will reduce the backside gas pressure below the 5 Torr value; therefore, the 1 sccm flow of backside gas compensates for any leakage.
After the chamber environment has been stabilized in step 208, a high pressure "soft" ignition of a plasma is executed. Specifically, a first plasma ramp up the step is executed at step 210. The first plasma ramp up step is executed by applying an RF bias to the electrostatic chuck. Specifically, an RF power of approximately 200 watts at a frequency of approximately 13.56 Mhz is applied to the electrostatic chuck via a power supply to bias the chuck to attract positive ions. After the first plasma ramp up step, a second plasma ramp up step 212 is executed. The second plasma ramp up step applies an RF power to a coil that is disposed on an outside of a lid enclosing the chamber to ionize the process gas into a plasma within the chamber. Specifically, the second plasma ramp up step occurs 0.5 seconds after the first plasma ramp up step by applying an RF power of approximately 300 watts at a frequency of 400 Khz to the coil. The RF power from the coil inductively couples through the lid to the process gas injected into the chamber during the stabilization step 208 and creates a plasma above the wafer which is suitable for processing (i.e. etching an oxide layer off the wafer to a depth of approximately 300-500 Å). The high pressure "soft" ignition represented by steps 210 and 212 minimize the interference of DC bias spikes on the electrostatic chuck surface.
Minimizing DC bias spikes interference is important because excessive spiking causes field emission between the chuck and the substrate. These field emissions induce extra charges in the substrate which become trapped and contribute to substrate sticking or residual chucking force after the chucking voltage power has been removed.
After the plasma has been ignited, process 200 continues at step 214 which is a standard etch process capable of removing an oxide layer from the substrate via an interaction between the oxide layer and the energetic molecules of the plasmolized process gas. For optimal etching conditions, a chamber pressure of 8 mT was set in the chamber by reducing the first process gas flow from approximately 100 sccm to 0 sccm while maintaining the second process gas flow at 5 sccm, maintaining the backside gas flow at 1 sccm, increasing the RF bias power to approximately 300 watts and maintaining the RF coil power at approximately 300 watts. In a preferred embodiment of the invention, the etch step 214 is carried out for approximately 60 seconds.
After the intended etch step has been completed, the substrate (i.e. semiconductor wafer) is dechucked and removed from the chamber. In order to properly dechuck the wafer however, a two step plasma ramp down must be executed in order to discharge any residual charges that remain in the wafer. Specifically at step 216, a first plasma ramp down step is executed wherein the RF coil power is increased to approximately 500 watts while maintaining the RF bias power at approximately 300 watts and reducing the backside gas flow to 0 sccm for a period of approximately 2 seconds. After the first plasma ramp down step 216 has been executed, a second plasma ramp down step 218 is executed. Specifically, the second plasma ramp down step is executed by maintaining the RF coil power at 500 watts and reducing the RF bias power to approximately 150 watts for a period of approximately 2 seconds. Reducing the backside gas flow reduces the upward force applied to the substrate via the pressurized gas. Increasing the RF coil power serves to sustain the plasma and thereby pull the excess charges within the wafer towards the grounded chamber walls hence reducing the DC bias on the wafer. Reducing the RF bias power at step 218 reduces the amount of ion bombardment and subsequently the amount of heat imparted to the wafer. Additionally, there is a lesser likelihood of residual charges building up in the wafer which further lowers the DC bias. The combination of reduced DC bias and residual charges on the wafer and lower backside gas pressure insures safe reliable dechucking of the wafer without unusual or unexpected movement of the wafer during removal from the chamber.
After the first and second plasma ramp down steps 216 and 218 respectively, a first low power dechucking step 220 is executed. Specifically, the RF bias power is reduced from 150 watts to approximately 1 watt where ionic bombardment is reduced to nearly zero and any residual charges can be further removed from the wafer. Additionally, the backside gas is pumped off the wafer backside to eliminate any remaining upward force. This first low power dechucking step 220 is executed for approximately 6 seconds. Next a second low power dechuck step 222 is executed. Specifically, the RF bias power and RF coil power are maintained at 1 watt and 500 watts respectively and the chucking voltage is reduced from approximately 250 volts to approximately 1 volt for a period of approximately 5 seconds. At this point mostly all residual charges and backside gas pressure have been removed and the wafer can be removed from the chamber via typical mechanical means such as a robot transfer arm extending into the chamber.
After the second low power dechucking step 222, a chamber purge step 224 is executed. Specifically, an inert gas is flowed into the chamber at a rate of approximately 25 sccm and both the RF bias power and RF coil power are turned down to 0 watts for approximately 5 seconds. This purge step allows residual process gas particles to be stirred up within the chamber and subsequently pumped out at pump step 226. Specifically, pump step 226 is executed for approximately 5 seconds wherein the inert process gas flow is shut off and a chamber pressure control device (i.e. a turbo pump) is activated. The pump pulls out the residual process gas particles as well as the inert purge gas so that the process can be started anew under nearly identical conditions as when the process was first started. That is to say, for maximum reliability and repeatability of a certain process, all conditions before, during and after the specific process should be identical or close thereto within a batch run of wafers.
Although various embodiments which incorporate the teachings of the present invention have been shown and described in detail herein, those skilled in the art can readily devise many other varied embodiments that still incorporate these teachings.
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Method for processing a semiconductor substrate in a chamber comprising the steps of establishing preprocess conditions in the chamber, executing a two-step plasma ignition, processing the substrate, executing a two-step plasma power down and executing a two-step substrate dechuck. A "softer" ignition of a plasma in two steps reduces DC bias spikes on the substrate. Reducing DC bias spikes reduces processing anomalies such as excess charge retention in the wafer after removing the chucking voltage and wafer repulsion and plasma discontinuity during processing. Additionally, the plasma ramp down after processing allows adequate time for discharging of residual charges in the wafer which allows for more reliable removal of the substrate from the chamber (dechucking).
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BACKGROUND OF THE INVENTION
[0001] A network device receives packets of information from a communication media access control device, e.g., an Ethernet controller. Each packet may contain data and the destination address of that data. Each receiving port of the device has a “ready signal” which indicates that a predetermined number of bytes or the last byte of the packet has been received. The predetermined number of bytes is usually 64 because that is the size of a minimum Ethernet packet. A high percentage of Ethernet packets (approximately 80%) are minimum length packets, e.g., 64 bytes. Optimizing for 64 byte packets by requesting 64 bytes increases the bandwidth of the processor.
SUMMARY OF THE INVENTION
[0002] According to one aspect of the invention, a method is described of receiving bytes of data from a media device includes issuing N consecutive requests, each for M bytes, to the media device and receiving N−1 responses of M bytes of data from the media device.
[0003] Other advantages will become apparent from the following description and from the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0004] [0004]FIG. 1 is a block diagram of a communication system employing a hardware-based multithreaded processor.
[0005] [0005]FIG. 2 is a detailed block diagram of the hardware-based multithreaded processor of FIG. 1.
[0006] [0006]FIG. 3 is a block diagram of a communication bus interface in the processor of FIG. 1.
[0007] [0007]FIGS. 4A and 4B are flowcharts illustrating the operation of a bus interface.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0008] Referring to FIG. 1, a communication system 10 includes a parallel, hardware-based multithreaded processor 12 . The hardware-based multithreaded processor 12 is coupled to a bus such as a PCI bus 14 , a memory system 16 , and a second bus 18 . The processor 12 includes a bus interface 28 that couples the processor 12 to the second bus 18 . Bus interface 28 in one embodiment couples the processor 12 to the so-called FBUS 18 (FIFO (first-in, first-out) bus). The FBUS interface (FBI) 28 is responsible for controlling and interfacing the processor 12 to the FBUS 18 . The FBUS 18 is a 64-bit wide FIFO bus, used to interface to MAC devices. The system 10 is especially useful for tasks that can be broken into parallel subtasks or functions. Specifically, a hardware-based multithreaded processor 12 is useful for tasks that are bandwidth oriented rather than latency oriented. The hardware-based multithreaded processor 12 has multiple microengines 22 each with multiple hardware controlled threads that can be simultaneously active and independently work on a task.
[0009] The hardware-based multithreaded processor 12 also includes a central controller 20 that assists in loading microcode control for other resources of the hardware-based multithreaded processor 12 and performs other general purpose computer type functions such as handling protocols, exceptions, and extra support for packet processing where the microengines pass the packets off for more detailed processing such as in boundary conditions. In one embodiment, the processor 20 is a Strong Arm® (Arm is a trademark of ARM Limited, United Kingdom) based architecture. The general purpose microprocessor 20 has an operating system. Through the operating system the processor 20 can call functions to operate on microengines 22 a - 22 f. The processor 20 can use any supported operating system, preferably a real time operating system. For the core processor implemented as a Strong Arm architecture, operating systems such as, MicrosoftNT real-time, VXWorks and μCUS, a freeware operating system available over the Internet, can be used.
[0010] The hardware-based multithreaded processor 12 also includes a plurality of function microengines 22 a - 22 f. Functional microengines (microengines) 22 a - 22 f each maintain a plurality of program counters in hardware and states associated with the program counters. Effectively, a corresponding plurality of sets of threads can be simultaneously active on each of the microengines 22 a - 22 f while only one is actually operating at any one time.
[0011] In one embodiment, there are six microengines 22 a - 22 f as shown. Each microengines 22 a - 22 f has capabilities for processing four hardware threads. The six microengines 22 a - 22 f operate with shared resources including memory system 16 and bus interfaces 24 and 28 . The memory system 16 includes a Synchronous Dynamic Random Access Memory (SDRAM) controller 26 a and a Static Random Access Memory (SRAM) controller 26 b. SDRAM 16 a and SDRAM controller 26 a are typically used for processing large volumes of data, e.g., processing of network payloads from network packets. SRAM 16 b and SRAM controller 26 b are used in a networking implementation for low latency, fast access tasks, e.g., accessing look-up tables, memory for the core processor 20 , and so forth.
[0012] The six microengines 22 a - 22 f access either the SDRAM 16 a or SRAM 16 b based on characteristics of the data. Thus, low latency, low bandwidth data is stored in and fetched from SRAM 16 b, whereas higher bandwidth data for which latency is not as important, is stored in and fetched from SDRAM 16 a. The microengines 22 a - 22 f can execute memory reference instructions to either the SDRAM controller 26 a or the SRAM controller 26 b.
[0013] Advantages of hardware multithreading can be explained by SRAM or SDRAM memory accesses. As an example, an SRAM access requested by a Thread — 0, from a microengine 22 a - 22 f will cause the SRAM controller 26 b to initiate an access to the SRAM 16 b. The SRAM controller 26 b controls arbitration for the SRAM bus 27 , accesses the SRAM 16 b, fetches the data from the SRAM 16 b, and returns data to the requesting microengine 22 a - 22 f. During an SRAM 16 b access, if the microengine, e.g., 22 a, had only a single thread that could operate, that microengine would be dormant until data was returned from the SRAM 16 b. The hardware context swapping within each of the microengines 22 a - 22 f enables other contexts with unique program counters to execute in that same microengine. Thus, another thread, e.g., Thread — 1, can function while the first thread, e.g., Thread — 0, is awaiting the read data to return. During execution, Thread — 1 may access the SDRAM memory 16 a. While Thread — 1 operates on the SDRAM unit 26 a, and Thread — 0 is operating on the SRAM unit 26 b, a new thread, e.g., Thread — 2, can now operate in the microengine 22 a. Thread — 2 can operate for a certain amount of time until it needs to access memory or perform some other long latency operation, such as making an access to a bus interface. Therefore, simultaneously, the processor 12 can have a bus operation, SRAM operation, and SDRAM operation all being completed or operated upon by one microengine 22 a and have one more thread available to process more work in the data path.
[0014] The hardware context swapping also synchronizes completion of tasks. For example, two threads could hit the same shared resource, e.g., SRAM 16 b. Each one of these separate functional units, e.g., the FBI 28 , the SRAM controller 26 b, and the SDRAM controller 26 a, when they complete a requested task from one of the microengine thread contexts reports back a flag signaling completion of an operation. When the flag is received by the microengine 22 a - 22 f, the microengine 22 a - 22 f can determine which thread to turn on.
[0015] Each of the functional units, e.g., the FBI 28 , the SRAM controller 26 b, and the SDRAM controller 26 a, are coupled to one or more internal buses. The internal buses are dual, 32-bit buses (i.e., one bus for read and one for write). The hardware-based multithreaded processor 12 also is constructed such that the sum of the bandwidths of the internal buses in the processor 12 exceeds the bandwidth of external buses coupled to the processor 12 . The processor 12 includes an internal core processor bus 32 , e.g., an ASB bus (Advanced System Bus), that couples the processor core 20 to the memory controller 26 a , 26 b and to an ASB translator 30 . The ASB bus 32 is a subset of the so-called AMBA bus that is used with the Strong Arm processor core. The processor 12 also includes a private bus 34 that couples the microengine units to SRAM controller 26 b, ASB translator 30 , and FBI 28 . A memory bus 38 couples the memory controllers 26 a, 26 b to the bus interfaces 24 and 28 and memory system 16 including a flashrom 16 c used for boot operations and so forth.
[0016] One example of an application for the hardware-based multithreaded processor 12 is as a network processor. As a network processor, the hardware-based multithreaded processor 12 interfaces to network devices such as a media access controller (MAC) device, e.g., a 10/100 BaseT Octal MAC 13 a or a Gigabit Ethernet device 13 b. In general, as a network processor, the hardware-based multithreaded processor 12 can interface to any type of communication device or interface that receives/sends large amounts of data. If communication system 10 functions in a networking application, it could receive a plurality of network packets from the devices 13 a , 13 b and process those packets in a parallel manner. With the hardware-based multithreaded processor 12 , each network packet can be independently processed.
[0017] Referring to FIG. 2, the FBI 28 supports Transmit and Receive flags for each port that a MAC device supports, along with an Interrupt flag indicating when service is warranted. The FBI 28 also includes a controller 28 a that performs header processing of incoming packets from the FBUS 18 . The controller 28 a extracts the packet headers and performs a microprogrammable source/destination/protocol hashed lookup (used for address smoothing) in an SRAM unit 26 b. If the hash does not successfully resolve, the packet header is sent to the processor core 20 for additional processing. The FBI 28 supports the following internal data transactions:
FBUS unit (Shared bus SRAM) to/from microengine FBUS unit (via private bus) writes from SDRAM Unit FBUS unit (via Mbus) Reads to DRAM
[0018] The FBUS 18 is a standard industry bus and includes a data bus, e.g., 64 bits wide, and sideband control for address and read/write control. The FBI 28 provides the ability to input large amounts of data using a series of input and output FIFOs 29 a - 29 b. From the FIFOs 29 a - 29 b, the microengines 22 a - 22 f fetch data from or command a SDRAM controller 26 a to move data from a receive FIFO in which data has come from a device on bus 18 into the FBI 28 . The data can be sent through SDRAM controller 26 a to SDRAM memory 16 a, via a direct memory access. Similarly, the microengines 22 a - 22 f can move data from the SDRAM 26 a to the FBI 28 and out to the FBUS 18 via the FBI 28 .
[0019] Referring to FIG. 3, communication between the microengines 22 a - 22 f and the FBI 28 is shown. The FBI 28 in a network application can perform header processing of incoming packets from the FBUS 18 . A key function that the FBI 28 performs is extraction of packet headers, and a microprogrammable source/destination/protocol hashed lookup in SRAM 26 b. If the hash does not successfully resolve, the packet header is promoted to the core processor 20 for more sophisticated processing.
[0020] The FBI 28 contains a transmit FIFO 29 b, a receive FIFO 29 a, a hash unit 29 c, and FBI control and status registers (CSR) 189 . These four units communicate with the microengines 22 a - 22 f via a time-multiplexed access to the SRAM bus 38 that is connected to transfer registers in the microengines 22 a - 22 f. All data transfers to and from the microengines 22 a - 22 f are via the transfer registers. The FBI 28 includes a push state machine 200 for pushing data into the transfer registers during the time cycles which the SRAM 26 b is not using the SRAM data bus (part of bus 38 ) and a pull state machine 202 for fetching data from the transfer registers in the respective microengine 22 a - 22 f.
[0021] The hash unit 29 c includes a pair of FIFOs 188 a and 188 b. The hash unit 29 c determines that the FBI 28 received an FBI_hash request from a microengine 22 a - 22 f. The hash unit 29 c fetches hash keys from the requesting microengine 22 a - 22 f. After the keys are fetched and hashed, the indices are delivered back to the requesting microengine 22 a - 22 f. Up to three hashes are performed under a single FBI_hash request. The buses 34 and 38 are each unidirectional: SDRAM_push/pull_data, and Sbus_push/pull_data. Each of these buses requires control signals which will provide read/write controls to the appropriate microengine 22 a - 22 f transfer registers.
[0022] Referring to FIGS. 4A and 4B, the FBI 28 may operate 40 in Fetch_N mode, e.g., Fetch — 8 mode, as shown in FIG. 4A, where the value of N may be programmable. In Fetch — 8 mode, the FBI 28 requests 42 packet data and status from a MAC device 13 , e.g., the 10/100 BaseT Octal MAC 13 a or the Gigabit Ethernet device 13 b over a 64-bit bus, e.g., FBUS 18 . In Fetch_N mode, the FBI 28 issues 42 N requests, each for M bytes, e.g., eight bytes (64 bits, one quadword), over N clock cycles (one request per cycle). The MAC device 13 responds to each request, and the FBI 28 receives 44 the M requested bytes in the receive FIFO 29 a four cycles after requesting 42 the data and waits to detect 46 an end of packet indicator. In Fetch — 8 mode, after receiving 44 all the requested bytes, e.g., 64 and getting the end of packet indicator, the FBI 28 requests 50 and receives another M bytes to obtain the status for minimum length packets, which uses additional clock cycles. The FBI 28 can process 54 a next operation.
[0023] Referring to FIG. 4B, the FBI 28 may operate 60 in Fetch — 9 mode. In Fetch — 9 mode, the FBI 28 requests 62 and receives 64 bytes generally as described above. After eleven cycles, the FBI 28 has received 64 all requested bytes. The receive FIFO 29 a contains sixteen elements, each capable of storing 64 bytes of packet data plus sixteen additional bytes (two quadwords) for associated packet status. The first 64 bytes of received packet data are stored in one element of the receive FIFO 29 a and the last eight bytes are stored in the first status quadword part of the receive FIFO 29 a for that element. In this way, for a minimum sized packet (64 bytes), the FBI 28 already has the status associated with the packet from the initial packet data requests 62 and does not have to wait four additional cycles to request 62 and receive 64 the status.
[0024] The FBI 28 checks 66 the requested bytes by looking for an end-of-packet indicator at the end of the first 64 bytes. If the packet is a minimum length packet 68 , the FBI 28 begins 70 its next operation, having received 64 a complete packet of data and its status. If the packet is between 64 and 72 bytes, the FBI 28 requests 72 another eight bytes so as to receive 52 the packet status four cycles later. These eight additional bytes are stored in the second status quadword for that element in the receive FIFO 29 a. The FBI 28 begins 70 its next operation having now received a complete packet of data and its status.
[0025] Still referring to FIG. 4B, the FBI 28 may operate in Fetch — 10 mode. Fetch — 10 mode optimizes bandwidth for a high frequency of packets having between 64 and 72 bytes, e.g., packets with VLAN (virtual local area network) tags from the Gigabit Ethernet device 13 b. In Fetch — 10 mode, the FBI 28 requests 62 and receives 64 bytes as described above in FIG. 4B, except the FBI 28 issues 62 ten requests, each for M bytes, over ten clock cycles (one request per cycle). The first 64 bytes are stored in one element of the receive FIFO 29 a, bytes 65 - 72 in the first status quadword of that element, and bytes 73 - 80 in the second status quadword of that element. As above, the FBI 28 checks 66 , 68 to see if the receive FIFO 29 a contains the packet data and its status. If so, the FBI 28 begins 48 its next operation 70 . If not, it requests 72 another M bytes. Once received, this quadword may be stored in a third status quadword of that element or in another receive FIFO 29 a element. The FBI 28 then begins 70 its next operation having now received a complete packet of data and its status.
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Receiving bytes of data from a media device includes issuing N consecutive requests, each for M bytes, to the media device and receiving N−1 responses of M bytes of data from the media device.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a divisional patent application of prior U.S. patent application Ser. No. 11/153,305, entitled “INSURANCE PRODUCT, RATING SYSTEM AND METHOD,” filed on Jun. 15, 2005.
STATEMENTS REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] N/A
REFERENCE TO A MICROFICHE APPENDIX
[0003] N/A
BACKGROUND OF THE INVENTION
Field of the Invention
[0004] Pricing and rating methods for property and property-related asset performance insurance products can be classified into two categories: Value-based (VB) rating and Frequency-Severity (FS) rating. In both cases insurance costs are directly related to the financial loss potentials, but the computational methods reflect the characteristics of the property or assets being insured.
[0005] VB rating generally is applied to situations where risk or loss potential can be characterized by a series of variables. For example, the loss potential and pricing for a new car may be determined by the car type, the type of loss (e.g., collision, liability, glass windshield) the amount and type of miles driven, the driving record of the insured, the geographical location and perhaps other variables. Given these variables, loss potentials have been analyzed and tables produced enabling the underwriter to look up the rates, expressed in dollars of premium/dollar of coverage, in tables. The underwriter typically multiplies the client-specific variables by the corresponding rates then adds in company-specific administrative costs to compute the overall policy premium.
[0006] For property VB insurance, some common underwriting variables are business type, building activity (e.g., hospitals, office buildings, laboratories, etc.), square footage or other attributes of size, construction attributes, fire sprinkler coverage, number of stories, location, and age. Premium rates expressed are generally categorized by these variables and together produce a premium rate. This value multiplied by the building value produces the policy premium. Actual premium values may vary by historical precedent of pricing, market demands, policy terms and conditions, contents type and property replacement values.
[0007] FS pricing is a rating and pricing method for situations where there can be large differences between insureds in the same type of industry and geographical area. In this method the probability or failure frequency (events/year) of an insurance claim or failure may be modeled or directly obtained from available data.
[0008] Engineering and underwriting risk modifiers are factors applied to the loss cost computed premium that adjust for specific customer attributes present in the current situation. For example, an engineering risk modification factor to increase the loss cost 10% could be applied for clients who have poor procedures for record-keeping and plant cleanliness. Engineering inspectors have identified a high correlation with these behaviors and customers who will have insurance claims. An underwriting risk modification factor of 10% could decrease the policy premium if high deductibles and restricted coverages are negotiated with the client. These engineering and underwriting risk modification factors make detailed premium changes based on the specific attributes of the client and the policy terms and conditions.
[0009] An example of the FS pricing method for a client is applied to an equipment breakdown premium development for a power generation station 100 shown in FIG. 1 . The station has two (2) simple cycle GE 7FA turbine generators 102 , 104 with two (2) transformers 106 , 108 and various types of electrical switchgear and equipment (only switch 110 is shown). The first part of the premium calculation contains the frequency and severity calculation which determines the loss cost component of the premium. There are risk modification factors that customize the loss cost component for the specific client being analyzed. These factors can increase or decrease the credit and debit percentage that allows underwriting to modify the loss cost to reflect the subjective attributes (e.g., engineering factors) of the client, for example, housekeeping, recordkeeping, reliability planning, the number of equipment spares available and underwriting factors such as the deductible value selected.
[0010] The next part of the premium calculation determines the client-specific expenses, costs and profit. Another component of the premium calculation, the Excess Loss Potential refers to a loss cost premium component that accounts for the very low frequency, but very high severity loss events that are appropriate for the client. Examples of such loss events include five hundred (500) year recurrence period earthquakes, tsunamis and hurricanes. The loss event severities may be determined by specialized catastrophic modeling software. A portion of the insurance company's total loss potential may be allocated to each client as the Excess Loss Potential component of the premium.
[0011] The client may also be subjected to engineering inspections associated with jurisdictional requirements of the state or other governmental bodies. The underwriting process also includes certain client-specific costs associated with meetings, travel and the like.
[0012] Expenses considered in the underwriting process can also include costs for re-insurance and are usually added when the underwriter buys facultative re-insurance—re-insurance on a specific account. Although other expenses that involve a pro-ration of portfolio, line of business, department, or division expenses to the account level may also be added. Other premium costs are typically taxes, commissions to brokers, profit margin and other specified premium cost adders in the company's underwriting guidelines.
[0013] The FS pricing for the example above is shown below for constructing an equipment breakdown insurance price for a simple cycle gas turbine generation facility:
[0000]
Annual Failure
Premium
Equipment
Frequency
Severity
(Loss Costs)
2 GE 7FA turbines
0.025
$80,000,000
$2,000,000
2 Transformers
0.015
$4,000,000
$60,000
Switchgear + Electrical
0.030
$1,000,000
$30,000
Total Loss Costs:
$2,090,000
Engineering/Underwriting Modifier (+20% − 15%)
[−10%]
$1,881,000
Excess Loss Potential:
$100,000
Engineering Expenses
$25,000
Underwriting Expenses
$10,000
Allocated Expenses
$300,000
Taxes, Commissions
$30,000
Profit (5%)
$115,000
Total Policy Premium:
$2,461,000
[0014] Policy rating and pricing applied to property-related insurance pricing generally is a combination of applying the VB and FS methods. The insured's (client) property often contains a mix of highly specific equipment and other activities that are common to many similar types of locations. A client's power generation company may own a small number of highly specialized power generation locations that are rated and priced using FS but also has several branch offices where the premium may be computed by the VB method.
BRIEF SUMMARY OF THE INVENTION
[0015] The present invention referred to herein as the insurance product, rating system and method generally relates to a rating and pricing system for quantifying the risk that the annual savings will not fall below specified levels associated with implementing and maintaining economic improvements. The invention typically involves a unique combination of qualitative and quantitative functions and factors combined in a novel fashion to develop premium costs for risk transfer associated with insuring a minimum savings amount annually or in aggregate over a multi-year policy term.
[0016] Insurance pricing systems where there may be a large amount of exposure and loss data available use standard statistical and probabilistic methods. Policies are often standardized in format and simplified to the point where underwriters construct premiums from tables where the risk attributes such as insured's age, car type, location, or building values are the key elements used to lookup the appropriate rates. Other insurance policies, such as for property insurance, may include a premium component developed from catastrophe models which estimate losses from earthquakes, for example.
[0017] Insurance pricing systems are normally designed for products which are marketed to a large number of customers usually on an annual basis, each with a relatively small loss potential. The present invention comprises an insurance product rating and pricing system designed for a relatively small number of insureds annually or over a multi-year term with each insured having a relatively large exposure. This situation cannot rely on the Law of Large Numbers principle of statistics but applies as much knowledge and actual performance data as possible into the development of the risk analysis and subsequently the premium development.
[0018] The insurance policy rating and pricing system according to the present invention may generally be based on a risk analysis where actual performance data, technical uncertainties, and other factors are combined to form input information for the pricing system. The input files, called annual aggregate risk distributions, quantify the net performance risk of all initiatives for achieving the net annual savings for each year of the policy period. For example, an improvement program may consist of work force reassignments, process re-designs, installation of advanced process controls, and energy efficiency capital projects. However, this invention is not so limited. As a further example, it also applies to other methods capable of quantifying the total net annual savings risk of potentially several hundred initiatives. These risk distributions quantify the probability of exceeding a given net annual savings value and serve as the fundamental input files, data, or equations according to the present invention. The present invention enables underwriters to apply similar procedures they would perform in standard insurance situations even though the nature of the insured risk is unique.
[0019] According to the present invention, “Savings” can be tangible or intangible and include but are not limited to increased revenue; reduced operational expenses maintenance expenses and capital expenditures; increased production through-put; reduced energy consumption; reduced emissions; increased emission credits; etc. These savings will produce additional benefits to the client in the form of enhanced creditworthiness and resulting increased availability of financing and reduced cost of financing. One skilled in the art will recognize that the present invention can generate other savings and benefits not articulated in the lists above.
[0020] The aggregate risk distributions are defined for each location on a similar basis as that applied to develop property insurance. Underwriting may be first performed at a location level and then viewed at the client level. One novel part of this invention is to enable the underwriter to develop pricing at either level. At the location level, the aggregate risk distributions are formed for the subset of all initiatives designed to be implemented at the location. At the client level, the aggregation produces only one aggregate risk distribution per year or other time periods.
[0021] If location level pricing is desired, then according to the present invention, aggregate risk distributions are applied at each location and the client level premium may be equal to the summation of the location level premiums. Some premium components may appear only at the client level, such as profit, tax, and commissions, but the system and method according to the present invention contains the flexibility to include all pricing elements in either version of the application of this insurance pricing system.
[0022] While the invention is generally discussed from the perspective of either pricing a single location or pricing at a single client level, a multi-client pricing system is also within the scope of the present invention. Multi-client as used herein includes but is not limited to an investor(s) in one or more facilities, for example power, refining, chemical, manufacturing facilities, etc. in any permutation or combination of ownership and/or geography.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] A better understanding of the present invention can be obtained when the following detailed description of the preferred embodiment is considered in conjunction with the following drawings, in which:
[0024] FIG. 1 is a block diagram of a power generation station.
[0025] FIG. 2 is a flowchart of an embodiment of the claimed product, system and method.
[0026] FIG. 3 is a flowchart of an embodiment of the claimed product, system and method.
[0027] FIG. 4 is a flowchart of an embodiment of the claimed product, system and method.
[0028] FIG. 5A is a flowchart of an embodiment of the claimed product, system and method.
[0029] FIG. 5B is a flowchart of an embodiment of the claimed product, system and method.
[0030] FIG. 6A is a flowchart of an embodiment of the claimed product, system and method.
[0031] FIG. 6B is a flowchart of an embodiment of the claimed product, system and method.
[0032] FIG. 7A is a spreadsheet of an embodiment of the claimed product, system and method.
[0033] FIG. 7B is a spreadsheet of an embodiment of the claimed product, system and method.
[0034] FIG. 8 is a flowchart of an embodiment of the claimed product, system and method.
[0035] FIG. 8A is a table of an embodiment of the claimed product, system and method.
[0036] FIG. 8B is a chart of an embodiment of the claimed product, system and method.
[0037] FIG. 8C is a chart of an embodiment of the claimed product, system and method.
[0038] FIG. 9 is a chart of an embodiment of the claimed product, system and method.
[0039] FIG. 10 is a system block diagram of one embodiment of the claimed product, system and method.
[0040] FIG. 11 is a block diagram of an insurance policy according to the claimed product, system and method.
[0041] FIGS. 12A-12D are tables of an embodiment of the claimed product, system and method.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0042] The underwriter first determines the insured floor dollar values for each year as shown in step 200 in FIG. 2 . This may be performed by specifying a confidence level that is used to return the indicated or computed minimum insured savings values for all years or confidence levels and can be applied on a year by year basis. Selecting insured floors by first specifying an explicit confidence level is one unique characteristic of this invention. For this invention, “confidence level” is defined as the probability that the annual savings will exceed the insured floor value. Performing this function is called risk acceptance. For each policy year, the underwriters select the risk acceptance level they believe represent insurable positions under the terms and conditions of the policy at step 202 . The insured floors are also called risk acceptance thresholds in that if the insured's annual Savings results are below these values and the insured is in compliance with the terms and conditions of the policy, the insurer would pay the insured the difference between the actual achieved results and the insured floor value at steps 204 and 206 , respectively. Under the insurance policy, the insurer is accepting the risk of paying up to the risk acceptance threshold dollar amount each year.
[0043] These risk acceptance values are also related to claim frequency as depicted in FIG. 3 . The method starts at step 300 where a confidence level percentage is determined at step 302 . The difference between 100 percent and the confidence level percentage constitutes the probability that the Savings may be less than the risk acceptance value at step 304 . For example, a 90% confidence level indicates that 10% of the time, the Savings is expected to be less than the indicated acceptance value. While additional claim frequency mitigation elements are applied in this invention, the 100 minus confidence level may be an upper limit on the expected annual claim frequency.
[0044] Another unique characteristic of this invention is to use the confidence level approach to enable underwriters to apply different risk acceptance judgments for different policy years. This may be but one major advantage of setting deductibles by confidence level rather than directly in terms of absolute dollar values. However, underwriters can choose a risk acceptance value directly and apply the input annual aggregate risk distributions to determine the corresponding risk acceptance confidence level. Both methods are included in this invention. Also the application of input annual aggregate risk distributions to help specify multi-year deductibles is a unique part of this invention.
[0045] The flexibility of specifying yearly or overall confidence values enable underwriters to set risk acceptance values higher for years they believe there is higher risk and lower amounts when the risk is within normal tolerances. This can occur if the underwriters believe that the insured's implementation and scheduling plan will not either meet the expected Savings targets or that the project schedule is too aggressive implying that the insured's Savings will be achieved but not in the policy year indicated in the implementation and scheduling plan. This feature gives underwriters the flexibility to adapt their risk acceptance analysis to consider in addition to the insured's engineering performance, the available personnel, project management, and several other key factors.
[0046] As an example of how this process can be performed, suppose a potential insured's cumulative Savings engineering project plan forecasts $20M in year 1, $30M in year 2, and $35M in year 3 as depicted in step 400 of FIG. 4 . After a detailed review of the implementation and scheduling plan by underwriting, the completion schedule for the year 1 is judged to be too optimistic. Underwriters believe that the Savings as forecast by year 1 will be obtained but some of the initiatives will extend into year 2. For the remaining initiatives, it is further concluded that the Savings targets will be achieved on the time schedule indicated in the implementation and scheduling plan for years 2 and 3.
[0047] For this situation underwriters may apply a higher confidence level for year 1 than for years 2 and 3 at step 402 . A 95% confidence level could be applied to year 1 with a 90% confidence applied to years 2 and 3. The resulting risk acceptance values may be $10M for year 1, $22M for year 2, and $25M for year 3. It may be expected that the risk acceptance values will be less than the stated engineering forecasts as a matter of proper underwriting, for example, to reduce the potential for moral hazard.
[0048] With the risk acceptance values selected, the next underwriting decision is to choose the confidence level associated with the loss cost analysis at step 404 . For example if an underwriter chooses a 95% confidence level, the corresponding loss costs actually experienced should be less than this value 95% of the time. A unique characteristic of this invention is the capability of the underwriter to select a loss cost confidence level by year or, by default, use the same value for all years.
[0049] Another unique characteristic of this invention is the ability to apply different savings measurement criteria as claim triggers. One embodiment of the invention contains two types of savings measurement criteria although a combination or other methods could be applied.
[0050] The underwriter selects the measurement method and for this example of the invention, the methods are Escrow or No Escrow. The Escrow approach accumulates the excess above the risk acceptance values, if any, in the Savings over the policy years. If there is a shortfall in a policy year, the Escrow account may be debited first. A claim occurs when the Escrow account is zero and a yearly savings target is not achieved. The No Escrow method simple compares the actually achieved value, A, to insured Savings value, B, and a claim for the dollar difference $B-A occurs if A<B.
[0051] While the underwriter selects the measurement method in the system, it is not necessarily an input that is determined by the underwriting function. The claim measurement method may be identified as part of the policy and may be agreed to by the insured, insurer, and other interested parties such as investment firms, banks, or rating agencies (e.g., Standards & Poor).
[0052] At this point, FIGS. 5A and 5B illustrate the system for computing loss costs using a stochastic model that utilized the input annual aggregate risk distributions, risk acceptance values, the claims measurement method, and the required loss cost confidence level shown at steps 500 and 502 . This is a dynamic system where at any one of these inputs change, the stochastic model is re-nm at step 504 . This combination of these policy-specific attributes and risk data to produce loss costs is a unique characteristic of this invention.
[0053] At the completion of the stochastic analysis which may require several thousands of different samples to accumulate the sufficient loss cost distributions, the loss costs at the underwriter specified levels is automatically placed into the pricing worksheet at step 506 . The values are summed over the years of the policy term (e.g., over a range of one to seven years) at step 508 and compared with a company-specific requirement of a minimum rate-on-line at step 510 . Rate-on-line is defined as the loss costs (or premium) divided by the total dollar exposure to the insurer. For example, a 5% rate-on-line requirement for a $1M total exposure produced a premium result of $50,000. The maximum of these two numbers: the sum of the loss cost values from the stochastic model and the rate-on-line estimated premium, is entered as the loss cost component of the multi-year policy premium at step 512 .
[0054] With the loss costs determined, the underwriter adds premium charges that are due to the engineering and underwriting fees that will be required to administrate the policy over the policy term at step 514 . These expenses include for example, on-site engineering review of work practices, initiative implementation progress, and the Savings measurement and verification procedures. These activities will generally vary according to the type of industry, facility location, policy term, policy conditions, and with several other factors. It is noted that the premium reflects the true costs of policy administration as well as the potential costs involved with actual losses. These costs are entered individually for each policy year, inflated using a supplied annual inflation rate, and summed to produce the overall engineering and underwriting (insurance) components at step 516 . These costs are mostly well defined expenses and are not typically risk-based nor do they possess a significant stochastic component. At this point in the premium development, these charges are placed into the year and category (Underwriting or Engineering). Additional analysis of factors that influence the loss cost premium component is generally required before the expense items can be used further.
[0055] Along with the quantitative aspects of underwriting and premium development, there are subjective factors that are designed to utilize the underwriter's intuition and experience to modify, if desired, the computed loss cost premium at step 518 . These factors can increase or decrease the loss cost component within prescribed percentage ranges. To facilitate the underwriter's use of these subjective factors, they are divided into engineering and underwriting categories. The actual list of risk modification factors and ranges will vary between industries and clients but they may include some of the items listed below.
[0056] A credit is interpreted as enhancing risk quality which then translates into a decrease the loss costs. A debit is configured as a decrease in risk quality which increases the loss cost component of the policy premium.
Engineering Quality Underwriting: [Debits, Credits]
[0057] 1) Organization/Culture: [+15%, −10%] Risk exposures, hazards, and human behaviors are inter-connected. A company's safety, environmental, reliability policies and basic cultural risk acceptance attitudes are important attributes for inferring how the corporation and its employees will routinely mitigate risk and also respond to accidents
[0058] 2) New Technology Applications: [+10%, −10%] Depending on the robustness of the new technology design, the operational and short term financial advantages can be offset by a decrease on reliability and availability in the long term. These factors need to be considered by the underwriter in this multiyear type of insurance policy which is intended to insure a minimum performance or Savings level.
[0059] 3) Management Motivation: [+15%, −10%]. The underwriter needs to understand how the company's management intends to leverage the financial applications of the overall implementation and scheduling plan. The multi-year program will require the long term commitment of management and the financial applications of the program will provide the underwriter valuable insights to judge the Savings sustainability.
[0060] 4) Supervisor Motivation: [+15%, −10%] The underwriting risk assessment for facility supervisors may be similar to what may be required for management. At the employee-level, supervisors need to be committed to the implementation and scheduling plan's success and to its sustainability over the multi-year policy term. One way for the underwriter to assess supervisor (and management) commitment may be to determine how the execution of the Savings implementation and scheduling plan is connected to the employee bonus program.
[0061] 5) Complexity: [+10%, −10%] Complexity refers to the difficulty of program execution. Some of the issues to be considered in this evaluation are initiative technical difficulty, volumetric inter-dependence, and schedule inter-dependence.
[0062] 6) Housekeeping and Recordkeeping: [+5, −5%] The cleanliness, arrangement, and organization of the insured's assets are valuable, observable indicators to infer employee reliability and safety awareness. Many studies have shown a strong productivity and reliability correlations to facility and asset cleanliness and organization. This characteristic may be easy to observe and inference to improved reliability may be a factor in the engineering aspects of policy underwriting. Also the level and accuracy of production and operational recordkeeping may be another visible indication of employees' and management's commitment to procedure compliance and attention to detail that also reflects the engineering risk quality of the insured's facilities.
[0063] Overall the summation of the debits and credits of one embodiment is generally limited to a total of a 20% credit (premium decrease) or a 25% debit (premium increase.)
[0064] Underwriting quality refers to the terms and conditions of the insurance policy that are negotiated given the operational and engineering conditions of the implementation and scheduling plan. These risk modification factors measure risk quality from a written contractual, rather than technical, perspective.
[0065] The credit and debit assignments follow the same convention as with the engineering risk modification factors. A credit is interpreted as enhancing risk quality which then translates into a loss cost reduction. A debit is configured as a decrease in risk quality which is expressed as an increase the loss cost component of the policy premium.
Underwriting Quality Underwriting: [Debits, Credits]
[0066] 1) Exclusions: [+10%, −10%] These policy terms refer to events for which the insurance policy would not respond to Savings achievement levels below the insured minimum. These events include, war, worker strikes, weather events, events covered under other insurances, failure of the insured to comply with policy conditions, and contractor performance errors.
[0067] 2) Self insured retention/Deductibles: (+10%, −10%] The self insured retention or deductibles determine the insured's total financial risk exposure. If the insured is willing to assume higher annual Savings levels, then the risk quality from an underwriting perspective can be increased since the insured accepts a larger annual Savings shortfall before the insurance policy would respond.
[0068] 3) Savings Measurement & Verification: [+15%, −10%] The type of Savings and the procedures for measurement verification are fundamental to insurance underwriting. These factors are essential to determine initiative implementation quality both in time and volumetric savings achievement. There are, however, different ways these functions can be accomplished. For example, the measurement and verification can be performed by the insured and audited by the insurer, or a third party can be charged with these tasks. Involving the insured in these actions can be problematic and provide a moral hazard if insufficient oversight is not maintained. Savings measurement and verification can also provide a proactive indication of initiatives which are behind implementation targets. The underwriter needs to assess the type of measurements being taken to measure the Savings, the frequency of measurement, the ability to access this data trending, and the propensity to obfuscate actual initiative performance.
[0069] Overall the summation of the debits and credits are limited to a total of a 20% credit (premium decrease) or a 25% debit (premium increase.)
[0070] The aforementioned factors are routinely applied in policy underwriting and premium development depending on the type of insurance, life, casualty, property, etc. and also on the nature of the insured's business. The actual number and type of Engineering and Underwriting risk modification factors will vary depending on the type and nature of asset performance under policy consideration.
[0071] The “Adjusted Premium” is now computed at step 520 . This term is defined as the aggregate policy term loss costs multiplied by the Engineering and Underwriting risk modification factors. If E=the aggregate engineering risk modification factor, U=the aggregate underwriting risk modification factor, and L the loss costs, then the adjusted premium, P adj is determined by
[0000] P adj =(1+ E+U )* L
[0072] The final stage of the premium development is to add premium components associated with insurance pricing elements at step 522 . These items typically include engineering & administrative expenses, profit, reinsurance costs, taxes and commissions.
[0073] There are several variations and combinations of these factors that can be applied to the insurance product, rating system and method. The most notable variation may be the decision on how to account for the engineering expenses. Some insurance policies of the present invention may include all engineering fees in the policy premium and some may exclude the charges from the policy premium and charge these fees as consulting expenses independent of the insurance policy.
[0074] As an example of how the insurance policy pricing according to the present invention is performed, the following example shows premium development according to the present invention for a three year policy where engineering fees are incorporated into the premium calculation and is used to develop the loss costs.
[0075] An embodiment of the overall claimed subject matter follows in FIGS. 6A and 6B .
[0076] 600 Input Basic Client Data into System.
[0077] At step 600 , the user enters: Insured Name, Lending Institution, Country & Region, Addresses of Covered Locations, Occupancy, Location Size in Production Output Metrics, and Application of Insured Savings. This basic data can be integrated with a client database so that other key variables required by the system can be automatically identified from this basic data.
[0078] 610 Develop the Numerical or Analytical Distributions of Savings by Year.
[0079] At this step an overall annual probability distributions are compiled and placed in a format so they can be accessed dynamically. The distributions describe the probability of exceeding annual Savings vs. the savings values. The distributions can be taken by analytical methods designed to compute aggregate Savings exceedance probabilities. There is a separate distribution for each location, plant, unit, or other segment under analysis for each year. These distributions are composed of Savings values and the corresponding probability of exceeding these values.
[0080] 620 Enter Market and Company Pricing Criteria Data.
[0081] At this step, the inflation rate that is representative for the policy period and the minimum and maximum rate-on-line company-specified criteria are entered into the system.
[0082] 630 Choose the Probability of Exceedance Thresholds to be Used to Set the Insured Floors: the Insured Savings Levels by Year, by Location, or by Other Groupings.
[0083] At this step the amount of risk that the insurer is willing to accept is determined by setting the exceedance probability threshold for coverage. There are two ways this can be done, the user can choose a probability of exceedance for all years or a different value for each year depending on the underwriting information. The probabilities are matched in the probability distributions compiled on step 610 and the corresponding Savings values are identified. For example, suppose the insurer is willing to accept an exceedance probability (measured in percentage) of 90% for a given location for a given year. This value is matched to the appropriate probability distribution discussed in step 610 and the corresponding Savings value is found to be $15M. This means there is a 90% chance that the location's annual savings that year will be greater than $15M. An insurance claim may be triggered if the annual savings achieved is less than the $15M value.
[0084] 640 Record the Savings Levels by Year, Location, or Other Grouping in the Loss Cost Component of the Pricing Development System.
[0085] At this step, the resulting Savings values that are calculated or accessed from the probability distributions compiled in step 610 , are entered into the loss cost component of the pricing system. These values are the resulting insured levels that correspond to the probability of exceedance values entered into the system in step 630 .
[0086] 650 Develop Logic to Test Annual Savings Results Selected from the Annual Probability Distributions Compiled in Step 610 to Measure Loss and Excess Event Frequency and Severity.
[0087] At this step for each year or other grouping, the logic is developed to compare a sampled distribution Savings value from the probability distributions compiled in step 610 to the recorded values savings floor Savings values. If the sampled Savings value is greater than the inured floor, then an excess is produced for that year. If the value is less than the insured level as given in step 640 , then a loss event is produced for that year.
[0088] 660 Develop Escrow Account and Claim Trigger Logic.
[0089] At this step, the comparison logic developed to accumulate the total or a fraction of the Savings results that are in excess of the insured savings values. For example, in one year if the computed Savings is $50 and the insured floor is $40, $10 would be credited to the escrow account. On the other hand, if the computed Savings was $35, then first the Escrow account would be debited $5 to obtain the insured level. If the escrow account contained insufficient funds then an insurance claim would be triggered for the difference between the insured level and the sum of the actual Savings results and any funds able to be drawn from the escrow account.
[0090] 670 Develop Claim Count, Claim Amount and Claim Risk Distribution Logic.
[0091] At this step, logic is developed to accumulate the number and financial amount of claims for both the escrow and no escrow accounting methods. The financial amount of the claims is called the loss costs. This information is used to compute numerical distributions for the cumulative probability of loss as a function of the loss amount. These distributions are called claim risk distributions.
[0092] 680 Run Stochastic Model to Develop Claim Risk Distributions.
[0093] At the step, a numerical procedure is applied using commercial software or specialized programming that applies steps 640 , 650 , and 660 to accumulate sufficient loss data to develop a numerical distribution of the probability of loss as a function of the loss amount for both the escrow and no escrow accounting approaches.
[0094] 690 Determine Rate-on-Line Premium.
[0095] At this step, the prescribed rate-on-line criteria selected in step 620 is applied to each annual exceedance threshold selected in step 640 . The rate-on-line premium calculation may be performed by multiplying the exceedance threshold, the insured Savings minimum, or floor by the decimal value of the rate-on-line. For example, if the insured floor is $10,000 and the rate-on-line is 10%, then the premium requirement is $10,000 *0.10 or $1,000. These calculations are applied to each insured annual savings floor as computed in step 640 . The results are summed and placed in a Term of Loss Cost Summary Section of the system.
[0096] 700 Determine Loss Cost Confidence Level and Loss Cost Values.
[0097] At this step the underwriter enters the likelihood requirement, in percent, that the loss costs obtained from the system will be actually less than the identified values. These percentages are then applied to the claim risk cumulative distributions for each year to determine corresponding value for the yearly loss costs contribution to the total multi-year premium. The resultant values are placed in the yearly loss cost fields. This is performed for the claim risk distributions with and without escrow accounting.
[0098] 710 Compute Loss Cost Policy Premium Component.
[0099] At this step, the rate-on-line premium values for each year are summed to compute the total policy premium via the rate-on-line method. Next, the annual loss costs determined in step 680 are summed over the policy years for the Escrow and No Escrow pricing methods. The system user then selects which Escrow pricing method may be required for the client. The system subsequently computes the policy loss cost premium component as the maximum of (1) prescribed rate-on-line, and (2) the summed loss costs via the Escrow method selected.
[0100] 720 Determine Underwriting Expenses.
[0101] At this step, the company expenses, required to perform the underwriting analysis and risk surveillance are entered. These costs are incurred in reviewing monthly, quarterly, and yearly Savings reports and periodically meeting with client management at the client sites. The underwriters' responsibility is to ensure the client is meeting their contractual responsibilities and the Savings targets. If the client is in compliance then coverage continues as defined in the policy. If the client is not in compliance, then it is the underwriters' responsibility to notify company engineering and notify client management, in writing. If compliance with engineering recommendations and other policy conditions are not met in the time constraints as specified in the policy, then the underwriters have the responsibility and the authority to terminate insurance coverage. The expenses incurred performing these activities are entered into the system for each policy year.
[0102] 730 Determine Engineering Expenses.
[0103] At this step the technical engineering, project management, and Savings oversight activities are reviewed for compiling their associated policy expense costs. Engineering activities provides technical data to support underwriting activities, provides periodic loss prevention and Savings reporting, provides technical directions for initiative implementation, and serves as the on-site liaison between the insurer and the insured. The expenses incurred performing these activities are entered into the system for each policy year.
[0104] 740 Determine Engineering Related Underwriting Credits and Debits.
[0105] At this step, pricing modification factors are determined that increase or decrease the premium based on engineering related attributes of the Savings implementation insured values as selected in step 620 . These factors include, but are not limited to, the insured's organization and business culture, new technology applications, management motivation to achieve the Savings targets, supervisor motivation, and plant complexity. The range of the modifiers will vary with application but generally are 10% for each factor with an aggregate factor of no less than −20% and no greater than +25%. The engineering risk modification factors are entered into the system for each policy year and an aggregate modification factor is computed.
[0106] 750 Determine Underwriting related Credits and Debits.
[0107] At this step, the pricing modification factors are determined that increase or decrease the premium based on the underwriting related attributes of the Savings insured values as selected in step 620 . These risk modification factors include, but are not limited to, policy exclusions that are in place, the insured self insured retention, deductibles, limits, and the Savings measurement and verification program quality. The range of the modifiers will vary with application but generally are 10% for each factor with an aggregate factor of no less than −20% and no greater than +25%. The underwriting premium modification factors are entered into the system for each policy year and an aggregate modification factor is computed.
[0108] 760 Compute Adjusted Policy Premium.
[0109] At this step, the numerical results determined in previous steps are combined to produce the basic policy premium. There are several versions or combinations of the steps outlined in this procedure that are claims. An example of one such embodiment is:
[0110] Adjusted Policy Premium=Step 710 (Loss Cost Policy Premium)*[1+Step 740 Engineering Modification Factors)+Step 750 Underwriting Modification Factors)]. This result is stored in the Premium: Insurance Adjusted Premium Section of the system.
[0111] 770 Compute Policy Underwriting and Engineering Expenses.
[0112] At this step the underwriting expenses determined in step 720 and the engineering expenses determined in step 730 are inflated using the inflation rate entered into the system in step 620 over the policy term and summed to compute the total policy level underwriting and engineering expenses. These results are stored in the Premium: Insurance and Engineering Expense Sections of the system.
[0113] 780 Compute Engineering and Underwriting Profit.
[0114] At this step, company-specific guidelines are applied to compute insurance and engineering profit based on the expenses computed in steps 760 and 770 . These results are stored in the Premium: Profit-Insurance and Engineering Sections.
[0115] 790 Compute Allocated Reinsurance Costs.
[0116] At this step, reinsurance costs, whether facultative or treaty related, are entered into the Reinsurance section of the system.
[0117] 800 Compute Taxes.
[0118] At this step, taxes are computed on the pertinent sections of the Premium Section of the system and entered in the system in the Premium—Insurance and Premium and Engineering: Taxes Section.
[0119] 810 Compute Commissions.
[0120] At this step insurance related commissions are computed on the pertinent sections of the Premium Section of the system and entered in the system in the Premium-Insurance: Commissions Section.
[0121] 820 Compute Total Policy Engineering Costs.
[0122] At this step, all premium costs entered into the Premium-Engineering related sections are summed to compute the total policy engineering costs.
[0123] 830 Compute Total Policy Premium.
[0124] At this step, all premium costs entered into the Premium-Insurance related sections are summed to compute the total policy premium. Also, based on the policy requirements and the pertinent accounting procedures, the total policy premium can also include the total engineering costs. In this scenario, all risk transfer and direct engineering costs required to support the policy are included in the total policy premium which is divided by the policy term to determine the annual premium. Depending on the insurance conditions, the insured may pay the whole premium at the beginning of the policy term or pay on an annualized basis.
[0125] FIGS. 7A and 7B depicts a spreadsheet encompassing the steps disclosed in FIG. 6 .
[0126] The methods disclosed above can be used to ascertain a securitization rating VB and FS ratings can be based on benchmark data for a particular asset, e.g. the power generation station of FIG. 1 .
[0127] For example, FIG. 8 illustrates such method. Engineering data such as improving yields 940 or other initiatives 950 , both depicted in FIG. 8A is collected for each required asset at step 900 . The engineering data is compared with benchmark data to create an action plan and financial goals at steps 910 and 920 . FIG. 8B illustrates an exemplary action plan while FIG. 8C illustrates the financial goals.
[0128] For example, FIG. 8B includes various actions to be initiated by employees 960 , such as detailed process evaluation 970 and train operators 980 . FIG. 8C shows how the risk curves can be used to select annual insurance levels and also provide information to select financial goals for the improvement program overall. For example, following general insurance company guidelines, a company chooses the 90% exceedance probability and moves horizontally over until we cross the Year #1 risk curve at 990 where at 90% risk acceptance value for insurance purposes is $20M at 995 . This typically means there is a 90% chance that the actual result will be greater than $20M. The company can also use these risk curves to set their internal financial goals at more aggressive risk acceptance values. For example, company management may target the 60 or 70% levels for the business unit targets which for year #1 would be a goal between approximately $22-$25M. The same procedure is applied for Year #2. The insurance risk acceptance percentile intersects the risk acceptance curve at 1000 which corresponds to $26.7M NCM annual savings at 1005 . This amount would be selected as the insured floor. For the company's internal financial goals, using the 60-70% guidelines as in Year #1, Year #2 company financial goals would be between $28-29$M. A securitization rating can be ascertained based on the action plan and financial goals at step 930 ( FIG. 8 ).
[0129] Implementation of the present invention may also improve an insured's bond rating. FIG. 9 illustrates cost savings as a result of a reduction of credit risk. For example, suppose improving the operations utilizing the present method can increase the Savings by $700 million of an insured over a ten (10) year period. In the course of developing this company's credit risk for the purpose of developing a bond issue, the lending institution and or credit agency involved may give the company credit for the enhanced operational and financial status by applying the margin benefit to the reduction of the principal at risk. This may be a subjective decision. However, the method applied to this situation offers a risk transfer of principal from the client to the insurer thereby securitizing at least a portion of the principal. Suppose the client has a credit rating of BB− by S & P. A policy utilizing the present invention for this client can have effect to reduce the principal at risk thereby also reducing the transaction's credit risk. Through the risk transfer of this principal to the insurance company, the initial transaction (now at effectively a lower principal) can have an equivalent credit risk of the full bond amount at a higher quality credit rating.
[0130] For example, if a client has an $600M policy according to the present invention for over the ten (10) years of a $800M bond, the reduced effective principal at risk ($200) make the transaction appears, from a credit risk perspective as slightly above investment grade, BBB−. This means mathematically the credit risk of a $200 BB− bond may be roughly equivalent to the credit risk of an $800M bond rated at BBB−. This situation illustrated at 1010 in FIG. 9 . This example assumes the insurance company's credit rating is at least BBB−.
[0131] Referring to FIG. 10 , a computer system used to implement some or all of the method and system is illustrated. The computer system consists of a microprocessor-based system 1100 that contains system memory 1110 to perform the numerical computations. Video and storage controllers 1120 enable the operation of the display 1130 , floppy disk units 1140 , internal/external disk drives 1150 , internal CD/DVDs 1160 , tape units 1170 , and other types of electronic storage media 1180 . These storage media 1180 are used to enter the risk distributions to the system, store the numerical risk results, store the calculation reports, and store the system-produced pricing worksheets. The risk distributions can be entered in spreadsheet formats using, e.g., Microsoft Excel. The risk calculations are generally performed using Monte Carlo simulations either by custom-made programs designed for company-specific system implementations or using commercially available software that is compatible with Excel. The system can also interface with proprietary external storage media 1210 to link with other insurance databases to automatically enter specified fields to the pricing worksheet, such as client name, location address, location size, location occupancy, and risk quality attributes applied in the “Credits and Debits” section. The output devices include telecommunication devices 1190 (e.g., a modem) to transmit pricing worksheets and other system produced reports via an intranet or the Internet to management or other underwriting personnel, printers 1200 , and electronic storage media similar to those mentioned as input device 1180 which can be used to store pricing results on proprietary insurance databases or other files and formats.
[0132] FIG. 11 is a block diagram that depicts the terms and conditions of an insurance policy 1300 according to the present invention. The insurance policy 1300 includes insured information 1310 such as a name of the insured, geographic or physical location(s) of the insured to be covered by the policy. Also included in the policy 1300 is a policy period 1320 . The policy period 1320 can be over a single year, multi-year or some other defined period of time. Policy terms 1330 , such as savings criteria is included. The savings criteria are generally crafted by a third party company (e.g., HSB Solomon Associates) that uses benchmark information in creating the savings criteria based on the particulars of the insured's business. The savings criteria include processes that if implemented by the insured establishes a sum certain savings to the insured. The third party company can serve as a facilitator in process execution enabling the insured to improve operating performance (resulting in a savings). If the process is implemented and the sum certain savings is not realized by the insured over the policy term (with certain exceptions outlined in the policy), the insurer will pay the insured the difference (referred to as a shortfall). The certain exceptions include, but are not limited to, hostile or warlike action, insurrection, rebellion, civil war, nuclear reaction or radiation, default or insolvency of the insured, vandalism, riot, failure of contractors to implement the processes, modification or alteration to the processes that were not approved by the insurer or other terms outlined in the policy. Other policy terms 1330 include duties of the insurer and duties of the insured such as execution of the processes in a timely manner, cooperation with the third party company, preparation of status reports, permission by others to audit the insured's accounts, performance records and data logs and other matters. Furthermore, if the savings are determined on a yearly basis and the policy is a multi-year policy, and as a result of the insured implantation of the processes, a shortfall occurs, such shortfall could be kept in an escrow account (herein referred to as a surplus account). The escrow could increase or decrease over the multi-year policy. Any surplus at the end of the policy term can be paid to the insured. Other terms can include cancellation terms, representations and warranty, assignment obligations and effects due to the sale or transfer of a covered location.
[0133] The policy 1300 also includes monetary policy limits (i.e. limit of liability) 1340 over the time period 1320 and premiums 1350 to be paid by the insured and endorsements 1360 . Such endorsements can include market price indexing and operational baselines unique to the insured's industry, the implementation plan and schedule, agreed metric plan, savings calculation procedures and baseline values, debt obligations and additional exclusions, definitions and conditions.
[0134] FIGS. 12A-12D illustrate an agreed metric plan. The agreed metric plan provides top level task lists of an implementation plan and schedule. For illustrative purposes, the plan is divided into four sections, namely, initiative 1400 , benefits and measurements 1402 , implementation 1404 , and savings 1406 .
[0135] For example, in FIGS. 12A , 12 B, 12 C and 12 D, the agreed metric plan pertains to a chemical industry policy. From the implementation plan and schedule, various top level initiatives 1400 are listed in FIG. 12A . For example, some of the initiatives from a chemical industry policy may include movement of an analyzer to trays and modification of regulatory controls on final product columns 1408 for a particular plant 1410 (Initiative #1). The column titled “area” refers to geographical or functional location the initiative, e.g., Plant 1. Another initiative for an insured's site may include the reduction of pressure in a stripper to save energy 1412 (Initiative #2). Furthermore, another initiative for another plant may include the reduction of time to dry catalyst after regeneration 1414 (Initiative #3). Documents or other deliverables 1418 are provided to document the results of the implantation of the initiatives. An example of such a document 1420 may include a report describing the savings achievement as a result of the implantation of initiative #3.
[0136] One embodiment of the benefits and measurement section of the agreed metric plan is provided in FIG. 12B . Implementation of the initiative may result in certain benefits that are described in this section. For example, for initiative #1, one benefit 1422 may be a production efficiency improvement. The plan includes various measurement values and methodologies that are directed to the results of the initiative. The values and methodologies may relate to engineering units (e.g., t/h) and time periods (e.g., measurements are done daily and then averaged over a period). Furthermore, the plan includes dates (target and actual) for the commencement of the initiatives and completion dates of the initiatives. The agreed metric plan typically requires the agreement and sign off (e.g., initials of the insured and insurer) 1424 of each initiative and initiative results (i.e., the agreement section).
[0137] The plan also includes target and actual dates as shown in FIG. 12C . Each initiative may have a target date of completion 1426 , actual date of completion 1428 and the number of days for completion 1430 .
[0138] The plan also include information regarding the economic Savings 1432 as a result of the implantation of the initiatives. Such information may include target Savings 1434 and actual Savings 1436 achieved as a result of the initiative.
[0139] The foregoing disclosure and description of the invention are illustrative and explanatory thereof, and various changes in the details of the illustrated method may be made without departing from the spirit of the invention.
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In the present invention, an insurance product, rating system and method generally relates to a rating and pricing system for quantifying the risk that the annual savings will not fall below specified levels associated with implementing and maintaining economic improvements. The product, system and method can be applied to various industries, including, power generation, petro-chemical, manufacturing and refining facilities. Various embodiments disclosed herein relate to systems and methods for determining optimal risk acceptance values associated with implementing an economic improvement plan for a facility.
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BACKGROUND OF THE INVENTION
The invention relates to a preparation and crushing device, particularly for refuse materials, having a rotatably driven drum and at least one eccentricly disposed high-speed rotor, which rotates in the direction opposite to the direction of rotation of the drum.
The invention described below is described chiefly in connection with refuse materials, e.g. garbage, but can of course also be used for many other materials, examples of some being given below.
It is known that the increasing quantities of refuse produced by cities, parishes and industry, necessitate the manufacture of large refuse disposal plants. In this connection, the problem of preparation and crushing occurs at numerous stages of the process. This is also true with regard to the utilisation of raw material stocks in world trade and industry or of residue produced during manufacturing. Thus, a preparation and crushing device is sought which is able to process continuously or discontinuously and in large quantities materials of very varying compositions. The process is concerned primarily with crushing, mixing and sorting or sieving, these being activities which are required to be carried out either consecutively or simultaneously.
A crushing device, which has the features of the kind described at the outset, is already known for processing garbage and refuse material. The high speed rotor used therein is provided with at least one toothed, disc, the plane of which extends at right angles to the rotor shaft and partially submerges into the material held against the container wall by means of the over-critical rotational speed. This known crushing device may already be used in a wide range of applications, such as the processing of refuse even supplied in refuse sacks, of boxes and of materials in bundles. The known device functions according to the principle that the materials to be processed, particularly in the case of fine crushing, are held firmly against the interior wall of the container by virtue of the rotating container being driven at an over-critical speed and are crushed by means of a toothed circular disc. The critical rotational speed represents that number of revolutions per minute for the drive of the drum at which the centrifugal force is greater than the weight of the material being processed, so that the material is pressed against the interior wall of the drum.
However, the inhomogenity of the material, particularly with regard to refuse materials, presents difficulties under certain circumstances which lead to problems even in the case of the crushing device described above. It has, for example, been shown that an extremely uneven feeding results in high load peaks of the rotor drive so that the known device functions at times with an excessively high energy consumption. These load and energy peaks occur in particular in the case of correspondingly unsuitable material to be processed due to the fact that the distance between the rotor and the interior wall of the drum is purposely kept small therein.
The over-critical rotational speed of the known drum requires the inner surface of the drum to be smooth of course. It has been shown in the case of wet, slippery material that under certain circumstances this material slides past the interior wall of the drum and leads to blockages. The reason for this is the lack of friction between the drum wall and the material to be processed. On the other hand it is not possible to attach entrainment members to the interior wall because they would collide with wall strippers which are required to detach the layer of material from the drum walling and cause sifting and circulation.
Particularly coarse-grained material can lead to damage to the known crushing device due to the fact that lumps of metal enter the area between the rotor and the inner wall of the drum and cause damage on the zones of contact. For this reason it has been found necessary to incorporate a pre-crushing means and to provide a magnetic cut-out.
The problem of the invention is therefore, to provide a preparation and crushing device of the kind described at the outset, which, while avoiding load peaks and the need for additional machinery, permits material which may be voluminous, lumpy, coarse and hard to be processed, prepared, mixed and crushed using simple tools; if necessary, right up to the fine-fibred or flour-like dressing of the particles.
SUMMARY OF THE INVENTION
A solution to this problem is provided in accordance with the invention in that the drum is driven at a sub-critical rotational speed and with a stationary covering hood, in which a feed means is disposed, that a discharge opening, preferably in the lower region of the device, is provided and that a plurality of splitting tools are mounted at intervals on the rotor along its pivot axis.
In the majority of preferred embodiments, the feed means is disposed in the upper part of the covering hood. In the new device according to the invention, the material to be processed is brought up to the processing tools certainly and evenly so that a secure grip is always ensured. The apparatus according to the invention is surprisingly insensitive to the feeding of varying materials in colourful succession in one operating cycle, e.g. filled sacks followed by compressed bales, empty crates and liquid as well as plastics components. Further suitable fields of application include the preparation, crushing, drying and cooling of combined moulding sands, the drying of silage and similar materials, the separation and recovery of plastics from refuse, the reprocessing and utilisation of refuse from livestock breeding and refuse materials from the metal processing industry, e.g. the preparation of lumpy masses of metal drillings which are produced. The function of the device according to the invention could be described by the words "impact tearing", since the breaking limit of the material being processed is loaded using impact and tough materials are torn. The many-sidedness of application is considerably increased over the known devices by the steps of the invention. The material being processed is no longer held against the inner wall of the drum by an over-critical rotational speed but is purposely designed to fall down onto the crushing rotor from a previously selected apex after being carried upwards.
A stationary covering hood prevents the emergence of dust and air pollution, protects the surroundings from parts which may possibly be spun out of the processing area of the device and permits the pivot axis of the drum to be disposed substantially horizontal, this being preferred in some embodiments of the invention. Good circulation of the material being processed is then ensured and the tumbling down of all material parts one after another is made certain. The fixed covering hood readily permits the incorporation of a feed means, which is preferably provided in the upper part of the covering hood and is of large dimensions, in order that lumpy materials, e.g. refuse sacks can also be fed in. The general construction of the device according to the invention is particularly simplified in that the discharge opening can be disposed in the fixed covering hood. Thus, special means for regulating the size of the material to be crushed can be easily provided at the discharge opening; as will be described below. The rotor of the device according to the invention has a large operating region both in the peripheral direction of the rotating drum through the circulating material to be processed and in the direction of the drum depth in that it has a plurality of splitting tools along its pivot axis. Among these preferred tools are cutting or striking tools, e.g. radially disposed bars, teeth, impact plates or other, if necessary, metal-clad striking tools, which load the material being processed with impact and tearing.
It is also expedient according to the invention if the outer periphery of the splitting tools of the rotor is disposed at a considerable distance from the inner wall of the drum. This embodiment of the device according to the invention avoids the disadvantageous jamming effect described above in conjunction with the state of the art, so that there is less need to fear damage but the preparation nevertheless takes place in a surprisingly thorough manner. The aforementioned distance is particularly advantageous when two rotors are incorporated since it enables such a large material flow to rise between the container wall and the first rotor in order that the second rotor can be acted upon sufficiently strongly.
The invention is also advantageously constructed in that the pivot axis of the rotor is disposed in the vicinity of the horizontal bisector of the floor of the drum. Particularly in the case of plate pivot axes extending substantially horizontally the splitting tools are free when the material being processed is resting, but is located chiefly in the lower half or the lower third of the drum.
If, for example, there is a power cut or the machine is stopped for any other reason when loaded normally, then the rotor can start up again immediately the machine is switched on because its tools stand free beyond the material being processed.
It is also advantageous according to the invention if entrainment means are distributed over the interior wall of the drum. This step, which is impossible in the case of a drum rotating at an over-critical speed, enables the material to be guided upwards reliably to the desired apex, from which the material tumbles down and streams directly into the rotor in the manner of a water fall. The action of these entrainment means is particularly intensive if they are staggered vertically in relation to one another in accordance with the invention.
In a further preferred embodiment of the invention, the entrainment means are cam or tooth shaped without acute angles. By avoiding acute angles fibres or fibre particles of the material are prevented from adhering. The cams or teeth ensure however, advantageously, the excellent crushing of textiles, foils, waste paper, wood, etc., because considerable cutting and shearing forces can be exerted on the material which is, as it were, braced by these entrainment means. If the walling of the drum were smooth the material could yield very easily so that the splitting tools of the rotor would not encounter sufficient resistance.
An expedient construction of the entrainment means is characterised in that the entrainment means are provided in the form of parallel rings spaced apart from one another. Thus there is provided a form of internally toothed rings, which are distributed vertically over the drum and parallel to the plate floor and attached to the inner walling of the drum. The splitting tools of the rotor are then expediently so disposed that they engage respectively in the space between two rings. Thus, particularly during the crushing of fibrous material, the cutting and shearing activity described above is benefited.
In another embodiment of the invention it is expedient if the wall of the drum is in the shape of a truncated cone. In this way, even in the case of relatively small drums, a large feed means is obtained or a large covering hood, which permits the mounting of a large feed means. Then, lumpy materials may also be processed. The conical shape of the drum wall enables the floor of the drum to be advantageously inclined relatively flatly, i.e. in the horizontal, and thus the period of duration of the material is extended.
The discharge ratios are also improved by the truncated-cone shaped drum. In certain fields of application the cone-shaped drum walling may be specially provided.
Such an embodiment is expediently characterised in accordance with the invention in that the casing surrounding the splitting tools of the rotor is a truncated cone. While in the case of normal rotors, whose outer shape is substantially cylindrical and whose pivot axis should be disposed at an angle to the pivot axis of the drum when the plate is in the shape of a truncated cone, in order that the rotors sweep as comprehensively as possible over the working surface, on which the material lies, the last-mentioned feature of the rotor enables its axis to be disposed parallel to the pivot axis of the drum. The diameters of the individual splitting tools disposed on the rotor or designed in the shape of a disc are graduated in such a way that the tools are positioned over the entire drum inner wall at the same distance from this wall. At the higher peripheral speed of the drum and the rotor in the region of the discharge it is even possible for a very thorough fine-crushing to be carried out once more in this region. At the same time a large part of the crushing energy and with it is the largest part of the forces would then become active in the upper region of the rotor shaft so that the shaft bearing would advantageously be subjected to a reduced load.
In an expedient further embodiment of the invention a straining wall is disposed at a distance from the drum wall. This step is beneficial in the processing, particularly crushing, of materials of straining consistency. According to this feature, no discharge opening is then provided in the device according to the invention. The entire crushing material, which has achieved the desired fineness, emerges through the straining opening in the straining wall. A stationary hood, which represents both protection against contact and collecting vessel for the fine crushed material, is laid around the rotating container, in this special case the crushing container for example. In the lower region this hood is preferably drawn together to form a funnel so that the fine material converging there can be delivered to a conveying means.
A further preferred embodiment of the invention is characterised in that the discharge opening is in the form of a discharge flap pivotally mounted on the covering hood and pre-stressed in the closing direction, which is inclined in the direction of the flow of the material. The emptying of the device according to the invention can be adjusted very accurately and provided with the means and features described without too great an effort. If the crushing device is processing household refuse and similar materials, for example, then it is important that any pieces of textiles, foil, etc., present in the crushing material does not adhere to the corners and gaps beside and at the discharge opening and lead to blockages there. Discharge openings constructed according to the foregoing features ensure trouble-free operation. The inclined position of the discharge flap enables the material flow to be guided from the covering hood into the interior space of the plate so that the dangerous strand-like materials do not adhere and lead to blockages. The discharge flap preferably does not reach quite to the upper rim of the rotating drum so that sufficient crushed materials can be continuously discharged as required. The pre-stressing of the discharge flap in the closing direction permits the regulation of the pressure, with which the flap acts in opposition to the crushed materials gushing out.
The flow characteristics of the material to be treated are, furthermore, advantageously influenced if, in accordance with the invention, deflectors and/or guiding blades are provided in the region of the discharge flap. The circulation of the material in the device of the invention leads, as a rule, to a certain automatic sorting, whereby the finer material comes to rest in the lower region of the layer of grinding material and the coarser material comes to rest in the upper region of the layer of grinding material.
This sorting effect causes mainly fine material to be discharged at the lower region of the discharge flap. The deflectors and/or guiding blades, which, of course, are mounted on the inner side in the region of the discharge flap, and the guiding blades, which are mounted preferably directly at the flap, held to deflect upwardly coarser material, which is not yet required to be discharged, and return it for reprocessing.
It has further been shown to be advantageous if entrainment means are mounted according to the invention on the inner wall ofthe drum and inclined to the pivot axis of the drum. The entrainment means convey the material to be processed from the lower region of the drum at its floor upwardly to the drum rim or inwardly towards the processing tools in the manner of a segmentally disposed screw depending upon their number and the angle at which they are positioned.
It is further expedient if a plurality of closeable discharge openings are provided in the drum wall in the vicinity of the plate floor. The discharge device preferably disposed in the lower region may then be omitted because it is replaced by the discharge opening. If dry, granular material, such as rock chippings, for example, is processed with the device according to the invention, it has been shown that the coarser grain frequently rolls against the discharge opening while the fine-grained material collects in large quantities at the lowest point in the bottom of the drum. If the device according to the invention is used as a crushing machine, then the fine-grained material is of principle interest and devices must be provided which effect discharge. This takes place in a surprisingly advantageous manner by means of the discharging openings. These may be in the form of slots, round, oval or have any other shape.
The number of openings is dependent upon the size of the device and the output capacity required. It has been shown that two, three or four discharge openings distributed over the drum periphery are preferred.
For the processing of dry and wet, non-fibrous materials, the possibility also exists of incorporating screening plates in the side wall of the drums so that sufficient crushed material passes outwards through the screens. A stationary collecting casing is provided in this case for collecting the fine-grained material.
In an advantageous further embodiment of the invention, the discharge openings can be closed by means of a ring with corresponding openings which is displaceable in the peripheral direction, or by means of a cover mounted on double-armed levers, wherein the end of the double-armed lever lying opposite the cover is provided with a roller secured to a guide rail. In the one embodiment, the drum has the same openings as the displaceable ring. Depending upon the degree of displacement of the ring the entire cross-section of the opening or part of the cross-section can be freed. In this way, the discharge quantity can be regulated. The discharge itself only takes place in the lower region of the drum. Thus, the sorting effect of the rotating drum is immediately used.
Another embodiment of the invention is characterised in that the guide rail is designed as a fixed curve template, preferably composed of replaceable pieces, against which the roller on the double-armed lever is pre-stressed for abutment. In this case each opening has a pivotable end plate, which frees the opening cross-section of the discharge openings completely or partially. If the guide rail or curve template is displaced at a distance to the drum floor the position of the end plate also alters. In a particular embodiment of the invention the arm carrying the drum is mounted on the outer surface of the plate floor in a guide tube or sleeve. A torsion spring is disposed in this sleeve and holds the plate in the closed position. The roller described above is provided on the second arm of the lever and rolls over the curved template in the opening and closing zone. This promotes the opening and closing movement. If the distance of the curved template to the drum floor is altered, the pivot movement of the lever alters simultaneously. In this way, the discharge cross-section can be completely or only partially freed. As soon as the plates have passed through the discharge zone, the openings are closed and remain closed. Adjustment can be made manually or automatically during operation, if necessary in dependence on the load of the drive means. The described arrangement of the movement mechanism offers the advantage that the curved template can be disposed not on the periphery of the drum but also in the vicinity of the plate axis. The peripheral speeds are lower at this point and a shorter curve template can be used. The distance between the outer periphery, at which the plates are disposed, and the curve template disposed further inwards is bridged by the aforementioned sleeves or the guide tube, which is also indicated below as a pivot axis in conjunction with the drawings. By altering the length of the curve template the opening time can also be varied. Intermediate pieces may also be inserted or removed and the duration of opening of the discharge openings thereby varied.
It is further expedient according to the invention if both rotors are driven in opposing directions and are disposed in that half of the drum having an upward direction of flow. For it has been shown that particularly during the processing of heavy materials there is a tendency for large pieces of material not to be carried out over the centre of the drum (vertical, central plane through the pivot axis between upward and downward material flow), even at a higher rotational speed of the drum, but for the material to tumble down almost vertically just before reaching the apex. If the two rotors are then arranged in the manner described above, there is the surprising advantage that a substantially larger surface for the feed opening, e.g. for lumpy material, is made available on the half of the drum extending downwards with the descending material and in addition the crushing action of both rotors can be suddenly increased, particularly if the lower rotor rotates in a direction opposite to the direction of rotation of the upper rotor but in the same direction as the direction of rotation of the drums.
It is further advantageous in accordance with the invention if small steel balls of the size of agitating balls are provided in the drum and can be accelerated by the rotors by means of centrifugal tools in order to increase the impact effects. The device according to the invention then functions with crushing balls in a manner similar to a ball mill. If the splitting tools of the rotors are appropriately constructed they can be used as centrifugal tools. Otherwise, other throwing tools of highly wear-resistant material, e.g. rubber or the like can be used. The centrifugal rotor is driven and acted upon by a mixture of balls and material to be treated. Strong impact, pressing and circulating forces become active immediately upon impingement. The same applies when the mixture of balls and material is spun off the rotor. The resultant trajectory stream is projected into the thick layer of rising material, whereby the energy contained in the stream is transformed into impact, pressing and friction action and results in an intensive grinding or crushing action. The acceleration imparted to the mixture of balls and material can, in contrast to normal ball mills, be selected as high as required. The upper limit is defined by the strength of the ball material. The high acceleration permits the use of small grinding balls, whose points of contact and impact--with respect to the ball weight are many times higher than in the case of balls having a larger diameter and greater net weights, such as are required in order to achieve sufficient impact effects during lower ball movement.
In grinding technology the good effect of so-called agitating balls is known. However, their field of application is substantially restricted to liquid grinding material, while the embodiment according to the invention is also suitable for dry and wet grinding material and can be constructed to any desirable dimension. In order to pass through a device according to the invention, the basic material can also be fed into the device as a substantially coarser grained material than in the case of agitator ball mills. It is further possible to provide the container and rotor with a higher wear-resistant rubber covering and to use grinding balls made of porcelain or another non-metallic hard material, if the material to be processed must remain iron-free.
BRIEF DESCRIPTION OF THE DRAWINGS
Further advantages, features and possible uses of the present invention are set forth in the following description, in conjunction with the drawings wherein:
FIG. 1 is a front view in diagrammatic form of a device according to the invention with two rotors, looking down onto the drum from above with the covering hood having been removed.
FIG. 2 is a plan view broken away and in diagrammatic form of the covering hood with discharge opening.
FIG. 3 is a lateral view broken away looking from beneath onto the the illustration of FIG. 2.
FIG. 4 is a lateral view broken away and in diagrammatic form looking from left to right at the illustration of FIG. 2.
FIGS. 5 to 8 are diagrammatic plan views or sections of the cylindrical drum, the entrainment means being disposed in the manner of a ring in various embodiments.
FIGS. 9 and 10 are a diagrammatic plan view and cross section of a particular embodiment with a suction tube for the pneumatic removal of moist or light material to be treated.
FIGS. 11 to 16 show various embodiments with conical or truncated cone shaped drums.
FIGS. 17 and 18 are a plan view and a cross-section of a truncated cone shaped drum with a straining wall incorporated therein.
FIG. 19a is a lateral view of a diagrammaically illustrated drum with closable discharge openings.
FIG. 19b is a plan view of the drum from its floor side.
FIGS. 20a and 20b are similar illustrations to that of FIG. 19, however, of another embodiment.
FIGS. 21a, 21b, 22a, 22b, are illustrations showing the same views as FIGS. 19a and 19b, showing two different closing devices, however, for the discharge openings.
FIG. 25 shows a diagrammatic front view of another device according to the invention with two rotors, however, according to another embodiment, wherein both rotors are disposed in that half of the drum in which the material ascends, and rotate in opposite directions with regard to one another and, FIGS. 24a and 24b are a lateral view and a plan view of a drum having entrainment means disposed on the inside of the periphery and inclined towards the pivot axis of the drum.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The preparation and crushing device illustrated in FIG. 1 has a pivotably driven drum 1 with a pivot axis 2 and a bearing (not illustrated), located on the diagrammatically indicated frame 3. The drum referred to generally by reference symbol 1 has a wall 4 and a floor 5, the stream of grinding material 6 being illustrated by the numerous arrows. When the drum 1 rotates in the direction of arrow 7 this stream is carried upwards by means of the entrainment means 8 in a clockwise direction and engages with the two rotors 21, 22, which rotate about their pivot axes 23 and 24. The rotors 21 and 22 have splitting tools 25. In the illustrated embodiment these are in the form of radially disposed bars. The rotors 21 and 22 rotate in the direction of the arrows 26, in other words in opposition to the direction of rotation of the drum 1. The five heavily printed arrows 27 illustrate the stream of material to be treated which has been fed through the feed means 28 into the machine.
During operation the material 27 first falls through the feed means 28 to the rotor 22 disposed on the right hand side, whose pivot axis 24 is higher than the pivot axis 23 of the left-hand rotor 21. The material seized by this rotor 22 is for the most part spun onto the rotor 21 with considerable pre-acceleration and is seized there by the splitting tools 25 with increased impact and tearing force. The speeds combine here so that good crushing forces become active. The rotor 22 spins the material into the layer of grinding material ascending the drum wall 4, whereby further autogenous grinding takes place.
The material transported upwards from the drum 1 is seized in the inner-lying layer by the left-hand rotor 21 in the contrarotating direction and is crushed. The layer lying against the drum wall 4 is, in contrast, carried upwards and plunges approximately at the uppermost point of the drum 1 in the manner of a waterfall back into the operating region of the two rotors 21 and 22. The trajectory parabola of the descending material can be controlled by the peripheral speed of the drum 1 in such a way that the material descends principally onto rotor 21 or principally onto rotor 22 or evenly distributed onto both rotors.
FIG. 2 is a plan view and FIGS. 3 and 4 are the above-mentioned sectional views of the discharge opening of the device of the invention, generally referred to by reference symbol 30. The grinding material flows in the direction of arrows 31 along the covering hood 32 down towards the discharge opening. At the end of the covering hood a wedge-shaped deflector 33 leads approximately in the direction of the interior of the drum 1 so that in principle the material passes over the gap between the discharge opening 30 and fixed covering hood 32 without contact. The discharge flap 34 does not quite reach to the plate rim, which can be seen in FIG. 2 in the region of the arrow 7, because the entrainment means 8 must have a passage beneath the discharge flap 34. The discharge flap 34 itself is inclined in the flow direction of the material, as can be seen particularly in FIG. 3, so that the gap between the covering hood 32 and the discharge flap 34 on the side, on which the material arrives, is displaced outwardly away from the material. On its exit side the discharge flap 34 is extended by means of a flexible member, e.g. of plastics or rubber, 35 to such an extent that it overlaps with the adjoining fixed covering hood 32. The gap is completely covered by this flexible member 35 so that no material can adhere there. At the same time the discharge flap 34 can, however, be folded out upwards in order to increase the width of the opening. A loading weight 36 serves to regulate the positioning of the flap as well as a hauling chain 37. A guide blade 38 is also mounted on the discharge flap 34, with the aid of which the coarse-grained particles of the material are deflected upwards into the drum.
In FIGS. 5 and 6 the drum 1 is only illustrated in rough diagrammatic form with its direction of rotation 7. The one rotor 21, which rotates in the direction of arrow 26, has four splitting tools 25 here in the direction of its pivot 23 and is driven by way of wedge belts 40 illustrated diagrammatically. The entrainment means are constructed here in the upper half in the form of teeth 8' and in the lower half in the form of cams 8".
They are--just as in the illustration in FIGS. 7 and 8--spaced vertically apart from one another and provided parallel to one another in the form of rings. The material is thereby secured on the drum wall in the best way, braced in as it were, so that it can be divided up by the splitting tools 25. The splitting tools 25 of the respective rotor 21 engage between these annular teeth 8' and cam 8" so that the material is supported on these cams and teeth and the splitting tools 25 can be offered sufficient resistance.
In addition, in the embodiment according to FIGS. 7 and 8 a cylindrical straining wall 41 is also provided, being mounted at a distance from the wall of the drum 1 on the inside of said plate. No discharge opening is provided in this embodiment. The material which is broken up or crushed after processing and has attained the desired fineness passes out downwardly through the openings in the straining wall 41. It is collected in a hood 42 enclosing the straining container 41, which hood is designed in its lower region as a funnel. Conveying means not illustrated convey out the fine ground material which has collected here. Naturally, the machine according to the embodiment of FIGS. 7 and 8 may also be constructed without the teeth 8' or cams 8" disposed in the shape of a ring.
Advantageously, the straining wall 41 can also be used for drying and/or cooling the material. In this connection the cooling or heating gases are supplied in the inner region of the drum 1. Suction is effected by way of the fixed casing or hood 42 so that the gases are passed transversely through the material and the straining wall 41. This method makes available a particularly large surface for thermal exchange.
In the case of very fine or light grinding materials the removal of the material from the crushing device according to the invention may also be effected pneumatically. This embodiment is illustrated in FIGS. 9 and 10. Here, a tube 50 connected to a suction fan not illustrated projects into the drum 1 and sucks up the fine or light material particles there. In this way it is possible to separate by suction foils, for example, or paper from household refuse or similar materials or to suck up very fine materials according to the air sifting principle. The tube acting as a suction nozzle may be of open, slotted, apertured or a similar construction. A bent plate 51 protects the tube 50 on the side of arrival of the stream of material. The intake opening is thus situated on the opposite side so that only material which can be transported with air finds its way to the suction nozzle 50 and thus the desired selection takes place. The tube 50 may be pivotally mounted, as shown in FIG. 10 by the dash-dotted lines. In order to empty the drum 1 completely the tube 50 can be pivoted right down to the rim of the floor.
FIGS. 11 and 12 are plan views in diagrammatic form of another embodiment of the device according to the invention, wherein the wall 4 of the drum 1 is in the shape of a truncated cone. It is possible by means of a conical drum to feed lumpy material into small machines as well because a large intake opening can be provided by virtue of the profiling. In addition, the floor 5 can be brought into the position illustrated in FIGS. 12, 14 and 15 by pivoting the frame 61 with the bearing 62 about the pivot point 63, in which position the floor 5 is inclined relatively flatly, i.e. the pivot axis 2 of the drum 1 is at a considerable angle to the horizontal. In this way, the filling or duration of the stay can be increased during processing. The rotor 21, which is only shown diagrammatically with the splitting tools 25 here, lies with its shaft 23 parallel to the lower side wall 4 of the drum 1.
In the embodiment according to FIGS. 13 and 14, wherein a conical drum 1 is also provided and a similar inclination is also possible, the shaft 23 of the rotor 21 is vertical to the floor 5 of the drum 1 and the diameter of the splitting tools 25 is graduated respectively so that the tools are at the same distance from the wall over the entire lower side wall of the drum 1. It has already been mentioned above that another thorough fine crushing can take place here in the region of the discharge. Also, the bearing of the shaft 23 of the rotor 21 is subjected to less load.
In the embodiment according to FIGS. 15 and 16 the shaft 23 of the rotor 21 is again vertical to the floor 5 of the drum 1 or parallel to the pivot axis 2 of the drum. However, the splitting tools 25 here have the same diameter over the entire vertical dimension of the rotor 21. In this way less tubulence is produced in the region of the discharge opening and thus a more even discharge is achieved. The principle decision as to which of the illustrated systems should be used, depends on the respective material to be processed.
FIGS. 17 and 18 illustrates a further different embodiment also having a conical drum 1 and a rotor 21, which rotate in the opposite direction according to the arrows illustrated in FIG. 17. Here, a cylindrical straining wall 70 is incorporated. It is not necessary for this embodiment to surround the rotating drum 1 by means of a covering hood (as referred to in FIGS. 7 and 8 by reference numeral 42), which also acts as a collecting funnel. The conical part, i.e. the side wall 4 of the drum 1, itself acts as a collecting funnel here.
FIGS. 19a to 22a illustrate a diagrammatic lateral view of the drum 1, which has discharge openings 80 in the vicinity of its floor 5. These can be closed at least partially, preferably completely, by means of various embodiments.
In the embodiment according to FIGS. 19a and 19b there is illustrated a ring 82 laid coaxially around the drum 1 in its lower region and displaceable in the direction of the double arrow 81, which ring has the same number of openings 83 spaced at the same distances apart, which, by actuating a threaded spindle 84 and displacing them in the direction of arrow 81, either free the discharge openings 80 completely and thus open them or close them completely. In this embodiment the drum 1 is stopped so that the threaded spindle 84 provided for this purpose can be adjusted. The discharge of the material is effected in the lower region of the drum on which a fixed collecting apron (not illustrated in the Figures) is provided. In order to prevent the emergence of dust at the openings in the upper region a fixed covering is, for example, disposed over the rotating ring 82.
In the embodiments according to FIGS. 19 to 22, a discharge opening disposed in the lower region of the device is not necessary.
In the embodiment according to FIGS. 20a and 20b each discharge opening 80 can be closed with a cover 85. The cover 85 is mounted on one end of a double-armed lever 86, which is pivotable about an axis 87 and has a roller 88 at its other end. This roller slides in a U-shaped guide rail 89, which is pivotally mounted on the drum 1. Naturally, it is of annular shape to correspond with the periphery of drum floor 5. If this guide rail 89 displaced in the direction of the double arrow 90 then the lever 86 is forced to pivot about its axis 87 so that consequently the cover 85 is moved in the direction of the double arrow 91. This displacement of the guide rail 89 can if necessary also be effected during operation, whereby the discharge openings 80 are then correspondingly opened or closed.
The collars 100 provided in all FIGS. 19 to 22 enable the covers 85 to be deposited flatly so that complete closure is ensured.
In FIG. 20b it can be seen that all covers 85 are in an approximately half-open position corresponding to a certain position of the guide rail 89.
FIG. 21a illustrates a stationary U-shaped guide rail 101 in bent form. The double arrow 102 illustrates both that it is possible to secure the guide rail 101 so that it is completely off-set and that the roller 88 on the lever 86 is forced to move in the direction of the double arrow 102 when it rotates with the drum 1 over the pivot axis 87 mounted on said drum depending upon whether the roller is guided in the lower part or the upper part of the rail. The covers 85 are correspondingly removed in the lower parts and free the discharge opening 80, while closing the openings partially or completely in the upper region. It can therefore be seen from FIG. 21b that the covers 85 are wider open in the lower region than in the upper region. The cover disposed uppermost is closed in the illustration while the lowermost cover frees the discharge opening completely.
FIGS. 22a and 22b illustrate a very similar embodiment, wherein, however, the guide rail is designed as a curve template 103 which is composed of exchangeable pieces 104.
FIG. 22a also shows the prestressing of the levers 86 with the covers 85, which is so directed that the roller 88 always abuts with the curve template 103. This prestressing is effected in the embodiment of FIG. 22a in such a way that the pivot axis 87 is formed as a bar mounted in a guide tube 105. A torsion spring 106 is disposed in the guide tube 105 and holds the covers 85 in the closed position.
FIG. 23 shows a similar illustration to that of FIG. 1. The drum 1 is practically divided into two halves by the vertical dash-dotted central axis a--a; in the right-hand half the material flows substantially downwards in the direction of the indicated arrows. In the left-hand half the material ascends in the direction of rotation 7, partially entrained, for example, by the entrainment means 8. In this left-hand half of the drum 1 with its ascending direction of flow the two rotors 21 and 22 are disposed. They rotate in opposing directions corresponding to the arrows 26 and 126. In the upper right-hand quadrant of FIG. 23 the large space available for feeding is also shown, the material to be fed again being indicated by arrows 27.
It can be seen from this embodiment that for operation the rotor 21 rotates in the same direction as the drum 1. The crushing action of both rotors 21 and 22 is enormously increased by this because the discharge stream of the lower rotor 21 is substantially projected into the side rotating in the opposite direction by the upper rotor 22 so that in this region, which is illustrated by several arrows substantially directed in opposition to one another, extremely strong impact, pushing and shearing effects are produced. Naturally, this embodiment can only be used when the material to be processed is not presented in pieces that are two large or in bundles because otherwise there would be blockages between the drum wall and the rotor 21. In the case of material with smaller particles, however, this risk of blockage is minimal, especially since the rotor 21 rotates with a substantially higher peripheral speed in comparison with the drum 1. The material arriving from below is conveyed rapidly from the narrow region upwards. If the finest possible separation of the material is required, the upper rotor 22 is driven at a substantially higher peripheral speed than the lower rotor 21.
FIGS. 24a and 24b illustrate the entrainment means (130) inclined towards the pivot axis 2 of the drum 1, these means being mounted on the inner wall of the drum 1. The angle and the number of entrainment means 130 can be suited to the characteristics of the material to be processed. The entrainment means 130 ensure above all that no undesirable collection of material takes place at the lowest point of the drum. Since a certain distance must always be maintained between the rotors 21 and 22 and the drum floor 5 for reasons of safety, the inclined entrainment means 130 ensure that the material is almost totally guided to the active region of the rotor or rotors. In addition, in the case of high output capacities, the discharge of the crushed material is accelerated, particularly when inclined entrainment means 130 reach almost into the region of the discharge opening.
Experiment has shown that the action and direction of trajectory of the upper rotor 22 of the embodiment of FIG. 23 can be substantially increased. When the drum 1 rotated at a slow speed, the load on the lower rotor could be relatively high for example, while the load on the upper rotor was still low. As the rotational speed of the drum 1 increased, the load on the lower rotor diminished while the load on the upper rotor could be increased. Thus, it is possible to equalise the load on both rotors to a large extent by constructing the entrainment means 130 correspondingly and graduating the speed of rotation correctly.
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A preparation and crushing tool, particularly for processing refuse material, including a drum mounted for rotation about a central axis at a subcritical speed, at least one rotor disposed within the drum eccentric to the axis of the drum and mounted for rotation about its own axis in a direction opposite to the direction of rotation of the drum and at a higher speed than the drum. The rotor includes a plurality of splitting tools which are disposed in axially and radially spaced locations along the axis of the rotor. A stationary hood is provided which forms an end wall of the drum and is in sealing engagement therewith. Material is fed into the device in the upper region and provision is made for discharge of the processed material from the lower portion of the device.
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TECHNICAL FIELD OF THE INVENTION
The present invention relates in general to the field of maintaining sanitary areas, to a method and apparatus for helping to assure the washing of hands, and, more particularly, to doing so by marking a person's hands with an easily identifiable substance that requires washing of their hands to remove the substance.
BACKGROUND OF THE INVENTION
In a variety of different fields and businesses, there is a need for assuring that persons who enter certain areas have sanitized their hands prior to entry. Obvious examples include food preparers and health care workers (although there are other potential examples too numerous to list). An example of a specific need for assuring sanitized hands is the restaurant industry. It has been known for many decades that food preparers, servers and so forth should clean and sanitize their hands prior to handling others' food. This need is self-evident after restaurant employees have been in restrooms/toilets. Bacteria (such as E-coli and fecal matter) in restrooms/toilets, are well known problems and without proper cleaning/sanitization of the hands of restaurant employees the problem can be transmitted to unknowing customers. There is also a need for sanitized hands in private residences. This is especially true of homes with children. Physicians have known for many years that washing one's hands frequently (and especially after use of the bathroom) is a very important factor in minimizing illness.
In the past, restaurants and parents have tried to address the problem by rules and regulations concerning hand washing. For instance, in many restaurants there are signs which state roughly "Employees must wash their hands before leaving." Obviously, methods which require adherence to a rule or policy by human beings are insufficient to assure foolproof compliance. Thus, there is a strong need for a method of assuring that people have sanitized their hands, and, in particular, have done so before entry is allowed into certain areas.
Presently there are both patented and un-patented systems intended to address this problem. These other systems are either not foolproof (i.e., require individual compliance with rules) or are complex and accordingly prohibitively expensive. U.S. Pat. No. 5,670,945, for example, discloses a complex system that has a sanitizing basin with moisture proof switches inside the sanitizing basin and proximity detectors. A person must insert both hands simultaneously into the sanitizing basin in order to initiate the desired output signal. U.S. Pat. Nos. 5,202,666; 4,896,144; 3,967,478; 5,610,589; 4,688,585 and 5,199,188 all involve complex systems containing such things as electronics, sensors, pumps and so forth. Additionally, none of these systems effectively assure that an unintentional improper sanitizing of a worker's hands will be detected.
There is a need for a foolproof, simple and inexpensive method to assure that persons wash their hands before entering sanitary areas. Especially desirable is a system that is simple and inexpensive enough to allow it to be retrofitted into existing bathrooms in commercial and residential locations.
SUMMARY OF THE INVENTION
In accordance with the present invention, a method and apparatus are disclosed for helping to assure the washing of hands that provide advantages over prior sanitization schemes.
According to one aspect of the present invention, a method for helping to assure washing of hands involves providing an easily identifiable substance which can be removed by washing. A marking mechanism is coupled to the easily identifiable substance, and a hand of a person is then marked with the easily identifiable substance when the marking mechanism is triggered.
According to another aspect of the present invention, an apparatus for helping to assure washing of hands includes an easily identifiable substance which can be removed by washing. A marking mechanism is coupled to the easily identifiable substance, and the marking mechanism is operable to mark a hand of a person with the easily identifiable substance when the marking mechanism is triggered.
In one implementation, a flush mechanism of a toilet or urinal is equipped with the marking mechanism, and the marking mechanism is triggered when a person flushes the toilet or urinal. In another embodiment, a door handle is equipped with the marking mechanism, and the marking mechanism is triggered when a person uses the door handle.
It is a technical advantage of the present invention that it assures individuals wash their hands by marking their hands with an easily identifiable substance.
It is another technical advantage that the present system and method is relatively simple and inexpensive and can be retrofitted into existing commercial and residential restrooms and entrances to existing commercial and residential sanitary areas.
Other technical advantages of the present invention should be apparent from the drawings, specification and claims.
BRIEF DESCRIPTION OF THE DRAWINGS
A more complete and thorough understanding of the present invention and advantages thereof may be acquired by referring to the following description taken in conjunction with the accompanying drawings, in which like reference numbers indicate like features, and wherein:
FIG. 1 is a cross-section of one embodiment of a toilet flushing mechanism with a marking mechanism; and
FIG. 2 is a cross-section of one embodiment of a door knob equipped with a marking mechanism.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 is a cross-section of one embodiment of a toilet flushing system with a marking mechanism. In the embodiment of FIG. 1, the marking mechanism comprises a compressible bulb 10 connected to (or integral with) a pneumatic hose 12. By squeezing bulb 10, this forces air into hose 12 which signal (or event) can be used in a variety of different ways to flush a toilet using flushing mechanism 15. Those skilled in the art should recognize that both the marking mechanism 10 or the flushing mechanism 15 could be any of a large number well known and commercially available mechanisms such as any of the following types of systems: (1) mechanical, (2) pneumatic, (3) pneumatic (mechanical), (4) electronic and (5) any combination thereof. The present invention can provide benefits to any such flushing mechanism, and the specific type of flushing mechanism is relatively unimportant.
In the embodiment of FIG. 1, the marking mechanism operates as a mechanical trigger and further comprises an absorbing material 11 which covers, or is an integral part of, bulb 10. Absorbing material 11 contains or is saturated with an easily identifiable substance 13 which is held in container 14. In one embodiment, container 14, the easily identifiable substance 13 and absorbing material 11 are designed such that absorbing material 11 always contains enough of the easily identifiable substance 13 to mark a person's hands who squeezes bulb 10. One of many methods to assure a steady supply of an easily identifiable substance 13 is to gravity feed the easily identifiable substance 13 to absorbing material 11. Easily identifiable substance 13 can be re-filled into container 14, for example through opening 16.
Easily identifiable substance 13 can be any of a number of substances which are commercially available and well known in the art. Important characteristics of substance 13 are that it clearly marks a person's hands, be non-toxic and be washable with soap and water or some other desirable cleansing or disinfecting solution. Likewise, the easily identifiable substance 13 should not dry out when it is on absorbing material 11. Easily identifiable substance 13 could be, for example, a paint, dye, chalk, stain, ink, grease, pigment or combination thereof which will clearly mark a person's hand(s). In addition to visual markings, there could be invisible markings which show up not to the naked eye, but when exposed to certain mediums such as ultraviolet light.
In this embodiment of the present invention the marking mechanism is manually triggered such that it will mark a person's hands quite thoroughly (e.g., even between the fingers) with an easily identifiable solution 13 and accordingly it forces the person to clean the marked hand (and obviously the other hand as well) even more thoroughly than might normally be done. This thorough cleaning of the hands is an added benefit of the present invention. Further, the thorough marking of the hand with an easily identifiable solution 13 can be optimized by designing the marking mechanism such that the easily identifiable substance 13 is deposited between the fingers. In another embodiment the marking mechanism has finger guides 17 which force a person's fingers apart such that when the person squeezes bulb 10 through absorbing material 11 the easily identifiable substance 13 is deposited between the person's fingers. The finger guides 17 have the added benefit of making it more difficult (or impossible) to bypass the entire system by using a paper towel or cloth to activate the marking mechanism and accordingly not getting an easily identifiable substance 13 on the person's hands. In another embodiment of the invention the marking mechanisms disclosed herein can be used redundantly with a back up electronic detection system to determine if a person has entered a restroom or not. One such electronic system using name tags is disclosed in U.S. Pat. No. 5,610,589.
In general, according to this aspect of the present invention, the flushing mechanism of a toilet (and/or urinal) can be equipped with a marking mechanism that marks a person's hand with an easily identifiable substance when the toilet is flushed. Thus, the person using the toilet must then either not flush the toilet (obviously not an viable alternative) or have their hand marked by the easily identifiable substance. The easily identifiable substance can then be removed only by using soap or other sanitizing agent which also sanitizes the person's hands. Depending on the situation, the easily identifiable substance can be designed to be compatible with an optimum cleaning medium. For example, in a restroom, the easily identifiable substance should be designed to optimize hand cleaning (e.g., both as to duration and effort) with an anti-bacterial soap.
As shown, the marking mechanism can be manually triggered and preferably designed such that in order to flush the toilet the hand doing the flushing is thoroughly marked with the easily identifiable substance. Accordingly it takes a thorough washing of the hand to clean off the easily identifiable substance. The easily identifiable substance is preferably non-toxic, highly visible and not washable with only water but washable quite easily with a thorough hand washing with a sanitizing solution (for example, an antibacterial soap). Clearly, the only practical way to thoroughly wash one hand is to use the other hand also, resulting in two clean and sanitized hands.
FIG. 2 is a cross-section of one embodiment of a door knob equipped with a marking mechanism. In this embodiment, the marking mechanism is connected to an entrance door 19 to a sanitary area. A shown in FIG. 2, the absorbing material 11 covers door knob 18 which allows entry to a sanitary area. The container 14 with an easily identifiable substance 13 is positioned above door knob 18 and gravity feeds the easily identifiable substance 13 onto absorbing material 11. If a person who wants to enter the sanitary area must use door knob 18, then their hand will be marked with the easily identifiable substance 13. Similar to the trigger mechanism of FIG. 1, the door knob can also have finger guides 17 to assure thorough marking of the hand and disallow using paper towels or cloth to bypass the system. Again, as with the above embodiment, once the hands are marked, the person must thoroughly clean their hands to remove the easily identifiable substance 13.
In general, according to this additional aspect of the present invention, the entrance to a sanitary area can be equipped with the marking mechanism. An example, as shown in FIG. 2, would be to equip the door knob of the sanitary area with the marking mechanism which is manually triggered. The design would ensure that a person entering must immediately thoroughly wash their hands after entering the sanitary area or alternatively be easily identifiable as not having washed their hands. This embodiment would work well, for example, in areas such as entrances to cooking areas in restaurants, sanitary areas in hospitals and high technology clean rooms. As discussed above, the easily identifiable substance could be chosen to optimize hand cleaning depending on the end use. For example, before entering a high-technology clean room the main goal may to minimize particulates rather than bacterial contamination. Accordingly, the easily identifiable substance may be chalk, pigment or another particulate substance rather than a liquid. This notion of "dirtying" one's hands in order to subsequently get them clean may be counter-intuitive, but it could result in especially clean hands if the easily identifiable substance and the cleaning medium are well chosen.
Although the present invention has been described with respect to a specific preferred embodiment thereof, various changes and modifications may he suggested to one skilled in the art and it is intended that the present invention encompass such changes and modifications fall within the scope of the appended claims.
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A method and apparatus are disclosed for helping to assure the washing of hands. An easily identifiable substance is provided which can be removed by washing, and a marking mechanism is coupled to the easily identifiable substance. A hand of a person is then marked with the easily identifiable substance when the marking mechanism is triggered. In one embodiment, a flush mechanism of a toilet or urinal is equipped with the marking mechanism, and the marking mechanism is triggered when a person flushes the toilet or urinal. In another embodiment, a door handle is equipped with the marking mechanism, and the marking mechanism is triggered when a person uses the door handle.
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BACKGROUND OF THE INVENTION
This invention relates to the construction, especially the lining, of furnace walls and is particularly concerned with installations utilizing blankets, bats, or blocks of relatively lightweight refractory or heat insulating materials usable at relatively high temperatures.
Many methods and devices have been previously suggested for securing refractory and/or insulating materials as linings to the interior walls of a furnace. In many of such methods or devices the lining is required to have a specific shape, or elaborate hardware on the furnace walls is required. In many instances an exorbitant amount of labor is required. Consequently, there has been a demand for a construction which permits the convenient attachment of refractory and/or insulating material in the form of blankets, sheets, bats, or blocks to furnace walls with a minimum of hardware and accessories and without exposing mounting hardware to furnace atmosphere and temperature.
It has been previously proposed to provide simple and convenient means for lining the walls by securing blankets, sheets, blocks, or bats of ceramic refractory and/or heat-insulating material on furnace walls either in a single layer or in a plurality of layers. In constructing or installing the lining the securing or mounting means may be easily applied wherever necessary or desired, thus giving a flexibility to furnace wall construction which is absent in many prior systems.
Essentially the mounting or securing devices utilized in said previous proposal consist of cup-like or truncated conical ceramic retaining members or anchors, and elongated metal studs by which the anchors are located. Each metal stud is adapted to be secured to a metal wall surface and to so engage an associated ceramic retainer as to hold it in position. More specifically, the metal studs are attached, such as by welding, to the surface of a wall to be insulated, extending essentially perpendicularly from said wall, and having such external configuration as to engage the body of refractory and/or insulating material. The truncated conical ceramic retaining members (hereinafter for convenience referred to as "anchors") may be installed with the desired spacing between them by locating the associated metal stud, forming a hole in the refractory or insulating material around the stud, inserting the anchor therein so as to engage the stud, and locking the anchor to the stud by rotating 90 degrees. The interior portion of the anchor may then be filled with a suitable refractory material so as to protect that portion of the stud projecting therein.
It is often necessary to support electrical heating elements in a furnace lined in the aforesaid manner and this has hitherto been achieved by mounting ceramic bobbins on separate, elongated metal studs secured to a metal wall surface of the furnace. This has the disadvantage that a number of extra components need to be held in stock.
It is an object of the present invention to obviate this disadvantage.
SUMMARY OF THE INVENTION
According to different aspects of the present invention there are provided:
1. A high temperature insulation construction comprising
(1) a structural supporting member,
(2) a body of insulating material superimposed over the structural supporting member,
(3) a metallic stud bearing a plurality of pairs of anchor-engaging notches, the stud being attached at one end of the stud to the structural supporting member and disposed essentially perpendicular to the structural supporting member; and
(4) an anchor positioned over the stud and engaging a first pair of notches in the metallic stud, to hold the body of insulating material between the anchor and the structural supporting member, the anchor having a cavity and being so shaped and dimensioned as to permit an identical anchor to be partially inserted within the cavity in the first anchor and engage a second pair of notches in the metallic stud, the second pair of notches being more distant from the structural supporting member than the first.
2. Such a construction, comprising in addition a removable second anchor fitted within the cavity of the first anchor, engaging the second pair of notches in the metallic stud, so as to permit supporting electrical heating elements.
3. An anchor for use in such a construction, having a tapering shank open at one end at which a radial flange provides a shoulder for trapping a body of insulating material, the other end being closed by a wall having an aperture therein for the passage of a stud, the anchor having a cavity and being so shaped and dimensioned as to permit an identical anchor to be partially inserted therein.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevation view, partly in section, of an insulation construction according to the invention.
FIG. 2 is a sectional view of a ceramic anchor forming part of the construction shown in FIG. 1.
FIG. 3 is a perspective view of a metal stud forming part of the construction shown in FIG. 1.
FIG. 4 is an end view of the anchor and stud assembly in locked position.
FIG. 5 is a sectional view of an insulation construction according to the invention when adapted to support electrical elements.
DETAILED DESCRIPTION
The invention will now be described in detail, by way of example only, with reference to the drawings.
In FIG. 1 there is depicted in section a portion of a furnace wall, designated 10, having a body of refractory and/or insulating material 11 superimposed thereon, each of said components being effectively united and secured together by means of studs 12 and ceramic locking anchors 13. The metal stud 12, may be secured to the structure 10 by any appropriate means, such as by welds, 14, and is adjacent to the exterior or cool face of the structure, and the ceramic anchor 13 extends through and beyond the insulation surface in the direction of the interior or hot face. To facilitate the mounting and positioning of the insulating body by means of impalement upon the stud 12, the terminal end of the stud is preferably formed in a point, 15. The ceramic anchor 13, is provided with a rectangular slot 16 in the base thereof, positioned and sized to cooperate and engage with the stud 12, whereby the anchor may be slipped over the end of the stud, past the notched sections 19 thereof (see FIG. 3), and then turned through 90 degrees to form a locking engagement.
FIG. 2 illustrates the ceramic anchor 13, which is in the form of a truncated cone. The anchor comprises a high temperature resistant body having shoulders 17, which function to hold insulating material 11 in position. The ceramic anchor 13 engages the metal stud 12, by means of a rectangular slot 16, located in anchor base 22. The end of the stud then extends into the cavity, or bowl of the cup, 18.
As illustrated in FIG. 3, the metal stud 12, is substantially rectangular in cross section and has one pair of opposed sides narrower than the other pair. A plurality of pairs of discrete opposed notches 19 are disposed along the end of stud 12 opposite the welding or attachment end 20. The notches 19 are cut into the narrower sides of stud 12. The aperture 16 in the ceramic anchor 13 is of a configuration complementary with but slightly larger than the unnotched portions 21 of the rectangular stud.
During assembly, anchor 13 will be pushed downwardly over the stud 12 until the proper compression has been applied to the lining 11, as shown in FIG. 1. When this point has been reached, the anchor is then rotated through 90 degrees in the particular pair of discrete opposed notches 19 that are available at the point that aperture 16 engages the stud, as illustrated in FIG. 4. The minimum distance between the opposed walls of notches 19 is less than the minor dimension of the aperture 16 in anchor 13, and consequently less than the minor dimension of the rectangular stud 12. Additionally, the length of notches 19 is substantially greater than the thickness of anchor base 22. By this arrangement, the anchor 13 may be moved along the stud 12 to the desired notch and freely rotated to the locking position. Once the anchor has been rotated into locking position, it is then released, and the resilient force of the lining 11 will push anchor 13 against the shoulders of the opposed notch. In this manner, anchor 13 is secured against unintentional rotation. If desired, the notches may be so designed as to taper outwardly from the longitudinal axis of the stud toward the pointed end 15. In this case, the resiliency of the lining will bring the tapered walls of the notch into contact with the sides of the aperture, affording greater freedom from possible rotation.
After engagement and locking of the stud and anchor assembly the end of the stud protrudes into cavity 18 of the anchor. Since metal is subject to oxidation and deterioration at elevated temperatures, it is desirable to insulate this portion of the stud. This may be accomplished simply, by packing the cavity with a suitable refractory material. For example, bulk fiber or blanket trim may be pressed into the cavity. Alternatively, a refractory cement may be placed in the cavity, which will harden upon heating. In the preferred embodiment, the stud is proportioned so that the pointed end 15 does not extend beyond the shoulder 17 of the ceramic anchor. If the stud extends beyond the shoulders it may be cut off, by snippers for example, to ensure insulating of all metallic components of the assembly.
Various high temperature resistant materials are suitable for the practice of this invention. For example, the metal stud 13 may be prepared from such metals as stainless steels 301 and 304, or Inconel™ 601, a high solids-solution alloy commercially available from The International Nickel Company. The ceramic anchor 13 is suitably made from refractory materials such as mullite, alumino-silicate refractories, Alfrax® fused alumina refractory, or Mullfrax®, a furnace mullite refractory available from The Carborundum Company of Niagara Falls, New York. The refractory lining materials 11 may suitably be any high temperature refractory fiber blanket or felt, such as alumino-silicate fibers. A particularly suitable material is Fiberfrax® refractory fiber insulation available from The Carborundum Company of Niagara Falls, New York.
The ceramic anchors 13 are all of the same size and shape and are designated to fit one within the other in the manner shown in FIG. 5, to provide a support, generally indicated at 23, for electrical heating elements (not shown). The support 23 has the general appearance of a bobbin of which the checks or flanges are defined by the shoulders 17 of the interfitting anchors 13 and the core or reel portion is defined by a section of the tapering body portion of the inner anchor 13. The electrical heating elements are trained over the cores of the supports 23 and are retained by the check or shoulder 17 of the inner anchor 13. "Inner" and "outer" anchors 13 are designated such according to their relationship to each other. Thus the outer anchor 13 is installed first, and is closer to the furnace wall 10.
It will be appreciated that when the inner anchor 13 is removed the construction shown in FIG. 5 is substantially the same as that shown in FIG. 1, and like parts have in fact been designated by the same reference numerals and are not further described. The mounting and positioning of the insulating body proceeds as described above with reference to FIG. 1. However, when packing the cavity of any anchor 13 with a suitable refractory material as described, account must be taken of whether that particular anchor is intended to locate an inner anchor 13 so as to provide an electrical heating element support 23. If it is so intended, then the cavity of the outer anchor 13 is either left unpacked or is only packed to a limited extent compatible with location of the inner anchor 13 therein.
At those locations where a support 23 is to be provided, the tapering body portion of an inner anchor 13 is inserted into the cavity of the outer anchor 13 forming part of the attachment means for the insulating body. The extent of such insertion is obviously limited by the design and when the inner anchor 13 has been inserted to the fullest extent possible it is twisted to lock it in position on stud 12. The cavity of the inner anchor 13 may now be packed with a suitable refractory material.
As has already been indicated the support 23 is provided by two identical components, namely the inner and outer anchors 13, fitting one within the other. It will be appreciated that the inner anchor 13 could be replaced by a different component having a suitable spigot formation adapted to be received in the socket formation provided by the cavity of the outer anchor 13. While such a modification would obviously vitiate some of the advantages of the preferred embodiment described with reference to the drawings, it would nevertheless afford an improvement over the previous proposal in utilizing a pre-existing attachment site of the insulating body for the additional purpose of supporting electrical heating elements. This modification would also afford the possibility of making the core portion of the bobbin-like support 23 cylindrical rather than tapering in shape, which may prove to be an advantage. The same end may be achieved by redesigning the external shape of the anchors 13 shown in the drawings although it is preferred that the outer anchor 13 have a tapering configuration over its full length for ease of penetration into the insulating body 11.
In a further modification the notched, rectangular section studs 12 having pairs of discrete opposed notches 19 are replaced by circular section studs in which the notches are connected to form a threaded stud and the anchors are held in position by nuts.
As previously pointed out, the construction of the present invention is adapted for use in lining a furnace wall with a ceramic insulating and/or refractory body comprising one or more layers. It will be understood that in many instances there is little difference chemically between the ceramic materials used in refractory compositions and heat-insulating compositions. For example, a dense, bonded alumina body has a fairly good heat conductivity while a bonded body in which the alumina is in the form of hollow bubbles will be a good heat insulator. Accordingly, the distinction between an insulating material or composition and a refractory material or composition as used herein may reside only in the density or form of the material. In general, when a plurality of layers is used, the outer layer is primarily chosen for refractory properties, while a ceramic material having a lower heat-conductivity is employed for the inner layer. However, in some cases only a single layer of adequately insulating refractory may be used. In other cases, three or more layers of varying properties may be used if desired. The layers of insulating and/or refractory materials may be provided in a choice of forms such as bats, blankets, sheets, blocks and the like. For primarily insulating purposes blankets, bats or sheets of mineral wool or other ceramic fiber and sheets or blocks of ceramic-bonded, hollow ceramic bubbles are among the useful materials. Where a higher refractoriness is wanted denser bodies or layers are used, for example blocks of sheets of bonded alumina-silica ceramic fiber are very satisfactory. If desired, for example to make installation more convenient, a plurality of the layers of insulating and/or refractory material may be secured together by suitable means, such as a silicate cement, or even glue, but this is not essential.
The assembly of the present invention has been described in respect to its use for securing refractory linings to the walls of furnaces and the like. However, it is anticipated that the assembly may have many other uses in environments other than refractory furnaces.
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There is disclosed a device for securing refractory and/or insulating material against a furnace wall. The device comprises a metal pin or stud which is attached to the wall at one end and is provided with a plurality of notched portions adjacent the other end. The stud cooperates with a hollow, preferably ceramic anchor, which is provided with a rectangular slot that fits over the notched portion of the stud and may be secured thereon by rotating an anchor through 90 degrees to effect a locking arrangement. The anchors may be interfitted in order to provide a support for electrical heating elements. The significant feature is that the size of the anchor is such as to allow another anchor to interlock and make a collar which can support electrical heating elements. As the anchor is preferably a ceramic support it is electrically insulating, and prevents the electrical heating elements from contacting the studs.
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BACKGROUND OF THE INVENTION
Garage door operators have been gaining in popularity and have evolved into two separate types for the majority of door operators produced in the United States. The first type is a screw drive and the second is a chain drive. The screw drive type of door operator is over 22 years old, as shown, for example, by U.S. Pat. No. 2,954,224. The screw drive type utilizes a one, two or three-start thread screw, disposed near the ceiling of the garage, and in the order of one-half inch diameter, with about 300 degrees of the screw enveloped and guided within an elongated guide rail. A partial nut is guided by the guide rail and engages the screw in the remaining exposed, about 60-degree, arcuate extent of the screw. The partial nut is connected to the garage door for establishing opening and closing movements, depending on clockwise or counterclockwise rotation of the screw.
The chain drive type of garage door operator utilizes an elongated guide channel, again disposed near the ceiling of the garage, and journaling the drive sprocket and an idler sprocket at opposite ends over which first and second runs of a link chain are trained. A carriage slides on the guide channel and is connected to one run of the chain for forward and reverse movements for opening and closing movements of the door. In the chain drive type of door operator, the guide channel for many years has been cut into two or three pieces for compactness of the shipping container and spliced together end-to-end at the garage site for use.
In order to be useful throughout the United States, both types of garage door operators must be usable with a large majority of the different types of garage doors in use. There are sectional doors of three, four, or five sections which move upwardly on a track to a position inside the garage and over the space in the garage for the automobile. Another door is a slab door of one piece which moves upwardly and outwardly to a position partially in and partially outside the garage as a canopy in a generally horizontal position. Another single slab-type door is one which moves on hardware upwardly and inwardly to a position entirely within the garage into a generally horizontal attitude. To be satisfactorily merchandised, both the screw drive and chain drive type of door operator must operate satisfactorily with at least these three different types of garage doors, and such types in a full range of common sizes.
The screw drive door operator currently enjoys the largest market share, one reason being that most of the screw is contained within the guide rail, with the slotted opening along the bottom edge for the partial nut. Therefore, lubrication of the screw may satisfactorily be provided for long life. On the other hand, the chain drive door operator is one which has the chain and sprockets relatively exposed, hence being much more subject to contamination, and therefore wear, for a more limited life. The fact that the chain drive door operator could have a rail cut into sections for a shorter package was a shipping advantage over the screw drive operator, which, until recently, was still shipped in a package about ten feet long. The doors with which both types of operator were used varied in height from 61/2 to 8 feet, so that a guide rail about 9 or 10 feet long mounted along the garage ceiling was generally required in order to be able to satisfactorily operate the great majority of garage doors installed in garages throughout the United States.
More recently, there has appeared on the market a screw drive operator, shown in U.S. Pat. No. 4,241,540, wherein the guide rail is provided with splice plates and the screw is provided with a double pivoted coupling so that the screw part and associated guide rail part may be folded upon itself for a shipping carton about half the total length of the unfolded and spliced guide rail. This shortens the length of the shipping package but introduces further problems of wear at the double pivoted coupling and shortened life of the product.
Installation of garage doors by a service man is becoming increasingly more expensive, and therefore a simplified door operator construction which may be installed by the homeowner is desirable. The average professional installer will have a truck to transport a 10-foot long package, but the average homeowner needs a shorter package so that he may take it home in the trunk of his automobile. Also, the average homeowner does not lubricate his garage door operator, not even once in five years, so a garage door operator which is troublefree without yearly lubrication is desirable.
The problem to be solved, therefore, is how to construct a garage door operator which is competitive in price, operable for a long life in relative quiet and safety without contamination of lubrication, and which may be packaged for shipping in a relatively short carton, yet which will be operable with the great majority of upward acting garage doors currently in use in the United States.
SUMMARY OF THE INVENTION
This problem is solved by a garage door operator comprising, in combination, a base, elongated guide rail means having one end secured to said base and adapted to be mounted in a garage in a direction substantially parallel to at least part of the opening and closing movement of a garage door, first and second lengthwise channels in said guide rail means a motor, a drive wheel journalled on said base, means connecting said drive wheel for drive by said motor, a flexible elongated tape having a first run longitudinally disposed in said first guide channel and a second run disposed in said second guide channel, means establishing a positive drive engagement between a portion of said tape and an arcuate portion of the periphery of said drive wheel, a carriage longitudinally guided on said guide rail means, means interconnecting said carriage and said tape for movement therewith, and a link connected to said carriage and adapted to be connected to any said garage door for opening and closing movements by movement of said tape.
Accordingly, an object of the invention is to provide a garage door operator with a flexible tape which may be guided in an elongated guide channel and which requires no separate lubrication.
Another object of the invention is to provide a tape drive garage door operator wherein the tape is utilized in tension for opening movements and in compression for closing movements of the garage door.
A further object of the invention is to provide a garage door operator wherein the operator may be knocked down and shipped in short sections for a compact door operator with a flexible tape formed into a coil, yet which is readily assembled at the garage site.
Other objects and a fuller understanding of the invention may be had by referring to the following description and claims, taken in conjunction with the accompanying drawing.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevational view of a garage door constructed to be movable by a garage door operator according to the invention;
FIG. 2 is a perspective view of the motor drive end of the door operator, with the cover removed;
FIG. 3 is a perspective view from the upper side of the motor drive end of the garage door operator;
FIG. 4 is an enlarged, side elevational view of the motor drive end of the door operator, and partially in section;
FIG. 5 is an enlarged, side elevational view of the carriage and rail assembly and partially in section on line 5--5 of FIG. 6; and
FIG. 6 is a sectional view on line 6--6 of FIG. 5.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The figures of the drawings show a garage door operator 11 for use with a garage door 12, which may be one-piece door which is upward acting but is shown as a door having five sections with rollers 13 rolling in a guide channel 14 so as to be movable from a closed position shown in solid lines to an open position shown in dotted lines. When closed, the door 12 rests on a door sill 15 and closes a door frame opening 16, which opening has a door header 17, and the garage in which the door is used has a ceiling 18.
The garage door operator 11 includes generally a motor base 21, a motor 22 mounted on the base 21, guide rail means 23 which guides a flexible tape 24, a carriage 25, and a link 26. The base 21 may be of sheet metal, and is adapted to be secured to the ceiling 18 of the garage by any suitable mounting support 28. The motor 22 is preferably an electric motor and is connected in some manner to drive a drive wheel 29, shown in FIG. 4. In the preferred embodiment, this drive connection is one wherein the motor 22 has a drive pinion 30 driving a gear 31 which is coaxial with and connected to a pinion 32 which meshes with and drives a gear 33. This gear 33 is fixed on a shaft 34 which is journaled in a bearing block 35 near one end of the shaft and the other end of the shaft is journaled in a drive wheel housing 36. This drive wheel housing is mounted in an aperture of the base plate 21 to extend partly above and partly below this base plate. The housing 36 is also formed in two halves split perpendicular to the shaft 34, receiving one end of the guide rail means 23 between the two halves. The drive wheel 29 is keyed on the shaft 34 and is disposed inside the housing 36. The flexible tape 24 may be formed of Delrin or some suitable long-chain polymer so as to be flexible, resilient, and self-lubricating in the guide rail means 23. A positive drive connection between the drive wheel 29 and flexible tape 24 is provided, with this positive drive connection being formed by projections on either the tape or the wheel entering apertures on the other member. As shown in the preferred embodiment, the drive wheel 29 has projecting teeth 38 entering apertures 39 on the tape 24. The housing 36 includes walls 40 defining slots 41 and 42 which guide the tape 24 into first and second runs 43 and 44 and guide the tape around and into drive engagement with the drive wheel 29. The slots 41 and 42 guide the tape so that the tape has drive engagement in excess of 180 degrees with the drive wheel 29, and, as shown, this is preferably about 200 degrees of drive engagement.
The motor 22 may be provided with a safety clutch 46 urged into engagement by a clutch spring 47, and this clutch will slip upon overload, whereupon a safety switch, not shown, may be actuated to de-energize the motor 22. The guide rail means 23 is shown as being formed in three pieces 23A, 23B, and 23C, which are butted together at joints 49 and then spliced by means of splice plates 50 and fasteners such as bolts 51. There may be one splice plate at each joint 49, or there may be a pair of splice plates one on each side of the guide rail means 23. These three guide rail sections 23A, 23B, and 23C are normally shipped disassembled in order to achieve a shorter length of shipping carton, and are assembled end-to-end to make a complete guide rail assembly at the garage site.
FIGS. 4, 5, and 6 better illustrate the guide rail means 23, with FIG. 6 illustrating that it was a web 54 interconnecting an upper flange 55 and a lower flange 56. The rail 23 may be of extruded aluminum, for example, to be a stiff, rigid member relative to the tape 24. Both of these flanges add stiffness to the guide rail means 23. The lower flange 56 is thickened in a vertical direction, as mounted, in order to provide first and second guide channels 59 and 60, respectively, with a wall 61 therebetween which defines generally an oval cross section open space. Centrally located longitudinally of the lower flange 56 are two opposite slots 62, and a lower slot 63 provides access to the first guide channel 59.
In FIGS. 3 and 4, it will be noted that the motor end of the guide rail means 23 enters the drive wheel housing aperture 37 in the motor base plate 21, with the base plate fitting within the slots 62 of the guide rail 23 in order to position this guide rail. A plate 64 is clamped to the base plate 21, and also a bolt 65 secures the motor end of the guide rail means 23 to the drive wheel housing 36.
FIGS. 5 and 6 better show the means of connecting the door operator 11 to the garage door 12. From FIG. 4, it will be noted that the first run 43 of tape 24 enters the lowermost or first guide channel 59 and the second run of tape 44 is guided to enter the uppermost or second guide channel 60.
In the position shown in FIG. 1, with the door 12 closed, the tape 24 has a length to reach through the carriage 25, substantially filling the entire length of the first guide channel 59, and then it wraps around the drive wheel 29 and enters a short distance in the second guide channel 60, with the end of the second run of tape 44 being at about the location 66 in FIG. 4. Therefore, it will be seen that the tape 66 is not an endless piece of tape, but need be of a length only sufficient to lie along the length of the guide rail means 23 with enough extra to enter the other guide channel. The second guide channel 60 is thus a storage channel for the unused end of the tape.
FIGS. 5 and 6 illustrate a slide block 70 which may be made of nylon, for example, to be self-lubricating. This slide block has a flange 71 which enters in and slides in the first guide channel 59. Projections 72 are provided on the upper surface of the slide block 70 plus a locking projection 73. The first run of tape 43 has an end 74 close to the flange 71 and the apertures 39 in the tape engage the projections 72 and the locking projection 73. Ramps 75 and 76 are provided on the lower surface of the slide block 70 on either side of a recess 77.
The carriage 25 is made of nylon, Delrin, or a glass-filled polyester resin to be self-lubricating relative to the guide rail means 23. The carriage 25 is made in two halves fastened together by rivets 78. The carriage 25 has a channel 81 disposed on the upper part thereof to embrace and slide along the lower flange 56 of the guide rail means 23. The link 26 is an L-shaped door arm which is pivoted by a pin 82 to the carriage 25, and the other end of this link 26 is pivoted by a pin 83 to a bracket 84 secured to the upper part of the door 12. As noted in FIG. 1, a bracket 85 secures the door end of the guide rail means 23 to the door frame header 17 to take the thrust of opening and closing of the door 12. The slide block 70 is interconnected with the carriage 25 by means of an interlock 86. This interlock includes a latch 87 and the recess 77. The latch 87 is disposed in a guide channel 88 in the carriage 25. A compression spring 89 urges the latch 87 upwardly toward engagement in the recess 77 and a cross pin 90 in a slot 91 limits the extent of movement of this latch 87. A chain 92 is connected to the lower end of the latch 87, and may be pulled to disengage the interlock 86.
OPERATION
FIG. 1 shows the garage door operator 11 as assembled. Initially, for shipping, the garage door operator would be shipped in a much shorter shipping carton. The three guide rail sections 23A, 23B, and 23C would be side-by-side in a shipping carton of only about 3 or 31/2 feet in length. The flexible tape 24 preferably would be threaded through the drive wheel housing 36, with the lower, long end formed into a coil of about 6 or 8 inches in diameter. The motor, gear unit and base plate would be preassembled and would determine the thickest part of the shipping carton.
To assemble the door operator 11, the splice plates 50 and fasteners 51 would be used to assemble the three sections of the guide rail into one elongated, rigid guide rail means 23. The door header bracket 85 could already be attached to one end of the guide rail means 23 by means of a pivot pin 94. The flexible tape could be unrolled and the locking projection 73 inserted through the seventh aperture from the end 74 of the flexible tape 24. The flange 71 on the slide block 70 would then be inserted into the motor end of the guide rail means 23, and this slide block 70 and the end of the tape slid into this first guide channel 59 any desired amount, and preferably for about the entire length of this guide rail means 23. The second end of the tape 66 would be already preassembled around the drive wheel 29, and extending a short distance out of the upper slot 42. It would be slid into the second guide channel 60 and the motor end of the guide rail means 23 could then be fastened in place in the base plate 21 by the clamp plate 64 and the bolt 65. The proper position on the door header 17 for the bracket 85 could be located and this bracket secured by lag screws 95 to the door header 17. The motor 22 and base plate 21 could be raised into position with the door operator 11 substantially horizontal and secured to the ceiling 18 by any suitable mounting support 28. The carriage 25 would be already in place on the guide rail means 23, and would be slid to about the position shown in full lines in FIG. 1. The link 26 would be fastened to the carriage 25 by the pivot pin 82 and the bracket 84 with the pivot pin 83 therein would be secured to the upper part of the door 12.
A DOWN limit switch 97 and an UP limit switch 98 would be slid along the guide rail means 23 to suitable positions to de-energize the motor 22 upon the carriage 25 reaching the closed and fully open positions, respectively. The electrical circuit may be the same as on the typical screw drive or chain drive operator. If the slide block 70 was not interlocked with the carriage 25, they could be interlocked in either of two ways. The door 12 could be actuated manually until the carriage 25 was moved to the position of the slide block 70, and as it approached, the latch 87 would ride along one of the ramps 75 or 76 to be cammed downwardly against the urging of the spring 89 and then the spring would force the latch into the recess 77 to interlock the slide block 70 and the carriage 25. Alternatively, the motor 22 could be energized and the tape moved within the guide rail means 23 to have the slide block 70 approach the carriage 25. At the final approach, the ramp surface 75 or 76 would depress the latch 87 and then the spring 89 would cause this latch to engage the recess 77 to complete this interlocking.
The assembled door operator 11 is one which has a guide rail means 23 adapted to be installed so that this guide rail is parallel to at least part of the movement of the garage door 12. As illustrated in FIG. 1, this is a horizontally disposed guide rail, with a part of the door movement being substantially horizontal. The flexible tape 24 is discontinuous, having first and second ends 74 and 66. This achieves an economy in the amount of tape used, and this is possible because the tape may have a thickness of about 0.085 inch and a width of about 1 inch, so that even with the apertures 39, it has sufficient tensile and compressive strength for opening and closing movements, respectively, of the door 12. The door may have a weight of several hundred pounds, and may have an unbalanced or noncounterbalanced weight of 50, or even 100, pounds. It has been determined that this flexible tape 24, when loaded in tension for opening movements and loaded in compression for closing movements of the door, is satisfactory to establish such door movements. A further advantage is the inherent safety of this door operator. The tape 24 will withstand about twice as much stress in tension as in compression, while sliding in the guide rail. The typical garage door requires about twice as much upward opening force as downward closing force, so the inherent safety is achieved, because one prefers limited down force so as not to crush an object or person. The tape is relatively noise free, without lubrication, so this is another advantage. The tape will withstand the bending around a 1.5 inch diameter drive wheel 29 despite variations of temperature from -10° F. to 120° F., and be self-lubricating in the guide channels 59 and 60.
The latch 87 extends through the lower slot 63 in the guide rail lower flange 56 so as to engage the slide block 70. Since this elongated slot 63 is on the lower side of the lower flange 56, dust and other contaminants do not readily enter the first guide channel 59, making the use of any greasy lubricant unnecessary to inhibit the entrance of any grit or other abrasive particles which might limit the life of the tape 24 within this guide channel 59. Thus, an economical yet long-life door operator 11 is achieved. The slots 41 and 42 and the guide channels 59 and 60 may have a clearance of only about 0.002 to 0.008 inch relative to the flexible tape 24. This means that the tape will be closely enveloped and guided both on the two flat sides thereof and on the two edges thereof, so that the tape does not buckle while being loaded in compression, i.e., for the closing direction of movement of the door 12.
The guide rail means 23, initially shipped in three different sections, achieves the short shipping carton for ease and economy of shipping, and also ease of transporting home by the homeowner, and achieves a lessening of the marketing problems of such door operators. When the three sections are secured together by the splice plates 50, the first and second guide channels 59 and 60 are aligned for easy passage of the two ends of the tape from one section of the guide rail to the next. As will be observed in the drawings, the first and second guide channels 59 and 60 are substantially parallel so that the second end of the tape 66 may extend 8 or 9 feet into this second guide channel 60 when the door 12 is in the open position. This is a storage of the tape 24 during one condition of use of the door operator 11, and hence the tape 24 is encased at all times to prevent dust and dirt from getting on the tape, which could cause contamination and abrasive wear of the tape and guide channels.
From FIG. 4, it will be observed that the first and second guide channels 59 and 60 are spaced apart a distance less than the diameter of the drive wheel 29. This assures that the tape 24 extends around the circumference of this drive wheel 29 a distance greater than 180° for a satisfactory positive drive of the tape by the drive wheel 29.
The flexible tape 24, during use of the door operator 11, is stored at all times within the guide rail means 23 or the drive wheel housing 36. More specifically, it is stored within one of the upper and lower flanges 55 and 56 of this guide rail means 23 and, as shown in the preferred embodiment, is stored within the lower flange 56. The first guide channel 59 is disposed in the distal exposed edge of the lower flange 56 and the second guide channel 60 is disposed in the proximal edge of the lower flange 56, proximate the web 54. The lower flange 56 has an inverted, U-shape, with the base of the U-shape forming part of the second guide channel 60. This helps establish the stiffness of the guide rail means 23.
It will be noted that the lower flange 56 performs three functions: (1) it houses the first guide channel 59 for the first run 43 of tape 24; (2) it houses the second guide channel 60 for the second run 44 of tape 24; and (3) it provides the longitudinal guide for the carriage 25. The carriage 25 has the channel 81 which envelops a majority of the lower flange and is longitudinally guided therealong. The result is a door operator which has satisfactory economy, one which utilizes a short shipping package, one which is readily installed by a homeowner, and one which has a satisfactory long life.
The present disclosure includes that contained in the appended claims, as well as that of the foregoing description. Although this invention has been described in its preferred form with a certain degree of particularity, it is understood that the present disclosure of the preferred form has been made only by way of example and that numerous changes in the details of construction and the combination and arrangement of parts may be resorted to without departing from the spirit and the scope of the invention as hereinafter claimed.
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A garage door operator is provided which includes a flexible, elongated tape within a relatively rigid, elongated guide rail mounted in a garage. The tape has first and second runs longitudinally disposed in first and second guide channels in the guide rail. A motor is connected to drive a drive wheel with the tape wrapped around a part of the drive wheel and having a positive drive engagement therewith. A carriage is longitudinally guided on the guide rail and is connected both to the tape for movement therewith and by a link to a garage door for opening and closing movements of the door. The guide rail may be cut into sections for a shorter shipping package, and the tape coiled in a loop during shipment but then disposed within the guide channels during operation, the guide rail being spliced into one long, continuous assembly for use in the garage. The foregoing abstract is merely a resume of one general application, is not a complete discussion of all principles of operation or applications, and is not to be construed as a limitation on the scope of the claimed subject matter.
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RELATED APPLICATIONS
The present application is a national stage entry according to 35 U.S.C. §371 of PCT application No.: PCT/EP2010/052648 filed on Mar. 3, 2010, which claims priority from German application No.: 10 2009 011 350.9 filed on Mar. 5, 2009.
TECHNICAL FIELD
The invention relates to a lighting device having at least one heat sink and an at least approximately flat base for accommodating at least one light source and at least one device connected to the lighting device for generating a cooling media flow, in particular an air flow.
BACKGROUND
Lighting devices, in particular when said lighting devices use light-emitting diodes (LEDs) for generating light, frequently require a cooling device by which the light sources are able to be cooled during operation, so that said light sources have a long service life and the desired lighting quality is achieved. To this end, the cooling devices generally have a preferably flat base, the LEDs being directly attached to said base or to a suitable support.
With higher outputs, passive heat sinks are no longer sufficient to ensure the desired cooling action and generally devices are used for generating a cooling media flow, which improve the dissipation of the heat output by convection. In the simplest and most common form, electrical fans which are mounted on the side of the heat sink remote from the base are used for this purpose and blow ambient air as cooling fluid approximately perpendicular to the heat sink. The cooling air flow is thus guided perpendicular to the plane of the base onto the heat sink and deflected to the side when it comes into contact with said heat sink.
Due to the deflection of the cooling air flow, greater pressures and lower flow rates result, whereby poor cooling action is achieved. If additionally the air flow is not accurately guided perpendicular to the heat sink, for example due to a slightly oblique position of the fan in relation to the heat sink, the uneven discharge of air may lead to an uneven cooling of the heat sink and thus to an undesirably uneven temperature distribution.
An optimal cooling action is particularly important in so-called retrofit lamps, which have light-emitting diodes as light sources and a conventional lamp base in order to be able to use light-emitting diodes instead of conventional incandescent lamps. Said retrofit lamps are intended to correspond in their external dimensions as closely as possible to conventional incandescent lamps and, therefore, have to have a particularly compact design and operate as far as possible in all installation positions. This promotes the occurrence of a thermal short circuit, i.e. the heated-up cooling air which has just been blown out is immediately drawn back in, particularly when the lamps are operated in spatially restricted conditions, for example due to a lamp shade.
SUMMARY
Various embodiments provide a lighting device having at least one heat sink and a base for accommodating at least one light source and at least one device connected to the lighting device for generating a cooling media flow, e.g. an air flow, which has a compact construction and a high degree of efficiency when the light source is cooled.
As the cooling media flow runs predominantly parallel to the plane of the base of the heat sink, a deflection of the air flow by a greater angle, in particular by more than 90°, is avoided. As a result, the cooling action is substantially increased with the same ventilation efficiency relative to an embodiment according to the prior art. Additionally, in such an arrangement, the flow path and thus the cooling action is able to be predicted more easily and is also substantially less sensitive relative to faulty positioning of the fan. In this case, the region of the heat sink may be regarded as the base which is provided for fastening components. Expediently, said base is at least approximately flat, as a particularly simple arrangement is thus achieved in which, for example, light-emitting diodes premounted on support plates may be used. However, bases of convex shape are also conceivable. In said bases, the plane is understood as the plane in which all the distances between the points of the base which are located above the plane are equal to all the distances between the points of the base which are located below the plane.
When the lighting devices are exclusively arranged on a base of the heat sink, a particularly simple design is achieved.
It is particularly advantageous if the cooling media flow runs substantially from a lateral surface of the lighting device to the opposing lateral surface of the lighting device. By means of this path of the cooling media flow, a particularly large distance is created between the inlet of the cooling media and the outlet of the cooling media from the lighting device and thus the heated-up coolant is prevented from being drawn in again (a so-called thermal short-circuit). This is advantageous, in particular with the use of ambient air as coolant, as ambient air is particularly difficult to control compared with other cooling media. In this case, in particular the outer boundaries of the lighting device may be regarded as the lateral surfaces, which are arranged perpendicular to a main direction of radiation of the light sources or perpendicular to a longitudinal axis of the lighting device. In retrofit lamps, said lateral surfaces are generally the side walls which are arranged between the base and the light source.
As the device for generating the cooling media flow is arranged in a cavity of the heat sink, a particularly compact design is achieved. The device for generating the cooling air flow is thus located within the outer contour of the heat sink, it is preferably completely enclosed by the heat sink and thus is particularly well protected from environmental effects.
Expediently, the heat sink includes cooling fins and/or cooling pins. As a result, the surface covered by the cooling media flow is maximized. By a suitable design of the cooling fins and/or cooling pins, the path of the cooling media flow may additionally be optimized.
As the cooling fins and/or cooling pins are arranged at least approximately parallel to a plane perpendicular to the base of the heat sink, it is ensured that the cooling media flow runs in the desired direction, whilst a very good thermal link is still provided between the cooling fins and/or cooling pins and the base of the heat sink.
The flow of the cooling media flow is also advantageously guided if the cooling fins and/or cooling pins are arranged approximately parallel to the plane of the base of the heat sink.
Advantageously, the heat sink has at least one lateral web. Said lateral web is particularly well-suited for accommodating other components of the heat sink. Also, a lateral web may be used to fasten the heat sink to other components.
Expediently, the cooling fins and/or cooling pins are arranged at least partially on the lateral web. As a result, cooling fins may also be arranged at a distance from the base which results in an improved discharge of heat, as the temperature of the air flowing past is generally lower at that point than in the vicinity of the base.
Expediently, the heat sink has at least one second base. Said base may be used to accommodate further components to be cooled, such as for example further light sources.
In an expedient development of the invention, the second base is in thermal cooperation with at least one electrical circuit, preferably a driver circuit for operating at least one light source of the lighting device. During operation, such components may also develop considerable waste heat and are thus effectively cooled by the heat sink. By the use of a second base, the heat sink is used as a connection member between the light source and driver circuit which results in a compact and simple design.
Expediently, in this case, the electrical circuit is arranged on the at least second base, as in this manner a particularly simple design is achieved.
It is also advantageous if the device for producing the cooling media flow is configured as a fan which may be electrically operated, in particular as an axial fan or radial fan. Such fans are simple and effective. However, it may also be advantageous to use a ventilation device, acting by means of an oscillating membrane or by means of accelerated ions.
Advantageously, the device for generating the cooling media flow is arranged in a cavity of the heat sink. As a result, a compact design is achieved and the device for generating the cooling media flow is reliably protected from environmental effects, in particular from the incursion of foreign bodies or from coming into contact with anything else.
As the cavity has at least partially a square or circular cross section, a simple design is achieved which is well-suited, in particular, for accommodating commercially-available electrical fans.
As the device for generating the cooling media flow is arranged on at least one of the lateral webs, said device is connected in a simple and reliable manner to the heat sink.
It is also advantageous if the lighting device has at least one standard base in order to be accepted into a standard lamp holder. Thus the lighting device may be fitted in conventional lamps, for example, in place of a different light source, such as for example an incandescent lamp or a fluorescent lamp.
The effects of the invention are particularly advantageous if the lighting device has light-emitting diodes as the light source and/or is configured as a so-called retrofit lamp. Retrofit lamps may be used instead of conventional incandescent lamps and mimic said lamps in their external dimensions. As a result, said retrofit lamps have to have a particularly compact design and have to operate as far as possible in all installation positions. Frequently, retrofit lamps have the conventional incandescent lamp (bulb) shape but, in particular, so-called candle lamps or reflector lamps i.e. lamps in which light is discharged by means of a reflector, may be understood thereby. Also linear lamps, i.e. lamps having a linear extension, may be included therein.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is intended to be described in more detail hereinafter with reference to exemplary embodiments. In the figures:
FIG. 1 shows a first exemplary embodiment of a lighting device according to the invention,
FIG. 2 shows a partial view of the lighting device according to FIG. 1 in perspective view,
FIG. 3 shows the lighting device according to FIG. 1 installed in a typical lamp,
FIG. 4 shows three embodiments of a lighting device according to FIG. 1 in a sectional view,
FIG. 5 shows a further embodiment of a lighting device according to the invention installed in a typical lamp,
FIG. 6 shows a further embodiment of a lighting device according to the invention installed in a typical lamp.
DETAILED DESCRIPTION
The following detailed description refers to the accompanying drawings that show, by way of illustration, specific details and embodiments in which the invention may be practiced.
FIG. 1 shows as a first exemplary embodiment of a lighting device 1 according to the invention a so-called LED retrofit lamp 1 in a lateral sectional view. The lamp 1 has a conventional screw base 2 (a so-called Edison thread), drive electronics 3 , a heat sink 4 , light-emitting diodes (LED) 5 as the light source 5 , as well as a bulb 6 which protects the LEDs 5 from environmental effects. The outer contour of the retrofit lamp 1 mimics the shape of a conventional incandescent lamp. The LEDs 5 are arranged on a first flat base 7 of the heat sink 4 and radiate into the upper half-space. On the side 8 of the first base 7 remote from the LEDs 5 , the heat sink 4 has two lateral webs 9 , of which in this case only the front lateral web is visible. At the end 10 of the lateral web 9 remote from the first base 7 , a second flat base 11 is arranged parallel thereto and which bears the drive electronics 3 and thus is used for the cooling thereof.
To the side on the lateral webs 9 , cooling fins 12 are attached which run parallel to the plane of the first base 7 . An electrical fan 13 , not visible here, is arranged between the lateral webs 9 and which is fastened to the lateral webs 9 . The fan 13 is designed as an axial fan 13 and generates an air flow parallel to the plane of the base 7 , the air entering the lamp 1 from the left-hand side and emerging again on the right-hand side.
The lower part 14 of the lamp 1 is reproduced in FIG. 2 in a perspective view. Light-emitting diodes 5 are attached to the upper base 7 . The two lateral webs 9 as well as the axial fan 13 arranged in a cavity 15 of the heat sink 4 may be clearly seen. The cooling fins 12 also serve to protect the fan 13 from contact and from the incursion of foreign bodies. The drive electronics 3 are arranged for reasons of safety in a closed housing 16 made of an electrically-insulating material.
FIG. 3 shows the arrangement of such a lamp 1 in a suspended light fixture 17 , which substantially consists of a lamp holder 18 and a lamp shade 19 . The air flow of the drawn-in cold air (A) and the expelled heated air (B) is symbolized by the arrows A and B. It may be seen clearly that by the arrangement of the intake opening 20 and the air outlet opening 21 on opposing sides of the lamp 1 , the heated-up expelled air is reliably prevented from being directly drawn back in.
FIG. 4 shows three different embodiments of the cavity 15 , in which the axial fan 13 is arranged between the two lateral webs 9 . By means of the free air space in front of and behind the fan 13 , the cavity 15 serves to improve the efficiency thereof and to reduce the generation of noise. In FIG. 4 , at the top, the cavity 15 has a circular cross section in a plane parallel to the plane of the first base 7 . As a result, the cooling fins 12 have the same width over their entire periphery, which ensures effective heat discharge. In FIG. 4 in the middle, the cross section of the cavity 15 is square, which simplifies the installation of the fan 13 and due to the large installation space also permits the use of fans 13 of variable thickness d. FIG. 4 at the bottom shows a further embodiment of a square cross-sectional surface in which the width of the cooling fins 12 is reduced towards the point which is located on the outside and which is therefore the coolest point, ensuring effective discharge of heat with low material consumption for the cooling fins 12 . Perpendicular to the plane of the base 7 , the cavity 15 in the present exemplary embodiment has a rectangular cross section as the fan 13 may be easily inserted therein and a simple design facilitates the production of the heat sink 4 . However, other cross-sectional shapes are also conceivable.
FIG. 5 shows a further exemplary embodiment of a lighting device 1 according to the invention, also installed in a suspended light fixture 17 . In this embodiment, the cooling fins 12 are attached in a slightly oblique manner, the distance from the first base 7 being reduced towards the outside. In this embodiment, although in contrast to the previous exemplary embodiment the air flow is no longer completely straight, it is still deflected by less than 90°, i.e. less than in the lighting device according to the prior art. In this arrangement, the direction in which the cooling air is sucked in or expelled, which is oriented away from the base 2 of the lamp 1 is advantageous and, as a result, produces effective cooling, in particular when using an open lamp shade 19 .
In FIG. 6 , a further exemplary embodiment is shown in which the cooling fins 12 are not oriented parallel to the first base 7 but approximately perpendicular thereto. Thus lateral webs 9 may be dispensed with. By the arrangement of the cooling fins 12 approximately parallel to the desired air flow direction, effective air guidance and thus an effective cooling action is achieved.
Naturally, further lighting devices 1 according to the invention are conceivable. Thus, for example, the arrangement of the cooling fins 12 may differ from those shown, by mixed shapes, with cooling fins 12 arranged perpendicular and parallel to the base 7 , for example, or even the use of cooling pins being conceivable. Also, the arrangement of the lateral webs 9 and the fastening of the fan 13 may vary. Instead of the axial fan 13 , further devices for generating a cooling media flow are also known to the person skilled in the art, in particular radial fans, systems based on an oscillating membrane or accelerated ions. Also, embodiments are conceivable in which a second base 11 may be dispensed with, by the drive electronics 3 being arranged, for example, on the base 7 carrying the LEDs 5 . Also a thermal separation of the heat sink 4 is conceivable, so that heat transmission from the part operatively connected to the drive electronics 3 to the part operatively connected to the light source 5 is prevented or reduced. As a result, different levels of cooling may be applied to the two components.
While the invention has been particularly shown and described with reference to specific embodiments, it should be understood by those skilled in the art that various changes in form and detail may be made therein without departing from the spirit and scope of the invention as defined by the appended claims. The scope of the invention is thus indicated by the appended claims and all changes which come within the meaning and range of equivalency of the claims are therefore intended to be embraced.
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In various embodiments, a lighting device may include at least one heat sink and a base configured to accommodate at least one light source and at least one device connected to the lighting device configured to generate a cooling media flow, wherein the cooling media flow runs predominantly parallel to the plane of the base of the heat sink.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a mechanical and/or electronic supercharger simulator. More particularly, the present invention relates to a mechanical and/or electronic supercharger simulator which generates a sound which resembles a race car emanating from a vehicle, for use in both cars and boats to enhance the sound thereof.
2. Description of the Prior Art
Electronic and mechanical devices which produce sound are well known in the art. They range in scope from bicycles to automobiles. However, none are mechanically and/or electronically linked to a motor's rpm.
Numerous innovations for a supercharger/transmission/engine sound duplicator have been provided in the prior art that are described as follows. Even though these innovations may be suitable for the specific individual purposes to which they address, they differ from the present invention as hereinafter contrasted.
In U.S. Pat. No. 4,949,068, titled Motorcycle Sound Simulator for a Child's Toy, invented by John Johnston and Dee Jordan, a device for simulating the sound of a motorcycle as a child's toy in which the simulated sound is composed of at least two rectangular waves partially out of phase with each other, mixed and amplified. The frequency (and preferably the volume) of the mixed rectangular waves varies with the position of a rotatable simulated throttle.
In U.S. Pat. No. 4,875,885, titled Engine Noise Simulating Device for a Bicycle, invented by Horton Johnson, a noisemaker for bicycles and the like includes a housing having a shoulder and a resonator plate seated in the housing on the shoulder. The resonator plate is biased against the shoulder by a compressed spring. A resonator chamber extends from the shoulder, away from the housing. Use of a camming mechanism which raises the resonator plate above the shoulder and releases same as it passes so that the resonator plate is urged back against the shoulder by the spring and a surface-engaging noise and air compression noise are directed into the resonator chamber to simulate the sound commonly associated with a vehicle engine.
In U.S. Pat. No. 4,680,020, titled Toy Vehicle Having Simulated Engine Noise, invented by Melvin R. Kennedy, Dietmar Nagel, and Abraham A. Arad, a free-wheeling toy vehicle which when propelled makes a repetitive sound simulating the noise of an internal combustion engine. The vehicle includes a chassis having bearings supporting front and rear wheel axles. Lying on top of the chassis between the axles is a drum having an elastic drum head. Cantilevered from one end of the chassis is a clapper formed of a flat metal spring terminating in a striker, the spring being biased so that the striker normally rests on the drum head. A finger projects downwardly from the clapper, the tip of the finger being successively engaged by the equispaced teeth of a hub mounted on one of the wheel axles and turning therewith. Each time the finger tip is engaged by a moving tooth, the finger is pushed forward to raise the striker above the drum head; and when the finger then falls between adjacent teeth, the striker is released to hit the drum head to generate a thumping sound. The repetition rate of the clapper action depends on the running speed of the vehicle and therefore acts to create a realistic motor noise.
In U.S. Pat. No. 4,290,054, titled Electrical Apparatus and Method for Electrically Simulating a Noise, invented by Michel Magnani and Moxhel Moulin, an electrical apparatus and method for electrically simulating noise resulting from the thermodynamic expansion of a gas inside a chamber whose volume is varied, is characterized in that it comprises, in series, a capacitor of fixed capacitance and means for varying with respect to time the potential at least one of the terminals of the capacitor, the potential variation depending on the variation of the volume with respect to time and on the nature of said expansion.
In U.S. Pat. No. 2,459,860, titled Engine Noise Equipment, invented by Claude K. Wilkinson, this invention relates to a noise maker and has for an object to provide an improved noise maker especially adapted for simulating the noise made by an engine or motor in operation, particularly that produced by an aircraft motor.
The above patented inventions differ from the present invention because the lack one or more features of the following described and claimed in the present invention: mechanical supercharger simulator housing having a mechanical supercharger simulator housing egress port and a mechanical supercharger simulator housing ingress port, a mechanical supercharger simulator shaft which comprises a plurality of mechanical supercharger simulator flexible fins longitudinally disposed thereon, an electronic supercharger/transmission/engine sound duplicator microprocessor, an electronic supercharger/transmission/engine sound rpm sensor, an electronic supercharger/transmission/engine sound speaker, an electronic supercharger/transmission/engine sound switch, an electronic supercharger/transmission/engine sound volume control, electronic supercharger/transmission/engine sound trim adjuster, and vacuum sensor.
Numerous innovations for a supercharger/transmission/engine sound duplicator have been provided in the prior art that are adapted to be used. Even though these innovations may be suitable for the specific individual purposes to which they address, they would not be suitable for the purposes of the present invention as heretofore described.
SUMMARY OF THE INVENTION
The present invention relates to a mechanical and/or electronic supercharger simulator. More particularly, the present invention relates to a mechanical and/or electronic supercharger simulator which generates a sound which resembles a race car emanating from a vehicle, such as the mechanical whine of a gear train from a high performance transmission, or such from a gear train of rotors of a type positive displacement blower or supercharger.
The types of problems encountered in the prior art are engines produced are so muffled for sound and pollution that the awesome sounds of the vehicles of yesteryears are not present in today's cars.
In the prior art, unsuccessful attempts to solve this problem were attempted namely: reducing muffling and back pressure. However, the problem was solved by the present invention because the heightened muffling and back pressure can remain while still emanating an awesome sound of yesteryears sound.
Innovations within the prior art are rapidly being exploited in the automotive field.
The present invention went contrary to the teaching of the art which teaches reduced muffling and back pressure.
The present invention solved a long felt need for a mechanical and or electronic supercharger/transmission/engine sound duplicator which is linked to a motor's rpm.
Accordingly, it is an object of the present invention to provide a supercharger/transmission/engine sound duplicator which comprises a mechanical supercharger simulator housing having a mechanical supercharger simulator housing egress port and a mechanical supercharger simulator housing ingress port.
More particularly, it is an object of the present invention to provide a supercharger/transmission/engine sound duplicator which comprises a mechanical supercharger simulator shaft which comprises a plurality of mechanical supercharger simulator flexible fins longitudinally disposed thereon.
In keeping with these objects, and with others which will become apparent hereinafter, one feature of the present invention resides, briefly stated, in a supercharger/transmission/engine sound duplicator which comprises an electronic supercharger/transmission/engine sound duplicator microprocessor and amplifier.
When the supercharger/transmission/engine sound duplicator is designed in accordance with the present invention, it further comprises an electronic supercharger/transmission/engine sound rpm sensor.
In accordance with another feature of the present invention, the supercharger/transmission/engine sound duplicator further comprises an electronic supercharger/transmission/engine sound speaker.
Another feature of the present invention is that the supercharger/transmission/engine sound duplicator further comprises an electronic supercharger/transmission/engine sound switch.
Yet another feature of the present invention is that the supercharger/transmission/engine sound duplicator further comprises an electronic supercharger/transmission/engine sound volume control.
Still another feature of the present invention is that the supercharger/transmission/engine sound duplicator further comprises an electronic supercharger/transmission/engine sound trim adjuster.
The novel features which are considered characteristic for the invention are set forth in the appended claims. The invention itself, however, both as to its construction and its method of operation, together with additional objects and advantages thereof, will be best understood from the following description of the specific embodiments when read and understood in connection with the accompanying drawings.
BRIEF LIST OF REFERENCE NUMERALS UTILIZED IN THE DRAWING
COMMON COMPONENTS OF EMBODIMENTS
24--battery (24)
24A--battery ground (24A)
24BA--battery first positive lead (24BA)
24BB--battery second positive lead (24BB)
26--motor (26)
26A--motor main pulley (26A)
26B--motor alternator (26B)
26BA--motor alternator belt (26B)
26BBA--motor alternator first positive lead (26BBA)
26BBB--motor alternator second positive lead (26BBB)
26BC--motor alternator second negative lead (26BC)
FIRST EMBODIMENT
10--mechanical supercharger simulator (10)
12--mechanical supercharger simulator housing (12)
12A--mechanical supercharger simulator housing egress port (12A)
12B--mechanical supercharger simulator housing ingress port (12B)
14A--mechanical supercharger simulator front bearing (14A)
14B--mechanical supercharger simulator back bearing (14B)
16--mechanical supercharger simulator shaft (16)
18--mechanical supercharger simulator flexible fin (18)
20--mechanical supercharger simulator pulley (20)
20A--mechanical supercharger simulator pulley groove (20A)
20B--mechanical supercharger simulator pulley belt (20B)
22A--mechanical supercharger simulator intake air (22A)
22B--mechanical supercharger simulator egress air (22B)
SECOND EMBODIMENT
110--electronic supercharger/transmission/engine sound duplicator simulator (110)
112--electronic supercharger/transmission/engine sound duplicator microprocessor (112)
114--electronic supercharger/transmission/engine sound rpm sensor (114)
116--electronic supercharger/transmission/engine sound speaker (116)
116A--electronic supercharger/transmission/engine sound speaker positive lead (116A)
116B--electronic supercharger/transmission/engine sound speaker negative lead (116B)
118--electronic supercharger/transmission/engine sound switch (118)
120--electronic supercharger/transmission/engine sound volume control (120)
122--electronic supercharger/transmission/engine sound trim adjuster (122)
124--amplifier
126--vacuum sensor
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a front view of a motor exhibiting a mechanical supercharger simulator and an electronic supercharger/transmission/engine sound duplicator simulator integrally incorporated thereon and electrically therein, respectively.
FIG. 2 is a longitudinal cross sectional view of a mechanical supercharger simulator along line 2--2 of FIG. 1.
FIG. 3 is a lateral cross sectional view of a mechanical supercharger simulator along line 3--3 of FIG. 2.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Firstly, referring to FIG. 1 which is a front view of a motor (26) exhibiting a mechanical supercharger simulator (10) and an electronic supercharger/transmission/engine sound duplicator simulator (110) integrally incorporated thereon and electrically therein, respectively. The mechanical supercharger simulator (10) comprises a mechanical supercharger simulator housing (12) which comprises a mechanical supercharger simulator housing egress port (12A) wherein mechanical supercharger simulator intake air (22A) enters and a mechanical supercharger simulator housing ingress port (12B) wherein mechanical supercharger simulator egress air (22B) emanates from producing a race car simulated sound, the sound of a gear train from a high performance transmission, and/or the sound produced by type positive displacement blowers gear train and rotors. The mechanical supercharger simulator (10) further comprises a mechanical supercharger simulator front bearing (14A) securely mounted at a front distal end within the mechanical supercharger simulator housing (12). The mechanical supercharger simulator (10) further comprises a mechanical supercharger simulator back bearing (14B)securely mounted at a rear distal end within the mechanical supercharger simulator housing (12). The mechanical supercharger simulator (10) further comprises a mechanical supercharger simulator shaft (16) rotatably mounted within and through the mechanical supercharger simulator front bearing (14A) and rotatably mounted within the mechanical supercharger simulator back bearing (14B). The mechanical supercharger simulator shaft (16) is mounted in an off-center position closer to the mechanical supercharger simulator housing egress port (12A). The mechanical supercharger simulator (10) further comprises at least one mechanical supercharger simulator pulley (20) securely mounted at a distal end of the mechanical supercharger simulator shaft (16). The at least one mechanical supercharger simulator pulley (20) comprises a mechanical supercharger simulator pulley groove (20A) where in a complimentary configured mechanical supercharger simulator pulley belt (20B) frictionally engages. The mechanical supercharger simulator (10) functions by the mechanical supercharger simulator pulley belt (20B) which is rotated by a motor main pulley (26A) of a motor (26). The mechanical supercharger simulator pulley belt (20B) engages the at least one mechanical supercharger simulator pulley (20) which in turn rotates the mechanical supercharger simulator shaft (16) and concurrently rotates the plurality of mechanical supercharger simulator flexible fins (18) which are extended entrapping air when rotating past the mechanical supercharger simulator housing ingress port (12B) and contracted compressing the air when rotating past the mechanical supercharger simulator housing egress port (12A) releasing the compressed air there through emanating a race car sound therefrom, and/or the sound of a gear train from a high performance transmission, and/or the sound produced by type positive displacement blowers gear train and rotors.
The mechanical supercharger simulator housing (12), the mechanical supercharger simulator shaft (16), and the mechanical supercharger simulator pulley (20) are manufactured from a material selected from a group consisting of metal, metal alloy, plastic, plastic composite, rubber composite, fiberglass, epoxy and carbon-graphite.
An electronic supercharger/transmission/engine sound duplicator simulator (110) which is incorporated into an electrical system of a motor (26) wherein the motor (26) comprises at least one battery (24) having a battery ground (24A), a battery first positive lead (24BA) and a battery second positive lead (24BB) which is electrically connected by a motor alternator first positive lead (26BBA) to a motor alternator (26B) having a motor alternator belt (26B) which is rotatably and frictionally connected to a motor main pulley (26A). The motor alternator (26B) further comprises a motor alternator second negative lead (26BC) which is electrically connected to a battery ground (24A). The electronic supercharger/transmission/engine sound duplicator simulator (110) comprises an electronic supercharger/transmission/engine sound rpm sensor (114) which is electrically connected to the motor alternator first positive lead (26BBA). The electronic supercharger/transmission/engine sound rpm sensor (114) functions to convert an engines rpm to an electronic signal. The electronic supercharger/transmission/engine sound duplicator simulator (110) comprises an electronic supercharger/transmission/engine sound duplicator microprocessor (112) and amplifier which are electrically connected to the electronic supercharger/transmission/engine sound rpm sensor (114) and receives the engine rpm electronic signal therefrom. The electronic supercharger/transmission/engine sound duplicator microprocessor (112) functions to convert the engine rpm electronic signal into a frequency modulated electric signal. The electronic supercharger/transmission/engine sound duplicator microprocessor (112) and amplifier are electrically connected to the battery (24) by a motor alternator second positive lead (26BBB). The electronic supercharger/transmission/engine sound duplicator simulator (110) comprises an electronic supercharger/transmission/engine sound speaker (116) which is electrically connected to the electronic supercharger/transmission/engine electronic supercharger/transmission/engine sound speaker positive lead (116A) which electrically transmits the frequency modulated electric signal from the electronic supercharger/transmission/engine sound duplicator microprocessor (112) and amplifier to the electronic supercharger/transmission/engine sound speaker (116) emanating sound therefrom. The electronic supercharger/transmission/engine sound speaker negative lead (116B) further comprises an electronic supercharger/transmission/engine sound speaker negative lead (116B) electrically connected to the battery ground (24A).
The electronic supercharger/transmission/engine sound duplicator microprocessor (112) optionally has removable microchips that can be changed to simulate different sounds. The microchip simulates a sound of a roots type positive displacement blower. The microchip simulates a sound of a high performance transmission/engine of a sports car selected from a group consisting of, but not limited to, FERRARI (Tm), BMW (Tm), CORVETTE (Tm), PORSCHE (Tm), MASERATI (Tm), and LAMBORDINI (Tm).
The electronic supercharger/transmission/engine sound duplicator simulator (110) further comprises an electronic supercharger/transmission/engine sound switch (118) electrically connected between the electronic supercharger/transmission/engine sound duplicator microprocessor (112), the switch (118) shuts off all power to the unit, and the electronic supercharger/transmission/engine sound speaker (116). The electronic supercharger/transmission/engine sound duplicator simulator (110) further comprises an electronic supercharger/transmission/engine sound volume control (120) electrically connected to the amplifier of the electronic supercharger/transmission/engine sound switch (118) which is connected to the electronic supercharger/transmission/engine sound speaker (116). The electronic supercharger/transmission/engine sound switch (118) is mounted on a vehicle's dashboard. The electronic supercharger/transmission/engine sound switch (118) further comprises indicia thereon, the indicia is "BOOST".
The sound duplicator simulator (/transmission/engine sound trim adjuster (122) is electrically connected between the electronic supercharger/transmission/engine sound duplicator microprocessor (112) and the electronic supercharger/transmission/engine sound switch (118), and may also be connected to the engine manifold by a vacuum sensor. The electronic supercharger/"transmission"/engine sound trim adjuster (122) functions to prevent the frequency modulated electric signal from the electronic supercharger/transmission/engine sound duplicator microprocessor (112) from transmission to the electronic supercharger/transmission/engine sound speaker (116) at low motor (26) rpms, when the transmission sound microprocessor is being used. While the vehicle is standing still at idle the trim would be in off position when the engine sound or blower sound microprocessors are being used.
Referring to FIG. 2 and FIG. 3 which are a longitudinal cross sectional view of a mechanical supercharger simulator (10) along line 2--2 of FIG. 1 and a lateral cross sectional view of a mechanical supercharger simulator (10) along line 3--3 of FIG. 2, respectively. The mechanical supercharger simulator (10) further comprises a plurality of mechanical supercharger simulator flexible fins (18) circumferentially longitudinally disposed upon the mechanical supercharger simulator shaft (16) between the mechanical supercharger simulator front bearing (14A) and the mechanical supercharger simulator back bearing (14B) within the mechanical supercharger simulator housing (12). The plurality of mechanical supercharger simulator flexible fins (18) are constructed from a flexible. The plurality of mechanical supercharger simulator flexible fins (18) are each constructed from a flexible resilient material selected from a group consisting of rubber, rubber composite, plastic, plastic composite and metal alloy.
It will be understood that each of the elements described above, or two or more together, may also find a useful application in other types of constructions differing from the type described above.
While the invention has been illustrated and described as embodied in a supercharger simulator, it is not intended to be limited to the details shown, since it will be understood that various omissions, modifications, 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 in any way from the spirit of the present invention.
Without further analysis, the foregoing will so fully reveal the gist of the present invention that others can, by applying current knowledge, readily adapt it for various applications without omitting features that, from the standpoint of prior art, fairly constitute essential characteristics of the generic or specific aspects of this invention.
What is claimed as new and desired to be protected by Letters Patent is set forth in the appended claims.
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The present invention relates to an electronic engine sound duplicator simulator used in combination with an internal combustion motor, a battery, and an alternator. The sound duplicator simulator includes a motor rpm sensor, a sound duplicator microprocessor, an amplifier, a sound trim adjuster and a switch. When the internal combustion engine is powered, the microprocessor converts the rpm signal into a frequency modulated electric signal which generates a sound simulating that of a high performance vehicle. The sound trim adjuster prevents the frequency modulated electrical signal from being transmitted to the speaker means when there is a predetermined low motor rpm. The stitch is mounted on the dashboard of a vehicle for turning the microprocessor and amplifier on and off.
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BACKGROUND OF THE INVENTION
The present invention relates to an arrangement for filling cavities of structures in general, and more particularly to an arrangement for filling bulk material into cavities of molds and the like.
There are various constructions of arrangements of this type already known and used. The present invention is concerned with an arrangement of this type which is particularly suited for filling cavities of molds provided in beds or platens of brick presses and the like. In this environment, it is already known to fill the respective cavity, which is upwardly open, by means of a filling receptacle which has an open bottom, and which is mounted for relative movement along the bed or platen in a given direction from a receiving position in which the bulk material is introduced into a feeding receptacle, towards a discharging position in which the open bottom of the feeding receptacle is juxtaposed with the open upper end of the respective cavity for discharge of the bulk material, into the respective cavity, and in which the walls of the feeding receptacle surround an open upper end of the respective cavity on all sides. A bottom wall may be movably mounted in the cavity, for vertical movement towards and away from the open upper end of the cavity.
Arrangements of this type are being used, in many instances, in connection with presses for refractory bricks. The requirements for the shape, accuracy, and quality of these refractory bricks are quite high. But the degree of filling of the mold cavity with ceramic material has a very substantial influence on the shape, accuracy, and quality of manufactured bricks.
In known brick presses of this type, the filled feeding receptacle is displaced from a filling position on the bed of the press over the cavity of the mold, while the bottom wall of the cavity of the mold is at the same elevation as the upper surface of the bed. The bottom wall of the cavity of the mold is constituted by a piston. Thereafter, the piston is lowered, so that the bulk or material to be compressed, in this case, a ceramic material, completely fills the cavity of the mold. At the same time, the feeding receptacle becomes empty. When this operation is terminated, the feeding receptacle is returned to the bed of the press. When this happens, the inner wall of the feeding receptacle which faces forwardly during the return displacement, compacts the ceramic material at, and during the movement over, the side of the cavity of the mold, which faces the same, to a higher degree than that obtained at the opposite side of the cavity during the sliding of the ceramic material into the cavity. This non-uniform compaction of the ceramic material in the cavity remains at least partially in existence during the following compressing operation, during which a further piston acts from above on the ceramic material, and it becomes apparent during the so-called breathing phase undergone by the compacted body, that the geometry of the compacted body, which is originally set by the shape of the cavity of the mold, changes.
Of course, it is conceivable to first let the feeding receptacle proceed further, after the filling of the cavity, in the original direction in which the feeding receptacle has been displaced from its discharging position, until the inner wall of the feeding receptacle which faces forwardly, as considered in the direction of displacement, is displaced beyond the side of the cavity which faces the same, so that a higher degree of compaction is first obtained there. Only thereafter can the return displacement of the feeding receptacle be commenced, so that a respectively higher degree of compaction is obtained at the sides of the cavity which are located opposite one another, as considered in the direction of displacement of the feeding receptacle. However, this alternate mode of operation would have the disadvantageous consequence of a considerable widening of the press at its side which is opposite the side at which the feeding receptacle is being filled. In addition thereto, if this procedure were resorted to, the ceramic material introduced into the cavity would be partially entrained for joint displacement by the outer wall of the feeding receptacle, and that could result, disregarding the possibility of soiling, in malfunctions of different kinds. Thus, any attempt at solving the above-mentioned problem of non-uniform degree of compaction in this manner is capable of only marginally improving the uniformity of compaction. The situation is not any different when the press platen includes a plurality of molds or cavities.
SUMMARY OF THE INVENTION
Accordingly, it is a general object of the present invention to avoid the disadvantages of the prior art.
More particularly, it is an object of the present invention to provide an arrangement for filling upwardly open cavities of molds and similar structures with bulk material, which does not suffer from any of the above-mentioned disadvantages of arrangements of this type known in the prior art.
Still another object of the present invention is to develop an arrangement of the above-mentioned type, which is capable of improving the uniformity of compaction of the material in a cavity of a mold.
A further object of the present invention is to design the arrangement so as not to substantially increase the amount of space assumed by the molding press and the feeding arrangement.
A concomittant object of the present invention is to develop an arrangement of the above-mentioned type which is simple in construction, inexpensive to manufacture and operate, and nevertheless reliable.
In pursuance of these objects and others which will become apparent hereafter, one feature of the present invention resides in an arrangement for filling upwardly open cavities of molds and similar structures with bulk material, which comprises a feeding receptacle having an open bottom bounded by a plurality of edges and mounted for relative movement along the respective structure in a predetermined direction from a receiving position, in which bulk material is introduced into a feeding receptacle, towards a discharging position, in which the open bottom of the feeding receptacle is juxtaposed with an open upper end of the respective cavity for discharging bulk material into the respective cavity, the open bottom having dimensions between leading and trailing edges, as considered in the above-mentioned direction, which exceeds the corresponding dimension of the cavity taken in the same direction; and at least one partition extending transversely of the direction, at least at the open bottom of the feeding receptacle, and being spaced from one of the leading and trailing edges by a distance at least equal to the corresponding dimension of the respective cavity. Advantageously, the open bottom of the feeding receptacle has a transverse dimension between two lateral edges, which at least equals that of the open upper end of the respective cavity. The arrangement advantageously further comprises a bottom wall of the structure mounted for vertical movement toward and away from the open upper end of the respective cavity, and cooperating with the feeding receptacle in a cyclical manner to fill the respective cavities.
Then, it is advantageous, when the bottom wall is located at the upper open end of the respective cavities, at least during a predominant part of the displacement of the feeding receptacle towards the discharging position thereof. A particularly advantageous aspect of the present invention resides in the fact that the above-mentioned distance is present between the parition and the trailing edge of the feeding receptacle.
The present invention is based on the idea that a higher degree of compaction can be achieved even at the side of the cavity of the mold which is closer to the filling position of the feeding receptacle, by using the feeding receptacle which is enlarged with respect to the opening of the cavity of the mold to a relatively small degree, and a suitable arrangement of the above-mentioned partition within the feeding receptacle, when the play between the feeding receptacle and the cavity of the mold is taken up in the direction of displacement towards discharge. Simultaneously therewith, the partition serves as a guide during the introduction of the bulk material into the cavity of the mold, so that a more uniform distribution of the bulk material in the cavity is achieved in this manner, too. The uniformity of the distribution can then be further enhanced by providing at least one additional partition, at least at the open bottom of the feeding receptacle, in accordance with a further facet of the present invention.
In order to avoid the possibility that the partition would entrain the above material already fed into the cavity, during the return displacement of the feeding receptacle toward its filling location, it is further proposed, in accordance with a further advantageous concept of the present invention, to compose the partition of an upper and a lower section, and to mount the lower section of the partition on the feeding receptacle for pivoting about an axis extending transversely of the above-mentioned direction. Then, it is further advantageous to provide means for maintaining the lower section of the partition in position against pivoting during displacement of the feeding receptacle towards the discharging position. Thus, the lower section of the partition can be made to yield during the return displacement of the feeding receptacle to be out of the way of the bulk material filled into the cavity, while the partition is to be considered as a rigid wall during the forward displacement of the feeding receptacle, the partition then assuring the desired degree of compaction at the corresponding side of the cavity.
In the event that the arrangement of the present invention is to be used in conjunction with a structure having a plurality of cavities, in accordance with the principle on which the present invention is based, and by using only a single feeding receptacle, the individual cavities of the multiple mold must be arranged behind one another, as considered in the above-mentioned direction, and at least one partition is required to be associated in the above-discussed manner with each individual cavity of the mold. This means, in the event that three individual cavities are arranged behind one another, that a partition which is associated with a first individual cavity as considered in the direction of displacement of the feeding receptacle towards its discharging position, is arranged at a distance from a wall of the feeding receptacle which faces in this direction, which is the same or larger than the length of the individual cavity in this direction, but smaller than the sum of this length and the length of the feeding receptacle in this direction, which exceeds the length of the multiple mold. Similarly, it is valid for the partition which is associated with the second individual cavity, that the distance from the trailing or rear wall of the feeding receptacle is the same or greater than the sum of the lengths of the first and second individual cavities, but smaller than the sum total of this sum and any excess length of the feeding receptacle. Finally, it is valid for the partition associated with the third individual cavity, that the distance from the rear wall of the feeding receptacle is greater than the sum of the lengths of the first, second, and third individual cavities. In this manner, it is assured, as is the case above, in conjunction with a single cavity, that the partition can respectively traverse the side of the individual cavity, which is close to the filling location of the feeding receptacle, while the rear wall of the feeding receptacle does not become juxtaposed with any one of the cavities.
Other features and advantages of the present invention will become more apparent from a consideration of the following detailed description, when taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevational view of a brick press equipped with an arrangement in accordance with the invention;
FIG. 2 is an axial sectional view through a part of the press of FIG. 1, prior to lowering of a bottom wall of the cavity;
FIG. 3 is a view similar to FIG. 2, but following the lowering of the bottom wall;
FIG. 4 is a view similar to FIG. 3, but illustrating a multiple mold; and
FIG. 5 is a view similar to FIG. 4, but illustrates the return movement of the feeding receptacle.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Considering now the drawings in detail, and first FIG. 1, thereof, it may be seen that it illustrates a hydraulically actuated four-column brick press. The press includes four columns 10 at the upper ends of which there is arranged a yoke 12, which is secured by nuts 14 to the columns 10, and thus prevented from sliding off during the pressing operation. A downwardly extending piston 16 is arranged in the center of the yoke 12, so as to be stationary relative thereto.
A pressing platen 18 is arranged at the lower ends of the columns 10, for longitudinal displacement along the columns 10. A piston 20 extends upwardly in the center of the pressing platen 18. A carrier 22 is arranged upwardly on the pressing platen 18, the carrier 22 being also slidable along the columns 10. A mold 24 is connected to the carrier 22. The mold 24 has a cavity 26, and the bottom wall of the cavity 26 is constituted by the piston 20. A support 28 is arranged next to the mold 24, outwardly of the space bounded by the columns 16. The support 28 is arranged on the carrier 22, and carries a hydraulic device 30, for displacing a feeding receptacle 32, which is open both upwardly and downwardly. The feeding receptacle 32 is guided by guide rods 34, during its displacement.
Furthermore, a filling hopper 36 for filling the above material into the feeding receptacle 32 is arranged on the support 28. In order to be able to fill the cavity 26, the mold 24 can be so aligned with respect to the support 28, that they together form a bed on which the feeding receptacle 32 is displaceable from the filling hopper 36 to the cavity 26.
Referring now particularly to FIGS. 2 and 3, it may be seen therein that the feeding receptacle 32 is constituted by a rectangular frame, in which there are arranged a first partition 38 extending transversely of the direction of displacement of the feeding receptacle 32, and a further partition 40. The lower edges of these partitions 38 and 40 extend all the way to the upper side of the above-mentioned bed. The frame of the feeding receptacle 32 is circumferentially larger than the cavity 26, so that it can assume a position in which it is located upwardly of the cavity 26, and surrounds the same completely from all sides. Especially, the length c of the feeding receptacle 32, in its direction of displacement, is greater than the length a of the cavity 26 in the same direction. The distance b of the first partition 38 from a wall 41 of the feeding receptacle 32, which is located rearwardly, as considered in the direction of displacement of the feeding receptacle towards its discharging position, is the same or greater than the length a of the cavity 26.
After the feeding receptacle 32 has been filled with the bulk or ceramic material by means of the filling cup 36, the hydraulic device 30 displaces the feeding receptacle 32 from the support 28 onto the mold 24, above the cavity 26. Under these circumstances, the mold 24 is situated at the same elevation as the support 28, and the bottom wall of the cavity 26, which is constituted by the piston 20, is moved up to the upper surface of the mold 24. When the bulk material is to be discharged from the feeding receptacle 32, the latter is brought into a position which is approximately illustrated in FIG. 2, where the above-mentioned partition 38 is still located ahead of a side 42 of the cavity 26, which faces the hydraulic device 30, while the feeding receptacle 32 completely surrounds the open upper end of the cavity 26 at the same time. Now, when the piston 20 is subsequently lowered, the feeding receptacle 32 discharges its contents into the cavity 26, which thus becomes gradually filled with the bulk or ceramic material. The partitions 38 and 40 serve as guides during the discharge of the ceramic material towards the cavity 26. Once the cavity 26 is filled with the ceramic material, the material feeding the receptacle 32 is displaced further to the right, as compared to the positions illustrated in FIGS. 2 and 3, until the rear wall 41 borders the cavity 26. Simultaneously therewith, the first partition 38 travels beyond the side 42 of the cavity 26, so that an increased degree of compaction is achieved at the region of the side 42 of the cavity 26. The lines of the same degree of compaction then extend approximately transversely from above to below, towards the side 42 of the cavity 26.
During the return displacement of the feeding receptacle 32, the lower inner edge of a wall 43, which is located frontwardly of the rear wall 41 of the feeding receptacle 32, and which inner edge faces towards the hydraulic device 30, will provide, in the same manner, for an increased degree of compaction at a side 44 of the cavity 26, which is located oppositely to the side 42, during the travel of the feeding receptacle 32 over the cavity 26. If the above-mentioned partition 38 were absent, a higher degree of compaction would only be achieved at the side 44 of the cavity 26.
A lower section 38', 40', of the respective partition 38 and 40 is pivotable during the return displacement of the feeding receptacle 32 of FIG. 2, in the backward direction, in a counter-clockwise manner, in order to avoid an entrainment and too pronounced compaction of the ceramic material filled in the cavity 26, at the side 44. However, the lower sections 38' and 40' are held in the illustrated positions thereof during the advancement of the feeding receptacle 32 in the rightward direction, against pivoting in a clockwise manner, by respective abutmens 38", and 40".
The conditions existing in connection with a multiple mold having a plurality of individual cavities 26a, 26b, and 26c, is illustrated in FIGS. 4 and 5. Pistons 20a, 20b, and 20c, are associated with each of the individual cavities of the molds 26a, 26b, and 26c, respectively, the pistons 20a, 20b, and 20c being jointly provided on the pressing platen 18. In a similar manner, the yoke 17 carries a piston 16 constituted by a plurality of individual pistons. The individual cavities 26a, 26b, and 26c are arranged behind one another, as considered in the direction of displacement of the feeding receptacle 32. The feeding receptacle 32 includes first partitions 38a, 38b, and 38c, which are associated with the individual cavities 26a, 26b, and 26c, respectively. When the thickness of the partitions 46 between the individual cavities 26a, 26b, and 26c is disregarded, then the partitions 38a, 38 b, and 38c of the illustrated embodiment are arranged at the same distances from one another and with respect to the walls 41, and 43 of the feeding receptacle 32, as considered in the direction of its displacement. This distance is equal to the length of an individual cavity, which cavities all have the same length in this direction.
In order to discharge the ceramic material, the feeding receptacle 32, filled with the ceramic material, is so displaced on top of the multiple mold, that its front wall 43 is flush with the side 42c of the individual cavity 26c, which faces the hydraulic device 30. The first partition 28a then registers with the side 44a of the individual cavity 26, which faces in the opposite direction. The partitions 38a and 38b are then located upwardly of the partitioning walls 46. In this condition, the pressing platen 18 is moved downwardly, so that the feeding receptacle 32 and the individual cavities 26a, 26b, and 26c are filled. Thereafter, the feeding receptacle 32 is displaced towards the position illustrated in FIG. 4, in which its rear wall 41 is aligned with the side 44a of the individual cavity 26a. The partitions 38a, 38b, and 38c travel past the individual cavities 26a, 26b, and 26c, and cause an increase in the degree of compaction at the sides 42a, 42b, and 42c of the individual cavities 26 a, 26b, and 26c, which face the hydraulic device 30. The direction of the wedge-shaped compaction zones obtained thereby is illustrated in FIG. 4, in broken lines.
In FIG. 5, there is illustrated a situation obtained when the feeding receptacle 32 moves in the return direction. The lower sections 38a', 38b', and 38c' of the partitions 38a, 38b, and 38c yield, when encountering the resistance of the ceramic material.
The front wall 43, which is located frontwardly as considered in the advancement direction of the feeding receptacle towards its discharging position travels, in succession, past the individual cavities 26c, 26b, and 26a, and produces a compaction on the opposite sides 44c, 44b, and 44a of the individual cavities 26c, 26b, and 26a. The shape of the compaction zones of generally wedge-shaped configurations, which results from the action of the wall 43 of the feeding receptacle 32, is illustrated for the individual mold 26c, also in broken lines, in FIG. 5.
When the cavity 26 or a respective corresponding cavity of a multiple mold is filled in the above-mentioned manner, and the feeding receptacle 32 is displaced back onto the support 28, the pressing operation proper is commenced. To this end, the pressing platen 18 with the piston 20, and the carrier 20 with the mold 24, are jointly displaced upwardly to such an extent that the upper piston 15 slightly penetrates into the cavity 26. The positioning is obtained by means of a limiting switch, which is of a conventional construction, and thus has been omitted from the drawing. Thereafter, the lower piston 20 is further pressed into the cavity 26, while the mold 24 is retained in its position, until a further limiting switch or pressure sensor terminates this phase of the pressing cooperation. For the removal of the pressed body, the mold 24 is moved downwardly, together with the piston 20. During this movement, the piston 20 is retarded or stopped, so that the pressed body is lifted out of the cavity 26. Non-illustrated conventional brick-gripping devices grip the pressed body and transport the same, with the aid of the shifting displacement of the feeding receptacle 32, onto a conveyor 48, which transports the pressed body towards a firing furnace.
While preferred embodiments of the invention have been shown and described herein, it will become obvious that numerous changes, additions, and omissions may be made to such embodiments, without departing from the spirit and scope of the present invention.
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An arrangement for filling an upwardly open cavity of a mold with bulk material includes a feeding receptacle which has an open bottom and is mounted for relative movement along the mold from a receiving position in which bulk material is introduced thereinto, towards a discharging position in which the bulk material is discharged from the feeding receptacle through its open bottom.
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[0001] This application claims priority from U.S. provisional application Ser. No. 60/527,268, filed on Dec. 5, 2003, herein incorporated in its entirety.
FIELD OF THE INVENTION
[0002] The present invention relates to the treatment of major depressive disorder (MDD), and the reduction or prevention of suicidality associated therewith, using the uncompetitive NMDA receptor antagonist memantine.
BACKGROUND OF THE INVENTION
[0003] Major depressive disorder (MDD) is associated with high mortality. According to the Diagnostic and Statistical Manual of Mental Disorders IV (DSM IV-Branden/Hill, published by the American Psychiatric Association, Washington D.C., 1994), 15% of individuals with sever MDD die by suicide. This rate increases by almost fourfold in individuals who are over age 55. Risk of suicide in MDD is especially high in individuals with psychotic features of MDD, a history of previous suicide attempts, a family history of suicides, or concurrent substance abuse. Attempted and completed suicide is correlated with reduced serotonin metabolites in the cerebrospinal fluid at autopsy, but the degree to which this is correlated with the severity of other depressive symptoms is unclear (Asberg et al., Arch Gen Psychiatry. 1976; 33:1193-1197). Greater levels of suicidal ideation have been correlated with increased risk for a relapse marked by persistent mild depressive symptoms in relapse, rather than fully asymptomatic status (Judd et al., Am J Psychiatry. 2000; 157:1501-1504).
[0004] Major depressive disorder can begin at any age, with average onset in the mid-20's. According to DSM-IV, women have a 10-25% chance of having at least one MDD episode, while men have a 5-12% chance. MDD is characterized by a period of at least two weeks of a depressed mood or loss of interest or pleasure in activities, and includes additional symptoms such as changes in appetite or weight, sleep, and psychomotor activities; decreased energy; feelings of worthlessness or guilt; difficulty thinking, concentrating or making decisions, or recurrent thoughts of suicide. Individuals with MDD often present with tearfulness, irritability, brooding, anxiety, excessive worry, phobias, and complaints of physical pain. In addition, there is evidence for a familial pattern of MDD being 1-3 times more common among first-degree biological relatives.
[0005] Other disorders that frequently occur concomitantly with MDD include panic disorder, obsessive-compulsive disorder, anorexia nervosa, bulimia nervosa, and borderline personality disorder.
Current Treatments
[0006] The primary approach to the treatment of major depressive disorder in the United States is the use of the selective serotonin reuptake inhibitors (SSRIs). Recently, the use of selective norepinephrine reuptake inhibitors (NARIs), and dual SSRI/NARIs, called SNRIs, has also become prevalent. 3-chloroimipramine, which inhibits both serotonin and norepinephrine reuptake, has been extensively used as an antidepressant in Europe and Canada. Other compounds which are of current interest or have been examined as antidepressants include fluvoxamine, citalopram, escitalopram, zimeldine, sertraline, bupropion and nomifensine. Fluvoxamine facilitates serotoninergic neurotransmission via potent and selective inhibition of serotonin reuptake into presynaptic neurons. Reboxetine is a selective norepinephrine reuptake inhibitor with potential utility in the treatment of severe depression. Other compounds, such as milnacipran, block both 5-HT and norepinephrine reuptake.
[0007] Many of these compounds have adverse side effects when administered at therapeutic levels. Potential side effects of SNRIs include nausea, headache, dry mouth, sedation, and tremors. The adverse effects occurring most frequently during treatment with selective SSRIs such as fluvoxamine are gastrointestinal disturbances, such as nausea, diarrhea/loose stools, constipation, with an incidence of 6 to 37% (Leonard, Drugs 1992, 43 (Suppl. 2): 3-9), and sexual dysfunction. Nausea is the main adverse effect in terms of incidence. These adverse effects, although mild to moderate in severity, deter some patients from treatment with SSRIs and SNRIs.
[0008] Suicide. Treatment of subjects at risk of committing suicide with antidepressants is considered to be beneficial because such subjects typically suffer from depression. However, certain clinicians and investigators believe that SSRI administration to such subjects has been linked to increased suicidality, based on meta-analyses of efficacy and epidemiological studies (Healy, J. Psychiatry Neurosci 2003; 28(5): 337-7). It has been hypothesized that the during the initial 2-3 week latency period prior to onset of anti-depressant activity of the SSRIs, there are increased neurotransmitter concentrations at neuronal synapses, including serotonin. This neurotransmitter increase can result in increased anxiety and agitation (i.e., akathisia) or more generally, irritability during the latency period, which may increase the risk of a suicide attempt. It has been reported that about 5% of patients (not suicidal patients but patients under treatment with SSRIs for depression) drop out of SSRI trials due to akathisia during this period (Healy, supra).
[0009] Accordingly, there is a need in the art to identify and develop therapeutic antidepressants having a different mechanism of activity than the SSRIs, and a faster onset of activity (and hence, a decreased latency period) than the SSRIs, in order to prevent or reduce suicidality in individuals suffering from suicidality.
NMDA Receptor Antagonists
[0010] The N-methyl-D-aspartate (NMDA) receptor is a postsynaptic, ionotropic receptor which is responsive to the amino acids glutamate and glycine, and the synthetic compound NMDA. The NMDA receptor controls the flow of both divalent (Ca++) and monovalent (Na+, K+) ions into the postsynaptic neural cell through a receptor associated channel (Foster et al., Nature 1987; 329:395-396; Mayer et al., Trends in Pharmacol. Sci. 1990; 11:254-260). There is also a strychnine insensitive glycine binding site proximate to the NMDA/glutamate/aspartate binding site. It has been shown that glycine site agonists are necessary for channel function and that low intrinsic activity partial agonists, such as HA-966 (3-amino-1-hydroxypyrrolid-2-one; Merck) behave as functional NMDA antagonists in the presence of sufficient agonist.
[0011] U.S. Pat. No. 5,086,072, issued to Trullas et al., described the use of 1-aminocyclopropanecarboxylic acid (ACPC), which was thought to be a functional antagonist of the NMDA site via its activity as a partial agonist of the strychnine-insensitive glycine binding site, to treat mood disorders including major depression, bipolar disorder, dysthymia and seasonal affective disorder. It was also therein described that intraperitoneally-administered ACPC, via this functional antagonism, mimicked the actions of clinically effective antidepressants in animal models. However, it was subsequently demonstrated that sustained exposure to ACPC in fact attenuated its protective effects and increased the receptors' sensitivity to glutamate (Fossom et al., Mol. Pharmacol. 1995; 48: 981-87), and that ACPC is actually a full glycine agonist (Nathum-Levy et al., Mol. Pharmacol. 1999; 56: 1207-18).
[0012] International (PCT) Application WO 00/02551, to Mueller et al., described novel compounds active at both the serotonin reuptake site and the NMDA receptor (i.e., inhibition of both sites) that can be used to treat different types of disorders such as depression, obsessive-compulsive disorders (OCD), sleep disorders, sexual dysfunction, and eating disorders. According to this PCT, potent activity at the serotonin reuptake site was favored, while an intermediate activity at the NMDA receptor was favored. Too potent an activity at the NMDA receptor is less preferred because of possible PCP-like side effects.
[0013] A number of preclinical experiments have been reported as evidence that glutamate and the NMDA receptor may be involved in the etiology of depressive disorders (Skolnick, Eur J. Pharmacol. 1999; 375: 31-40; and Skolnick et al., Pharmacopsychiatry. 1996; 29:1, 23-6). NMDA receptor antagonists have been shown to exhibit antidepressant like activity in animal models of depression (Rogoz et al., Neuropharmacology. 2002; 42(8): 1024-30). Memantine, a moderate affinity, uncompetitive N-methyl-D-aspartate (NMDA) receptor antagonist, reduces glutamatergic output via open-channel block of the NMDA receptor-associated ion channel thereby reducing or preventing neuronal damage from excitotoxicity. See, e.g., U.S. Pat. Nos. 6,071,966; 6,034,134; and 5,061,703, all incorporated herein by reference. Memantine is also widely used for the treatment of Parkinson's disease, dementia, and spasticity in Germany, and has been approved for the treatment of moderately severe to severe Alzheimer's disease in the European Union and in moderate to severe Alzheimer's disease the United States. It is also currently being evaluated in the United States in clinical studies of patients with painful diabetic neuropathy.
SUMMARY OF THE INVENTION
[0014] The present invention provides a method of treating major depressive disorder (MDD) using memantine.
[0015] The present invention also provides a method of preventing or reducing suicide risk by administering memantine to a subject suffering from suicidality.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] FIG. 1 compares treatment with memantine, citalopram and escitalopram using the Montgomery Asberg Depression Rating Scale (MADRS) to demonstrate change from baseline in MDD patients.
[0017] FIG. 2 compares treatment with memantine, citalopram and escitalopram using the Hamilton Depression Rating Scale (HDRS) to demonstrate change from baseline in MDD patients.
[0018] FIG. 3 is a graph showing the CGI-S change from baseline as a function of treatment time.
[0019] FIG. 4 is a bar graph showing CGI-I Response as a function of treatment time.
DETAILED DESCRIPTION
[0020] The present invention is based on results from an open-label, flexible-dose, 12-week study of memantine in eight patients with MDD. This study was designed to evaluate the safety and efficacy of memantine in the treatment of major depressive disorder. Unexpectedly, the results demonstrated a rapid-onset therapeutic benefit in the treatment of MDD (after 1 week). Not only is this an indication that memantine would be particularly useful in treating persons with major depressive disorder wherein a rapid onset of relief is indicated, but it also supports a utility for memantine to treat suicidality, as will be explained below.
Definitions
[0021] “Memantine” refers to 1-amino-3,5-dimethyladamantane hydrochloride. In the United States, the trade name for memantine is Namenda®, in Germany as Akatinol and Auxura, and Ebixa in the European Union.
[0022] “Major depressive disorder”, or “MDD”, is described above and also according to the criteria in DSM-IV, incorporated herein by reference. The DSM-IV criteria can be used to diagnose patients as suffering from depression. The term also contemplates all diseases and conditions which are associated with MDD, including those classified in the IDC-10 (World Health Organization) and DSM-IV rating scales.
[0023] The term “treating”, as used herein, refers to reversing, alleviating, inhibiting the progress of, or preventing at least one overt symptomatic manifestation of the disorder or condition to which such term applies, or one or more symptoms of such disorder or condition. The term “treatment”, as used herein, refers to the act of treating, as “treating” is defined immediately above. For the present invention, the term “treat” means to alleviate or eliminate one or more of the symptoms, behavior or events associated with MDD, or with suicidality (e.g., reduction in suicidal ideation).
[0024] The term “prevention” refers to the prevention of the onset of a disease, which means to prophylactically interfere with a pathological mechanism that results in a disease or undesirable effect. In the context of the present invention, such a pathological mechanism can be prevention of symptoms associated with MDD, such as but not limited to those as identified using the DSM-IV diagnostic criteria, the HAM-D criteria, the MADRS, or the IDC-10 criteria. The term “prevent” also means prophylactic use of memantine in a subject to avert behavior or events associated with MDD or with suicidality. Subjects having or at risk for developing MDD, such as those with a familial patterns of MDD, can be identified by a diagnostic or prognostic assays according to the ordinary skill in the art.
[0025] The term “suicide” refers to completed suicide.
[0026] The term “suicidality” refers to a condition or disorder characterized by the occurrence, particularly the repeated occurrence, of suicidal thoughts (“suicidal ideation”) or suicidal impulse (loss of impulse control) or behavior. Suicidal behavior may include acts of self-harm with a fatal (“completed suicide”) or non-fatal (“attempted suicide”) outcome.
[0027] The term “suicidal ideation” more specifically refers to having thoughts of suicide or of taking action to end one's own life. Suicidal ideation includes all thoughts of suicide, both when the thoughts include a plan to commit suicide and when they do not include a plan.
[0028] The term “therapeutically effective amount” is used herein to mean an amount or dose of memantine that is effective to ameliorate or prevent a symptom, behavior or event associated with MDD or suicidality or suicidal ideation. Alternatively, a therapeutically effective amount is sufficient to cause an improvement in a clinically significant condition or parameter associated with MDD in an individual in need thereof. Such symptoms, behaviors or events are described above and in DSM-IV.
[0029] The terms, “about” and “approximately” shall generally mean an acceptable degree of error or variation for the quantity measured given the nature or precision of the measurements. Typical, exemplary degrees of error or variation are within 20 percent (%), preferably within 10%, and more preferably within 5% of a given value or range of values. Numerical quantities given herein are approximate unless stated otherwise, meaning that the term “about” or “approximately” can be inferred when not expressly stated.
Dosage and Administration
[0030] Memantine (NAMENDA™) is commercially available as the hydrochloride salt in 5 or 10 mg film-coated tablets. However, according to the present invention, the dosage form of memantine may be a solid, semisolid or liquid formulation. Formulation of memantine in semi-solid or liquid form is within the skill of the art, as the active ingredient is highly soluble in aqueous media. Usually the active substance, i.e., memantine, will constitute between 0.1 and 99% by weight of the formulation, more specifically between 0.5 and 20% by weight for formulations intended for injection and between 0.2 and 50% by weight for formulations suitable for oral administration.
[0031] The pharmaceutical formulation comprises the active ingredients, optionally in association with adjuvants, diluents, excipients and/or inert carriers.
[0032] To produce pharmaceutical formulations of memantine in the form of dosage units for oral application, the memantine (and any additional compounds) may be mixed with a solid excipient, e.g., lactose, saccharose, sorbitol, mannitol, starches such as potato starch, corn starch or amylopectin, cellulose derivatives, a binder such as gelatine or polyvinylpyrrolidone, disintegrants e.g., sodium starch glycolate, crosslinked PVP, cross-carmellose sodium and a lubricant such as magnesium stearate, calcium stearate, polyethylene glycol, waxes, paraffin, and the like, and then compressed into tablets. If coated tablets are required, the cores, prepared as described above, may be coated with a concentrated sugar solution which may contain e.g., gum arabic, gelatine, talcum, titanium dioxide, and the like. Alternatively, the tablets can be coated with a polymer known to one skilled in the art, wherein the polymer is dissolved in a readily volatile organic solvent or mixture of organic solvents. Dyestuffs may be added to these coatings in order to readily distinguish between tablets containing different active substances or different amounts of the active compounds.
[0033] For the formulation of soft gelatin capsules, the active substances may be admixed with e.g., a vegetable oil or poly-ethylene glycol. Hard gelatin capsules may contain granules of the active substances using either the above mentioned excipients for tablets e.g., lactose, saccharose, sorbitol, mannitol, starches (e.g., potato starch, corn starch or amylopectin), cellulose derivatives or gelatine. Also liquids or semisolids of the drug can be filled into hard gelatine capsules.
[0034] Dosage units for rectal application can be solutions or suspensions or can be prepared in the form of suppositories comprising the active substances in a mixture with a neutral fatty base, or gelatin rectal capsules comprising the active substances in admixture with vegetable oil or paraffin oil. Liquid formulations for oral application may be in the form of syrups or suspensions, for example solutions containing from about 0.2% to about 20% by weight of the active substances herein described, the balance being sugar and mixture of ethanol, water, glycerol and propylene glycol. Optionally such liquid formulations may contain coloring agents, flavoring agents, saccharine and carboxymethyl-cellulose as a thickening agent or other excipients known to a person skilled in the art.
[0035] Solutions for parenteral applications by injection can be prepared in an aqueous solution of a water-soluble pharmaceutically acceptable salt of the active substances, preferably in a concentration of from about 0.5% to about 10% by weight. These solutions may also contain stabilizing agents and/or buffering agents and may conveniently be provided in various dosage unit ampoules.
[0036] Suitable daily doses of the active compounds, i.e., memantine, in therapeutic treatment of humans are about 0.01-10 mg/kg bodyweight on peroral administration and 0.001-10 mg/kg bodyweight on parenteral administration.
[0037] In a preferred embodiment, memantine will be administered within the range from about 5 mg to about 100 mg per day, preferably, from about 20 to about 40 mg per day.
[0038] Treatment duration can be short-term, e.g., several weeks (for example 10-14 weeks), or long-term until the attending physician deems further administration no longer is necessary.
EXAMPLE
[0039] The invention is also described by means of a particular example or examples. However, the use of such examples is illustrative only and in no way limits the scope and meaning of the invention or of any exemplified term. Likewise, the invention is not limited to any particular preferred embodiments described herein. Indeed, many modifications and variations of the invention will be apparent to those skilled in the art upon reading this specification and can be made without departing from its spirit and scope. The invention is therefore to be limited only by the terms of the appended claims along with the full scope of equivalents to which the claims are entitled.
Example 1
Evaluation of Onset of Efficacy of Memantine on Symptoms and Behavior Associated with Major Depressive Disorder
[0040] The present study was a single-center, open-label, flexible dose, 12-week study designed to provide a preliminary assessment of the efficacy and safety of memantine in patients with major depressive disorder (MDD). In order to assess the efficacy of treatment on depressive symptomatology, the primary efficacy assessment was the Montgomery Depression Rating Scale (MADRS). Secondary efficacy assessments included the Hamilton Depression Rating Scale (HAM-D), the Clinical Global Impressions—Severity Scale (CGI-S), the Clinical Global Impressions—Improvement Scale (CGI-I), the Patient Global Evaluation (PGE), and the Quality of Life Scale (QOL).
Methods
[0041] Study Design. The study was designed as a single-center, open-label, flexible dose 12-week study. Memantine was to be administered at 20 mg/day (10 mg b.i.d.) (titrated over a 4 week period), and, if warranted, up-titrated to a maximum of 40 mg/day (20 mg b.i.d.) (titrated in increments of 10 mg/day after Week 4).
[0042] Entrance Criteria. Criteria for enrollment were as follows: (i) male or female outpatients between 18 and 80 years of age at screening; (ii) diagnosis of MDD consistent with DSM-IV; (iii) Montgomery Asberg Depression Rating Scale (MADRS) score of 22 or greater; and CGI severity score of 4 or greater. None of the patients had attempted suicide or were diagnosed as being at risk for committing suicide.
[0043] Endpoints. The primary endpoint was improvement according to Montgomery Asberg Depression Rating Scale (MADRS). Secondary endpoints were improvements according to the Hamilton Depression Rating Scale (HAM-D), the Clinical Global Impressions-Severity Scale (CGI-S), the Clinical Global Impressions-Improvement Scale (CGI-I), Patient Global Evaluation (PGE), and Quality of Life Scale (QOL).
[0044] MADRS. MADRS is either self-administered (MADRS-S) or interviewer administered evaluation of symptoms of depression in adults. MADRS evaluates ten areas of depressive symptomatology: apparent sadness, reported sadness, inner tension, reduced sleep, reduced appetite, concentration difficulties, lassitude, inability to feel, pessimistic thoughts, and suicidal thoughts. Each area is rated on a seven-point scale (0-6).
[0045] MADRS was administered to each of the study participants at baseline, and weeks 1, 2, 3, 4, 6, 8, 10 and 12.
[0046] HAM-D. HAM-D criteria were assessed at weeks 1, 2, 4, 8 and 12. HAM-D is a 24-item scale that evaluates depressed mood, vegetative and cognitive symptoms of depression, and comorbid anxiety symptoms. It provides ratings on current DSM-IV symptoms of depression, with the exceptions of hypersomnia, increased appetite, and concentration/indecision. There are several ways of analyzing HAM-D. According to one analysis, the first 17-items are rated on either a 5-point (0-4) or a 3-point (0-2) scale. In general, the 5-point scale items use a rating of 0=absent; 1=doubtful to mild; 2=mild to moderate; 3=moderate to severe; 4=very severe. A rating of 4 is usually reserved for extreme symptoms. The 3-point scale items used a rating of 0=absent; 1=probable or mild; 2=definite. The second analysis uses the same scale to rate the first 21 items, and the third analysis uses the scale to rate all 24 items. All three analyses were used in the present study and used statistically in the results.
[0047] Response to medication (i.e., memantine) was defined as a reduction in the HAM-D 24 score of 50%, while remission was defined as a reduction in the HAM-D total score to 7 or less.
[0048] DSM-IV. DSM-IV diagnostic criteria were determined at week 1 and again at the end of the study. The DSM-IV checklist consists of 9 criteria for MDD as follows: a) depressed mood most of the day, subjectively or observed by others; b) markedly diminished interest or pleasure in all or almost all activities most of the day (subjective or objective); c) significant weight loss or weight gain (more than 5% in a month), or a decrease or increase in appetite nearly every day; d) insomnia or hypersomnia nearly every day; e) psychomoter agitation or retardation nearly every day (as observed by others); f) fatigue or loss of energy nearly every day; g) feelings of worthlessness or exessive or inappropriate guilt nearly every day; h) diminished ability to think or concentrate, or indecisiveness, nearly every day (subjective or objective); and i) recurrent thoughts of death, recurrent suicidal ideation without a specific plan, or a suicide attempt or a specific plan for committing suicide.
[0049] CGI-I and CGI-S. Clinical Global impression of Change (CGI-I) scores were assessed by the participants at baseline and visits 8 and 12. This assesses the patient's impression of his/her change. Clinical Global impression of Severity (CGI-S) were rated by the clinician at baseline, and at visits 8 and 12. This assesses the physician's impression of totality of response, including information about functioning and impairment, as well as relief of symptoms, from baseline.
[0050] Subset analyses. In addition, several items on the HAM-D and/or MADRS and/or DSM-IV checklist were considered in combinations of several items, as measures of change.
[0051] The combination HAM-D items were combinations of items 2 (guilt), 3 (suicide), 9 (agitation), 19 (depersonalizaton and derealization) and 21 (obsessive and compulsive symptoms). This combination is referred to as the ECDEU cognitive disturbance factor, and is a measure of cognitive disturbance.
[0052] To further evaluate effects of memantine on cognition, a combination of HAM-D item 8 (retardation) was combined with MADRS item 6 (concentration).
[0053] Other HAM-D combinations assessed were items 1 (depressed mood), 2 (guilt), 7 (work and activities), 8 (retardation and concentration), 10 (psychic anxiety) and 13 (agitation), referred to as the Bech Melancholia criteria; items 10, 11 (somatic anxiety), 12 (gastrointestinal somatic symptoms), 13, 15 (hypochondriasis), and 17 (insight regarding illness), known as the ECDEU anxiety factor criteria; items 1, 7, 8, and 14, as a measure of psychomotor retardation; and items 4-6 (insomnia-early, middle and late) as a measure of insomnia.
[0054] Statistics. The efficacy analyses were based on the ITT population using both last observation carried forward (LOCF) and observed cases (OC) approaches. For each of the parameters, descriptive statistics were presented for the actual values and change from baseline by visit. For categorical variables, frequency distributions were presented.
[0055] Patient Demographics and Baseline Characteristics. Seven of the eight patients were female. The mean age was 42 years (range: 22-71 years old). All patients were Caucasian. All patients had prior treatment with antidepressants. Seven of the eight patients had recurrent depression. The duration of major depressive disorder ranged from 2 to 43 years. At baseline, the mean MADRS score was 32 and the mean HAM-D score was 30. These scores are indicative of a population with severe depression.
[0056] Drug Treatment. All eight patients were initially given 5 mg/day and titrated over a 3-week period to a minimum dose of 20 mg/day. Patients with an unsatisfactory therapeutic response (CGI-I score greater than 2) could increase to a maximum of 40 mg/day (2 patients, 30 mg/day and 40 mg/day, respectively). One patient was titrated to 30 mg/day after Week 8, and two patients were titrated to 40 mg/day after Week 10. The mean treatment duration was 82 days (range: 57-86 days) and the mean daily dose was 18.1 mg/day.
[0057] All eight patients enrolled in the study received study medication and had at least one post baseline efficacy assessment of the primary efficacy variable, MADRS. Seven of the eight patients completed the study. One patient (#19005) was lost to follow-up after Week 8 (57 days).
[0058] Safety. Safety was assessed throughout the course of the study by monitoring vital signs and spontaneously reported adverse events.
Results
[0059] Significant improvement from baseline to Week 12 for memantine treatment was observed on the primary and all secondary efficacy variables using both the LOCF and OC approaches (see Table 1, below).
TABLE 1 Mean Change from Baseline in Efficacy Assessments MADRS HAM-D CGI-S CGI-I* LOCF OC LOCF OC LOCF OC LOCF OC Baseline 31.9 31.9 30.0 30.0 4.3 4.3 — — Week 1 −7.9 −10.5 −6.1 −8.2 −0.5 −0.7 2.7 2.7 Week 2 −12.1 −12.1 −11.8 −11.8 −0.6 −0.6 2.8 2.8 Week 3 −14.3 −14.7 — — −0.9 −1.0 2.4 2.3 Week 4 −15.6 −17.0 −16.8 −20.8 −1.3 −1.4 2.3 2.1 Week 6 −15.0 −15.0 — — −1.3 −1.3 2.4 2.4 Week 8 −18.6 −20.4 −16.8 −19.0 −1.5 −1.6 2.0 1.9 Week 10 −18.5 −16.7 — — −1.8 −1.6 2.1 2.3 Week 12 −18.5 −16.7 −17.8 −16.0 −1.5 −1.3 2.1 2.3 ITT Population. *CGI-I mean score at each week.
[0060] At week 12, the mean change from baseline to endpoint was about 18.5 on the MADRS and about 17.8 on the HAM-D, with 62.5% of patients meeting criteria as CGI-I responders.
[0061] In addition, the reduction in MADRS and HAM-D (17-, 21-, and 24-question versions) at endpoint by LOCF analyses, of a magnitude of approximately 18 points, was greater than would be expected for 8 weeks of drug exposure to a proven SSRI, escitalopram (Burke et al., J Clin Psychiatry. 2002; 63 (4): 331-6). Further, much of the therapeutic effect appeared to occur even before the full maximal dose was achieved for each patient (i.e., by Week 4), suggesting an unusually rapid onset of effect.
[0062] Specific items of HAM-D chosen for analysis (items 1, 2, 3 and 7) also showed a positive change with memantine administration.
[0063] FIG. 1 presents the change from baseline in the MADRS by visit (through Week 8), by treatment group, for studies MEM-MD-09 (present study) and SCT-MD-01, a prior study. Study SCT-MD-01 was an 8-week fixed dose study that compared 10 mg/day citalopram and 20 mg/day escitalopram, to placebo and to 40 mg/day citalopram in outpatients. Escitalopram and citalopram at the doses tested are established treatments for use in patients with MDD.
[0064] FIG. 2 presents the change from baseline in the HAM-D by visit (through Week 8), by treatment group for studies MEM-MD-09 and SCT-MD-01.
[0065] By the end of Week 8, 5 of the 7 patients responded to treatment, as measured by the MADRS and the HAM-D (responder defined as 50% improvement from baseline), and 6 of 7 patients were considered as “Very Much Improved” or “Much Improved” as measured by the CGI-I. Particularly striking was the rapid onset of relief which was marked already at the first assessment (one week). This is much faster than that measured for citalopram and escitalopram, the latter being considered the fastest onset of any SSRI.
[0066] This short latency period makes memantine a particularly suitable treatment for suicidality, as rapid relief from suicidal ideation or behavior is particularly desirable in such a patient population. Moreover, this feature makes memantine a particularly suitable treatment for patients who are afflicted with both suicidality and major depression, for whom physicians may have been reluctant to prescribe antidepressants because of the relatively long latency period, and because of reports that some SSRIs may contribute to suicidal ideation or behavior. The rapid onset of memantine coupled with its non-SSRI mode of action fills a perceived need in the art.
[0067] DSM-IV checklist. There was a reduction in the degree of symptomology in all DSM-IV categories, with a complete remission of symptoms in all patients in the categories of appetite and agitation/retardation.
[0068] CGI-I and CGI-S. After 12 weeks, there was an overall impression of improvement as measured using CGI-I in all patients with the exception of one ( FIG. 3 ). Similarly, there was a marked shift during the 12 week period of the trial; patients who were ranked as moderately to severely ill improved to “mildly depressed” or to “not depressed” (with the exception of one patient— FIG. 4 ).
[0000] Subsets
[0069] Cognitive disturbance. Although no direct measures of cognitive functioning were included, symptoms that might be the result of such a change were assessed. Each independent measure for HAM-D item 8 (retardation and concentration), MADRS item 6 (concentration difficulties), and DSM-IV criterion “h” (diminished ability to think or concentrate) improved during the 12 week treatment period.
[0070] Similarly, each measure in the HAM-D ECDEU combination, as a measure of cognition, improved with memantine treatment over the 12 week period. However, it is possible that the changes are secondary to the improvement in depressive mood and not to improvement in cognition per se.
[0071] Melancholy, anxiety, psychomotor retardation and insomnia. An improvement at week 12 from baseline was shown for all of the HAM-D item combinations specific for these criteria.
[0072] Suicide. A steady improvement in the score of item 3 of HAM-D was demonstrated throughout visit 8. One patient dropped out of the study during this time, asserting maximal improvement on this item. This further supports the suitability of memantine for treating suicidality.
[0073] Appetite. The overall scores on the two appetite items, HAM-D 12 and MADRS item 5 both showed a decrease from baseline, as did the appetite item “c” from the DSM-IV criterion list.
[0074] Safety and Adverse Events. Memantine 20-40 mg/day was safe and well tolerated. No deaths, serious adverse events or discontinuations due to adverse events were reported. The incidence of treatment emergent adverse events (TEAE) patients are provided in Table 2, below. There were no safety findings of concern for clinical laboratory parameters, vital signs or ECG values.
TABLE 2 Number of Patients Reporting Treatment Emergent Adverse Events by Preferred Term Adverse Event Preferred Term Memantine (N = 8) Patients with at least one TEAE 8 Influenza-like Symptoms 2 Dizziness 2 Headache 2 Somnolence 3 Anxiety 2 Amnesia 2 Insomnia 2 Safety Population (events reported by 2 or more patients).
Conclusions
[0075] This study demonstrates significant improvement in MDD symptomology by each of four different scales with memantine treatment, which was observed during the first assessment one week following treatment, and continued for the duration of the study. The results were robust as improvement was consistently observed across all the primary and secondary efficacy parameters including the MADRS, the HAM-D, and the CGI. In addition, the rapid onset of effect occurred prior to the completion of the 4-week titration period and the antidepressant effect of memantine appeared considerably faster than that reported for other proven antidepressants, notably citalopram and escitalopram.
[0076] In summary, the conclusion drawn from this study was that memantine at doses of 20-40 mg/day, was safe and well tolerated, and demonstrated a larger magnitude and faster onset of overall therapeutic response compared to proven antidepressants citalopram and escitalopram. In particular, because of the faster onset of relief, and because of the non-SSRI mechanism of action, the study permits the inference that memantine is particularly suited for administration to subjects suffering from suicidality, and from major depression in patients also afflicted with suicidality or suicidal ideation. Additionally, the present data support the use of memantine, at least as initial therapy, in other cases of major depressive disorder which are in need of a rapidly effective treatment.
Example 2
Evaluation Memantine on Symptoms and Behavior Associated with Major Depressive Disorder in Alzheimer's Disease
[0077] The objective of this study (MEM-MD-17) was to evaluate the safety and efficacy of memantine and memantine in combination with escitalopram in patients with depression of Alzheimer's disease.
[0078] The clinical study was conducted in two phases —12-weeks of open-label treatment with memantine (MEM) followed by 12-weeks of randomized double-blind treatment with memantine+placebo (MEM+PBO) or memantine+escitalopram (MEM+SCT).
Methods
[0079] Study design. Patients were started on memantine 5 mg/day which was increased to 10 mg/day at end of Week 1. The dose could be further increased to a maximum of 20 mg/day in patients with inadequate response in weekly increments of 5 mg. At end of Week 12, patients were randomized to one of the two treatment groups: MEM+PBO or MEM+SCT. The dose of memantine during the double-blind treatment period was fixed at the same level as at the end of Week 12 and the dose of escitalopram was fixed at 10 mg. Dose adjustments during the double-blind period were not permitted.
[0080] Patient Population. A total of 15 patients were enrolled in 2 sites. Three of the 15 patients discontinued during the open-label phase. The remaining 12 were randomized to double-blind treatment, 5 in the MEM+PBO treatment group, and 7 in the MEM+SCT treatment group. A total of 10 patients completed the study.
[0081] Endpoints. Several rating scales were used to assess efficacy for depression. The Cornell Scale for Depression in Dementia (CSDD); the HAMD; and the MADRS. The HAMD and MADRS have been described above.
[0082] CSDD. This is a 16 question scale which is subdivided into five sections: (A) Mood-Related Signs (questions 1-4); (B) Behavioral Disturbances (questions 5-8); (C) Physical Signs (questions 9-11); (D) Cyclic Functions (questions 12-15); and (E) Ideational Disturbances (questions 16-19). Question 16 is explicitly directed to suicidal ideation. The scoring system ranges from a=unable to evaluate; 0=absent; 1=mild to intermittent; and 2=severe.
[0083] Statistics. The efficacy analyses were based on the ITT population using both last observation carried forward (LOCF) and observed cases (OC) approaches. For each of the parameters, descriptive statistics were presented for the actual values and change from baseline by visit. For categorical variables, frequency distributions were presented.
Results
[0084] The extent of improvement was similar to that observed in the previous open-label study with memantine in depressed patients (Study MEM-MD-09) which enrolled patients with moderate to severe depression.
[0085] Suicidality. Questions 16, 3 and 10, on the CSDD, HAMD, and MADRS respectively are specifically directed to suicide. Descriptive statistics are shown for suicide items in CSDD, HAMD and MADRS scales. Table 3 presents the mean change from baseline to Week 12 for all 15 patients who were enrolled in the study and received memantine. Table 4 presents the mean change from baseline at Week 12 and Week 24 for the 5 patients who received memantine throughout the study.
TABLE 3 Change from Baseline to Week 12 (LOCF) in Suicide Items ITT Population Memantine (N = 15) Baseline Change at Week 12 CSDD Item #16 0.4 −0.3 MADRS Item #10 0.9 −0.6 HAMD Item #3 0.5 −0.5
[0086]
TABLE 4
Change from Baseline to Week 24 in Suicide items
ITT Population Memantine (N = 5)
Change at
Change at Week
Baseline
Week 12
24
CSDD item #16
0.4
−0.4
−0.3
MADRS item #10
1.0
−1.0
−0.5
HAMD item #3
0.8
−0.8
−0.5
[0087] Based on the change from Baseline at Weeks 12 and 24, memantine treatment led to modest but consistent numerical improvement in suicidality as measured by 3 different depression rating instruments.
[0088] As evidenced above, treatment with memantine for 12 and 24 weeks demonstrated a trend towards reduced suicidal thoughts and ideation.
[0089] Patents, patent applications, publications, product descriptions, and protocols are cited throughout this application, the disclosures of which are incorporated herein by reference in their entireties for all purposes.
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The present invention relates to the treatment of major depressive disorder (MDD), and the prevention of suicidality associated therewith, using the uncompetitive NMDA receptor antagonist memantine.
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CROSS REFERENCE TO RELATED APPLICATIONS
The present invention is a continuation-in-part of application Ser. No. 08/920,732, filed Aug. 29, 1997, now U.S. Pat. No. 5,865,144.
BACKGROUND OF THE INVENTION
The present invention relates to caging systems for laboratory animal care and more particularly to a cage and system which has controlled ventilation, waste containment and does not require bedding.
Most all existing ventilated rodent cage systems are made with plastic solid-bottom cages. Clear cages are used so it is possible to inspect the condition of the inside of the cage without disturbing the animals. The cage ensemble generally consists of a metal wire bar lid containing a feed hopper and water bottle capabilities and a plastic top that holds a piece of filter media. The wire bar lid is convenient to use because feed and water bottles in a cage can be moved to a clean cage in one motion. The cages are contained in a rack that holds a plurality of cages either single or double sided. An automatic water system introduces water into the cage for the rodent using lixits or water valves located either outside or inside the cage. It must be monitored for proper water pressure and must be flushed periodically. Problems of leakage, high intracage humidity levels and cage flooding are associated with automatic watering systems. A plenum, either a separate duct system or made up of components of the rack (i.e. the shelves or the tubing uprights), supply the cage with filtered air through a cage mounted air supply diffuser. The front of the cage, perimeter of the cage lid and the cage body (where the leakage occurs) is open to the environment of the animal room. The air flow is either transversely across the cage or from an inlet in the side or top of the cage to an outlet in the junction of the top and body or top of the cage. A removable bottom portion for animal waste has been disclosed but air flow through the waste tray has not been reported.
Exhausted air is drawn either through a plenum system or into a "U" shaped metal exhaust collar surrounding three sides of each cage or a metal or plastic canopy. It is drawn into a horizontal exhaust manifold on each shelf, travels up the vertical exhaust plenum, then finally into a filtered exhaust system. This system, designed for limited capture of exhausted cage air, allows contaminated air to escape into the room from the cage lid perimeter and may present health problems for personnel. The systems scavenge room air and introduce air into the room, thus disturbing the macroenvironment. Present systems allow the pressurized air to blow any contaminants on the filter media into the room. Another type allows contaminants on the filter media to blow into the cage.
The applicant is aware of the following U.S. patents which are related to cages for laboratory animals:
______________________________________Inventor(s) U.S. Pat. No.______________________________________Fricke 2,467,525Fuller et al 3,063,413Barney 3,397,676Holinan 3,924,571Gland et al 4,085,705Gass 4,154,196Nace 4,201,153Thomas 4,402,280Picard et al 4,435,194Sedlacek 4,480,587LoMaglio 4,526,133Spengler 4,528,941Peters et al 4,798,171Niki 4,844,018Spina 4,869,206Niki et al 4,940,017Sheaffer 4,989,545Niki et al 5,003,022Niki et al 5,048,453Coiro, Sr. et al 5,148,766Coiro, Sr. et al 5,307,757Sheaffer et al 5,311,836Harr Re 32,113Semenuk D 351,259Semenuk D 383,253______________________________________
Current ventilated caging systems, of which the applicant is aware, for laboratory animal care and use in biomedical research/testing is suboptimal because of the lack of environmental control. Also, animal activity over contact bedding material, husbandry techniques and laboratory procedures generate aerosols and allergens that spread through cage leakage into the work area and pose a risk of contamination to the animals and to the workers. In addition to suspension of particulates, chilling and dehydration of neonates, hairless and nude strains, existing ventilated racks have provoked animal losses due to hypothermia. While the systems currently in use may provide some biological exclusion and save labor, the use of bedding material, the lack of animal comfort, the leakage problem, and the high cost of maintenance pose serious problems in research.
In present systems, bedding and nesting materials are placed directly on the floor of the solid-bottom cages, since rodents are nesting and burrowing animals. The primary requirements of bedding materials are: (1) the material must not be harmful to the animal; (2) it must be capable of absorbing moisture without causing dehydration of newborn animals, (3) it must not create excessive dust, (4) it must be economical to use and dispose of. So far, existing bedding materials fail to achieve these standards. A major goal is eliminating the cost of bedding and bedding-related activities including bedding ordering, receiving, storage, dispensing, autoclaving, dust removal, bedding dumping, cage-scraping, bagging, disposal and finally removal of soiled bedding. Dispensing of used bedding can engender both problems of storage and aerosol contamination including allergen exposure. Expensive engineering and operation systems are required to prevent these problems. Modern bedding disposal systems are basically vacuums, which prevent contaminated particles from getting into the air that workers breathe. The location of such systems throughout a facility and the transportation of waste bedding are major operational expenses. Moreover as greater demands are put on available space, clean bedding storage add a burden to husbandry-related costs. Thus, there is a need for a laboratory animal cage and a system of cages which solve these problems.
BRIEF SUMMARY OF THE INVENTION
It is an object of the invention to provide a cage for laboratory animal care which has a laminar air flow from top to bottom to permit a healthy environment.
It is a further object of the invention to provide a cage for laboratory animal care which permits waste products to pass through the floor of the cage and requires no bedding in the cage.
It is still another object of the present invention to provide a cage for laboratory animal care which can exhaust excess water automatically preventing cage flooding.
It is yet another object of the present invention to provide a system of cages in a rack in which the air flow through each individual cage is controlled, adjustable by the user and there is no cross contamination between the cages.
It is still a further object of the present invention to provide a cage for laboratory animal care to permit optimal animal housing flexibility, protect animal and occupational health by providing a barrier at cage level for exclusion, containment or both, validate data reproducibility; and provide for optimal animal comfort and well-being. It will also avoid animal limb soreness and stiffness as found in wire bottom cages, promote rapid waste desiccation, eliminate waste contaminants accumulation, save husbandry-related costs, and convey a positive image to the public.
In accordance with the teaching of the present invention there is disclosed an animal cage for laboratory purposes. The cage has a floor means provided with a plurality of perforations formed therein, the perforations being interspersed with a plurality of upwardly-projecting convex projections to assure that the solid and liquid waste from the animal will substantially fall through the perforations in the floor means. The waste will not substantially cling to the floor means adjacent to the perforations. A removable waste tray is disposed below the floor to receive the animal waste.
In further accordance with the teachings of the present invention, there is disclosed a cage for laboratory animal care. The cage has a body having four walls and a perforated floor defining living space for the animal. A waste tray is detachably connected beneath the perforated floor of the body. A lid is removably connected to the body. There is provided means for circulating clean air through the cage. The cage is air tight.
Also, there is disclosed a cage for laboratory animal care. The cage has a body having four walls and a floor defining living space for the animal. A lid is removably connected to the body. An air inlet port is formed in the lid. An air outlet port is formed in one of the walls of the body. Means are provided to circulate air between the air inlet port and the air outlet port.
Additionally, there is disclosed a cage for laboratory animal care. The cage has a body having four walls and a perforated floor defining living space for the animal. A waste tray is detachably connected beneath the perforated floor of the body. The waste tray has an air outlet port formed therein. A lid is removably connected to the body, the lid having an air inlet port formed therein. A clean air supply is connected to the air inlet port wherein the clean air flows through the air inlet port, into the lid and the body, the clean air flowing laminarly downwardly through the living space for the animal, through the perforated floor, across the waste tray and out the air outlet port. The air flow removes from the cage, particulate matter, allergens and gases associated with waste products.
In another aspect, there is disclosed a ventilated cage system for laboratory animal care having at least one cage having a body. The body has a top and a bottom. A separate lid is connected to the top, an air inlet port being formed in the lid. A detachable waste tray is connected to the bottom, wherein each cage is air tight. An air outlet port is formed in the waste tray. A rack is provided for supporting the at least one cage. An air supply introduces air into the air inlet port in the lid. The air flows laminarly from the lid of each cage, through each cage, through the waste tray of each cage, and through the air outlet port of each waste tray. In this manner, fresh air is maintained in the at least one cage and waste air is removed from the at least one cage.
In still another aspect there is disclosed a cage system for laboratory animal care including at least one cage having a body having a top, four side walls and a perforated floor. A detachable waste tray is connected to the body beneath the perforated floor of the body. A lid is removably connected to the top of the body. A rack and means for supporting the at least one cage on the rack is provided.
These and other objects of the present invention will become apparent from a reading of the following specification taken in conjunction with the enclosed drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front elevation view of a rack in which are mounted a plurality of cages for laboratory animal care of the present invention.
FIG. 2 is a side elevation view of two cages mounted vertically and connected to the air supply system.
FIG. 3 is a schematic diagram of the ventilated cage system of the present invention.
FIG. 4 is a perspective view of the cage.
FIG. 5 is an exploded view of the cage.
FIG. 6 is a partial cross section view of the cage showing the sealant means.
FIG. 7 is a top plan view of a portion of the bottom of the cage.
FIG. 8 is a cross-section view of a portion of the bottom of the cage along the lines 8--8 of FIG. 7 showing an animal in the cage.
FIG. 9 is a perspective exploded view of a cage of an alternate embodiment viewed from the top.
FIG. 10 is the embodiment of FIG. 9 viewed from the bottom.
FIG. 11 is a perspective view of the waste tray showing the water overflow valve formed thereon.
FIG. 12 is a perspective view of the cage with a water bottle attached externally.
FIG. 13 is an exploded perspective view of another embodiment of the cage with a non-perforated floor.
FIG. 14 is a partial cross-section end view showing the cage supported on the rack with the lid removed and the waste tray detached.
FIG. 15 is an end view showing the cage supported from the rack with the lid removed.
FIG. 16 is an end view showing the waste tray and lid attached to the body and the waste tray supported on the rack.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to FIGS. 1-5, a plurality of cages 10 are supported on a rack 12. Preferably, the rack 12 is a frame mounted on wheels with a plurality of cage suspension brackets having one or more cages 10 on each bracket.
Each cage 10 is individually connected to an air supply 14 which serves all of the cages 10 in the rack 12. A filter 16 is provided in the air supply. The filter may be a HEPA filter and may also include a prefilter. A blower 20 is disposed in the air supply system to move the air through the cages 10 and the filter 16. The filtered air enters a manifold 18 which is connected by hoses to the individual cages 10. The filter system removes particulate matter and pathogens larger than 0.003 microns in size.
Each cage 10 has a body 22 having four walls and a bottom surface 24 to define a living space for the laboratory animals. A separate lid 26 is removably connected to the top of each body 22. An air inlet port 28 is formed in each lid 26. The bottom surface of each lid 26 has a plurality of spaced-apart orifices 30 formed therein. Preferably, the orifices are distributed over the entire area of the bottom surface of each lid 26.
It is preferred that all corners and the intersections of walls and bottom surface of the cage be rounded to reduce the accumulation of dirt and waste and to facilitate cleaning of the cage. It is preferred that the body of the cage be made of high temperature plastic and that the cage be transparent to permit observation of the animal within the cage.
It is preferred that a feeder plate 32 be disposed between the lid 26 and the body 22 of each cage 10. The feeder plate 32 may be a frame structure which has an angled portion 34 which extends downwardly into the living space of the animal within the body 22 of the cage. The angled portion 34 may have a "V" shape. The feeder plate may be metal or plastic. The feeder plate 32 supports containers of food, water and/or special liquid supplements 38 for the animal. The perforated feeder plate 32 also optimally acts as an air diffuser creating a plenum when coupled with the lid 26.
The body surface (or floor) 24 of the cage 22 is perforated. The floor 24 is formed having a plurality of spaced-apart raised domes 40. Each dome is disposed among a plurality of spaced-apart perforations 42 (FIGS. 7 and 8). Although not limited to these sizes, it has been found that a satisfactory floor has domes 40 which are approximately 0.5 inches in diameter and approximately 3/32 inch in height above the surface of the floor. The perforations 42 are approximately 5/16 inch in diameter. Solid and liquid waste from the animal is deflected from the domes 40 and through the perforations 42 into the waste tray 44. The floor 24 of the present invention replaces wire floors as used in cages of the prior art and solves problems which were caused by the wire floors such as injury to the feet of the animals.
The waste tray 44 is a tray having walls and a bottom which covers the entire bottom surface 24 of the cage 10. Preferably, a gasket 46 is fitted between the waste tray 44 and the body 22 of the cage 10 and another gasket 48 between the lid and the body 22 of the cage 10 (FIG. 6). The waste tray 44 is attached onto the cage 10 and is easily installed and removed by applying pressure on the waste tray 44 to snap on and off over the gasket 46. In this manner the waste tray 44 can be easily replaced with a clean tray saving costly man hours. The gasket 48 and 46 may be any sealable closure between the body 22 and the lid 26 and the body and the waste tray. By use of similar sealing techniques known to persons skilled in the art, each cage system is air tight and the air flow within each cage is restricted to the specific cage. There is no leakage of air from any cage into the room in which the cage is housed nor is there any air interchange between any cages. Cage to cage contamination is prevented.
The waste tray 44 further has an outlet port 50 formed therein through which the air exiting the cage 10, may flow. Also, water or liquid waste products from the animal may exit from the outlet port 50. The waste air, after flowing out of the outlet port 50 is directed preferably through a hose, to the exhaust filter 16 and the particulates and toxic gases are removed. Air is then resupplied through the inlet filter 16 to the cage system under an approximately neutral to slightly positive pressure. An adjustable blower 52 in the air supply system is used to control the rate of air flow as needed depending upon the desired conditions and the strain of animal within the cage. Due to the configuration of the cage system and the perforated lid 26 and perforated floor 24 of the individual cage, the air flow through each cage is laminar from the top of the cage to the bottom of the cage (FIGS. 2 and 3). In this manner, the animal is continuously provided with fresh air. The air, after passing through the body 22 of the cage 10, sweeps over any waste products which may be in the waste tray 44 and removes ammonia and other vapors from the system.
A water valve 54 is fitted into the body 22 of the cage 10 and is connected to a water supply 56. The water valve 54 may be manually or automatically controlled to supply the animal with water. The perforated floor 24 of the cage and the outlet port 50 of the waste tray 44 permit the water to drain from the cage and prevent flooding. The excess water flows to a reservoir 58 and to a drain to be removed from the system.
FIG. 3 diagrammatically depicts the air flow in the system by arrows having longer shafts and the water flow by arrows having shorter shafts.
The cages 10 may be made in a variety of sizes to accommodate laboratory animals of varying sizes.
The intracage airflow system serves as an effective barrier system by preventing the transmission of contaminated particulates and aerosols from cage-to-cage and rack-to-rack. The system uses airflow to prevent or control airborne infection of laboratory animals. The flow of air sweeps the bedding-free cage of gases, particulate matter, allergens and other contaminants down into the attached waste tray, keeping the cage environment cleaner than other filtered air cage designs. The HEPA filter (both supply and exhaust) is connected to a baffling system which reduces turbulence and directs the airflow into a distribution plate. This plate houses the connections for the flexible tubing that act as a plenum and either delivers or exhausts air from each cage. Preferably, each tube is of equal length thus supplying or exhausting each cage the same no matter where it is located on the rack. Each tube is housed in a hollow shelf and preferably terminated at the cage with a stainless steel nipple. The air flow to each individual cage is automatically balanced to provide approximately the same air flow into each cage in the system. This may be accomplished by controlling the lengths of the tubing, baffles, varying duct size and other means known to persons skilled in the art.
FIGS. 9 and 10 show another embodiment of the cage 10. The body 22 has four walls and a perforated floor 24 to define the living space for the laboratory animal. A lid 26 is removably connected to the top of the body 22 and a waste tray 44 is detachably connected to the body 22 beneath the floor 24. An air inlet 28 is formed in the lid and an air outlet 50 is formed in the waste tray 44. Preferably, the bottom surface of the lid 26 has a plurality of spaced-apart orifices 30 formed therein to facilitate laminar flow of the air through the cage 10. A water valve 54 is formed in one of the walls of the body 22. The cage 10, preferably is formed of a transparent plastic. Thus, the embodiment of FIGS. 9 and 10 is very similar to the embodiment of FIGS. 4 and 5. However, the feeder preferably is omitted from the embodiments of FIGS. 4 and 5, although it could be included. The lid 26 and the waste tray 44 have handles 60 formed thereon to assist in removing and attaching the lid 26 and the waste tray 44 from the body 22. Also, it is preferred that the waste tray 44 has a water overflow outlet 62 formed therein to drain water and liquid waste from the waste tray 44 (FIG. 11). It is preferred that the water overflow outlet operate automatically so that there is very little accumulation of liquid in the waste tray 44. If desired, a tube or hose 64 may be connected to the water overflow outlet 62 externally of the waste tray 44 to direct the water and waste liquid to a collector (not shown).
As previously described, the cage 10 has a source of water 56 connected to the water valve 54 to provide automatic water feed to the laboratory animal. As shown in FIG. 12, a water bottle 38 may be connected to the water valve 54 where the water bottle 38 is external to the cage 10. This arrangement permits the water to be replenished when necessary without opening the cage 10. Each cage 10 may be disposed in the rack 12 with the respective water valve 54 directed outwardly from the rack 12 such that each externally connected water bottle 38 is readily accessible to an attendant. This construction is especially useful for situations where special diets or additives in the water are provided to the laboratory animals and the water bottles are easily and rapidly accessible.
In another embodiment and as shown in FIG. 13, the floor 66 is imperforate and consequently, has no detachable waste tray. A separate lid 26 is removably connected to the top of the body 22. An air inlet port 28 is formed in the lid 26 and an air outlet port 50 is formed in one of the walls of the body 22. Preferably, the air outlet port 50 is located close to the floor 66. The air flow pattern within the cage, preferably, is across the top in the lid and downwardly throughout the cage. Thus, fresh air is provided throughout the cage and vapors from waste products are exhausted out of the air outlet port 50. In this embodiment, the water valve 54 is preferably in a wall of the body 22 opposite from the wall in which the air outlet port is located. This is because air supply and air exhaust are constructed in plenums internally in the rack 12 to be centralized to all cages 10 and each cage is placed in the rack 12 with the air inlet port 28 and the air outlet port 50 on each cage adjacent to and connected to the plenums. By having the water valve 54 on a wall opposite from the air inlet and air outlet valves, the externally connected plurality of water bottles 38 are arranged outwardly of the rack for ready access by the attendant.
The cages 10 of the present invention may be supported in the rack 12 in several ways (FIGS. 14-16). The lid 26 is removed and the top of the body 22 may be attached to a shelf 66 of the rack using tracks, clips or other means known to persons having ordinary skill in the art. The waste tray 44 is separated from the body 22 and the spaced-apart waste tray 44 is supported on the shelf 68 directly beneath the floor of the suspended body 22 (FIG. 14). Alternately, the body 22 may be supported from the shelf 68 and the waste tray 44 remain detachably connected to the body 22 (FIG. 15). In this configuration, the hose 64 from the water overflow outlet 62 is readily directed to a collection container (not shown). In still another configuration (FIG. 16), the cage with the lid 26 and waste tray 44 attached, is supported by a shelf 68 beneath the cage 10 without contacting the shelf 68 above the cage 10, such that the waste tray is directly supported by the shelf beneath the cage.
Devices may be secured (snap-on) to the perforated floor. These devices are made from appropriate non-toxic material that favors isolation, nest building and thigmotactic behaviors, as well as providing protective or escape mechanisms for submissive animals. The bedding-free environment prevents the secondary dust problem of using conventional bedding material. Additionally, the elimination of bedding results in considerable cost savings. A central HEPA filtering unit may be mounted on each rack, room mounted to supply several racks or centrally located in a facility to supply many rooms with racks. These systems are all equipped with visual and audible alarms and monitors to alert facility personnel of problems or failures of air flow, temperature, humidity, water leakage, or filters. A battery-operated power supply system can be provided in the event of a power failure.
In summary, the cage system of the present invention provides the following unique features:
bedding free cage uses a perforated floor
a plenum lid
the lid has spaced-apart orifices for air flow
an adjustable blower to vary the air supply and exhaust
unit can accommodate various animal strains by user adjusted airflow
separates air and water from the exhaust (prevents cage flooding)
air is supplied into top of cage and removed at bottom. Air flow direction is laminarly downward.
a snap-on waste tray is provided
closed system maintains an approximately neutral pressure in the cage
airflow is delivered and exhausted via a unique distribution system which automatically balances the airflow in each cage
maintains and monitors temperature and humidity at cage level
snap-on enrichment devices
battery back-up for the HEPA unit
monitors and alarms when problems occur
centralized air supply at room or facility level
uses non-toxic material or devices for nesting
sealed cages
a water valve connected to a source of water
a water bottle external to the cage connected to the water valve
water and waste liquid automatically drain from the waste tray
alternate means for supporting the cages in the rack.
Obviously, many modifications may be made without departing from the basic spirit of the present invention. Accordingly, it will be appreciated by those skilled in the art that within the scope of the appended claims, the invention may be practiced other than has been specifically described herein.
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A cage system for laboratory animal care has a plastic cage with a molded perforated-bottom, a snap-on plenum cage top, a cage top feeder lid and a snap on waste tray. The floor of the cage is shaped with rounded perforations and domed protrusions to deflect both liquid and solid waste down to the attached waste tray. A filtered air supply is introduced into the lid of the cage and passes through orifices in the bottom of the lid, flowing laminarly through the body of the cage and out perforations in the floor over the waste tray. A water supply system for the cage is provided. No bedding is required in the cage. The system is air tight and air in any one cage is isolated from air in all other cages in the system which can be mounted on a rack. A drain for liquids is provided in the waste tray. In an alternate embodiment, the cage has an imperforate floor. A plurality of cages are supported in a rack. Several configurations to support the cage within the rack are provided.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention is directed to the field of spinning machines. More particularly, the present invention relates to the fine cleaning of textile fibers and to a method and a device for performing the method.
2. Description of the Related Art
Textile fibers, particularly cotton fibers, are subjected to coarse cleaning after the fiber bales have been opened, during which the coarse contaminants are removed. The fibers are then subjected to a fine cleaning. With the fine cleaning, all the particles of dirt remaining in the fibers after the coarse cleaning should be removed as much as possible. After the fine cleaning, the fibers are then transported to the next preparation step of the spinning process, for example, to a carding machine.
In the fine cleaning machine, the fibers, in the form of a fiber bat, are conveyed over a toothed, central opening roller through various cleaning steps. During the rotation of the opening roller, the bat is continuously subjected to centrifugal force and, thereby, the contamination particles are concentrated in the outer layers of the bat. In one of the cleaning steps, the centrifuged bat is guided under separating blades in such a way that the uppermost layer with the concentration of particles is separated from the remainder of the bat.
Typically, a guide element is provided which projects into the bat in front of a separating blade, that is, against the transport direction of the fibers. On this guide element the bat is deflected inwardly, i.e., against the centrifugal force, whereby the concentration of the contamination particles is increased. The succession of separating blades and guide elements are repeated at least twice within the same cleaning step.
So that a cleaning step of this type, with separating blades and guide elements, can operate optimally for every fiber origin and for every blend of fiber origin, it must be appropriately adjustable so that all the contamination particles and, as much as possible, only the contamination particles are separated from the fibers.
The fine cleaning machines at the present stage of technology are manually adjustable in such a way, that through adjusting screws or other means, the position of the separating blades and guide elements are adjustable and such that guide elements of different sizes can be fitted. Since every adjustment and setting requires manual intervention with the machine, such adjustments and settings tend to be inconvenient and costly. Further, it is only possible to reset the positions of the separating blades and guide elements for different fiber origins or blends of origins during a machine stoppage.
SUMMARY OF THE INVENTION
It is an object of the invention to provide a device for the fine cleaning of textile fibers with which the fiber bat, rotating on an opening roller, is guided past separating blades and guide elements for the purpose of cleaning of the fiber bat. The device is to be remotely controlled and finely optimized and set for a fiber origin or a blend of fiber origins without manual intervention. Further, the device is to be capable of adjusting the settings of the separating blades and guide elements during the cleaning process cycle. The number of parameters with can be set, and the range of adjustment, are to be of such a type that the optimal fine cleaning can be carried out for a broad spectrum of fiber origins. The settings for all the pairs of separating blades and guide elements comprising the same cleaning steps are to be possible with the same setting mechanism.
It is a particular object of the invention to provide a device for use in a cleaning process of textile fibers, adapted for use in conjunction with an opening roller, the device including:
a plurality of separating blades adapted to be spaced from the opening roller during the cleaning process;
a plurality of guide elements adapted to be spaced from the opening roller during the cleaning process; and
means for adjustably positioning a plurality of the separating blades and the guide elements during the cleaning process.
It is an additional object of the invention to provide a device for use in a cleaning process of textile fibers, adapted for use in conjunction with an opening roller, the device including:
a plurality of separating blades adapted to be spaced from the opening roller during the cleaning process;
a plurality of guide elements adapted to be spaced from the opening roller during the cleaning process; and
means for remote positioning a plurality of the plurality of separating blades and the plurality of guide elements.
According to a specific aspect of the invention, the separating blades and the guide elements are adapted to be located in respective positions in relation to the opening roller, the positioning means includes (i) means for adjusting together respective positions of each of the plurality of the separating blades and (ii) means for adjusting together respective positions of each of the plurality of the guide elements.
According to another aspect of the invention, the positioning means includes means for adjusting respective positions of the separating blades and means for adjusting respective positions of the guide elements, the device further including means for connecting (i) the means for adjusting respective positions of the separating blades and (ii) the means for adjusting respective positions of the guide elements.
More specifically, the connecting means includes a common support frame upon which the plurality of separating blades and the plurality of guide elements are mounted, for selectively adjustably positioning all of the separating blades and the guide elements.
Still further according to the invention, the connecting means includes means for positioning a plurality of the separating blades and the guide elements to a motorized control assembly for selectively remotely adjusting respective positions of the separating blades and the guide elements.
Further, the connecting means includes a lever unit, including a plurality of levers, each of which is operatively connected to one or more of the separating blades and one or more of the guide elements for performing a respective adjustment parameter.
Specifically, according to the invention, the positioning means includes means for selectively setting three respective parameters of adjustment: (i) a distance between the separating blades and the opening roller; (ii) a distance between the guide elements and the opening roller; and (iii) a distance between at least the first separating blade and the first guide element.
According to a particular embodiment of the invention, the positioning means further includes a plate with respect to which at least the first and second separating blades and the first and second guide elements are mounted for movement, the means for selectively setting the distance between the separating blades and the opening roller includes a first lever connected for selectively moving the plate to affect movement of at least the first and second separating blades and the first and second guide elements in a generally radial direction toward and away from the opening roller.
In this embodiment, the means for selectively setting the distance between the guide elements and the opening roller includes a second lever and means for operatively connecting the guide elements and the plate for moving at least the first and second guide elements independently of the first and second separating blades in a generally radial direction toward and away from the opening roller.
Still further, the means for selectively setting the distance between at least the first separating blade and the first guide element includes a third lever and means for operatively connecting at least one of the first separating blade and the first guide element for affecting relative movement between the first separating blade and the first guide element in a direction generally perpendicular to the radial direction.
It is a still further object of the invention to provide a method of cleaning textile fibers, adapted for use in conjunction with an opening roller, the method including the following steps:
positioning a plurality of separating blades with respect to the opening roller;
positioning a plurality of guide elements with respect to the opening roller;
rotating the opening roller for conveying a quantity of textile fibers along an outer periphery of the opening roller; and
adjusting respective positions of the separating blades and/or the guide elements during rotation of the opening roller.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and additional objects, characteristics, and advantages of the present invention will become apparent in the following detailed description of preferred embodiments, with reference to the accompanying drawings which are presented as non-limiting examples, in which:
FIG. 1 is a diagram of the device according to the invention, taken in a direction parallel to the axis of rotation of the opening roller;
FIG. 2 is a partial view of the device according to the invention, taken in a direction which is perpendicular to the axis of the opening roller;
FIG. 3 is a perspective view of the lever unit, comprising a partial device for the adjustment of the space between the entire device and the beater circle;
FIG. 4 is a view similar to FIG. 3, illustrating a partial device for the adjustment of the space between the guide element and the beater circle;
FIG. 5 is a view similar to FIG. 3, illustrating a partial device for the adjustment of the space between the guide element and the separating blade; and
FIGS. 6, 7, and 8 illustrate the step-by-step assembly of the device according to the invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
FIG. 1 shows the device according to the invention with all of its component parts. Shown therein is an exemplary embodiment with two separating blades and three guide elements. Other numbers of separating blades and guide elements could alternatively be provided within the scope of the invention.
On the extreme outside of the periphery of a toothed opening roller 1, the so-called "beater circle" S, the fiber bat is moved to be cleaned by the device according to the invention in the direction of the heavy arrows. In the transport direction, the bat, which is previously subjected to the centrifugal force before the particular cleaning device according to the invention, and through which the contamination particles have concentrated in the outside zone, is first passed under a guide element 10.1. The guide element projects into the transport path of the fiber bat and deflects the bat inwardly, that is, against the centrifugal force, which thereby further intensifies the radial separation into contaminants and fibers.
A separating blade 9.1 follows the guide element in the transport direction of the fibers. The bat is passed beneath separating blade 9.1 and, by means of this arrangement, is separated into a fiber portion and a contamination portion. A second guide element 10.2, a second separating blade 9.2, and a third guide element 10.3 follow the separating blade 9.1.
So that the device according to the invention can be set for fibers from different origins or blends from different origins, the following dimensions can be set:
the space 1 between the separating blades 9.1 and 9.2 and the beater circle S;
the space 1 between the guide elements 10.1, 10.2, and 10.3 and the beater circle S; and
the space 1: between each guide element 10.1 and 10.2 and a respective separating blade 9.1 or 9.2.
In FIG. 1, three levers 2, 4, and 6 are also shown, with the help of which the aforementioned three spaces 1 1 , 1 2 , 1 3 , can be remotely set through a motorized drive. For example, it is contemplated that each of the levers could be operatively connected with a respective fluid-actuated jack which is selectively controllably positionable by means of a controller. Upon a determination that a fiber bat of a particular origin, or blend of origins, is to be cleaned, the appropriate control signal(s) would be sent to the controller(s) for the respective jacks for appropriately positioning any number or all of the levers 2, 4, and 6, based upon the fiber origin, the blend of fiber origins, or other known characteristic of the fiber or the fiber bat. It is also contemplated that the respective levers 2, 4, and 6 could be remotely manually operated to appropriately set the aforementioned spaces 1 1 , 1 2 , 1 3 .
With more specific reference to the motion of the lever unit, when the lever 2 moves about axis B, as shown with dash-dotted lines in FIG. 1, then the entire device moves away from the beater circle, that is, 1 1 and 1 2 become greater to the same extent. The respective positions of the lever 2 and the separating blades 9.1 and 9.2 shown in FIG. 1 represent their nearest positions to the beater circle during operation of the cleaning device of the invention.
When the lever 4 is moved about axis C, as shown in FIG. 1 with dash-dotted lines, then the guide elements 10.1, 10.2, and 10.3 move away from the beater circle, while the separating blades 9.1 and 9.2 retain their positions, that is, 1 2 becomes greater while 1 1 remains the same. The respective positions of the lever 4 and the guide elements 10.1, 10.2, and 10.3 shown in FIG. 1 represent the nearest positions to the beater circle with relation to the separating blades.
When the lever 6 is moved about axis G, as shown in FIG. 1 with dash-dotted lines, then all of the guide elements 10.1, 10.2, and 10.3 move in the transport direction of the bat, without alteration of their own radial positions or that of the separating blades 9.1 and 9.2 relative to the beater circle S. In other words, each of the guide elements 10.1, 10.2 move against a respective one of the separating blades 9.1, 9.2 and, thereby , distance 1 3 becomes smaller. In the position of the lever 6, the guide elements 10.1, 10.2, 10.3, and the separating blades 9.1, 9.2, distance 1 3 has the greatest possible value.
Variations of the embodiment of the invention shown in FIG. 1 are contemplated. For example:
the first element 10.1 can be omitted;
a third separating blade can follow behind the third guide element 10.3, i.e., the separating device can consist of three pairs, each comprising one guide element and one separating blade; and
the entire cleaning step can comprise more than three pairs, each comprising one separating blade and one guide element.
FIG. 2 shows the device according to the invention from a direction which is perpendicular to the axis of the opening roller 1. From this, it can be seen how the device according to the invention is arranged on the front face of the opening roller.
The face of the opening roller is covered by a housing 11. The lever unit for the operation of the setting of the guide elements and the separating blades, which is explained in greater detail below in conjunction with the remaining figures, is fitted on the side of the housing 11, which faces away from the opening roller. The separating blades 9.1 and 9.2, as well as the guide elements 10.1, 10.2, and 10.3 extend parallel to the axis of the opening roller 1 over their entire length. Neither the separating blades nor the guide elements can be seen in FIG. 2. However, the three pairs of pins L1/M1, L2/M2 and L3/M3 can be seen, which make the connection between the lever unit and the guide elements 10.1, 10.2 and 10.3. Likewise, the two pairs of pins J1/K1 and J2/K2 which connect the lever unit with the separating blades 9.1 and 9.2 are also shown.
The pins L1/M1, L2/M2, L3/M3, and J1/K1, J2/K2, as well as B, C, G, I, H, and E are generally represented in FIG. 2 with dashed lines.
A lever unit on the opposite face of the opening roller is contemplated, which would be formed as a mirror image of the lever unit shown in FIG. 2. In this case, this lever unit could be operatively connected in parallel with the aforementioned motorized drive, although both lever units could be activated by a common controller.
The lever unit consists of three devices, each for the setting of a respective cleaning parameter 1 1 , 1 2 , 1 3 . Thereby, the lever 2 and the plate 3 comprise a first device for the radial setting of the entire device (i.e., controlling 1 1 and 1 2 together) on which all the other parts of the device are fitted.
In addition to the lever 4, an intermediate lever 5 and a transverse lever 8 comprise a second device for the setting of the radial position of the guide elements 10.1, 10.2, and 10.3 (i.e., controlling only parameter 1 2 ).
In addition to the lever 6, a transverse lever 7 comprises a third device for setting the spacing between the guide elements and the separating blades (i.e., controlling parameter 1 3 ).
FIG. 3 illustrates the device for setting the spacing between the entire device and the beater circle S (for setting the parameters 1 1 and 1 2 ). The pair of pins J1/K1 and J2/K2 which rigidly connect the plate 3 with the separating blades 9.1 and 9.2, extend parallel in the housing 11 in guides Z, (see also FIGS. 1 and 2), which run parallel to the radius of the opening roller 1 through the middle of the plate 3. Pin C is pivoted on the plate 3 and connects the plate with the lever 2. When the lever 2 swivels on the pin B on the housing 11, the plate 3 moves in guides Z mentioned above. The slippage resulting from such a movement of the pin C moves this along the appropriate slot in the lever 2. The two separating blades 9.1 and 9.2 and the guide elements 10.1, 10.2, and 10.3 move in the radial direction of the opening roller 1.
FIG. 4 illustrates the device for setting the spacing between the guide elements 10.1, 10.2, and 10.3 and the beater circle S (setting of parameter 1 2 ). This spacing is primarily determined through the position of the plate 3 in relation to the beater circle S, but it can, however, still be increased independently of the position of the plate 3. The guide elements 10.1, 10.2, and 10.3 are connected to the transverse lever 8 through the pairs of pins L1/M1, L2/M2, L3/M3. In turn, the transverse lever 8 is connected with the intermediate lever 5 through the pin I. The intermediate lever 5 is pivoted on the lever 4 through the pin G. When the lever 4 is swivelled on the pin C pivoted on the plate 3, the pin G, which has an appropriate guide on the plate 3 (visible in FIG. 3) moves and draws the intermediate lever 5 with it, whereby the pin E, which is rigidly connected with the intermediate lever 5, is guided in a radially running guide (seen in FIG. 3) in the plate 3 and the pin I carries the transverse lever 8 with it. Since the transverse lever 8 is connected to the pairs of pins L1/M1, L2/M2, and L3/M3, these pins move with the guide elements 10.1, 10.2, and 10.3, neglecting the swivel motion of the intermediate lever 5, parallel to the radius of the opening roller 1 running through the middle of the plate 3.
FIG. 5 shows the device for the setting of the clearance between each guide element 10.1, 10.2 and a respective separating blade 9.1, 9.2 (setting of parameter 1 3 ). The pairs of pins L1/M1, L2/M2 (and also L3/M3) also connect the guide elements 10.1, 10.2 (and also 10.3) with the transverse lever 7. The transverse lever 7 however does not join in the movement actuated by the lever 4 (see FIG. 4), since the pins L1, M1, L2, M2, L3, and M3 slide in corresponding radial slots U.M1, U.L1, U.M2, U.M3,, and U.L3 in the transverse lever 7. The transverse lever 7 is connected through the pin I with the lever 6 which pivots on the pin G. If the lever 6 is swivelled on the pin G, then the pin I moves in its guide V on the intermediate lever 5 in a concentric circle to the beater circle S. Thereby, the pins G and E slide in appropriate slots of the plate 3 (shown in FIG. 3). The transverse lever 7 joins in this movement and is thereby guided through the pin H in the appropriate slot T in the plate 3. The guide elements 10.1, 10.2 (and 10.3) are thereby displaced on a circle concentric to the axis of the opening roller 1, in the direction towards the appropriate separating blades 9.1 and 9.2. Thereby, their radial position relative to the opening roller and relative to the separating blades 9.1, 9.2 is not altered.
No further functions are described with reference to FIGS. 6, 7, and 8, although these figures provide an instruction for the assembly of the lever unit of the invention.
FIG. 6 shows the plate 3, the lever 2 with the pin B, and the intermediate lever 5, as well as the pairs of pins L1/M1, L2/M2, and L3/M3, which project through the plate 3 and the housing 11, the points where the pairs of pins J1/K1 and J2/K2 which are fastened on the side of the plate 3 facing away from the lever unit, the pin C, which is pivoted in the plate 3, the pins G, E, and H, which are guided in the appropriate guides in the plate 3, and the pin I, which is pivoted in the intermediate lever 5.
FIG. 7 shows the lever 6 and the transverse lever 7, additionally to the parts of the lever unit which have already been explained in connection with FIG. 6.
FIG. 8 shows the transverse lever 8 and the lever 4, additionally to the parts of the lever unit which have already been explained in connection with FIGS. 6 and 7.
Finally, although the invention has been described with reference of 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.
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An apparatus and method for use in a cleaning process of textile fibers, and for use in conjunction with an opening roller. The apparatus includes a plurality of separating blades and guide elements which are spaced from the opening roller during the cleaning process. An assembly is provided for adjustably positioning a plurality of the separating blades and the guide elements during the cleaning process. The adjustment of the spacing of the separating blades and the guide elements from the opening roller can be accomplished remotely, either manually or by a motorized drive. A lever unit enables appropriate connection for effecting the various adjustments of the separating blades and the guide elements. The guide elements and the separating blades can be controlled and adjusted to suit the fibers to be processed.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to computer systems and, more particularly, to a RAMDAC (random access memory-digital-to-analog converter) used to transfer and process data from a frame buffer to an output display device.
2. History of the Prior Art
One of the significant problems involved in increasing the operational speed of desktop computers has been in finding ways to increase the rate at which information is transferred to an output display device. Many of the various forms of data presentation which are presently available require that large amounts of data be transferred. For example, if a computer output display monitor is operating in a color mode in which 1280×1024 pixels are displayed on the screen at once and the mode is one in which thirty-two bits are used to define each pixel, then a total of over forty million bits of information must be transferred to the screen with each individual picture (called a "frame") that is displayed. Typically, sixty frames are displayed each second so that over one and one-half billion bits must be transferred each second in such a system. This requires a very substantial amount of processing power.
In order to provide such a large amount of information to an output display device, computer systems typically utilize a frame buffer which holds the pixel data which is to be displayed on the output display.
Typically a frame buffer offers a sufficient amount of random access memory to store one frame of data to be displayed. The information in the frame buffer is transferred to the display from the frame buffer sixty or more times each second. After (or during) each transfer, the pixel data in the frame buffer is updated with the new information to be displayed in the next frame.
Various improvements have been made to speed access in frame buffers. In DRAM frame buffers, pixel data may be read from the same port as data is written. This approach severely reduces the time available for rendering graphics data to the frame buffer. VRAM frame buffers add a separate video data port so that the main pixel port remains free for rendering. Two-ported video random access memory (VRAM) or frame buffer random access memory (FBRAM) has been substituted for dynamic random access memory so that information may be transferred from the frame buffer to the display at the same time other information is being loaded into the frame buffer.
One of the problems which all frame buffers have faced is caused by the method by which data is transferred from the frame buffer to an output display device. Typically, the display device is a cathode ray tube which renders the pixel data stored in the frame buffer on a screen in a series of rows. A typical display is comprised of 1024 horizontal rows, each of which includes as many as 1280 individual pixels. A frame is described on the display by writing individual rows of pixels starting at the upper left corner of the display. Each row of pixels is rendered from left to right across the display before a next row in sequence is begun, When a row is completed, the next row below is begun at the left side of the screen. Each row is rendered in order until the last row at the bottom of the screen is completed. This completes one frame. Then the process starts over from the beginning with the next frame at the upper left corner of the display. As explained above, in the typical display sixty individual frames are presented each second.
In order to cause each of the pixels stored in the frame buffer to be presented at the appropriate position on the display, it is necessary to read the data for each pixel and transfer that data to the circuitry which controls its rendering on the output display device.
Frame buffers exist today that time multiplex the pixel data output of a RAM in order to pack 24-bit pixels onto a 32-bit data bus. This invention differs from such prior art approaches in that full 32-bit pixels are used, and the purpose is to allow a whole 32-bit pixel to live in a single RAM chip.
VRAMs of Samsung (Samsung WRAM) select 16 pins per RAM for their video port. However, this approach does not suggest that a whole 32-bit pixel be stored in the frame buffer, nor does it suggest that a 32-bit pixel be time multiplexed to get the pixel out of the frame buffer.
The data from the frame buffer is input to circuitry which converts the data from the frame buffer to a form usable by the output display device. FIGS. 1 and 2 each show a computer system in which the present invention may be utilized where data in a memory 11 from a host CPU 12 is placed on host bus 13 and passed by rendering controller 14 to the frame buffer memory shown in FIGS. 1 and 2 as VRAMs 15a-15d, although FBRAMs could be used as well. A RAMDAC 21 is coupled to the host bus through the rendering controller and to the frame buffer and includes a look-up table (or LUT which is the RAM part of the RAMDAC) and other elements for translating 16 bit data from VRAMs 15a-15d to a 64 or 128 bit digital RGB signal which is converted by a digital to analog converter (DAC) to three analog signals representing voltage levels for red, blue and green which when combined at a pixel location in monitor 25 create a desired color at that pixel. The particulars of the frame buffer, rendering controller and monitor components are well known in the art and will not be described herein except as necessary for a proper understanding of the invention. In this connection, for the most part, the present invention is directed to certain improvements to RAMDAC 21 which provide the enhanced capabilities of the invention.
SUMMARY OF THE INVENTION
For many graphics operations optimal performance is achieved by storing an entire 32-bit pixel in a single RAM chip. These operations may be Z-buffering, blending, and raster operations using an XOR function. When displaying video data from a frame buffer, pixels must be read out serially from the frame buffer at real-time speeds. The problem to be solved is how to get 32-bit pixels out of a frame buffer RAM chip with the fewest pins. Pins add cost, so limiting pins provides a lower cost solution.
As noted above, VRAM or FBRAM frame buffers add a separate video data port so that the main pixel port remains free for rendering. The number of pins used for this second port will affect the frame buffer's RAM, board and digital to analog components cost.
In this connection, according to the present invention, a frame buffer memory with 16 pins for serial video output is used. An entire 32-bit pixel is stored in a single RAM chip. For convenience of notation, the 32-bit pixel is designated as containing four byte (8-bit) quantities: X, B, G and R.
On the first clock cycle, the X and B bytes are made available on the 16 pins of the frame buffer. On the next clock cycle, the G and R bytes are made available. Thus, over two cycles the entire 32-bit pixel is output from the frame buffer.
Another component called a DAC (from digital to analog converter) samples the X and B bytes on 16 input pins. The DAC stores these X and B bytes in an internal register. On the next clock cycle it samples the G and R bytes. The DAC then reassembles the X, B, G and R bytes into a single 32-bit pixel for conversion into video.
With this invention, 32-bit pixels are communicated across a 16-bit pixel data bus. A 16-bit data bus saves a total of 32 pins (16 at the RAM for sending and 16 at the DAC for receiving) over a non-multiplexed 32 bit data bus. The 32 pins saved results in a lower frame buffer cost.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram showing a system having a 64 bit frame buffer memory in which the present invention may be utilized.
FIG. 2 is a block diagram showing a system having a 128 bit frame buffer memory in which the present invention may be utilized.
FIG. 3 is a detailed block diagram of a RAMDAC which employs the invented time multiplexing of pixel data hardware.
FIG. 4 is a timing diagram showing 2:1 single buffered interleaved pixel format.
FIG. 5 is a timing diagram showing 2:1 double buffered interleaved pixel format.
FIG. 6 is a timing diagram showing 4:1 single buffered interleaved pixel format.
FIG. 7 is a timing diagram showing 4/2:1 single buffered interleaved pixel format.
FIG. 8 is a timing diagram showing 4/2:1 double buffered interleaved pixel format.
FIG. 9 is a timing diagram showing 8/2:1 single buffered interleaved pixel format.
FIG. 10 is a timing diagram showing timing for the pixel port.
FIG. 11 shows the SC pixel clock input to the pixel port.
FIG. 12 is a timing diagram similar to FIG. 10 showing further detail of pixel port timing.
FIG. 13 is a circuit diagram of an implemenation of the pixel port input registers and serialization according to the present invention.
FIG. 14 shows a pixel port interleaving format circuit for pixel 0.
FIG. 15 shows a pixel port interleaving format circuit for pixel 1.
FIG. 16 shows a pixel port interleaving format circuit for pixel 2.
FIG. 17 shows a pixel port interleaving format circuit for pixel 3.
FIG. 18 shows a pixel port interleaving format circuit for pixel 4.
FIG. 19 shows a pixel port interleaving format circuit for pixel 5.
FIG. 20 shows a pixel port interleaving format circuit for pixel 6.
FIG. 21 shows a pixel port interleaving format circuit for pixel 7.
FIG. 22 is a circuit timing diagram for the pixel port for pixel 0.
FIG. 23 illustrates the interleaving format circuits 51 routing table.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 3 shows the components of a RAMDAC 21 which can be utilized to implement the present invention. The RAMDAC includes several functional blocks as follows: CPU port, interface logic, address pointers and data registers 31, pixel port, pixel input registers and serialization 33, shadow and RAM look-up tables, transfer control and overlay/underlay logic 35, color model selection 37, cursor logic serialization 39, monitor serial port 41, diagnostic registers and control logic 43, digital-analog converters (DAC) 45a-45c and PLL clock synthesizer, pixel clock divider and video timing generator 49. The invention lies mainly in an implementation of the pixel port, pixel input registers and serialization 33 component of the RAMDAC. Therefore, the following description will be limited to the pixel port, pixel input registers and serialization, with information pertaining to the other components of the RAMDAC provided only as needed for an understanding of the present invention. Although the other components shown in FIG. 3 may vary between RAMDACs of different manufacturers, persons skilled in the relevant art will recognize these various components and know how they or their equivalents may be implemented
The pixel port is a synchronous input port which accepts interleaved pixel data. Several interleaving formats are required. Selection among these utilizes register programming and is done as part of a boot time configuration process. RAMDAC 21 has two pixel ports, labeled A and B, with a programmable interleaving factor. This configuration accommodates double buffered operation for animation. Here, as in all other cases, the interleaving selection is made during configuration. The selection of port A or port B is made by decoding a window attribute field of port A. In 4:1 and 8/2:1 pixel formats an X field comes from ports A and B. The contents of the X data field are interpreted as either a Window Identification (WID) index or as an Overlay Color. The Overlay Color case and selecting the particular interpretation of the X data field is discussed below.
For the case where the X field is interpreted as a WID, Window ID's (WIDs) are index addresses into a WID look up table which serve to select the pixel source, e.g. port A or B, and to associate the pixel with a particular color model. The X field is a component of every pixel and its content may differ in contiguous pixels. Therefore, port and color model selection must be performed for each individual pixel.
The described interleaving formats are divided into two broad categories. These are the single buffered interleaving format, and the double buffered interleaving format.
In 2:1 and 4/2:1 input formats, the X field from port A is used. The X field from port B is ignored.
In 4:1 and 8/2:1 input formats, the X field from each pixel is used.
The X field does not directly control port and color model selection. The contents of the lower five bits of the X field, X 04:00!, constitute the address to the active WID LUT; hereafter called WID 05:00!. It is contained in the locations corresponding to these addresses and is used to effect the port and control color model selection according to definitions shown in Table 1, "Color Model Table Data Entry Codes," below.
TABLE 1______________________________________"Color Model Table Data Entry Codes, Color Model ControlSelected Input Port and Color Model 5* 4 3 2 1 0______________________________________Input Port B - 24-Bit Non-Linear True Color 1 1 1 0 x xInput Port B - 24-Bit Linear True Color 1 1 0 1 x xInput Port B - 24-Bit Direct Color 1 1 0 0 x xInput Port B - 8-Bit Non-Linear Grey Scale 1 0 1 0 1 1from B ChannelInput Port B - 8-Bit Non-Linear Grey Scale 1 0 1 0 1 0from G ChannelInput Port B - 8-Bit Non-Linear Grey Scale 1 0 1 0 0 1from R ChannelInput Port B - 8-Bit Non-Linear Grey Scale 1 0 1 0 0 0from X Channel (8/2:1 or 4:1 only)Input Port B - 8-Bit Linear Grey Scale from 1 0 0 1 1 1B ChannelInput Port B - 8-Bit Linear Grey Scale from 1 0 0 1 1 0G ChannelInput Port B - 8-Bit Linear Grey Scale from 1 0 0 1 0 1R ChannelInput Port B - 8-Bit Linear Grey Scale from 1 0 0 1 0 0X Channel (8/2:1 or 4:1 only)Input Port B - 8-Bit Pseudo Color from B 1 0 0 0 1 1ChannelInput Port B - 8-Bit Pseudo Color from G 1 0 0 0 1 0ChannelInput Port B - 8-Bit Pseudo Color from R 1 0 0 0 0 1ChannelInput Port B - 8-Bit Pseudo Color from X 1 0 0 0 0 0Channel (8/2:1 or 4:1 only)Input Port A - 24-Bit Non-Linear True Color 0 1 1 0 x xInput Port A - 24-Bit Linear True Color 0 1 0 1 x xInput Port A - 24-Bit Direct Color 0 1 0 0 x xInput Port A - 8-Bit Non-Linear Grey Scale 0 0 1 0 1 1from B ChannelInput Port A - 8-Bit Non-Linear Grey Scale 0 0 1 0 1 0from G ChannelInput Port A - 8-Bit Non-Linear Grey Scale 0 0 1 0 0 1from R ChannelInput Port A - 8-Bit Non-Linear Grey Scale 0 0 1 0 0 0from X ChannelInput Port A - 8-Bit Linear Grey Scale from 0 0 0 1 1 1B ChannelInput Port A - 8-Bit Linear Grey Scale from 0 0 0 1 1 0G ChannelInput Port A - 8-Bit Linear Grey Scale from 0 0 0 1 0 1R ChannelInput Port A - 8-Bit Linear Grey Scale from 0 0 0 1 0 0X ChannelInput Port A - 8-Bit Pseudo Color from B 0 0 0 0 1 1ChannelInput Port A - 8-Bit Pseudo Color from G 0 0 0 0 1 0ChannelInput Port A - 8-Bit Pseudo Color from R 0 0 0 0 0 1ChannelInput Port A - 8-Bit Pseudo Color from X 0 0 0 0 0 0Channel______________________________________
PIXEL DISPLAY ORDERING
In each of the following described formats, pixel data port pin group 0 always has the leftmost pixel as viewed on the screen of all pixels coming in to the pixel port on a clock. Higher-numbered bits in each pixel are the more significant bits of the pixels, i.e. cause a larger change in the DAC output voltage when selected for color palette bypass.
PIXEL PORT SIGNALS
RED, GREEN, BLUE and Window Attribute Field Pixel Inputs
These are the video data and window attribute inputs. To facilitate discussion, assume that the pixel inputs are divided into two ports, labeled A and B which consist of four groups per port. Furthermore, each group is divided into an upper byte and a lower byte. Thus, the pixel port comprises a total of 128 pixel bits contained in groups 0 through 7. Table 2 illustrates these assignments.
TABLE 2______________________________________Pixel Port Naming ConventionPixel Port Group Group Bits Device Bits______________________________________B 15:8! PB(63-56) 7 7:0! PB(55-48) 15:8! PB(47-40) 6 7:0! PB(39-32) 15:8! PB(31-24) 5 7:0! PB(23-16) 15:8! PB(15-08) 4 7:0! PB(07-00)A 15:8! PA(63-56) 3 7:0! PA(55-48) 15:8! PA(47-40) 2 7:0! PA(39-32) 15:8! PA(31-24) 1 7:0! PA(23-16) 15:8! PA(15-08) 0 7:0! PA(07-00)______________________________________
The arrangement of data arriving at the pixel port is hereafter referred to as an interleaving format. RAMDAC 21 accommodates five interleaving formats which are selected by configuration register programming performed at boot time. The five interleaving formats are defined below.
PIXEL FORMATS SUPPORTED
Each of the pixel formats is explained and illustrated in the following sections. It should be noted that the serialized pixel detail is not intended to show a cycle relationship with data coming in. The pixel format is selected by programming the Video Format Control Register. The mapping of this register is shown in Table 3.
TABLE 3______________________________________ ResetBit(s)Field Value Description______________________________________15-4 Reserved 0x003 Transparent 0 When set to a logical zero, the overlayOverlay Enable disabled state, the enable bit causes the(0) Disabled multiplexer to select the Underlay path,(1) Enabled i.e., WID 05:00! are passed to CMC 05;00!. When set to a logical 1, the overlay enabled state, the action of the multiplexer is controlled by the result of the equality comparison.2 Double Buffer 0 This field is valid only when in the 4/2:1Enable or 2:1 pixel format. Other formats require(0) Single that this bit be set to 0.Buffered(1) DoubleBuffered1,0 Pixel Format 00 Selects the pixel interleaving format. TheControl LD frequency for each multiplex rate is:(00) 2:1 .sup.f LD = fp/2 MHz,(01) 4:1 .sup.f LD = fp/4 MHz,(10) 4/2:1 .sup.f LD = fp/2 MHz,(11) 8/2:1 .sup.f LD = fp/4 MHz.______________________________________
2:1--Single and Double Buffered Interleaving Formats
These formats are applicable when operated at pixel frequency, fp, ≦135 MHz, with a LD frequency, f LD =fp/2 MHz. These formats are illustrated in FIGS. 4 and 5. The function of the X field was explained above.
4:1--Single Buffered Interleaving Format
This mode is valid for fp,≦220 MHz. LD frequency. f LD =fp/4 MHz. This format is illustrated in FIG. 5.
4/2:1--Single and Double Buffered Interleaving formats
This mode is applicable when operated at pixel frequency, fp, ≦135 MHz. LD frequency, f LD =fp/2 MHz.
This format is illustrated in FIG. 6 and FIG. 7.
8/2:1--Single Buffered Interleaving Format
This format is applicable when operated at frequencies fp,≦220 MHz. LD frequency, f LD =fp/4 MHz.
This format is illustrated in FIG. 8.
PIXEL PORT TIMING
The design incorporates circuitry to insure correct entry of pixel port data as the phase relationship of LD and pixel clock is varied between certain limits. This circuitry performs the required internal adjustments either during every vertical blanking interval or when invoked by an external mechanism. The mode of operation is controlled by register programming. The timing relationships of SC, LD, pixel clock and pixel data are specified FIGS. 10-12.
Table 4 provides a description of the various signals utilized by the RAMDAC.
TABLE 4______________________________________Signal Name I/O/Z Description______________________________________D(7:0) I/O/Z CPU Data Bus. Bidirectional data. The CPU port will zero fill unused bits on data reads.C(1:0) I CPU Control Bus Input. These signals serve a dual purpose. They define major divisions in the RAMDAC address space and the access type.R/W I CPU Read/Write Control Input. Defines the transaction direction.LB* I CPU Low Byte Control.CE* I CPU Chip Enable Input. When negated, this signal causes the RAMDAC to ignore all CPU interface signals with the exception of reset.P(A,B)(63:0) I Pixel Port Inputs. These inputs have internal pullup resistors that cause the logic level to be high if they are left unconnected.LD I Pixel Port Load Clock. The rising edge of this signal captures input pixel data.PVLD I Pixel Port Data Valid. This input is captured on the rising edge of LD, along with pixel data.SC O Serial Clock Output. This signal is produced by the Pixel Clock Divider. It is meant to be used as the clock for the serial port of the video memory. Please refer to the description of the Pixel Clock Divider for details.SCEN O Serial Clock Enable Output. This signal is produced by the timing generator and is meant to control the serial port of the video memory.STSCAN O Horizontal scan line indicator. This signal is produced by the timing generator and is meant for use by external circuitry for the purpose of indexing the serial port of the video memory.FIELD I/O Odd Field Indicator. This signal is produced by the timing generator and is meant for use by external circuitry for the purpose of indexing the serial port of the video memory.XTAL1, I,O PLL Reference Crystal.XTAL2COMP, Compensation for internal reference amplifier.COMP2CSYNC* O Composite Sync Output.MON(3:0) I Monitor Serial Port DataRESET* I Reset Input. This is the Reset signal. Its' assertion causes a number of actions, these are described in following paragraphs.______________________________________
Referring now to FIG. 13, the pixel port of the present invention may be implemented using interleaving format circuits 51, the specifics of which are described with reference to FIGS. 14-21, multiplexor 53 (MPX1), pipeline register 55 (D REG), multiplexor 57 (MPX 2) and shift register 59 (SHIFT REG).
FIG. 13 depicts the flow of signals and elements involved in converting video pixels provided in parallel into a serial stream of single pixels. Here, the various interleaving formats are accommodated and the selection of display buffer, in double buffer modes, is made.
Pixels are received from interleaving format circuits block 51 from the frame buffer memory, in several allowed parallel formats. These formats are described in FIGS. 4-9. The interleaving format circuits block 51 performs the task of undoing the interleaving and providing complete, 32 bit pixels at its output.
The interleaving format circuits block utilizes eight subblocks, each one manipulating incoming data to assemble one pixel. The circuits comprising these blocks are illustrated in FIGS. 14-21 for pixels 0-7 respectively. Note that these circuits are not identical but that they do have elements in common. These elements are flip-flop M2, flip-flop M3B and flip-flop M3C in the diagrams for pixels 0-3 and flip-flops M2, M3A and M3B in the diagrams for pixels 4-seven (the mnemonics differ but the functions are identical). These elements deal with the time multiplexed interleaving formats 4/2:1 and 8/2:1. FIG. 22 depicts the action of the pixel 0 circuit in the 4/2:1 case, which is identical to the remaining cases in every respect except the period of LD and LD/2. FIG. 22 shows the manner in which a complete 32 bit pixel is assembled from two LD clock cycles each containing half of the pixel information. When either the 4/2:1 or 8/2:1 interleaving format is selected, bit 1 of the video format control register is set to logic 1. This level causes multiplexer M4 to pass the output of flip-flip M3B to shift register M5; this is the lower half of a pixel and comprises the GREEN and RED components of the pixel. The output of flip-flop M3C also connects to shift register MS. This connection conveys the upper half of the pixel, comprising the X and BLUE components of the pixel. The manner in which pixel 0 is assembled in the 2:1 and 4:1 interleaving formats is not described in the timing diagram. This subject is discussed in subsequent paragraphs.
As previously notedm the format circuits differ. They do so as an artifact of the design which utilizes simple circuitry to implement a seemingly complex task. That task is the reorganization of the incoming data, not only to satisfy the time multiplexing requirement, but also to accommodate single and double buffered operation as well as modes which are not time multiplexed. All of this is accomplished by routing the various groups of incoming pixels to the appropriate interleaving format circuit. This routing is depicted in FIG. 23.
Returning to FIG. 13, portions of the output of the interleaving format circuits are passed to two blocks. The first of these, titled D REG 55, is nothing more than a pipeline register. It accepts P0 through P7 from the interleaving format circuits. The second block multiplexor 53 is titled MPX 1. It accepts P0 through P3. Multiplexor MPX 1 is used to select the appropriate buffer when the system is operated in 2:1 double buffered mode. The multiplexer is controlled by bits 1 and 0 of the video format control register as well as bit number 5 of the of the X components of P0 and P1. Not shown in the diagram is the connection to bit 2 of the user control register which enables or disables the double buffered mode. The combined action of these signals is as follows. If the double buffered mode is enable, (user control register) and if the 2:1 mode has been selected (video format control register) and bit 5 of the X component of P0 (for example) is 1 then the multiplexer passes P2, which is P0 of buffer B. If bit 5 were 0 instead of 1 than the multiplexer would pass P0 from buffer A. If the double buffered mode is not selected, or if the 2:1 mode is not selected, the multiplexer passes P0 and P1.
The output of the pipeline register, D REG, is treated in a manner similar to that described in the previous paragraph. However, in this instance, multiplexor MPX 2 deals with the 4/2:1 double buffered mode. The control of this multiplexer is similar to that described, however it is the 4/2:1 mode (from the video format control register) which forms part of the qualifier instead of the 2:1 mode.
The final element of the circuit is the shift register which receives P0 through P7 in parallel and produces a serial output consisting of one 32 bit pixel per pixel clock, starting with the location occupied by P0 in the illustration. That is the device shifts in the direction of the lowest numbered pixel occupying the register. Although the register is shown to have eight levels, it does not always shift eight pixels. Indeed, eight pixels are only shifted in the 8/2:1 mode. Four pixels are shifted in the 4:1, 4/2: (single and double buffered) and two pixels are shifted in the 2:1 mode. This variation in depth is not accomplished by special control circuitry but rather by the nature of the PAR(ALLEL) LOAD clock driven by LD/n. The circuit which produces LD/n is not shown but its operation is described as follows. The state of bits 1 and 0 of the video format control register control a divider which acts to divide the input, LD, by two when in 8/2:1 mode or 4/2:1 mode. When in 2:1 or 4:1 mode, LD is not altered but is simply passed to the output LD/n. The effect of this circuit is to make the period of its output LD/n equal to the period occupied by m pixels, where m is equal to the interleaving factor.
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A method and for multiplexing pixel data from a frame buffer to a RAMDAC to reduce the number of pins required. For many graphics operations optimal performance is achieved by storing an entire 32-bit pixel in a single RAM chip. When displaying video data from a frame buffer, pixels must be read out serially from the frame buffer at real-time speeds. A frame buffer memory with 16 pins for serial video output is used. An entire 32-bit pixel is stored in a single RAM chip. For a 32-bit pixel containing four byte (8-bit) quantities designated X, B, G and R, on the first clock cycle, the X and B bytes are made available on the 16 pins of the frame buffer. On the next clock cycle, the G and R bytes are made available. Thus, over two cycles the entire 32-bit pixel is output from the frame buffer to a RAMDAC which samples the X and B bytes on 16 input pins. The RAMDAC stores these X and B bytes in an internal register. On the next clock cycle it samples the G and R bytes. The DAC then reassembles the X, B, G and R bytes into a single 32-bit pixel for conversion into video. In this manner, 32-bit pixels are communicated across a 16-bit pixel data bus.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Patent Applications 60/377,645, 60/377,646, 60/377,647 and 60/377,650, all of which were filed May 6, 2002. This application is a continuation-in-part of a U.S. patent application entitled “Collaboration Between Wireless LAN Access Points,” filed Aug. 7, 2002. All these, related applications are incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention relates generally to wireless communications, and specifically to methods and devices for improving the performance of wireless local area networks.
BACKGROUND OF THE INVENTION
[0003] Wireless local area networks (WLANs) are gaining in popularity, and new wireless applications are being developed. The original WLAN standards, such as “Bluetooth” and IEEE 802.11, were designed to enable communications at 1-2 Mbps in a band around 2.4 GHz. More recently, IEEE working groups have defined the 802.11a, 802.11b and 802.11g extensions to the original standard, in order to enable higher data rates. The 802.11a standard, for example, envisions data rates up to 54 Mbps over short distances in a 5 GHz band, while 802.11b defines data rates up to 22 Mbps in the 2.4 GHz band. In the context of the present patent application and in the claims, the term “802.11” is used to refer collectively to the original IEEE 802.11 standard and all its variants and extensions, unless specifically noted otherwise.
[0004] The theoretical capability of new WLAN technologies to offer enormous communication bandwidth to mobile users is severely hampered by the practical limitations of wireless communications. Indoor propagation of radio frequencies is not isotropic, because radio waves are influenced by building layout and furnishings. Therefore, even when wireless access points are carefully positioned throughout a building, some “black holes” generally remain—areas with little or no radio reception. Furthermore, 802.11 wireless links can operate at full speed only under conditions of high signal/noise ratio. Signal strength scales inversely with the distance of the mobile station from its access point, and therefore so does communication speed. A single mobile station with poor reception due to distance or radio propagation problems can slow down WLAN access for all other users in its basic service set (BSS—the group of mobile stations communicating with the same access point).
[0005] The natural response to these practical difficulties would be to distribute a greater number of access points within the area to be served. If a receiver receives signals simultaneously from two sources of similar strength on the same frequency channel, however, it is generally unable to decipher either signal. The 802.11 standard provides a mechanism for collision avoidance known as clear channel assessment (CCA), which requires a station to refrain from transmitting when it senses other transmissions on its frequency channel. In practice, this mechanism is of limited utility and can place a heavy burden on different BSSs operating on the same frequency channel.
[0006] Therefore, in 802.11 WLANs known in the art, access points in mutual proximity must use different frequency channels. Theoretically, the 802.11b and 802.11g standards define 14 frequency channels in the 2.4 GHz band, but because of bandwidth and regulatory limitations, WLANs operating according to these standards in the United States actually have only three different frequency channels from which to choose. (In other countries, such as Spain, France and Japan, only one channel is available.) As a result, in complex, indoor environments, it becomes practically impossible to distribute wireless access points closely enough to give strong signals throughout the environment without substantial overlap in the coverage areas of different access points operating on the same frequency channel.
SUMMARY OF THE INVENTION
[0007] It is an object of some aspects of the present invention to provide methods and devices for enhancing the coverage and speed of WLAN systems.
[0008] In preferred embodiments of the present invention, a WLAN system comprises multiple wireless access points, which are distributed within a service region and are available for data communications with mobile stations in the region. The access points are connected together in a wired LAN for conveying data to and from the mobile stations and, typically, between the mobile stations and external networks. The wired LAN comprises a cable, such as CAT-5 cable, having multiple conductors, not all of which are needed for conveying data to and from the mobile stations. The access points therefore use one or more of the conductors that are not needed for LAN data communications in order to pass control messages among themselves.
[0009] The access points typically use these control messages for coordinating operations among themselves. For example, the access points may use the control messages to decide which of the access points will respond to a mobile unit sending an uplink message over the WLAN. The “spare” conductors of the LAN cabling are preferably configured as a high-speed shared medium, whose latency is low enough to permit this sort of coordination without adverse effect on WLAN operation. (Typically, an Ethernet LAN has message latency on the order of milliseconds, while the shared medium of the present invention can be configured for latency in the microsecond range.) High-speed coordination among access points improves significantly the speed and consistency of service that the WLAN can provide to mobile stations. By using spare conductors in existing LAN cabling, this enhanced WLAN service can be provided with almost no additional infrastructure cost in comparison to WLANs known in the art.
[0010] In some preferred embodiments of the present invention, the “spare” conductors in the LAN cabling are also used to convey DC electrical power to some or all of the access points. The control messages may be sent over the same conductors as the DC power by high-frequency modulation. Suitable AC couplers are used at the access points to separate the modulated control messages from the DC power.
[0011] There is therefore provided, in accordance with a preferred embodiment of the present invention, apparatus for network communication, including:
[0012] a cable arranged to form a wired local area network (LAN), the cable including at least first and second conductors; and
[0013] a plurality of access points interconnected by the cable and arranged in a wireless local area network (WLAN) to communicate over the air on a common frequency channel with a mobile station, the access points being adapted to convey data to and from the mobile station over the LAN via the first conductor and to exchange control messages among the access points via the second conductor.
[0014] Typically, the access points are adapted to convey the data over the LAN in accordance with a first media access control (MAC) protocol, and to exchange the control messages using a second MAC protocol, different from the first MAC protocol, wherein the first MAC protocol is characterized by a first latency, and wherein the second MAC protocol is characterized by a second latency, which is lower than the first latency. The first MAC protocol may include an Ethernet protocol. The second MAC protocol preferably includes a multiple access protocol, which can be used by two or more of the access points to transmit the control messages over the second conductor substantially simultaneously. In a preferred embodiment, the multiple access protocol includes a code division multiple access (CDMA) protocol.
[0015] Preferably, the second conductor is configured as a shared medium, so that the control messages transmitted onto the second conductor by any of the access points are received by all the other access points via the shared medium. Typically, the apparatus includes a switching hub, which is coupled to the first conductor so as to control a flow of the data to and from the access points over the LAN, substantially without affecting the control messages on the second conductor.
[0016] In a preferred embodiment, the apparatus includes a DC power source, which is coupled to provide electrical power to the access points over the second conductor, wherein the access points include modulation circuitry, coupled to the second conductor, for conveying the control messages over the second conductor simultaneously with the electrical power.
[0017] Typically, the cable includes multiple twisted wire pairs, including at least a first wire pair that includes the first conductor, and at least a second wire pair that includes the second conductor. For example, the cable may include a Category 5 (CAT-5) cable.
[0018] In a preferred embodiment, the access points include message processors, coupled to the second conductor, which are adapted, upon receiving at one or more of the access points an uplink signal transmitted over the WLAN by the mobile station on the common frequency channel, to arbitrate among the access points receiving the uplink signal by sending and receiving the control messages over the second conductor so as to select one of the access points to respond to the uplink signal.
[0019] There is also provided, in accordance with a preferred embodiment of the present invention, a method for network communication, including:
[0020] arranging a plurality of access points in a wireless local area network (WLAN) to communicate over the air on a common frequency channel with a mobile station;
[0021] linking the access points together by a cable to form a wired local area network (LAN), the cable including at least first and second conductors; and
[0022] conveying data via the first conductor over the LAN to and from the access points for transmission over the air to and from the mobile station; and
[0023] exchanging control messages among the access points via the second conductor.
[0024] The present invention will be more fully understood from the following detailed description of the preferred embodiments thereof, taken together with the drawings in which:
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] [0025]FIG. 1 is a block diagram that schematically illustrates a WLAN system, in accordance with a preferred embodiment of the present invention;
[0026] [0026]FIG. 2 is a schematic illustration of a mobile station communicating with multiple wireless access points, in accordance with a preferred embodiment of the present invention;
[0027] [0027]FIG. 3 is a flow chart that schematically illustrates a method for establishing a communication link between a mobile station and a wireless access point, in accordance with a preferred embodiment of the present invention;
[0028] [0028]FIG. 4 is a block diagram that schematically illustrates communication links among multiple access points in a WLAN system, in accordance with a preferred embodiment of the present invention;
[0029] [0029]FIG. 5 is a block diagram that schematically illustrates communication and power links between an access point and a hub in a WLAN system, in accordance with a preferred embodiment of the present invention; and
[0030] [0030]FIG. 6 is a block diagram that schematically illustrates a message packet exchanged between access points in a WLAN system, in accordance with a preferred embodiment of the present invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0031] [0031]FIG. 1 is a block diagram that schematically illustrates a wireless LAN (WLAN) system 20 , in accordance with a preferred embodiment of the present invention. System 20 comprises multiple access points 22 , which are configured for data communication with mobile stations 24 . The mobile stations typically comprise computing devices, such as desktop, portable or handheld devices, as shown in the figure. In the exemplary embodiments described hereinbelow, it is assumed that the access points and mobile stations communicate with one another in accordance with one of the standards in the IEEE 802.11 family and observe the 802.11 medium access control (MAC) layer conventions. Details of the 802.11 MAC layer are described in ANSI/IEEE Standard 801.11 (1999 Edition), and specifically in Part 11: Wireless LAN Medium Access Control (MAC) and Physical Layer (PHY) Specifications, which is incorporated herein by reference. The principles of the present invention, however, are not limited to the 802.11 standards, and may likewise be applied to substantially any type of WLAN, including HiperLAN, Bluetooth and hiswan-based systems.
[0032] Access points 22 are typically connected to an Ethernet hub 26 by a wired LAN 28 . The LAN serves as a distribution system (DS) for exchanging data between the access points and the hub. This arrangement enables mobile stations 24 to send and receive data through access points 22 to and from an external network 30 , such as the Internet, via an access line 32 connected to hub 26 . LAN 28 is typically capable of carrying data at high speeds—greater than the aggregate speed of wireless communications between the access points and mobile stations. Message latency on the LAN is high, however, generally on the order of milliseconds, due mainly to collision avoidance mechanisms that are inherent in the operation of Ethernet and other conventional LANs.
[0033] In addition to the conventional DS provided by LAN 28 , access points 22 are also connected by a novel shared communication medium 34 to a MAC collaboration hub 36 . Medium 34 may comprise substantially any suitable high-speed communication means, including wire, fiberoptics, or even free-space optical or radio communications (in an allowed frequency band that does not interfere with WLAN operation). For the sake of economy, medium 34 preferably comprises wires that run parallel to LAN 28 . For example, medium 34 may comprise a twisted pair of wires that already exists in cabling of LAN 28 , but which is not required for carrying LAN data. The function of MAC collaboration hub 36 is simply to connect medium 34 in such a way as to allow all access points 22 to broadcast and receive messages to and from all other access points. Therefore, unlike Ethernet hub 26 , MAC collaboration hub 36 typically need not include a switch. Exemplary implementations of medium 34 and hub 36 are described hereinbelow with reference to FIGS. 4 and 5. Although the hub-and-spokes topology shown in FIGS. 1, 4 and 5 is generally the most convenient way to configure medium 34 , alternative configurations will be apparent to those skilled in the art and are considered to be within the scope of the present invention.
[0034] [0034]FIG. 2 is a schematic illustration of simultaneous radio communications between mobile station 24 and multiple access points 22 in system 20 , in accordance with a preferred embodiment of the present invention. It is assumed that the access points labeled AP 1 , APT and AP 3 are all operating on the same band, over which mobile station 24 seeks to communicate. (Access points AP 4 and AP 5 are assumed to be operating in a different band, and thus do not participate directly in this communication process.) Radio waves 40 , 42 and 44 reach mobile unit 24 from AP 1 , AP 2 and AP 3 , respectively, with similar amplitudes. By the same token, radio messages transmitted by mobile unit 24 are received at about the same time by AP 1 , AP 2 and AP 3 . In WLAN systems known in the art, under these circumstances, mobile station 24 would receive downlink messages from two or more access points 22 , which would probably result in inability of the mobile station to communicate with any of the access points. In preferred embodiments of the present invention, access points AP 1 , AP 2 and AP 3 communicate with one another over medium 34 in order to resolve this conflict, as described hereinbelow.
[0035] [0035]FIG. 3 is. a flow chart that schematically illustrates a method for establishing communications between mobile station 24 and one of access points 22 in system 20 , in accordance with a preferred embodiment of the present invention. Access points 22 (say AP 1 , AP 2 and AP 3 ) transmit beacon signals on their common frequency channel, at a beacon transmission step 50 . In accordance with the 802.11 standard, the beacon signals transmitted by any given access point provide the time base with which the mobile station should synchronize its communications and indicate the BSS identification (BSSID) of the access point. The BSSID can be regarded as the MAC address of the access point. In 802.11 WLAN systems known in the art, each access point has its own unique BSSID. In system 20 , however, access points AP 1 , AP 2 and AP 3 share the same BSSID, so that they appear logically to the mobile station to be a single, extended, distributed access point, which has multiple antennas at different locations. The time bases of AP 1 , AP 2 and AP 3 are mutually synchronized using medium 34 , and the beacon signals transmitted by the access points are interlaced to avoid collision between them.
[0036] When mobile station 24 receives a beacon signal of sufficient strength, it extracts the BSSID and time base from the signal, at a beacon processing step 52 . This step, as well as subsequent steps taken by the mobile station, is completely in accordance with the 802.11 standard. In other words, the present invention can be implemented in a manner that is transparent to and requires no modification of legacy mobile stations. Using the time base and BSSID it has acquired, mobile station 24 sends an uplink signal, in the form of an association request message that is addressed to the BSSID and indicates the MAC address of the mobile station, at an association request step 52 .
[0037] Ordinarily, in a conventional WLAN, the access point to which the association request is addressed will answer immediately with an acknowledgment (ACK). If the mobile station does not receive the ACK within a given timeout period, typically 10 μs, it submits an automatic repeat request (ARQ). Ultimately, the mobile station will treat the association request as having failed if it does not receive the required ACK. Therefore, to maintain 802.11 compatibility in system 20 , one—and only one—of access points AP 1 , AP 2 and AP 3 must return an ACK to mobile station 24 within the 10 μs limit.
[0038] To determine which of the access points will respond to the association request message, access points AP 1 , AP 2 and AP 3 carry out an arbitration procedure using medium 34 . For this purpose, all access points that received the association request message from mobile station 24 broadcast messages over medium 34 , at a broadcast step 56 , giving notice to the other access points that they have received an uplink message. Each broadcast message indicates the identity of the access point sending the message (i.e., a unique, internal identity, not the BSSID) and the MAC address of the mobile station in question. Preferably, to reduce the length of the broadcast message, the MAC address of the mobile station is hashed.
[0039] The access points send their messages over medium 34 in accordance with a predetermined protocol that makes it possible to distinguish messages sent simultaneously (or almost simultaneously) by different access points. For example, a time division multiple access (TDMA) protocol may be used, in which each access point has its own, assigned time slot. Alternatively, a code division multiple access (CDMA) protocol is used, as described below with reference to FIG. 6. Further alternatively, a frequency division multiplexing scheme may be used (or if medium 34 is implemented as a fiberoptic network, wavelength division multiplexing, as is known in the art).
[0040] The access points receive and process the broadcast messages sent over medium 34 , at a processing step 58 . Each access point is able to determine whether it was first to send its message, or whether another access point preceding it, by comparing the time of receipt of these broadcast messages to the time at which the access point sent its own broadcast message. (Access points operating on other frequency channels, as well as access points on the same frequency channel that did not receive an uplink signal from the mobile station identified in the broadcast message, may ignore the message.) Typically, the access point that was able to send its broadcast message first in response to an uplink message from a given mobile station is in the best position to continue communications with the mobile station, since this access point is generally the closest one to the mobile station. Therefore, all the access points independently choose this first access point to respond to mobile station 24 . Alternatively, other criteria, such as received signal power, may be applied in choosing the “winning” access point, as long as the criteria are applied uniformly by all the access points. Preferably, if a deadlock occurs (such as when two access points send their broadcast messages at the same instant), a predetermined formula is applied by all the access points to resolve the deadlock uniformly.
[0041] The winning access point sends the required ACK message to mobile station 24 , at an acknowledgment step 60 . As noted above, the ACK must be sent within a short time, typically 10 μs, and steps 56 , 58 , and 60 must all be completed within this time. Access points 22 are able to meet this time constraint by using medium 34 as a dedicated, shared medium for this purpose, and by implementing a fast arbitration protocol, based on short broadcast messages, as described above. After sending the ACK, the winning access point typically sends an association response message to mobile station 24 , and then continues its downlink transmission to the mobile station as appropriate, at a downlink step 62 .
[0042] The winning access point continues serving the mobile station until the mobile station sends another uplink message, at a new uplink step 64 . The arbitration protocol described above is then repeated, starting from step 56 . A different access point may be chosen to serve the mobile station in the next round, particularly if the mobile station has moved in the interim. Even if the mobile station has moved, there is no need to repeat the association protocol. As noted above, all the access points belong to the same BSS, as though they were a single extended access point. Therefore, the same association of the mobile station is therefore maintained even if the arbitration process among the access points chooses a different “winner” to respond to the next uplink packet from the mobile station.
[0043] [0043]FIG. 4 is a block diagram that schematically shows details of communications by access points 22 over medium 34 , in accordance with a preferred embodiment of the present invention. Medium 34 in this embodiment comprise pairs of wires 68 connecting each of access points 22 to hub 36 . Hub 36 comprises a splitter 70 , which joins wires 68 in such a way that medium 34 functions as a shared medium, i.e., so that signals transmitted onto wires 68 by any of access points 22 are received by all the other access points on medium 34 . In the simplified embodiment shown in FIG. 4, splitter 70 comprises a passive, inductive coupler, which couples together all the pairs of wires. Alternatively or additionally, splitter 70 may comprise one or more amplifiers or other active elements, as are known in the art.
[0044] Each access point 22 comprises a message processor 72 for communicating with the other access points over medium 34 and carrying out the MAC-level collaboration protocol described above. Message processor 72 typically comprises a transmit circuit 74 and a receive circuit 76 , for transmitting and receiving broadcast messages over medium 34 . Preferably, to meet the timing requirements of an 802.11 WLAN, as noted above, circuits 74 and 76 and medium 34 operate with a bandwidth of at least 30 MHz. Message processor 72 interacts with and controls a WLAN transceiver 78 , in compliance with the collaboration protocol. Transceivers 78 communicate over the air with mobile stations 24 in accordance with the applicable WLAN standards.
[0045] [0045]FIG. 5 is a block diagram that shows further details of communications between one of access points 22 and hubs 26 and 36 , in accordance with a preferred embodiment of the present invention. For the sake of simplicity, only a single access point is shown in this figure. Typically, multiple access points are connected in like manner, as shown in FIG. 4.
[0046] In the present embodiment, a multi-conductor cable 86 is used to connect access points 22 in LAN 28 . Typically, cable 86 comprises Category 5 (CAT-5) cabling, as is common in Ethernet LANs. Two twisted pairs of wires 82 and 84 (the 1-2 and 3-6 pairs in a CAT-5 cable) are used for transmitting and receiving data packets over LAN 28 , between Ethernet hub 26 and an Ethernet interface 80 in access point 22 . These data packets may comprise data sent between mobile stations 24 and network 30 , via the access points. A remaining twisted pair 88 (the 4-5 pair) is not generally used for LAN data communications. Therefore, pair 88 serves as medium 34 , carrying MAC collaboration messages between message processor 72 and hub 36 . This novel use of pair 88 eliminates the need for separate wiring of medium 34 .
[0047] In some LANs (and particularly LANs that are used to connect wireless access points) , pair 88 is also used to convey DC power to access points 22 . A power distribution hub 90 , associated with Ethernet hub 26 , is connected by pair 88 to a power supply circuit 92 in access point 22 . In accordance with the IEEE 802.3af draft standard, hub 90 supplies 48 VDC over pair 88 . This voltage is stepped down and regulated by power supply circuit 92 in order to provide operating power to the communication circuits of access point 22 . The DC level on the wires of pair 88 , however, does not prevent pair 88 from serving as medium 34 . Rather, message processor 72 comprises a high-frequency coupler 94 , typically an inductive coupler, which separates the high-speed communication traffic on medium 34 from the DC power.
[0048] [0048]FIG. 6 is a block diagram that schematically illustrates a broadcast packet 100 sent over medium 34 by one of access points 22 , in accordance with a preferred embodiment of the present invention. Packet 100 is used by the access points to convey broadcast notice messages when they receive uplink communications from one of mobile stations 24 , as described above with reference to FIG. 3 (step 56 ). The present embodiment assumes that the access points communicate over medium 34 using a CDMA protocol. CDMA has the advantage, by comparison with TDMA, that it allows all the access points to broadcast simultaneously and does not require a master clock, delay compensation or an intelligent central unit.
[0049] Packet 100 comprises a preamble 102 , which is typically made up of a synchronization word 104 and an access point identifier 106 . As noted above, identifier 106 is a proprietary, internal identification code, which uniquely identifies the access point sending the packet. Message processor 72 in each of access points 22 preferably has a set of data masks, which correspond respectively to preambles 102 of all the other access points that are configured to transmit and receive on the same WLAN frequency channel. As the message processor receives data over medium 34 , it compares the data against each of its masks in order to detect the beginning of a new packet and the identity of the access point that sent the packet. Walsh codes may be used advantageously for this purpose, as is known in the CDMA art.
[0050] Preamble 102 is followed by a broadcast message 108 , which identifies the mobile station that sent the uplink message reported by packet 100 . After message processor 72 has succeeded in decoding preamble with one of its data masks, it uses the same data mask to decode message 108 . The message processor thus identifies both the mobile station that sent the uplink message and the access point that received it first, and in this way is able to decide which access point should respond to the uplink message, as described above. optionally, message 108 may include other parameters, such as the power level of the received uplink message and/or an identification of the antenna on which the access point received the message. (For diversity purposes, access points generally have multiple antennas.) These additional parameters may be used, in addition to or instead of the time of receipt of packet 100 , in arbitrating among the access points.
[0051] As noted above, although preferred embodiments are described herein with reference to particular types of wireless and wired LANs and particular communication standards, the principles of the present invention are similarly applicable to other types of LANs and WLANs, which may operate in accordance with other standards. In addition, these principles may be applied in wireless personal area networks (PANs), as defined by IEEE Standard 802.15, including ultra-wide band (UWB) PANs. It will thus be appreciated that the preferred 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.
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Apparatus for network communication includes a cable arranged to form a wired local area network (LAN), the cable comprising at least first and second conductors. A plurality of access points are interconnected by the cable and are arranged in a wireless local area network (WLAN) to communicate over the air on a common frequency channel with a mobile station. The access points are adapted to convey data to and from the mobile station over the LAN via the first conductor and to exchange control messages among the access points via the second conductor.
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[0001] This application is a divisional of U.S. patent application Ser. No. 11/532,167 filed Sep. 15, 2006.
BACKGROUND
[0002] The present invention relates to a system for separating water vapor and siloxanes from a gas.
SUMMARY
[0003] The invention provides a system for processing gas that contains water vapor and siloxanes, the system comprising: means for expanding the gas to freeze at least some of the water vapor into ice; means for separating the ice and siloxanes from the gas; and means for consuming the gas after removal of the water and siloxanes. In some embodiments, the means for expanding includes a turbine. In some embodiments, the means for separating includes one of a cyclonic separator, a coalescing filter, and a low-velocity plenum. In some embodiments, the means for consuming includes a flare. In some embodiments, the means for consuming includes an engine. In some embodiments, system further comprises a compressor compressing the gas to a pressure of about 90 psig prior to the fuel entering the means for consuming. In some embodiments, the system further comprises a heat exchanger exchanging heat from the gas upstream of the means for expanding to the gas flowing out of the means for separating.
[0004] In another embodiment, the invention provides a method for conditioning and consuming gas, the method comprising: (a) receiving wet, dirty gas containing water and siloxanes from a source of gas; (b) expanding the wet, dirty gas to a temperature below the freezing temperature of water to create a flow of gas containing ice; (c) separating ice and siloxanes from the flow of gas containing ice to create a dry, clean flow of gas; and (d) consuming the dry, clean gas in a fuel consuming device. In some embodiments, step (a) includes receiving the wet, dirty gas from a landfill or waste water treatment facility. In some embodiments, the method further comprises, prior to step (b), lowering the temperature of the gas to below the dew point of the gas but above the freezing temperature of water to condense at least some of the water in the gas, and removing at least some of the condensed water. In some embodiments, step (b) is performed with a turbine. In some embodiments, the method further comprising boosting the pressure of the gas to about 90 psig prior to step (d).
[0005] Other aspects of the invention will become apparent by consideration of the detailed description and accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] FIG. 1 is a schematic illustration of a first embodiment of a fuel conditioner of the present invention.
[0007] FIG. 2 is a schematic illustration of a second embodiment of a fuel conditioner of the present invention.
[0008] FIG. 3 is a schematic illustration of an optional fuel booster.
[0009] FIG. 4 is a schematic illustration of a microturbine engine generator system for use with the present invention.
DETAILED DESCRIPTION
[0010] Before any embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. The use of “including,” “comprising,” or “having” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. Unless specified or limited otherwise, the terms “mounted,” “connected,” “supported,” and “coupled” and variations thereof are used broadly and encompass both direct and indirect mountings, connections, supports, and couplings. Further, “connected” and “coupled” are not restricted to physical or mechanical connections or couplings. Also, although the illustrated embodiments include specific gas pressure and temperature data, such data is specific to the illustrated embodiments and should not be regarded as limiting the scope of the invention except to the extent specified in the claims.
[0011] FIG. 1 illustrates a fuel conditioning system 10 that receives gas from a fuel source 15 , removes water and impurities from the gas, and delivers the gas to a fuel consuming device 20 . The system 10 includes a scrubber 25 , a compressor 30 , an energy input mechanism 35 , a turbine 40 coupled for rotation with the compressor 30 by way of a shaft 45 , an aftercooler 50 , an airflow mechanism 55 , an economizer 60 , a moisture separator 65 , and a solids separator 70 .
[0012] The fuel source 15 may be, for example, a waste water treatment facility, landfill, or other site from which gas is extracted. The impurities in the gas may be, for example, siloxanes or other contaminants that would cause pollution or damage to a combustion chamber and associated moving parts if not removed from the gas. The fuel consuming device 20 may be, for example, a flare that burns the gas to reduce the amount of unburned hydrocarbons that are released into the environment. Alternatively, the fuel consuming device may be an engine that uses the gas fuel for doing work. Examples of such engines include reciprocating engines, microturbine engines, and larger gas turbine engines. Examples of work done by such engines include production of electricity, driving chillers, refrigerators, or compressors, cogeneration of hot water, and raising, lowering, or otherwise moving objects.
[0013] In a typical waste water treatment facility or landfill, gas is extracted from the site at about 0 psig and 100° F., which is the pressure and temperature at which certain reactions take place in a gas digester at the facility. In some cases, the temperature and pressure of the gas will vary depending on the type of reaction taking place. The gas is fed into the scrubber 25 , which removes water droplets that are entrained in the gas. The gas is 100% saturated (e.g., at its dewpoint) at the outlet of the scrubber 25 . The saturated gas flows into the compressor 30 , in which the pressure of the gas is raised to about 15 psig and the temperature is raised to 179° F. In this regard, the compressor 30 energizes the gas prior to the gas entering the turbine 40 . In other embodiments, the gas can be energized by different means, such as a blower.
[0014] The inherent inefficiencies of the compressor-turbine assembly require additional work to make the fuel conditioning system 10 function. This additional energy is provided by the energy input mechanism 35 , which may also be used to start the process. The illustrated energy input mechanism 35 includes a Pelton wheel 75 mounted for rotation with the compressor 30 (e.g., on the shaft 45 ), an electric motor 80 , an oil compressor 85 , and a variable frequency drive control system 90 . The variable frequency drive control system 90 senses a parameter within the fuel conditioning system 10 and adjusts the speed of the motor 80 to maintain the parameter within a desired range. The measured parameter may be, for example, the pressure, temperature, or volumetric flow of the gas at the inlet or outlet of the turbine 40 , or some other parameter that is indicative (i.e., from which can be calculated or inferred) the temperature of the gas. The motor 80 drives the oil compressor 85 , which in turn causes a flow of oil to impinge upon the Pelton wheel 75 to cause rotation of the Pelton wheel 75 and compressor 30 . In the illustrated embodiment, the control system 90 controls the motor 80 to maintain a turbine outlet temperature of about −20° F.
[0015] In alternative embodiments, the compressor 30 and turbine 40 may not be coupled for rotation together and the energy input mechanism 35 may only drive rotation of one of them. For example, if the energy input mechanism 35 drives rotation of the compressor 30 only, the energy in the compressed gas will cause rotation of the turbine 40 . In other embodiments, a pre-compressor (driven by an energy input mechanism) may be positioned upstream of the compressor 30 to provide sufficient energy to the flow of gas to drive rotation of the compressor/turbine assembly, in which case the compressor/turbine assembly may be free-spinning. In other embodiments, the energy input mechanism 35 may include an electric motor 80 directly driving the compressor 30 or driving the compressor 30 through a magnetic coupling. The energy input mechanism 35 may take on many other forms in other embodiments, provided that the energy input mechanism 35 provides energy to perform work.
[0016] From the compressor 30 , the gas flows through the aftercooler 50 , which in the illustrated embodiment utilizes a flow of air to cool the compressed gas. The flow of air is supplied by the airflow mechanism 55 . In the illustrated embodiment, the airflow mechanism 55 includes a motor 95 , a fan 100 , and a variable frequency drive control system 105 . The variable frequency drive control system 105 controls the speed of operation of the motor 95 and fan 100 to maintain another parameter within a desired range. In the illustrated embodiment, for example, the variable frequency drive control system 105 attempts to maintain the gas temperature at the outlet of the economizer 60 at around 40° F. There will be some pressure drop in the gas as it flows through the aftercooler 50 , and the pressure in the illustrated embodiment will be around 15.01 psig at the aftercooler outlet. The temperature of the gas upon exiting the aftercooler is about 83° F. In other embodiments, a temperature-controlled mixing valve can be used in place of the variable frequency drive control system 105 .
[0017] Then the gas flows through the economizer 60 , which in the illustrated embodiment is a counterflow heat exchanger that cools the gas about to enter the turbine 40 (the “inflowing gas”) while warming the gas leaving the solids separator 70 (the “outflowing gas”). The economizer 60 may be, for example, a plate-fin heat exchanger that permits heat to flow from the relatively hot inflowing gas to the relatively cold outflowing gas without mixing the gas flows. As mentioned above, the airflow mechanism 55 is controlled to create a gas temperature of about 40° F. at the outlet of the economizer 60 . A slight pressure drop across the economizer 60 will drop the gas pressure to around 14.72 psig.
[0018] In alternative embodiments, the aftercooler 50 or the economizer 60 or both may be replaced with a refrigeration system that cools the gas temperature to the temperatures described above.
[0019] Prior to flowing into the turbine 40 , the gas flows through the moisture separator 65 . The moisture separator 65 removes any droplets of water that have formed within the gas as a result of condensation during the reduction of the gas temperature through the aftercooler 50 and economizer 60 . Because the gas temperature has been maintained above the freezing temperature of water (such temperature referred to herein as “freezing” for simplicity) to this point, there should not be significant ice or frost buildup within the aftercooler 50 and economizer 60 . The aftercooler 50 and economizer 60 are helpful, however, in reducing the gas temperature to slightly above freezing so that the temperature reduction that results from expansion through the turbine 40 drops the gas temperature well below freezing.
[0020] For embodiments in which a relatively large turbine 40 is used, the pressure of the gas may be reduced in an optional expander prior to the gas entering the turbine 40 , such that the gas pressure is within a range that matches the turbine size. Examples of relatively large turbines for this application include the Garrett Corporation models GT1241 and GT1544, which are sized for small displacement applications, including motorcycles. These relatively large turbines are suitable for a pressure drop of about 7 to 15 psig as contemplated in the embodiments of FIGS. 1 and 2 . Relatively small turbines for this application, such as those used in dental equipment, may be more appropriate for high pressure applications.
[0021] The gas next flows through the turbine 40 , which rotates with the compressor 30 under the influence of the energy input mechanism 35 . As the gas expands through the rotating turbine 40 , its temperature drops to about −20° F. and its pressure drops to about 0.76 psig. This causes remaining water in the gas to condense and freeze, which results in a flow of gas and ice at the outlet of the turbine 40 . Conventional heat exchangers rely on contact between air and large cooling surfaces to transfer heat. When gas having moisture content is passed through such conventional heat exchangers and the temperature is dropped below freezing, such conventional heat exchangers are prone to freezing up and becoming fouled with ice because of such contact, reducing the effectiveness of the heat exchanger. The expanding turbine of the present invention cools through expansion of the gas, not heat transfer across surfaces, which greatly reduces the incidence of ice fouling. Additionally, the turbine 40 in the illustrated embodiment rotates at a rate of between about 40,000 and 100,000 or higher rpm, depending on the size of the turbine 40 , and such high rate of rotation naturally sheds most ice that may form. To further inhibit the formation of ice in the illustrated turbine 40 , the temperature of oil lubricating the turbine 40 bearings can be adjusted to maintain warmer turbine blade temperatures and keep the material of the turbine blade at temperature above the temperature of the gas flowing through the turbine 40 . In alternative embodiments, the turbine 40 may be replaced with an air motor, a gear pump, a vane pump, a nozzle (e.g., a Joule-Thompson valve), or another mechanism for indirectly cooling the gas through expansion without substantial contact of the gas on the mechanism.
[0022] The gas and ice flows into the solids separator 70 , in which the ice is separated from the gas. As the vapor pressure and temperature of the gas drops in the turbine 40 , siloxanes nucleate around the water and ice. Siloxanes are thus removed with the ice in the separator 70 . The gas flowing out of the solids separator 70 (i.e., the above-mentioned outflowing gas) is therefore dry and clean, is still at a temperature of about −20° F., and is at a pressure of about 0.45 psig (owing to a pressure drop through the solids separator 70 ). In the illustrated embodiment, the solids separator 70 includes two separators 110 so that if one separator 110 is fouled with ice, a valve 115 may be actuated to direct the flow to the other separator 110 while the fouled separator 110 is thawed. In one embodiment, the solids separator 70 takes the form of a cyclonic separator, and in other embodiments it may be a coalescer filter or a low-velocity plenum.
[0023] The outflowing gas then flows through the economizer 60 to pre-cool the inflowing gas. This increases the temperature of the outflowing gas to about 23° F., and decreases the gas pressure to about 0.30 psig. Raising the outflowing gas temperature through the economizer 60 ensures that the gas will be above its dewpoint, thereby creating dewpoint suppression. Although the outflowing gas should be completely dry upon leaving the separator 70 , the dewpoint suppression reduces the likelihood that any remaining water will condense in the gas while it is being consumed in the fuel consuming device 20 . From the economizer 60 , the gas flows into the fuel consuming device 20 , or is directed back (via a valve 120 ) to mix with and cool the wet, dirty gas as it flows into the scrubber 25 .
[0024] FIG. 2 schematically illustrates an alternative construction 125 of the fuel conditioning system, in which like components are identified with the same reference numerals used in FIG. 1 . In this embodiment, there is no aftercooler 50 . The gas flowing out of the scrubber 25 is first run through the economizer 60 to reduce its temperature to about 40° F. A bypass valve 130 controls the amount of gas flowing into the cold side of the economizer 60 to ensure that the gas flowing out of the economizer is kept above freezing. Condensed water within the gas is then removed in the moisture separator 65 . Then the gas flows through the turbine 40 , in which the gas pressure is reduced to −7.5 psig and the gas temperature is reduced to −20° F. Then the gas flows through the solids separator 70 to remove ice and siloxanes. The gas then flows through the economizer 60 , where its temperature is raised to about 40° F. Finally, the gas flows through the compressor 30 , where the gas pressure is raised to about −1 psig and the gas temperature is raised to about 102° F. The compressor 30 is driven by an energy input mechanism 35 similar to the first embodiment.
[0025] With reference to FIG. 3 , some fuel consuming devices 20 , such as microturbine engine generators, operate most efficiently if the fuel gas is provided at elevated pressures (e.g., around 90 psig). Should the fuel consuming device 20 require relatively high-pressure fuel gas, an optional compressor or gas booster assembly 135 may be used to raise the gas pressure upstream of the fuel consuming device 20 . The illustrated optional compressor assembly 135 includes a compressor 140 driven by a motor 145 and a variable frequency drive control system 150 that is referenced to a parameter (e.g., gas pressure) of the gas entering the compressor assembly 135 . In the compressor 140 , the gas pressure is raised to about 90 psig and the gas temperature is raised to about 200° F. Also within the compressor assembly 135 is an aftercooler 155 that reduces the gas temperature to about 100° F. A fan 160 powered by a motor 165 blows air across the aftercooler 155 to facilitate heat transfer. In other embodiments, the gas booster 135 can be positioned upstream of the fuel conditioning system 10 such that relatively high pressure gas enters the system 10 . In such embodiments the boosted gas may provide sufficient energy to drive the compressor 30 and turbine 40 in the fuel conditioning system 10 , which would obviate the energy input mechanism 35 . For that matter, in a closed system, positioning the gas booster 135 downstream of the fuel conditioning system 10 may augment the expansion ratio across the turbine 40 of the fuel conditioning system 10 , and this may also obviate the energy input mechanism 35 .
[0026] FIG. 4 schematically illustrates one type of fuel consuming device 20 that may be used in conjunction with either of the fuel conditioning systems 10 , 125 described above and illustrated in FIGS. 1 and 2 . The fuel consuming device in FIG. 3 is a microturbine engine generator 170 , which is useful in distributed power applications, and can even be mounted on skids and moved between job sites. Microturbine engine generators usually generate 2 MW of power or less, and are therefore relatively small when compared to power generators in power plants that are on the grid.
[0027] The illustrated microturbine engine generator 170 includes a compressor 175 , a recuperator 180 , a combustor 185 , a power turbine 190 , and an electric power generator 195 . Air is compressed in the compressor 175 and delivered to a cool side of the recuperator 180 . The recuperator 180 may be, for example, a counterflow plate-fin type heat exchanger. The compressed air is preheated within the recuperator 180 and mixed with a gaseous fuel from a fuel supply (e.g., one of the fuel conditioning systems 10 , 125 described above and illustrated in FIGS. 1 and 2 ) to create a combustible mixture. It is advantageous in a microturbine engine generator 170 to raise the pressure of fuel gas used in the combustible mixture to 90 psig, and the temperature to about 100° F. For such applications, the above-mentioned compressor assembly 135 may be positioned downstream of the fuel conditioning system 10 , 125 and upstream of the microturbine engine generator 170 .
[0028] The combustible mixture is combusted in the combustor 185 to create products of combustion. The products of combustion are then permitted to expand through the power turbine 190 to impart rotational energy to the power turbine 190 . Rotation of the power turbine 190 drives operation of the electric generator 195 through an optional gearbox 200 to produce electrical power at a useful frequency. In other embodiments, the power electronics may be used in place of the gearbox to condition the electrical signal into a useful frequency. In the illustrated microturbine 170 , the power turbine 190 and compressor 175 are coupled for rotation together via a shaft 205 , so rotation of the power turbine 190 also drives rotation of the compressor 175 . In other embodiments, the power turbine 190 may only drive the power generator 195 , and an additional gasifier turbine may be used to drive the compressor 175 . In such embodiments, the products of combustion are expanded through both the power turbine 190 and the gasifier turbine. Prior to exhausting the products of combustion from the microturbine engine 170 , they flow into a hot side of the recuperator 180 to preheat the inflowing compressed air. Any remaining heat in the products of combustion is used for some other useful purpose (e.g., heating water) in a final heat exchanger 210 before the products of combustion are exhausted.
[0029] Various features and advantages of the invention are set forth in the following claims.
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A method of removing siloxanes from a gas that contains siloxanes and water, the method comprising: (a) expanding the gas to cool the gas and freeze at least some of the water in the gas; and (b) removing the siloxanes and frozen water from the expanded and cooled gas. The method may also include compressing the gas prior to expanding it. The step of expanding the gas may include expanding it through a turbine. The method may also include using an energy input mechanism to drive one or both of the compressor or turbine. The ice and siloxanes may be removed from the gas with a cyclonic separator.
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FIELD OF THE INVENTION
The present invention generally relates to a vehicle door lock device and more particularly to a one-motion opening mechanism and a self-canceling mechanism of a door lock device. Incidentally, a one-motion opening mechanism is defined herein as a mechanism through which a door can be opened by operating an inner opening handle mounted on the inside of a door even when the lock device is in a locked state. Moreover, a self-canceling mechanism is defined as a mechanism by which the state of the lock device is automatically changed into an unlocked state when a door is closed after the lock device is put into a locked state.
DESCRIPTION OF THE RELATED ART
Both of a one-motion opening mechanism and a self-canceling mechanism are typical options or parts having additional functions, with which a lock device is endowed, and have been proposed previously.
These kinds of mechanisms may be used in a lock device singly or in combination. Thus automakers select and employ the most appropriate one of three types of variations of a lock device.
A lock-device maker designs a lock device of the types which the automaker desires, according to the environment thereof, such as the structure and size of a door of an automobile, to which the lock device is mounted. However, if the design of the lock device has been once accomplished, it becomes difficult to replace a kind of a mechanism already mounted in the lock device with the other kind of a mechanism and to add the latter mechanism to the lock device. Even if such alterations are necessary, the details of the lock device should be redesigned. Alternatively, in order to save redesigning the lock device, an unnecessary part is kept secured to in the lock device.
SUMMARY OF THE INVENTION
Accordingly, an object of the present invention is to provide a lock device which can be freely selected from the three variations thereof by simply replacing a part thereof with another part.
To achieve the foregoing object, in accordance with the present invention, there is provided a lock device which comprises a first group lever consisting of three kinds of levers connected to a ratchet, and a second group lever consisting of two kinds of levers connected to an outer opening handle, wherein a lever of each of the group levers is selected according to a desired variation of the configuration of the lock device.
BRIEF DESCRIPTION OF THE DRAWINGS
Other features, objects and advantages of the present invention will become apparent from the following description of preferred embodiments with reference to the drawings in which like reference characters designate like or corresponding parts throughout several views, and in which:
FIG. 1 is a front view of a lock device;
FIG. 2 is a rear view of the lock device which is in an unlocked state;
FIG. 3 is a rear view of the lock device which is in a locked state;
FIG. 4 is a diagram for illustrating operations of a one-motion opening mechanism and a self-canceling mechanism;
FIG. 5 is a plan view of an interlocking link;
FIG. 6 is a plan view of an opening lever;
FIG. 7 is a plan view of a ratchet lever;
FIG. 8 is a sectional view taken on line A--A of FIG. 7;
FIG. 9 is a rear view of a simplified lock device which is in an unlocked state;
FIG. 10 is a rear view of the simplified lock device which is in a locked state;
FIG. 11 is a diagram for illustrating an operation of a one-motion opening mechanism of the simplified lock device;
FIG. 12 is a diagram for illustrating the structure of the simplified lock device which is provided with no self-canceling mechanism;
FIG. 13 is a plan view of a ratchet lever of the simplified lock device;
FIG. 14 is a sectional view taken on line B--B of FIG. 13;
FIG. 15 is a rear view of another simplified lock device which is in an unlocked state;
FIG. 16 is a rear view of this simplified lock device which is in a locked state;
FIG. 17 is a diagram for illustrating an operation of a self-canceling mechanism of this simplified lock device;
FIG. 18 is a plan view of an opening lever of this simplified lock device;
FIG. 19 is a plan view of a ratchet lever of the simplified lock device; and
FIG. 20 is a sectional view taken on line C--C of FIG. 19.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Hereinafter, the preferred embodiments of the present invention will be described in detail by referring to the accompanying drawings.
First, a lock device (hereunder referred to as a basic lock device), which is provided with both of a one-motion opening mechanism and a self-canceling mechanism, will be described hereinbelow by referring to FIGS. 1 to 8. A lock body 1 of the basic lock device has a concave or recess portion 2 in the front portion thereof. In the concave portion 2, a latch 4 engaging with a striker 3 secured to a vehicle body and a ratchet 5 engaging with the latch 4 are enclosed. On the ratchet 5, a pin 7 protruding therefrom to the rear of the lock device through a through hole 6 formed in the body 1 is provided. When the ratchet 5 moves in the direction of an arrow X against the resilience of a spring 8, the ratchet 5 is disengaged from the latch 4. Consequently, a door is opened. As is well known, the concave portion 2 is closed or covered with a cover plate (not shown).
As shown in FIG. 2, a lock lever 10 is fixed to an upper position or a first space on the rear surface of the lock body 1 through a shaft 9. An inside lock button 11 and a door key cylinder 12 are attached to the lock lever 10. By operating these elements, the position of the lock lever 10 is changed between the unlocked position (of FIG. 2) and the locked position (of FIG. 3), as is well known.
The top end of an interlocking lever 13 is fixed to the lock lever 10 by means of a pin 14. As illustrated in FIG. 5, the L-shaped link 13 is composed of a vertical portion 15, a horizontal portion 16, a convex portion 17 formed at a corner part thereof and a pin 18 formed at the tip of the horizontal portion 16.
A ratchet lever 20 is fixed to a lower position or a second space on the rear surface of the lock body 1 through a shaft 19. The ratchet lever 20 of the basic lock device is an important part for realizing a one-motion opening mechanism and a self-canceling mechanism. The plan view of the ratchet lever 20 is illustrated in FIG. 7. The ratchet lever 20 has a right arm 23, which can be put into abutting engagement with an inner lever 22 to be connected to an inner opening handle 21 of a door, and a left arm or releasing arm 25 provided with an end portion 24 which can be engaged with the convex portion 17 of the link 13. A cylindrical portion 26, into which the pin 7 of the ratchet 5 is inserted, is formed on the back surface of the left arm 25. As a result of engaging the pin 7 with the cylindrical portion 26, the ratchet 5 and the ratchet lever 20 rotates about the shaft 19 as one body. Thus, when the ratchet lever 20 rotates counterclockwise as a consequence of engaging the ratchet lever 20 with the inner lever 22, the ratchet 5 rotates in the direction of the arrow X against the resilience of the spring 8. Consequently, the door is opened.
The end portion 24 of the ratchet lever 20 faces the convex portion 17 of the link 13 when being in the locked state of FIG. 3. The anticlockwise rotation of the ratchet lever 20 results in the end portion 24 being engaged with the convex portion 17. Consequently, the position of the lock lever 10 is changed into the unlocked position (see FIG. 4) through the link 13. Thus, if the inner lever 22 is turned when being in the locked state, an operation of changing the state of the lock lever into the unlocked state and an operation of opening the door can be achieved simultaneously (namely, the one-motion opening mechanism can be realized).
An opening lever 29 connected to an outer opening handle 27 of the door through a rod 28 is fixed to the shaft 19. The opening lever 29 has an elongated hole 30 with which the pin 18 of the link 13 engages. The pin 18 is located in a lower part of the elongated hole 30 and faces an engagement portion 31 of the ratchet lever 20 when being in the unlocked state of FIG. 2. Thus, in the case where the lock lever is in the unlocked state, the rotation of the opening lever 29 causes the pin to engage with the engagement portion 31 and also causes the ratchet lever 20 to rotate. Thereby, the ratchet 5 is disengaged from the latch 4. However, in the case where the lock lever is in the locked state of FIG. 3, the pin 18 is located in an upper part of the elongated hole 30. Thus the pin 18 is disengaged from the engagement portion 31. Therefore, when the lock lever is in the locked state, the rotation of the opening lever 29 does not cause the pin 18 to engage with the engagement portion 31. Consequently, the door is left closed.
In the case of the aforementioned basic lock device, the self-canceling mechanism is realized by engaging the pin 7 of the ratchet 5 with the cylindrical portion 26 of the ratchet lever 20. When the latch 4 is engaged with the striker 3 by closing the door and is further rotated, the ratchet 5 is pushed by the peripheral portion 32 of the latch 4. Thus the ratchet 5 is moved in the direction of the arrow X against the resilience of the spring 8. Moreover, the ratchet lever 20 is turned counterclockwise, as viewed in FIG. 3. Therefore, even when the door is closed after the state of the lock device has been changed into the locked state, the link 13 is pushed down by the end portion 24 of the ratchet lever 20. As a result, the lock lever 10 is put back to the unlocked position thereof. When causing the self-canceling mechanism to stop functioning, the state of the lock device is first changed into a locked state and subsequently, the outer opening handle 27 is turned. Thereupon, the opening lever 29 rotates anticlockwise, as viewed in FIG. 3. Thus the link 13 swings around the pin 14, so that the projection 17 is disengaged from the end portion 24 of the ratchet lever 20. If the door is closed by maintaining this state, the end portion 24 of the ratchet lever 20 does not engage with the link 13. Consequently, the locked state is not canceled.
Next, a simplified lock device obtained by removing the self-canceling mechanism from the aforementioned basic lock device will be described hereinafter with reference to FIGS. 9 to 14. The simplified lock device uses a ratchet lever 20a of FIG. 13 instead of the ratchet lever 20 of FIG. 7, though the remaining parts of the simplified lock device are entirely the same as the corresponding parts of the basic lock device, respectively. Outwardly, the ratchet lever 20a is the same as the ratchet lever 20 of FIG. 7. The ratchet lever 20a, however, has a projection-like member 26a in place of the cylindrical member 26 of the basic lock device. The member 26a is situated over the pin 7 of the ratchet 5 as illustrated in FIG. 9 so that the rotation of the ratchet lever 20a is transmitted to the ratchet 5 but a motion in the direction of the arrow X of the ratchet 5 is not transmitted to the ratchet lever 20a as is seen from FIG. 11. In the case where the one-way connection between the ratchet lever 20a and the ratchet 5 is established in this way, the ratchet lever 20a does not rotate even if the ratchet 5 moves in the direction of the arrow X when closing the door. Thus the link 13 does not move as is seen from FIG. 12. Consequently, the locked state is not canceled.
The simplified lock device has an one-motion opening mechanism naturally. If the ratchet lever 20a is turned by operating the inner lever 22 when being in the locked state of FIG. 10, the member 26a engages with the pin 7 as shown in FIG. 11. Thus the ratchet 5 is disengaged from the latch 4. Simultaneously, the end portion 24a is brought into abutting engagement with the projection 17 of the link 13. Consequently, the lock lever 10 is put in the unlocked position.
Thus, the lock device, which does not have a self-canceling mechanism but have a one-motion opening mechanism, can be obtained.
Next, another simplified lock device, which is equipped with a self-canceling mechanism but with no one-motion opening mechanism, will be described hereinbelow by referring to FIGS. 15 to 20. Each of the parts of this simplified lock device, which are other than a ratchet lever 20b and an opening lever 29b, is completely the same as the corresponding part of the basic lock device. A right arm being capable of engaging with the inner lever 22 is formed in an opening lever 29b instead of the ratchet lever 20b and is designated by reference character 23b. As a result of this alteration, the inner lever 22 comes to be able to rotate the ratchet lever 20b through the opening lever 29b only when being in the unlocked state. In other words, the door can not be opened by operating the inner lever 22 when being in the locked state. Therefore, in the case of this simplified lock device, a one-motion opening mechanism can not be realized.
The ratchet lever 20b has a cylindrical member 26b, into which the pin 7 of the ratchet 5 is inserted, similarly as in the case of the basic lock device. Thus, when the ratchet 5 is moved in the direction of the arrow X against the resilience of the spring 8 by closing the door, the ratchet lever 20b is turned counterclockwise as illustrated in FIG. 17. Further, an end portion 24b of the ratchet lever 20b pushes down the link 13, so that the position of the lock lever 10 is changed into an unlocked position (namely, the self-canceling mechanism is realized).
Thus, in accordance with the present invention, the configuration of a lock device can be freely selected from the three variations thereof by performing a simple replacement of parts thereof.
Although the preferred embodiments of the present invention have been described above, it should be understood that the present invention is not limited thereto and that other modifications will be apparent to those skilled in the art without departing from the spirit of the invention.
The scope of the present invention, therefore, is to be determined solely by the appended claims.
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A vehicle door lock device comprises a first group lever consisting of three kinds of ratchet levers connected to a ratchet, and a second group lever consisting of two kinds of opening levers connected to an outer opening handle. First variation of the lock device having one-motion opening and self-canceling mechanisms can be realized by the first combination of a first ratchet lever and a first opening lever. Second variation of the lock device having one-motion opening mechanism but self-canceling mechanism can be realized by the second combination of a third ratchet lever and the first opening lever. Third variation of the lock device having self-canceling mechanism but one-motion opening mechanism can be realized by the third combination of a second ratchet lever and a second opening lever.
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BACKGROUND OF THE INVENTION
1. Field of the invention
The present invention relates to a tree shear for felling trees and to a tree harvester having a tree shear-and-grapple head incorporating the aforesaid tree shear.
2. Description of the prior art
Known tree shears of the type to which the invention relates comprise a pair of shear blades that are pivoted, by powerful hydraulic jacks, like the two blades of scissors. When applied about the trunk of a tree to be felled and at its butt end, the sharp edges of the blade elements are forced into the trunk until the tree is severed from its base. The shearing pressure that must be applied to achieve felling has to be considerable since the knives or blade elements have to cut across the fibres of the tree trunk. In fact, severing of the tree is due to crushing as well as to shearing of the fibres. Now, this crushing action does not take place only in the shear plane but extends appreciably beyond that plane and, as a consequence, a not negligible part of the lower end of the tree is irremediably damaged insofar as using that part for making lumber boards is concerned.
SUMMARY OF THE INVENTION
It is an object of the invention to alleviate the damage caused by the shear blade crushing action mentioned above. This is obtained, according to the invention, by applying to the shear blades an oscillatory motion as well as the conventional scissors-like pivot motion so that the blades act much like the more efficient linearly-reciprocating manner of a straight saw.
More specifically and according to the invention, this principle is applied in a tree shear which comprises: a frame; a pair of shear blades mounted on the frame for pivotal movement relative to one another in scissors fashion, and power means for pivoting the blades, the tree shear being improved in that the blades are mounted on the frame by pivot means which include oscillation means for causing the blades to move back and forth in their own planes as they are pivoted by the power means.
Such oscillation means could be eccentric means which may, for instance, comprise, for each blade, a rotary shaft having an eccentric center portion on which the blade is mounted.
In a preferred form, the frame has a pair of parallel plates between which the shear blades are located, each rotary shaft then having a pair of coaxial trunnions solid with the eccentric center portions; bearing means mounting the trunnions on the plates for free rotation of the shafts and motor means for rotating the shaft.
The invention also relates to a tree harvester comprising:
an elongated boom;
a tree working head comprising: an elongated frame having a longitudinal axis; a pair of shear blades mounted on the frame for pivotal movement in scissors fashion relative to one another in a plane normal to the frame longitudinal axis, and power means for pivoting the blades;
wherein the blades are mounted on the frame by pivot means including oscillation means for causing the blades to move back and forth in the normal plane as the blades are pivoted by the power means;
means pivotally mounting the head on one end of the boom, and
power means, on the head and on the boom, for so pivoting the head between a position wherein the head stands essentially parallel to the boom and a vertical position for shearing trees.
Other features of the invention will appear from the description that follows of a preferred embodiment having reference to the appended drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a plan view of a tree shear made according to the invention while FIG. 2 is a cross-section taken in a plane along line II--II in FIG. 1 and shown on an enlarged scale;
FIGS. 3 and 4 are side elevation views of a tree working head incorporating the improved tree shear of the invention and showing the head in the tree delimbing position and an intermediate position, in FIG. 3, and in tree-shearing position in FIG. 4;
FIG. 5 is a plan view of a grapple assembly used in the head of FIGS. 3 and 4, and
FIG. 6 is a side elevation view of a tree harvester making use of the head of FIGS. 3 and 4.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIGS. 1 and 3 to 5, the tree shear 1 made according to the invention is mounted on a frame 3 made up of two spaced channel members 5, 5', each having a web 7, 7', and a pair of side flanges 8, 8'; 9, 9'; the two webs 7, 7', facing one another at a suitable distance between them defining a space 10 allowing insertion of the end of a boom 11; the side flanges 8, 8'; 9, 9', projecting away from this space 10.
The channel-shaped members 5, 5', are held in spaced apart relationship by a series of plates 13, 15, 17 and 19, of which one edge is secured to the flanges 8, 9, of the two channel members 5, 5', as best seen in FIGS. 1 and 5. Plates 15, 17 and 19, are further interconnected by rods 21, 22. A series of ears 23, 25, 27 and 29, project from each of the opposite flanges 8', 9', of the channel members 5, 5', being preferably coplanar respectively with plates 13 to 19. The latter ears are also interconnected by rods 31, 32.
The two channel members 5, 5'; the plates 13 to 19, the ears 23 to 29 and the rods 21, 31, 32, constitute the frame 3.
As shown, the tree shear 1 is mounted on and between the plates 13 and 15 in a manner more fully described hereinbelow.
Above the tree shear 1, in FIG. 4, are a pair of conventional grappling arms 33, 35, which are pivotally mounted at one end on the rods 21, 22, (FIG. 5) and are spaced from one another, along the rods, to properly grasp the tree to be sheared. The grappling arms also serve to delimb the tree, as is known and as is briefly described hereinbelow with respect to FIG. 6. Arms 33, 35, are operated by hydraulic jacks 37, 39, of which the cylinders free ends are pivotally mounted on the rods 31, 32, and the piston rods free ends connected to the arms 33, 35, by pivot means 41, 43, intermediate their ends.
Finally, a conventional topping mechanism 45 having a retractible topping knife 47 (FIG. 3), for cutting off the tips of delimbed trees, is secured at the top end of the two channel members 5, 5', being for instance welded to their plate 19 and ears 29.
The frame 3, the tree shear 1, the grappling arms 33, 35, and the topping mechanism 45 form the working head 49 of the tree harvester. The head is pivotally mounted at the end of the boom 11 by two sets of cooperating brackets 51, 53, along each lateral edge of the boom 11 and on the flanges 8', 9', of the channel members 5, 5', only one set being shown. The brackets 51, 53, of each set are interconnected by a pivot 55. Pivoting motion is obtained by a hydraulic jack 57 pivoted, at its ends, respectively to a bracket 59 of the boom 11 and a further bracket 61 secured to and beneath the casing of the topping mechanism 45.
With the above arrangement, the working head 49 can be moved between a tree delimbing and topping position, where it stands essentially parallel to the boom 11 (FIG. 3), and a tree shearing position (FIG. 4).
The working head 49 may be used particularly efficiently with the tree harvester as described fully in my prior applications in Canada No. 550,073 of Oct. 23, 1987 and in the U.S., No. 110,428 of Oct. 20, 1987, and diagrammatically shown in FIG. 6. It comprises a pedestal 63 mounted on a tracked vehicle 65 for rotation about a vertical axis. An operating base 67 is pivoted at 69 on the pedestal 63, being tilted by a hydraulic jack 71. A grapple assembly 73, having grappling arms 103, 105, similar to arms 33, 35, is mounted at the forward end of the base 67. The latter and the body of the grapple assembly 73 are formed with a through passage 75 into which the straight boom 11 may be slid, being guided by suitable rollers 77. Sliding movement of the boom 11 is obtained by means of a hinged boom 79 having an inner section 81 and an outer section 83 articulated at their common end by a pivot 85. Section 81 is additionally pivoted at 87 to the bas 67 while section 83 is pivoted at 89 to the bracket 59 (see FIGS. 3 and 4) at the free end of the boom 11. A first hydraulic jack 91 interconnects the boom section 81 and the base 67 while a pair of further jacks 93, one on either side of the hinged boom 79, joins the two sections 81, 83, over the pivot 85; the interconnections being by means of pivot joints 95, 97, 99, 101.
It will be appreciated that synchronized actuation of the jacks 91, 93, moves the free end of the boom 11 and the working head 49 toward or away from the base 9.
In operation, once a tree has been felled by the shear 1 and held by the gripping arms 33, 35, the working head 49 is brought close to the base 67, by closing in of the hinged boom sections 81, 83, and the butt end of the tree solidly gripped by the jaws 103, 105, of the grapple assembly 73. At that time, the grapple arms 33, 35, of the working head 49, slightly loosen their hold on the tree and the hinged boom sections 81, 83, made to open up, causing the boom 11 and the head 49 to be moved leftward. With butt end of the tree held fast by the jaws 103, 105, of the grapple assembly 73, the grapple arms 33, 35, then act as delimbing members shearing the branches off the tree trunk.
Referring now to FIGS. 1 and 2, the tree shear 1 has a pair of shear blades 107, 109, of essentially standard construction, mounted on and between the two plates 13, 15, (edgedly fixed to the flanges 8 and 9 of the channel members 5, 5',) by pivot means 111, 113. As said before, the latter pivot means include oscillation means that cause the blades 107, 109, to move back and forth, in their own planes, as shown by the arrows, when the blades are pivoted by suitable power jacks 115, 117, of which the ends are pivoted on the rods 31, 32, and on peripheral ears 119, 121, of the blades 107, 109. The pivot means 113 are shown in detail in FIG. 2; pivot means 111 being identical to means 113 so that only the latter need be described.
As shown, pivot means 113 comprises a pivot shaft 116 formed by a pair of coaxial trunnions 118, 119, separated by an eccentric center shaft portion 121, solid with the trunnions. The latter are mounted respectively on the plates 13, 15, conventionally by ball bearings 123, 125, for free rotation relative to the plates. The eccentric center portion 121, on the other hand, is similarly mounted on the shear blade 109 by roller bearings 127. The latter are separated from the frame plates 13, 15, by annular trust plates.
In this manner, it will be appreciated that the shaft 116 is free to rotate with respect to the plates 13, 15, and the shear blade 109. When thus rotating, the shear blade oscillates by virtue of the eccentric portion 121.
Rotation of the shaft 116, independently of the pivoting of the blade 109, is obtained by an electric motor 129 fixed to the plate 15 and of which the output shaft 131 is inserted in and properly keyed to the trunnion 119.
Thus, and according to the invention, the above pivot arrangement allows an oscillating motion as well as a conventional scissors-like shear motion to be applied to the shear blades 107, 109. The latter can then act more efficiently in felling trees by alleviating the crushing pressure present when only a shear motion is applied.
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A tree shear is disclosed which has a frame on which is mounted a pair of blades for pivotal movement relative to one another in scissors fashion; the blades being pivoted by hydraulic jacks. Each blade pivots on a rotary shaft having an eccentric center portion, each blade being mounted on the eccentric portion so that, as the shaft rotates, it causes the blade to oscillate.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] Inventor claims the benefit pursuant to 35 U.S.C. §119(e) of the Nov. 9, 2009 filing date of Provisional Application No. 61/280,838 by the same inventor.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH AND DEVELOPMENT
[0002] This invention was not made using Federally Sponsored Research and Development. The inventor retains all rights.
THE NAMES OF THE PARTIES TO A JOINT RESEARCH AGREEMENT
[0003] N/A.
REFERENCE TO A SEQUENCE LISTING
[0004] N/A.
BACKGROUND OF THE INVENTION
[0005] The nation's ability to compete in the global economy requires American students be proficient in Science, Technology, Engineering and Mathematics (STEM). Their lack of proficiency has become a nationally recognized concern. The National Center for Education Statistics, run by the United States Department of Education provides standardized test scores for American fourth graders and eighth graders in basic reading, writing, math and science. The data clearly shows that despite ever increasing levels of spending on education, American students continue to fail standardized tests designed to measure their proficiency in these four subjects. What is apparent in the data is that a different approach to education is needed.
[0006] As further evidence of the national concern over student performance, particularly in STEM, NASA is developing a $1.3 million massively multi-player on-line [video] game (MMOG) just to explore methods for stimulating student interest in these subjects. Other organizations engaged in STEM education include the Challenger Center for Space Science Education. They have developed a simulation system designed to replicate near-term NASA missions in an attempt to teach and inspire the pursuit of STEM and STEM-related subjects. Other less prominent efforts to address STEM education are underway across the nation by organizations both public and private.
[0007] NASA's MMOG approach will need to produce a competitive version of the genre capable of captivating student interest while effectively addressing STEM education issues. The NASA product will be up against popular on-line video games such as Halo® and World of Warcraft®:
“IRVINE, Calif.—Jan. 23, 2007—Blizzard Entertainment® today announced that World of Warcraft®: The Burning Crusade™ has broken the day-one sales record to become the fastest-selling PC game ever in North America and Europe, with a worldwide total of nearly 2.4 million copies sold in the first 24 hours of availability. The Burning Crusade, the first expansion set for World of Warcraft, was simultaneously released in North America, Europe, Singapore, Thailand, and Malaysia on January 16 and on January 17 in Australia and New Zealand.”
[0009] It remains to be seen whether NASA can produce a competitive product. Further, if NASA's on-line approach is successful, it would likely be accessible worldwide and thus would do little to help American students develop a competitive edge over their foreign counterparts.
[0010] The Challenger Center for Space Science Education currently offers their 20-year old technology simulating not-too-distant-future NASA-like missions. Their system price, currently near $850,000, is prohibitively high and effectively limits its availability to students. Further, Challenger programs are designed for middle school students (grades 5 through 8) yet another restriction on student access to simulation-based STEM education tools and methods. The Challenger network of about 55 centers collectively reach approximately 400,000 students per year, a very small percentage of our overall student population. The Challenger system simply fails to adequately address the STEM education issues facing the nation.
[0011] Preliminary evaluations of TREC's Advanced Spaceflight Laboratory (ASL) have demonstrated its potential to raise the level of student interest in STEM subjects while simultaneously delivering standards-oriented instruction in these areas. Mr. Paul McFarlane, Lead Flight Director at the Challenger Learning Center of Northern Nevada is currently evaluating an Advanced Spaceflight Laboratory prototype simulator named “Horizon” and has provided the following feedback:
“Over the course of several months, we had the opportunity to utilize the lab with pre-school students, elementary school students, middle school students, high school students, Civil Air Patrol Cadets, university students, university faculty (including professors of astronomy, astrobiology, and planetary geology), Reno Air Racing Foundation Board Members, and members of the community at large . . . For each of the groups, the experiences, educational content and storylines were adapted and increased or decreased in detail or complexity depending on their age or educational level; however, the one constant was that each age and interest level was thoroughly engrossed by their excursions into the Solar System . . . and beyond.”
[0013] Mr. McFarlane also provided this comment:
“I've had teachers tell me that their middle and high school students truly ‘came alive’ during their simulated journeys. One teacher even commented that several students she'd had for eight months had never talked, asked questions, or really ever been engaged in class until the hour they spent on board Horizon. What an incredible testimony to this project's potential to fire the imaginations of our young people!”
[0015] The prototype hardware and software, developed by TREC to explore STEM education issues clearly shows that its approach to immersive simulation can positively impact education. This invention is intended to dramatically improve immersive simulation techniques both in terms of educational impact and cost.
BRIEF SUMMARY OF THE INVENTION
[0016] Current ASL technology is comprised of a copyrighted software simulation of the Solar System presented from the perspective of a futuristic spacecraft capable of flying through the Solar System to its various planets and moons. The existing software produces accurate, photo-realistic imagery and also provides features designed to support the teaching of a variety of concepts related to math and science. These additional software features include maps, latitude and longitude overlays, constellation outlines, multiple orbit modes (polar, solar, equatorial and retrograde motion demonstration) and overhead slides to support lectures and other on-board student activities.
[0017] The aforementioned software can be presented in a variety of packages including trailers, structures built inside buildings or other forms. The intent is that the software be presented to students and others in a cabin designed to look and feel like a futuristic spacecraft, similar to ones seen in popular science fiction television programs and movies. The spacecraft cabin design, operating in conjunction with the software, provides a completely unique and flexible educational environment that effectively takes students out of their normal frame of mind. It is one thing to see photographs of Jupiter and its moons on a personal computer in the classroom. It is quite a different experience to see the same view out the window of your spacecraft. The experience is especially powerful for younger students whose vivid imaginations are more easily stimulated.
[0018] TREC has built two prototype simulators, each operates in a large enclosed trailer and each has been taken to schools and other venues for program delivery. In particular, TREC has delivered multiple lectures on the planets to young students in kindergarten, first and second grades. Without exception, these young students were captivated by the experience and invariably one of the children would ask: “Are we really in space?” The unique ASL environment clearly fascinates young minds and TREC believes that as they absorb the details of their surroundings they will also more readily absorb STEM related materials. That is the benefit and power of the credible immersive simulated environment ASL technology provides.
[0019] This invention, comprising five disparate components, represents a significant expansion of TREC's existing ASL technology and the positive impact it can have on learning. The incorporation of these additional components will allow the experience had by young students to be extended to older students whose imaginations are more tempered by their growing maturity. When integrated, the following five components constitute a patentable method that creates a new, unique and effective education process. The components are:
[0000] Invention Component 1—Physical items that represent facsimiles of real and/or fictional equipment, vehicles or facilities.
Physical items comprised of combinations of computers, displays, user interlaces, software, networking technologies and enclosures, or other combinations of hardware and or software, that are intended to represent some physical item. TREC's Advanced Spaceflight Laboratory simulators/trailers are composed of the aforementioned elements and create a facsimile of a futuristic research spacecraft that is an example of this type of component. A Challenger Learning Center with its mission control room and space station simulators are another example of this element.
Invention Component 2—Real facilities and people.
These are items that represent themselves or that act as facsimiles of other facilities or persons real or fictional. For example, the staff and/or installation at the National Radio Astronomy Observatory—Very Large Array (Socorro N. Mex.) could represent itself or a futuristic scientific research facility while it interacts with students on-board ASL simulators participating in an educational event through the linking technologies described below. Another example of this type of element would be college professor or other professional that plays a character in the educational event serving as an expert in a particular field.
Invention Component 3—Simulated and/or real broadcast or Internet media elements such as advertising, news stories, music, entertaining and/or documentary programs and or films and/or other such items.
These elements are used to inject pertinent information into the educational environment and in cases serve to enhance the believability of the environment. They can also be incorporated into the educational event as the primary educational objective. For example, of particular value would be the incorporation of excerpts from historical documentaries presented as though the events were surreptitiously captured live. Using the fictional ability of ASL simulators to travel back in time and launch probes, an educational event for students could involve watching the signing of the Declaration of Independence while the significance of the event is discussed. ASL-NET technologies and the environment they can create would allow for this unique and more interesting perspective on historical events.
Invention Component 4—Dramatic stories designed to control the introduction and interaction of components one, two and three and which help engage and guide students toward knowledge and understanding of the ASL-NET lesson content.
The degree of drama introduced into ASL-NET educational events can vary. It is possible to create valuable educational experiences with little or no dramatic enhancement. However, whether introduced formally or informally, dramatic elements accentuate the importance of learning activities and the raise the level of engagement students have vis-à-vis that activity. Using classical dramatic structure, educational activities can be choreographed in a fashion that accentuates their importance for the students that are acting as the story's characters. For example, at some point in the educational drama the plot may call for the ‘ship’ (e.g. an ASL simulator) to be immobilized placing it, the crew and the ‘mission’ in grave danger. The intent of this example of a plot point is to accentuate the importance of a STEM learning activity such as an engineering task to repair a circuit on board the ship so that it and the crew can move to safety. The “dramatic consequence” is that the ship and or the mission could fail if the students responsible for the repairs are unsuccessful in their efforts.
Invention Component 5—Linking technologies. These are the items that, for the purpose of data transmission and control, connect the underlying physical hardware, software, media and personnel that are associated with the ASL-NET lesson.
An example of a linking technology is one that allows visual communications between the students and other persons associated with the physical elements (equipment and facilities—simulated or real) important to the dramatic story. In the ASL-NET education method, video conferencing is one example of a generic linking technology that allows a scientist at a government sponsored research facility to assume the role of a “guest star” in an educational drama. The link allows a scientist to interactively engage students providing them with important educational material. The link also allows the scientist to inject elements into the drama (e.g. foreshadowing) that enhance the dramatic quality of the overall experience with its anticipated benefits for students. This educational interaction and dramatic story enhancement cannot be achieved by other means. Other linking technologies may involve the transmission of specific data from simulator to simulator via the internet, physically wired local area networks and/or cellular telephone networks. Data is defined as a more specific set of information (e.g. the mass of a planet, the position of a ship, etc.) than the information associated with video or audio transmissions.
[0028] The integrated/choreographed application of combinations of these five components to new and existing equipment and facilities can create an educational environment that fundamentally changes the relationship between students and curricula. ASL-NET will transform students from third party observers of educational material, to first person participants in an adventure that allows them to interact with the content in a much more engaging fashion. The result is that students will be more interested and will more readily absorb and retain the educational content presented to them via ASL-NET.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0029] FIG. 1 is a diagram of how learning centers, research facility, and advanced spaceflight laboratory can be networked.
[0030] FIG. 2 is a diagram showing that geographically remote facilities in various states can be networked.
[0031] FIG. 3 is a sample design of the inside of a simulator van.
[0032] FIG. 4 is a second sample design of the inside of a simulator van.
[0033] FIG. 5 is a system diagram showing how the networked facilities can be combined with external data and programs.
[0034] FIG. 6 is a plan view of an example of a simulator van design.
[0035] FIG. 7 is a side elevation view of a simulator van design.
DETAILED DESCRIPTION OF THE INVENTION
[0036] To provide a detailed description of an application of this invention, the five components to be used in a demonstrative application must first be identified. For this example the following will be used:
1) Representing Invention Component 1 are two ASL simulators. They represent the futuristic research spacecraft and will be operating in separate and distant locations (e.g. Reno Nev. and Yuma Ariz.). 2) Representing Invention Component 2 is a person that serves as an officer in a futuristic space exploration organization. His or her role will be to explain the rules of the both competitive and collaborative educational event and inject dramatic elements, information and education content during the mission. This person will operate from a third location (e.g. Phoenix Ariz.). 3) Representing Invention Component 3 will be simulated news relayed via the character representing Invention Component 2 discussing the discovery of two asteroids on potential collision courses with Earth. 4) Representing Invention Component 4 will be dramatic story elements introduced via video communications equipment on board the simulators and installed at the location in Phoenix. These elements are designed to accentuate the need for student action with respect to a STEM education task. An example of a dramatic element to be injected is information regarding the discovery of new asteroids and the subsequent imperative of surveying these objects because they may impact Earth. 5) Representing Invention Component 5 will be a linking technology that allows visual communications between the students and others associated with the story. As one of the many possible examples, Skype @ operating over internet connections will serve as the video links between the character operating in Phoenix Ariz. and the two classes operating in Reno Nev. and Yuma Ariz.
[0042] As additional background information, the structure of a classical drama can be roughly defined by the following elements:
[0043] 1) Act 1—Image
This short section of the drama sets the stage for what the story will be about. A classic example of Act 1—Image is the opening set of scenes of the first Star Wars movie where Princess Leia's ship is being attacked by Darth Vader's. The Image clearly tells the audience that the story is going to be a space-based action adventure.
[0045] 2) Act 1—Introduction
This element introduces the characters of the story and the central problem, conflict or question about which the plot will revolve.
[0047] 3) Act 1—Action
This element involves the characters and their initial attempts to resolve the central problem or conflict. In some dramas their first attempt at problem resolution may fail but it leads to information that turns and accelerates the plot in a different direction.
[0049] 4) Act 2—Turning Point 1
This is a dramatic point in the plot that changes the story direction and imparts a sense of urgency. It requires the characters to reassess their situation and embark on a new course of action. It may be a point where a change in the central problem or conflict may be foreshadowed.
[0051] 5) Act 2—Action
This portion of the plot is where the characters attempt to resolve the central problem with the new information and/or decisions prompted by the knowledge and events of the first turning point.
[0053] 6) Act 2—Turning Point 2
The second turning point again provides information that guides the characters and their efforts in a new direction with an even greater sense of urgency. It can foreshadow the ultimate consequence of their success or failure. The second turning point propels the story toward the climax where success or failure is determined.
[0055] 7) Act 3—Action
Act 3 action sets up the climax of the story where success of failure is determined. It often involves the search for critical information, a battle, or some other action on the part of the characters that is required for the successful outcome of the story.
[0057] 8) Act 3—Climax
The climax of the story is where the dramatic intensity of the story is highest. During the climax, the specific actions of the characters determine whether they will succeed in resolving the conflict or solving the problem or whether they attempts will fail.
[0059] 9) Act 3—Resolution
This element concludes the story by wrapping up “loose ends” and by summarizing the ramifications of the characters' efforts at resolving the problem or conflict of the story.
[0061] The following sections describe a story developed for an educational event designed to teach middle-school students required Earth Space science material based on state mandated education standards. The educational event, designed using the five invention components described previously, involves students serving as crewmen on research spacecraft tasked with surveying select planets of our Solar System. The survey mission provides an opportunity to expose students to the mandated educational materials while presenting those materials in a much more interesting way. The addition of dramatic elements prompts students to apply their skills under the pressure in order to successfully complete their mission. The following sections describe the educational event in terms of the structural elements of a classical drama titled “Survey of the Solar System”.
Act 1—Image
[0062] Students board their respective ASL spacecraft ‘Horizon’ and ‘Voyager.’ The simulators having been purposely designed to look and feel like a futuristic research spacecraft and immediately inform students that they are to participate in some sort of space oriented activity.
Act 1—Introduction
[0063] As students take their places on-board the ships, a message from Admiral Johnson at ‘Corps of Discovery’ Headquarters is received. It is displayed on the main view screen of both vessels (using the linking technology Skype @ ). Admiral Johnson chats with the commanders of ‘Horizon’ and ‘Voyager’ as they prepare to get underway. He then addresses the students and explains their mission.
[0064] The students ('Corps Cadets') are participating in a survey of our Solar System. The two ships will each survey four of the system's eight planets. They will collect data on the planet, analyze portions of that data during their flight, and return with other data that they will process in the classroom. The mission is both competitive and collaborative. The competitive element involves the time it takes each crew to collect raw survey data and accurately analyze it. These time and accuracy factors determine each crew's score during the event. The collaborative element involves the sharing of each team's data, analysis and conclusions with their counterparts on the other ship once the surveys of their planets are completed.
[0065] After reviewing the mission and its objectives, Admiral Johnson wishes both teams good luck and orders them to get underway immediately.
Act 1—Action
[0066] ‘Horizon’ and ‘Voyager’ launch from their respective bases on Earth (e.g. Reno Nev. and Yuma Ariz.) and proceed to their first survey targets. Each ship will fly to a pre-assigned planet in the Solar System. Once in orbit around their assigned target, students begin collecting and analyzing data using displays and other tools built into the spacecraft simulator. The data collection and analysis for this mission is designed to teach students the major characteristics of the planets of our Solar System as required by State and Federal education guidelines. Planetary mass, radius, location, composition, length of year and length of day, and whether rings, moons or atmospheres are present constitute the bulk of the survey data to be collected and analyzed. Students will learn required terminology including the meaning of the terms rotation and revolution. In addition, concepts such as phases of the moon and other Earth space science related items will be integrated into their survey activities.
[0067] A survey of a planet is deemed complete when the crew advises their Commander that they are ready for a review of their findings. When the ship's commander signs off on the data collected, he advises Admiral Johnson (using the ship's video conferencing system) that his team has completed their survey. Admiral Johnson logs the time and orders the ship to proceed to their next survey planet.
[0068] At this point, a team that has completed its survey may contact the other ship and share its findings with its crew as part of the collaborative element of this mission. As an alternative activity, this collaborative work may be done back in the classroom after the simulated survey is completed.
[0069] Once the students complete the survey of their first planet, their ship will proceed to its next assigned planet. There it will again collect and analyze planetary data.
Act 2—Turning Point One
[0070] After completing their surveys of their second assigned planets, the Commanders of ‘Horizon’ and ‘Voyager’ each contact Admiral Johnson and report their findings. On the main view screen the Admiral acknowledges receipt of the second survey data and then advises the crew of the discovery of two previously unknown asteroids by ‘MPR’ or Minor Planet Research.
[0071] The Admiral informs the Commanders of ‘Horizon’ and ‘Voyager’ that these new objects may be added to their survey mission if ‘MPR’ analysis indicates any risk of these asteroids impacting Earth. The two ships are to continue with their survey missions as planned until advised otherwise.
[0072] The purpose of this communication is to inject dramatic tension into the educational event by implying that Earth may be damaged or destroyed by an asteroid impact. That students will need to survey these objects because of the threat they potentially represent imparts additional importance to the STEM tasks the students are already performing.
[0073] Also note that ‘MPR’ is a non-profit organization operating out of Scottsdale Ariz. in partnership with the Lowell Observatory in Flagstaff Ariz. for the purpose of identifying asteroids whose orbits cross those of Earth thereby representing an impact hazard. The inclusion of ‘MPR’ is an example of Invention Component 2; a real person or organization participating in the educational event. A variant of this educational event could include direct video communications with an ‘MPR’ representative who could interactively work with students explaining the many interesting attributes of asteroids and why they represent a potential hazard to Earth.
Act 2—Action
[0074] The two ships continue to collect and analyze data at their third and fourth survey planets, but their respective commanders ask their crews to perform their work quickly and efficiently as they may need to add another target to their survey. If an asteroid is to be added to the survey mission, the extra time required will consume fuel and fuel reserves may become an issue.
Act 2—Turning Point 2
[0075] ‘Horizon’ and ‘Voyager’ are each surveying their fourth planets when another video message comes in from Admiral Johnson. On the main view screen he announces that ‘MPR’ has continued to track the asteroids and it appears they may be on a collision course with Earth. He informs the two ships that more accurate information on the position, mass and composition of the asteroids is critical to assessing the impact threat. Admiral Johnson also informs the crew that new autopilot software will be uploaded into the ships' computers to allow them to rendezvous with the asteroids.
[0076] Voyager’ and ‘Horizon’ are informed that given their fuel reserves, they'll have just minutes to complete their surveys, but that under no circumstances are they to remain on post beyond the time when they can safely return to Earth. They are ordered to wrap up their work at their fourth planets and proceed to their assigned asteroids as quickly as possible.
Act 3—Action
[0077] With their new autopilot software installed, both ‘Horizon’ and ‘Voyager’ proceed to the asteroids. During transit however, both ships are struck by micro-meteoroids as their deflector systems were improperly calibrated for the flight to the asteroids. The damage is not sufficient cause for cancelling the mission, but it has caused leaks in the fuel systems of both ships, further reducing the time they can spend at the asteroids. As their fuel reserves dwindle, the crews of the two ships race to finish their data collection and analysis activities.
Act 3—Climax
[0078] With knowledge that their fuel reserves are being depleted at a faster than expected rate, both ‘Horizon’ and ‘Voyager’ begin their survey of the asteroids they've been assigned. The commanders of both vessels instruct their crews to focus on the position data calculations and on determining the mass and composition of the asteroid as these are the critical elements in determining its trajectory. Composition will also determine how best to deal with the asteroid should it be on a collision course with Earth. The crew must work quickly as fuel and time are running out.
[0079] When the critical data is collected, processed and analyzed, the Commander conveys the information to Admiral Johnson at ‘Corps of Discovery’ command. He informs the crew that their data will be forwarded to Minor Planet Research where they will use it to refine their orbital calculations for the asteroid surveyed. The Admiral then orders the ship to return home at best possible speed.
Act 3—Resolution
[0080] Upon returning to Earth, the two ships land at their respective bases. Before the crew's disembark, their commanders contact ‘Corps’ Command and ask for an update from Admiral Johnson, who congratulates the crew on their performance. The Admiral advises the two crews that ‘MPR’ has yet to complete their analysis but that when the information is available it will be forwarded on to them. Note that the analysis results will be included in the teacher's mission preparation packet and during the post-mission classroom activities the results that showed the asteroids will pass very close to Earth, but not hit it, can be shared.
[0081] In FIG. 1 there are learning centers ( 1 ), a research facility ( 2 ), and an advanced spaceflight laboratory ( 3 ). In FIG. 5 there is a learning center ( 1 ), a research facility ( 2 ), a dramatic story context ( 4 ), linking technologies ( 5 ), media components ( 6 ), student interfaces ( 7 ), a class A ( 8 ), a class B ( 9 ), and a class X ( 10 ). FIGS. 6 and 7 have an advanced Spaceflight Simulator design in plan and side views showing various design features used to create the look and feel of a futuristic research spacecraft and to provide facilities for teaching STEM and other subject matter. There is a wheelchair ramp access ( 11 ), a main view screen ( 12 ), seats ( 13 ), a command console ( 14 ), a chart center ( 15 ), an engineering systems panel ( 16 ), LCD monitors ( 17 ), a periscope/telescope ( 18 ), crew data collection and analysis stations ( 19 ), a simulated air lock ( 20 ), and lab facilities (glove boxes) ( 21 ).
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This invention is intended to improve immersive simulation techniques. The integration of five components constitutes a new method creating an educational experience that will improve student levels of interest and performance in STEM and other subjects. The five components are:
Physical hardware (representing real or simulated items), Facilities and supporting staff (representing themselves or facsimiles of non-contemporary facilities and staff) Media in various forms and formats including: advertising, news, music, film or other types produced for either broadcast or internet outlet. Dramatic stories that cohesively integrate items 1, 2 and 3 to enhance the educational experience. Linking technologies that enable the control and transmission of data and other information between the physical hardware and applicable personnel.
The combination of these components constitutes an education method that creates a networked ‘virtual reality’ designed to engage the imaginations of students and raise their level of interest in educational materials.
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This application claims priority under 35 U.S.C. § 119(e)(1) of provisional application Ser. No. 60/071,994, filed Jan. 20, 1998.
FIELD OF THE INVENTION
This invention relates generally to data communications over public switched telephone networks (PSTN) 10 (refer to FIG. 3 for an exemplary system useful for implementing the present invention) and similarly operated private branch exchanges (PBX) and other like networks; and, in particular, to the high speed transmission of digital data using the voiceband frequencies over such networks.
BACKGROUND OF THE INVENTION
Transmissions over the public switched telephone network (PSTN) 10 using voiceband frequencies are described in Townshend U.S. Pat. Nos. 5,801,695; 5,809,075; and 5,835,538 relating to “High Speed Communications System for Analog Subscriber Connections,” and Internet white papers of 3Com U.S. Robotics on x2™ technology (http://x2.usr.com /technology/whitepapers.html) and of Rockwell Semiconductor Systems on K56flex™ technology (http:// www.nb.rockwell.com/K56flex/whitepapers/k56whitepaper.html), the entireties of which (including entireties of all references cited therein) are incorporated herein by reference.
The feature that distinguishes x2™ and K56flex™ modem technologies from xDSL (digital subscriber line) technologies is its use of the line card 12 presently used in the local exchange 14 for digitization of voice as a data symbol generator. In this manner, a digital modem effectively sits in the local exchange 14 without any new equipment being placed in the exchange and with the local telco (telephone company) being unaware of the use of its line card 12 as a symbol generator. An important aspect of this idea is that the transmitter physically resides in the service provider's building and that only the final conversion to symbols is done by the line card 12 . If there is a lot of redundancy in the symbols, bandwidth will be wasted on the trunk. For instance, if the modulation requires an 8-bit symbol to transmit 6 bits of data then for every 8 bits transmitted over the digital telephony trunk there will be two “wasted” bits that do not contribute to the data rate of the modem. In the x2 technology, data rates of 56kbps are claimed for the standard digital telephone call rate of 7 bits (one bit often being lost to telco signaling) at 8 kHz. There is therefore no redundancy in the bits sent from the remote transmitter in the service provider 16 , over the telco trunk digital network, to the line card 12 . Therefore, without changing the line card 12 , we cannot increase the “arithmetic” capacity above 56 kbps. By arithmetic capacity we mean the capacity obtained by counting the number of bits per second used to generate the signal put onto the wire by the line card 12 . The Shannon capacity of the wire is probably much higher, but to get closer to this capacity we require to transmit a signal onto the wire with more degrees of freedom than 56 kbps.
SUMMARY OF THE INVENTION
In order to increase the capacity further, we modify the line card 12 in the local exchange 14 to increase the arithmetic capacity of the system in a manner that minimizes the increase in cost of the line card 12 . We propose increasing the sampling rate of the card 12 as a method for increasing the data rate of the modem. This method comes at a minimal cost as TI (Texas Instruments') chipsets in the line cards 12 presently in use are capable of higher sampling rates and the data rate can be increased over band limited channels by using partial response techniques to send data symbols above the Nyquist limit.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a plot of a standard sinc pulse.
FIG. 2 is a plot of the sum of two shifted sincs in accordance with the invention.
FIG. 3 is a simplified block diagram of a system for implementing an embodiment of the present invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
One way of increasing the capacity of the channel is to increase the number of bits in the line card 12 DAC (digital-to-analog converter). It is often assumed that there is no point in increasing the 8 kHz sampling rate because the voiceband channel bandwidth is less than 4 kHz. However, this restriction is only true for intersymbol interference-free transmission. It is possible to transmit using controlled interference using what is commonly called partial response signaling. As the line cards 12 presently in use are capable of higher sampling rates (but not higher resolutions), this is a minimal cost solution to higher data rates than 56 kbps.
For example, if for each symbol A k we transmit, the symbol A k−1 +1.2732A k +A k+1 is received, then the received signal has significantly more levels compared to the transmitted signal but that is okay because only the number of transmit levels is constrained in the line card 12 ; the user modem 18 can sample with a much higher resolution. The advantage of receiving a signal with controlled ISI (intersymbol interference) can be seen as follows. In FIG. 1, a standard sinc pulse is plotted. For a given bandwidth, a sinc pulse gives the maximum symbol rate for no intersymbol interference. In FIG. 1, the pulse is sampled at twice the zero ISI symbol rate so that the ISI caused by sending data at twice the usual rate can be seen. The power in the ISI (all coefficients of the pulse except the center coefficient) in this case is equal to the power in the center coefficient of the pulse and is spread over many coefficients on either side of the center pulse. It would be difficult to get a good signal-to-interference ratio from such a pulse. The pulse shape in FIG. 2 generates the controlled ISI A k−1 +1.2732A k +A k+1 as described above and is the sum of two shifted sinc pulses. If the three central coefficients are thought of as the effect of the main pulse, then the residual ISI is about a tenth of the power in the three central coefficients. This is a 9 dB improvement over the sinc pulse and requires only a three tap feedback filter 20 in the receiver 18 to implement. Compared to FIG. 1, most of the residual ISI energy in FIG. 2 is closer to the central pulse and therefore easier to cancel. Therefore, using new pulses such as the one above with controlled ISI allows the sampling rate to be doubled without incurring a 0 dB ISI penalty. Even if the central three coefficients of the filter are considered to carry the signal in the sinc pulse, there is still a 6 dB gain to be had by using the pulse in FIG. 2 . The amount of controlled ISI required will depend on the required SNR and the complexity of the receiver.
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The operation of a line card in the local exchange of a point-to-point switched telephone network is modified to increase the data rate of voiceband modem transmission by increasing the sampling rate and providing controlled intersymbol interference using partial response techniques.
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CROSS-REFERENCE TO RELATED APPLICATIONS
The present application is related to co-pending nonprovisional application Ser. No. 09/050,507, filed Mar. 30, 1998 (the '507 application), and claiming priority to provisional application Ser. No. 60/041,791, filed Apr. 2, 1997. The '507 application is hereby incorporated by reference as though fully set forth herein. This application also claims priority to provisional application Ser. No. 60/090,278, filed Jun. 22, 1998 (the '278 application). The '278 application is hereby incorporated by reference as though fully set forth herein.
BACKGROUND OF THE INVENTION
a. Field of the Invention
The instant invention is directed toward a control and suspension system for a covering for architectural openings. More specifically, it relates to hardware for suspending and controlling the operation of a panel used to cover an architectural opening.
b. Background Art
It is well known to place coverings over architectural openings. It is also well known to make these coverings retractable so that the architectural opening may be exposed or hidden as desired. A common problem with the use of such retractable coverings is ensuring that the retractable covering is not over-extended or over-retracted. For example, if an architectural covering that is mounted on a roll bar is over-extended, it may detach from the roll bar. This type of detachment is highly undesirable and may damage the architectural covering permanently. If a window covering that is mounted on a roll bar is over-retracted, that is also highly undesirable. For example, if the covering is over-retracted, it may jam in the head rail, making the architectural covering unusable. Another common problem that occurs with retractable coverings is skewing of the covering as it is retracted. For example, if the architectural covering is mounted on a roll bar, it may wind onto the roll bar unevenly or unwind from the roll bar unevenly for a variety of reasons. Such uneven winding or unwinding is known as skewing. Skewing may result from a manufacturing defect, an error in hanging the retractable covering in proximity to the architectural opening, wear on the hardware and support system, or a variety of other reasons.
Various suspension and control systems have been proposed heretofore to address these common problems with retractable coverings for architectural openings. There remains, however, a need for more efficient means of compensating for the above types of problems encountered during the use of retractable coverings for architectural openings.
SUMMARY OF THE INVENTION
It is desirable to have a control and suspension system for retractable coverings or barriers that avoids over-extensions and over-retractions of the retractable covering. It is also desirable that the control system be able to compensate for any undesirable skewing that might occur. Accordingly, it is an object of the disclosed invention to provide an improved control and suspension system for retractable coverings.
A more detailed explanation of the invention is provided in the following description and claims, and is illustrated in the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an isometric view in partial section of a retractable covering for an architectural opening in an extended configuration;
FIG. 2 is a left-end view of the retractable covering depicted in FIG. 1 with the covering in a fully retracted configuration;
FIG. 3A is a fragmentary sectional view taken about line 3 A— 3 A of FIG. 2, depicting control system hardware;
FIG. 3B is a fragmentary view of the covering depicted in FIG. 3A, depicting skew compensation;
FIG. 4 is a downward fragmentary cross-sectional view taken about line 4 — 4 of FIG. 2, depicting control system hardware;
FIGS. 5A, 5 B, and 5 C together depict an exploded isometric view of control system hardware located at each end of the head rail;
FIG. 6A is an isometric view of hardware also depicted in FIG. 5A, but from the opposite direction;
FIG. 6B is an isometric view of the releasable mounting plate, the other side of which is depicted in FIG. 5C;
FIG. 7 is a cross-sectional view of the clutch mechanism of the control system taken about line 7 — 7 of FIG. 4;
FIG. 8 is a cross-sectional view of the clutch mechanism of the control system taken about line 8 — 8 of FIG. 4;
FIG. 9 is a partial sectional view of the left end of the bottom rail taken about line 9 — 9 of FIG. 1;
FIG. 10 is a view of the inside surface of a bottom rail end cap, depicting the projections extending from the inside surface of the bottom rail end cap;
FIG. 11 is a top planform view of the bottom rail end cap depicted in FIG. 10;
FIG. 12 is an end view of the compression plate, which forms a portion of the bottom rail;
FIG. 13 is an end view of the bottom plate, which forms a portion of the bottom rail;
FIG. 14 is a fragmentary cross-sectional view of the bottom rail and a portion of the covering taken about line 14 — 14 of FIG. 9;
FIG. 15 is a fragmentary cross-sectional view of the bottom rail and the covering taken about line 15 — 15 of FIG. 9;
FIG. 16 is an exploded, fragmentary cross-sectional view of the bottom rail depicting how the first and second flexible sheets are attached to the bottom rail;
FIG. 17 depicts the control system hardware at the left end of the head rail, showing that the internal, roll bar support wheel moves left and right (as depicted) along the threaded shaft as the covering is extended or retracted;
FIG. 18 is an enlarged sectional view of a portion of the control system taken about line 18 — 18 of FIG. 17;
FIG. 19 is a second view of the control system depicted in FIG. 18, depicting abutment of the stopping ledge and the intercepting ledge;
FIG. 20 depicts adjustment of the control system hardware that controls the fully retracted configuration of the covering;
FIG. 21 is an enlarged cross-sectional view of control system hardware taken along line 21 — 21 of FIG. 20, depicting adjustment of the hardware that controls when during the covering-retraction process the covering is fully retracted;
FIG. 22 depicts the internal, roll-bar-support wheel installed in the roll bar, and shows the covering wrapped around the outer surface of the roll bar;
FIG. 23A shows the left end of the head rail in partial cross-section taken along line 23 A— 23 A of FIG. 4, depicting the covering approaching full extension;
FIG. 23B depicts the head rail components depicted in FIG. 23A, but shows the covering at full extension;
FIG. 24A depicts control system components shown in FIG. 23A in partial cross-section taken along line 24 A— 24 A of FIG. 4 as the covering approaches full extension;
FIG. 24B shows the control system hardware depicted in FIG. 24A after the covering has reached full extension;
FIG. 24C is a fragmentary cross-sectional view taken about line 24 C— 24 C of FIG. 24B; and
FIG. 25 depicts, in partial cross-section and partially broken out, control system components that facilitate skew adjustment.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention relates most directly to devices 10 for covering architectural openings and control systems for retractable coverings or barriers for architectural openings. A sample of the type of covering contemplated for use with the disclosed control system is depicted in FIG. 1 . In this figure, the covering 12 comprises a first flexible sheet 14 , a second flexible sheet 16 , and substantially horizontal vanes 18 attached between the first and second sheets. A bottom rail 20 is attached to the first and second flexible sheets in a manner more fully discussed below. The upper end (as depicted) of the covering is attached to a roll bar, which is not visible in FIG. 1 . The control system hardware responsible for limiting the travel of the covering (i.e., the hardware that sets the fully extended position and the fully retracted position of the covering) is incorporated into the head rail 22 . The head rail 22 comprises a left end cap 24 and a right end cap 26 , and includes an arcuate cover plate 28 . The head rail 22 is attached to a support structure (e.g., a wall) by a pair of mounting brackets 30 .
FIG. 2 is an enlarged view of a portion of the left end of the apparatus 10 for covering an architectural opening. In this view an access door 32 through which the system components that control the fully retracted position is clearly visible. A slot 34 is formed into the left end cap 24 . In order to gain access to the control system hardware inside the head rail 22 , the access door 32 depicted in FIG. 2 is first removed by using a flat blade screwdriver, for example, into the door removal slot 34 molded into the left end cap 24 and prying the access door 32 from the door support ledge 44 (see FIG. 5 A). Once the desired adjustments have been made, the access door 32 may be popped or snapped back into position in the left end cap 24 to restore a more aesthetically pleasing appearance to the head rail 22 . Also, as depicted in FIG. 2, the covering 12 is fully retracted such that the bottom rail 20 is adjacent to the bottom side of the end caps 24 , 26 .
FIGS. 3A, 3 B, and 4 depict fragmentary cross-sectional views of the head rail 22 taken along two perpendicular planes passing through the longitudinal axis of rotation of the roll bar 36 . In particular, FIGS. 3A and 3B show a partial cross-sectional view of the head rail 22 taken along line 3 A— 3 A of FIG. 2 . These views are taken along a vertical plane that passes through the longitudinal axis of rotation of the roll bar 36 incorporated in the head rail 22 . FIG. 4, on the other hand, is a fragmentary cross-sectional view taken along the plane containing line 4 — 4 of FIG. 2, which passes horizontally through the longitudinal axis of rotation of the roll bar 36 mounted in the head rail 22 depicted in FIG. 1 . The left end, as depicted, of these three figures show details concerning the skew adjustment features of the invention, and details concerning the system components that permit adjustment of an upper stop limit (i.e., the components that control how far the covering may be retracted). The right-hand end, as depicted in FIGS. 3A, 3 B, and 4 , show components of the control system that control retraction and extension of the covering via a clutch mechanism. The clutch mechanism used in the present invention is closely related to the clutch mechanism described in co-pending application Ser. No. 09/050,507, which has been incorporated herein by reference as though fully set forth in the present application. The reader should refer to this related application for details concerning the break away cord system used in the right-hand end of the head rail 22 of the present invention.
FIGS. 5A, 5 B, and 5 C together depict the major components of the control system 10 comprising part of the head rail 22 of the present invention. These three figures together comprise an exploded perspective view of components comprising the control system. Referring first to FIG. 5 A and the top half of FIG. 5B, the components associated with the left end, as depicted, of the head rail 22 are described first. Depicted at the left-hand edge of FIG. 5A is the access door 32 . The access door 32 covers the access port 42 in the left end cap 24 . When in position, the circumferential edge of the access door rides in a door support ledge 44 formed in the left end cap 24 . Also formed in the left end cap 24 is a slot 34 that permits someone desiring to make adjustments in the head rail components to remove the access door 32 . The access door 32 fits into position by pressing it into the access port 42 until it snaps or pops into position.
Moving from left to right in FIG. 5A following the dashed line, the next component encountered is the plunger 46 . The plunger 46 comprises a plunger head 48 followed by a large cylindrical portion 50 , an intermediate cylindrical portion 52 , a small cylindrical portion 54 , and two flexible arms 56 . A screwdriver slot 58 is formed into the plunger head 48 . The large cylindrical portion 50 has a cross-sectional diameter that accommodates a setting retention spring 60 , also depicted in FIG. 5A (see, e.g., FIGS. 3A, 3 B, and 4 ). The inside diameter of the generally cylindrical cavity within the setting retention spring 60 is slightly larger than the outside diameter of the large cylindrical portion 50 of the plunger 46 . As shown in FIG. 3A, for example, the setting retention spring 60 slides over the large cylindrical portion 50 of the plunger 46 when the head rail 22 is assembled. The diameter of the intermediate cylindrical portion 52 is slightly smaller than the diameter of a spring retention ring 62 (see, e.g., FIG. 3A) located inside a cylindrical housing 64 extending longitudinally from the inward side of a skew adjustment plate 66 . The spring retention ring 62 is an integral part of the skew adjustment plate 66 . In particular, the spring retention ring 62 is formed on the inner surface of the cylindrical housing 64 projecting from the skew adjustment plate 66 . In the assembled head rail 22 , the setting retention spring 60 is mounted around the large cylindrical portion 50 of the plunger 46 and is trapped between the underside of the plunger head 48 and the spring retention ring 62 of the cylindrical housing 64 that is part of the skew adjustment plate 66 .
As shown in FIG. 5A, the intermediate cylindrical portion 52 of the plunger 46 includes two interlocking channels 68 , which are offset from each other by approximately 180° in the preferred embodiment. As will be described further below, these interlocking channels receive interlocking tabs 70 of a threaded shaft 72 (see FIG. 5 B). Locking tabs 74 are located at the distal ends of the two flexible arms 56 of the plunger 46 . As explained in more detail below, these locking tabs 74 help ensure that the plunger 46 and the threaded shaft 72 in the assembled head rail 22 move as a single unit.
Continuing from left to right in FIG. 5A, the next components of interest are the skew adjustment plate 66 and a threaded skew adjustment plug 76 . The cooperation or relationship between the left end cap 24 , the threaded skew adjustment plug 76 , and the skew adjustment plate 66 is best seen by considering FIG. 5A in conjunction with FIG. 6 A and FIG. 3 B. As best seen in FIG. 6A, the left end cap has molded on its inner surface a plug bed 78 . The threaded skew adjustment plug 76 rides in the plug bed such that the screwdriver slot 58 in the bottom end of the skew adjustment plug 76 is accessible through an access hole 80 , which is also molded on the inner surface of the left end cap 24 . When the skew adjustment plate 66 , which also mounts the roll bar 36 , is positioned in a pair of the channels 82 located on the back side of the left end cap 24 , the threaded skew adjustment plug 76 is pinched between the bottom of the plug bed 78 (FIG. 6A) and an arcuate threaded surface 84 (FIG. 5A) on the left-hand side, as depicted, of the skew adjustment plate 66 . The skew adjustment plug 76 is thereby trapped in the plug bed 78 between the left end cap 24 and the skew adjustment plate 66 . The pressure exerted on the threaded skew adjustment plug 76 by the left end cap 24 and the skew adjustment plate 66 prevents the skew adjustment plug 76 from easily rotating, but it remains possible to rotate the skew adjustment plug 76 using a flat-blade screwdriver inserted through the access hole 80 molded in the left end plate 24 as depicted in FIG. 3 B.
Referring again to FIG. 5A, a roll-bar-end support wheel 86 and its associated down limit stop 88 are described next. As depicted, the down limit stop comprises three primary components: a mounting tang 90 , a wedge 92 , and an arcuate arm 94 . As depicted, the distal end of the mounting tang 90 is split, and a locking tab 96 is integrally formed on opposing sides of the mounting tang 90 adjacent to the split. The opposite end of the mounting tang 90 is integrally formed with one end of the arcuate arm 94 . The arcuate arm 94 includes an arcuate outer edge 98 and a substantially flat leading edge 100 . The wedge 92 is attached to the same side of the arcuate arm 94 as the mounting tang 90 , but the wedge 92 is attached adjacent, but not flush with, the leading edge 100 of the arcuate arm 94 , whereas the mounting tang 90 is integrally formed with the opposite end of the arcuate arm 94 . The wedge 92 includes an outer surface 102 , a leading edge 104 , and a trailing edge 106 .
The roll-bar-end support wheel 86 includes a mounting hole 108 that accommodates the mounting tang 90 of the down limit stop 88 . When the mounting tang 90 is properly inserted into the mounting hole 108 , the locking tabs 96 on the distal end of the mounting tang 90 rotatably lock the down limit stop 88 to the roll-bar-end support wheel 86 . Since the diameter of the mounting hole 108 substantially corresponds to the diameter of the mounting tang 90 , the locking tabs 96 snap outward once they pass an annular ledge 526 inside the mounting hole 108 (see FIG. 24 C). The portion of the mounting tang 90 between the back side of the arcuate arm 94 and the bottom of the slot existing in the distal end of the mounting tang 90 substantially corresponds to the length of the mounting hole 108 in the roll-bar-end support wheel 86 . When the down limit stop 88 is thus snapped into position onto the roll-bar-end support wheel 86 , and after the roll-bar-end support wheel 86 is positioned in the roll bar 36 (see FIG. 22 ), the wedge 92 of the down limit stop 88 rides in an elongated channel 110 (FIG. 5B) of the roll bar 36 .
The roll-bar-end support wheel 86 also includes an alignment groove 112 . The alignment groove 112 accommodates an alignment tongue 114 (FIG. 5B) comprising an integral part of the roll bar 36 . The alignment groove 112 , when slipped over the alignment tongue 114 , forces the roll-bar-end support wheel 86 to rotate in unison with the roll bar 36 . Also visible in FIG. 5A on the roll-bar-end support wheel 86 are alignment ribs 116 . As may be clearly seen, these alignment ribs 116 are slightly tapered to facilitate easy insertion of the roll-bar-end support wheel 86 into the end of the roll bar 36 during assembly of the apparatus 10 for covering an architectural opening. A smooth barrel 118 is supported at the center of the roll-bar-end support wheel 86 by a plurality of spokes 120 . The left end of the smooth barrel 118 includes an annular bearing surface 122 , which rides in a channel 124 (FIG. 6A) on the inside surface, as depicted, of the skew adjustment plate 66 , adjacent the cylindrical housing 64 . Also visible in FIG. 5A is a complimentary channel 126 and its side walls 128 , which accommodate the elongated channel 110 (FIG. 5B) of the roll bar 36 in the assembled head rail 22 .
Referring now to FIGS. 5A and 6A, additional details concerning the skew adjustment plate 66 are provided. The left-hand side of the skew adjustment plate 66 , as depicted, includes the arcuate threaded surface 84 previously described. The cylindrical housing 64 projects from the right side of the skew adjustment plate 66 and is integrally molded in the preferred embodiment with the skew adjustment plate 66 . A bore 132 passes completely through the skew adjustment plate 66 and the center of the cylindrical housing 64 . Referring in particular to FIG. 6A, the right side, as depicted, of the skew adjustment plate 66 includes a substantially annular channel wall 134 defining the substantially annular channel 124 . Two support wheel locks 138 are arranged on the surface of the cylindrical housing 64 . When the roll-bar-end support wheel 86 is slid into position over the cylindrical housing 64 and is fully seated so that the annular bearing surface 122 of the roll-bar-end support wheel 86 is against the skew adjustment plate 66 , the support wheel locks 138 , which are located approximately 180° apart on the surface of the cylindrical housing 64 , snap over the annular ledge 527 visible in FIGS. 5A and 24C to rotatably lock the roll-bar-end support wheel 86 into position. When the roll-bar-end support wheel 86 is thus positioned over the cylindrical housing 64 , the arcuate arm 94 of the down limit stop 88 rides in the substantially annular channel 124 visible in FIG. 6 A. The arcuate arm 94 riding in this channel 124 is also clearly depicted in FIG. 24 A. Locking fingers 140 are molded into the distal end of the cylindrical housing 64 (FIG. 6 A). When the head rail 22 is fully assembled as depicted in FIGS. 3A, 3 B, and 4 , for example, the locking fingers 140 are engaged by the four locking lugs 142 depicted on the left end in FIG. 5 B.
Referring now to FIG. 5B, the components of the threaded shaft 72 are described next. In the preferred embodiment, the threads on the threaded shaft are left-handed threads. The left end, as depicted, of the threaded shaft 72 comprises a head 144 . On the interior of the head 144 are the two short interlocking tabs 70 , which engage the interlocking channels 68 on the plunger 46 (see FIG. 5A) after the head rail 22 is assembled. Moving outward radially from the interlocking tabs, an annular abutment surface 146 is next encountered. As may be seen, for example, in FIG. 17, this annular abutment surface rides against the inward side of the spring retention ring 62 . Moving further out radially on the left-hand end, as depicted in FIG. 5B, of the threaded shaft 72 , the four locking lugs 142 are next present. These four locking lugs 142 , which are positioned at substantially 90° intervals around the circumference of the annular abutment surface 146 , engage the locking fingers 140 of the cylindrical housing 64 to facilitate adjustment of the maximum amount of retraction of the covering 12 that is possible. The four locking lugs 142 project leftward, in FIG. 5B, from a finger seat 148 , which is annular in configuration. The reader is referred, for example, to FIG. 19, which shows the locking fingers 140 of the cylindrical housing 64 resting against the finger seat 148 located on the head 144 of the threaded shaft 72 when the head rail 22 is assembled and is not being adjusted. Finally, on the back side, as depicted in FIG. 5B, of the head 144 of the threaded shaft 72 is a stopping ledge 150 . The function of the stopping ledge 150 , which may also be clearly seen in FIGS. 18 and 19, will be described in further detail below.
Referring again to FIG. 5B, the next component encountered is the internal, roll-bar-support wheel 152 . This internal, roll-bar-support wheel 152 may also be seen in at least FIGS. 3A, 3 B, 4 , and 22 . The internal, roll-bar-support wheel 152 includes an internally threaded barrel 154 . This threaded barrel 154 makes it possible to thread the internal, roll-bar-support wheel 152 onto the threaded shaft 72 adjacent the wheel 152 in FIG. 5 B. The threaded barrel 72 is supported by a plurality of barrel support spokes 156 which extend radially between the outer surface of the threaded barrel 154 and the outer ring 157 of the internal, roll-bar-support wheel 152 . The outer ring 157 of this wheel 152 is not completely rounded. In particular, contact ribs 158 are present on the outer surface of the outer ring 157 . When the internal, roll-bar-support wheel 152 is inserted into the roll bar 36 , these contact ribs 158 ride on the inner surface of the roll bar 36 and help ensure that the alignment of the internal, roll-bar-support wheel 152 is correct. Also present on the outer surface of the outer ring 157 is an alignment groove 160 . The alignment groove 160 accommodates the alignment tongue 114 running down the inside of the roll bar 36 parallel to the longitudinal axis of the roll bar 36 . When the internal, roll-bar-support wheel 152 is properly inserted into the interior of the roll bar 36 , the alignment tongue 114 rides in the alignment groove 160 , which helps ensure that the internal, roll-bar-support wheel 152 and the roll bar 36 rotate in unison. The outer ring 157 of the internal, roll-bar-support wheel 152 also includes a complimentary channel 162 and side walls 164 , which accommodate a similar elongated channel 110 and its corresponding channel side walls 165 formed integrally with the roll bar 36 . Thus, when the internal, roll-bar-support wheel 152 is properly inserted into the interior of the roll bar 36 , the alignment tongue 114 is trapped within the alignment groove 160 , and the elongated channel 110 of the roll bar is similarly captured in the complimentary channel 162 in the internal roll-bar-support wheel 152 . Also visible on the internal roll-bar-support wheel 152 depicted in FIG. 5B is an intercepting ledge 166 . If the internal, roll-bar-support wheel 152 is threaded far enough onto the threaded shaft 72 , the intercepting ledge 166 of the roll-bar-support wheel 152 will impact on the stopping ledge 150 of the threaded shaft 72 . This interaction is described further below with reference to FIGS. 18 and 19.
Next, depicted in the upper half of FIG. 5 B and in the lower leftmost portion of FIG. 5B are fragmentary portions of the roll bar 36 . The primary features of the roll bar 36 , including the alignment tongue 114 and the elongated channel 110 have been described previously.
The remaining components depicted in FIG. 5B (namely the screw 168 , drive member 170 , clutch coil spring 172 , and mounting hub 174 ) cooperate with several components depicted in FIG. 5C to rotatably support the right-hand end, as depicted, of the roll bar 36 . These components include a break away operating cord system 176 substantially identical to that described in co-pending applications Ser. No. 09/050,507, filed Mar. 30, 1998, which disclosure is incorporated in the present application as though fully set forth herein. The reader is referred to that prior application for further details concerning the construction and operation of the break away cord mechanism in addition to the disclosure provided in the present application. The drive member 170 (FIG. 5B) includes a generally cylindrical main body 178 having a plurality of generally radial support ribs 180 projecting from an outer surface of the cylindrical main body 178 . One of the support ribs includes an alignment groove 182 , which is similar to the alignment groove 160 previously described in connection with the internal, roll-bar-support wheel 152 . When the drive member 170 is inserted into the right end, as depicted, of the roll bar 36 and is properly aligned, the alignment tongue 114 , which is an integral part of the internal surface of the roll bar 36 , rides in the alignment groove 182 , thereby forcing the drive member 170 and roll bar 36 to rotate in unison. A tapered barrel 184 is suspended by a plurality of barrel support spokes 186 extending between the exterior surface of the tapered barrel 184 and the internal surface of the generally cylindrical main body 178 of the drive member 170 . At the right-hand end, as depicted, of the drive member 170 is a drive wheel 188 . The drive wheel 188 includes alternate radially extending teeth 190 , which define a channel 192 between them. As shown in other figures (e.g., FIG. 8 ), the channel 192 accommodates an operating cord 193 .
The tapered barrel 184 suspended in the center of the generally cylindrical main body 178 does not extend the full length of the inside of the generally cylindrical main body 178 . Rather, as is clearly depicted in FIGS. 3A, 3 B, and 4 , for example, the tapered barrel 184 extends only approximately half way through the generally cylindrical main body 178 . Subsequently, the inside of the generally cylindrical main body 178 becomes larger. The diameter of this larger portion of the internal surface of the generally cylindrical main body 178 is designed to accommodate the clutch coil spring 172 depicted in FIG. 5 B. The internal surface of the generally cylindrical main body 178 is merely notched a sufficient amount to accommodate the clutch coil spring 172 . When the clutch coil spring 172 is properly installed, the internal surface of the spring 172 is substantially coplanar with the internal surface of the generally cylindrical main body.
A mounting hub 174 is the final component visible in FIG. 5 B. The mounting hub 174 has a central cylindrical axial passage 198 and includes a generally U-shaped longitudinally extending channel 200 . On the right-hand end, as depicted, of the mounting hub 174 is a bearing surface 202 . This bearing surface is substantially annular and rides on the inner ring-like bearing surface 204 (FIG. 5C) located on the inward side of the relatively flat base of the right end cap 26 when the head rail 22 is fully assembled.
Even though FIG. 5B shows only one clutch spring 172 in the preferred embodiment there are two clutch springs placed back-to-back in the drive member 170 .
Referring now to FIG. 5C, additional components of the right end of the head rail 22 are depicted. First, a releasable mounting plate 206 is shown. This releasable mounting plate 206 includes a generally U-shaped notch 208 . This generally U-shaped notch 208 is defined by side edges 210 , 210 ′ that extend from the distal end of a pair of clamp arms 212 , 212 ′ toward a pair of horizontal lips 214 , 214 ′ and then around an arcuate segment 216 defining an enlarged recess area 218 . This enlarged recess area 218 and the horizontal lips 214 , 214 ′, conform to the shape molded into the rear side, as depicted, of the mounting hub 196 (see FIG. 6B, which shows the rear side of the mounting hub 174 ). The releasable mounting plate 206 also includes a pair of mounting blocks 220 on the peripheral edges of each clamp arm 212 , 212 ′. These mounting blocks 220 each define a pulley channel 222 that is substantially U-shaped. A pin hole 224 is located on the legs of the pulley channel and a shaft hole 226 is located in the base of the pulley channel 222 . During assembly, a pulley wheel 228 is mounted in each pulley channel 222 by inserting the shaft 229 of the pulley wheel 228 into the shaft hole 226 of the pulley channel 222 . Then, the operating cord 193 (FIG. 8) is threaded above the pulley wheel 228 between the upper portion of the mounting block 220 and the top of the pulley wheel 228 . Then, the pulley plate 300 , which comprises a pair of mounting pins 302 on its back side 303 and includes a shaft hole on its back side (not depicted) is positioned to rotatably secure the pulley wheel 228 in position in the pulley channel 222 . When the pulley plate 300 is properly positioned over the mounting block 220 , the top side 301 of the pulley plate is substantially coplanar with the top surface 305 of the semi-circular guide plate 304 .
The lock plate 306 depicted in FIG. 5C may be used to disable the break-away feature of the operating cord 193 . The lock plate 306 is slid into position after the other components of the break away operating cord system are assembled. When properly positioned, the upstanding legs 308 of the lock plate 306 prevent the two clamp arms 212 , 212 ′ of the releasable mounting plate 206 from permitting the releasable mounting plate 206 from releasing. Since it may be difficult to remove the lock plate 306 after it has been inserted, the lock plate 306 includes an elongated slot 310 . If the lock plate 306 is difficult to remove, a flat-blade screwdriver may be inserted into the elongated slot 310 to facilitate removal of the lock plate 306 .
Various details of the inner surface of the right end cap 26 are visible in FIG. 5 C. Protruding from the relatively flat base 311 of the right end cap 26 is a tapered support shaft 312 . This tapered support shaft 312 supports the mounting hub 174 and the drive member 170 as shown in FIG. 4, for example. Extending substantially parallel to the tapered support shaft is the stop arm 314 . A pair of abutment surfaces 316 are visible on each side of the right end cap 26 . These abutment surfaces 316 are impacted by the abutment surfaces 213 on the clamp arms 212 , 212 ′, one of which is visible on the releasable mounting plate depicted in FIG. 5 C. Also visible in FIG. 5C is a top wall 318 , which is an integral part of the right end cap 26 . When the head rail 22 is fully assembled, as depicted in FIG. 1, for example, an end portion 400 of the top wall abuts a corresponding surface on the arcuate cover plate 28 . The back side of the arcuate cover plate 28 is supported by the arcuate, plate-like projection 402 depicted in FIG. 5 C. This arcuate, plate-like projection 402 is integrally molded as a part of the right end cap 26 in the preferred embodiment. Finally, a cord guide surface 404 is also depicted in FIG. 5C as being integrally formed on the back side or internal side, as depicted, of the right end cap 26 .
When the break away clutch system is completely assembled, it appears as depicted in FIGS. 4, 7 , and 8 , for example. FIG. 7 depicts a cross-sectional view taken along line 7 — 7 of FIG. 4 . Clearly visible in FIG. 7 are the abutment surfaces 213 on each of the clamp arms 212 , 212 ′ of the releasable mounting plate 206 in proximity to the corresponding abutment surfaces 316 of the right end cap 26 . FIGS. 7 and 8 are included in the present application primarily for context. For additional details and explanation concerning the assembly and operation of the break away clutch mechanism, the reader is referred to co-pending application Ser. No. 09/050,507, which has been incorporated herein by reference.
Referring now to FIGS. 9, 10 , 11 , 12 , 13 , 14 , 15 , and 16 , the bottom rail 20 of the present invention is next discussed. The bottom rail 20 , an isometric view of which is clearly shown in FIG. 1, comprises a bottom plate 412 , a compression plate 414 , a pair of end caps 416 and an optional weight 418 . FIG. 9 is a fragmentary cross-sectional view of a portion of the bottom rail 20 taken along line 9 — 9 of FIG. 1 . FIG. 9 depicts the relationship between the left bottom rail end cap 416 , the first and second flexible sheets 14 , 16 , the compression plate 414 , and the optional weight 418 . As seen in FIGS. 9, 10 , and 11 , the bottom rail end caps 416 (the right end cap is not depicted but is the same as the left end cap) include an upper projection 500 and two lower projections 502 extending from the inside surface 504 of the end caps 416 . The upper projection 500 is shown in phantom in FIG. 9, but additional details concerning the upper projection 500 may be clearly seen in FIGS. 10 and 11. The two lower projections 502 depicted in FIG. 10 extend in the preferred embodiment approximately the same distance from the inside surface 504 of the rail end caps 416 as does the upper projection 500 . These three projections frictionally engage the compression plate 414 and the bottom plate 412 of the bottom rail 20 to removably secure the end caps 416 to the bottom rail 22 .
Referring in particular to FIG. 13, the bottom plate 412 is next described. As shown in FIG. 13, the bottom plate has a winged U-shape when viewed in cross-section perpendicular to the longitudinal axis of the bottom rail 20 . Two strips of gripping material 506 extend along the interior surface of the bottom plate 412 . These strips of gripping material 506 are substantially parallel to the longitudinal axis of the assembled bottom rail 20 . When the first and second sheets 14 , 16 arc trapped during bottom sheet assembly (see, for example, FIG. 16 ), the gripping material 506 helps hold the flexible sheet material in position. In the preferred embodiment, the bottom plate 412 itself is made from a plastic material, and the gripping material is a type of gummier, rubber-like material. Extending upward (leftward as depicted in FIG. 13) from the bottom plate 412 and continuing for the entire length of the bottom rail 20 in a longitudinal direction are a pair of inwardly projecting ledges 508 . The ledges 508 project inwardly from a distal end of a vertical wall 509 and are substantially perpendicular to the vertical wall 509 . The vertical walls 509 are attached at one end to the bottom plate 412 . A weight channel 510 is defined by the substantially rectangular pocket created between the undersides of the inwardly projecting ledges 508 and the inside surface of the bottom plate 412 . If the optional weight 418 were used, it is preferably placed in the weight channel 510 as shown in FIG. 15 . The weight 418 may be used to help the covering 12 extend more easily, and the optional weight could also assist in anti-skew adjustment. On the opposite sides of the substantially vertical walls 509 , are two other ledges 516 , 516 ′ extending toward the longitudinal edges 413 of the bottom plate 412 . Each of these latter two ledges 516 , 516 ′ also extend for the entire longitudinal length of the bottom plate 412 in the preferred embodiment. Each of these latter ledges 516 , 516 ′ also interlocks with a corresponding ledge 517 , 517 ′, respectively, on the compression plate 414 to secure the bottom plate 412 to the compression plate 414 .
Referring now to FIG. 12, the compression plate 414 in the preferred embodiment has a substantially arcuate cross-section. A pair of substantially vertical walls 512 extend from the underside of the compression plate 414 and extend for the entire longitudinal length of the compression plate 414 in the preferred embodiment. The distal edges 514 of each of the substantially vertical walls 512 comprises an interlocking ledge 517 , 517 ′. Each of these interlocking ledges 517 , 517 ′ corresponds with an interlocking ledge 516 , 516 ′, respectively, on the bottom plate 412 . In the preferred embodiment, the compression plate 414 is made from aluminum or some similar rigid material, while the bottom plate 412 is made from a flexible plastic material. Thus, when the compression plate 414 is forced toward the bottom plate 412 , the interlocking ledges 516 , 516 ′ on the flexible bottom plate 412 snap around the interlocking ledges 517 , 517 ′, respectively, on the substantially rigid compression plate 414 , thereby locking the two components together as shown in FIGS. 14 and 15, for example.
Referring now to FIG. 16, the assembly of the bottom plate 412 , compression plate 414 , and the covering 12 is described. As shown in FIG. 16, the first flexible sheet 14 and the second flexible sheet 16 of the covering 12 each has a trailing edge 518 extending below the lowest horizontal vane 18 connecting these two flexible sheets. To attach the bottom rail 20 to the covering 12 , the relatively rigid compression plate 414 is placed between the trailing edges 518 of the first and second flexible sheets 14 , 16 . Then, the bottom plate 412 is pressed toward the compression plate 414 while ensuring that the trailing edges 518 extending past the compression plate 414 are placed on top of the longitudinally extending strips of gripping material 506 affixed along the longitudinal edges 413 of the bottom plate 412 . With the trailing edges 518 of the two flexible sheets 14 , 16 positioned as shown in FIG. 16, the bottom plate 412 is pressed toward the compression plate 414 until the first and second interlocking ledge pairs 516 / 517 , 516 ′, 517 ′ snap together, as shown in FIG. 15 . When the bottom rail 20 has been properly assembled, the trailing edges 518 of the first and second flexible sheets 14 , 16 are trapped between the gripping material 506 and the interior surface of the compression plate 414 .
Referring now to FIGS. 17, 18 , 19 , 20 , and 21 , operation and adjustment of the control system hardware that controls the upper retraction limit is next described. FIG. 17 shows a cross section of the left-hand end of the assembled head rail 22 . As shown in FIG. 17, the plunger 46 is snapped together with the threaded shaft 72 , and the setting retention spring 60 is trapped between the spring retention ring 62 and the underside of the plunger head 48 . Tension within the setting retention spring 60 causes the spring to press against the spring retention ring 62 and the plunger head 48 , thereby biasing the plunger head 48 toward the left, which simultaneously biases the threaded shaft 72 to the left as depicted in FIG. 17 . When the threaded shaft 72 is thus biased to the left, as depicted, this causes the four locking lugs 142 on the head 144 of the threaded shaft 72 (see FIG. 5B) to engage the locking fingers 140 on the distal end of the cylindrical housing 64 of the skew adjustment plate 66 (see FIG. 5A for a clear view of the locking fingers 140 ). When in this configuration, the threaded shaft 72 is kept from rotating by the pressure between the four locking lugs 142 and the locking fingers 140 . Therefore, if the roll bar 36 is rotated in one of the directions indicated by the bent arrows 520 , 522 at the right side of FIG. 17, this causes the internal roll-bar-support wheel 152 to move left or right, as depicted in FIG. 17, parallel to the axis of rotation 196 of the roll bar 36 . Rotation of the roll bar 36 thus rotates the internal roll-bar-support wheel 152 , which must rotate substantially in unison with the roll bar 36 because of the interaction between the alignment tongue 114 and the alignment groove 160 (visible in FIG. 5B) and interaction between the elongated channel 110 and the complimentary channel 162 (also visible in FIG. 5 B). Since the internal roll-bar-support wheel 152 comprises a threaded barrel 154 that is threaded on the threaded shaft 72 , any rotation of the internal, roll-bar-support wheel 152 results in a proportional longitudinal movement of the internal roll-bar-support wheel 152 as the threaded barrel 154 rotates along the threaded shaft. For example, when the covering 12 is extended (i.e., when the roll bar 36 is rotated in the direction indicated by the arrow 522 in FIG. 17 ), the internal roll-bar-support wheel 152 is driven toward the right as depicted in FIG. 17 . This occurs because in the preferred embodiment, the threaded barrel 154 and the threaded shaft 72 have left-handed threads. Obviously, the length of the threaded shaft 72 is at least partially dependent upon the size of the covering 12 that must be unrolled (i.e., the number of rotations that the internal roll-bar-support wheel 152 will complete during extension of the covering). If the threaded shaft 72 is not sufficiently long, extension of the covering will eventually force the internal roll-bar-support wheel 152 to fall off the right end, as depicted, of the threaded shaft. Of course, one could implant a pin or shaft (not shown) perpendicular to the threaded shaft 72 near its free end in order to prevent the internal roll-bar-support wheel 152 from falling off the right end (as depicted in FIG. 17) of the threaded shaft 72 . Such a pin or shaft that stops the lateral or longitudinal movement of the internal roll-bar-support wheel 152 could act as a backup to the gravity lock disclosed herein and described further below.
FIGS. 18 and 19 each shows a fragmentary cross-sectional view along line 18 — 18 of FIG. 17 to demonstrate how the upper stop limit for the covering 12 is set. In FIG. 18, the covering 12 (shown in FIG. 1) is at least partially extended. This is apparent because the intercepting ledge 166 is displaced from the stopping ledge 150 since the internal roll-bar-support wheel 152 is displaced partway down the threaded shaft 72 . As the covering 12 is retracted (i.e., the roll bar 12 is rotated in the direction 520 indicated in FIG. 17 ), the threaded barrel 154 and, thus the internal roll-bar-support wheel 152 , moves to the left in FIGS. 18 and 19 until the intercepting ledge 166 on the edge of the threaded barrel 154 intercepts the stopping ledge 150 on the head 144 of the threaded shaft 72 . When the intercepting ledge 166 intercepts the stopping ledge 150 , no further retraction of the covering 12 may occur. Thus, if the stopping ledge 150 and the intercepting ledge 166 have met, but the covering 12 is not retracted as far as desired, it is necessary to adjust the relative position between the internal roll-bar-support wheel 152 and the threaded shaft 72 to prevent the intercepting ledge 166 from intercepting the stopping ledge 150 until the covering 12 is retracted the desired amount. Adjustment of this relationship between the internal roll-bar-support wheel 152 and the threaded shaft 72 is depicted in FIGS. 20 and 21.
FIGS. 20 and 21 show adjustment of the relative position of the internal roll-bar-support wheel 152 relative to the threaded shaft 72 . Referring first to FIG. 20, a screwdriver 524 is shown inserted in the screwdriver slot 58 (FIG. 5A) in the plunger head 48 . In order to gain access to the screwdriver slot, the access door 32 (visible in FIGS. 1 and 5A) has been removed, and the screwdriver 524 has been inserted through the access port 42 in the left end cap 24 . When the screwdriver 524 is forced with sufficient pressure into the screwdriver slot 58 in the plunger head 48 , this action compresses the setting retention spring 60 as the plunger 46 travels rightward as depicted in FIG. 20 . The plunger 46 and the threaded shaft 72 move in unison because of the interaction among several components, including the intermediate cylindrical portion 52 of the plunger, the interlocking channels 68 on the intermediate cylindrical portion 52 , the locking tabs 74 on the flexible arms 56 , the interlocking tabs 70 on the interior of the head 144 of the threaded shaft 72 , and the annular abutment surface 146 on the left end (as depicted in FIG. 5B) of the threaded shaft 72 . Thus, when the plunger 46 is driven rightward in FIG. 20, this simultaneously disengages the locking lugs 142 of the threaded shaft 72 from the interlocking fingers 140 of the cylindrical housing 64 of the skew adjustment plate 66 after the setting retention spring 60 has been compressed a sufficient amount. Once the interlocking lugs 142 are thus disengaged from the locking fingers 140 , rotation of the screwdriver 524 directly rotates the threaded shaft 72 . Thus, if the roll bar 36 remains motionless, this rotation of the threaded shaft 72 will force the internal roll-bar-support wheel 152 to move left or right, depending upon the direction of rotation of the screwdriver 524 . For example, if the screwdriver 524 is rotated in a first direction 523 while the roll bar 36 is kept from moving, the internal roll-bar-support wheel 152 will be pulled to the left in FIG. 20 by the interaction between the threads of the threaded barrel 154 and the threads on the threaded shaft 72 . Similarly, if the screwdriver 524 is turned in the second direction 525 while the roll bar 36 is prevented from rotating, the internal roll-bar-support wheel 152 will be pushed to the right in FIG. 20 by the interaction between the threaded barrel 154 and the threaded shaft 72 . By making these adjustments, which increase or decrease the number of threads between the left edge of the internal roll-bar-support wheel 152 and the head 144 of the threaded shaft 72 , it is possible to adjust the number of rotations that the roll bar 36 is permitted to go through before the intercepting ledge 166 on the internal roll-bar-support wheel 152 intercepts the stopping ledge 150 on the back side of the finger abutment ring 149 on the head 144 of the threaded shaft 72 . When the pressure driving the screwdriver 524 rightward in FIG. 20 is released, the setting retention spring 60 drives the plunger 46 and threaded shaft 72 to the left in FIG. 20 until the four locking lugs 142 engage locking fingers 140 on the cylindrical housing 64 , and the tips of the locking fingers 140 rest against the finger seat 148 (FIG. 5B) of the finger abutment ring 149 . Once the interlocking lugs 142 are locked into the locking fingers 140 , the threaded shaft 72 again becomes effectively fixed to the left end cap 24 and, thus, remains stable during rotation of the roll bar 36 . FIG. 21 is a fragmentary view taken along line 21 — 21 of FIG. 20 and depicts disengagement of the locking lugs 142 (two of which are depicted) from the locking fingers 140 .
FIG. 22 is a partial cross-sectional view taken along line 22 — 22 of FIG. 20 through the center of the internal roll-bar-support wheel 152 . The threaded barrel 154 of the internal roll-bar-support wheel 152 is shown as threaded onto the threaded shaft 72 , the edge of the threads shown in phantom as a ring around the threaded shaft 72 . Placement of the internal roll-bar-support wheel 152 within the roll bar 36 is also clearly visible in FIG. 22 . The alignment tongue 114 is shown as riding in the alignment groove 160 , and the complimentary channel 162 of the internal roll-bar-support wheel 152 is shown accommodating the elongated channel 110 built in to the roll bar 36 . The wedge 92 of the down limit stop 88 is also visible riding on the outside of the roll bar 36 in the elongated channel 110 . The threaded barrel 154 is supported by a plurality of barrel support spokes 156 . Although spokes 156 are used in the preferred embodiment, clearly the spokes 156 could be replaced by solid material or the number of barrel support spokes 156 could be increased or decreased at the whim of the designer. Several layers of the covering 12 are shown as still being wound around the roll bar 36 in FIG. 22, and a portion of the covering 12 has been unwound and is hanging down from the right-hand side, as depicted, in FIG. 22 .
Referring now to FIGS. 23A, 23 B, 24 A and 24 B, operation of the extension limit (gravity lock) in the present invention is described next. FIG. 23A is a fragmentary cross-sectional view taken about line 23 A— 23 A in FIG. 4 . Clearly visible in FIG. 23A is the left end cap 24 , the arcuate cover plate 28 , a portion of the roll bar 36 , the roll-bar-end support wheel 86 with the down limit stop 88 (FIG. 5A) mounted thereon, and a portion of the covering 12 . As shown by the direction arrow 91 in FIG. 23A, the roll bar 36 is rotating clockwise and extending the covering 12 comprising the first flexible 14 , the second flexible sheet 16 , and the horizontal vanes 18 . As depicted in FIG. 23A, the covering 12 is nearing complete extension. The interior side of the first flexible sheet 14 is pressing against the outer surface 102 of the wedge 92 on the down limit stop 88 , thereby keeping the wedge 92 from rotating about its mounting tang 90 . FIG. 24A shows the covering and roll bar 36 in approximately the same position from the opposite direction since FIG. 24A is a partial cross-sectional view taken about line 24 A— 24 A in FIG. 4 . In FIG. 24A it is clearly visible that the flexible sheet 14 pressing against the outer surface 102 of the wedge 92 is keeping the arcuate arm 94 within the semi-annular channel 124 (see also FIG. 6A) defined between the semi-annular channel wall 134 and the annular bearing surface 122 (FIG. 5A) on the roll-bar-end support wheel 86 .
FIG. 23B is similar to FIG. 23A; however, rotation of the roll bar 36 has been stopped by the down limit stop 88 and the covering 12 is in its fully extended configuration. When the roll bar 36 rotates from the position shown in FIG. 23A to that shown in FIG. 23B, no covering material remains on the roll bar 36 to press against the outer surface 102 of the wedge 92 and keep the down limit stop 88 from rotating about the mounting tang 90 . Therefore, shortly after being in the position shown in FIG. 23 A and shortly before reaching the position shown in FIG. 23B, gravity causes the down limit stop 88 to rotate about its mounting tang 90 to the position shown in FIG. 23 B and in FIG. 24B, which shows the same position from the opposite side. With the down limit stop 88 thus rotated, the leading edge 100 of the arcuate arm 94 impacts the edge of the semi-annular channel wall 134 since the arcuate arm 94 of the down limit stop 88 is no longer forced to remain within the semi-annular channel 124 by the pressing of the covering material on the outer surface 102 of the wedge 92 . When the leading edge 100 of the arcuate arm 94 impacts the semi-annular channel wall 134 , as depicted most clearly in FIG. 23B, the trailing edge 106 of the wedge 92 is simultaneously driven into a side wall 165 of the elongated channel 110 in the roll bar 36 . Thereby, any further downward motion of the covering 12 toward the extended position is prevented. When the roll bar 36 is rotated in the opposite direction to that depicted by the direction arrow 91 in FIG. 23A in order to retract the covering 12 by winding it back on to the roll bar 36 , the opposite edge 135 (FIG. 24B) of the semi-annular channel wall 134 impacts the outer edge 98 of the arcuate arm 94 , thereby rotating the down limit stop 88 counterclockwise as depicted in FIG. 24B about the mounting tang 90 and pushing the arcuate arm 94 back into the semi-annular channel 124 defined between the semi-annular channel wall 134 and the annular bearing surface 122 of the roll-bar-end support wheel 86 . Then, as the roll bar 36 continues to retract the covering 12 and completes its first full rotation, the down limit stop 88 is prevented from rotating about its mounting tang 90 since a layer of the covering 12 will then be present to press against the outer surface 102 of the wedge 92 during further retraction of the covering 12 .
FIG. 24C is a fragmentary cross-sectional view taken about line 24 C— 24 C of FIG. 24 B. This figure clearly shows how the support wheel locks 138 , which in the preferred embodiment is an integral part of the cylindrical housing 64 on the skew adjustment plate 66 (see, e.g., FIG. 6 A), snap behind the annular ledge 527 on the inside of the otherwise smooth barrel 118 suspended in the center of the roll-bar-end support wheel 86 by a plurality of spokes 120 . When the roll-bar-end support wheel 86 is slid onto the cylindrical housing 64 of the skew adjustment plate 66 , the support wheel locks 138 are flexed toward the axis of rotation 196 of the roll-bar-end support wheel 86 until the roll-bar-end support wheel 86 is slid sufficiently far onto the cylindrical housing 64 that the support wheel locks 138 can trap the support wheel 86 onto the cylindrical housing 64 by springing out behind the ledge 527 . Also clearly visible in FIG. 24C is the method of attaching the down limit stop 88 to the roll-bar-end support wheel 86 . When the mounting tang 90 is pushed sufficiently into the mounting hole 108 on the support wheel 86 , the locking tabs 96 on the distal end of the mounting tang 90 snap past a ridge 526 on the inside of the mounting hole 108 where the mounting hole diameter increases slightly.
Referring next to FIGS. 3B, 5 A, 6 A, and 25 , the control system components that permit one type of skew adjustment available with the present invention are described next. As shown in FIG. 3B, if the left end cap 24 is incorrectly mounted higher than the right end cap 26 , for example, a skew angle 528 will be present between an imaginary horizontal line 530 and a second imaginary line 532 extending between the top of the right end cap 26 and the top of the left end cap 24 . This skew angle 528 can be compensated for or corrected by turning the threaded skew adjustment plug 76 in the plug bed 78 (FIG. 6A) by inserting a screwdriver 524 (FIG. 3B) through the access hole 80 (most clearly visible in FIG. 6 A). When the skew adjustment plug 76 is rotated, the threads on the skew adjustment plug 76 , which engage the arcuate threaded surface 84 (FIGS. 5 A and 3 B), molded into the skew adjustment plate 66 , drive the skew adjustment plate 66 upward or downward, depending on the direction of rotation of the skew adjustment plug 76 . The skew adjustment plate 66 is capable of moving up and down relative to the left end cap 24 since the front vertical edge 534 and the rear vertical edge 536 (see FIG. 6A) of the skew adjustment plate 66 ride in complimentary channels 82 molded onto the interior surface of the left end cap 24 (FIG. 6 ). Since the cylindrical housing 64 of the skew adjustment plate 66 moves the axis of rotation of the roll bar 36 via the interaction between the cylindrical housing 64 , the roll-bar-end support wheel 86 , and the roll bar 36 , as the skew adjustment plate 66 is driven upward or downward by rotation of the skew adjustment plug 76 , the entire left end (as depicted in FIG. 3B) of the roll bar 36 moves upward or downward. It is thereby possible to position one end of the roll bar 36 relative to the other end of the roll bar 36 without having to move the end caps 24 , 26 , which may be fixed relative to a mounting surface by mounting brackets 30 (see FIG. 1 ). FIG. 25 provides a view of the skew adjustment plate 66 in position in the channels molded on the inward surface of the left end cap 24 . The skew adjustment plug 76 is pinched between the arcuate threaded surface 84 of the skew adjustment plate 66 and the plug bed 78 (FIG. 6A) of the left end cap 24 . The skew adjustment plug 76 is pinched with sufficient pressure that the skew adjustment plate 66 will not move due merely to the weight of the roll bar 36 and covering 12 , but the skew adjustment plug 76 is not pinched so hard that desired skew adjustment is difficult to achieve.
Although preferred embodiments of this invention have been described above, those skilled in the art could make numerous alterations to the disclosed embodiments without departing from the spirit or scope of this invention. For example, each of the support wheels 86 , 152 could be made with more or fewer spokes or they could be made with no spokes to support the central barrels, whether threaded or unthreaded. Also, in the preferred embodiment, the threaded shaft 72 and the threaded barrel 154 in the internal-roll-bar support wheel 152 are left-hand threaded. If desired, a right-hand thread could be used, but the covering 12 may be required to roll on the roll bar 36 from the opposite side from that depicted in the enclosed drawings, or the control system components that make it possible to control the maximum retraction and maximum extension of the covering could be incorporated into the right-hand end of the head rail 22 . In the break away operating cord system depicted in the present application, a single clutch coil spring 172 is shown in FIG. 5B, but more than one clutch coil spring could be incorporated into this portion of the control system without deviating from the scope of the present invention. The applicant has obtained favorable results from using two clutch coil springs. Also, as depicted in the drawings and discussed above, the covering 12 comprises two flexible sheets 14 , 16 with a plurality of horizontal vanes 18 extending between them. Any type of roll up covering, however, could be used in conjunction with the control system components of the present invention. It is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative only and not limiting.
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A control and suspension system for a retractable covering mounted on a rotating element includes an apparatus for mechanically limiting over-extensions of the covering and an apparatus for mechanically limiting over-retractions of the covering. The apparatus for limiting over-retraction includes a threaded shaft and an internal, roll-bar-support wheel treaded on the threaded shaft. An intercepting ledge comprising part of the internal, roll-bar-support wheel, and a stopping ledge comprising part of the threaded shaft. Over retraction of the covering is prohibited when the intercepting ledge impacts the stopping ledge. The apparatus for limiting over-extension includes a roll-bar-end support wheel having a down limit stop pivotally mounted thereto. When the covering material is fully extended, the limit stop rotates away from the roll-bar-end support wheel and impacts a substantially annular channel wall associated with an end cap, thereby preventing further rotation of the roll bar and thus further extension of the covering. The control and suspension system also includes an apparatus to compensate for any undesirable skewing of the covering that might occur. The skew adjustment apparatus includes a skew adjustment plate that is slidably mounted in channels on an end cap. A threaded skew adjustment plug is threadingly engaged with the skew adjustment plate such that rotation of the skew adjustment plug moves the skew adjustment plate. Finally, the control and suspension system also includes a bottom rail that attaches to the bottom of the covering by trapping a portion of the covering between a compression plate and a bottom plate.
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GOVERNMENT INTEREST
The invention described herein may be manufactured, used, sold, imported, and/or licensed by or for the Government of the United States of America.
FIELD OF THE INVENTION
This invention relates in general to optics, and more particularly, to dual field of view optics.
BACKGROUND OF THE INVENTION
Smaller size and weight factor greatly into user selection for many handheld, head-mounted, or airborne imaging systems, even when the added weight or size can provide otherwise useful capabilities. The conventional means for field of view (FOV) switching generally requires more elements and/or longer optical paths over equivalent fixed FOV systems. As reconfigurable optic technologies are becoming more mature, switchable optic elements integrated with static optics can provide FOV switching capability in a smaller size and weight than a conventional zoom system. A variety of reconfigurable lenses are discussed in literature. Ye, et al. (2004) and Li, et al. (2010) give examples of two different types of Liquid Crystal (LC) lenses that vary the radial index profile of the LC material by changing the voltage across different electrode configurations. See, Ye et al., “Liquid-crystal lens with a focal length that is variable in a wide range.” Applied Optics, Vol. 43, No. 35, pp. 6407-6412 (2004). See, also, Li et al., “Liquid crystal lenses: Liquid crystals promise compact lenses with variable focus.” Laser Focus World, December 2010, accessible online. As long as the effects of diffraction are small, color dispersion is expected to be similar to that experienced by a conventional lens of the same optical power. Liquid Crystal Diffractive Lenses (LCDLs) are discussed in Valley, et al. (2010) and U.S. Pat. No. 5,751,471 to Chen, et al (1998). See, Valley et al., “Nonmechanical bifocal zoom telescope,” Optics Letters, Vol. 35, No. 15, pp. 2582-2584 (2010). See, also, U.S. Pat. No. 5,751,471, entitled, “Switchable lens and method of making,” issued May 12, 1998 to Chen et al. The color dispersion in LCDLs is much more pronounced.
Bagwell, et al. (2005 and 2006) describe several LC and non-LC reconfigurable elements assembled into non-mechanical zoom configurations, including one employing Liquid Crystal Diffractive Lenses (LCDLs). See, Bagwell et al., “Adaptive Optical Zoom Sensor,” Sandia Report SAND2005-7208, Sandia National Laboratories, November 2005. See, also, Bagwell et al., “Liquid crystal based active optics,” Proc. SPIE 6289, Novel Optical Systems Design and Optimization IX, 628908-1 (2006). From the above cited literature, two main challenges exist when integrating LCDLs into a zoom system, namely large color dispersion and sensor illumination changes with FOV.
SUMMARY OF THE INVENTION
The present disclosure has resolved these challenges and enables a dual FOV lens to be made using LCDLs. Specifically, an exemplary compact optical imager that can switch field of view (FOV) without mechanical motion is disclosed. Alternatively, an exemplary compact two field of view imager which uses switchable lenses to generate two different effective focal lengths for the system. Yet, in another aspect, an exemplary compact two field of view refractive imager is disclosed which uses the finite focus (“lens”) and infinite focus (“clear”) states of switchable lenses to alter the effective focal length of the imager such that two different f/numbers and FOVs are achieved. While the various exemplary solutions may have been developed for the particular case of LCDLs, it should be noted that the described exemplary solutions also encompass other reconfigurable elements that may be configured in the disclosed exemplary FOV switching systems.
An exemplary five-element (two reconfigurable and three static) imaging system is disclosed where the field of view is changed by switching the two reconfigurable elements between a finite focus (“lens”) state and an infinite focus (“clear”) state. The wide FOV images broad-band Short Wave InfraRed (SWIR) radiation at an f/number of 1.7, while the narrow FOV images narrow-band illuminated SWIR at f/4.9. The f/number in both cases is defined by a fixed aperture. The ratio of focal length change between the two FOVs is three. This results in an FOV change of the same ratio.
Two aspects of the present invention help to resolve the challenges encountered when implementing LCDLs in a FOV switching imager. First, the disclosed exemplary dual field of view system is configured such that the switchable diffractive elements are switchable between a “lens” state and a “clear” state. In the “clear” state, the LCDLs have no optical power and color dispersion is effectively zero. This state is designed into the wide FOV, such that suitable optical performance is achieved across the natural broad-band SWIR illumination in a scene. The five elements are configured to be well corrected for color dispersion in broad-band SWIR at the wide FOV setting. A second aspect of this invention that resolves much of the concern over high dispersion and low sensor illumination in the narrow FOV is that the system is configured to use a narrow-band illuminator on the scene at this FOV, in a manner similar to US Patent Application Publication US 2013/0044221 (Vizgaitis, 2011), incorporated herein by reference. See, U.S. Patent Application Publication No. US 2013/0044221 A1 by Vizgaitis, J, entitled, “Dual Field of View Multi-Band Optics,” published Feb. 21, 2013. In the narrow FOV configuration, the LCDLs are in the “lens” state. Narrow-band illumination ensures that 1) the narrow-band signal overwhelms any broad-band signal that would otherwise be highly dispersed by the LCDLs and 2) the sensor has sufficient illumination to compensate for the smaller throughput at this larger f/number. This helps the narrow FOV illumination to be comparable to that of the larger throughput wide FOV.
BRIEF DESCRIPTION OF THE DRAWINGS
Additional advantages and features will become apparent as the subject invention becomes better understood by reference to the following detailed description when considered in conjunction with the accompanying drawings wherein:
FIG. 1 a shows an exemplary optical raytrace of the five-element imager in the (a) wide FOV with the rays traced for broad-band SWIR radiation.
FIG. 1 b shows an exemplary optical raytrace of the five-element imager in the narrow FOV with the rays traced for a narrow spectral band centered around 1.55 microns.
FIG. 2 is a table of raytrace parameters for the exemplary five-element imager from FIGS. 1 a and 1 b.
FIG. 3 a illustrates an exemplary infinite focus state for switchable lenses, wherein the infinite focus state imparts a radially uniform phase, such that the passing wavefront maintains its original form.
FIG. 3 b illustrates an exemplary positive focus state for switchable lenses, wherein the positive focus state impose a radially varying phase change on the light passing through the lens, creating curvature to the initially flat optical wavefront.
FIG. 3 c illustrates an exemplary negative focus state for switchable lenses, wherein the negative focus state also imposes a radially varying phase change on the light passing through the lens, creating curvature to the initially flat optical wavefront, whereby the resulting wavefront curvature is opposite in sign to that shown in FIG. 3 b.
FIG. 4 illustrates a side profile view of an exemplary electronically switchable lens made from a liquid crystal cell.
FIG. 5 a shows a microscope image of an exemplary electronically switchable lens generated in a liquid crystal cell, wherein the microscope image was captured while the element was in the “lens” state with no voltage applied to the element.
FIG. 5 b shows a microscope image of an exemplary electronically switchable lens generated in a liquid crystal cell, wherein the microscope image was captured while the element was in the “clear” state as a result of applying a voltage signal.
FIG. 6 a illustrates an exemplary total Optical Path Difference (OPD) over a full aperture, wherein the OPD is measured in optical waves and indicates departure from a plane (flat) wavefront.
FIG. 6 b illustrates an exemplary close-up view of the Optical Path Difference (OPD) near the edge of an aperture showing the difference between the total OPD (focus and 4th order aspheric term) and the contribution by the focus term alone.
FIG. 7 a illustrates an exemplary wide FOV optical raytrace for an alternate exemplary embodiment using alternate materials.
FIG. 7 b illustrates an exemplary narrow FOV optical raytrace for an alternate exemplary embodiment using alternate materials.
FIG. 8 is a table of raytrace parameters for the five-element imager exemplified in FIGS. 7 a and 7 b.
DETAILED DESCRIPTION
Before entering into the detailed description of one embodiment of the present invention according to the accompanying Figure, the theory of the present invention will be explained hereinafter.
An exemplary five-lens imaging system is disclosed where the field of view is changed by electrically switching 1 and 5 between an infinite focus state and finite focus states. Electrically switchable lenses are separately described below with respect to FIGS. 3 a - 3 c.
In one aspect, Figure 1 a shows an exemplary optical raytrace of the five-element imager in the wide FOV with the rays traced for broad-band SWIR radiation (e.g., of 1.0-1.7 μm). As tabulated in FIG. 2 , both the front and back aperture diameters of an electrically switchable lens 1 can be 38.1 mm. The electrically switchable lens 1 is depicted in FIG. 1 a as receiving wide FOV broadband rays (e.g., of 1.0-1.7 μm) on its front aperture. Lens 2 is configured as an exemplary meniscus lens with its front aperture facing the back aperture of the electrically switchable lens 1 . The front aperture of lens 2 can have an aperture diameter of 33 mm and Radius of Curvature (ROC) of 37.33 mm, its back aperture having an aperture diameter of 29 mm and ROC of 112.85 mm. Further, the material composition of lens 2 can be based on ZnS. Lens 3 is configured as an exemplary negative lens with its front aperture facing the back aperture of lens 2 . The front aperture of lens 3 can have an aperture diameter of 17 mm and ROC of −56.55 mm, its back aperture having an aperture diameter of 20 mm and ROC of 33.23 mm. Further, the material composition of lens 3 can be based on AMTIR-1. Lens 4 is configured as an exemplary positive lens with its front aperture facing the back aperture of lens 3 . The front aperture of lens 4 can have an aperture diameter of 30 mm and ROC of 67.46 mm, its back aperture having an aperture diameter of 30 mm and ROC of −58.07 mm. Further, the material composition of lens 4 can be based on ZnSe. Electrically switchable lens 5 configured to face the back aperture of lens 4 can have both its front and back aperture diameters being 25.4 mm. Its front aperture is configured to face the back aperture of lens 4 . The wide FOV of such an exemplary five-element imager as depicted in FIG. 1 a can be achieved by electrically setting both electrically switchable lenses 1 and 5 in an infinite focus state. The infinite focus (“clear”) state allows the lens elements to pass broad-band SWIR illumination, which when coupled with the achromatic configuration of lens 2 through lens 4 allows unfiltered light to be collected into a highly resolved image on an appropriate SWIR focal plane array 6 .
In another aspect, FIG. 1 b shows an exemplary optical raytrace of the five-element imager in the narrow FOV with the rays traced for a narrow spectral band centered around 1.55 microns (e.g., 1.54-1.56 μm). As tabulated in FIG. 2 , both the front and back aperture diameters of an electrically switchable lens 1 can be 38.1 mm. The electrically switchable lens 1 is depicted in FIG. 1 b as receiving narrow FOV rays centered around 1.55 microns (e.g., 1.54-1.56 μm) on its front aperture. Lens 2 is configured as an exemplary meniscus lens with its front aperture facing the back aperture of the electrically switchable lens 1 . The front aperture of lens 2 can have an aperture diameter of 33 mm and Radius of Curvature (ROC) of 37.33 mm, its back aperture having an aperture diameter of 29 mm and ROC of 112.85 mm. Further, the material composition of lens 2 can be based on ZnS. Lens 3 is configured as an exemplary negative lens with its front aperture facing the back aperture of lens 2 . The front aperture of lens 3 can have an aperture diameter of 17 mm and ROC of −56.55 mm, its back aperture having an aperture diameter of 20 mm and ROC of 33.23 mm. Further, the material composition of lens 3 can be based on AMTIR-1. Lens 4 is configured as an exemplary positive lens with its front aperture facing the back aperture of lens 3 . The front aperture of lens 4 can have an aperture diameter of 30 mm and ROC of 67.46 mm, its back aperture having an aperture diameter of 30 mm and ROC of −58.07 mm. Further, the material composition of lens 4 can be based on ZnSe. Electrically switchable lens 5 configured to face the back aperture of lens 4 can have both its front and back aperture diameters being 25.4 mm. The FOV change to the depicted narrow FOV of FIG. 1 b occurs by electrically switching lens 1 to a state of positive-focus, and electrically switching lens 5 to a state of negative-focus towards an appropriate SWIR focal plane array 6 . Active illumination of a narrow FOV scene helps to boost the total light energy collected at the focal plane array 6 .
In the infinite focus (“clear”) state ( FIG. 1 a ), the elements pass broad-band SWIR illumination, which when coupled with the achromatic design of elements 2 through 4 allows unfiltered light to be collected into a highly resolved image on an appropriate SWIR focal plane array 6 . The light throughput in this FOV is high, such that the imager operates in passive image collection mode. The FOV is switched to narrow mode ( FIG. 1 b ) by changing the states of elements 1 and 5 to positive focus and negative focus, respectively. The focus states of these elements are highly dispersive with wavelength, and the optical performance of the imager depends on active illumination of the scene with a narrow-band illuminator, having a 20 nanometer bandwidth and center wavelength of 1.55 microns. The clear aperture of element 2 serves as a fixed system aperture, rendering a roughly 3× increase in f/number based on the 3× focal length increase when switching from wide FOV to narrow FOV. The active illumination of the narrow FOV scene helps the total light energy collected at 6 to match that collected in the wide FOV. Light throughput is also dependant on the transmission of the optical elements, which are designed to pass SWIR illumination from 1.0 to 1.7 microns. Zinc Sulfide, AMTIR 1, and Zinc Selenide are used for the static elements and suitable anti-reflection coatings are needed for high SWIR transmittance. The switching elements are also designed to transmit SWIR light.
FIG. 2 depicts exemplary raytrace parameters for the imager shown in FIG. 1 . Lenses 2 and 3 are entirely made with spherical surfaces, the first surface of 2 being also used for the aperture stop. Lens 4 has a 10 th order even asphere on the front surface and a spherical surface on the back. The aspheric terms contribute to the lens sag (linear departure from the vertex plane) z:
z = r 2 R + R 2 - ( 1 + k ) r 2 + A 1 r 4 + A 2 r 6 + A 3 r 8 + A 4 r 10 ,
where r is the radial distance from the vertex, R is the radius of curvature, k is the conic constant, and A n indicates aspheric coefficients. The asphere helps to correct spherical aberration and coma that would otherwise render the image at 6 highly aberrated. The full aperture of elements 4 and 5 is only used in the wide FOV, as the narrow FOV requires a much longer system focal length and thus the rays have a much smaller footprint on these last two elements. The smaller footprint on 5 for the narrow FOV also means that any patterning used to generate the lens state for that element need only extend as far as the smaller footprint requires. The remaining aperture can be clear, as this is the state element 5 will be using in the wide FOV (full aperture).
FIGS. 3 a - 3 c variously illustrate three exemplary states of focus for switchable lenses: FIG. 3 a illustrates an exemplary infinite focus state; FIG. 3 b illustrates an exemplary positive focus state; and FIG. 3 c illustrates an exemplary negative focus state. The positive and negative focus states impose a radially varying phase change on the light passing through the lens, applying curvature to the initially flat optical wavefront. The infinite focus state imparts a radially uniform phase, such that the passing wavefront maintains its original form. The states of a switchable lens (e.g., FIGS. 3 a - 3 c ) enable the FOV change in the exemplary imager shown in FIGS. 1 a and 1 b . A wavefront of light, shown in this case as a plane wave 7 , enters the switchable lens 8 and either passes through unchanged 9 or changes 10 curvature, based on whether the lens is infinite focus ( FIG. 3 a ), positive focus ( FIG. 3 b ), or negative focus ( FIG. 3 c ).
A common procedure for generating a switchable lens is to write a holographic image of the desired lens power into the photosensitive layer of an LC cell. FIG. 4 illustrates a side profile view of an exemplary electronically switchable lens generated by a holographic technique. An LC material 12 is suspended in a glass cell 13 that is highly transparent to light. The inside walls of the cell 11 are coated with a transparent electrode, such that an electrical signal applied to wires 14 generates an electric field across the LC material 12 . The holographic pattern that constitutes a lens phase distribution resides in the LC material layer 12 . The lens pattern thus recorded is a periodic phase profile, whose amplitude is controlled by applying a voltage signal across the LC cell. Light passing through the LCDL will undergo deformation of its wavefront according to this phase profile. A special subset of LCDLs using concentric polarization gratings (Oh, 2009) is constructed to switch between two possible states: clear ( FIG. 3 a ) and a superposition of both lens states ( FIGS. 3 b - c ). Oh, C., “Broadband Polarization Gratings for Efficient Liquid Crystal Display, Beam Steering, Spectropolarimetry, and Fresnel Zone Plate.” PhD Dissertation, North Carolina State University, 2009 is hereby incorporated by reference. In the lens state, a polarizer is used to select between positive focus and negative focus with high efficiency.
FIGS. 5 a and 5 b show microscope images of an exemplary electronically switchable lens generated with the above referenced technique. FIG. 5 a was captured while the element was in the lens state with no voltage applied to the element. In the lens state, the concentric rings characteristic of a lens holographic diffraction pattern can be seen in the image. FIG. 5 b shows the element switched to the clear state as a result of applying a 3.0 volt peak to peak square wave oscillating at 2 kilohertz to the LC cell wires 14 . In the clear state, the diffraction pattern clears and the illumination from the microscope backlighting is seen in the image. Both microscope images are taken through parallel polarizers with a narrow-band SWIR filter centered on 1.55 μm.
FIGS. 6 a and 6 b illustrate the Optical Path Difference (OPD) imposed by element 1 in the positive focus state. The OPD is measured in optical waves and indicates departure from a plane (flat) wavefront. Specifically, the total OPD over the full exemplary aperture is shown in FIG. 6 a , whereas FIG. 6 b illustrates an exemplary close-up view of the OPD near the edge of the aperture showing the difference between the total OPD (focus and 4th order aspheric term) and the contribution by the focus term alone.
The positive-focus state of element 1 in the above exemplary embodiment imposes a radial profile to the wavefront described in FIGS. 6 a and 6 b as the Optical Path Difference (OPD) from a plane wave. The curvature of the OPD increases with distance from the vertex of the element. The effective focal length of this element is 233.03 millimeters at a design wavelength of 1.55 microns. This particular element was designed not only to have positive optical power in the lens state, but it also imparts small amounts of additional OPD (as seen in FIG. 6 b ) as a 4 th order correction to what would otherwise be spherical aberration at the image. The amount of 4 th order correction is 4.548 waves at 1.55 microns. Element 5 is designed to have a focal length of 18.46 millimeters at 1.55 microns, and there is no 4 th order term. Negative focus is selected for element 5 when in the lens state.
An alternate exemplary embodiment for this invention is shown in FIGS. 7 a and 7 b . Specifically, the figures illustrate the optical raytrace of an alternate embodiment of the invention using alternate materials. Electrically switchable lenses have been separately described above with respect to FIGS. 3 a - 3 c , 4 , and 5 a - 5 b.
In one aspect of the alternate exemplary embodiment, FIG. 7 a shows an exemplary optical raytrace of the alternate five-element imager in the wide FOV with the rays traced for broad-band SWIR radiation (e.g., of 1.0-1.7 μm). As tabulated in FIG. 8 , both the front and back aperture diameters of an electrically switchable lens 15 can be 38.1 mm. The electrically switchable lens 15 is depicted in FIG. 7 a as receiving wide FOV broadband rays (e.g., of 1.0-1.7 μm) on its front aperture. Lens 16 is configured as an exemplary meniscus lens with its front aperture facing the back aperture of the electrically switchable lens 15 . The front aperture of lens 16 can have an aperture diameter of 33 mm and Radius of Curvature (ROC) of 35.82 mm, its back aperture having an aperture diameter of 29 mm and ROC of 141.22 mm. Lens 17 is configured with its front aperture facing the back aperture of lens 16 . The front aperture of lens 17 can have an aperture diameter of 22 mm and ROC of 78.65 mm, its back aperture having an aperture diameter of 19 mm and ROC of 20.84 mm. Lens 18 is configured with its front aperture facing the back aperture of lens 17 . The front aperture of lens 18 can have an aperture diameter of 29 mm and ROC of 97.31 mm, its back aperture having an aperture diameter of 29 mm and ROC of −74.69 mm. Electrically switchable lens 19 can have both its front and back aperture diameters of 25.4 mm. Its front aperture is configured to face the back aperture of lens 18 . The wide FOV of such an exemplary five-element imager as depicted in FIG. 7 a can be achieved by electrically setting both electrically switchable lenses 15 and 19 in an infinite focus state. The infinite focus (“clear”) state allows the lens elements to pass broad-band SWIR illumination, which when coupled with the achromatic configuration of lens 16 through lens 18 allows unfiltered light to be collected into a highly resolved image on an appropriate SWIR focal plane array 20 .
In another aspect of the alternate exemplary embodiment, FIG. 7 b shows an exemplary optical raytrace of the alternate five-element imager in the narrow FOV with the rays traced for a narrow spectral band centered around 1.55 microns (e.g., 1.54-1.56 μm). As tabulated in FIG. 8 , both the front and back aperture diameters of an electrically switchable lens 15 can be 38.1 mm. The electrically switchable lens 15 is depicted in FIG. 7 b as receiving a narrow spectral band centered around 1.55 microns (e.g., 1.54-1.56 μm) on its front aperture. Lens 16 is configured as an exemplary meniscus lens with its front aperture facing the back aperture of the electrically switchable lens 15 . The front aperture of lens 16 can have an aperture diameter of 33 mm and Radius of Curvature (ROC) of 35.82 mm, its back aperture having an aperture diameter of 29 mm and ROC of 141.22 mm. Lens 17 is configured with its front aperture facing the back aperture of lens 16 . The front aperture of lens 17 can have an aperture diameter of 22 mm and ROC of 78.65 mm, its back aperture having an aperture diameter of 19 mm and ROC of 20.84 mm. Lens 18 is configured with its front aperture facing the back aperture of lens 17 . The front aperture of lens 18 can have an aperture diameter of 29 mm and ROC of 97.31 mm, its back aperture having an aperture diameter of 29 mm and ROC of −74.69 mm. Electrically switchable lens 19 can have both its front and back aperture diameters of 25.4 mm. Its front aperture is configured to face the back aperture of lens 18 . The FOV change to the depicted narrow FOV of FIG. 7 b occurs by electrically switching lens 15 to a state of positive-focus, and electrically switching lens 19 to a state of negative-focus towards an appropriate SWIR focal plane array 20 . An active illumination of a narrow FOV scene helps to boost the total light energy collected at the focal plane array 20 .
Like the exemplary embodiment described in FIGS. 1 a and 1 b , the alternate exemplary imager (e.g., of FIGS. 7 a and 7 b ) is comprised of five elements, with elements 15 and 19 being switchable lenses and elements 16 through 18 being static optics. FIG. 8 is a table that shows the exemplary raytrace parameters and switchable lens specifications used in this alternate exemplary embodiment. Switchable element 19 is identical to 5 , and element 15 differs only slightly from 1 . The effective focal length of element 15 is 243.86 millimeters at a design wavelength of 1.55 microns. The amount of its 4 th order correction is 2.757 waves at 1.55 microns.
The static optics for the alternate exemplary embodiment are based on glass and ceramic materials developed by Naval Research Laboratories (Bayya, et al., 2013). See, Bayya et al., “New Multiband IR Imaging Optics,” Proc. SPIE 8704, Infrared Technology and Applications)XXXIX, 870428 (2013), incorporated herein by reference. These materials are more amenable to molding than are crystalline materials, which may be an attractive economic consideration. Lens 16 has a conic term and a 10 th order even asphere on the front surface and a spherical surface on the back. The front surface of 16 is also used for the aperture stop. Lens 16 is made of Miltran ceramic. Lens 17 is made of NRL 4 glass and has only spherical surfaces. Lens 18 has a conic and a 10 th order even asphere on the front surface and a spherical surface on the back. NRL 7 glass is used for this element. By comparison to the exemplary embodiment in FIGS. 1 a and 1 b , the alternate exemplary embodiment illustrated in FIGS. 7 a and 7 b uses two aspheric surfaces (instead of one), but the NRL materials do not need to be as thick, saving on overall weight. Aside from these noted differences, the functional description of this alternate exemplary embodiment is the same as described for that in FIG. 1 .
It is obvious that many modifications and variations of the present invention are possible in light of the above teachings. It is therefore to be understood that within the scope of the appended claims, the invention may be practiced otherwise than as described.
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An all-refractive optical system that images a scene at two different fields of view or FOVs, with switching between FOVs enabled by switchable lens elements is disclosed. The two fields of view vary in focal length by a factor of three. The wide FOV images broad-band Short Wave InfraRed SWIR radiation at an f/number of 1.7, while the narrow FOV images narrow-band illuminated SWIR at f/4.9. A voltage change across the switchable lens elements generates an optical power change between finite focus and infinite focus. Situated among static optical elements, the switching elements enable FOV changes with no mechanical movement. The given f/numbers at each FOV are a result of a fixed aperture in the system. The smaller throughput in the narrow FOV mode is augmented by narrow-band illumination of the scene to maintain equivalent sensor response between the two FOVs.
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CROSS REFERENCE TO RELATED APPLICATIONS
The present application is a U.S. National Phase Application pursuant to 35 U.S.C. §371, of International Application No. PCT/EP2011/060502, filed Jun. 22, 2011,, which claims priority to European Patent Application No. 10167478.6, filed Jun. 28, 2010, and U.S. Patent Application No. 61/413,782, filed Nov. 15, 2010. The entire disclosure contents of these applications are herewith incorporated by reference into the present application.
FIELD OF INVENTION
The invention relates to a shuttering mechanism for controlling translation of a longitudinally moveable component within an elongate housing, in particular for application in an auto-injector for delivering a dose of a liquid medicament.
BACKGROUND
Administering an injection is a process which presents a number of risks and challenges for users and healthcare professionals, both mental and physical.
Injection devices (i.e. devices capable of delivering medicaments from a medication container) typically fall into two categories—manual devices and auto-injectors.
In a manual device—the user must provide the mechanical energy to drive the fluid through the needle. This is typically done by some form of button/plunger that has to be continuously pressed by the user during the injection. There are numerous disadvantages for the user from this approach. If the user stops pressing the button/plunger then the injection will also stop. This means that the user can deliver an underdose if the device is not used properly (i.e. the plunger is not fully pressed to its end position). Injection forces may be too high for the user, in particular if the patient is elderly or has dexterity problems.
The extension of the button/plunger may be too great. Thus it can be inconvenient for the user to reach a fully extended button. The combination of injection force and button extension can cause trembling/shaking of the hand which in turn increases discomfort as the inserted needle moves.
Auto-injector devices aim to make self-administration of injected therapies easier for patients. Current therapies delivered by means of self-administered injections include drugs for diabetes (both insulin and newer GLP-1, class drugs), migraine, hormone therapies, anticoagulants etc.
Auto-injectors are devices which completely or partially replace activities involved in parenteral drug delivery from standard syringes. These activities may include removal of a protective syringe cap, insertion of a needle into a patient's skin, injection of the medicament, removal of the needle, shielding of the needle and preventing reuse of the device. This overcomes many of the disadvantages of manual devices. Forces required of the user/button extension, hand-shaking and the likelihood of delivering an incomplete dose are reduced. Triggering may be performed by numerous means, for example a trigger button or the action of the needle reaching its injection depth. In some devices the energy to deliver the fluid is provided by a spring.
Auto-injectors may be disposable or single use devices which may only be used to deliver one dose of medicament and which have to be disposed of after use. Other types of auto-injectors may be reusable. Usually they are arranged to allow a user to load and unload a standard syringe. The reusable auto-injector may be used to perform multiple parenteral drug deliveries, whereas the syringe is disposed after having been spent and unloaded from the auto-injector. The syringe may be packaged with additional parts to provide additional functionality.
US 2002/0095120, A1, discloses an automatic injection device which automatically injects a pre-measured quantity of fluid medicine when a tension spring is released. The tension spring moves an ampoule and the injection needle from a storage position to a deployed position when it is released. The content of the ampoule is thereafter expelled by the tension spring forcing a piston forward inside the ampoule. After the fluid medicine has been injected, energy stored in the tension spring is released and the injection needle is automatically retracted back to its original storage position.
SUMMARY
It is an object of the present invention to provide a novel means for controlling translation of a longitudinally moveable component within an elongate housing, e.g. movement of a plunger within the housing of an auto-injector.
The object is achieved by a shuttering mechanism according to claim 1 .
Preferred embodiments of the invention are given in the dependent claims.
In the context of this specification the term proximal refers to the direction pointing towards the patient during an injection while the term distal refers to the opposite direction pointing away from the patient.
According to the invention a shuttering mechanism for controlling translation of a longitudinally moveable component within an elongate housing comprises at least one set of castellations on the housing, preferably on an inner surface and at least one resilient arm associated with the longitudinally moveable component. The resilient arm has a dog resiliently biased towards the castellations so as to engage between or behind the castellations and block the translation. A respective shutter arm is arranged alongside the set of castellations, the shutter arm having a number of consecutive ramped protrusions spaced from each other. The castellations and the ramped protrusions have the same pitch. A profiled surface is formed by the castellations and the ramped protrusions. The shutter arm is moveable in longitudinal direction with respect to the set of castellations. The shutter arm has at least one locking position with its ramped protrusions essentially in phase with the castellations thus allowing the dog of the resilient arm to catch between or behind the castellations. Furthermore the shutter arm has at least one unlocking position with its ramped protrusions out of phase with the castellations in such a manner that the ramped protrusions prevent the dog from engaging with the castellations or disengage them so the dog of the resilient arm may travel along the surface without catching behind the castellations. This allows translation of the longitudinally moveable component. The ramps of the ramped protrusions are arranged to push the dog away from behind or between the castellations upon translation of the shutter arm into the unlocked position.
When the longitudinally moveable component, e.g. a plunger of an auto-injector is translated the dog follows the profiled surface. Due to the ramped protrusions this surface is uneven thus providing an audible and tactile feedback to a user that the component is moving or that an injection is taking place, respectively. The motion can be paused by shifting the shutter arm into the locking position during translation of the longitudinally moveable component. Thus an injection or needle insertion may be paused and restarted if the user is finding the injection too fast or painful. Furthermore an injection may be prematurely halted without releasing the entire dose of medicament in the auto-injector.
The shuttering mechanism is preferably applied in an auto-injector for administering a dose of a liquid medicament, the auto-injector having a distal end and a proximal end with an orifice intended to be applied against an injection site and comprising:
an elongate housing arranged to contain a syringe with a hollow needle and a stopper for sealing the syringe and displacing the medicament, wherein the syringe is slidably arranged with respect to the housing,
a drive means capable of, upon activation: pushing the needle from a retracted position into an advanced position through the orifice and past the proximal end, and operating the syringe to supply the dose of medicament, a plunger for transmitting power from the drive means to the syringe and/or stopper, and activating means arranged to lock the drive means in a compressed state prior to manual operation and capable of, upon manual operation, releasing the drive means for injection.
The shuttering mechanism is arranged as the activating means and for controlling translation of the plunger being the longitudinally moveable component. The resilient arm of the shuttering mechanism is a plunger arm attached to the plunger.
In a preferred embodiment of the invention the shutter arm is connected to a sheath, telescoped within the proximal end of the housing and arranged to protrude proximally from the housing at least in an initial position in an as delivered state of the auto-injector. In the initial position of the sheath the shutter arm is in the locking position. From the initial position the sheath may be translated in distal direction into a triggering position thereby shifting the shutter arm into the unlocking position. This occurs when the user presses the proximal end of the auto-injector against an injection site, i.e. the skin of a patient. Thus the dog of the plunger arm comes clear of the castellations and the plunger is translated under load of the drive means so needle insertion and injection can take place.
In another preferred embodiment a syringe carrier is arranged inside the housing for holding the syringe. The syringe carrier is slidable with respect to the housing and comprises at least one clip locking it to the housing in a distal position in order to prevent relative axial motion of the syringe carrier. The sheath is arranged to disengage the clip upon translation in distal direction before the shutter arm reaches its unlocking position thus allowing the syringe carrier to move in proximal direction. The syringe is thus locked before triggering so the needle cannot be exposed unintentionally. If the auto-injector is removed from the injection site before the shutter arm reaches the unlocking position the clip can re-engage so the syringe is locked in a safe position again.
The sheath and the shutter arms may be connected by at least one resilient beam in a manner to allow the sheath to be moved away from the shutter arms by a defined maximum distance. This allows the sheath to move out of the housing even if the auto-injector is removed from the injection site mid-injection. In this case the shutter arms would be caught by the plunger arms. The resilient beam allows enough translation of the sheath to cover the needle, so the auto-injector is needle safe.
A spring may be arranged for biasing the sheath in proximal direction, so the sheath does not translate in distal direction unintentionally and is pushed into the needle safe position automatically.
The sheath spring is preferably arranged to bias the sheath against the syringe carrier. The sheath spring is thus compressed during needle insertion by the advancing syringe carrier so it is able to push the sheath beyond the initial position for covering the needle after the injection.
The sheath is preferably engaged with the syringe carrier in a manner to allow a maximum distance between the sheath and the syringe carrier so that a maximum proximal position of the sheath is restricted by the longitudinal position of the syringe carrier thus allowing the sheath to move proximally beyond its position of the initial state when the syringe carrier is proximal from its distal position. As long as the syringe carrier is engaged with the housing by the clip in its distal position the sheath is prevented from translating further than the initial position.
At least one snap may be provided near the proximal end of the housing for preventing the sheath from translating back in distal direction when the sheath has moved into a locking position proximally beyond its initial position, where the needle is covered post injection. The engagement of the sheath with the needle carrier prevents the sheath from locking behind the snap before triggering.
In a preferred embodiment the drive means is a compression spring grounded distally in the housing and bearing against the plunger.
A rotating damper may be arranged between the compression spring and a thrust plate at a distal end of the plunger. The rotating damper may have a cam arranged in a cam track on an inner surface of the housing, the cam track having at least one helical section for forcing the rotating damper to rotate upon axial translation under load of the compression spring thus generating friction between the rotating damper and the thrust plate. This allows for controlling the speed of the advancing plunger since the load of the drive spring is shared between the plunger and the friction. The amount of friction can be controlled by the pitch of the cam. This pitch can vary over the length of the helical section thus compensating for the decay in force with increasing expansion of the compression spring.
In yet another embodiment the cam track may have a straight section for preventing rotation of the rotating damper during needle insertion. Fast needle insertion and slow injection is thought to be less painful for a patient.
The injection may be paused by slightly reducing pressure on the sheath so the shutter arm translates by a small distance in proximal direction so the ramped protrusions and the castellations get in phase and the dog gets caught by the distal edge of the respectively nearest castellation in proximal direction. The injection will not pause immediately since the dog can only stop at these edges so the respective amount of medicament will still be injected or leak out of the needle tip if the auto-injector is removed from the injection site. However, this amount can be reduced by finer castellations with a shorter clearance between them.
In an alternative embodiment the shutter arm may be actuated by a pause button. When depressed, the pause button moves the shutter arm into phase with the castellations on the housing, preventing further injection, and also holds the sheath back. The user may then move the auto-injector with the needle exposed, reinsert the needle manually and release the pause button to continue the injection.
In yet another embodiment means for latching the sheath back when in the triggering position may be arranged, wherein the plunger arms are arranged to disengage the latch means when the stopper has nearly bottomed out in the syringe. When latching the sheath back, enough clearance for the shutter ramps to move through half a pitch should be left in order to keep the pause functionality by slightly reducing pressure against the injection site.
A ‘make safe’ button may be arranged to allow the user to release the latch and hence the sheath at will, for example if they have stopped the injection prematurely. This mechanism requires the user to insert the needle manually if they change to a second site.
The auto-injector may preferably be used for subcutaneous or intra-muscular injection, particularly for delivering one of an analgetic, an anticoagulant, insulin, an insulin derivate, heparin, Lovenox, a vaccine, a growth hormone, a peptide hormone, a protein, antibodies and complex carbohydrates.
Further scope of applicability of the present invention will become apparent from the detailed description given hereinafter. However, it should be understood 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
The present invention will become more fully understood from the detailed description given herein below and the accompanying drawings which are given by way of illustration only, and thus, are not limitive of the present invention, and wherein:
FIG. 1 is an isometric view of a longitudinal section of an auto-injector in an as delivered configuration,
FIG. 2 is a longitudinal section of the auto-injector in the as delivered configuration,
FIG. 3 is a longitudinal section of the triggered auto-injector,
FIG. 4 is a longitudinal section of the auto-injector during an injection,
FIG. 5 is a detail view of a set of castellations in the situation illustrated in FIG. 4 ,
FIG. 6 is a longitudinal section of the auto-injector with the injection paused,
FIG. 7 is a longitudinal section of the auto-injector at the end of injection, and
FIG. 8 is a longitudinal view of the auto-injector after the end of injection with an advanced needle shroud.
Corresponding parts are marked with the same reference symbols in all figures.
DETAILED DESCRIPTION
FIG. 1 shows an isometric view of a longitudinal section of an auto-injector 1 in an as delivered configuration. FIG. 2 is a lateral view of the longitudinal section in the as delivered configuration. The auto-injector 1 comprises an elongate housing 2 , which is essentially tubular with a closed distal end D and an open proximal end P. A syringe carrier 3 is arranged in the housing 2 and slidable in longitudinal direction between a proximal stop 2 . 1 and a distal stop 2 . 2 provided inside the housing 2 . The syringe carrier 3 holds a syringe 4 and supports it at its proximal end in order to avoid stress to its finger flanges 4 . 1 . A hollow injection needle 5 is attached to the proximal end of the syringe 4 . A stopper 6 serves for sealing a distal end of the syringe 4 . A liquid medicament M stored in the syringe 4 may be displaced through the needle 5 by pushing the stopper 6 in proximal direction P by means of a plunger 7 . The plunger 7 has a thrust plate 7 . 1 arranged at its distal end with two or more plunger arms 7 . 2 extending from the edges of the thrust plate 7 . 1 in proximal direction P, the plunger arms 7 . 2 having a respective outwardly protruding dog 7 . 3 . The plunger arms 7 . 2 are radially outwardly biased with respect to a longitudinal axis of the auto-injector 1 .
A number of sets of longitudinal castellations 2 . 3 corresponding to the number of plunger arms 7 . 2 are arranged on the internal surface of the housing 2 . Each set of castellations 2 . 3 consists of a number of consecutive castellations spaced from each other.
In the as delivered configuration in FIGS. 1 and 2 the dogs 7 . 3 of the plunger arms 7 . 2 abut against the most distal castellation of the respective set 2 . 3 .
A drive spring 8 for inserting the injection needle 5 into an injection site, e.g. a patient's skin and for displacing the liquid medicament M from the syringe 4 through the hollow injection needle 5 is arranged near the distal end D of the auto-injector 1 inside the housing 2 . The distal end of the drive spring 8 is grounded in the housing 2 . The proximal end of the drive spring 8 bears against a cup-shaped rotating damper 9 which in turn bears against the distal side of the thrust plate 7 . 1 . The rotating damper 9 has a cam 9 . 1 (see FIGS. 4 and 6 ) which is guided in a cam track 2 . 4 on the inner surface of the housing 2 .
A sheath 10 . 1 of a sheath arrangement 10 is telescoped within the proximal end of the housing 2 . The sheath arrangement 10 comprises the essentially tubular sheath 10 . 1 and a number of shutter arms 10 . 2 corresponding to the number of sets of castellations 2 . 3 in the housing 2 and extending in distal direction D from the sheath 10 . 1 alongside the respective sets of castellations 2 . 3 . Each shutter arm 10 . 2 has a number of consecutive ramped protrusions spaced from each other. The pitch between the ramped protrusions equals the pitch between the castellations of the respective castellation sets 2 . 3 . A sheath spring 11 is arranged so as to bias the sheath 10 . 1 against the syringe carrier 3 .
The sheath 10 . 1 is prevented from moving out of the housing 2 by a sheath arm 10 . 3 extending distally from the sheath 10 . 1 and engaged behind the distal side of the syringe carrier 3 (not illustrated).
In the configuration as delivered the drive spring 8 is held in a compressed state between the distal end of the housing 2 and the rotating damper 9 . The plunger 7 cannot be pushed in proximal direction P because of the plunger arms 7 . 2 caught behind the most distal castellation.
In FIGS. 1 and 2 the syringe 4 is held by the syringe carrier 3 which is prevented from moving by one or more clips on the case (not illustrated). There may be an aperture or a recess in the case where the clip is engaged in. The clip may be disengaged from the recess by a feature on the sheath arm 10 . 3 .
The needle 5 is covered inside the housing 2 and the sheath 10 . 1 thus preventing a user from finger-stick injuries.
In order to trigger the auto-injector 1 its proximal end with the sheath 10 . 1 must be pushed against the injection site. Thereby the sheath 10 . 1 is moved in distal direction D into the housing 2 against the load of the sheath spring 11 . The shutter arms 10 . 2 are also moved in distal direction D until the most distal ramped protrusion meets the respective dog 7 . 3 on the plunger arm 7 . 2 . At this point in the axial motion of the sheath 10 . 1 the sheath arm 10 . 3 has released the clips between the syringe carrier 3 and the housing 2 so the syringe carrier 3 and syringe 4 may translate in proximal direction D. However, this is prevented by the relatively weak force of the sheath spring 11 in this situation. If the auto-injector 1 is removed from the injection site at this point the sheath arrangement 10 returns to the position shown in FIGS. 1 and 2 under the load of the sheath spring 11 and the clip re-engages the syringe carrier 3 with the housing 2 . If the auto-injector 1 is pushed further, as illustrated in FIG. 3 , the dogs 7 . 3 of the plunger arms 7 . 2 are pushed inwardly thus resiliently deforming the ends of the plunger arms 7 . 2 . In order to do this the user has to exert an increased force on the sheath 10 . 1 , in other words there is a step in required force level thus providing a two stage triggering of the auto-injector 1 . In the illustrated embodiment the proximal ends of the plunger arms 7 . 2 are bent around the finger flange 4 . 1 of the syringe 4 so the force required to do this is higher because of the relatively short lever formed by the plunger arm 7 . 2 between the finger flange 4 . 1 and the dog 7 . 3 . An indent 7 . 4 is provided outwardly in the plunger arm 7 . 2 so as to be at a level with the finger flange 4 . 1 in the configuration as delivered. The indent 7 . 4 provides a defined resilience of the plunger arms 7 . 2 and thus a defined force for bending them inwards.
When the ramped protrusion has pushed the dog 7 . 3 inwards (see FIG. 3 ) the dog 7 . 3 is no longer engaged with the most distal castellation of the set 2 . 3 so the plunger 7 may be translated in proximal direction P. The compressed drive spring 8 pushes the rotating damper 9 , the plunger 7 and the stopper 6 in proximal direction P. The force of the sheath spring 11 in this situation has to be greater than a counteracting force of the stopper 6 due to friction between the stopper 6 and the inner wall of the syringe 4 and due to the hydrostatic resistance of the liquid medicament M to be displaced through the hollow needle 5 . Therefore, the sheath spring 11 is compressed and the syringe carrier 3 travels in proximal direction P together with the syringe 4 and the needle 5 . Hence, the needle 5 is inserted into the injection site. The injection depth is controlled by the syringe carrier hitting the proximal stop 2 . 1 on the housing 2 . From this point on the syringe 4 is no longer forwarded. Instead the stopper 6 is translated by the expanding drive spring 8 in proximal direction P within the syringe 4 thus ejecting the medicament M through the needle 5 into the injection site.
As the drive spring 8 expands, the plunger arms 7 . 2 slide over the surface provided by a combination of the castellations of a set 2 . 3 and the ramped protrusions of the shutter arms 10 . 2 which are staggered in an unlocking position in such a manner that the ramped protrusions of the shutter arms 10 . 2 are out of phase with the castellations or at least nearly in phase with the spaces between the castellations of a set 2 . 3 (cf. FIG. 5 ).
Throughout the translation in proximal direction P, the rotating damper 9 follows the cam track 2 . 4 . This provides a controllable friction force between the rotating damper 9 and the thrust plate 7 . 1 of the plunger 7 which cannot rotate as it is keyed into the housing 2 . The cam track 2 . 4 can be specified to control the speed of needle insertion and drug delivery. In the embodiment shown the cam track 2 . 4 comprises a straight section 2 . 4 . 1 in parallel to the longitudinal axis of the auto-injector 1 . During needle insertion the cam 9 . 1 of the rotating damper 9 is guided along this straight section 2 . 4 . 1 so the rotating damper 9 does not rotate and the power of the drive spring 8 is entirely forwarded to the plunger 7 . When the needle 5 has reached its injection depth the cam 9 . 1 of the rotating damper 9 enters a helical section 2 . 4 . 2 of the cam track 2 . 4 . This causes the rotating damper 9 to rotate when being translated further. Hence the load of the drive spring 8 is split between the plunger 7 and the friction force generated by the rotation of the rotating damper 9 on the thrust plate 7 . 1 providing a slower injection. Fast needle insertion and slow injection is thought to be less painful for a patient.
FIG. 4 is a longitudinal section of the auto-injector 1 during the injection. FIG. 5 is a detail view of the set of castellations 2 . 3 in the situation illustrated in FIG. 4 .
The user may pause the delivery of the medicament M by reducing the pressure on the sheath 10 . 1 , whereby the shutter arms 10 . 2 move in proximal direction P into a locking position with the ramped protrusions essentially in phase with the castellations. This changes the profile of the surface consisting of the set 2 . 3 of castellations and the ramped protrusions of the shutter arms 10 . 2 in such a manner that a distal edge of the castellations is being exposed so the plunger arms 7 . 1 may flex outwards and get caught behind one of these edges thus interrupting the injection. If the user increases the pressure on the sheath 10 . 1 once more the ramped protrusion will push the plunger arm 7 . 1 inwards again until it comes clear of the protrusion so the injection continues. In the embodiment shown it would not be possible to restart the injection if the auto-injector 1 were completely removed from the injection site.
In FIG. 7 the auto-injector 1 is shown at the end of injection. The stopper 6 has bottomed out in the syringe 4 and the medicament M has been at least almost entirely been ejected from the syringe 4 .
As the user removes the auto-injector 1 from the injection site, the sheath 10 . 1 moves in proximal direction P due to the force of the sheath spring 11 which was compressed by the drive spring 8 during needle insertion (see FIG. 8 ). When the sheath 10 . 1 is far enough moved in proximal direction P to protect the user from the needle 5 , snaps 2 . 5 on the proximal end of the housing 2 move inwards permanently thus preventing the sheath 10 . 1 from moving back into the housing 2 .
In the embodiment illustrated in FIG. 8 the sheath arrangement 10 comprises two or more resilient beams 10 . 4 which link the sheath 10 . 1 to the shutter arms 10 . 2 in a manner to allow the sheath 10 . 1 to be moved away from the shutter arms 10 . 2 so sheath 10 . 1 can be moved even if the shutter arms 10 . 2 are caught on the plunger arms 7 . 2 as is the case if the auto-injector 1 is removed from the injection site prematurely, i.e. before the entire dose has been ejected.
The sheath 10 . 1 cannot move further beyond the proximal end P of the auto-injector 1 as the sheath arm 10 . 3 is latched to the syringe carrier 3 .
In an alternative embodiment of the invention the sheath 10 . 1 and the shutter arms 10 . 2 may be manufactured as separate parts.
In an alternative embodiment an intermediary component may be provided for first coupling the plunger 7 to the syringe carrier 3 or the syringe 4 directly without acting on the stopper 6 until the needle 5 has reached its injection depth. The plunger 7 would then be decoupled from the syringe 4 or syringe carrier 3 by the intermediary component and instead be coupled to the stopper 6 in order to displace the medicament M from the syringe 4 . Thus, wet injection is avoided, i.e. the medicament M is not leaking out of the needle tip before the needle 5 is inserted.
In another alternative embodiment the auto-injector 1 may be designed to allow the injection to be paused, the auto-injector removed from the injection site, moved to another site and the injection continued, i.e. split dose use. This may be achieved by one of the following options (not illustrated):
The ramped shutter arm 10 . 2 may be made as a separate component from the sheath 10 . 1 and may be actuated by a pause button. When depressed, the pause button moves the shutter arms 10 . 2 in phase, preventing further injection, and also holds the sheath 10 . 1 back. The user may then move the auto-injector 1 with the needle 5 exposed, reinsert the needle 5 manually and release the pause button to continue the injection. If the pause button is not depressed, functionality does not differ from that described in the illustrated embodiments. The sheath 10 . 1 may be latched back on triggering, leaving enough clearance for the shutter ramps to move through half a pitch if the auto-injector 1 is subsequently removed from the injection site, thereby causing the injection to ‘pause’ and leaving the needle exposed. This mechanism requires the user to insert the needle 5 manually if they change to a second site. Immediately prior to the stopper 6 reaching the end of the syringe 4 , the plunger 7 releases the latch, and sheath 10 . 1 is freed to move to a fully proximal position, shielding the needle. Additionally a ‘make safe’ button allows the user to release the latch and hence the sheath 10 . 1 at will, for example if they have stopped the injection prematurely. The sheath 10 . 1 will then latch in the fully proximal position by means of the snaps 2 . 5 when the device is removed from the injection site A more complex design may allow the auto-injector to be ‘re-cocked’ and hence automatically insert the same needle 5 in different injection sites. An implementation of this may be a sleeve over the outside of the auto-injector 1 which can be slid towards the user for latching both the syringe carrier 3 and the plunger 7 through a slot in the housing 2 . The auto-injector 1 can then be removed from the injection site, the outer sleeve pulled in distal direction D (moving the plunger control surfaces to an earlier castellation) and the auto-injector 1 can be reused with the rest of the dose. In order to allow the plunger arms 7 . 2 to move in distal direction D, the castellations may be changed to ramps facing in the opposite direction of the shutter ramps.
In yet another alternative embodiment the pause functionality may be removed by modifying the profile of the shutter ramps and castellations.
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The invention refers to a shuttering mechanism for controlling translation of a longitudinally moveable component within an elongate housing, the shuttering mechanism comprising at least one set of castellations on the housing and at least one resilient arm associated with the longitudinally moveable component, the resilient arm having a dog resiliently biased towards the castellations so as to engage between or behind the castellations and block the translation, wherein a respective shutter arm is arranged alongside the set of castellations, the shutter arm having a number of consecutive ramped protrusions spaced from each other, wherein the castellations and the ramped protrusions have the same pitch, wherein a profiled surface is formed by the castellations and the ramped protrusions, wherein the shutter arm is moveable in longitudinal direction with respect to the set of castellations, wherein the shutter arm has at least one locking position with its ramped protrusions essentially in phase with the castellations thus allowing the dog of the resilient arm to catch between or behind the castellations and wherein the shutter arm has at least one unlocking position with its ramped protrusions out of phase with the castellations in such a manner that the ramped protrusions prevent the dog from engaging with the castellations or disengage them thus allowing translation of the longitudinally moveable component.
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FIELD OF THE INVENTION
The present invention relates to a self-propelled mobile system. Although for convenience, the description describes such a system that includes an artillery gun, such as a howitzer, mounted onto a vehicular platform for rapid deployment in the battlefield, it should be appreciated that the invention need not include such an artillery gun. In particular the system is lightweight and maneuverable.
BACKGROUND OF THE INVENTION
The emerging trend in today's battlefield is to employ a rapid deployment force, which is lighter more lethal and less dependent on logistic tails. A highly agile and capable force must be sufficiently versatile to sustain a high operating tempo and defeat the opponent with minimum losses. They must then quickly re-position, re-focus end execute subsequent missions against an opponent by employing asymmetric means.
Currently, artillery support brigades operate large artillery weapons, such as howitzers which are towed. These howitzers are not integrated with the vehicles by which they are towed but may have auxiliary power units that are capable of propelling them to a maximum speed of about 20 km/h on paved roads and half that speed off-road. An example of such a system is the 155 mm/52 caliber FH2000 self propelled howitzer, which consists of a howitzer mounted with an auxiliary power unit (APU). These howitzer systems are relatively heavy and may need to be supported by a tow vehicle and ammunition supply train during long-distance operations. The main problem with such equipment is its limited maneuverability, which largely depends on the tow vehicle and the ability of the logistics support train to reequip. Loading onto fixed-wing aircraft is also difficult due to its weight and bulk and/or the need for it to be towed into the aircraft. Other howitzer systems may be tracked, but these are unable to attain high speeds of say up to 80 km/h and are not capable of being airlifted.
In today's battlefield, the lack of mobility can well mean a lower survival probability, as shoot and scoot capability is important. It is with this motivation that the present invention of a lightweight self-propelled howitzer was conceptualized.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a field artillery system that has improved firepower, in terms lethally and accuracy.
It is another object of the invention to provide a field artillery system that is mobile, both strategically and tactically, whether in the air or on the ground.
It is also an object of this invention to provide a field artillery system that has improved survivability in the field of operations and which requires minimal logistics support.
According to one aspect of the present invention, there is provided a self-propelled mobile artillery system characterized by a lightweight space frame chassis on which is mounted a large caliber artillery place.
An artillery system in accordance with the invention has the advantage that it is lighter, faster and more maneuverable than existing long range artillery systems such as those disclosed above.
Preferably, the weight of the system is loss then 8,000 kg, and the artillery piece has a caliber of up to 155 mm 52 caliber. Furthermore, it is advantageous for the artillery piece to have a firing system which includes an evaluating and traversing mass and gun chassis mounted on the space frame vehicle having a weight which does not exceed 3.800 kg.
In the preferred embodiment, the system includes duel-purpose hydro-pneumatic cylinders which provide suspension damping of the rear wheels and also are operable to move me rear wheels away from the ground for firing of the artillery piece. This has the advantage that stability of the system is improved during firing. The stability may be further improved by provision of retractable outriggers built at the rear of the gun chassis, each of which has a spade on its free end, the outriggers being operable to engage the ground with the spades embedded therein upon firing of the artillery piece. This will result in the transfer of most of the recoil load to the ground.
Front wheels of the system are preferably mounted on the chassis by means of a multi-link independent suspension system. Advantageously, each such suspension system includes a hydro-pneumatic strut, which preferably utilizes nitrogen gas as a spring and hydraulic fluid as a damper, connected to a suspension arm which not only absorbs both shock and vibrations from the front wheels which arise during transit of the system and counter-recoil forces which arise during firing of the artillery piece, but also can have their length adjusted to vary the ride height of the system. This has be advantage that the ground clearance of the chassis can be adjusted to suit the particular terrain over which it is traveling and also to enable it to be loaded more easily onto transport vehicles such as fixed or rotary wing aircraft. A lower gun elevation can also be attained to enable the gun to fire at a lower elevation angle. This will contribute to the direct fire capability of the gun.
The drive of the system is preferably provided by a turbo-charged inter-cooled diesel engine which is coupled to a hydromechanical transmission. One drive line, preferably the rear wheel drive, may then be effected by use of radial piston in-hub moors in the rear wheels, which have the advantage that they provide good spatial configuration for mounting the weapon platform and allow the weapon recoil force to be fully transferred to the ground. As a result, there is a smaller overall lading on the vehicle structure so that further weight saving is possible.
Front wheel drive may also be provided by means or a hydromechanical gearbox which drives the front wheels. A microprocessor may also then be provided to enable drive modes to be switched between front wheel drive, roar wheel drive and four wheel drive modes to suit the particular terrain and circumstances.
Other improvements and advantages of the invention will become apparent from the specific embodiment described below.
It will be convenient to hereinafter describe an embodiment of the present invention with reference to the accompanying drawings which illustrate one form of a mobile artillery system incorporating the invention. It is to be understood that the particularity of the drawings and the related description is not to be under as superseding the generality of the broad description of the invention as defined in the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a mobile artillery system according to one embodiment of the invention.
FIG. 1 a is a perspective view of only the space frame of the mobile artillery system of FIG. 1 with all the other parts removed.
FIG. 2 is a side view of the mobile artillery system locking from position A of FIG. 1 .
FIG. 3 is a side prospective view of the mobile artillery system of FIG. 1 .
FIG. 4 is a side view of the mobile artillery system, including shock
FIGS. 5 a to 5 c illustrate the travelling positions of the rear wheels of the mobile artillery system from an extended to a fully retracted position.
FIG. 6 is a side view of the mobile artillery system illustrating the suspension system.
FIG. 7 is an enlarged view of the suspension system of the mobile artillery system.
FIG. 8 is a schematic diagram illustrating the various components of the drive mechanism of the mobile artillery system.
FIG. 9 is a diagrammatical representation of the components of a hydromechanical transmission comprising a mechanical transmission and hydrostatic transmission used in one embodiment of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Incorporation of a Space Frame Chassis
FIG. 1 is a perspective view of a mobile artillery system according to one embodiment of the invention. The system includes a light weight vehicle 10 with a chassis 12 that comprises primarily of a space frame structure 14 . The space frame structure can be more clear seen from FIG. 1 a , wherein all the other parts of the mobile artillery system have been removed. The space frame 14 requires less material to manufacture and makes the whole structure light-weight. The lightweight space frame design makes the complete system both air-portable and heli-portable. The design of the space frame 14 can thus be relatively light but achieve both structural and dynamic rigidity. The space frame 14 not only has to carry the intended payload, but can also withstand the stress and fatigue from pronged travelling on off-road terrain.
The space frame 14 of the vehicle 10 is reinforced at the points where the load is being transferred. The members of the apace frame 14 are positioned to achieve maximum torsional and structural rigidity. The vehicle may be powered by a 125 kW turbo-charged intercooled diesel engine. The engine and necessary transmission lines are held on the vehicle chassis 12 via the space frame 14 . This is to reduce the weight of the comply system.
The chassis 12 has front wheels 16 and rear wheels 17 mounted to it, and a driver compartment 18 towards the front of the vehicle 10 for steering the vehicle. A compartment for ammunition storage 20 may be incorporated to the chassis 12 .
Mounted on top of the vehicle chassis 12 and integrated with the vehicle chassis 12 is a weapons system including a howitzer gun 22 , supported by a cradle 24 and saddle 26 . The howitzer gun 22 includes a barrel 28 and muzzle brake 30 . A barrel clamp 32 clamps the barrel 28 to the space frame 14 when the howitzer gun 22 is not in use.
At the rear of the vehicle, a pair of outriggers 34 are mounted for stabilising the system structure during firing. The outriggers 34 are movable and retractable using hydraulic pistons (not shown) such that they may be raised in the position shown or lowered to engage the ground when in the firing position.
In order to preserve the integrity of the lightweight space frame structure 14 , the recoil force is isolated by means of shock isolators 36 positioned between the gun chassis and the vehicle structure. They can also dampen vibration when the vehicle is travelling from point to point. The shock isolators are sized and mounted onto the space frame structure 14 by four mounting brackets. These mounting brackets are preferably welded onto the space frame 14 as shown in FIGS. 3 and 4 . Two shafts (not shown) run the length of the gun chassis through the holes of the shock isolators 36 . The vehicle chassis 12 will then be supported by these shock isolators which help to reduce the amount of force that is being transmuted to the space frame structure 14 . During firing, the recoil load is transmitted from the union to the gun chassis, shock isolator shafts and finally to the shock isolator 36 . The shock isolators 36 serve to isolate the firing load that is being transmitted to the space frame 14 , thereby protecting it from damage. FIGS. 3 and 4 show only one embodiment of the shock isolators 36 and the mounting brackets mounted to the space frame. It should be apparent that other embodiments are possible, wherein the firing load is transmitted to the space frame 14 . As such the vehicle structure can be optimized to be as light as possible and yet able to handle the tremendous firing load.
In addition, rollover bars 38 are designed to surround the driver compartment 18 to protect the driver and passengers in the event the vehicle rolls over, for example in undulating terrain. Each outrigger 34 has a spade structure 35 at its end. The spade structure 35 is self-embedding once the outrigger 34 is lowered by the hydraulic pistons. The embedding of the spade structure 35 enhances the stability of the howitzer gun 22 once deployed to be fixed to the ground and enables the first shot to be fired at high accuracy.
FIG. 2 is a side view of the mobile artillery system looking from position A of FIG. 1 . FIG. 3 is a side perspective view of the mobile artillery system of FIG. 1 .
The capability of the system to be both lightweight and attain structural rigidity enhances the effectiveness of the rapid deployment force to respond quickly to an emerging crisis in less time from base to a global theatre of operation. The integrated system offers high ground tactical mobility because of its capability to move rapidly about the battlefield. The howitzer 72 can thus be rapidly deployed to, critical areas immediately upon landing so as to exert influence on the battlefield. Likewise, the howitzer 22 has the capability to evacuate from critical areas immediately. In the battlefield, high mobility means higher survival probability. The system, including the howitzer gun 22 also functions as the tow vehicle and logistic train, thus eliminating the dependency on a separate tow vehicle and logistics train.
There are two operating modes of the artillery firing system, the traveling mode and the fling mode. In the travelling mode, the elevation of the gun barrel 28 is kept low and passes through the cab of the vehicle (see FIG. 1 ). The safety roll-over bar 38 is hinged at both sides of the vehicle. It can be opened up from the midline at the top to allow transgressing and elevation of the gun barrel 28 (sea FIG. 2 ). In the firing mode, the outriggers 34 are lowered so that the spade structure 35 engages the ground to stabilize the howitzer gun 22 during firing, and the rear wheels 17 are lifted off the ground using trailing arms powered by hydro-pneumatic cylinder ( 72 in FIGS. 6 a - 5 c ) which function also as a rear wheel suspension. This lowers the rear end of the chassis 12 together with the gun platform to touch the ground.
Rear Wheel Assembly
FIGS. 5 a to 5 c illustrate the travelling positions of the rear wheels from a extended position wherein the wheels are in contact with the ground, to a fully extended retracted position, wherein the wheels are lifted off the ground. The rear wheels 17 are mounted onto specially designed wheel arms 70 . The wheel arms 70 are pivotally attached to the chassis 12 . Alternatively, it could be pivotally attached to the structure of the space frame 14 . Adjacent to the point of attachment of the wheel arm 70 to the chassis 12 , side hydro-pneumatic struts 72 are pivotally connected to the wheel arms 70 . As can be observed, extension and contraction of the side hydro-pneumatic struts 72 result in the raising and lowering of the rear wheels 17 in a leveraged arrangement. Between the side hydro-pneumatic struts 72 , a centre hydro-pneumatic strut 74 is positioned to provide an additional force to ensure that the rear wheels 17 are fully raised when the side hydro pneumatic struts 72 are extended. The side hydro-pneumatic struts 72 and centre hydro-pneumatic struts 74 are interconnected by a portion of the space frame 14 .
FIG. 5 a shows the side hydro-pneumatic struts 72 in a extended position and the rear wheels 17 lowered to be in contact with the ground. FIG. 5 b shows the side hydro-pneumatic struts 72 in an extended retracted position such that the rear wheels 17 are rotated counter-clockwise and are raised off the ground. In this position, the rear wheels 17 are still not fully retracted. FIG. 5 c shows the rear wheels 17 in a fully retracted position.
The centre hydro-pneumatic strut 74 has been extended to push the axle 76 further so that the wheel arm 70 is almost horizontal and the rear wheels 17 are brought further towards the front of the vehicle.
Multi-Link Suspension System
FIG. 6 is a side view of the mobile artillery system giving an overview of the suspension system associated with the front wheels 16 . A multi-link suspension 80 is incorporated to the front wheels 16 .
FIG. 7 is an enraged view of the multi-link suspension system of the mobile artillery system. The suspension system utilizes a multi-link independent suspension comprising a lower link 82 and an upper link 84 with hydro-pneumatic struts for optimum off-road performance. The front wheel 16 is attached to the front wheel hub 00 . The suspension system is designed for three functions. The main function is to damp as well as to absorb the shock that is present from the undulating off-road terrain. The hydro-pneumatic struts 85 may use nitrogen gas as their spring and hydraulic fluid as the damper. Some of the advantages of incorporating the multi-link suspension with the hydro-pneumatic suspension are:
1) small space requirement; 2) a kinematic or elasto-kinematic toe-in change tending inwards understeering; 3) easier steerability with existing drive; 4) low weight 5) independence by there being no mutual wheel influence; 6) ability to counteract the change of wheel chamber due to roll pitch of the vehicle body; 7) l lighter off-road mobility and speed; 8) Larger wheel travel; 9) Progressive suspension characteristics allow for high driving speeds while providing improved comfort for driver and crew.
The secondary function of the suspension system is to serve as a shock absorber for the counter-recoil force during firing. The gun recoil force during firing causes the front of the vehicle to lift off the ground. A counter-recall force is usually generated after gun recoil due to a whip-lash effect. As the counter-recall force is tremendous, the suspension at the front of the vehicle has to be sized to absorb and damp the shock so as to prevent damage to the vehicle instrumentation and other systems on-board.
The third function of the suspension system is to provide height adjustment control of the vehicle. This is accomplished by depressurizing the fluid in the cylinders of the hydro-pneumatic struts 86 by means of relief valves (not shown) that are incorporated into the cylinders and thus allow the cylinders to be compressed. The reason for allowing the height adjustment is to enable the howitzer gun 22 to fire at a lower elevation angle. This will contribute to the direct fire capability of the gun. The height outside control will also provide more height clearance in situations where lower height is required, eg. when the vehicle is loaded onto a C-130 airplane.
It should be appreciated that hydro-pneumatic struts using hydro-pneumatic cylinders can also be added to the rear suspension. One advantage of doing so is that the height of the rear of the vehicle is adjustable. This will be very useful for clearing obstacles or difficult terrain.
Hydraulic Drive System
FIG. 8 is a schematic diagram illustrating the various components of the driving mechanism of the mobile artillery system. The system includes a turbo-charged inter-cooled diesel engine 100 which is coupled to a rear pump 102 , auxiliary pump 104 and steering/brake pump 106 . The rear pump 102 is operatively connected to a manifold 120 and to radial in-hub motors 112 towards the rear of the vehicle via fluid drivelines.
There is a switch on the drivers instrumental panel (not shown) which allows the drier of the vehicle to select between front wheel drive mode (on-road), four-wheel drive mode (off-road) and automatic mode. Front wheel drive mode allows the vehicle to travel on rods at lighter speeds. Four-wheel drive mode allows the vehicle to travel off-road up to a maximum speed of about 25 km/h, depending on the hydraulic radial piston in-hub motor. The automatic mode allows the vehicle to travel in a mixed configuration of four wheel drive and two wheel drive depending on the speed of the vehicle. A vehicle speed below 25 km/h will have a four wheel drive configuration while a speed above 25 km/h will have a two wheel drive configuration. The switching of these two modes is controlled automatically by a microprocessor 122 . The turbo-charged diesel engine 100 drives a hydromechanical transmission 108 comprising 2 shafts: 1) a hydrostatic transmission and 2) a mechanical transmission. The hydromechanical transmission is connected to a differential 110 which drive propeller shafts 18 to which the front wheels 16 are attached.
The input from the engine is split by using two gears (not shown). The hydrostatic transmission consists of a variable displacement pump which is closely coupled to a fixed displacement motor or variable displacement motor. The mechanical transmission consists of a set of planetary gears and a clutch. The purpose of the clutch is to engage and disengage the hydrostatic; and mechanical modes.
The hydrostatic transmission and mechanical transmission will now be described with reference to FIG. 9 . In the hydrostatic transmission, whom the engine flywheel rotates a gear G 1 in the clockwise direction (as seen from the engine), another gear G 2 will rotate in the anti-clockwise direction. The rotation will be transmitted via a shaft S 1 to a gear G 3 . A shaft S 2 will drive the input of hydrostatic transmission (pump) and the output win be shaft 83 (from the motor). The torque from the motor will subsequently be transmitted to gear G 5 by gear G 4 . The direction of Gear G 5 is the same as the engine rotation. The speed of the hydrostatic transmission can be varied by adjusting the swash plate in the variable displacement pump. As the angle of the swash plate in the pump is increased, more flow results and the motor will turn faster. This will increase the speed of gear G 4 and eventually to the output speed N 0 .
In the mechanical transmission, rotation of gear G 5 is effected by gear G 3 . Gear G 5 rotates the shaft S 4 in the same direction. Shaft S 4 is directly connected to the planetary carrier. The rotation of the planetary carrier will cause all the planetary gears G 8 to rotate. Since the sun gear G 7 is in direct contact with the planetary gears the sun gear will also rotate together with the planetary gears, which will in turn cause the shaft S 5 to rotate in the same direction. With the clutch engaged (hydromechanical mode), this rotation will be transmitted to gear G 8 via shaft S 6 . Gear G 8 will then rotate gear G 9 via a shaft. The rotation from the gear G 9 will be transmitted to the ring gear, which will eventually cause the output shaft to the differential to rotate at the speed of N 0 .
There are three different drive modes: I) the hydrostatic mode whereby the swashplate is varied to cause the motor to rotate with the clutch disengaged; II) the hydromechanical mode whereby the swashplate is varied and the clutch is disengaged; iii) the swashplate is at zero displacement (no flow to the motor) and the clutch is engaged (fully mechanical).
The front wheels 16 are steerable via a steering system 110 and steeling pump 106 . The rear pump 102 also transmits power to a pair of in-hub radial piston motors 112 , each of which drives a rear wheel 17 . A brake pump 106 is operatively connected to brake calipers 112 which control brake discs 114 at the front and rear wheels 16 , 17 . The components of the system are generally controlled by a microprocessor 122 .
The use of the radial piston in-hub motors 112 provide good spatial configuration for the mounting of the weapon platform and allow the weapon recoil force to be fully transferred to the ground through an integrated firing platform. Due to this design, there are fewer requirements on the strength of the space fame 14 , thus allowing for weight savings.
The vehicle can move at up to speeds of 80 km/h on 4×2 drive (front wheel drive) on paved roads and the two rear wheels 17 can be activated for 4×4 drive off-road. The vehicle is capable of being deployed and displaced within 30 seconds to 1 minute. It can move 500 meters within 30 seconds and can be ready for firing in less than 30 seconds from the deployed position.
During highway travelling, the hydromechanical transmission is used to drive the front wheels 16 while the rear radial platen motors 112 are allowed to freewheel. During off-road travelling, all the four wheels 16 , 17 are activated to optimize wheel traction.
The extensive application of lightweight materials such as titanium alloys further helps to reduce the weight of the whole system and enhance its operational mobility.
While a particular embodiment of the invention has boon shown and described, it will be appreciated by those skilled in the art that changes and modifications of the present invention may be made without departing from the invention in broadest aspects. As such, the scope of the invention should not be limited by the particular embodiment and specific construction described herein but should be defined by the appended claims and equivalents thereof. Accordingly, the aim in the appended claims is to cover all such changes and modifications as fall within the spirit and scope of the invention.
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The invention provides a self-propelled mobile system that is characterized by a lightweight space frame chassis on which is mounted a large caliber artillery piece. The weight of the system is preferably less than 8,000 kg and the artillery piece preferably has a caliber of up to a 155 mm 52 caliber gun. The artillery piece may include a lightweight elevating and traversing mass and gun chassis mounted on a space frame vehicle, such vehicle having a weight which does not exceed 3,800 kg.
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CROSS REFERENCE TO RELATED APPLICATION
This application claims the benefit of priority of our co-pending Provisional Application Serial No. 60/126,490 filed Mar. 26, 1999.
FIELD OF THE INVENTION
The present invention relates to a process and apparatus for purifying carbon dioxide using a sequence of adsorbents including a metal oxide, silica gel, and activated carbon.
BACKGROUND OF THE INVENTION
Carbon dioxide has been known for centuries, with Pliny the Elder describing it in the context of poisonous vapors coming from caverns. In the seventeenth century, Van Helmont obtained carbon dioxide by such means as fermentation and acidification of carbonates, and also studied many of its properties. Later it was recognized as an acidic gas but it was not until the end of the eighteenth century that Lavoisier recognized it as a compound of carbon and oxygen of a given proportion.
Since mineral waters (solutions of carbon dioxide in water) were thought to have medicinal properties, there was from the onset an incentive to commercially exploit carbon dioxide. Farady made liquid and solid carbon dioxide using a hydraulic pump and studied solid carbon dioxide as a refrigerant. Its uses over time have proliferated to include such diverse applications as beverage carbonation, chemical manufacture, fire fighting, food freezing, greenhouses, oil well secondary recovery, as an atmosphere in welding, and even more recently in supercritical extraction processes.
The bulk of carbon dioxide is generated from ammonia and hydrogen plants as process gas carbon dioxide resulting from the reaction between hydrocarbons and steam. The carbon dioxide produced by such methods has a high purity but may contain, inter alia, traces of hydrogen sulfide, sulfur dioxide, and hydrocarbons including high molecular weight hydrocarbons from compression and pump oils which are particularly detrimental to its use in the semiconductor industry. Carbon dioxide use in the semiconductor and silicon wafer production industries has seen much recent growth. However, these industries require extremely pure carbon dioxide in order to ensure that the products do not become contaminated by impurities that might be present in the carbon dioxide. It is particularly important that compounds containing about ten or more carbon atoms be removed from the carbon dioxide, and most important the compounds containing greater than about 15 carbon atoms be removed. This application is primarily concerned with purification of carbon dioxide for use in the semiconductor and silicon wafer production industries, where high purity carbon dioxide is required.
The most commonly used purification method is treatment with potassium permanganate or potassium dichromate. Both potassium permanganate and potassium dichromate are active oxidizing agents, consequently scrubbing generally results in oxidation of unwanted materials. In the case of hydrogen sulfide as a contaminant, oxidation results in the formation of sulfur that is readily removed as a solid. Where it is necessary to also remove water from the carbon dioxide, a separate drying step over alumina has sometimes also been used. Nonetheless, the presence of residual impurities often remains a problem in providing even food-grade carbon dioxide which meets the Compressed Gas Association commodity specifications much less the particular needs of the semiconductor and silicon wafer production industries.
Although the commercial production of carbon dioxide has been ongoing for many years now, and although the purification of the carbon dioxide has been the subject of many efforts, nonetheless a truly high purity carbon dioxide is expensive to produce and not widely available. In answer to this need, the present invention uses a combination of adsorbents to very effectively and very efficiently remove impurities such as water, sulfur-containing compounds, nitrogen-containing compounds, and hydrocarbons. In particular, the present invention provides a combination of adsorbents that are uniquely suited to removing compounds containing greater than about ten carbon atoms.
SUMMARY OF THE INVENTION
The invention described within is a method of purifying liquid or gaseous carbon dioxide. In particular, the present invention is a process for preparing high purity carbon dioxide suitable for use in the semiconductor and silicon wafer production industries. An embodiment comprises passing gaseous carbon dioxide through one or more beds containing (1) a metal oxide, (2) silica gel, and (3) activated carbon. The silica gel may be commonly available silica get such as Grade 3, 8 mesh silica gel, or may be alumina- or magnesia- stabilized silica gel, mixtures thereof, or a bed of each type of silica gel may be used. In a more specific embodiment a molecular sieve such as 4 A molecular sieve may be used as the first bed to remove water. In another specific embodiment, silicalite may be used as a bed to remove a wide variety of low molecular weight organic compounds and oxygen-containing compounds. More specific embodiments of the invention involve additional adsorbents such as ZSM-5, ZSM-12, ZSM-23, silver-exchanged faujasite, reduced metal on matrix material, and combinations thereof. Other embodiments and applications will be apparent from the ensuing description.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a simplified side view of the apparatus for purifying carbon dioxide. Additional pieces of apparatus that may be employed in connection with the apparatus of the invention are not shown.
FIG. 2 is a chromatogram of a solvent blank as described in the Example.
FIG. 3 is a chromatogram of a solvent wash of a silicon wafer exposed to carbon dioxide that has been purified according to the present invention as described in the Example.
FIG. 4 is a chromatogram of a solvent wash of a silicon wafer exposed to carbon dioxide as described in the Example.
DESCRIPTION OF THE INVENTION
The need for high purity carbon dioxide in the semiconductor and silicon wafer production applications has been recently growing. Such applications have unique requirements including that the carbon dioxide be essentially free of impurities that would contaminate the semiconductor and silicon wafer products. It is especially important in these applications that the carbon dioxide be free of compounds containing greater than about ten carbon atoms. Lube oils have been found to be a problematic contaminant of carbon dioxide since it is believed that lube oils having greater than about 10 carbon atoms may fold into configurations that prevents entry into the pores and hence adsorption by many molecular sieves. The present invention is a process for purifying gaseous or liquid carbon dioxide to sufficient levels so as to enable its use in the foregoing applications. The purification process of the present invention relies on a sequence of specific adsorbent beds including a metal oxide, silica gel, activated carbon, and optionally a 3 A, 4 A or 5 A molecular sieve, and silicalite to remove, most importantly, compounds containing greater than about 10 carbon atoms and sulfur-containing compounds. The use of the additional adsorbents, e.g., zeolites such as 3 A, 4 A and 5 A and silicalite, is optional but they may be employed to remove other impurities such as oxygen-containing compounds, water, and lower molecular weight hydrocarbons where desired. It is the unique combination of adsorbents in the present invention that is so effective to purify carbon dioxide as needed for the semiconductor and silicon wafer processing industries.
An advantage of the present method is that the purification is conveniently done on-site, on demand, and is conveniently scaled from relatively small to quite large amounts of carbon dioxide. For example, one may purify small quantities of carbon dioxide for laboratory use from a tank of carbon dioxide using a cartridge containing the materials described herein affixed to the tank outlet, with carbon dioxide being purified as it is drawn from the tank. At another end of the scale, carbon dioxide may be generated, and/or stored in large quantities on-site, then purified by passage through commensurately sized beds of adsorbent as described herein. The core advantage of the present invention in both cases is that carbon dioxide is purified as and when used, which is inherently a more efficient process of purification than one that purifies the carbon dioxide long before it is used.
The preferred adsorbent which serves to purify the carbon dioxide is the combination of a metal oxide, silica gel, and activated carbon. The metal oxide may be any metal oxide that is capable of reacting with sulfur containing compounds. Preferred metal oxides include molybdenum oxide and tungsten oxide. The metal oxide may be composited with or without a binder to form particle shapes known to those skilled in the art such as spheres, extrudates, rods, pills, pellets, tablets, or granules. Spherical particles may be formed directly by the oil-drop method or from extrudates by rolling extrudate particles on a spinning disk. The metal oxide may be a separate bed, or may be mixed with any of the adsorbents described below. When each of the adsorbents of the present invention are used as separate layers or beds, it is preferred that the metal oxide be positioned so that the carbon dioxide encounters the metal oxide prior to encountering the silica gel or activated carbon.
An example of a commonly available acceptable silica gel is Grade 3, 8 mesh silica gel readily available from sources such as Aldrich Chemical Company, Inc. Other acceptable silica gels include alumina- or magnesia-stabilized silica gel, also readily available from sources such as Aldrich Chemical Company. Magnesia-stabilized silica gel is also available under the name of Fluorosil. The invention may utilize only one type of silica gel, or preferably the invention may contain a bed of at least one Grade 3, 8 mesh silica gel and at least one alumina- or magnesia-stabilized silica gel. It is also contemplated that the invention may utilize a bed containing a mixture of two or more types of silica gel. As used herein, the general term “silica gel” is meant to include Grade 3, 8 mesh silica gel as well as alumina- or magnesia-stabilized silica gel. The activated carbon used in the present invention, may be any of the commonly-available activated carbon brands, such as Norit Calgon, Colonut Wood, and Sadinited Visis. A preferred weight ratio of metal oxide to silica gel to alumina is 1:4:4.
The foregoing adsorbents are well suited for the removal of compounds containing greater than about 10 carbon atoms and sulfur-containing compounds which are likely to be found as impurities in gaseous carbon dioxide. Impurities containing greater than about 10 carbon atoms are usually the result of contamination from compressor or pump oils. An example of a common contaminant that is successfully removed from carbon dioxide via the present invention is Windsor Lube oil, an oxygenated compound having 26 carbon atoms. Another example are the polychlorinated biphenyls or PCBs such as those found in lubricating or cutting oils.
We have also found that zeolites such as 3 A, 4 A, and 5 A also may be optionally used as a guard bed or prebed, especially to remove other impurities such as water. Although less preferred, the zeolites such as 3 A, 4 A, and 5 A may be mixed with or placed in sequence at any position before or after other above-described adsorbents. Whether yet other zeolites or molecular sieves such as are used in combination with the above-described metal oxide-silica gel-activated carbon adsorbent is largely a matter of choice and depends mainly upon the nature of the impurities to be removed from the carbon dioxide stream. Silicalite would be included in applications where it is desired to remove lower molecular weight compounds such as hydrocarbons or oxygen-containing compounds. When zeolites such as 3 A, 4 A, and 5 A, or a mixture thereof, are employed in the present invention, it is preferred to position a bed of the 3 A, 4 A, and/or 5 A zeolite so that the carbon dioxide passes through the 3 A, 4 A, and/or 5 A zeolite prior to passing through any other adsorbent thereby preventing other adsorbents from needless contact with moisture.
A preferred embodiment of the invention is one where the first bed contains 4 A molecular sieve, a second bed contains molybdenum oxide, a third bed contains alumina-stabilized silica gel, a fourth bed contains activated carbon, a fifth bed contains Grade 3, 8 mesh silica gel, and a sixth bed contains silicalite. It is further preferred that the weight ratio of the above beds is 1:1:2:4:2:1. However, the amount of each adsorbent used is determined by the particular application and the amount of each impurity present in the carbon dioxide.
It is preferred to activate the series of adsorbent beds prior to use. A preferred activation includes holding the adsorbents at 225° C. in a flowing nitrogen atmosphere for a time sufficient to deplete contaminants that may be adsorbed on the adsorbents. For a 2.7 liter volume of adsorbent, an activation time of about 4 hours is sufficient.
The present invention is carried out in a relatively uncomplicated way, merely by passing a stream of liquid or gaseous carbon dioxide through one or more beds of adsorbent. One may use only a single bed of a mixture of the adsorbents, a bed containing different adsorbents in layers, or one can use more than one bed, each of a particular adsorbent. It is also possible to practice the present invention using some combination of the foregoing. Which method is chosen is largely a matter of choice and the success of the present invention is generally not dependent thereon. It is preferred to use a cartridge containing layers of individual adsorbents with the cartridge being of a design for facile insertion into a carbon dioxide flow conduit. The resultant purified carbon dioxide is depleted in impurities such as water, compounds containing greater than ten carbon atoms, sulfur-containing compounds, nitrogen-containing compounds, oxygen-containing compounds and organic compounds. That is, the concentration of impurities in the resultant purified carbon dioxide is less than in carbon dioxide before it is purified by the present invention. As to the removal of oxygen-containing compounds, if the carbon dioxide being purified is in the liquid state, it is expected that oxygen-containing compounds containing 4 or more carbon atoms would be removed by the present invention.
It is expected that the invention will be most useful in the carbon dioxide in semiconductor and silicon wafer production applications, but other applications exist as well. The invention is also contemplated to be successful in the purification of carbon dioxide for use in the dry cleaning industry as well as for use in the food and beverage industry. However, the dry cleaning industry and the food and beverage industry have different concerns as to possible contaminants. Therefore, several other adsorbents may be combined with those already discussed above in order to more effectively remove the impurities of particular concern to these industries.
In one specific embodiment of the invention, preferred additional adsorbents which serves to purify the carbon dioxide are a silver-exchanged zeolite having a faujasite structure, an MFI-type molecular sieve, ZSM-12, or ZSM-23. It is particularly preferred to use the silver-exchanged zeolite having a faujasite structure in combination with one of the MFI-type molecular sieve, ZSM-12, or ZSM-23. The zeolite having a faujasite structure may be naturally occurring or a synthetic analog such as zeolite X and is referred to herein as a “faujasite”. The faujasite may be silver exchanged to the extent of from about 5 up to about 90%. That is, from about 5 up to about 90 percent of the available sites in faujasite are exchanged with silver, which corresponds to material having 0.1-3 weight percent silver. A preferred silver-exchanged faujasite is silver-exchanged zeolite X. The molecular sieve may be one of the MFI-type molecular sieves with a Si:AI ratio of at least 10 (i.e., silica:alumina is at least 20) and preferably greater than about 20 such as ZSM-5 and silicalite. The molecular sieve adsorbent may also be ZSM-12 or ZSM-23. The foregoing adsorbents are well suited for the removal of sulfur-containing compounds, especially hydrogen sulfide, nitrogen-containing compounds, oxygen-containing compounds, and hydrocarbons which are likely to be found as impurities in gaseous carbon dioxide. As a class of hydrocarbons, alcohols are also readily removed by the additional adsorbents. The faujasite and molecular sieve may be used as a mixture of the two additional components, as a mixture with any of the above-described adsorbents, or as a sequence of separate beds. Molecular sieves with a pore diameter in the 4-6 angstrom range are especially suitable in the practice of this embodiment of the invention. It is possible to use solely the MFI-type molecular sieve or solely the silver-exchanged faujasite along with the above-described combination of adsorbents: the metal oxide, silica gel and activated carbon.
Similarly, in yet another embodiment of the invention, reduced metals, i.e., metals in the zero valent state, supported on a matrix material may be optionally employed in combination with any of the above embodiments of the invention to remove impurities such as oxygen to levels as low as, for example, less than 1 ppm oxygen. Preferred reduced metals include nickel and copper, with the most preferred being copper. Matrix materials may be a high surface area refractory inorganic oxide such as those commonly known in the art including silicas, aluminas, and zeolites. The silicas may be amorphous or crystalline, and examples of aluminas include gamma, theta, and delta. The preferred matrix material is alumina. Such matrix materials are well known to one skilled in the art and are not discussed in detail here; for reference see U.S. Pat. No. 5,659,099 hereby incorporated by reference. The reduced metal may be impregnated so as to result in a composite having from about 0.1 weight % to about 20 weight %, and preferably from about 0.1 weight % to about 10 weight %, of the metal deposited with high dispersion and even distribution throughout the matrix material, with the weight percent of reduced metal being measured as a percent of the composite. The reduced metal and matrix material may be composited with or without a binder to form particle shapes known to those skilled in the art such as spheres, extrudates, rods, pills, pellets, tablets, or granules. Spherical particles may be formed directly by the oil-drop method or from extrudates by rolling extrudate particles on a spinning disk. The reduced metal and matrix material may be a separate bed, or may be mixed with any of the above-described adsorbents. In an embodiment employing a silver-exchanged faujasite, a molecular sieve, and a reduced metal on a matrix material all as separate beds, it is preferred that the reduced metal on matrix material be positioned between the silver-exchanged faujasite and the molecular sieve.
Turning to FIG. 1, the apparatus of the invention is shown as a vessel 2 having a gas fluid inlet 4 and a gas fluid outlet 6 . The vessel may be constructed of any suitable material able to conduct carbon dioxide at the flow rate and pressure of the particular application. The gas fluid inlet and outlet may further be equipped with connectors so that the apparatus may be readily placed in a flowing carbon dioxide stream. Furthermore, the gas fluid inlet and outlet may contain a retainer to prevent the solid contents of the vessel from being removed from the vessel. The first bed, 8 , contains 3 A, 4 A, and 5 A molecular sieves, 10 is a second bed containing metal oxide, 12 is a third bed containing aluminastabilized silica gel and magnesia-stabilized silica gel, 14 is a fourth bed containing activated carbon, 16 is a fifth bed containing silica gel, 18 is a sixth bed containing a MFI-type molecular sieve, ZSM-5, ZSM-12, ZSM-23 or combinations thereof, 20 is a seventh bed containing silver-exchanged faujasite, 22 is an eighth bed containing reduced metal on a matrix material and 24 is a ninth bed containing silicalite.
EXAMPLE
Two silicon wafers were each exposed to 1 kg of commercially purchased grade 5 carbon dioxide from the same cylinder. However, the first wafer (wafer 1 ) was exposed to carbon dioxide that was purified by passing the carbon dioxide through 2.8 L total volume of particles where the particles are 9% 4 A molecular sieve, 9% of particles containing about 30% tungsten oxide and about 70% alumina, 18% silica-alumina, 38% activated carbon, 18% Grade 3 silica gel, and 8% silicalite prior to encountering the silicon wafer. The second wafer (wafer 2 ) was exposed to carbon dioxide directly from the cylinder of commercially purchased grade 5 carbon dioxide. A visual inspection of the two wafers after exposure to the carbon dioxide resulted in the observation of a thin film of deposit on wafer 2 which was exposed to carbon dioxide directly from the cylinder. No deposit was observed on the wafer 1 which was exposed to carbon dioxide that was first purified by passing the carbon dioxide through the 2.8 L of particles prior to encountering the silicon wafer.
Wafer 1 and wafer 2 described above were further analyzed using a solvent wash followed by gas chromatography-mass spectroscopy (GC-MS). A solvent containing 10 percent methanol in methylene chloride was prepared. A 5 mL aliquot of the solvent was used to wash wafer 1 and another 5 mL aliquot of the solvent was used to wash wafer 2 . The wafer rinsings were then concentrated by evaporation with nitrogen gas A solvent blank was also processed in the same manner as the samples.
The concentrated extracts were analyzed by GC-MS using a boiling point type column. The oven was ramped from 100° C. to 325° C. at 8° C. per minute. The resulting chromatograms are provided in FIGS. 2-4. FIG. 2 is the chromatogram resulting from the solvent blank, and no contaminates are detected. FIG. 3 is the chromatogram resulting from the solvent wash of wafer 1 . The spikes shown in FIG. 3 are due to electrical noise and FIG. 3 shows no contaminate peaks. FIG. 4 is the chromatogram resulting from the solvent wash of wafer 2 . Note that several large peaks are shown. A comparison of FIG. 3 and FIG. 4 reveals that wafer 1 yielded no detectable contaminates into the solvent wash while wafer 2 yielded at least three detectable contaminates into the solvent wash. The data demonstrates the effectiveness of purifying carbon dioxide by passing the carbon dioxide through the specified particles prior to contact with silicon wafers.
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Commonly available carbon dioxide may contain unacceptable amounts of compounds containing greater than about ten carbon atoms, sulfur-containing materials, and nitrogen-containing materials which are particularly detrimental to semiconductor and silicon wafer processing-related uses of carbon dioxide. These impurities can be effectively removed by a combination of metal oxide, silica gel, and activated carbon, thus permitting an on-site, on-demand, convenient, and economic method of purifying carbon dioxide ranging from laboratory scale operations to tank car scale operations.
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BACKGROUND OF THE INVENTION
Field of the Invention
[0001] Most modern automobiles and motor vehicles have many electronic systems that have developed over the years. One such system is the automatic seat belt warning indicator. This system typically sounds an audio alarm when the vehicle is operated and a seat belt has not been inserted into a seat belt receiving device. There are however, instances where one may wish to operate a motor vehicle and not utilize a seat belt. In these situations, operating the motor vehicle without utilizing the seat belt produces a continual audio alarm. One such example, without limitation would be moving cars around parking on a private property.
[0002] Therefore, a need exists for a device that will disable a seat belt alarm in a vehicle.
SUMMARY OF THE INVENTION
[0003] The present invention provides a device having a conventional seat belt male connector that is constructed and arranged to be inserted into a conventional seat belt receiver. The device of the present invention is further constructed and arranged to have a seat belt receiving cavity such that the article of the present invention can be secured into position in an automobile seat belt receiver and as desired can receive a conventional seat belt connecting buckle therein.
[0004] In one embodiment, the present invention is an article being a seat belt adapter for use in a motor vehicle seat belt system comprising:
[0005] a central body;
[0006] a male seat belt buckle attachment on one end of said main body;
[0007] a seat belt receiving cavity on an opposite end of said main body;
[0008] and seat belt securing mechanism contained therein.
[0009] The central body has incorporated therewith, a release mechanism for releasing a vehicle male seat belt connector from attachment to said main body through said receiving cavity. The release mechanism acts in concert with the internal securing mechanism for locking a seat belt into a closed and secured configuration.
[0010] Also contemplated is a method of using a seat belt adapter comprising the steps of:
[0011] providing an adapter according to the present invention; attaching said male buckle attachment to a vehicle seat belt receiving device.
[0012] In one embodiment, the attaching of the adapter deactivates a vehicle seat belt connection alarm. This can be done such that the seat belt connection alarm found in most vehicles is deactivated without a seat belt being worn by the user.
[0013] The method further comprises attaching a male vehicle seat belt connector to said main body by placing said male vehicle seat belt attachment into said receiving cavity of said article main body and actuating attachment by engaging said seat belt securing mechanism contained therein.
[0014] Some seat belt beepers and alarms are so deafening that a person can't even start the car in a garage without having the seatbelt closed first. If a person needs to do maintenance on the car, and simply drive it 10 feet to the front of the garage, the driver constantly have to fasten/unfasten the seat belt without purpose.
[0015] This often leads to people closing the seatbelt on an empty seat, and simply sitting on the closed seatbelt—very dangerous, as there is no way to properly fasten the seat belt around the body anymore once sat on.
[0016] Also contemplated is the device of the present invention making the buckle longer, for instance when using a baby seat. The problem with buckling up baby seats is that a user always has to reach very far to the other side to find the receiver buckle. with this “extension” inserted, car seat attachment becomes a significantly easier.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
[0017] FIG. 1 is a separated view showing the article of the present invention in an environment of use.
[0018] FIG. 2 shows the article of the present invention in a connected configuration.
[0019] FIG. 3 is a top view of the article of the present invention.
[0020] FIG. 4 is a front view of the article of the present invention.
[0021] FIG. 5 is a side view of the article of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0022] The present invention provides an article and system for use with automobile seat belts. Article 10 is constructed and arranged to receive a conventional male automobile seat belt buckle 16 that is connected on buckle support 14 . Buckle support 14 , as is known in the art has connected thereto automobile seat belt 12 . As is generally known, an automobile has a seat belt receiver 40 . Seat belt receiver 40 , come in many different configurations, and the figures are for illustrative purposes only. As is generally understood, seat belt receiver platform 42 defines a seat belt buckle receiving cavity 44 and a seat belt buckle is inserted therein. In the present invention, instead of inserting seat belt buckle 16 into seat belt buckle receiving cavity 44 , assembly buckle 28 is inserted into cavity 44 . This is generally shown in the progression from FIG. 1 to FIG. 2 . The article 10 of the present invention has a main body 20 . On one end of main body 20 is article fastening buckle 28 . On the opposite end from article fastening buckle 28 is article platform 20 that defines article buckle receiving cavity 22 . When article buckle 28 is inserted into seat belt receiving cavity 44 , as is generally known in automobiles that are manufactured today, the seat belt sensor is deactivated. At this point a user can choose to use a convention automobile seat belt 12 or to not use automobile seat belt 12 . In the case of non-use,because buckle 28 is inserted into cavity 44 , the seat belt warning devices on automobiles will not be activated.
[0023] As is generally understood the article 10 of the present invention utilizes conventional fastening and unfastening mechanisms that are known in the art. For example, when automobile seat belt buckle 16 is inserted into the apparatus cavity 22 internal attachment may be by any mechanism as is commonly known in the art for attaching and securing seat belt buckles. The same is true whereby apparatus buckle 28 inserts into automobile supplied seat belt connector 40 by inserting buckle 28 into cavity 44 , and ultimately securing into a fastened position in manners that are known in the art. The securing is in accordance with established safety standards such that a buckle secures into position and is not released until a releasing mechanism is activated. Article 10 has on it a convention spring loaded release mechanism whereby release is activated by pressing platform 24 such that internal mechanisms (not shown) release a buckle that is secured within article 10 . The present invention further encompasses a method for disabling automobile seat belt sensors whereby buckle 28 of article 10 is inserted into cavity 44 of seat belt receiver 40 . In this use, a seat belt is not required to be fastened and secured, yet the seat belt warning device of an automobile is deactivated.
[0024] While the invention has been described in its preferred form or embodiment with some degree of particularity, it is understood that this description has been given only by way of example and that numerous changes in the details of construction, fabrication, and use, including the combination and arrangement of parts, may be made without departing from the spirit and scope of the invention.
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A system and method is provided whereby an article being a seat belt adapter is provided with a first male attachment and a second female receiving cavity in which said article is used with a vehicle seat belt system.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part of U.S. application Ser. No. 08/587,616, filed Jan. 17, 1996, now abandoned.
FIELD OF THE INVENTION
This invention relates to the field of implantable internal fixation devices for repair of bone fractures, and more specifically to resorbable bone implant biomaterials which contain a buffering compound.
BACKGROUND OF THE INVENTION
The trend in internal fixation devices for repair of damaged bone is toward the use of resorbable, tissue compatible biopolymers. Biopolymers such as poly(glycolic acid) (PGA), poly(lactide) (PLA), and copolymers of lactic and glycolic acids, (poly(lactide-co-glycolide) or PLGA) have been used in the production of internal fixation devices, such as screws, pins, and rods to hold bone together following surgery, or to repair broken bones. Other polymers, such as poly(dioxanone), have also been considered for use in the manufacture of surgical internal fixation devices. However, it has been observed that tissue response to resorbable implants fabricated from these biopolymers is not uniformly acceptable (Bostman, J. Bone and Joint Surg. 73, 148-153 (1991)).
The tissue response to biopolymer-based implants has been well documented. Late sterile inflammatory foreign body response (sterile abscess) has been reported in about 8% of fractures repaired with these polymers (Bostman, supra). In a randomized study of 56 open reduction and internal fixation of malleolar fractures of the ankle with metal ASIF screws and plates or with rods of PLGA, two cases of sterile inflammatory wound sinus were observed 3 to 4 months after the operation in the injuries fixed with the polymer rods (Rokkanen et al., Lancet 1, 1422-1425 (1985); Bostman et al., J. Bone and Joint Surg., 69-B(4), 615-619 (1987)). Other studies have also documented an inflammatory reaction following implantation of PGA or PLGA fixation devices. The fraction of patients suffering from this reaction ranges from 4.6 to 22.5% (Bostman et al., Clin. Orthop. 238, 195-203 (1989); Bostman et al., Internat. Orthop. 14, 1-8 (1990); Hirvensalo et al., Acta Orthop. Scandinavica, Supplementum 227, 78-79 (1988); Hoffman et al., Unfallchirurgie 92, 430-434 (1989); Partio et al., Acta Orthop. Scandinavica, Supplementum 237, 43-44 (1990); Bostman et al., Internat. Orthop. 14, 1-8 (1990)). The inflammatory reaction is not limited to poly(glycolide) polymers. Internal fixation devices made from poly(lactide) have also been observed to exhibit an inflammatory reaction. Eitenmuller et al. reports that 9 of 19 patients (47.7%) who had fractures of the ankle treated with absorbable plates and screws of poly(lactide) had an inflammatory response. (J. Eitenmuller, A. David, A. Pomoner, and G. Muhyr: "Die Versorgung von Sprunggelenlzsfrakturen unter Verwendung von Platten und Schrauben aus resorbserbarem Polymermaterial", Read at Jahrestagung der Deutschen Gesellschaft fur Unfallheilkunde, Berlin, Nov. 22, 1989).
In vitro studies have been performed to monitor pH changes as well as weight loss and the appearance of lactic acid from screws fabricated from poly(lactide-co-glycolide) with a lactide:glycolide ratio of 85:15. (Vert et al., J. Controlled Release 16, 15-26 (1991)). An induction period of about ten weeks was observed before any significant change in media pH or weight loss occurred. This time period corresponds to the induction periods of seven to twenty weeks noted by clinicians. However, no attempt has been made to alleviate the source of inflammation.
SUMMARY OF THE INVENTION
The invention is a bioerodible implantable material, comprising a bioerodible polymer that produces acidic products upon hydrolytic degradation, and a buffering compound that buffers the acidic products and maintains the local pH within a desired range. The buffer compound incorporated into the material of the invention acts to neutralize the acidic degradation products which cause inflammatory foreign body response upon degradation of the bioerodible polymer. Thus, the invention reduces the sterile abscess condition that occurs in the bioerodible implant materials of the prior art. Materials made according to the invention may be used for internal fixation devices (IFDs) for bone repair.
The bioerodible materials and methods of the invention include a bioerodible polymer that forms acidic products as it degrades. The bioerodible polymer undergoes hydrolysis in the body and generates acidic products that cause irritation, inflammation, and swelling (sterile abscess formation) in the treated area. To counteract this effect, a buffer is included in the bioerodible material to neutralize the acidic degradation products and thereby reduce the sterile abscess reaction. The buffer included in the bioerodible material of the invention maintains the pH surrounding the area of surgery to approximately neutrality (i.e., pH 7), or any other pH chosen by the surgeon. Preferably, the pH is maintained in the range of 6-8, and more preferably in the range of 6.8-7.4.
According to the invention, the bioerodible material includes a bioerodible polymer that undergoes hydrolysis to produce acidic products when exposed to an aqueous medium. The bioerodible polymers useful in the invention include polydioxanone, poly(ε-caprolactone); polyanhydrides; poly(ortho esters); copoly(ether-esters); polyamides; polylactones; poly(propylene fumarates) (H --O--CH(CH 3 )--CH 2 --O-CH═CH--CO--! n OH); and combinations thereof. In a preferred embodiment, the polymer poly(lactide-co-glycolide) (H --OCHR--CO--! n OH, R═H, CH 3 ) (PLGA) is used. The PLGA polymers used according to the invention have a lactide to glycolide ratio in the range of 0:100% to 100:0%, inclusive, i.e., the PLGA polymer can consist of 100% lactide, 100% glycolide, or any combination of lactide and glycolide residues. These polymers have the property of degrading hydrolytically to form lactic and glycolic acids.
The buffering compound included in the bioerodible material of the invention may be any base or base-containing material that is capable of reacting with the acidic products generated upon hydrolysis of the bioerodible polymer. Exemplary buffering materials that may be implemented according to the invention include the salts of inorganic acids, the salts of organic acids, or the salts of polymeric organic acids. Preferably, the calcium salts of weak acids are used, such as calcium carbonate, although calcium phosphates, calcium acetates, calcium citrates and calcium succinates may also be used.
Polymeric buffers may also be used as buffering compounds according to the invention. Suitable polymeric buffers preferably include basic groups which neutralize the acidic products generated upon hydrolysis of the bioerodible polymer. Such polymeric buffers include hydrolyzable polyamines, hydrolytically stable polymers, such as poly(N-vinyl carbazole), poly(N-vinyl pyrrolidone), poly(acrylic acid), poly(acrylamide), or a copolymer based on acrylic acid.
Another class of buffering compounds useful in the materials and methods of the invention are compounds which, on exposure to water, hydrolyze to form a base as one reaction product. The generated base is free to neutralize the acidic products produced upon hydrolysis of the bioerodible polymer. Compounds of this type include aryl or alkyl carbamic acids and imines. The base-generating compounds used according to the invention offer the advantage that the rate of hydrolysis of the base generator may be selected to correlate to the rate of hydrolysis of the bioerodible polymer.
Preferably, the buffering compound has an acid dissociation constant that is smaller than the acid dissociation constant of the acidic products generated upon hydrolysis of the bioerodible polymer. Alternatively, the buffering compound preferably has a hydrolysis constant that is greater than the hydrolysis constant of the acidic products.
Preferably, the buffering compound included in the material of the invention is only partially soluble in an aqueous medium. In general, buffers of lower solubility are preferred because buffer loss from the polymer by diffusion will be minimized (Gresser and Sanderson, "Basis for Design of biodegradable Polymers for Sustained Release of Biologically Active Agents" in Biopolymeric Controlled Release Systems, Ch. 8, D. L. Wise, Ed., CRC Press, 1984).
The invention also includes methods of making a buffered bioerodible material for implantation into a surgical site. In one embodiment, the method according to the invention includes the steps of dissolving a bioerodible polymer in a solvent, and mixing a buffering compound with the dissolved bioerodible polymer, the buffering compound capable of buffering the acidic products within a desired pH range. The resulting mixture is cast into a sheet, and the solvent is evaporated to produce a buffered bioerodible implantable material in film form. The resulting film may be further processed, for example, compacted under pressure, extruded through a die, injection molded, or shaped into a form useful for bone repair.
In another embodiment, the method according to the invention includes mixing dry, solid bioerodible polymer particles of a specific size with dry, solid buffering compound particles of a specific size, and mixing the bioerodible polymer particles and the buffering compound particles in a desired proportion. This mixture may then be processed as described above.
In another embodiment, the method of the invention includes providing an open celled bioerodible foam polymer of controlled density and providing a buffer dissolved in a solvent wherein the foam polymer is not soluble in the solvent, such as described in U.S. Pat. No. 5,456,917 to Wise et al., the whole of which is incorporated by reference herein. The buffer is loaded into the foam polymer, and the loaded foam polymer is freeze dried to remove the solvent. The resulting loaded bioerodible polymer may be further ground into particles of a predetermined size, extruded through a die, or shaped into useful forms.
In another embodiment, the method of the invention includes providing a bioerodible polymer having a melting temperature and producing acidic products upon hydrolytic degradation, providing buffer particles comprising buffer material coated with a polymer having a melting temperature greater than the melting temperature of the bioerodible polymer. The bioerodible polymer is heated to a temperature between the melting temperatures of the bioerodible polymer and the coating polymer, and the heated bioerodible polymer is mixed with the coated buffer particles. The mixture is then cooled and processed into useful forms.
As used herein, the term "bioerodible" is defined as the susceptibility of a biomaterial to degradation over time, usually months. The term "buffer" is defined as any material which limits changes in the pH in the implant and its near environment only slightly upon exposure to acid or base. The term "acidic products" is defined herein as any product that has a pH less than 7.
DETAILED DESCRIPTION OF THE INVENTION
The invention relates to the field of internal fixation devices (IFD) used for surgical repair of orthopaedic and maxillofacial fractures. The invention is a bioerodible implantable material, comprising a bioerodible polymer capable of producing acidic products upon hydrolytic degradation, and a buffering compound that buffers the acidic products within a desired pH range.
The bioerodible material of the invention includes at least one bioerodible polymer that undergoes hydrolysis to produce acidic products when exposed to an aqueous medium. The bioerodible polymers useful in the invention include, but are not limited to, polydioxanone (H --O--CHR--CO--! n OH); poly(ε-caprolactone); polyanhydrides; poly(ortho esters); copoly(ether-esters); polyamides; polylactones; poly(propylene fumarates) (H --O--CH(CH 3 )--CH 2 --O--CH═CH--CO--! n OH); and combinations thereof. A preferred polymer material useful in the invention is poly(lactide-co-glycolide) (H --OCHR--CO--! n OH, R═H, CH 3 ) with a lactide to glycolide ratio in the range of 0:100% to 100:0%. Accordingly, the PLGA polymer can consist of 100% lactide, 100% glycolide, or any combination of lactide and glycolide. This polymer has the property of degrading hydrolytically to form organic acids (lactic acid and glycolic acid) which accumulate in the region surrounding the implant.
The buffering compound included in the bioerodible material of the invention includes base capable of reacting with the acidic products generated upon hydrolysis of the bioerodible polymer. Exemplary buffering materials that may be implemented according to the invention include the salts of inorganic acids, the salts of organic acids, or polymeric organic acids. Preferably, the calcium salts of weak acids are used, such as calcium carbonate, although calcium phosphates, calcium acetates, calcium citrates and calcium succinates may also be used.
In general, buffers of lower solubility are preferred because buffer loss from the polymer by diffusion will be slower (Gresser and Sanderson, supra). Preferably, the buffering compound has an acid dissociation constant that is smaller than the acid dissociation constant of the acidic products generated upon hydrolysis of the bioerodible polymer. Ionic buffers will, in general, be the salts of weak acids. The acid, of which the buffer is a salt, should have an ionization constant (acid dissociation constant, Ka) which is less than the Ka for the acid products of polymer hydrolysis. Alternatively, the buffering compound has a hydrolysis constant that is greater than the hydrolysis constant of the acidic products.
According to the invention, a preferred buffering compound is calcium carbonate. Upon reaction with an acid, calcium carbonate forms a calcium salt and the weakly acid carbonic acid (H 2 CO 3 ). The carbonic acid undergoes decomposition to carbon dioxide (CO 2 ) and water (H 2 O) according to the following reaction sequence:
2R-CO 2 H+CaCO 3 →(R-CO 2 ) 2 Ca+H 2 CO 3 H 2 CO 3 →CO 2 +H 2 O.
Gaseous carbon dioxide generated from the neutralization reaction is observed to be absorbed by the surrounding aqueous medium. The solubility of gaseous CO 2 in water at 760 mm Hg and 37° C. is approximately 0.95 mg/ml (Merck Index, 1989). Thus, upon being generated in situ, gaseous CO 2 dissolves in and is eliminated from tissue fluids. In addition, free acid generation from the polymers of the invention proceeds slowly. Thus, degradation of the polymer component is the rate limiting step in the reaction, and even during the period of most rapid degradation, generation of acidic products occurs slowly. The slow rate of degradation and associated acid production gives carbon dioxide ample time to dissolve in the surrounding fluids.
The amount of calcium carbonate required to be loaded into a bioerodible polymer matrix to neutralize a given quantity of lactic and glycolytic acids can be estimated by calculating the moles of monomeric acid produced at 100% hydrolysis. For PLGA of any composition (i.e., -- --O--CH(CH 3 )--CO--! x -- O--CH 2 --CO--!.sub.(1-x), where x and (1-x) are the fractions of lactide and glycolide respectively, the molecular weight of the lactide component is 72 g/mol and the molecular weight of the glycolide component is 58 g/mol), the average monomer residue molecular weight is
72x+58(1-x)=14x+58.
Thus, one gram of PLGA-50:50 (where x=0.5) will generate approximately 0.0154 moles of monomeric acid upon hydrolysis. Referring to the neutralization reaction above, the amount of calcium carbonate buffer needed to neutralize this quantity of acid is 0.0077 moles, or 0.77 grams (MW of CaCO 3 =100 g/mol). Thus, the fraction of calcium carbonate buffer loaded into the polymer matrix is 43.5% by weight. Similar determinations can be calculated for other polymer and buffer combinations and are within the skills of the ordinary skilled practitioner. Other calculations may also be made, for example, calculation of the amount of buffer required to neutralize a percentage of the acid groups generated upon hydrolysis.
An appropriate buffer should have a low aqueous solubility so that it will not be rapidly lost by dissolution. The basic component of the buffer (the anion) should react easily with the protons of the acid products of hydrolysis. Letting B - represent the buffer anion and L - the lactate (or glycolic) anion, the equilibrium can be expressed as:
HL+B.sup.- .sub.←.sup.→ L.sup.- +HB
In other words, HB must be a weaker acid than HL (or B - must be a stronger base than L - ). These relationships may be expressed quantitatively by ionization constants of the respective acids (Ka):
KaHB<KaHL
Thus a viable buffer would be CaHPO 4 (dibasic calcium phosphate). The reaction of lactic acid with the anion HPO 4 -2 is:
HL+HPO.sub.4.sup.-2 .sub.←.sup.→ L.sup.- +H.sub.2 PO.sub.4
The H 2 PO 4 - anion has an acid dissociation constant of approximately 6.31×10 -8 whereas the various racemates of lactic acid have dissociation constants in the range of approximately 1.38×10 -4 to 1.62×10 -4 . Taking 1.5×10 -4 as a mean value, the equilibrium constant for the above reaction may be calculated as: ##EQU1## Thus, the equilibrium lies to the right and protons produced by ionization of lactic or glycolic acids will be removed by the buffer.
Buffers are included in the polymer in solid form preferably should have a relatively small particle size, for example, between less than 1.0 and 250 μm. Particle size reduction can be accomplished by any standard means known in the art, such as ball milling, hammer milling, air milling, etc. If buffer and polymer are to be blended by the dry mixing method (described below), the polymer particle size must also be considered. Polymers such as the PLGAs have relatively low glass transition temperatures and melting temperatures. Thus, polymer particle size reduction must be accompanied by cooling, for example using a Tekmar A-10 mill with a cryogenic attachment.
Following milling, the desired particle size range of the buffer and the polymer may be recovered by sieving through, for example, U.S. Standard sieves. Particles in the size ranges of <45, 45-90, 90-125, 125-180, 180-250 μm may be conveniently isolated.
In selection of particle size range, it is sometimes desirable to combine two or more ranges, or to use a wide range of sizes, for instance all sizes less than 250 μm. Larger particles may be preferred in some applications of the invention because larger particles take longer to be eroded by the acids and will therefore extend the useful lifetime of the buffer. In some cases particle size reduction will not be necessary, such as when commercially available precipitated calcium carbonate is used (e.g., Fisher Scientific, Inc., Catalog No. C-63).
The effectiveness of calcium carbonate in neutralizing the acid products of polymer hydrolysis depends not only on the quantity of calcium carbonate present in the matrix, but also on particle size and distribution, total surface area in contact with the polymer, and degree of solubility. Each of these parameters may be controlled by methods chosen for preparation of calcium carbonate.
Calcium carbonate exists in two major crystalline forms: calcite and aragonite. By choice of one form or the other for inclusion in the polymer, the volume fraction occupied by calcium carbonate may be adjusted within limits. Thus, for a given loading (weight percent), the aragonitic form, because of its higher specific gravity, will occupy about 9.1% less volume than will an equal weight percent of the calcitic form.
The two forms differ in their aqueous solubilities, the aragonitic form being about 46% more soluble than the calcitic form. The rate at which neutralization occurs will depend in part on the solubility of the buffering agent. Thus aragonite reacts more rapidly with a given concentration of a given acid than calcite. Thus the presence of the aragonitic form of calcium carbonate is preferred when rapid hydrolysis of the bioerodible polymer is expected. Because of its higher solubility, the aragonitic form of calcium carbonate will also be leached out of the bioerodible polymer more rapidly. Thus, it may be desirable to incorporate both forms of calcium carbonate into the buffered material.
During the preparation of calcium carbonate, reaction conditions determine the preponderance of crystal type, mean particle size, and particle size distribution. In general, rapid precipitation, high reactant concentrations, and high temperatures increase the tendency to produce aragonite. On the other hand, calcite formation is encouraged by precipitation at temperatures below 30° C. During preparation of the buffer, reaction conditions are chosen to produce the most desirable form of calcium carbonate for a particular application. The choice of reaction conditions is well known in the art and within the skills of the ordinary skilled practitioner.
In an exemplary embodiment, calcium carbonate or calcium magnesium carbonate may be precipitated by mixing an aqueous solution containing a soluble calcium salt or soluble calcium magnesium salt with another aqueous solution containing a soluble ionic carbonate. The temperature of the process is limited by the freezing or boiling points of the solutions. The temperature at which precipitation is performed determines the relative abundance of the calcite and aragonite forms. Calcite formation is favored by precipitation (crystallization) below 30° C., and aragonite formation is favored at higher temperatures.
The range of temperatures at which precipitations can be performed may be greatly extended by taking advantage of the solubility of certain calcium compounds and carbonates in solvents other than water. For example, water soluble calcium nitrate is also freely soluble in methanol, ethanol, and acetone. These solvents may be used at temperatures limited by the freezing points of the solutions. The solution freezing points will be lower than the freezing points of the pure solvents, which are, in the order given above, -95.4° C., -117.3° C., and -93.9° C. These solvents are also freely miscible with water thus allowing aqueous solutions of these solvents to be employed as solvents for the calcium or carbonate compounds. Both forms of calcium carbonate are also soluble in glycerol or glycerol and water. Glycerol has a boiling point in excess of 290° C., at which temperature it begins to decompose. Thus mixtures of glycerol and water may be used as solvents at temperatures above the boiling point of water to perform precipitation.
It should be noted that the viscosities of acetone and methanol are less than that of water, while those of ethanol and glycerol are higher. Control of solution viscosity may be achieved by performing precipitation in mixtures of water with the above solvents. Viscosity effects may also be employed in varying morphology precipitated particles. It is well known that precipitation and crystallization from solution may be markedly affected by the presence of second solvents. This phenomenon can be used to control of particle form.
Control of buffer particle size is also important in producing the materials of the invention because solubility of the buffer is affected by particle size. In general, small crystals (e.g., <1 μm) exhibit greater solubility than larger ones.
Calcination of metallic carbonates may be employed for creating highly porous particles of buffer useful in the materials of the invention. Calcination of calcium acetate at temperatures in the range 450°-700° C. produces porous calcium carbonate particles and acetone (which decomposes to CO 2 and H 2 O). At higher temperatures (700°-1000° C.), calcium carbonate is further decomposed to calcium oxide and carbon dioxide. Similarly, calcination of calcium magnesium acetate in this temperature range produces a mixed calcium magnesium carbonate. Other materials suitable for calcination include formates, propionates, gluconates, lactates, and benzoates. Calcination above 700° C. produces particles with diameters of <100 μm and with porosities as high as 0.7, and surface areas of about 27 m 2 /g. Further reduction in particle size may be accomplished by standard techniques such as grinding, air milling, etc., and sieving. Porous calcium carbonate has the advantage of presenting a large surface area to solutions of the acid products of hydrolysis; thus, the rate of neutralization is increased.
The method of calcination to produce carbonates and then metallic oxides may be applied to any salt comprising a metallic ion and a carboxylate anion. The products are a metallic carbonate and a ketone. Further, heating of the carbonate will produce a metallic oxide, carbon dioxide, and water. As shown by Steciak et al., (A. I. Ch. E. J., 41, 712-722 (1995)) calcium magnesium acetate, when calcined at 950° C., produces particles with a porosity of 0.7, and a surface area of 27 m 2 /g.
The presence of calcium ions in the buffered device has advantages with respect to the physical properties of the device as it undergoes erosion. It has been shown that calcium ions form ionic bridges between carboxylate terminal polymer chains (Domb et al., J. Polymer Sci. A28, 973-985 (1990); U.S. Pat. No. 4,888,413 to Domb). Calcium ion bridges increase the strength of composites in which the polymer chains are terminated with carboxylate anions over similar chains terminated with hydroxyl groups of terminal glycol moieties. In an analogous manner, the polyesters comprising the family of PLGA's are expected to be strengthened by calcium bridges between carboxylate anion terminated chains.
In addition to organic or inorganic salts which can serve as buffers, polymeric buffers may also be implemented in the materials and methods of the invention. Polymeric buffers useful in the invention preferably include at least one basic group which is capable of neutralizing the acidic products generated upon hydrolysis of the bioerodible polymer. As used herein, the term "base" and "basic group" is defined as any chemical group capable of donating an electron pair. The basic groups of the polymeric buffer may be attached to substituents pendant to the polymeric buffer backbone, or may be attached directly to the polymer backbone, or may be included as part of the polymer backbone itself. The polymers serving as buffers may be stable to hydrolysis, such as "addition" or "vinyl-type" polymers, i.e., those polymers formed by polymerization of monomers containing carbon-carbon double bonds (substituted ethylenes) to form a chain of repeating units in which the repeating unit has the same composition as the monomer. Alternatively, the buffering polymers may themselves be subject to hydrolytic action, such as "condensation" or "step" polymers, i.e., those polymers formed from polyfunctional monomers with loss of material at each step. Examples of useful condensation polymers are polyesters and polyamides.
As with buffering compounds, the negative ions of the polymeric buffers act as bases which neutralize the acids produced by hydrolysis of bioerodible polymer. A generalized structure of an exemplary polymeric buffer is shown below. In the following diagram, M represents the monomeric units which form the buffer polymer backbone, and R represents a hydrogen atom, an alkyl group or an aryl group. ##STR1##
As shown in the diagram, the monomeric units M may have substituents which bear basic groups, such as carboxyl, amine, or phosphonate groups. Each monomeric unit may bear a basic group, but this is not a necessary requirement. In addition, the basic groups of a given polymeric molecule may not all be the same. As shown in the diagram above, carboxyl, amine or phosphonate groups may be used alone, or in combination. Moreover, some polymeric buffers may be synthesized from two or more monomers so that in a given polymeric buffer, the M groups differ.
Thus, according to the invention, many polymeric buffers may be selected based on properties such as buffering capacity and pKa value. An important parameter in choosing a polymeric buffer is that the pKa of the acid formed by the polymeric buffer be less than the pKa of the hydrolysis products of the bioerodible polymer. Exemplary polymeric buffers include, but are not limited to, hydrolyzable polyamines, such as poly(aspartic acid), poly(glutamic acid), poly(lysine), poly(amino-γ-benzyl glutamate); hydrolytically stable polymers (vinyl or addition polymers), such as poly (N-vinyl carbazole), poly(N-vinyl pyrrolidone), poly(acrylic acid), poly(acrylamide), or a copolymer based on acrylic acid, such as ##STR2##
where R=H, alkyl, or aryl, (R groups need not be identical). In copolymers, such as copolymers of acrylic acid, the residue monomer units forming the backbone may be distributed randomly or may occur in sequential blocks (random or block copolymers). Hydrolyzable polyesters of the general structure ##STR3## may also be used. In the structures shown above, R=H, alkyl, or aryl; n 1 and n 2 ≧0; n 3 ≧3; B=a basic group, such as --CO 2 -, --NR 2 , or --PO 3 R-.
In an alternative embodiment, the basic group of the polymeric buffer may be covalently bonded within the monomeric unit. An example of this type of polymeric buffer is poly(ethylamine)-(CH 2 --CH 2 --NH) n --.
Another class of buffer compounds useful in the invention are compounds which, on exposure to water, hydrolyze to form a base as one reaction product. This generated base is then free to react with the acidic products produced upon hydrolysis of the bioerodible polymer.
In one embodiment, compounds such as aryl and alkyl carbamic acids may be implemented to generate the basic compounds that act as buffers. The hydrolysis reaction which results in base generation is: ##STR4##
The carbonic acid generated during the reaction is in equilibrium with carbon dioxide and water:
HOOC--OH .sub.←.sup.→CO.sub.2 +H.sub.2 O
The basic product H 2 NR reacts with the acid products of bioerodible polymer hydrolysis in a neutralization reaction. In one embodiment, the hydrolysis products of poly(lactide-co-glycolide) (hereinafter designated as HL) may be neutralized by the generated base:
H.sub.2 NR+HL →H.sub.3.sup.+ NR+L.sup.-
In an alternative embodiment, imines may also be used to generate bases on hydrolysis according to the general equation: ##STR5##
The groups labelled R above may be a hydrogen atom, an alkyl group, or an aryl group.
Following protonation of the imine nitrogen, hydrolysis proceeds by nucleophilic attack by water at the carbon atom of the C═N bond. This process is facilitated by electron withdrawing groups attached to the nitrogen. Such substituents would thus increase the rate of hydrolysis. Conversely, the rate of hydrolysis would be diminished by electron donating substituents on the carbon and an electron withdrawing group on the nitrogen. Bulky groups, such as long alkyl substituents would tend to offer steric hindrance to the approach of the water molecules and thus would suppress the hydrolysis rate. Accordingly, by appropriate choice of R, the rate of hydrolysis of the imine may be either increased or decreased. This characteristic of base generating compounds is advantageous in that the rate of hydrolysis of the base generator may be selected to correlate to the rate of hydrolysis of the bioerodible polymer. Thus, in a given period of time, the quantity of base formed from the base generating compound will be equivalent to the quantity of acidic products formed by bioerodible polymer hydrolysis, and the stoichiometry of the reaction will be in the correct proportions to neutralize the appropriate amount of acid to maintain the pH within the desired range.
Several methods may be used to incorporate the buffer into the polymer. These methods include solution casting coupled with solvent evaporation, dry mixing, incorporating the buffer into a polymer foam, and the polymer melt method.
Method 1. Solution Casting-Solvent Evaporation
This method may be used with buffers which are either soluble or insoluble in the solvent. The bioerodible polymer is dissolved in any suitable volatile solvent, such as acetone, tetrahydrofuran (THF), or methylene chloride. The buffer, which may be soluble or insoluble in this solvent, is added to give the final desired ratio of polymer to buffer. If particle size reduction of the buffer is necessary, it may be accomplished by ball milling the suspension of buffer in the polymer solution. In contrast, if the buffer is soluble in the chosen solvent, particle size reduction at any stage is not necessary.
The suspension or co-solution is cast as a film on a glass or other inert surface, and the solvent is removed by air drying. Residual solvent remaining in the film may be further removed by subjecting the film to vacuum drying at elevated temperatures. As an example, if calcium carbonate is to be used as a buffering compound and it is desired to neutralize 50% of the acid formed by hydrolysis of PLGA-50:50, the buffer content of the composition should be 27.8%.
In an exemplary embodiment, to prepare 50 grams of composite, 36.1 grams of PLGA-50:50 are dissolved in approximately 250 ml of tetrahydrofuran, and 13.9 grams of calcium carbonate of the desired particle size range is added to the solution mixture. After distributing the calcium carbonate homogeneously by mixing, the suspension is dried to a film as described above.
The resulting film may be processed by compaction under high pressure, extruded through a die, injection molded, or other method known in the art. Further definition of the final shape may be accomplished at this point by any desirable machining process, such as lathing.
Method 2. Dry-Mixing
A polymer of appropriate particle size range is mixed with the buffer, also of chosen particle size range, in proportions to give the desired stoichiometric buffering capacity. The dry mixture is thoroughly blended by rotating the mixture in a ball mill jar from which the grinding balls have been omitted, or other suitable mixing device. The blended mixture may then be processed by compaction, extrusion, injection molding, etc., as described above.
Method 3. Incorporating the Buffer into a Polymer Foam
This method deposits the buffer as microcrystals within the pores of a foamed polymer. An open celled polymer foam of controlled density may be formed by lyophilization of a polymer solution as described in U.S. Pat. No. 5,456,917 to Wise et al., the whole of which is incorporated by reference herein. For example, open celled PLGA-85:15 foams (i.e., foams with 85% lactide and 15% glycolide by weight) with different morphologies are created by lyophilization of frozen solutions of the polymer from either benzene or glacial acetic acid. The density and void volume of the foam is a function of the initial polymer solution as shown in TABLE 1.
TABLE 1______________________________________FOAM DENSITY AS A FUNCTIONOF SOLUTION CONCENTRATIONConcentration of solution, mg/ml Density of Foam, mg/cm.sub.3______________________________________30.0 43.040.0 60.145.0 65.050.0 70.1 ± 0.966.7 87.5______________________________________
In this method, buffers which are soluble in a solvent which does not dissolve the polymer foam are preferred, such as water soluble buffers or low molecular weight alcohols, such as ethanol. The weight fraction of the buffer in the polymer/buffer composite, f, will depend on both absolute density of the polymer, d p , the density of the foam, d f , and the concentration of the buffer in the solvent, C. This dependency is given by the loading equation:
f= 1+d.sub.f d.sub.p /C(d.sub.p -d.sub.f)!.sup.31 1
TABLE 2 shows loading of PLGA-85:15 foams prepared from acetic acid solutions with the anti-tuberculosis drug isoniazid dissolved in water. Results of these loading experiments are given in TABLE 2.
TABLE 2______________________________________INH CONTENT (WEIGHT PERCENT) IN FOAMS AS A FUNCTIONOF INH SOLUTION CONCENTRATION AND FOAM DENSITYINH Soln. Foam Density, mg/cm.sup.3Conc., mg/ml 43.0 70.1 87.5______________________________________13.0 20.0.sup.a (22.8.sup.b) -- --21.5 26.5 (32.8) -- --29.4 35.0 (44.0) -- -- 5.1 -- 6.0 (6.5) --11.5 -- 12.0 (13.6) --25.0 -- 24.7 (25.5) --10.0 -- -- 9.0 (9.8)21.5 -- -- 18.4 (18.9)39.5 -- -- 28.0 (30.0)______________________________________ .sup.a Measured values of loading. .sup.b Loadings as predicted by the loading equation.
A buffer solution comprising a chosen buffer in a suitable solvent is forced into the pores of the open celled foam by repeated cycles of evacuation (degassing) and repressurization (by emitting air at atmospheric pressure or higher). After the foam has been impregnated with the buffer solution, excess solution is drained off and the saturated foam is subjected to a second lyophilization to remove the solvent. Following this loading process, the polymer/buffer composite may be processed as described above.
Method 4. Polymer Melt
A known weight of the buffer is incorporated by mixing into a known weight of a suitable melted polymer. A quantity of polymer is heated to a temperature above its melting point, and a suitable buffer is blended into the melted polymer. The resulting polymer/buffer composite is solidified by cooling, and may be processed as described above, or ground and sieved prior to processing.
In some applications, it may be desirable to protect the buffering compound, for example, during processing according to the melt method, or to make the buffering compound available at the later stages of polymer degradation. In such cases, it is desirable to coat the buffering compound particles with a material that degrades at a slower rate than the material chosen for the fixation devices. Thus, the buffering compound is exposed only after the body of the device and the coating material have partially degraded. Exemplary materials used to coat the buffering compound particles include high molecular weight poly(L-lactide) or poly(ε-caprolactone).
The particles of buffering compound may be coated with the protective material by any method that coats particles, such as spray coating with a solution of protecting polymer or micro-encapsulation. Alternatively, a chosen protective polymer may be made in a melted state and buffer particles are added. The melt is cooled and ground and milled to the desired particle size range. Alternatively, the buffering compound may be added to a solution of the protective polymer and removing the solvent by evaporation. The dried mass is compacted in a mold under high pressure and grinding or milling the compacted mass to the appropriate particle size range.
Although PLGA polymers are used in the preceding examples, one of ordinary skill in the art will appreciate that other polymers, such as polydioxanone, poly(ε-caprolactone); polyanhydrides; poly(ortho esters); copoly(ether-esters) ; polyamides; polylactones; poly(propylene fumarates); and combinations thereof, may be similarly processed according to the methods of the invention. Moreover, selection of a particular polymer is based primarily on the known properties of the polymer such as the degree of cross-linking, polymer strength, polymerization rate, rate of hydrolytic degradation, etc. One of ordinary skill in the art may take these and/or other properties into account in selecting a particular polymer for a particular application. Thus, such a selection of a particular polymer is within the skills of the ordinary skilled practitioner.
Having showed the preferred embodiments, those skilled in the art will realize many variations are possible which will still be within the spirit and scope of the claimed invention. Therefore, it is the intention to limit the invention only as indicated by the scope of the claims.
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A bioerodible implantable material, comprising a bioerodible polymer that produces acidic products upon hydrolytic degradation, and a buffering compound that buffers the acidic products and maintains the local pH within a desired range. The buffer compound acts to reduce the inflammatory foreign body response generated by the acidic products and reduces the sterile abscess condition that occurs at the site of the bioerodible implant materials of the prior art. Materials made according to the invention may be used for internal fixation devices (IFDs) for bone repair.
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[0001] This application is a Continuation of application Ser. No. 10/052,246, filed Jan. 23, 2002, which is a Divisional of application Ser. No. 09/376,375 filed Aug. 18, 1999, the entire disclosure of which is hereby incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a full automatic washing machine, and more particularly, to a penetration type washing machine which makes washing by penetrating washing water through laundry; a method for controlling the same; and, a tub cover for the same.
[0004] 2. Background of the Related Art
[0005] Being a device for peeling off contaminant by applying energies, such as impact, to the laundry, there are pulsator washing machines, drum washing machines, agitator washing machine, and the like according to types of energy application. Washing of the laundry is made by applying impacts to the laundry using pulsator or agitator, or dropping the laundry using rotation of the drum.
[0006] [0006]FIG. 1 illustrates a cross section of a related art pulsator type washing machine, referring to which a related art pulsator type washing machine will be explained.
[0007] There is an inner tub 3 having a plurality of washing holes 5 formed therein rotatably mounted inside of an outer tub 2 provided for storage of washing water, inside of which inner tub 3 there is a pulsator 4 rotatably mounted therein. There is a drain valve 9 under the outer tub 2 for draining the washing water outside of the washing machine. A rotation power from a motor 8 mounted on an underside of the outer tub 2 is transmitted to a dewatering shaft 6 a coupled to the inner tub 3 and the washing shaft 6 coupled to the pulsator 4 , for rotating the inner tub 3 and the pulsator 4 . The washing shaft 6 and the dewatering shaft 6 a are coupled/decoupled by a clutch 7 .
[0008] There is a tub cover 11 on the outer tub 2 , which will be explained with reference to FIG. 2. The tub cover 11 , of substantially an annular form, has an upper surface portion 11 a disposed on top both of the outer tub 2 and the inner tub 3 , a tight fit portion 11 b extended in an upper and a lower direction from an end of the upper surface portion 11 a for tight fit to an inside surface of the outer tub 2 , and a fastening portion 11 c projected from the tight fit portion 11 b in a substantially vertical direction for being fastened to the outer tub 2 with screws 14 . The tub cover 110 is provided for prevention of noise and overflow of foam as well as prevention of infiltration of foreign matters into a space between the inner tub and the outer tub.
[0009] The operation of the aforementioned related art pulsator type washing machine will be explained with reference to FIGS. 1 and 2.
[0010] The washing machine is operative in a washing cycle, a rinsing cycle, and a dewatering cycle, by proceeding through each of which mode in a sequence the washing can be done. In the washing cycle, upon putting the washing machine into operation after placing the laundry in the inner tub 3 , the washing water is supplied until it fills to certain levels of the inner tub 3 and the outer tub 2 . Upon finishing the water supply, the motor 8 makes intermittent rotations in regular and reverse directions in a state the inner tub 3 is standstill, that leads the pulsator 4 to rotate in the regular and reverse directions for washing the laundry. That is, the pulsator 4 repeats the regular/reverse direction rotation, to rotate the laundry in of the inner tub 3 and to form water circulation, as well. Then, the laundry is washed by the impact from the pulsator 4 , the water circulation, friction with the inner tub 3 , and softening effect of the detergent, and the like. After proceeding the washing cycle for a preset time period, the drain valve 9 is opened, to drain contaminated washing water to outside of the washing machine. Then, clean washing water is supplied to inside of the inner tub 3 , and the pulsator 4 is rotated, to make rinsing cycles for a preset number of times. In the dewatering cycle, the inner tub 3 is rotated in a high speed together with the pulsator 4 in one direction in a state the washing shaft 6 and the dewatering shaft 6 a are coupled. Consequently, the washing water is discharged to the outer tub 2 through the washing holes 5 , and drained to outside of the washing machine through the drain valve 9 .
[0011] However, the related art washing machines, making the washing mostly using mechanical energies, of such as pulsator or agitator, is required to have a rotating power of a certain speed for making an adequate washing, that causes entangle of or damage to the laundry. And, the related art washing machine is involved in an increased washing water and detergent consumed during the washing because the washing machine is operative under a state the washing water is filled in the inner tub and the outer tub, as well as an increased overall washing time period due to increased water supply and drain time periods, that are not directly related to the washing time period.
[0012] Accordingly, there has been researches for making washing without rubbing the laundry or applying impact to laundry, one of which is the penetration type washing machine. That is, according to what is known, if a relative flow speed of water passing through between textile fibers of the laundry is greater than a certain level, the water can make a washing, without rubbing or twisting the laundry. A washing machine employing such a principle is a penetration type washing machine. In general, as disclosed in U.S. Pat. No. 5,191,667, a related art penetration type washing machine is provided with a washing water sprayer for spraying the washing water to the laundry in an inner tub over a required speed, and a separate pump for pumping the washing water to the washing water sprayer. Therefore, the related art penetration type washing machine has problems in that a complicated system and a large sized pump for obtaining a spraying power for the washing are required. Therefore, the related art penetration type washing machine has been mostly used as a supplementary means for the pulsator type washing machine.
[0013] And, though JP S51-13416 discloses a washing machine which makes a penetration washing by rotating an inner tub, the washing machine has the following problems.
[0014] First, as the inner tub rotates only in one direction, the washing water penetrates a fixed position of the laundry, to cause a wash difference in which a washed portion and a non-washed portion are happened.
[0015] Second, the only use of penetration washing makes a washing efficiency poor. Because, though the penetration type washing machine can prevent damage to, and entangling of the laundry, in general, the washing efficiency is poor compared to the pulsator type washing machine.
[0016] Third, since the washing machine fails to provide a guide means for guiding the washing water to an inside surface of the inner tub when the washing water is pumped to an upper portion between the inner tub and the outer tub, and then, circulated into the inner tub, the washing machine has a poor pumping efficiency.
[0017] Use of a related art tub cover for the penetration type washing machine causes leakage of spray of the washing water. That is, as shown in FIG. 2, since the related art tub cover 11 is merely fastened to the outer tub 2 with screws 14 , the washing water leaks through gaps between the tight fit portion 11 b of the tub cover 11 and the outer tub, and the fastening portion 11 c and a top of the outer tub 2 . And, a pumped washing water splashes from an inside of the tub cover to outside of the outer tub 2 , to generate noise as the splash hits a washing water case, and to deteriorate washing and rinsing performances of the washing machine as the splash causes a loss of the washing water. Moreover, the leaked or splashed washing water to outside of the outer tub 102 wets various electric components of the washing machine, that is liable to cause malfunction or disorder of the washing machine.
[0018] The above references are incorporated by reference herein where appropriate for appropriate teachings of additional or alternative details, features and/or technical background.
SUMMARY OF THE INVENTION
[0019] An object of the invention is to solve at least the above problems and/or disadvantages and to provide at least the advantages described hereinafter.
[0020] Accordingly, the present invention is directed a penetration type washing machine, a method for controlling the same, and a tub cover for the same that substantially obviates one or more of the problems due to limitations and disadvantages of the related art.
[0021] An object of the present invention is to provide a penetration type washing machine, and a method for controlling the same, which has a simple structure and can improve a washing efficiency.
[0022] Another object of the present invention is to provide a tub cover for use in a penetration type washing machine which can improve a pumping efficiency and a washing efficiency.
[0023] Additional features and advantages of the invention will be set forth in the description which follows, and in part will be apparent from the description, or may be learned by practice of the invention. The objectives and other advantages of the invention will be realized and attained by the structure particularly pointed out in the written description and claims hereof as well as the appended drawings.
[0024] To achieve these and other advantages and in accordance with the purpose of the present invention, as embodied and broadly described, the method for controlling a full automatic washing machine, includes a washing cycle, a rinsing cycle, and a dewatering cycle, wherein the washing or the rinsing cycle includes the step of rotating an inner tub at a high speed higher than a preset speed in one direction, thereby making a centrifugal force caused by high speed rotation of the inner tub, to push laundry against a wall of the inner tub, to enforce washing water in the inner tub to penetrate through the laundry at a speed higher than required to make the washing done, and to pump the washing water penetrated through the laundry and discharged into an outer tub upward, to recirculate to the inner tub.
[0025] In other aspect of the present invention, there is provided a tub cover mounted on a top of an outer tub of a washing machine for preventing noise and foam overflow, including an upper tub cover for being fastened to the outer tub, and a lower tub cover under the upper tub cover spaced therefrom for being fastened to the upper tub cover, thereby forming washing water passages between the upper tub cover and the lower tub cover.
[0026] It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory and are intended to provide further explanation of the invention as claimed.
[0027] Additional advantages, objects, and features of the invention will be set forth in part in the description which follows and in part will become apparent to those having ordinary skill in the art upon examination of the following or may be learned from practice of the invention. The objects and advantages of the invention may be realized and attained as particularly pointed out in the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0028] The invention will be described in detail with reference to the following drawings in which like reference numerals refer to like elements wherein:
[0029] The accompanying drawings, which are included to provide a further understanding of the invention and are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and together with the description serve to explain the principles of the invention:
[0030] In the drawings:
[0031] [0031]FIG. 1 illustrates a section of a related art pulsator type washing machine;
[0032] [0032]FIG. 2 illustrates a section showing an enlarged view of “A” part in FIG. 1;
[0033] FIGS. 3 A˜ 3 C illustrate sections of a penetration type washing machine in accordance with a preferred embodiment of the present invention, wherein FIG. 3A illustrates a penetration washing process, FIG. 3B illustrates an agitation washing process, and FIG. 3C illustrates a restoration circulation washing process;
[0034] FIGS. 4 ˜ 6 illustrate sections of a tub cover in accordance with a first preferred embodiment of the present invention;
[0035] [0035]FIG. 7 illustrates a disassembled perspective view of a tub cover in accordance with a second preferred embodiment of the present invention;
[0036] [0036]FIG. 8 illustrates a perspective assembly view of the tub cover in FIG. 7 with partial sections of the components;
[0037] [0037]FIG. 9 illustrates an assembled sectional view of a tub cover, a modified version from FIG. 8;
[0038] [0038]FIG. 10 illustrates a perspective view of a tub cover in accordance with a third preferred embodiment of the present invention;
[0039] [0039]FIG. 11 illustrates a section showing the tub cover in FIG. 10 fitted to a washing machine;
[0040] [0040]FIG. 12 illustrates an operation principle of the tub cover shown in FIG. 10;
[0041] [0041]FIG. 13 illustrates a perspective view of a tub cover modified from one shown in FIG. 10;
[0042] [0042]FIG. 14 illustrates a disassembled perspective view of a tub cover in accordance with a fourth preferred embodiment of the present invention;
[0043] [0043]FIG. 15 illustrates a section showing an assembled view of the tub cover in FIG. 14;
[0044] [0044]FIG. 16 illustrates a section showing an enlarged part “B” in FIG. 15;
[0045] [0045]FIG. 17 illustrates a disassembled view of the tub cover shown in FIG. 14;
[0046] [0046]FIG. 18 illustrates a section showing a modified version of a fastening structure of the tub cover in accordance with a fourth preferred embodiment of the present invention;
[0047] FIGS. 19 ˜ 22 illustrates sections showing different modifications of the tub cover in FIG. 14;
[0048] [0048]FIG. 23 illustrates a cross section showing another modification of the tub cover in FIG. 14;
[0049] [0049]FIG. 24 illustrates a disassembled perspective view of a tub cover in accordance with a fifth preferred embodiment of the present invention;
[0050] [0050]FIG. 25 illustrates a partial cut away perspective view for explaining an operation of the tub cover shown in FIG. 24;
[0051] [0051]FIG. 26 illustrates a disassembled perspective view showing a modification from the tub cover in FIG. 24;
[0052] [0052]FIG. 27 illustrates a disassembled perspective view of a tub cover in accordance with a sixth preferred embodiment of the present invention;
[0053] [0053]FIG. 28 illustrates a section across line I-I in FIG. 27;
[0054] [0054]FIG. 29 illustrates a section across line II-II in FIG. 27;
[0055] [0055]FIG. 30 illustrates a disassembled perspective view showing a modification of the tub cover shown in FIG. 27;
[0056] [0056]FIG. 31 illustrates a section across line III-III in FIG. 30;
[0057] [0057]FIG. 32 illustrates a disassembled perspective view showing another modification of the tub cover shown in FIG. 27;
[0058] [0058]FIG. 33 illustrates a section across line IV-IV in FIG. 32;
[0059] [0059]FIG. 34 illustrates a bottom view of a tub cover in accordance with a seventh preferred embodiment of the present invention;
[0060] [0060]FIG. 35 illustrates a bottom perspective view of the tub cover shown in FIG. 34;
[0061] [0061]FIG. 36 illustrates a longitudinal section view of the tub cover shown in FIG. 34;
[0062] [0062]FIGS. 37A and 37B illustrate bottom perspective views each showing a modification of the tub cover shown in FIG. 34;
[0063] [0063]FIG. 38 illustrates a bottom view showing a tub cover in accordance with an eighth preferred embodiment of the present invention;
[0064] [0064]FIG. 39 illustrates a bottom perspective view of the tub cover shown in FIG. 35; and,
[0065] [0065]FIGS. 40 and 41 illustrate bottom perspective views each showing a modification of the tub cover shown in FIG. 38.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0066] Reference will now be made in detail to the preferred embodiments of the present invention, examples of which are illustrated in the accompanying drawings. A penetration type washing machine, and a method for controlling the same will be explained with reference to FIGS. 3 A˜ 3 C.
[0067] Referring to FIGS. 3 A˜ 3 C, there is an inner tub 103 having a plurality of washing holes 104 rotatably mounted in an outer tub 102 , with a pulsator 105 formed as a unit with the inner tub 103 . There is a fluid balancer 108 provided on a top of the inner tub 103 for balancing the inner tub 103 during rotation. And, there is a tub cover 400 on a top of the outer tub 102 for preventing noise, suppressing foam formation, and guiding the washing. There is a motor 107 for generating a rotation power under the outer tub 102 and a drain valve 109 . The motor 107 is preferably a variable speed motor, with a rotating shaft thereof being directly coupled to a single driving shaft 106 which rotates the inner tub 103 and the pulsator 105 without introduction of additional power transmission device. The aforementioned penetration type washing machine of the present invention facilitates a penetration washing, an agitation washing, and a restoration circulation washing by varying a rotation speed of the motor 107 .
[0068] The operation of the aforementioned penetration type washing machine of the present invention will be explained with reference to FIGS. 3 A˜ 3 C.
[0069] The penetration type washing will be explained with reference to FIG. 3A. When the washing machine is put into operation, the motor 107 is rotated in a high speed. Then, the driving shaft 106 connected to the motor 107 is rotated, and the pulsator 105 and the inner tub 103 connected to the driving shaft is also rotated in a high speed. As has been explained in the related art, the penetration washing requires a relative flow speed of the washing water passing through the laundry to be higher than a certain level, and the flow speed should be enough to generate a centrifugal force that can force the washing water to flow from the inner tub to the outer tub and, therefrom to circulate to the inner tub again. When the pulsator 105 and the inner tub 103 is rotated at a high speed, a centrifugal force is generated, to push the laundry in the inner tub 103 to a wall of the inner tub 103 , and to push the washing water in the inner tub 103 to the outer tub 102 through the washing holes 104 in the inner tub 103 , when the washing water penetrates through between textile fabrics of the laundry, thereby making the penetration washing. And, the washing water pushed out to the outer tub 102 and the washing water present on a bottom surface of the outer tub 102 is pumped upward along a space between the inner tub 103 and the outer tub 102 by the centrifugal force, until the washing water hits the tub cover 400 where the washing water turns a flow direction to flow into the inner tub 103 again. The washing water flowed into the inner tub 103 has a substantially high pressure caused by the centrifugal force coming from the high speed rotation of the inner tub 103 . Therefore, the washing water can apply an impact to the laundry by the pressure from the centrifugal force and a gravity of the washing water, to provide a beating effect to the laundry, that improves a washing efficiency.
[0070] In the meantime, as has been explained in the related art, in the case when the inner tub rotates only in one direction, the wash difference is happened in which extents of wash differ depending on portions of the laundry because positions of the laundry are always fixed. Therefore, the inner tub is rotated in a reverse direction after the inner tub is rotated in a regular direction for a preset time period. Then, the laundry pushed to wall of the inner tub is gathered to a center of the inner tub when the inner tub changes its direction of rotation from regular direction to reverse direction, and the laundry is pushed onto the wall again as the inner tub is accelerated. Accordingly, as a position of the laundry through which the washing water penetrates is changed, the wash difference can be prevented.
[0071] In the meantime, as has been explained, the penetration type washing machine of the present invention permits, not only the penetration type washing, but also agitation type and restoration circulation washings by changing a speed and a direction of rotation of the motor. FIG. 3B illustrates an agitation washing process, referring to which the agitation washing process will be explained.
[0072] The agitation washing is available by setting the rotation speed to be below a certain level. That is, if the rotation speed of the motor is set to be comparatively low, the pulsator and the inner tub 103 also rotate at a low speed, at which the centrifugal force is dropped unable to push up the washing water between the inner tub 103 and the outer tub 102 , but to keep a certain level. And, the laundry pushed to the wall of the inner tub 103 drops down to the bottom of the inner tub 103 to be submerged in the washing water. Under this state, a water circulation caused by rotation of the inner tub 103 and the pulsator 105 facilitates an agitation washing in a principle identical to a related art pulsator type washing machine. The availability of the penetration washing as well as the agitation washing can provide an excellent washing efficiency.
[0073] [0073]FIG. 3C illustrates a section showing a restoration circulation washing process, referring to which the restoration circulation process will be explained.
[0074] If the inner tub 103 which is rotating at a high speed in a penetration washing is stopped or has a speed dropped, the laundry pushed to the inside wall of the inner tub 103 by an inertia is gathered to a central portion of the inner tub 103 to hit one another. That is, the hitting among the laundry or with the pulsator 105 can make washing. In this instance, for conduction of the restoration circulation washing, though the rotating inner tub 103 may be stopped, the restoration circulation washing is available without a separate restriction. Because the inner tub repeats regular and reverse rotations in the penetration washing, the restoration circulation washing is automatically and continuously made whenever the direction of rotation is changed.
[0075] Upon completion of the penetration washing, the agitation washing, and the restoration circulation washing, a dewatering cycle is conducted. And, upon completion of the dewatering cycle, a water re-supply process is conducted to conduct a following rinsing process. Though the penetration type washing machine of the present invention may only carry out the penetration type washing, it is preferable that the penetration type washing machine carry out an appropriate combination of the penetration type washing, an agitation type washing and a restoration circulation washing depending on an extent of contamination and an amount of the laundry. And, as has been explained, one washing cycle or a rinsing cycle may be divided into small intervals for repeating the penetration washing and the agitation washing in the intervals, or different from this, it is also possible that re-water supply is made to conduct the agitation washing after completion of the penetration washing.
[0076] Advantages of the penetration type washing machine and a method for controlling the same of the present invention will be explained.
[0077] As the penetration type washing machine of the present invention makes the penetration type washing mostly, entangling of, and damage to the laundry is reduced compared to the pulsator type washing machine. The re-supply of the washing water into the inner tub in the penetration type washing facilitates consumption of less washing water, with use of less detergent, and faster washing water supply and drain, that minimizes waste of time in the supply and drain of the washing water. Moreover, the washing water in the outer tub do nothing but interferes the rotation of the inner tub 103 in the pulsator type washing machine because the washing water in the outer tub generates a friction when the inner tub is rotated even though the washing water in the inner tub act an important role as the washing water in the inner tub is brought into contact with the laundry to make washing. Therefore, in order to make a smooth rotation, it is important for the inner tub to make a less contact with the washing water in the outer tub as far as possible. By the way, the penetration type washing machine of the present invention has a small amount (approx. 50%) of washing water supplied to the inner tub and the outer tub, and the washing water is pumped into the inner tub again in conducting the washing. That is, as the outer tub has less amount of washing water, rotation of the inner tub is smoother. Different from the related art penetration type washing machine, the penetration type washing machine has a simple system as no separate pumping device are required, and facilitates a satisfactory washing efficiency while preventing entangling of, or damage to the laundry by an appropriate combination of the penetration washing, the agitation washing and the restoration circulation washing. The penetration type washing machine of the present invention has the washing water in the inner tub 103 pumped up to the top portion thereof through a space between the inner tub 103 and the outer tub 102 at a substantially high pressure, to be re-circulated into the inner tub 103 . Consequently, the high pressure of the washing water pumped upward may cause leakage if the related art tub cover is used as it was. Though this leakage may be prevented by providing gasket on a top surface of the outer tub 102 , accurate fitting of the gasket to a large diametered outer tub 102 is not practicable. Therefore, it is preferable that the tub cover structure of the penetration type washing machine is changed, appropriately. The tub cover of the present invention will be explained.
[0078] A first embodiment tub cover of the present invention will be explained with reference to FIGS. 4 ˜ 6 . The first embodiment tub cover is substantially identical to the one of the related art except that a leakage prevention means is additionally provided in the first embodiment tub cover.
[0079] That is, similar to the related art tub cover, the first embodiment tub cover 400 includes an upper surface portion 411 , a tight fit portion 413 , and a fastening portion 412 . However, different from the related art, the fastening portion 412 has a downward projection at an approx. center thereof in parallel to the tight fit portion 413 , and there is a slot on a top portion of the outer tub 102 for insertion of the projection 415 thereto. And, there is a sealing member 417 in a space formed between the tight fit portion 413 and the projection 415 for prevention of leakage.
[0080] And, referring to FIG. 5, a length of the projection 415 may be formed shorter, for providing the sealing member 417 in a space formed below the projection 415 .
[0081] And, as shown in FIG. 6, the sealing member may be disposed on a top end of the outer tub 102 . In detail, as the sealing member 417 is fitted to the top end of the outer tub 102 , a support 102 b is projected in an outward radial direction of the outer tub 102 from a portion below the top end portion 102 a of the outer tub 102 . And, a horizontal portion 441 is formed at an outer circumference of the upper surface portion 411 of the tub cover 400 , with an end of the horizontal portion 441 bent downward, to form a tight fit portion 413 which fit to an inside surface of the support 102 b in the outer tub 102 , without providing the fastening portion. And, in order to make the assembly easy, the sealing member 417 is preferably attached to the horizontal portion 441 of the tub cover with adhesive 452 . And, it is preferable that a position the support 102 b in the outer tub 102 is projected is to be below the top end of the outer tub 102 , to provide a space between the top end 102 a of the outer tub 102 and the support 102 b. Because if leakage of the washing water is happened despite of the sealing member 417 , the leakage of washing water may be collected in the space. The washing water collected in the space is drained using overflow hose(not shown) connected to an air vent hose. The first embodiment tub cover can prevent leakage of the washing water even if the washing water is pumped to the tub cover 400 at a high pressure by means of the sealing member 417 . And, as the fitting of the tub cover 400 to the outer tub 102 only requires insertion of the projection 415 at the tub cover to the slot in the outer tub 102 , the assembly is simple. And, as the slot serves as a guide, for accurate fitting of the tub cover 400 to the outer tub 102 , preventing vibration during operation of the washing machine.
[0082] In the meantime, even if the first tub cover 400 can prevent leakage of the washing water, neither spray of the washing water caused by hitting the tub cover can be prevented, nor an exact guide of the washing water into the inner tub 103 is possible. Therefore, the following second to seventh embodiments tub covers of the present invention will provide improved tub covers. The second embodiment tub cover will be explained with reference to FIGS. 7 and 8.
[0083] The second embodiment tub cover 200 includes an upper tub cover 201 fastened to the outer tub 102 , and a lower tub cover 203 mounted under the upper tub cover 201 with a space therefrom, wherein there are washing water guide passages P 1 and P 2 formed between the upper and lower tub covers. The upper tub cover 201 has a substantially annular form of an upper surface portion 211 , a tight fit portion 214 projected from an outer end of the upper surface portion 211 vertically for tight fit to an inside wall of the outer tub 102 , and a fastening portion 215 extended from the tight fit portion 214 in a horizontal direction for fastening to a top end of the outer tub, forming an “L” section, substantially. The lower tub cover 203 has an upper surface portion 221 , and a vertical portion 225 projected downward from an outer end of the upper surface portion 221 , with a plurality of reinforcing brackets 224 connected between the upper surface portion and the vertical portion. There are a plurality of height adjustment members 222 formed at fixed intervals. In order to couple the upper tub cover 201 to the lower tub cover 203 , it is preferable that the height adjustment members 222 have a female thread 223 , and the upper surface portion 221 of the upper tub cover 201 has a plurality of fastening holes 212 formed at positions corresponding to the height adjustment members 222 .
[0084] Referring to FIG. 8, a fastened state will be explained. The upper tub cover 201 and the lower tub cover 203 are fastened with screws 213 , and the upper tub cover 203 is fastened to a top end of the outer tub 102 with screws. Therefore, as shown in FIG. 8, the washing water pumped to the tub cover 200 is guided by the guide passage P 1 and P 2 between the upper tub cover and the lower tub cover, to guide the washing water into the inner tub 103 smoothly, which improves a pumping efficiency. And, the spray of the washing water can be prevented. And, a pressure of the washing water sprayed to the inner tub 103 from the tub cover 200 is adjustable by adjusting a space S between the upper tub cover and the lower tub cover, i.e., a height of the height adjustment member 222 . By the way, there is a possible leakage through a gap between the fastening holes in the upper tub cover 201 and the screws in FIG. 8. Therefore, as shown in FIG. 9, it is preferable that height adjustment members 222 a are formed on the upper tub cover 201 , and pass-through holes are formed in the lower tub cover 203 . Because the washing water flowing from the tub cover 200 to the inner tub 103 advances in a tangential direction of an inside diameter of the inner tub 103 by the centrifugal force.
[0085] A tub cover having modified such drawback is the third embodiment tub cover, which will be explained with reference to FIGS. 10 ˜ 11 .
[0086] The third embodiment tub cover 300 includes an upper surface portion 301 and a tight fit portion 303 , and there are a plurality of deflectors 302 on an underside of the upper surface portion 301 for deflecting a flow direction of the washing water. The deflector 302 is fitted in a radial direction for deflecting the washing water advancing in a tangential direction to a center direction. There are a plurality of deflectors fitted as fixed intervals to divide the flow paths. As shown in FIG. 12, this structure permits the washing water pumped and flowed into the tub cover 300 hits the deflectors 302 , to change a direction of flow toward, not the tangential direction, but the center direction, substantially. And, as shown in FIG. 13, there may be a guide rib 305 on the deflector 302 for reducing a friction of the washing water. And, a plate drop preventor 305 may preferably be fitted at a bottom of the deflector 302 for preventing drop of the washing water, flowing into the tub cover, into a space between the inner tub 103 and the outer tub 102 by gravity, but to be supplied to the inner tub 103 . Of course, the drop preventor 305 may be provided with a larger area or the lower tub cover of the second embodiment may be provided. And, the height adjustment members 222 and 222 a in the second embodiment may be formed to have forms of the deflectors 302 , for combined use of the height adjustment members 222 and 222 a as the deflectors.
[0087] Because outlets of the washing water passages P 2 are substantially horizontal in the first to third embodiments tub covers, the washing water flows out substantially in the horizontal direction. Opposite to this, the following fourth to seventh embodiment tub covers are provided with an adjustable spray angle, with a convenience of assembly.
[0088] The fourth embodiment tub cover will be explained with reference to FIGS. 14 ˜ 16 .
[0089] Alike the second embodiment tub cover, the fourth embodiment tub cover also include an upper tub cover 501 and a lower tub cover 503 for forming a washing water passage. The upper tub cover 501 has an upper surface portion 521 , a tight fit portion 522 , and a fastening portion 523 , and the lower tub cover 503 also has an upper surface portion 512 and a vertical portion 511 , except that there are a plurality of guide members 505 fitted at fixed intervals provided between the upper tub cover and the lower tub cover for combined use as the height adjustment members and the deflectors in the aforementioned embodiments. The guide member 505 is preferably formed extended from inlet to outlet of the flow passage to cover the entire washing water passage. In this embodiment, the horizontal passage P 2 is formed to direct a lower portion of the inner tub 103 , and the upper tub cover 501 and the lower tub cover 503 are provided with downward curvatures to provide a stream lined horizontal passage P 2 for minimize a friction. The lower tub cover 503 is mounted spaced from the fluid balancer 108 by a preset distance T1, with a chamfer 507 in the fluid balancer 108 to suit to a contour of the passage P 2 . Because this configuration can prevent bumping between the fluid balancer 108 and the tub cover 500 . And, in order to prevent bumping between the fluid balancer 504 and the outer tub 102 and 502 , a second gap T2 formed between the fluid balancer 504 and the outer tub 102 and 502 may be further provided. The distance T1 is preferably identical to the gap T2 between the fluid balancer 108 and the outer tub 102 , substantially.
[0090] A fastening structure of the fourth embodiment tub cover of the present invention will be explained with reference to FIG. 17.
[0091] Alike the previous embodiment, if the upper tub cover, the guide member and the lower tub cover are fastened with screws, the washing water may leak. Therefore, it is preferable that the upper tub cover 501 , the guide members 505 and the lower tub cover 503 are fabricated separately and jointed them together by means of welding and the like. Of course, it is possible that either the upper tub cover 501 and the guide members 505 may be fabricated as a unit, to which the lower tub cover 503 is welded, or the lower tub cover 503 and the guide members 505 may be fabricated as a unit, to which the upper tub cover 501 is welded. In this instance, for the sake of convenience of assembly and preventing projection of the upper tub cover 501 to an outward radial direction, there is a stepped portion 532 at one side of the lower tub cover 503 for catching a bottom end of the upper tub cover 501 . As shown in FIG. 18, fastening with screws is also possible, particularly, fastening the lower tub cover 503 to the guide member 505 with screws 534 is effective in view of leakage prevention. Similar to the previous embodiments, this embodiment tub cover serves for a smooth guidance of the washing water, prevention of spray, and prevention of leakage. In addition to this, this embodiment tub cover can further improve a pumping performance and washing performance because the washing water passage is streamlined with a preset curvature, which minimizes a loss caused by friction to guide the washing water into a lower portion of the inner tub 103 effectively. By the way, in this embodiment, fore ends of the upper tub cover 501 and the lower tub cover 503 , i.e., a width W of an outlet of the washing water may be adjusted for adjusting the pressure of the washing water. That is, the more the width W of the outlet of the washing water is reduced, the higher the pressure of the washing water. The width W may preferably be adjusted by decreasing or increasing a fore end of the upper tub cover 501 by an angle θ toward a fore end direction of the lower tub cover 503 . And, as shown in FIGS. 20 and 21, the fore end of the upper tub cover 501 may be extended or shortened with respect to the fore end of the lower tub cover 503 , for adjusting an angle of spray of the washing water. That is, if the fore end of the upper tub cover is shortened by a distance H1 with respect to the fore end of the lower tub cover 503 , the washing water is sprayed upward, and extended by a distance H2, sprayed downward. In conclusion, this embodiment allows an appropriate adjustment of the spray pressure and the spray angle. And, as shown in FIG. 23, a radius R1 formed by the fore end of the upper tub cover 501 and a radius R2 formed by the fore end of the lower tub cover 503 may preferably be made different, to improve a washing water supply efficiency.
[0092] In the meantime, as the guide members 505 are not curved, the washing water is adapted to hit the guide member 505 as a right angle, to cause a friction and a consequential reduction of a pumping efficiency. And, the abrupt change of the flow direction of the washing water causes noise coming from impact. And, because the third embodiment tub cover has the deflectors fitted perpendicular to the washing water flow, a portion of the washing water hit onto the deflector turns a flow direction, not to the inner tub, but backwardly opposite to the flow direction of the washing water due to a reaction force. And, a vortex may be occurred in a space formed by an outer circumference of the deflector and the tight fit portion. Those are causes of dropping the pumping efficiency. Accordingly, the following embodiment is a modification for improving such problems.
[0093] The fifth embodiment tub cover is the one in which those disadvantages are improved, which will be explained with reference to FIG. 24.
[0094] The guide member 505 of this embodiment is formed to have a curvature, for guiding the washing water smoothly with a minimum friction at the guide member 505 . As the inner tub 103 rotates in regular and reverse directions, it is preferable that regular direction guide members 505 a and reverse direction guide members 505 b are provided, respectively. Because others are the same with the fourth embodiment, the explanation will be omitted. According to this, as shown in FIG. 25, since the washing water pumped by high speed rotation of the inner tub 103 is supplied to the inner tub 103 smoothly with a minimum friction, the pumping efficiency can be improved. However, as shown in FIG. 24, if the regular direction guide members 505 a and the reverse direction guide members 505 b are integrated, a fore end 505 c has no curvature, which has a great friction. Therefore, the fore end 505 also need to have a curvature, preferably. To do this, as shown in FIG. 26, the regular direction guide members 505 a and the reverse direction guide members 505 b are preferably provided with curvatures throughout entire lengths, with the fore ends thereof connected with a curved portion 507 c. Thus, since the washing water pumped during a regular direction rotation of the inner tub 103 is guided by the regular direction guide member 507 a, with a reduced friction, and the washing water pumped during a reverse direction rotation of the inner tub 103 is guided by the reverse direction guide member 507 b, with a reduced friction, the curved members 507 a and 507 b can improve the pumping efficiency.
[0095] In the meantime, even though the aforementioned tub covers of the present invention can prevent spray of the washing water effectively, once sprayed, the sprayed washing water flows to outside of the outer tub 102 . Therefore, the following sixth embodiment tub cover is provided for an effective prevention of spray to outside of the outer tub 102 . The sixth embodiment tub cover will be explained with reference to FIG. 27.
[0096] Similar to the fourth and fifth embodiment tub covers, the sixth embodiment tub cover 700 includes an upper tub cover 701 and a lower tub cover 703 each having a curvature, and a guide members 705 . And, the upper tub cover 701 has an upper surface portion 714 , a tight fit portion 715 and a fastening portion 711 . The lower tub cover 703 also has an upper surface portion 722 and a vertical portion 721 . However, in this embodiment, the tight fit portion 715 of the upper tub cover 701 is projected upward to form a projection 715 a, to form a recess 712 between an outer circumference and the projection 715 a, to collect the sprayed washing water. Then, the washing water collected in the recess 712 is drained into the inner tub 103 by washing water drain means 720 . The washing water drain means 720 is sloped flow passages 713 recessed in the upper surface of the upper tub cover at fixed intervals, with walls 713 a and 713 b on both sides of the passage 713 . The sloped flow passage 713 is sloped inward downwardly.
[0097] In this embodiment, the guide member 705 may only be provided on the vertical flow passage 705 , because the walls 713 a and 713 b of the sloped flow passages 713 act as the guide members in the horizontal flow passage P 2 . Accordingly, as shown in FIG. 28, the washing water sprayed and collected in the recess 712 of the upper tub cover 701 flows into the inner tub 103 along the sloped flow passage 713 . And, as shown in FIG. 29, the pumped washing water flows to the inner tub 103 through the flow passages formed between the upper tub cover 701 and the lower tub cover 703 , when the walls 713 a and 713 b divide the passage. The walls 713 a and 713 b are formed with curvatures for guiding the washing water with a reduced friction in correspondence to the regular and reverse rotation.
[0098] The washing water drain means may be as shown in FIG. 30 and 31 . That is, a plurality of drain holes 725 are formed in the recess of the upper tub cover 701 at fixed intervals. And, guide members for guiding the washing water into the inner tub 103 from the drain holes 725 are preferably provided in the lower tub cover 703 . Because if there are no guide members, the washing water drained through the drain holes will flow the space between the inner tub 103 and the outer tub 102 again, to resist against the circulation of the washing water as the lower tub cover 703 also has a curvature. The guide member has one pair of walls 726 and 727 formed vertical to the upper surface of the lower tub cover 703 at a width slightly greater than the width of the discharge hole 725 and a sloped passage 728 connecting the walls 726 and 727 and sloped downwardly in an inner radial direction. The walls 726 and 727 also serve as the height adjustment member. And, a front portion 723 with a supply hole 724 may be provided in front of the walls 726 and 727 .
[0099] The operation of this embodiment tub cover will be explained. The pumped washing water is collected in the recess 712 of the upper tub cover 701 . The washing water collected in the recess 702 flows into the lower tub cover 703 through the drain holes 725 , and into the inner tub 103 along the sloped passage 728 . Thus, spray of the washing water out of the outer tub 102 can be prevented. In the meantime, as shown in FIG. 32 and 33 , it is, of course, possible that the upper surface of the upper tub cover 701 is provided with a slope α without the washing water drain means, for natural flow of the washing water sprayed to the upper tub cover 701 into the inner tub 103 along the upper surface of the upper tub cover 701 . In this instance, it is preferable that the guide member 705 is extended to the horizontal passage, i.e., to form a vertical portion 705 a and a horizontal portion 705 b.
[0100] The second to sixth embodiment tub covers have complicated structures and high cost because the tub covers include the upper tub covers, the lower tub covers and guide members, which are comparatively many components that is difficulty in assembly. Therefore, the following seventh and eighth embodiment tub covers provide tub covers which have simple structures but have effects the same with the aforementioned embodiments. Different from the foregoing second to sixth tub covers, the following embodiment tub covers have one single tub cover(corresponding to an upper tub cover in the related art). And, different from the first embodiment tub cover, these embodiment tub covers are provided with means on a bottom surface of the tub cover for guiding the washing water into the inner tub. The pumped washing water can be guided into the inner tub only using a tub cover corresponding to an upper tub cover without using a lower tub cover owing to the following reason. The penetration washing requires fast running of the motor for pumping the washing water. That is, in the penetration washing, the washing water should be pumped upwardly to move upward to overcome a gravity of the washing water itself Therefore, as the washing water pumped toward the tub cover does not fall down even if the lower tub cover is used substantially, formation of the washing water passage is possible even if no lower tub cover is used. And, in the case of agitating washing, since the washing water is not circulated and the tub cover only serves for prevention of noise, and foam reduction, the lower tub cover may be dispensed with, too. The seventh embodiment tub cover will be explained in detail with reference to FIGS. 34 to 36 .
[0101] The seventh embodiment tub cover 800 includes a tight fit portion 810 for tight fit on an inside surface of a top end of the outer tub, an upper surface portion 811 extended upwardly from the tight fit portion 810 at an angle for serving as a guide for the washing water, and a fastening portion 810 a projected from the tight fit portion 810 in a horizontal direction for being fastened to the outer tub with screws. The upper surface portion 811 may preferably have a curvature, rather than at a right angle to the tight fit portion 810 for reducing friction with the washing water. And, there is a vertical deflector 813 formed downwardly at a fore end of the upper surface portion 811 for downward guide of the washing water to a lower portion of the inner tub, and preferably there is a vertical protector 811 a on an outer circumference of the upper surface portion 811 for protecting the spray of the washing water to outside of the outer tub. There are a plurality of main deflectors 812 formed on an underside of the upper surface portion 811 at fixed intervals, for deflecting a direction of the washing water pumped to the tub cover to a center direction of the inner tub. The main deflector 812 is formed to connect an inner and an outer diameters of the upper surface portion of the tub cover, with an angle θ 1 to a radial direction of the tub cover. And, supplementary deflectors 814 may be further provided for smoother guide of the washing water. The supplementary deflector 814 has a fore end started from the inner diameter, extended along a concentric circle with the tub cover substantially, and an aft end ended at a position of the main deflector 812 . In this instance, the fore end of the supplementary deflector is preferably spaced from the fore end of the main deflector 812 by a preset distance L2. Therefore, the tub cover 800 is divided by the main deflectors 812 by fixed intervals S, wherein a space between the intervals S has a main flow passage W 1 formed by the main deflector 812 and the supplementary deflector 814 and a supplementary passage W 2 formed by the supplementary deflector 814 and the vertical deflector 813 .
[0102] The operation of this embodiment will be explained.
[0103] The washing water pumped to the tub cover 800 is guided by the tub cover 800 into the inner tub with a minimum friction. In detail, the washing water risen upwardly is brought in contact with a bottom surface of the tub cover 800 . Then, the washing water is guided by the main deflectors 812 and the supplementary deflectors 814 to deflect a flow direction from a tangential direction to a center direction of the inner tub. And, the washing water having a direction changed by the main passage W 1 formed by the main deflector 812 and the supplementary deflector 814 hits onto the vertical deflector 813 again, to deflect a flow direction from horizontal to vertical downwardly, to supply the washing water to the inner tub lower portion. Most of the pumped washing water is guided by the main flow passages to be sprayed into the inner tub 103 , while a portion of the pumped washing water flows into the inner tub 103 directly from the supplementary flow passage W 2 . Because most of the pumped washing water is guided by the main flow passages and the outlet P of each main passage W 1 has a small width L2 and a limited number, that built up a pressure of the washing water, the washing water is intensely sprayed from the outlets, to improve the washing efficiency. In comparison to this, in the related art, since the washing water is sprayed from an entire inner diameter of the tub cover, the washing efficiency is poor because the spraying pressure is dispersed. Though the washing water flowed in a horizontal direction and hit onto the vertical deflector 813 turns its flow direction downwardly into the inner tub, a portion of the washing water is scattered by the impact of the hit. However, this embodiment tub cover can minimize scattering of the washing water, generation of noise, and foam formation because the washing water hits the supplementary deflector 814 before the washing water hits the vertical deflector 813 . And, the washing water still scattered is prevented from leaking beyond an outer wall of the outer tub 102 by the projection 811 a on the tub cover 800 . And, as shown in FIG. 37A, a damping member 815 may preferably be provided at the outlet P side of the main passage W 1 , so that the washing water hits the damping member 815 beforehand, for effective prevention of the scattering of the washing water occurred when the washing water hits the vertical deflectors 813 . The damping member 815 is disposed substantially perpendicular to a flow direction of the washing water, i.e., connected from a fore end of the supplementary deflector 814 to a fore end of the main deflector 812 , with a height lower than heights of the main deflector 812 and the supplementary deflector 814 . As shown in FIG. 37B, instead of the damping member, a sloped portion 817 may be provided at an outlet P of the main flow passage.
[0104] The following eighth embodiment tub cover is a modification from the seventh embodiment tub cover to suit to a case of both direction, i.e., regular and reverse direction rotation of the inner tub 103 . An overall structure of the eighth embodiment tub cover will be explained with reference to FIG. 8.
[0105] Alike the seventh embodiment tub cover, the eighth embodiment tub cover 800 of the present invention also includes the main deflectors, the supplementary deflectors, and the vertical deflectors, except that first main deflectors 812 and second main deflectors 812 a are provided in correspondence to the both direction rotation, and a structure of the supplementary deflectors 814 a is modified. In detail, the first main deflectors 812 are formed on an underside of the upper surface portion of the tub cover 800 at fixed intervals, and the second deflectors 812 a are formed in symmetry to the first main deflectors 812 . And, a fore end of the supplementary deflector 814 a has a fore end started from the inner circumference and extended along a concentric circle of the tub cover, and an aft end connected to the inner circumference of the tub cover. That is, the fore end of the supplementary deflector 814 a is positioned spaced from the fore end of the first main deflector 812 , and the aft end of the supplementary deflector 814 a is positioned spaced from the fore end of the second main deflector 812 a. And, preferably there are a plurality of ribs 818 between the first main deflectors and the second main deflectors 812 a for preventing distortion, and more preferably concentric to the tub cover circumference. And, a portion of an outer rib may be cut away. The ribs 818 are fitted under the following reasons. The washing water passed over the main deflectors 812 and 812 a may cause a vortex between the first and the second main deflectors 812 and 812 a, or may flow to the outlet of the main flow passage, to interfere the washing water flow in the main flow passage. Therefore, the ribs 818 are provided to confine the washing water between the first and second deflectors 812 and 812 a to some extent, for preventing interference to the washing water in the main flow passage. Thus, the tub cover is divided by the first main deflectors 812 and the second main deflectors 812 a into fixed intervals S. And, a space between the intervals S has a main flow passage W 1 formed by the main deflector 812 and a just prior supplementary deflector 812 a, and a supplementary passage W 2 formed by the supplementary deflector 812 a and the vertical deflector 813 . And, there is a space formed by the first main deflector 812 and an adjacent second main deflector 812 a. Accordingly, when the inner tub rotates in a regular direction(a counter clockwise direction on the drawing), most of the washing water pumped to the tub cover is guided by the tub cover as shown in arrows of solid lines to be sprayed into the inner tub through the regular direction outlets P 3 with a minimum friction. Opposite to this, when the inner tub rotates in a reverse direction(a clockwise direction on the drawing), most of the washing water pumped to the tub cover is guided by the tub cover as shown in arrows of dotted lines to be sprayed into the inner tub through the reverse direction outlets P 4 with a minimum friction. Therefore, the eighth embodiment tub cover can cope with all the regular and reverse direction rotation, effectively.
[0106] In the meantime, as shown in FIG. 39, a portion of the regular direction outlet P 3 and the reverse direction outlet P 4 a may be cut away to form an opening 816 , for minimizing the scattering of the washing water caused by the washing water hitting onto the vertical deflector 813 . In the meantime, as shown in FIGS. 40 and 41, identical to the seventh embodiment, either the damping member 815 or the sloped portion 817 is provided for effective prevention of the washing water scattering. And, it is preferable that a sealing member is provided between the tub cover and the outer tub.
[0107] As has been explained, the penetration type washing machine, the method for controlling the same, and the tub cover for the same have the following advantages.
[0108] First, the penetration type washing machine can make washing using an appropriate combination of the penetration washing, the agitating washing, and the restoration circulation washing. Therefore, a washing efficiency can be improved while damage to, and entangling of the laundry is minimized. And, the washing can be carried out only with a small amount of washing water, consumption of water and detergent may be reduced, with consequential reduction of drain time period, to reduce an overall washing time.
[0109] Second, the tub cover of the present invention can improve a pumping efficiency of the washing water because leakage or scattering of the pumped washing water can be prevented and the washing water can be guided into the inner tub without friction loss. And, the noise and foam caused by the circulated washing water at the high speed rotation of the inner tub can be minimized.
[0110] Third, as the tub cover of the present invention facilitates spray of the pumped washing water toward a center of the inner rub, a washing efficiency can be improved.
[0111] It will be apparent to those skilled in the art that various modifications and variations can be made in the penetration type washing machine, the method for controlling the same, and the tub cover for the same of the present invention without departing from the spirit or scope of the invention. Thus, it is intended that the present invention cover the modifications and variations of this invention provided they come within the scope of the appended claims and their equivalents.
[0112] The foregoing embodiments and advantages are merely exemplary and are not to be construed as limiting the present invention. The present teaching can be readily applied to other types of apparatuses. The description of the present invention is intended to be illustrative, and not to limit the scope of the claims. Many alternatives, modifications, and variations will be apparent to those skilled in the art. In the claims, means-plus-function clauses are intended to cover the structures described herein as performing the recited function and not only structural equivalents but also equivalent structures.
|
Method for controlling a full automatic washing machine, the method comprising a washing cycle, a rinsing cycle, and a dewatering cycle, wherein the washing or the rinsing cycle includes the step of rotating an inner tub at a high speed higher than a preset speed in one direction, thereby making a centrifugal force caused by high speed rotation of the inner tub, to push laundry against a wall of the inner tub, to enforce washing water in the inner tub to penetrate through the laundry at a speed higher than required to make the washing done, and to pump the washing water penetrated through the laundry and discharged into an outer tub upward, to recirculate to the inner tub.
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GOVERNMENT SUPPORT
This research was supported by grants from the National Institutes of Health grant numbers NIH/NCRR/RCMI G12RR03020, and NIH/NCRR/HHS1 C06 RR012512-01.
FIELD OF THE INVENTION
The present invention pertains to 3-substituted quinolinium and 7H-indolo[2,3,-c]quinolinium antiinfective compounds and pharmaceutically acceptable salts, compositions, and methods of treatment.
BACKGROUND OF THE INVENTION
Infections caused by Staphylococcus aureus , methicillin resistant Staphylococcus aureus (MRSA) and related gram positive pathogens are growing and continuous medical concern. Vancomycin and other glycopeptide antibiotics, are currently the agents of choice for combating these infections which are predominantly encountered in hospital settings. With the increased usage of Vancomycin, resistant strains have been found and are referred to as vancomycin intermediate-resistant Staphylococcus aureus (VISA). Schito, G. C., The Importance of the Development of Antibiotic Resistance in Staphylococcus Aureus, Clin. Microbiol. Infect., 2006, 12 Suppl. 1:3-8. Additionally, there is currently an epidemic of community-acquired MRSA (CA-MRSA) pneumonia in this country, which is reportedly linked to Staphylococcus aureus (SA) infection. Hageman, J. C., et al., Severe Community - Acquired Pneumonia Due to Staphyloccus aureus, 2003-04 Influenza Season, Emerg. Infect. Dis. 2006, available at the Centers for Disease Control website. Consequently, there is a dire need to develop new structural entities with a new mode of action against MSRA, other nosocomial and CA-MRSA opportunistic infections.
Furthermore, infections caused by opportunistic pathogens such as Cryptococcus neoformans (Cn or C. neoformans ), Candida albicans (Ca or C. albicans ), Aspergillus fumigatus (Af or A. fumigatus ) are growing medical concerns for immunucompromised patients such as those with AIDS. If not properly treated, these mycotic infections are often fatal. Despite tremendous progress in the development of new antifungal agents, drugs currently on the market including Amphotericin B in combination with Flucytosine and azoles present serious limitations. Echinocandins, the newest antifungal agents are fungistatic against clinically relevant Aspergillus species and are resistant in vitro to Cryptococcus and Zygomycetes. Thus, with the rising incidence of systemic mycoses due to immunosuppresion and neutropenia, there is an urgent need to develop novel systemic antifungal drugs.
It has been reported that cryptolepine and other alkyl substituted indolo[3,2-b]quinolines, also referred to as quindolines constitutes an important structural moiety in the literature because it possesses antiinfective activity against some opportunistic infectious organisms. Etukala, J. R.; Suresh Kumar, E. V. K.; Ablordeppey, S. Y., A Short and Convenient Synthesis and Evaluation of the Antiinfective Properties of Indoloquinoline Alkaloids: 10 H indolo[ 3,2- b]quinoline and 7 H - indolo[ 2,3- c]quinolines. J. Heterocycl Chem., 2008, 45, 507-511, Ablordeppey S. Y.; Fan, P.; Li, S.; Clark, A. M.; Hufford, C. D, Substituted Indoloquinolines as New Antifungal Agents, Bioorganic and Medicinal Chemistry, 2002, 10, 1337-1346. Zhu, et al., Synthesis and Evaluation of Isosteres of N - Methyl indolo[ 3,2- b ]- quinoline ( cryptolepine ) as New Antiinfective Agents, Bioorg. Med. Chem., 2007, 15, 686-695. However, the action of these compounds appears to operate through intercalation to DNA. Bonjean, K., et al., The DNA Intercalating Alkaloid Cryptolepine Interferes With Topoisomerase II and Inhibits Primarily DNA Synthesis in B 16 Melanoma Cell, Biochemistry, 1998, 37, 5236-5146. PCT/US2007/007976 referenced various publications showing that alkylation of nitrogen at the 5-position with omega-phenylpentyl and omega-cyclohexylpentyl groups produced high antifungal potency and broadened the spectrum of activities.
The present invention relates to novel 3-substituted quinolinium and 7H-indolo[2,3-c]quinolinium antiinfective compounds, which are ring-opened and angular quindoline analogs/isosteres that are capable of entering the cells and more importantly in crossing the blood-brain barrier to elicit anti-infective actions. These novel 3-substituted quinolinium antiinfectives have been shown to be more potent, yet less toxic than the parent tetracyclic quindoline. The angular quindolinium compounds have been shown to have better anti-MRSA, anti-cryptococcal and cytoxicity profiles than those of the linear quindolinium salts represented by cryptolepine. The antiinfectives of the present invention thus comprise an important contribution to therapy for treating infections caused by difficult to control pathogens. There is an increasing need for agents effective against pathogens such as MRSA, C. neoformans , and other fungal pathogens and protozoa which are at the same time relatively free from undesirable side effects.
BRIEF SUMMARY OF THE INVENTION
In accordance with the purpose(s) of this invention, as embodied and broadly described herein, this invention in one aspect, relates to quinolinium antiinfectives for—MRSA and anti-opportunistic pathogens. The 3-substitued and 7H-indolo[2,3-c]quinolinium compounds impart MRSA and Cryptococcal activity with less concerns associated with current glycopeptide antibiotics and antifungal treatments.
In another aspect, this invention relates to a compound having the formula (I):
or a pharmaceutically acceptable salt thereof, wherein:
Rn is an electron withdrawing or electron donating group, and n is the position of substitution of R;
R 5 is a straight or branched 1-5 carbon or heteroatom chain, which is unsubstituted or substituted terminally by a cycloalkyl or aromatic ring, which is unsubstituted or substituted, or a cycloalkyl or aromatic ring, or a heteroaromatic ring, or other structural isomer or complex thereof; and
Q is NH, N—CH 3 , N—R 5 , S, SO and O
In yet another aspect this invention relates to a compound of formula (II):
or a pharmaceutically acceptable salt thereof, wherein:
R 5 may be the same or different and is a straight or branched 1-5 carbon or heteroatom chain, which is unsubstituted or substituted terminally by a cycloalkyl or aromatic ring, which is unsubstituted or substituted, or a heteroaromatic ring, or other structural isomer or complex thereof;
Q is NH, N—CH 3 , N—R 5 , S, SO or O; and
A is a cycloalkyl or heterocyclic system, which is unsubstituted or substituted with electron donating or electron withdrawing groups.
In another aspect this invention relates to a compound of formula (III):
or a pharmaceutically acceptable salt thereof, wherein:
R n is an electron withdrawing or electron donating group, and n is the position of substitution on R and;
R 5 and R 10 may be the same or different and are a straight or branched 1-5 carbon or heteroatom chain, which is unsubstituted or substituted terminally by a cycloalkyl or aromatic ring, which is unsubstituted or substituted, or a cycloalkyl or aromatic ring, or a heteroaromatic ring or other structural isomer or complex thereof.
Pharmaceutical compositions, methods of treatment and an article of manufacture are also included herein.
DETAILED DESCRIPTION OF THE INVENTION
The invention is described herein in detail using the terms defined below unless otherwise specified.
It must be noted that as used in the specification and the appended claims, the singular forms “a” “an” and “the” include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to “a cyclic compound” includes mixtures of aromatic compounds.
Ranges are often expressed herein as from “about” one particular value, and/or to “about” another particular value. When such a range is expressed, another embodiment includes from the one particular value and/or to the other particular value. Similarly, when values are expressed as approximations, by use of the antecedent “about,” it will be understood that the particular value forms another embodiment.
The term “alkyl” refers to a monovalent alkane (hydrocarbon) derived radical from 1 to 10 carbon atoms unless otherwise defined. It may be straight, branched or heteroatom chain, or cyclic. Preferred alkyl groups are methyl, ethyl, propyl, isopropyl, butyl, t-butyl, pentyl and the like. When substituted, alkyl groups may be substituted terminally by a cycloalkyl or aromatic ring, or other structural isomer or complex, including omega-phenylpentyl and omega-cyclohexyl pentyl moieties.
Cycloalkyl is a specie of the alkyl containing from 3 to 15 carbon atoms without alternating or resonating double bonds between carbon atoms. It may contain from 1 to 4 rings which are fused.
Aromatic ring or “aryl” includes for example phenyl, substituted phenyl and the like, as well as rings that are fused, e.g. naphthyl, phenanthrenyl and the like. An aryl group thus contains at least one ring having at least 6 atoms, with up to five such rings being present, containing up to 22 atoms therein, with alternating (resonating) double bonds between adjacent carbon atoms or suitable heteroatoms.
The term “quaternary nitrogen” and “positive charge” refer to tetravalent, positively charged nitrogen atoms including, e.g., the positive charged nitrogen in a tetraalkylammonium group (e.g., tetramethylammonium), heteroarylium (e.g., N-methyl pyridinium), basic nitrogens which are protonated at physiological pH and the like. Cationic groups thus encompass positively charged nitrogen-containing groups, as well as basic nitrogen-containing groups which are protonated at physiologic pH.
The term “quaternary amine” defines the pharmaceutically acceptable quaternary ammonium salts which the antiinfective compounds of the instant invention are able to form by reaction between a basic nitrogen of a compound of formula (I), ((II) or (III) and an appropriate quaternizing agent, such as, for example, an optionally substituted alkylhalide, arylhalide or arylalkylhalide, e.g. alkyliodide or benzyliodide. A quaternary amine has a positively charged nitrogen. Pharmaceutically acceptable counterions include chloro, bromo, iodo, trifluoromethanesulfonate (triflate) and tosylate.
Other salts encompassed within the term “pharmaceutically acceptable salts” refer to non-toxic salts of the compounds of this invention which are derived from organic or inorganic acids. Representative salts include the following salts: acetate, adipate, alginate, aspartate, benzenesulfonate, benzoate, bisulfate, butyrate, citrate, camphorate, camphorsulfonate, cyclopentanepropionate, digluconate, dodecylsulfonate, ethanesulfonate, fumarate, glucoheptanoate, glycerophosphate, hemisulfate, heptanoate, hexanoate, hydrocloride, hydrobromide, hydroiodide, 2-hydroxyethanesulfonate, lactate, maleate, methanesulfonate, 2-naphthlenesulfonate, nicotinate, oxalate, pamoate, pectinate, persulfate, 3-phenylpropionate, picrate, pivalate, propionate, succinate, tartrate, thiocyanate, tosylate, and undecanoate.
The term “heteroatom” means O, S or N selected on an independent basis.
Halogen and “halo” refer to bromine, chlorine, fluorine and iodine.
When a group is termed “substituted”, unless otherwise indicated, this means that the group contains 1 to 4 substituents thereon.
The quinolinium compounds of the present invention are useful per se and in their pharmaceutically acceptable salt forms for the treatment of bacterial, fungal and protozoan infections in humans and animal subjects. The term “pharmaceutically acceptable ester, salt or hydrate,” refers to those salts, and hydrated forms of the compounds of the present invention which would be apparent to the pharmaceutical chemist, i.e., those which are substantially non-toxic and which may favorably affect the pharmacokinetic properties of said compounds, such as palatability, absorption, distribution, metabolism and excretion. Other factors, more practical in nature, which are also important in the selection are cost of the raw materials, ease of crystallization, yield, stability, solubility, hygroscopicity and flowability of the resulting bulk drug. Conveniently, pharmaceutical compositions may be prepared from the active ingredients in combination with pharmaceutically acceptable carriers. Thus, the present invention is concerned with pharmaceutical compositions and methods for treating bacterial, fungal and protozoan infections utilizing as an active ingredient the novel quinolinium compounds.
X represents a pharmaceutical acceptable counterion to maintain the appropriate charge balance. Most anions derived from inorganic or organic acids are suitable. Representative examples of such counterions are the following: acetate, adipate, aminosalicylate, anhydromethylenecitrate, ascorbate, aspartate, benzoate, benzenesulfonate, iodide, bromide, chloride, fluoride, citrate, camphorate, camphorsulfonate, estolate, ethanesulfonate, fumarate, glucoheptanoate, gluconate, glutamate, lactobionate, malate, maleate, mandelate, methanesulfonate, nitrate, pantothenate, pectinate, phosphate/diphosphate, polygalacturonate, propionate, salicylate, stearate, succinate, sulfate, tartrate, tosylate, triflate, and trifluoromethanesulfonate. Other suitable anionic species will be apparent to the ordinary skilled chemist.
The compounds of the present invention can be formulated in pharmaceutical compositions by combining the compound with a pharmaceutically acceptable carrier. Examples of such carriers are set forth below.
The compounds may be employed in powder or crystalline form, in liquid solution, or in suspension. They may be administered by a variety of means; those of principal interest include: topically, orally and parenterally by injection (intravenously or intramuscularly).
Compositions for injections, a preferred route of delivery, may be prepared in unit dosage form in ampules, or in multidose containers. The injectable compositions may take such forms as suspensions, solutions, or emulsions in oily or aqueous vehicles, and may contain various formulating agents. Alternatively, the active ingredient may be in powder (lyophilized or non-lyophillized) form for reconstitution at the time of delivery with a suitable vehicle, such as sterile water. In injectable compositions, the carrier is typically comprised of sterile water, saline or another injectable liquid, e.g., peanut oil for intramuscular injections. Also, various buffering agents, preservatives and the like can be included.
Topical applications may be formulated in carriers such as hydrophobic or hydrophilic bases to form ointments, creams, lotions, in aqueous, oleaginous or alcoholic liquids to form paints or in dry diluents to form powders.
Oral compositions may take such forms as tablets, capsules, oral suspensions and oral solutions. The oral compositions may utilize carriers such as conventional formulating agents, and may include sustained release properties as well as rapid delivery forms.
The dosage to be administered depends to a large extent upon the condition and size of the subject being treated, the route and frequency of administration, the sensitivity of the pathogen to the compound selected, the virulence of the infection and other factors. Such matters, however, are left to the routine discretion of the physician according to principals of treatment well known in the antiinfective arts. Another factor influencing the precise dosage regimen, apart from the nature of the infection and peculiar identity of the individual being treated, is the molecular weight of the compound.
The term “effective amount” means that amount of a drug or pharmaceutical agent that will elicit the biological or medical response of a tissue, system, animal or human that is being sought by a researcher or clinician. The term “therapeutically effective amount” means any amount which, as compared to a corresponding subject who has not received such amount, results in improved treatment, healing, prevention, or amelioration of a disease or disorder, or a decrease in the rate of advancement of a disease or disorder, and also includes amounts effective to enhance normal physiological function.
Using standard susceptibility tests, the compounds of the invention were determined to be active against MRSA, C. neoformans and several other bacteria, fungi and protozoa. More specifically, the antibacterial and antifungal testing was carried out in the following manner. Cryptococcus neoformans ATCC 90113 and MRSA were obtained from the American Type Culture Collection (Manassas. Va.). Several others including Candida albicans ATTC 90028, Aspergillus fumigatus ATCC 90906 and Mycobacterium intracellulare ( M. intracellulare ) ATCC 23086 were also procured. Susceptibility testing was performed using a modified version of the National Committee for Clinical Laboratory Standards method. M. intracellulare was tested using a modified method of Franzblau, et al., J. Clin. Microbiol., 1998, 36, 362-366. DMSO solutions of samples were serially diluted in saline, and transferred in duplicate to 96 well microplates. Microbial suspensions were diluted in the broth to afford desired colony forming units/mL according to the 0.5 McFarland Standard [ C. Albicans : either Saboraud Dextrose broth (SDB) or RPMI 1640, C. neoformans : SDB, A fumigatus : either YM broth (for MICS) or RPMI-1640+5% Alamar Blue.] After adding microbial cultures to the sampled afforded a final volume of 200 μL and final test concentration starting with 20 μg/mL, plates were read prior to and after final incubation using either fluorescence at 544ex/590em ( M intracellulare, A. fumigatus ) using the Polarstar galaxy reader (Biotek Instruments, Vermont). Growth (saline only), solvent and blank (media only) controls were included on each test plate. Drug controls [Ciprofloxacin (ICN Biomedicals, Ohio) for bacteria and Amphotericin B (ICN Biomedicals, Ohio) for fungi] were included in each assay. Percent growth was calculated and plotted versus test concentration to afford IC 50 (sample concentration that affords 50% inhibition or growth of the organism). The minimum inhibitory concentration (MIC) was determined by visually inspecting the plate, and is defined as the lowest test concentration that allows no detectable growth (for Almar Blue assays, no color change from blue to pink).
The biological activities of the compounds of the invention were evaluated and the results are shown below in Tables 1, 2 and 3.
TABLE 1
Physicochemical Data and Antifungal/Anti-MRSA Activities (in μg/mL) of Synthetic Compounds
%
Ca
Cn
A fu
MRS
TC 50 Vero
Comp
R 1
R 2
Q
Yield b
MP °(C) c
IC 50
MIC
MFC
IC 50
MIC
MFC
IC 50
MIC
MFC
IC 50
MIC
MFC
Cells
XYZ-III-53
H
S
81
145-146
—
—
—
—
—
—
—
—
—
—
—
—
XYZ-III-54
H
S
75
166-167
5.5
10
—
15
5.0
10
1.3
—
1.0
2.5
10
XYZ-III-62
4-F
S
78
174-175
—
—
—
—
—
—
—
—
—
—
—
—
XYZ-III-63
4-F
S
85
159-160
20
—
—
7.0
—
—
—
5.5
10
—
XYZ-III-65
4-CF 3
S
78
148-150
—
—
—
—
—
—
—
—
—
—
—
—
XYZ-III-66
4-CF 3
S
74
129-130
5.5
10
—
2.0
5.0
10
3.0
5.0
—
NC
XYZ-III-71
4-OMe
S
87
179-180
—
—
—
—
—
—
—
—
—
—
—
—
XYZ-III-72
4-OMe
S
72
172-173
—
—
—
9.5
20
—
3.5
10
—
2.0
5.0
10
XYZ-III-74
2-Cl
S
68
125-126
—
—
—
2.0
5.0
20
0.70
2.5
—
1.0
2.5
10
XYZ-III-83
H
O
79
164-165
—
—
—
—
—
—
2.0
—
—
15
20
—
XYZ-III-85
2-Br
S
78
141-142
20
—
—
1.5
5.0
10
0.50
5.0
—
0.95
2.5
10
XYZ-III-87
3-Br
S
80
172-173
—
—
—
2.0
5.0
20
3.0
10
—
2.0
5.0
20
XYZ-III-89
4-Br
S
86
181-182
15
—
—
1.0
2.5
10
1.5
2.5
—
1.5
2.5
10
XYZ-IV-18
2-OMe
S
82
142-143
3.0
10
—
0.85
2.5
5.0
0.09
1.3
10
0.25
0.63
5.0
XYZ-IV-19
2-F
S
74
172-173
2.5
10
20
0.25
0.63
2.5
0.20
0.31
—
0.40
0.63
5.0
XYZ-IV-20
3-OMe
S
80
168-169
7.0
20
—
1.5
2.5
10
0.55
1.3
—
0.70
1.3
10
XYZ-IV-21
3-F
S
78
144-145
3.0
10
20
0.40
0.63
2.5
0.10
0.16
—
0.20
0.63
20
XYZ-IV-25
2-CF 3
S
87
182-183
0.4
1.3
2.5
0.06
0.16
0.63
0.03
0.08
10
0.05
0.16
2.5
XYZ-IV-54
3-CF 3
S
81
186-188
6.0
10
—
1.5
2.5
20
1.5
5.0
—
0.85
2.5
10
NC
XYZ-IV-58
3,5-(CF 3 ) 2
S
87
194-196
ND
ND
ND
ND
XYZ-IV-79
H
SO
86
192-193
—
—
—
15
—
—
—
—
—
1.5
5.0
—
XYZ-IV-84
4-F
SO
81
184-185
—
—
—
15
—
—
—
—
—
0.80
5.0
20
XYZ-IV-87
3-CF 3
SO
83
176-177
—
—
—
6.5
20
20
—
—
—
0.25
1.3
20
XYZ-IV-90
2-CF 3
SO
82
184-186
15
—
—
5.5
20
—
—
—
—
0.25
0.63
10
XYZ-IV-98
2-Br
SO
78
194-195
—
—
—
5.5
20
—
15
—
—
0.35
1.3
—
XYZ-IV-100
2-F
SO
76
187-188
—
—
—
15
—
—
—
—
—
1.5
5.0
—
XYZ-V-9
2-Cl
SO
76
191-192
—
—
—
10
20
—
—
—
—
0.75
2.5
—
XYZ-V-13
3,5-(CF 3 ) 2
SO
78
166-167
10
20
20
3.0
5.0
20
—
—
—
0.20
0.63
10
XYZ-V-20
4-Br
SO
77
203-204
—
—
—
7.0
10
—
—
—
—
0.50
2.5
—
XYZ-V-21
4-OMe
SO
52
200-201
—
—
—
—
—
—
—
—
—
7.00
20
—
XYZ-V-23
3-OMe
SO
45
158-160
—
—
—
15
—
—
—
—
—
2.50
10
—
XYZ-V-27
4-CF 3
SO
81
189-190
—
—
—
6.0
10
20
—
—
—
0.50
1.3
—
XYZ-V-29
3-Br
SO
79
173-174
—
—
—
5.5
10
20
—
—
—
0.90
2.5
—
XYZ-IV-45
74
175-176
—
—
—
0.60
2.5
20
9.0
20
—
0.95
5.0
—
NC
XYZ-IV-52
45
154-156
—
—
—
4.0
10.0
—
5.0
10
—
2.0
5.0
—
NC
XYZ-IV-55
64
167-168
15
—
—
0.95
2.5
20
7.5
—
—
0.80
2.5
10
NC
XYZ-IV-59
54
206-208
XYZ-IV-51
83
158-160
6.5
—
—
1.5
2.5
20
0.90
2.5
—
0.85
2.5
20
NC
XYZ-VI-15
2-CN
S
69
174-175
ND
ND
ND
ND
XYZ-V-62
4-Cl
CO
81
160-161
7.0
10
—
2.0
5.0
10
10
20
—
0.20
3.1
—
Amph B
0.25
0.63
1.3
0.85
2.5
2.5
0.90
2.5
2.5
ND
6.5
Abbreviations: Ca = Candida albicans ; Cn = Cryptococcus neoformans ; Af = Aspergillus fumigatus ; Amph B = Amphotericin B; NC = Not toxic at 10 μg/mL; Cp = Cyclohexypentyl; (-) = >20 μg/mL.
a Recrystallization solvents are A = MeOH, B = MeOH—CH 2 Cl 2 , C = MeOH—Et 2 O, D = MeOH—EtOAc
b Yields were not optimized.
c Melting points were uncorrected.
d All compounds were subjected to CHN analysis and each passed within 0.4% of the theoretical value.
TABLE 2
Physicochemical Data and Antifungal/Anti-MRSA Activities (in μg/mL) of Synthetic Compounds
Ca
Cn
A fu
MRSA
TC 50 Vero
Comp
R 1
R 2
R 3
MP °(C) c
IC 50
MIC
MFC
IC 50
MIC
MFC
IC 50
MIC
MFC
IC 50
MIC
MFC
Cells
JRE-3-20-1
4-CF 3
154-156
0.65
1.6
3.1
0.65
1.6
3.1
1.0
3.1
6.3
0.40
0.78
1.6
25
JRE-3-61-1
3-CF 3
111-112
1.0
2.5
2.5
0.85
1.3
2.5
1.5
2.5
10
0.45
0.63
1.3
>10
JRE-4-9-1
4-Cl
176-177
0.45
1.3
5.0
0.40
0.63
2.5
0.80
1.3
10
0.40
0.63
0.63
10
JRE-4-3-1
3-Cl
85-87
0.90
2.5
10
0.85
1.3
5.0
1.0
2.5
10
0.80
1.3
2.5
>10
JRE-3-19-1
H
156-158
1.0
3.1
13
0.55
0.78
6.3
1.0
1.6
25
0.85
1.6
6.3
JRE-3-68-1
4-OMe
181-183
0.80
1.3
1.3
0.50
1.3
5.0
0.80
1.3
10
0.50
1.3
1.3
>10
JRE-3-69-1
3-OMe
165-167
0.85
2.5
2.5
0.55
1.3
5.0
0.70
1.3
10
0.50
1.3
1.3
>10
JRE-3-99-1
4-OCF 3
161-163
0.45
1.3
10
0.70
1.3
1.3
0.95
2.5
2.5
0.65
1.3
1.3
>10
JRE-2-81-1
3-C1
211-213
—
—
—
—
—
—
—
—
—
—
—
—
JRE-2-42-1
2-Cl
208-210
—
—
—
—
—
—
—
—
—
—
—
—
JRE-3-45-1
4-OMe
135-136
—
—
—
—
—
—
—
—
—
—
—
—
JRE-2-83-1
4-Cl
177-178
2.0
25
—
1.0
1.6
—
—
—
—
0.50
0.78
1.6
12.5
JRE-3-88-1
3-Cl
128-129
2.0
6.3
13
2.0
3.1
50
3.5
6.3
—
0.55
0.78
1.6
12.5
EVK-III-001
0.20
0.39
3.1
0.35
0.78
1.6
0.95
1.6
3.1
0.30
0.78
0.78
9.0
EVK-III-002
0.60
1.6
13
0.85
1.6
1.6
1.0
1.6
6.3
0.45
0.78
1.6
6.0
JRE-4-16-1
228-230
ND
ND
ND
ND
JRE-4-1-1
124-125
3.5
10
—
1.5
2.5
5.0
0.90
1.3
1.3
1.5
5.0
5.0
8.3
JRE-2-89-1
182-183
15
50
—
4.0
6.3
13
10
50
—
1.5
3.1
13
>25
EVK-II-091
0.80
1.3
—
0.45
0.63
5.0
0.50
1.3
5.0
0.45
0.63
2.5
>10
Amph B
0.25
0.63
1.3
0.85
2.5
2.5
0.90
2.5
2.5
ND
6.5
Abbreviations: Ca = Candida albicans ; Cn = Cryptococcus neoformans ; Af = Aspergillus fumigatus ; Amph B = Amphotericin B; NA = Not active at 20 μg/mL; Cp = Cyclohexypentyl; (-) = >20 μg/mL; ND = Not determined
a Recrystallization solvents are A = MeOH, B = MeOH-CH 2 Cl 2 , C = MeOH-Et 2 O, D = MeOH-EtOAc
b Yields were not optimized.
c Melting points were uncorrected.
d All compounds were subjected to CHN analysis and each passed within 0.4% of the theoretical value.
TABLE 3
Physicochemical Data and Antifungal/Anti-MRSA Activities (in μg/mL) of Synthetic Compounds
E
F
TC 50
Com-
Str;
MP
Ca
Cn
A fu
MRSA
Vero
pound a
R n
(°C) b
IC 50
MIC
MFC
IC 50
MIC
MFC
IC 50
MIC
MFC
IC 50
MIC
MFC
Cells
JRE-
E;
210-
2.0
6.3
13
9.0
—
—
10
—
—
1.0
1.6
3.1
10.5
3-4-1
10CF 3
212
JRE-
E;
223-
>20
—
—
>20
—
—
>20
—
—
5.0
25
—
9.3
3-10-
9-
225
1
Cl
JRE-
F;
249-
0.80
2.5
10
1.5
2.5
5.0
3.5
5.0
10
0.70
1.3
1.3
>10
3-
H
251
100-1
JRE-
F;
266-
0.70
1.3
2.5
0.80
1.3
2.5
1.5
2.5
5.0
0.80
1.3
1.3
>10
3-84-
9-
268
1
Cl
JRE-
F;
246-
0.90
1.6
1.6
0.90
1.6
1.6
2.0
6.3
25
0.50
0.80
0.80
>10
3-13-
10-
248
1
Cl
JRE-
F;
238-
0.80
1.3
—
0.85
1.3
2.5
1.5
5.0
10
0.70
1.3
1.3
>10
5-31-
9-
240
1
CF 3
JRE-
F;
231-
3.5
5.0
10
3.0
5.0
5.0
3.5
10
10
1.5
2.5
5.0
>10
4-17-
10-
233
1
CF 3
JRE-
F;
215-
ND
ND
ND
ND
ND
4-46-
9-
217
1
OMe
JRE-
F;
242-
ND
ND
ND
ND
>10
4-24-
CO 2 -
243
1
Isop
Cipro
0.09
0.5
>20
>10
Amph
0.25
0.63
1.3
0.85
2.5
2.5
0.90
2.5
2.5
ND
6.5
B
Abbreviations: Ca = Candida albicans ; Cn = Cryptococcus neoformans ; Af = Aspergillus fumigatus ; Amph B = Amphotericin B; NA = Not active at 20 μg/mL; Cp = Cyclohexypentyl; (-) = >20 μg/mL; ND = Not determined
a All compounds were subjected to CHN analysis and each passed within 0.4% of the theoretical value.
b Melting points were uncorrected.
The quinolinium compound of the present invention may be used in the manufacture of a drug product that is useful for the treatment of bacterial, fungal and protozoan infections in animal and human subjects.
The invention is further described in connection with the following non-limiting examples.
EXAMPLE 1
Synthesis of 3-(2-Trifluoromethyl-phenylsulfanyl)quinolinium salt
A mixture of 3-iodoquinoline (6 g, 23.5 mmol), 2-trifluoromethyl benzenethiol (5 g, 28 mmol), CuI (225 mg, 3.89 mmol), ethylene glycol (3.5 g, 56.4 mmol), K 2 CO 3 (8 g, 58 mmol) in isopropanol (20 mL) was refluxed under N 2 for 12 h. The reaction mixture was filtered through a short pad of silica gel and the filtrate was concentrated in vacuo to dryness. The product was purified by flash column chromatography on silica gel to give the product 3-(2-trifluoromethyl-phenylsulfanyl)-quinoline (8.1 g, 95%)
A mixture of 3-(2-trifluoromethyl-phenylsulfanyl)-quinoline (370 mg, 1.21 mmol), (5-iodo-pentyl)-benzene (520 mg, 1.9 mmol) in tetramethylene sulfone (1 mL) was sealed in a tube and heated at 100° C. for 12 h. Ether (10 mL) was added resulting in a solid product. The product was crystallized from MeOH-Et 2 O to yield 1-(5-phenyl-pentyl)-3-(2-trifluoromethyl-phenylsulfanyl)-quinolinium iodide (632 mg, 90%). Mp 227-229° C.
1 H NMR (DMSO), 9.72 (1H, s), 9.24 (1H, s), 8.60 (1H, d, J=8.7 Hz), 8.42 (1H, d, J=7.8 Hz), 8.27 (1H, dd, J=3.9, 8.1 Hz), 8.04 (1H, dd, J=7.2, 7.8 Hz), 7.92 (1H, d, J=5.7 Hz), 7.61 (3H, m), 7.22 (2H, m), 7.13 (3H, m), 5.04 (2H, br s), 2.54 (2H, t, J=6.6 Hz), 1.98 (2H, br s), 1.60 92H, br s), 1.37 (2H, br s).
EXAMPLE 2
Part A
Step 1: Synthesis of [Ph 3 Bi(OAc) 2 ]
To a solution of Ph 3 Bi (5 g, 11.3 mmol) in 30 ml of CH 2 Cl 2 /THF (7:3) at 0° C., was added drop wise CH 3 CO 3 H (2.9 ml of a 32% solution in CH 3 COOH, 1.2 eq). The mixture was stirred at room temperature for 1 hr. Diethyl ether (30 ml) was added and the resulting precipitate was filtered, washed with Et 2 O, collected and dried, (5.7 g).
Mp: 192-194° C.
1 H NMR (CDCl 3 ): δ 1.82 (s, 6H), 7.45-7.60 (m, 9H), 8.15 (d, J=8.1 Hz, 6H).
Step 2: Synthesis of Phenyl-quinolin-3-yl-amine
A mixture of 3-aminoquinoline (800 mg, mmol) in 30 ml of CH 2 Cl 2 , Cu powder (272 mg,) and triphenylbismuth diacetate (4.64 gm) was stirred at room temperature overnight. The crude reaction mixture was diluted with CH 2 Cl 2 , (20 ml) and filtered, the filtrate was washed with H 2 O followed by brine. The organic phase was dried over anhydrous Na 2 SO 4 solvent was removed under reduced pressure and the crude product was purified by column chromatography using EtOAc and hexane (1:9) as eluent. The pure product was a pale greenish solid (800 mg).
1 H NMR (CDCl 3 ): δ 6.0 (brs, NH), 7.05 (t, 1H, J=7.2 Hz), 7.15 (d, 2H, J=8.10 Hz), 7.35 (t, 2H, J=8.4 Hz), 7.45-7.55 (m, 2H), 7.60 (dd, 1H, J=1.8, 7.5 Hz), 7.70 (d, 1H, J=2.7 Hz), 8.00 (d, 1H, J=7.8 Hz), 8.70 (d, 1H, J=2.7 Hz).
Step 3: Synthesis of (5-Bromo-pentyl)-cyclohexane
To a solution of 1,5-dibromopentane (16 gm, 69.97 mmol) in THF (20 ml) was added a solution of (Li 2 CuCl 4 in ether, 14 ml) under nitrogen at 5-10° C. and stirred for 25 minutes. Cyclohexyl magnesium bromide (10 gm, 69.97 mmol) was added dropwise with stirring for about 30 minutes. The reaction mixture was stirred at 0° C. for another 1 h and stirred at room temperature for 12 hr. The reaction mixture was cooled to 0° C. in ice, saturated NH 4 Cl solution (20 ml) was added and the resulting mixture was extracted with EtOAc (4×25 ml). The organic layer was separated, washed with brine and dried over anhydrous Na 2 SO 4 . The solvent was removed under reduced pressure and the crude product was purified by column chromatography using hexane as an eluent. The pure product was an oily liquid (12.84 gm).
1 H NMR (CDCl 3 ): 0.8 (t, 2H, J=10.2 Hz), 1.00-1.38 (m, 9H), 1.52-168 (m, 6H), 1.70-1.80 (m, 2H), 3.38 (t, 2H, J=7.2 Hz).
Step 4: Synthesis of (5-Iodo-pentyl)-cyclohexane
A mixture of (5-bromopentyl)cyclohexane (2 gm, 8.6 mmol) in acetone (20 ml), and sodium iodide (2.57 g, 17.1533 mmol) was heated for 60° C. for 12 hrs. The mixture was allowed to cool to room temperature and the solvent was evaporated. The residue was diluted with EtOAc (30 ml), H 2 O (20 ml) was added, separated and the organic phase was washed with brine (30 ml). The organic layer was dried over anhydrous Na 2 SO 4 ; solvent was evaporated under reduced pressure and the crude product was purified by column chromatography using hexane as eluent. The pure product was an oily liquid (1.36 gm).
1 H NMR (CDCl 3 ): δ 0.8 (t, 2H, J=10.2 Hz), 1.00-1.38 (m, 9H), 1.52-168 (m, 6H), 1.70-1.80 (m, 2H), 3.10 (t, 2H, J=6.9 Hz).
Step 5: Synthesis of 1-(5-Cyclohexyl-pentyl)-3-phenyl-quinolinium iodide
A mixture of phenyl-quinolin-3-yl-amine (100 mg, 0.4539 mmol) in toluene (3 ml) and 5-iodopentylcyclohexane (636 mg, 2.3 mmol) in a sealed pressure tube was stirred at 110° C. for 24 hours. The reaction mixture was allowed to cool to room temperature, diluted with Et 2 O (15 ml) and the resulting precipitate was filtered and washed with Et 2 O (3×20 ml). The crude product was purified by column chromatography using MeOH/Et 2 O as eluent. The pure product was an orange solid (65 mg). Mp: 156-158° C.).
1 H NMR (CD 3 OD): δ 0.80-1.00 (m, 2H), 1.00-1.38 (m, 7H), 1.40-1.58 (m, 4H), 1.60-1.80 (m, 4H), 2.00-2.20 (m, 2H), 5.00 (t, 2H, J=7.2 Hz), 7.20 (t, 1H, J=6.8 Hz), 7.35 (d, 2H, J=8.6 Hz), 7.46 (t, 2H, J=7.0 Hz), 7.80 (t, 1H, J=7.6 Hz), 7.82-8.00 (m, 1H), 8.10 (d, 1H, J=8.4 Hz), 8.38 (d, 1H, J=9.0 Hz), 8.45 (d, 1H, J=2.4 Hz), 9.0 (d, 1H, J=2.7 Hz). Anal Calcd for: C 26 H 33 IN 2 .1.4 H 2 O: C, 56.69; H, 6.55; N, 5.08. Found: C, 56.73; H, 6.26; N, 4.93.
Step 6: Synthesis of (5-Iodopentyl)benzene
A mixture of 5-phenyl-pentane-1-ol (1.0 gm, 6.09 mmol) in CH 2 Cl 2 (20 ml), triphenyl phosphine (2.35 gm, 8.52 mmol), imidazole (0.58 gm, 8.52 mmol) and elemental iodine (2.16 gm, 8.52 mmol) was stirred at room temperature for 12 h. The solvent was evaporated under reduced pressure. The residue was diluted with EtOAc (30 ml), H 2 O (20 ml) was added, separated and the organic phase was washed with brine (30 ml). The organic layer was dried over anhydrous Na 2 SO 4 ; solvent was evaporated under reduced pressure and the crude product was purified by column chromatography using hexane as eluent. The crude product was purified by column chromatography using hexane as eluent. The pure product was an oily liquid (750 mg).
1 H NMR (CDCl 3 ): δ 1.30-1.70 (m, 4H), 1.80 (m, 2H), 2.6 (t, 2H, J=7.2 Hz), 3.10 (t, 2H, J=7.8 Hz), 7.00-7.34 (m, 5H).
Step 7: Synthesis of 1-(5-cyclohexyl-pentyl)-3-phenylquinolinium iodide
A mixture of phenylquinolin-3-yl-amine (100 mg, 0.46 mmol) in toluene (2 ml) and 5-iodopentylbenzene (373 mg, 1.36 mmol) in sealed pressure tube was stirred at 110° C. for 24 hours. The reaction mixture was allowed to cool to room temperature, diluted with Et 2 O (15 ml), and the resulting precipitate was filtered and washed with Et 2 O (3×20 ml). The crude product was purified by column chromatography using MeOH/Et 2 O as eluent. The pure product was an orange solid (75 mg). Mp: 140-141° C.
1 H NMR (CD 3 OD): δ 1.42-1.56 (m, 2H), 1.66-178 (m, 2H), 2.04-2.18 (m, 2H), 2.58-2.68 (t, 2H, J=7.2 Hz), 4.88-5.04 (t, 2H, J=7.8 Hz), 7.08-7.24 (m, 6H), 7.14 (dd, 2H, J=0.9, 7.5 Hz), 7.40-7.44 (t, 2H, J=8.4 Hz), 7.76-7.84 (t, 1H, J=7.5 Hz), 7.86-7.94 (m, 1H), 8.08 (d, 1H, J=8.4 Hz), 8.30 (d, 1H, J=9.0 Hz), 8.46 (d, 1H, J=2.4 Hz), 9.04 (d, 1H, J=2.7 Hz). Anal Calcd for: C2 6 H 27 IN 2 .1H 2 O: C, 60.92; H, 5.70; N, 5.47. Found: C, 60.79; H, 5.33; N, 6.38.
Part B
Synthesis of 3-Anilinoquinolinium salt
(A): General Procedure for the synthesis of phenyl-quinoline amine derivatives
To a solution of 3-amino quinoline (1 gm, mmol) in CH 2 Cl 2 (30 mL) and 4-chlorophenyl boronic acid (2 gm, mmol, 1.6 eq) was added portion wise, triethylamine (1.5 gm, 1.6 eq), Cu(OAc) 2 (1.5 gm, mmol, 1.6 eq) and molecular sieves (2 gm) powder. The reaction mixture was stirred at room temperature for 12-24 hrs. The reaction was quenched with aqueous NH 3 (15 ml) and extracted with CH 2 Cl 2 , (3×25 ml) washed with brine solution and dried over anhydrous Na 2 SO 4 . The solvent was evaporated under reduced pressure and the pure product was obtained by column chromatography using EtOAc and hexane as eluent. 1H-NMR (DMSO-d 6 ): δ 7.24 (d, 2H, J=8.7 Hz), 7.34 (d, 2H, J=9.0 Hz), 7.46-7.52 (m, 2H), 7.78-7.82 (m, 1H), 7.84-7.90 (m, 2H), 8.68 (d, 1H, J=3.0 Hz), 9.40 (s, NH).
(B): General procedure for the synthesis of (5-Cyclohexyl-pentyl)-phenyl-quinolin-3-yl-amines
A mixture of 4-(chlorophenylquinolin-3-yl-amine (100 mg), DME (5 ml), NaH (20 mg) 5-iodo-pentyl-cyclohexane (636 mg) was stirred at room temperature for 12 hours. Solvent was evaporated, the residue diluted with H 2 O (10 mL), extracted with EtOAc (2×30 mL), washed with brine and dried over anhydrous Na 2 SO 4 . The solvent was removed under reduced pressure and the crude product was purified by column chromatography to yield the pure product as an oily liquid (70 mg). 1H-NMR: (CDCl 3 ): δ 8.64 (d, 1H, J=2.4 Hz), 8.00 (d, 1H, J=8.4 Hz), 7.66 (dd, 1H, J=, 8.1, 1.8 Hz), 7.58-7.44 (m, 3H), 7.26 (d, 2H, J=9.0 Hz), 7.00 (d, 2H, J=8.8 Hz), 3.70 (t, 2H, J=7.8 Hz), 1.76-1.60 (m, 7H), 1.40-1.30 (m, 5H), 1.20-1.10 (m, 5H), 0.80-0.60 (t, 2H, J=9.3 Hz).
(C): General procedure for the synthesis of-3-[(5-Cyclohexyl-pentyl)-phenyl-amino]-1-methyl-quinolinium iodides
JRE-4-9-1: A mixture of [(4-chlorophenyl)-(5-cyclohexylpentyl)]-quinolin-3-yl-amine (65 mg), in toluene (3 ml) and CH 3 I (0.2 mL) in a sealed pressure tube was stirred at 110° C. for 24 hours. The reaction mixture was allowed to cool to room temperature, diluted with Et 2 O (15 ml) and the resulting precipitate was filtered and washed with Et 2 O (20 ml) to yield the pure product as an orange solid (50 mg). Mp: 176-177. 1 H-NMR: (DMSO-d 6 ): δ 9.10 (d, 1H, J=2.7 Hz), 8.46 (d, 1H, J=2.4 Hz), 8.26 (d, 1H, J=8.7 Hz), 8.20-8.18 (dd, 1H, J=7.2, 1.2 Hz), 7.96-7.90 (m, 1H), 7.84 (t, 1H, J=7.8 Hz), 7.50 (d, 2H, J=9.0 Hz), 7.36 (d, 2H, J=9.0 Hz), 4.54 (s, 3H), 3.86 (t, 2H, J=7.5 Hz), 1.70-1.50 (m, 7H), 1.40-1.24 (m, 4H), 1.20-1.04 (m, 6H), 0.84-0.74 (t, 2H, J=10.2 Hz).
EXAMPLE 3
Synthesis of Indolo[2,3-c]quinolinium Iodides
The above synthesized 3-anilinoquinoline was used as the starting material. A palladium catalyzed ring closure reaction was utilized to obtain both linear and angular quindoline ring systems, which is described by Etukala, J. R.; Suresh Kumar, E. V. K.; Ablordeppey, S. Y., A Short and Convenient Synthesis and Evaluation of the Antiinfective Properties of Indoloquinoline Alkaloids: 10 H indolo[ 3,2- b]quinoline and 7 H - indolo[ 2,3- c]quinolines, J. Heterocycl Chem., 2008, 45, 507-511, and Fan Pingchen, et al., An Alternativie Synthesis of the 10 H - Indolo[ 3,2- b]quiniline and its Selective N - Alkylation, J. Heterocycl. Chem., 1997, 34, 1789-1794, both publications herein incorporated by reference. The ratio of linear to angular ring systems are dependent on the ring substituents. Overall, the angular systems were found to predominate in all cases except for the 9-substituted analogs.
(A): General procedure for the synthesis of 7H-indolo-[3,2-c]quinoline analogs
A mixture of 4-(chlorophenylquinolin-3-yl-amine (400 mg), CF 3 COOH (8 ml), Pd(OAc) 2 (300 mg) was refluxed for 6 hr at 80° C. The reaction mixture was allowed to cool to room temperature, poured in ice cold water (15 ml), neutralized with aqueous ammonia and extracted with EtOAc (3×50 mL), washed with brine and dried over anhydrous Na 2 SO 4 . The solvent was removed under reduced pressure and the crude product was purified by column chromatography to yield the pure solid product (130 mg). Mp: 146-148° C. 1H-NMR: (DMSO-d 6 ): δ 9.52 (s, 1H), 8.96 (d, 1H, J=8.1 Hz), 8.86 (d, 1H, J=1.5 Hz), 8.24 (d, 1H, J=8.1 Hz), 7.88-7.78 (m, 3H), 7.70-7.66 (dd, 1H, J=6.6, 2.1 Hz).
(B): General procedure for the synthesis of 7-(5-Cyclohexyl-pentyl)-7H-indolo quinolines
A mixture of 10-chloro-7H-indolo[2,3-c]-quinoline (120 mg), DME (5 ml), NaH (30 mg) and 5-iodo-pentyl-cyclohexane (636 mg) was stirred at room temperature for 12 h, solvent was evaporated and the residue diluted with H 2 O (10 mL). The resulting mixture was extracted with EtOAc (2×30 mL), washed with brine and dried over anhydrous Na 2 SO 4 . The solvent was removed under reduced pressure and the crude product was purified on column chromatography to yield the pure solid product (70 mg).
1H NMR: (CDCl 3 ): δ 9.26 (s, 1H), 8.62 (d, 1H, J=8.4 Hz), 8.54 (d, 1H, J=1.2 Hz), 8.32 (d, 1H, J=8.4 Hz), 7.74 (t, 1H, J=7.2 Hz), 7.70 (t, 1H, J=8.1 Hz), 7.60-7.52 (m, 2H), 4.52 (t, 2H, J=7.2 Hz), 1.94 (t, 2H, J=6.9 Hz), 1.70-1.50 (m, 5H), 1.40-1.30 (m, 4H), 1.20-1.00 (m, 6H), 0.86-0.76 (t, 2H, J=10.8 Hz).
EXAMPLE 4
General procedure for the synthesis of 10-substituted-7-(5-cyclohexyl-pentyl)-5-methyl-7H-indolo[2,3-c]quinolin-5-ium iodide
(A): 10-Chloro-7-(5-cyclohexyl-pentyl)-5-methyl-7H-indolo[2,3-c]quinolin-5-ium iodide
A mixture of 10-chloro-7-(5-cyclohexyl-pentyl)-7H-indolo[2,3-c]-quinoline (65 mg) in toluene (3 ml) and CH 3 I (0.3 mL) was stirred in a sealed pressure tube at 110° C. for 24 hours. The reaction mixture was allowed to cool to room temperature, diluted with Et 2 O (15 ml) and the resulting precipitate was filtered and washed with Et 2 O (3×20 ml) to yield the pure angular product as an orange solid (50 mg). Mp 246-248° C.
1H-NMR: (DMSO-d 6 ): δ 10.28 (s, 1H), 9.26-9.20 (m, 1H), 9.06 (d, 1H, J=1.5 Hz), 8.58-8.54 (m, 1H), 8.14 (d, 1H, J=9.0 Hz), 8.10-8.06 (m, 2H), 7.94-7.90 (dd, 1H, J=7.5, 1.8 Hz), 4.76-4.70 (m, 5H), 1.90-1.80 (t, 2H, J=6.6 Hz), 1.64-1.50 (m, 5H), 1.34-1.20 (m, 4H), 1.16-1.00 (m, 6H), 0.80-0.72 (t, 2H, J=9.9 Hz).
(B): 10-Trifluoromethyl-7-(5-cyclohexyl-pentyl)-5-methyl-7H-indolo[2,3-c]quinolin-5-ium iodide
Mp: 231-233° C.
1H-NMR: (DMSO-d 6 ): δ 10.34 (s, 1H), 9.40-9.32 (m, 1H), 9.30 (s, 1H), 8.64-8.58 (m, 1H), 8.30 (d, 1H, J=9.0 Hz), 8.20-8.10 (m, 3H), 4.80-4.70 (m, 5H), 1.94-1.86 (t, 2H, J=7.2 Hz), 1.64-1.50 (m, 5H), 1.40-1.26 (m, 4H), 1.10-1.00 (m, 6H), 0.80-0.74 (t, 2H, J=10.2 Hz).
It must be emphasized that the law does not require and it is economically prohibitive to illustrate and teach every possible embodiment of the present claims. Hence, the above-described embodiments are merely exemplary illustrations of implementations set forth for a clear understanding of the principles of the invention. Many variations and modifications may be made to the above-described embodiments without departing from the scope of the claims. All such modifications, combinations, and variations are included herein by the scope of this disclosure and the following claims.
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The present invention relates to quinolinium antiinfective agents in which the qunolinium nucleus is fused to an indole ring or the qunolinium nucleus is linked to a cyclic structure through an opened indole or a benzothiophene or benzofuran ring. The compound is further substituted with various substituent groups.
The compounds are represented by formula (I), (II) and (III):
Pharmaceutical compositions and methods of use are also included.
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FIELD OF THE INVENTION
The present invention relates, in general, to intravenous (IV) catheters and, more particularly, to a safety IV catheter with a needle tip protector that will automatically cover the needle tip upon needle withdrawal.
BACKGROUND OF THE INVENTION
I.V. catheters are used primarily to administer fluids directly into a patient's vascular system. The catheter is inserted into a patient's vein by a clinician using a handheld placement device that includes a needle with a sharp distal end. The needle is positioned in the interior hollow portion of the catheter with its sharp distal tip extended slightly beyond the distal edge of the catheter. The proximal end of the needle is connected to a needle hub which is held by the clinician during the insertion procedure.
During the insertion procedure, the clinician inserts the needle and catheter together into the patient's vein. After insertion of the needle point into the vein, the catheter is forwarded into the vein of the patient by the clinician pushing the catheter with their finger. The clinician then withdraws just the needle by grasping the hub attached to the proximal end of the needle while at the same time applying pressure to the patient's skin at the insertion site, thus holding the catheter fixed in place. The clinician then typically tapes the proximal end of the now inserted catheter to the patient's skin and connects the proximal end of the catheter, containing a Luer connector catheter hub, to the source of the fluid to be administered into the patient's vein.
It is the period of time just as the needle is withdrawn from the catheter that poses great risk to the clinician. The clinician is at risk of an accidental needle stick from the sharp needle which has just been contaminated with a patients blood. This leaves the clinician vulnerable to the transmission of dangerous blood-borne pathogens, including hepatitis and AIDS. The risk of a contaminated needle stick is not isolated just to clinicians. Careless disposal of used needles can put other health care workers at risk as well. Even others outside the health care profession, for example those involved in the clean-up and final disposal of medical waste, are at risk of an accidental needle stick from a carelessly discarded needle.
A number of “safety” IV catheters have been developed to address the issue of accidental needle stick. For example, in U.S. Pat. No. Re. 34,416 to Lemieux, a safety catheter is disclosed which includes an element which covers the needle tip upon removal of the needle from the catheter. The safety element includes a split flange at its proximal end which is expanded by the needle as the needle is inserted into an undersized hole at the center of this flange. The safety element is thus held secure within the catheter hub by inserting the needle through the undersized hole which forces the outside perimeter of the split flange against the inside wall of the catheter hub.
One of the drawbacks to this design is the amount of friction force exerted against the needle by the split flange. A tight fit of the flange against the catheter wall causes great friction against the needle making it difficult to be withdrawn from the catheter by the clinician. A loose fit leaves the flange prone to releasing prematurely from the catheter as the needle is withdrawn, creating the potential that the needle tip will be left exposed.
In U.S. Pat. No. 6,117,108 to Woehr et al, a safety IV catheter is described including a resilient needle guard which protects the needle tip upon removal of the needle from the catheter hub. The needle guard includes an arm that includes an opening through which a needle passes causing radial movement of the arm. This radial movement forces the arm into a groove or behind a rib located on the inside of the catheter hub, capturing the needle guard in the catheter hub. A potential issue with this design develops when the needle guard is not properly seated into the catheter hub. If the distal end of the needle guard arm is not in alignment with the groove in the catheter hub, excessive forces are placed on the needle causing a high drag force as the clinician removes the needle. And, since the needle guard arm is not properly seated in the groove, it may prematurely release from the catheter hub upon the removal of the needle leaving the needle tip exposed.
The prior art safety catheters all exhibit one or more drawbacks that have thus far limited their usefulness and full acceptance by health-care workers. What is needed therefore is a safety IV catheter that functions reliably, is easy and inexpensive to manufacture, and easy to use.
SUMMARY OF THE INVENTION
In accordance with the present invention there is provided a catheter and introducer needle assembly including a needle having a diameter, proximal end, attached to a needle hub, a distal end, and a enlarged area disposed therebetween. The assembly further includes a tubular catheter having proximal and distal ends, the introducer needle being coaxially received within the catheter, and a hollow catheter hub having a distal end attached to the proximal end of the catheter and in fluid communication with the catheter. The catheter hub includes an interior having a raised annular rib disposed thereon. The assembly also includes a needle tip protector having a proximal end and a distal end disposed within the catheter hub. The proximal end including at least one unrestrained radially extending lip disposed distal to the annular rib so as to retain the protector within the hub, wherein the distal end of the protector does not abut against the hub interior. The protector having a proximal opening at the proximal end having an unrestrained size greater than the size of the needle diameter and smaller than the enlarged area such that when the needle is removed from the catheter the protector remains attached to the needle.
BRIEF DESCRIPTION OF THE DRAWINGS
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:
FIG. 1 is a perspective view of the catheter and needle assembly of the present invention;
FIG. 2 is an exploded perspective view of the catheter assembly and needle assembly including the needle tip protector of the present invention;
FIG. 3 is a perspective view of the needle tip protector of the present invention;
FIG. 4 is an elevation view of FIG. 3 taken along line 4 — 4 illustrating the hole positions in the rear flanges of the needle tip protector as manufactured;
FIG. 5 is a section view of the catheter assembly and needle assembly taken along line 5 — 5 of FIG. 1;
FIG. 6 is an enlarged partial section view of FIG. 5 illustrating the relative position of the needle tip protector tab and catheter hub rib;
FIG. 7 is a section view of the catheter hub with needle tip protector installed taken along line 7 — 7 of FIG. 5;
FIG. 8 is a perspective view of the needle tip protector shown as installed in the catheter hub with the needle inserted there through, catheter hub not shown for clarity;
FIG. 9 is a perspective view of the needle tip protector shown as removed from the catheter hub and illustrating the needle tip covered by the protector;
FIG. 10 is a perspective view of an alternate embodiment of the needle tip protector of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
As used herein, the term “proximal” refers to a location on the catheter and needle assembly with needle tip protector closest to the clinician using the device and thus furthest from the patient on which the device is used. Conversely, the term “distal” refers to a location farthest from the clinician and closest to the patient.
As illustrated in FIGS. 1 and 2, IV catheter assembly 20 comprises catheter assembly 22 and needle assembly 24 . Needle assembly 24 further includes needle tip protector 26 . Catheter assembly 22 includes catheter 28 which is a tubular structure having a proximal end 31 and distal end 29 . Proximal end 31 of catheter 28 is fixedly attached to catheter hub 30 . Catheters are well known in the medical art and one of many suitable materials, most of which are flexible thermoplastics, may be selected for use in catheter 28 . Such materials may include, for example, polyurethane or fluorinated ethylene propylene. Catheter hub 30 is a generally tubular structure having an internal cavity in fluid communication with the internal lumen of catheter 28 . Catheter hub 30 may be made from a suitable, rigid medical grade thermoplastic such as, for example, polypropylene or polycarbonate. For illustration purposes catheter hub 30 is shown translucent, though in actual use it may be translucent or opaque. At the proximal end of catheter hub 30 is integrally attached Luer fitting 32 , commonly known in the medical art. Luer fitting 32 provides for secure, leakproof attachment of tubing, syringes, or any of many other medical devices used to infuse or withdraw fluids through the catheter assembly. As is more clearly illustrated in FIGS. 5 and 6, rib 34 is a raised annular ring integral to and extending from internal sidewall 36 of catheter hub 30 . Rib 34 is located approximately mid way between the proximal end and distal end of sidewall 36 . Rib 34 plays an important role in securing needle tip protector 26 in catheter hub 30 , as will be described in more detail later.
Referring again to FIGS. 1 and 2, needle assembly 24 comprises needle 38 , which is a tubular structure with a proximal end 39 and distal end 41 , needle hub 40 , and needle tip protector 26 . Needle tip protector 26 is assembled slidably on needle 38 . Needle 38 is preferably made of stainless steel. Proximal end 39 of needle 38 is fixedly attached to needle hub 40 . A bevel 42 is located at the most distal end of needle 38 creating a sharp piercing tip. Needle crimp 44 is located at the distal end of needle 38 proximal to bevel 42 and is larger in diameter than the nominal diameter of needle 38 . Needle crimp 44 is created by “coining” an area on the outside diameter of needle 38 resulting in two opposed bumps located approximately 180 degrees across the center axis of needle 38 . Coining is a process well known in the metal forming art and involves using a hardened tool to strike a softer object to deform or displace a portion of the softer object. In the present case a portion of the exterior surface of the softer metal needle 38 is displaced by a harder metal tool so as to raise bumps on the exterior surface of needle 38 . The resulting crimp 44 is larger in dimension than the nominal diameter of needle 38 . Crimp 44 is larger in dimension than the diameter of second flange hole 72 in needle tip protector 26 and is important in preventing the complete removal of needle tip protector 26 from needle 38 , as will be described in more detail later. In the preferred embodiment the dimension across crimp 44 is 0.0001-0.004 inches larger than second flange hole 72 , dependant upon needle “gauge” size.
Needle hub 40 is generally a tubular structure having an internal cavity in fluid communication with the lumen in needle 38 . It is preferably made of a translucent or transparent generally rigid thermoplastic material such as, for example, polycarbonate. At the most proximal end of the internal cavity in needle hub 40 is fixedly attached porous plug 46 . A flashback chamber 48 is created in the cavity distal to porous plug 46 . Porous plug 46 contains a plurality of microscopic openings which are large enough to permit the passage of air and other gasses but small enough to prevent the passage of blood. Flashback chamber 48 fills with blood upon successful entry of the needle tip into the targeted vein, providing the clinician visual conformation of the correct placement of the needle.
Referring now to all figures, needle tip protector 26 has a proximal end 49 and distal end 50 and is preferably a unitary structure formed from a single piece of thin, resilient material, preferably stainless steel. First flange 66 and second flange 68 are generally square and are integrally connected at right angles to first outer wall 74 and second outer wall 76 , respectively. First outer wall 74 is connected at a right angle to first tab flange 78 . First tab flange 78 and second tab flange 80 are each formed at angles slightly greater than 90 degrees to second outer wall 76 so that the resulting dimension c is slightly larger than inside diameter d (see FIGS. 6-7) across rib 34 in catheter hub 30 . In the preferred embodiment angles a and b are each approximately 94.25 degrees. In the preferred embodiment dimension c is approximately 0.001-0.009 inches larger than dimension d. First flange hole 70 is located in the center of first flange 66 and is over-sized to slidably receive needle 38 . Second flange hole 72 and skirt 82 are located in the center of second flange 68 . Skirt 82 is integral to second flange hole 72 and is formed by extruding material from second flange hole 72 in a direction distal to second flange 68 . This permits for a very close but slidable fit over the nominal diameter of needle 38 . Skirt 82 also functions to help maintain alignment of needle 38 to the center axis of needle tip protector 26 . As would be understood by one skilled in the art, flange hole 72 would be appropriately sized to the particular needle “gauge” size to which it is designed to receive.
First tab 86 and second tab 88 are connected at right angles to first tab flange 78 and second tab flange 80 , respectively, and protrude outward away from the center axis of needle tip protector 26 . First tab edge 90 , located on the outer portion of first tab 86 , and second tab edge 92 , located on the outer portion of second tab 88 , are each arcuate to approximately match the curve of sidewall 36 in catheter hub 30 .
Referring again to FIG. 3, first beam 96 extends distally from first outer wall 74 and is angled toward and extends past the center axis of needle tip protector 26 . At the distal end of first beam 96 is integrally formed curved first lip 98 which extends across and through the center axis of needle tip protector 26 . Second beam 100 extends distally from second outer wall 76 and is angled toward and extends past the center axis of needle tip protector 26 . At the distal end of second beam 100 is stop flange 102 which extends across and normal to the center axis of needle tip protector 26 . At the end of stop flange 102 opposite its connection to second beam 100 is integrally formed curved second lip 104 .
Referring now to all figures, needle tip protector 26 is assembled to needle 38 as follows;
The proximal end of needle 38 is fixedly attached to the distal end of needle hub 40 , which contains porous plug 46 fixedly attached to its proximal end;
The distal end of needle 38 is inserted through first flange hole 70 and then through second flange hole 72 in needle tip protector 26 , moving from proximal to distal;
First beam 96 and second beam 100 are flexed, as a result of their resilient properties, normal to the center axis of needle tip protector 26 so that needle 38 will pass between first lip 98 and second lip 104 (see FIG. 8 );
Needle crimp 44 is added to the distal end of needle 38 just proximal to bevel 42 . Crimp 44 increases the diameter of needle 38 locally to a dimension larger than the inside diameter of second flange hole 72 (see FIG. 9) thus preventing the complete removal of needle tip protector 26 from the distal end of needle 38 .
Now needle assembly 24 , including needle tip protector 26 , is assembled into catheter assembly 22 as follows;
The distal end of needle 38 is positioned into the proximal end of catheter hub 30 and needle assembly 24 is moved distally causing needle 38 to enter catheter 28 ;
As needle assembly 24 continues to move distally, needle tip protector 26 enters the opening in the proximal end of catheter hub 30 ,
Continued distal movement of needle assembly 24 causes the distal edge of needle hub 40 to push first tab 86 and second tab 88 on needle tip protector 26 into contact with rib 34 located on hub sidewall 36 ;
Continued distal movement forces first tab 86 and second tab 88 , due to the resilient properties of needle tip protector 26 , past rib 34 and in contact with sidewall 36 , just distal to rib 34 .
Needle tip protector 26 is thus held distal to rib 34 inside the cavity in catheter hub 30 by the flexural forces of first tab 86 and second tab 88 since dimension c on needle tip protector 26 is larger than dimension d across rib 34 inside catheter hub 30 . (see FIG. 6 ).
As is best illustrated in FIG. 7, the movement of first tab 86 and second tab 88 as needle tip protector 26 is finally seated distal to rib 34 causes flexure in second outer wall 76 and first tab flange 78 resulting in the approximate alignment of first flange hole 70 and second flange hole 72 .
Now, in actual clinical use, the IV catheter assembly 20 of the present invention functions as follows;
The distal end of needle 38 which extends just past the distal end of catheter 28 is inserted into the patient's vein;
The clinician observes blood in the flash chamber in needle hub 40 ;
The clinician grasps needle hub 40 , and catheter assembly 22 alone is moved distally into the vein;
The clinician applies slight pressure to the insertion site to hold catheter assembly 22 secure;
The clinician grasps the needle hub and begins withdrawal of needle assembly 24 from catheter assembly 22 . During this process, needle tip protector 26 remains secure inside catheter hub 30 until raised crimp 44 on the distal end of needle 38 comes into contact with second flange hole 72 . Just before raised crimp 44 encounters second flange hole 72 , the biasing forces of first beam 96 and second beam 100 cause stop flange 102 and first lip 98 to move normal to and across the center axis of needle 38 , blocking any further distal movement of needle 38 relative to needle tip protector 26 ;
Since crimp 44 is larger than second flange hole 72 , continued proximal movement of needle 38 carries needle tip protector 26 proximal as well, forcing first tab 86 and second tab 88 on needle tip protector 26 against rib 34 . First tab 86 and second tab 88 are forced to flex normal to and toward the center axis of needle tip protector 26 , permitting continued movement proximal, past rib 34 ;
Needle assembly 24 is now removed entirely from catheter assembly 22 , with the needle tip covered by needle tip protector 26 of the present invention.
FIG. 10 shows an alternate embodiment of the present invention. In this embodiment, needle tip protector 126 , is preferably a unitary structure formed from a single piece of thin, resilient material such as, for example, stainless steel, similar to needle tip protector 26 . Needle tip protector 126 includes first flange 166 and second flange 168 . First flange 166 and second flange 168 are generally arcuate and are integrally connected to first outer wall 174 and second outer wall 176 , respectively. Extending distally from first outer wall 174 of needle tip protector 126 is first beam 196 . First beam 196 , which has an arcuate outer edge, is angled toward and extends past the center axis of needle tip protector 126 . First beam 196 further includes first rib 314 coined therein to add stiffness.
At the distal end of first beam 196 is integrally formed curved first lip 198 which extends across and through the center axis of needle tip protector 126 . Extending distally from second outer wall 176 of needle tip protector 126 is second beam 200 . Second beam 200 , which has an arcuate outer edge, is angled toward and extends past the center axis of needle tip protector 126 . Second beam 200 further includes second rib 316 (not visible) coined therein to add stiffness. The distal end of second beam 200 is connected to the proximal end of wing base 306 . Wing base 306 extends across and parallel to the center axis of needle tip protector 126 . Wing base 306 further comprises first wing side 308 and second wing side 310 . Integrally attached to first wing side 308 of wing base 306 at approximately a 90° angle is wing 312 . Wing 312 , which extends parallel to the center axis of needle tip protector 126 , prevents any further radial movement of needle 138 by retaining it within needle tip protector 126 . Connected to the distal end of wing base 306 is the proximal end of stop flange 302 . Stop flange 302 extends across needle 138 and is angled toward the center axis of needle tip protector 126 . At the distal end of stop flange 302 opposite its connection to wing base 306 is integrally formed curved second lip 304 . Second lip 304 is curved toward proximal end 149 of needle tip protector 126 to prevent any further distal movement of needle 138 .
While preferred embodiments of the present invention have been shown and described herein, it will be obvious to those skilled in the art that such embodiments are provided by way of example only. Numerous variations, changes, and substitutions will now occur to those skilled in the art without departing from the invention. Accordingly, it is intended that the invention be limited only by the spirit and scope of the appended claims. In addition, it should be understood that every structure described above has a function and such structure can be referred to as a means for performing that function.
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A catheter and introducer needle assembly having a needle attached to a needle hub, and a enlarged area disposed thereon, and a tubular catheter wherein the introducer needle being coaxially received within the catheter. The device has a hollow catheter hub attached to the catheter and in fluid communication therewith. The catheter hub has an interior having a raised annular rib disposed thereon. The assembly includes a needle tip protector disposed within the catheter hub and including at least one unrestrained radially extending lip disposed distal to the annular rib so as to retain the protector within the hub. The distal end of the protector does not abut against the hub interior. The protector has a proximal opening at the proximal end having an unrestrained size greater than the size of the needle diameter and smaller than the enlarged area such that when the needle is removed from the catheter the protector remains attached to the needle.
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CROSS-REFERENCE TO RELATED APPLICATION
This application claims priority from U.S. Provisional Patent Application No. 61/771,340 filed on Mar. 1, 2013 entitled METHODS FOR CONTROLLING 3-WAY HEAT EXCHANGERS IN DESICCANT CHILLERS, which is hereby incorporated by reference.
BACKGROUND
The present application relates generally to the use of liquid desiccants to dehumidify and cool, or heat and humidify an air stream entering a space. More specifically, the application relates to the control systems required to operate 2 or 3 way liquid desiccant mass and heat exchangers employing micro-porous membranes to separate the liquid desiccant from an air stream. Such heat exchangers can use gravity induced pressures (siphoning) to keep the micro-porous membranes properly attached to the heat exchanger structure. The control systems for such 2 and 3-way heat exchangers are unique in that they have to ensure that the proper amount liquid desiccant is applied to the membrane structures without over pressurizing the fluid and without over- or under-concentrating the desiccant. Furthermore the control system needs to respond to demands for fresh air ventilation from the building and needs to adjust to outdoor air conditions, while maintaining a proper desiccant concentration and preventing desiccant crystallization or undue dilution. In addition the control system needs to be able to adjust the temperature and humidity of the air supplied to a space by reacting to signals from the space such as thermostats or humidistats. The control system also needs to monitor outside air conditions and properly protect the equipment in freezing conditions by lowering the desiccant concentration in such a way as to avoid crystallization.
Liquid desiccants have been used parallel to conventional vapor compression HVAC equipment to help reduce humidity in spaces, particularly in spaces that require large amounts of outdoor air or that have large humidity loads inside the building space itself. Humid climates, such as for example Miami, Fla. require a lot of energy to properly treat (dehumidify and cool) the fresh air that is required for a space's occupant comfort. Conventional vapor compression systems have only a limited ability to dehumidify and tend to overcool the air, oftentimes requiring energy intensive reheat systems, which significantly increase the overall energy costs, because reheat adds an additional heat-load to the cooling system. Liquid desiccant systems have been used for many years and are generally quite efficient at removing moisture from the air stream. However, liquid desiccant systems generally use concentrated salt solutions such as ionic solutions of LiCl, LiBr or CaCl 2 and water. Such brines are strongly corrosive, even in small quantities, so numerous attempts have been made over the years to prevent desiccant carry-over to the air stream that is to be treated. In recent years efforts have begun to eliminate the risk of desiccant carry-over by employing micro-porous membranes to contain the desiccant. An example of such as membrane is the EZ2090 poly-propylene, microporous membrane manufactured by Celgard, LLC, 13800 South Lakes Drive Charlotte, N.C. 28273. The membrane is approximately 65% open area and has a typical thickness of about 20 μm. This type of membrane is structurally very uniform in pore size (100 nm) and is thin enough to not create a significant thermal barrier. However such super-hydrophobic membranes are typically hard to adhere to and are easily subject to damage. Several failure modes can occur: if the desiccant is pressurized the bonds between the membrane and its support structure can fail, or the membrane's pores can distort in such a way that they no longer are able to withstand the liquid pressure and break-through of the desiccant can occur. Furthermore if the desiccant crystallizes behind the membrane, the crystals can break through the membrane itself creating permanent damage to the membrane and causing desiccant leaks. And in addition the service life of these membranes is uncertain, leading to a need to detect membrane failure or degradation well before any leaks may even be apparent.
Liquid desiccant systems generally have two separate functions. The conditioning side of the system provides conditioning of air to the required conditions, which are typically set using thermostats or humidistats. The regeneration side of the system provides a reconditioning function of the liquid desiccant so that it can be re-used on the conditioning side. Liquid desiccant is typically pumped between the two sides which implies that the control system also needs to ensure that the liquid desiccant is properly balanced between the two sides as conditions necessitate and that excess heat and moisture are properly dealt with without leading to over-concentrating or under-concentrating the desiccant.
There thus remains a need for a control system that provides a cost efficient, manufacturable, and efficient method to control a liquid desiccant system in such a way as to maintain proper desiccant concentrations, fluid levels, react to space temperature and humidity requirements, react to space occupancy requirements and react to outdoor air conditions, while protecting the system against crystallization and other potentially damaging events. The control system furthermore needs to ensure that subsystems are balanced properly and that fluid levels are maintained at the right set-points. The control system also needs to warn against deterioration or outright failures of the liquid desiccant membrane system.
BRIEF SUMMARY
Provided herein are methods and systems used for the efficient dehumidification of an air stream using a liquid desiccant. In accordance with one or more embodiments, the liquid desiccant is running down the face of a support plate as a falling film. In accordance with one or more embodiments, the desiccant is contained by a microporous membrane and the air stream is directed in a primarily vertical orientation over the surface of the membrane and whereby both latent and sensible heat are absorbed from the air stream into the liquid desiccant. In accordance with one or more embodiments, the support plate is filled with a heat transfer fluid that preferably flows in a direction counter to the air stream. In accordance with one or more embodiments, the system comprises a conditioner that removes latent and sensible heat through the liquid desiccant and a regenerator that removes the latent and sensible heat from the system. In accordance with one or more embodiments, the heat transfer fluid in the conditioner is cooled by a refrigerant compressor or an external source of cold heat transfer fluid. In accordance with one or more embodiments, the regenerator is heated by a refrigerant compressor or an external source of hot heat transfer fluid. In accordance with one or more embodiments, the cold heat transfer fluid can bypass the conditioner and the hot heat transfer fluid can bypass the regenerator thereby allowing independent control of supply air temperature and relative humidity. In accordance with one or more embodiments, the conditioner's cold heat transfer fluid is additionally directed through a cooling coil and the regenerator's hot heat transfer fluid is additionally directed through a heating coil. In accordance with one or more embodiments, the hot heat transfer fluid has an independent method or rejecting heat, such as through an additional coil or other appropriate heat transfer mechanism. In accordance with one or more embodiments, the system has multiple refrigerant loops or multiple heat transfer fluid loops to achieve similar effects for controlling air temperature on the conditioner and liquid desiccant concentration by controlling the regenerator temperature. In one or more embodiments, the heat transfer loops are serviced by separate pumps. In one or more embodiments, the heat transfer loops are services by a single shared pump. In one or more embodiments, the refrigerant loops are independent. In one or more embodiments, the refrigerant loops are coupled so that one refrigerant loop only handles half the temperature difference between the conditioner and the regenerator and the other refrigerant loop handles the remaining temperature difference, allowing each loop to function more efficiently.
In accordance with one or more embodiments, a liquid desiccant system employs a heat transfer fluid on a conditioner side of the system and a similar heat transfer fluid loop on a regenerator side of the system wherein the heat transfer fluid can optionally be directed from the conditioner to the regenerator side of the system through a switching valve, thereby allowing heat to be transferred through the heat transfer fluid from the regenerator to the conditioner. The mode of operation is useful in case where the return air from the space that is directed through the regenerator is higher in temperature than the outside air temperature and the heat from the return air can be thus be used to heat the incoming supply air stream.
In accordance with one or more embodiments, the refrigerant compressor system is reversible so that heat from the compressor is directed to the liquid desiccant conditioner and heat is removed by the refrigerant compressor from the regenerator thereby reversing the conditioner and regeneration functions. In accordance with one or more embodiments, the heat transfer fluid is reversed but no refrigerant compressor is utilized and external sources of cold and hot heat transfer fluids are utilized thereby allowing heat to be transferred from one side of the system to the opposite side of the system. In accordance with one or more embodiments, the external sources of cold and hot heat transfer fluid are idled while heat is transferred from one side to the other side of the system.
In accordance with one or more embodiments, a liquid desiccant membrane system employs an indirect evaporator to generate a cold heat transfer fluid wherein the cold heat transfer fluid is used to cool a liquid desiccant conditioner. Furthermore in one or more embodiments, the indirect evaporator receives a portion of the air stream that was earlier treated by the conditioner. In accordance with one or more embodiments, the air stream between the conditioner and indirect evaporator is adjustable through some convenient means, for example through a set of adjustable louvers or through a fan with adjustable fan speed. In accordance with one or more embodiments, the heat transfer fluid between the conditioner and indirect evaporator is adjustable so that the air that is treated by the conditioner is also adjustable by regulating the heat transfer fluid quantity passing through the conditioner. In accordance with one or more embodiments, the indirect evaporator can be idled and the heat transfer fluid can be directed between the conditioner and a regenerator is such a fashion that heat from return air from a space is recovered in the regenerator and is directed to provide heating to air directed through the conditioner.
In accordance with one or more embodiments, the indirect evaporator is used to provide heated, humidified air to a supply air stream to a space while a conditioner is simultaneously used to provide heated, humidified air to the same space. This allows the system to provide heated, humidified air to a space in winter conditions. The conditioner is heated and is desorbing water vapor from a desiccant and the indirect evaporator can be heated as well and is desorbing water vapor from liquid water. In one or more embodiments, the water is seawater. In one or more embodiments, the water is waste water. In one or more embodiments, the indirect evaporator uses a membrane to prevent carry-over of non-desirable elements from the seawater or waste water. In one or more embodiments, the water in the indirect evaporator is not cycled back to the top of the indirect evaporator such as would happen in a cooling tower, but between 20% and 80% of the water is evaporated and the remainder is discarded.
In accordance with one or more embodiments, a liquid desiccant conditioner receives cold or warm water from an indirect evaporator. In one or more embodiments, the indirect evaporator has a reversible air stream. In one or more embodiments, the reversible air stream creates a humid exhaust air stream in summer conditions and creates a humid supply air stream to a space in winter conditions. In one or more embodiments, the humid summer air stream is discharged from the system and the cold water that is generated is used to chill the conditioner in summer conditions. In one or more embodiments, the humid winter air stream is used to humidify the supply air to a space in combination with a conditioner. In one or more embodiments, the air streams are variable by a variable speed fan. In one or more embodiments, the air streams are variable through a louver mechanism or some other suitable method. In one or more embodiments, the heat transfer fluid between the indirect evaporator and the conditioner can be directed through the regenerator as well, thereby absorbing heat from the return air from a space and delivering such heat to the supply air stream for that space. In one or more embodiments, the heat transfer fluid receives supplemental heat or cold from external sources. In one or more embodiments, such external sources are geothermal loops, solar water loops or heat loops from existing facilities such as Combined Heat and Power systems.
In accordance with one or more embodiments, a conditioner receives an air stream that is pulled through the conditioner by a fan while a regenerator receives an air stream that is pulled through the regenerator by a second fan. In one or more embodiments, the air stream entering the conditioner comprises a mixture of outside air and return air. In one or more embodiments, the amount of return air is zero and the conditioner receives solely outside air. In one or more embodiments, the regenerator receives a mixture of outside air and return air from a space. In one or more embodiments, the amount of return air is zero and the regenerator receives only outside air. In one or more embodiments, louvers are used to allow some air from the regenerator side of the system to be passed to the conditioner side of the system. In one or more embodiments, the pressure in the conditioner is below the ambient pressure. In further embodiments the pressure in the regenerator is below the ambient pressure.
In accordance with one or more embodiments, a conditioner receives an air stream that is pushed through the conditioner by a fan resulting in a pressure in the conditioner that is above the ambient pressure. In one or more embodiments, such positive pressure aids in ensuring that a membrane is held flat against a plate structure. In one or more embodiments, a regenerator receives an air stream that is pushed through the regenerator by a fan resulting in a pressure in the regenerator that is above ambient pressure. In one or more embodiments, such positive pressure aids in ensuring that a membrane is held flat against a plate structure.
In accordance with one or more embodiments, a conditioner receives an air stream that is pushed through the conditioner by a fan resulting in a positive pressure in the conditioner that is above the ambient pressure. In one or more embodiments, a regenerator receives an air stream that is pulled through the regenerator by a fan resulting in a negative pressure in the regenerator compared to the ambient pressure. In one or more embodiments, the air stream entering the regenerator comprises a mixture of return air from a space and outside air that is being delivered to the regenerator from the conditioner air stream.
In accordance with one or more embodiments, an air stream's lowest pressure point is connected through some suitable means such as through a hose or pipe to an air pocket above a desiccant reservoir in such a way as to ensure that the desiccant is flowing back from a conditioner or regenerator membrane module through a siphoning action and wherein the siphoning is enhanced by ensuring that the lowest pressure in the system exists above the desiccant in the reservoir. In one or more embodiments, such siphoning action ensures that a membrane is held in a flat position against a support plate structure.
In accordance with one or more embodiments, an optical or other suitable sensor is used to monitor air bubbles that are leaving a liquid desiccant membrane structure. In one or more embodiments, the size and frequency of air bubbles is used as an indication of membrane porosity. In one or more embodiments, the size and frequency of air bubbles is used to predict membrane aging or failure.
In accordance with one or more embodiments, a desiccant is monitored in a reservoir by observing the level of the desiccant in the reservoir. In one or more embodiments, the level is monitored after initial startup adjustments have been discarded. In one or more embodiments, the level of desiccant is used as an indication of desiccant concentration. In one or more embodiments, the desiccant concentration is also monitored through the humidity level in the air stream exiting a membrane conditioner or membrane regenerator. In one or more embodiments, a single reservoir is used and liquid desiccant is siphoning back from a conditioner and a regenerator through a heat exchanger. In one or more embodiments, the heat exchanger is located in the desiccant loop servicing the regenerator. In one or more embodiments, the regenerator temperature is adjusted based on the level of desiccant in the reservoir.
In accordance with one or more embodiments, a conditioner receives a desiccant stream and employs siphoning to return the used desiccant to a reservoir. In one or more embodiments, a pump or similar device takes desiccant from the reservoir and pumps the desiccant through a valve and heat exchanger to a regenerator. In one or more embodiments, the valve can be switched so that the desiccant flows to the conditioner instead of flowing through the heat exchanger. In one or more embodiments, a regenerator receives a desiccant stream and employs siphoning to return the used desiccant to a reservoir. In one or more embodiments, a pump or similar device takes desiccant from a reservoir and pumps the desiccant through a heat exchanger and valve assembly to a conditioner. In one or more embodiments, the valve assembly can be switched to pump the desiccant to the regenerator instead of to the conditioner. In one or more embodiments, the heat exchanger can be bypassed. In one or more embodiments, the desiccant is used to recover latent and/or sensible heat from a return air stream and apply the latent heat to a supply air stream by bypassing the heat exchanger. In one or more embodiments, the regenerator is switched on solely when regenerator of desiccant is required. In one or more embodiments, the switching of the desiccant stream is used to control the desiccant concentration.
In accordance with one or more embodiments, a membrane liquid desiccant plate module uses an air pressure tube to ensure that the lowest pressure in the air stream is applied to the air pocket above the liquid desiccant in a reservoir. In one or more embodiments, the liquid desiccant fluid loop uses an expansion volume near the top of the membrane plate module to ensure constant liquid desiccant flow to the membrane plate module.
In accordance with one or more embodiments, a liquid desiccant membrane module is positioned above a sloped drain pan structure, wherein any liquid leaking from the membrane plate module is caught and directed towards a liquid sensor that sends a signal to a control system warning that a leak or failure in the system has occurred. In one or more embodiments, such a sensor detects the conductance of the fluid. In one or more embodiments, the conductance is an indication of which fluid is leaking from the membrane module.
In no way is the description of the applications intended to limit the disclosure to these applications. Many construction variations can be envisioned to combine the various elements mentioned above each with its own advantages and disadvantages. The present disclosure in no way is limited to a particular set or combination of such elements.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates a 3-way liquid desiccant air conditioning system using a chiller or external heating or cooling sources.
FIG. 2A shows a flexibly configurable membrane module that incorporates 3-way liquid desiccant plates.
FIG. 2B illustrates a concept of a single membrane plate in the liquid desiccant membrane module of FIG. 2A .
FIG. 3A depicts the cooling fluid control system and chiller refrigerant circuit of a 3-way liquid desiccant system in cooling mode in accordance with one or more embodiments.
FIG. 3B shows the system of FIG. 3A with the cooling fluid flow connecting the return air and supply air of the building and the chiller in idle mode providing an energy recovery capability between the return air and the supply air in accordance with one or more embodiments.
FIG. 3C illustrates the system of FIG. 3A with the chiller in reverse mode supplying heat to the supply air and retrieving heat from the return air in accordance with one or more embodiments.
FIG. 4A shows the cooling fluid control circuit of a liquid desiccant membrane system that utilizes external cooling and heating sources in accordance with one or more embodiments.
FIG. 4B shows the system of FIG. 4A wherein the cooling fluid provides a sensible heat recovery connection between the return air and the supply air in accordance with one or more embodiments.
FIG. 5A shows a liquid desiccant air conditioning system utilizing an indirect evaporative cooling module in summer cooling mode in accordance with one or more embodiments.
FIG. 5B illustrates the system of FIG. 5B wherein the system is set up as a sensible heat recovery system in accordance with one or more embodiments.
FIG. 5C shows the system of FIG. 5A wherein the system's operation is reversed for winter heating operation in accordance with one or more embodiments.
FIG. 6A illustrates the water and refrigerant control diagram of a dual compressor system employing several control loops for water flows and heat rejection in accordance with one or more embodiments.
FIG. 6B shows a system employing two stacked refrigerant loops for more efficiently moving heat from the conditioner to the regenerator in accordance with one or more embodiments.
FIG. 7A shows an air flow diagram with a partial re-use of return air using a negative pressure housing compared to environmental pressure in accordance with one or more embodiments.
FIG. 7B shows an air flow diagram with a partial re-use of return air using a positive pressure housing compared to environmental pressure in accordance with one or more embodiments.
FIG. 7C shows an air flow diagram with a partial re-use of return air and a positive pressure supply air stream and a negative pressure return air stream wherein a portion of the outdoor air is used to increase flow through the regeneration module in accordance with one or more embodiments.
FIG. 8A illustrates a single tank control diagram for a desiccant flow in accordance with one or more embodiments.
FIG. 8B shows a simple decision schematic for controlling the liquid desiccant level in the system in accordance with one or more embodiments.
FIG. 9A shows a dual tank control diagram for a desiccant flow, wherein a portion of the desiccant is sent from a conditioner to a regenerator in accordance with one or more embodiments.
FIG. 9B shows the system of FIG. 9A wherein the desiccant is used in an isolation mode for conditioner and regenerator in accordance with one or more embodiments.
FIG. 10A illustrates the flow diagram of a negative air pressure liquid desiccant system with a desiccant spill sensor in accordance with one or more embodiments.
FIG. 10B shows the system of FIG. 10A with a positive air pressure liquid desiccant system in accordance with one or more embodiments.
DETAILED DESCRIPTION
FIG. 1 depicts a new type of liquid desiccant system as described in more detail in U.S. Patent Application Publication No. 2012/0125020 entitled METHODS AND SYSTEMS FOR DESICCANT AIR CONDITIONING USING PHOTOVOLTAIC-THERMAL (PVT) MODULES. A conditioner 10 comprises a set of plate structures 11 that are internally hollow. A cold heat transfer fluid is generated in cold source 12 and entered into the plates. Liquid desiccant solution at 14 is brought onto the outer surface of the plates 11 and runs down the outer surface of each of the plates 11 . The liquid desiccant runs behind a thin membrane that is located between the air flow and the surface of the plates 11 . Outside air 16 is now blown through the set of wavy plates 11 . The liquid desiccant on the surface of the plates attracts the water vapor in the air flow and the cooling water inside the plates 11 helps to inhibit the air temperature from rising. The treated air 18 is put into a building space.
The liquid desiccant is collected at the bottom of the wavy plates 11 in a separate collector 19 for each plate 11 and is transported at 20 through a heat exchanger 22 to the top of the regenerator 24 to point 26 where the liquid desiccant is distributed across the wavy plates 27 of the regenerator. Return air or optionally outside air 28 is blown across the regenerator plates 27 and water vapor is transported from the liquid desiccant into the leaving air stream 30 . An optional heat source 32 provides the driving force for the regeneration. The hot transfer fluid 34 from the heat source can be put inside the wavy plates 27 of the regenerator similar to the cold heat transfer fluid on the conditioner. Again, the liquid desiccant is collected at the bottom of the wavy plates 27 at a separate collector 29 for each plate 27 without the need for either a collection pan or bath so that also on the regenerator the air can be vertical. An optional heat pump 36 can be used to provide cooling and heating of the liquid desiccant. It is also possible to connect a heat pump between the cold source 12 and the hot source 32 , which is thus pumping heat from the cooling fluids rather than the desiccant.
FIG. 2A describes a 3-way heat exchanger as described in more detail in U.S. patent application Ser. No. 13/915,199 filed on Jun. 11, 2013 entitled METHODS AND SYSTEMS FOR TURBULENT, CORROSION RESISTANT HEAT EXCHANGERS. A liquid desiccant enters the structure through ports 50 and is directed behind a series of membranes on plate structures 51 as described in FIG. 1 . The liquid desiccant is collected and removed through ports 52 . A cooling or heating fluid is provided through ports 54 and runs counter to the air stream 56 inside the hollow plate structures, again as described in FIG. 1 and in more detail in FIG. 2B . The cooling or heating fluids exit through ports 58 . The treated air 60 is directed to a space in a building or is exhausted as the case may be.
FIG. 2B shows a schematic detail of one of the plates of FIG. 1 . The air stream 251 flows counter to a cooling fluid stream 254 . Membranes 252 contain a liquid desiccant 253 that is falling along the wall 255 that contain a heat transfer fluid 254 . Water vapor 256 entrained in the air stream is able to transition the membrane 252 and is absorbed into the liquid desiccant 253 . The heat of condensation of water 258 that is released during the absorption is conducted through the wall 255 into the heat transfer fluid 254 . Sensible heat 257 from the air stream is also conducted through the membrane 252 , liquid desiccant 253 and wall 255 into the heat transfer fluid 254 .
FIG. 3A illustrates a simplified control schematic for the fluid paths of FIG. 1 in a summer cooling mode arrangement, wherein a heat pump 317 is connected between the cold cooling fluid entering a liquid desiccant membrane conditioner 301 and the hot heating fluid entering a liquid desiccant membrane regenerator 312 . The conditioner and regenerator are membrane modules similar to the membrane module depicted in FIG. 2A and have plates similar to the concept in FIG. 2B . The 3-way conditioner 301 receives an air stream 319 that is to be treated in the 3-way conditioner module. The 3-way conditioner also receives a concentrated desiccant stream 320 and a diluted desiccant stream 321 leaves the conditioner module. For simplicity, the liquid desiccant flow diagrams have been omitted from the figure and will be shown separately in later figures. A heat transfer fluid 302 which is commonly water, water/glycol or some other suitable heat transfer fluid, enters the 3-way module and removes the latent and sensible heat that has been removed from the air stream. Controlling the flow rate and pressure of the heat transfer fluid is critical to the performance of the 3-way module as is described in U.S. patent application Ser. No. 13/915,199. A circulating pump 307 is chosen to provide high fluid flow with low head pressure. The module's plates (shown in FIGS. 1 and 2A ) have large surface areas and operate best under slightly negative pressure as compared to the ambient air pressure. The flow is set up in such a way that the heat transfer fluid 302 undergoes a siphoning effect to drain the fluid from the conditioner module 301 . Using a siphoning effect makes a marked improvement on the flatness of the module plates since the liquid pressure is not pushing the plates apart. This siphoning effect is achieved by letting the heat transfer fluid 302 fall into a fluid collection tank 305 . Temperature sensors 303 located in the heat transfer fluid before and after the 3-way module and the flow sensor 309 , allow one to measure in the thermal load captured in the heat transfer fluid. Pressure relief valve 311 is normally open and ensures that the heat transfer fluid is not pressurized which could damage the plate system. Service valves 306 and 308 are normally only used during service events. A liquid to refrigerant heat exchanger 310 a allows the thermal load to be transferred from the heat transfer fluid to a refrigeration loop 316 . A bypass valve 304 a allows a portion of the low temperature heat transfer fluid to bypass the 3-way conditioner. This has the effect as to lower the flow rate through the 3-way conditioner and as a result the conditioner will operate at higher temperatures. This in turn allows one to control the temperature of the supply air to the space. One could also use a variable flow of the liquid pump 307 , which will change the flow rate through the heat exchanger 310 a . An optional post-cooling coil element 327 ensures that the treated air temperature supplied to the space is very close to the heat transfer fluid temperature.
A refrigerant compressor/heat pump 317 compresses a refrigerant moving in a circuit 316 . The heat of compression is rejected into a refrigerant heat exchanger 310 b , collected into an optional refrigerant receiver 318 and expanded in an expansion valve 315 after which it is directed to the refrigerant heat exchanger 310 a , where the refrigerant picks up heat from the 3-way conditioner and is returned to the compressor 317 . As can be seen in the figure, the liquid circuit 313 around the regenerator 312 is very similar to that around the conditioner 301 . Again, the siphoning method is employed to circulate the heat transfer fluid through the regenerator module 312 . However, there are two considerations that are different in the regenerator. First, it is oftentimes not possible to receive the same amount of return air 322 from a space as is supplied to that space 319 . In other words, air flows 319 and 322 are not balanced and can sometimes vary by more than 50%. This is so that the space remains positively pressurized compared to the surrounding environment to prevent moisture infiltration into the building. Second, the compressor itself adds an additional heat load that needs to be removed. This means that one has to either add additional air to the return air from the building, or one has to have another way of rejecting the heat from the system. Fan-coil 326 utilizes an independent radiator coil and can be used to achieve the additional cooling that is required. It should be understood that other heat rejection mechanism besides a fan coil could be employed such as a cooling tower, ground source heat dump etc. Optional diverter valve 325 can be employed to bypass the fan coil if desired. An optional pre-heating coil 328 is used to preheat the air entering the regenerator. It should be clear that the return air 322 could be mixed with outdoor air or could even be solely outdoor air.
The desiccant loop (details of which will be shown in later figures) provides diluted desiccant to the regenerator module 312 through port 323 . Concentrated desiccant is removed at port 324 and directed back to the conditioner module to be reused. Control of the air temperature and thus the regeneration effect is again achieved through an optional diverter valve 304 b similar to valve 304 a in the conditioner circuit. The control system is thus able to control both the conditioner and regenerator air temperatures independently and without pressurizing the membrane plate module plates.
Also in FIG. 3A is shown a diverter valve 314 . This valve is normally separating the conditioner and regenerator circuits. But in certain conditions the outside air needs little if any cooling. In FIG. 3B the diverter valve 314 has been opened to allow the conditioner and regenerator circuits to be connected creating an energy recovery mode. This allows the sensible heat from the return air 322 to be coupled to the incoming air 319 essentially providing a sensible energy recovery mechanism. In this operating mode the compressor 317 would normally be idled.
FIG. 3C shows how the system operates in winter heating mode. The compressor 317 is now operating in a reversed direction (for ease of the figure the refrigerant is shown flowing in the opposite direction—in actuality a 4-way reversible refrigerant circuit would most likely be employed). Diverter valve 314 is again closed so that the conditioner and regenerator are thermally isolated. The heat is essentially pumped from the return air 322 (which can be mixed with outdoor air) into the supply air 319 . The advantage that such an arrangement has is that the heat transfer (properly protected for freezing) and the liquid desiccant membrane modules are able to operate a much lower temperatures than conventional coils since none of the materials are sensitive to freezing conditions, including the liquid desiccant as long as its concentration is maintained between 15 and 35% in the case of Lithium Chloride.
FIG. 4A illustrates a summer cooling arrangement in a flow diagram similar to that of FIG. 3A however without the use of a refrigeration compressor. Instead, an external cold fluid source 402 is provided using a heat exchanger 401 . The external cold fluid source can be any convenient source of cold fluid, such as a geothermal source, a cooling tower, an indirect evaporative cooler or centralized chilled water or chilled brine loop. Similarly FIG. 4A illustrates a hot fluid source 404 that uses heat exchanger 403 to heat the regenerator hot water loop. Again such a hot fluid source can be any convenient hot fluid source such as from a steam loop, solar hot water, a gas furnace or a waste heat source. With the same control valves 304 a and 304 b the system is able to control the amount of heat removed from the supply air and added to the return air. In some instances it is possible to eliminate the heat exchangers 401 and 403 and to run the cold or hot fluid directly through the conditioner 301 and/or regenerator 312 . This is possible if the external cold or hot fluids are compatible with the conditioner and/or regenerator modules. This can simplify the system while making the system also slightly more energy efficient.
Similar to the situation described in FIG. 3B , it is again possible to recover heat from the return air 322 by using the diverter valve 314 , as is shown in FIG. 4B . As in FIG. 3B , the hot and cold fluid sources are most likely not operating in this condition so that heat is simply transferred from the return air 322 to the supply air 319 .
FIG. 5A shows an alternate summer cooling mode arrangement wherein a portion (typically 20-40%) of the treated air 319 is diverted through a set of louvers 502 into a side air stream 501 that enters a 3-way evaporator module 505 . The evaporator module 505 receives a water stream 504 that is to be evaporated and has a leaving residual water stream 503 . The water stream 504 can be potable water, sea water or grey water. The evaporator module 505 can be constructed very similar to the conditioner and regenerator modules and can also employ membranes. Particularly when the evaporator module 505 is evaporating seawater or grey water, a membrane will ensure that none of the salts and other materials entrained in the water become air borne. The advantage of using seawater or grey water is that this water is relatively inexpensive in many cases, rather than potable water. Off course seawater and grey water contain many minerals and ionic salts. Therefore the evaporator is set up to evaporate only a portion of the water supply, typically between 50 and 80%. The evaporator is set up as a “once-through” system meaning that the residual water stream 503 is discarded. This is unlike a cooling tower where the cooling water makes many passes through the system. However in cooling towers such passes eventually lead to mineral build up and residue that needs to the be “blown down”, i.e., removed. The evaporator in this system does not require a blow down operation since the residues are carried away by the residual water stream 503 .
Similar to the conditioner and regenerator modules 301 and 312 , the evaporator module 505 receives a stream of heat transfer fluid 508 . The transfer fluid enters the evaporator module and the evaporation in the module results in a strong cooling effect on the heat transfer fluid. The temperature drop in the cooling fluid can be measured by temperature sensor 507 in the heat transfer fluid 509 that is leaving the evaporator 505 . The cooled heat transfer fluid 509 enters the conditioner module, where it absorbs the heat of the incoming air stream 319 . As can be seen in the figure, both the conditioner 319 and the evaporator 505 have a counter flow arrangement of their primary fluids (heat transfer fluid and air) thus resulting in a more efficient transfer of heat. Louvers 502 are used to vary the amount of air that is diverted to the evaporator. The exhaust air stream 506 of the evaporator module 505 carries off the excess evaporated water.
FIG. 5B illustrates the system from FIG. 5A in an energy recovery mode, with the diverter valve 314 set up to connect the fluid paths between the conditioner 302 and regenerator 313 . As before this setup allows for recovery of heat from the return air 322 to be applied to the incoming air 319 . In this situation it is also better to bypass the evaporator 505 , although one could simply not supply water 504 to the evaporator module and also close louvers 502 so not air is diverted to the evaporator module.
FIG. 5C now illustrates the system from FIG. 5A in a winter heating mode wherein the air flow 506 through the evaporator has been reversed so that it mixes with the air stream 319 from the conditioner. Also in this figure, the heat exchanger 401 and heat transfer fluid 402 are used to supply heat energy to the evaporator and conditioner modules. This heat can come from any convenient source such as a gas fired water heater, a waste heat source or a solar heat source. The advantage of this arrangement is that the system is now able to both heat (through the evaporator and the conditioner) and humidify (through the evaporator) the supply air. In this arrangement it is typically not advisable to supply liquid desiccant 320 to the conditioner module unless the liquid desiccant is able to pick up moisture from somewhere else, e.g., from the return air 322 or unless water is added to the liquid desiccant on a periodic basis. But even then, one has to carefully monitor the liquid desiccant to ensure that the liquid desiccant does not become overly concentrated.
FIG. 6A illustrates a system similar to that of FIG. 3A , wherein there are now two independent refrigerant circuits. An additional compressor heat pump 606 supplies refrigerant to a heat exchanger 605 , after which it is received in a refrigerant receiver 607 , expanded through a valve 610 and entered into another heat exchanger 604 . The system also employs a secondary heat transfer fluid loop 601 by using fluid pump 602 , flow measurement device 603 and the aforementioned heat exchanger 604 . On the regenerator circuit a second heat transfer loop 609 is created and a further flow measurement instrument 608 is employed. It is worth noting that in the heat transfer loops on the conditioner side 2 circulating pumps 307 and 602 are used, whereas on the regenerator a single circulating pump 307 is used. This is for illustrative purposes only to show that many combinations of heat transfer flows and refrigerant flows could be employed.
FIG. 6B shows a system similar to that of FIG. 3A where the single refrigerant loop is now replaced by two stacked refrigerant loops. In the figure heat exchanger 310 a exchanges heat with the first refrigerant loop 651 a . The first compressor 652 a compresses the refrigerant that has been evaporated in the heat exchanger 310 a and moves it to a condenser/heat exchanger 655 , where the heat generated by the compressor is removed and the cooled refrigerant is received in the optional liquid receiver 654 a . An expansion valve 653 a expands the liquid refrigerant so it can absorb heat in the heat exchanger 310 a . The second refrigerant loop 651 b absorbs heat from the first refrigerant loop in the condenser/heat exchanger 655 . The gaseous refrigerant is compressed by the second compressor 652 b and heat is released in the heat exchanger 310 b . The liquid refrigerant is then received in optional liquid receiver 654 b and expanded by expansion valve 653 b where it is returned to the heat exchanger 655 .
FIG. 7A illustrates a representative example of how air streams in a membrane liquid desiccant air conditioning system can be implemented. The membrane conditioner 301 and the membrane regenerator 312 are the same as those from FIG. 3A . Outside air 702 enters the system through an adjustable set of louvers 701 . The air is optionally mixed internally to the system with a secondary air stream 706 . The combined air stream enters the membrane module 301 . The air stream is pulled through the membrane module 301 by fan 703 and is supplied to the space as a supply air stream 704 . The secondary air stream 706 can be regulated by a second set of louvers 705 . The secondary air stream 706 can be a combination of two air streams 707 and 708 , wherein air stream 707 is a stream of air that is returned from the space to the air conditioning system and the air stream 708 is outside air that can be controlled by a third set of louvers 709 . The air mixture consisting of streams 707 and 708 is also pulled through the regenerator 312 by the fan 710 and is exhausted through a fourth set of louvers 711 into an exhaust air stream 712 . The advantage of the arrangement of FIG. 7A is that the entire system experiences a negative air pressure compared to the ambient air outside the system's housing—indicated by the boundary 713 . The negative pressure is provided by the fans 703 and 710 . Negative air pressure in the housing helps keep tight seals on door and access panels since the outside air helps maintain a force on those seals. However, the negative air pressure also has a disadvantage in that it can inhibit the siphoning of the desiccant in the membrane panel ( FIG. 2A ) and can even lead to the thin membranes being pulled into the air gaps ( FIG. 2B ).
FIG. 7B illustrates an alternate embodiment of an arrangement where fans have been placed in such a way as to create a positive internal pressure. A fan 714 is used to provide positive pressure above the conditioner module 301 . Again the air stream 702 is mixed with the air stream 706 and the combined air stream enters the conditioner 301 . The conditioned air stream 704 is now supplied to the space. A return air fan 715 is used to bring return air 707 back from the space and a second fan 716 is needed to provide additional outside air. There is a need for this fan because in many situations the amount of available return air is much less than the amount of air supplied to the space so additional air has to be provided to the regenerator. The arrangement of FIG. 7B therefore necessitates the use of 3 fans and 4 louvers.
FIG. 7C shows a hybrid embodiment wherein the conditioner is using a positive pressure similar to FIG. 7A but wherein the regenerator is under negative pressure similar to FIG. 7B . The main difference is that the air stream 717 is now reversed in direction compared to the mixed air stream 706 in FIGS. 7A and 7B . This allows a single fan 713 to supply outside air to both the conditioner 301 and the regenerator 312 . The return air stream 707 is now mixed with the outside air stream 717 so that ample air is supplied to the regenerator. The fan 710 is pulling air through the regenerator 312 resulting in a slightly negative pressure in the regenerator. The advantage of this embodiment is that the system only requires 2 fans and 2 sets of louvers. A slight disadvantage is that the regenerator experiences negative pressures and is thus less able to siphon and has a higher risk of the membrane being pulled into the air gap.
FIG. 8A shows the schematic of the liquid desiccant flow circuit. Air enthalpy sensors 801 employed before and after the conditioner and regenerator modules give a simultaneous measurement of air temperature and humidity. The before and after enthalpy measurements can be used to indirectly determine the concentration of the liquid desiccant. A lower exiting humidity indicates a higher desiccant concentration. The liquid desiccant is taken from a reservoir 805 by pump 804 at an appropriately low level because the desiccant will stratify in the reservoir. Typically the desiccant will be about 3-4% less concentrated near the top of the reservoir compared to the bottom of the reservoir. The pump 804 brings the desiccant to the supply port 320 near the top of the conditioners. The desiccant flows behind the membranes and exits the module through port 321 . The desiccant is then pulled by a siphoning force into the reservoir 805 while passing a sensor 808 and a flow sensor 809 . The sensor 808 can be used to determine the amount of air bubbles that are formed in the liquid desiccant going through the drain port 321 . This sensor can be used to determine if the membrane properties are changing: the membrane lets a small amount of air through as well as water vapor. This air forms bubbles in the exit liquid desiccant stream. A change in membrane pore size for example due to degradation of the membrane material will lead to an increase in bubble frequency and bubble sizes all other conditions being equal. The sensor 808 can thus be used to predict membrane failure or degradation well before a catastrophic failure happens. The flow sensor 809 is used to ensure that the proper amount of desiccant is returning to the reservoir 805 . A failure in the membrane module would result in little or no desiccant returning and thus the system can be stopped. It would also be possible to integrate the sensors 808 and 809 into a single sensor embodying both functions or, e.g., for sensor 808 to register that no more air bubbles are passing as an indication of stopped flow.
Again in FIG. 8A , a second pump 806 pulls dilute liquid desiccant at a higher level from the reservoir. The diluted desiccant will be higher in the reservoir since the desiccant will stratify if one is careful not to disturb the desiccant too much. The dilute desiccant is then pumped through a heat exchanger 807 to the top of the regenerator module supply port 323 . The regenerator re-concentrates the desiccant and it exits the regenerator at port 324 . The concentrated desiccant then passes the other side of the heat exchanger 807 , and passes a set of sensors 808 and 809 similar to those used on the conditioner exit. The desiccant is then brought back to the reservoir into the stratified desiccant at a level approximately equal to the concentration of the desiccant exiting the regenerator.
The reservoir 805 is also equipped with a level sensor 803 . The level sensor can be used to determine the level of desiccant in the reservoir but is also an indication of the average concentration desiccant in the reservoir. Since the system is charged with a fixed amount of desiccant and the desiccant only absorbs and desorbs water vapor, the level can be used to determine the average concentration in the reservoir.
FIG. 8B illustrates a simple decision tree for monitoring the desiccant level in a liquid desiccant system. The control system starts the desiccant pumps and waits a few minutes for the system to reach a stable state. If after the initial startup period the desiccant level is rising (which indicates that more water vapor is removed from the air then is removed in the regenerator then the system can correct by increasing the regeneration temperature, for example by closing the bypass valve 304 b in FIG. 3A or by closing the bypass loop valve 325 also in FIG. 3A .
FIG. 9A shows a liquid desiccant control system wherein two reservoirs 805 and 902 are employed. The addition of the second reservoir 902 can be necessary if the conditioner and regenerator air not in near proximity to each other. Since the desiccant siphoning is desirable having a reservoir near or underneath the conditioner and regenerator is sometimes a necessity. A 4-way valve 901 can also added to the system. The addition of a 4-way valve allows the liquid desiccant to be sent from the conditioner reservoir 805 to the regenerator module 312 . The liquid desiccant is now able to pick up water vapor from the return air stream 322 . The regenerator is not heated by the heat transfer fluid in this operating mode. The diluted liquid desiccant is now directed back through the heat exchanger 807 and to the conditioner module 301 . The conditioner module is not being cooled by the heat transfer fluid. It is actually possible to heat the conditioner module and cool the regenerator which makes them function opposite from their normal operation. In this fashion it is possible to add heat and humidity to the outside air 319 and recover heat and humidity from the return air. It is worthwhile noting that if one wants to recover heat as well as humidity, the heat exchanger 807 can be bypassed. The second reservoir 902 has a second level sensor 903 . The monitoring schematic of FIG. 8B can still be employed by simply adding the two level signals together and using the combined level as the level to be monitored.
FIG. 9B illustrates the flow diagram of the liquid desiccants if the 4-way valve 901 is set to an isolated position. In this situation no desiccant is moved between the two sides and each side is independent of the other side. This operating mode can be useful if very little dehumidification needs to be obtained in the conditioner. The regenerator could effectively be idled in that case.
FIG. 10A illustrates a set of membrane plates 1007 mounted in a housing 1003 . The supply air 1001 is pulled through the membrane plates 1007 by the fan 1002 . This arrangement results in a negative pressure around the membrane plates compared to the ambient outside the housing 1003 as was discussed earlier. In order to maintain a proper pressure balance above the liquid desiccant reservoir 805 , a small tube or hose 1006 is connecting the low pressure area 1010 to the top of the reservoir 805 . Furthermore a small, vertical hose 1009 is employed near the top port 320 of the membrane module wherein a small amount of desiccant 1008 is present. The desiccant level 1008 can be maintained at an even height resulting in a controlled supply of desiccant to the membrane plates 1007 . An overflow tube 1015 ensures that if the level of desiccant in the vertical hose 1009 rises too high—and thus too much desiccant pressure is applied on the membranes—excess desiccant is drained back to the reservoir 805 , thereby bypassing the membrane plates 1007 and thereby avoiding potential membrane damage.
Again referring to FIG. 10A , the bottom of the housing 1003 is slightly sloped towards a corner 1004 wherein a conductivity sensor 1005 is mounted. The conductivity sensor can detect any amount of liquid that may have fallen from the membrane plates 1007 and is thus able to detect any problems or leaks in the membrane plates.
FIG. 10B shows a system similar to that of 10 A except that the fan 1012 is now located on the opposite side of the membrane plates 1007 . The air stream 1013 is now pushed through the plates 1007 resulting in a positive pressure in the housing 1003 . A small tube or hose 1014 is now used to connect the low pressure area 1011 to the air at the top of the reservoir 805 . The connection between the low pressure point and the reservoir allows for the largest pressure difference between the liquid desiccant behind the membrane and the air, resulting in good siphoning performance. Although not shown, an overflow tube similar to tube 1015 in FIG. 10A can be provided to ensure that if the level of desiccant in the overflow tube rises too high—and thus too much desiccant pressure is applied on the membranes—excess desiccant is drained back to the reservoir 805 , thereby bypassing the membrane plates 1007 and thereby avoiding potential membrane damage. Having thus described several illustrative embodiments, it is to be appreciated that various alterations, modifications, and improvements will readily occur to those skilled in the art. Such alterations, modifications, and improvements are intended to form a part of this disclosure, and are intended to be within the spirit and scope of this disclosure. While some examples presented herein involve specific combinations of functions or structural elements, it should be understood that those functions and elements may be combined in other ways according to the present disclosure to accomplish the same or different objectives. In particular, acts, elements, and features discussed in connection with one embodiment are not intended to be excluded from similar or other roles in other embodiments. Additionally, elements and components described herein may be further divided into additional components or joined together to form fewer components for performing the same functions. Accordingly, the foregoing description and attached drawings are by way of example only, and are not intended to be limiting.
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A desiccant air conditioning system for treating an air stream entering a building space, including a conditioner configured to expose the air stream to a liquid desiccant such that the liquid desiccant dehumidifies the air stream in the warm weather operation mode and humidifies the air stream in the cold weather operation mode. The conditioner includes multiple plate structures arranged in a vertical orientation and spaced apart to permit the air stream to flow between the plate structures. Each plate structure includes a passage through which a heat transfer fluid can flow. Each plate structure also has at least one surface across which the liquid desiccant can flow. The system includes a regenerator connected to the conditioner for causing the liquid desiccant to desorb water in the warm weather operation mode and to absorb water in the cold weather operation mode from a return air stream.
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CROSS-REFERENCES TO RELATED APPLICATIONS
This application is related to Korean Patent Application No. 99-14763, filed Apr. 23, 1999, and takes priority from that date.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an organic anti-reflective coating material which allows the stable formation of ultrafine patterns suitable for 64M, 256M, 1 G, 4 G and 16 G DRAM semiconductor devices. More particularly, the present invention relates to an organic anti-reflective coating material which contains a chromophore with high absorbance at the wavelengths useful for submicrolithography. A layer of said anti-reflection material can prevent back reflection of light from lower layers or the surface of the semiconductor chip, as well as eliminate the standing waves in the photoresist layer, during a submicrolithographic process using a 248 nm KrF, 193 nm ArF or 157 nm F 2 laser light sources. Also, the present invention is concerned with an anti-reflective coating composition comprising such a material, an anti-reflective coating therefrom and a preparation method thereof.
2. Description of the Prior Art
During a submicrolithographic process, one of the most important processes for fabricating highly integrated semiconductor devices, there inevitably occur standing waves and reflective notching of the waves due to the optical properties of lower layers coated on the wafer and to changes in the thickness of the photosensitive film applied thereon. In addition, the submicrolithographic process generally suffers from a problem of the CD (critical dimension) being altered by diffracted and reflected light from the lower layers.
To overcome these problems, it has been proposed to introduce a film, called an anti-reflective coating (hereinafter sometimes referred to as “ARC”), between the substrate and the photosensitive film. Generally, ARCs are classified as “organic” and “inorganic” depending on the materials used, and as “absorptive” and “interfering” depending on the mechanism of operation. In microlithographic processes using I-line (365 nm wavelength) radiation, inorganic ARCs, for example TiN or amorphous carbon coatings, are employed when advantage is taken of an absorption mechanism, and SiON coatings are employed when an interference mechanism is employed. The SiON ARCs are also adapted for submicrolithographic processes which use KrF light sources.
Recently, extensive and intensive research has been and continues to be directed to the application of organic ARCs for such submicrolithography. In view of the present development status, organic ARCs must satisfy the following fundamental requirements to be useful:
First, the peeling of the photoresist layer due to dissolution in solvents in the organic ARC should not take place when conducting a lithographic process. In this regard, the organic ARC materials have to be designed so that their cured films have a crosslinked structure without producing by-products.
Second, there should be no migration of chemical materials, such as amines or acids, into and from the ARCs. If acids are migrated from the ARC, the photosensitive patterns are undercut while the egress of bases, such as amines, causes a footing phenomena.
Third, faster etch rates should be realized in the ARC than in the upper photosensitive film, allowing an etching process to be conducted smoothly with the photosensitive film serving as a mask.
Finally, the organic ARCs should be as thin as possible while playing an excellent role in preventing light reflection.
Despite the variety of ARC materials, those which are satisfactorily applicable to submicrolithographic processes using ArF light have not been found, thus far. As for inorganic ARCs, there have been reported no materials which can control the interference at the ArF wavelength, that is, 193 nm. As a result, active research has been undertaken to develop organic materials which act as superb ARCs. In fact, in most cases of submicrolithography, photosensitive layers are necessarily accompanied by organic ARCs which prevent the standing waves and reflective notching occurring upon light exposure, and eliminate the influence of the back diffraction and reflection of light from lower layers. Accordingly, the development of such an ARC material showing high absorption properties against specific wavelengths is one of the hottest and most urgent issues in the art.
U.S. Pat. No. 4,910,122 discloses an ARC which is interposed under photosensitive layers to eliminate defects caused by reflected light. The coating described therein can be formed thinly, smoothly and uniformly and includes a light absorbing dye which eliminates many of the defects caused by reflected light, resulting in increased sharpness of the images in photosensitive materials. These types of ARCs, however, suffer from disadvantages of being complicated in formulation, extremely limited in material selection and difficult to apply for photolithography using Deep Ultraviolet (DUV) radiation. For example, the ARC of the above reference comprises 4 dye compounds, including polyamic acid, curcumin, Bixin and Sudan Orange G, and 2 solvents, including cyclohexanone and N-methyl-2-pyrrolidone. This multi-component system is not easy to formulate and may intermix with the resist composition coated thereover, bringing about undesired results.
SUMMARY OF THE INVENTION
Therefore, it is an object of the present invention to overcome the problems encountered in the prior art and to provide a novel organic compound which can be used as an ARC for submicrolithography using 193 nm ArF, 248 nm KrF and 157 nm F 2 lasers.
It is another object of the present invention to provide a method for preparing an organic compound which prevents the diffusion and reflection caused by the light exposure in submicrolithography.
It is a further object of the present invention to provide an ARC composition containing such a diffusion/reflection-preventive compound and a preparation method therefor.
It is a still further object of the present invention to provide an ARC formed from such a composition and a preparation method therefor.
The present invention pertains to acrylate polymer resins which can be used as an ARC. Preferred polymer resins contain a chromophore which exhibits high absorbance at 193 nm and 248 nm wavelengths. A crosslinking mechanism between alcohol groups and other functional groups is introduced into the polymer resins, so that a crosslinking reaction takes place when coatings of the polymer resins are “hard baked”, thereby greatly improving the formation, tightness and dissolution properties of the ARCs. In particular, optimum crosslinking reaction efficiency and storage stability are realized in the present invention. The ARC resins of the present invention show superior solubility in all hydrocarbon solvents, but are of so high solvent resistance after hard baking that they are not dissolved in any solvent at all. These advantages allow the resins to be coated without any problem, and the coating prevents the undercutting and footing problems which can occur upon forming images on photosensitive materials. Furthermore, the coatings made of the acrylate polymers of the present invention are higher in etch rate than photosensitive films, improving the etch selection ratio therebetween.
DETAILED DESCRIPTION OF THE INVENTION
The ARC resins of the present invention are selected from the group consisting of acrylate polymers represented by the following general formulas I, II and III:
wherein,
R, R I , R II , and R III are independently hydrogen or a methyl group;
R 0 is a methyl group or an ethyl group;
R 1 to R 9 , which are the same or different, each represents hydrogen, hydroxy, methoxycarbonyl, carboxyl, hydroxymethyl, or a substituted or unsubstituted, linear or branched C 1 -C 6 alkyl, alkane, alkoxyalkyl or alkoxyalkane;
x, y and z each is a mole fraction in the range from 0.01 to 0.99; and
m and n are independently an integer of 1 to 4. In a preferred compound of Formula I, m is 1 or 2 and n is an integer of 1 to 4. In a preferred compound of Formula II, m is 1 or 2 and n is an integer from 2 to 4.
The polymers of the present invention are designed to provide greater absorbance at 193 nm and 248 nm wavelengths. To accomplish this result, a chromophore substituent which is able to absorb light at a wavelength of 193 nm as well as 248 nm is grafted to the backbone of the polymer.
The polymer of the general formula I, as illustrated in the following reaction formula 1, can be prepared by polymerizing 9-anthracenemethyl acrylate type monomers (I) and hydroxy alkylacrylate type monomers (II) with the aid of an initiator in a solvent. Each of the monomers has a mole fraction ranging from 0.01 to 0.99.
wherein R, R I , R 1 to R 9 , x, y, m and n each is as defined above.
The polymers of the general formula II can be prepared in a similar manner to the polymers of the general formula I, using 9-anthracenemethyl acrylate type monomers (I), hydroxy alkylacrylate type monomers (II) and methylmethacrylate monomers (III) at a mole fraction of 0.01 to 0.99 for each monomer, as illustrated in the following reaction formula 2:
wherein R, R I , R II , R 1 to R 9 , x, y, z, m and n each is as defined above.
The preparation of the polymer of the general formula III is illustrated in the following reaction formula 3. As shown, first, methacryloyl chloride (IV) is reacted with 4-hydroxy benzaldehyde (V) to give 4-formylphenylmethacrylate (VI) which is then polymerized with the aid of an initiator in a solvent, followed by substituting the 4-formylphenyl groups with methanol or ethanol:
wherein R III and R 0 each is as defined above.
For initiating the polymerization reaction for the polymers of the general formulas I, II and III, ordinary initiators may be used, with preference given to 2,2-azobisisobutyronitrile (AIBN), acetylperoxide, laurylperoxide and t-butylperoxide. Also, ordinary solvents may be used for the polymerization. Preferably the solvent is selected from the group consisting of tetrahydrofuran, toluene, benzene, methylethyl ketone and dioxane.
Preferably, the polymerization of the polymers of the general formulas I and II is carried out at 50-90° C.
The 9-anthracene alkyl acrylate type monomers (I) used to prepare the polymers of the general formulas I and II, are novel compounds which can be prepared by the reaction of 9-anthracene alcohol with acryloyl chloride type compounds in a solvent, as illustrated in the following reaction formula 4:
wherein R, R 1 to R 9 , and n each is as defined above. The hydroxyalkylacrylate type monomers (II) and methylmethacrylate monomers (III) used in the above reactions are commercially available, or they may be prepared using known preparation methods.
Also, the present invention pertains to an ARC composition which is based on a polymer mixture comprising the polymer of the general formula I or II and the polymer of the general formula III, in combination with at least one additive selected from the group consisting of the anthracene derivatives shown in Table 1, below.
TABLE 1
Chemical Formula 1
Chemical Formula 2
Chemical Formula 3
Chemical Formula 4
Chemical Formula 5
Chemical Formula 6
Chemical Formula 7
Chemical Formula 8
Chemical Formula 9
Chemical Formula 10
Chemical Formula 11
Chemical Formula 12
Chemical Formula 13
Chemical Formula 14
Chemical Formula 15
Chemical Formula 16
Chemical Formula 17
Chemical Formula 18
In Table 1, R 11 , R 12 , R 13 , R 14 and R 15 independently represent hydrogen, hydroxy, hydroxymethyl, or substituted or unsubstituted linear or branched C 1 -C 5 alkyl, alkane, alkoxyalkyl or alkoxyalkane.
ARC compositions according to the present invention may be prepared by (i) dissolving a polymer of the general formula I or II and a polymer of general formula III in a solvent to form a solution; (ii) optionally adding a compound selected from Table 1 to said solution, at an amount of 0.1 to 30% by weight, and (iii) filtering the solution.
Ordinary organic solvents may be used in preparing the composition, with preference given to ethyl 3-ethoxypropionate, methyl 3-methoxy propionate, cyclohexanone and propylene methyletheracetate. The solvent is preferably used at an amount of 200 to 5000% by weight based on the total weight of the ARC resin polymers used.
In another aspect of the present invention, an ARC is formed from the coating composition described above. After being filtered, this coating composition may be applied on a wafer in a conventional manner and then “hard-baked” (i.e., heated to a temperature of 100-300° C. for 10-1000 seconds) to form a crosslinked ARC. Quality semiconductor devices can be fabricated using ARCs of the present invention, because this crosslinked structure of the ARC offers optically stable light exposure conditions when forming an image in the photosensitive layer.
It has been found that the ARCs of the present invention exhibit high performance in submicrolithographic processes using 248 nm KrF, 193 nm ArF and 157 nm F 2 lasers as light sources. The same was also true when 157 nm E-beams, EUV extreme ultraviolet) and ion beams are used as light sources.
A better understanding of the present invention may be obtained in light of following examples which are set forth to illustrate, but are not to be construed to limit, the present invention.
EXAMPLE I
Synthesis of Poly[9-anthracenemethylacrylate-(2-hydroxyethylacrylate)]binary Copolymer
Synthesis of 9-Anthracenemethylacrylate
0.5 moles of 9-anthracene methanol and 0.5 moles of pyridine are dissolved in tetrahydrofuran and then, 0.5 moles of acryloyl chloride are added. After completion of the reaction, the product is filtered out and extracted with ethyl acetate. The extract is washed many times with distilled water and dried by distillation under vacuum, to give 9-anthracenemethylacrylate, represented by the following chemical formula 19. Yield 84%.
Synthesis of Poly[9-anthracenemethylacrylate-(2-hydroxyethylacrylate)]binary Copolymer
In a 500 ml round-bottom flask are placed 0.5 moles of 9-anthracenemethylacrylate and 0.5 moles of 2-hydroxyethylacrylate. This mixture is added to 300 g of separately prepared tetrahydrofuran (THF) with stirring. Thereafter, in the presence of 0.1-3 g of 2,2′-azobisisobutyronitrile (AIBN), the reaction is subjected to polymerization at 60-75° C. for 5-20 hours in a nitrogen atmosphere. After completion of the polymerization, the solution is precipitated in ethyl ether or normal-hexane and the precipitate is filtered out and dried to produce a poly[9-anthracenemethylacrylate-(2-hydroxyethylacrylate)] copolymer, a polymer according to the present invention, represented by the following chemical formula 20, at a yield of 83%.
EXAMPLE II
Synthesis of Poly[9-anthracenemethylacrylate-(3-hydroxypropylacrylate)]binary Copolymer
In a 500 ml round-bottom flask are placed 0.5 moles of the 9-anthracenemethylacrylate synthesized in Example I and 0.5 moles of 3-hydroxypropylacrylate. This mixture is added to 300 g of separately prepared THF with stirring. Thereafter, in the presence of 0.1-3 g of AIBN, the reaction is subjected to polymerization at 60-75° C. for 5-20 hours in a nitrogen atmosphere. After completion of the polymerization, the solution is precipitated in ethyl ether or normal-hexane and the precipitate is filtered out and dried to produce a poly[9-anthracenemethylacrylate-(3-hydroxypropylacrylate)] copolymer, a polymer according to the present invention, represented by the following chemical formula 21, at a yield of 82%.
EXAMPLE III
Synthesis of Poly[9-anthracenemethylacrylate-(4-hydroxybutylacrylate)] Copolymer
In a 500 ml round-bottom flask are placed 0.5 moles of 9-anthracenemethylacrylate and 0.5 moles of 4-hydroxybutylacrylate. This mixture is added to 300 g of separately prepared THF with stirring. Thereafter, in the presence of 0.1-3 g of AIBN, the reaction is subjected to polymerization at 60-75° C. for 5-20 hours in a nitrogen atmosphere. After completion of the polymerization, the solution is precipitated in ethyl ether or normal-hexane and the precipitate is filtered out and dried to produce a poly[9-anthracenemethylacrylate-(4-hydroxybutylacrylate)] copolymer, a polymer according to the present invention, represented by the following chemical formula 22. Yield 81%.
EXAMPLE IV
Synthesis of Poly[9-anthracenemethylmethacrylate-(2-hydroxyethylacrylate)]binary Copolymer
Synthesis of 9-Anthracenemethylmethacrylate
0.5 moles of 9-anthracene methanol and 0.5 moles of pyridine are dissolved in THF and then, 0.5 moles of methacryloyl chloride are added. After completion of the reaction, the product is filtered out and extracted with ethyl acetate. The extract is washed many times with distilled water and dried by distillation under vacuum, to give 9-anthracenemethylmethacrylate, represented by the following chemical formula 23. Yield 83%.
Synthesis of Poly[9-anthracenemethylmethacrylate-(2-hydroxyethylacrylate)]binary Copolymer
In a 500 ml round-bottom flask are placed 0.5 moles of 9-anthracenemethylmethacrylate and 0.5 moles of 2-hydroxyethylacrylate. This mixture is added to 300 g of separately prepared THF with stirring. Thereafter, in the presence of AIBN, the reaction is subjected to polymerization at 60-75° C. for 5-20 hours in a nitrogen atmosphere. After completion of the polymerization, the solution is precipitated in ethyl ether or normal-hexane and the precipitate is filtered and dried to produce a poly[9-anthracenemethylmethacrylate-(2-hydroxyethylacrylate)] copolymer, a resin according to the present invention, represented by the following chemical formula 24, at a yield of 79%.
EXAMPLE V
Synthesis of Poly[9-anthracenemethylmethacrylate-(3-hydroxypropylacrylate)]binary Copolymer
In a 500 ml round-bottom flask are placed 0.5 moles of the 9-anthracenemethylmethacrylate synthesized in Example IV and 0.5 moles of 3-hydroxypropylacrylate. This mixture is added to 300 g of separately prepared THF with stirring. Thereafter, in the presence of 0.1-3 g of AIBN, the reaction is subjected to polymerization at 60-75° C. for 5-20 hours in a nitrogen atmosphere. After completion of the polymerization, the solution is precipitated in ethyl ether or normal-hexane and the precipitate is filtered and dried to produce a poly[9-anthracenemethylmethacrylate-(2-hydroxypropylacrylate)] copolymer, a polymer according to the present invention, represented by the following chemical formula 25. Yield 81%.
EXAMPLE VI
Synthesis of Poly[9-anthracenemethylmethacrylate-(4-hydroxybutylacrylate)]binary Copolymer
In a 500 ml round-bottom flask are placed 0.5 moles of the 9-anthracenemethylacrylate synthesized in Example IV and 0.5 moles of 4-hydroxybutylacrylate. This mixture is added to 300 g of separately prepared THF with stirring. Thereafter, in the presence of 0.1-3 g of AIBN, the reaction is subjected to polymerization at 60-75° C. for 5-20 hours in a nitrogen atmosphere. After completion of the polymerization, the solution is precipitated in ethyl ether or normal-hexane and the precipitate is filtered and dried to produce a poly[9-anthracenemethylmethacrylate-(4-hydroxybutylacrylate)] copolymer, a polymer according to the present invention, represented by the following chemical formula 26, at a yield of 81%.
EXAMPLE VII
Synthesis of Poly[9-anthracenemethylacrylate-(2-hydroxyethylacrylate)-methylmethacrylate]ternary Copolymer
In a 500 ml round-bottom flask are placed 0.3 moles of 9-anthracenemethylacrylate, 0.5 moles of 2-hydroxyethylacrylate and 0.2 moles of methylmethacrylate. This mixture is added to 300 g of separately prepared THF with stirring, after which, in the presence of 0.1-3 g of AIBN, the reaction was subjected to polymerization at 60-75° C. for 5-20 hours in a nitrogen atmosphere. After completion of the polymerization, the solution is precipitated in ethyl ether or normal-hexane and the precipitate is filtered and dried to produce a poly[9-anthracenemethylacrylate-(2-hydroxyethyl)-methylmethacrylate] copolymer, a polymer according to the present invention, represented by the following chemical formula 27. Yield 80%.
EXAMPLE VIII
Synthesis of Poly[9-anthracenemethylacrylate-(3-hydroxypropylacrylate)-methylmethacrylate]ternary Copolymer
In a 500 ml round-bottom flask are placed 0.3 moles of 9-anthracenemethylacrylate, 0.5 moles of 3-hydroxypropylacrylate and 0.2 moles of methylmethacrylate. This mixture is added to 300 g of separately prepared THF with stirring, after which, in the presence of 0.1-3 g of AIBN, the reaction was subjected to polymerization at 60-75° C. for 5-20 hours in a nitrogen atmosphere. After completion of the polymerization, the solution is precipitated in ethyl ether or normal-hexane and the precipitate is filtered and dried to produce a poly[9-anthracenemethylacrylate-(3-hydroxypropyl)-methylmethacrylate] copolymer, a polymer according to the present invention, represented by the following chemical formula 28, at a yield of 82%.
EXAMPLE IX
Synthesis of Poly[9-anthracenemethylacrylate-(4-hydroxybutylacrylate)-methylmethacrylate]ternary Copolymer
In a 500 ml round-bottom flask are placed 0.3 moles of 9-anthracenemethylacrylate, 0.5 moles of 4-hydroxybutylacrylate and 0.2 moles of methylmethacrylate. This mixture is added to 300 g of separately prepared THF with stirring, after which, in the presence of 0.1-3 g of AIBN, the reaction is subjected to polymerization at 60-75° C. for 5-20 hours in a nitrogen atmosphere. After completion of the polymerization, the solution is precipitated in ethyl ether or normal-hexane and the precipitate is filtered and dried to produce a poly[9-anthracenemethylacrylate-(4-hydroxybutyl)-methylmethacrylate] copolymer, a polymer according to the present invention, represented by the following chemical formula 29. Yield 81%.
EXAMPLE X
Synthesis of Poly[9-anthracenemethylmethacrylate-(2-hydroxyethylacrylate)-methylmethacrylate]ternary Copolymer
In a 500 ml round-bottom flask are placed 0.3 moles of the 9-anthracenemethylmethacrylate synthesized in Example IV, 0.5 moles of 2-hydroxyethylacrylate and 0.2 moles of methylmethacrylate. This mixture is added to 300 g of separately prepared THF with stirring, after which, in the presence of 0.1-3 g of AIBN, the reaction is subjected to polymerization at 60-75° C. for 5-20 hours in a nitrogen atmosphere. After completion of the polymerization, the solution is precipitated in ethyl ether or normal-hexane and the precipitate is filtered and dried to produce a poly[9-anthracenemethylmethacrylate-(2-hydroxyethyl)-methylmethacrylate] copolymer, a polymer according to the present invention, represented by the following chemical formula 30. Yield 82%.
EXAMPLE XI
Synthesis of Poly[9-anthracenemethylmethacrylate-(3-hydroxypropylacrylate)-methylmethacrylate]ternary Copolymer
In a 500 ml round-bottom flask are placed 0.3 moles of the 9-anthracenemethylacrylate synthesized in Example IV, 0.5 moles of 3-hydroxypropylacrylate and 0.2 moles of methylmethacrylate. This mixture is added to 300 g of separately prepared THF with stirring, after which, in the presence of 0.1-3 g of AIBN, the reaction is subjected to polymerization at 60-75° C. for 5-20 hours in a nitrogen atmosphere. After completion of the polymerization, the solution is precipitated in ethyl ether or normal-hexane and the precipitate is filtered and dried to produce a poly[9-anthracenemethylmethacrylate-(3-hydroxypropyl)-methylmethacrylate] copolymer, a polymer according to the present invention, represented by the following chemical formula 31, at a yield of 81%.
EXAMPLE XII
Synthesis of Poly[9-anthracenemethylmethacrylate-(4-hydroxybutylacrylate)-methylmethacrylate]ternary Copolymer
In a 500 ml round-bottom flask are placed 0.3 moles of the 9-anthracenemethylacrylate synthesized in Example IV, 0.5 moles of 4-hydroxybutylacrylate and 0.2 moles of methylmethacrylate. This mixture is added to 300 g of separately prepared THF with stirring, after which, in the presence of 0.1-3 g of AIBN, the reaction is subjected to polymerization at 60-75° C. for 5-20 hours in a nitrogen atmosphere. After completion of the polymerization, the solution is precipitated in ethyl ether or normal-hexane and the precipitate is filtered and dried to produce a poly[9-anthracenemethylmethacrylate-(4-hydroxybutyl)-methylmethacrylate] copolymer, a polymer according to the present invention, represented by the following chemical formula 32. Yield 80%.
EXAMPLE XIII
Synthesis of Poly[9-anthraceneethylacrylate-(2-hydroxyethylacrylate)]binary Copolymer
Synthesis of 9-Anthraceneethylacrylate
0.5 moles of 9-anthracene ethanol and 0.5 moles of pyridine are dissolved in THF and then, 0.5 moles of acryloyl chloride are added. After completion of the reaction, the product is filtered out and extracted with ethyl acetate. The extract is washed many times with distilled water and dried by distillation under vacuum, to give 9-anthracenemethylacrylate, represented by the following chemical formula 33. Yield 80%.
Synthesis of Poly[9-anthraceneethylacrylate-(2-hydroxyethylacrylate)] Copolymer
In a 500 ml round-bottom flask are placed 0.5 moles of 9-anthraceneethylacrylate and 0.5 moles of 2-hydroxyethylacrylate. This mixture is added to 300 g of separately prepared THF with stirring. Thereafter, in the presence of 0.1-3 g of AIBN, the reaction is subjected to polymerization at 60-75° C. for 5-20 hours in a nitrogen atmosphere. After completion of the polymerization, the solution is precipitated in ethyl ether or normal-hexane and the precipitate is filtered out and dried to produce a poly[9-anthraceneethylacrylate-(2-hydroxyethylacrylate)] copolymer, a resin according to the present invention, represented by the following chemical formula 34, at a yield of 82%.
EXAMPLE XIV
Synthesis of Poly[9-anthraceneethylacrylate-(3-hydroxypropylacrylate)]binary Copolymer
In a 500 ml round-bottom flask are placed 0.5 moles of the 9-anthraceneethylacrylate synthesized in Example XIII and 0.5 moles of 3-hydroxypropylacrylate. This mixture is added to 300 g of separately prepared THF with stirring. Thereafter, in the presence of 0.1-3 g of AIBN, the reaction is subjected to polymerization at 60-75° C. for 5-20 hours in a nitrogen atmosphere. After completion of the polymerization, the solution is precipitated in ethyl ether or normal-hexane and the precipitate is filtered out and dried to produce a poly[9-anthraceneethylacrylate-(3-hydroxypropylacrylate)] copolymer, a polymer according to the present invention, represented by the following chemical formula 35, at a yield of 81%.
EXAMPLE XV
Synthesis of Poly[9-anthraceneethylacrylate-(4-hydroxybutylacrylate)] Copolymer
In a 500 ml round-bottom flask are placed 0.5 moles of 9-anthraceneethylacrylate and 0.5 moles of 4-hydroxybutylacrylate. This mixture is added to 300 g of separately prepared THF with stirring. Thereafter, in the presence of 0.1-3 g of AIBN, the reaction solution is subjected to polymerization at 60-75° C. for 5-20 hours in a nitrogen atmosphere. After completion of the polymerization, the solution is precipitated in ethyl ether or normal-hexane and the precipitate is filtered and dried to produce a poly[9-anthraceneethylacrylate-(4-hydroxybutylacrylate)] copolymer, a polymer according to the present invention, represented by the following chemical formula 36. Yield 80%.
EXAMPLE XVI
Synthesis of Poly[4-(1,1-dimethoxymethyl)phenylmethacrylate)
Synthesis of poly[4-formylphenylmethacrylate]
In a 300 ml round-bottom flask, 31.3 g of (0.3 moles) of methacryloyl are completely dissolved in 200 g of THF by stirring and 26 g of pyridine are added. To this solution 36.6 g (0.3 moles) of 4-hydroxybenzaldehyde are added dropwise, after which these reactants are allowed to react for 24 hours or longer. The product solution is washed with deionized water to separate an aqueous layer from which the desired compound is extracted and dried.
0.4 moles of the 4-formylphenylmethacrylate thus obtained are placed, together with 300 g of THF, in a 500 ml round-bottom flask and 0.1-3 g of AIBN are added thereto with stirring. Polymerization is conducted at 60-75° C. for 5-20 hours in a nitrogen atmosphere. After completion of the polymerization, the solution is precipitated in ethyl ether or normal hexane and the precipitate is filtered and dried to provide a poly[4-formylphenylmethacrylate] polymer at a yield of 80%.
Synthesis of poly[4-(1,1-dimethoxymethyl)phenylmethacrylate]
In a 400 ml Erlenmeyer flask are placed 15 g of the polymer obtained above and 200 ml of THF and then, 100 g of methanol are added, together with 0.5 g of HCl, after which these reactants are allowed to react at 60° C. for about 12 hours. The product solution is precipitated in ethyl ether or normal hexane and the precipitate is filtered and dried to give poly[4-(1,1-dimethoxymethyl)phenylmethacrylate], a polymer according to the present invention, represented by the following chemical formula 37. Yield 82%.
EXAMPLE XVII
Synthesis of Poly[4-(1,1-diethoxymethyl)phenylmethacrylate]
In a 400 ml Erlenmeyer flask are placed 15 g of the poly[4-formylmethacrylate synthesized in Example XVI and 200 ml of THF and then, 150 g of ethanol are added, together with 0.5 g of HCl, after which these reactants are allowed to react at 60° C. for about 12 hours. The product solution is precipitated in ethyl ether or normal hexane and the precipitate is filtered and dried to give poly[4-(1,1-diethoxymethyl)phenylmethacrylate], a resin according to the present invention, represented by the following chemical formula 38. Yield 80%.
EXAMPLE XVIII
Preparation of Arc
A polymer prepared in each of Examples I to XV and a polymer prepared in Example XVI or XVII are dissolved in propyleneglycol methylether acetate (PGMEA). This solution, alone or in combination with 0.1-30% by weight of at least one additive selected from the compounds of the chemical formulas 1 to 18 in Table 1, is filtered, coated on a wafer, and hard-baked at 100-300° C. for 10-1,000 sec to form an ARC. A photosensitive material may be applied on the ARC thus formed and imaged to ultrafine patterns in the conventional manner.
As described hereinbefore, the ARC of the present invention, which is obtained from a mixture comprising a polymer of the general formula I or II and a polymer of the general formula III, alone or in combination with an additive of chemical formulas 1 to 18 in Table 1, contains chromophore substituents sufficient to exhibit absorbance at the wavelengths useful for submicrolithography.
Particularly, the ARC of the present invention provides maximal crosslinking reaction efficiency and storage stability. The ARC polymer resins of the present invention show superior solubility in all hydrocarbon solvents, but are of such high solvent resistance after hard baking that they are not dissolved in any solvent at all. These advantages allow the resins to be coated without any problem, and the resulting coating prevents undercutting and footing problems which may occur when forming images on photosensitive materials. Furthermore, coatings made of the acrylate polymers of the present invention are higher in etch rate than photosensitive films, improving the etch selection ratio therebetween.
Thus, ARCs of the present invention can play an excellent role in forming ultrafine patterns. For example, it can prevent the back reflection of light from lower layers or the surface of the semiconductor element, as well as eliminate the standing waves caused by light and the thickness changes in the photoresist layer itself, during a submicrolithographic process using a 248 nm KrF, 193 nm ArF or 157 nm F2 laser. This results in the stable formation of ultrafine patterns suitable for 64M, 256M, 1 G, 4 G and 16 G DRAM semiconductor devices and a great improvement in the production yield.
The present invention has been described in an illustrative manner, and it is to be understood the terminology used is intended to be in the nature of description rather than of limitation. Many modifications and variations of the present invention are possible in light of the above teachings. Therefore, it is to be understood that within the scope of the appended claims, the invention may be practiced otherwise than as specifically described.
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Polymers are provided having the following formula I, II or III:
Polymers of the present invention can be used to provide an anti-reflective coating (ARC) material useful for submicrolithography processes using 248 nm KrF, 193 nm ArF and 157 nm F 2 lasers. The polymers contain chromophore substituents which exhibit sufficient absorbance at wavelengths useful for such submicrolithography process. The ARC prevents back reflection from the surface of or lower layers in the semiconductor devices and solves the problem of the CD being altered by the diffracted and reflected light from such lower layers. The ARC also eliminates the standing waves and reflective notching due to the optical properties of lower layers on the wafer, and due to the changes in the thickness of the photosensitive film applied thereon. This results in the formation of stable ultrafine patterns suitable for 64M, 256M, 1 G, 4 G and 16 G DRAM semiconductor devices and a great improvement in the production yield.
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RELATED APPLICATIONS
[0001] This application claims priority as a continuation-in-part of co-pending nonprovisional patent application serial numbers:
Ser. No. 14/808,418, filed Jul. 24, 2015, titled “Processing Machinery Protection and Fault Prediction Data Natively in a Distributed Control System,” Ser. No. 14/807,202, filed Jul. 23, 2015, titled “Parallel Digital Signal Processing of Machine Vibration Data,” and Ser. No. 14/807,008, filed Jul. 23, 2015, titled “Intelligent Configuration of a User Interface of a Machinery Health Monitoring System,”
and to provisional patent application Ser. No. 62/240,250, filed Oct. 12, 2015, titled “Universal Sensor Interface for Machinery Monitoring System,” the entire contents of which are incorporated herein by reference.
FIELD
[0005] This invention relates to the field of machine control and machine condition monitoring. More particularly, this invention relates to a universal sensor interface for accommodating multiple sensor types for use in a machinery monitoring system.
BACKGROUND
[0006] In conventional machine protection and prediction monitoring systems, many different types of sensors are used to measure various properties of a machine, such as eddy current sensors, seismic sensors, passive magnetic sensors, piezo electric sensors, Hall-effect sensors, and low frequency sensors. Each of these sensor types has its unique characteristics related to sensor supply voltages and currents and signal output voltage ranges. To accommodate these many different types of sensors, a large number of different sensor input modules have to be developed, tested and stocked. Separate modules are typically also needed for tachometer inputs. If a single sensor interface module could handle all these various sensors and measurements, project management would be easier, production and procurement would be more cost-effective, and the number of devices in stock and the spare parts needed could be significantly reduced.
[0007] Supplying power to a plurality of sensors from a single multichannel vibration acquisition card has historically necessitated cumbersome circuit complexity due to practical application considerations, including:
Avoidance of potential adverse consequences arising from a sensor or wiring fault that results in shorted sensor power, including:
Damage to the immediate hardware; Excessive power dissipation causing smoke or fire hazard; Excessive demand placed upon the singular sensor power supply; Adverse impact upon healthy adjacent sensor functionality; Generation of incorrect control or alarm values derived from adversely affected adjacent sensor readings; and Overall acquisition card failure;
Avoidance of potential adverse consequences arising from a concurrent plurality of sensor wiring faults, including:
Adverse impact upon cards adjacent to and upstream from the faulted card; Excessive demand placed upon the common board-level and the upstream sensor power supplies; Excessive temperature elevation within the system enclosure; and Overall acquisition system failure;
Minimization of adverse data integrity effects in healthy sensor channels arising from the make/break chatter of faulty or loose adjacent sensor wiring connections; Minimization of adverse data integrity effects in healthy sensor channels arising from the practice of “hot wiring” adjacent sensor connections; Avoidance of adverse consequences resulting from sensor-terminal miss-wiring, e.g., connecting a +24V output to a −24V output; Avoidance of adverse consequences resulting from connecting an external DC voltage source to a sensor supply output; and Minimization of instantaneous energy available for the generation of hazardous sparks (pertinent to safety-critical environments, e.g. Class 1 Division 2).
[0025] The above considerations can present significant challenges to realizing cost-effective and space-constrained implementations of sensor power supply circuitry. There exists a dearth of effective integrated solutions from electronic component manufacturers, possibly due to the uncommon nature of sensor power, i.e., relatively high DC voltage at relatively low current. It is more typical to find integrated solutions for the mirror condition of low voltage and high current.
[0026] Hardware implementations of sensor interfaces in the prior art apply various combined techniques to accomplish the overall desired performance goals. These techniques tend to involve high complexity and over-specification of components and power supplies, and are often not congruent with practical space constraints. Fundamentally, a comprehensive sensor supply implementation for a multichannel sensor interface card should:
(1) provide a fast (virtually instantaneous) limiting response to a short-circuit fault; (2) provide an accurate limiting response to a short-circuit fault; (3) survive a continuous short-circuit fault; (4) survive a plurality of concurrent continuous short-circuit faults in congruence with uninterrupted electrical and thermal integrity of the acquisition system; (5) automatically recover from short circuit faults; (6) reduce power consumption/dissipation when in a faulted condition; (7) isolate adverse effects of a faulted channel from uninvolved channels on the same card; (8) isolate adverse effects of loose wiring termination “chatter” from uninvolved channels on the same card; (9) protect against adverse effects resulting from the practice of “hot wiring” sensors; (10) protect the card and the system against reasonably anticipated installation wiring errors; and (11) minimize the availability of spark-inducing energy to the field wiring.
[0038] Although the sensible application of discrete semiconductors can realize attribute (1) above, the electrical DC parameters of those devices exhibit significant variability, particularly when evaluated over the industrial temperature range. This variability hampers the ability to achieve attribute (2) when using the same circuitry as used to achieve attribute (1). Alternatively, one can readily implement attribute (2) through the use of a common op-amp, with the resulting solution exhibiting a response time that is too slow to achieve attribute (1). It follows that it may be reasonable to combine the op-amp and discrete solutions together in a parallel path, thereby achieving coarse, but nearly instantaneous limiting, that eventually settles into accurate long-term limiting. This approach has been implemented in prior art. However, due to variability of the initial coarse limiting stage, the method is not an optimum approach for realizing attributes (7), (8), (9) and (11) above.
[0039] What is desired is a universal sensor interface for a machine protection and prediction monitoring system that includes a sensor power control circuit that adequately achieves all of attributes (1) through (11) listed above.
SUMMARY
[0040] To overcome DC parameter variability in the discrete bipolar transistor and take full advantage of its fast response to transients, the highly variable parameter of base-emitter turn-on voltage (V BEon ) must be removed from the equation. Embodiments of the invention described herein adequately fulfill this requirement by use of a small capacitor to hold the instantaneous DC operating value of V BEon , whatever that voltage may be. Because the voltage on a capacitor cannot change instantaneously, this held value can act as a current-controlling reference for the transistor over a very short period of time, e.g., immediately following an output short-circuit event. Preferred embodiments also provide an adequately fast secondary controlling mechanism for the indefinitely longer time period immediately following the initial fault event.
[0041] While the use of a capacitor can overcome the issue of V BEon variability during the initial stage of a fault, the response time of a typical op-amp impedes its ability to provide the follow-up controlling mechanism. A comparator would appear to be more commensurate with that function, since even some ultralow-power devices (with consumption measured in the tens of microamperes) have acceptable response times. However, comparators are not intended for use as continuous signal amplifiers, and many contain internal positive feedback that prevents their application in this manner. Comparators can, however, be useful building blocks for switching topologies. The result of this line of thought are embodiments of a switching topology that provide optimal solutions to the problem at hand. After significant time spent in conceptualization and simulation, the inventors have derived a simple and practical implementation that has been realized and verified in hardware.
[0042] Although one might suggest that providing protection against sensor or wiring fault scenarios is not a core function of sensor interface hardware, this viewpoint would justifiably be rejected by equipment end users. Sensor wiring issues are not uncommon occurrences, and if the effects from a single-channel fault are not contained to the faulted channel, a likely consequence will be a disgruntled equipment user. Absent the inclusion of the solutions described herein, a multi-channel sensor interface card design may need to incorporate a separate sensor power supply for each channel, incurring extra cost and complexity, and having the channel density per card, cabinet or rack dictated by spacing constraints. Preferred embodiments described herein consume minimal printed circuit board area.
[0043] Also described herein is sensor signal conditioning circuitry that conditions sensor signals prior to digitization. A preferred embodiment of the signal conditioning circuitry uses precision components (0.1% thin film resistors) to avoid the need for calibration of gain and offset and to minimize front-end resistor current noise (also known as “extra” noise). Precision components (1% capacitors) also are used to maintain good common-mode rejection throughout the pass-band.
[0044] Further, implementation of 64 x oversampling in a delta-sigma ADC pushes the frequency dependency outside of the measurement range. Such oversampling greatly loosens requirements of the antialiasing filter that is part of the signal conditioning circuitry, thereby reducing the filter's effect upon pass-band signals, and likewise reducing sensitivity to filter component tolerances.
[0045] Preferred embodiments of the signal conditioning circuitry use only passive filter circuits, which can be much less complex than active circuitry due at least in part to the absence of active components. The placement of passive Nyquist filtering upstream of active signal conditioning circuitry helps to shield the active circuitry against RF energy that might potentially be introduced by sensor field wiring.
[0046] Embodiments of the invention described herein provide a sensor power and signal conditioning circuit of a machinery health monitoring module. The sensor power and signal conditioning circuit includes a sensor interface connector, signal conditioning circuitry, sensor power supply circuitry, configuration circuitry, and analog-to-digital conversion circuitry.
[0047] The sensor interface connector receives an analog sensor signal generated by a connected sensor. In preferred embodiments, the sensor interface connector is operable to connect to multiple types of sensors that may be attached to a machine to monitor various characteristics of the machine.
[0048] The signal conditioning circuitry includes a plurality of sensor signal conditioning circuits, each for accommodating a sensor signal input range that is different from one or more sensor signal input ranges accommodated by other of the sensor signal conditioning circuits. The signal conditioning circuitry also includes a first software controllable switch that, based on an input range selection signal, selects one of the plurality of sensor signal conditioning circuits to receive the analog sensor signal generated by the connected sensor.
[0049] The sensor power supply circuitry, which supplies power to the connected sensor, includes a plurality of individually selectable sensor power circuits, each for providing power over a voltage range that is different from one or more voltage ranges provided by other of the sensor power circuits. The sensor power supply circuitry also includes a second software controllable switch that, based on a power range selection signal, selects one of the plurality of sensor power circuits to provide power to the connected sensor. The configuration circuit generates the input range selection signal and the power range selection signal based at least in part on a user selection of the type of connected sensor.
[0050] In some embodiments, the sensor interface connector is operable to connect to multiple types of sensors, including piezo accelerometers, Integrated Circuit Piezoelectric (ICP) vibration sensors, piezo dynamic pressure sensors, electro-dynamic velocity sensors, eddy current displacement sensors, AC vibration sensors, DC displacement sensors, passive electro-magnetic sensors, Hall Effect tachometer sensors, shaft encoder sensors, and TTL pulse sensors.
[0051] In some embodiments, the sensor signal conditioning circuits support input signals over a +12 volt to −12 volt range, a +24 volt to −24 volt range, a 0 volt to +24 volt range, and a 0 volt to −24 volt range. In some embodiments, the individually selectable sensor power circuits include a zero milliamp to 20 milliamp constant current source.
[0052] In another aspect, embodiments of the invention provide a sensor power controlling circuit of a machinery health monitoring module. The sensor power controlling circuit includes (1) a positive voltage input for receiving a positive voltage from a galvanically isolated voltage source within the machinery health monitoring module, (2) a sensor power connector for providing power to a sensor, (3) a push-pull comparator having a positive input, a negative input, and an output, (4) a first resistor, (5) a PNP transistor, and (6) a first capacitor.
[0053] The PNP transistor has a base, an emitter and a collector. The base is electrically coupled to a second side of the first resistor. The emitter is electrically coupled to the negative input of the push-pull comparator through a first resistor divider network, to the positive voltage input of the sensor power circuit through a second resistor, and to the positive input of the push-pull comparator through a second resistor divider network. The collector is electrically coupled to the sensor power connector.
[0054] The first resistor has a first side that is electrically coupled to the output of the push-pull comparator. The first capacitor has a first side that is electrically coupled to the second side of the first resistor and to the base of the PNP transistor. The first capacitor has a second side that is electrically coupled to the positive voltage input of the sensor power circuit and to the positive input of the push-pull comparator via the second resistor divider network.
[0055] When a base current at the base of the PNP transistor is at a level sufficient to cause the PNP transistor to be in a saturated ON state, the PNP transistor electrically couples the positive voltage input of the sensor power circuit to the sensor power connector.
[0056] During normal operation, current flowing through the second resistor into the emitter of the PNP transistor is below a nominal threshold current level, which causes a first bias voltage on the positive input of the push-pull comparator to be less than a second bias voltage on the negative input of the push-pull comparator, thereby causing a low-state voltage to appear at the output of the push-pull comparator.
[0057] A first RC time constant exists as determined by the capacitance of the first capacitor and a total effective resistance at the base node of the PNP transistor. When the transistor collector current increases abruptly relative to the first RC time constant, such as would occur immediately following a short circuit across the sensor power connector, voltage across the second resistor increases faster than voltage across the first capacitor increases, resulting in an instantaneous net reduction of emitter-base voltage of the PNP transistor. The net reduction of the emitter-base voltage of the PNP transistor impedes the PNP transistor from delivering increased load current for a time period that is greater than the propagation delay from the inputs to the output of the push-pull comparator.
[0058] When load current demand exceeds the nominal threshold current level, such as would occur when a short circuit exists across the sensor power connector, three events occur:
(1) The current flowing through the second resistor into the emitter of the PNP transistor rises to above the nominal threshold current level, which causes the first bias voltage on the positive input of the push-pull comparator to be greater than the second bias voltage on the negative input of the push-pull comparator, thereby causing a high-state voltage to appear at the output of the push-pull comparator. (2) The high-state voltage at the output of the push-pull comparator sources current into the first capacitor, which reduces the base current available to the PNP transistor. (3) The reduced base current of the PNP transistor causes reduction of current into the emitter of the PNP transistor, which causes the current flowing through the second resistor to decrease to below the nominal threshold current level. This causes the first bias voltage on the positive input of the push-pull comparator to be less than the second bias voltage on the negative input of the push-pull comparator, which in turn causes the low-state voltage to reappear at the output of the push-pull comparator.
Events (1), (2) and (3) repeat at a first rate while the load current demand exceeds the nominal threshold current level. In some embodiments, the first rate is about 1.0 MHz.
[0062] In some embodiments, the sensor power circuit includes a non-linear foldback circuit comprising a Zener diode and a third resistor. The Zener diode has a cathode that is electrically coupled to the negative input of the push-pull comparator. The third resistor is electrically coupled between the anode of the Zener diode and the collector of the PNP transistor. When a voltage on the collector of the PNP transistor falls below a threshold voltage, the Zener diode begins to conduct, thereby drawing current through the third resistor from the negative input node of the push-pull comparator. The current drawn from the negative input node of the push-pull comparator modifies the second bias voltage of the push-pull comparator. This results in a reduced current level flowing through the PNP transistor and thus reduced power dissipation in the PNP transistor when the sensor power connector is shorted or is pulled negative by an external voltage source.
[0063] In some embodiments, the output voltage (V OUT ) and the output current (I OUT ) at the sensor power connector are characterized by the following nominal foldback limiting function:
V OUT ≧6V, I OUT =39.2 mA Max V OUT =5V, I OUT =35.9 mA Max V OUT =4V, I OUT =31.7 mA Max V OUT =3V, I OUT =27.3 mA Max V OUT =2V, I OUT =23.0 mA Max V OUT =1V, I OUT =18.6 mA Max V OUT =0V, I OUT =14.2 mA Max.
[0071] In some embodiments, the sensor power circuit includes a fourth resistor, a second capacitor, a third capacitor and a fourth capacitor. The fourth resistor is coupled between the base and the emitter of the PNP transistor and assists with cutoff of the PNP transistor. The second capacitor is electrically coupled between the second side of the first capacitor and the positive input of the push-pull comparator. The third capacitor is electrically coupled between the emitter of the PNP transistor and the negative input of the push-pull comparator. The fourth capacitor is electrically coupled between the positive input of the push-pull comparator and the output of the push-pull comparator. The second, third and fourth capacitors promote deterministic astable behavior of the sensor power circuit.
[0072] In some embodiments, the sensor power circuit includes a fifth capacitor that is electrically coupled between the collector of the PNP transistor and electrical ground. The fifth capacitor promotes closed-loop stability when current limiting is in effect.
[0073] In yet another aspect, preferred embodiments of the invention provide a sensor signal conditioning circuit of a machinery health monitoring module. The sensor signal conditioning circuit, which is disposed between a machine sensor and an analog-to-digital converter (ADC), includes a sensor interface connector, a first and second operational amplifier, a passive Nyquist filter, and first and second gain flattening feedback networks.
[0074] The sensor interface connector is operable to connect to multiple types of sensors that may be attached to a machine to monitor various characteristics of the machine. The sensor interface connector includes a negative sensor signal input and a positive sensor signal input for receiving a differential analog sensor signal generated by a connected sensor.
[0075] The first operational amplifier, which provides a high impedance differential interface to the analog sensor signal and a low impedance interface to the positive ADC input, has a negative signal input, a positive signal input, and a signal output. The second operational amplifier provides an inverted copy of the signal output from the first operational amplifier and a low impedance interface to the negative ADC input, the operational amplifier having a negative signal input, a positive signal input, and a signal output.
[0076] The passive Nyquist filter is connected between the negative sensor signal input of the sensor interface connector and the negative signal input of the first operational amplifier. The passive Nyquist filter is also connected between the positive sensor signal input of the sensor interface connector and the positive signal input of the first operational amplifier.
[0077] The first gain flattening feedback network is connected between the negative signal input of the first operational amplifier and the output of the second operational amplifier. The second gain flattening feedback network is connected between the positive signal input of the first operational amplifier and the output of the first operational amplifier.
[0078] Connections to the ADC include a positive ADC input connection and a negative ADC input connection. Both of these connections are electrically coupled to the signal outputs of the operational amplifiers.
[0079] In some embodiments, the passive Nyquist filter includes resistors R 15 , R 16 , R 18 and R 19 , and capacitors C 8 , C 9 and C 10 . A first side of the resistor R 15 is electrically coupled to the negative sensor signal input of the sensor interface connector. A first side of the resistor R 16 is electrically coupled to the second side of the resistor R 15 . A second side of the resistor R 16 is electrically coupled to the negative signal input of the first operational amplifier. A first side of the resistor R 18 is electrically coupled to the positive sensor signal input of the sensor interface connector. A first side of the resistor R 19 is electrically coupled to the second side of the resistor R 18 . A second side of the resistor R 19 is electrically coupled to the positive signal input of the first operational amplifier. The capacitor C 8 has a first side that is electrically coupled to the second side of the resistor R 15 , and a second side that is electrically coupled to electrical ground. The capacitor C 9 has a first side that is electrically coupled to the second side of the resistor R 15 , and a second side that is electrically coupled to the second side of the resistor R 18 . The capacitor C 10 has a first side that is electrically coupled to the second side of the resistor R 18 , and a second side that is electrically coupled to electrical ground. The resistors R 15 , R 16 , R 18 and R 19 are preferably thin film resistors having a resistance value tolerance of no more than 0.1%. The capacitance values of the capacitors C 8 , C 9 and C 10 preferably have a tolerance of no more than 1%.
[0080] In some embodiments, the sensor signal conditioning circuit includes a resistor R 17 having a first side that is electrically coupled to the negative signal input of the first operational amplifier, and a second side that is electrically coupled to the positive ADC input connection. The gain of the sensor signal conditioning circuit of these embodiments is determined by twice the ratio of the resistance value of the resistor R 17 to a sum of the resistance values of the resistors R 15 and R 16 . The resistor R 17 is preferably a thin film resistor having a resistance value tolerance of no more than 0.1%.
[0081] In some embodiments, the sensor signal conditioning circuit includes an adjustable DC offset input. These embodiments also include a resistor R 20 having a first side that is electrically coupled to the positive signal input of the first operational amplifier, and a second side that is electrically coupled to the adjustable DC offset input. The input differential voltage offset of the sensor signal conditioning circuit is preferably determined by the product of a multiplicand: the ratio of the sum of the resistance values of the resistors R 18 and R 19 to the resistance value of the resistor R 20 , and a multiplier: the difference between the fixed +2.5V DC offset voltage and the adjustable DC offset voltage. The resistor R 20 is preferably a thin film resistor having a resistance value tolerance of no more than 0.1%.
[0082] In some embodiments, the first gain flattening feedback network includes a capacitor C 13 and a resistor R 25 . A first side of the capacitor C 13 is electrically coupled to the negative signal input of the first operational amplifier. The resistor R 25 has a first side that is electrically coupled to the second side of the capacitor C 13 , and a second side that is electrically coupled to the signal output of the second operational amplifier.
[0083] In some embodiments, the second gain flattening feedback network includes a capacitor C 14 and a resistor R 26 . A first side of the capacitor C 14 is electrically coupled to the positive signal input of the first operational amplifier. The resistor R 26 has a first side that is electrically coupled to the second side of the capacitor C 14 , and a second side that is electrically coupled to the signal output of the first operational amplifier. The resistors R 25 and R 26 preferably have a tolerance of no more than 1%. The capacitance values of the capacitors C 13 and C 14 preferably have a tolerance of no more than 1%.
[0084] In some embodiments, the operational amplifier is powered by a single rail +5 VDC power connection, with no need for a negative power connection.
[0085] In some embodiments, the variation in signal gain from the sensor interface connector through to the input of the ADC over a frequency range of zero to 40 KHz is no more than about 0.8%, even with no calibration.
BRIEF DESCRIPTION OF THE DRAWINGS
[0086] Other embodiments of the invention will become apparent by reference to the detailed description in conjunction with the figures, wherein elements are not to scale so as to more clearly show the details, wherein like reference numbers indicate like elements throughout the several views, and wherein:
[0087] FIG. 1 depicts a machinery health monitoring (MHM) module according to an embodiment of the invention;
[0088] FIG. 2 depicts field digital FPGA signal processing circuitry according to an embodiment of the invention;
[0089] FIG. 3 depicts an example of control logic executed by a DCS controller according to an embodiment of the invention;
[0090] FIG. 4 depicts a preferred embodiment of a universal signal conditioning and sensor power card according to an embodiment of the invention;
[0091] FIGS. 5 and 6 depict a preferred embodiment of a sensor power control circuit having instantaneous current limiting and incorporating nonlinear foldback according to an embodiment of the invention;
[0092] FIG. 7 depicts a sensor signal conditioning amplifier according to an embodiment of the invention;
[0093] FIGS. 8, 9 and 10 depict normalized amplifier gain versus frequency curves for a preferred embodiment of the sensor signal conditioning amplifier;
[0094] FIGS. 11 and 12 depict nominal foldback characteristics provided by a preferred embodiment of a sensor power circuit;
[0095] FIGS. 13 and 14 depict simulation plots showing currents and voltages associated with the power control circuit components of a preferred embodiment in response to an output short circuit event;
[0096] FIG. 15 depicts the results of a Monte Carlo simulation of the pass-band gain of a preferred embodiment of a signal conditioning amplifier from DC to 4 KHz, using a purely random distribution of component tolerances; and
[0097] FIG. 16 depicts the results of a Monte Carlo simulation of the common mode rejection (CMR) of a preferred embodiment of a signal conditioning amplifier at 100 Hz, using a Gaussian distribution of component tolerances.
DETAILED DESCRIPTION
[0098] Preferred embodiments of a universal sensor interface may be implemented in a vibration data acquisition and analysis module that interfaces directly to a distributed control system I/O backplane to allow direct acquisition of vibration data by the DCS for purposes of machinery protection and predictive machinery health analysis. As the term is used herein, a “distributed control system (DCS)” is a type of automated control system used in a process or plant in which control elements are distributed throughout a machine or multiple machines to provide operational instructions to different parts of the machine(s). As the term is used herein, “protection” refers to using data collected from one or more sensors (vibration, temperature, pressure, etc.) to shut down a machine in situations in which severe and costly damage may occur if the machine is allowed to continue running. “Prediction” on the other hand refers to using data collected from one or more vibration sensors, perhaps in combination with data from other types of sensors, to observe trends in machine performance and predict how much longer a machine can operate before it should be taken offline for maintenance or replacement.
[0099] FIG. 1 depicts a machinery health monitoring module (MHM) 10 that directly interfaces with a DCS 11 . In the preferred embodiment, the module 10 includes a field analog signal conditioning and sensor power card 12 that receives and conditions sensor signals, a field digital FPGA signal processing card 14 that processes the sensor signals, and a DCS logic generator card (LGC) 16 that provides an interface to a DCS I/O bus 18 . The field card 12 can preferably accept input from up to eight measurement sensors 20 through a field signal interface connector 22 . In a preferred embodiment, two of the sensor input channels may be configured as tachometer channels.
[0100] Preferably, galvanic electrical isolation is provided between the analog field card 12 and the digital field card 14 . This electrical isolation prevents unintentional current flow, such as due to ground loops, between the mounting locations of the sensors 20 and the DCS 11 .
[0101] As described in more detail hereinafter, sensor power circuit 24 and signal conditioning circuit 26 can support a wide range of sensors 20 , including piezo accelerometers, piezo ICP velocity, piezo dynamic pressure, electro-dynamic velocity, eddy current displacement, AC vibration, and DC displacement. Tachometer sensors that are supported include eddy current displacement sensors, passive electro-magnetic sensors, Hall Effect tachometer sensors, N pulse/rev shaft encoders, and TTL pulse sensors. Many additional sensor types are supported over the frequency range of DC to 20 KHz as long as they fall within the following exemplary voltage input ranges: 0 to +24V, −24V to +24V, −12V to +12V, and 0 to −24V. In the preferred embodiment, up to eight sensor power circuits 24 can be individually programmed for a constant current of between 0 and 20 mA, which may also be used as lift current for an electro-dynamic (passive) velocity sensor. Constant voltage sources (+24 VDC or −24 VDC) may be selected as well as constant current. The input voltage ranges listed above are also individually programmable on each sensor channel. This permits any mix of sensor power and input range configuration between the channels, thereby enabling a mix of supported sensors.
[0102] With timing provided by a clock 26 , an 8-channel analog-to-digital converter (ADC) 28 converts the eight analog signals into a single serial data stream comprising eight simultaneously sampled interleaved channels of data. In some preferred embodiments, two tachometer triggering circuits 30 convert the two analog tachometer signals into tachometer pulses.
[0103] On the field card 14 is an 8-channel field programmable gate array (FPGA) 36 for processing the vibration data. The FPGA 36 receives the 8-channel digital waveform data and 2-channel tachometer data and processes the raw data in parallel to generate scalar overall vibration parameters and waveforms. The processed waveforms may include low-pass filtered, PeakVue™, order tracking, high-pass filtered (DC blocked), and selectable single-integrated (velocity), double-integrated (displacement), or non-integrated (acceleration) waveforms. Prediction data channels also preferably include an up-sampling data block to provide higher resolution data for Time Synchronous Averaging (TSA) or order tracking applications.
[0104] The vibration card configuration circuit 32 of the analog field card 12 preferably includes of a set of serial-to-parallel latch registers that accept a serial data stream of configuration data from the application firmware of the LGC 16 . This data is loaded into a parallel-to-serial shift register in the interface of the FPGA 36 . The FPGA 36 then handles shifting the serial data to the control latches using a synchronous SPI format.
[0105] During operation of the preferred embodiment, the MHM module 10 appears to the DCS controller 19 as a multichannel analog input card having scalar outputs similar to those of a standard DCS input module 21 , such as may be outputting measured temperature, pressure, or valve position values. As discussed in more detail hereinafter, vibration signals are converted to scalar values by the module 10 and presented to the DCS controller 19 via the backplane of the DCS. One example of a DCS controller 19 is the Ovation™ controller manufactured by Emerson Process Management (a division of Emerson Electric Co.). In the typical DCS architecture, only sixteen scalar values are presented as high speed scan values to the DCS controller 19 . In a high speed scan, the DCS controller 19 can read these sixteen scalar values at up to a 10 mS rate.
[0106] Time waveform block data (and some scalar values) may be transferred to the DCS controller 19 via the DCS I/O bus 18 using a block data transfer method, such as Remote Desktop Protocol (RDP), at a rate that is lower than the scan rate of the sixteen scalar values.
[0107] As the scalar values generated by the machinery health monitoring module 10 are read by the DCS controller 19 , they are processed by software running in the DCS controller 19 in the same manner as any other DCS data. One primary function of the DCS controller 19 is to compare the scalar values with alarm limits. If the limits are exceeded, alarms are generated. Logic within the DCS controller 19 may also determine whether any actions should be taken based on alarm conditions, such as closing a relay. Operations including alarm relay logic, voting, and time delays are also performed in software by the DCS controller 19 . Preferably, DCS control outputs, such as relay outputs and 4-20 mA proportional outputs, are driven by standard output modules 23 of the DCS. Bulk prediction data is formatted in the LGC host processor 48 and is transmitted via an Ethernet port 52 a to a machine health management (MHM) analysis computer 54 for detailed analysis and display. Bulk protection data is also formatted in the LGC host processor 48 , but is transmitted via a separate Ethernet port 52 b to the DCS operator computer 60 .
[0108] In preferred embodiments, a DCS operator computer 60 includes an interface for displaying vibration parameters and other machine operational data (pressures, temperatures, speeds, alarm conditions, etc.) that are output from the DCS controller 19 .
[0109] A functional block diagram of a single channel of the field digital FPGA 36 is depicted in FIG. 2 . A preferred embodiment includes seven additional channels having the same layout as the one channel depicted in FIG. 2 . As described in more detail hereinafter, the channel digital waveform data may be routed through a variety of digital filters and integration stages before being converted to vibration overall values or packaged as “bulk” time waveforms for further analysis by software running on the LGC card 16 or for transmission to DCS software or MHM software.
[0110] As shown in FIG. 2 , an ADC interface 70 receives the eight channels of continuous, simultaneously sampled data from the ADC 28 of the field analog card 12 through the connector 34 (shown in FIG. 1 ). The data is preferably in the form of a multiplexed synchronous serial data stream in Serial Peripheral Interface (SPI) format. The ADC interface 70 de-multiplexes the data stream into eight separate channel data streams.
[0111] Although all eight channels could be used for vibration signal processing, in a preferred embodiment two of the eight channels may be used for tachometer measurement processing. Each tachometer measurement channel preferably includes:
a one-shot 110 , which is a programmable trigger “blanking” function that provides noise rejection for tachometer pulse trains having excessive jitter or noise; a divide-by-N 111 , which is a programmable pulse divider that divides pulse rates of tachometer signals produced by gears or code wheels; a reverse rotation detector 112 that determines the direction of shaft rotation by comparing the phase of two tachometer pulse signals; an RPM indicator 115 that calculates the RPM of the tachometer pulse stream as a scalar overall value. a zero-speed detector 113 that provides a “zero speed” indication when the tachometer has been inactive for a programmable interval, such as 0.1 s, 1 s, 10 s, or 100 s; and an over-speed detector 114 that provides an “over speed” indication when the tachometer exceeds a fixed 2 KHz or 62 KHz threshold. In alternative embodiments, this threshold may be programmable.
[0118] With continued reference to FIG. 2 , each of the eight independent parallel channels of signal processing in the FPGA 36 preferably includes the following components:
a high pass filter 72 for DC blocking, which is preferably be set to 0.01 Hz, 0.1 Hz, 1 Hz, or 10 Hz, and which may be selected or bypassed for the integrators described below based on the position of a switch 74 ; two stages of digital waveform integration, including a first integrator 76 and a second integrator 78 , which provide for data unit conversion from acceleration to velocity, acceleration to displacement, or velocity to displacement; a digital tracking band pass filter 82 having a band pass center frequency that is set by the tachometer frequency or multiples of the tachometer frequency, and that receives as input either the “normal” data stream (no integration), the single integration data stream, or the double integration data stream based on the position of a switch 80 , as described in more detail below; and scalar overall measurement calculation blocks 88 - 100 that determine several different waveform scalar overall values as described below.
[0123] In the preferred embodiment, the purpose of the digital tracking band pass filter 82 is to provide a narrow (high Q) band pass response with a center frequency determined by the RPM of a selected tachometer input. The center frequency may also be a selected integer multiple of the tachometer RPM. When a waveform passes through this filter, only vibration components corresponding to multiples of the turning speed of the monitored machine will remain. When the RMS, peak, or peak-to-peak scalar value of the resultant waveform is calculated by the corresponding FPGA calculation block ( 88 , 90 or 92 ), the result is same as a value that would be returned by an “nX peak” calculation performed in the application firmware of the LGC 16 . Because this scalar calculation is performed as a continuous process in the FPGA 36 rather than as a calculation done in firmware, it is better suited to be a “shutdown parameter” as compared to a corresponding value produced at a lower rate in firmware. One application of this measurement is in monitoring aero-derivative turbines, which generally require a tracking filter function for monitoring.
[0124] For several of the scalar overall values, the individual data type from which the values are calculated may be selected from the normal data stream, the single-integrated data stream, the double-integrated data stream, the high-pass filtered (DC blocked) data stream, or the tracking filter data stream based on the positions of the switches 84 a - 84 d . Also, several of the scalar overall channels have an individually-programmable low-pass filter 88 a - 88 d . In the preferred embodiment, these scalar overall values are generated independently of and in parallel to the time waveforms that are used for prediction or protection. The scalar overall measurement calculation blocks preferably include:
an RMS block 88 that determine the RMS value of the time waveform, where the RMS integration time may preferably be set to 0.01 s, 0.1 s, 1 s, or 10 s; a peak block 90 that determines the greater of the positive or negative waveform peak value relative to the average value of the waveform, which is preferably measured over a period determined by either the tachometer period or a programmable time delay; a peak-peak block 92 that determines the waveform peak-to-peak value over a period determined by either the tachometer period or a programmable time delay; an absolute +/− peak block 94 that determines the value of the most positive signal waveform excursion and the value of the most negative signal waveform excursion relative to the zero point of the measurement range, which is preferably measured over a period determined by either the tachometer period or a programmable time delay; a DC block 96 that determines the DC value of the time waveform, which has a measurement range preferably set to 0.01 Hz, 0.1 Hz, 1 Hz, or 10 Hz; and a PeakVue™ block 100 that determines a scalar value representing the peak value of the filtered and full-wave-rectified PeakVue™ waveform as described in U.S. Pat. No. 5,895,857 to Robinson et al. (incorporated herein by reference), which is preferably measured over a period determined by either the tachometer period or a programmable time delay. Full wave rectification and peak hold functions are implemented in the functional block 98 . The PeakVue™ waveform from the block 98 is also made available as a selectable input to the prediction time waveform and protection time waveform processing described herein.
[0131] The prediction time waveform processing section 116 of the FPGA 36 provides a continuous, filtered time waveform for use by any prediction monitoring functions. An independent lowpass filter/decimator 104 a is provided so that the prediction time waveform may be a different bandwidth than the protection time waveform. A waveform up-sampling block 106 provides data rate multiplication for analysis types such as Time Synchronous Averaging (TSA) and Order Tracking. Input to the prediction time waveform processing section 116 may be selected from the normal data stream, the single-integrated data stream, the double-integrated data stream, the high-pass filtered (DC blocked) data stream, or the PeakVue™ data stream based on the positions of the switch 102 a.
[0132] The protection time waveform section 118 of the FPGA 36 provides a continuous, filtered time waveform for use by protection monitoring functions. An independent low pass filter/decimator 104 b is provided so that the protection time waveform may be a different bandwidth than the prediction time waveform. Input to the protection time waveform processing section 118 may be selected from the normal data stream, the single-integrated data stream, the double-integrated data stream, the high-pass filtered (DC blocked) data stream, or the PeakVue™ data stream based on the positions of the switch 102 b.
[0133] Preferred embodiments provide for transient data collection, wherein continuous, parallel time waveforms from each signal processing channel may be collected for transmission to external data storage. Transient waveforms are preferably fixed in bandwidth and are collected from the protection time waveform data stream.
[0134] As shown in FIG. 1 , the scalar overall values, as well as the digitally filtered time waveforms, pass through the LGC interface 38 to the LGC logic board 16 for further processing and transportation to the DCS controller 19 via the DCS I/O backplane 18 or to external software applications running on the MHM data analysis computer 54 via the Ethernet port 52 .
[0135] FIG. 3 depicts an example of a control logic routine (also referred to herein as a control sheet) that is performed by the DCS controller 19 . In preferred embodiments, a control sheet is scheduled to execute at a predetermined rate, such as 1 sec, 0.1 sec, or 0.01 sec, by the DCS software running in the controller 19 . As the control sheet that controls the vibration process is executed, scalar overall vibration values are scanned from the DCS I/O bus 18 and output values are generated at the execution rate of the control sheet.
[0136] Logic functions performed by the control sheets preferably include:
Voting logic, such as logic to determine that an alert condition exists if 2 out of 2 scalar values are over threshold, or 2 out of 3 are over threshold. Combining vibration data with other DCS process parameter data (such as pressure and temperature). Trip multiply, which is a temporary condition determined by current machine state or by manual input that increases an alarm level. Trip multiply is typically used during the startup of a rotational machine, such as a turbine. As the turbine speeds up, it normally passes through at least one mechanical resonance frequency. Since higher than normal vibration conditions are measured during this resonance, “trip multiply” is used to temporarily raise some or all of the alarm levels to avoid a false alarm trip. The trip multiply input may be set manually with operator input, or automatically based on RPM or some other “machine state” input. Trip bypass, which is typically a manual input to suppress operation of the output logic to disable trip functions, such as during machine startup. Trip bypass is a function that suppresses either all generated vibration alarms, or any outputs that would be used as a trip control, or both. The trip bypass input may be set manually with operator input, or automatically based on some “machine state” input.
Time delay, which is a delay that is normally programmed to ensure that trip conditions have persisted for a specified time before allowing a machine trip to occur. Trip time delays are normally set to between 1 and 3 seconds as recommended by API 670 . The purpose of this delay is to reject false alarms caused by mechanical or electrical spikes or glitches.
[0141] Universal Sensor Interface
[0142] FIG. 4 depicts a preferred embodiment of a single channel of the field analog signal conditioning and sensor power card 12 . In this embodiment, the sensor power circuit 24 includes a software controllable switch 28 that is operable to switch between a +24V power supply 24 a , a −24V power supply 24 b , or a programmable constant current source 24 c . The signal for activating the switch 28 is preferably provided by the card configuration circuit 32 . As shown in FIG. 4 , the signal conditioning circuit 25 includes a software controllable switch 27 that is operable to switch between multiple sensor signal conditioning circuits having multiple input signal ranges, including a 0 to +24V circuit 25 a , a −24V to +24V and −12V to +12V circuit 25 b , and a 0 to −24V circuit 25 c . The signal for activating the switch 27 is preferably provided by the card configuration circuit 32 .
[0143] In a preferred embodiment, software running on the MHM data analysis computer 54 ( FIG. 1 ) receives input from a user to indicate the type of sensor 20 connected to each measurement channel. This input may be made by selection of the sensor type from a list of sensors in a dropdown menu displayed on a screen of the computer 54 . Based on the sensor type selection, the LGC 16 generates the data stream to set the latches of the card configuration circuit 32 to effect the appropriate settings of the switches 27 and 28 .
[0144] As discussed above, to minimize the complexity of the diagram, only one sensor channel is shown in FIG. 4 . In a preferred embodiment, there are eight sensor input channels that each include a software controllable sensor power circuit 24 and signal conditioning circuit 25 that are operated independently of the circuits 24 and 25 in the other channels. Thus, the channel input configurations are independent from channel to channel so that a variety of different sensor types may be supported simultaneously.
[0145] As the phrase is used herein, when two electrical components in a circuit are “electrically coupled,” it means that a terminal or pin of one component is in electrical communication with a terminal or pin of the other component, either directly or through one or more intervening components. Thus, for example, when a pin or terminal of a first component is electrically connected directly to a pin or terminal of a second component, the first and second components are “electrically coupled.” As another example, when a pin or terminal of the first component is electrically connected to a pin or terminal of an intervening component, and a pin or terminal of the intervening component is electrically connected to a pin or terminal of the second component, the first and second components are “electrically coupled.”
[0146] A detailed circuit diagram of a preferred embodiment of the +24V sensor power control circuit 24 a for one sensor channel is provided in FIG. 5 . Positive 24 VDC nominal power comes in from the left side (+24V_IN) and is low-pass filtered by resistor R 1 and capacitor C 1 . This filter attenuates residual switching noise from the input source and provides 3.3Ω of series resistance to impede sensor-induced transient currents traveling back into the circuit. Also coming in on the left side is the POWER_ENABLE digital control signal. A nominal threshold voltage of greater than +1.7V on POWER_ENABLE begins turning on the NPN transistor Q 2 (power enable switch) via the resistor divider composed of resistors R 13 a and R 14 a . With +3.3V applied to POWER_ENABLE, the collector voltage of transistor Q 2 approaches ground potential, pulling the bottom leg of resistor R 12 a down to about 0.05V. The resultant current through resistor R 12 a charges the bypass capacitor C 6 , pulling the LOW_RAIL net voltage level down to where it is clamped against the 20V LOW_RAIL_BIAS voltage by the Schottky diode D 2 B. This establishes 4.3V rails across the supply pins of the low-power push-pull comparator U 1 , the output of which turns on the PNP transistor Q 1 . While in the on state, the transistor Q 1 connects +24V through the Schottky diode D 3 to the external load.
[0147] When powered, the comparator U 1 continuously monitors the emitter current of the transistor Q 1 via the voltage developed across the resistor R 7 to detect a high load current demand indicative of a short circuit at the sensor power connector 22 . (The resistor R 7 is also referred to herein as the “second resistor.”) Because the voltage across the capacitor C 5 cannot change instantaneously, the response of the circuit to a shorted output is immediate. (The capacitor C 5 is also referred to herein as the “first capacitor.”) A sudden increase in the load current demand, which is reflected in the collector current of transistor Q 1 , causes a proportionate sudden increase in the voltage across resistor R 7 (developed by the emitter current of transistor Q 1 ). This drives the emitter voltage of transistor Q 1 lower relative to its base voltage which is AC “locked” by the capacitor C 5 , thereby prohibiting a further rise in collector current of transistor Q 1 and allowing time for the comparator U 1 to respond to the short circuit condition.
[0148] During normal operation, the voltage divider composed of resistors R 4 , R 2 and R 5 provides bias to the positive input of the comparator U 1 that is some tens of millivolts lower than the R 3 and R 6 resistor divider provides to the negative input, thereby sending the push-pull output voltage of the comparator U 1 to its negative limit. If the load current exceeds the nominal overload threshold of −39 mA, the output of the comparator U 1 changes state rapidly, swinging to its positive limit, which is bolstered by the feedback from the NPO capacitor C 4 (which integrates onto an NPO capacitor C 3 , increasing the effective time-constant). (The capacitors C 3 and C 4 are also referred to herein as the “third capacitor” and the “fourth capacitor”, respectively.) The output drive from the comparator U 1 injects charge into the capacitor C 5 through the resistor R 8 . (The resistor R 8 is also referred to herein as the “first resistor.”) This starves transistor Q 1 of base current, thereby causing the collector current to decay to about 36 mA before the comparator U 1 again changes state after about 0.5 uS. The collector current of transistor Q 1 then climbs back to 39 mA and the cycle repeats at a rate of about 1.0 MHz for as long as the load demand exceeds the overload threshold current. Output capacitor C 7 reduces the output switching noise to a level of only a few millivolts during limiting. (The capacitor C 7 is also referred to herein as the “second capacitor.”)
[0149] Nonlinear foldback limiting is provided by feedback through resistor R 10 and Zener diode Z 1 , for the reduction of Q 1 dissipation during the output short-circuit fault condition. (The resistor R 10 is also referred to herein as the “third.”) The NPO capacitor C 2 reduces the switching threshold jitter caused by avalanche noise from the diode Z 1 . When the output (Q 1 collector voltage) is pulled lower than about 6V, the diode Z 1 begins to conduct, thereby drawing current from the inverting node of the comparator U 1 . This modifies the comparator input bias level, and likewise the switching threshold of the circuit, thereby resulting in a lowered current limit that prevents excess Q 1 dissipation when the SENSOR_PWR output is shorted or pulled negative by an external source. The nominal foldback characteristic is depicted in FIG. 11 , wherein the following values indicate the relationship between output voltage and limiting current:
SENSOR_PWR=23.5V IOUT=38.7 mA SENSOR_PWR=6V IOUT=39.2 mA SENSOR_PWR=5V IOUT=35.9 mA SENSOR_PWR=4V IOUT=31.7 mA SENSOR_PWR=3V IOUT=27.3 mA SENSOR_PWR=2V IOUT=23.0 mA SENSOR_PWR=1V IOUT=18.6 mA SENSOR_PWR=0V IOUT=14.2 mA.
[0158] The output capacitor C 7 provides loop stability during foldback limiting. The 40V Schottky diode D 3 defends the circuitry against positive injected voltage of greater magnitude than the internal +24V supply. The protection diode TVS 1 has a bipolar surge clamping voltage just under 50V. In conjunction with diode D 3 , the diode TVS 1 protects against base-emitter breakdown of the transistor Q 1 . The −100V collector-emitter rating of transistor Q 1 defends against negative voltage injection. The resistor R 9 assists in the turnoff of transistor Q 1 during limiting and when the POWER_ENABLE input is in the low (off) state.
[0159] FIG. 13 depicts a simulation plot showing voltages associated with the power control circuit components in response to an output short circuit event. The voltage curves have been offset-normalized and scaled (the comparator output) for the purpose of display. The collector of the transistor Q 1 is sourcing 20 mA of current prior to the short circuit event, which initiates at the 100 μsec mark. After the short circuit event, the collector current rises sharply, peaking at about 300 mA within 4 nanoseconds. The peak magnitude of the current is limited by the finite available base drive and the finite beta of the transistor Q 1 . Due to the short duration of this transient, negligible power is involved. The voltage across the resistor R 7 (first resistor) increases in conjunction with the collector current, whereas the voltage across the capacitor C 5 (first capacitor) increases at a much lower rate, resulting in an abrupt and significant reduction of the emitter-base voltage. With the base drive thusly removed, the collector current drops off rapidly, crossing below 50 mA approximately 25 nanoseconds into the event. At approximately 50 nanoseconds, the comparator U 1 responds (bottom trace), removing base drive for the longer term.
[0160] FIG. 14 depicts the same events on an expanded the time scale to show the long term steady-state short circuit response. As shown in FIG. 14 , the Q 1 collector current is firstly reduced (via the nonlinear foldback) and secondly controlled by the output voltage of the comparator U 1 , oscillating at a rate of approximately 1 MHz.
[0161] A detailed circuit diagram of a preferred embodiment of the −24V sensor power control circuit 24 b for one sensor channel is provided in FIG. 6 . Negative 24 VDC nominal power comes in from the left side (−24V_IN) and is low-pass filtered by the combination of resistor R 1 and capacitor C 1 . This filter attenuates residual switching noise from the input source and provides 3.3Ω of series resistance to impede sensor-induced transient currents traveling back into the circuit. Also coming in on the left side is the POWER_ENABLE digital control signal. A nominal threshold voltage greater than +1.85V begins turning on the PNP transistor Q 2 (power enable switch) via the resistor divider formed by resistors R 13 b and R 14 b . With +3.3V applied to POWER_ENABLE, the Q 2 collector voltage closely follows the emitter, so that a +3.3V input control level on Q 2 pulls the bottom leg of resistor R 12 b up to about 3.2V. The resultant R 12 current charges the bypass capacitor C 6 , pulling the HIGH_RAIL voltage up until clamped against the −20V HIGH_RAIL_BIAS voltage by a Schottky diode D 2 B. This establishes 4.3V rails across the supply pins of the low-power comparator U 1 the output of which turns on the NPN transistor Q 1 . While in the on state, transistor Q 1 connects −24V through the Schottky diode D 3 to the external load.
[0162] When powered, the comparator U 1 continuously monitors the emitter current of transistor Q 1 via the voltage developed across resistor R 7 . During normal operation, the voltage divider composed of resistors R 4 , R 2 and R 5 provides bias to the positive input of comparator U 1 that is some tens of millivolts higher than the R 3 and R 6 divider provides to the negative input, thereby sending the push-pull output voltage of comparator U 1 to its positive limit. If the load current exceeds the nominal overload threshold of −39 mA the output of comparator U 1 changes state rapidly, swinging to its negative limit, being bolstered by the feedback from the NPO capacitor C 4 (which integrates onto an NPO capacitor C 3 , increasing the effective time-constant). The output sink from comparator U 1 pulls charge from capacitor C 5 through resistor R 8 . This starves transistor Q 1 of base current, causing the collector current to decay to about 36 mA before comparator U 1 again changes state after about 0.5 uS. The collector current then climbs back to 39 mA and the cycle repeats at a rate of about 1.0 MHz as long as the load demand exceeds the overload threshold current.
[0163] Output capacitor C 7 reduces the output switching noise to the level of only a few millivolts during limiting. Because the voltage across capacitor C 5 cannot change instantaneously, the response of the circuit to a shorted output is immediate. If the voltage across resistor R 7 suddenly increases, the emitter of transistor Q 1 is driven higher relative to the base, which is “locked” by capacitor C 5 . This prohibits a further rise in collector current and allows time for comparator U 1 to respond. Nonlinear foldback limiting is provided by feedback through resistor R 10 and Zener diode Z 1 , for the reduction of Q 1 dissipation during the output short-circuit fault condition. The NPO capacitor C 2 reduces the switching threshold jitter caused by avalanche noise from diode Z 1 . When the output magnitude (absolute value of transistor Q 1 collector voltage) is pulled lower than about 6V, diode Z 1 begins to conduct, thereby sourcing current into the inverting node of comparator U 1 . This modifies the comparator input bias level, and likewise the switching threshold of the circuit, resulting in a lowered current limit that prevents excess Q 1 dissipation when the SENSOR_PWR output is shorted or pulled positive by an external source. The nominal foldback characteristic is depicted in FIG. 12 , wherein the following values indicate the relationship between output voltage and limiting current:
SENSOR_PWR=−23.5V IOUT=−39.3 mA SENSOR_PWR=−6V IOUT=−39.8 mA SENSOR_PWR=−5V IOUT=−36.6 mA SENSOR_PWR=−4V IOUT=−32.4 mA SENSOR_PWR=−3V IOUT=−28.0 mA SENSOR_PWR=−2V IOUT=−23.6 mA SENSOR_PWR=−1V IOUT=−19.2 mA SENSOR_PWR=0V IOUT=−15.1 mA.
[0172] Output capacitor C 7 provides loop stability during foldback limiting. The 40V Schottky diode D 3 defends the circuitry against negative injected voltage of a magnitude greater than the internal −24V supply. Protection diode TVS 1 has a bipolar surge clamping voltage just under 50V. In conjunction with diode D 3 , the diode TVS 1 protects against base-emitter breakdown of transistor Q 1 . The 100V collector-emitter rating of transistor Q 1 defends against positive voltage injection. The resistor R 9 assists in the turnoff of transistor Q 1 during limiting and when the POWER_ENABLE input is in the low (off) state.
[0173] To minimize the complexity of the circuit diagrams, sensor power control circuits for only one sensor channel are depicted in FIGS. 5 and 6 . In a preferred embodiment, there are eight sensor input channels that each include sensor power control circuits 24 a and 24 b that operate independently of the circuits 24 a and 24 b in the other channels.
[0174] Sensor Signal Conditioning Amplifier
[0175] In a preferred embodiment, the sensor signal conditioning circuit 25 is a precision differential input and output amplifier designed to provide an optimal match from the various supported sensor signals to the range and frequency requirements of the ADC 28 . Some notable features of the amplifier 25 include the following:
Precision gain provided by use of 0.1%, 25 ppm/° C. resistors; Low DC offset (for accurate DC sensor measurements); Low offset drift with temperature (for consistent DC sensor measurements); Low noise levels, both wideband and 1/f noise; Nearly flat gain from DC to 40 KHz by use of gain equalization network; Incorporates requisite ADC Nyquist filtering; Differential input rejects common mode signals; High impedance inputs minimize sensor signal loading; Pre-filters protect op-amp inputs from RF interference; Nearly constant group delay from DC to 40 KHz; Better than 1% gain accuracy with no calibration from DC to 40 KHz; Single-rail 5 volt power avoids the need for negative supply; and Low material cost.
[0189] As depicted in the schematic diagram of FIG. 7 , the preferred embodiment of the signal conditioning amplifier 25 is a minimalist differential op-amp design that directly interfaces to the sensor signal input terminals 22 to provide signal scaling and offset, and additionally directly drives the differential inputs of the ADC 28 . It also incorporates the function of Nyquist filtering ahead of the ADC 28 , thereby providing a nominal 110 dB rejection of out-of-band signals. Gain flattening is provided by balanced positive feedback networks 56 a and 56 b , providing a nearly flat gain response from DC to 40 KHz.
[0190] With reference to FIG. 7 , the gain is established by the ratio of precision resistor R 17 to precision resistors R 15 plus R 16 . The differential balance is provided by the ratio of precision resistor R 20 to precision resistors R 18 and R 19 . The Nyquist filtering is partially realized by the RC network composed of resistors R 15 , R 16 , R 18 , R 19 , and capacitors C 8 , C 9 and C 10 . Further filtering is achieved by the interaction of resistor R 17 and capacitor C 11 , with balance provided by resistor R 20 and capacitor C 12 . Finally, resistors R 23 and R 24 and capacitor C 15 contribute filtering in the low MHz range in conjunction with op-amp bandwidth limitation. The balanced RC networks composed of C 13 /R 25 and C 14 /R 26 provide modest gain peaking to flatten the gain curve within the 0 to 40 KHz band of interest. Resistors R 23 and R 24 isolate the op-amp outputs from the capacitive load of capacitor C 15 to insure op-amp stability. Capacitor C 15 satisfies the interface requirement of the differential ADC input.
[0191] In the preferred embodiment, the DC feedback signal for the op-amp U 1 B (facilitated by R 22 ) and the feedback signals driving both gain flattening networks 56 a - 56 b are derived from the ADC+ and ADC− nets, i.e., from the output side of the stability-enhancing resistors R 23 and R 24 . The DC negative feedback for the 1st op-amp (facilitated by R 17 ) is derived from the ADC+ net. The AC feedback signals facilitated by C 11 and C 16 are derived directly from the op-amp outputs. Assuming ideal components (including the op-amps), this preferred embodiment introduces no DC error into measurements, i.e., it is ideally balanced for DC signals. FIG. 16 depicts Common Mode Rejection (CMR) histogram results of Monte Carlo simulations for the preferred circuit topology as depicted in FIG. 7 . Although this data was derived for a 100 Hz signal, the DC performance would be virtually identical.
[0192] The simulation curve of FIG. 8 shows the nominal normalized gain vs frequency of a preferred embodiment of the amplifier 25 up to the ADC over-sampling Nyquist frequency of 6.5536 MHz.
[0193] The normalized curve of FIG. 9 shows the flatness of the DC to 40 KHz pass-band gain of a preferred embodiment of the amplifier 25 , from the sensor signal inputs 22 to the input of the ADC 28 . FIG. 15 depicts a 10,000-run Monte Carlo simulation of the pass-band gain of a preferred embodiment of the amplifier 25 from DC to 40 KHz, using a purely random distribution of component tolerances. As FIG. 15 indicates, the pass-band gain varies by no more than about 0.8%, as calculated based on ((1002.7 mV−995.6 mV)÷999.15 mV)×100%.
[0194] FIG. 10 shows the normalized gain and output phase shift of a preferred embodiment of the amplifier 25 on a linear frequency scale. The phase (dotted curve) has a near-linear relationship to frequency. Input-to-output group delay is approximately 1.5 microseconds in the preferred embodiment.
[0195] The foregoing description of preferred embodiments for this invention have been presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the invention to the precise form disclosed. Obvious modifications or variations are possible in light of the above teachings. The embodiments are chosen and described in an effort to provide the best illustrations of the principles of the invention and its practical application, and to thereby enable one of ordinary skill in the art to utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated. All such modifications and variations are within the scope of the invention as determined by the appended claims when interpreted in accordance with the breadth to which they are fairly, legally, and equitably entitled.
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A universal sensor interface for a machine data acquisition system includes a sensor power control circuit that: (1) provides a fast and accurate limiting response to a short-circuit fault, (2) survives and automatically recovers from multiple concurrent continuous short-circuit faults with no interruption to the electrical and thermal integrity of the acquisition system, (3) reduces power consumption/dissipation when in a faulted condition, (4) isolates adverse effects of a faulted channel from uninvolved channels, (5) isolates adverse effects of loose wiring termination “chatter” from uninvolved channels, (6) protects against adverse effects resulting from “hot wiring” of sensors, (7) protects the acquisition system against reasonably anticipated installation wiring errors, and (8) minimizes the availability of spark-inducing energy to the data acquisition system.
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CROSS-REFERENCES TO RELATED APPLICATIONS
[0001] The present application claims benefit under 35 USC 119(e) of U.S. provisional Application No. 60/881,782 filed on Jan. 19, 2007, entitled Wireless Audio Streaming Transport System and U.S. provisional Application No. 60/885,624 filed on Jan. 18, 2007, entitled Wireless Audio Streaming Transport System, the contents of which are incorporated herein by reference in their entirety.
STATEMENT AS TO RIGHTS TO INVENTIONS MADE UNDER FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] NOT APPLICABLE
REFERENCE TO A “SEQUENCE LISTING,” A TABLE, OR A COMPUTER PROGRAM LISTING APPENDIX SUBMITTED ON A COMPACT DISK.
[0003] NOT APPLICABLE
BACKGROUND OF THE INVENTION
[0004] This patent application relates to the streaming of audio data in audio systems. In particularly, this invention relates to audio sound reproduction using addressable loudspeakers from as few as one to a typical number of eight loudspeakers and up to 128 addressable loudspeakers, all of which are disposed to provide an effect of sound surrounding the listener. Depending upon the embodiment, a larger number of audio speakers can also be used.
[0005] In order to understand the current invention, it is helpful to understand the manner in which a conductor conducts a band. A transmitter, or audio server, is analogous to a band conductor. The receivers, or speakers, are analogous to the band members. All the band members are always watching the conductor. They follow exactly what the conductor does. When the conductor has the baton in his hand and is moving it, the music is playing. If the conductor speeds up his rhythm, the band will also speed up. If the conductor slows down, the band will slow down. If the conductor should stop for any reason, the music will stop. The band members are very disciplined and only do what the conductor tells them to do. They are completely dependent upon the conductor and only take orders from the conductor.
[0006] The following patents relate generally to wireless audio speaker systems.
[0007] PCT Publication WO 97/29550 describes a wireless speaker system using a digital receiver/controller for controlling audio transducing equipment.
[0008] PCT Publication WO 99/23856 describes a home remote wireless speaker system as for earphone applications and which employs analog to digital and digital to analog conversion.
[0009] U.S. Pat. No. 6,590,982 describes a specific type of wireless transmitter with an infrared analog wireless stereo speaker system in a surround sound environment using either wireless stereo speakers or stereo earphones, as well as wired speakers.
[0010] Japanese Publication JP2004336252 and Korean Publications KR20020080153, KR20030021986, KR20040076983, and KR20040097506 describe various wireless speaker arrangements.
SUMMARY OF THE INVENTION
[0011] According to the invention, a sound reproduction and amplification system includes a digital central controller, a wireless transmitter and a plurality of addressable wireless digital receivers and digital amplifiers for driving loudspeakers or earphones, wherein Differential Pulse Width Modulation (DPWM) signals from the central control of the audio transmitter are sent to the addressable receivers, but no DPWM signals are sent unless there are changes in the target PWM signals. The control signaling is based on position mapping in each repetitive sequence of bits (i.e., each frame or word) in a digital communication channel, where only a single bit per channel per word is allotted to each receiver/amplifier/loudspeaker. If there is any change in output of any transmitter PWM from the audio processor (decoder), all the channel bits are sent to all the addressable loudspeakers. For example, in a 7.1 SS (Surround Sound) system, all 8 bits would be sent—not just one—for the seven distributed speakers plus one bass woofer. Depending upon the embodiment, a larger number of audio speakers can also be used.
[0012] Upon initial setup, each speaker is made addressable by assigning it a certain bit in the bit stream, and only looks at its own bit. For example, speaker # 3 would be assigned bit # 3 , and in a 7.1 SS system, when 8 bits are sent, speaker # 3 only looks at bit # 3 . All other bits are ignored. The bit that is assigned to each speaker is part of the initial set-up and can be performed wirelessly.
[0013] In operation, when the RF IC associated with a particular receiver/amplifier/speaker receives a packet of eight (8) audio data bits, it simply finds its own bit and outputs its bit to the output port immediately. The output port is connected to the input of a suitable amplifier, preferably a Class-D amplifier. This signal is connected to a transducer (driver), which then creates sound. The foregoing is assuming 8 speakers in the system, as for type 7.1 SS systems. However, the number of receivers is not in theory limited, although as a practical matter, any number of speakers may be in the system, from 1 to 128. This enables operation under monophonic, stereophonic, binaural, 2.1SS, 5.1SS, 7.1SS, etc. systems.
[0014] A number of advantages characterize the invention.
It enables high-quality wireless sound at a minimum cost. An all digital audio stream to the speakers provides high-quality audio. It eliminates the need for audio cables in audio systems. It eliminates the need for a central power amplifier in the audio system, as power amplifiers are built into the speakers themselves. It eliminates the need for a central or table-top A/V receiver in the audio system. All receiving units/speakers receive exactly the same audio data at exactly the same time frame. All speakers will always be in synchronization with each other, and the master device (audio server) will control the timing of all the speakers. The timing for decoding of any bit (inside the speaker) in the audio bit stream is exactly the same for all speaker/receiver amplifiers. It doesn't matter where the bit is in the stream, the time to output the bit is exactly the same, so all speakers are always in sync with each other. All speakers (sound stream) can be made to always be in synchronization with the video stream in audio/video systems by exacting preprogrammed delays to the audio in order to compensate for the time required to decode the video relative to the audio. There is no need for special audio decoding chip inside the speakers. It is bandwidth and power efficient, since only audio data that changes is sent wirelessly. The transmitter radio need not even be turned on unless there is a data change. The only cord required is the power cord for the amplifier in the speakers (for non-battery powered speakers). The speaker amplifiers provide only digital amplification within each speaker—there are no analog stages. All audio processing done on transmitter side. No need for each speaker to do individual processing. The controller/transmitter can do equalization, crossover, and all control. A system is readily adapted to any number of receiving elements. One only needs to increase the number of audio bits that are sent to equal the number of speakers in the system. For example, a surround sound system with 16 speakers would send 16 bits of DPWM signals over-the-air, and so on. Receiving units simply receive data, extract their own bits, and send its own bits out to drivers, so there is less hardware inside the receiving/speaker units, which reduces the cost. The vastly simpler hardware and firmware within each speaker lowers overall systems cost. PWM signals sent over-the-air are independent of the audio server decode scheme. Code going into the audio decoder on the audio server is independent of the addressing scheme. It may for example be CD, SACD, DVD-audio, DTS, DTS-HD, Dolby, or anything else. All of these encoding formats will be translated into PWM outputs to be sent over-the-air. The decoder PWM signals inside the transmitter define the maximum possible rate per channel, of the wireless links. For example, if the decoder output is programmed to be 384 Kbps, this is the maximum over-the-air rate per channel. The average over-the-air data rate, however, will be much lower, since only the PWM changes are sent over-the-air. The average over-the-air rate depends heavily on the type of audio--voice or music--that is played. The PWM transmit/receive scheme is independent of the wireless technology used. The radio may be Bluetooth, 2.4 GHz, 900 MHz, Cypress Wireless USB, or Ultra Wide Band (UWB), for example. The only requirement is that the data bandwidth of the radio must be greater than the number of channels times the PWM data rate used per channel (Number of channels×PWM data rate). For example, using stereo (2 channels) at a rate of 384 Kbps would require at least (2×384 Kbps)=768 Kbps data rate for the radio. Differential Pulse Width Modulation (DPWM) RF Encoding itself has certain advantages. There is no need for translation from PCM to PWM inside the speaker. The speed of PWM signals to receiving/speakers can be any speed. The receiver circuit can be readily adapted to work for virtually any PWM speed of interest. Normal speed for good audio quality would be 192 Kbps or higher, however. There are minimal delays in the decoding circuitry since no or very little audio processing is needed. The PWM signals may be stored directly on storage media, such as a CD, DVD, or a digital media player, so that no audio decoder would be needed at all, thus further simplifying system design. Ternary states are transparent to the transmitter so they can be generated automatically within each receiver/speaker unit, and so the transmitter never needs to generate any special Ternary codes. The invention will be better understood from the following detailed description in reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0042] FIG. 1 is a block diagram of a typical multiple-speaker audio system of the prior art with loudspeakers surrounding the listening space.
[0043] FIG. 2 is a block diagram of a first embodiment of a multiple-speaker audio system according to the invention with loudspeakers surrounding the listening space.
[0044] FIG. 3 is a block diagram of a second embodiment of a multiple-speaker audio system according to the invention with loudspeakers surrounding the listening space.
[0045] FIG. 4 is a block diagram of an audio transmitter section according to the invention.
[0046] FIG. 5 is a block diagram of an audio receiver section according to the invention.
[0047] FIG. 6 is a block diagram of an audio transmitter control logic subsystem according to the invention.
[0048] FIG. 7 is a diagram of a frame of digital information that is transmitted and received by an exemplary eight-speaker system according to the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0049] According to the invention a wireless audio streaming transport system is provided which redefines the basic architecture of a conventional surround sound audio system. Using Ultra Wide Band Radio (UWB) technology as a basic means of audio transport, the audio system no longer uses table-top components, such as audio players, including CD or DVD players, table-top audio amplifiers and/or Audio/Video (A/V) receivers.
[0050] FIG. 1 is a block diagram of the typical prior art surround sound audio system 10 with an audio server 12 , also conventionally called a preamplifier, coupled to a power amplifier 14 . A single power supply 16 services the audio server 12 , the audio amplifier 14 and a powered subwoofer speaker 18 . The audio amplifier 14 is coupled to and drives passive loudspeakers 21 - 27 with the various voices programmed for each channel.
[0051] By comparison, FIG. 2 is a block diagram of an audio system 100 of the present invention. The system 100 according to the invention includes a wireless audio server 112 with built-in short-range ultra wide band (UWB) transmitter 113 , coupled to receive power from a power line 130 from the AC power supply 116 , while transmitting to all (8) wireless UWB receivers 131 - 138 in addressable loudspeakers 121 - 128 . A power supply 116 is coupled to each of the loudspeakers 121 - 128 , including the subwoofer 128 , so that power for the speakers 121 - 128 is now inside each speaker 121 - 128 , thus obtaining energy to drive the internal amplifiers. Each speaker has its own A/C converting power module (not shown), which may be customized.
[0052] FIG. 3 shows a further embodiment the audio system 200 of the present invention wherein a portable or handheld wireless audio server 212 (e.g., powered by batteries) is employed. The wireless audio server 212 has a built-in UWB or similar short-range transmitter UWB 113 transmitting to all (8) wireless UW or similar receivers 131 - 138 in addressable loudspeakers 121 - 128 . The power supply 116 is coupled to the loudspeakers 121 - 128 , including the subwoofer 128 , for the internal amplifiers.
[0053] This configuration has many advantages over the current architecture. Some of these advantages are:
[0054] 1. The table-top audio amplifier is completely eliminated.
[0055] 2. The table-top Audio/Video (A/V) receiver is completely eliminated.
[0056] 3. All external speaker wires are completely eliminated.
[0057] 4. All external cables between audio amplifier and A/V receiver are completely eliminated.
[0058] 5. The Audio Server 212 is completely mobile. It can be taken to other rooms inside a house and instantly connected to speakers in that room. It can be carried by the user and used as a standalone device with earphones, albeit without the benefits of more than two channels of sound. In this way, a single Audio Server 212 is sufficient for an entire location, which may have many sets of audio speakers.
[0059] Properly configured, the overall cost of the audio system is reduced while the quality of audio and increasing the end-user flexibility and satisfaction is improved. As an extension of the wireless architecture and this unique technology, using an Ultra Wide Band Radio allows for, under appropriate circumstances, up to 128 speaker surround sound.
[0060] FIGS. 4 and 5 show in block diagram form a wireless audio transmitter section 113 and receiver section 131 of a system 100 , 200 according to the invention. In a typical embodiment of the wireless audio system 100 , 200 , the transmitter section 113 is inside an audio server, such as a CD player, DVD player, digital player such as an Apple iPod or MP3 player, even a mobile phone/PDA combination. The receiver section 131 is disposed inside a speaker 121 or even a wireless headphone (not shown). The receivers 131 etc. are slaved to the transmitter 113 and do only a minimal level of audio decoding in order to reproduce the intended audio output of their associated speaker.
[0061] The transmitter 113 includes or is coupled to an audio player 140 , such as a CD/DVD player or MP3 player, which serve as the storage media on which the music or audio program is stored in digitally encoded form or even analog audio form. The digital form is reproduced typically as a Pulse Code Modulation (PCM) audio stream 142 , but there are many different formats in which the audio may be encoded. The audio stream 142 is supplied to an audio processor PCM to PWM (pulse width modulation) decoder 144 , which outputs, under supervision of a control microprocessor 146 , a multi-channel PWM audio stream 148 for further processing. The audio processor PCM to PWM decoder 144 is ideally a semiconductor chip that decodes the audio stream 142 supplied from the storage media 140 . It may be a microprocessor or a digital signal processor (DSP), with special decoding firmware/software for the decoding scheme. For example, if the audio stream is encoded in DTS format, then the decoder 144 needs the codes necessary to decode the DTS format and then it re-encodes it in the multi-channel PWM audio stream 148 .
[0062] The N-channel PWM audio stream 148 is sent from the decoder 144 to a control logic subsystem 150 , ideally a special semiconductor chip. This chip 150 is operative to detect changes in the PWM audio stream, whereupon it latches the data if there is a change, outputs a filtered PWM audio stream 152 and runs cycles to a UWB transmitter subsystem 154 so that the audio data can be sent out on the air immediately.
[0063] FIG. 6 is a block diagram of the audio transmitter control logic 150 of the invention. In this example, stereo (two-channel) audio is illustrated, although the extension to eight or more channels is straightforward based on these principles. The control logic 150 includes an edge detector circuit 160 , a cycle control module 162 , data latches 164 , 166 in typical groups of redundant pairs, and a data multiplexer 166 .
[0064] If there is any change in any of the PWM audio channels (rising or falling edge), the data will be latched inside this control chip 150 and sent to the UWM chip 154 for immediate wireless transport to the speakers. In this manner, only changes in the PWM signals are sent. If there are no changes, nothing is sent. All the PWM channels latch simultaneously, and all the PWM signals are sent simultaneously to all the speakers. However, in the event one set of data latches 1 - 4 162 is occupied servicing a transmit cycle while PWM changes are occurring, the other set of data latches 164 is used to capture the change. After the first transfer is finished, a second data transfer to the UWB chip 154 is performed, transferring the data from latches 5 - 8 . This way no data is lost. After this transfer is finished, the controller reverts back to transferring data from latches 1 - 4 .
[0065] This control chip 150 works on rising and falling PWM edges from the decoder 144 . It does not use any form of sampling. It is therefore much faster and much more efficient than sampling techniques, and is also much more accurate.
[0066] In operation, the design PWM pulse length in the UWB receiver 131 ( FIG. 5 ) inside the speaker 121 should exactly match the PWM pulse length from the decoder chip 144 inside the transmitter. Otherwise the sound quality is affected. In addition, there should be minimum delay or offset to allow for speaker phase matching and synchronization.
[0067] The receiver of FIG. 4 is described as if a 7.1 surround sound system (8 speakers in 8 channels) is employed. The description is readily generalized to more or fewer channels. Upon initial setup, each receiver 131 - 138 (speaker 121 - 128 ) is assigned a number from 1 to 8. These numbers can be sent wireless to initialize each of the receivers 131 - 138 with a unique assignment code. These numbers or equivalent assignment codes are each then stored in non-volatile memory within each receiver. When the transmitter 113 on behalf of the audio server 112 , 212 sends the receiver 131 actual audio programming such as music, the individual receivers, being only interested in information related to the bit number that was assigned to it, ignores all other bits. The addressed receiver 131 using its receiving logic UWB chip 170 , filters out the bits of non-interest, captures the bit of interest and immediately send it to its output port 172 . This bit then goes to the power amplifier section 174 . If the bit has not changed, nothing will happen. If the bit has changed, the power amplifier 174 , typically a Class-D digital amplifier adapted to respond to bit-level changes, reacts accordingly. In this way, each receiver 131 only does minimal decoding and thus does not require a powerful processor. A rudimentary processor within the UWB chip 170 can easily perform this function. No external processor or complicated logic is needed, a noteworthy and inventive simplification and cost savings. This also reduces the overall system cost, since there are many simple receivers in the system, yet only one transmitter. As long as there is a reliable wireless connection between the transmitter and the receiver, audio and music quality is not compromised.
[0068] Delays are needed to assure synchronized audio output from the speakers. The receivers 131 may each receive a packet of audio data at the rate that the transmitter sees fit to send it. The receiver itself does not care how fast (or slow) the audio data is sent to it. The receiver simply gets the data when it is sent and outputs this bit to its port 172 . Better audio quality can be achieved, however, if the transmitter 113 sends audio data at a higher rate. The data rate determines the granularity of the possible audio changes, such as dynamic range, audio spectrum and the like. Faster data rates translate into finer granularity. As an example, the transmitter may send the audio data at 384 Kbps to each speaker. The data rate 384 Kbps translates into an allocation of 2.60 milliseconds per bit at each speaker. Thus the individual receivers normally are able to output data changes to its power section no faster than every 2.60 milliseconds. This does not mean the receiver output is always changing every 2.60 milliseconds, only that this is the fastest possible rate at which it can change. The average rate of change is actually much lower and depends heavily on the nature of the audio program. In addition, since bits are not set simultaneously at each speaker for instantaneous reproduction, it is necessary that a delay of at least one clock cycle be built in at the receivers to assure that each speaker responds in synchronism with all speakers in the system.
[0069] Bit Mapping is used to implement the invention. FIG. 7 is a chart illustrating the bit mapping that can be used for the PWM payload transmitted to the receivers. This illustrates bit mapping for 7.1 Surround Sound. In 8-Speaker (7.1) Surround Sound, the following applies:
Maximum number of speakers in system is 8. Can be any number of speakers from 1 to 8. Includes stereo, 2.1SS, 5.1SS, 7.1SS. 8 DPWM bits can be sent to all receivers/speakers simultaneously, allowing the receivers to filter out the bits not addressed to it. Each bit is mapped to a single receiver/speaker. Each receiver only looks at its own bit for changes. If no changes, then the receiver outputs nothing. If there is change in its own bit, then a receiver outputs this change to its port connected to the speaker amplifier. Timing for decode of any bit in stream is exactly the same. It doesn't matter where the bit is in the stream, the time to output the bit is exactly the same. This way speakers are always in sync with each other. Receivers and speakers may be redundant. More than one receiver can receive the same bit and output identical sound with another. A maximum 128-Speaker Surround Sound is within the contemplation of the invention, where the maximum number of unique receivers and associated transmitters in a system is 128. In fact, there can be any number of speakers from 1 to 128, including stereo, 2.1SS, 5.1SS, 7.1SS, etc. With a 128 bit long word, properly encoded, 128 DPWM bits can be sent so as to be received at all amplifiers of all speakers simultaneously, with each bit mapped to a speaker. Timing for decode of any bit in stream is exactly the same. It doesn't matter where the bit is in the stream, the time to output the bit is exactly the same. Thus speakers are always in synchronism with each other.
[0080] The invention has been explained with reference to specific embodiments. Other embodiments will be evident to those of ordinary skill in the art. Therefore it is not intended that this invention be limited, except as indicated by the appended claims.
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A sound reproduction and amplification system includes a digital central controller, a wireless transmitter and a plurality of addressable wireless digital receivers and digital amplifiers for driving loudspeakers or earphones, wherein Differential Pulse Width Modulation (DPWM) signals from the central control of the audio transmitter are sent to the addressable receivers, but no DPWM signals are sent unless there are changes in the target PWM signals. The control signaling is based on position mapping in each repetitive sequence of bits (i.e., each frame or word) in a digital communication channel, where only a single bit per channel per word is allotted to each receiver/amplifier/loudspeaker. If there is any change in output of any transmitter PWM from the audio processor (decoder), all the channel bits are sent to all the addressable loudspeakers.
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FIELD OF THE INVENTION
The present invention relates to a fuel injection device for an internal combustion engine.
BACKGROUND INFORMATION
With a conventional fuel injection device (described in British Patent Application No. 2 281 101), a fuel vaporizer has a vaporizer chamber into which fuel is injected by an injection valve through an inlet orifice. When an ordinary glow plug that is arranged in the vaporizer chamber is heated, it causes the fuel to evaporate. The fuel vapor formed in the vaporizer chamber can escape through a small nozzle into the intake area of a downstream combustion chamber together with air entering the vaporizer chamber through a corresponding air inlet.
When the glow plug is deactivated after the warm-up phase after a cold start, fuel is discharged through the vaporizer chamber only due to the internal combustion engine intake air flowing through the vaporizer chamber, with the small nozzle causing the fuel to be atomized.
With another conventional fuel injection device (described in German Patent Application No. 28 43 534), a heating element-with vaporizer surfaces is provided upstream from the spray orifice in the fuel discharge area of an injection valve on the intake side, so that the fuel to be vaporized is sprayed onto the vaporizer surfaces of the heating element. A vaporizer area defined by the heating element is open on the outlet side. With this convential fuel injection device, a heating element with a honeycomb structure that is likewise open on the outlet side may also be provided to improve the heat transfer to the fuel.
If such a heating element in the spray area of the injection valve is not heated, it presents a relatively large obstacle for the sprayed stream of fuel and interferes with fuel processing to produce the mixture.
Therefore, with conventional fuel vaporizers arranged in the spray area of an injection valve, problems occur in processing the mixture, i.e., in processing the fuel to produce the fuel-air mixture when the fuel vaporizer is not heated electrically during continuous operation of the internal combustion engine, because the fuel vaporizer has a negative effect on the fuel stream produced by the injection valve and thus interferes with fuel delivery.
Another conventional fuel injection device described in German Patent No. 20 57 972 includes injection valves that are assigned to the individual combustion chambers of an internal combustion engine and receive fuel through pipelines from a fuel metering device. The fuel thus supplied enters a valve chamber of the respective injection valve that is closed by an outlet valve on the outlet end. The outlet valve includes a valve body that is preloaded in its closed position by a spring and is opened by the fuel pressure in the valve chamber when the force exerted by the fuel on the valve body exceeds the closing force of the spring.
Each injection valve has a heating body in its interior with which the fuel in the injection valve can be heated so that it evaporates even when the engine is cold, namely when it flows out through the outlet valve and expands in the outlet area of the injection valve.
SUMMARY OF THE INVENTION
One of the advantages of a fuel injection device according to the present invention is that a fuel vaporizer of the fuel injection device assures a very good fuel processing in all heating states, i.e., in heating operation for complete or partial vaporization and in the unheated state, because the fuel is always discharged at a preset pressure. The metering function of a standard injection valve is not affected by the fuel vaporizer because a constant difference between the fuel pressure in the injection valve and the pressure in the fuel vaporizer is guaranteed by the opening pressure of the outlet valve.
Therefore, the fuel injection device according to the present invention makes it possible to reduce both fuel consumption and pollution emissions, especially in a cold start and during the warm-up phase, because it eliminates any enrichment of the fuel-air mixture during start-up and acceleration.
Since the entire heating area in the fuel vaporizer is repeatedly rinsed with liquid fuel, deposits can be prevented reliably.
The danger of spontaneous ignition of the fuel in the heating area of the fuel vaporizer, i.e., in the area of the vaporizer, is practically eliminated, because only fuel and/or fuel vapor is present there.
If a gas channel is provided around the fuel vaporizer in the fuel injection device according to the present invention, heating of the fuel during continuous operation of the internal combustion engine can be provided, even when the electric heating is turned off, by supplying hot exhaust gas from the internal combustion engine to the gas channel. If air is supplied to the gas channel instead of exhaust gas, any fuel leaving the outlet valve in liquid form is finely atomized by the air stream.
In addition to using PTC heating elements, i.e., heating elements with a positive temperature coefficient, it is also possible to use NTC heating elements, i.e., heating elements with a negative temperature coefficient that can be controlled by an external control device. Use of NTC heating elements is advantageous with regard to manufacturing costs and tolerances and is economical in particular when external temperature control for the heating elements is necessary because of differences in fuel throughput.
Since the fuel vaporizer can readily be adapted to any injection valve, the fuel injection device according to the present invention can be used with any conventional injection valve that has a metering function.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a schematic section through a fuel injection device according to a first embodiment of the present invention.
FIG. 2 shows a schematic section through a fuel vaporizer of the fuel injection device according to a second embodiment of the present invention.
FIG. 3 shows a schematic section through the fuel vaporizer of the fuel injection device according to a third embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIG. 1, a fuel injection device for an internal combustion engine has a fuel-metering injection valve 10 that has a spray orifice 12 in its outlet face 11. A valve seat 14 that works together with a valve needle 13 is provided for the spray orifice 12.
In the illustrated embodiment, valve needle 13 has a spray pin 13' that extends through spray orifice 12 and is arranged in outlet orifice 12 when injection valve 10 is opened so that it shapes the fuel spray in a layer. The sprayed fuel layer essentially forms the envelope of a cone in spray area 15. However, the shape development of the fuel layer or of a stream of fuel may also be achieved by other methods including using one or more parts formed in an appropriate manner to achieve a desired shape. For example, it is possible to provide a perforated spray disk with one or more spray holes or to design the outlet orifice as an annular gap.
A fuel vaporizer 16 including a casing 17 with a sleeve-like mounting section 18 is tightly attached to the end of injection valve 10 on the intake side. An annular web 19 provided on the inside circumference of mounting section 18 engages with an annular groove 20 provided on the intake end of injection valve 10 and thus keeps fuel vaporizer 16 tightly on injection valve 10. Fuel vaporizer 16 may also be mounted differently. For example, it is also possible to provide an annular web on injection valve 10 to engage with a ring flange extending radially inward or a suitable annular groove provided on the inside of mounting section 18. The present invention also contemplates a tight pressure-fitting connection between fuel vaporizer 16 and injection valve 10.
Mounting section 18 of casing 17 is connected to receptacle sleeve 22 that extends away from injection valve 10 and peripherally surrounds the free spray area 15 of injection valve 10 and a vaporizer area 21 attached to it. Two heating elements 23 are arranged in the receptacle sleeve with some distance between them in the axial direction, are secured mechanically by metallic holding parts 24, and are electrically grounded. Holding parts 24 are for assisting the heat transfer from heating elements 23 to the sprayed fuel without interfering with the flow of fuel into vaporizer area 21.
Heating elements 23 are connected to a voltage source (not shown) through an electric line 25 that is electrically insulated. The electric line 25 is introduced into casing 17 with a gas-tight seal.
As illustrated in FIG. 1, heating elements 23 include ring disks. However, other geometric designs of heating elements 23 are also contemplated by the present invention.
FIG. 2 shows as an example of two sleeve-shaped heating elements 23' that are coaxial with one another and with receptacle sleeve 22. The heating elements 23' are secured by a common holding part 24. Holding part 24 is provided on the side of heating element 23' facing away from injection valve 10 and is designed (in a manner not shown in detail here) not to interfere with the discharge of fuel vapor out of vaporizer area 21. Inner heating element 23' is preferably designed to be shorter in the axial direction than the outer element 23. Heating elements 23' are connected electrically to line 25 through a branch line 26.
FIG. 3 shows another embodiment of heating elements 23", wherein heating elements 23" are arranged concentrically with one another and with receptacle sleeve 22. The two heating elements 23" are secured at their axial ends by holding parts 24. Vaporizer area 21 between heating elements 23" is packed with a porous material 27, e.g., a porous ceramic or a fine metal wool, to further improve the transfer of heat to the fuel.
Regardless of geometric design, individual heating elements 23, 23' and 23" may be made of a PTC resistance material, i.e., a resistance material with a positive temperature coefficient. However, it is also possible to use an NTC resistance material, i.e., a resistance material with a negative temperature coefficient. In this case, an external temperature control must be provided. For this purpose, a temperature signal corresponding to the temperature of heating elements 23, 23' and 23" is sent to a temperature control device (not shown) that may be integrated into a controller for the internal combustion engine. To form the temperature signal, either the temperature-dependent internal resistance of heating elements 23, 23', and 23" may be used, or a temperature probe (not shown) may be provided on one of heating elements 23, 23', and 23".
It is especially advantageous to use heating elements 23, 23' and 23" made of an NTC resistance material when temperature control is necessary for heating elements 23, 23' and 23" due to, for example, differences in fuel throughput.
In the outflow direction of the fuel vapor, an outlet valve 30, preferably pressure regulated, which closes vaporizer area 21 at the outlet, is provided behind vaporizer area 21, i.e., on the side of heating elements 23, 23' and 23" facing away from injection valve 10.
Outlet valve 30, which includes a valve seat 33 and a needle-shaped valve body 31 with a closing head 32 on its end facing away from injection valve 10, is arranged in holding sleeve 34. Holding sleeve 34 has a seal ring 35 on its outside that is in contact with the inside of receptacle sleeve 22. The seal ring 35 is inserted between a flange 36 projecting radially outward from holding sleeve 34 and a flange 37 that also projects outward from a supporting sleeve 38 arranged on holding sleeve 34. On its outlet end, holding sleeve 34 has a holding flange 34' that extends radially inward and has a valve seat body 39 carrying valve seat 33 attached to it.
Valve body 31 that extends through a through opening 40, surrounded by valve seat 33 in valve seat body 39 is preloaded by a closing spring 41, preferably designed as a compression spring. The closing spring 41 is mounted between valve seat body 39 and a supporting disk 42 arranged on the end of valve body 31 facing away from closing head 32. The valve body 31 is preloaded to keep injection valve 10 in its closed position where closing head 32 provided for the outside area of outlet valve 30 is in contact with valve seat 33.
The valve closing force produced by closing spring 41 is preset so that outlet valve 30 opens at an internal pressure of 2000 hPa to 4000 hPa.
Instead of the mechanically produced closing force, the present invention also contemplates a magnetically produced closing force supplied by, for example, a permanent magnet.
Another sleeve-shaped heating element 43 that is provided for outlet valve 30 is mounted on valve seat body 39 and surrounds valve body 31 as well as closing spring 41. Heating element 43 is connected both to electric line 25 and to holding sleeve 34 at an outside circumferential section.
In one embodiment, a jacket sleeve 50 may optionally be provided around casing 17, forming together with casing 17 a cylindrical annular gas channel 51 that can receive at its inlet either air or preferably exhaust gas recycled from the internal combustion engine through a connection 52. At the outlet end, jacket sleeve 50 is bent inward like a flange and is in airtight contact with casing 17 at bent section 53. Casing 17 has several outlet orifices 54 behind the contact area of ring gasket 35 on the end facing away from injection valve 10 as seen in the direction of fuel injection; these orifices may be arranged at equal intervals around the periphery, for example.
To guide a stream of air or exhaust along the outside of holding sleeve 34, the end of casing 17 or receptacle sleeve 22 facing away from injection valve 10 extends as far as the front end of holding sleeve 34 for outlet valve 30 and thus together with holding sleeve 34 it forms a cylindrical annular outlet channel 55 surrounding the holding sleeve. The front section of receptacle sleeve 22 which serves as a gas baffle wall for the stream of air or exhaust gas and surrounds outlet channel 55 on the outside may have a slight inward conical taper.
Gas channel 51 surrounding fuel vaporizer 16 is designed together with outlet orifices 54 so that intake air or recycled exhaust from the internal combustion engine escapes at a high velocity from an annular gap-shaped gas outlet orifice 56 formed between holding sleeve 34 and receptacle sleeve 22.
For installation of the fuel injection device described herein the wall of an intake tube 60, shown only with dotted lines in FIG. 1, a holding ring 61 with a U-shaped cross section that is open to the outside radially is provided on jacket sleeve 50 into which a seal ring 62 is inserted; when installed, the seal ring 62 is in tight contact with inside wall 63 of a corresponding orifice 64 in intake tube 60. Holding ring 61 together with ring gasket 62 provide thermal insulation between fuel vaporizer 16 and intake tube 60 of the internal combustion engine. If jacket sleeve 50 is not provided to form gas channel 51 surrounding fuel vaporizer 16, holding ring 61 is placed directly on casing 17.
In operation of the internal combustion engine, heating elements 23, 23' and 23" in the vaporizer area and heating element 43 provided for outlet valve 30 are electrically heated during the warm-up phase after starting the engine. Fuel injected by fuel metering injection valve 10 into spray area 15 in fuel vaporizer 16 goes from there to vaporizer area 21, where it strikes heating elements 23, 23', 23", holding parts 24 and, with a third embodiment shown in FIG. 3, also the porous material 27 in vaporizer area 21 and is heated and at least partially vaporized therein. Depending on the shape of the injected fuel stream, some of the liquid fuel may also strike the inside surface of receptacle sleeve 22, where it is also evaporated if receptacle sleeve 22 is hot enough.
Due to the vaporization of fuel, the pressure inside fuel vaporizer 16 increases until it reaches the preset opening pressure, then outlet valve 30 opens and fuel is discharged. The hot discharged fuel, partially liquid and partially vapor, is additionally heated by heating element 43 and by outlet valve 30 which is also heated by the heating element 43.
As the hot mixture of liquid and vaporized fuel is discharged into intake tube 60 under a defined pressure, its expansion causes additional vaporization of liquid fuel. Heating elements 23, 23' and 23" are designed and/or are controlled by the temperature regulator to regulate the vapor/liquid ratio of fuel in the intake tube to the required level to supply an optimum fuel/air mixture for operation of the internal combustion engine.
An important advantage of fuel vaporizer 16 according to the present invention is that the injection of liquid fuel and the discharge of the hot mixture of liquid and vaporized fuel can overlap in time without impairing the fuel metering function of injection valve 10.
Even when heating elements 23, 23' and 23" are turned off, the pressure in fuel vaporizer 16 increases up to the opening pressure due to fuel at a higher pressure being injected by injection valve 10. If the fuel pressure in the fuel vaporizer reaches the opening pressure when the heating is turned off, the essentially liquid fuel is discharged under this defined preset pressure, typically between 2000 hPa and 4000 hPa, and is thus atomized, so that neither the fuel delivery nor the fuel processing is impaired by fuel vaporizer 16 with vaporizer area 21 closed by outlet valve 30.
If, during continuous operation of the internal combustion engine, hot exhaust from the internal combustion engine is supplied to the optional gas channel 51, then the fuel vaporizer 16 is heated, and fuel is vaporized without any additional electric heating. Alternatively, atomization of fuel is supported by introducing air into gas channel 51.
The fuel metering function of injection valve 10, i.e., the amount of fuel metered per unit of injection time, is maintained unchanged due to the utilization of the pressure gradations between the pressure in injection valve 10 and the outlet pressure of fuel vaporizer 16 and between the outlet pressure and the pressure in intake tube 60.
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A fuel injection valve for an internal combustion engine includes a metering injection valve and a fuel vaporizer that is arranged upstream from an outlet spray orifice of the injection valve (10) on the intake end and has a vaporizer area with at least one assigned electric heating element. To assure in particular that the fuel vaporizer guarantees very good fuel processing in all heating states, i.e., in heating operation for complete or partial vaporization and in the unheated state, the vaporizer area that accommodates at least one heating element is closed at the outlet end by an outlet valve.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. application Ser. No. 11/412,001, filed on Apr. 25, 2006, which is hereby incorporated herein in its entirety by reference.
FIELD OF THE INVENTION
[0002] Example embodiments of the present invention relate generally to processing an insurance claim. Example embodiments further relate to processing insurance claims according to a plurality of rules.
BACKGROUND OF THE INVENTION
[0003] In many cases, insurance providers will contract with other companies to process the numerous insurance claims submitted by customers of the insurance provider. These companies, referred to as “insurance processors,” will receive policy information from the various insurance providers and then use this information to process the incoming claims. The policy information received may include, for example, information relating to one or more authorized providers (e.g., specific medical doctors or facilities, psychiatrists, etc.), the different benefits provided, and/or various eligibility requirements for each of the respective insurance policies offered by the insurance provider.
[0004] Because the insurance processor receives policy information from multiple sources (e.g., different insurance providers), it is often the case that the insurance processor will receive information in many different formats; each source, for example, having a different format for the policy information provided. For example, one insurance provider may designate the authorized providers using a five-digit numeric code. By contrast, another may use a seven-digit alphanumeric code. In addition, various insurance providers may have different ways of describing the fee schedule or method of calculating the benefit.
[0005] When an insurance processor receives policy information from various sources in various formats, it would be beneficial, and perhaps may even be necessary, for the insurance processor to be able to put all of the received information into a consistent format. The insurance processor may select a format that is used by a majority of the insurance providers, if such a format exists, or the insurance processor may have a particular format that is preferred or even necessary for use with the insurance processor's system.
[0006] A need, therefore, exists for enabling the insurance processor to efficiently and consistently reformat received insurance-related data into a consistent format that can be used when processing incoming insurance claims.
[0007] In addition, the policy information received by an insurance processor, such as the list of authorized providers and/or the various benefits and eligibility requirements, will often be in the form of, or in addition to, a set of complex rules and parameters to be used when processing the submitted insurance claims. These rules and parameters may be used to determine, for example, if the service on the claim is covered by the policy for the particular recipient, if there is a copay, coinsurance or other penalty, if the service is in or out of network, and/or which pricing methodology/fee schedule should be used to compute the allowed charges.
[0008] In a typical scenario, each parameter or rule of each insurance policy for each insurance provider would need to be translated into its own coding structure, or set of computer programming instructions. This can be very time consuming. Processing an insurance claim would then require running each set of computer programming instructions sequentially. In addition to being time consuming, this process may prevent a person who is unfamiliar with programming languages to ascertain whether or not the rule or parameter has been accurately translated. It further makes it difficult for the various rules or parameters to be changed at a later point in time, since this would likely require retranslating the entire rule or parameter into a new set of computer programming instructions.
[0009] A need, therefore, exists for an improved process of receiving incoming insurance policy information and converting the information, if necessary, into a format that can be easily understood and, if necessary, changed, yet still capable of being used by a claims processing engine when processing a submitted insurance claim.
BRIEF SUMMARY OF THE INVENTION
[0010] Generally described, example embodiments of the present invention provide an improvement over the known prior art by, among other things, providing a method, system and computer program product for creating software that can be used to reformat incoming insurance-related data into a format that conforms to the requirements or preferences of the receiving party. In particular, the software generated is capable of causing a particular action to be taken which will result in the transfer of the received data from one format to another in response to certain conditions being met. These conditions are defined by a decision table, from which the software is automatically generated. Example embodiments of the present invention further provide a means for using the incoming insurance-related data, which has been reformatted where necessary, to create a user-friendly table that defines the rules and parameters of a particular insurance policy. The table is capable of being easily understood by those unfamiliar with the intricacies of insurance claim processing and programming code, and is further capable of being read by a claims processing engine when processing an insurance claim.
[0011] According to one aspect of the present invention a method is provided for creating software for reformatting insurance-related data received from a first party to a format that is acceptable to a second party. In one example embodiment, the method includes: (1) creating a decision table based on a combination of conditions defining when a respective one of a plurality of reformatting actions should be taken with respect to the data received; (2) providing the decision table to a software generator; and (3) automatically generating computer programming instructions based upon the decision table and configured to cause the respective reformatting action to be taken based on the combination of conditions from the decision table upon execution thereof.
[0012] In one example embodiment, a first party offers one or more insurance policies to one or more third parties, and a second party processes insurance claims submitted by the third parties under the insurance policies. In this embodiment, the insurance-related data may include data relating to one or more providers authorized under a respective insurance policy offered by the first party. Alternatively, the insurance-related data may include data relating to one or more benefits under a respective insurance policy offered by the first party, or data relating to one or more eligibility requirements for respective insurance policies.
[0013] In one example embodiment, creating a decision table is repeated for each of the plurality of reformatting actions, such that a different decision table is created for each reformatting action based on a different combination of conditions defining when the reformatting action, with which the decision table is associated, should be taken. The method of this example embodiment may further include repeatedly providing the decision table to the software generator for each of the decision tables created. In this case, for each of the different decision tables, a different set of computer programming instructions is automatically generated that causes the respective reformatting action, with which the decision table is associated, to be taken based on the combination of conditions from the decision table.
[0014] According to another aspect of the invention, a system is provided for creating software for reformatting insurance-related data received from a first party to a format that is acceptable to a second party. In one example embodiment, the system includes a software generator and a decision table. The decision table, which is instantiated in a memory device and accessible by the software generator, defines a combination of conditions that must occur in order for a respective one of a plurality of reformatting actions to be taken with respect to the data received. The software generator automatically generates computer programming instructions based upon the decision table and configured to cause the respective reformatting action to be taken based on the combination of conditions from the decision table upon execution thereof.
[0015] According to yet another aspect of the invention, a computer program product is provided for creating software for reformatting insurance-related data received from a first party to a format that is acceptable to a second party. The computer program product includes at least one computer-readable storage medium having computer-readable program code portions stored therein. In one example embodiment, the computer-readable program code portions include: (1) a first executable portion for receiving a decision table that defines a combination of conditions that must occur for a respective one of a plurality of reformatting actions to be taken with respect to the data received; and (2) a second executable portion for automatically generating computer programming instructions based upon the decision table and configured to cause the respective reformatting action to be taken based on the combination of conditions from the decision table upon execution thereof.
[0016] According to another aspect of the present invention, a method is provided for processing an insurance claim. In one example embodiment, the method includes: (1) receiving policy information associated with a particular insurance policy, wherein the policy information comprises a plurality of rules that define one or more benefits under the insurance policy; (2) organizing the plurality of rules into a predefined tabular format; (3) providing a claims processing engine with the organized plurality of rules; and (4) thereafter processing the insurance claim in accordance with the plurality of rules.
[0017] According to a further aspect of the present invention, a method is provided for processing an insurance claim. In one example embodiment, the method comprises receiving policy information associated with a particular insurance policy. In this example embodiment, the policy information comprises a plurality of rules that define one or more benefits under the insurance policy. The method of this example embodiment further comprises organizing the plurality of rules into a predefined tabular format. Additionally, the method of this example embodiment comprises providing a claims processing engine with the organized plurality of rules; and thereafter processing the insurance claim in accordance with the plurality of rules.
[0018] According to a further aspect of the present invention, a computer program product is provided for processing an insurance claim. The computer program product comprises at least one computer-readable storage medium having computer-readable program code portions stored therein. In one example embodiment, the computer program product comprises an executable portion for receiving policy information associated with a particular insurance policy. In this example embodiment, the policy information comprises a plurality of rules that define one or more benefits under the insurance policy. The computer program product of this example embodiment further comprises an executable portion for organizing the plurality of rules into a predefined tabular format. Additionally, the computer program product of this example embodiment comprises an executable portion for providing a claims processing engine with the organized plurality of rules; and thereafter processing the insurance claim in accordance with the plurality of rules.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0019] Having thus described the invention in general terms, reference will now be made to the accompanying drawings, which are not necessarily drawn to scale, and wherein:
[0020] FIG. 1 illustrates a system which may be used in accordance with example embodiments of the present invention;
[0021] FIG. 2 is a flow chart illustrating a method of generating software to be used for reformatting incoming insurance-related data in accordance with example embodiments of the present invention;
[0022] FIG. 3 is a decision table which may be defined for each of a plurality of actions to be taken when reformatting incoming insurance-related data and from which software may be automatically generated in accordance with example embodiments of the present invention;
[0023] FIG. 4 is a flow chart illustrating a method of converting the insurance-related data received into a user-friendly table and using the table to process insurance claims in accordance with example embodiments of the present invention; and
[0024] FIG. 5 illustrates a user-friendly table created in accordance with example embodiments of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0025] The present inventions now will be described more fully hereinafter with reference to the accompanying drawings, in which some, but not all embodiments of the inventions are shown. Indeed, these inventions may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements. Like numbers refer to like elements throughout.
[0026] Reference is now made to FIG. 1 , which very generally illustrates a system in which example embodiments of the present invention may be implemented. As shown, the system may include a decision table 102 , which may be stored in a memory device and an example of which is illustrated in FIG. 3 . The decision table 102 defines a set of conditions that must be met in order for a particular action to be taken with respect to incoming insurance-related data. As is discussed in more detail below, an insurance processing company (hereinafter “an insurance processor”) may receive data from one or more customers (i.e., insurance providers) that define the insurance policies offered by those customers. For example, the data may define the authorized providers, the available benefits and/or the eligibility requirements for each policy offered. The data received from the various customers is likely in a format that is particular to each customer. For example, one customer may use provider ID numbers that are five digits long, while another uses provider ID numbers that are six digits long. In some instances none of these formats conform to the format preferred, or at least predefined, by the insurance processor (e.g., the insurance processor may use a 10-digit provider ID).
[0027] It would, therefore, be advantageous for the insurance processor to be able to reformat the incoming insurance-related data to its predefined format. Doing so may require that certain actions be taken with respect to the incoming data. For example, one action may be to change the provider IDs. The change may be based on a database maintained by the insurance processor that correlates the provider IDs used by its customers to those used by the insurance processor. Other examples of actions to be taken will be readily apparent to those of ordinary skill in the art, such as moving information contained in one field from an input to an output, or vice versa, translating data in a particular field from one format to another, left or right justifying data in one or more fields, removing dollar signs ($), filling in particular data fields with leading or ending zeros, or converting leading or ending zeros to spaces. In order to effect a change (or other action) at the appropriate time, such as the reformatting of certain incoming data, a set of conditions is first defined and then combined in a manner that dictates when the action will be taken. It is this combination of conditions that is defined by the decision table 102 . Once the decision table has been defined and stored, it is fed into a software generator 104 , which automatically generates a software application 106 , which can then be executed to evaluate incoming data in order to take actions that will effect a format change of the data where applicable. A software generator 104 is a computing application including or capable of accessing the decision table 102 in memory. The software generator 104 is capable of translating a set of instructions implied by the decision table 102 into a computer executable set of instructions (i.e., the software application 106 ) and storing that set of instructions or application for future execution. Either the same or a different computing application is capable of executing the software application 106 , which is stored in the same or different memory device. In general, therefore, the software generator 104 is a computer program or set of computer executable instructions configured to create another set of computer executable instructions (i.e., the software application 106 ) from a set of parameters (i.e., derived from the decision table 102 ).
[0028] FIG. 2 illustrates in more detail the steps which may be taken in example embodiments of the present invention when generating software for reformatting incoming insurance-related data. As shown, the first step, Step 201 , may be to receive the insurance-related data from a first party (e.g., one of several insurance providers for which the insurance processor processes incoming insurance claims). It may then be determined, in Step 202 , which actions may need to be taken with respect to the type of data received. For example, where different field sizes are used, varying provider IDs are used, or where it is necessary that specific fields be populated in order to function within the insurance processor's system, specific actions relating to each of these inconsistencies in data will need to be taken. For example, where different field sizes are used, the information contained in a field may need to be truncated or, alternatively, to have one or more spacers (e.g., leading or ending zeroes) added to it. As discussed above, another action which may be taken may be to access a database that correlates various values (e.g., provider ID numbers) used by a customer to those predefined by the claims processor.
[0029] Once it is determined which potential actions may need to be taken with respect to the received data, the next step, Step 203 is to define each action. In general, this step includes first defining various conditions that must be met in order for the action to be taken and then creating a decision table which reflects these conditions. In particular, in one example embodiment, the action is described by defining a set of conditions using various data fields from within the data received. Each condition may include, for example, a field name plus a predicate. The predicate may consist of a comparison (e.g., <, >, =, IN, etc.) plus (1) another field name, (2) a constant or fixed value, (3) a simple computation (e.g., the sum of various fields), (4) a list number (in the instance where the comparison is TN), or (5) a system parameter. For example, the condition may be defined as Provider ID (i.e., a field name)<(i.e., a comparison) 10 digits (i.e., a constant or fixed value).
[0030] A decision table, like the one illustrated in FIG. 3 , can then be generated for each action based on a combination of such conditions. To illustrate, in the example shown in FIG. 3 , Conditions 1 , 2 and 3 were defined, for example, in the above-described manner. These conditions are then combined in the decision table to indicate that data from a particular field should be moved to another field when: (1) conditions 1 , 2 and 3 are all met; (2) conditions 1 and 3 , but not 2, are met; (3) condition 3 , but not 1 or 2, is met; and (4) condition 1 , but not 2 or 3, is met. As shown, all other combinations of conditions 1 , 2 and 3 do not cause the action to be taken (i.e., they do not cause the data to be moved from a particular field to another).
[0031] A software application can then be automatically generated, in Step 204 from each decision table. As will be recognized by those of ordinary skill in the art, the software application may be written in any programming language, such as Java, XML, or Cobalt. The generated software application, when applied to the insurance-related data received, will cause each of the defined actions to take place in the instance where the appropriate conditions are met, as defined by the decision table. In particular, the software generator writes additional software that causes the evaluation defined in the decision table to be performed upon execution. By way of example, the software generator effectively creates a series of if-then statements that effectuate the decision table. With reference to the decision table of FIG. 3 , for example, the software generator would generate software equivalent to the following pseudocode, albeit in the programming language of choice:
[0000]
IF (COND 1 = Y) AND (COND 2 = Y) AND (COND 3 = Y),
THEN ACTION =Y
ELSE,
IF (COND 1 = Y) AND (COND 2 = N) AND (COND 3 = Y),
THEN ACTION = Y
ELSE,
IF (COND 1= N) AND (COND 2 = N) AND (COND 3 = Y),
THEN ACTION = Y
ELSE,
IF (COND 1 = Y) AND (COND 2 = N) AND (COND 3 = N),
THEN ACTION = Y
ELSE, ACTION = N
[0032] Finally, once a software application has been generated for each action, in Step 205 , the software will be applied to the received insurance-related data, which will consequently be reformatted to the format preferred or predefined by the receiving party (e.g., the insurance processor). As will be understood by those of ordinary skill in the art, in alternative embodiments Steps 202 - 204 may be performed prior to receiving the data in Step 201 . In this instance, for example, various actions may be determined and defined for each of the various insurance providers from which the insurance processor receives policy information based on past experience with those insurance providers. Based upon the predefined decision table and corresponding computer program instructions automatically generated therefrom, incoming data can be immediately processed without repeating Steps 202 - 204 of FIG. 2 .
[0033] As discussed above, insurance processors receive information from various insurance providers regarding the different policies offered by them. The information, which may require reformatting in the manner described above, may include, for example, a list of providers that are authorized, the benefits that are available, the eligibility requirements, and a complex set of rules and parameters for determining what, if any, benefit to which a particular claimant is entitled. The insurance processor can use this information to process insurance claims received from customers of the insurance providers. According to a typical scenario, each parameter or rule received for each policy of each provider would have to be translated into its own coding structure (i.e., set of computer programming instructions), and processing a claim would require running each set of computer programming instructions sequentially. In addition to being time consuming, this process may prevent a person unfamiliar with basic programming languages from being able to review the translated coding structure in order to verify that that the rules or parameters were translated accurately. In addition, it is a complex and time consuming process to modify or add any rules or parameters in the instance where a particular policy changes.
[0034] Example embodiments of the present invention provide an improvement over this typical scenario by enabling the insurance processor to capture the benefit information provided by the insurance providers in a user-friendly format, which can be directly read by a claims processing engine (i.e., a computing application capable of applying various policy rules and conditions to claimant-specific information in order to determine, among other things, what, if any, benefit the claimant is eligible to receive) in order to process an incoming insurance claim. In particular, the claims processing engine is able to extract the necessary information from the user-friendly table, or other similar format, in order to process the claim. The process, therefore, eliminates the requirement of a complex computer program code for each individual rule or parameter. As a result, one can intuitively see what the various rules and conditions are for receiving different benefits, and is able to easily modify and add to those rules and conditions.
[0035] Reference is now made to FIG. 4 , which illustrates the steps which may be taken in order to process an insurance claim in the foregoing manner. As shown, in Step 401 , one or more complex rules or parameters are received from an insurance provider that define the benefits under a particular insurance policy. These parameters may relate to, for example, the type of procedure (e.g., defining which procedures are covered and which are not), the bill type (e.g., was it for a visit to the hospital, or a stay in a nursing home or mental health facility), a revenue code (e.g., corresponding to the particular service provided), the diagnosis of the patient (e.g., was the patient in critical condition) and/or characteristics of the patient (e.g., age group, gender, race, etc.).
[0036] Once the complex rules and parameters have been received, they can be organized, in Step 402 , into a user-friendly format, such that the complex rules can be easily understood and modified. This format may include, for example, a table comprising various fields with pull-down options for defining the particular policy. How the table is laid out (i.e., what fields are included and what pull down options there are for each field) is dependent upon the various parameters and rules for the policy. The effect of how the fields are populated on the calculated benefit for the claim being processed is also determined by the parameters or rules of the policy. To illustrate, FIG. 5 is a screen shot of such a user-friendly table that may be used to define a particular policy in accordance with example embodiments of the present invention. As shown, in order to define the policy an individual (e.g., an insurance provider employee) may, for example, first select the organization or line of business for which the policy applies (e.g., SHB-Samp, which may represent a School Board). The individual may then select which benefit plan option he or she is defining (e.g., 00-PPO), as well as what dates for which the service is provided, what provider type the policy pertains to, and the like. A similar table may be created for each policy offered by the particular insurance provider.
[0037] Once the user-friendly table has been created and defines the insurance policy including all of the specific rules and parameters, the table may be provided, in Step 403 , to the claims processing engine, which is capable of extracting the rules and parameters from the table when processing incoming insurance claim. In particular, in Step 404 an insurance claim from either a provider or a member (i.e., a claimant) is received and in Step 405 , the claims processing engine uses the user-friendly table to process the incoming insurance claim. For example, the claims processing engine may use the table and the claimant-specific data extracted from the insurance claim received to determine: (1) if the service on the claim is covered by the policy for the particular recipient; (2) if the provider is authorized to perform the service; (3) if there is a copay, coinsurance or other penalty (e.g., for lack of approval or hospital certification); (4) if the service is in or out of network; (5) which pricing methodology/fee schedule should be used to compute the allowed charges; (6) how much to pay the provider; (7) how much the claimant/patient is responsible to pay; and/or (8) what service limitations apply.
[0038] To further illustrate, in one example embodiment, an insurance processor may first use the parameters and rules received from an insurance provider to create a user-friendly table. The table may be specific to a particular policy, or it may be applicable for several policies offered by the same insurance provider, or even still it may be applicable for several policies offered by several insurance providers. As discussed above, its appearance, including the fields and the pull down options for each field, are dictated by the rules and parameters of the corresponding policies. The table, which now defines the particular policy, can then be provided to the claims processing engine that is able to extract the rules/parameters from the user-friendly table in order to determine what, if any, benefit a claimant is entitled to upon receipt of an insurance claim.
[0039] In an alternative embodiment, the insurance processor may provide the generated user-friendly table (absent the user-specific data) along with the claims processing engine that is capable of reading the table, to the insurance provider, so that the insurance provider itself is able to process incoming insurance claims from its customers using the table.
[0040] As described above, therefore, the method of example embodiments of the present invention enables the party that is processing an insurance claim (whether it be an independent insurance processor or the insurance provider itself) to easily read and comprehend the complex rules and parameters of an insurance policy being administered without requiring that the party be able to read complex programming code. In addition, the table format provides an easy way to change policy parameters and to enter information about particular claims.
[0041] Many modifications and other embodiments of the inventions set forth herein will come to mind to one skilled in the art to which these inventions pertain having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is to be understood that the inventions are not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.
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A method and a computer program product are provided for processing an insurance claim. In particular, an example method may comprise receiving policy information associated with a particular insurance policy. The policy information may comprise a plurality of rules that define one or more benefits under the insurance policy. The example method may further comprise organizing the plurality of rules into a predefined tabular format. Furthermore, the example method may comprise providing a claims processing engine with the organized plurality of rules and thereafter processing the insurance claim in accordance with the plurality of rules.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application claims priority to Provisional Application No. 60/474,096 filed May 29, 2003, the disclosure of which is incorporated herein by reference in its entirety.
TECHNICAL FIELD
[0002] The present invention relates to pharmaceutical formulations; in particular to solid dosage forms of pharmaceutical compositions comprising lithium carbonate, and methods of preparing such compounds.
BACKGROUND OF THE INVENTION
[0003] Bipolar disorder is a chronic, cycling, and often debilitating mental illness that affects more than 2 million adults in the United States, or about 1 percent of the adult population 18 and over in any given year, according to the National Institute of Mental Health. Bipolar disorder typically develops in late adolescence or early adulthood, although first occurrence at younger and older ages has been recognized. Bipolar disorder is often not recognized as a medical illness, and affected persons may suffer for years before their condition is properly diagnosed and treated. Bipolar disorder causes sometimes dramatic mood swings, from overly “high” and/or irritable to sad and hopeless, and then back again, often with periods of normal moods in between. Signs and symptoms of mania, sometimes called a manic episode, include increased energy, activity, and restless; overly good, euphoric mood; extreme irritability; racing thoughts and fast, pressured speech; distractibility; difficulty sleeping and decreased need for sleep; and poor judgment that may manifest itself as spending sprees, abuse of drugs, intrusive or aggressive behavior, or other harmful or dangerous activities. Signs and symptoms of depression associated with bipolar disorder, sometimes called a depressive episode, include lasting sad, anxious, or empty mood; feelings of hopelessness, guilt, worthlessness, or helplessness; loss of interest in normally pleasurable activities; difficulty concentrating or with memory loss; restlessness or irritability; and sleeping too much or inability to sleep. A person with bipolar disorder is prone, in depressive episodes, to suicidal thoughts or even suicide attempts.
[0004] Without treatment, the natural course of bipolar disorder tends to worsen, with a person suffering more severe extremes of mood fluctuation, as well as a more frequent (faster-cycling) occurrence of mood swings. There appears to be at least some familial component to the disorder, as children of bipolar parents are at increased risk of developing the disease, as are identical twins where one twin has been diagnosed with bipolar disorder. Genetic studies suggest that multiple genes contribute to bipolar disorder.
[0005] Lithium, the first mood stabilizing medication approved in the United States by the U.S. Food and Drug Administration (FDA) for treatment of mania, is often very effective in controlling mania and preventing the recurrence, of both manic and depressive episodes. While other drugs, particularly anticonvulsants such as valproate (Depakote®) or carbamazepine (Tegretol®); benzodiazepines such as clonazepam (Klonopin®); antipsychotics such as clozapine (Clozaril®); or electroconvulsive (ECT) therapy are in use or under study for bipolar disorder, lithium remains a first line treatment. Accordingly, the art has sought ever improved methods of delivering pharmacologically effective dose, with minimum side effects, to sufferers of bipolar disorder.
[0006] Lithium has been used for medical purposes in various formulations for more than 150 years, although the modern use of lithium as an effective antimanic treatment and as prophylactic therapy for bipolar (manic-depressive) disorder dates to the early 1950's.
[0007] Lithium is abundant in some alkaline mineral spring waters and is present in trace amounts in animal tissues, although it has no known physiological role. Since its earliest use, lithium has been associated with potentially toxic effects, due both to its relative low therapeutic index, in the range of 2 or 3, and in part to the difficulty in achieving regulated dissolution and uptake in the human body. Both lithium carbonate and lithium citrate are currently in therapeutic use in the United States.
[0008] Lithium shares many of the physicochemical properties of the alkali metals group (Group Ia of the Periodic Table, which also includes sodium and potassium), of which it is the lightest member. It is a monovalent cation and has the highest electrical field density and largest energy of hydration of Group Ia, yet it has an ionic radius similar to those of the divalent cations magnesium and calcium. Lithium has a relatively small gradient of distribution across biological membranes, unlike sodium and potassium.
[0009] Therapeutic concentrations of lithium ion (Li + ) have almost no discernible psychotropic effects in normal individuals. It is not a sedative, depressant, or euphoriant to normal individuals, and this lack of characteristic effects differentiate it from other psychotropic agents.
[0010] Li + is absorbed readily and almost completely from the gastrointestinal tract, although rate of absorption is considerably affected by the type of formulation administered. Complete absorption occurs in about 8 hours, with peak concentrations in plasma occurring 2 to 4 hours after an oral dose. However, in certain formulations, absorption can occur considerably faster. For example, in a paper by Nielsen-Kudsk and Amdisen entitled, “Analysis of the Pharmacokinetics of Lithium in Man,” in European Journal of Clinical Pharmacology, 16, 271-77 (1979), a single liquefied dose of lithium chloride administered to volunteers in a pharmacokinetic study was shown to have a mean absorption half-time of only 0.15 hours (9 minutes).
[0011] Slow release formulations of lithium carbonate provide a slower rate of absorption and thereby minimize early peaks in plasma concentration of the Li + ion. For example, in a paper entitled, “In vivo Evaluation of Two Controlled Release Lithium Carbonate Tablets ,” in Lithium (1992) 3, 221-23, Gai, et al., reported on a formulation consisting of lithium carbonate, Avicel®, Lactose, Eudragit®(aqueous methacrylic polymer) and a lubricant (magnesium stearate) that demonstrated a slower lithium release when compared to a conventional formulation control. A commercial lithium carbonate dosage form is available from GlaxoSmithKline and is marketed as Eskalith CR 450®. The Eskalith CR 450® dosage form comprises:
Lithium Carbonate 450 mg Iron Oxide 1 mg Gelatin - 200 bloom 40 mg Sodium Starch Glycolate 0.75 mg Alginic Acid 1 mg Magnesium Stearate 5.25 mg TOTAL 498 mg
[0012] The convenience of administering a single dose of a medication which releases active ingredients in a controlled fashion over an extended period of time, as opposed to the administration of a number of single doses at regular intervals, has long been recognized and desired in the pharmaceutical arts. The advantage to the patient and clinician in having consistent and uniform blood levels of medication over an extended period of time are likewise recognized. Among the most important advantages are: (1) increased contact time for the drug to allow for local activity in the stomach, intestine or other locus of activity; (2) increased and more efficient absorption for drugs which have specific absorption sites; (3) the ability to reduce the number of dosages per period of time; (4) employment of less total drug; (5) minimization or elimination of local and/or systemic side effects; (6) minimization of drug accumulation associated with chronic dosing; (7) improved efficiency and safety of treatment; (8) reduced fluctuation of drug level; and (9) better patient compliance with overall disease management.
[0013] The administration of slow release formulations is not without problems. These problems are particularly relevant in the case of lithium formulations. Slow release preparations tend to shift a higher percentage of total absorption into time periods further from administration, during which time the medication has further traversed the gastrointestinal tract, and therefore may cause a higher proportion of the lithium to be absorbed in the lower intestinal tract. This may cause such symptoms as nausea, vomiting, abdominal pain, and diarrhea. Li + is poorly tolerated in as many as one third of all patients treated. Accordingly, the art has needed a means for maximizing the dissolution rate of lithium formulations in the intermediate time ranges for absorption, that is, within approximately three hours of administration.
[0014] Li + is initially distributed in the extracellular fluid and then gradually accumulates in various human tissues. Passage through the blood-brain barrier is slow, and when a steady state is achieved, the final concentration of Li + in the cerebrospinal fluid is about half or less of the concentration in plasma. In a study of both immediate release and controlled release dosages in a paper entitled “Absorption and disposition kinetics of lithium carbonate following administration of conventional and controlled release formulations,” in the International Journal of Clinical Pharmacology, Therapy and Toxicology, Vol. 24, 5:240-45 (1986), Arancibia, et al., found that a single oral dose of lithium confers upon the body the pharmacokinetic characteristics of an open two-compartment model with apparent first order absorption. The volume of distribution of lithium was found to be near the volume of the total body water with the volume of the central compartment approximately corresponding to the volume of the extracellular water.
[0015] Ninety-five percent of a single dose of Li + is eliminated in the urine, with an initial excretion of one half to two thirds of an acute dose being excreted in a 6 to 12 hour period. This initial phase is followed by slow excretion over the next 10 to 14 days. Small amounts of Li + are excreted in sweat and feces. The elimination half-life averages 20 to 24 hours, although any factor leading to Na + depletion will tend to promote Li + retention and thereby prolong the half-life of Li + . There is no specific treatment for Li + overdose, which can manifest as mental confusion, hyperreflexia, gross tremor, dysarthria, seizures, cranial nerve and focal neurologic signs, and cardiac arrhythmias. These symptoms can progress to coma and death. Treatment is supportive, with maintenance of appropriate Na + levels and hydration. Dialysis is the most effective means of removing Li + from the body and is used in severe cases of lithium intoxication.
[0016] Accordingly, what the pharmaceutical arts have long sought is a means of formulating lithium that exhibits improved dissolution rates in an intermediate time period, as compared to presently available formulations. Formulations that are too quickly dissolved tend to create quick spikes in serum levels with an increased risk of toxicity, while those that are too slowly dissolved will tend to have a higher proportion of lithium absorbed in the lower gastrointestinal tract, leading to unpleasant symptoms and possible interference with patient compliance. Additionally, practical dispensing requirements mandate that commercial formulations have acceptable stability levels over time under a wide variety of storage conditions.
[0017] The purpose of the present invention is to replace a formulation and manufacturing process that is associated with poor control of dissolution rate with a formulation and process that is less complex to perform, more reproducible, and eliminates formulation and dissolution rate dependencies on raw material density and tablet press parameters. An example of current lithium carbonate (Eskalith CR 450®) product specifications, shown in Table 1, calls for dissolution rates of not more than 40% at 1 hour, 45-75% at three hours, and not less than 70% at seven hours.
TABLE 1 Eskalith CR 450 ® Product Dissolution Specifications Time Dissolution % 1 Hour Not more than 40% 3 Hour 45%-75% 7 Hour Not less than 70%
[0018] To this end, a series of experiments were undertaken to examine formulations of lithium carbonate combined with various excipients and formulated via different manufacturing techniques. The following materials were examined as sustained release agents for lithium carbonate and all of them failed:
[0019] Alginic Acid
[0020] Sodium Alginate
[0021] Guar Gum
[0022] Carbopol 971
[0023] Carbopol 974
[0024] Hydroxypropylmethylcellulose E4M
[0025] Hydroxypropylmethylcellulose E50
[0026] PVP K30
[0027] PVP K90
[0028] Hydroxypropylcellulose (solvent based)
[0029] Gelatin 125 bloom
[0030] Gelatin 150 bloom
[0031] Aquacoat (aqueous ethylcellulose)
[0032] Starch NF
[0033] Starch 1500 (partially pregelatinized starch)
[0034] Starch 1551 (totally pregelatinized starch)
[0035] Gelatin 200 bloom
[0036] Maltodextran M150
[0037] PEG4000
[0038] The only sustained release agent that merited further investigation was sodium carboxymethylcellulose.
SUMMARY OF THE INVENTION
[0039] Drugs are seldom dispensed in pure form, instead they are commonly mixed with varying non-active agents, deemed excipients, to facilitate production, improve dispersal and dissolution characteristics, promote stability, and to increase palatability. Sodium carboxymethylcellulose (NaCMC) is known to be a stability and viscosity enhancer. It is widely used in oral and topical pharmaceutical preparations for its viscosity enhancing properties, to stabilize emulsions, and, as in the present invention, as a tablet binder and disintegrant. Chemically, NaCMC is the sodium salt of a polycarboxymethyl ether of cellulose, typically with a molecular weight in the range of 90,000-700,000. NaCMC is highly insoluble in organic solvents such as acetone, ethanol, ether, and toluene; but is easily dispersed in water at all temperatures. It is generally considered as a non-toxic and nonirritant material that is safe at a wide level of dosage. NaCMC has no acceptable daily intake level set by the World Health Organization, is listed as a substance that may be added to all foodstuffs in the European Council Directive No. 95/2/EC, and is included in the FDA Inactive Ingredients Guide. In doses exceeding 4 grams daily, NaCMC may have a bulk laxative effect due to its hygroscopic properties and ability to bind water during stool transit through the intestine.
[0040] As long ago as 1986, NaCMC was shown, by Arancibia et al., in concentrations of 30 percent, to slow an experimental rise seen in serum concentrations of lithium. A single dose NaCMC-lithium carbonate formulation, compared to a single dose immediate release preparation, showed a delay in the development of peak serum levels from less than two hours to approximately four hours. The effect of NaCMC formulations in altering the dissolution rates does not appear specific to lithium, as Singh demonstrated faster dissolution of lorazepam with NaCMC added, in a paper entitled, “Effect of Sodium Carboxymethylcellulose on the Disintegration, Dissolution, and Bioavailability of Lorazepam from Tablets,” in Drug Development and Industrial Pharmacy, 18(3): 375-83 (1992). There is evidence suggesting that the viscosity grade of NaCMC used may affect the balance of forces between those which hold the formulation particles together in tablet form and those which promote separation of the particles in water, as seen in a paper entitled, “Evaluation of different viscosity grades of sodium carboxymethylcellulose as tablet disintegrates, ” in Pharm. Acta Helv. 50(4): 99-102 (1975).
[0041] In the instant invention, the addition of a relatively small quantity (as compared to the prior art) of sodium carboxymethylcellulose to a formulation of lithium carbonate was found to enhance the dissolution profile of the formulation. Additionally, the utilization of a secondary release agent, glycine, was found to enhance dissolution rates. Furthermore, a manufacturing variation in which a portion of the active ingredient lithium carbonate was reserved from the initial granulation and then added later, with excipients, was found to enhance dissolution. Thus, there is disclosed a pharmaceutical composition for oral administration, comprising:
[0042] a. lithium carbonate,
[0043] b. optional pharmacologic excipients,
[0044] c. at least one dissolution rate stabilizer, and
[0045] d. at least one secondary release agent.
[0046] The pharmaceutical compositions according to the invention, may also contain iron oxide as a colorant. Preferably, the iron oxide does not exceed a level of about 1 mg/tablet. The pharmaceutical compositions according to the invention may also contain an optional pharmacological excipient, which may be a lubricant. The lubricants may be selected from the group consisting of a stearic acid at a concentration between about 0.1 percent and about 1 percent by weight of the composition, sodium sterol fumerate at a concentration of from about 0.1 to about 1.0 percent of the composition by weight, calcium stearate at a concentration of about 0.1 to 1.0 percent by weight of the composition, and magnesium stearate at a concentration of about 0.1 to 1.0 percent of the composition by weight.
[0047] The compositions according to the invention are preferably compressed in a conventional pharmaceutical tableting press at a tablet hardness of about 7 kPa to 20 kPa.
[0048] Most preferably, the pharmaceutical compositions according to the invention contain at least one dissolution rate stabilizer which is most preferably sodium carboxymethylcellulose. The sodium carboxymethylcellulose is usually present at about 5 to about 15 percent by weight of the composition. More preferably, the sodium carboxymethylcellulose comprises not more than about 5 percent by weight of the composition.
[0049] Still more preferably, the pharmaceutical composition according to the invention additionally comprises at least one secondary release agent and most preferably this secondary release agent is glycine. The glycine is typically present comprises between about 0.5 to about 40 mg/tablet.
[0050] Thus, there is further disclosed a pharmaceutical composition for oral administration, comprising:
[0051] a. lithium carbonate,
[0052] b. iron oxide,
[0053] c. stearic acid,
[0054] d. sodium carboxymethylcellulose,
[0055] e. glycine, and
[0056] f. optionally pharmaceutically acceptable excipients.
[0057] There is further disclosed a process for preparing controlled release solid dosage forms of lithium carbonate which comprises the steps of:
[0058] a. mixing lithium carbonate and iron oxide into a blend,
[0059] b. solubilizing a water solution of water, sodium carboxymethylcellulose, and at least one secondary release agent,
[0060] c. placing the blend of lithium carbonate and iron oxide in a bed of a fluid bed granulator,
[0061] d. creating a top sprayed blend by top spraying the solution into the blend in the bed of the fluid bed granulator,
[0062] e. granulating the top sprayed blend in the fluid bed granulator into a granulation,
[0063] f. forming a composition by milling the granulation with at least one excipient, and
[0064] g. pressing the granulation with at least one excipient composition into tablets in a tablet press.
[0065] The present invention also relates to methods of treatment of bipolar disorder consisting of orally administering to a patient a therapeutically effective amount of a composition in accordance with the invention. Another aspect of the present invention simply relates to the discovery that fairly low levels of carboxymethylcellulose are effective in preparing lithium carbonate dosage forms. Thus, there is disclosed a pharmaceutical composition for oral administration, comprising:
[0066] a. lithium carbonate,
[0067] b. optional pharmacological excipients, and
[0068] c. at least one dissolution rate stabilizer.
[0069] As discussed previously, iron oxide and lubricants may be present in the composition. The preferred dissolution rate stabilizer is sodium carboxymethylcellulose in this aspect of the invention wherein glycine is not required. Typically this sodium carboxymethylcellulose is present in a concentration from about 5 to about 15 percent by weight of the composition. Usually the lithium carbonate is present in a concentration of about 85 to 95 percent by weight of the composition.
[0070] Processes for the production of the pharmaceutical composition are as described above except the glycine would be omitted.
[0071] Yet another aspect of the present invention relates to the discovery that dividing the bowl charge will dramatically impact upon the stability and dissolution rates of the inventive dosage forms. Thus there is disclosed a process for manufacturing a pharmaceutical composition for oral administration, which comprises the steps of:
[0072] a. lithium carbonate,
[0073] b. optional pharmacological excipients, and
[0074] c. at least one dissolution rate stabilizer.
[0075] In a preferred embodiment, the pharmaceutical composition of the present invention has a dissolution profile as follows: 1 hour, no greater than 40 percent; at 3 hours, from 45 to 75 percent; and at 7 hours, not less than 70 percent. More preferably, the pharmaceutical composition of the present invention has a dissolution profile as follows: 1 hour, no greater than 40 percent; at 3 hours, from 50 to 65 percent; and at 7 hours, not less than 70 percent
DETAILED DESCRIPTION OF THE INVENTION
[0076] Given the history of utility of using NaCMC and other excipients known in pharmaceutical manufacture with properties for alteration of drug dissolution rates, experiments were undertaken using lithium carbonate and NaCMC. The objectives of these experiments was to simplify the process, increase capacity, decrease batch variability, decrease batch failure rates, eliminate the formulation dependence on raw material density, eliminate the dependence on tablet press parameters as the release rate controlling factor, and to achieve acceptable stability.
[0077] For all experiments, a 45-liter granulation insert fluid bed granulator (GPCG) was charged with 16 to 18 kilograms of lithium carbonate with 1 mg/tablet of iron oxide added as a colorant. A release sustaining agent solution or suspension containing various release controlling agents was top sprayed in a volume of 20 to 40 kg onto the fluidized lithium carbonate and then dried. The granulation was milled with a GS 180 mill fitted with a 1.0 mm round hole cone. The milled granulation was blended in a PK 8-quart V blender with various extragranular ingredients, including a lubricant. Each blend was compressed using a Manesty 30 station high-speed commercial tablet press with 1.1 cm deep cup round punches.
[0078] The effect of modifying the type, amount, and ratio of the release sustaining agents and lubricants along with adjustments in compression were evaluated by examining the dissolution profile of the finished tablets. In an attempt to determine the robustness of the formulations, some studies were repeated, holding the excipients constant, utilizing different lots of lithium carbonate. The most promising formulations were placed on stability in glass and plastic packages.
EXAMPLE I
Lithium Carbonate—NaCMC Formulations
[0079] To test the dissolution rates of lithium carbonate with NaCMC, and stability of these rates; tests of potency, dissolution, and stability were performed on lithium carbonate formulated with varying amounts of added NaCMC, as shown in Table 2. There was some variation seen in loss on drying (LOD). The addition of approximately 10%, or 51.07 mg, added NaCMC resulted in an improved dissolution at the three hour point, and the addition of further NaCMC did not appreciably improve this dissolution rate, as shown in Table 2. Therefore, a level of approximately 10% added NaCMC was selected for further experimentation. Additionally, the effects on dissolution of varying the levels of stearic acid lubricant in a lithium carbonate/iron oxide formulation were observed, as shown in Tables 3 and 4, and found to have little effect on dissolution. However, it was found from a manufacturing standpoint that a stearic acid level of approximately 1%, or 5.07 mg/tablet, was found to give optimal results in tablet appearance and consistency, and this level was selected for further experimentation. Various combinations of other lubricants at differing concentrations showed no improvement in dissolution parameters when compared to the use of stearic acid as a lubricant, as shown in Tables 4-7.
TABLE 2 Effects of Varying Levels of NaCMC on Dissolution Stearic Tablet 1 Hour 3 Hour 7 Hour NaCMC Acid Weight Dissolution Dissolution Dissolution Formula mg/tablet mg/tablet Mg % % % % LOD 3892 25.54 4.79 481.33 25 60 102* 0.9 3891 51.07 4.79 506.86 23 59 99 0.9 5037 51.07 4.79 506.86 23 59 101* 0.6 3893 76.61 4.79 532.4 21 62 95 1.7 100115 51.07 5.07 507.14 24 60 107* 0.69
[0080] [0080] TABLE 3 Effects of Varied Levels of Stearic Acid on Dissolution in NaCMC Granulation Stearic Tablet 1 Hour 3 Hour 7 Hour NaCMC Acid Weight Dissolution Dissolution Dissolution Formula mg/tablet mg/tablet Mg % % % % LOD 100115 51.07 5.07 507.14 24 60 107* 0.69 100116 51.07 2.5 504.57 28 73 114* 0.7 3891 51.07 4.79 506.86 23 59 99 0.9 5037 51.07 4.79 506.86 23 59 101* 0.6 5495 51.07 5.07 507.14 23 53 95 1.2
[0081] [0081] TABLE 4 Effect on Dissolution of NaCMC Granulation Utilizing Varying Levels of Stearic Acid as Lubricant Stearic Tablet 1 Hour 3 Hour 7 Hour Acid Hardness at 7 kPa Dissolution Dissolution Dissolution Formula Level (kPa) Hardness Hardness % % % 0105327 1.0% 7 Porous 17.2 19 51 93 0105326 0.5% 7 Porous 18.0 NA NA NA 0105325 0.25% 7 Porous 17.3 20 52 95 0105337 0.1% 7 * * * * * 0105340 0.05% 7 Poor 16.2 NA NA NA
[0082] [0082] TABLE 5 Effects on NaCMC Granulation Dissolution Varying Sodium Stearyl Fumerate as Lubricant Sodium Stearyl Tablet 1 Hour 3 Hour 7 Hour Fumerate Hardness at 7 kPa Dissolution Dissolution Dissolution Formula Level (kPa) Hardness Hardness % % % 0105327 1.0% 7 Porous 19.3 20 51 92 0105329 0.5% 7 Porous 22.0 NA NA NA 0105328 0.25% 7 Porous 18.5 21 52 94 0105335 0.1% 7 Porous 22.1 NA NA NA 0105336 0.05% 7 Poor 18.5 20 51 94
[0083] [0083] TABLE 6 Effects on NaCMC Granulation Dissolution Varying Calcium Stearate as Lubricant Calcium Tablet at 1 Hour 3 Hour 7 Hour Stearate Hardness 7 kPa Dissolution Dissolution Dissolution Formula Level (kPa) Hardness Hardness % % % 0105343 1.0% 7 Porous 17.9 19 43 76 0105342 0.5% 7 Porous 17.3 NA NA NA 0105341 0.25% 7 Porous 16.6 20 47 90 0105344 0.1% 7 Porous 12.6 NA NA NA 0105345 0.05% 7 Poor 19.5 NA NA NA
[0084] [0084] TABLE 7 Effects on NaCMC Granulation Dissolution Varying Magnesium Stearate as Lubricant Magnesium Tablet at 1 Hour 3 Hour 7 Hour Stearate 7 kPa Dissolution Dissolution Dissolution Formula Level Hardness Hardness Hardness % % % 0105332 1.0% 7 Porous 19.6 18 43 79 0105331 0.5% 7 Porous 23.7 NA NA NA 0105334 0.25% 7 Porous 22.7 20 47 86 0105339 0.1% 7 Fair 23.0 NA NA NA 0105338 0.05% 7 Poor 19.2 NA NA NA
[0085] The use of NaCMC in the formulation showed great promise, as these formulations exhibited desirable dissolution characteristics (between approximately 50% to 55% released at the three hour time point). These formulations were also shown to be the most robust with respect to dissolution, with little or no change in the dissolution rates occurring even when multiple parameters, such as relative percentage composition of NaCMC and stearic acid were changed, as shown in Tables 2 and 3. Various lubricant modifications and alterations in tablet hardness resulted in little change in dissolution rates, as shown in Tables 4 through 7.
[0086] In sum, when using NaCMC as the sole release sustaining agent, the following observations were made from the material presented in Tables 4-7:
[0087] 1. Increasing the level of NaCMC beyond 5.3% produced no effect on the dissolution rate.
[0088] 2. Processing several blends and compressions from the same lot of granulation (using a single lot of lithium carbonate) produced no change in the dissolution rate.
[0089] 3. The use of multiple lots of lithium carbonate (for granulation) produced no change in the dissolution rate.
[0090] 4. The compression rate of tablets at multiple hardness levels (7, 10, or approximately 20 kPa) produced no change in the dissolution rate.
[0091] 5. Modifying the level (0.05 to 1.0%) or type of lubricant did not significantly alter the release rate.
[0092] Stability testing performed in both glass bottles and in the current commercial packaging, however, showed a decrease in dissolution rates of the lithium carbonate-NaCMC formulations over time, as shown in Table 8. At higher temperature, higher relative humidity, and longer storage times, the lithium carbonate-NaCMC formulations tended to fall close to, or even outside of, current product specifications for the three hour dissolution period, which call for a dissolution rate of 45% to 75% within three hours, as shown in Table 1.
[0093] This decrease in dissolution was seen both when testing in the current commercial packaging, and in glass bottles, as seen in Tables 8 and 9. It was hypothesized that a modest improvement in the initial dissolution rates, possibly to approximately the high 50% to low 60% range, would provide a margin for the observed deterioration in dissolution rates over time, and allow new formulations demonstrating acceptable dissolution rates both upon manufacture, and after storage.
[0094] In attempts to overcome this loss of dissolution stability over time, multiple experiments were undertaken with a goal to enhance the release rate ranging from approximately 60% to approximately 65% in the three hour time period, in order to provide a margin for the observed loss of dissolution stability at longer storage periods, which caused the NaCMC formulation to fall outside of specifications at the six month, higher temperature and higher relative humidity conditions, as shown in Tables 8 and 9.
TABLE 8 Dissolution Stability Summary, NaCMC - Lithium (Current Commercial Packaging) Potency 1 Hour 3 Hour 7 Hour Storage Age (% of Dissolution % Dissolution % Dissolution % Conditions (Months) Claimed) High Low Avg. High Low Avg. High Low Avg. Initial 00 98.8 21 20 20 52 49 51 94 91 93 25° C./60% 01 NR 22 21 21 55 48 53 97 92 94 Rel. Hum. 02 NR 22 21 21 55 48 53 97 92 94 03 99.4 20 19 19 52 49 50 95 87 90 04 100.2 21 19 20 52 49 50 95 87 90 05 98.2 19 ]8 18 51 49 50 93 87 90 06 98.7 20 19 19 50 48 49 91 86 88 09 18 17 18 48 46 47 81 87 89 30° C./60% 03 NR NR NR NR NR NR NR NR NR NR Rel. Hum. 05 98.9 19 17 18 51 49 49 93 87 90 06 98.2 20 16 18 50 44 47 93 83 88 09 19 18 18 48 47 47 87 85 86 40° C./75% 01 NR 21 20 20 52 50 51 94 90 92 Rel. Hum. 02 NR 19 19 18 51 48 50 93 89 91 03 99.5 19 19 18 51 48 50 93 89 91 04 99.5 17 16 17 44 40 42 81 76 79 06 96.9 17 15 16 44 40 41 82 75 79 Spec. Limits 99.0-110.0 Not More Than 45% - 75% Not Less Than 40% 75%
[0095] [0095] TABLE 9 Stability Summary, Lithium Carbonate - NaCMC (Glass Bottles) 1 Hour 3 Hour 7 Hour Storage Age Dissolution % Dissolution % Dissolution % Conditions (Months) Potency High Low Avg. High Low Avg. High Low Avg. Initial 00 99.5 20 20 20 52 50 51 93 89 92 25° C./60% 01 NR 22 20 21 50 53 52 97 92 94 Rel. Hum. 02 NR 20 19 20 52 50 51 93 89 91 03 99.2 22 18 20 54 49 51 94 91 93 04 98.8 20 19 20 51 49 50 94 87 91 05 98.4 19 18 19 50 48 49 91 88 89 06 97.6 23 21 23 52 48 50 89 84 87 09 17 16 17 49 46 48 91 86 89 30° C./60% 03 NR NR NR NR NR NR NR NR NR NR Rel. Hum. 05 98.5 20 18 19 49 48 48 89 85 87 06 98.0 20 16 18 50 44 47 93 84 88 09 20 18 19 50 47 49 92 87 91 40° C./75% 01 NR 20 19 20 52 50 51 96 84 92 Rel. Hum. 02 NR 19 18 18 50 48 48 94 87 88 03 100.0 19 18 19 49 44 46 88 81 84 04 99.2 18 17 17 49 44 46 88 81 84 06 98.4 15 17 16 44 40 42 83 77 80 Spec. Limits 99.0-110.0 Not More Than 45% - 75% Not Less Than 40% 75%
EXAMPLE II
Lithium Carbonate—NaCMC with Additional Excipients
[0096] Attempts were made to improve three hour dissolution rates using aqueous NaCMC as the release sustaining agent combined with other extragranular excipients. NaCMC was dissolved in water and used to granulate the lithium carbonate/iron oxide blend. The granulation was milled in a cone mill fitted with a 1 mm round hole cone. Prior to lubrication, the granulation was blended with additional excipients including multiple levels of Aerosil 200® (colloidal silica), Avicel PH102® (microcrystalline cellulose), Starch 1500 (partially gelatinized starch), and/or lactose. The blend was then lubricated and compressed at multiple hardness levels (7 and 10 kPa). Experimental variables included the manufacture of batches using different lots of lithium carbonate, the manufacture of multiple batches from a single lot of lithium carbonate, the manufacture of multiple batches of tablets from a single batch of granulation, the manufacture of batches with different levels of NaCMC, the manufacture of batches with different levels of Aerosil 200®, the manufacture of batches with different levels of Starch 1500, the manufacture of batches with different levels of Avicel PH102®, the manufacture of batches with different levels of lactose, and the manufacture of batches using different levels of lubricant, utilizing either stearic acid or magnesium stearate.
[0097] The extragranular addition of these materials to the lithium carbonate/iron oxide/NaCMC formulation reduced the dissolution rate to low borderline or below (45%) for the three hour time point, as shown in Tables 10-13
TABLE 10 Effects on Dissolution of Avicel ® in NaCMC Granulation Starch Aerosil Stearic NaCMC Avicel ® 1500 200 ® Acid Tab wt. Dissolution % Formula mg/tablet mg/tablet mg/tablet Mg/tablet mg/tablet mg 1 Hr. 3 Hr. 7 Hr. % LOD 5499 51.07 0 25 6 5.4 538.45 19 51 92 .8 5498 51.07 10 25 6 5.5 548.56 20 49 93 .3 4519 51.07 15 25 6 5.5 553.61 18 45 88 .1 5035 51.07 15 25 6 5.5 553.61 17 41 74 .1
[0098] [0098] TABLE 11 Effects on Dissolution of Starch 1500 and Lithium Lot in NaCMC Granulations Starch Stearic NaCMC Avicel ® 1500 Acid Tab Wt. Dissolution % Lithium Granulation Formula mg/tablet Mg/Tablet mg/tablet mg/tablet Mg 1 Hr. 3 Hr. 7 Hr. % LOD Lot Batch # 100106 51.07 15 45 5.7 573.8 14 40 83 0.84 2632 6265 100111 51.07 15 45 5.7 573.81 17 48 89 0.8 2632 6266 100104 51.07 15 35 5.6 563.7 14 39 77 0.84 2632 6265 100103 51.07 15 25 5.5 553.6 15 42 79 0.84 2632 6265 100107 51.07 15 25 5.5 553.6 19 49 90 0.83 2632 6266 100114 51.07 15 25 5.5 553.61 18 51 92 0.74 2603 6264 100106 51.07 15 45 5.7 573.8 14 40 83 0.84 2632 6265 100112 51.07 15 45 5.7 573.81 17 47 87 0.81 2603 6264 100110 51.07 15 15 5.4 543.51 20 52 97 0.75 2632 6266 100113 51.07 15 15 5.4 543.51 18 51 91 0.71 2603 6264
[0099] [0099] TABLE 12 Effects on Dissolution of Aerosil 200 ® in NaCMC Granulations Starch Aerosil Stearic NaCMC Avicel ® 1500 200 ® Acid Tab Wt. Dissolution % Formula mg/tablet mg/tablet mg/tablet Mg/tablet mg/tablet mg 1 Hr. 3 Hr. 7 Hr. % LOD 5497 51.07 15 25 0 5.48 547.55 19 48 91 2.2 4520 51.07 15 25 4 5.51 551.58 18 49 92 1.2 5036 51.07 15 25 4 5.52 551.59 18 46 85 1.0 5496 51.07 15 25 4 5.52 551.59 18 48 88 2.1 5035 51.07 15 25 6 5.54 553.61 17 41 74 1.1 5034 51.07 15 25 8 5.56 555.63 16 44 82 1.3 5038 51.07 15 25 8 5.56 555.63 15 43 81 0.8 4518 51.07 15 25 10 5.58 557.65 18 45 91 1.3 5033 51.07 15 25 10 5.58 557.65 17 41 74 0.9
[0100] [0100] TABLE 13 Effect of Lactose Replacement of Avicel ® on Dissolution of NaCMC Granulations Starch Aerosil Stearic NaCMC Lactose 1500 200 ® Acid Tab Wt. Dissolution % Formula mg/tablet mg/tablet mg/tablet Mg/tablet mg/tablet mg 1 Hr. 3 Hr. 7 Hr. % LOD 101438 51.07 5 25 6 5.44 543.51 15 43 85 0.63 101442 51.07 15 25 6 5.54 553.61 16 44 87 0.60 101440 51.07 45 25 6 5.84 583.91 16 44 84 0.62
[0101] Variations in stearic acid lubricant concentrations were also tested with representative formulations containing NaCMC, Avicel®, Starch 1500, and Aerosil 200®. Experimentations in tablet compression revealed that the compression of tablets to pressures of either 7 kPa or 10 kPa produced no change in the dissolution rates.
TABLE 14 Effects on Dissolution of Varying Levels of Stearic Acid Lubricant in Representative NaCMC Granulations Containing Avicel ®, Starch 1500, and Aerosil 200 ® Starch Aerosil Stearic NaCMC Avicel ® 1500 200 ® Acid Tab Wt. Dissolution % Formula mg/tablet Mg/tablet mg/tablet mg/tablet mg/tablet mg 1 Hr. 3 Hr. 7 Hr. % LOD 100109 51.07 15 25 6 8.35 556.42 18 47 89 0.8 5496 51.07 15 25 4 5.52 551.59 18 46 88 2.1 100107 51.07 15 25 6 5.53 553.6 19 49 90 0.83 6296 51.07 15 25 4 4.1 550.17 21 51 94 1.7 6295 51.07 15 25 4 2.75 548.82 21 53 98 1.5 100108 51.07 15 25 6 2.8 550.87 19 54 100 0.76
[0102] The following observations were made from the results presented in Tables 10-14:
[0103] 1. Modification in the levels of Aerosil® produced no change in the dissolution rate.
[0104] 2. Modification in the levels of starch produced no change in the dissolution rate.
[0105] 3. An increase in the level of Avicel® 0 produced aminor slowing of the dissolution rate.
[0106] 4. Replacement of Avicel® with lactose produced no change in the dissolution rate.
[0107] 5. Modification in the levels of lactose produced no change in the dissolution rate.
[0108] 6. Processing several blends and compressions from the same lot of granulation, using a single lot of lithium carbonate, produced no change in the dissolution rate.
[0109] 7. The use of multiple lots of lithium carbonate for different batches of granulation produced no change in the dissolution rate.
[0110] 8. A reduction of 50 % in the level of lubricant produced aminor increase in dissolution.
[0111] 9. A 50% increase in the lubricant level did not produce a slowing effect on the dissolution rate.
EXAMPLE III
Replacement of NaCMC With Other Binding Agents
[0112] To test the efficacy of other binding agents in improving the dissolution characteristics of lithium carbonate, NaCMC was replaced with various other release sustaining agents, including starch, gelatin, aqueous polyvinylpyrrolidone (PVP), and hydroxypropylcellulose (HPC). Starch NF, Starch 1500 (partially pregelatinized starch), or Starch 1551 (totally pregelatinized starch) was suspended in water and used in place of NaCMC to granulate the lithium carbonate/iron oxide blend. The granulation was milled in a cone mill fitted with a 1 mm round hole cone. Prior to the lubrication the granulations were blended with additional excipients including multiple levels of Aerosil 200® (colloidal silica), Avicel PH102® (microcrystalline cellulose), and/or Starch 1500 (partially pregelatinized starch). The blends were then lubricated and compressed at hardness levels of either 7 or 10 kPa. With starch as the release sustaining agent, with or without additional extragranular excipients, the dissolution rates were found to be highly erratic and all work was stopped on these formulations.
[0113] In a second series of experiments, gelatin (Gelatin A, 125 and 200 bloom, or Gelatin B, 200 bloom) was suspended/dissolved in water and used to granulate the lithium carbonate/iron oxide blend. The granulation was milled in a cone mill fitted with a 1 mm round hole cone. In a sub-series of experiments using gelatin, the granulation was blended, prior to lubrication, with additional excipients, including multiple levels of Aerosil 200® (colloidal silica), Avicel PH102® (microcrystalline cellulose), Starch 1500 (partially gelatinized starch), Explotab (sodium starch glycolate), and/or Ac-Di-Sol (Croscarmellose sodium). The blends were then lubricated and compressed at hardness levels of either 7 or 10 kPa. Variations using different lots of lithium carbonate, the manufacture of multiple batches from a single lot of lithium carbonate, the manufacture of multiple batches or tablets from a single batch of granulation and differing levels of both stearic acid and magnesium stearate lubricant were all tested. When using gelatin as the release agent, with or without additional extragranular excipients, the dissolution rates were very erratic and all work was stopped on these formulations.
[0114] In a third series of experiments, polyvinylpyrrolidone (PVP), K30, K90, and K30 plus K90 (difference in molecular weights) was dissolved in water and used to granulate the lithium carbonate/iron oxide blends. The granulation was milled in a cone mill fitted with a 1 mm round hole cone. In a sub-series of experiments using polyvinylpyrrolidone, the granulation was blended, prior to lubrication, with additional excipients, including multiple levels of Aerosil 2000 (colloidal silica), Avicel PH102® (microcrystalline cellulose), and/or Starch 1500 (partially gelatinized starch). The blend was then lubricated and compressed at hardness levels of either 7 or 10 kPa. Variations including the manufacture of multiple batches from a single lot of lithium carbonate, the manufacture of multiple batches of tablets from a single granulation batch, the manufacture of batches with different levels and types of PVP and the manufacture of batches using different levels of both stearic acid and magnesium stearate lubricants were tested. When using PVP as the release sustaining agent, with or without extragranular excipients, the dissolution rates were highly erratic and all work was stopped on these formulations.
[0115] In a fourth series of experiments, hydroxypropylcellulose (HPC) was dissolved in an organic solvent (isopropyl alcohol) and used to granulate the lithium carbonate/iron oxide blend in an attempt to eliminate the use of water in the formulation process. The granulation was milled using a cone mill fitted with a 1 mm round hole cone. In a sub-series of experiments using HPC, the granulation was blended, prior to lubrication, with additional excipients including multiple levels of Aerosil 200® (colloidal silica), Avicel PH102® (microcrystalline cellulose), and/or Starch 1500 (partially gelatinized starch). The blend was then lubricated and compressed to hardness levels of either 7 or 10 kPa. Varying levels of stearic acid lubricant were tested. When using HPC as the release sustaining agent, with or without additional extragranular excipients, the dissolution rates were very fast and all work was stopped on these formulations.
EXAMPLE IV
Lithium Carbonate—NaCMC With Secondary Release Agent (Glycine)
[0116] With the failure of other release sustaining agents to improve the dissolution profile obtained with NaCMC as the release sustaining agent, experiments were undertaken utilizing a secondary release sustaining agent, glycine, in addition to the formulations including NaCMC. Multiple levels of glycine were used in conjunction with lithium carbonate/iron oxide. NaCMC formulations and release rates were found to be modified in a controllable manner, ranging from three hour dissolution rates of approximately 50% with no added glycine, and ranging upwards to three hour dissolution rates of nearly 100% with 40 mg/tablet added glycine, as shown in Table 15. As the goal of the experimental protocol was to achieve only a modest increase in the baseline dissolution rate using NaCMC as the sole release sustaining agent (see, e.g., three hour dissolution rate for Na-CMC in Tables 8 and 9), a level of 8 mg/tablet of added glycine, which produced an increase in the three hour dissolution rate to 63%, as seen in Table 15, was chosen for additional inquiry.
TABLE 15 Effects of Varying Levels of Glycine as Secondary Releasing Agent in NaCMC Granulations Glycine Stearic Dissolution % Formula NaCMC Level Acid 1 Hr. 3 Hr. 7 Hr. 0106033 25 mg 0.5 mg 2.4 mg 22 57 90 0106977 25 mg 2 mg 2.4 mg 22 57 96 0106976 25 mg 5 mg 2.4 mg 23 59 99 0106975 25 mg 8 mg 2.45 mg 25 63 100 0107229 25 mg 8 mg 4.9 mg 26 63 100 0107232 25 mg 11 mg 4.9 mg 25 63 100 0107230 25 mg 14 mg 4.9 mg 28 67 100 0106774 25 mg 20 mg 2.5 mg 30 78 101* 0106772 25 mg 40 mg 2.6 mg 35 96 101*
[0117] [0117] Formula Tablet Weights (mg) 0106033 477.9 0106977 479.4 0106976 482.4 0106975 485.45 0107229 487.9 0107232 490.9 0107230 493.9 0106774 497.5 0106772 517.6
[0118] In a preferred embodiment, the glycine ranges from, at a lower end, about 0.1, 1, 2, or 3 percent to about, at a higher end, 6, 8, 9, or 10 percent based on the weight of the composition.
[0119] Several other experiments were performed using this combination release controlling formulation. It was found, as shown in Table 16, that the density of the lithium carbonate did not affect the release profile. It was also found, as shown in Table 17, that increasing the lubricant level, utilizing either stearic acid or sodium stearyl fumerate, did slow the release rate. During these experiments the level of stearic acid was increased from 0.5% to 1.0% because although the tablets showed no dissolution problems at a 0.5% stearic acid level, the tablet tooling showed a relative lack of tablet lubricant. The increase in the level of stearic acid from 0.5% to 1.0% did not affect the dissolution profiles, however, levels above 1% did cause some slowing of dissolution, as shown in Tables 16 and 17.
TABLE 16 Effect of Different Lithium Bulk Densities on NaCMC-Glycine Granulations Glycine Stearic NaCMC Lithium Level Acid Dissolution % Formula mg/tablet Density Mg/tablet mg/tablet 1 Hr. 3 Hr. 7 Hr. 0200578 25 mg 0.49 8 mg 4.9 mg 23 61 97 0200575 25 mg 0.51 8 mg 4.9 mg 24 60 98 0200581 25 mg 0.525 8 mg 4.9 mg 25 61 100 0200756 25 mg 0.55 8 mg 4.9 mg 33 70 101* 0106975 25 mg 0.55 8 mg 4.9 mg 28 64 100
[0120] [0120] TABLE 17 Effect of Increasing Lubrication on NaCMC-Glycine Granulations Sodium Glycine Stearyl Stearic NaCMC Level Fumerate Acid Dissolution % Formula mg/tablet mg/tablet Mg/tablet mg/tablet 1 Hr. 3 Hr. 7 Hr. 0200586 25 mg 8 mg 0 mg 4.9 mg 33 70 100 0200771 25 mg 8 mg 0 mg 9.8 mg 26 57 96 0200770 25 mg 8 mg 0 mg 14.9 mg 23 51 86 0200773 25 mg 8 mg 4.9 mg 0 mg 26 62 102* 0200774 25 mg 8 mg 9.8 mg 0 mg 25 57 95
[0121] Experiments were performed utilizing different levels of moisture and demonstrated that when drying the granulation, it is very difficult to dry to a moisture level much lower than 0.5% to 1.0%. A single compression was attempted with granulation at a 4.25% moisture level. The compression was only able to achieve a 4.0 kPa hardness level. This, however, did give a respectable dissolution rate of 60% at the three hour point.
[0122] Dissolution stability studies were undertaken for both low density and high density lithium, utilizing the lithium carbonate—NaCMC—Glycine formulation, as seen in Tables 18 and 19. These showed an improved dissolution rate compared to the dissolution stabilities seen with the lithium carbonate—NaCMC formulations, in the current commercial packaging, reported in Table 8.
TABLE 18 Dissolution Stability Summary Lithium Carbonate - NaCMC -Glycine Formulations Utilizing Low Density Lithium in Current Commercial Packaging 1 Hour 3 Hour 7 Hour Storage Age Dissolution % Dissolution % Dissolution % Conditions (Months) High Low Avg. High Low Avg. High Low Avg. Initial 00 26 25 26 61 58 59 98 97 98 25° C./60% 01 27 24 25 62 56 59 103* 96 100 Rel. Hum. 02 26 24 25 62 59 60 102* 98 100 03 25 23 24 58 55 57 96 91 94 04 26 22 25 61 56 59 96 93 95 30° C./60% 03 NR NR NR NR NR NR NR NR NR Rel. Hum. 40° C./75% 01 30 26 27 67 59 62 101* 94 99 Rel. Hum. 02 26 23 25 63 58 61 102* 99 101* 03 26 23 25 64 55 59 85 69 76 04 20 16 19 48 43 45 85 69 76 Spec. Limits Not More Than 45%-75% Not Less Than 40% 75%
[0123] [0123] TABLE 19 Dissolution Stability Summary Lithium Carbonate - NaCMC -Glycine Formulations Utilizing High Density Lithium in Current Commercial Packaging 1 Hour 3 Hour 7 Hour Storage Age, Dissolution % Dissolution % Dissolution % Conditions (Months) High Low Avg. High Low Avg. High Low Avg. Initial 00 31 28 29 66 62 64 102* 99 100 25° C./60% 01 28 23 26 65 55 61 103* 94 99 Rel. Hum. 02 26 25 26 64 61 62 103* 98 101* 03 27 23 25 62 58 60 99 93 96 04 26 24 25 62 59 60 99 96 97 30° C./60% 03 NR NR NR NR NR NR NR NR NR Rel. Hum. 40° C./75% 01 28 25 26 68 62 65 106* 102* 104* Rel. Hum. 02 29 25 26 67 63 65 104* 102* 103* 03 23 20 22 55 51 54 100 85 94 04 22 19 20 53 49 51 96 88 93 Spec. Limits Not More Than 45%-75% Not Less Than 40% 75%
EXAMPLE V
Lithium Carbonate—NaCMC—Bowl Charge Modification
[0124] A modification to the manufacturing method of the preceding examples was made in an additonal series of experiments with the NaCMC granulation. Standard commercial testing preparations equivalent to a bowl charge of 40,000 tablets at 450 mg lithium carbonate per tablet were utilized. Varying amounts of lithium carbonate, in an amount equal to either 5, 10, or 15 mg/tablet, were removed from the fluid bed bowl. The amount removed from the fluid bed bowl was then dissolved in water containing the desired amount of NaCMC and returned to the final formulation as part of the granulation solution spray. The effect of the bowl charge modification on the formulation dissolution rate varied from the baseline of approximately 50% dissolution at three hours (no lithium removed from granulation bowl and sprayed back onto granulation mixture with NaCMC), to an increase in dissolution rates, as shown in Table 20, that increased to as much as 75% at three hours with a 15 mg bowl modification (i.e., an amount of lithium equal to 15 mg/tablet removed from bowl charge, dissolved with water containing NaCMC, and then sprayed back onto the granulation mixture). In keeping with the experimental goal of achieving a modest increase in three hour dissolution rates, a bowl modification of 10 mg/tablet was chosen for further experimentation with varying lithium densities, as shown in Table 21.
TABLE 20 Effect of Bowl Charge Modification on Dissolution Rates of NaCMC-Glycine Granulations Stearic NaCMC Bowl Modification Acid Dissolution % Formula mg/tablet mg/tablet mg/tablet 1 Hr. 3 Hr. 7 Hr. 0106980 25 mg 5 mg 2.4 mg 24 59 97 0106978 25 mg 10 mg 2.4 mg 26 63 100 0107231 25 mg 15 mg 4.8 mg 32 75 101*
[0125] [0125] TABLE 21 Effect of Different Densities of Lithium NaCMC using Glycine Granulations With 10 mg/tablet Bowl Charge Modification Stearic Lithium NaCMC Acid Bulk Dissolution % Formula mg/tablet mg/tablet Density 1 Hr. 3 Hr. 7 Hr. 0200582 25 mg 4.8 mg 0.49 33 68 101* 0200579 25 mg 4.8 mg 0.51 27 61 97 0200576 25 mg 4.8 mg 0.525 35 73 102* 0200755 25 mg 4.8 mg 0.55 35 70 103* 0200774 25 mg 4.8 mg 0.55 27 62 98
[0126] Dissolution stability studies were undertaken for both low density and high density lithium, utilizing the lithium carbonate—NaCMC—10 mg/tablet bowl charge modification formulations, as seen in Tables 22-24. The results of these studies, shown in Table 22-24, showed an improved dissolution rate in most time periods and storage conditions compared to the dissolution stabilities seen with the lithium carbonate—NaCMC formulations of Table 8. There was, however, a drop in dissolution rates at the highest experimental temperatures and relative humidity. This effect showed slight variation in two different granulation lots of high density lithium carbonate (Lot 0200755, manufactured in 2002; reported in Table 23 and Lot 0106978, manufactured in 2001).
TABLE 22 Stability Summary of Low Density Lithium Carbonate - NaCMC Formulations With 10 mg/tablet Bowl Charge Modification 1 Hour 3 Hour 7 Hour Storage Age Dissolution % Dissolution % Dissolution % Conditions (Months) High Low Avg. High Low Avg. High Low Avg. Initial 00 40 32 37 74 67 71 103* 100 102* 25° C./60% 01 34 28 32 70 66 68 103* 100 101* Rel. Hum. 02 36 29 33 71 64 68 103* 81 97 03 33 28 31 66 62 64 97 95 96 04 36 25 32 71 65 68 97 91 93 30° C./60% 03 NR NR NR NR NR NR NR NR NR Rel. Hum. 40° C./75% 01 35 33 31 72 67 69 102* 99 100 Rel. Hum. 02 40 30 33 74 64 67 104* 97 102* 03 40 29 35 78 64 70 95 84 87 04 25 24 25 55 51 53 95 84 87 Spec. Limits Not More Than 45%-75% Not Less Than 40% 75%
[0127] [0127] TABLE 23 Stability Summary of High Density Lithium Carbonate - NaCMC Formulations With 10 mg/tablet Bowl Charge Modification - Lot 0200755 1 Hour 3 Hour 7 Hour Storage Age Dissolution % Dissolution % Dissolution % Conditions (Months) High Low Avg. High Low Avg. High Low Avg. Initial 00 29 26 28 67 63 65 98 98 98 25° C./60% 01 29 26 28 69 62 65 103* 100 102* Rel. Hum. 02 30 25 28 70 53 64 101* 88 94 03 29 26 27 66 63 65 99 92 97 04 31 28 29 71 67 69 101* 99 100 30° C./60% 03 NR NR NR NR NR NR NR NR NR Rel. Hum. 40° C./75% 01 41 28 31 81 69 72 103* 99 101* Rel. Hum. 02. 27 25 26 64 61 62 99 95 97 03 25 21 23 54 50 52 95 87 90 04 17 17 17 38 36 37 60 56 58 Spec. Limits Not More Than 45%-75% Not Less Than 40% 75%
[0128] [0128] TABLE 24 Stability Summary of Appendix G High Density Lithium Carbonate - NaCMC Formulations With 10 mg/tablet Bowl Charge Modification - Lot 0106978 1 Hour 3 Hour 7 Hour Storage Age Dissolution % Dissolution % Dissolution % Conditions (Months) High Low Avg. High Low Avg. High Low Avg. Initial 00 30 26 29 65 61 63 100 96 98 25° C./60% 01 34 29 31 67 65 66 105* 100 103* Rel. Hum. 02 31 29 30 68 66 67 107* 101* 103* 03 30 29 30 64 63 64 100 95 98 04 29 27 28 66 62 64 101* 99 100 30° C./60% 03 NR NR NR NR NR NR NR NR NR Rel. Hum. 40° C./75% 01 30 29 30 67 64 65 101* 96 99 Rel. Hum. 02 30 27. 28 65 55 62 101* 96 99 03 24 22 23 52 49 51 92 85 88 04 21 20 20 46 43 45 84 74 79 Spec. Limits Not More Than 45%-75% Not Less Than 40% 75%
EXAMPLE VI
Dissolution Profiles With Altered Commercial Packaging
[0129] The effects of product packaging was hypothesized to play a role in the changes in dissolution profiles seen over time with various lithium carbonate formulations. In the first experiment, as a control, Eskalith CR 450® from several lots, in the current commercial packaging of Eskalith CR®, was placed on stability. All sample performed outside of specifications after six months testing at high levels of heat and humidity, with representative studies shown in Table 25.
TABLE 25 Stability Summary of Currently Marketed, Gelatinized Lithium Carbonate (Eskalith CR 450 ®) in Current Commercial Packaging 1 Hour 3 Hour 7 Hour Storage Age Dissolution % Dissolution % Dissolution % Conditions (Months) Potency High Low Avg. High Low Avg. High Low Avg. Initial 00 98.3 26 22 24 70 57 64 99 96 97 25° C./60% 01 NR 24 20 22 65 59 63 100 95 98 Rel. Hum. 02 NR 27 23 25 65 60 63 102* 98 101* 03 97.3 23 21 22 60 54 58 100 94 97 06 97.5 22 20 21 58 52 54 96 91 95 09 98.6 22 20 21 57 54 55 96 92 94 12 99.7 20 19 20 57 52 54 98 93 95 30° C./60% 03 NR NR NR NR NR NR NR NR NR NR Rel. Hum. 06 97.4 20 18 19 52 46 49 99 94 96 09 99.9 21 18 20 55 53 54 97 92 95 12 100.0 19 17 18 55 49 51 92 88 90 40° C./75% 03 99.3 20 19 19 50 46 48 89 84 87 Rel. Hum. 06 97.8 18 16 17 40 38 39 79 73 76 Spec. Limits 99.0-110.0 Not More Than 45%-75% Not Less Than 40% 75%
[0130] In accompanying experiments, the effects of altering the current commercial packaging of the currently available, gelatinized, form of lithium carbonate (Eskalith CR 450®) was studied in an attempt to develop improved dissolution profiles, particularly at longer storage times at highter heat and humidity levels, than those seen in the representative baseline reported in Table 25. In this follow up study, the currently marketed packaging of Eskalith CR 450®, consisting of a 100 cc, High Density Polyethylene (HDPE) white bottle with a 33 mm white polypropylene plastic cap, desiccant, and cotton fill was modified with the addition of an induction heat seal and two, 2 in 1 desiccant canisters placed within the bottle. This modification of the current commercial packaging, carried out in three separate experiments, as shown in Tables 26-28, showed considerable improvement in the three hour dissolution profiles of the currently marketed gelatinized form of lithium carbonate studied (Eskalith CR 450®), whose baseline values are shown in Table 25. In the test, averages in the modified packaging performed within specifications after six months storage at high temperature and humidity.
TABLE 26 Stability Summary of Currently Marketed, Gelatinized Lithium Carbonate (Eskalith CR 450 ®) in Proposed Commercial Packaging (Addition of Induction Heat Seal and Two, 2 in 1 Desiccant Canisters) - Lot 0102583 1 Hour 3 Hour 7 Hour Storage Age Dissolution % Dissolution % Dissolution % Conditions (Months) Potency High Low Avg. High Low Avg. High Low Avg. Initial 00 102.8 27 24 26 69 65 67 105* 101* 103* 25° C./60% 03 103.3 28 23 25 73 61 67 112* 102* 106* Rel. Hum. 06 102.3 28 24 26 73 61 67 112* 102* 106* 30° C./60% 01 99.9 27 25 26 73 67 69 103* 99 101* Rel. Hum. 02 102.3 28 26 27 72 65 69 104* 102* 103* 03 101.4 34 26 29 75 70 73 104* 100 102* 06 102.5 25 24 24 67 64 65 105* 102* 103* 40° C./75% 01 101.2 26 23 24 68 61 64 105* 102* 103* Rel. Hum. 02 101.4 23 22 23 62 58 60 102* 100 101* 03 100.9 22 20 21 59 55 57 102* 98 100 06 102.9 20 18 19 55 52 54 100 96 98 Spec. Limits 99.0-110.0 Not More Than 45%-75% Not Less Than 40% 75%
[0131] [0131] TABLE 27 Stability Summary of Currently Marketed, Gelatinized Lithium Carbonate (Eskalith CR 450 ®) in Proposed Commercial Packaging (Addition of Induction Heat Seal and Two, 2 in 1 Desiccant Canisters) - Lot 0102584 1 Hour 3 Hour 7 Hour Storage Age Dissolution % Dissolution % Dissolution % Conditions (Months) Potency High Low Avg. High Low Avg. High Low Avg. Initial 00 103.7 25 23 24 64 60 63 104* 97 102* 25° C./60% 03 103 27 23 25 70 63 66 106* 98 104* Rel. Hum. 06 102.5 25 23 24 67 57 63 106* 98 104* 30° C./60% 01 99.9 26 24 25 66 62 64 102* 99 101* Rel. Hum. 02 101.5 27 24 25 67 60 63 103* 100 101* 03 101.8 25 22 23 65 59 62 102* 100 101* 06 101.9 24 22 23 67 63 65 106* 102* 104* 40° C./75% 01 101 25 22 24 64 61 62 100 98 99 Rel. Hum. 02 101.2 23 21 22 59 53 56 100 95 97 03 100.3 29 22 24 71 55 61 103* 94 100 06 101.7 19 16 18 51 43 48 97 83 91 Spec. Limits 99.0-110.0 Not More Than 45%-75% Not Less Than 40% 75%
[0132] [0132] TABLE 28 Stability Summary of Currently Marketed, Gelatinized Lithium Carbonate (Eskalith CR 450 ®) in Proposed Commercial Packaging (Addition of Induction Heat Seal and Two, 2 in 1 Desiccant Canisters) - Lot 0102588 1 Hour 3 Hour 7 Hour Storage Age Dissolution % Dissolution % Dissolution % Conditions (Months) Potency High Low Avg. High Low Avg. High Low Avg. Initial 00 102.8 26 21 24 68 55 63 102* 98 101* 25° C./60% 03 103.2 29 23 26 75 62 68 102* 98 100 Rel. Hum. 06 102.6 27 21 24 68 58 64 109* 97 103* 30° C./60% 01 99.4 26 24 25 66 60 63 101* 99 100 Rel. Hum. 02 101.2 24 22 23 64 63 64 103* 101* 102* 03 101.3 25 22 23 66 61 63 101* 98 99 06 102.1 28 22 25 76 61 68 107* 99 103* 40° C./75% 01 100.7 24 22 23 67 59 62 100 97 99 Rel. Hum. 02 101.4 23 22 22 62 60 61 102* 99 100 03 101.5 22 18 21 65 61 63 104* 100 102* 06 101.9 18 16 17 55 48 52 102* 95 97 Spec. Limits 99.0-110.0 Not More Than 45%-75% Not Less Than 40% 75%
INDUSTRIAL APPLICABILITY
[0133] While many drugs are conveniently dosed using conventional delayed release or sustained release technology, pharmaceuticals such as lithium compounds that have highly variable dissolution rates and narrow ranges of clinically therapeutic plasma concentrations present difficult problems. The present inventors, have, through an extensive amount of research, determined that a formulation of lithium carbonate including the excipients Sodium Carboxymethylcellulose (NaCMC) and glycine has an enhanced dissolution profile at three hours, compared to a formulation not containing glycine, and that the formulation including glycine has a more stable three hour dissolution profile following prolonged periods of storage under varying conditions. In addition, a process modification wherein approximately 10 mg/tablet of the lithium—NaCMC granulation is removed from the fluid bed, solubilized, and then top sprayed on the remaining granulation, also exhibits an improved three hour dissolution profile, and that the formulation produced by this method has a more stable three hour dissolution profile following prolonged periods of storage under varying conditions. Testing of the dissolution stability of a currently marketed lithium carbonate formulation in a modified packaging indicates that the improved dissolution stability profile of lithium carbonate—NaCMC, lithium carbonate NaCMC—glycine, and lithium carbonate—NaCMC formulated in a bowl charge modification process may all be further improved with modification of the current commercial packaging of lithium carbonate formulations.
[0134] The compositions of the present invention may be administered according to various dosage regiments, i.e., once-daily or multiple daily occurrences (e.g., two), or at various intervals (e.g., every 12 hours). The amount of lithium carbonate employed per dosage form (e.g., tablet) may vary and include, without limitation, 300 mg and 450 mg. The compositions may be employed in various dosage forms including, without limitation, tablets, pills, powders, elixirs, suspensions, emulsions, solutions, syrups, capsules (such as, for example, soft and hard gelatin capsules), suppositories, sterile injectable solutions, and sterile packaged powders.
[0135] Having thus described the present invention in detail, it will be obvious to those skilled in the art that various changes or modifications may be made without departing from the scope of the invention define in the appended claims and described in the specification.
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The present invention pertains to a controlled release solid dose formulations of lithium carbonate, comprising lithium carbonate, optional pharmacologically acceptable excipients, lubricants including stearic acid, sodium stearyl fumerate, calcium stearate, and magnesium stearate, optionally glycine, and sodium carboxymethylcellulose. Tablet forms are compressed at various pressures. The sodium carboxymethylcellulose and optionally glycine increases the dissolution rate profiles for lithium carbonate formulations, particularly for those formulations stored for extended periods of time and at varying conditions of heat and humidity. A process of formulating such compositions, comprising the steps of mixing lithium carbonate with excipients, top spraying a solution of sodium carboxymethylcellulose and glycine onto the lithium mixture in a fluid bed granulator, milling, and pressing the resultant compound into tablets is also described. The formulations of the invention are useful in a method of treatment of Bipolar Disorder (Manic Depressive Disorder).
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The present invention generally relates to a method, a computer program element and a system for processing alarms that have been triggered by a monitoring system such as an intrusion detection system, a firewall or a network management system.
The present invention specifically relates to a method and a system for processing alarms triggered by a host or network intrusion detection system, operating by means of behavior-based or knowledge-based detection, in order to extract information about the state of the monitored system or activities of its users.
More particularly, the present invention relates to a method and a system for processing alarms, possibly containing a high percentage of false alarms, which are received at a rate that can not be handled efficiently by human system administrators.
This invention is related to an invention disclosed in a copending U.S. application Ser. No. 10/286,708 entitled “METHOD, COMPUTER PROGRAM ELEMENT AND A SYSTEM FOR PROCESSING ALARMS TRIGGERED BY A MONITORING SYSTEM”, filed in the name of International Business Machines Corporation, claiming as priority EP patent appl. EP 01811155.9 filed on Nov. 29, 2001, that is herewith incorporated by reference in its entirety.
BACKGROUND OF THE INVENTION
According to Kathleen A. Jackson, INTRUSION DETECTION SYSTEM (IDS) PRODUCT SURVEY, Version 2.1, Los Alamos National Laboratory 1999, Publication No. LA-UR-99-3883, Chapter 1.2, IDS OVERVIEW, intrusion detection systems attempt to detect computer misuse. Misuse is the performance of an action that is not desired by the system owner; one that does not conform to the system's acceptable use and/or security policy. Typically, misuse takes advantage of vulnerabilities attributed to system misconfiguration, poorly engineered software, user neglect or abuse of privileges and to basic design flaws in protocols and operating systems.
Intrusion detection systems analyze activities of internal and/or external users for explicitly forbidden and anomalous behavior. They are based on the assumption that misuse can be detected by monitoring and analyzing network traffic, system audit records, system configuration files or other data sources (see also Dorothy E. Denning, IEEE TRANSACTIONS ON SOFTWARE ENGINEERING, VOL. SE-13, NO. 2, February 1987, pages 222-232).
The types of methods an intrusion detection system can use to detect misuse can vary. Essentially, there are two main intrusion detection methods known, which are described for example in EP 0 985 995 A1 and U.S. Pat. No. 5,278,901.
The first method uses knowledge accumulated about attacks and looks for evidence of their exploitation. This method, which on a basic level can be compared to virus checking methods, is referred to as knowledge-based, also known as signature-based or pattern-oriented or misuse detection. A knowledge-based intrusion detection system therefore looks for patterns of attacks while monitoring a given data source. As a consequence, attacks for which signatures or patterns are not stored, will not be detected.
According to the second method a reference model is built, that represents the normal behavior or profile of the system being monitored and looks for anomalous behavior, i.e. for deviations from the previously established reference model. Reference models can be built in various ways. For example in S. Forrest, S. A. Hofineyr, A. Somayaji and T. A. Longstaff; A Sense of Self for Unix Processes, Proceedings of the 1996 IEEE Symposium on Research in Security and Privacy, IEEE Computer Society Press 1996, pages 120-128, normal process behavior is modeled by means of short sequences of system calls.
The second method is therefore referred to as behavior-based, also known as profile-based or anomaly-based. Behavior-based intrusion detection, which relies on the assumption that the “behavior” of a system will change in the event that an attack is carried out, therefore allows to detect previously unknown attacks, as long as they deviate from the previously established model of normal behavior. Under the condition that the normal behavior of the monitored system does not change, a behavior-based intrusion detection system will remain up-to-date, without having to collect signatures of new attacks.
However, since the behavior of a system normally changes over time, e.g. due to changes in the activities of authorized users or installation of new or updated system elements, without immediate adaptation of the used reference model deviations from the modeled behavior will frequently be detected without any intrusions taking place. Behavior-based intrusion detection systems will therefore normally produce a large number of false alarms (false positives) deriving from non-threatening events.
Knowledge-based intrusion detection systems tend to generate fewer false alarms. However, depending on the quality of the stored knowledge of known attacks and the condition of the monitored system these systems may also produce numerous false alarms which can not easily be handled by human system administrators. For example, some network applications and operating systems may cause numerous ICMP (Internet Control Message Protocol) messages (see Douglas E. Corner, INTERNETWORKING with TCP/IP, PRINCIPLES, PROTOCOLS, AND ARCHITECTURES, 4th EDITION, Prentice Hall 2000, pages 129-144), which a knowledge-based detection system may interpret as an attempt by an attacker to map out a network segment. ICMP-messages not corresponding to normal system behavior may also occur during periods of increased network traffic with local congestions.
It is further known that an intrusion detection system may interpret sniffed data differently than the monitored network elements, see Thomas H. Ptacek, Timothy N. Newsham, Insertion, Evasion, and Denial of Service: Eluding Network Intrusion Detection, Secure Network Inc., January 1998, which under certain conditions could also lead to false alarms.
False alarms, appearing in large numbers, are a severe problem because investigating them requires time and energy. If the load of false alarms in a system gets high, human system administrators or security personnel might become negligent. In Klaus Julisch, Dealing with False Positives in Intrusion Detection, RAID, 3rd Workshop on Recent Advances in Intrusion Detection, 2000, it is described that filters could be applied in order to remove false alarms. Filters can also use a knowledge-based approach (discarding what are known to be false positives) or a behavior-based approach (discarding what follows a model of normal alarm behavior). Either way, maintaining and updating models or knowledge bases of filters and intrusion detection systems requires further efforts.
It would therefore be desirable to create an improved method and a system for processing alarms triggered by a monitoring system such as an intrusion detection system, a firewall or a network management system in order to efficiently extract relevant information about the state of the monitored system or activities of its users.
It would further be desirable for this method and system to operate in the presence of a large amount of false alarms, which are received at a rate that can not be handled efficiently by human system administrators.
Still further, it would be desirable to receive the results of said data processing procedures, in a short form but with a high quality of information, that can easily be interpreted by human system administrators or automated post processing modules.
SUMMARY OF THE INVENTION
In accordance with the present invention there is now provided a method, a computer program element and a system according to claim 1 , claim 14 and claim 15 .
The method allows to process alarms triggered by a monitoring system such as an intrusion detection system, a firewall or a network management system in order to extract relevant information about the state of the monitored system or activities of its users.
In order to obtain relevant information about the state of the monitored system or activities of its users,
a) similarity between alarms is evaluated, b) similar alarms are grouped into so-called alarm clusters, c) alarm clusters that satisfy a predetermined criterion, e.g. exceed a minimum number are summarized by so-called “generalized alarms” and d) generalized alarms constituting the output of the method are forwarded for further processing.
In the event of high rates of alarm messages, possibly containing a high percentage of false alarms, human system administrators will not be confronted with a flood of messages with little significance. Instead, only generalized alarms, which are more meaningful and less in number, are presented to human system administrators. This fosters understanding of alarm root causes and facilitates the conception of an appropriate response to alarms (e.g. by suppressing false alarms in the future, or by repairing a compromised system component).
Key to alarm clustering is the notion of alarm similarity. Different definitions of alarm similarity are possible, but in a preferred embodiment, alarm similarity is defined as the sum of attribute similarities and attribute similarity is preferably defined via taxonomies. Examples of attributes include the alarm source, the alarm destination, the alarm type, and the alarm time. A taxonomy is an “is-a” generalization hierarchy that shows how attribute values can be generalized to more abstract concepts. Finally, two attribute values are all the more similar, the closer they are related by means of their taxonomies.
By way of illustration, a taxonomy on the time attribute might establish the following “is-a” hierarchy:
timestamp ts 1 is-a monday and a monday is-a workday; timestamp ts 2 is-a tuesday and a tuesday is-a workday; a workday is-a day of the week; timestamp ts 3 is-a sunday and a sunday is-a holiday; a holiday is-a day of the week.
Given this taxonomy, timestamp t 1 is more similar to t 2 than to t 3 . This is because t 1 and t 2 are related via the concept “workday”. In contrast, t 1 and t 3 are only related via the concept “day of the week”, which is less specific, thus resulting in a smaller similarity value. Finally, as stated earlier, alarm similarity is defined as the sum of attribute similarities.
Alarm clusters can easily comprise thousands of alarms. Therefore, it is not viable to represent alarm clusters by means of their constituent alarms. Indeed, doing so would mean to overwhelm a recipient with a vast amount of information that is hard to make sense of. To solve this problem, alarm clusters are represented by so-called generalized alarms. Generalized alarms are like ordinary alarms, but their alarm attributes can assume higher-level concepts from the taxonomies. To continue the above example, the time-attribute of a generalized alarm might assume any of the values “monday”, . . . , “sunday”, “workday”, “holiday”, or “day of the week”.
The rationale for clustering similar alarms stems from the observation that a given root cause generally results in similar alarms. Thus, by clustering similar alarms, it is attempted to group alarms that have the same root cause. Finally, generalized alarms provide a convenient vehicle for summarizing similar alarms in a succinct and intuitive manner. The end result is a highly comprehensible, extremely succinct summary of an alarm log that is very adequate for identifying alarm root causes. Identifying alarm root causes is of value as it is the basis for finding an appropriate response to alarms (such as shunning attackers at the firewall, or suppressing false positives in the future, etc.). In this way, the described invention offers an effective and efficient method for managing large amounts of alarms.
BRIEF DESCRIPTION OF THE DRAWINGS
Some of the objects and advantages of the present invention have been stated, others will appear when the following description is considered together with the accompanying drawings, in which:
FIG. 1 shows a schematic view of a computer network topology comprising firewalls and a DMZ;
FIG. 2 shows a sample alarm log with unprocessed alarms and the corresponding generalized alarms in a cluster log; each generalized alarm covers, as indicated in the size field, a number of alarms of the alarm log;
FIG. 3 shows a sample taxonomy, hierarchically listing the organization of IP-addresses of the network in FIG. 1 ;
FIG. 4 shows a sample taxonomy, hierarchically listing the organization of port numbers;
FIG. 5 shows a sample taxonomy, hierarchically listing the days of a week;
FIG. 6 shows a sample taxonomy, hierarchically listing the days of a month; and
FIG. 7 shows a table comprising generalized alarms.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows a schematic view of a computer network topology comprising firewalls 13 , 14 and a demilitarized zone 10 , below referred to as DMZ. DMZ is a term often used when describing firewall configurations. The DMZ 10 is an isolated subnet between a secure network 19 and an external network such as the Internet 15 . Clients 16 operating in the Internet 15 may access Web servers and other servers 11 , 12 in the DMZ 10 , which are provided for public access. The servers 11 , 12 are protected to some degree by placing an outer firewall 13 , often a packet-filtering router, between the Internet 15 and the servers 11 , 12 in the DMZ 10 . The outer firewall 13 forwards only those requests into the DMZ 10 which are allowed to reach the servers 11 , 12 . Further the outer firewall 13 could also be configured to block denial-of-service attacks and to perform network address translation for the servers 11 , 12 in the DMZ 10 . The inner firewall 14 is designed to prevent unauthorized access to the secure network from the DMZ 10 and perhaps to prevent unauthorized access from the secure network to the DMZ 10 or the Internet 15 . Network traffic in the DMZ 10 is sensed and analyzed by an intrusion detection system 18 which, as described above, triggers alarms when detecting patterns of attacks or anomalous behavior.
In the examples presented below, alarms are modeled as tuples over a multidimensional space. The dimensions are called alarm attributes or attributes for short. Examples of alarm attributes include the source and destination IP address, the source and destination port, the alarm type which encodes the observed attack, and the timestamp which also includes the date.
Formally, alarms are defined as tuples over the Cartesian product X 1≦i≦n dom, where {A 1 , . . . , A n } is the set of attributes and dom is the domain (i.e. the range of possible values) of attribute A i . Furthermore, for an alarm a and an attribute A i , the projection a[A i ] is defined as the A i value of alarm a. Next, an alarm log is modeled as a set of alarms. This model is correct if the alarms of alarm logs are pairwise distinct—an assumption made to keep the notation simple. Unique alarm-IDs can be used to make all alarms pairwise distinct.
A i shall be an alarm attribute. A tree T i on the elements of dom is called a taxonomy (or a generalization hierarchy). For two elements x, {circumflex over (x)}εdom, {circumflex over (x)} is called a parent of x, and x a child of {circumflex over (x)} if there is an edge {circumflex over (x)}→x in T i . Furthermore, {circumflex over (x)} is called a generalization of x if the taxonomy T i contains a path from {circumflex over (x)} to x, in symbols: x {circumflex over (x)}. The length of this path is called the distance δx, {circumflex over (x)}) between x and {circumflex over (x)}. δ(x, {circumflex over (x)}) is undefined if x {circumflex over (x)} is not satisfied. Finally, x {circumflex over (x)} is trivially satisfied for x={circumflex over (x)}, and δ(x, {circumflex over (x)}) equals 0 in this case.
By way of illustration, FIG. 1 shows a network topology and FIGS. 3 and 4 the taxonomies one might want to use for IP addresses and port numbers in this environment.
The domain of IP addresses is the union of “elementary” IP addresses (i.e. the set {p.q.r.s|p, q, r, sε{0, . . . , 255}}) and “generalized” IP addresses (i.e. the set {FIREWALL, WWW/FTP, DMZ, EXTERN, ANY-IP}).
Analogously, the domain of port numbers is {1, . . . , 65535, PRIV, NON-PRIV, ANY-PORT}.
Next, according to FIG. 3 , the IP address ip 1 is a FIREWALL, is a DMZ machine, is any IP address. More succinctly, this relationship can be expressed as ip 1 FIREWALL DMZ ANY-IP.
Furthermore,
δ
(
ip1
,
ANY
-
IP
)
=
1
+
δ
(
FIREWALL
,
ANY
-
IP
)
=
1
+
1
+
δ
(
DMZ
,
ANY
-
IP
)
=
1
+
1
+
1
+
δ
(
ANY
-
IP
,
ANY
-
IP
)
=
1
+
1
+
1
+
0
=
3.
Finally, δ(ip 1 ,ip 2 ) is not defined because ip 1 ip 2 is false.
Next, the notation is extended from attributes to alarms. To this end, a, âεX 1≦i≦n dom shall denote two alarms. The alarm â is called a generalization of alarm a if a[A i ] â[A i ] holds for all attributes A i . In this case, a â.
Furthermore, if a â holds, then the distance δ(a, â) between the alarms a and â is defined as
δ
(
a
,
a
^
)
:
=
∑
n
i
=
1
δ
(
a
[
A
i
]
,
a
^
[
A
i
]
)
If a â is not satisfied, then δ(a, â) is undefined. Finally, in the case of a â, a is more specific than â, and â is more abstract than a.
As a convention, the symbols A i , . . . , A n are used to stand for alarm attributes. Furthermore, the symbols T 1 , . . . , T n are reserved for taxonomies on the respective attributes. Finally, the symbol L will be used to denote an alarm log and the symbol G will be used to denote a cluster log.
Below, similarity is defined. To this end, S L shall denote a set of alarms a. The cover of S is the most specific alarm c,
CεX 1≦i≦n dom
to which all alarms a in S can be generalized. Thus, the cover c satisfies ∀aεS:a c, and there is no more specific alarm c′ (c′ c) that would also have this property. The cover of S is denoted by cover (S).
For example, according to the taxonomies shown in FIGS. 3 and 4 , cover({(ip 1 ,80),(ip 4 ,21)})=(DMZ,PRIV).
Finally, the dissipation of S is defined as
Δ
(
S
)
:=
1
/
S
∑
a
∈
S
δ
(
a
,
cover
(
S
)
)
.
(
1
)
It is verified that Δ({(ip 1 ,80), (ip 4 ,21)})=1/2*(3+3)=3 (cf. FIGS. 2 , 3 , 4 ). Intuitively, the dissipation measures the average distance between the alarms of S and their cover. The alarms in S are all the more similar, the smaller the value of Δ(S) is. Therefore, it is attempted to minimize dissipation in order to maximize intra-cluster alarm similarity.
Next, the alarm clustering problem is described. To this end, L shall be an alarm log, min-sizeεN, N being the set of natural numbers, an integer, and T i , i=1, . . . , n, a taxonomy for each attribute A i in L.
Definition 1 (Alarm Clustering Problem)
(L, min-size, T i , . . . , T n .) shall be an (n+2)-tuple with symbols as defined above. The alarm clustering problem is to find a set C L that minimizes the dissipation Δ, subject to the constraint that |C|≧min-size holds. C is called an alarm cluster or cluster for short.
In other words, among all sets C L that satisfy |C|≧min-size, a set with minimum dissipation shall here be found. If there are multiple such sets, then anyone of them can be picked. Once the cluster C has been found, the remaining alarms in L\C can be mined for additional clusters. One might consider to use a different min-size value for L\C, an option that is useful in practice. Further, also another criterion may be defined for the completion of a cluster.
Imposing a minimum size on alarm clusters has two advantages. First, it decreases the risk of clustering small sets of unrelated but coincidentally similar alarms. Second, large clusters are of particular interest because identifying and resolving their root causes has a high payoff. Finally, the decision to maximize similarity as soon as the minimum size has been exceeded minimizes the risk of including unrelated alarms in a cluster.
Clearly, stealthy attacks that trigger fewer than min-size alarms do not yield any clusters. Here it is intended however, to identify a predominant root cause that accounts for a predetermined amount of alarms. By removing the root cause, ne number of newly generated alarms can be reduced. This reduction is of advantage as screening the reduced alarm stream for attacks is much more efficient.
For a practical alarm clustering method, the following result is relevant:
Theorem 1: The alarm clustering problem (L, min-size, T i , . . . , T n .) is NP-complete. The proof can be obtained by reducing the CLIQUE problem to the alarm clustering problem.
Below, an approximation method for the alarm clustering problem will be described. Before, it is assumed that alarm clusters can be discovered. Then, the question arises how alarm clusters are best presented, e.g. to the system administrator. Alarm clusters can comprise thousands of alarms. Therefore, it is not viable to represent clusters by means of their constituent alarms. Indeed, doing so would mean to overwhelm the receiving system administrator with a vast amount of information that is hard to make sense of. To solve this problem, clusters are represented by their covers. Covers correspond to what is informally called “generalized alarms”.
In order to obtain generalized alarms that are meaningful and indicative of their root cause, it is valuable to take advantage of several or even all alarm attributes. In particular, string and time attributes can contain valuable information, and the following discussion shows how to include these attribute types in this framework. For brevity, the discussion will rely on examples, but the generalizations are clear.
Time attributes are considered first. Typically, one wishes to capture temporal information such as the distinction between weekends and workdays, between business hours and off hours, or between the beginning of the month and the end of the month. To make the clustering method aware of concepts like these, one can use a taxonomy such as the ones in FIGS. 5 and 6 . For example, the taxonomy of FIG. 5 shows that the time-stamp ts 1 can be generalized to the concepts SATURDAY, WEEKEND, and ultimately, ANY-DAY-OF-WEEK.
String attributes are considered next. String attributes can assume arbitrary text values with completely unforeseeable contents. Therefore, the challenge lies in tapping the semantic information of the strings. This problem is solved by means of a feature extraction step that precedes the actual alarm clustering. Features are bits of semantic information that, once extracted, replace the original strings. Thus, each string is replaced by the set of its features. Subset-inclusion defines a natural taxonomy on feature sets. For example, the feature set {f 1 , f 2 , f 3 } can be generalized to the sets {f 1 , f 2 }, {f 1 , f 3 }, or {f 2 , f 3 }, which in turn can be generalized to {f 1 }, {f 2 }, or {f 3 }. The next level is the empty set, which corresponds to “ANY-FEATURE”.
One can select features that capture as much semantic information as possible, using well established techniques that support feature selection.
Given the NP completeness of alarm clustering, an approximation method has been developed as follows. An approximation method for the problem (L, min-size, T i , . . . , T n .) finds a cluster C L, that satisfies a predetermined criterion of |C|≧min-size, but does not necessarily minimize Δ. The closer an approximation method pushes Δ to its minimum, the better.
The proposed approximation method is a variant of attribute-oriented induction (AOI). The modification according to the invention over known AOI is twofold: First, attributes are generalized more conservatively than by known AOI. Second, a different termination criterion is used, which is reminiscent of density-based clustering.
To begin with, the proposed approximation method directly constructs the generalized alarm c that constitutes the algorithm's output. In other words, the method does not make the detour over first finding an alarm cluster and then deriving its cover. The method starts with the alarm log L, and repeatedly generalizes the alarms a in L. Generalizing the alarms in L is done by choosing an attribute A i and replacing the A i values of all alarms by their parents in T i . This process continues until an alarm c has been found to which at least min-size of the original alarms a can be generalized. This alarm constitutes the output of the method. Below, the resulting method is shown.
Input: An alarm clustering problem (L, min-size, T i , . . . , T n .)
Output: An approximation solution for (L, min-size, T i , . . . , T n .)
Method:
TABLE 1
Alarm clustering method
1:
G := L,;
// Make a copy of L
2:
loop forever {
3:
for each alarm c ε G do {
4:
z := number of alarms a ε L, with a c;
5:
if z ≧ min −size then terminate and return alarm c;
6:
}
7:
use heuristics to select an attribute A i , i ε {1, ..., n};
8:
for each alarm c ε G do
// Generalize c[A i ]
9:
c[A i ] := parent(c[A i ], T i );
10:
}
In more detail, line 1 of table 1 makes a copy of the initial alarm log L. This is done because the initial alarm log L is used in line 4. Below, the copy of the alarm log L is called cluster log G since it will contain generalized alarms c that cover clusters C of alarms a contained in the alarm log L. The alarm log L therefore contains the initial unchanged alarms a while the cluster log contains covers or generalized alarms c that may change during the generalization process.
In line 5, the method terminates when a generalized alarm c has been found to which the predetermined criterion applies, i.e. here at least min-size alarms aεL can be generalized. If the method does not terminate, then the generalization step (lines 8 and 9) is executed. Here, selecting an attribute A i is guided by the following heuristic:
For each attribute A i , f i εN, with N being the set of natural numbers, shall be maximum with the property that there is an alarm c*εG such that a[A i ] c*[A i ] holds for f of the original alarms aεL. If f i is smaller than min-size, then it is clear that one will not find a solution without generalizing A i and, therefore, select A i for generalization. This will not eliminate the optimal solution from the search space. If, on the other hand, f i ≧min-size holds for all attributes, then the attribute A i with the smallest f i value is selected.
Although further heuristics are applicable, it has been found that the above heuristic works well in practice, and it is the heuristic of the preferred embodiment.
Based on the above, one could conceive a completely different approximation method, for example one that is based on partitioning or hierarchical clustering. The above method is advantageous for its simplicity, scalability, and noise tolerance.
FIG. 2 shows an alarm log L with unprocessed alarms a and corresponding generalized alarms c in a cluster log G; each generalized alarm covers, as indicated in the size field, a number of alarms a in the alarm log L. As described above the cover of a set S of alarms, i.e. the cover of an alarm cluster, is the most specific alarm c,
CεX 1≦i≦n dom
to which all alarms a in S can be generalized. The cluster log G therefore contains generalized alarms c, each with a size field indicating the number of alarms a covered in the alarm log L.
Before an attribute of an alarm is selected for generalization as indicated in line 7 of the alarm clustering method, generalized alarms c are preferably created for alarms that are identical. The section of the alarm log L shown in FIG. 2 contains two identical alarms with TARGET-IP equal ip1 and TARGET-PORT equal 80. The generalized alarm c covering these two elementary alarms comprises therefore the same attributes A 1 , A 2 , and a size field indicating the number of alarms covered. It is possible that the number z of alarms covered after this preliminary generalization already satisfies the predetermined criterion that exists for terminating and triggering the forwarding of the generalized alarms c. If the predetermined criterion is satisfied, e.g. the number of alarms a covered exceeds the value of min-size, being the minimum size, also referred to as minimum number, of the alarm clustering method will return one or more generalized alarms c (see line 5 of the method) before generalization of alarm attributes has taken place.
However, as long as z<min-size, an attribute A i is selected which is generalized for each alarm aεG. As shown in FIG. 2 , generalization of attribute A 2 (TARGET-PORT) would result in a generalized alarm ({(ip 4 ,80),(ip 4 ,21)})=(ip 4 ,PRIV) covering the two alarms (ip 4 ,80),(ip 4 ,21) as indicated in the size field.
Another example is given in FIG. 7 , which shows the cluster log G with the generalized alarms c of the thirteen largest alarm clusters C found in an alarm log L that has been taken from a commercial intrusion detection system over a time period of one month, and that contained 156380 alarm messages. The IDS sensor was deployed in a network that is isomorphic to the one shown in FIG. 1 .
In the example of FIG. 7 , alarms are modeled as 7-tuples. In detail, the individual alarm attributes A i are the source and destination IP address, the source and destination port, the alarm type, the timestamp, and the context field which is optional, but when present, contains the suspicious network packet.
For IP addresses and port numbers, the taxonomies in FIGS. 3 and 4 can be used. For timestamps, the taxonomies in FIGS. 5 and 6 can be used. No taxonomy is defined for the alarm types. Finally, for the context field (a string attribute) frequent substrings are used as features. More precisely, defining V:=<a[Context]|aεL> to denote the multi-set (or bag) of values that the context field assumes in the alarm log L, then, preferably the Teiresias method is run on V in order to find all substrings that have a predetermined minimum length and minimum frequency. These substrings are the features and each original string s is replaced by the most frequent feature that is also a substring of s. Thus, all feature sets have size one. Finally, each feature set can only be generalized to the “ANY-FEATURE” level. A strength of this feature extraction method is that the resulting features are better understandable and interpretable, thus increasing the overall understandability of alarm clusters.
Each line of the cluster log G describes one generalized alarm c indicating in the “Size” column the size of the covered cluster C. The size of the cluster is the number of covered alarms. The AT column shows the Alarm Types, for which mnemonic names are provided below the table. Within the cluster log G, “ANY” is generically written for attributes that have been generalized to the root of their taxonomy T i . It is worth noting that only alarm types 1 and 2 have context attributes. Therefore, the context attribute is undefined for all the other alarm types. Also, the port attributes are occasionally undefined. For example, the ICMP protocol has no notion of ports. As a consequence, the port attributes of alarm type 5 are undefined. Finally, the names ip 1 ip 2 , . . . refer to the clients and servers in FIG. 1 .
The clusters in cluster log G shown in FIG. 7 cover 95% of all alarms resulting in a summary of almost the entire alarm log. Moreover, using this summary for root cause discovery is a simplification over using the original alarm log L. Having understood the alarm root causes, the future alarm load can therefore significantly be decreased by
a) filtering alarms that with a given probability have a benign root cause, b) shunning an attacker at a firewall of the computer network, c) fixing a configuration problem, and/or d) repairing a compromised system component.
What has been described above is merely illustrative of the application of the principles of the present invention. Other arrangements can be implemented by those skilled in the art without departing from the spirit and scope of protection of the present invention. In particular, the application of the inventive method is not restricted to processing alarms sensed by an intrusion detection system. The method can be implemented in any kind of decision support application, that processes amounts of data.
The method can be implemented by means of a computer program element operating in a system 20 as shown in FIG. 1 that is arranged subsequent to a monitoring system. As described in U.S. Pat. No. 6,282,546 B1, a system designed for processing data provided by a monitoring system may be based on known computer systems having typical computer components such as a processor and storage devices, etc. For example the system 20 may comprise a database which receives processed data and which may be accessed by means of an interface in order to visualize processed alarms.
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A method and system is designed for processing alarms, that have been triggered by a monitoring system such as an intrusion detection system, a firewall, or a network management system, comprising the steps of entering the triggered alarms into an alarm log, evaluating similarity between alarms, grouping similar alarms into alarm clusters, summarizing alarm clusters by means of generalized alarms, counting the covered alarms for each generalized alarm and forwarding generalized alarms for further processing if the number of alarms covered satisfies a predetermined criterion.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application claims the benefit of U.S. Provisional Patent Application No. 60/794,739 filed Apr. 25, 2006, which is incorporated herein by reference.
BACKGROUND
[0002] The present application generally relates to flow restrictors and more particularly, but not exclusively, to flow restrictors applied to flow paths of gas turbine engines.
[0003] Structures embedded within flow sections of gas turbine engines may generate wakes of various proportions that traverse through ducts downstream of the structures. These wakes, furthermore, may adversely impact gas turbine engine integrity and performance. Presently, many flow path designs have a variety of shortcomings, drawbacks and disadvantages. Accordingly, there is a need for further contributions in this area of technology.
SUMMARY
[0004] One embodiment of the present application is a unique non-axisymmetric flow member for a gas turbine engine. Other embodiments include unique apparatuses, systems, devices, hardware, methods, and combinations of these non-axisymmetric flow members in gas turbine engines. Further embodiments, forms, objects, features, advantages, aspects, and benefits of the present invention shall become apparent from the following description and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] FIG. 1 is a schematic representation of a gas turbine engine.
[0006] FIG. 2 is a side view of a duct.
[0007] FIG. 3 is a rear view of duct.
[0008] FIG. 4 is a perspective view of a duct.
[0009] FIG. 5 is a side view of a duct.
[0010] FIG. 6 is a rear view of duct.
[0011] FIG. 7 is a perspective view of a duct.
[0012] FIG. 8 is a side view of an s-shaped duct.
[0013] FIG. 9 is a side view of another duct.
DETAILED DESCRIPTION
[0014] For purposes of promoting an understanding of the principles of the invention, reference will now be made to the embodiments illustrated in the drawings and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended, such alterations and further modifications in the illustrated device, and such further applications of the principles of the invention as illustrated therein being contemplated as would normally occur to one skilled in the art to with the invention relates.
[0015] The present inventions were developed for application in the field of turbo machinery, including but not limited to, gas turbine engines. While the present invention is broadly applicable to gas turbine engines, it has specific, but is not limited to, application in gas turbine engines utilized in aircraft. It is understood that the term aircraft is generic and includes, but is not limited to, helicopters, tactile fighters, trainers, unmanned vehicles, space reentry vehicles and other types of related apparatus. Historically, there has also been application of gas turbine engines as industrial gas turbine engines, electricity generation, naval propulsion and land vehicles.
[0016] With reference to FIG. 1 , there is illustrated one non-limiting embodiment of a gas turbine engine 8 . The gas turbine engine 8 in FIG. 1 is illustrative and there is no intention to limit the types and/or configurations of gas turbine engines contemplated herein unless specifically provided to the contrary. Gas turbine engine 8 includes a fan 10 , compressor 11 , combustor 12 and a turbine 13 . It is important to realize that are multitudes of ways in which the components of the gas turbine engine can be linked together. Additional compressors could be added with an inter-cooler connecting between the compressors, and reheat combustion chambers could be added between the turbines. Further, in one other embodiment the gas turbine engine does not include a fan stage.
[0017] The gas turbine engine 8 includes at least one rotatable bladed rotor 15 for interacting with a working fluid. The bladed rotor 15 includes a disk/wheel that carries a plurality of blades 16 . As the flow passes from the compressor it flows through a plurality of outlet guide vanes 20 . The compressor may have one or a plurality of stages and in one embodiment has a plurality of stages. The compressor may be of an axial or centrifugal configuration.
[0018] With reference to FIGS. 2 , 3 , and 4 , there is illustrated the fluid flow path thru outlet guide vanes 20 of the compressor 11 . In one form the plurality of outlet guide vanes 20 define a guide vane stage. In the embodiment illustrated in FIGS. 2 , 3 , and 4 , the working fluid flows through a duct or diffuser 21 defined by inner wall member 35 and outer wall member 36 . Inner wall member 35 has an inner wall diffusion; likewise, outer wall member 36 has an outer wall diffusion. Depending upon geometry and relative flow conditions, the inner wall diffusion may be higher than the outer wall diffusion. In one form the present application includes a non-axisymmetric flow member 25 disposed adjacent to at least one of the walls defining the duct or diffuser 21 . In some implementations, the non-axisymmetric flow member 25 may be disposed in the wall having the higher rate of diffusion. The present application contemplates that the non-axisymmetric flow member 25 could be located at the hub portion 30 , tip portion 31 or both portions of the duct or diffuser 21 . In one form the non-axisymmetric flow member 25 is located downstream of the trailing edge 26 of vane 20 . In one form the duct or diffuser 21 is an annular flow path with a plurality of circumferentially distributed vanes 20 located upstream thereof. Disposed downstream of each of the trailing edges 26 is one of the non-axisymmetric flow members 25 .
[0019] The non-axisymmetric flow members 25 are located downstream of the outlet guide vanes 20 and may or may not extend to the diffuser exit or downstream in an S-shaped duct. Non-axisymmetric flow members 25 may be protrusions into the fluid flow path or may act as restrictors to the flow. In one form the non-axisymmetric members 25 extend up to about 30% of the distance between inner wall member 35 and outer wall member 36 , and in another form extends about 30% of the distance between inner wall member 35 and outer wall member 36 . However, the flow members 25 may extend other distances between the inner wall member 35 and the outer wall member 36 . The application of a plurality of non-axisymmetric flow members 25 causes a localized reduction in the cross-sectional fluid flow area. The non-axisymmetric flow members 25 may be elongate and have a variety of shapes such as, but not limited to tapered, tear drop, and rectangular. In another form contemplated herein, the flow members may have other geometries including but not limited to symmetric, square, circular, non-elongate. In one form the flow members 25 are defined by elongate restrictors which may have a length to width ratio of 3:1. In another form the non-axisymmetric flow member 25 has a peak bump distance 32 located between the leading end 33 and the trailing end 34 . In another embodiment the peak bump distance 32 may be located proximate duct end 99 . However the present application contemplates a broad variety of configurations for the peak bump distance location. In some embodiments the non-axisymmetric flow members 25 have a width that extends up to 90% of half pitch. In other embodiments, the non-axisymmetric flow member 25 have a sinusoidal profile when viewed from the front or back.
[0020] The non-axisymmetric flow members 25 may be oriented parallel to the fluid flow or at an angle to cause swirl in the fluid flow. In one form the non-axisymmetric flow members 25 leading edge is disposed adjacent to the outlet guide vane and in another embodiment the non-axisymmetric flow members 25 leading edge is spaced from the outlet guide vane. In another embodiment each of the non-axisymmetric flow members 25 are attached to one of the outlet guide vanes. In still another embodiment the non-axismmetric flow members 25 may extend upstream past the trailing edge of the outlet guide vane towards the leading edge.
[0021] The present application contemplates that the non-axisymmetric flow members 25 may be fixed structures or may be a structures actuated to extend into or retract from the flow path. In one embodiment, the non-axisymmetric flow members 25 that are fixed structures are utilizable as passive fluid flow control devices. In the embodiment where the non-axisymmetric flow members 25 are actuated there can be tailoring to match the flow conditions. In one form, non-axisymmetric flow members 25 take the shape of a plate that can be selectively placed in the fluid flowpath. In other forms, non-axisymmetric flow members 25 may be actuated via pneumatic or thermal devices or may take the form of a metallic bladder. For example, the non-axisymmetric flow members 25 may be partially extended into the flow path or may be cycled at varying frequencies or rapidly actuated to fixed positions depending on conditions in the flow path. The command signals that drive the actuators may be determined by a computer, such as a FADEC, or other similar device. Various types of actuation systems may be used such as linear actuators and rotary actuators to state just a few nonlimiting examples. The utilization of the actuated non-axisymmetric flow members 25 would allow for the controlling of the diffusion rate in the duct or diffuser.
[0022] In one form the non-axisymmetric flow members 25 creates blockage for the outlet guide vane wake fluid that accelerates the wake fluid locally. In another form the flow members 25 creates blockage that keeps the wake fluid from diffusing along with the core working fluid flow. The flow members 25 function to keep the duct or diffuser 21 and/or S-ducts attached since it is the wake fluid that generally causes the flow to separate in diffusing flow.
[0023] In fluid flow in ducts or diffuser 21 , the non-axisymmetric flow members 25 keep the wake fluid momentum raised in comparison to an axisymmetric duct or diffuser and the wake fluid flow is less likely to separate. The fluid flow in the duct or diffuser with the plurality of non-axisymmetric flow member 25 stays attached longer than the fluid flow in an axisymmetric duct or diffuser. The non-axisymmetric fluid flow members 25 generate a blockage in the flow region where the outlet guide vane wake fluid would normally occupy in an axisymmetric duct or diffuser. The blockage associated with the non-axisymmetric flow members 25 prevents the wake fluid from diffusing at the same rate as the core working fluid flow.
[0024] Turning now to FIGS. 5 , 6 , and 7 , there is illustrated a diffuser having non-axisymmetric flow members 50 disposed towards duct end 99 to provide a duct having a lobed appearance. The flow members 50 are substantially identical to the flow members 25 . The working fluid flows through a duct or diffuser 21 defined by inner wall member 45 and outer wall member 46 . Inner wall member 45 has an inner wall diffusion; likewise, outer wall member 46 has an outer wall diffusion. Depending upon geometry and relative flow conditions, the inner wall diffusion may be higher than the outer wall diffusion. The present application includes a non-axisymmetric flow member 50 disposed adjacent to at least one of the walls defining the duct or diffuser 21 . In some implementations, the non-axisymmetric flow member 50 may be disposed in the wall having the higher rate of diffusion. The present application contemplates that the non-axisymmetric flow member 50 could be located at the hub portion 30 , tip portion 31 or both portions of the duct or diffuser 21 . In one form the non-axisymmetric flow member 50 is located downstream of the trailing edge 26 of vane 20 . In one form the duct or diffuser 21 is an annular flow path with a plurality of circumferentially distributed vanes 20 located upstream thereof. Disposed downstream of each of the trailing edges 26 is one of the non-axisymmetric flow members 50 . In the embodiment illustrated in FIGS. 5 , 6 , and 7 the non-axisymmetric flow members 50 have a sinusoidal cross-sectional shape and extend downstream to create a lobed appearance in duct end 99 .
[0025] With reference to FIG. 8 , there is schematically illustrated the application of non-axisymmetric flow members 40 and 42 to S-shaped duct 44 . Flow members 40 and 42 are substantially identical to the flow members 25 . Non-axisymmetric flow member 40 is disposed on the hub side of S-shaped duct 44 and is oriented downstream from vane 46 . In similar fashion, non-axisymmetric member 42 is disposed on the tip side of S-shaped duct 44 and is oriented downstream of vane 46 . The geometry of non-axisymmetric flow members 40 and 42 causes the structure to smoothly blend back into the flow path where the flow turns back to the axial direction.
[0026] Non-axisymmetric flow members 40 and 42 generate a blockage in the flow region where the wake fluid from vane 46 would normally occupy in an axisymmetric S-shaped duct. The blockage associated with non-axisymmetric flow members 40 and 42 prevents the wake fluid from diffusing at the same rate as the core working fluid thereby delaying or preventing flow separation.
[0027] With reference to FIG. 9 , there is schematically illustrated the application of non-axisymmetric flow member 65 to bifurcated duct 66 . Non-axisymmetric flow member 65 is disposed on the hub side of core flow path 67 and is oriented downstream from vane 68 . The geometry of non-axisymmetric flow member 65 causes the structure to smoothly blend back into the flow path where the flow turns back to the axial direction.
[0028] Many other embodiments of the present application are envisioned. For example, non-axisymmetric flow members can be disposed within any duct downstream of an outlet guide vane, stator, strut or other structure. A number of potential locations exist where non-axisymmetric flow members may be located. In particular, non-axisymmetric flow members may reside in an s-shaped duct downstream of a turbine or can reside in a bifurcated duct downstream of the fan stage of the turbofan engine. Furthermore, a non-axisymmetric flow member may reside downstream of each vane member or, alternatively, may reside downstream of only a select number of vane members. In addition, each vane may have a protrusion on each of the upper and lower walls that define the ends of the vane.
[0029] In further embodiments, the non-axisymmetric flow members may be disposed on a rotor downstream of compressor blades. In this way non-axisymmetric flow members rotate with rotor blades.
[0030] In still further embodiments, the non-axisymmetric flow members may be placed in a flow path downstream of a centrifugal compressor.
[0031] In other embodiments, certain non-axisymmetric flow members disposed within the duct may be actuated to extend or retract while others remain passive during the entire operation of a gas turbine engine. Some non-axisymmetric flow members may have a larger peak bump distance than others. Still others may have different locations of peak bump distance relative to the leading or trailing edge of the non-axisymmetric flow members. Still other non-axisymmetric flow members disposed within a duct may have varying shapes and sizes.
[0032] In still other embodiments, a gas turbine engine is provided comprising an inner wall member, an outer wall member spaced from the inner wall to define a fluid flowpath, a compressor including a guide vane stage located upstream from the fluid flowpath, the guide vane stage including a plurality of vanes positioned around a portion of the fluid flowpath, and a plurality of elongated protrusions located downstream of the guide vane stage and extending into the fluid flowpath.
[0033] In a further embodiment, an apparatus is provided comprising a fluid flowpath, a compressor stage located upstream from the fluid flow path, a plurality of guide vanes positioned circumferentially around a portion of the fluid flowpath, and a plurality of restrictors located in the fluid flowpath for preventing separated flow downstream of the guide vanes.
[0034] In still another embodiment, an apparatus is provided comprising a gas turbine engine having a duct configured to support a fluid flow, a vane disposed within the duct, and means for altering the diffusion of the fluid flow downstream of the vane.
[0035] In still a further embodiment, a method is provided comprising rotating a rotatable stage of a compressor to increase the pressure of a working fluid, flowing the working fluid through an outlet guide vane stage and into a fluid flow passageway, and controlling the diffusion rate in the fluid flow passageway after said flowing.
[0036] In still a further embodiment, the diffusion rate can be controlled by extending at least one elongate protrusion into the flowpath axially downstream of the outlet guide vane stage. The diffusion rate can also be controlled by actuating fewer than all of the protrusions. The diffusion rate can also be controlled by changing the diffusion rate of the fluid flow after the vane from that of the core flow in the duct.
[0037] While the invention has been described in connection with what is presently considered to be the most practical and preferred embodiment, it is to be understood that the invention is not to be limited to the disclosed embodiment(s), but on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims, which scope is to be accorded the broadest interpretation so as to encompass all such modifications and equivalent structures as permitted under the law. Furthermore it should be understood that while the use of the word preferable, preferably, or preferred in the description above indicates that feature so described may be more desirable, it nonetheless may not be necessary and any embodiment lacking the same may be contemplated as within the scope of the invention, that scope being defined by the claims that follow. In reading the claims it is intended that when words such as “a,” “an,” “at least one” and “at least a portion” are used, there is no intention to limit the claim to only one item unless specifically stated to the contrary in the claim. Further, when the language “at least a portion” and/or “a portion” is used the item may include a portion and/or the entire item unless specifically stated to the contrary.
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The present invention provides a non-axisymmetric flow member disposed in a duct of a gas turbine engine. The flow member narrows the area aft of a vane to reduce the cross sectional area through which a wake from the vane traverses.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to an opening roller for a spinning mill machine for the opening and cleaning of cotton fibers. It is concerned particularly with an opening roller provided with a predetermined number of beater elements distributed on and fixed to the periphery of the opening roller for grasping and opening flocks of cotton fibers.
2. Description of Related Art
Opening rollers for so-called coarse cleaning machines are well known. For example, Maschinenfabrik Rieter AG markets such a machine under the brand name Mono Roller Cleaner B4/1. The same company has applied for letters patent in Switzerland for a further machine of this type under the number CH-00321/89-0.
These machines have beater elements distributed on the periphery of the opening roller. Such beater elements are round rods fastened radially to the periphery. They are distributed in a predetermined manner over the peripheral surface.
In these machines the fibrous material is fed toward the periphery of the roller at one axial end thereof and collected there by the beater elements. The beater elements pull the material (usually in the form of flocks over cleaning grid bars. Gradually the material is brought to the other axial end of the opening roller by means of guide chambers, where the opened fibers are conveyed through the outlet of the machine by means of centrifugal force.
The cleaning machine disclosed in Switzerland Patent Application No. CH-00321/89-0 is represented semischematically in FIGS. 1 and 2, to facilitate explanation later on of the principles of the present invention on the basis of this representation.
3. SUMMARY OF THE INVENTION
It is desirable that the opening effect of such machines be more efficient, that is to say, that the flocks be fed more efficiently with the power input remaining the same or smaller, and/or with the fiber flocks fed in being opened more efficiently and if possible, more gently. Hence, the term "more efficiently," means an increase in the opening of large fibers flocks into a plurality of smaller flocks. As far as possible according to the principle of cotton cleaning, the cleaning means primarily opens the flocks, in order to be able to remove the dirt adhering to and between the fibers more effectively.
According to the present invention, the beater elements no longer have simple surfaces directed radially to the axis of rotation of the opening roller. Rather, the beater elements according to the invention have fiber-contacting rod portions that are inclined forwardly in the direction of rotation of the opening roller surface on which they are received.
An advantage of the beater elements according to the invention lies in that the fiber flocks are thrown about less by impacts with the beater elements. Rather, they are grasped by means of the beater elements in a small part of the fiber bunch and the fiber bunch is subsequently pulled through the surrounding air as a tuft which is opened into smaller parts through the retarding tendency of the surrounding air.
For good cleaning in a machine of this type, it is desirable that the fiber bunch remain as long as possible on the beater elements and be pulled by the beater elements over the cleaning grid. That is to say, the relative speed between the fiber bunch and the beater elements should be as small as possible while the fiber bunch is being pulled over the cleaning grid.
The desired action might be likened to a kind of pinching of the fiber bunches in a way that only a small part of each fiber bunch is actually engaged by the pinching components, leaving the biggest part of the fiber bunch free to be beaten intensively by means of the grids without producing a rolling effect between the beater element and the grid bars. Rolling of the fiber bunches is disadvantageous, because rolling effects are accompanied by a danger of producing entanglement of fibers which may lead later on at least to a certain amount of neps.
The present invention provides a beater rod arrangement that functions in a manner comparable in some respects to a fiber pinching system. The fiber bunch contacting portions of the beater rods are not too thick and are arranged in a way that the bunch is kept by the rod portions over the grid bars for as long a distance as possible.
Also, the fiber bunch should come back to the beater elements after the cleaning grid, in order to be transported properly through the cleaning machine. The fiber flocks move a stage further in the axial direction of the opening roller in a transfer chamber to be described later. Subsequently they are grasped again by further beater elements, and so on stage by stage, until the fiber bunch, reduced in size and cleaned, leaves the machine on the other axial end of the opening roller.
BRIEF DESCRIPTION OF THE DRAWINGS
Exemplary embodiments of the invention are depicted in the accompanying drawings, in which
FIG. 1 is a cross section through a cleaning machine according to the Swiss Patent Application No. CH-00321/89-0 with an opening roller according to the present state of technology represented semi-schematically;
FIG. 2 is another view of the cleaning machine of FIG. 1, with the opening roller being represented semi-schematically in a longitudinal section;
FIG. 3 is a partial section through a peripheral portion of the opening roller in a radial plane containing the longitudinal axis of the roller, with a beater element according to the invention being represented as fixed to the surface of the opening roller;
FIG. 4 is a top view in the direction IV (FIG. 3) of the beater element of FIG. 3;
FIG. 5 is a lateral view in the direction V (FIG. 4) of the beater element of FIG. 3;
FIG. 6 is similar to FIG. 3 but showing another form of beater element in accordance with the present invention;
FIG. 7 is a top view similar to FIG. 4 but showing the beater element of FIG. 6;
FIG. 8 is a lateral view similar to FIG. 5 but showing the beater element of FIG. 6;
FIG. 9 is a view similar to FIG. 3 but showing another form of beater element in accordance with the present invention;
FIG. 10 is a top view similar to FIG. 4 but showing the beater element of FIG. 9; and
FIG. 11 is a lateral view similar to FIG. 6 but showing the beater element of FIG. 9.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows a cleaning machine 1 provided with a rotatable opening roller 2 which can be driven. Beater elements 3 (also called "beating " elements) are distributed over the roller periphery in a predetermined manner as seen in the axial direction as well as in the radial direction. These beater elements 3 are fastened to the opening roller and extend radially with respect to the axis of rotation of the opening roller.
The cleaning machine also has a cleaning grid 4 assembled from single grid bars 5. This grid 4 is positioned opposite a part of the periphery of the opening roller, with a predetermined spacing between the tips of the beater elements 3 and the bars of the grid.
Opposite to the cleaning grid 4, the cleaning machine has chamber walls 6 above the opening roller, as seen in FIG. 1. These walls are arranged inclined to the axial direction of the opening roller, as in FIG. 2, in order to define guide chambers (not shown) through which the fibers may pass. In these guide chambers, the fiber flocks fed in are transported spirally in an axial direction as the opening roller rotates in the direction D, until the opened flocks again leave the cleaning machine through an outlet 8.
This general arrangement is present in the Mono Roller Cleaner B4/1 referred to above, which also employs beater elements like the beater elements 3 shown in FIGS. 1 and 2.
FIGS. 3-5 show a beater element 3.1 according to the invention. This beater element 3.1 includes a rod 10 and a rod 11, which together form a double hook shaped element with a fixing loop 12. The fixing loop 12 serves for fixing the beater element 3.1 on the opening roller 2 by means of a screw 13.
As can be seen from FIG. 3, each of the rods 10 and 11 has a free end portion disposed at an angle alpha opposite to the surface of the opening roller. That is, each rod 10 and 11 protrudes outwardly from the peripheral surface at an inclination substantially less than the radial protrusion characteristic of the beater elements used prior to the present invention. With the help of this oblique position, the surfaces of the beater elements are inclined relative to the surface of the opening roller as explained above, to improve their action on the fibers.
Furthermore, FIG. 3 shows that the rods 10 and 11 have a predetermined diameter G. This diameter can vary between four and eight millimeters. However, a diameter of five millimeters is preferred. A replaceable, round wire, preferably of spring steel, may be used for the production of the beater element 3.1.
It can be seen from FIG. 5 that a free end portion of each of the rods 10 and 11 has a predetermined angle beta to a tangential plane E, parallel to the axis of rotation of the opening roller. The point of tangency between the roller surface and the plane E is located at the fixing axis B of the screw 13.
The angle beta is about 90 in the example shown, so that a free end portion of each of the rods 10 and 11 opposite to a prolongation A.1 of the radius A of the cross section of the opening roller is inclined forwardly at an angle gamma in the direction of rotation D. This angle gamma is the angle between the rear face of the outer end portion of a rod and a radius A of the roller so located as to touch the trailing surface of the rod. An angle γ of four degrees (4°) has been found to give good results. However, the selection of the angle beta, and consequently of the angle gamma, can be different, according to the size of the flocks to be cleaned and the flock material and can best be determined empirically. The same applies to the angle alpha in FIG. 3.
However, as the beater elements can be manufactured from flexible steel wire, it is a simple matter to form to the angles so as to suit the requirements in a particular instance.
In FIGS. 3 and 4, it is additionally represented with dash dotted lines, that a beater element 3.2 can have only one rod 14, instead of two. The rod 14 is shown fixed on the opening roller 2 in FIG. 4 and has angles beta and gamma, as represented with FIG. 5.
A further variant is provided when a beater element 3.1 is combined with beater element 3.2. The beater element 3.2 is arranged over the beater element 3.1 and fixed together with an appropriate extended screw 13, so that a threefold rod combination exists as shown in FIGS. 3 and 4. The end surfaces (not shown) of the rods 10, 11 and 14 must be at the same distance from the surface of the opening roller 3 and must have the same spacing from the grid bars 5.
FIGS. 6 to 8 show variants of the beater elements of FIGS. 3 to 5. In FIG. 6, each beater element 3.3 has rods 16 and 17 selected with the same diameter D as the rods 10 and 11 of the beater element 3.1. However, the rods 16 and 17 have outer end portions provided with a type of wave shaped bends, designated with R. The remaining parts correspond to parts of the beater elements 3.1 and they are designated with the same reference symbols.
These bends have the purpose that the fibers, which are grasped by the respective rods 16 and 17 and are gliding thereby along the bends against the free ends of the rods 16 and 17, are braked correspondingly to the bends R.
It is also represented in this variant, that a single rod 18, for example from the beater element 3.4, can be provided. This single rod also has bends R, with the same effect as with the rods 16 and 17. The beater elements 3.3 and 3.4 can be combined in the manner described above in connection with FIGS. 3 to 5.
FIGS. 9 to 11 depict still another form of beater element 3.5 that includes rods 19 and 20, each provided with notches which are open in the direction along the surface of the opening roller 2. The remaining parts correspond to the beater element 3.1 and are designated with the same reference symbols. A beater element 3.6 is represented as a variant of the beater element 3.2 of FIG. 5. The notches 22, as represented with FIG. 11, open in the direction of rotation D of the opening roller.
The object of these notches, as with the object of the sinusoidal shaped bends of FIG. 6, is to increase the friction between the fibers and the rods 19 and 20, for those fibers which, as described earlier for the rods 9 and 10, work their way against the free ends of the rods 19 and 20.
It is not in all instances essential that the beater elements of the present invention be formed of steel wire. Nor is it always essential that they be of a round cross section. Other materials and other profiles can be used. A profile which is more favorable aerodynamically than the round profile which is similar to the profile on the carrier flap.
Furthermore, the use of the opening roller is not limited to the cleaning machine described. The beater elements of the invention can also be used on rollers which are used in bale opening devices. The present state of technology for opening rollers in bale opening machines consists as a rule of toothed rollers, which are arranged with each other in a row to form a toothed roller body, which opens the fiber flocks from the surface of fiber bales and passes them to a pneumatic transport device.
The possibility is completely feasible in that, instead of the toothed rollers, a roller body as described is used, which is fitted to the opening roller of a bale opening device with the beater elements described.
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A fiber opening and cleaning machine includes an opening roll provided with inclined beater elements. Such beater elements have a wave shaped design and are considerably less in diameter than the relatively larger diameter beater rods customarily used in such machines. The advantage of the wave shaped beater elements lies in the grasping and spiral conveying of the fiber flocks fed into the machine.
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This is a division of application Ser. No. 08/111,892, filed on Aug. 26, 1993, U.S. Pat. No. 5,34,619.
BACKGROUND OF INVENTION
1. Field of the Invention
The present invention relates to a hollow blade for a turbomachine, especially a large chord fan blade.
The advantages of using large chord blades in turbomachines are known, particularly in the case of the fan rotor blades in a bypass turbojet engine. These blades must cope with severe operating conditions, and, in particular, must possess mechanical properties giving adequate anti-vibration characteristics and resistance to impact by foreign bodies. The aim of achieving adequate speeds at the tips of the blades has also led to research into reducing the masses of the blades. This has resulted in the use of hollow blades.
2. Description of the Prior Art
French Patent No. 1 577 388 discloses one example of a hollow blade in which the blade is made up of two wall elements between which a honeycomb structure is arranged, the wall elements being made of a titanium alloy and being formed to the desired profile and shape by hot pressing.
U.S. Pat. No. 3 628 226 describes a method of manufacturing a hollow compressor blade involving a metal bonding by diffusion welding of two elements or half-blades having a flat grooved assembly surface.
Other known techniques for obtaining hollow blades, particularly for the fans of turbojet engines, combine operations or pressurized metal diffusion welding and pressurized gas superplastic forming. One example of this technique is disclosed in U.S. Pat. No. 4 882 823.
SUMMARY OF THE INVENTION
One of the aims of the invention is to avoid making use of these known techniques, which are complex to implement and particularly delicate to tune.
Accordingly, the invention provides a hollow blade for a turbomachine, said blade including an aerofoil shaped portion having an intrados face and an extrados face, said blade comprising a unitary body, means in said body defining a multiplicity of transverse cavities in said aerofoil shaped portion according to the thickness thereof, and plugs disposed within said cavities to restore the surface continuity of said intrados and extrados faces of said aerofoil shaped portion of said blade, said plugs being rigidly secured to said unitary body.
The invention also provides a method of manufacturing the hollow blade comprising the following steps:
a) producing a unitary blade blank by forging, said blade blank including an aerofoil shaped portion;
b) machining a multiplicity of holes in said aerofoil shaped portion such that a zone of specific width is left clear at the edge of said aerofoil shaped portion and said holes are substantially evenly distributed over the remaining area of said aerofoil portion and provide a cavity ratio of about 90% in said remaining area;
c) producing plugs with a shape adapted to the holes formed during step (b) and to the profile of the respective surface of said aerofoil shaped portion, be it the intrados face or the extrados face;
d) placing said plugs in position in said holes formed during step (b);
e) fixing said plugs to said blade blank by high energy beam welding while said plugs are in position in said holes; and
f) finishing said blank to obtain the required aerodynamic profile.
Depending on the mechanical characteristics required, the cavities may have a circular cross-section, or may have other shapes, such as hexagonal. The cavities may be through holes or blind holes, and in the latter case they may be situated in the intrados face or the extrados face of the aerofoil shaped portion of the blade.
When the cavities are through holes, a first plug may be placed in each hole on the intrados face side of the blade, and a second plug placed in each hole on the extrados face side. Alternatively, the second plugs may be welded together in pairs as a preliminary assembly step before-being placed and fixed in the holes.
Other features and advantages of the invention will become apparent from the following description of the preferred embodiments of the invention, which are given by way of example only, with reference to the attached drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagrammatic view of a unitary forged blade blank, at the initial stage of manufacturing a hollow turbomachine blade in accordance with the invention.
FIG. 2 is a diagrammatic view of the blade blank of FIG. 1, at an intermediate stage in the manufacture of the blade.
FIG. 3 is a cross-section through the blade blank shown in FIG. 2.
FIG. 4 is a diagram showing the distribution of the cavities over the aerofoil portion of one embodiment of a blade in accordance with the invention.
FIG. 5 is a cross-section through part of a blade showing the arrangement of the plugs in the cavities in one embodiment of the invention.
FIG. 6 is a view similar to FIG. 4 but showing the shape and distribution of the cavities in another embodiment.
FIG. 7 is a view similar to FIGS. 4 and 6, but showing the shape and distribution of cavities in yet another embodiment.
FIG. 8 is a view similar to FIG. 5, but showing the arrangement of the plugs in a different embodiment.
FIG. 9 is a diagrammatic cross-sectional view along line VIII--VIII of FIG. 2 showing a plugged cavity in the root of the blade.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Embodiments of a hollow turbomachine blade in accordance with the invention may be obtained by carrying out the following manufacturing stages.
a) In the first stage of the manufacture a unitary blade 1, such as diagrammatically shown in FIG. 1, is roughly formed to a size close to its final dimensions by forging, applying a process known per se. This blade 1 has a fixing base or root 2, and a streamlined aerofoil shaped portion 3 intended to be located in the air flow path of the turbomachine, this portion 3 having two outer walls, defining the intrados face 4 and the extrados face 5 of the blade, connected by a leading edge 6 and a trailing edge 7. Depending on the particular application, the blade may include an intermediate part, termed a transition portion or shank 8, between the root 2 and the aerofoil shaped portion 3.
b) In the next stage, a multiplicity of transverse holes 9 are machined in the aerofoil shaped portion 3 of the blade 1 substantially perpendicularly to the profile of the portion 3 as shown in FIGS. 2 and 3, any suitable method being used for this purpose. An area 10, the width 1 of which is determined depending on the mechanical characteristics desired for the blade 1, is left free of holes 9 in the vicinity of the leading and trailing edges 6 and 7, and at the tip of the blade 1. Holes 9 may also be formed in the transition portion 8 of the blade 1. As can been seen in FIGS. 2 and 3, and also in FIG. 4 which illustrates one distribution arrangement of the holes 9, the holes 9 form a close network and the wall thickness 11 between adjacent holes 9 is determined according to the mechanical characteristics desired for the blade 1. In the designated areas the cavity ratio may be close to 90%. It is also possible, in certain applications, to drill the holes 9 in a direction substantially perpendicular to the chord of the blade profile.
c) At the same time, plug-like elements 12 are made having a peripheral outline which corresponds to that of the holes 9 of the blade 1, the sizing being such as to achieve a sliding fit between the plugs 12 and the holes. By using suitable machining means, which may be digitally controlled, the outer surface 13 of each plug 12 is matched to the desired profile of the surface of the aerofoil portion 3 of the blade at the intended position of the plug 12. The thickness 14 of the bottom wall of the plug 12 corresponds to the specific thickness desired for the blade wall. On its inner side a suitable transition radius 15 is provided between the bottom wall and the cylindrical side wall 16 of each plug 12.
d) All the plugs 12 are then placed and held in position in the holes 9, both on the intrados face side and the extrados face side of the blade 1.
e) Each plug 12 is then permanently secured by high energy beam welding at the periphery of the plug 12 within the housing formed by the respective hole 9 of blade 1. Depending on particular applications the method of carrying this out may vary. For example, welding may be carried out simultaneously on a first plug 12 situated on the intrados side of the blade 1 and on a second plug 12 situated on the extrados side of the blade 1. Alternatively, the welding may be effected in succession, in the appropriate order, on one side and then on the other side, this enabling the risk of deformation to be minimized. The high energy beam used for welding may be an electron beam originating from a laser source.
f) When all the plugs have been secured by welding, the usual verification operations are carried out followed by the finishing work necessary to obtain the desired final aerodynamic profile and surface finish of the blade.
A hollow blade 1 obtained by the production process which has just been described with reference to FIGS. 1 to 5 has appreciable advantages, in addition to the ease of carrying out the said process, with regard to the making of the plugs 12 and their welding. Compared to some previously known methods which require the use of two rough parts, the invention requires only one rough forged part. The technical characteristics of the hollow blade 1 obtained are also advantageous. In particular, an overall cavity ratio of the order of 60% to 70% is obtained for the finished blade 1. The shape of the plugs 12, and particularly the definition of the transition radius between the bottom wall and side wall, gives them a good resistance to impact, which is an important characteristic of the fan blades to which the invention applies. In addition, the orientation of the plug welds is favorable relative to the direction of mechanical stresses experienced during operation, and provides adequate resistance to fatigue stresses.
The structure of the hollow blade 1 as described above may be the subject of various modifications within the scope of the invention. In particular, the geometrical shape of the cavities or holes 9 and the shape resulting therefrom for the periphery of the corresponding plugs 12 is shown as circular in FIGS. 2 and 4. However, other geometrical shapes may be envisaged, such as rectangular with rounded corners, and a shape which is particularly advantageous in certain applications is a hexagonal shape as diagrammatically shown at 9a in FIG. 6. FIG. 7 shows another possible arrangement for the geometry of the cavities 9b and the corresponding plugs. The geometry chosen is optimized in each case by strength calculations corresponding to the conditions of use.
FIG. 8 shows diagrammatically another alternative embodiment. Each plug 12a is in this case formed from two parts, or half plugs, 12b and 12c which are welded together before being placed in position in a hole 9 of the blade 1. After being placed in position, an outer surface 13a of the plug 12a forms a part of the extrados face of the blade 1, while the other outer surface 13b of the plug 12a forms a part of the intrados face of the blade 1. The stages of (d) placing in position, (e) welding, and (f) finishing in this embodiment may be carried out as previously described.
The holes or cavities 9 or 9a in the embodiments described above are through holes, but it is envisaged that, for certain particular applications, blind holes, either in the intrados face or in the extrados face of the blade 1, may be used. It follows that in this case only one plug is placed in each hole on the recessed side of the blade.
In addition, in certain applications cavities may also be formed in the root 2 of the blade. In this case, blind holes 17 are made in the root 2, and a plug 18 is fitted and welded in each hole 17, as diagrammatically shown in FIG. 9.
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A hollow blade for a turbomachine includes a unitary body having a multiplicity of transverse cavities in at least the aerofoil shaped portion of the blade, and plugs disposed within the cavities for restoring the surface continuity of the intrados and extrados faces of the aerofoil shaped portion, the plugs being rigidly secured to the unitary body, such as by welding.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation-in-part of U.S. Ser. No. 11/070,789, filed Mar. 2, 2005, which is hereby incorporated by reference herein in its entirety.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] This invention relates broadly to methods and apparatus for performing a heart reshaping intervention. More particularly, this invention relates to methods and apparatus for minimally invasive restoration of the left ventricle in patients suffering from congestive heart failure.
[0004] 2. State of the Art
[0005] In the U.S., approximately 5 million patients are currently diagnosed with congestive heart failure (CHF). CHF generally relates to a dysfunction of the left ventricle. About one third of the patients suffering from CHF have a form of CHF which results from a myocardial infarction (MI). The Ml progressively increases the residual volume of blood in the left ventricle, due to stagnation from decreasing contractility of the heart muscle.
[0006] The increase in blood volume also results in an increase in left ventricular pressure which increases stress on the wall of the left ventricle. The stress requires the myocardium to work harder which increases oxygen demand. Since oxygen delivery to the heart has already been reduced because of coronary artery disease, the Ml and the resulting reduced ventricular output, heart muscle tissue dies and the ventricle expands. This causes the myocardium to stretch, thin out and distend, further decreasing heart performance, decreasing the thickness of the ventricle wall and increasing wall stress.
[0007] FIG. 1 shows a normal heart 10 having right ventricle 12 , left ventricle 14 , right atrium 16 and left atrium 18 . Though not illustrated, those skilled in the art will appreciate that there are a pair of valves between each ventricle and its associated atrium. The ventricles are separated by an inter-ventricular septum 20 . The left ventricle 14 has what is called a generally elliptical (ellipsoidal) shape.
[0008] FIG. 2 shows a heart 10 ′ suffering from CHF. The left ventricle 14 ′ is enlarged and assumes a circular (spherical) shape. The stress on the ventricle wall is determined by the Laplace Law as illustrated in Equation 1, below.
wall stress = ( pressure in cavity ) · ( radius of cavity ) 2 · ( wall thickness ) ( 1 )
[0009] Thus, as wall thickness is decreased, wall stress increases. This increased wall stress and oxygen demand cause a relative chronic myocardial ischemic state which results in decreased pump function.
[0010] It has also been discovered that the change in the shape of the left ventricle adversely affects the way the heart muscle fibers work. The normal ellipsoidal shape most efficiently assists in blood flow through the left ventricle.
[0011] State of the art methods for treating CHF involve extremely invasive open heart surgery. For example, use of a “ventricular restoration patch” installed via “purse string” sutures is disclosed in U.S. Pat. No. 6,544,167. The patch seals off a portion of the ventricle thereby reducing the volume and restoring the shape of the cavity. However, installation of the patch requires incision into the left ventricle which severs muscle fibers and the subsequent healing scar increases the risk of arrhythmia.
[0012] Another method described in U.S. Pat. No. 6,126,590 involves wrapping the heart in a mesh and suturing the mesh to the heart. The mesh constricts both right and left ventricles, thus not allowing them to fill completely in diastole. It also may cause a constrictive effect on the ventricles known as the tamponade effect.
[0013] Yet another method for treating CHF is described in U.S. Pat No. 6,537,198 and involves the use of trans-ventricular wires anchored by external fixation buttons on either side of the left ventricle. This method puts a compressive force on the ventricle but also results in a mid-level constriction without favorably altering volume, pressure, or wall stress.
[0014] Because of the highly invasive nature of these treatments, many CHF patients are not suitable candidates for the surgery.
SUMMARY OF THE INVENTION
[0015] It is therefore an object of the invention to provide methods and apparatus for treating CHF.
[0016] It is another object of the invention to provide methods and apparatus for reducing the volume of the left ventricle.
[0017] It is a further object of the invention to provide methods and apparatus for restoring the left ventricular cavity to an ellipsoidal shape
[0018] It is also an object of the invention to provide minimally invasive methods and apparatus for achieving the above objects without the side effects of the prior art methods and apparatus.
[0019] In accord with these objects, which will be discussed in detail below, the methods of the present invention include delivering an implantable expandable device into the left ventricle via a catheter. The expandable device is anchored either to/through the wall of the left ventricle or to/through the inter-ventricular septum and then expanded. When expanded, the device assumes a size and shape which fills the lower portion of the ventricular cavity thus restoring the volume and ellipsoidal shape of the remaining portion of the cavity. According to one embodiment, the device is a balloon which is expanded by filling it with fluid such as saline. It is anchored with an anchor which extends into or through either the wall of the left ventricle or the inter-ventricular septum. There are two versions of the first embodiment, one having a central stem that extends all the way through the balloon to its opposite end. The other has a very short stem which just extends into the balloon. In both cases the stem includes a valve and an inflation tube coupling. The coupling allows the inflation tube to be coupled to and uncoupled from the balloon and the valve prevents saline from leaking out of the balloon after the tube is uncoupled from it. A second embodiment includes a pair of umbrella-like structures, at least one of which is covered with a biocompatible membrane and is provided with peripheral barbs which engage the wall of the left ventricle and the inter-ventricular septum. A third embodiment utilizes a single umbrella covered with a biocompatible membrane and provided with peripheral barbs which engage the wall of the left ventricle and the inter-ventricular septum. In both of the umbrella embodiments an aspiration tube coupling and valve are provided. The aspiration tube coupling allows an aspiration tube to aspirate the blood which has been segregated from the remaining portion of the ventricle and the valve prevents blood from reentering when the aspiration tube is uncoupled.
[0020] The catheter sheath with which the device is delivered to the left ventricle includes conduit channels, ports and other means for deploying the device, stabilizing it, anchoring it, expanding it, and disengaging from it. A suitable catheter for practicing the invention is one of the type used to install heart pacing electrodes, e.g. the catheter disclosed in U.S. Pat. No. 5,571,161 which is hereby incorporated by reference herein in its entirety.
[0021] The invention thus provides a percutaneous, intra-cardiac implantation device that directly reduces the amount of volume load on the left ventricle. As less volume is received in the left ventricle, the intra-cavity pressure is decreased, thereby reducing wall stress on the myocardium, decreasing oxygen demand and improving pump function. It is the shape, volume and size of the cavity of the ventricle that determines wall stress and not the external shape of the heart. In several embodiments of the invention, the dimensions of the cavity of the ventricle are changed but not the external shape of the ventricle. In other embodiments, the dimensions of the cavity are initially changed and thereafter as ventricular remodeling occurs the external shape of the ventricle is also favorably altered.
[0022] Additional objects and advantages of the invention will become apparent to those skilled in the art upon reference to the detailed description taken in conjunction with the provided figures.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] FIG. 1 is a schematic sectional view of a normal human heart;
[0024] FIG. 2 is a schematic sectional view of a human heart afflicted with CHF;
[0025] FIG. 3 is a schematic longitudinal sectional view of a first embodiment of an implantable expandable device in a catheter;
[0026] FIG. 3A is a schematic longitudinal sectional view of the first embodiment of an implantable expandable device in a catheter illustrating a preferred locking mechanism between the inflation tube and the central stem;
[0027] FIG. 4 is a schematic longitudinal sectional view of the first embodiment being anchored to the wall of the ventricle;
[0028] FIG. 5 is a schematic longitudinal sectional view of the first embodiment with the catheter partially withdrawn;
[0029] FIG. 6 is a schematic sectional view of the first embodiment anchored and inflated with the catheter partially withdrawn;
[0030] FIG. 7 illustrates an alternate embodiment with a hinged anchor for anchoring to the inter-ventricular septum;
[0031] FIG. 8 illustrates an alternate embodiment with a threaded connector rather than a snap connector;
[0032] FIG. 8A is a illustrates another embodiment similar to FIG. 8 ;
[0033] FIGS. 9 and 10 illustrate an alternate embodiment having a claw anchor;
[0034] FIG. 11 illustrates an alternate embodiment having a cork screw anchor;
[0035] FIG. 12 illustrates an alternate embodiment having a short stem;
[0036] FIG. 13 is a schematic perspective view of a second embodiment of an implantable expandable device;
[0037] FIG. 14 is a schematic side elevation view of the second embodiment implanted in a ventricle;
[0038] FIG. 15 is a schematic perspective view of the cog-wheel arrangement of the second embodiment of the invention;
[0039] FIG. 16 is a schematic perspective view of a third embodiment of an implantable expandable device;
[0040] FIG. 17 is a schematic side elevation view of the third embodiment implanted in a ventricle;
[0041] FIG. 18 is a schematic side elevation view of a fourth embodiment implanted in a ventricle;
[0042] FIG. 19 is a schematic side elevation view of the fourth embodiment implanted in a ventricle and evacuated;
[0043] FIG. 20 is a schematic side elevation view of a fifth embodiment implanted in a ventricle;
[0044] FIGS. 21 through 23 are schematic side elevation views of a sixth embodiment being implanted in a ventricle;
[0045] FIGS. 24 through 26 are schematic side elevation views of a seventh embodiment being implanted in a ventricle;
[0046] FIGS. 27 and 28 are schematic side elevation views of an eighth embodiment being implanted in a ventricle; and
[0047] FIGS. 29 and 30 are schematic side elevation views of a ninth embodiment being implanted in a ventricle.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0048] Turning now to FIG. 3 , an implantable expandable device 100 is shown inside a catheter sheath 102 and coupled to an inflation tube 104 . The device 100 includes a central shaft 106 having a distal anchor 108 , an inflatable balloon 110 surrounding the shaft 106 , and a proximal coupling 112 with a self-closing valve 114 . The valve 114 is in fluid communication with inflation ports 116 . In this embodiment, the coupling 112 is a snap fit to which the inflation tube 104 is removably coupled. Referring to FIG. 3A , the snap fit coupling 112 includes a male-female type connection. The distal end of the inflation tube 104 has a cable operating or similar control mechanism, whereby, in a resting state, two spring loaded, lateral expansions 117 of the distal end of 104 itself, are opened to engage within the proximal end of the lumen of the central shaft 106 . To disengage, the control mechanism (a button, lever etc) at the proximal control end (operator end) of the inflation tube 104 is activated to pull on control wires 115 , whereby, the two lateral expansions are pulled radially inward and the snap fit into the central shaft is released, thus separating the inflation tube 104 from the central shaft 106 . Reengagement is accomplished by, similarly, compressing the lateral expansions first, aligning the inflation tube and the central shaft (via fluoroscopic/ultrasound guidance) and then allowing the lateral expansions 117 to deploy, thereby securing a fit between the two.
[0049] The methods of the invention include delivering the catheter sheath 102 with the device 100 and inflation tube catheter 104 therein to the interior of the left ventricle in a trans-atrial septal fashion via the femoral vein or jugular vein. Alternatively, the device may be delivered via the femoral or brachial artery in a retrograde fashion through the aorta. The inflation tube 104 is then advanced relative to the catheter sheath 102 until the anchor 108 extends beyond the end of the catheter sheath 102 . When entering through the jugular vein, the approach is to the right atrium, then across the inter-atrial septum to the left atrium and through the mitral valve into the left ventricle. The anchor 108 is then deployed into or through the apex of the left ventricle or into the septum or through the septum into the right ventricle. FIG. 4 illustrates the anchor 108 piercing the apex of the left ventricle 14 ′. It will be appreciated that the anchor is important to prevent balloon migration during cardiac contractions which could otherwise result in blockage of the mitral and/or aortic valves.
[0050] In the closed (un-deployed) position, the anchor 108 resembles a dart, and is advanced into the wall of the apex or beyond the apex of the ventricle or into the other ventricular cavity across the inter-ventricular septum. Once the desired position of the anchor is confirmed (on x-ray fluoroscopy), the anchor is deployed thereby preventing removal. This anchor deployment mechanism is activated via a wire passing along the catheter to the anchor either through the central stem of the balloon or on the outside of the balloon (when the balloon is in a collapsed position). Upon twisting the central wire, a torquing motion at its tip activates the anchor device. If the need arises to retrieve the balloon at a later date, the anchor can be reconfigured into a narrow dart to permit removal by twisting/untwisting (e.g., clockwise-anti-clockwise) a mechanism at the junction of the anchor 108 and the central shaft 106 of the balloon.
[0051] With the anchor 108 in place, the catheter sheath 102 is withdrawn exposing the inflatable balloon 110 as illustrated in FIG. 5 . The balloon 110 is then inflated by injecting saline (or another biocompatible fluid preferably having a specific gravity equal to or less than that of blood) through the inflation tube 104 as shown in FIG. 6 . It is important to note the preferred shape of the balloon 110 . The shape is designed to reduce the size and also to restore the ellipsoidal shape of a healthy left ventricular cavity, and define a new ventricular apex 22 ′. The shape of the balloon can be described as “rotationally asymmetric about an axis”. In the illustrated embodiment of FIG. 6 the axis can be considered the axis of the central shaft 106 . More particularly, the shape is a paraboloid which is truncated at an angle relative to its directorix thereby producing the inclined upper surface shown in FIG. 6 . The balloon is oriented so that the inclined upper surface preferably slopes down from the inter-ventricular septum as shown. With the high end of the upper surface positioned against the septum, there is no impedance to contraction by the middle and upper portions of the lateral wall of the left ventricle. In addition, pressure in the balloon should be sufficient to distend the balloon appropriately and yet keep the balloon compliant enough to avoid impeding the contraction of the myocardium.
[0052] As discussed above, the catheter 102 may be provided with a distal stabilizing configuration 103 which grips the inflation tube 104 to prevent lateral or other movement while engaging/disengaging from the balloon 110 .
[0053] When the balloon 110 is expanded to the correct volume, the inflation tube 104 is decoupled from the coupling 112 ( FIG. 3 ), as discussed above, and the self-closing valve 114 retains the saline inside the balloon. The inflation tube 104 and the catheter sheath 102 are then removed from the patient's body.
[0054] It will be appreciated that different size balloons 110 may be provided so that different size hearts may be treated. The expansion of the balloon can be monitored by fluoroscopy. Alternatively, each different size balloon can be indicated to contain a certain volume of saline when fully inflated. Inflation can then be monitored by metering the amount of saline which is injected into the balloon. It is presently preferred that pre-shaped balloons be provided in volumetric increments of 10 or 20 ml and that balloons range in size from 40 ml to 350 ml.
[0055] According to the preferred embodiments, the balloon 110 and anchor 108 are removable via the catheter 102 and inflation tube 104 . The inflation tube is preferably re-attachable to the coupling 112 should the balloon ever need to be removed. When the inflation tube 104 is coupled to the coupling 112 , the self-closing valve 114 opens and allows the saline to be suctioned, thus deflating the balloon.
[0056] The balloon is preferably soft, light weight, and compliant/compressible in order to prevent any interference with cardiac muscle contractions. It is also non-thrombogenic, inert (e.g. made from PTFE or suitable polyester) and impervious. It is capable of sustaining long-term implantation. It is preferably of unitary construction and capable of delivery via established catheter delivery systems. Radiopaque markers may be placed at strategic locations on the balloon and anchoring mechanisms to enable detection of the location and expansion of the balloon within the cavity during its insertion and future surveillance. Marker locations may be, for example, at the anchor, rim of the balloon, the self-closing valve, attachment/detachment location of balloon to catheter, central injection stem, etc.
[0057] Turning now to FIG. 7 , an alternate embodiment 100 ′ of the invention is similar to the embodiment 100 described above with similar reference numerals referring to similar parts. In this embodiment the central shaft has a distal hinge 107 ′ which allows the anchor 108 ′ to be rotated up to 90° so that it can be anchored to or through the septum 20 ′ or other suitable areas of the apex of the ventricle. The hinge 107 ′ is activated and controlled and fixed in position by control cables/channels or similar devices running the length of the inflation tube 104 and controlled by lever mechanisms at the operator end of the device. Anchoring is achieved by the central wire control system as described in the other embodiments. Sufficient lateral force is achieved by torquing of the inflation tube and if necessary by stabilizing the inflation tube within the catheter sheath 102 and thereby translating torquing force on 102 to the hinge 107 . This is an established and standard industry method in widespread use, such as with steerable catheters and the trans-atrial septum catheters, when such lateral torquing motion is applied to pass through the inter atrial septum at right angles to the axis of catheter passage into the heart.
[0058] FIG. 8 shows yet another alternate embodiment 100 ″ which is similar to the embodiment 100 described above with similar reference numerals referring to similar parts. The difference here is that the coupling 112 ″ between the inflation tube 104 ″ and the central shaft 106 ″ is a rotational locking mechanism, such as a threaded coupling or a luer lock, with the inflation tube catheter 104 and central shaft 106 deployed in precoupled state. When adequate anchor to the apex and inflation of the balloon 110 ″ is confirmed, the inflation tube and the central shaft are disengaged by a counter-clockwise torque motion of the inflation tube 104 ″.
[0059] In order to facilitate torquing motion of the inflation tube 104 ″, the distal end of the catheter sheath 102 ″ may be also provided with a constricting mechanism which couples the catheter sheath and inflation tube catheter together for application of torquing motion to the inflation tube by the catheter sheath. For example, control wires 118 ″ may be coupled to compressible elements such as leaves or pincers 121 ″ at the distal end of the catheter sheath 102 ″ producing a grasping/gripping effect, or a Teflon/ PTFE cuff can be inflated at or purse-string coupled to the distal end of the catheter sheath. These mechanisms serve to stabilize the central shaft 106 ″ or the distal end of the inflation tube catheter 104 ″ for disengagement or reengagement as needed, and while the torquing motion is applied.
[0060] FIG. 8A shows a similar embodiment to FIG. 8 , wherein the central shaft 106 a ″ at its proximal alignment end to the inflation tube 104 a ″ is preferably slightly longer than its balloon 110 a ″ component so that enough purchase is afforded to the catheter sheath 102 a ″ stabilizing mechanism to act upon. FIGS. 9 and 10 illustrate another alternate embodiment 100 ′″ which is similar to the embodiment 100 described above with similar reference numerals referring to similar parts. The difference here is that the anchor 108 ′″ is a group of claws. After the apparatus 100 ′″ is delivered to the ventricle, the claws are opened as shown in FIG. 9 . The claws are brought into engagement with the inside wall of the ventricle at the apex or the septum. After an adequate amount of myocardial tissue is grasped between the claws, they are closed as shown in FIG. 10 .
[0061] More particularly, the anchor claws 108 ′″ are aligned around the periphery of a cog wheel arrangement, the center of which has an opening for passage and insertion of the aligning end of the central wire passed through the inflation tube. The central wire is inserted into the lumen of the cog wheel arrangement and a torquing clockwise motion opens the cog wheel and the claws, and a counterclockwise motion closes it. After the desired effect, the central wire maybe withdrawn. Claws deployable into cardiac tissue and mechanisms for their deployment and release are well known to individuals skilled in the art of cardiac active pacing leads.
[0062] FIG. 11 illustrates another alternate embodiment 100 ″″ which is similar to the embodiment 100 described above with similar reference numerals referring to similar parts. The difference here is that the anchor 108 ″″ is a “cork screw” which is controlled by a wire passing through the central shaft 106 ″″. Alternatively, the cork screw may be threaded into the wall by a twisting motion of the whole catheter and central shaft without need for a central wire. Alternatively, the corkscrew may be threaded into the anchor site by stabilizing, fixing and immobilizing the distal end of the catheter sheath on the inflation tube and central shaft, thus making all three of these components into one single rigid torque tube.
[0063] FIG. 12 illustrates another alternate embodiment 100 ′″″ which is similar to the embodiment 100 described above with similar reference numerals referring to similar parts. The difference here is that the central shaft 106 ′″″ is relatively shorter and does not extend through to the anchor 108 ′″ 41 after the balloon 110 ′″″ is inflated.
[0064] Turning now to FIGS. 13 and 14 , a second embodiment 200 of the device of the invention includes a catheter sheath 202 and a deployment/suction tube 204 . In lieu of an inflatable balloon, this embodiment has two spaced apart biocompatible umbrellas 206 , 208 which are each covered with a biocompatible membrane 210 , 212 . The periphery of each umbrella is provided with barbs 214 , 216 which are located on the ends of radial spokes 215 , 217 , and the umbrellas are coupled to each other by a semi-rigid stem 218 which is provided with aspiration ports 220 . The top of the stem 218 has a coupling 222 for removably coupling to the end of the tube 204 . The coupling 222 includes a valve which automatically seals the passage into the stem 218 when the tube 204 is decoupled from it. Clock-wise or anti-clockwise rotation of the tube 204 (when coupled to the stem 218 ) produces an expanding or retracting motion on the radial spokes of the umbrellas. The articulating part of the catheter and the umbrella spoke attachments have a cog wheel configuration linkage that allows torque motion which opens or closes the umbrellas.
[0065] More particularly, referring to FIGS. 13-15 , the distal tip of the stem 218 (anchor end) and the distal tip of the tube 204 have circular cog wheel arrangements 226 , which fit into complimenting recesses 228 in hubs 230 of the radial spokes of the distal and proximal umbrellas 206 , 208 . The device is pre-assembled in this fashion. Upon deployment of the anchor mechanism, the catheter sheath 202 , tube 204 , and the central shaft 218 are fixed by the stabilizing mechanism of the catheter sheath into a rigid component that torques the distal cog wheel 226 and the proximal cog wheel (not shown) such that it rotates clockwise the hub 228 of the radiating spokes, which expands the umbrellas 206 , 208 and causes engagement of the barbs 214 , 216 upon expansion to anchor the umbrellas. Now, the proximal end of the central shaft is disengaged from the inflation tube, and the stabilizing mechanism of the catheter sheath is deactivated, thus leaving the deployed umbrellas with their connecting central shaft in place inside the heart cavity. It will be appreciated from the figures that one umbrella is upside down and the other is right side up. The upside down umbrella 208 engages the apex of the ventricle and expands less and/or is smaller that the other umbrella 206 .
[0066] The catheter, tube and umbrellas are delivered to the left ventricle with the umbrellas closed and inside the catheter. The umbrellas are pushed out of the catheter either by pulling back on the catheter while holding the tube or pushing forward on the tube while holding the catheter. The umbrellas are then opened until their barbs engage the ventricular wall and septum as shown in FIG. 4 . Blood trapped between the umbrellas is aspirated via the ports and the tube. The vacuum used to aspirate also causes the umbrellas to further engage the ventricle wall and septum.
[0067] FIGS. 16 and 17 illustrate a third embodiment 300 which is similar to the second embodiment just described. It includes a catheter 302 , a deployment/aspiration tube 304 , and an umbrella 306 . The umbrella is covered with a biocompatible membrane 310 . The periphery of the umbrella is provided with barbs 314 and the center of the umbrella is provided with a valved coupling 322 . The valved coupling 322 allows the tube 304 to couple and uncouple from the umbrella. When the tube 322 is coupled to the umbrella, rotation of the tube causes the umbrella to open or close, as discussed above. After the umbrella is deployed, blood trapped between the apex of the ventricle and the umbrella is aspirated through the tube 304 and the tube is then uncoupled from the umbrella. At uncoupling, the valve 322 closes and prevents blood from reentering the space between the apex of the ventricle and the umbrella. Another alternate (non-illustrated) embodiment is similar to the embodiment 300 but includes a central stem extending from the center of the umbrella to the apex of the ventricle with an anchor at its tip.
[0068] Turning now to FIG. 18 , another embodiment of device for percutaneous ventricular restoration is shown. The device 400 includes a balloon 410 with a central perforate stem 406 . The balloon 410 is coupled at the apex of the left ventricular substantially as described above, with an anchor 408 . The sides of the balloon 410 include an abrasive and/or porous surface 416 preferably provided with an irritant coating 418 , such as tetracycline or bleomycin or other such sclerosing agent. Such surface 416 and coating 418 enhances adhesion of the balloon 410 to the ventricular wall and promotes ingrowth of fibrous tissue from the ventricular wall onto the balloon. Inflation fluid 420 is delivered through a delivery tube (not shown) and valve 414 to expand the balloon within the apex of the ventricle so that the porous surface is in contact with the heart wall tissue. The expanded balloon, as shown in FIG. 18 , is left in place for a period of time, e.g., eight to twelve weeks, to allow such ingrowth and tissue-to-balloon adhesion. Then, after the period of time required for tissue ingrowth, the patient undergoes a subsequent procedure during which the inflation fluid is percutaneously removed from the balloon by re-coupling a tube at the valve 414 and applying suction. Referring to FIG. 19 , as the balloon 410 is evacuated and collapsed its volume is reduced, the diameter of the balloon decreases, thereby reshaping the ventricular cavity by causing movement of the left ventricular wall and the septum toward each other. Thus, not only the shape and size of the cavity of the ventricle is restored, but the external shape of the ventricle is also favorably altered. In an alternate embodiment, the top surface of the balloon may be thicker and non-compliant relative to the sides of the balloon, e.g., provided with stiffening ribs. Then, upon evacuation of the balloon, reshaping is limited to the sides of the balloon (rather than its top surface), maximizing movement of the lateral ventricular wall toward the septum.
[0069] Referring to FIG. 20 , the wall 516 of the balloon 510 may be provided with a porous trabeculae or lattice 518 that forms a thin wall chamber 520 that is communicable with a suction source tube 522 applied at valve 514 . By rotating suction source tube 522 relative to the valve 514 suction may be selectively applied to the interior of the balloon 524 or the chamber 520 . Upon application of suction to the balloon wall chamber 520 , the perforate outer surface of the balloon wall 516 adheres to the ventricular wall by way of negative pressure. The negative pressure can be maintained on the wall even after the active application of negative pressure is discontinued, creating adhesion similar to that created by a suction cup. In use, the balloon is inflated at the apex as described in prior embodiments to provide good balloon wall/tissue contact. Then, suction adhesion is created between the balloon wall and the ventricular wall. After suction adhesion is effected, the balloon may be evacuated of fluid by application of suction to the interior of the balloon. Such will reduce weight in the left ventricle in addition to reducing volume.
[0070] Turning now to FIGS. 21 to 23 , another embodiment of a percutaneous device for modifying the volume of the left ventricle of the heart is shown. Referring to FIG. 21 , the device is initially inserted as a balloon 610 anchored to the apex and about its upper surface, substantially as previously shown and described. The balloon is preferably, but not necessarily, inflated. Referring to FIG. 22 , then through valve 614 , a delivery device 624 provided with a collapsed basket 626 at its distal end is inserted into the interior of the balloon 610 . The basket 626 is preferably spring-loaded to self expand to the interior periphery of the balloon upon retraction of a covering sheath (not shown). After basket insertion, the delivery device is then operated to retract the covering sheath to allow the basket to expand and decouple the basket into the interior of the balloon. Alternatively, the basket may be made from a shape memory alloy that can be activated to assume an expanded configuration upon application of heat or other energy, and the delivery device is then configured and operated to activate the basket to reconfigure from a collapse state into an expanded state once inserted into the balloon. Referring to FIG. 23 , after expansion of the basket 626 , if fluid is initially used to inflate the balloon 610 , the fluid may be evacuated coupling a tube 622 to valve 614 and applying appropriate suction to the interior of the balloon.
[0071] Turning now to FIGS. 24 to 26 , another embodiment of a percutaneous device for modifying the volume of the left ventricle is shown. The device 700 , provided at the distal end of a delivery instrument 724 , is initially in the form of a radially collapsed wire basket 726 within a balloon 710 . An outer sheath 728 confines the device 700 to the collapsed state ( FIG. 24 ). The device 700 is delivered to the apex of the left ventricle and coupled thereat. Referring to FIG. 25 , then the outer sheath 728 is retracted causing the device 700 to expand within the apex of the left ventricle. Finally, referring to FIG. 26 , the delivery instrument 724 is decoupled from the device 700 and removed from the heart.
[0072] Turning now to FIGS. 27 and 28 , the volume of the left ventricle may also be reduced in a non-percutaneous, but relatively minimally invasive approach via a sub-xiphoid incision or through a thoracoscope 832 via a left anterior thoracotomy incision. A delivery device 830 including an introducer 822 , a balloon 810 preferably substantially similar to one of the embodiments described above at the distal end thereof, and a retractable sheath 828 over the balloon is advanced to the apex of the heart through the selected approach. The distal end of the delivery device 830 is inserted trans-apically into the left ventricle. The apical side of the balloon 810 includes an anchor 808 with an inflation valve 814 . The balloon 810 is inflated through the inflation valve 814 and the anchor 808 is then pulled back through the apex of the heart wall. The anchor 808 is preferably locked to the wall with a button 809 or other suitable fastener. The anchor and button may be reliably coupled permitting removal of the balloon if necessary. A preferred attachment includes a releasable ratchet mechanism. The button 809 may be introduced over the introducer 822 and seated prior to releasing the introducer from the balloon 810 , or the introducer may be released from the balloon and the button attached thereafter.
[0073] Referring to FIGS. 29 and 30 , another minimally invasive embodiment is shown and now described. A balloon 910 is delivered trans-apically into the left ventricle. The balloon 910 has a valve 914 at its apical side. A collapsed basket 916 is introduced on a delivery device 922 into the balloon 910 and then expanded. The basket 916 may be self-expanding or comprised of a shape memory alloy expandable via application of appropriate energy. If energy is required, the delivery device 922 also includes an energy applicator to deliver the required energy for basket expansion. The apical end of at least one of the balloon and the basket includes an anchor 908 , optionally for receiving a button 909 , to couple the balloon/basket within the left ventricle. Such anchor 909 additionally comprises the site for energy reception to expand the basket, if necessary. Alternatively, the balloon 910 and basket 916 can be introduced together, as discussed above, into the left ventricle trans-apically.
[0074] There have been described and illustrated herein several embodiments of apparatus and a methods for ventricular restoration. While particular embodiments of the invention have been described, it is not intended that the invention be limited thereto, as it is intended that the invention be as broad in scope as the art will allow and that the specification be read likewise. Thus, while particular anchors have been disclosed, it will be appreciated that other anchors could be used as well. For example, a simple bayonet anchor could be used. In addition, while the presently preferred embodiment of the balloon has been described as a truncated paraboloid with the truncation plane at an angle to the directorix plane, other shapes could be used provided they yield equivalent results. For example, and not by way of limitation, the top surface of the balloon could be concave, convex, flat or angled. Other types of couplings between the inflation tube and the balloon could also be used, e.g. a bayonet coupling. Also, while the term balloon has been used, it is not necessary that the balloon be made of an elastic element, but such balloon should be made of a material relatively impermeable to the fluid (saline, blood) that must be kept in and/or out of the interior of the balloon for the given embodiment. It will therefore be appreciated by those skilled in the art that yet other modifications could be made to the provided invention without deviating from its scope as claimed.
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Methods for cardiac ventricular restoration include delivering an implantable expandable device into the ventricle via a catheter. The expandable device is anchored either to the wall of the left ventricle or to the inter-ventricular septum and then expanded. When expanded, the device assumes a size and shape which fills the lower portion of the ventricular cavity restoring the normal volume and ellipsoid shape of the remaining portion of the cavity and favorably altering myocardial oxygen demand and wall stress.
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BACKGROUND OF THE INVENTION
This invention relates to new and useful improvements in agricultural injection sprayers and particularly to a method of setting the desired rate of chemical application to suit the chemical being utilized.
Conventionally, the operator of an injection system adjusts the rate of chemical application in one of two ways:
(1) By using charts and/or graphs, the corresponding indices of the machine are ascertained, i.e. where a flow meter ball should be located, etc. and then the machine is set to these indices;
(2) By inputting the rate directly into a monitor in the cab by either a thumb wheel system where the numbers are manually rolled into their proper position, or electrically by pushing buttons until the rate on the display equals the desired rate.
The first method is, of course, lengthy, cumbersome and prone to misorientation and error.
The second system is an improvement and gives the appearance initially of being the optimum solution to assuring the proper rate of chemical application. How ever, several factors enter into the second system indicating that this system is not as advantageous as initially believed.
Firstly, the units of measurement vary to such a degree that there exists three systems in use today in Western Canada, namely Metric, Imperial and "bastard" (liters/acre).
Secondly, conversion may be required if the monitor demands Imperial measure and only Metric information is found on the container or, if the monitor can accept all three systems, the switch may be on "Metric" when the operator believes it is on "Imperial". It will therefore be appreciated that conversion of any kind by the operator is prone to error.
Thirdly, the operator may read the rate from the chemical container, but as it is rarely possible to take the container with him inside the cab, memory is relied upon to input the proper numbers and this is awkward and difficult to check.
Fourthly, to input information into a monitor correctly usually requires a certain procedure to prevent inadvertent input or change of the input information. Errors may occur including incorrect registration of numbers or information placed in the wrong location. If programming is direct as with the thumbwheel system, the rate of application may be changed inadvertently during operation, again relying on memory to signal that the input information is now correct.
A third system type is described in Coffee et al U.S. Pat. No. 4,553,702 where, in an injection sprayer, the chemicals to be sprayed are supplied in special containers equipped with pre-coded electronic memory chips that are interrogated by a microprocessor controlled sprayer control system. Included in the information coded on the chip are acceptable application rates for the chemical This is a very complex piece of equipment and, in the preferred embodiment, it still requires the operator to select the application rate using a manual push button control.
The present invention is concerned with an alternative form of application rate control.
SUMMARY
In accordance with the invention there is provided, for use with an agricultural sprayer comprising:
a vehicle for propelling the sprayer over the ground and having an operator's station;
spray booms transported by the vehicle and having spray nozzles thereon;
a water tank;
a water pump;
water lines delivering water from the water tank to the water pump and from the water pump to the nozzle;
a chemical supply;
a metering pump; and
chemical lines for delivering chemical from the chemical supply to the metering pump and from the metering pump to the water lines, control means for controlling operation of at least the metering pump, said control means comprising:
a key having information coded thereon in machine readable form, said information including at least a rate of chemical application;
visible indicia on the key reproducing information coded on the key, including at least a rate of the chemical application;
key decoding means for receiving and holding the key, for decoding the information code on the key and for generating signals representing the decoded information, the decoding means being mounted in the vehicle adjacent an operator's station for continuing observation by an operator, the key decoding means retaining the key with the visible indicia displayed for continuing observation of the indicia by the operator;
processor means responsive to said signals for controlling operation of at least the metering pump thereby controlling application and dilution parameters of the chemical.
Preferably, the decoding means include a source of light and a plurality of individual light detectors spaced from and confronting the source of light. The detectors are operatively connected to the processor. The key is removably insertable between the source of light and the detectors so that a pattern of apertures through the key allows illumination of a corresponding pattern of detectors, thus producing a coded signal for the processor.
A plurality of keys with different codings may be provided with the system or, alternatively, an individual coded key may be attached to the container of chemical when purchased and discarded once the chemical has been used up.
With the foregoing in view, and other advantages as will become apparent to those skilled in the art to which this invention relates as this specification proceeds, the invention is herein described by reference to the accompanying drawings forming a part hereof, which includes a description of the best mode known to the applicant and of the preferred typical embodiment of the principles of the present invention, in which:
DESCRIPTION OF THE DRAWINGS
FIG. 1 is an isometric fragmentary partially schematic view of the control portion of the controller.
FIG. 2 is a block diagram of the invention including the optional LCD portion.
FIG. 3 is a front elevation of one of the keys.
FIG. 4 is a partially schematic view of the key of FIG. 3 showing the infrared emitters and detectors.
FIG. 5 is a schematic view showing the key assembly operation.
FIG. 6 is an isometric view of a chemical container with a control key attached thereto.
FIG. 7 is an isometric schematic view of an agricultural sprayer.
In the drawings like characters of reference indicate corresponding parts in the different figures.
DETAILED DESCRIPTION
Referring first to FIG. 2, reference character 10 illustrates a pump motor having RPM feedbacks 11 to an analog control and drive assembly collectively designated 12 which in turn is operatively connected to a microprocessor collectively designated 13.
This microprocessor (68705R3) is operated by nine volt battery 14 and is provided with various inputs such as thumb wheel input 15, boom pressure input 16, reference memory check 17, tank levels 18, ground speed indicator 19 and the like.
It also has optical reader inputs TIL 78 and TIL 32 indicated schematically by reference character 20. It will be noted that there are two analog control and drivers 12 and two pump motor and feedback assemblies 10 and 11.
There is also an LCD option included within the dotted box 21 operatively connected to the microprocessor.
The optical readers 20 comprise the input from the controller shown schematically in FIG. 1 and collectively designated 22. This preferably forms part of a monitor assembly 40 situated within the cab 42 of the tractor or sprayer 44 (if self-propelled, see FIG. 7) and may include the aforementioned thumb wheel inputs 15 and LCD inputs 21.
The control means includes a circuit board 23 upon which is mounted on one side 24 thereof, a light source 25 with a dispersion reflector built therein.
The light source may take many forms which are conventional and the dispersion reflector insures that an approximately equal amount of light is available over the entire surface of the light source bounded by the sides 26, the upper side 27 and the base 28 thus forming a substantially rectangular enclosure Although the term "light source" is utilized, any convention electromagnetic radiation may be used such as infrared, magnetic, and the like.
Spaced and parallel from this light source and attached to the front side 29 of the circuit board, is a plurality of light (or electro-magnetic radiation) sensors collectively designated 30. These sensors are conventional and include directional shields 31 surrounding same and extending forwardly therefrom.
They may be mounted in a grid fashion and connected to a source of electro-magnetic power (not illustrated). These light sensors and the light source define a rectangular aperture 32 therebetween which is adapted to receive a key collectively designated 33, details of which will hereinafter be described. The circuit board is cut out or provided with apertures between the light source 25 and the sensors 30.
Also attached to the circuit board 23 is a main pump switch 34 operatively connected to the pump motors 10 and it is desired that a readout 35 also be provided on the circuit board adjacent the location of the light source and sensors hereinbefore described.
The aforementioned key 33 is preferably formed from a rigid synthetic plastic substantially rectangular in configuration although of course other configurations can be used depending upon the location and configuration of the aforementioned light source and detectors or sensors.
The key 23 includes an upper portion 36 upon which information may be provided together with identification. In the present instance, the name of the chemical is indicated together with the preferred rate of application. namely, 3.0 liters per hectare.
However, this information may be in Imperial measure such as gallons or pints per acre or what is known as "bastard" configuration such as liters per acre which is quite common.
The key may be provided with a plurality of apertures which match corresponding apertures in the circuit board and which are aligned with the individual light sensors 30.
In FIG. 1, nine such apertures are shown but any combination of apertures and blanks may be provided so that the combination of apertures and blanks accommodates all possible rates and any other commands which may be required such as informing the monitor that a key is in place, informing the monitor relative to the measuring units which apply, and the like.
The number of possible combinations is defined as 2 to the power of the number of holes. Therefore, for four holes or apertures, 2 4 or 16 different combinations exist: for nine holes, 2 9 or 512 different combinations exist.
The light source 25 either with a dispersion reflector or individual bulbs for each aperture is provided on one side of the key when inserted into the monitor and floods that side with light. The light sensors 30 are highly directional in order to avoid picking up stray light, and are positioned opposite each potential aperture. If a key is inserted and interrupts the beam of light indicating no aperture, the sensor will see no light and register this information. In this general manner, the individual key transmits its coded information to the monitor with no requirement from the operator short of putting the key into the monitor. The key can be formed so that it can only be inserted in one orientation thus preventing inadvertent incorrect insertion. (Not illustrated)
The location of the key relative to the pump switch 26 indicates to the operator the type of chemical and rate of injection by the pump activated by the switch confirmed by the information from the microprocessor 13 displayed on readout 35.
A set of keys may be supplied with the monitor with perhaps yearly updates being made available by the monitor manufacturer. However, it is believed that the ideal system is to have the key 33 supplied with the container 33A containing the chemical as shown in FIG. 6. Under these circumstances the operator merely inserts the key, sprays the fields and then discards the key upon finishing that particular supply of chemical.
It will be appreciated that a rate can be programmed into the monitor in the usual way (i.e. thumbwheel, pushbuttons or the like) in case of key loss or if a rate is desired which is not available in key code form.
However, use of the key which continually displays the desired rate and the display of "actual" rate at 35 will reduce many errors that would result in incorrect application.
FIGS. 3 and 4 show key 33 diagrams with a lower row of four apertures 37 which may be used to indicate to the processor that a key has been inserted. These can be by infrared emitters 38 transmitting a signal to the micro processor by infrared detectors 39, but if the pump is switched on with no card inserted, then it may use the previously programmed rate. If, however, a new card is inserted, then the microprocessor checks the required rate from the software (not illustrated) and adjusts the pump to the correct requirements.
In operation, the motors 10 driving the pumps are preferably controlled only by the analogue portion 12. The microprocessor 13 just calculates the proper motor speed and then corrects the analogue controller 12.
FIG. 7 illustrates an agricultural sprayer 2 including booms 4 with nozzles 5. A water tank 6 and a chemical container 7 are carried by the sprayer. Water is supplied from water tank 6 to the booms 4 using a water supply including a water pump 3 and a pump motor 10. The agricultural chemicals are injected into the water supply by a metering pump 8 driven by the other pump motor 10. The motors 10 are controlled by monitor 40 in the cab 42 of the tractor 44.
It will be appreciated that the detailed description above is only an example of how one could accomplish the idea of monitor user-friendliness illustrated herein. It should be realized that the device used to carry the coded information could be many varied shapes and configurations; the method used to detect the coded information could be one of many possibilities (magnetic, infrared, mechanical, etc.); and the method used to vary the pump speed based on the inputted coded information could be one of many possibilities (analogue, microprocessor, etc.).
Since various modifications can be made in our invention as hereinabove described, and many apparently widely different embodiments of same made within the spirit and scope of the claims without departing from such spirit and scope, it is intended that all matter contained in the accompanying specification shall be interpreted as illustrative only and not in a limiting sense.
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A liquid chemical proportion and application rate controller for agricultural injection type sprayers is connected to a microprocessor and to one or more pumps. Depending upon the chemical being used, a control key is inserted into a monitor which controls the output of the microprocessor to the pump or pumps and automatically controls the rate of application, the dilution proportions, indicates and adapts the output for Metric, Imperial instructions or in combination of both (i.e. liters per acre). Such a key may be provided with the container of chemical and discarded when the spraying is completed.
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RELATED APPLICATIONS
This application is the U.S. National Phase under 35 U.S.C. §371 of International Application No. PCT/JP2011/065895, filed on Jul. 12, 2011, which in turn claims the benefit of Japanese Application No. 2010-160959, filed on Jul. 15, 2010, the disclosures of which Applications are incorporated by reference herein.
FIELD
The present invention relates to a propeller fan manufactured by injection molding of a resin material and a manufacturing method thereof, and more specifically, to a propeller fan with high durability, and a manufacturing method thereof.
BACKGROUND
In the related art, as a propeller fan that is included in an outdoor unit of an air conditioner, an air cleaner, a ventilator or the like and is used for fluid feeding of air or the like, it has been known a propeller fan formed, using a fiber reinforced plastic (FRP) in which a glass fiber or the like is mixed with a thermoplastic resin such as an acryl resin at a predetermined rate (for example, 30 weight %), through an injection molding by setting molding conditions such as an injection pressure and a metal mold temperature to predetermined values.
FIG. 5 illustrates a general injection molding machine 110 that is used for the injection molding of the above-mentioned propeller fan. The injection molding machine 110 includes an injection unit 111 that melts a resin material serving as a material in order to inject the resin material, a metal mold 112 that molds the molten resin from the injection unit 111 , a mold opening and closing mechanism 113 that closes the metal mold 112 after molding, and a projection mechanism 114 that projects the molded article to release the molded article from the mold after opening the mold.
Next, a molding machining sequence using the metal mold 112 will be described based on FIGS. 6 to 8 . As illustrated in FIG. 6 , the metal mold 112 is a three piece type metal mold including a stationary mold 121 , a mobile mold 122 , and an intermediate metal mold 123 located between both of them, and a plurality of projection pins 124 driven by the projection mechanism 114 is placed on a back side of the mobile mold 122 .
Moreover, in a state of joining the stationary mold 121 , the mobile mold 122 and the intermediate metal mold 123 at a predetermined clamping pressure, the molten resin is injected from the injection unit 111 into a cavity, not illustrated, formed between the mobile mold 122 and the intermediate metal mold 123 through a runner, not illustrated, formed throughout the stationary mold 121 and the intermediate metal mold 123 , and thereby a molded article corresponding to an internal surface shape of the cavity is formed.
FIG. 7 illustrates a state of mutually separating the stationary mold 121 , the mobile mold 122 and the intermediate metal mold 123 after molding to open the mold. Due to the opening of the mold, a molded article 116 molded in the cavity remains in a state of being attached to a molding surface of the mobile mold 122 , and a runner portion 117 solidified in the runner remains in a state of being attached to the stationary mold 121 side.
In a state of opening the metal mold 112 , as illustrated in FIG. 8 , the projection pins 124 are caused to advance, the molded article 116 is separated from the mobile mold 122 by the projection pins 124 , and the runner portion 117 is separated from the stationary mold 121 . The molded article 116 manufactured in this manner is a propeller fan 101 serving as a molding object illustrated in FIG. 3 . Furthermore, the injection molding state of the propeller fan 101 in the metal mold 112 is illustrated in FIG. 4 .
As illustrated in FIG. 3 , the propeller fan 101 has a peripheral wall 105 and an end surface wall 106 , and includes a hub 102 which is approximately cylindrical with a bottom provided with a boss 104 for inserting a driving shaft of a motor, not illustrated, configured to rotate the propeller fan 101 in a central portion of the end surface wall 106 , and three blades 103 having the same shape integrally attached onto the peripheral wall 105 of the hub 102 . As mentioned above, the propeller fan 101 is manufactured by the injection molding using the injection molding machine 110 including the metal mold 112 illustrated in FIG. 4 .
As illustrated in FIG. 4 , when joining the mobile mold 122 with the intermediate metal mold 123 , a cavity 127 is formed between the mobile mold 122 and the intermediate metal mold 123 . Furthermore, when joining the stationary mold 121 with the intermediate metal mold 123 , a runner 128 for supplying the molten resin injected from an injection nozzle 111 a of the injection unit 111 to the cavity 127 is formed between the stationary mold 121 and the intermediate metal mold 123 .
Furthermore, the shape of the cavity 127 is set so that a molding surface 125 of the mobile mold 122 side forms a positive pressure surface 103 a of the blade 103 , and a molding surface 126 of the intermediate metal mold 123 forms a negative pressure surface 103 b of the blade 103 in consideration of mold release characteristics of the hub 102 . Furthermore, as illustrated in FIG. 3 , the runner 128 forms a three-pronged branched road shape corresponding to the number of the blades 103 of the propeller fan 101 , and a downstream end of each branched road of the runner 128 is a gate 129 serving as an injection hole of the molten resin into the cavity 127 .
Thus, the molten resin is injected into the cavity 127 through the runner 128 from the injection nozzle 111 a at a predetermined injection pressure, the cavity 127 is filled with the molten resin, and thereby the propeller fan 101 having a shape corresponding to the inner surface shape of the cavity 127 is molded.
At this time, the runner portion 117 having a shape corresponding to the inner surface shape of the runner 128 is molded in the runner 128 by the molten resin supplied thereto, and the runner portion 117 is integrally connected to the propeller fan 101 by each gate 129 . The propeller fan 101 and the runner portion 117 are cut and separated by each gate 129 when the metal mold 112 is opened. Thus, as illustrated in FIG. 3 , cutting traces in the runner portion 117 , that is, three gate marks 118 remain on the end surface wall 106 of the propeller fan 101 after the molding.
However, in general, since the shape of the blade of the propeller fan greatly affects the blowing performance, the shape is designed under extremely exact calculations, and thus there is a need to pay a close attention so as to obtain the shape of the blade corresponding to the design shape, particularly when manufacturing the propeller fan.
For example, when setting the gate 129 of the runner 128 to a position corresponding to a blade surface (the negative pressure surface 103 b illustrated in FIG. 4 ) of the blade 103 of the cavity 127 , the gate marks 118 remain on the blade surface of each blade 103 of the molded propeller fan 101 , the blade surface becomes uneven due to the presence of the gate marks 118 , the blade surface shape is different from the design shape, and thus the blowing performance may decline.
Thus, in the related art, generally, as illustrated in FIGS. 3 and 4 , each gate 129 is set to a position corresponding to a root of the blade 103 of the peripheral wall 105 on the end surface wall 106 of the hub 102 while avoiding the provision thereof on the blade 103 side.
Furthermore, the shape of the propeller fan of the related art and the manufacturing method thereof mentioned above is, for example, described in the description of the related art in Patent Literature 1.
However, in the propeller fan of the related art mentioned above, the number of the gates 129 at the time of the injection molding is one with respect to each blade 103 , as illustrated in FIG. 9 , the molten resin that flowed into the cavity 127 from the gate 129 flows like the flow of the resin indicated by reference numeral 400 .
Specifically, the molten resin that flowed into the cavity 127 from the gate 129 flows so as to spread in the cavity 127 from the gate 129 , and flows like the flow 400 ( 400 a to 400 f ) of the resin illustrated in FIG. 9 . Although the blade 103 is jointed to the peripheral wall 105 of the hub 102 by a root portion 200 , as illustrated in FIG. 4 , a thickness from a root portion 200 to the leading end portion of the blade 103 becomes thinner toward the leading end portion of the blade 103 from the root portion 200 .
The molten resin that flowed from the gate 129 initially reaches the root portion 200 just below the gate 129 (the gate mark 118 ). The molten resin that reaches this then flows in a direction along the root portion 200 , that is, like the flows 400 a and 400 b of the resin illustrated in FIG. 9 before flowing in the direction of the blade 103 for a difference in thicknesses from the above-mentioned root portion 200 to the leading end portion of the blade 103 . Moreover, the molten resin that reached the root portion 200 by other courses is pressed into the flows 400 a and 400 b of the resin, and flows in a direction along the root portion 200 like the flows 400 c to 400 f of the resin illustrated in FIG. 9 .
The molten resin is a fiber reinforced plastic, and includes a continuous fiber 300 . However, since the orientation direction of the continuous fiber 300 is parallel to the flow of the resin, the orientation direction thereof is oriented in a direction along the root portion 200 by the above-mentioned flows 400 a to 400 f of the resin. There is concern that cracks may occur in the root portion 200 in the direction along the root portion 200 due to force applied to the root portion 200 when rotating the propeller fan 101 . However, when the occurrence direction of the cracks is equal to the orientation direction of the continuous fiber 300 , strength of the force applied to the root portion 200 is degraded. Thus, when rotating the propeller fan 101 , the blade 103 might break in the root portion 200 at a relatively low revolution number (for example, 2,500 rpm).
CITATION LIST
Patent Literature
Patent Literature 1: Japanese Patent No. 3928380 (pages 2 to 3, FIGS. 3 to 8)
SUMMARY
Technical Problem
The present invention has been made to solve the above-mentioned problems, and an object thereof is to provide a propeller fan in which a root portion of a blade does not break even if strength of the root portion of the blade is raised so as to rotate the root portion at a higher revolution number, and a manufacturing method thereof.
Solution To Problem
In order to solve the afore-mentioned problems, a propeller fan molded by injection molding using a resin material containing a continuous fiber includes, a hub having an end surface wall and a peripheral wall, and a plurality of blades on an outer periphery of the hub. The propeller fan is molded by providing a plurality of injection positions for injecting the resin material containing the continuous fiber in a part of the end surface wall corresponding to a root portion of one of the blades of the hub. A flow direction of the resin material containing the continuous fiber is regulated by the flow of the resin material from the injection positions adjacent to each other, and is in a direction perpendicular to a width direction of the root portion of the blade.
The plurality of injection positions is dispersed and placed in a circumferential direction around a rotation center of the propeller fan. The plurality of injection positions is dispersed and placed on the same circumference around the rotation center of the propeller fan.
In order to solve the afore-mentioned problems, a method of manufacturing a propeller fan includes molding the propeller fan containing a hub having an end surface wall and a peripheral wall, and a plurality of blades on an outer periphery of the hub, and using a metal mold containing a cavity and a runner connected to the cavity via a gate and serving as an injection passage of a molten resin having a continuous fiber, by injecting the molten resin into the cavity through the runner. The plurality of gates is set at a part of the end surface wall corresponding to a root portion of the blade of the propeller fan in the cavity.
Advantageous Effects of Invention
According to the propeller fan and the manufacturing method thereof of the present invention, a plurality of gates is set into a metal mold so that a plurality of injection positions is included for one blade, and the propeller fan is manufactured by the injection molding. Accordingly, the molten resin flows in a direction perpendicular to the width direction of the root portion in the root portion of the blade, and an orientation direction of a continuous fiber contained in the molten resin is also perpendicular to the width direction of the root portion. Thus, it is possible to provide a propeller fan in which strength of the root portion of the blade is improved, and durability is further increased.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1A is a perspective view of a propeller fan manufactured by a manufacturing method according to the present invention.
FIG. 1B is a view taken in a direction of an arrow A of the propeller fan in FIG. 1A .
FIG. 2 is a view that illustrates a state of a root portion of a blade of the propeller fan according to the manufacturing method of the present invention.
FIG. 3 is a perspective view of the propeller fan manufactured by the manufacturing method of the related art.
FIG. 4 is a cross-sectional view that illustrates an injection molding state of the propeller fan according to the manufacturing method of the related art.
FIG. 5 is a general view of an injection molding machine.
FIG. 6 is a view that illustrates an injection molding state of a metal mold.
FIG. 7 is a view that illustrates a mold opening state of the metal mold.
FIG. 8 is a view that illustrates a mold release state of a molded article from the metal mold.
FIG. 9 is a view that illustrates a state of the root portion of the blade of the propeller fan according to the manufacturing method of the related art.
DESCRIPTION OF EMBODIMENTS
Hereinafter, an embodiment of the present invention will be described in detail based on the accompanying drawings. Furthermore, in the embodiment, a propeller fan provided in an outdoor unit of an air conditioner will be described as an example. Furthermore, the present invention is not limited to the embodiment mentioned below and can be variously modified within a scope that does not depart from the gist of the present invention.
EXAMPLE
FIG. 1A is a perspective view of a propeller fan manufactured by a manufacturing method related to the present invention, and FIG. 1B is a view taken in a direction of an arrow A of the propeller fan in FIG. 1A . A propeller fan 1 is formed, using a fiber reinforced plastic (FRP) in which a thermoplastic resin such as an acryl resin and a polystyrene resin is mixed with a continuous fiber (length of 0.2 to 0.5 mm) having a needle-like shape and a strip-like shape such as a glass fiber, a carbon fiber and talc at a predetermined ratio (for example, 10 to 40 weight %), through the injection molding by setting molding conditions such as an injection pressure and a metal mold temperature to predetermined values. Furthermore, the continuous fiber is an additive for improving strength of the propeller fan 1 , and may be oriented approximately parallel to a flow direction of the thermoplastic resin becoming to a molten state at the time of the injection molding.
As illustrated in FIG. 1A , the propeller fan 1 has a peripheral wall 5 and an end surface wall 6 . A hub 2 which is approximately cylindrical with a bottom provided with a boss 4 for inserting a driving shaft of a motor, not illustrated, driving the propeller fan 1 , and three blades 3 having the same shape integrally attached onto the peripheral wall 5 of the hub 2 are included in the central portion of the end surface wall 6 . Furthermore, since the metal mold for manufacturing the propeller fan 1 is the same as a metal mold of the related art illustrated in FIG. 4 except for a runner shape and an injection position described later, the detailed description thereof will be omitted. Furthermore, since the injection molding machine used for the injection molding of the propeller fan 1 , and the molding machining sequence using the metal mold are the same as the injection molding machine and the molding machining sequence of the related art illustrated in FIGS. 5 to 8 , the detailed descriptions thereof will be omitted.
Between a stationary mold and an intermediate metal mold, not illustrated, of the metal mold for manufacturing the propeller fan 1 , a runner 8 for supplying the molten resin injected from the injection molding machine illustrated in FIG. 1A into a cavity is formed. The runner 8 has a three-pronged branched road shape corresponding to the number (three) of the blades 3 of the propeller fan 1 , a downstream end of each branched road is further branched into three branched roads, and a leading end thereof becomes a gate 9 (a center thereof is 9 a , a leading edge 3 c side of the blade 3 is 9 b , and a trailing edge 3 d side of the blade 3 is 9 c ).
A runner portion, not illustrated, formed by the molten resin supplied to the runner 8 is integrally connected to the propeller fan 1 by each gate 9 . As illustrated in FIGS. 1A and 1B , the cutting trace with the runner portion, that is, a gate marks 7 serving as the injection positions of three locations with respect to one blade 3 remains on the end surface wall 6 of the propeller fan 1 after the molding.
As illustrated in FIG. 1B , the gate marks 7 of three locations are located at positions (on a straight line L passing through a central portion of the root portion 20 in the width direction from a rotation center of the propeller fan 1 ) of each size H from a right end (the trailing edge 3 d side) and a left end (the leading edge 3 c side) of the root portion 20 with respect to the width direction of the root portion 20 in the peripheral wall 5 of the blade 3 so that a central gate mark 7 a is placed on a circumference C around the rotation center of the propeller fan 1 , and left and right gate marks 7 b and 7 c are each placed at positions each rotated by 20° to the left side and the right side around the rotation center of the propeller fan 1 from the gate mark 7 a , and on the circumference C around the rotation center of the propeller fan 1 . Furthermore, the root portion 20 may be provided with a curve surface having a predetermined radius of curvature (for example, 3 mm) at the positive pressure surface side and/or the negative pressure surface side of the blade 3 so as to cause the molten resin to easily flow, and so as to increase strength.
Furthermore, as illustrated in FIG. 1B , since the blade 3 is configured so that an angle between the adjacent blades 3 is placed at an interval of 120° around the rotation center of the propeller fan 1 , the gate marks 7 ( 7 a , 7 b and 7 c ) of three locations corresponding to each blade 3 are also each placed at an interval of 120° as in the blade 3 . Furthermore, the respective gates 9 a , 9 b and 9 c are provided in the metal mold so as to be located at positions each corresponding to the gate marks 7 a , 7 b and 7 c.
Next, effects of the propeller fan 1 manufactured by the manufacturing method related to the present invention will be described using FIGS. 1A, 1B and 2 . As mentioned above, on the end surface wall 6 of the propeller fan 1 , three gates 9 are provided for one blade 3 . The gate 9 is a joining portion with a runner portion, not illustrated, and when performing the injection molding of the propeller fan 1 , the molten resin flows into the cavity of a metal mold, not illustrated, of the propeller fan 1 from the gate 9 .
In the manufacturing method of the propeller fan of the related art, as mentioned above using FIGS. 3 and 9 , since there is one gate for each blade, the continuous fiber contained in the molten resin in the root portion of the blade is oriented parallel to the root portion, and thus the root portion might break at a relatively low revolution number (for example, 2500 rpm) due to strength of the root portion declining.
On the contrary, in the manufacturing method of the propeller fan of the present invention, since three gates 9 are provided for each blade 3 , as illustrated in FIG. 2 , the molten resin flows toward the root portion 20 along the peripheral wall 5 (cavity corresponding thereto) from the gates 9 of the three locations in the same course as the flow of the resin indicated by reference numeral 40 .
Specifically, the molten resin that flowed in the cavity from the three gates 9 flows so as to radially spread from each gate 9 , and flows like the flows 40 ( 40 a to 40 i ) of the resin illustrated in FIG. 2 . Although the blade 3 is joined to the peripheral wall 5 of the hub 2 by the root portion 20 , the thickness from the root portion 20 to the leading end portion of the blade 3 becomes thinner toward the leading end portion of the blade 3 from the root portion 20 .
The molten resin that flowed from the gate 9 (the gate mark 7 ) and reached the root portion 20 tries to flow in a direction along the root portion 20 having a wide cross-sectional area before flowing in a direction of the blade 3 having a narrow cross-sectional area. However, since the molten resin that flowed into the cavity from the respective gates 9 a to 9 c (the gate marks 7 a to 7 c ) and reached the root portion 20 , in order to reach the root portion 20 at almost the same timing, the flows 40 a to 40 i of the resin each regulate the flow direction thereof, and thus the flows 40 a to 40 i of the resin becomes directions perpendicular to the root portion 20 .
Since the molten resin is a fiber reinforced plastic, the molten resin contains a continuous fiber 30 . However, since the orientation direction of the continuous fiber 30 is parallel to the flow of the resin, as illustrated in FIG. 2 , the continuous fiber 30 is oriented in a direction perpendicular to the width direction of the root portion 20 along the flow of the molten resin. Although there is concern that cracks may occur in the root portion 20 in a direction along the root portion 20 due to force applied to the root portion 20 when rotating the propeller fan 1 , in the present embodiment, the direction of the crack is perpendicular to the orientation direction of the continuous fiber 30 . Thus, strength of the force applied to the root portion 20 is improved, and even when rotating the propeller fan 1 at a higher revolution number (for example, 3500 rpm), the root portion 20 does not break.
Although a case of providing the three gates 9 has been described in the above-mentioned embodiment, the number of the gate may be two or greater than or equal to four. However, when describing a position of the corresponding gate mark, there is a need to disperse and place the plurality of gates on left and right sides on the boundary of the straight line L (the central portion of the root portion 20 ) of FIG. 1B . Furthermore, a case has been described where three gates 9 are dispersed and placed on the same circumference around the rotation center of the propeller fan 1 . However, if another gate is not placed on the straight line that connects one gate (the gate mark corresponding thereto) with the rotation center, as illustrated in FIG. 1B , for example, the gate mark 7 a may be placed with a gate mark 7 d located at a position close to the rotation center with respect to the gate mark 7 c , and the gate mark 7 b may be placed with a gate mark 7 e located at a position close to the rotation center with respect to the gate mark 7 d.
As mentioned above, according to the propeller fan and the manufacturing method thereof of the present invention, since a plurality of gates is set into the metal mold so as to include a plurality of injection positions in one blade, and the propeller fan is manufactured by the injection molding, the molten resin flows in a direction perpendicular to the width direction of the root portion in the root portion of the blade, and the orientation direction of the continuous fiber contained in the molten resin is also perpendicular to the width direction of the root portion. Thus, it is possible to provide a propeller fan in which strength of the root portion of the blade is improved, and durability is further improved.
REFERENCE SIGNS LIST
1 propeller fan
2 hub
3 blade
3 c leading edge
3 d trailing edge
4 boss
5 peripheral wall
6 end surface wall
7 , 7 a to 7 e gate mark
8 runner portion
8 a distribution portion
9 , 9 a to 9 c gate
20 root portion
30 continuous fiber
40 , 40 a to 40 i flow of the resin
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A propeller fan molded by injection molding using a resin material containing a continuous fiber, includes a hub having an end surface wall and a peripheral wall; and a plurality of blades on an outer periphery of the hub, the propeller fan being molded by providing a plurality of injection positions for injecting the resin material containing the continuous fiber in a part of the end surface wall corresponding to a root portion of one of the blades of the hub.
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FIELD OF THE INVENTION
The present teachings relate generally to packaging containers, and more specifically to container assemblies that includes a base and a preferably transparent folded blank for enclosing and displaying an item within the packaging
BACKGROUND OF THE INVENTION
Currently in the market, there are two approaches for transparent packaging that utilizes a pedestal with a transparent top viewing portion. One is traditionally referred to as a jewel box and includes a plexiglass top, and a rigid chip board base. The other utilizes a plastic folding carton top with and a rigid bottom, generally comprising paper board (e.g, SBS). The jewel box approach is costly and not a sustainable solution. The appearance of the plastic folding carton is not desirable as tucks, flaps, and glue lines are all visible after assembly. It would thus be desirable to provide a transparent pedestal packaging that is both inexpensive and recyclable and avoids the appearance of tucks, flaps and glue lines.
SUMMARY OF THE INVENTION
The container assemblies according to the teachings herein solve one or more of, or even all of the aforementioned needs by employing a scored piece that is locked in with two small molded side caps (which may be injection molded or vacuum formed). The scored piece may be a plastic piece and may preferably be a recyclable material which may be an amorphous polyethylene terephthalate (APET) material. The combination of the scored plastic piece and molded side caps results in a top portion for a pedestal packaging that is both robust and substantially free of any visible tucks, flaps or glue lines. Further, the piece can ship completely flat and be assembled to final shape post-shipping. Because of the way the resulting top portion is paired to the base portion (e.g. pedestal portion) in combination with the molded caps on the ends, it provides a desirable stiffness to the packaging by allowing viewing and handling while protecting the package contents.
One aspect of the teachings herein is directed to a container assembly comprising an upper portion including a scored plastic piece, wherein the scored plastic piece can be assembled to form a three-dimensional shape and one or more side caps, wherein the scored plastic piece is locked in shape with the one or more side caps. The upper portion may be substantially free of any visible tucks, flaps, or glue lines. The container assembly may further comprise a base portion, wherein an area of the base portion receives the upper portion to connect the upper portion and the base portion.
It is contemplated that any of the following, or combination thereof, may also be present within an embodiment of the present invention. In one embodiment, the scored plastic piece may include a center panel and a first side panel and a second side panel. The first and second side panels may be located on opposing sides of the center panel. The center panel may include two end flaps located on opposite ends of the center panel. The first side panel may include two end flaps located on opposite ends of the first side panel, and the second side panel may include two end flaps located on opposite ends of the second side panel. The upper portion may be formed by folding each end flap of the center panel downward and folding the end flaps of each end of the panels inward toward each other and overlapping each of the end flaps on each end. It is contemplated that the upper portion further comprises side caps having an upward panel and a base panel, the upward panel being located in a substantially parallel and overlying relationship with the end flaps of the center panel and the first side panel and second side panel.
In this or another embodiment, it is contemplated that the center panel may lie substantially parallel to the area of the base portion that receives the upper portion. The base portion may have a substantially similar footprint shape as the upper portion. It is also contemplated that the scored plastic piece comprises an amorphous polyethylene terephthalate material. The one or more side caps may be molded. The one or more side caps may be formed by injection molding or vacuum forming. The upward panel of the one or more molded side caps may include raised side edges, a raised end edge for receiving the upper portion, or both. The upward panel may further include one or more indentations for assisting in connecting or removing the side cap portions.
It is also contemplated that one or more corners of free ends of the upper portion may be rounded or sharp. The scored plastic piece may include includes regions having creases, regions having slits, regions having perforations, or a combination thereof. It is contemplated that the perforations may be located along only a portion of a crease. It is also contemplated that the upper portion may comprise two or more scored plastic pieces. The upper portion, the base portion, or both, may further comprise one or more support features, which may ensure that side panels are maintained in a generally orthogonal orientation relative to the base portion, that adjacent side panels are maintained in a generally orthogonal orientation relative to each other, or both. It is also contemplated that the upper portion, the base portion or both may further comprise a paperboard material. The upper portion, the base portion, or both may comprise an opaque material. The upper portion, the base portion, or both may comprise a translucent or transparent material. The upper portion may comprise a translucent or transparent material and the base portion may comprise an opaque material. An item may be releasably connected to the base portion. An item may be releasably connected to the base portion and may be viewed through a translucent or transparent upper portion.
The packaging described herein provides a simple, sustainable, and elegant solution for packages intended to both contain and display. Assembly of the package is simple, the materials are preferably recyclable, and the package is both sturdy and pleasing to the eye.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of an illustrative top portion of a packaging prior to assembly in accordance with the present teachings.
FIG. 2 is a perspective view of partially assembled top portion of FIG. 1 .
FIG. 3 is a perspective view showing the addition of illustrative cap portions during assembly of the top portion of FIG. 1 .
FIG. 4 is a perspective view of an assembled top portion of FIG. 1 .
FIG. 5 is a perspective view of an illustrative base portion in accordance with the present teachings.
FIG. 6 is a perspective view of a fully assembled top portion and base portion in accordance with the present teachings.
FIG. 7 is a perspective view of an illustrative cap portion in accordance with the present teachings.
DETAILED DESCRIPTION
This application claims the benefit of the filing date of U.S. Provisional Application Ser. No. 61/887,505 filed Oct. 7, 2013, the contents of this application being hereby incorporated by reference for all purposes.
The explanations and illustrations presented herein are intended to acquaint others skilled in the art with the teachings, its principles, and its practical application. Those skilled in the art may adapt and apply the teachings in its numerous forms, as may be best suited to the requirements of a particular use. Accordingly, the specific embodiments of the present teachings as set forth are not intended as being exhaustive or limiting of the teachings. The scope of the teachings should, therefore, be determined not with reference to the above description, but should instead be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled. The disclosures of all articles and references, including patent applications and publications, are incorporated by reference for all purposes. Other combinations are also possible as will be gleaned from the following claims, which are also hereby incorporated by reference into this written description.
The packaging described herein includes a base adapted for receiving an item and a top portion or cover portion for being located onto the base and over an item located on the base. The base and top portion may have similar shapes for forming the appearance of a single integrally formed package, or may be shaped differently. The top portion may be provided with a support means for maintaining the structural integrity of the top portion of the packaging. These support means may be side caps which may be formed of a more rigid material than the remainder of the top portion. The top portion may include one side cap, two side caps, three side caps or more.
The packaging or portions of the packaging may start in a substantially flat format. The flat format may include at least three distinct flat portions including the top portion and two side cap portions. Alternatively, a single integrally formed flat piece may include the top portion and side cap portions. The top portion may be assembled in a substantially rectangular format or may be formed into any three dimensional shape for receiving an item. The top portion may be formed of a polymeric material or may be formed of a paperboard-based material. The side caps may be formed separately from the top portion or may be integrally formed with the top portion. The side caps may be formed separately from one another or be formed as a single integrally formed side cap device that extends to cover one or more ends of the top portion. It is possible that the entire packaging may be formed from one integrally formed piece.
The base portion may be formed as a single flat blank that can be folded to form a three dimensional base portion. Alternatively, the base portion may be pre-formed as a three-dimensional base portion. The base portion may include a variety of connector means. The base portion may include a means for receiving and connecting with the top portion. Such means may include a channel, an edge, a divot, an opening, an extension, an adhesive or any other suitable means maintaining connection between the top portion, the side caps, and the base portion upon assembly. The base portion may also include a means for releasably attaching an item to the base portion (which may be any item offered for sale within the packaging). The means may include an opening, a platform, a trough, an adhesive, a mechanical fastener (e.g., a screw, a tie, a snap, a protrusion, a pin or any combination thereof).
The side caps may be formed with means for receiving and connecting to the top portion, the base portion, or both. Such means may include a channel, an edge, a divot, an opening, an extension, an adhesive or any other suitable means maintaining connection between the side caps and one or more of the base portion and top portion. The side caps may also be formed with means for assembling the side caps onto the top portion and/or base portion. Such means may include tabs, snaps, rivets, openings or any combination thereof.
It is preferable that one or more of the connecting means addressed herein are not visible or are minimally visible upon assembly of the packaging. One or more portions of the packaging may be transparent or translucent. The side caps may be transparent or translucent, or may alternatively be formed from opaque materials. The base portion may be opaque, or may alternatively be transparent or translucent. The top portion may be transparent or translucent. It is possible that only a portion of the top portion is transparent or translucent, while another portion of the top portion is opaque. The top portion may preferably be formed to allow prospective customers to view an item located within the packaging without having to remove the item from the packaging. The packaging may be sufficiently sturdy for holding collectable items after purchase.
As shown for example in FIG. 1 , the packaging assembly includes a top portion 10 having a center panel 12 and two side panels 14 , 16 each located on opposing sides of the center panel and adjacent with the center panel. The center panel includes two end flaps 18 , 24 located on opposite ends of the center panel. Each of the side panels 14 , 16 also include two end flaps 20 , 26 and 22 , 28 respectively.
FIG. 2 depicts the top portion during partial assembly, whereby each side panel is 14 , 16 is folded downward from the center panel 12 (side panel 14 is shown prior to downward folding). Each end flap of the center panel 18 , 24 is folded downward as well. The end flaps of the side panels 20 , 22 , 26 , 28 are folded downward prior to folding the side panels such that they fold inward toward each other (end flap 20 toward end flap 22 and end flap 26 toward end flap 28 ) once the side panels are folded downward. The assembly further results in overlap of each of the end flaps such that end flaps 18 , 20 and 22 all overlap upon assembly and 24 , 26 , and 28 all overlap during assembly.
FIG. 3 shows each cap portion 30 a , 30 b being connected to the top portion. Each cap portion includes an upward panel 32 a , 32 b and a base panel 34 a , 34 b such that upon assembly, the upward panel is substantially perpendicular to its associated base panel. Upon attachment of the cap portions, each upward panel 32 a , 32 b will be located in a substantially parallel and overlying relationship with the end flaps 18 , 20 , 22 and 24 , 26 , 28 respectively.
FIG. 4 shows the fully assembled top portion including the cap portions and their upward panels 32 a , 32 b located on each external end flap. FIG. 5 shows an exemplary base portion 36 . FIG. 5 shows the top portion 10 connected to the base portion such that the center panel 12 lies substantially parallel to the area of the base portion 36 that receives the top portion 10 .
FIG. 7 shows a more detailed view of the cap portions 30 a , 30 b . The cap portion includes an upward panel 32 and a base panel 34 . The upward panel includes raised side edges 38 a , 38 b and a raised end edge 40 for receiving the end of the top portion (not shown). The upward panel may also include one or more indentations 44 a , 44 b , 44 c for assisting in connection to and/or removal of the cap portions, such as with protrusions 42 a , 42 b , 42 c . The base panel 34 may include one or more small protrusions for maintaining the cap portions in association with the top portion.
The creases and/or scores depicted in the drawings may include perforations, or may be free of perforations. These may be located as depicted in the drawings or moved. Additional scores, creases and perforations may be may be added. Perforations may be omitted, or may be located intermittently or substantially entirely along a crease. For example, perforations may be located along only a portion of a crease (e.g., a total length of slit material being about 90% or less, about 60% or less, about 40% or less, about 20% or less, or about 10% or less).
Any of the various components of the container assembly may be formed from a single continuous sheet, or from one or more sheets. For example, any of the top portion, base portion or side caps may be formed of a first sheet that provides a structure to the component and a second sheet may be used that covers some or all of the first sheet. As such, a second sheet may provide an aesthetic appearance to the component. A component of the packaging assembly may include sufficient support features, such as side wall connection features so that one or more of the side walls are maintained in a generally orthogonal orientation relative to the base portion, so that adjacent side walls are maintained in a generally orthogonal orientation relative to each other, or both. For example the packaging may include a sufficient number of support features so that the base portion and any pair of adjacent side walls are generally mutually orthogonal.
A sheet (i.e., a blank) for a component or element of the packaging may be formed by die cutting a sheet stock material. As such, the single continuous sheet may be a die cut preform for any of the packaging assembly components. Any material suitable for folding, die cutting, or both may be employed. The sheet material may be a single layered material or may have multiple layers. For example the sheet may include a layer of a polymer, a layer of a paper, or both. A particularly preferred material is a paperboard. Any paperboard may be employed. The sheet material preferably has a thickness that is sufficiently low so that the sheet can be easily folded, the cut, or both. The thickness of the sheet material preferably is about 2 mm or less, more preferably about 1.5 mm or less, even more preferably about 1.2 mm or less, even more preferably about 1.0 mm or less and most preferably about 0.8 mm or less. The thickness of the sheet material preferably is sufficiently high so that the container can be assembled without having to fold an excessive number of layer (e.g., for forming a base). The thickness of the sheet material preferably is about 0.1 mm or more, more preferably about 0.2 mm or more, even more preferably about 0.25 mm or more, even more preferably about 0.30 mm or more, and most preferably about 0.35 mm or more. For example, the sheet material may be a paperboard characterized as about 8 point, 10 point, about 12 point, about 14 point, about 16 point, about 18 point, about 20 point, about 22 point, about 24 point, or about 26 point, about 28 point, about 30 point, or about 32 point.
The blanks for forming the packaging may include regions having creases, regions having slits, regions having perforations, or any combination thereof. Creases preferably are employed in areas that provide a structural feature, such as a connection between two adjacent side walls. Creases are also preferably employed to allow easy folding, defined folding, or both in regions that will be visible in the assembled container. Preferably, the assembled container is free of visible slits or perforations. Perforations and/or slits preferably are employed for folding in regions that are not visible in the assembled container and may not be required to provide a structure between the areas on either side of the fold.
The packaging assemblies according to the teachings herein may be configured to receive one or more items for retail packaging purposes, for displaying purposes, for storage purposes, for transportation purposes, or any combination thereof. For example the container may be configured for receiving an electronic device (such as a consumer electronic device), a cosmetic, a perfume, a bonus gift, a key chain, jewelry, a kit, an article of clothing, a houseware item, an automotive accessory, paper goods, a food item, or any combination thereof. The container assemblies according to the teachings herein may be used for a single-use packaging, or a multiple-use packaging.
Though not necessarily drawn to scale, geometries, relative proportions and dimensions shown in the drawings are also part of the teachings herein, even if not explicitly recited. However, unless otherwise stated, nothing shall limit the teachings herein to the geometries, relative proportions and dimensions shown in the drawing.
The teachings herein contemplate the structures and features depicted in the accompanying drawings. Variations to the structures and features are also contemplated within the teachings. For example, any dimensions, angles, tolerances and/or proportions shown in the drawings are part of the teachings herein. Departures from the dimensions, angles, tolerances and/or relative proportions shown in the drawings are part of the teachings herein to the extent that such variations do not materially affect the intended operation or functionality of the depicted structures and features. For example, variations in an amount of less than 50%, 30% or 10% are envisioned; variations in an amount of more than 50%, 30% or 10% are also envisioned.
Unless otherwise stated or reasonably apparent from the context of the teachings, geometries may vary from those depicted in the drawings. Sharp corners at free ends of the structures may be rounded. Rounded corners at free ends of structures may be sharp.
Unless stated otherwise, dimensions and geometries of the various structures depicted herein are not intended to be restrictive of the invention, and other dimensions or geometries are possible. Plural structural components can be provided by a single integrated structure. Alternatively, a single integrated structure might be divided into separate plural components. In addition, while a feature of the present invention may have been described in the context of only one of the illustrated embodiments, such feature may be combined with one or more other features of other embodiments, for any given application. It will also be appreciated from the above that the fabrication of the unique structures herein and the operation thereof also constitute methods in accordance with the present invention.
The preferred embodiment of the present invention has been disclosed. A person of ordinary skill in the art would realize however, that certain modifications would come within the teachings of this invention. Therefore, the following claims should be studied to determine the true scope and content of the invention.
The explanations and illustrations presented herein are intended to acquaint others skilled in the art with the invention, its principles, and its practical application. Those skilled in the art may adapt and apply the invention in its numerous forms, as may be best suited to the requirements of a particular use. Accordingly, the specific embodiments of the present invention as set forth are not intended as being exhaustive or limiting of the invention. The scope of the invention should, therefore, be determined not with reference to the above description, but should instead be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled. The disclosures of all articles and references, including patent applications and publications, are incorporated by reference for all purposes. Other combinations are also possible as will be gleaned from the following claims, which are also hereby incorporated by reference into this written description.
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A packaging assembly comprising a base or pedestal portion ( 36 ) and a top portion ( 10 ) including a plurality of foldable panels ( 12, 14, 16 ) and flaps ( 18, 20, 22, 24, 26, 28 ) and one or more rigid cap portions ( 30 a, 30 b ).
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RELATED APPLICATION
[0001] This application claims the benefit of U.S. Provisional Patent Application No. 60/825,147 filed Sep. 11, 2006, the contents of which are incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The invention, in some embodiments thereof relates to transmission of data over power lines.
BACKGROUND OF THE INVENTION
[0003] It is generally known to use power lines and power line networks to transmit data. An industry standard protocol referred to as CEBus has been established for data transmission between appliances, sensors and control devices in a household over the power network in the household. Utility companies use power lines to transmit data to control and monitoring base stations from sensors that monitor power line equipment, such as transformers and switches, and/or power line operating conditions at different locations along a power line.
[0004] Transmitters and receivers (hereinafter denoted collectively as “T/R”s) used to transmit and receive data over a low power line network (up to about 250 volts), such as a typical household network, are often electrically connected to power lines in the network via direct conductive contact with the power lines.
[0005] U.S. Pat. No. 5,933,073 to Shuey, the disclosure of which is incorporated herein by reference, describes a communication system that transmits data over power lines in a household power network in which T/Rs are connected via conductive contacts to a power line and a ground line in the network. U.S. Pat. No. 5,485,040 to Sutterlin, the disclosure of which is incorporated herein by reference, describes a communication system in which “power line communication apparatus” is electrically connected via conductive contacts to the “hot” line and neutral line of a power network of a household to transmit data over the network.
[0006] Russian Patent SU 554623, the disclosure of which is incorporated herein by reference, describes a system for generating signals on power lines of a first power line network responsive to signals received on power lines of a second power line network. The first and second power line networks are connected by a power transformer and the system routes the signals from the second power line network around the power transformer. Signals on the second power network are inductively sensed. The system is coupled to power lines in the first power line network using conductive contacts.
[0007] PCT Publication WO 98/20658, the disclosure of which is incorporated herein by reference, describes a “Non-Invasive Powerline Communication System” in which T/Rs are coupled capacitively or inductively to a power line in a power line system to transmit and sense signals. Signals are transmitted between a first and a second T/R over a same single power line to which both the transmitting and receiving T/R are coupled. To mount a T/R on a power line, the T/R is stressed mechanically to enlarge an opening in the T/R through which the power line is passed into the T/R. The publication states that it is an object of the invention that the T/R be capable of being installed inexpensively and safely without interrupting service to the customer.
[0008] Further systems for inductive and capacitive coupling of a T/R to a power line are described, for example, in PCT publication WO 92/16920, the disclosure of which is incorporated herein by reference.
[0009] U.S. Pat. No. 6,407,987 to Abraham, the disclosure of which is incorporated herein by reference, describes couplers that have capacitive circuits serially connected with an air-core transformer. One of the described couplers is a differential capacitive coupler.
[0010] Not all coupling methods suitable for low voltage wires (e.g., up to about 250 Volts) may be used for medium voltage wires, i.e., above 2000 volts, generally above 6000 volts. For example, wires carrying higher voltages generally require larger capacitors which add higher distortion levels. In addition, the distance between high voltage wires is generally larger than for low voltage wires and therefore requires a relatively long wire length between the T/R and the high voltage wires. Such long wires generally add high distortion levels (e.g., phase skew) to the transmitted signals.
[0011] UK patent application GB 2,048,622, the disclosure of which is incorporated herein by reference, describes a device for reducing the amplitude of a signal in a conductor, in order to allow detection of one wire from a group of wires, without signals from the other wires interfering in the detection. The device includes an inductive sensor for sensing signals from the wire and an inductive signal injector to apply a counter signal to the wire.
[0012] US Patent Application 2007/0076505 the disclosure of which is incorporated herein by reference describes a method of providing communications over a medium voltage power line having a plurality of segments. The aforesaid method comprises steps amplifying data signal in passing from one segment of power line to another.
[0013] U.S. Pat. Nos. 5,592,914 and 5,257,006, the disclosures of which are incorporated herein by reference, describe transmitting data signals using both hot and neutral lines and using a signal choke to reduce noise.
SUMMARY OF THE INVENTION
[0014] An aspect of some embodiments of the Invention relates to data communications over power transmission lines in which data is transmitted over a neutral line. In an exemplary embodiment of the invention, the voltage of the distribution network of which the neutral line is a part is above 300V, optionally above 1000V, optionally above 3000V, optionally above 10,000V, optionally above 20,000V, optionally above 35,000V or intermediate voltages. In an exemplary embodiment of the invention, the transmission lines are medium voltage transmission lines. In an exemplary embodiment of the invention, data is not transmitted over a hot line. Optionally, this allows for faster setting up and/or simpler and/or lower cost coupling elements. Optionally, the ground is used as a common return. Optionally or alternatively, data is transmitted using two or more neutral lines. In an exemplary embodiment of the invention, the neutral line is selectively grounded or shorted to another neutral line at low frequencies, substantially lower than data modulation frequencies. In an exemplary embodiment of the invention, selective grounding or shorting is provided by using an inductive element between the neutral line and the ground. Optionally, an induction of an existing link is enhanced by adding a ferrite core (e.g., in the form of a bead or slotted bead) which increases the induction of a grounding line so that high frequencies do not pass on the line. In an exemplary embodiment of the invention, a core is provided between a communication box and a ground line, alternatively or additionally, to a core between a neutral wire and a grounding connection.
[0015] An aspect of some embodiments of the invention relate to a method of installing a powerline communication device, in which an existing set up, for example, a powerline pole, which is grounded, is upgraded to not add noise at high frequencies to a data carrying line. In an exemplary embodiment of the invention, the upgrading comprises mounting a ferrite core (or other induction increasing element) on an existing grounding line and optionally without physically damaging or applying deforming force to the line and/or without substantially disturbing communications along the neutral line. Optionally, the core is clamped. Optionally, the core is a split core that is formed in two parts and mounted on the line and then held together (e.g., with a mounting or a clip) as a single core. Optionally, the grounding wire is wound around the core. In an exemplary embodiment of the invention, a communication box, for example, a modem, is mounted at each medium voltage pole which includes a transformer. Optionally, the grounding of the pole is modified as described herein. Optionally, signal blocking inductors and/or high induction connections are provided on neutral lines in a manner which delimits the data transmission network, for example, to a certain area.
[0016] There is provided in accordance with an exemplary embodiment of the invention, a system for transmitting data over power lines, comprising:
[0017] (a) an electric power distribution network including at least one hot line, one neutral line and at least one grounding connection between the neutral line and the ground; and
[0018] (b) a plurality of communication boxes, each box being coupled to said neutral line and each including a modem, so that at least one box can modulate data onto said neutral line and at least a second box can read modulated data off said neutral line, such that said data can be read without coupling to said hot line.
[0019] In an exemplary embodiment of the invention, the system comprises an inductance element mounted on said grounding connection and configured to prevent leakage of currents at frequencies used by said modem for said modulation.
[0020] Optionally, said element comprises an element mountable on an existing grounding connection without damage thereto.
[0021] Optionally, said grounding connection is a high inductance connection configured to prevent leakage of currents at frequencies used by said modem for said modulation.
[0022] Optionally, said element comprises a ferrite bead.
[0023] Optionally, said power distribution network comprises a low-voltage network.
[0024] Optionally, said power distribution network comprises a medium-voltage network.
[0025] Optionally, said power distribution network comprises a high-voltage network.
[0026] Optionally, said power distribution network comprises a mixed-voltage network.
[0027] Optionally, said communication boxes are on opposite sides of a step-down transformer.
[0028] Optionally, said communication boxes are each coupled to a plurality of neutral lines for transmission of data thereby.
[0029] Optionally, the system comprises at least one high inductance element configured to isolate between at least two of said neutral lines at high frequencies.
[0030] Optionally, the system comprises at least a second high inductance element configured to isolate at least one of said neutral lines and said grounding connection.
[0031] Optionally, at least one of said communication boxes is additionally coupled to a hot line for transmission of data thereby.
[0032] Optionally, said box is coupled to said neutral line by a wire connection.
[0033] Optionally, said box is coupled to said grounding connection.
[0034] Optionally, the system comprises a network of a plurality of such pairs of boxes adapted for data transmission over a region.
[0035] Optionally, said box is coupled to said neutral line by coupler.
[0036] Optionally, said box is coupled to said neutral line by a wireless connection.
[0037] Optionally, said system is underground and said grounding connection is to a physical ground.
[0038] Optionally, said system is based on a medium voltage underground system, with wire shield cables, such that transmission is based on the cable shields instead of or in addition to the neutral wire.
[0039] There is provided in accordance with an exemplary embodiment of the invention, a method of transmitting data over an electrical distribution system, comprising:
[0040] (a) modulating said data to produce a signal;
[0041] (b) injecting said signal into a neutral power line; and
[0042] (c) reading said signal off said neutral line.
[0043] Optionally, the method comprises:
[0044] (d) retrofitting an existing electrical distribution system by mounting inductance elements over a plurality of grounding connections of said neutral power line.
[0045] Optionally, said data comprises packet data.
[0046] Optionally, the method comprises coupling a communication device which performs said modulating to said distribution network without shutting down power distribution on said network and without causing a safety violation.
[0047] Optionally, the method comprises not coupling a signal into a hot line for sending of said data.
[0048] There is provided in accordance with an exemplary embodiment of the invention, a neutral line communication apparatus, comprising:
[0049] (a) a coupler adapted to be connected to a medium voltage neutral line; and
[0050] (b) a modem adapted to at least read or write data via said coupler to said medium voltage neutral lines.
[0051] Unless otherwise defined, all technical and/or scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which the invention pertains. Although methods and materials similar or equivalent to those described herein can be used in the practice or testing of embodiments of the invention, exemplary methods and/or materials are described below. In case of conflict, the patent specification, including definitions, will control. In addition, the materials, methods, and examples are illustrative only and are not intended to be necessarily limiting.
[0052] Implementation of the method and/or system of embodiments of the invention can involve performing or completing selected tasks manually, automatically, or a combination thereof. Moreover, according to actual instrumentation and equipment of embodiments of the method and/or system of the invention, several selected tasks could be implemented by hardware, by software or by firmware or by a combination thereof using an operating system.
[0053] For example, hardware for performing selected tasks according to embodiments of the invention could be implemented as a chip or a circuit. As software, selected tasks according to embodiments of the invention could be implemented as a plurality of software instructions being executed by a computer using any suitable operating system. In an exemplary embodiment of the invention, one or more tasks according to exemplary embodiments of method and/or system as described herein are performed by a data processor, such as a computing platform for executing a plurality of instructions. Optionally, the data processor includes a volatile memory for storing instructions and/or data and/or a non-volatile storage, for example, a magnetic hard-disk and/or removable media, for storing instructions and/or data. Optionally, a network connection is provided as well. A display and/or a user input device such as a keyboard or mouse are optionally provided as well.
BRIEF DESCRIPTION OF DRAWINGS
[0054] Some embodiments of the invention are herein described, by way of example only, with reference to the accompanying drawings. With specific reference now to the drawings in detail, it is stressed that the particulars shown are by way of example and for purposes of illustrative discussion of embodiments of the invention. In this regard, the description taken with the drawings makes apparent to those skilled in the art how embodiments of the invention may be practiced.
[0055] FIG. 1 is a schematic block diagram of a power line communications system using above ground and neutral lines;
[0056] FIG. 2 is a schematic block diagram of a power line communications system using cable shields connected to the neutral line; and
[0057] FIG. 3 is a schematic block diagram of a power line communications system using low and middle network neutral lines.
[0058] It will be appreciated that for simplicity and clarity of illustration, elements shown in the drawings have not necessarily been drawn to scale. For example, the dimensions of some of the elements may be exaggerated relative to other elements for clarity. Further, where considered appropriate, reference numerals may be repeated among the drawings to indicate corresponding or analogous elements throughout the serial views.
DETAILED DESCRIPTION OF THE INVENTION
[0059] The present invention, in some embodiments thereof, relates to transmitting data over power lines, including neutral power lines, using a filtering element to reduce noise on the line.
[0060] Before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not necessarily limited in its application to the details of construction and the arrangement of the components and/or methods set forth in the following description and/or illustrated in the drawings. The invention is capable of other embodiments or of being practiced or carried out in various ways.
[0061] Reference is now made to FIG. 1 which is a schematic block diagram illustration of an electricity system 100 including one of a plurality of communication devices 105 which enable transmission and/or receiving of data using neutral lines. The devices are optionally remotely disposed from each other as can be seen in FIG. 1 . Optionally, the device 105 is located on a power line pole or electricity tower or base 110 , which may support a variety of power or transmission lines, for example, one or more low voltage lines 120 , one or more medium voltage lines 118 , and a neutral line 130 , neutral line 131 , or any other variety or combination of lines. The neutral line 130 , for example, may also be connected to a ground line 180 , for example, to ground current flowing through neutral line at selected locations in an electricity system. Typically grounding is provided at power poles and/or transformer stations. Electricity system 100 may include a transformer drum 140 , which may be connected to neutral line 130 . Optionally, some of the devices provide links to outside the data network, for example to individual subscribers or to other networks (e.g., telephone, cellular, WAN). Optionally, some of the devices act as repeaters. Optionally, substantially all powerline poles with transformers in a network are configured with a communication box. Optionally selected powerline poles with transformers are configured with a communication box, so as to enable signals to be adequately transmitted and received between the various communication boxes.
[0062] Communication device 105 , optionally includes a communication box 160 , optionally in a housing (e.g., water proof, heat proof, highly durable etc.) of device 105 , which optionally includes one or more coupling devices adapted to attach to power lines and/or grounding connection. The communication box 160 may include, for example, a communication modem. The communication box 160 may have two or more exiting lines, for example, a line 150 connecting the communication box 160 to the neutral line 130 , and an additional line 185 connecting communications box 160 to ground line 180 .
[0063] According to one embodiment of the invention, at least one core, such as a ferrite core 170 , or an alternative element with similar features, is placed on grounding wire 180 between the neutral line 130 and the ground. The core 170 may be for example, a powdered, compressed and/or sintered magnetic material having high resistivity. Alternatively or additionally, other objects or materials characterizing by high resistance at high frequencies may be used. For example, core 170 conducts low frequency current (e.g., 50-60 Hz) from the neutral wire 130 to the ground wire 180 , thereby grounding this current. The core 170 simultaneously prevents high frequency current in the data transmittance range, for example, frequencies high enough to transmit data signals, from neutral wire 130 to ground wire 180 , thereby allowing the high frequency currents to travel through the neutral wire 130 along the electric system 100 with reduced noise. In some embodiments of the invention high frequency signals may be between, for example, 1-100 MHz, however other frequencies may be used. Low frequencies that may be grounded may be in the range of, for example, 0-100 Hz, however other frequencies may be used. Intermediate frequencies, for example in the kilohertz range may be grounded or used for data, depending on the particular embodiment. Optionally, core 170 prevents the ground from injecting high frequency noise at one or more selected bands of interest. Alternatively or additionally, core 170 prevents the data signal from being bled to the ground and thereby having a reduced propagation distance. Thus, the core element 170 can act as a high frequency filtering element conducting low frequency currents to the ground line 180 and preventing high frequency signals from being grounded. Optionally, the core is placed on an existing grounding wire. Alternatively, a new grounding wire with a core is provided.
[0064] Optionally or alternatively, the core is placed on a ground wire. Optionally, cores are provided both on a connection between device 105 and the grounding wire and along the grounding wire, between the device and the ground and/or between a connection of the grounding wire to a neutral wire.
[0065] Alternatively to a ferrite, other core compositions may be used, for example, ceramic elements with mixed ferromagnetic materials characterized by high electrical resistivity. In accordance with embodiments of the invention, shape, size and composition of the core 170 are substantially unlimited. Core types, composition, size, number, shape etc. may be selected in accordance to a variety of factors, including, for example, one or more of material, shape of wire, connection possibilities, frequency requirements and/or communication signal requirements. For example, in order to prevent grounding of high frequency signals, an inductor with a relative high impedance may be used, so as to prevent transfer of frequencies in the selected range.
[0066] According to an alternative embodiment, one or more devices 105 may be disposed on one or more poles or bases 110 and connected to the system 100 . Since the various devices 105 are optionally placed in close association to communication boxes 160 , data communication between one or more communication boxes may be enabled, using neutral lines as the primary or only medium for transfer of the communications signals.
[0067] In such a way a power lines communication network may be formed substantially using neutral lines to transfer data signals throughout the network. Optionally, the network covers several hundreds or thousands or more of square meters. Optionally or alternatively, the network includes 10, 20, 30, 40 or more (or intermediate numbers of) boxes interconnected. Optionally or alternatively, the distance between two devices is, for example, 10 meters, 100 meters, 300 meters or larger or intermediate distances.
[0068] Reference is now made to FIG. 2 which is a schematic block diagram illustration of a part of an underground electricity system enabling data communications to be communicated along neutral lines using the underground electricity system. As seen in FIG. 2 , a transformer box 240 , which is grounded, includes a device 205 which includes a communications box 260 . Transformer box 240 may include screw 242 , or any other suitable connection mechanism, to secure wires to the box 240 . In an exemplary configuration, medium voltage lines 218 , one phase or multi-phase (e.g., 3) low voltage lines 220 , and neutral lines 230 A and 230 B are connected to first and second windings of a step-down transformer. The neutral lines 230 A and 230 B may are connected to the ground line 280 . The medium voltage line 218 is insulated by an insulation layer 225 . The insulation layer 225 is surrounded by a shield 230 A, which functions as the neutral line (hereinafter referred to as 230 A) for the medium voltage line 218 . The shield 230 A is covered by the insulating layer 233 . Other configurations of the transformer and lines (or other number of lines) may be used as well.
[0069] The device 205 enabling transmitting or receiving data by means of the neutral lines, optionally includes a communication box 260 . The box 260 may include, for example, a communication modem. The communication box 260 may have two or more output lines, for example, the line 250 connecting the communication box 260 to the neutral line 230 A, and the line 285 connecting communications box 260 to the ground line 280 A. In an exemplary embodiment of the invention, a ferrite core 270 , or alternative element with similar features, is placed between the cable shields 230 a and the screw 242 (or other grounding connector. Optionally, the core is provided integral with the line 285 . Optionally, line 285 is wound to provide a desired inductance. Data is optionally transmitted and received through the low voltage line network, the medium voltage line network, or through both networks. Optionally, by using only neutral lines and not power lines, data can pass by a transformer which uses a common neutral line for multiple voltages. Optionally or alternatively, a communication box (not shown) is provided to pass data around the transformer.
[0070] Optionally, in this or other embodiments, at least one additional core may be added to the connection between neutral line 230 B and the ground wire or ground source.
[0071] Optionally, an underground configuration such as described may also be used if there is no transformer, or for ground level or elevated transformers.
[0072] In an exemplary embodiment of the invention, an inductance element is provided between a communication box and a grounding wire. Alternatively or additionally, the inductance element is provided between neutral lines and ground, for example, along grounding wire 280 .
[0073] According to an embodiment of the present invention, the core 270 is adapted to substantially prevent grounding of high frequency signals, for example, signals capable to transmit data through a power line network. For example, data being communicated in electricity system 200 , using communications box 260 , may be transmitted to neutral line 230 A and ground line 280 . Data represented by high frequency waves may flow through ground wire 280 , yet may be substantially filtered by core 270 , thereby preventing the current supporting the data from causing a shortage in the circuit. In this way, for example, communications box 260 may transmit data beyond transformer box 240 , using high frequency waves transmitted through neutral lines.
[0074] Core 270 may have a shape, size and composition which fits appropriately on the wires or lines being used, and which appropriately filters the current frequencies being used. Core types, composition, size, number, shape and/or other properties may be selected in accordance to a variety of factors, including, for example, one or more of material, shape of wire, connection possibilities, frequency requirements and/or communication signal requirements.
[0075] According to an alternative embodiment, one or more apparatuses 205 may be connected to one or more transformer boxes 200 . Since the various communications boxes 260 are generally placed in close association (e.g., physically close and/or connected by wired or wireless means, for example, device 205 including a coupler and box 260 including a data processing element) to communication boxes 260 , a network may be formed between the communication boxes substantially using neutral lines as the primary medium for transfer of the communications signals. In an exemplary embodiment of the invention, the wireless connection is a short range connection, such as following the Bluetooth standard, a 802.11 standard and/or a point-to-point radio or RF link.
[0076] In an exemplary embodiment of the invention, the follow method is used to enable data communications using neutral wires.
[0077] (a) A communications box may be connected to a power line pole and/or transformer box, in an over ground and/or underground electricity system.
[0078] (b) A first wire from the communications box is connected to a neutral line.
[0079] (c) A second wire from the communications box is connected to a ground line.
[0080] (d) An inductor is mounted on or around the ground wire or the ground wire is replaced by a high-inductance ground wire, or spliced to include such a wire. Optionally, by mounting a core on a wire, interruption of power (for safety reasons) is avoided.
[0081] (e) An inductor or high inductance connect is optionally used between the neutral lien and any grounding thereof.
[0082] (f) The neutral communication network is optionally delimited from the rest of the power network using inductors.
[0083] (g) Data communications are commenced from the communications box over the neutral line. Alternatively or additionally, data communications may be received by the communications box from the neutral line.
[0084] Optionally, at least one of the communication boxes is connected to both hot and neutral lines. For example, part of the network may send data over hot lines and part over neutral lines. Alternatively or additionally, two or more communication boxes may communicate data using both neutral line transmission and hot line transmission, in parallel. In an exemplary embodiment of the invention, however, data is transmitted exclusively over the neutral line (or line) without the need for interfacing with a hot line. For example, the hot line may be used for communicating other data or as a backup (e.g., it may cover only part of the data network or have a reduced bandwidth). In an exemplary embodiment of the invention, a communication box and/or device are configured to not include protection against high voltage, as such voltages are not expected on a neutral line. Optionally or alternatively, the coupler (to the neutral wire) is selected so that it is suitable for low power lines and not for hot lines.
[0085] Reference is now made to FIG. 3 which is a schematic block diagram illustration of an electrical system 300 including a system or apparatus 305 to enable transmission or communication of data using two or more neutral lines and optionally without a ground connection. As can be seen in FIG. 3 , the apparatus may include a power line pole or electricity tower or base 310 , which may support a variety of power or transmission lines, for example, low voltage phase lines and medium voltage phase lines, as well as medium voltage neutral line 331 and low voltage neutral line 330 . Neutral line 330 and neutral line 331 may be connected using grounding wire 380 , or they may use separate grounding wires. Line 380 may connect transformer 340 to neutral line 331 , may connect neutral line 331 and neutral line 330 , and/or may connect neutral line 330 to ground. System 300 may include a communications box 360 coupled to powerline pole 310 .
[0086] In an exemplary embodiment of the invention, system 300 includes a first core, such as a ferrite core 370 , or alternative element with similar features, which electrically isolates high frequencies between neutral wire 330 and the ground, for example, the core may be placed on ground wire 380 between neutral line 330 and ground. Alternatively or additionally, system 300 includes a second core which isolates neutral line 330 from line 331 , for example, a ferrite core 371 , or alternative element with similar features, which is placed on (or formed with) ground wire 380 between neutral line 330 and neutral line 331 . Cores 370 and 371 may be for example, powdered, compressed and/or sintered magnetic material having high resistivity. Other suitable objects or materials may be used to increase resistance thereby lowering current losses at high frequencies. For example, cores 370 and 371 may allow low frequency current (e.g., 50-60 Hz) to be conducted between neutral wire 330 and neutral wire 331 . Core 370 may simultaneously prevent high frequency current (e.g., Radio band) from being conducted between neutral wires 330 and 331 , thereby causing the high frequency currents flowing through neutral wires 330 and 331 to continue being conducted through electric system 300 . In this way, core elements 370 and 371 act to prevent high frequency signals from being grounded, and enable these high frequency signals to continue being transmitted through neutral lines 330 and 331 through and beyond electricity system 300 . If neutral line 331 is separately grounded, a core may be mounted on a connection to the grounding.
[0087] Devices 305 , which enable transmission or communication of data using neutral lines, may include a communications box 360 . Communications box 360 may include, for example, a communications modem. Communications box 360 may have two or more exiting lines, for example, line 350 connecting communications box 360 to neutral line 330 , and line 351 connecting communications box 360 to neutral line 331 . According to one embodiment, apparatus 305 may include at least one core 370 and 371 , or an alternative element with similar properties, which may be placed on or around ground line 380 .
[0088] According to an embodiment of the present invention, core 370 may be configured so as to substantially prevent data in the RF range transported in electricity system 300 from being grounded. For example, data being communicated in electricity system 300 , using communications box 360 , may be transmitted to neutral lines 330 and 331 . Data represented by high frequency waves may flow between neutral lines 330 and 331 , yet may be substantially filtered by core 370 , thereby preventing the current supporting the data from causing a shortage in the circuit. In this way, for example, communications box 360 may transmit data beyond electricity pole 310 , using high frequency waves transmitted through neutral lines 330 and 331 . Alternatively or additionally to sending data using two neutral lines, two communication systems, each using one of the neutral lines and a ground (or other return) may be used. The two systems may be provided in a single box. Optionally, a core is placed on one or both of the lines connecting the communication boxes to the ground lines, or between the attachment points of the communication box to the grounding wire, so that a commonly used grounding wire does not cause cross-talk between the two communication boxes.
[0089] In an exemplary embodiment of the invention, medium voltage cables may be covered by shields 230 a and 230 b, and these shields may be used to transmit data. In some embodiments data may be transmitted exclusively and/or additionally along the cable shields.
[0090] Optionally, one or more apparatuses 305 may be connected to one or more electricity poles or bases 310 . Since the various apparatuses 305 are generally placed in close association to communication boxes 360 , data communication between one or more communication boxes may be enabled, using neutral lines as the primary medium for transfer of the communications signals.
[0091] It is expected that during the life of a patent maturing from this application many relevant inductance elements will be developed and the scope of the term core is intended to include all such new technologies a priori.
[0092] As used herein the term “about” refers to ±10%.
[0093] The term “comprising” means that other acts, elements and/or ingredients can be added.
[0094] The phrase “consisting essentially of” means that the composition or method may include additional ingredients and/or steps, but only if the additional ingredients and/or steps do not materially alter the basic and novel characteristics of the claimed composition or method.
[0095] As used herein, the singular form “a”, “an” and “the” include plural references unless the context clearly dictates otherwise. For example, the term “a compound” or “at least one compound” may include a plurality of compounds, including mixtures thereof.
[0096] Throughout this application, various embodiments of this invention may be presented in a range format. It should be understood that the description in range format is merely for convenience and brevity and should not be construed as an inflexible limitation on the scope of the invention. Accordingly, the description of a range should be considered to have specifically disclosed all the possible subranges as well as individual numerical values within that range. For example, description of a range such as from 1 to 6 should be considered to have specifically disclosed subranges such as from 1 to 3, from 1 to 4, from 1 to 5, from 2 to 4, from 2 to 6, from 3 to 6 etc., as well as individual numbers within that range, for example, 1, 2, 3, 4, 5, and 6. This applies regardless of the breadth of the range.
[0097] Whenever a numerical range is indicated herein, it is meant to include any cited numeral (fractional or integral) within the indicated range. The phrases “ranging/ranges between” a first indicate number and a second indicate number and “ranging/ranges from” a first indicate number “to” a second indicate number are used herein interchangeably and are meant to include the first and second indicated numbers and all the fractional and integral numerals therebetween.
[0098] It is appreciated that certain features of the invention, which are, for clarity, described in the context of separate embodiments, may also be provided in combination in a single embodiment. Conversely, various features of the invention, which are, for brevity, described in the context of a single embodiment, may also be provided separately or in any suitable subcombination or as suitable in any other described embodiment of the invention. Certain features described in the context of various embodiments are not to be considered essential features of those embodiments, unless the embodiment is inoperative without those elements.
[0099] Although the invention has been described in conjunction with specific embodiments thereof, it is evident that many alternatives, modifications and variations will be apparent to those skilled in the art. Accordingly, it is intended to embrace all such alternatives, modifications and variations that fall within the spirit and broad scope of the appended claims.
[0100] All publications, patents and patent applications mentioned in this specification are herein incorporated in their entirety by reference into the specification, to the same extent as if each individual publication, patent or patent application was specifically and individually indicated to be incorporated herein by reference. In addition, citation or identification of any reference in this application shall not be construed as an admission that such reference is available as prior art to the present invention. To the extent that section headings are used, they should not be construed as necessarily limiting.
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A system for transmitting data over power lines between a plurality of communication boxes, wherein each box is coupled to a neutral line such that at least one box can modulate data onto the neutral line and at least a second box can read modulated data off the neutral line. Accordingly, the system enables data to be transmitted over neutral lines, without requiring coupling to hot lines.
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FIELD OF THE INVENTION
The present invention relates to an aquaculture process for nourishing fish through adding gas to liquid streams which comprises a more energy efficient way to add gas, such as oxygen or ozone, to a liquid, such as contaminated aqueous streams. Two eductors are aimed at each other and directly impinge in a closed environment at particular velocities. The subsequent impact shatters the already small bubbles into micro bubbles. By elevating the apparatus above the. discharge water level sufficient to offset the pressure loss due to the impact and discharge, high levels of gas are entrained in the discharge stream.
BACKGROUND OF THE INVENTION
In the field of aquaculture, a substantial number of aqueous streams must be treated to meet governmental laws and regulations to certify them for aquaculture, for drinking purposes, for release into the environment, or to supply sufficient oxygen, for example, for aerating ponds to grow fish. Non limiting examples of such aqueous streams include: those waste water streams emanating from municipal water supplies, streams from the petrochemical, refining and chemical; waste treatment plants, particularly lagoon systems with algae populations. Of particular interest are commercial fish ponds. When oxygen levels are too low (dissolved oxygen (DO)<5 ppm), fish are stressed, which causes them to move more rapidly, using more oxygen and requiring more food. Ideally oxygen levels of 7-10 ppm should be maintained for the economic production of healthy fish. If these levels can be sustained, production density can be raised, food requirements will be minimized, growth will accelerate, and fish will be healthier.
Experiments on wastewater aeration started in England as early as 1882. In the early experiments, air was introduced through open tubes or perforations. More recently, diffusers of a variety of types from porous ceramic plates, to slit bladders to perforated plates were tried. An alternate approach was to use mechanical means for aeration. These included paddles, turbines, venturis and air added under pressure in U-tubes.
More recently, Dickerson (5,397,480) patented a novel eductor that created micro bubbles in a pressurized tank. This invention was used to transfer high doses of ozone to oxidize recalcitrant paper making wastes. A Canadian company, Aquatex, has commercialized a product where a standard venturi discharges into a controlled pressure vessel for sufficient time to dissolve and supersaturate the water with oxygen or ozone. This combination of small-bubble-making in the venturi with further size reduction by added back pressure and then extraction of only the small bubbles creates a very fine bubble population with a mean diameter of 0.007 mm. St. Pierre (U.S. Pat. No. 5,460,731) describes this process as also having large gas bubbles separated mechanically and later micronized by gravity impingement of the liquid/small-bubble-stream on top of the previously separated large bubbles. An engineered down flow velocity extracts the small bubbles and allows the oversized bubbles to float to the top where they are broken up again by new impinging liquid. All this takes place in a pressurized large diameter column.
Air Products, Inc. has developed an impingement mixing aeration device based on a patent by Damann (U.S. Pat. No. 4,735,750). In this system, two streams of gas/liquid mixture are aimed at each other in the middle of a reactor filled with water. The impingement velocity fractures the already small bubbles into micro bubbles. Unfortunately, the impingement zone is not tightly contained. This creates some glancing blows that do the opposite and some of the once-small bubbles coalesce into large bubbles. The result is a non-ideal bi-modal distribution of bubble sizes.
MacLaren (U.S. Pat. No. 5,484524) describes a non impingement apparatus for improving productivity of a sewage treatment plant by micronizing bacteria in a venturi and recirculating through an immobilized reactor bed. In this invention, he reports significant reductions in residence time for the bacteria by increasing bubbles and bacteria surface area. Using the impingement technology of the present invention will further reduce the necessary residence time by further increasing dissolved oxygen and the appropriate surface areas.
Earlier practitioners (Baker, U.S. Pat. No. 4,085,171) describe aiming two venturis at each other, at a variety of angles and allowing the commingled sprays to strike the surface of the pond to create a bubble population with some smaller bubbles.
In the Manual of Practice FD-13, Aeration, 1988, the authors describe the important factors in efficient aeration. Some of the key points are:
1. "the rate of transfer is proportional to the area of contact between the liquid and the oxygen. This is the basic advantage of small bubbles. . . There seems to be a limit to the effectiveness of decreasing bubble size. . . Although smaller bubbles may increase oxygen transfer efficiency (OTE), the additional power required to offset the increased head loss across the diffuser may negate any potential savings.". . . page 33.
2. "Uniformity of air distribution, both across an entire aeration system and within individual diffusers, is of utmost importance if high OTE is to be obtained . . . if larger bubbles form . . . OTE will decrease . . ." page 34.
3. "In general, the standard oxygen transfer efficiency (SOTE) for diffused air systems increases with diffuser depth because of increased oxygen partial pressure and increased contact time with the bubble and mixed liquor". . . page 34.
4. "All types of diffusers occasionally become fouled with use. Diffuser fouling is generally detrimental in wastewater treatment . . .". . . page 41.
In the Handbook of Ozone Technology & Applications, 1982, Rice et al, page 163, the terminal velocity of a single bubble is plotted versus that bubble's radius. For bubbles with a radius less than 1 mm, the terminal velocity is 43 cm/(sec*mm) times radius (vel=43*r). Thus, for a given water depth, the smaller the radius of the bubble, the longer the residence (dissolving) time in the water column.
In Metcalf and Eddy's Wastewater Engineering text book, 1991, page 134, they describe "the principal elements of Operations and Maintenance (O&M) costs are labor, energy, chemicals and materials and supplies". Even though the science of aeration has been studied for over a century, there is still a need to find more efficient ways to add gas to aqueous liquids.
Most aeration systems use a mechanical means to add air to water. This involves either a high maintenance air compressor pumping air through a stagnant pond, or a mechanical device to move the water through the atmosphere and thus dissolve oxygen in the water. Still a third way is to pump water through an air/water contacting device such as a static mixer, an eductor, or a venturi. Dickerson suggests a fourth way, to pump gas through a compressor and water through a pump and mix them under pressure in a novel eductor. All these prior art strategies use considerable energy at considerable expense per cubic foot of gas transferred per kWh.
The venturi method as practiced by Aquatex has the advantage of apparent simplicity, mechanical conversion of all entrained gas into micro bubbles and the lack of fouling. Water is pumped through a venturi, held under pressure until it is dissolved and supersaturated (much as the carbonated soda industry does when water is carbonated with carbon dioxide). The disadvantage of this approach is that the gas induction capability of a venturi is inversely proportional to the back pressure. That is, as the discharge pressure increases, less total gas is added through the venturi. So the Aquatex approach has tradeoffs . . . they increased back pressure to get better dissolving via uniformly small bubbles, but added less total gas to the water column.
Dickerson tries to solve this problem by pressurizing the gas and forcing it to mix in his novel eductor. His trade off is higher energy consumption for pressurizing the gas.
It would reduce the overall cost of aeration if a method were available that could produce a narrow distribution of micro bubbles, with a high gas-to-liquid flow rate, that was impervious to fouling, that did not require a high maintenance, high cost gas compressor, yet still transferred high volumes of gas.
SUMMARY OF THE INVENTION
In accordance with the present invention, there is provided a method and apparatus for adding gas to liquid streams, preferably oxygen or ozone to aqueous streams. There is provided a process for directly impinging two or more streams containing liquid and gas in a contained environment such that substantially all the gas and liquid directly impinge one on the other at velocities such that each stream is substantially turbulent before impact, then subsequently discharging as a combined turbulent stream.
In a preferred embodiment of the present invention, gas is drawn into two opposing venturis by liquid flowing through said venturis. In one preferred embodiment the venturi discharge velocity is 4 ft/second in each venturi. The two venturi streams meet at opposite ends of a piping T and discharge through the down leg of the T through a long straight pipe into the bottom of a pond to be aerated. In a second preferred embodiment, water flow is split with the uppermost portion communicating through a venturi and the bottom most portion communicating through a connecting means such that the two flows directly impinge on the other. The combined flows discharge from the point of impingement along an extended circumference such that the discharge area of the cylinder defined by the distance separating the two communicating means and the immediate circumference of the means is equal to about half the combined cross sectional areas of the two fluid communication means. There may be one or more venturis in this embodiment.
In another preferred embodiment, the venturis and the point of impingement are elevated above the water line of the discharge pond. In still another preferred embodiment, the venturis and point of impingement are further elevated above the water line a distance equal to the underwater discharge depth plus a height substantially equal to the pressure drop caused by the force of impingement and subsequent discharge to the pond. In this embodiment, there is no back pressure on the venturis and total gas flow is maximized. In another embodiment, the discharge path does not turn any corners, thus reducing the potential for bubble coalescing.
In yet another preferred embodiment, pairs of impinging venturis are linked together in parallel.
In yet another preferred embodiment, gas/liquid from one venturi and water from a recycle means are directly impinged one at the other at substantially turbulent velocities. Part of the stream is discharged and part of the stream is recycled back to said impingement point. In this embodiment, there is only one venturi.
In yet another preferred embodiment, the impingement technology is used to accelerate the performance of sewage treatment plants or septic systems. In this embodiment, the recirculating water contains bacteria from the waste water and sludge. Not only are the bubbles micronized, so are the bacteria. This has a double effect of increasing dissolved oxygen and increasing the surface area of the microorganisms.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 is a simplified schematic of the experimental impinging apparatus in two views. Figure la is a simplified schematic of the parallel apparatus used as a control. It is also shown in two views. FIG. 2 is a chart of manufacturer's literature for Mazzei venturis, Model 1583-A showing the relationship between total gas added as a function of venturi back pressure for a variety of water inlet pressures. FIG. 3 is a sketch showing the distribution of bubbles and liquid in the venturi discharge downcomer at recommended diameter and at an oversize, lower pressure drop diameter. FIG. 4 is a sketch of a production apparatus using four pairs of venturis. FIG. 5 is a sketch of a another preferred embodiment particularly useful for adding ozone to aqueous streams. FIG. 6 is a sketch of still another preferred embodiment for adding ozone to aqueous streams. FIG. 7 is a sketch of a preferred embodiment for improving waste treatment.
DETAILED DESCRIPTION OF THE INVENTION
The instantly claimed invention can be practiced on any aqueous stream which contains an unacceptable level of impurities such as suspended matter, organics, algae, sludge, dissolved mineral matter, dioxins, microorganisms, and color bodies or merely lacks sufficient gas, such as oxygen or ozone in the liquid. In particular, commercial fish growing operations require large levels of dissolved oxygen. Fish tend to gather in areas of higher dissolved oxygen. When oxygen levels are low, fish are stressed and tend to move around more to find sufficient oxygen. More fish movement requires more feed and more total oxygen. Depending on variety of fish, when dissolved oxygen reaches a critically low level, mass suffocation can occur within 20 minutes. In warmer water ponds, it is more difficult to maintain sufficient oxygen because oxygen solubility declines as water temperature increases.
Fish farming is also a low margin business, so operating costs are important. Operating costs are a combination of energy costs to add oxygen, and the allocated costs of occasional catastrophic failure of the entire crop due to failure of the oxygen dissolving system.
Typically, air is pumped into distribution headers to form relatively coarse bubbles. The air is pumped with air compressors or blowers, both of which are relatively high maintenance, high energy devices. Very reliable water pumps are used to recirculate water. In some installations, ozone gas is added to the air stream to clean the water and control algae blooms.
Adding oxygen-in-air to water is a very well known art, and many alternate approaches are in commercial practice all over the world. In general, they all try and make small bubbles, they attempt to be non fouling and to have long MTBF's (mean time between failures). In general, the efficiency increases as bubbles get smaller. The industry uses a standardized clean water test to measure the oxygen transfer efficiency, called SOTE (standard oxygen transfer efficiency). Most handbooks report actual field efficiencies to be 40%±20% versus SOTE. In other words, there is considerable room for improvement in practiced efficiencies.
As important as efficiency is, real fish breath moles of oxygen, not efficiency. That is, a gross amount of oxygen has to be dissolved to satisfy the farmer's need. There are four key factors that affect the macro amount of oxygen transferred in a given water situation: The surface area per bubble, the total number of bubbles, the time the bubble is in contact with the water and the concentration of oxygen in the water adjacent to a bubble. These are factors that are hard to measure directly, but relative measures that demonstrate real improvements are easy to execute.
Turning now to FIG. 1 hereof, there is shown a test apparatus of the present invention wherein water from a brackish Louisiana bayou is pumped into two identical Mazzei # 1583-A venturis 3,4 at substantially identical pressures. The two venturis discharge directly at each other through a pipe T 5. The pipe T 5 discharge is angled away from the horizontal at a 45° angle to the plane of the body of water. The impinging venturis are 11 feet (D+h) above the water line and the 45° discharge means continues down to the water line until finally discharging through a piping cross at a depth of 6 feet (D).
As a result, the gas/water mixture has a down discharge velocity vector (Vd) and a horizontal discharge velocity vector (Vh). When water flows through a venturi, gas is drawn in, intimately mixed with the water and discharges as a two phase fluid with uniform, relatively large bubbles. It is well known that when gas/liquid mixtures impinge on fixed surfaces or on a second gas/liquid stream, that the uniform large bubbles from the venturi are changed into a broader distribution of bubble sizes, some micronized and some very large. St. Pierre ('731) recognized this and invented an apparatus to separate out the oversize bubbles and remicronize them under above-atmospheric pressures.
Surprisingly, it was discovered that when a gas/liquid stream directly impinges on a second stream and that the "collision" is contained in a pipe with a single, substantially equal or smaller outlet cross sectional area, that substantially all the entering bubbles are fractionated. Further, it was discovered that there are critical impingement velocities. Velocities too slow did not fracture the bubbles and velocities too fast used too much energy and thus reduced the overall efficiency of the system.
It is well known that bubbles tend to coalesce when they turn corners. It is also well known that the total amount of gas pulled through a venturi is directly proportional to the pressure at the discharge of said venturi, as shown in FIG. 2, a plot of published data for the Mazzei 1583-A venturi. FIG. 2 shows the amount of gas pulled into the venturi as a function of the pressure at the discharge of said venturi for a variety of liquid inlet pressures. It is also well known that fluids require energy (pressure drop) to flow through pipelines. What is not known is that gas/liquid mixtures separate into gas/liquid "slugs" and gas-only "gaps" when flowing down oversized lines. As shown in FIG. 3, these gaps are believed to be low pressure zones that remove gas bubbles from the liquid. The net effect is to cause coalescing in a straight downcomer pipe, and a loss of the narrow distribution, small bubble population created by the impingement method.
Referring again to FIG. 1, a novel apparatus was designed to impinge two gas/liquid streams in a contained pipe at preferred individual velocities of about 4 feet/second, then discharge the combined stream at 8 feet/second to the required depth without the fluid changing direction or allowing slugs and gaps to appear in the downcomer means. Further this novel apparatus was elevated above the water line sufficient distance (h) such that the back pressure at the impingement point was substantially equal to atmospheric pressure. That is, there was substantially zero back pressure on the venturi because the elevation (h) offset the pressure drop due to fluid flow in the discharge means.
Referring once more to FIG. 1, Pump 1 draws water from the bayou and pumps it through connecting means 2 to venturis 3 & 4. Venturis 3 & 4 directly impinge in T 5. T 5 subsequently discharges through conveying means 6 to the bayou through pipe cross 7. Liquid and micro bubbles spread out from pipe cross 7 away from the impingement point in T 5. In a series of experiments detailed in Table 1, the diameter of T 5 and conveying means 6 was changed from 1", to 11/4", to 11/2" and finally 2". The pressure from pump 1 was varied from 10 psig to 30 psig. Changing pressure changes the liquid flow slightly and the gas flow through venturis 3 & 4 substantially as shown in FIG. 2, a plot of the Manufacturer's literature comparing gas flow to venturi back pressure.
FIG. 2 demonstrates that dramatic increases in the amount of gas passing through a venturi can be enormously increased merely by reducing the back pressure. For example in a Mazzei 1583-A venturi, almost 15 times more gas is mixed with liquid @ zero back pressure versus 10 psig back pressure. For example, if the Aquatex system was operated at only 5 psig back pressure versus this invention @1.5 psig back pressure, the Aquatex system would have to operate @ 27 psig inlet pressure vs. 15 psig for the instant invention to transfer the same amount of oxygen. This small difference consumes more than 50% more energy per cubic foot of air injected into the water. The apparatus in FIG. 1 was elevated 11 feet off the waterline to reduce back pressure and save energy by requiring less inlet pressure.
The back pressure at the discharge of venturis 3 & 4 is equal to the depth of pipe cross 7 below the water line plus the pressure drop in the impingement T 5 plus the fluid friction pressure drop from traveling down conveying means 6 minus the elevation of T 5 (D+h). From the data in FIG. 2, it is advantageous to minimize the pressure drop in conveying means 6. However, if an oversize line is used, slugs and gaps appear which alters the eventual bubble size distribution in the bayou as shown in FIG. 3.
Referring now to Table 1, the experimental data, it is shown the criticality of these seemingly small details. In the experiment, bayou water (BOD=5 mg/l; TSS =30 mg/l) was pumped through the FIG. 1 apparatus at different pressures and with different diameter impingement T's 5. The time for bubbles to rise was determined by allowing the system to reach equilibrium, then shutting pump 1 off. The rising time was the time from pump shut off until bubbling ceased. Venturi back pressure was measured with a pressure gauge 8 installed on T 5. It was observed that the experimental conditions created large variations in the area over which bubbles from cross 7 were observed. These data are also recorded.
In a second experiment, apparatus described in FIG. 1 was altered as shown in FIG. 1a. Instead of the venturis impinging in a T, T 5 was replaced with two pipe elbows 9 & 10 and separate conveyance means 11&12. Pipe cross 7 was replaced with two pipe T's 13 & 14. The net effect was to simulate the apparatus in FIG. 1 with gas/liquid flows in parallel rather than by impingement. There was up to a 7-fold increase in efficiency with the two venturis in contained impingement versus the same two venturis in parallel.
TABLE 1______________________________________EXPERIMENT 1BAYOU AERATION______________________________________inletpressure back pressure bubble rise bubble(psig) (psig) (sec) coverage (ft.sup.2)______________________________________1" IMPINGEMENT10 0 8.47 415 3.5 8.47 1620 6.5 9.96 2525 9.5 10.14 2530 11.5 11.77 2511/4" IMPINGEMENTT10 0 8.73 1615 1.5 8.70 2520 2.25 9.38 2525 3.0 9.43 2530 3.75 9.91 3611/2" IMPINGEMENTT10 2.0 7.50 415 2.25 7.31 1620 3.0 8.07 1625 3.75 7.96 2530 4.0 8.12 362" IMPINGEMENTT10 0 5.59 115 1.75 7.06 920 2.0 7.38 1625 2.0 7.23 1630 2.0 7.20 2511/4" PARALLELELS10 0 5.60 115 0 6.67 120 0 6.89 425 0 6.94 430 0 6.23 911/2" PARALLELELS10 1 5.60 115 1 6.67 120 0 6.89 425 0 6.94 430 0 6.23 9Energy Consumptionwith four pairs ofventuris (8 total)______________________________________inlet Liquid flowpressure horsepower per venturi(psig) (centrifugal) (gpm)______________________________________10 1.9 15.115 2.6 18.120 3.8 20.525 5 23.030 6.9 25.3______________________________________
Chart 1 compares the total macro gas surface area efficiency with changes in impingement velocity achieved by changing the impingement T diameter. The differences were most pronounced at 15 psig, shown in Chart 1. The impact of the impingement velocity is dramatic, in fact there is a 7 fold improvement in gas surface area efficiency by impinging directly at the optimum velocity versus traditional parallel processing.
Chart 2 compares the total gas surface area created by the two venturis per horsepower in consistent units at a variety of inlet pressures. The top line compares the results for direct impingement, while the lower line compares the results for parallel configuration. It is immediately obvious that direct impingement creates more total gas surface area per kilowatt hour than with parallel flow. This is an expected result based on the prior art work with gas/liquid impingement processes. What was unexpected is that there is a clear impingement optimum at 15 psig.
The units for calculating relative gas area need explanation. The total gas flow was calculated from the manufacturer's data shown in FIG. 2 since the back pressure and the inlet pressure are known. The total gas in the water column was calculated by using the calculated total gas flow (ft 3 /sec) times the number of seconds (sec) it required for the gas to cease rising to the surface after the pump was shut off. The surface area of the individual bubbles was calculated indirectly. Since the gas/liquid mixture was discharged at 45° to the water surface, there was a substantial horizontal water velocity component. It is well known that bubbles smaller than 1.0 mm in radius have a terminal velocity equal to 43 cm/(sec*mm) times the bubble radius (mm) . . . Rice, Handbook of Ozone Technology and Applications, page 163. Although the amount of water flowing through the venturis varied somewhat with inlet pressure, the variation is nominal (Table 1). Therefore the horizontal water velocity was essentially constant throughout the experiment protocol, and the vertical buoyancy force was also constant because the discharge depth was unchanged in all experiments. Therefore, a particular bubble would be entrained horizontally only as its own radius dictated. Thus the horizontal distance the bubble travels is directionally proportional to the bubble radius. Since bubble surface area is proportional to the square of the bubble radius, the bubble surface area is proportional to the area over which bubbles percolate to the surface. To get a relative measure of the macro surface area, one multiplies the total gas flow times the time to rise times the percolation surface area. To measure the relative energy efficiency, this macro surface area term is divided by the horsepower required with typical centrifugal pumps to move the liquid at specified pressures.
Observations during the experiment verified this procedure. With relatively inefficient apparatus set-ups, large bubbles rose up close to pipe cross 7. With more efficient operation, the bubbles were hardly visible, but the water surface was elevated relative to the adjacent, gas-free water.
In a preferred embodiment based on the present invention, eight venturis (4 impinging pairs) were arranged in a square as shown in FIG. 4. (This apparatus was used to determine the energy term in the efficiency calculation. These data are shown in Table 1). The velocity at impingement was 4 ft/sec and 15 psig, the optimum operating point. The discharge legs for four pairs of venturis covered an area of almost 5,000 ft 2 in a Louisiana fish pond with striped bass. The energy consumption for this aeration was 3 hp. The results demonstrate that a simple system, using off the shelf parts and chemical industry-type water pumps are capable of aerating large fish ponds more efficiently than prior art devices.
Referring now to FIG. 4, this preferred embodiment has four pairs of impinging venturis (20 & 22, 24 & 26, 27 & 28, 30 & 32). Water is pumped from the pond through pump 33 to connecting means 34 which distributes water substantially evenly to all eight venturis. The venturi pairs impinge directly in T's 35, 36, 38 & 40 then discharge, without a pipe changing the direction of the gas/liquid stream, through conveying means 42, 44, 46, & 48. The apparatus is elevated at height h sufficiently to make the pressure at 49 substantially zero gauge.
Those skilled in the art will recognize that many variations of this invention are possible. For example, in place of venturis, any other gas/liquid mixer is possible prior to impingement. Non limiting examples are mixing gas and liquid in a static or vortex shedding mixer then impinging.
As shown in FIG. 5, another preferred embodiment uses a single venturi and a second water stream, with or without added gas, as the impinging fluids. This strategy also micronizes the bubbles and is particularly useful for dissolving high doses of ozone. As shown in FIG. 5, water is recirculated through pump 50 via means 52 to venturi 56 hence to impingement T 58 as well as through means 60 also to T 58 to discharge from T 58 into vessel 62 as fluid containing substantially micro bubbles only. As those skilled in the art will realize, the method shown in FIG. 5 builds up a large, constant concentration of ozone depending on the ratio of fluid in means (52+60) divided by the fluid exiting in means 62. In practice, because there are substantially no oversized bubbles reaching the inlet of the pump means, normal centrifugal pumps can pump fluid with gas/liquid ratios (v/v) of almost 0.5 to 1 without cavitation. (Those skilled in the art will recognize that the pump 50 outlet pressure is substantially reduced versus published pump curves for pure water because the apparent fluid is a significantly lower density than water alone.)
Those skilled in the art will also recognize that a pipe T is only one means to contain the impingement process and to release the gas/liquid mixtures under control at turbulent velocities. The T technique is shown merely as an illustration. Another preferred embodiment of this novel impingement art is shown in FIG. 6. In FIG. 6, water is pumped from containment means 70 via connecting means 72 by pump 74. Pressurized water from pump 74 traverses through connecting means 76 to venturi 78 then to connecting means 80 and connecting means 82 to impingement area 84 at preferred velocities. Impingement area 84 connects connecting means 82 and 80 which are substantially directly aimed one at the other. The distance h, separating connecting means 82 and 80, each with diameter D, is such that the discharge cylinder (IID 2 h/4) is substantially equal to the cross sectional area of connecting means 82 (or 80) alone. Substantially flat platforms 88 and 89 are attached to connecting means 80 and 82, respectively and act as stationary platforms to direct impinged flow substantially uniformly and radially away from impingement zone 84. This embodiment is particularly effective at uniformly distributing micro-bubble-containing fluid away from the impingement point. For example in a circular column of fluid, this embodiment distributes bubbles substantially equally across the diameter of a round tank.
FIG. 7 is a preferred embodiment of an improved wastewater treatment system that improves the reduction of BOD and reduces the level of nitrogen using the instant impingement technology. Treatment tank 89 receives raw sewage from connecting means 90 which discharges into anaerobic tank 91. Partially treated fluid transfers from anaerobic treatment tank 91 via means 94 into anoxic tank 96. Denitrification takes place in anoxic tank 96. Denitrified fluid 100 exits denitrifying tank 96 via connecting means 98 to aeration tank 97. Aerated water is recirculated through pump means 104 via connecting means 110 into impinging apparatus 112, previously described. Water with micronized gas and micronized bacteria discharge back into aeration tank 97 through connecting means 114. The gas creates an upwelling of gassy fluid that increases the elevation at surface 116. The increased elevation recycles a small portion of water back to anoxic tank 96 via connecting means 118. This partially oxidized fluid provides the small amount of oxygen for denitrification in anoxic tank 96.
Meanwhile gassy fluid flows over immobilized reactor medium 118, where the BOD is reduced. Treated fluid exits into clarifier 120 via connecting means 122. Sludge 124 settles out in a conventional way and clarified water 126 discharges through exit means 130 to discharge. What is unexpected is the ability to incorporate denitrification into a septic system by using impingement technology to cause nitrification to occur in tank 96. Flows are shown by directional arrows.
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An aquaculture process for dissolving gas in liquid by impinging two or more streams substantially and directly one to the other wherein the two streams enter an impingement zone from conveying means of substantially equal shape with a velocity greater than 2 ft/sec, wherein at least one of the streams is a gas/liquid mixture and at least one of the streams passes through a venturi prior to impingement, the impingement of the two streams taking place above a water line of an environment being discharged into so as to offset the pressure of the fluid discharging from the process, the impingement of the two streams further taking place in a contained environment such that the fluid dynamics of each stream just prior to and after the point of impingement is substantially turbulent, whereby after impingement, the streams are discharged at velocities that have substantially turbulent fluid dynamics with the discharge from the impingement zone not changing direction before discharge to the surrounding environment, the gas/liquid being partially recirculated back to the impingement zone with a recirculation ratio that is sufficiently large so as to maintain the gas concentration in the liquid substantially constant.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to the separation of entrained solids from industrial waste water, and particularly to an apparatus which operates on the principle of a centrifuge, i.e., the use of centrifugal force to separate materials of different density, accompanied by means for segregating a high percentage of the solid material from the liquid phase in which they were previously entrained.
2. Description of the Prior Art
The prior art relating to the subject matter of this invention is believed found in Class 210, sub-classes 76, 78, 82, 256, 408, 297, 360, 390, 394 and 396. A search conducted in the class and classes noted has revealed the existence of the following U.S. Pat. Nos.: 790,081; 978,238; 2,113,321; 1,262,146; 2,657,803; and 3,797,662.
The concept of utilizing centrifugal force to effect the separation of materials having different densities has long been known and has been used in many different fields, including the medical field where many different types of equipment are utilized which operate on the principle that centrifugal force properly applied in a suitable apparatus will effect a separation of materials having different densities or different specific gravities. Thus, blood plasma is separated from whole blood in this manner. In the dairy industry, centrifugal force has been used as the basic principle for separating high density cream from raw milk. There is even available for use in the kitchen a spin dryer which operates similar to the spin cycle of an automatic washing machine in which a rapidly rotating drum causes centrifugal force to drive moisture from lettuce or other leafy vegetables contained in the rapidly rotating basket. Accordingly, no claim is made to the concept of utilizing centrifugal force to effect a separation of materials having different specific gravities or densities. Rather, what is presented herewith and what is sought to be protected by letters patent of the United States constitutes a novel structure which in tests appears to be highly efficient for separating entrained solids from industrial waste water.
In the food processing industry, such as canneries and packing plants, the discharge of waste water into the sanitary sewer system in most cities is monitored by the taxing authorities, and a tax is imposed in proportion to the number of gallons of water discharged into the sanitary sewer system, regardless of whether that waste water contains solids. In addition to the charge imposed for "clean" waste water, an additional charge is imposed that is proportional to the "solids" that are entrained in the stream of waste water. Obviously, it is much more difficult for the sanitary sewer system to handle waste water that carries a high proportion of solids.
The determination of how much to charge for the discharge of waste water, whether it be "clean" or loaded with "solids" is determined by periodic sampling of the waste water stream just prior to its discharge into the sanitary sewer system. From such samples, the volume of water and the volume of "solids" entrained therein are computed. It is not unusual for a food processing cannery or a packing plant to be charged a flat fee of say $35,000.00 per year for the hook-up to the sanitary sewer system, and to be charged an additional $35.000.00 per year computed from the volume of water and the volume of waste "solids" entrained in such water discharged into the sanitary sewer system. Thus, a burden of $70,000.00 per year is imposed on the food processing plant, which must of course be passed on to the ultimate consumer in the form of higher prices for the commodity being processed or packed. Accordingly, it is one of the important objects of the present invention to provide an apparatus that effectively separates from 75% to 95% of the entrained "solids" from the stream of waste water, thus providing a basis for reducing the amount of service charge that is imposed on the facility, with the result that such saving can be passed on to the ultimate consumer in the form of lower prices.
In most canneries and packing plants, a preliminary separation is effected through appropriate screens or sieves through which waste water is passed in an effort to collect as much of the larger particles of "solids" as is possible to prevent such "solids" from entering into the sanitary sewer system. It is not intended that the apparatus forming the subject matter of this invention replace such preliminary screening methods or devices. Rather, it is intended that the apparatus forming the subject matter of this invention be installed downstream from any such devices, and that it be effective in separating and collecting the types of solids that are entrained in the waste water stream that would require too fine a screen for separation purposes, thus imposing a back pressure on the waste water stream that cannot be accommodated, or which would clog the screen, requiring periodic shut-down of the plant to effect cleaning of such screens. Accordingly, another object of the present invention is the provision of a waste water centrifuge apparatus that may be operated on a continuous basis, which may have all of the waste water stream diverted through the centrifuge apparatus to effect a high percentage of separation of entrained solids from such waste water, or which may be incorporated in series with other like centrifuge apparatuses to minimize the entrained solids, or connected in parallel with similar centrifuge apparatuses to increase the volumetric capacity that can be handled at any given time.
Another object of the invention is the provision of a centrifuge separating apparatus for industrial waste waters that may be operated by either an internal combustion engine or an electric motor.
A still further object of the invention is the provision of a centrifuge apparatus for separating solids from industrial waste water which incorporates inner and outer housings that may be rotated at different speeds so as to control the efficiency of extraction of solids from the waste water stream.
A still further object of the invention is the provision of a centrifuge apparatus for separating solids from industrial waste water and which incorporates inner and outer housings operating at the same rotational speed, and a "solids" pickup device within the outer housing that rotates at a controllably different speed.
Still another object of the invention is the provision of a centrifuge apparatus for industrial waste water that converts a stream of industrial waste water from a high velocity stream at the input end of the apparatus to a relatively lower velocity stream at the output end thereof.
Still another object of the invention is the provision of a centrifuge apparatus for separating solids from industrial waste water in which two conically configured coaxially arranged internal and external shells are provided, including baffles extending therebetween and defining a high velocity zone associated with the input end of the industrial waste water and a low velocity or "quiet" zone associated with the separation of solids from the stream of waste water, and means within the low velocity or quiet zone for extracting separated solids from inside the housing and depositing such solids outside thereof.
The invention possesses other objects and features of advantage, some of which, with the foregoing, will be apparent from the following description and the drawings. It is to be understood however, that the invention is not limited to the embodiments illustrated and described, since it may be embodied in various forms within the scope of the appended claims.
SUMMARY OF THE INVENTION
In terms of broad inclusion, the centrifuge apparatus of the invention is particularly useful for separating entrained solids from a stream of industrial waste water such as is produced in canned food processing plants such as canneries, fresh food packing plants, and frozen food processing plants. In one aspect, the invention comprises coaxially arranged rotatable inner and outer housings adapted to rotate at controlled and different rotational speeds, with the inlet water admitted to one end of the housing, means within the housing intermediate the ends thereof for collecting solids in a solids-collection zone and means associated with the collection means for picking up and transporting the collected solids out of the housing, while the treated waste water is discharged from the opposite end of the housing.
In another aspect of the invention, inner and outer housings are provided that rotate at a similar rotational speed, with industrial waste water having entrained solids being admitted to one end of the housing in what may be categorized a high velocity zone, the waste water progressing through the housing between inner and outer shells that increase in diameter downstream so as to increase the volumetric capacity of the housing and thereby reduce the velocity of the waste water with maximum velocity reduction occurring at a separation zone which may be categorized a "quiet" zone within the housing, and means within the separation zone for picking up and transporting the separated solids from the interior of the housing to the outside thereof. Means are also provided for controlling the speed of rotation of either the inner or outer or both of the housings and controlling the speed of rotation of the pick-up device.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevational view of the apparatus shown mounted for rotation about a horizontal axis.
FIG. 2 is a plan view of the apparatus shown mounted for rotation about a horizontal axis and with parts of the structure broken away to reveal underlying structure.
FIG. 3 is a vertical cross-sectional view taken in the plane indicated by the line 3--3 in FIG. 2.
FIG. 4 is a horizontal sectional view of a second embodiment of the invention, shown mounted for rotation about a horizontal axis.
FIG. 5 is a fragmentary sectional view taken in the plane indicated by the line 5--5 in FIG. 3.
FIG. 6 is a fragmentary sectional view showing another embodiment for extracting solids from the apparatus.
DESCRIPTION OF THE PREFERRED EMBODIMENT
In terms of greater detail, the centrifuge apparatus for separating solids from industrial waste water and forming the subject matter of this invention comprises, in the embodiment illustrated in FIGS. 1 and 2, a two-part outer housing assembly designated generally by the numeral 2, and including an input shell designated generally by the numeral 3, and an output shell designated generally by the numeral 4, the input shell 3 being hollow and configured in the form of a truncated cone arranged symmetrical about a longitudinal axis designated generally by the numeral 7, which in FIGS. 1 and 2 is illustrated as being in a horizontal attitude. The truncated shells 3 and 4 possess hollow interiors, and each is provided with a radially outwardly extending flange designated as 8 for the truncated shell 3, and designated as 9 for the truncated shell 4. The interior of the inlet shell 3 is connected by an inlet passageway 12, while the shell 4 is connected by an outlet passageway 13.
The truncated conical shell 3 includes conical side wall 14, and end wall 16 centrally apertured to provide an opening 17 communicating with the interior of the truncated conical shell, the opening 17 communicating with the interior of a conduit 18 that connects with the inlet passageway 12.
In like manner, the truncated conical shell 4 includes a conical wall 19 converging toward end wall 21 having a central aperture 22 communicating with the interior of a conduit 23 that connects with the outlet passageway 13. The shell 3 is provided with a plurality of baffles 24 that are plate-like in their configuration and which are attached by their edges to the inner periphery 26 of the shell, and each of which includes an extension 27 fixed by its edge to the inner peripheral surface 28 of the end wall 16.
In like manner, the truncated conical shell 4 is provided interiorly with a plurality of baffles 29 similarly secured to the inner peripheral surface 31 of the shell, with each of the baffles extending in a portion 32 that is similarly secured, as by welding for instance, to the inner peripheral surface 33 of the end wall 21. As illustrated in FIG. 2, the inner edges of the baffles 24, 27, and 29, 32 cooperate to define a space within the assembled shells 3 and 4 that is generally cylindrical in its configuration. As also illustrated in FIG. 2, the base flanges 8 and 9 of the shells 3 and 4 sealingly abut a seal member 34 disposed therebetween which is held in a water-tight fashion by appropriate bolts 36 extending through the base flanges 8 and 9 and the sealant material 34 in the manner illustrated in FIGS. 1 and 2 in sufficient numbers to ensure a water tight union between the two base flanges 8 and 9.
From this construction it will be seen that the side walls 14 and 19 of the shells 3 and 4, respectively, are significantly reinforced by the radially inwardly projecting baffles 24 and 29, respectively, while the end plates 16 and 21 are also significantly reinforced by the axially extending flanges or baffles 27 and 32, respectively. To further reinforce the union between end plates 16 and 21 and the associated conduits 18 and 23, respectively, gusset plates 37 and 38 are appropriately welded between the end plates and the associated conduits in the manner illustrated.
Collection means are provided within the housing 2 in a zone intermediate the ends thereof and constitutes an annular chamber 39 defined by the root sections of the base flanges 8 and 9 and the inner periphery of the seal member 34. Thus, the chamber 39 forms the outermost extremity of the interior surface of the hollow housing 2 and forms the zone or chamber into which solids separated from the industrial waste water will collect, as will hereinafter be explained.
To rotatably support the housing assembly 2, there is provided for rotation about a horizontal axis an elongated hollow shaft 41 having an interior bore 42 extending the entire length of the shaft 41 and having positioned in the bore 42 a splitter plate 43, which is positioned with its edge lying in a median plane centrally disposed between the base flanges 8 and 9 and generally in the plane indicated by the line 3--3 in FIG. 2. Suitably welded or otherwise secured to the shaft 41 in the same plane containing the splitter plate, and communicating with the interior bore 42 diametrically opposite from the splitter plate 43, is a pick-up tube 119 that extends radially outwardly and circumferentially from the shaft 41 and which lies disposed between the opposed edges of the baffle plates 24 and 29 as shown.
The pick-up tube 119 preferably is circular in its cross-section and is provided at its extreme outer end with a chisel point 121, the outer extreme end of which rides very closely to the inner periphery 47 of the seal 34 within the collection chamber 39. Additionally, the pick-up tube 119 is preferably arcuate in its configuration, turning in the direction in which it is to be rotated, so that upon rotation, the open chisel point 121 of the pick-up tube rides in the collection zone or chamber 39 and scoops up whatever solids have collected there, the ram-jet effect of rotation of the pick-up tube 119 in relation to the outer housing assembly 2, causing the solids that have collected in the chamber 39 to be transported through the collection tube 119 and to be deposited in the interior bore of the shaft 41.
It is at this point that the splitter plate 43 comes into play, splitting the stream of high content solid and liquidous material into two different streams, one passing to the left and exiting through the central bore 42 of the shaft 41, while another stream passes to the right and exits through the central bore 42' of the shaft 41. Thus, the placement of the splitter increases the volumetric capacity that the apparatus can handle by providing twice the cross-sectional area through which solids may flow.
As illustrated in FIGS. 1 and 2, the outer housing assembly 2 is journaled on the shaft 41 by means of appropriate bearings 48 and 49 disposed between the outer periphery of the shaft 41 and the inner periphery of the conduit portions 18 and 23 at opposite ends of the assembled shell structure or housing 2. It should be noted that the conduit portions 18 and 23 rotate with the outer housing 2 while the inlet passageways 12 and 13 are stationary yet have their interior bores communicating with the interior passageways of the conduits 18 and 23 so as to admit industrial waste water into the interior of the housing tube. To accommodate such relative rotation between the fixed inlet and outlet passageways 12 and 13 and the conduits 18 and 23, there is provided adequate slip joints 51 and 52 between these parts so that one may rotate while the other remains stationary while functioning to seal the union therebetween so as to prevent the leakage of industrial waste water through this slip joint. Conventional slip joints of this type are readily available commercially and the specific structure thereof will not be described in detail in the interest of brevity.
Since all of the industrial waste water that is admitted to the housing tube must pass through the inlet passageway 12 and thus through the bearing assembly 48, it is noted that the bearing assembly 48 is a spider-type bearing assembly that provides considerable space or openings between the inner and outer races while providing a rigid attachment therebetween so that water may flow easily through the spaces between the inner and outer races. However, since any such structure causes an impediment to the passage of water, there is provided on the interior surface of the rotating conduit portion 18, a plurality of impeller blades 53 that rotate with the conduit 18 and which serve to impel the industrial waste water admitted to the housing in the proper direction, i.e., the impeller blades 53 impose a certain amount of pressure on the water to force it through the spider bearing assembly 48.
Since the baffle assembly 24, 27, 29 and 32 define within their inner edges a generally cylindrical configuration within the outer housing 2, and since it is not in the best interest of the efficient operation of the apparatus that this entire volume be filled with industrial waste water, there is provided within the confines of the outer housing, an inner housing or shell designated generally by the numeral 54 and including a cylindrical wall 56 that is symmetrical about the longitudinal axis of the shaft 41 and proportioned so that the cylindrical surface 56 lies spaced a short distance, say approximately one inch, from the inner edges of the baffle plates 24 and 29. At each end, the shell 54 is provided with end plates 57 and 58, the end plate 57 being spaced a short distance from the baffles 27, while the end plate 58 is spaced a short distance from the baffles 32.
The drum 54 is fixed for rotation on the shaft 41 by collars 59 and 59' that are appropriately secured to the shaft 41 by set screws. Additionally, the collars 59 and 59' provide seal means 61 for preventing the entrance of water into the hollow housing or shell 54. Additionally, it should be noted that the pick-up tube 119 passes through the interior of the hollow shell 54 and passes through an appropriate aperture 62 in the cylindrical wall 56. The union of the pick-up tube 119 and the cylindrical wall 56 is sealed to prevent water from passing into the interior of the hollow shell 54.
It will thus be seen that the interior of the assembled housing 2 is converted by the baffle assembly and the inner shell or housing 54 into a generally peripheral passageway that forces the industrial waste water in the interior of the housing to be initially guided toward the outer periphery of the housing. This tendency of the water to flow outwardly toward the outer periphery is enhanced by rotation of the outer housing and by the inner housing and such rotation is effected as indicated above either by an internal combustion engine appropriately connected to the outer housing and to the shaft 41, or by an electric motor so connected. For this purpose, a two-stage pulley assembly is fixedly mounted on the rotatable conduit portion 18, the main drive pulley 63 being driven by a belt 64 from an appropriately geared internal combustion engine or electric motor (not shown) and effective to drive the pulley 66 associated therewith which, through a belt 67, drives a pulley 68 mounted on a mandrel 69 which is in turn journaled on appropriate bearings 71 and 72.
Also mounted on the mandrel 69 is a pulley 73 associated with a variable drive mechanism 74 that controls the rotational speed of the belt 76 and the drive pulley 77 to which it is connected and which is fixedly mounted on the shaft 41 to effect rotation thereof. The variable drive assembly 73-74 effects a variable rotational speed by increasing or decreasing the effective diameter of the drive pulley 73. These types of devices are commercially available and are thereof not explained in detail herein in the interest of brevity in this description.
Obviously, the entire assembly is supported on the shaft 41 through appropriate bearings 78 and 79 mounted on any type of suitable support which is preferably some type of concrete pedestal appropriately arranged adjacent opposite ends of the shaft 41 so as to underlie the bearings 78 and 79.
Thus, in the embodiment illustrated in FIGS. 1 and 2, industrial waste water laden with solids is admitted through the passageway 12, encounters the impellers 53 and is impelled under pressure through the spider bearing assembly 48 and into the interior of the housing assembly 2, where it spreads radially outwardly, is caught and channelled by the baffles 27, thus being directed radially outwardly toward the outer periphery of the inner shell 54 where the waste water continues to flow between the baffles 24 toward the collection channel 39.
Since the outer housing 2 is rotating, the heavier particles of greater density are forced radially outwardly against the inner surface 26 of the shell 3 and migrate longitudinally toward the collection chamber 39 where, because of the relative velocities of the outer housing and the scoop end 46 of the pick-up tube 119, such particles or "solids" are picked up by the pick-up tube 119 and transported therethrough and through the bores 42 and 42' of the shaft 41. At each opposite end of the shaft 41 the solid materials are collected in a manner which is not shown, but which can be a gondola truck, for instance, which is arranged to permit whatever residual water remains in the solids to drain off and permits the solid material to collect in the gondola car for transport to an appropriate dumping area. In some instances, depending upon what the content of the solids is, such solid waste material may be used for fertilizer either by dumping it directly on the land, or by processing it to some further extent and mixing it with other ingredients.
In the embodiment of the invention illustrated in FIG. 4, the same principle of centrifugal force is utilized to effect a separation of the higher density materials from lower density materials and from the water in which such higher density materials are entrained. Structurally, the embodiment of the invention illustrated in FIG. 4, comprises a housing assembly designated generally by the numeral 81, and is generally symmetrical about a longitudinal axis 82, and is formed from a conical shell 83, truncated in its configuration to provide a base flange 84 and an apex end portion 86 that is connected integrally with an auxiliary truncated conical shell 87, the apex end 88 of which is connected to an inlet conduit 89 the interior passageway 91 of which is connected with the interior 92 of the truncated conical shell 87, which interior is in turn connected with the interior of the truncated conical shell 83.
Since it is undesirable that the entire volume of the interior of the truncated conical shell 83 be filled with industrial waste water laden with entrained solids, and since it is more efficient that such industrial waste water be channelled near the outer periphery of the truncated conical shell 83, there is provided on the interior of such truncated conical shell 83, an inner housing or shell 93 also having a truncated conical outer wall 94 spaced radially inwardly from the conical shell 83 and provided with end walls 96 and 97 as shown. In this embodiment, the outer housing 81, and specifically the truncated conical shell portion 83 thereof, is mechanically interconnected with the inner housing 93, and specifically the truncated conical shell wall 94, by longitudinally extending baffle plates 98 that are welded or otherwise secured along their outer edges to the inner peripheral surface 99 of the truncated conical shell wall 83, and welded or secured in like manner to the outer surface 101 of the truncated conical shell 94 so that the two shells are integrally connected so that when one revolves the other revolves with it. The baffle plates 98 disposed between the two shells are conveniently at least six in number, however an additional number or fewer number might be provided.
The base flange 84 of the housing assembly 81 is sealingly connected on the discharge side of the housing to a shell structure 102 having a base flange 103 connected by appropriate bolts 104 and an annular seal member 106 to the base flange 84. The shell housing 102 is provided with a sharply conical wall portion 107 that merges with a flat wall portion 108 which in turn merges with an outlet chamber or passageway 109 symmetrically disposed about the longitudinal axis 82 and which provides an outlet passageway 112 to discharge industrial waste water from which the solid entrained matter has been removed.
As with the embodiment illustrated in FIGS. 1 and 2, the inner peripheral surface 113 of the seal ring 106 is proportioned to define an annular chamber 114 between the base flanges 84 and 103 as illustrated, to constitute a collection means between the two conical shells 81 and 102 for the collection of entrained solids from the industrial waste water stream passing therethrough. As with the embodiment illustrated in FIGS. 1 and 2, note that the inlet passageway 91 feeds into a relatively larger volume within the interior 92 of shell 87, which in turn feeds into the openings defined between the baffles 98 at the apex end of the outer shell 83 and the apex end of the inner housing shell 94. It should be noted that the cross sectional area of these openings increase progressively as the diameter of the conical shell increases, thus increasing the volumetric capacity of the longitudinal passages defined by the baffle 98. Thus, as the volumetric capacity increases, the longitudinal velocity of the industrial waste water passing the housing diminishes while the rotational velocity increases because of the larger diameter. The suspended solid matter carried by the stream of industrial waste water is thus subjected to high centrifugal forces that tend to effect collection of such solid materials adjacent the inner peripheral surface 99 of the outer housing. At the same time, the force of the water passing therethrough causes such material to migrate longitudinally and ultimately be deposited in the collection chamber 114.
To effect rotation of the housing assembly 81, including the shell 102, the entire housing assembly is mounted on a central shaft 116, with the inner housing assembly 93, through the end walls 96 and 97, being rotatably mounted on the shaft 106 through appropriate seal and thrust bearing assemblies 117 and 118 arranged adjacent opposite ends of the inner housing assembly. Thus, the housing assembly, including the outer housing 81 and the inner housing 93 which is connected to it by virtue of the interconnecting baffles 98, may be rotated at one speed in a manner previously described, while the shaft 116 is rotated at a different rotational speed or not at all as might be selected by the operator.
To effectively pick up the solid material that is deposited in the collection chamber 114, the shaft 116 at its end adjacent the discharge end shell 102, is provided with a radially outwardly projecting pick-up tube 119 the outer end of which is provided with a chisel point 121 adapted to plow through the solid material gathered in the collection chamber 114 and through the ram-jet effect thus produced, cause such solid material, which of course has a small amount of water mixed therewith, to be transported through the pick-up tube 119, from which it is deposited through an appropriate opening 122 into the interior bore 123 of the shaft 116. From the bore 123, the solid waste material is discharged into an appropriate catch basin or collected in some other manner (not shown) for disposition in whatever way may be economically feasible.
Referring to FIGS. 3 and 5, it will be seen that the pick-up tube 119 in the embodiment of FIG. 4, is provided with an arcuate configuration so that the chisel point 121 of the pick-up tube points in the direction in which the tube rotates with the shaft 116. Additionally, because high centrifugal forces might tend to straighten the tube 119, thus disrupting the clearance that must exist between the chisel point 121 of the pick-up tube and the inner peripheral surface 113 of the collection chamber 114, there is provided a radially extending brace 124 connecting the outermost end of the pick-up tube with the shaft 116, thus functioning to withstand any centrifugal force stresses that might be imposed on the pick-up tube.
Additionally, it has been found that high centrifugal force tends to pack the solids entrained within the industrial waste water stream into the chamber 114. It has been found that occassionally, such solid materials may be packed in the chamber with such compactness that it is difficult for the ram-jet effect of rotation of the pick-up tube to pick up such compacted material. Accordingly, as illustrated in FIGS. 3 and 5, there is provided in advance of the chisel point 121 of the pick-up tube, a generally tubular assembly 126 having a chisel point 127 displaced 180° from the chisel point 121 of the pick-up tube, and being suspended on a brace or gusset 128 as shown.
Also as shown, the chisel assembly 126-128 is positioned ahead of the pick-up tube chisel point 121 to provide a small space 129 therebetween to facilitate mixture of the solid material with an appropriate amount of water in the collection chamber 114 to enhance flow of such solid material through the pick-up tube and through the interior of the shaft 116. Preferably, the plow-like chisel point 126-128 is somewhat larger than the chisel point 121 and is proportioned and configured to literally plow through the compacted material in the collection chamber 114, loosen it, cause it to mix with an appropriate amount of water, so that it may be picked up by the following chisel point 121. Additionally, it has been found that a baffle plate 131 may be positioned above the tubular plow-like assembly 126 so as to confine in the collection chamber the solid material that is plowed up until it is picked up by the following chisel point 121 on the pick-up tube 119.
While this construction of the pick-up tube 119 has been described in connection with FIG. 4, it is obvious that this same configuration of pick-up tube may be used in the embodiment of the apparatus illustrated in FIGS. 1 and 2.
In the embodiment of FIGS. 1 and 2, the pick-up tube 44 has been described as associated with a splitter 43 which functions to split the stream of solid material transported through the pick-up tube 119 and into the interior bores 42 and 41" so as to cause the solid material to flow in opposite directions out of the central shaft 41. Where entrained solids constitute a high proportion of the stream of industrial waste water, it may be desirable to provide two pick-up tubes positioned in diametrically opposed relationship as indicated in broken lines in FIG. 3. In such an assembly, in order that the discharge of the solid waste materials from the pick-up tube 119 into the central bore 123 of the discharge shaft not oppose the discharge from the opposite pick-up tube, the arrangement illustrated in FIG. 6 may be utilized where one pick-up tube 119 discharges into the interior bore 123 of the central shaft 116 in the manner previously discussed, while the second pick-up tube 119' also discharges into the interior of the shaft 116, with the discharges being offset and the interior bore 123 being divided to provide a second interior bore 123' that is separated from the interior bore 123 by a baffle plate 124 positioned in the interior bore as illustrated. In this way, in order to handle particularly heavy proportions of solid-to-liquidous material, the discharge paths of the two pick-up tubes do not work against each other and solid material may be discharged from opposite ends of the central shaft 116.
Having thus described the invention, what is considered to be patentable and sought to be protected by Letters Patent of the United States is as follows:
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Presented is a centrifuge apparatus for separating a high percentage of entrained solids from industrial waste water. The apparatus utilizes centrifugal force to separate materials according to their densities, and a novel scoop arrangement for scooping up the separated high density solid materials and ejecting them from the apparatus.
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Background of the Invention
[0001] 1. Field of the Invention
[0002] The methods and apparatus of the present invention relate generally to the field of location-based services, and more particularly to applications of location information for location-aware products.
[0003] 2. Background
[0004] The deployment in modern times of communication satellites in earth orbit, such as those which form the well-known Global Positioning System (GPS), have enabled, first, military systems, and subsequently, commercial systems to use signals from orbiting satellites to determine their location on earth. In this way, the navigation of military and commercial vehicles by automatic guidance systems has been facilitated.
[0005] In addition to guidance system applications, signals from the Global Positioning System have been used in conjunction with various hardware and software products for providing terrestrial coordinates to users such as hikers or backpackers who want or need to know their locations. Similarly, fleets of trucks have been equipped with GPS systems so that their location can be monitored.
[0006] As the application and acceptance of GPS based location systems has grown the cost of such GPS hardware and software has begun to decline. With declining prices, it is anticipated that the deployment of such location information resources in a wide variety of electronic products will become feasible.
[0007] What is needed are practical uses for such location information resources in consumer products, such as, but not limited to mobile consumer electronics devices.
SUMMARY OF THE INVENTION
[0008] Briefly, a location-aware product includes a location information resource for providing the present location of the location-aware product to within some margin of error, and such present location information is included by the location-aware product in various outputs, including but not limited to, location stamps in files for create, open, and/or modify file operations, and signature blocks in email or other documents. In a further aspect, location information may be included in email such as in an automatically applied signature block. The location-aware product may be a computer, a personal digital assistant, a cellular telephone, or any such product that includes location-awareness. The location information resource may be a Global Positioning System module that provides at least latitude and longitude. In one aspect of the invention a map database is used to convert latitude and longitude to the geographical name of the location specified by the latitude and longitude.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] [0009]FIG. 1 is a block diagram representation of a computer equipped with an exemplary module that provides location information to the computer in accordance with the present invention.
[0010] [0010]FIG. 2 is a flowchart of an illustrative process in accordance with the present invention that incorporates location information into a file in connection with a file open operation.
[0011] [0011]FIG. 3 is a flowchart of an illustrative process in accordance with the present invention that incorporates location information into a file in connection with a both a file open and a file modify operation.
[0012] [0012]FIG. 4 is a flowchart of an illustrative process in accordance with the present invention that incorporates location information into a file in connection with a file modify operation.
[0013] [0013]FIG. 5 is a flowchart of an illustrative process in accordance with the present invention that incorporates location information in a cookie file.
[0014] [0014]FIG. 6 is a flowchart of an illustrative process in accordance with the present invention that reads location information from a cookie file.
[0015] [0015]FIG. 7 is a flowchart of an illustrative process in accordance with the present invention that incorporates location information in a signature block of an email message.
[0016] [0016]FIG. 8 is a flowchart of an illustrative process in accordance with the present invention that includes converting latitude and longitude information into geographical name information and inserting that geographical name information into a signature block of an email message.
DETAILED DESCRIPTION
[0017] Generally, various embodiments of the present invention may obtain location information from a location information resource, such as but not limited to, a GPS receiver and processing circuitry, incorporate that location information into one or more files, such as, but not limited, to text files, email files, word processing files, and so on; or 2) subsequently provide such stored location information to a display, such as, but not limited to, a directory listing of files that includes the location of creation or modification of the file, in addition to, or in place of, other file parameters such as, for example, file size, file type, or time of creation or modification of the file.
[0018] Reference herein to “one embodiment”, “an embodiment”, or similar formulations, means that a particular feature, structure, or characteristic described in connection with the embodiment, is included in at least one embodiment of the present invention. Thus, the appearances of such phrases or formulations herein are not necessarily all referring to the same embodiment. Furthermore, various particular features, structures, or characteristics may be combined in any suitable manner in one or more embodiments.
[0019] [0019]FIG. 1 is a block diagram representation of a computer equipped with an exemplary module that provides location information to the computer in accordance with the present invention. More particularly, a central processing unit (CPU) 102 is shown coupled to a bus 104 . Similarly, a memory 106 , peripherals 108 , 110 , and a location-aware module 112 are included in the computer and are also coupled to bus 104 . It should be noted that various other computer or digital system architectures may be used in accordance with the present invention. For example, some computer systems use a different bus to couple system memory to the CPU, than is used to couple peripheral devices to the CPU, and such systems may be used in embodiments of the present invention. In the illustrated embodiment, location-aware module 112 includes a GPS receiver and processing circuitry to convert the received GPS signals into location coordinates, such as, but not limited to, latitude and longitude. An antenna suitable for receiving GPS signals is typically included within location-aware module 112 , but such antenna may be spaced apart from location-aware module 112 . If the antenna is spaced apart from location-aware module 112 , then the antenna is appropriately coupled to module 112 . Although FIG. 1 represents a computer equipped with a location resource, it will be understood, that this functionality may be included in a wide variety of electronic products, including consumer products, that include some computational capability, such as, but not limited to, cellular phones, personal digital assistants (PDA), electronic games, and so on. It will be further understood, that the utility of the present invention is greatest in mobile devices (e.g., laptop computer cellular phones, personal digital assistants (PDA), and electronic games) but the invention is not limited to devices that are typically mobile.
[0020] [0020]FIG. 2 is a flowchart of an illustrative process in accordance with the present invention that includes (i.e., inserts or incorporates) location information into a file in connection with a file open operation. More particularly, in this embodiment, a file is opened 202 . File open operations are common in computer systems and are well understood. Such a file open operation is commonly initiated by a computer user by, for example, double-clicking on an iconic representation of the file in a graphical user interface. It is known that there are other means of opening files, including the opening of files by an operating system without the need for specific user action. Files opened in this way include, but are not limited to, text files, word processing files, spreadsheet files, database files, sound files, graphics files, video files, and so on. Subsequent to, or concurrent with, the opening of the file, location information is read 204 from a location information resource, such as the location-aware module 112 of FIG. 1. It is within the scope of the present invention to read the location information prior to the file opening, however, this may result in location information that is not contemporary with the actual location of the computer at the time that the file is open. Subsequent to reading the location information, at least a portion of the location information is written into the file 206 . All the information obtained from the location resource may be written to the file, but depending on the particular implementation, the location resource may provide other information that does not need to be included in the file, such as information on altitude, time of day, speed, and so on. It is a designer's choice as to how much location and location-related data obtained from the location resource to include in the file. In a presently preferred embodiment, latitude and longitude information are stored in the file. In this way, a translation from latitude/longitude information, to geographical place name can be performed when the file is read. In this way, another aspect of the present invention is supported. That is, providing the geographical place name in the language of the present location. In other words, if a file on a laptop computer is opened in the United States, and the latitude/longitude information are included in the file, then on subsequent accesses of the file, it may be determined where that file open operation took place, and that location displayed in English if the laptop is still in the United States, but however, it may be displayed in French if the current location of the laptop is somewhere in France. Of course, other implementations of the present invention may elect to perform a latitude/longitude to geographical place name translation at the time of originally reading the latitude/longitude information, and incorporating the text of the geographical place name into the file. The location information is read from the location information resource is indicative of the physical location of the computer. The location information may be in any suitable format, and such formats include, but are not limited to, latitude/longitude, and geographical location name. It will be understood that although a computer is used in this example, other the present invention applies to other electronic devices, such as for example mobile consumer electronic devices, as well.
[0021] It should be noted that reading location information from location-aware module 112 is similar to reading information from any commonly available type of computer peripheral device. For example, one or more fixed addresses in a memory, or I/O space, of a computer may be read and the resulting data represents the location information. In an alternative embodiment, a command is written to location-aware module 112 and as a consequence, location information is transferred by location-aware module 112 to some pre-determined address. Those skilled in the art will appreciate that communication between a CPU and peripheral device in a computer system is a well-understood matter.
[0022] [0022]FIG. 3 is a flowchart of an illustrative process in accordance with the present invention that includes (i.e., inserts or incorporates) location information into a file in connection with a both a file open (as shown in FIG. 2) and a file modify operation. More particularly, in this embodiment, a file is opened 302 . Subsequent to, or concurrent with, the opening of the file, location information is read 304 from a location information resource, such as location-aware module 112 of FIG. 1. Subsequent to reading the location information, at least a portion of the location information is written 306 into the file. The location information read from the location information resource is indicative of the physical location of the computer. The location information may be in any suitable format, and such formats include, but are not limited to, latitude/longitude, and geographical location name. In this embodiment of the present invention, the file that was opened at 302 is now modified 308 . Subsequent to, or concurrent with, the modification of the file, location information is read 310 from the location information resource. Subsequent to reading the location information, at least a portion of the location information is written 312 into the file. In this example, the incorporated location information is appropriately labelled as being associated with the file open operation or with the file modify operation. The computer system may include a history of location information associated with each open or modify operation, or only the most recent open or modify operation, or a combination. These implementation specific options can be chosen by the system designer, or can be made a user definable option in the computer system, similar to the user selecting a preferred screensaver, or desktop color.
[0023] [0023]FIG. 4 is a flowchart of an illustrative process in accordance with the present invention that includes (i.e., inserts or incorporates) location information into a file in connection with a file modify operation. More particularly, in this embodiment, a file is opened 402 . Subsequent to the opening of the file, the file is modified 404 . Location information is read 406 from a location information resource, such as location-aware module 112 of FIG. 1. Subsequent to reading the location information, at least a portion of the location information is written 408 into the file. The location information read from the location information resource is indicative of the physical location of the computer. The location information may be in any suitable format, and such formats include, but are not limited to, latitude/longitude, and geographical location name. This example is similar to that described in connection with FIG. 3, but does not include incorporating location information in connection with file open operations.
[0024] [0024]FIGS. 2 through 4 provide illustrative embodiments of the present invention. In a further aspect of the present invention, various embodiments including reading back the location information that was written into the files and displaying or otherwise utilizing that information. Location information that was stored, either in an opened or modified file, or some other file (e.g., a system file maintained by the computer's operating system) that is associated with the opened or modified file, can be read back and displayed alone or with other file attributes such as, for example, the date and time of the file open or modify operation. When a directory listing is obtained that includes location information, the directory listing may be sorted according to location, whether by latitude, longitude, alphabetically in accordance with geographical place name, or by regions (e.g., North America, Western Europe, Asia, and so on).
[0025] The operations writing and reading back location information from files, as described above, are typically implemented in software. Such software may be included in a computer's operating system, or may be installed on a computer as an application program.
[0026] [0026]FIG. 5 is a flowchart of an illustrative process in accordance with the present invention that incorporates location information in a cookie file. Cookies or cookie files are terms that describe files stored on a client computer because of an interaction between, for example, a web browser software program running on the client computer, and a software program than runs on a web server computer. Typically such an interaction occurs when a computer user visits, or accesses a web site. Cookies are generally relatively small files that allow the software running on the web server to determine whether and when the client computer has accessed the web site. In one embodiment of the present invention, a cookie file is created on a client computer 502 . Location information is obtained 504 from a location information resource present (such as, for example, location information resource 112 of FIG. 1) in the client computer. This location information is indicative of the location of the client computer at the time of the interaction with the web site. The location information may be in any suitable format, and such formats include, but are not limited to, latitude/longitude, and geographical location name. The location information is then written 506 into the cookie file. Such information in the cookie file can be useful to a web site operator in determining geographical usage patterns of the web site, i.e., from where the site is being accessed. Furthermore, the location information may be updated upon subsequent accesses of the cookie file. Similarly, a history, or log, of location information may be formed in the cookie file by additional accesses of the cookie file during, or as a consequence of, one or more interactions with the web site.
[0027] [0027]FIG. 6 is a flowchart of an illustrative process in accordance with the present invention that reads location information from a cookie file. More particularly, a cookie file that includes location information relative to where the client computer was located at the time the cookie file was created, last opened, or last modified, is opened 602 . The cookie file may be opened in connection with a visit to a web site, or such similar interaction with a web server, or other computer system or process. Subsequently, at least one item of location information is read 604 from the cookie file. The location information may constitute a record in the file, although no particular file format is required by the present invention. The location information read from the cookie file may be transmitted back to the web server, mentioned above, so that geographical usage patterns may be determined. Methods and apparatus for communication between a web browser (client) and a web site (server) are well known and are not described further herein.
[0028] [0028]FIG. 7 is a flowchart of an illustrative process in accordance with the present invention that incorporates location information into a signature block of an email message. Some of the well-known and widely available email programs provide users with a feature that automatically appends a signature block to their email. These signature blocks are typically defined by the email users and often include information such as, but not limited to, the name of the user, the user's phone number and address, business title, mail-stop, and so on. In this example, a computer system, or other information handling device, having a location information resource (such as location information resource 112 of FIG. 1), and capable of preparing and sending email, receives a command to send an email 702 . A decision is then made 704 as to whether such an automatic signature feature is active for this message. If the automatic signature feature is not active, then the email is sent 710 . If the automatic signature feature is active, then the current location of the computer, or other information handling device is obtained from the location information resource 706 . That location information is appended to, or inserted into, the email message, for example into the signature block 708 . The email is then sent 710 . It is to be understood, that in this context sending an email may mean actually transmitting the email to another computer or information handling device, directly or through some communication network, or simply spooling the email for subsequent transmission.
[0029] [0029]FIG. 8 is a flowchart of an illustrative process in accordance with the present invention that includes converting latitude and longitude information into geographical name information and inserting that geographical name information into a signature block of an email message. This example is similar to the general example of FIG. 7, but illustrates a more specific example. More particularly, a computer system or other information handling device, having a location information resource (such as location information resource 112 of FIG. 1), and capable of preparing and sending email, receives a command to send an email 802 . A decision is then made 804 as to whether a signature block feature is active for this message. If the signature block feature is not active, then the email is sent 812 . If the signature block feature is active, then the current location of the computer or other information handling device, in the format of latitude and longitude, is obtained from the location information resource 806 . The latitude and longitude information are then converted to a geographical place name of the location that corresponds to the latitude and longitude 808 . The geographical place name information is then inserted into the signature block 810 . The email with the included geographical name information is then sent 812 . It is to be understood, that in this context sending an email may mean actually transmitting the email to another computer, or information handling device, directly or through some communication network, or simply spooling the email for subsequent transmission.
[0030] The present invention may be implemented as circuit-based processes, including possible implementation on a single integrated circuit. As would be apparent to one skilled in the art, various functions of circuit elements may also be implemented as processing operations in a software program. Such software may be employed in, for example, a digital signal processor, micro-controller, or general-purpose computer.
[0031] The present invention can be embodied in the form of methods and apparatuses for practicing those methods. The present invention can also be embodied in the form of program code embodied in tangible media, such as punched cards, magnetic tape, floppy disks, hard disk drives, CD-ROMs, flash memory cards, or any other machine-readable storage medium, wherein, when the program code is loaded into and executed by a machine, such as a computer, the machine becomes an apparatus for practicing the invention. The present invention can also be embodied in the form of program code, for example, whether stored in a storage medium, loaded into and/or executed by a machine, or transmitted over some transmission medium or carrier, such as over electrical wiring or cabling, through fiber optics, or via electromagnetic radiation, wherein, when the program code is loaded into and executed by a machine, such as a computer, the machine becomes an apparatus for practicing the invention. When implemented on a general-purpose processor, the program code segments combine with the processor to provide a unique device that operates analogously to specific logic circuits.
[0032] It is to be understood that the present invention is not limited to the embodiments described above, but encompasses any and all embodiments within the scope of the following claims.
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A location-aware product includes a location information resource for providing the present location of the location-aware product to within some margin of error, and the present location information is included by the location-aware product in various outputs, including but not limited to, location stamps in files for create, open, and/or modify file operations, and signature blocks in email or other documents. In a further aspect, location information may be included in email such as in an automatically applied signature block. The location-aware product may be a computer, a personal digital assistant, a cellular telephone, or any such product that includes location-awareness. The location information resource may be a Global Positioning System module that provides at least latitude and longitude. In one aspect of the invention a map database is used to convert latitude and longitude to the geographical name of the location specified by the latitude and longitude.
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FIELD OF THE INVENTION
[0001] The invention relates to a method for enabling in a processing system a communication between at least two activated processes. The invention equally relates to a corresponding processing system, to an integrated chip comprising at least one processor for running processes in said integrated chip, and to a module for such an integrated chip.
BACKGROUND OF THE INVENTION
[0002] A process is an active part of a processing system which is run by a processor and which is capable of performing certain basic data transfer operations. It is known in particular to implement processes in integrated circuits (IC), like Application Specific Integrated Circuits (ASIC), or in independent functional blocks, either integrated in a chip.
[0003] Such a process can be implemented as hardware or software process. Modern software architectures for example are based on multiple processes that are controlled by an operating system. The architecture can comprise a single or several processors. In a single processor system, processes are executed one after another, even though within a larger time window they seem to operate in parallel. Since the operations performed by different processes may be interdependent, a possibility has to be provided which enables the processes to share information among each other.
[0004] In a single processor system this is usually done via a common database or memory to which the respective information is stored by a source process and from which the information is retrieved by a destination process, since multiple processes of a single processor cannot transfer information simultaneously. In systems with more than one processor as active components, processes can be executed simultaneously. Still they need to transfer information, like data, to each other. In that case, data can be transferred directly by a source process to a destination process. If the two processes are running in different chips, the message transfer will usually cause in addition an automatic notification of the destination process when the receiver of the chip with the destination process has received the data. Alternatively, processes can send pure notifications to each other, e.g. for waking up the destination process.
[0005] [0005]FIG. 1 illustrates different communications that might be required between different processes running in an integrated circuit, e.g. in an ASIC, on a single chip. In the figure, a chip 10 comprises at least one processor capable of running several processes 11 . Each process 11 is depicted in the figure as a cloud. The chip 10 further comprises several interfaces 12 depicted as rectangles. Several communications that might be required between different processes 11 and between processes 11 and interfaces 12 are indicated by arrows. Equally, communications between processes of the depicted chip with processing running on other chips not shown in the figure might become necessary.
[0006] The required communication structure, i.e. all communications that might become necessary in a processing system between different processes, can be quite different depending on the application. In particular, the number of required parallel processes and the number of physical components can vary. But also for a specific processing system, the communication structure is often difficult to predict. Thus it is commonly agreed upon that the communication structure has to be flexible enough to allow a communication between all possible combinations of processes. Another requirement is that all communication within one chip should be carried out in a similar manner in order to decrease the communication burden. Ideally, also processes in different chips should communicate in a similar manner.
[0007] Moreover, it is usually two different basic types of messages that have to be transferred between a source process and a destination process, namely data messages and notification messages.
[0008] A data transfer commonly consists of a stream of multiple bits, for example audio or video streams. The length of the streams can vary, and they can contain different header information to allow various message protocols.
[0009] Notification messages, in contrast, provide some additional information to the destination process, and can inform e.g. about some transmitted data. The additional information can be for example a status or an interrupt signal. Notification messages between different processes are currently transferred as separate flag signals for which no coding is used. The number of flags can be quite high if multiple integrated chips are interconnected.
[0010] Notification and data transfer have different characteristics. A notification has to be fast and predictable in its timing with a fixed latency time, while a data transfer requires a reasonable average communication bandwidth to enable the transfer of a large amount of data within a certain time. Because of these different requirements, notification and data transfer are dealt with separately, i.e. all communication channels and status and/or interrupt signals are currently transferred separately for each process. The data transfer is done on one or multiple communication wires, and each notification message requires a separate physical flag signal. This has lead to a solution with many buses and status signals, and thus with many hardware resources.
[0011] In conventional communication structures, the number of possible connections and the additional division into notification messages and data leads to a problem because of tight pin limitations on the chips. The number of pins is considerable if all possibly required communication are to be made possible. Since all independent functional blocks need flags, the number of pins required for the connections also increases significantly with the number of independent functional blocks. The great number of pins is a common problem in almost all current ASIC and standard processors.
[0012] Since in conventional solutions, moreover all possible connections have to be fixed in hardware design, which affects the hardware development schedule and might not lead to an optimal solution, because all requirements are usually not know in the hardware implementation phase.
[0013] The problem arises equally for hardware and software processes, since the required communications are similar.
SUMMARY OF THE INVENTION
[0014] It is an object of the invention to improve the communication between different processes of a processing system.
[0015] This object is reached with a method for enabling in a processing system a communication between at least two activated processes. For the communication, signals are transmitted between the at least two processes in at least two virtual channels using the same physical channel. That is, the processing system comprises one or more physical channels of which at least one is employed for transmitting signals in virtual channels.
[0016] The object is equally reached with a processing system comprising at least one processor for running different processes, i.e. the different processes may be run by the same processor or by different processors. The system moreover comprises at least one physical channel provided for enabling a communication between at least two of said different processes, and means for distributing signals which are to be transmitted for such a communication between at least two of said different processes to different virtual channels on said at least one physical channel.
[0017] The object of the invention is further reached with an integrated chip comprising at least one processor for running at least two different processes in said integrated chip. The chip comprises in addition at least one physical channel provided for enabling a communication between different processes run in said integrated chip, and means for distributing signals that are to be transmitted for such a communication between processes run in the integrated chip to different virtual channels on the at least one physical channel. The latter means are to correspond to those of the proposed processing system.
[0018] Alternatively or in addition, the physical channel is arranged between two different integrated chips each comprising at least one processor for running at least one process. In this case, the proposed integrated chip has to comprise an interface to the external physical channel provided for enabling a communication between the at least one process in the integrated chip and at least one other process running in another integrated chip. Moreover, the alternative integrated chip comprises means for distributing signals that are to be transmitted for such a communication between processes running in said integrated chip and in another integrated chip to different virtual channels using said at least one external physical channel. The means for distributing signals to virtual channels are to correspond again to those of the proposed processing system.
[0019] The proposed integrated chips can be in particular constituted by ASICs.
[0020] Finally, the object of the invention is reached with a module for an integrated chip comprising processing means for handling signals that are to be transmitted between different processes running in said integrated chip and/or between a process running in said integrated chip and a process running in another integrated chip. The proposed module is capable of distributing signals that are to be transmitted between the processes for enabling a communication between said processes to virtual channels on a physical channel within said integrated chip and/or a physical channel connecting said integrated chip and another integrated chip. The means for distributing signals to virtual channels are to correspond again to those of the proposed processing system. The module can be in particular an intellectual property (IP) block.
[0021] The use of several virtual or logical channels on one physical channel are described for communications between different network nodes of a network in “Virtual-channel flow control”, IEEE Transactions on Parallel and Distributed Systems, Vol. 3, Issue 2, March 1992, pages 194-205, by W. J. Dally. The invention proceeds from the idea that virtual channels could equally be employed for communications between different processes of a processing system, e.g. within or between ASICs. To this end, at least one physical channel is provided which can be used for transmitting signals between different processes in virtual channels. The invention thereby allows to utilize the available physical communication channels more efficiently by increasing the performance per wire and pin.
[0022] It is an advantage of the invention that it can be employed flexibly for different communication topologies and the physical communication interface can be serial or parallel. Moreover, the invention can be employed with different communication protocols. That means that the most suitable communication protocol can be selected. Further, the invention is scalable to any number of processes.
[0023] As an advantage for the hardware design, the invention allows to minimize the hardware complexity, and the number of pins. Since the power consumption is dependent on external pins, reducing the number of pins will moreover decrease the power consumption. In addition, the wiring area required for connecting processes can be decreased. If the involved processes are implemented in several integrated chips, e.g. in ASICs, the wiring can be decreased both inside each chip and in a printed wire board (PWB) by which several chips are connected.
[0024] As an advantage for the software design, the number of available logical channels can be increased and used more flexibly. The purpose of the channels can be designed in the software development and thus decision on possibly required connections is not critical anymore. The logical channels are seen by the software similarly as the physical channels are seen in conventional processing systems.
[0025] In sum, an economical solution for communications between processes in a processing system is presented, which solution is capable of fulfilling the communication requirements described above.
[0026] Preferably, a physical channel is employed for transmitting different kind of messages between said processes in different virtual channels. It is thus proposed to convert multiple physical channels provided for different transfer requirements to one physical channel, which comprises multiple logical channels provided according to the requirements. This enables a significant decrease in the number of physical channels between functional units. The different kinds of messages can include in particular notification messages and data. Notification messages are transmitted in special logical channels that do not transfer data, but only a one bit notification messages like for example an interrupt request.
[0027] The number of logical data streams and the number of notification messages are not limited, and a simple bi-directional serial bus is sufficient for the combined notification message and data stream transfer. Thus the communication requirements can be met while utilizing the available physical communication channels more effectively than separate data and notification channels.
[0028] Advantageously, different priorities are assigned to different kinds of signals which are to be transmitted in different virtual channels on the same physical channel. The different priorities can be assigned directly and individually to the signals that are to be transmitted, or indirectly to different virtual channels to which the signals are assigned for transmission according to their characteristics. The proposed prioritisation enables a guarantee of short and predictable latency times for notification messages and a large average bandwidth for data streams. Compared to the current solutions, the performance will thus remain about the same, since with such a prioritization, even long data streams do not delay instant notification messages.
[0029] Virtual channels can have different latencies, but the maximum latencies in a specific processing system can be calculated. The maximum latency allows to guarantee a transmission time of messages and thus to build a real-time communication system. The possibility of real time handling enables the use of the invention also in devices like mobile terminals which require that the time for certain operations be predictable.
[0030] The processes between which a communication is to be enabled can be hardware or software implemented processes, since the communication between such processes can be handled similarly.
[0031] The involved processes can be running on a single chip or on two or more different chips.
[0032] Preferably, the communication according to the invention is handled by a dedicated process provided in each chip. This dedicated process can be implemented in software or hardware with the same functionalities. Still, a better and more predictable performance can be expected to be achieved with a hardware implementation, which can be critical in real-time applications. The dedicated process is in particular responsible for dealing with different required properties of the virtual channels. The channel mapping is preferably not fixed and any process can communicate with all other processes. Thus all processes can also utilize all hardware blocks. This moves the decision for hardware resource mapping from hardware design to software design, and thus increases the flexibility of the hardware and allows late changes and task partitions in the software design.
[0033] In a hardware implementation, the invention is related in particular to the communication between integrated circuits. Software is a seamless part of an embedded system and thus the usage of the invention can be done with software.
[0034] If the processes and the communications between the processes are implemented independently from each other, the number and kind of supplied processes can vary. Communication channels between all processes can thus be made virtually available to allow each process to communicate with all other processes.
[0035] The signaling can be realized e.g. similar to the signaling described in “IEEE Standard for a High Performance Serial Bus-Amendment 1”, IEEE Std 1394a-2000, for a public serial bus implementation.
BRIEF DESCRIPTION OF THE FIGURES
[0036] In the following, the invention is explained in more detail with reference to drawings, of which
[0037] [0037]FIG. 1 illustrates the communication between different parallel processes within one chip;
[0038] [0038]FIG. 2 illustrates the communication between different parallel processes in different chips;
[0039] [0039]FIG. 3 shows several ASICs connected to the same physical wires in a PCB;
[0040] [0040]FIG. 4 shows the connection of different components of an ASIC to an internal bus;
[0041] [0041]FIG. 5 shows an embodiment of a hardware implementation of the invention within one ASIC;
[0042] [0042]FIG. 6 shows an embodiment of a transmitter unit of the implementation of FIG. 5; and
[0043] [0043]FIG. 7 shows an embodiment of a receiver unit of the implementation of FIG. 5.
DETAILED DESCRIPTION OF THE INVENTION
[0044] [0044]FIG. 1 has already been described in the background of the invention.
[0045] [0045]FIG. 2 schematically shows a part of a processing system with two IC chips like the one depicted in FIG. 1. In both chips 20 , 21 , processes 22 , 23 that can be activated by integrated processors are shown again as clouds, interfaces 24 , 25 as rectangles and possible communications as arrows. The depicted processes 22 , 23 do not only have to communicate within one chip, but also between the two chips 20 , 21 , as indicated by additional arrows between processes 22 , 23 of different chips 20 , 21 . Moreover, a bi-directional physical channel 28 is shown which interconnects an additional interface 5 included in both of the two chips 20 , 21 , which interfaces are referred to in the figure by 26 , 27 .
[0046] According to the invention, communications can be carried out freely between all processes 22 , 23 of the two chips 20 , 21 , even though there is only one bi-directional physical communication channel 28 provided between the two chips 20 , 21 . This is achieved according to the invention by transmitting the signals in virtual channels which are formed on the physical channel 28 . The virtual channels can be obtained for example by dividing the available transmission time into transfer frames and by distributing the data and notifications to selected frames or to selected time slots in these frames.
[0047] The processing system of FIG. 2 can be extended by additional chips. FIG. 3 schematically illustrates a possible structure for a communication according to the invention between the processes of a processing system with more than two ASICs.
[0048] In FIG. 3, five different ASICs 30 - 34 of a processing system are depicted, ASIC 1 , 2 , 3 , A and B. Each of these ASICs 30 - 34 is connected to the same physical wires 35 of a printed circuit board (PCB). A suitable implementation takes care that all requests of communications are served in a timely manner in virtual channels using the same physical wires 35 . External flag signals for notification messages are not needed. The structure of FIG. 3 can be enlarged by any number of chips.
[0049] [0049]FIG. 4 schematically illustrates an exemplary internal structure of any of the ASICs 30 of FIG. 3. The ASIC comprises a processor 40 , a direct memory access controller (DMA) 41 , a message and data stream block interface 42 , and a memory interface 43 . All these components 40 - 43 are connected to an internal bus 44 of the ASIC. Externally, the ASIC can further be connected directly to an I/O bus via the message and data stream block interface 42 and to a memory bus via the memory interface 43 . The memory bus can connect the ASIC with an external memory, while the I/O bus can be provided by the physical wires 35 of FIG. 3 and thus be used as connection to other ASICs 31 - 34 .
[0050] For communications between different processes of the depicted processor 40 , notification messages are transmitted from one process to another one of the processes via the internal bus 44 . Data is transmitted from one process via the internal bus 44 , the memory interface 43 and the external memory interface to the external memory. A destination process receiving a corresponding notification then demands the stored data from the memory and receives it again via the external memory bus, the memory interface 43 and the internal bus 44 . The access to the memory is controlled by the DMA 41 .
[0051] For communications between a process of the depicted ASIC and a process of another ASIC, notification message and data are transmitted from the processor 40 via the internal bus 44 , the message and data stream block interface 42 and the external I/O bus to the other ASIC.
[0052] For each or selected ones of the busses, signals are distributed to virtual channels for transmission.
[0053] [0053]FIG. 5 schematically illustrates a more specific modular hardware implementation of the invention for an ASIC of a processing system. The implementation is independent of the employed communication protocol and can be realized on top of any physical communication channel. The ASIC can be e.g. one of the ASICs of FIG. 3 or the ASIC of FIG. 4. The ASIC is able to run several processes which have to communicate with each other and with processes of other ASICs.
[0054] The ASIC of FIG. 5 comprises three processors 50 - 52 having access to a connection network 53 , which is formed by internal communication busses corresponding to the internal bus 44 of FIG. 4. The ASIC further comprises a direct memory access controller 54 , a communication assistance hardware 55 , a receiver unit 56 and a transmitter unit 57 . The processors 50 - 52 correspond to the processor 40 of FIG. 4, the DMA 54 to the DMA 41 of FIG. 4, and the receiver unit 56 and the transmitter unit 57 in combination to the message and data stream block interface 42 of FIG. 4.
[0055] Each of these components of the ASIC have access to the connection network 53 . The transmission unit 57 has further access via external pins to an external bi-directional I/O bus. Equally, the receiver unit 56 has access via external pins to the external bus. The pins of the ASIC and the external bus are not depicted in FIG. 5. The receiver unit 56 is moreover able to forward signals directly to the communication assistance hardware 55 . The communication assistance block 55 is able to transmit signals directly to the direct memory access controller. Communication assistance hardware 55 and direct memory controller 54 are software controllable.
[0056] Each of the depicted processors 50 - 52 is designed to run one or more processes, and frequently, several processes of the processing system will be running in parallel or quasi in parallel. Each process may have to communicate with another process run by a processor of the same or of another ASIC, as illustrated in FIG. 2. Each communication includes either only a notification message informing the respective other process about some status change, or a notification message associated to a data transfer. The corresponding signals are written by the source process to the connection network 53 of the ASIC. Communications internal to the ASIC are transmitted via said connection network 53 to the destination process, while communications with external processes are further transmitted in virtual channels via the external I/O bus.
[0057] The communication assistance 55 is responsible that all signals transmitted by a source process run by one of the processors 50 - 52 of the depicted ASIC are transferred correctly and efficiently in virtual channels to a destination process. The communication assistance 55 takes care in particular of special channel requirements for some signals like fast notification transfer and of keeping status registers in each communication assistance coherent. Thus each process sees similar status registers and they do not even have to know where a destination process is located, or where an interface required to perform a specific task is located. Chip boundaries are thus invisible to the processes. Each virtual channel can have a different priority, which affects the information transfer order in case of multiple simultaneous requests. The notification transfer is made fast and predictable with this priority mechanism, by assigning a higher priority to notification messages than to data streams. Thus the worst-case latency time for notification messages is less than two data transfer frame, wherein the frame length can be configured. A transfer frame could have for example a 32-bit data field and a 8-bit header to implement a virtual channel. The worst-case latency time is then the transfer time of 80 bits plus a few clock cycles needed by the communication assistance state machine.
[0058] The communication assistance 55 or the processors 50 - 52 can configure the priorities of each virtual channel inside the receiver unit 56 and the transmission unit 57 by programming. In normal operation mode, the communication assistance 55 and the processors 50 - 52 thus do not have to take care of the priorities. The processors 50 - 52 then only need to the know the different properties of the channels, since each message can be assigned automatically in the transmission unit 57 according to its characteristics to an appropriate virtual channel.
[0059] In an alternative embodiment, priorities could be assigned individually to each message, but this would imply that each message has to contain in addition an indication of the required priority.
[0060] In a first communication example, a source process running in an ASIC with the depicted modular hardware implementation of FIG. 5 wants to transfer a notification implying a status change to a destination process. The source process writes the notification message and transmits it via the connection network 53 . The communication assistance 55 of the ASIC is informed about the required transfer of a notification message via the connection network 53 . The communication assistance 55 takes care that the status change is transmitted to the destination process, even if the destination process is not in the same integrated chip. To this end, the communication assistance 55 transmits the notification either via the connection network 53 to a process run by a processor 50 - 52 of the same ASIC, or via the connection network 53 , the transmission unit 57 and the external I/O bus to some other ASIC which corresponds to the first ASIC. In the latter case, the notification message is transmitted by the transmission unit 57 in a virtual channel with a high priority on the external I/O bus to the other ASIC with the destination process.
[0061] The destination process receives the notification either directly via the connection network or via the communication assistance and the connection network of its ASIC and behaves accordingly. It can for example clear the message indicator. The communication assistance of the second ASIC then takes care that the status change goes back to the source process. In case the destination process is running in another ASIC, the message with the status change is received in the depicted ASIC via the receiver unit 56 . The status change is transferred to the communication assistance 55 for updating the status registers. The message is further forwarded either directly via the connection network 53 or via the communication assistance 55 and the connection network 53 to the source process. The actions of the communication assistance 55 , or assistances in case of two involved ASICs, is invisible to both processes.
[0062] In a second communication example, a source process running in the depicted ASIC has to transfer data to a destination process running in another ASIC connected to the depicted ASIC via the external I/O bus. The second ASIC corresponds again as well to the ASIC depicted in FIG. 5.
[0063] The source process writes data targeted to the destination process to the connection network 53 . The data reaches the communication assistance 55 of the ASIC via the connection network 53 . The communication assistance 55 takes care that the data is transferred correctly to the destination process via the transmission unit 57 in virtual channels on the external I/O bus. The data is transmitted by the transmission unit 57 in a virtual channel to which a low priority but a high bandwidth was assigned. The second ASIC buffers the data preliminarily in its receiver unit before forwarding it via the connection network to the destination process. However, in case a large data stream is received, the data can be transferred automatically by the DMA of the second ASIC to a connected physical memory like an SDRAM, an SRAM or similar.
[0064] The destination process further has to be notified that data was transmitted for it. Therefore, the receiver unit of the second ASIC generates a notification message for the destination process. Alternatively, the source process could transmit for each data message a corresponding notification message which would be transmitted like a separate notification message. The communication assistance of the second ASIC also takes care of transferring the notification message to the destination processes. The destination process receives the notification and reads as reaction the transmitted data from the connection network. In case the data was stored in a physical memory, the processor running the destination process can retrieve the data when it has time for handling it. The destination process can then clear the notification status to indicate the end of the communication operation. The communication assistance of the second ASIC takes care as in the first example that the status change is transmitted to the source process. The operations of the communications assistances 55 are again invisible to both processes.
[0065] In the ASIC of FIG. 5, the processors 50 - 52 see many communication channels that can be equally used. The processors do not have to know that the channels are virtual. All hardware operation is hidden from the processors and thus all kind of processors can use the presented communication mechanism.
[0066] In the embodiment of FIG. 5, signals are transmitted in virtual channels only between processes running in different ASICs. Virtual channels could be employed in addition within each ASIC.
[0067] [0067]FIGS. 6 and 7 schematically show in more detail an embodiment of the receiver unit 56 and an embodiment of the transmission unit 57 of FIG. 5.
[0068] The transmission unit 57 of FIG. 6 comprises an internal bus interface 60 which is connected at its input to the connection network 53 of the ASIC. One output of the internal bus interface 60 is connected via a data stream transmit status block 61 and another output via a status signals block 62 to a selection and priorisation logic 63 . This selection and priorisation logic 63 is further connected via an external interface 64 to external pins of the ASIC. The pins are not depicted in the figure.
[0069] The transmission unit receives via the internal bus interface 60 notification messages or data streams that are to be transmitted. The signals are forwarded via the corresponding block 61 , 62 to the selection and priorisation logic 63 . Inside the ASIC there are different registers and buffers for data and notifications that are to be sent, e.g. in the transmission unit for enabling smooth communication and priorisation. The status blocks 61 , 62 show the status of these registers or of an internal state machine. Status signals provided by the status blocks 61 , 62 prevent new data from being written before older data is transmitted. The selection and priorisation logic 63 assigns received signals to virtual channels according to programming by the communication assistance 55 , and forwards the signals via the external interface 64 to the external bus in the respective virtual channels.
[0070] [0070]FIG. 7 schematically shows a corresponding receiver unit 56 with an internal bus interface 70 , a data stream receive status block 71 , a status signals block 72 , a selection and priorisation logic 73 and an external interface 74 . The structure of the receiving unit depicted in FIG. 7 is the same as the structure of the transmission unit of FIG. 6. In addition to the connections of the receiving unit of FIG. 6, in the transmission unit of FIG. 7 the status signals block 72 has a direct connection to the communication assistance 55 of FIG. 5 for status signals relating to notifications from the block 72 .
[0071] The receiver unit receives signals originating from processes of other ASICs via the external interface 74 distributed to virtual channels. The selection and priorisation logic 73 assembles the original notification messages and data messages again according to a programming by the communication assistance 55 . If a data message is received, a notification message is generated to inform the destination process about the received data. The regained and/or generated messages are then transmitted to the addressed processes via the corresponding block 71 , 72 , the internal bus interface 70 and the connection network 53 of the ASIC. The ASIC comprises different registers and buffers for data and notifications that are received. Similar to the status blocks 61 , 62 of the transmission unit of FIG. 6, the status signals provided by status blocks 71 , 72 of the receiver unit therefore indicate when received data is ready to be read by the processors. Moreover, status signals of notification messages are transferred to the communication assistance 55 by the status signals block 72 . The communication assistance 55 is thus able to keep the status registers in coherence with the communication assistances of connected ASICs of the same processing system. Notification messages could also be transmitted via the communication assistance 55 to the destination process.
[0072] The functions integrated in the receiver unit 56 and the transmission unit 57 can vary. If the receiver and the transmitter units 56 , 57 are not designed for handling virtual channels, for example, then all communication operations, like prioritisation and sending the highest priority message first, are taken care of by the communication assistance 55 .
[0073] On the other hand, the functionalities of the communication assistance 55 of FIG. 5 could also be integrated into the receiver unit and the transmission unit of FIGS. 6 and 7.
[0074] Alternatively to the hardware implemented communication assistance of FIG. 5, a software process could be implemented for the communication based on the receiver and the transmitter block and on a microprocessor unit or a general purpose processor. Higher and more predictable performance will usually be achieved with a communication assistance hardware, though.
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The invention relates to a method for enabling in a processing system a communication between at least two activated processes 22,23. In order to improve the communication between different processes 22,23 of a processing system, it is proposed that for said communication signals are transmitted between said at least two processes 22,23 in virtual channels using the same physical channel 28. This enables an efficient use of physical resources. A corresponding processing system comprises at least one processor 50 - 52 for running different processes, at least one physical channel provided for enabling a communication between at least two of said different processes, and means 55 - 57 for distributing signals which are to be transmitted for such a communication between said at least two different processes to different virtual channels on said at least one physical channel.
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BACKGROUND OF THE INVENTION
This invention generally relates to reclining seats and, particularly to a novel locking and positioning apparatus capable of retaining the back members of such seats in an infinite number of inclined positions.
Reclining seats are widely used in airplanes, railway cars, automobiles, vans, buses, and the like. Many types of structures for positioning the backs of reclining seats have been produced and examples are illustrated in U.S. Pat. Nos. 2,595,240; 2,662,585; 3,271,071; 3,383,135; 3,893,730 and 3,419,306.
Typically, the structures illustrated in the above-mentioned patents include a pair of elongate members slidably arranged in telescopic relation for movement between extended and retracted positions with respect to each other, and one or more friction washers capable of frictional engagement with one of the members for restraining the associated member against relative movement. The washer arrangement may be moved to an unlocking position, permitting free relative movement between the associated members. The friction washers are normally biased to the locking position, and are typically released by a cam selectively operable to move the washers to the unlocking position against the biasing action of an associated spring. Conventionally, the friction washers are mounted on a fulcrum member, and biased to tilt about the fulcrum member to the locking position. The structure of these prior art devices is typically, rather complex, and costly to produce. Further, these devices have means for locking the telescopic members together in one direction of movement while permitting the members to relative to each other in the opposite direction of movement. Accordingly, these devices lack the necessary structures which are required to satisfy the commercial application of their intended use.
SUMMARY OF THE INVENTION
Briefly, the preferred embodiment of the invention includes a pair of elongate members arranged in telescopic relation for movement in extended and retracted positions relative to each other. An end of one elongate member is pivotally connected to the seat member of a reclining seat and the opposite end of the other associated elongate member is pivotally connected to an arm depending from and affixed to the back member below the pivotal connection of the seat. Gripping means, comprising a pair of spaced friction applying washers, is carried by one of the elongate members and surrounds the other elongate member. The pair of spaced washers, carried on a fulcrum arm extending from one of the elongate members, surrounds the other elongate member and the washers are biased apart to a locked position by a spring or springs to frictionally retain the elongate members in any selective position between extended and retracted positions in each direction of movement. The washers are moved to an unlocked position by members overcoming the action of the spring or springs for permitting free relative movement between the telescoping members.
An object of the invention is to produce a locking and positioning apparatus which utilizes a minimum number of elements and controls movement of telescoping members in both directions.
Another object of the invention is to produce a locking and positioning apparatus which utilizes a pair of friction applying washers which are biased by a spring or springs to assert pressure thereon to instantaneously frictionally engage the telescoping members.
A further object of the invention is to produce a locking and positioning apparatus which utilizes an actuating lever for simultaneously applying compressive pressure to a pair of friction washers for quickly releasing the frictional engagement between the telescoping members.
BRIEF DESCRIPTION OF THE DRAWINGS
The above, as well as other objects of the invention will become readily apparent to one skilled in the art from reading the following detailed description of the preferred embodiments of the invention when considered in the light of the accompanying drawings, in which:
FIG. 1 is a schematic perspective view of a reclining seat assembly incorporating the locking and positioning apparatus constructed in accordance with the invention;
FIG. 2 is an enlarged view of the locking and positioning apparatus illustrated in FIG. 1 in the locked position;
FIG. 3 is an enlarged side elevational view of the apparatus illustrated in FIG. 2;
FIG. 4 is an enlarged perspective view of another embodiment of a locking and positioning apparatus constructed in accordance with the invention; and
FIG. 5 is an enlarged side elevational view of the apparatus illustrated in FIG. 4.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the drawings, where like reference numerals designate similar parts throughout, there is illustrated in FIG. 1 a reclining seat assembly 10. The seat assembly 10 includes a relatively stationary seat member 12, a back member 14 pivotally connected, as at 16, to the seat member 12, thus allowing the back member 14 to pivot relative to the seat member 12 between an upright position and various inclined positions. A locking and positioning device 18, extending between the front edge of the seat 12 and an arm 14a depending from the back member 14, controls the positioning of the back member with respect to the seat 12. The opposed ends of the locking and positioning device 18 are pivotally connected, as at 20 and 22, to the seat and back members 12 and 14, respectively.
Referring particularly to FIGS. 2 and 4, the locking and positioning device 18 includes first and second elongate tubular members 24 and 26, respectively. As illustrated, the second tubular member 26 is slidably received within the first tubular member 24 for telescoping movement with respect thereto from a retracted position (back member 14 upright) to an extended position (back member 14 inclined).
Carried by the free end of the first tubular member 24 is a gripping means 28 which frictionally grips the second tubular member 26 in selected positions with respect to the tubular member 24. The gripping means 28 is structured to prevent relative telescoping movement between the first and second tubular members 24 and 26 in either direction. To this end, the gripping 28 includes a pair of friction washers 30 and 32 adapted to surround second tubular member 26 and arranged to exert pressure in opposite directions parallel to the second member 26 and in directions opposite to both directions of pivotal movement of the back member 14.
Referring now to FIGS. 2 and 3, the washers 30 and 32 are generally elliptical in shape and provided with central openings 30a and 32a, respectively, for receiving the second tubular member 26. The openings 30a and 32a are larger than the cross-sectional configuration of the member 26 so as to permit annular movement of the washers 30 and 32 in order to permit the edges of the openings 30a and 32a to engage the outer surface of the second member 26 and prevent movement of the member 26 through washers 30 and 32 to retain the back member 14 in any selected adjusted positions. The washers 30 and 32 are individually carried by a fulcrum arm 34 extending through apertures 30b and 32b provided in the lower end of the washers 30 and 32, respectively. The fulcrum arm 34 may be a headed pin which is attached, as by riveting 36, (see FIG. 3) to a collar 38 secured, as by welding, to the free end of the tubular member 24. The washer 32 is longitudinally spaced from the free end of the member 24 by an elongate tubular spacer member 40 extending between the opposing faces of the washer 32 and collar 38 and surrounding the fulcrum arm 34. In this first position, the washers 30 and 32 are respectively urged into edge gripping engagement by a spring 42 surrounding the member 26 and reacting against the opposing facing surfaces of the washers 30 and 32.
The washers 30 and 32 are compressed into a second release position against the action of spring 42 by headed pin elements 44 and 46, respectively. The pin elements 44 and 46, extend through apertures 30c and 32c parallel to the member 26, are provided with head portions 44a and 46a adapted to act against the outside surfaces of tabs 30d and 32d provided on the upper end of the washers 30 and 32, respectively. The pin elements 44 and 46 are pivotally connected, as at 44b and 46b, in spaced relation relative to an end of the lever 48 for longitudinal movement relative to the member 26. More specifically, the lever 48 projects between the washer tabs 30d and 32d and is adapted for rotary movement about the ends of the pins 44 and 46 for moving the pins longitudinally relative to the member 26. In the gripping position of the washers 30 and 32, the pin elements 44 and 46 allow the washers 30 and 32, respectively, to be tilted into gripping engagement with the sides of the member 26 by the biasing action of the spring 42. In the disengaged position of the washers, the lever 48 is rotatable from the first position to a second position (see dotted line position in FIG. 3) where the pin elements 44 and 46 move the washers toward each other to tilt the washers 30 and 32 and thus releasing the gripping engagement of the openings 30a and 32a from the sides of the tubular member 26.
In the embodiment of the invention illustrated in FIGS. 4 and 5, gripping means 28' includes a pair of friction washers 30' and 32' adapted to surround the second tubular member 26 and arranged to exert pressure in opposite directions parallel to the second member 26 and in directions opposite to both directions of pivotal movement of the back member 14.
The washers 30' and 32' are generally elliptical in shape and provided with a central opening 30a' and 32a', respectively, for receiving the second tubular member 26. The washers 30' and 32' each are carried by a fulcrum arm 34' extending through apertures 30b' and 32b' (see FIG. 5) provided in the lower end of the washers 30' and 32', respectively. The fulcrum arm 34' may be a headed bolt attached in a threaded aperture 36 provided in a collar 38 attached, as by welding, to the free end of the tubular end member 24. In this first position, the washers 30' and 32' are respectively urged into edge gripping engagement by springs 50 and 52, respectively, adapted to react against the outer surfaces of the washers 30' and 32'. More specifically, a headed bolt 54, extending through apertures 30c' and 32c', is attached in a threaded aperture provided in a tab 38a' projecting from the collar 38'. The springs 50 and 52 surround the shank of the bolt with the spring 50 extending between the head of the bolt 54 and the outer surface of the washer 30' and the spring 52 extending between the opposing surfaces of the washer 32' and the collar tab 38a'.
The washers 30' and 32' are moved into a second release position against the action of the springs 50 and 52 by camming means 56. The camming means 56 are provided on a lever arm 58 pivotally connected at one end to the collar 38a'. The camming means 56 is adapted to act against the inside surfaces of the tabs 30d' and 32d' provided on the upper ends of the washers 30' and 32', respectively, for compressing the ends of the washers against their respective springs. In the gripping position of the washers 30' and 32', the cam means 56 allows the washers 30' and 32' to be tilted into gripping engagement with sides of the member 26 by the biasing action of the springs 50 and 52. In the disengaged position of the washers, the lever 58 is rotatable from the first position to a second position (see FIG. 5) wherein the camming means 56 is effective to move the washers away from each other to tilt the washers 30' and 32' to release the gripping engagement of the openings 30a' and 32a' from the sides of the tubular member 26.
In operation, the back member, when released, may be adjusted to an inclined position by moving the actuating lever into the second position, thus releasing the washers from gripping engagement as illustrated in FIGS. 2 and 4. When the desired position of the back 14 has been obtained the actuating lever is released and the member 26 is again gripped by the washers to hold the back member 14 in the exact position to which it has been moved. The back member 14 may be positioned from an upright position, as illustrated in FIG. 1, to a substantially horizontal position, or an infinite number of positions therebetween.
It will be appreciated from the foregoing description that the locking and positioning device 18 controls movement in both directions of travel of the telescoping tubular members relative to each other. Also, it should be noted that the biasing spring or springs cooperate with the two washers to exert pressure thereon so that frictional engagement with the member 26 is applied without delay. Further it should be noted that frictional engagement of the two washers with the tubular member 26 is simultaneously released.
In accordance with the provisions of the patent statutes, the principle and mode of operation has been explained and what is considered to represent its preferred embodiment has been illustrated and described. It should, however, be understood that the invention may be practices otherwise than as specifically illustrated and described without departing from the spirit and scope.
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A locking and positioning apparatus for reclining seats including a back member pivotally connected to a seat member for movement between an upright position and various inclined positions. The locking and positioning apparatus includes first and second telescoping members innerconnected by a pair of gripping elements which are normally biased into frictional gripping engagement with one of the members for preventing relative movement between the members in either direction of travel between the members. A manually actuatable pivotal lever having portions disposed between the pair of gripping elements is provided for releasing the pair of gripping elements from gripping engagement with the one member for preventing relative movement between the members in either direction of travel.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to EP Application No. 14169673.2, having a filing date of May 23, 2014, the entire contents of which are hereby incorporated by reference.
FIELD OF TECHNOLOGY
[0002] The following describes a blade tip clamp arrangement, a rotor blade transport and storage arrangement, and a method of handling a wind turbine rotor blade during transport and storage.
BACKGROUND
[0003] After manufacturing a wind turbine rotor blade, the blade may need to be transported to a short-term or long-term storage facility, and ultimately the blade will be transported to an installation site, for example at an offshore windfarm. Transport modes can include ship transport or road and/or rail transport over land. For a wind turbine with a rated power output of several megawatts, a rotor blade can have a length in excess of 75 m, and may weigh several tons. Generally, a wind turbine rotor blade comprises a circular root end for mounting to a pitch interface of a hub. The root end of a blade for such a large wind turbine can have a diameter in the range of 2.0 to 4.0 m or more. The circular shape of the root end undergoes a transition towards the blade airfoil portion, which accounts for most of the blade length. The airfoil portion is generally widest close to the root end, and tapers to a narrow end or tip. The airfoil section of the blade has a rounded leading edge and a relatively sharp trailing edge. Between the leading edge and the trailing edge, the airfoil section has a curved convex upper surface (the “suction” side), and a curved concave lower surface (the “pressure side”). The unwieldy shape and dimensions of a wind turbine rotor blade make transport difficult. Furthermore, the blade is quite vulnerable to damage and must therefore be treated with care throughout all transport and handling stages to ensure that the surface remains smooth and intact.
[0004] The own weight of a rotor blade may present a problem during a lifting manoeuvre. For this reason, it is generally preferred to bring the blade into an “upright” position, i.e. a position in which the airfoil is essentially “vertical” or upright with the leading edge of the blade underneath and the trailing edge on top, while the blade itself is suspended horizontally from root end to tip end. This blade orientation also helps ensure that the vulnerable trailing edge of the blade is protected from damage, while the relatively straight leading edge has sufficient structural strength to prevent the blade from bending while suspended in the air.
[0005] During a storage or transport stage, several rotor blades may be arranged in an array of stacked frames. To fit many blades into a relatively small volume, the blades may be “inter-leaved” with the tip ends of some blades facing towards the root ends of other blades. Such a stacking arrangement must consider the height difference between the root portion of a blade and the relatively flat and narrow airfoil portion near the tip end. Furthermore, a blade should be stored so that it is not distorted by its own weight.
[0006] Between manufacture and installation of a rotor blade, it must be moved and handled several times, for example from a manufacturing facility to a storage facility, from storage to truck, from truck to ship, etc. Each handling stage may involve a change in orientation of the blade for the reasons given above. Furthermore, the blade must at all times be securely connected to any holding, lifting, hoisting or transport means. This may involve transfer between different holding means, for example because of different mounting structures or connection interfaces of a storage means and/or a transport means. Such connection procedures are time-consuming and costly and can significantly add to the overall costs of a wind turbine.
SUMMARY
[0007] An aspect relates to improving handling wind turbine rotor blades during transport and storage.
[0008] According to embodiments of the invention, the blade tip clamp arrangement is realised to support a wind turbine rotor blade and comprises at least a tip clamp assembly realised to clamp about the leading edge of the rotor blade along an airfoil portion of the rotor blade; and a pivot connection interface realised to pivotably connect the tip clamp assembly to a wheeled transport means.
[0009] In the context of embodiments of the invention, the expression “to hold the rotor blade along an airfoil portion” is to be understood to mean that the tip clamp assembly grips or otherwise securely holds the rotor blade at a point, or over a length of, the airfoil portion of the blade, which, as described above, is that part of the blade which has an airfoil shape in cross-section. The blade can be supported at one or more other points during transport and storage. For example, a blade is usually also held at the root end of the blade by an appropriate root end support structure.
[0010] An advantage of the blade tip clamp arrangement according to embodiments of the invention is that transport and storage of the blade can be greatly simplified. The pivot connection allows the blade tip clamp arrangement to be easily connected to the wheeled transport means, which can be any of a dolly, a trailer, a truck, a railcar, etc. As mentioned above, the length of a rotor blade for an offshore installation can exceed 70 m, and prior art methods of transport and storage are made costly and time-consuming by the difficulty in manoeuvring such a long blade. The tip clamp assembly according to embodiments of the invention is characterized by the pivot connection, which allows the wheeled transport means to alter its path of travel independently of the blade. This makes it easier to move the blade from one location to another, for example, from a storage facility to a transport vessel, while at the same time ensuring that the blade is always held securely by the tip clamp assembly.
[0011] According to embodiments of the invention, the rotor blade transport and storage arrangement is realised for the storage and transport of a wind turbine rotor blade and comprises a blade tip clamp arrangement according to embodiments of the invention for supporting the rotor blade along an airfoil portion of the rotor blade, and a root end bracket for supporting the rotor blade root end.
[0012] An advantage of the rotor blade transport and storage arrangement according to embodiments of the invention is that the blade tip clamp arrangement, used to assist in moving the rotor blade from one location to another, can also be used to support the airfoil portion during short-term or long-term storage. The root end bracket of the transport and storage arrangement according to embodiments of the invention can also be used during both storage and transport phases. This means that relatively little direct handling of the blade is required, since the tip clamp assembly and the root end bracket can be mounted to the rotor blade once during an initial preparation step, and can remain in their mounted state until a final stage, for example, until the blade has arrived at the installation site.
[0013] According to embodiments of the invention, the method of handling a wind turbine rotor blade during transport and storage comprises the steps of clamping a tip clamp assembly of a blade tip clamp arrangement according to embodiments of the invention about an airfoil portion of the rotor blade, mounting the tip clamp assembly to a supporting means in a first blade orientation for blade storage and/or blade transport, and/or mounting the tip clamp assembly to a supporting means in a second blade orientation for storage and/or transport, and/or connecting the pivot connection interface of the blade tip clamp arrangement to a wheeled transport means for a transport manoeuvre.
[0014] An advantage of the method according to embodiments of the invention is that, with relatively little effort, the rotor blade can be manoeuvred safely and securely during different transport stages, and can be held safely and securely during storage stages. Throughout these transport and storage stages, it is not necessary to alter the position of the tip clamp assembly relative to the blade; neither is it necessary to remove it or to re-attach it, even though the blade may need to be held in two different positions, for example in a first position with an essentially “flat” airfoil, and a second position with an essentially “upright” airfoil. The method according to embodiments of the invention may therefore offer considerable savings in the cost of handling and storing wind turbine rotor blades, particularly when many blades, intended for an offshore windfarm site, must be loaded from an initial storage facility onto a road or rail vehicle for transport to another storage facility, and then transferred again to an installation vessel for transport to the offshore site. During all these stages, the blade tip clamp arrangement securely holds the airfoil portion of the blade and protects it from damage.
[0015] Features of different claim categories may be combined as appropriate to give further embodiments not described herein.
[0016] In the following, without restricting embodiments of the invention in any way, it may be assumed that the wheeled transport means is a vehicle such as a trailer or dolly that can fit underneath the rotor blade in the airfoil section, and that can be used to support the blade while this is being moved from one location to another. A dolly or trailer can be selfpropelled and can have its own drive means, and can be directly or remotely controlled by an operator. In the following, the terms “wheeled transport means” and “dolly” may be used interchangeably as appropriate.
[0017] As mentioned above, it can be necessary or advantageous to be able to orient a rotor blade in different positions during the various storage and transport stages between manufacture and installation. For example, a horizontal or “flat” orientation may be more practicable during storage, while a vertical or “upright” orientation may be desirable during transport. Therefore, in a preferred embodiment of the invention, blade tip clamp arrangement is realised for use in at least a first blade orientation (“upright” or essentially vertical) and a second blade orientation (“flat” or essentially horizontal). It is to be understood that the blade need not be removed from the blade tip clamp arrangement in order to alter its position; instead the orientation of the blade tip clamp arrangement can be altered while it holds the blade.
[0018] In either position or orientation, the blade tip clamp arrangement can be realised to rest securely on a surface such as the ground, a truck flatbed etc. For example, the blade tip clamp arrangement might have a supporting structure connected to the tip clamp arrangement, and with sufficient height to ensure that the longitudinal axis of the blade is essentially horizontal when the blade is supported by the blade tip clamp arrangement. Since the blade tip clamp arrangement is preferably realised to support the blade in two distinct orientations, two such supporting structures may be preferable, arranged at 90° angles to each other. However, when the blade is being held in a first orientation, the supporting structure corresponding to the second orientation may protrude outward by some considerable distance. Therefore, in a particularly preferred embodiment of the invention, the blade tip clamp arrangement comprises a separate support foot realised to support the tip clamp assembly in the first and/or second blade orientation. The support foot and the tip clamp assembly are preferably realised as physically independent units that can be connected together for at least two distinct blade orientations. In this way, the overall dimensions of the blade tip clamp arrangement can be kept favourably compact. To ensure that the blade is always held securely by the blade tip clamp arrangement without any risk of the tip clamp assembly detaching from the support foot, in a preferred embodiment of the invention the tip clamp assembly comprises a first support foot mounting interface for mounting the tip clamp assembly to the support foot in the first blade orientation, and a second support foot mounting interface for mounting the tip clamp assembly to the support foot in the second blade orientation. A mounting interface can be realised as a locking mechanism to lock the tip clamp assembly to the support foot.
[0019] In a preferred embodiment of the invention, the pivot connection interface to the wheeled transport means is realised to allow free rotation (in a horizontal plane) of the rotor blade relative to the wheeled transport means. This is to be understood to mean that if the position of one of the blade or wheeled transport means changes, the other remains stationary. For example, the blade can remain stationary relative to the wheeled transport means as this changes its orientation. In this way, the wheeled transport means can be steered to alter its course during a blade transfer manoeuvre. Preferably, the pivot connection interface is realised to allow a rotation of the rotor blade of at least 20°, preferably at least 30° in the horizontal plane. This rotation is preferably relative to a longitudinal axis of the wheeled transport means so that, for example, a longitudinal axis of the blade can “pivot” about a kingpin connector on either side of the longitudinal axis of a dolly.
[0020] The pivot connection interface can be realised in any appropriate way. For example, flexible joint arrangements such as a universal joint, gimbal, or other may be considered. However, in a particularly preferred embodiment of the invention, a kingpin connector is used since this is relatively simple in construction, is quite robust, and is comparatively economical. The kingpin can be arranged on any suitable part of the blade tip clamp arrangement. For example, a kingpin connector can be arranged on one side of the tip clamp assembly. It may be preferred to have two such kingpin connectors on the tip clamp assembly, arranged essentially at a 90 ° angle to one another, so that the blade tip clamp arrangement can interface to a dolly or trailer in the two distinct orientations mentioned above. Such a kingpin can interface with a suitable connecting part on the wheeled transport means. For example, the kingpin can fit into a “fifth wheel” arranged on a dolly, a tractor unit, etc.
[0021] It may be preferred to connect the blade tip clamp arrangement to a wheeled transport vehicle with or without a support foot connected to the tip clamp assembly. Therefore, in a preferred embodiment of the invention, the blade tip clamp arrangement comprises one or more pivot connection interfaces arranged on the tip clamp assembly and/or one or more pivot connection interfaces arranged on the support foot. In this way, various mounting arrangements are possible so that transfer of a blade from one location to another and/or from one orientation to another can be favourably simplified.
[0022] The root end bracket of the rotor blade transport and storage arrangement according to embodiments of the invention may also comprise such a pivot connector, so that the root end bracket can also connect to a wheeled transport means. In this way, a very manoeuvrable arrangement can be obtained, so that transfer operations can be carried out quickly and safely even in a relatively confined area such as a harbour loading area, for example when a blade must be transferred onto a ship for transport to an installation site.
[0023] The tip clamp assembly can be realised in any suitable manner. For example, the tip clamp assembly can be realised as a clamp that extends about the blade to enclose a section of the blade in a holding arrangement. However, it can be awkward and time-consuming to put such a holding arrangement in place and/or to release such a holding arrangement again. Therefore, in a particularly preferred embodiment of the invention, the tip clamp assembly comprises a number of leading edge clamps, whereby a leading edge clamp is to be understood as a clamping device that fits about the leading edge only, and does not extend across towards the trailing edge side of the blade.
[0024] A leading edge clamp can be realised to “connect” to the blade in any suitable manner. In a particularly preferred embodiment of the invention, a leading edge clamp comprises a pair of pivotably mounted friction pads, wherein a friction pad is shaped according to the shape of the rotor blade about the leading edge, and wherein the leading edge clamp is realised to press the friction pads against opposing faces of the rotor blade on either side of the leading edge. For example, the friction pads can have a shallow concave shape to fit over the curved outer surface of the blade. In the context of a leading edge clamp, a pivot mount is to be understood to mean that the friction pads of a pair are hinged so that these can adjust their position relative to the curvature of the blade surface. The friction pads can be made of a suitable high-friction material that will not damage the blade surface. Examples of suitable materials are elastomers, synthetic rubber, ethylene propylene diene monomer rubber (EPDM), etc. A high-friction rubber material, pre-forced by 0.2 MPa, is preferred. A leading edge clamp can be connected to a pressure control means, for example to a hydraulic drive unit which can be realised to press a pair of friction pads to the blade surface about the leading edge, and the pressure may be adjusted as necessary. For example, the pressure may be increased prior to a lifting or transfer operation, and may be decreased when the blade is to be left in storage for a while.
[0025] Preferably, a leading edge clamp is realised to clamp about the leading edge of the blade over a distance extending over at most 33%, more preferably at most 25% of the distance between leading edge and trailing edge. For example, if the leading edge to trailing edge distance comprises 1.85 m over the suction side and 1.80 m over the pressure side, a leading edge clamp may be placed such that each friction pad of a friction pad pair covers a portion of the blade surface commencing at some point outward from the leading edge, and extending up to a distance of about 0.62 m in the direction of the trailing edge.
[0026] A single long leading edge clamp may be sufficient to hold the blade, for example a leading edge clamp with a pair of friction pads, each about 1.0 m in length. However, in a particularly preferred embodiment of the invention, the tip clamp assembly comprises a plurality of individually operable leading edge clamps. Preferably, the tip clamp assembly comprises at least three such leading edge clamps. In this way, the independently operable leading edge clamps can adjust to slight changes in the curvature of the blade over the section supported by the blade tip clamp arrangement. Preferably, the leading edge clamps are arranged essentially in line along a section of the leading edge of the rotor blade. For example, in a preferred embodiment, the hinge or shared pivot upon which the friction pads are mounted are in line with the leading edge of the blade, i.e. arranged in a line that is essentially parallel (but offset from) the leading edge. In this way, when the blade is held in the upright orientation, the weight of the blade is optimally counteracted by the friction pads of the leading edge clamps.
[0027] As indicated above, the rotor blade may be moved from a storage facility to a transport means, and vice versa. This can involve the use of various heavy-duty load lifting means. For example, one or more heavy-duty forklifts may be used to support the blade and also to raise or lower the blade as appropriate. Therefore, in a further preferred embodiment of the invention, the blade tip clamp arrangement comprises at least one interface to a load lifting vehicle. For example, the interface may comprise a pair of lugs spaced to correspond to the distance between the forks, and to fit closely about the forks. The blade tip clamp arrangement can comprise one or more such pairs of lugs. For example, a pair of lugs may be incorporated in the tip clamp assembly and/or a pair of lugs may be incorporated in the support foot.
[0028] Moving the blade from place to place may be performed using apparatus such as a forklift as described above, but it may also be advantageous to use a crane to hoist the blade or to assist in moving the blade in conjunction with a forklift. Therefore, in another preferred embodiment of the invention, the blade tip clamp arrangement also comprises a number of eyelets for connecting to a crane hoisting cable. Eyelets can be incorporated in the structure of the blade tip clamp arrangement so that when the blade is suspended from the crane, the blade assumes a horizontal position or an “upright” position.
[0029] By equipping the blade tip clamp arrangement with such connecting interfaces to lifting/hoisting means, a change in blade orientation can easily be achieved using the method according to embodiments of the invention. Preferably, the tip clamp assembly is connected to a crane and then lifted out of the supporting means of the blade tip clamp arrangement. The crane is then operated to effect a quarter turn rotation of the blade, i.e. a rotation of about 90°, resulting in a change between first and second blade orientations. Subsequently, the tip clamp assembly is lowered back onto the supporting means.
BRIEF DESCRIPTION
[0030] Some of the embodiments will be described in detail, with reference to the following figures, wherein like designations denote like members, wherein:
[0031] FIG. 1 is a schematic representation of a first embodiment of a blade tip clamp arrangement;
[0032] FIG. 2 shows a side view of an embodiment of the blade tip clamp arrangement of FIG. 1 ;
[0033] FIG. 3 shows an embodiment of the blade tip clamp arrangement of FIG. 1 mounted to a dolly;
[0034] FIG. 4 is a schematic perspective view of a support foot of an embodiment of a blade tip clamp arrangement;
[0035] FIG. 5 is a further detailed view of the embodiment of the support foot of FIG. 4 ;
[0036] FIG. 6 is a schematic representation of a blade held by an embodiment of a rotor blade transport and storage arrangement;
[0037] FIG. 7 shows an embodiment of a root end bracket of a rotor blade transport and storage arrangement; and
[0038] FIG. 8 is a schematic representation of another embodiment of a rotor blade transport and storage arrangement during a road transport operation.
DETAILED DESCRIPTION
[0039] FIG. 1 is a schematic representation of a first embodiment of a blade tip clamp arrangement 1 according to the invention in place about a rotor blade 2 . For clarity, only the clamped length portion of the rotor blade 2 is shown. The blade tip clamp arrangement 1 comprises a tip clamp assembly 10 which is detachably mounted on a support foot 12 .
[0040] The tip clamp assembly 10 uses a number of leading edge clamps 100 to securely press against the rotor blade pressure side 20 P and suction side 20 S surfaces, in a region close to the leading edge 2 L of the blade 2 . The blade 2 is being held in a vertical orientation V, so that the trailing edge 2 T is uppermost, and the leading edge 2 L is underneath. The leading edge clamps 100 are operable independently of each other. Each leading edge clamp 100 uses a pair of opposing friction pads 101 to press against the surface of the blade 2 . A kingpin connector (not visible in the diagram) is arranged within a kingpin plate 110 , which is realised to rest against a surface of a wheeled transport vehicle as will be explained below.
[0041] The support foot 12 is shaped to securely bear the weight of the blade 2 when held in the tip clamp assembly 10 . Here, the curved shape of the main body of the support foot 12 can offer a degree of flexibility while at the same time being structurally strong enough to bear the blade's weight.
[0042] The blade tip clamp arrangement 1 can rest on the ground using a pair of resting plates 122 , and can be lifted as a whole, for example by a forklift truck, with the help of a pair of lugs 13 . In this embodiment, the support foot 12 has one pair of lugs 13 , and the detachable tip clamp assembly 10 also has a pair of forklift lugs. Therefore, these elements 10 , 12 can be handled separately or as a single unit.
[0043] FIG. 2 shows a side view of the blade tip clamp arrangement 1 of FIG. 1 , arranged about the blade airfoil portion 20 . The airfoil 20 is shown in cross-section. The diagram shows more clearly the shape of the main body of the tip clamp assembly, and also shows lifting eyelets 14 with which the tip clamp assembly 1 (on its own or as part of a blade tip clamp arrangement) can be hoisted by a crane. The diagram also shows two independent connector arrangements 108 for connecting to a support foot. These allow the tip clamp assembly 10 to be mounted, in one of two different orientations, onto a support foot.
[0044] The diagram also clearly shows the manner in which opposing friction pads 101 of leading edge clamps 100 act to grip the airfoil portion 20 of a rotor blade 2 . Each friction pad 101 is mounted at the end of a pad arm 105 , which in turn is pivotably mounted about a pivot 102 . In this embodiment, the pad arms 105 on each side of the blade 2 are pivotably mounted about a shared pivot 102 . To press the friction pads 101 of a pair against the rotor blade surface, for example in preparation for a lifting or transfer operation, a spindle 103 can be tightened. The spindle 103 , when tightened, acts to push the lower ends of two opposing pad arms 105 outward, thus forcing the friction pads 101 inward against the surface of the rotor blade 2 . The diagram shows that a friction pad 101 of the tip clamp assembly 10 only clamps the blade 2 up to about 25%-30% of the distance from leading edge 2 L to trailing edge 2 T. Before removing the blade 2 , or before leaving the blade 2 in short-term storage, the spindle 103 can be loosened to relax the pressure. Each friction pad pair can be adjusted by its own dedicated spindle.
[0045] The diagram shows the blade 2 in an upright orientation V with its trailing edge 2 T uppermost. The illustration shows that the leading edge clamps 100 are tilted by an angle α. In this embodiment, the angle α corresponds to an angle between the horizontal, and a perpendicular through the airfoil chord at that part of the blade 2 . As an added precautionary measure during a transport operation, each friction pad pair can be connected by a strap 104 arranged to lie against the leading edge 2 L of the blade 2 . A downward motion of the blade 2 will cause the strap 104 to pull the corresponding friction pads 101 inward, pressing them against the blade surface, even if for some reason the spindle 103 should fail or become loosened.
[0046] FIG. 3 shows the blade tip clamp arrangement 1 of FIG. 1 mounted to a dolly 3 . This is achieved by inserting the kingpin connector of the blade tip clamp arrangement 1 into a corresponding component 30 on the dolly 3 , in this case into a “fifth wheel” 30 mounted on the end of a hydraulic lifting arrangement 31 . The kingpin plate 110 of the blade tip clamp arrangement 1 rests on the fifth wheel 30 , so that the blade tip clamp arrangement 1 can freely rotate relative to the dolly 3 , at least within a certain angular region as will be explained below. A forklift truck (not shown) can be used to lift the blade tip clamp arrangement 1 —using a pair of lugs as described above—and to lower it so that the kingpin connector fits into the fifth wheel 30 , which also acts as an automatic locking device. The dolly 3 is realised as a self-propelled vehicle 3 with a drive motor and control unit 32 , for example with a remote control unit for receiving commands issued by an operator (not shown). The dolly 3 can be equipped with sensors (not shown) for detecting a path of travel and/or any obstacles that may be present.
[0047] FIG. 4 is a schematic perspective view of a support foot 12 of an embodiment of a blade tip clamp arrangement 1 according to embodiments of the invention. Here, the view is from “underneath” the support foot 12 , and shows the kingpin connector 11 and kingpin plate 110 . In this embodiment, the main body 121 of the support foot 12 is rotatably mounted between the pair of lugs 13 . A pair of resting plates 122 allow the entire support foot 12 to rest securely on the ground. A locking mechanism 128 is used to lock the connectors 108 (as shown in FIG. 2 ) of the tip clamp assembly 10 to the support foot 12 in one of two distinct orientations.
[0048] FIG. 5 is a further schematic drawing of the support foot 12 of a blade tip clamp assembly, showing how the support foot 12 can be realised as two parts 12 A, 12 B—an upper part 12 A and a lower part 12 B—that can be assembled or dis-assembled as required. The upper part 12 A comprises the main body 121 , the kingpin and kingpin plate 110 , the tip clamp assembly locks 128 , etc. The lower part 12 B comprises the forklift lugs 13 and the resting plates 122 . For example, when the blade is being held in storage, the upper part 12 A of the support foot 12 can be connected to the lower part 12 B and secured using a number of bolts or other fastening means. When the blade is to be moved using a blade mover or dolly, in a transport procedure involving turns, the lower part 12 B can be disconnected. This allows more freedom of movement between blade and dolly, since these can pivot relative to one another about the kingpin, and the movement is not hampered by the resting plates 122 or lugs 13 . For a transport operation that does not involve turns, the two parts 12 A, 12 B may remain connected.
[0049] FIG. 6 is a schematic representation of a blade 2 held by an embodiment of a rotor blade transport and storage arrangement 5 according to the invention. The diagram shows the entire blade 2 , with a root end 21 held in a root end bracket 6 , and the airfoil portion 20 held by a blade tip clamp arrangement 1 . The root bracket 6 and the support foot 12 of the blade tip clamp arrangement 1 are shown resting on the ground. The tip clamp assembly 10 is shown connected to a crane hoisting cable in preparation for, or after completion of, a lifting manoeuvre (for example to change the orientation of the blade 2 from “upright” to “flat” or vice versa). In the diagram, the blade 2 is shown to be held in the vertical or “upright” position, with the trailing edge 2 T uppermost and the leading edge 2 L underneath.
[0050] FIG. 7 is a more detailed schematic of the root end bracket 6 , showing a brace 60 realised to fit over some of the ring bolts protruding from the circular root end 21 . The brace 61 is shown to have a number of transport connectors 63 for connecting to a hydraulic holding arrangement of a truck, as will be explained below. The brace 60 is realised to fit onto a root end support foot 61 , so that the root end 21 of the blade 2 can be supported during short-term or long-term storage. This support foot 61 can be disengaged as required for a transfer or transport operation. An additional multi-piece support flange 62 is shown to be arranged about the root end 21 , and its purpose is to prevent a distortion of the root end 21 while the blade 2 is being transported and/or stored.
[0051] FIG. 8 is a schematic representation of another embodiment of a rotor blade transport and storage arrangement 5 according to the invention during a road transport operation. Here, the root end 21 is held in a root end bracket 6 , which in turn is secured to a truck 41 or road tractor 41 . The airfoil portion 20 of the blade 2 is held by a blade tip clamp arrangement 1 which in turn is mounted to a dolly 3 or self-propelled trailer 3 . In the diagram, the blade 2 is shown to be held in the horizontal or “flat” position, with the suction side 20 S uppermost and the pressure side 20 P underneath. A portion of the blade 2 close to the tip end is clamped by the tip clamp assembly 10 of the blade tip clamp arrangement 1 . Since the tip clamp assembly 10 is rotatably mounted to the dolly 3 by means of the pivotable connection or kingpin, the dolly 3 can change its course direction relative to a longitudinal axis of the blade 2 with a certain angular region. This is indicated in the diagram as the shaded angular portion β about a longitudinal axis L 3 of the dolly 3 . In this way, road transport is made easier since the dolly is not constrained to follow a straight line according to the longitudinal axis of the blade 2 but can “twist” essentially freely to turn corners in the road, for example.
[0052] Although the present invention has been disclosed in the form of preferred embodiments and variations thereon, it will be understood that numerous additional modifications and variations could be made thereto without departing from the scope of the invention.
[0053] For the sake of clarity, it is to be understood that the use of “a” or “an” throughout this application does not exclude a plurality, and “comprising” does not exclude other steps or elements. The mention of a “unit” or a “module” does not preclude the use of more than one unit or module.
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A blade tip clamp arrangement configured to support a wind turbine rotor blade, including at least a tip clamp assembly configured to hold the rotor blade along an airfoil portion of the rotor blade, and a pivot connection interface configured to pivotably connect the tip clamp assembly to a wheeled transport means, is provided. A rotor blade transport and storage arrangement configured for the storage and transport of a wind turbine rotor blade, and a method of handling a wind turbine rotor blade during transport and storage is also provided.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation of Application Ser. No. 313,907, filed Dec. 11, 1972, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to thickened liquid shampoo compositions with conditioning properties, particularly those which are very mild.
2. Prior Art
Compositions containing the reaction products of ethoxylated anionic surfactants and certain specific amphoteric surfactants and polyethoxylated nonionic surfactants have been disclosed in U.S. Pat. Nos. 2,999,069 and 3,055,836, Masci and Poirier. Similar disclosures are contained in the corresponding foreign patent applications such as British Pat. Nos. 850,514, 850,515, and 921,122; and Canadian Pat. No. 595,532. In each of these patents, the disclosure is of a reaction product formed between the anionic surfactant and the amphoteric surfactant which contains ternary nitrogen groups, and there is no disclosure of thickeners.
Similarly, U.S. Pat. No. 3,580,853, Parran, discloses the cationic cellulose ether thickening and conditioning agents of this invention in shampoos to improve the deposition of particulate materials, but without a specific disclosure of the surfactant systems disclosed herein. The cationic cellulose ethers of this invention are known, having been generically disclosed in U.S. Pat. No. 3,472,840, Fred W. Stone and John M. Rutherford, Jr.
The compositions of this invention are all mild. This is a very desirable characteristic. The mildness apparently results from having a combination of anionic and cationic species present. However, as a result, many anionic, cationic, and nonionic polymers are incompatible with such formulas. It is extremely difficult to thicken such formulas and keep a single-phase clear composition. It is even more difficult to prepare a thick clear shampoo composition comprising anionic, zwitterionic or amphoteric, and nonionic surfactants which has good conditioning properties.
THE INVENTION
This invention relates to the discovery of a thickened mild liquid shampoo composition having conditioning properties comprising:
A. from about 4% to about 8% of an anionic surfactant selected from the group consisting of
1. A SURFACTANT OF THE FORMULA R(OC 2 H 4 ) n OSO 3 M, wherein R is a hydrophobic group selected from the group consisting of alkyl groups containing from about 8 to about 16 carbon atoms, alkylphenyl groups wherein the alkyl group contains from about 6 to about 15 carbon atoms, and fatty acid amido groups wherein the fatty acid contains from about 8 to about 16 carbon atoms, wherein n is a number from about 1 to about 10 (preferably 1 to 5) and M is a non-toxic cation which makes the surfactant water-soluble, preferably a cation selected from the group consisting of sodium, potassium, ammonium and triethanolammonium cations, (2) a water-soluble (e.g., sodium, potassium, ammonium or triethanolammonium) polyethoxylated fatty alcohol sulfosuccinate monoester wherein said fatty alcohol contains from about 8 to about 16 carbon atoms, preferably from about 10 to about 14 carbon atoms, and said polyethoxylated fatty alcohol contains from about 1 to about 10 (preferably 1 to 5) ethoxy moieties per molecule, (3) a water-soluble (e.g., sodium, potassium, ammonium, triethanolammonium, etc.) N-fatty acyl sarcosinate containing a fatty acyl group containing from about 8 to about 16 carbon atoms, (4) a water-soluble alkyl sulfate containing from about 8 to about 16 carbon atoms, and (5) a water-soluble N-fatty acyl-N-methyl taurine containing a fatty acyl group containing from about 8 to about 16 carbon atoms;
B. a surfactant selected from the group consisting of (1) a zwitterionic surfactant having the formula
(R.sup.2).sub.A N.sup.(.sup.-) (R.sup.3).sub.3.sub.-A CH.sub.2.sub.-B (R.sup.2).sub.B (R.sup.4).sub.C Y.sup.(.sup.-)
wherein A, B, and C are each selected from the group consisting of 0 and 1, wherein A is 0 when B is 1 and A is 1 when B is 0, wherein C can only be 1 when Y is a sulfonate group, wherein each R 2 is selected from the group consisting of alkyl groups containing from about 8 to about 16 carbon atoms and a moiety having the formula R 5 -- C(O)NH -- R 6 -- wherein R 5 is an alkyl group containing from about 8 to about 16 carbon atoms and R 6 is an alkylene group containing from 1 to about 5 carbon atoms (preferably 2-4 carbon atoms and most preferably 3 carbon atoms), wherein each R 3 is selected from the group consisting of alkyl, hydroxyalkyl and alkoxyalkyl groups which can be connected to form a ring and each of which contains from 1 to about 3 carbon atoms, wherein Y is selected from the group consisting of sulfonate and carboxylate groups, and wherein R 4 is an alkylene group containing from 1 to about 5 carbon atoms when Y is a carboxylate group and is selected from the group consisting of alkylene and hydroxyalkylene groups containing from about 2 to about 5 carbon atoms when Y is a sulfonate group and wherein the hydroxy group is on a secondary carbon atom,
2. a water-soluble N-alkyl β-aminopropionate wherein the alkyl group contains from about 8 to about 16 carbon atoms, and (3) a water-soluble N-alkyl β-iminodipropionate wherein the alkyl group contains from about 8 to about 16 carbon atoms;
C. a polyethoxylated nonionic surfactant selected from the group consisting of: (1) polyethoxylated alcohols, said alcohols containing an alkyl group either primary or secondary and either straight or branched chain, containing from about 8 to about 16 carbon atoms and said polyethoxylated alcohols containing from about 10 to about 45 ethoxy moieties per molecule, (2) polyethoxylated alkylphenols wherein the alkyl group contains from about 6 to about 15 carbon atoms and wherein the polyethoxylated alkylphenol contains from about 10 to about 45 ethoxy moieties per molecule, (3) polyethoxylated mono fatty acid esters of sorbitol wherein said fatty acids contain from about 8 to about 18 carbon atoms and said polyethoxylated mono fatty acid ester of sorbitol contains from about 10 to about 45 ethoxy moieties per molecule, (4) polyethoxylated polypropylene glycol having a molecular weight of from about 2,000 to about 6,000 and containing from about 40% to about 60% by weight of polyethoxy groups, and (5 ) polyethoxylated fatty acids wherein said fatty acid contains from about 8 to about 16 carbon atoms and said polyethoxylated fatty acid contains from about 10 to about 45 ethoxy moieties per molecule;
D. from about 50% to about 85% water; and
E. as a thickener and hair conditioning agent, from about 0.2% to about 4% (preferably from about 0.4% to about 2%) of a quaternary nitrogen-containing cellulose ether having substituent groups of the formula
(C.sub.2 H.sub.4 O--).sub.m [--CH.sub.2 CHO(CH.sub.2 N.sup.(.sup.+) (R.sup.7).sub.3 Cl.sup.(.sup.-))--].sub.n (C.sub.2 H.sub.4 O--).sub.p H
wherein each R 7 is selected from the group consisting of methyl and ethyl groups, m + p ranges from about 1 to about 10 (preferably from about 1 to about 4, most preferably from about 1 to about 2), n is from about 0.1 to about 0.5, the degree of substitution of the cationic group on the cellulose is from about 0.1 to about 0.5, and the viscosity of a 1% solution of the cellulose ether at 25°C. ranges from about 100 to about 2000 centipoises, the molecular ratio of (A) to (B) being from about 1:1 to about 4:1; the weight ratio of (A) + (B) to (C) being from about 2:1 to about 1:2; and the pH of the composition being from about 6.0 to about 8.0.
DESCRIPTION OF THE INVENTION
1. The Thickener. The products of this invention are, in part, described in the copending application of Raymond Edward Bolich, Jr. and Robert Benson Aylor entitled "MILD SHAMPOO COMPOSITIONS," Ser. No. 313,908, filed Dec. 11, 1972. These compositions, and other compositions disclosed herein are very mild. However, it is very difficult to thicken such compositions while maintaining the composition in a clear, liquid single-phase form. Most anionic, cationic and nonionic polymers are incompatible with such formulas. It was discovered, however, that the quaternary nitrogen-containing cellulose ether described hereinbefore is unique in its ability to thicken the compositions of this invention while maintaining the clarity of these compositions. In addition, it has been discovered that a surprising result is obtained upon dilution of the compositions of this invention with water, as occurs during use of the shampoos. Upon dilution, an effective hair conditioning precipitate is obtained which conditions the hair to provide, e.g., superior wet-combing properties. Thus, the thickener is also a hair conditioner.
Specific thickeners are described hereinafter. Those thickeners with lower degrees of substitution of the cationic group, e.g., from about 0.15 to about 0.25, are preferred. Also preferred are those thickeners having a value of m + p of about 1.5 and those thickeners whose 1% solutions have a viscosity of 125-1000 centipoises at 25°C.
2. The anionic surfactant. The polyethoxylated anionic surfactants of this invention are very mild. It is essential that the anionic surfactant be mild since it is used in a molar excess over the amount of zwitterionic surfactant present so as to minimize the amount of cationic species present. The anionic surfactant provides good lather properties. Typically, the composition will contain from about 4% to about 8% of the anionic surfactant. The sodium salts of the polyethoxylated anionic surfactants are preferred, but any non-toxic, water-soluble salt can be used, including potassium, triethanolammonium, and ammonium salts.
The preferred polyethoxylated anionic surfactants are the sodium salt of C 10 -C 14 fatty alcohol polyethoxy(3) ether sulfate, the sodium salt of polyethoxylated(3) C 10 -C 14 mono fatty alcohol sulfosuccinate, the sodium salt of C 10 -C 14 fatty acyl amido polyethoxy(4) ether sulfate. Other suitable polyethoxylated anionic surfactants are disclosed hereinafter in the examples.
3. The zwitterionic surfactants. The zwitterionic surfactant provides major lather benefits while modifying the nature of the composition so that it is less strongly anionic. The molecular ratio of the anionic to zwitterionic surfactant is from about 1:1 to about 4:1, preferably from about 1:1 to about 3:1, most preferably from about 1:1 to about 2:1.
Preferred zwitterionic surfactants are propylamido betaines derived from C 10 -C 16 fatty acids, and the corresponding propylamido sultaines, and C 10 -C 16 alkyl sultaines wherein the cationic and sulfonate anionic groups are separated by a propylene group and the remaining groups are methyl groups. Specifically, preferred zwitterionic surfactants are (a) those having the formula
R.sup.6 CO--NH-- C.sub.3 H.sub.6 -- N.sup.(.sup.+) (R.sup.7).sub.2 -- R.sup.8 -- Y.sup.(.sup.-)
wherein R 6 is an alkyl group containing from about 9 to about 15 carbon atoms, wherein each R 7 is selected from the group consisting of methyl, ethyl, and 2-hydroxyethyl groups, wherein Y is selected from the group consisting of sulfonate and carboxylate groups, and wherein R 8 is a methylene group when Y is a carboxylate group and is selected from the group consisting of propylene and 2-hydroxypropylene groups when Y is a sulfonate group; and (b) those having the formula
R.sup.9 N.sup.(.sup.+) (R.sup.10).sub.2 CH.sub.2 CHXCH.sub.2 SO.sub.3.sup.(.sup.-)
wherein R 9 contains from about 10 to about 16 carbon atoms, wherein each R 10 is selected from the group consisting of methyl, ethyl, and 2-hydroxyethyl groups, and wherein X is selected from the group consisting of hydrogen and hydroxyl groups. Examples of other zwitterionic surfactants are given in the examples hereinafter.
4. The polyethoxylated nonionic surfactant. The polyethoxylated nonionic surfactant provides a mildness benefit. It also contributes to the character of the lather, although in general, the nonionic surfactant tends to control and diminish the amount of the lather. The ratio of the polyethoxylated nonionic surfactant and zwitterionic surfactant to the polyethoxylated nonionic surfactant is from about 2:1 to about 1:2, preferably from about 1:1 to about 1:2, and most preferably from about 1:1 to about 1:1.2.
Preferred nonionic surfactants include polyethoxylated (15-40) sorbitan monoacylate (C 10 -C 16 ; preferably monolaurate), polyethoxylated (40-80% by weight of the molecule) polypropylene glycol (M.W. about 3-5,000), and polyethoxylated (15-40) fatty alcohols (C 10 -C 14 ). Other examples of nonionic surfactants are disclosed hereinafter in the examples.
5. Water. Water is used to make up the shampoo compositions to the desired physical form. For liquid shampoos, there will normally be from about 50% to about 85% of water present, preferably from about 65% to about 80%.
6. Other ingredients. In addition to the ingredients described hereinbefore, the shampoo compositions of this invention can also contain other conventional shampoo components, including dyes, preservatives such as ethanol, perfumes, opacifiers, antibacterial agents, antidandruff agents, buffering agents, conditioning agents, etc. Desirably, only ingredients which are not irritating to the eye are added.
It is especially desirable and preferred to have buffering agents present to maintain the pH of the composition within the range from about 6.0 to about 8.0, preferably from about 6.5 to about 7.5. Such buffering agents include NaOH, HCl, NaHPO 4 , boric acid, etc. It is also very desirable to include antidandruff agents such as zinc pyridinethiol N-oxide.
The choice of a proper thickener is complicated by the fact that the ingredients react with many anionic thickeners and many nonionic thickeners fail to thicken the compositions. The compositions of this invention can also contain another nonionic thickener, e.g., a hydroxyethyl cellulose (e.g., one with a D.S. of about 2.5 whose 1% solution has a viscosity of 3-4,000 centipoises at 25°C.). This auxilary thickener is desirable in that it also tends to provide clear, single-phase compositions.
All patents and applications referred to herein are specifically incorporated by reference.
All percentages, ratios, and parts herein are by weight unless otherwise specified.
EXAMPLE IIngredient Percent by Weight3-(N,N-dimethyl-N-laurylamino) propane- 4.5 1-sulfonate (sultaine)Sodium salt of sulfated polyethoxylated 7.0 coconut fatty alcohol (AE.sub.3 S)Polyethoxylated(20)tridecyl alcohol 14.0 (β-methyl dodecanol) (PTA)Ethanol 7.0Cationic thickener -2 (cationic cellulose 1.25 ether of Claim 7 of U.S. Pat. No. 3,472,840, wherein a is 2, b is 2, q is 0, m + p is about 1.5, n and the degree of substi- tution (D.S.) of the cationic group are about 0.2, and the viscosity of a 1% solu- tion is 125-1000 centipoises at 25°C.)Water balancepH adjusted to 7.0 with HClEXAMPLE IIIngredient Percent by WeightN-(3-coconutacylamidopropyl)-N,N- 5.0 di(2-hydroxyethyl)-3-aminopropane- sulfonateSodium salt of sulfated polyethoxylated(4) 8.0 lauroylamide (ethoxylated amido sulfate)Tween 20 13.0Natrosol 250 HH [A hydroxyethyl cellulose 0.5 (D.P. -- 2.5) having a viscosity at 1% in water at 25°C of 3-4,000 centipoises]Cationic thickener -2 0.5Ethanol 7.0Water balance Adjusted to pH of 7.0 with NaH.sub.2 PO.sub.3EXAMPLE IIIIngredient Percent by WeightSultaine 4.00AE.sub.3 S 5.50Polyethoxylated(50%)polypropyleneglycol 14.00 (molecular weight 3,000) (PPG)Cationic thickener -2 .60Ethanol 7.00Perfume 0.25Distilled water balanceAdjusted pH to 7.0 with HCl.EXAMPLE IVIngredient Percent by weightN-(3-coconutacylamidopropyl)-N,N- 3.00 dimethyl-2-aminoacetate (Amido betaine)Sodium polyethoxylated(3)lauryl sulfo- 7.00 succinate (Ethoxylated sulfosuccinate)Polyethoxylated(20)sorbitol monolaurate 15.00 (Tween 20)Cationic thickener -2 0.50Ethanol 7.00Distilled water balanceAdjusted pH to 7.0 with NaOH.EXAMPLE VIngredient Percent by Weight3-[N-undecyl-N-ethyl-N-(2-hydroxyethyl) 4.5 ammonio]-butyratePotassium polyethoxylated(3) 6.6 tridecanolether sulfatePolyethoxylated(30)sorbitol 17.0 monococonutacylateEthanol 6.0Cationic thickener -1 (same as thickener 1.0 of Example I except having a D.S. of the cationic group of 0.4 and a viscosity at 25°C. with a 1% solution of about 1,500-3,000)Water balanceAdjusted pH to 7.0 with HCl.EXAMPLE VIIngredient Percent by WeightAE.sub.3 S 6.50Tween 20 14.0Amido betaine 5.00Cationic thickener -1 1.00Water balanceEXAMPLE VIIIngredient Percent by WeightSultaine 4.90AE.sub.3 S 6.60Tween 20 14.0Cationic thickener -2 0.50Ethanol 7.00Water balanceEXAMPLE VIIIIngredient Percent by WeightAmido betaine 4.00Ethoxylated sulfosuccinate 8.15PTA 14.00Ethanol 7.00Cationic thickener -2 0.48Na.sub.3 HPO.sub.4.12H.sub.2 O 0.65NaH.sub.2 PO.sub.4.H.sub.2 O 0.35Water balanceEXAMPLE IXIngredient Percent by WeightAmido betaine 5.00AE.sub.3 S 7.15PTA 14.00Cationic thickener -1 0.50Water balanceEXAMPLE XIngredient Percent by WeightSultaine 4.90AE.sub.3 S 6.60PTA 14.00Ethanol 7.00Cationic thickener -1 0.50Water balanceEXAMPLE XIIngredient Percent by WeightAmido betaine 4.00Ethoxylated sulfosuccinate 8.15PTA 14.00Ethanol 7.00Cationic thickener -1 0.50Water balanceEXAMPLE XIIIngredient Percent by WeightSultaine 4.50AE.sub.3 S 7.00PTA 14.00Ethanol 7.00Cationic thickener -2 0.46Water balanceEXAMPLE XIIIIngredient Percent by WeightAmido betaine 4.00Ethoxylated sulfosuccinate 8.15Tween 20 14.00Ethanol 7.00Cationic thickener -2 0.46Water balanceEXAMPLE XIVIngredient Percent by WeightSodium N-alkyl(C.sub.12 ;C.sub.14) β-aminopropionate 4.00AE.sub.3 S 6.70Tween 20 14.00Ethanol 7.00Cationic thickener -2 0.50Water balanceEXAMPLE XVIngredient Percent by WeightSultaine 4.50AE.sub.3 S 7.00Tween 20 14.00Ethanol 7.00Natrosol 250 HH 0.30Cationic thickener -2 0.30Water balanceEXAMPLE XVIIngredient Percent by WeightSultaine 5.00Sodium N-coconut acyl-N-methyl taurate 5.50PTA 14.00Cationic thickener -2 0.50Distilled water balanceEXAMPLE XVIIIngredient Percent by WeightC-cetyl betaine 4.00AE.sub.3 S 7.50Tween 20 14.00Cationic thickener -2 0.50Water balanceEXAMPLE XVIIIIngredient Percent by WeightAmido betaine 5.40Na N-lauroyl sarcosinate 5.20PTA 14.00Cationic thickener -2 0.50Distilled water balanceEXAMPLE XIXIngredient Percent by WeightAmido betaine 5.00Sodium coconut alkyl sulfate 6.00Tween 20 14.00Cationic thickener -2 0.50Distilled water balance
When in the above Examples I-XIX the following zwitterionic surfactants are substituted for the specifically named zwitterionic surfactants, substantially equivalent results are obtained in that the shampoos are exceptionally mild to the eyes.
1. 4-[N-coconutacylamidopropylene-N,N-di(2-hydroxypropyl)-ammonio]butane-1-sulfonate;
2. 2[N-pentadecylamidopropylene-N-(3-hydroxypropyl)-N-propylammonio]ethane-1-sulfonate;
3. 4(N-laurylmorpholino)2-hydroxybutanoate;
4. 3-(N-laurylmorpholino)propane-1-sulfonate;
5. 3-(N-tridecyl-N-methyl-N-propyl)-aminopropanoate;
6. 4-(N,N,N-trimethylammonio)stearate;
7.3-[N-methyl-N-(2-hydroxyethyl)-N-propylammonio]eicosane-1-sulfonate;
8. 5-[N,N-(3-hydroxypropyl)-N-methylammonio]-3-hydroxydocosane-1-carboxylate;
9. N-coconutalkyl betaine;
10. C-cetyl betaine;
11. C-hexadecyl betaine;
12. 3-(N,N-dimethyl-N-coconutalkylammonio)-2-hydroxypropane-1-sulfonate;
13. 6-coconutacylamido-3-trimethylammoniohexanoate;
14. 7-coconutacylamido-4-tri(2-hydroxyethyl)-heptane-1-sulfonate;
15. 3-[N-(3-coconutacylamidopropyl)-N,N-dimethylammonio]-propane-1-sulfonate;
16. 3-[N-(3-coconutacylamidopropyl)-N,N-di(2-hydroxyethyl)ammonio]-2-hydroxypropane-1-sulfonate;
17. 6-(N-coconutalkyl-N,N-dimethyl)hexanoate;
18. 5-(N,N-dipropyl-N-dodecylammonio)pentane-1-sulfonate;
19. 3-(N-methylmorpholino)stearate;
20. Potassium N-coconutalkyl β-aminopropionate;
21. Ammonium N-coconutalkyl β-iminodipropionate.
When in the above Examples I-XIX, the following ethoxylated anionic surfactants are substituted for the specifically named ethoxylated anionic surfactants, either totally or in part (e.g., a 1:1 ratio), substantially equivalent results are obtained in that the shampoos are exceptionally mild to the eyes:
1. Ammonium polyethoxylated(10)octanol ether sulfate;
2. Triethanolammonium polyethoxylated(2)2-ethyltetradecanol sulfate;
3. Potassium polyethoxylated(4) octylphenol ether sulfate;
4. Sodium polyethoxylated(6)pentadecylphenol ether sulfate;
5. Diethanolammonium polyethoxylated(4)dodecane-2-ol ether sulfate;
6. Monoethanolammonium polyethoxylated(5)tetrapropylene phenol ether sulfate;
7. Sodium polyethoxylated(8)3-nonylphenol ether sulfate;
8. Potassium polyethoxylated(4)octoylamide ether sulfate;
9. Triethanolammonium polyethoxylated(5)hexadecoylamide ether sulfate;
10. Potassium polyethoxylated(2)octanol sulfosuccinate monoester;
11. Triethanolammonium polyethoxylated(10)hexadecanol sulfosuccinate monoester;
12. Potassium N-coconutacyl sarcosinate.
When in the above Examples I-XIX, the following ethoxylated nonionic surfactants are substituted for the specifically named ethoxylated nonionic surfactants, either totally or in part (e.g., a 1:1 ratio), substantially equivalent results are obtained in that the shampoos are exceptionally mild to the eyes:
1. Polyethoxylated(40)octanol;
2. Polyethoxylated(10)hexadecanol;
3. Polyethoxylated(25)2-ethylnonanol;
4. Polyethoxylated(18)dodecane-2-ol;
5. Polyethoxylated(35)hexylphenol;
6. Polyethoxylated(30)pentadecylphenol;
7. Polyethoxylated(40)tetrapropylenephenol;
8. Polyethoxylated(25)3-nonylphenol;
9. Polyethoxylated(35)sorbitan monostearate;
10. Polyethoxylated(25)sorbitan monooctanoate;
11. Polyethoxylated(25)polypropylene glycol (M.W. 1000);
12. Polyethoxylated(25)octanoate;
13. Polyethoxylated(30)hexadecanoate.
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Mild thickened liquid shampoo compositions with conditioning properties comprise anionic surfactants, specific zwitterionic and amphoteric surfactants, polyethoxylated nonionic surfactants and a cationic cellulose ether thickening and conditioning agent.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part to U.S. patent application Ser. No. 09/704,086, filed on Nov. 1, 2000, entitled PARTIAL RESPONSE SIGNALING FOR ORTHOGONAL FREQUENCY DIVISION MULTIPLEXING claiming the benefit of U.S. Provisional Application No. 60/229,571, filed Aug. 31, 2000. Both applications assigned to assignee of present application and both are herein incorporated by reference.
BACKGROUND OF THE INVENTION
The present invention relates generally to communication systems. More particularly, the present invention relates to the stabilization of a signal envelope for communication systems.
Typical communication systems transmit information from one location or source to a second location or destination. The information travels from the source to the destination through a channel; this channel is typically a noisy channel. Thus, the channel introduces various forms of noise. The term “noise” is used herein to define various forms of signal corruption, such as interference, fading, attenuation, environmental impact, and electronic noise, that alter the characteristics of a signal as it travels through a channel. Accordingly, the signal that is transmitted through the channel and received at a receiver may be a combination of the transmitted signal and the effects of noise introduced by the channel as a result of travelling through the channel.
In a cellular communications system, one type of noise is called “interference”. More specifically, there may be at least two forms of interference in communication systems: co-channel interference (CCI) and inter-symbol interference (ISI). CCI arises in communication systems due in part to the fact that there are several transmitters in communication with the same receiving unit. The signal from one transmitter may interfere with the signal from another transmitter. Each transmitter may be an omni-directional transmitter. However, a signal being transmitted from one transmitter may take several paths as the signal travels from the transmitter to the receiver. This leads to ISI, which is a form of self-interference. In a cellular communication system, there are several mobile stations in communication with the same base station which often leads to CCI.
As indicated above, in a communication system, information is transmitted through the channel from the source to the destination. The information may be carried by a carrier signal that is modulated to contain or carry the information. Various forms of modulation may be used for transmission of the information through the channel. Modulation is the process of varying the characteristic of a carrier according to an established standard or scheme; the carrier is prepared or “modulated” by the information to produce a “modulated” carrier signal that is transmitted by the source to the destination through the channel. For example, in a cellular communication system, modulation is the process of varying the characteristics of the electrical carrier as information is being transmitted. The most common types of modulation are Frequency Modulation (FM), Amplitude Modulation (AM), and Phase Modulation (PM).
One modulation technique currently used in the industry is called Orthogonal Frequency Division Multiplexing (OFDM). OFDM is one of the techniques for multi-carrier modulation. Multi-carrier modulation is a technique for modulating multiple carriers with different information, all of which may be transmitted simultaneously or parallel in time. OFDM has high spectral efficiency as well as tolerance to multipath fading. As indicated above, transmitters are omni-directional and transmit in all directions. Thus, a signal emerging from a transmitter, or the source, may travel multiple paths to reach the receiver, or the destination. Accordingly, multipath fading occurs on a carrier signal's intensity, which results in alteration of the information being carried.
The efficiency of a system utilizing OFDM stems from the simultaneous or parallel transmission of several subcarriers in time. While this lowers the bit-rate on each of the subcarriers, it provides an “N”-fold increase in aggregate bit-rate, wherein “N” is the number of subcarriers. Additionally, because the low bit-rate signals hardly suffer any ISI and the subcarriers are orthogonal, it is possible to demodulate the subcarriers independent of each other. A conventional OFDM system comprises a set of sub-symbols X[k] transmitted in time using an Inverse Fast Fourier Transform (IFFT). The time-domain baseband signal can be represented as:
x [ n ] = 1 N ∑ k = 0 N - 1 X [ k ] · exp ( j 2 π kn N ) , n = 0 , 1 … N - 1
Thus, the N-sample long transmitted OFDM symbol vector can be expressed as:
x N=IFFT{X N }
where, x N and X N are the time and frequency domain symbol vectors, respectively.
In a typical OFDM system, binary symbols or bit streams are encoded in the form of complex valued numbers. The complex valued numbers are drawn from an M-ary alphabet. The complex valued numbers are then used to modulate a set of orthogonal sub-carriers to generate a time-domain signal using an Inverse Discrete Fourier Transform (IDFT). The resulting baseband signal, which is usually complex valued, is quadrature modulated on a Radio Frequency (RF) carrier and transmitted through an air interface channel. The transmitted signal is corrupted by channel noise and dispersion before being received. At the receiver end, by estimating the channel, equalizing for it and detecting the transmitted complex-valued numbers, the data is decoded.
There are several problems associated with systems that utilize OFDM modulation techniques. For example, the channel is subject to fading due to multipath and path loss. Additionally, the channel may suffer from ISI which poses a problem at the receiver when data has to be detected. Furthermore, manufacturers of devices that transmit and receive data are always faced with the challenge of increasing the amount of and the rate at which information can be transmitted over a finite bandwidth while overcoming signal loss due to channel noise.
Embodiments of the present invention are related to the implementation of Orthogonal Frequency Division Multiplexed (OFDM) systems. One of the persistent drawbacks of OFDM is the high peak-to-average power ratio (PAPR) encountered in OFDM systems. Coherent addition of the modulating sub-symbols can lead to an occasional peak in the signal that is several dB above average. A high PAPR usually implies that a very linear but inefficient power amplifier (PA) must be used for RF transmission. Furthermore, to make allowance for the high PAPR, we need to operate the power amplifier with several dbs of input power backoff; thus, limiting the average power of the output signal. Clipping is often the simplest solution proposed, but can lead to out-of-band distortion. Clipping also causes signal loss and often yields unacceptable bit error rates (BER). Other techniques considered have been block-coding and constellation translation. A high PAPR typically implies that the power amplifiers at the transmitter end and the amplifiers at the receiver end need to be of very high linearity, and preferably of high efficiency too. It is very common to trade-off high linearity for efficiency in OFDM type of applications so that often highly linear but inefficient amplifiers end up being utilized. An embodiment of the present invention enables the use of efficient amplifiers potentially by stabilizing the envelope of the RF carrier in an OFDM system. Alternatively, it enables the use of the traditional amplifiers with greater output power. Partial response signaling is employed to compress the signal in time. Then the power envelope is shaped or more specifically, squared.
It is in light of this background information related to high peak-to-average power ratio (PAPR) encountered in OFDM systems described above that the present invention has evolved.
SUMMARY OF THE INVENTION
The present invention, accordingly, advantageously provides a system and method to reduce the peak to average power ratio (PAPR) for an OFDM system by stabilizing the signal envelope. By using partial response (PR) signaling to spread each sub-symbol over multiple subcarriers, the signal is first compressed in time. The signal is then rearranged such that it is possible to stabilize the envelope, thus improving the PAPR without using excessive time-bandwidth resources. The compression provides extra time in which to stabilize the envelope.
An advantage of an embodiment of the present invention is to be able to use an inexpensive and efficient amplifier or to be able to use a traditional class A amplifier with greater average output power.
A more complete appreciation of the present invention and the scope thereof can be obtained from the accompanying drawings which are briefly summarized below, the following detailed description of the presently-preferred embodiment of the invention, and the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a graphical representation illustrating the real part of a partial response (PR) OFDM time-symbol with about 50% of the symbol duration carrying significant energy.
FIG. 2 is a graphical representation illustrating the imaginary part of a partial response (PR) OFDM time-symbol with about 50% of the symbol duration carrying significant energy.
FIG. 3 is a block diagram illustrative of a envelope shaping/squaring system for a Partial Response Orthogonal Frequency Division Multiplexing (PR-OFDM) in accordance with an embodiment of the present invention.
FIG. 4 is a graphical representation of the probability of clipping for different pad-powers using linear feedback and quadratic feedback.
FIG. 5 is a table listing the PAPR before and after envelope shaping/squaring.
DETAILED DESCRIPTION
A novel apparatus and method to enable the use of inexpensive relatively more efficient amplifiers (instead of less efficient and expensive class-A amplifiers) with an OFDM system is provided. The use of high-efficiency amplifiers requires that signals with very stable envelopes only be amplified. An embodiment of the present invention provides a system and method by which the envelope of an OFDM signal (which fluctuates a lot under normal circumstances) is stabilized with tolerable loss in system bandwidth. In other words, the system strives to balance the envelope's amplitude and keep it nominally close to a predetermined value.
The embodiments provided involve the use of partial response signaling. Partial response signaling has been described in co-pending U.S. patent application Ser. No. 09/704,086, filed on Nov. 1, 2000, entitled PARTIAL RESPONSE SIGNALING FOR ORTHOGONAL FREQUENCY DIVISION MULTIPLEXING. By choosing a suitable partial response polynomial, up to 50% of the signal in time can be rendered practically insignificant. That is to say, the signal across 50% of the OFDM symbol time-period can be closely approximated to zero with little loss of accuracy.
FIGS. 1 & 2 illustrate the real and imaginary parts, respectively, of a partial response (PR) OFDM time-symbol with about 50% of the symbol duration carrying significant energy. It can be shown that using PR-signaling of lower orders (M=2,3 etc.), a relatively smaller fraction of the OFDM symbol may be suppressed. Embodiments of the present invention may be used with any order M, although the bandwidth traded off (for envelope stability) is higher at lower M.
Referring now to FIG. 3 , communication system 10 in accordance with a preferred embodiment of the present invention is provided. System 10 may comprise transmitter 14 , channel 16 , and receiver 18 , wherein system 10 may utilize a Partial Response (PR)-Orthogonal Frequency Division Multiplexing (OFDM) signal modulation technique. Transmitter 14 may comprise mapper 22 , cyclic convolver 24 , serial-to-parallel converter unit 26 , Inverse Fast Fourier Transform (IFFT) unit 28 , parallel-to-serial converter unit 30 , and signal folder with envelope squarer 50 . Transmitter 14 transmits the information to receiver 18 through channel 16 . Channel 16 may be a noisy channel. Receiver 18 may comprise signal unfolder 60 , serial-to-parallel convener unit 34 , Fast Fourier Transform (FFT) unit 36 , parallel-to-serial converter unit 38 , Maximum Likelihood (ML) estimator unit 40 , and demapper unit 42 .
Information in the form of binary signals are received at transmitter 14 and inputted to mapper 22 for mapping to or encoding in the form of a set of complex numbers drawn from an M-ary alphabet to produce a complex signal, which is then used to modulate or prepare a carrier signal for transmission as discussed in detail below. Transmitter 14 transmits the carrier signal through channel 16 to receiver 18 . As to carrier signal, which may bc a time based signal, travels through channel 16 , which may introduce noise to the carrier signal, such as x[n], corresponding to a channel impulse response, such as h[n], of channel 16 . Cyclic convolver unit 24 performs a cyclic convolution on the complex signal. Additionally, cyclic convolver unit 24 may append a cyclic prefix (CP) at the leading edge or the beginning of the complex signal that also helps compensate for the effects of channel 16 and helps suppress Inter-Symbol Interference (ISI) in each of the low bit-rate sub-channels of the PR-OFDM signal.
The CP ensures that when channel 16 performs a convolution on each OFDM time-symbol the effect of channel 16 may be eliminated at receiver 18 . In a partial response (PR) technique inter-subcarrier (i.e., inter-channel) interference (ICI) is generated and introduced in the frequency domain based signal so as to shorten the effective time-domain symbol. The generated ICI is introduced to the complex signal by cyclic convolver unit 24 , as indicated above. Cyclic convolver unit 24 introduces, based on the desired or generated ICI, systematic or known amounts of dispersion to produce a partial response signal. In the system 10 , the frequency symbol X N is subjected to a cyclic convolution by a known polynomial C N of order M, which is defined as follows:
c N =[c ( 0 ) c ( 1 ). . . c (M−1) 00 . . . 0 ]
The PR polynomial can be expressed as a zero-padded vector of length N with M non-zero terms. The resulting time-domain symbol vector can now be expressed as follows:
x N =IFFT{ X N C N }
where, denotes cyclic convolution performed by cyclic convolution unit 24 , which disperses the information in each frequency-domain sub-symbol over M successive sub-carriers. Accordingly, receiver 18 requires a sequence-detection mechanism to unravel the input sub-symbols X N , and this is performed by ML detector unit 40 . Additionally, the other outcome of the cyclic convolution with C N is that the original time vector-symbol X N now bears an amplitude envelope given by the following:
e N=IFFT{c N }
By appropriately choosing the polynomial vector C N , the transmitter 14 can effectively suppress energy in parts of the OFDM time symbol-vector, thereby producing a PR-OFDM symbol. For example, consider the set of polynomials obtained from the coefficients of powers of r in p(r), where:
p ( r )=(1 −r ) m ; m= 1, 2, . . .
The envelope vector resulting from such a polynomial has a null at each of its extremities. Consequently, the energy at the extremities or the tails of the OFDM time symbol-vector is effectively suppressed and can be dropped. Thus, cyclic convolver unit 24 generates a partial response signal with near zero energy at the extremities in the time domain.
The partial response signal, which is a frequency domain based signal, is then received by serial-to-parallel unit 26 . Serial-to-parallel unit 26 converts the partial response signal from serial to parallel signaling and passes the parallel partial response signal to IFFT unit 28 . IFFT unit 28 performs a modulation that is a transformation on the parallel partial response signal to generate real and imaginary components in the time domain. The transformed parallel partial response signal is derived from the partial response signal. The real and imaginary components of the transformed parallel partial response signal are received by the parallel-to-serial unit 30 , which coverts to serial signaling to produce a transformed partial response (PR) signal that is ready for signal folding, envelope shaping or squaring and transmission.
The envelope amplitude at any instant is given by |X Re 2 +X Im 2 where, X Re and X Im are the signal's in-phase and quadrature components. The compressed PR signal may now be rearranged in time. The signal is rearranged such that all the significant time-samples (in-phase and quadrature-phase samples) are placed on the in-phase carrier adjacent to one another. The quadrature-phase carrier may be used as a degree of freedom to shape or square the envelope of the modified signal. Squaring the envelope essentially means stabilizing it to a nominally constant value.
To proceed with signal folding and envelope shaping or squaring, the PR signal is received by signal folder and envelope squarer 50 . Signal folder and envelope squarer 50 separates the real and imaginary parts of the significant section of the symbol and places the real and imaginary parts adjacent to one another.
At the end of signal folding process, the rearrangement may be represented by the time vector:
x′={x Re [ 0 ], . . . , x Re [N−d], x Im [ 0 ], . . . x Im [N−d]}
The in-phase carrier (I) is modulated with signal samples x″ derived from x′. The quadrature phase carrier (Q) is used as a degree-of-freedom to shape or “square” the envelope by placing suitably calculated samples on the quadrature-phase carrier. For every sample on the in-phase carrier, a corresponding sample is placed on the quadrature-phase carrier. This process balances the envelope amplitude and keeps it nominally close to a predetermined value so that amplitude may be maintained within the linear threshold of an amplifier, thus, avoiding any non-linear effects.
To illustrate various embodiments of the present invention, the envelope-stabilized signal may be represented as X″ and the nominal envelope value may be denoted as α. Two embodiments of the present invention: one using linear feedback and another using Quadratic feedback may be described by means of the following equations: Linear Feedback Equations
x ′ < α ⇒ x Im ″ = ( α - x ′ ) · sgn ( x ′ ) ; x Re ″ = x ′ : STEP-I x ′ > α ⇒ x Im ″ = - 1 2 x ′ ; x Re ″ = + 1 2 x ′ : STEP-I I
Quadratic Feedback Equations
x ′ < α ⇒ x Im ″ = ( α 2 - x ′ 2 ) · sgn ( x ′ ) ; x Re ″ = x ′ : STEP-I x ′ > α ⇒ x Im ″ = - 1 2 x ′ ; x Re ″ = + 1 2 x ′ : STEP-II
Since the samples on the quadrature-phase carrier are used as feedback terms, the equations describing their generation are referred to as “feedback equations”.
In linear feedback embodiment, an attempt is made to keep the sum of the magnitudes of the in-phase and quadrature samples constant, In quadrature feedback embodiment, an attempt is made to keep the sum of the magnitude squares a constant. When the envelope has already been exceeded by the in-phase sample's magnitude (Step-II), the amplitude is halved. Notice that in one case (Step-I), the two samples x″ Re and x″ Im bear the same sign, while in another case (Step-II), the two samples x″ Re and X″ Im bear opposite signs. This is a simple artifice that will later help us reconstruct the original signal x at the receiver from the received signal X″.
At the receiver end, the signal is reconstructed utilizing the in-phase signal received, and the quadrature-phase signal received [x″ Re and x″ Im ]. The reconstruction essentially does the reverse of x′={x Re [0], . . . , x Re [N−d]x Im[ 0], . . . , x Im [N−d]} yielding a noise corrupted version of the (N−d) samples long PR signal x[n].
The signal is reconstructed utilizing the estimated magnitude of y (y_mag) which is the absolute value of (x″ Im +X″ Re ). The idea behind this estimation is to infer whether Step-I or Step-II was used in constructing the signal x″ from x′. If Step-1 was used, then the magnitude of y (y_mag) should ideally be close to α; else, if Step-II was used, the value of (y_mag) is ideally close to 0. Thus, the magnitude of Y (y_mag) becomes a tool to figure out whether we employed Step-I or Step-II in constructing the transmitted signal x″.
The folded partial response signal is transmitted through the channel 16 and received at the receiver 18 as a transmitted folded partial response signal. The transmitted folded partial response signal is received and unfolded at signal unfolder 60 . This may be implemented as an adder and a thresholding device.
Signal unfolder 60 extracts the original PR-OFDM signal from the envelope squared PR-OFDM signal. A systematic way to decipher the phase (i.e. sign) of x′ from the transmitted signal values is provided. The quantity y_sign=sign(x″ Re +x″ Im ) or sign(x″ Re −x″ Im ), depending on whether Step-I or Step-II was used, respectively, in constructing x″. The way x″ is devised from x′, one can look at y_sign and reliably extract the sign of the in-phase component (which has the real and imaginary parts of the PR-OFDM symbol). Thus, using the quantities y_mag and y_sign, we can estimate the magnitude and phase of each of the real and imaginary components of the original PR-OFDM symbol.
If the absolute of (x″ Im +x″ Re ) is greater than half the nominal envelope value (α/2) then STEP-I was used. Thus, x′=sign(x″ Re +x″ Im ) times the absolute value of x″ Re .
If the absolute of x″ Im +x″ Re is less than or equal to half the nominal envelope value (α/2) then STEP-II was used. Thus, x′=sign(x″ Re −x″ Im ) times the absolute value of (x″ Re −x″ Im ).
The unfolded signal undergoes zero-padding (to fill up to an N-long vector) and then passes to serial-to-parallel unit 34 and converted to a parallel transmitted partial response signal and passed to FFT unit 36 . FFT unit 36 performs the inverse transformation of the transformation performed by IFFT unit 28 and, hence, transforms the signal from a time domain based signal to a frequency domain based signal to produce a converted parallel transmitted partial response signal. The converted parallel transmitted partial response signal is passed to the parallel-to-serial unit 38 . Parallel-to-serial unit 38 changes the converted parallel transmitted partial response signal to a converted transmitted partial response signal. The converted transmitted partial response signal is passed to maximum likelihood (ML) detector unit 40 . ML unit 40 unravels the converted transmitted partial response signal to produce or recover the complex-number based signal. Demapper unit 42 converts the complex-number based signal into a binary stream that is outputted from the receiver.
As described above, the signal envelope is maintained at some constant value. In the preferred embodiment, this value is represented by α. The value of α is fixed at a few dB above the existing expected envelope power. The extra dBs added to the envelope is what is referred to as pad-power. It is an objective of an embodiment of the present invention to be able to use inexpensive and efficient amplifiers or use traditional amplifiers at greater output power.
The time-extent of PR signal has been doubled from (N−d) to 2(N−d). The fractional time-overhead can be quantified as 2(1−d/N). The real objective of using PR signaling is to reduce this time-overhead incurred when compared to not using PR signaling. Not using PR signaling essentially leads to a 100% time-overhead, which is a significant cost to pay. Since the PR signal helps omit d time-samples, it correspondingly reduces the time-overhead incurred for envelope squaring.
FIG. 4 is a graph of the probability of clipping for different pad-powers using linear feedback and quadratic feedback. With linear feedback, we pad the envelope with 3–6 dB of extra power whereas with quadratic feedback we employ 1–4 dB pad-power (relative to the normal, average signal envelope). In both cases, the clipping probability substantially decreases after using envelope squaring. Clearly, quadratic feedback seems to offer comparable clipping probabilities at lower pad-powers than a linear feedback system. At least two orders of magnitude decrease in clipping probability can be observed at a clipping threshold of about 6 dB using both linear and quadratic feedback.
FIG. 5 lists the PAPR before and after envelope squaring. Simulations were performed for QPSK modulation with 64 subcarriers. The nominal PAPR for normal OFDM signals turned out to be 12–13 dB. The PAPR improvement ranged from 3–6 dB as we increased the pad-power from 1–4 dB for quadratic feedback, and from 3–6 dB for linear feedback. These are fairly high improvements in PAPR that cannot be obtained by normal techniques such as using transform signaling (example: Hadamard transform) or using companding as suggested by some others.
Although described in the context of particular embodiments, it will be apparent to those skilled in the art that a number of modifications to these teachings may occur. Thus, while the invention has been particularly shown and described with respect to one or more preferred embodiments thereof, it will be understood by those skilled in the art that certain modifications or changes, in form and shape, may be made therein without departing from the scope and spirit of the invention as set forth above and claimed hereafter.
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A system and method is proposed to significantly reduce the peak to average power ratio (PAPR) for an OFDM system by stabilizing the signal envelope. By using partial response (PR) signaling to spread each sub-symbol over multiple subcarriers, the signal is first compress in time. The signal is then rearranged such that it is possible to stabilize the envelope at some constant value α, thus improving the PAPR without using excessive time-bandwidth resources.
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This is a continuation of prior International application number PCT/EP99/07437 filed Oct. 5, 1999 and designating the United States of America, which International application claims priority from German patent application number 19846451.7 filed Oct. 8, 1998.
BACKGROUND OF THE INVENTION
The invention relates to an apparatus for the sealing of inflatable articles, in particular tires, comprising a container, containing a sealant and having a gas inlet which can be connected to a gas pressure source and an outlet which can be coupled to the article to be sealed, with the gas inlet and the outlet communicating with one another via the internal space of the container.
Such apparatuses are known (for example from DE 196 52 546 A1) and serve to seal a leak in an inflatable article, for example in a punctured tire, or a tire damaged during travel, by introducing a special sealant into the tire via the tire valve and by subsequently pumping up the tire at least to a pressure at which it can be run.
SUMMARY OF THE INVENTION
It is the problem (object) underlying the invention to so further develop an apparatus of the initially named kind that is as price worthy as possible and versatile in use.
The solution of this object takes place through the features of claim 1 directed to an apparatus of the kind initially named and through the features of claim 14 directed to the extraction unit
The provision in accordance with the invention of a separate extraction unit makes it possible to exchange the container when the sealant has been used up or is time expired, without the entire sealing apparatus having to be renewed. Furthermore, the reusable extraction unit can be used with containers of different size, and the sealing apparatus of the invention can thus be ideally matched to the respective inflatable article. Since the extraction unit is provided with a standing surface at its side remote from the container, it allows an operating position with the extraction unit standing on the ground and the container inverted.
In accordance with a preferred embodiment of the invention, the extraction unit for the in particular bottle-like container has at least one substantially cylindrical connection stub, preferably for receiving a connection section of the container resembling a bottleneck.
In this way the container and the extraction unit can be connected to one another in a particularly simple manner. The connection stub can be provided with an internal thread, so that the container, in particular its connection section provided with a corresponding external thread, simply needs to be screwed into the connection stub.
In accordance with a further preferred embodiment of the invention, an inlet duct and an outlet duct respectively extend, within a connection stub of the removal unit, in the region of their free end communicating with the container inner space, with the free ends of the inlet duct and of the outlet duct in each case not extending beyond the free end of the connection stub.
In this way the sealing apparatus of the invention can be used in two different operating positions. With the extraction unit standing on the ground, and with the container inverted with an opening disposed downwardly and connected to the connection stub of the extraction unit, the gas flows via the inlet duct into the container and—when the container is not completely full—through the sealant upwardly to the container base remote from the extraction unit. The free space above the sealant level is thereby pressurized so that the sealant is pressed through the outlet duct into the article to be sealed.
After a part of the sealant has been introduced into the article to be sealed, the sealing apparatus can be turned round and arranged with the extraction unit at the top. The sealant which remains in the container collects in the region of the base of the container, so that the free ends of the inlet duct and of the outlet duct are now exposed and are no longer dipped into the sealant. The gas which flows via the inlet duct into the container now fills the free space between the opening of the container and the sealant level and can thus flow directly via the outlet duct into the article to be sealed, whereby the latter is pumped up.
This manner of proceeding is of particular advantage in cases in which several tires of a vehicle or several chambers of an air mattress are damaged. After the introduction of a part of the sealant into, for example, the first tire to be sealed, the sealed tire can be pumped up—as explained above—by turning the sealing apparatus around, before the repair is continued with the next damaged tire. The sealing and pumping up of a plurality of damaged articles in series can be carried our particularly efficiently in this manner.
The fact that the gas entering into the container flows through the sealant during the introduction of the sealant into the article to be sealed furthermore ensures, in advantageous manner, a through-mixing of the sealant. Shaking of the sealing apparatus or of the container prior to use is thus not necessary.
When, in accordance with a further preferred embodiment of the invention, the container and extraction unit are manufactured from a preferably recyclable plastic, the sealing apparatus can be easily transported as a result of its then comparatively low inherent weight and can, in particular, be sued by people of weak stature, without effort. This is especially advantageous having regard to the above explained repair of several damaged articles in series, in which the sealing apparatus is turned around several times.
Further preferred embodiments of the invention are set forth in the subordinate claims, in the description and also in the drawing.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be described in the following by way of example and with reference to the drawing in which are shown:
FIG. 1 a sectional side view of a sealing apparatus in accordance with the invention, and
FIG. 2 the inventive sealing apparatus of FIG. 1 in an environment of use.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the embodiment of the invention in accordance with FIG. 1 the sealing apparatus includes a bottle-shaped, pressure-tight container 10 of recyclable plastic, which has an approximately cylindrical connection section 24 formed in the manner of a bottleneck, which will be termed the neck in the following.
The neck 24 is provided at its outer side with a thread, which permits the container 10 to be screwed into a connection stub 22 having a matching inner thread of a pressure-tight extraction unit 20 , likewise consisting of recyclable plastic and manufactured in one piece, in such a way that the internal space of the container is sealed off relative to the environment.
The neck 24 of the container 10 and the connection stub 22 of the extraction unit 20 have approximately the same length. At its inner side the neck 24 is provided with a constriction 21 in the form of a radially inwardly projecting, ring-like bead.
The container 10 contains a liquid sealant, such as is, for example, described in the German patent application 196 52 546. In the state shown in FIG. 1 the container 10 is less than half full of the sealant, as is shown by the broken line indicating the sealant level 40 . The container 10 can, for example, be designed to receive a volume of 700 to 800 ml. In the original state, prior to its first use, the container 10 is preferably fully filled with the sealant, without the inclusion of air, so that no disturbing skin formation can arise. The sealant level 40 indicated in FIG. 1 consequently represents an intermediate state after it has been taken into use, i.e. represents an already partly emptied container 10 .
The connection stub 22 forms a free end of a cylindrical connection section 32 of the extraction unit 20 , which is broadened in the radial direction to a pedestal section 34 at its end remote from the container 10 . The maximum radial dimension of the pedestal section 34 amounts to more than twice the diameter of the connection section 32 , whereby reliable standing of the sealing apparatus is ensured.
In the connection section 32 of the extraction unit 20 two base plates 42 , 44 are arranged spaced apart from one another, which separate the pedestal section 34 from the connection stub 22 . In the screwed in state in accordance with FIG. 1 the edge of the connection section 24 which bounds the opening of the container 10 lies on the upper base plate 44 .
Between the two base plates 42 , 44 , inner section 26 , 29 of an inlet duct 25 or of an outlet duct 28 extend in the radial direction, with their lower and upper boundary walls in each case being formed by the lower and upper base plates 42 and 44 respectively.
Outside of the connection section 32 of the extraction unit 20 , the inner sections 26 , 29 each merge into an outer section 27 , 30 . The inner sections 26 , 29 and the outer section 27 , 30 lie with their central axes on a common longitudinal axis 31 .
The outer section 27 of the inlet duct 25 is formed as a gas inlet and has, in the region of its free end, a thread 46 preferably formed as VG8-valve thread for the connection onto a gas pressure source, not shown in FIG. 1 .
The outer section 30 of the outlet duct 28 is provided with a portion 48 of reduced diameter, with hook-like coupling elements 49 formed onto its outer side, which serves for the connection to a filling line which will be explained in more detail in the following with reference to FIG. 2, via which the sealing apparatus can be connected to an article to be sealed.
Whereas the free inner cross-sectional areas of the inlet duct 25 and of the outlet duct 28 are of the same size, the outer section 30 of the outlet duct 28 has a greater wall thickness than the outer section 27 of the inlet duct 25 . In deviation from the illustrated embodiment, the free inner cross-sectional areas of the inlet duct 25 and of the outlet duct 28 can also be of different size.
The inner section 26 of the inlet duct 25 merges into an inflow passage 50 , the longitudinal axis of which coincides with the longitudinal axis 23 of the connection stub 22 , and the free inner cross-sectional area of which is smaller than that of the inner section 26 . The inflow passage 50 projects into the connection stub 22 of the removal unit 20 , and thus into the neck 24 of the screwed-in container 10 , with the inflow passage 50 , however, not extending beyond the free end of the connection stub 22 .
The inflow passage 50 is regionally arranged in the interior of a removal passage 52 of the outlet duct 28 , which concentrically surrounds the inflow passage 50 and the removal passage 52 form a coaxial line system and a ring space 54 arises, onto which the inner section 29 of the outlet duct 28 is connected. The free end of the inflow passage 50 projecting out of the extraction passage 52 and the free end of the extraction passage 52 are in each case chamfered off.
The neck 24 and the container 10 can be designed such that an adapter element formed as a Venturi nozzle can be introduced into the neck 24 , and in particular screwed into it.
In accordance with FIG. 2 a filling line 36 formed as a hose is connected onto the extraction unit 20 via the section 48 of the outlet duct 28 and is provided at its free end with a sleeve nut 56 , mating with a VG8-valve thread in order that the filling line 36 can be connected to the tire 18 which is to be sealed. The filling line 36 can either be releasably or fixedly connected to the extraction unit 20 .
At the left alongside the sealing apparatus of the invention, a gas pressure source 12 is schematically illustrated in FIG. 2 with a pressure display and with operating elements for the pressure regulation and has a connection line, to the free end of which a sleeve nut 58 , corresponding to the sleeve nut 56 , is arranged for the connection of the gas pressure source 12 onto the inlet duct 25 of the extraction unit 20 .
The gas pressure source 12 is preferably formed to make pressure air available and can, for example, be formed as a small compressor, motorcar central compressor, stationary pressure air supply system or portable pressure storage container, such as is, for example, available at filling stations, or as a hand or foot air pump. The maximum pressure which can be supplied from the gas pressure source 12 does not need to be greater than the pressure required for at least an emergency operation of the tire 18 . For the emptying of the container 10 the gas pressure source 12 does not have to be able to supply any specific minimum pressure.
It can be recognized from FIG. 2 that the pedestal section 34 of the extraction unit 20 includes four feet 35 which extend in star-like manner in the radial direction away from the connection section 32 .
The manner of operation of the sealing apparatus of the invention is described in the following with reference to the example of a tire 18 which is to be sealed.
First of all the filling line 36 connected to the outlet duct 28 of the extraction unit 20 is connected to the valve 38 of the tire 18 in that the sleeve nut 56 is screwed onto the valve thread. The gas pressure source 12 can in this arrangement already be connected to the extraction unit 20 or can still be separated from the latter.
Any possibly present residual pressure in the tire 18 can either escape via a non-illustrated valve arranged in the filling line 36 , in the extraction unit 20 or in the container 10 , or can escape through the entire sealing apparatus via the inlet duct 25 , provided the gas pressure source 12 has not yet been connected. It is also possible to first connect the filling line 36 to the tire 18 and only then to the extraction unit 20 when the residual pressure has escaped from the tire 18 via the filling line 36 . When a container 10 has not yet been screwed into the extraction unit 20 , it is also possible to allow the residual pressure in the tire 18 to escape directly via the connection stub 22 .
In any case, a compulsory venting of the tire consequently arises so that no non-return valve is required and, in particular when using a small compressor as a gas pressure source, a starting current which is too high is avoided. For the emptying of the container 10 the gas pressure source 12 must therefore not work against a counter-pressure applied by the tire 18 .
Thereafter, the gas pressure source 12 is connected, if necessary, onto the inlet duct 25 of the extraction unit 20 .
If the extraction unit 20 is not already provided with a container 10 filled with sealant, then the neck 24 of a new container 10 is screwed into the connection stub 22 of the extraction unit 20 , prior to or after the connection of the gas pressure source 12 onto the extraction unit 20 . The opening of the container 10 is preferably sealed by means of a foil, for example, which is broken open by the chamfered ends of the inflow passage 50 and of the outflow passage 52 on being screwed into the connection stub 22 .
It is also possible to provide a securing ring, formed as an extension of the connection stub 22 or as a separate component, which, on screwing in of the container 10 , is arranged between the container 10 and the extraction unit 20 in the manner of securing rings, such as are, for example, present at the lids of bottled drinks. In the case of a securing ring formed as an extension of the connection stub 22 , the latter can be connected via desired kink points, in particular in the form of film hinges, to the connection stub 22 , and can have a smaller wall thickness than the connection stub 22 .
A securing ring of this kind is designed so that it is first pressed apart on screwing in of the container 10 by the application of a certain minimum force via the oblique shoulder 11 of the container 10 , which acts as a wedge. The securing ring can be executed as a burstable ring, which is destroyed by full screwing in of the container 10 .
The provision of such a securing ring makes it possible, for the simplification of the handling of the sealing apparatus, to screw the container 10 in the context of a pre-installation at first only loosely against the securing ring, with the latter being supported in the pre-installed state on the oblique shoulder 11 of the container 10 . A single thread turn is sufficient to keep the container 10 on the extraction unit 20 in a manner secured against loss.
In this pre-installed state the foil which seals the opening of the container 10 is still unharmed, so that no sealant can run out. Only by overcoming the resistance offered by the securing ring to the container can the foil be broken open by the chamfered ends of the inflow passage 50 and of the extraction passage 52 .
In order to prevent sealant running out of the extraction unit 20 via the inlet duct 25 prior to taking the arrangement into use, a blocking device can, for example, be provided in the inlet duct 25 , or the container 10 can be screwed in the upright state to the extraction unit 20 .
For the introduction of the sealant preparation into the tire 18 , the sealing apparatus of the invention is placed with the extraction unit 20 on the ground, as is shown in FIG. 2, so that the container 10 is arranged with its opening to the bottom.
After activation of the gas pressure source 12 , the gas flows in accordance with the path indicated by arrows in FIG. 1 via the inlet duct 25 , and via its inflow passage 50 surrounded by sealant, into the container 10 and through the sealant into the region above the sealant level 40 . The gas which stands under elevating pressure in this region presses the sealant via the ring space 54 of the outlet duct 28 formed by the inflow passage 50 and by the extraction passage 52 through the filing line 36 into the tire 18 . The restriction 21 formed in the neck 24 during manufacture, preferably in one working step with the container 10 , is so designed that it advantageously acts on the course of the flow of the sealant.
Even in the case of a container 10 which is completely filled without an air inclusion, the sealant is driven, as a result of the pressure increase caused by the gas flowing into the container 10 , via the extraction passage 52 out of the container 10 .
When the sealant quantity required to overcome the tire leak has been introduced into the tire 18 and a residual quantity of sealant is still present in the container 10 , the sealing apparatus of the invention is turned through 180° and inverted. For this purpose, in deviation from the embodiment shown in FIGS. 1 and 2, the base side of the container 10 remote from the extraction unit 20 can be formed as a standing surface.
The sealant now collects at the side of the container 10 remote from the extraction unit 20 in the region of the container base, so that the gas which continues to flow through the inlet duct 25 into the container 10 , flows directly into the outlet duct 28 and into the tire 18 . In this manner the tire 18 can be pumped up to its operating pressure directly following introduction of the sealant, or at least to a pressure at which the relevant vehicle can travel over a certain distance.
After the sealing apparatus has been turned again and again placed with the removal unit 20 on the ground, then further damaged tires can optionally be sealed, with the sealant remaining in the container 10 in accordance with the above described procedure.
In order to be able to dissipate the residual pressure prevailing in the container 10 during use or after the conclusion of use, a valve, which is not shown in FIGS. 1 and 2, can be provided in the container wall. In accordance with a particularly simple embodiment, this can be executed as a relief bore with a diameter of, for example, 0.5 mm, which is formed in the lower base plate and which opens into the inlet duct 25 .
For the adaptation to different conditions of use, different adapter elements can be used in conjunction with the inlet duct 25 , the outlet duct 28 and/or the filling line 36 and also filling lines of different length.
Furthermore, the extraction unit 20 can be combined in advantageous manner with different containers 10 which differ with respect to their shape, their size and/or the sealant contained therein.
Particularly having regard to the danger from passing vehicles to a person with a tire puncture, an advantage of the sealing apparatus of the invention is to be seen in the fact that the user merely needs to stand in the near vicinity of the tire 18 for the connection of the filling line 36 to the valve 38 . The operation of the gas pressure source 12 , the screwing in of the container 10 , the turning around of the sealing apparatus and also the monitoring of the sealing and pumping up processes via the display of the gas pressure source 12 can take place at a secure location remote from the tire to be sealed.
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The invention relates to a device for sealing inflatable objects, especially tires, comprising a container ( 10 ) with sealing agent and a gas inlet ( 25 ), which can be connected to a gas pressure source, and an outlet ( 28 ) that can be coupled to an object that is to be sealed. The gas inlet and the outlet are linked to each other via the interior of the container. The gas inlet and the outlet are embodied in a discharge unit ( 20 ) that is detachably connected to the container ( 10 ).
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REFERENCE TO RELATED APPLICATIONS
This application is related to the copending applications of Curtis H. Porter Ser. No. 225,287 filed July 28, 1988 entitled "Push-to-Release Cable Operating Apparatus", Vernon E. Stewart Ser. No. 164,422 filed Mar. 4, 1988 entitled "Reaction Cable Assembly Including Cable Slack Adjusting Means", and Tave Hass et al Ser. No. 221,204 filed July 19, 1988 entitled "Soft Release Cable Operating Means", each assigned to the same assignee as the present invention.
BRIEF DESCRIPTION OF THE PRIOR ART
It is known in the patented prior art to provide brake cable operating controls including a foot-operated parking brake lever that is operable between brake-released and brake-engaged positions, and that is maintained in place by releasable pawl and ratchet means. Examples of such parking brake systems are shown, among others, by Hirst U.S. Pat. No. 3,487,716, 3,693,472 and Lipshield U.S. Pat. No. 4,127,042, also assigned to the same assignee as the present invention.
It is also well known in the prior art to provide cable slack adjusting means in cable systems for automotive vehicles. Evidence of such devices is presented by the patents to Gale U.S. Pat. No. 3,768,612, Dau et al U.S. Pat. No. 3,789,967, Bopp et al U.S. Pat. No. 4,271,718, and Haskell et al U.S. Pat. No. 4,378,713, among others.
SUMMARY OF THE INVENTION
The present invention relates to a pedal-or lever-operated parking brake or similar control mechanism, including a lever arm which is pivotally connected with a suitable mounting means and which provides indirect drive by means of conventional ratchet and pawl to a cable take-up mechanism with direct locking thereof, the system having a two-stage release. This mechanism is equipped with an automatic tension compensating device for maintaining a desired minimum cable tension.
A primary object of this invention is to provide a parking brake control mechanism which automatically compensates for lack of cable tension and/or slack due to wear. The self-adjuster insures a constant tension prior to and after each cycle. When the control is in the "OFF" position, the self-adjuster maintains a state of equilibrium with respect to the cable tension and/or slack.
According to a more specific object of the invention, the inner parking brake cable member is connected with a tensioning ratchet that is rotatably mounted on the same pivot shaft that supports the parking brake applying lever. Spring means bias the ratchet the cable-tensioning direction relative to the lever, and lock and drive pawls connect the ratchet with the stationary housing and with the lever, respectively. A conventional pedal pawl connects a ratchet associated with the lever to the housing, said pedal pawl being released either manually by manually-operable release means, or automatically by a vacuum-responsive motor. Release lever means are provided for disengaging the lock pawl as the lever returns to its brake-disengaged position, and stationary tab means are provided on the housing for disengaging the drive pawl when the lever is immediately adjacent the fully brake-disengaged position, thereby to permit automatic taking up of cable slack by the tension adjuster spring.
Another object of this invention is to provide a control mechanism which eliminates high energy impact on the return stroke, hereinafter referred to as "slam off". This is accomplished through the use of a spiral spring which acts as a dampening device to absorb slam off as it occurs during the release process.
In a traditional parking brake control mechanism, the relatively massive assembly of the pedal, the ratchet, clevis and/or other connecting means, traditionally return simultaneously. In the present control, the mass of the pedal has been separated on the return stroke with respect to the cable track and ratchet. The cable track and ratchet have the greatest amount of inertia upon the return due to the high energy in the cable upon instantaneous release and have no direct impact to the mounting bracket upon that release, therefore no "slam off" effect.
Another object of this invention is to provide a mechanism which allows for the option of a vacuum release. The vacuum canister is simply an "add on" part which requires no additional tooling or special fabrication.
A further object of this invention is to provide a mechanism which makes use of a conventional ratchet/pawl locking device. This device, in operation, uses the same ratchet for the self-adjuster and locking mechanisms resulting in fewer parts used. The ultimate result is a more cost-effective mechanism.
Another object of the present invention is to provide a mechanism which operates in the apply mode as a normal parking brake control and upon release, the pedal initiates the release of the cable load by its return to an OFF position.
Still another object of this invention is to provide a mechanism with a limit device to the adjuster so that it may not be wound past its designed torque and a minimal limit, thereby to simplify cable service.
BRIEF DESCRIPTION OF THE DRAWINGS
Other objects and advantages of the invention will become apparent from a study of the following specification when viewed in the light or the accompanying drawings, in which:
FIGS. 1 and 1A are perspective and exploded views, respectively, or the improved brake control apparatus of the present invention;
FIG. 2 is a detailed somewhat schematic side elevational view, with certain parts removed, of the apparatus when in the brake-released at-rest condition;
FIGS. 3-6 are detailed schematic side elevational views illustrating the operation of the brake control apparatus in the brake-applying, locked, first phase of a release cycle, and final phase of a release cycle, respectively;
FIG. 7 is a detailed bottom plan view of the parking brake and lock pawl release lever arrangement;
FIGS. 8 and 9 illustrate the operation of the tension adjuster; and
FIG. 10 is a detailed sectional view taken along line 10--10 of FIG. 1.
DETAILED DESCRIPTION
Referring first and more particularly to FIGS. 1, 1A and 10, the foot-operated parking brake apparatus 2 for operating the coaxial brake control cable 4 associated with the parking brake 6 of a motor vehicle includes a riser bracket 8 to which is secured (by clinching, welding, or the like) a mounting bracket 10. This unit is fastened to the fire wall of the vehicle by suitable fastening means, such as bolts (not shown). The outer cable member 4a is fastened at one end in an opening 10a contained in the mounting bracket 10, and the inner cable strand 10b is connected for operation by the foot-operated parking brake lever 12, as will be described below.
A main pivot shaft 14 is secured at one end in an opening 10b contained in mounting bracket 10, and successively mounted in concentric relation on this shaft are drive plate 16, ratchet 18, longitudinally-split pivot sleeve 20, and the plate-like upper portion 12a of lever 12. The other end of pivot shaft 14 is supported in an opening 22a of cover member 22 that is secured (by clinching, welding or the like) to mounting bracket 2. Mounted concentrically about the pivot sleeve 20 are a cable track member 24 and a spiral adjuster spring 26, the cable track member having a curved flange portion 24a that extends concentrically beneath the adjuster spring and that is connected at its upper edge with the inner strand member 4b of the parking brake cable. Ratchet 18 contains an arcuate slot 18a that receives a drive stud 27 the ends of which are supported in openings 12b and 16b contained in lever 12 and drive plate 16, respectively. Associated with the teeth 18b of ratchet 18 are a lock pawl 30 and a drive pawl 32. Lock pawl 30 is pivotally mounted on a pivot pin 34 that is supported at one end in opening 10c contained in mounting bracket 10, the other end of this pivot pin extending through a corresponding opening 22b contained in cover member 22. Coil spring 38 mounted on pivot pin 34 normally biases pawl 30 toward engagement with the ratchet teeth 18b. Similarly, drive pawl 32 is pivotally mounted on pivot pin 40 the ends of which are supported in corresponding openings 12c and 16c contained in lever 12 and drive plate 16, said drive pawl being normally biased by coil spring 41 toward engagement with ratchet 18. Lever 12, drive stud 27 and drive plate 16 are further connected together as a first assembly by a bolt (not shown) that extends through lever opening 12d and drive plate opening 16d, and cable track member 24 is bolted to ratchet 18 by bolts (not shown) that extend through corresponding openings 18d and 24d, and 18e, and 24C, respectively, thereby to define a second assembly. The outer end 26a of the adjuster spring is bent outwardly for reaction with drive stud 27, and the inner end of the adjuster spring is bent inwardly for insertion within longitudinal slot 20a of pivot sleeve 20. The left hand end of pivot sleeve 20 is secured (by welding or clinching, for example) with the ratchet 18. Thus, one end of the adjuster spring reacts with the first assembly including drive stud 27, drive plate 16 and foot-operated lever plate 16 and foot-operated lever 12, and the other end of the adjuster spring reacts with the second assembly including pivot sleeve 20, ratchet 18 and cable track 24.
Pivotally mounted on a pivot pin 50 mounted in opening 22c contained in cover 22 is a pedal pawl 52 that is biased by coil spring 54 into engagement with ratchet teeth 12e provided on the plate-like upper portion 12a of lever 12. Also pivotally mounted on pivot pin 50 is a manual release lever 58 that is biased in the counterclockwise direction in FIG. 1A by a coil spring 60. This lever 58 is operable by the parking brake manual release means 59 via cable 59a (FIG. 1.), hereby to pivot pedal pawl 52 to the released position relative to pedal ratchet teeth 12e. Pivotally mounted at one end on the end of pivot pin 34 that extends through the pivot opening 30a of lock pawl 30 is a lock pawl release lever 64 having a first lateral tab portion 64a arranged to engage the lock pawl 30 for pivoting the same in the pawl-released direction relative to ratchet 18 against the biasing force of the return spring 38. At its other end, the lock pawl lever has a second lateral tab portion 64 b provided with a synthetic plastic button 66 arranged for engagement by the adjacent surface of foot pedal 12, so that when the foot pedal is in its brake-released position, release lever 64 pivots pawl 30 to the unlocked condition relative to ratchet 18. Spring 60 is connected between lock pawl release lever 64 and manual release lever 58.
A vacuum-responsive diaphragm motor 70 is secured to the cover 22 and includes an output shaft 70a arranged for cooperation with slot 52b to disengage pedal pawl 52 from pedal ratchet teeth 12e upon the occurrence of vacuum from source 72 (for example, upon firing of the internal combustion engine of the vehicle). A shipping pin 76 is inserted through the cover 22, adjuster/track sub-assembly 24, 26, and into the mounting bracket 10, thereby to maintain the adjuster mechanism in a pre-load state until the cable is installed, whereupon pin 76 is pulled and the self-adjuster operates to take up cable slack.
Operation
Referring now to FIG. 2, the mechanism is illustrated in the fully-released the condition where the adjuster/track sub-assembly 26,24 is allowed to freely rotate in a direction so as to cause greater cable tension until a point of equilibrium is reached, thereby insuring a minimum tension and lack of cable slack at each stroke. The lock pawl 30 is held out by the lock pawl release lever 64 which is rotated to the "release position" by the pedal 12 owing to the engagement between lever 12 and button 66. The drive pawl 32 is held out of engagement with ratchet teeth 18b by a fixed tab 10e on the mounting bracket 10, thereby allowing free rotation of the self-adjuster in either the clockwise or the counterclockwise direction. The ends 26a and 26b of the preloaded spring 26 react between the drive stud 27 and with the ratchet pivot sleeve 20, thereby to rotate the ratchet 18 and the cable tract 24 in the cable-tensioning direction relative to lever 12. Thus, the advantage is presented of "over adjust" safeguard, owing to the lock pawl 20 and drive pawl 32 being maintained in the disengaged condition.
Referring now to FIG. 3, when the operator applies a brake-engaging force F to the pedal 12, rotation direction about the main pivot axis 14 is initiate. Owing to the drive pawl 32 being fixed between the pedal 12 and the drive plate 16, it begins to rotate away from the fixed tab 10e, thereby allowing the drive pawl 32 to engage in the ratchet teeth 18a to initiate cable take up. At this point, the ratchet 18 is connected with the pedal 12, and both legs of the adjuster spring 26a and 26b are locked so as to retain spring position during the "apply" and "lock" cycle. After a specified amount of stroke otherwise known as "free travel", the lock pawl release lever 64 is rotated to an off position by the release lever spring 60 which in turn allows the lock pawl 30 to engage in the ratchet 18, thereby allowing the cable load to be held by the connection between ratchet 18 and the mounting bracket means 10.
Referring now to FIG. 4, as the operator continues the brake-applying force from the position in FIG. 3, at a point designed to be the end of the "free travel", the pedal pawl 52 engages pedal ratchet notches 12e integral with the lever 12. At any time after the pedal pawl (52) begins to ratchet, the operator's foot may be removed and the mechanism will maintain the resultant cable load. At the time that the operator's foot is removed, the pedal pawl 52 is driven to the end of an internal slot 52a (FIG. 1A) to position 52'. At the same time the pedal 12 "back drives" to position 12' The drive pawl 32 is relieved to position 32' shown in phantom, and at this time the adjuster spring end 26a is allowed to relax to position 26a' insuring that the lock pawl 30 is fully engaged in a notch of the ratchet 18, thereby holding the cable load.
Referring now to the first phase of the release cycle shown in FIG. 5, after the control mechanism has been set, and upon actuation of the manual release lever 58 (either manually by the manual release control means 59, or automatically by the vacuum means 72 upon the starting of the vehicle), the manual release lever 58 pivots about its pivot shaft 50 to position 58' which in turn causes the pedal pawl 52 to rotate to a released position 52' shown in phantom, thereby disengaging the pedal teeth 12e to allow the pedal 12 to rotate in the clockwise direction of arrow "X", owing to the force created by the adjuster spring end 26a transmitted through the drive stud 27. If the control apparatus is optionally equipped with the vacuum canister, the vacuum canister arm 70a will cycle under vacuum to position 70a, thereby engaging slot 52b to release the pedal pawl 52, initiating the sequence discussed above.
Referring now the final phase of the release cycle shown in reference to FIG. 6, as the adjuster spring leg 26a rotates with the pedal, the adjuster spring leg 26b remains fixed with the ratchet. Once the adjuster spring leg 26a reaches position 26a', it has driven the pedal 12 to position 12' at which time the pedal 12' starts to rotate the lock pawl release lever 64, and once the pedal 12 reaches position 12", it has rotated the lock pawl release lever to position 64" which in turn rotates the lock pawl 30 to a released position 30".
During the return of the pedal 12 toward intermediate position 12'", the drive pawl 32 freely moves in and out of the ratchet teeth 18b between the positions 32 and 32'. As the pedal rotates from position 12'" to position 12", the drive pawl at position 32" becomes disengaged as a result of contact with the mounting bracket fixed tab portion 10e, thereby allowing the ratchet 18 and cable track member 24 to pivot to the OFF positions 18' and 24', respectively, whereupon the adjuster spring leg 26b rewinds the adjuster spring 26 owing to its attachment through slot 20a in the pivot sleeve 20, and since the pivot sleeve 20 is fixed to the ratchet 18, a dampening effect is created upon the cable load release. Simultaneously, the adjuster spring leg 26b rewinds to the position 26b'.
There is no "hard stop" in the mechanism to react against the ratchet 18 and cable track member 24 resulting in no impact, shock or "slam off" upon cable load release. The mechanism also compensates for "over travel" resulting from the release cycle by simply allowing the ratchet 18 and cable track 24 to continue past the "at rest" positions 18" and 24", respectively, carrying the adjuster spring leg 26b to the position 26b". At a point when all return forces from the cable have been dissipated, the adjuster leg 26b will unwind the adjuster spring 26 until it reaches a point of equilibrium with respect to the cable tension (i.e. during displacement of spring end 26b from position 26" to position 26', the cable track member from position 24" to position 24', and the ratchet from position 18" to position 18').
Referring now to FIG. 7, as the pedal 12 is released (as discussed with regard to FIGS. 5 and 6), it contacts the lock pawl release lever 64 as shown. In FIG. 8, when in the shipped position, during assembly the ratchet 18 and track subassembly is fully rotated in the clockwise direction driving the adjuster spring leg 26a to wind the adjuster spring 26 while the drive stud 27 holds the adjuster spring leg 26a stationary, thereby winding the adjuster spring 26 to is maximum load position.
FIG. 9 shows the minimum torque position of the adjuster spring 26. If the cable were to break at any time, the drive stud 27 acts as a limit for the ratchet 18 and track sub-assembly 24, preventing it from fully unwinding and therefore simplifying service.
While in accordance with the provisions of the Patent Statutes, the preferred embodiments and modifications of the invention have been illustrated and described, it will be apparent to those skilled in the art that other modifications may be made in the apparatus described without deviating from the inventive concepts set forth above.
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An improved parking brake cable control apparatus includes an automatic cable tensioning device that is operable at the beginning and end of every parking brake operating cycle to take up cable slack and maintain uniform cable tension. The foot-operated parking brake lever pivots on a main pivot shaft between brake-engaged and brake-released positions, a releasable pedal pawl being provided that cooperates with a conventional pedal ratchet. A cable-tensioning ratchet connected with the parking brake cable is rotatably mounted on the main pivot shaft, and cooperating therewith are a lock pawl and a drive pawl connected with the apparatus housing and with the lever, respectively. The lock pawl is released by a release lever when the pedal is pivoted toward the released position, and the drive pawl is disengaged when the lever is adjacent the disengaged position, thereby to activate the cable tensioning device.
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FIELD OF THE TECHNOLOGY
[0001] The present invention concerns a control valve, particularly a control reciprocating displacement valve with proportionally pressure reducing and high frequency up to 100 Hz. It can be used for controlling the operation of inlet and exhaust valves of various internal combustion engines so as to make them attain optimum operating condition.
BACKGROUND OF THE TECHNOLOGY
[0002] A traditional electro-hydraulic three-way direction control valve is a variety of electro-hydraulic directional valve. It has three oil ports, respectively called a port P, a port A and a port T. One side of a cylindrical valve spool of the electro-hydraulic three-way directional valve is equipped with electromagnet, at the other side with spring. Normally in application the port A is connected to an executive component, for instance, a chamber of an operating hydraulic cylinder, the spool of electro-hydraulic three-way directional valve by alternative action of a electromagnet and a spring moves over from one extreme position to the other, performing reciprocating movement. This operation can change open/close state between oil ports. If the cylindrical valve spool is situated at a certain extreme position, the port A and the port T open through, then the internal pressure is zero; when it is changed over to the other extreme position, the port A and the port P open through, then the internal pressure is high pressure P so as to push the executive component operating. If an electro-hydraulic four-way direction control valve blocks up an oil port of the four, it also can be used as the three-way direction control valve.
[0003] In operation, there are two states for the pressure at the port A of the electro-hydraulic three-way direction control valve: When the electromagnet is switched off, the port A and the port T open through, so the pressure at the port A is equal to that at the port T, then the pressure is minimum; when the electromagnet is switched on, the port A and the port P open through, so the pressure at the port A is equal to that at the port P, then the pressure is maximum. However, it is unable arbitrarily to take a pressure value between minimum and maximum values and keep a certain time at the port A for the existing electro-hydraulic three-way direction control valve, that is to say, the existing technology can settle direction-changing qualitative control, but cannot settle the midcourse control of pressure variation quantitative. In particular, it cannot get with control for the inlet and exhaust valves in a internal combustion engine, for at that time, it needs to attain direction-changing-over control necessary for the valve to make reciprocating movement and perform the control of the movement velocity and acceleration for the valve displacing. And this kind of control is quantitative, which must meet the requirement of “Pressure Displacement” control at the given mathematical function.
SUMMARY
[0004] The present invention mainly provides a three-way proportional pressure reducing valve, which is simple in construction and reasonable in design. It can be achieved to control arbitrary pressure course change between the constant pressure source and the oil tank pressure at zero, it can be adjusted by a first and second control edges and the pressure feedback means of a chamber. The aim of the present invention is to solve the technological problem of change-over only within two limit values of zero pressure and maximum pressure and unable to control the intermediate pressure, which exists in the technology now available.
[0000] The above described technological problem is to be solved mainly through the technological project described below:
[0005] A three-way proportional pressure reducing control valve, including:
[0006] a valve body having a first and a second end,
[0007] a cylindrical valve spool aperture being located in the valve body, the cylindrical valve spool aperture having a plurality of under-cut grooves,
[0008] a cylindrical valve spool being located in the cylindrical valve spool aperture, the cylindrical valve spool being equipped with at least one shoulder, wherein an external diameter of the shoulder is equal to that of an inner diameter of the cylindrical valve spool aperture,
[0009] the valve body having three openings, including a high pressure inlet port P connected with a pump source, an oil port A connected with an executive component, and a low pressure outlet port T connected with an oil tank,
[0010] a plurality of chambers formed in the valve body between the cylindrical valve spool and the cylindrical valve spool aperture, the plurality of chambers including a first chamber connected to the high pressure inlet port P, a second chamber connected to the oil port A and a third chamber connected to the low pressure outlet port T, the second chamber being located between the first chamber and the third chamber,
[0011] a first control edge being fitted between the first chamber and the second chamber,
[0012] a second control edge being fitted between the second chamber and the third chamber,
[0013] a proportional force signal device being located at the first end of the valve body,
[0014] a fourth chamber being located at the first end of the valve body,
[0015] a fifth chamber being located at the second end of the valve body,
[0016] a first passage being located between the fifth chamber and the second chamber for connecting the second chamber to the fifth chamber, a second passage being located between the fourth chamber and the third chamber for connecting the third chamber to the fourth chamber, and
[0017] a notch providing damping being located on the first control edge and the second control edge.
[0018] Connecting the fifth chamber with the second chamber and the fourth chamber with the third chamber make the electromagnetic force acting on the cylindrical valve spool with the pressure of the oil chamber form a closed loop feedback thereby automatically adjust the pressure of the port A by means of external electromagnetic force. The notch opening at the control edge provides the damping, which not only adjusts the differential pressure between the port A and the port P but also increases the stability and the resolution factor of the control valve. The said notch can be triangle, also can be ladder shape, etc., for purpose of providing a non-linear damping for liquid flowing.
[0019] There is different damping when the cylindrical valve spool has displacement, because the liquid in two adjacent chambers exists flowing differential pressure, thus the pressure value at the low pressure end becomes different one. This different pressure value transfers pressure to the fifth chamber through the first passage connecting the fifth chamber and the second chamber, then the pressure of the fifth chamber immediately feedbacks to the proportional force signal device being located at the first end of the valve body Since both pressure are different, the cylindrical valve spool displaces until it reaches a new balance position, however the damping of the first control edge at the new balance position will be different, the pressure value at the low pressure end is different value, thus move in cycles, the pressure value at low pressure end (that is the second chamber ) changes continuously according to the setting demand.
[0020] For the a cylindrical valve spool, alloy steel or tool steel can be adopted, and for the material of the valve body casting iron or high strength aluminum can be used as raw material.
[0021] There is more than one shoulder as optimization. The cylindrical valve spool has two shoulders including a first shoulder and a second shoulder and a first under-cut groove, a second under-cut groove and a third under-cut groove, the first shoulder is adjacent to the fifth chamber, the second shoulder is adjacent to the fourth chamber, the first and second control edges are respectively constituted by annular end surfaces of the first and the second shoulders and corresponding sides of the under-cut groove; the first chamber is formed by the first shoulder and the first under-cut groove, the third chamber is formed by the second shoulder and the third under-cut groove, the second chamber is formed by a space between the cylindrical valve spool and the valve body that are located between the first chamber and the third chamber. The first chamber and the third chamber formed by the shoulder and the under-cut groove, so the first and the third chamber are circular ring shape. For the first and second control edges, there are three kinds of opening state: zero opening, positive opening and negative opening, the concrete condition depends on the requirement of the performance of the control valve.
[0022] As optimization, the cylindrical valve spool has three shoulder including a right shoulder, a left shoulder and a middle shoulder and a first under-cut groove, a second under-cut groove and a third under-cut groove the right shoulder is adjacent to the fourth chamber. The left shoulder is adjacent to the fifth chamber, the middle shoulder is located in the middle of the cylindrical valve spool. The first and second control edges are respectively composed of both side end surfaces of the middle shoulder and corresponding side edges of the second under-cut groove, the second chamber is formed by a space between the middle shoulder and the second under-cut groove, the third chamber is formed by a space between the cylindrical valve spool and the valve body that are located between the left shoulder and the middle shoulder, the first chamber is formed by a space between the cylindrical valve spool and the valve body that are located between the middle shoulder and the right shoulder.
[0023] As optimization, the said proportional force signal device is an electromagnet, a torque motor or an electrical-mechanical converter.
[0024] The fourth chamber can be equipped with the spring, and also can be not equipped with the spring, the spring force can be substituted by gravity by means of placing the valve body vertically. As optimization, the fourth chamber includes a spring, one end of the spring is contacted to an end surface of the cylindrical valve spool. Fitting with the spring in the fourth chamber can ensure that the movement of the cylindrical valve spool becomes much more stable.
[0025] The first passage can be situated at the cylindrical valve spool, the valve body or made as a connecting piece via external pipe. As optimization, the first passage is situated at the cylindrical valve spool, that is constituted by a horizontal transverse passage and a vertical passage perpendicular to the horizontal transverse passage, the horizontal transverse passage and the vertical passage are T shaped. It is convenient to be machined for being situated at the valve spool. This passage consists of the horizontal passage and the vertical passage so as to make uniform flowing speed of the pressure oil, decrease of the speed and even distribution of the pressure.
[0026] As optimization, the first passage is located on the valve body.
[0027] As optimization, the second passage is located on the cylindrical valve spool or the valve body.
[0028] Therefore, the present invention of three-way proportional pressure reducing control valve possesses the advantages described below: 1. the present invention of three-way proportional pressure reducing control valve can perform displacement adjustable reciprocating movement operation; 2. the inside of proportional electromagnet of present invention is at low pressure, so it is reliable in operation; 3. the present invention of three-way proportional pressure reducing control valve is applicable for the displacement adjustable reciprocating movement operation only by single stage, open-loop control, proportional adjustment, it needs not any position feedback, it is simple and reliable in the oil passage of its system and control circuit-; 4. the present invention of three-way proportional pressure reducing control valve has not any attached flow loss because only one control edge of the first and second control edges operates at all times in operation; 5. the present invention of valve body and cylindrical valve spool can be miniaturized, it is saving in materials, low in manufacturing cost and fine in economy.
BRIEF DESCRIPTION OF THE DRAWINGS
[0029] FIG. 1 is the ensemble cut-away view of present invention of three-way proportional pressure reducing control valve with two shoulders;
[0030] FIG. 2 is the ensemble cut-away view of present invention of three-way proportional pressure reducing control valve with three shoulders;
[0031] FIG. 3 is the ensemble drawing of three-way proportional pressure reducing control valve ( FIG. 1 ) applicable for the driving control of the internal combustion engine valve;
[0032] FIG. 4 is the ensemble drawing of three-way proportional pressure reducing control valve ( FIG. 2 ) applicable for the driving control of the hydraulic cylinder;
[0033] FIG. 5 is the ensemble view of the cylindrical valve spool ( FIG. 1 );
[0034] FIG. 6 is the ensemble view of the cylindrical valve spool ( FIG. 2 )
DETAILED DESCRIPTION
[0035] The following is the further concrete explanation for the present invention of technological project by means of implementation examples with attached drawings.
[0036] Implementation Example 1:
[0037] As shown in FIGS. 1 and 5 , a three-way proportional pressure reducing valve including the valve body 1 made of casting iron, it has a first and second end, there is the cylindrical valve spool aperture 10 being located in the valve body 1 , there are three ring-shaped under-cut grooves in the circumferential space of valve spool aperture 10 ,including the first under-cut groove 171 , the second under-cut groovel 72 and the third under-cut groove 173 . The cylindrical valve spool 2 made of tool steel being located in the cylindrical valve spool aperture 10 . In the circumference of cylindrical valve spool 2 there are the two ring-shaped shoulders, including first shoulder 21 and second shoulder 22 , the outer diameter of the shoulder is equal to that of the inner wall of valve spool aperture 10 . After having assembled the valve body 1 and the cylindrical valve spool 2 , five chambers are formed between the cylindrical valve spool 2 and the valve spool aperture 10 thereof, successively from left to right the fifth chamber 11 , the first chamber 12 , the second chamber 13 , the third chamber 14 and the fourth chamber 15 . The first shoulder 21 is adjacent to the fifth chamber 11 , the second shoulder 22 is adjacent to the fourth chamber 15 , the first chamber 12 is formed by the first shoulder 21 and the first under-cut groove 171 , the third chamber 14 is formed by the second shoulder 22 and the third under-cut groove 173 , the second chamber 13 is formed by a space between the cylindrical valve spool 2 and the valve body 1 that are located between the first shoulder 21 and the third shoulder 22 . The first control edge C 1 and the second control edge C 2 are respectively constituted by annular end surfaces of the first and the second shoulders and corresponding sides of an under-cut groove, The first control edge C 1 and the second control edge C 2 are ring edges. At the first and second control edges are uniformly set triangle notch 18 so as to provide variable damping.
[0038] The fifth chamber 11 includes a spring 3 , one end of the spring 3 is contacted to an end surface of the cylindrical valve spool 2 , the other end of the spring 3 is contacted to a spring seat 31 which is contacted to the seal of the second end of the valve body 1 so as to make the cylindrical valve spool 2 have the tendency to displace toward right side all the time. In the fourth chamber 15 is located a crown bar 4 of the electromagnet 41 . The crown bar 4 is throughout contacted with the right end surface of the cylindrical valve spool 2 . The second chamber 13 is all along situated between the first chamber 12 and the third chamber 14 . The first chamber 12 is the high pressure source connecting with the oil pump, the third chamber 14 is the zero pressure source connecting with the oil tank, the second chamber 13 is the chamber to produce the necessary working pressure.
[0039] At the bottom surface of the valve body 1 there are openings, respectively a pressure inlet port P connected with pump source, an oil port A connected with any executive components and a low pressure outlet port T connected with the oil tank. The first chamber 12 connected to the high pressure inlet port P, the second chamber 13 connected to the oil port A and the third chamber 14 connect to the low pressure outlet port T.
[0040] A first passage 23 is situated at the cylindrical valve body 2 for connecting the second chamber 13 to the fifth chamber 11 , the first passage 23 is constituted by a horizontal transverse passage and a vertical passage perpendicular to the horizontal transverse passage, the horizontal transverse passage and the vertical passage are T shaped. The fourth chamber 15 is connected with the third chamber 14 , the fifth chamber 11 is connected with the second chamber 13 . A second passage 16 is situated at the valve body 1 for connecting the third chamber 14 to the fourth chamber 15 .
[0041] When the electromagnet 41 is under natural condition (i.e. in initial state), the input current of the electromagnet 41 is zero. Due to the combined action of the recompression of the spring 3 and the residual pressure of the second chamber 13 which is caused by the leakage existing from the first chamber 12 to the second chamber 13 , the cylindrical valve spool 2 is pushed to first end of the valve body 1 so as to make the first control edge C 1 being closed, the second control edge C 2 being opened and the oil pressure of the second chamber 13 becoming zero.
[0042] In operation, the electromagnet 41 of the three-way proportional pressure reducing valve is energized with fixed current, the electromagnetic thrust F in proportion to the current is produced on the electromagnet 41 . The electromagnetic thrust F overcomes the acting force of the spring 3 to make the cylindrical valve spool 2 displace toward the side of the fifth chamber 11 thereby make the first control edge C 1 being opened and the second control edge C 2 being closed, at that time the pressure oil flows into the oil port A after it has successively passed through the high pressure inlet port P, the first chamber 12 , the first control edge C 1 , the second chamber 13 , then the high pressure inlet port P is communicated with the oil port A and a pressure P A of the oil port A increases. At the same time, the pressure P A passes to the fifth chamber 11 through the first passage 23 of the cylindrical valve spool 2 and acts on the left end surface of the cylindrical valve spool 2 , this force for the electromagnet 41 is feedback acting force. Under joint action of the feedback acting force and the spring 3 , the speed of the cylindrical valve spool 2 displacing to the fifth chamber 11 is decreased. When the pressure P A of the oil port A increases to be equal to the electromagnetic thrust F, the cylindrical valve spool 2 reaches up to a dynamic balance.
[0043] The adjusting procedure for the balance position of the cylindrical valve spool 2 is automatically realized. The movement of the cylindrical valve spool 2 stands the joint action of the control the port pressure, a spring force, the electromagnetic thrust and a friction. Its balance position is satisfied to the equation below:
π d 2 P A /4+ F s =F+F f that is: P A =4( F+F f −F s )/π d 2
[0044] Where: d—diameter of the cylindrical valve spool
P A —pressure of chamber A F s —spring force F—electromagnetic thrust F f —friction
[0049] The spring force is much smaller than the electromagnetic thrust because the selected the spring 3 possesses not large elastic force, and a friction usually is much more smaller than the electromagnetic one. Since the electromagnetic thrust is in proportion to the input current signal of the electromagnet 41 , the adjustment in a certain sense results in realizing the control of the pressure P A of the control port in proportion to the input current signal.
[0050] As shown in FIG. 3 , when the three-way proportional pressure reducing control valve used for the valve control of the internal combustion engine, the variation of pressure P A of oil port A will be directly applied on the left chamber of a oil cylinder 6 with the change of the electrical signal, because the oil port A of the three-way proportional pressure reducing control valve is connected with the left chamber of the oil cylinder 6 through a oil inlet pipe 61 , and a right chamber of the oil cylinder 6 is directly connected with a oil return tank. If the pressure P A of the oil port A increases, a spring 7 is gradually compressed, a piston 8 moves to the right chamber of the oil cylinder 6 to carry a valve head 9 to move to the right via a piston rod 82 until the pressure P A of the oil port A is balance with the acting force of the spring 7 . Similarly, if the pressure P A of the oil port A decreases, the piston 8 moves to the left chamber of the cylinder at the acting force of the recovery force of the spring 7 to carry the valve head 9 to move toward the left until the resultant force and the recovery force of the spring 7 are balance. In the above mentioned two kinds of balance state, the piston 8 is static without any motion, a corresponding space is obtained between the valve head 9 and a valve seat 91 .
[0051] If in the above mentioned dynamic balance state, the electromagnetic thrust F of the electromagnet 41 increases when the current signal increases. The electromagnetic thrust F pushes the cylindrical valve spool 2 to move toward the fifth chamber 11 so as to make the opening of the first control edge C 1 enlarge, then the pressure P A of the oil port A rises which acts on the left end surface of the cylindrical valve spool 2 through a oil hole 23 of the cylindrical valve spool 2 to push the cylindrical valve spool 2 move toward the fourth chamber 15 . Finally, it gets another dynamic balance with the electromagnetic thrust F. Meanwhile, the pressure of the left chamber of the oil cylinder 6 also increases with it to overcome the acting force of the spring 7 so as to make the piston 8 move toward the right chamber of the oil cylinder 6 until it sets a new balance with the spring 7 , then the piston 8 is in static state again, and correspondingly suitable space is also obtained between the valve head 9 and the valve seat 91 .
[0052] Conversely, in the above described dynamic balance state, the electromagnetic thrust decreases with the decrease of the current signal of the electromagnet 41 , then the cylindrical valve spool 2 at the action of the pressure P A carries the first and second shoulders 21 , 22 move toward the fourth chamber 15 so as to make the opening of the first control edge C 1 smaller, and the pressure P A of the oil port A also decreases with it. The pressure P A after decreased acts on the left end of the cylindrical valve spool 2 so as to make the cylindrical valve spool 2 stop moving toward the fourth chamber 15 . Finally, it gets dynamic balance again with the electromagnetic thrust F. Meanwhile, the pressure of the left chamber of the cylinder 6 is also caused to decrease. At the action of the recovery force of the spring 7 , the piston 8 moves toward the left chamber of the oil cylinder 6 until a new balance is established with the spring 7 , the piston 8 then is again in static state without any motion, the correspondingly suitable space is obtained again between valve head 9 and valve seat 91 .
[0053] Thus, the piston 8 moves left and right quickly with the change of the external electrical signal so as to make a corresponding opening obtained between the valve head 9 and the valve seat 91 . If you want to make the valve close, you must let the current of the proportional electromagnet 41 suddenly drop down to zero or smaller initial value, the acting force at the end of the cylindrical valve spool 2 facing the electromagnet 41 disappears, then at the action of a reset spring, there is still a certain pressure in the left chamber of the cylinder 6 , the second chamber 13 of three-way proportional pressure reducing control valve and the fifth chamber 11 . At the action of this pressure, the cylindrical valve spool 2 promptly moves to the electromagnet 41 so as to make the first control edge C 1 being closed and the opening of the second control edge C 2 be maximum, the resistance for removing the oil from the left chamber of the cylinder 6 be minimum, thus the valve can be promptly closed.
[0054] Implementation Example 2:
[0055] As shown in FIGS. 2, 4 and 6 , the three-way proportional pressure reducing control valve contains the valve body 1 made of high strength aluminum. In the valve body 1 is located the cylindrical valve spool aperture 10 . At the circumference of the valve spool aperture 10 is set three ring-shaped under-cut grooves 17 , including the first under-cut groove 171 , the second under-cut groove 172 and the third under-cut groove 173 . In the cylindrical valve spool aperture 10 is seated the cylindrical valve spool 2 made of alloy steel which also is cylindrical shape. At the circumference of the cylindrical valve spool 2 there are three ring-shaped shoulders, including a right shoulder 22 ′ a left shoulder 21 ′ and a middle shoulder 24 , the external diameter of the shoulders is equal to the inner wall diameter of the cylindrical valve spool aperture 10 . The right shoulder 22 ′ is adjacent to the fourth chamber 15 , the left shoulder 21 ′ is adjacent to the fifth chamber 11 , the middle shoulder 24 is located in the middle of the cylindrical valve spool 2 , the first control edge C 1 and second control edge C 2 are respectively composed of both side end surfaces of the middle shoulder 24 and corresponding side edge of the second under-cut groove 172 . Between the cylindrical valve spool 2 and the cylindrical valve spool aperture 10 five chambers are formed successively from left to right: the fifth chamber 11 , the third chamber 14 , the second chamber 13 , the first chamber 12 and the fourth chamber 15 . The second chamber 13 is formed by a space between the middle shoulder 24 and the second under-cut groove 172 , the third chamber 14 is formed by a space between the cylindrical valve spool 2 and the valve body 1 that are located between the left shoulder 21 ′ and the middle shoulder 24 , the first chamber 12 is formed by between the cylindrical valve spool 2 and the valve body 1 that are located between the middle shoulder 24 and the right shoulder 22 ′. The other constructions of the three-way proportional pressure reducing control valve are the same with the implementation 1 .
[0056] Similarly, when the input current of the electromagnet 41 is zero, due to the combined action of the precompression of the spring 3 and the residual pressure of the second chamber 13 which is caused by a leakage existing from the first chamber 12 to the second chamber 13 , the cylindrical valve spool 2 is pushed to the side of the electromagnet 41 so as to make the first control edge C 1 being closed, the second edge C 2 being opened and the pressure of the oil in the second chamber 13 become zero. The principle of the action is the same with the implementation example 1.
[0057] The protection range of the present invention is not restricted in the provided implementation examples
[0058] Even if some changes are made for the construction project of the implementation examples such as the electromagnet 41 is replaced by the toque motor or electric-mechanical converter; or the notch shape is changed for the control edges, the notch is set as a chute, squire or ladder-shaped etc. Thus with the movement of the cylindrical valve spool, the first control edge C 1 and the second control edge C 2 are formed between the chute notch, squire or trapeze notch and the valve body, or the above mentioned springs are removed or the oil hole is set at the outside of the valve body etc. This project still belongs to the protection range of the present invention.
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A three-way proportional pressure reducing valve includes a valve body and a cylindrical valve spool. Five chambers are formed between the valve body and the cylindrical valve spool, respectively a fifth chambers, a first chamber, a second chamber, a third chamber and the fourth chamber. The first chamber connected to a high pressure inlet port P, the second chamber connected to a oil port A and the third chamber connected to a low pressure outlet port T. A first control edge being fitted between the first chamber and the second chamber, a second control edge being fitted between the second chamber and the third chamber. A first passage being located between the fifth chamber and the second chamber for connecting the second chamber to the fifth chamber, a second passage being located between the fourth chamber and the third chamber for connecting the fourth chamber to the third chamber. The present invention mainly provides a three-way proportional pressure reducing valve which can be achieved to control arbitrary pressure course change between pressure P at the constant pressure source and the oil tank at zero pressure by two damping adjustable control edges and the pressure feedback means of the chamber. The aim of the present invention is to solve the technological problem of change-over only within two limit value of zero pressure and maximum pressure and unable to control the intermediate pressure, which exists in the technology now available.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] Applicants claim priority under 35 U.S.C. §119 of European Application No. 08103166.8 filed Mar. 28, 2008.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The invention relates to a vibration generator comprising at least two groups of shafts, on which at least two groups of imbalances are disposed, and which are connected with at least one drive, in such a way that they are driven at different speeds of rotation. Means are provided for changing the phase position of at least two imbalance groups, relative to one another, thereby achieving targeted advance.
[0004] 2. The Prior Art
[0005] In construction, vibration generators are used to introduce objects, such as profiles, into the ground, or to draw them from the ground, or also to compact ground material. The ground is excited by means of vibration, and thereby achieves a “pseudo-fluid” state. The goods to be driven in can then be pressed into the construction ground by a static top load. The vibration is characterized by a linear movement and is generated by rotating imbalances that run in opposite directions, in pairs.
[0006] The vibration generators are vibration exciters having a linear effect, whose centrifugal force is generated by rotating imbalances. The size of the imbalance is also referred to as a static moment. The progression of the speed of the linear vibration exciter corresponds to a periodically recurring function, particularly a sine function. On the basis of the sine-shaped progression of the force effect generated by the rotating imbalance masses, a drive that acts alternately in the forward drive direction and counter to it, with time offset, is produced. In this connection, it is possible to bring about a directed force effect in the forward drive direction, by coupling with imbalances that rotate at different speeds of rotation.
[0007] Depending on the stated task, however, different orientations of the operating force generated are desirable. For example, a pile-driving process requires a directed force in the forward drive direction, while a retraction process requires a force in the opposite direction. It is a disadvantage of the previously known systems that a vibration generator for introducing material to be pile-driven, having a force effect directed in the forward drive direction, cannot be used for retraction processes, or can only be used by superimposition of significant static forces.
SUMMARY OF THE INVENTION
[0008] It is therefore an object of the invention to provide a vibration generator that allows a directed effect of the force, depending on the set task, both in the pile-driving direction and in the retraction direction. According to the invention, this task is accomplished by a vibration generator comprising at least two groups of shafts, on which at least two groups of imbalances are disposed, and which are connected with at least one drive. The shafts rotate at different speeds of rotation relative to one another, thereby achieving a directed advance. There are also means for adjusting the effective direction of the vibration generator.
[0009] With the invention, a vibration generator is created that allows a directed force in the forward drive direction or the retraction direction, depending on the task. In this way, adaptation of the vibration generator to different process requirements, such as pile-driving and retraction, is made possible.
[0010] In an embodiment of the invention, the means for adjustment of the effect direction comprise a swivel motor by way of which the relative phase position of at least two imbalance groups that rotate at different speeds of rotation can be changed. In this way, a change in the effect direction is made possible, without any conversion measures being required.
[0011] In a further embodiment of the invention, the at least two imbalance groups are connected with the swivel motor by way of gear wheels. At least one imbalance group is connected with the stator, and at least one imbalance group is connected with the rotor of the swivel motor. In this way, direct adjustment of the imbalance groups by way of the swivel motor is made possible.
[0012] It is advantageous if the swivel motor is a rotary vane swivel motor. Alternatively, the swivel motor can also be a swivel motor having a steep thread.
[0013] In a further development of the invention, two shaft groups are connected with the at least one drive in such a manner that the speed of rotation of the first shaft group amounts to half the speed of rotation of the second shaft group. The ratio of the static moments of the shaft groups provided with the imbalance groups amounts to between six to one and ten to one. By coupling at least two shaft groups having a speed of rotation ratio of 2:1 and a ratio of the static moment of between 6:1 and 10:1, a directed characteristic line in the forward drive direction is produced by superimposition of the sine-shaped force characteristic lines generated by the rotating imbalances. A significantly greater maximal force in the forward drive direction comes about, as compared to the opposite direction. Since the ground cannot follow the great acceleration in the pile-driving direction during the pile-driving process, the goods to be driven in uncouple from the ground, which is also vibrating, at every forward drive pulse. Because of this periodic uncoupling of ground and goods to be driven in, little energy is transferred to the construction ground. As a result, the vibration stress on the surroundings is also clearly further reduced.
[0014] Preferably, the static moment of the first shaft group is eight times as great as the static moment of the second shaft group. In this way, a marked force peak in the forward drive direction is brought about.
[0015] In another embodiment of the invention, three shaft groups are disposed, on which at least three imbalance groups are disposed. The shaft groups are connected with the at least one drive in such a manner that the speed of rotation of the first shaft group amounts to half the speed of rotation of the second shaft group and to one-third of the speed of rotation of the third shaft group. The ratio of the static moments of the shaft groups provided with the imbalance groups, relative to one another, amounts to essentially 100:16.64:3.68. In this way, the maximally active force is increased by a further marked force peak in the forward drive direction. As a result, a further increase in energy efficiency, connected with acceleration of the pile-driving process, is achieved.
[0016] In another embodiment of the invention, there are four shaft groups on which at least four imbalance groups are disposed. The shaft groups are connected with the at least one drive in such a manner that the ratio of the speeds of rotation of the shaft groups amounts to essentially 1:2:3:4, and the ratio of the static moments of the shaft groups provided with the imbalance groups, relative to one another, amounts to essentially 100:18.72:5.6:1.38. As a result, a further particular emphasis of the force progression in the forward drive direction is achieved.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] Other objects and features of the present invention will become apparent from the following detailed description considered in connection with the accompanying drawings. It is to be understood, however, that the drawings are designed as an illustration only and not as a definition of the limits of the invention.
[0018] In the drawings, wherein similar reference characters denote similar elements throughout the several views:
[0019] FIG. 1 is a schematic representation of a gear mechanism of a vibration generator for directed vibration, having two shaft groups;
[0020] FIG. 2 shows the vibration gear mechanism from FIG. 1 , with an additional swivel motor for changing direction;
[0021] FIG. 3 is a schematic representation of a gear mechanism that acts in a directed manner, having two shaft groups, each consisting of three shafts;
[0022] FIG. 4 is a schematic representation of different variants of vibrator gear mechanisms that act in a directed manner, having
a) a six-shaft, short construction; b) a seven-shaft, simple construction; c) a seven-shaft, short construction;
[0026] FIG. 5 is a schematic representation of vibrator gear mechanisms that act in directed manner and can change direction, having
a) a six-shaft, simple construction; and b) a six-shaft, short construction;
[0029] FIG. 6 is a representation of the vibrator gear mechanism from FIG. 5 , in a compact embodiment, and
[0030] FIG. 7 is a schematic representation of a vibrator gear mechanism that can change direction, having eight shafts.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0031] Referring now in detail to the drawings, the vibration generators selected as exemplary embodiments are configured as vibrator gear mechanisms. Such vibrators consist essentially of a housing, in which shafts provided with gear wheels are mounted. The gear wheels are provided with imbalance masses, in each instance. Such vibrator gear mechanisms having imbalance masses mounted to rotate are known to a person skilled in the art, for example from German Patent No. DE 20 2007 005 283 U1. The following explanation of the exemplary embodiments is essentially limited to the arrangement of shafts and imbalance masses.
[0032] In the assembly according to FIG. 1 , two shaft groups 1 , 2 are disposed. Shafts 11 , 12 of shaft group 1 are provided with gear wheels 112 , 122 , on which imbalance masses 111 , 121 , are disposed. Imbalance masses 111 , 121 are configured in the same manner here. Shafts 21 , 22 of shaft group 2 are also provided with gear wheels 212 , 222 , on which imbalance masses 211 , 221 of the same type are disposed. Gear wheels 112 , 122 , 212 , 222 are configured in such a manner that during rotation, the speed of rotation of shafts 21 , 22 of shaft group 2 is twice as great as the speed of rotation of shafts 11 , 12 . Imbalance masses 111 , 121 , 211 , 221 are disposed in such a manner that the static moment of shaft group 1 is eight times as great as the static moment of shaft group 2 .
[0033] In the embodiment according to FIG. 2 , a swivel motor 5 is additionally disposed, whose stator has a gear wheel 51 and whose rotor has a gear wheel 52 . Shaft groups 1 , 2 are connected with one another, by way of swivel motor 5 , in such a manner that gear wheel 112 of shaft 11 engages gear wheel 52 of swivel motor 5 ; gear wheels 212 , 222 of shaft group 2 engage gear wheel 51 of swivel motor 5 . It is now possible to adjust a phase shift of the vibrations of shaft group 2 relative to the vibrations of shaft group 1 by relative swiveling of the rotor with regard to the stator, thereby making it possible to set a change in direction. In the present example, swivel motor 5 is a rotary vane motor having one vane.
[0034] In the assembly according to FIG. 3 , shaft groups 1 , 2 are formed from three shafts 11 , 12 , 13 , 21 , 22 , 23 , which are provided with imbalance masses 111 , 121 , 131 , 211 , 221 , 231 , respectively. Gear wheels 112 , 122 , 132 , 212 , 222 , 232 of shafts 11 , 12 , 13 , 21 , 22 , 23 , in turn, are selected so that during rotation, the shafts of shaft group 2 demonstrate twice the speed of rotation compared to the shafts of shaft group 1 . A more compact construction can be achieved by offsetting shafts 21 , 22 , 23 of shaft group 2 (cf. FIG. 4 a )). The number of shafts of the shaft groups 1 , 2 can also be selected to be different. In the exemplary embodiment according to FIG. 4 b ), an additional shaft 24 with a corresponding imbalance mass 241 has been added. Again, a compact construction can be achieved by means of an offset arrangement of shafts 21 , 22 , 23 , 24 of shaft group 2 (cf. FIG. 4 c )).
[0035] In the embodiment according to FIG. 5 , a swivel motor 5 is disposed between shafts 11 , 12 , 13 of shaft group 1 and shafts 21 , 22 , 23 of the shaft group 2 . In this connection, gear wheels 112 , 122 , 132 of shaft group 1 engage gear wheel 51 of the stator of swivel motor 5 , and gear wheels 212 , 222 , 232 of shaft group 2 engage gear wheel 52 of the rotor of swivel motor 5 . Again, switching of the effect direction is made possible by a relative rotation of stator and rotor of swivel motor 5 . Again, a more compact construction height can be achieved by an offset arrangement of the shafts of shaft group 2 (cf. FIG. 5 b )).
[0036] In FIG. 6 , a modified construction of the aforementioned assembly according to FIG. 5 is shown, which permits a clear reduction in the construction length, but in which eight shafts are required in place of six shafts. This results in less stress on the shaft bearings and brings with it advantages with regard to the centripetal force that can be achieved, suitability for high speeds of rotation, and less sensitivity with regard to great angle accelerations.
[0037] To achieve the most balanced characteristic line shape possible, an additional speed of rotation stage, whose imbalances rotate at three times the speed of rotation, can be used. In the embodiment according to FIG. 7 , such an assembly, based on the gear mechanism concept according to FIG. 5 , is shown. This turns out to be slightly wider, since the lower large gear wheel 132 , which drives the two shafts 31 , 32 , which are disposed next to one another, is displaced relative to the center of the gear mechanism. In the adjustment of the effect direction, the angle setting of slow imbalances 111 , 121 , 131 and fast imbalances 311 , 321 , relative to one another, remains unchanged. Adjustment of the medium-speed imbalances 211 , 221 , 231 , relative to the others, is made possible by swivel motor 5 .
[0038] In the embodiment according to FIG. 7 , the ratio of the speeds of rotation of shaft groups 1 , 2 , 3 , relative to one another, amounts to approximately 1:2:3; the static moment of the shaft groups 1 , 2 , 3 , relative to one another, amounts to essentially 100:16.64:3.68.
[0039] Using the aforementioned and claimed ratios of the speeds of rotation and the static moments, respectively, relative to one another, a very effective force effect in the forward drive direction can be achieved. This effect can be achieved even with a slight change in the ratio figures in the range of up to ten percent, but some efficiency is lost. Such modifications of the ratios of the speed of rotation and the static moments, respectively, relative to one another, are also considered to be part of the invention.
[0040] Accordingly, while only a few embodiments of the present invention have been shown and described, it is obvious that many changes and modifications may be made thereunto without departing from the spirit and scope of the invention.
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A vibration generator has at least two groups of shafts, on which at least two groups of imbalances are disposed, and which are connected with at least one drive that rotates the shafts relative to one another, at different speeds of rotation, thereby achieving a directed advance. The operating direction of the vibration generator can be adjusted.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to the use of acid labile colorants which may be decolorized by acid hydrolysis. In particular, the invention relates to acid labile colorants in the form of polyoxyalkylene substituted azomethine and indophenol chromophores.
2. Prior Art
Fugitive tints which have achieved wide acceptance in the textile industry include the polyethyleneoxy-substituted tints described in Kuhn, U.S. Pat. No. 3,157,633. These tints are normally applied to yarn such as nylon yarn before heat setting. Such tints are a combination of a dyestuff radical and one or more polyethyleneoxy groups. Dyestuff radicals disclosed in the patent above include nitroso, nitro, azo, diphenylmethane, triarylmethane, xanthene, acridine, methine, thiazole, indamine, azine, oxazine, and o-anthraquinone radicals. Preferably, such radicals may be attached to the polymeric constituents of the tint composition by an amino nitrogen.
Fugitive coloration of nylon in particular presents special problems since the tinted yarn, or fabric woven or knitted therefrom, may be subjected to a heat-setting treatment, usually with steam. This heat-setting treatment can at times fix the tint in the fibers so that the yarns remain stained or colored, and the tint cannot be removed readily in later finish-scouring operations. Special and inconvenient reducing or oxidizing treatments to remove the tint may therefore be required.
Also, with the advent of improved continuous carpet dyeing techniques (such as the Kuster Dyer) scouring of the carpet with copious quantities of water is becoming unnecessary and, in fact, may be undesirable, except for the necessity of removing the fugitive tint. These continuous carpet dye ranges are being run at higher speed in order to increase production, further reducing the amount of scouring time that a fugitive tint would experience during dyeing.
Previously, consumers chose darker shades of carpet because they were easier to maintain and did not easily show stains. If the traditional fugitive tint inadvertently left some color on a dark colored carpet, it was often not detectable and did not detract from the appearance of the carpet. With the advent of stain-blocker technologies, consumers are choosing lighter shades of carpet because it is now possible to clean and maintain light colored carpet as easily as dark colored carpet. If any residual fugitive tint is left on light colored carpet, it is more easily noticed and is more likely to detract from the appearance of the carpet.
Furthermore, while conventional fugitive tints have in the past generally been applied at levels below about 0.2% of tint based upon the weight of the fiber, at the present time increasing tint levels are being called for to maintain proper identification of yarn ends during carpet tufting operations. When conventional fugitive tints are used at such higher levels, e.g., above about 0.2%, removal of all of the tint may become increasingly difficult or impossible.
SUMMARY OF THE INVENTION
Therefore, an object of the invention is to provide a colorant suitable as a fugitive tint for textile fibers which can be used with heat setting treatment, lighter shades of product and at increased tint levels.
Another object of the invention is to provide a process whereby residual tint not removed from a textile fiber is decolorized. A further object is to provide a decolorization process which may be easily adapted to existing dyeing and stain-blocker treatments.
Still another object of the invention is to provide a colorant suitable for use as a washable ink which may be decolorized to prevent permanent staining.
Accordingly, a process for temporarily coloring an article is provided by applying a colorant solution in the form of a polyoxyalkylene substituted chromophore to the article. The chromophore is selected from azomethine and indophenol chromophores characterized by a carbon-nitrogen pair joined by a double bond. The polyoxyalkylene substituent is a straight or branched polymer chain of at least 10 monomers selected from ethylene oxide, propylene oxide and glycidol. The colorant is provided in an amount sufficient to provide coloration to the solution. The colorant is decolorized by hydrolysis of the carbon-nitrogen pair by the addition of an aqueous acid, having a pH of 5 or less, to the colorant.
The invention features embodiments which are water soluble for easy application and clean up. The invention also features relatively high molecular weight chromophore which resist penetration into the interstices of textile fibers. Thus, the polyoxyalkylene substituted chromophores herein have an advantage over other acid labile tints which may penetrate deeply within the fiber and become difficult to hydrolyze. Another advantage of the present invention is that decolorization of textile fibers may be achieved during typical acid dyeing and stain-blocker treatment and without the need to add process steps.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Without limiting the scope of the invention, the preferred features of the invention are hereinafter set forth.
The colorants useful in the present invention are characterized by a chromophore containing a C=N bond, referred to herein as a carbon-nitrogen pair. An electron withdrawing group to one element of the pair and an electron donating is bonded to an opposite element of the pair. Strong electron donating and withdrawing groups are recommended to facilitate subsequent hydrolysis. Preferably, two electron withdrawing groups or two electron donating groups are bonded to carbon. Compounds suitable for use may be found in the class of azomethine and indophenol chromophores.
By way of example and not limitation, suitable electron withdrawing groups are: selected from NO 2 , CN, cyanophenyl, nitrophenyl, alkyl ester, ketone, aryl ester, aldehyde, sulfonic acid, carboxylic acid, ammonium ion and vinyl ketone groups, and said electron donating group is selected from: arylamine, arylalkoxide and alkylaryl groups.
In addition to the presence of electron donating and withdrawing groups, the chromophores of interest herein may be substituted with a variety of compounds known to those with skill in the art which shift the absorption spectrum of the chromophore or intensify its color, without deviating from the spirit of the invention.
The colorants useful herein are further characterized by one or more polyoxyalkylene substituents covalently bonded to the chromophore. The polyoxyalkylene substituents are straight or branched polymers of primarily ethylene oxide, propylene oxide and glycidol monomers. Minor amounts of butylene oxide and other compatible monomers may be present in amounts not to exceed 25%. The polyoxyalkylene substituents contain at least 10 monomers units selected from ethylene oxide, propylene oxide and glycidol. In a preferred embodiment, all of the polyoxyalkylene substituents combined, typically from one to six substituents, contain from 20 to 400 ethylene oxide, propylene oxide and/or monomer units, and more preferably from 50 to 400 of such monomer units.
In order to enhance water solubility of the colorant, at least 50% of the monomer units of the polyoxyalkylene substituent should be comprised of ethylene oxide units, and preferably, at least 75% of the monomers are ethylene oxide. Glycidol monomers can be incorporated into the polyoxyalkylene substituent to promote branching. Substituents having glycidol monomers within ten monomer units of the chromophore appear to provide greater stability to the chromophore in solution. In a preferred embodiment, less than 20% of the monomer units are glycidol.
Propylene oxide may be advantageously added onto the polyoxyalkylene substituent directly after the glycidol units.
The propylene oxide reacts with the primary hydroxyl sites of glycidol and provides a secondary hydroxyl site for further chain growth. Additional alkylene oxide monomer units may react with either the secondary hydroxyl site of the recently added propylene oxide or with the secondary hydroxyl site of the glycidol units to achieve branching. Preferably, less than 50% of the monomer units in the polyoxyalkylene substituent is propylene oxide, and more preferably less than 20% of the monomer units are propylene oxide.
The polyoxyalkylene substituents are covalently linked to the chromophores by a linking agent such as N, O, S, CO 2 , SO 2 , SO 2 N and CON. When nitrogen is used as the linking agent, typically two polyoxyalkylene substituents are linked to the chromophore.
Examples of suitable end groups on the polyoxyalkylene substituent are H, alkyl, acetyl, ketone, aryl and benzoyl groups. Alternatively, a terminal oxygen of the substituent chain may be substituted with Cl, Br or F.
Synthesis of chromophores containing polyoxyalkylene substituents and fugitive colorants are disclosed in Kuhn, U.S. Pat. No. 3,157,633, Brendle, U.S. Pat. No. 4,167,510 and Cross et al., U.S. Pat. No. 4,284,729 incorporated by reference herein.
For most applications, the colorant is not applied to an article at full strength, but rather is dispersed or dissolved in a suitable carrier or solvent. Depending upon the particular application, concentrations of colorant in solution from 0.5 weight percent to 50 weight percent are useful. Preferably, the colorant solution contains from 1 weight percent to 40 weight percent colorant. Examples of suitable solvents are water, propylene glycol, ethylene glycol, C 1 -C 4 alcohols and methylene chloride. In most instances, for considerations of cost, toxicity and availability, water is preferred. If the colorant is not a liquid at room temperature, it may be heated to slightly above its melting point before blending with a solvent.
In the first step of the invention, the solution containing suitable concentration of colorant, at least enough colorant to visibly color the solution, is applied to an article. In one embodiment, the solution is applied to a textile fiber to maintain identification of the fiber during subsequent weaving, knitting or tufting operations. The solution may be applied to the textile fiber by any of a variety of methods known in the art, such as mixing the solution with a lubricant and spraying it on the fiber.
The invention is applicable to virtually every known textile fiber and is especially useful with fibers that stain easily, such as synthetic polyamides, cotton, wool and silk. In particular, the invention is useful as a fugitive tint for nylon 6 and nylon 6,6 fibers.
The colorant solution may be employed as an ink. For example, the solution may be applied to a writing surface with a felt tip pen applicator. The colorant may be removed from hands and clothing by washing due to the enhanced water solubility of the chromophore, especially when a large percentage of polyoxyalkylene monomers are ethylene oxide.
However, as discussed previously, even a small amount of residual colorant on lighter shades of textile materials and clothing is undesirable. Due to the unique structure of the chromophores employed in the invention, residual colorant can be decolorized by hydrolysis with an application of an acid solution to the colorant. The colorant may be hydrolyzed regardless of whether it has dried on the article or been heat set.
Preferably, the acid solution is aqueous and has a pH of 5 less, and more preferably, a pH of 3 or less. Application of the acid solution at higher temperatures and lower pH enhances hydrolysis of the colorant. However, the invention may be practiced at room temperatures.
In many fugitive tint applications, the textile fibers are acid dyed, treated with a stain-blocker or both. Dyeing and stain-blocker treatments are typically performed at a pH of 3 or less and at temperatures of between 40° C. and 100° C. Hydrolysis of the C=N pair of the chromophore occurs soon after contact with the acid solution.
Alternatively, the colorant can be removed from articles of clothing by brief soaking in a dilute acid solution such as citric acid or acetic acid. A solution of the colorant applied as an ink may be wiped with a swab soaked in dilute sulfuric acid. The colorant is easily decolorized, even after it has dried on writing paper.
The invention may be further understood by reference to the following examples, but the invention is not to be construed as being unduly limited thereby. Unless otherwise indicated, all parts and percentages are by weight.
EXAMPLE 1
Synthesis of N,N-bis(hydroxyethylpolyoxyethylene)aniline (I) ##STR1##
Ninety three grams of aniline were allowed to react with 4400 grams ethylene oxide in the presence of potassium hydroxide following well known ethoxylation procedures. About 100 molar equivalents of ethylene oxide were thus added to the starting material.
EXAMPLE 2
Synthesis of N,N-bis(hydroxyethylpolyoxyethylene)-4-nitrosoaniline (II) ##STR2##
Two hundred twenty-five grams of N,N-bis(hydroxyethylpolyoxyethylene)aniline (I where n=50) were heated in a three liter, three-necked, round-bottomed flask until the material had melted A solution of 15 g concentrated HCl in 115 ml water was charged to the flask and is thoroughly mixed. The resulting solution was then cooled to 5° C. and kept under a nitrogen atmosphere. A solution of 3.7 g sodium nitrite in 20 ml water was slowly added. The solution was allowed to stir for one hour, then it was cut to 65% solids with water and bottled.
EXAMPLE 3
Synthesis of N,N-bis(acetoxyethylpolyoxyethylene)-4-formylaniline (III) ##STR3##
Two hundred twenty grams of N,N-bis(hydroxyethylpolyoxyethylene)aniline (I where n=50) were heated in a three liter, three-necked, round-bottomed flask until the material had melted. 20 g acetic anhydride was added to the melted material which was then heated to 100° C. and stirred for two hours. The product was then cooled and 50 ml water was added. The reaction mixture was vacuum stripped to dryness. Two hundred grams of the dried product and 100 g N,N-dimethylformamide were charged to a 3-L, three-necked, round-bottomed flask and heated to 44° C. under a nitrogen blanket. Seventy-five grams phosphorus oxychloride were then charged dropwise to the reaction mixture. The mixture was continually stirred and the temperature was kept below 47° C. for the entire addition. The reaction was heated to 90° C. and held there for 1.5 hrs. The reaction mixture was cooled to 40° C. and then neutralized slowly with caustic. The product mixture was vacuum stripped to dryness.
EXAMPLE 4
Synthesis of N,N-bis(hydroxyethylpolyoxyethylene)-4-aminoaniline (IV) ##STR4##
A solution of 226 g of N,N-bis(hydroxyethylpolyoxyethylene)-4-nitrosoaniline (II where n=50) in 115 ml of water was made. A solution of 22 g concentrated HCl in 50 ml water was charged to the first solution. Then, 8.8 g powdered zinc metal was slowly added while maintaining the reaction below 25° C. After the addition of the zinc and the exotherm of the reaction had stopped, the reaction was allowed to stir for 24 hrs at room temperature. The reaction was then neutralized with saturated sodium bicarbonate, filtered, and vacuum stripped to dryness.
EXAMPLE 5
Synthesis of N,N-bis(hydroxyethylpolyoxyethylene)-m-toluidine (V) ##STR5##
A solution of 1369 of m-toluidine in 200 ml toluene was allowed to react with 88 g of ethylene oxide following well known ethoxylation procedures. Then 3 g potassium hydroxide followed by 4312 g of ethylene oxide were charged to the reaction which was allowed to proceed by means of well known ethoxylation procedures. About 100 molar equivalents were thus added to the starting material. The toluene was vacuum stripped from the product.
EXAMPLE 6
Synthesis of N,N-bis(hydroxyethylpolyoxyethylene)-4-nitroso-m-toluidine (VI) ##STR6##
Two hundred sixty-eight grams of N,N-bis(hydroxyethylpolyoxyethylene)-m-toluidine (V, n=50) was heated in a three liter, three-necked, round-bottomed flask until the material was melted. A solution of 15 g concentrated HCl in 115 ml water was charged to the flask and was thoroughly mixed. The resulting solution was then cooled to 5° C. and kept under a nitrogen atmosphere. A solution of 3.7 g sodium nitrite in 20 ml water was slowly added. The solution was allowed to stir for one hour, and then it was cut to 65% solids and bottled.
EXAMPLE 7
Synthesis of N,N,O-tris(hydroxyethylpolyoxyethylene)-m-aminophenol (VII) ##STR7##
A solution of 109 g of m-aminophenol in 200 ml toluene was allowed to react with 132 g of ethylene oxide following well known ethoxylation procedures. Then 3 g potassium hydroxide followed by 4268 g of ethylene oxide were charged to the reaction which was allowed to proceed by means of well known ethoxylation procedures. About 100 molar equivalents were thus added to the starting material. The toluene was vacuum stripped from the product.
EXAMPLE 8
Synthesis of N,N,O-tris(hydroxyethylpolyoxyethylene)-6-nitroso-3-aminophenol (VIII) ##STR8##
Two hundred fifty-five grams of N,N,O-tris(hydroxyethylpolyoxyethylene)-m-aminophenol (VII, n=33.3) were heated in a three liter, three-necked, round-bottomed flask until the material was melted. A solution of 15 g concentrated HCl in 115 ml water was charged to the flask and was thoroughly mixed. The resulting solution was then cooled to 5° C. and kept under a nitrogen atmosphere. A solution of 3.7 g sodium nitrite in 20 ml water was slowly added. The solution was allowed to stir for one hour, and then it was cut to 65% solids and bottled.
EXAMPLE 9
Synthesis of N,N-bis(hydroxyethylpolyoxyethylenepolyoxypropyleneoxyethylene)aniline (IX) ##STR9##
Ninety three grams of aniline were allowed to react with 88 grams ethylene oxide following well known ethoxylation procedures. Two grams of potassium hydroxide were then charged to the reaction flask and 1740 g of propylene oxide were then added following well known propoxylation procedures. Another 3080 g ethylene oxide were then added to the reaction mixture. About 72 molar equivalents of ethylene oxide and 30 molar equivalents of propylene oxide were thus added to the starting material.
EXAMPLE 10
Synthesis of N,N-bis(hydroxyethylenepolyoxyethyleneployoxypropylene)aniline (X) ##STR10##
Ninety three grams of aniline were allowed to react with 88 grams ethylene oxide following well known ethoxylation procedures. Two grams of potassium hydroxide were then charged to the reaction flask and 4972 g of ethylene oxide were then added following well known propoxylation procedures. Another 2030 g propylene oxide were then added to the reaction mixture. About 115 molar equivalents of ethylene oxide and 35 molar equivalents of propylene oxide were thus added to the starting material.
EXAMPLE 11
Synthesis of N,N-oxyethylpolyoxyethylenepolyoxypropyleneoxyethylene)-4-nitrosoaniline (XI) ##STR11##
Two hundred fifty grams of N,N-bis(hydroxyethylenepolyoxyethyleneployoxypropylene)aniline (IX where n=35, m=15, p=1) were heated in a three liter, three-necked, round-bottomed flask until the material had melted. A solution of 15 g concentrated HCl in 115 ml water was charged to the flask and was thoroughly mixed. The resulting solution was then cooled to 5° C. and kept under a nitrogen atmosphere. A solution of 3.7 g sodium nitrite in 20 ml water was slowly added. The solution was allowed to stir for one hour, then it was cut to 65% solids with water and bottled.
EXAMPLE 12
Synthesis of N,N-bis(hydroxyethylpolyoxyethylenepolyoxypropylene)-4-nitrosoaniline (XII) ##STR12##
Three hundred fifty-nine grams of N,N-bis(hydroxyethylpolyoxyethylenepolyoxypropylene)aniline (X where n=56.5 and m=17.5) were heated in a three liter, three-necked, round-bottomed flask until the material had melted. A solution of 15 g concentrated HCl in 115 ml water was charged to the flask and was thoroughly mixed. The resulting solution was then cooled to 5° C. and kept under a nitrogen atmosphere. A solution of 3.7 g sodium nitrite in 20 ml water was slowly added. The solution was allowed to stir for one hour, then it was cut to 65% solids with water and bottled.
EXAMPLE 13
Synthesis of N,N-bis(hydroxyethylpolyoxyethylene, polyglycidol)aniline (XIII) ##STR13##
Ninety three grams of aniline were allowed to react with 296 grams glycidol by heating the aniline to 130° C. and dripping the glycidol in slowly under a nitrogen atmosphere. The product was then allowed to react with 8800 grams ethylene oxide in the presence of potassium hydroxide following well known ethoxylation procedures. About 200 molar equivalents of ethylene oxide were thus added to the starting material.
EXAMPLE 14
Synthesis of N,N-bis(hydroxyethylpolyoxyethylene, polyglycidol)-4-nitrosoaniline (XIV) ##STR14##
Four hundred fifty-nine grams of N,N-bis(hydroxyethylpolyoxyethylene, polyglycidol)aniline (XIII, n=3, m=2) are heated in a three liter, three-necked, round-bottomed flask until the material has melted. A solution of 15 g concentrated HCl in 115 ml water was charged to the flask and was thoroughly mixed. The resulting solution was then cooled to 5° C. and kept under a nitrogen atmosphere. A solution of 3.7 g sodium nitrite in 20 ml water was slowly added. The solution was allowed to stir for one hour, then it was cut to 65% solids with water and bottled.
EXAMPLE 15
Synthesis of N,N-bis(hydroxyethylpolyoxyethylene, polyoxypropylene, polyglycidol)-m-toluidine (XV) ##STR15##
Ninety three grams of aniline were allowed to react with 296 grams glycidol by heating the aniline to 130° C. and dripping the glycidol in slowly under a nitrogen atmosphere. The product was then allowed to react with 232 grams propylene oxide followed by 8800 grams ethylene oxide in the presence of potassium hydroxide following well known ethoxylation procedures. About 4 molar equivalents of propylene oxide and 200 molar equivalents of ethylene oxide were thus added to the starting material.
EXAMPLE 16
Synthesis of N,N-bis(hydroxyethylpolyoxyethylene, polyoxypropylene, polyglycidol)-4-nitroso-m-toluidine (XVI) ##STR16##
Four hundred seventy-two grams of N,N-bis(hydroxyethylpolyoxyethylene, polyoxypropylene, polyglycidol)-m-toluidine (XV, n=33.3, m=1, p=2) were heated in a three liter, three-necked, round-bottomed flask until the material has melted. A solution of 15 g concentrated HCl in 115 ml water was charged to the flask and was thoroughly mixed. The resulting solution was then cooled to 5° C. and kept under a nitrogen atmosphere. A solution of 3.7 g sodium nitrite in 20 ml water was slowly added. The solution was allowed to stir for one hour, then it was cut to 65% solids with water and bottled.
EXAMPLE 17
Synthesis of N,N-bis(hydroxyethylpolyoxyethylene, polyoxypropylene, polyglycidol)-m-anisidine (XVII) ##STR17##
One hundred twenty-three grams of m-anisidine were allowed to react with 296 grams glycidol by heating the m-anisidine to 130° C. and dripping the glycidol in slowly under a nitrogen atmosphere. The product was then allowed to react with 232 grams propylene oxide followed by 8800 grams ethylene oxide in the presence of potassium hydroxide following well known ethoxylation procedures. About 4 molar equivalents of propylene oxide and 200 molar equivalents of ethylene oxide were thus added to the starting material.
EXAMPLE 18
Synthesis of N,N-bis(hydroxyethylpolyoxyethylene, polyoxypropylene, polyglycidol)-4-nitroso-m-anisidine (XVIII) ##STR18##
Four hundred seventy-nine grams of N,N-bis(hydroxyethylpolyoxyethylene, polyoxypropylene, polyglycidol)-m-anisidine (XVII, n=33.3, m=1, p=2) were heated in a three liter, three-necked, round-bottomed flask until the material has melted. A solution of 15 g concentrated HCl in 115 ml water was charged to the flask and was thoroughly mixed. The resulting solution was then cooled to 5° C. and kept under a nitrogen atmosphere. A solution of 3.7 g sodium nitrite in 20 ml water was slowly added. The solution was allowed to stir for one hour, then it was cut to 65% solids with water and bottled.
EXAMPLE 19
Synthesis of N,N,O-tris(hydroxyethylpolyoxyethylene, polyoxypropylene, polyglycidol)-m-aminophenol (XIX) ##STR19##
One hundred nine grams of m-aminophenol were allowed to react with 296 grams glycidol by heating the m-aminophenol to 130° C. and dripping the glycidol in slowly under a nitrogen atmosphere. The product was then allowed to react with 232 grams propylene oxide followed by 8800 grams ethylene oxide in the presence of potassium hydroxide following well known ethoxylation procedures. About 4 molar equivalents of propylene oxide and 200 molar equivalents of ethylene oxide were thus added to the starting material.
EXAMPLE 20
Synthesis of N,N,O-tris(hydroxyethylpolyoxyethylene, polyoxypropylene, polyglycidol)-4-nitroso-m-aminophenol (XX) ##STR20##
Four hundred seventy-two grams of N,N,O-tris(hydroxyethylpolyoxyethylene, polyoxypropylene, polyglycidol)-m-aminophenol (XIX, n=29.5, m=0.8, p=1.7) were heated in a three liter, three-necked, round-bottomed flask until the material has melted. A solution of 15 g concentrated HCl in 115 ml water was charged to the flask and was thoroughly mixed. The resulting solution was then cooled to 5° C. and kept under a nitrogen atmosphere. A solution of 3.7 g sodium nitrite in 20 ml water was slowly added. The solution was allowed to stir for one hour, then it was cut to 65% solids with water and bottled.
EXAMPLE 21
Synthesis of N,N-bis(acetoxyethylpolyoxyethylene)-4-aminobenzylidene amino-6-methoxybenzothiazole Tint (XXI) ##STR21##
A solution of 92 g N,N-bis(acetoxyethylpolyoxyethylene)-4-formylaniline (III, n=100) and 32 ml water was mixed with 3.6 g 2-amino-6-methoxybenzothiazole and 0.5 g morpholine and heated to 90° C. for one hour. The reaction was then vacuum stripped to remove the water and the morpholine. The yellow tint was then cut the desired absorbency and bottled.
EXAMPLE 22
Synthesis of N,N-bis(hydroxyethylpolyoxyethlene)-4-amino-m-toluidine cyano-4-nitrobenzylidene Tint (XXII) ##STR22##
A solution of 123 g of 65% N,N-bis(hydroxyethylpolyoxyethylene)-4-nitroso-m-toluidine (VI, n=100) in water was mixed with 3.2 g 4-nitrophenylacetonitrile and 0.5 g morpholine and heated to 90° C. for one hour. The reaction was then vacuum stripped to remove the water and the morpholine. The red tint was then cut the desired absorbency and bottled.
EXAMPLE 23
Synthesis of N,N-bis(hydroxyethylpolyoxyethylene)-4-amino-m-toluidine 5-hydroxynaphthylidene Tint (XXIII) ##STR23##
A solution of 123 g of 65% N,N-bis(hydroxyethylpolyoxyethylene)-4-nitroso-m-toluidine (VI, n=100) in water was mixed with 3.2 g 1,5-naphthalenediol and 0.5 g morpholine and heated to 90° C. for one hour. The reaction was then vacuum stripped to remove the water and the morpholine. The blue tint was then cut the desired absorbency and bottled.
EXAMPLE 24
Synthesis of N,N-bis(hydroxyethylpolyoxyethylene)-4-aminoaniline 2-cyano-2'-cyanobenzylidene Tint (XXIV) ##STR24##
A solution of 122 g of 65% N,N-bis(hydroxyethylpolyoxyethylene)-4-nitrosoaniline (II, n =50) in water was mixed with 2.8 g 2-cyano-o-tolunitrile and 0.5 g morpholine and heated to 90° C. for one hour. The reaction was then vacuum stripped to remove the water and the morpholine. The orange tint was then cut the desired absorbency and bottled.
EXAMPLE 25
Synthesis of N,N-bis(hydroxyethylpolyoxyethylene)-4-aminoaniline dicyanomethine Tint (XXV) ##STR25##
A solution of 122 g of 65% N,N-bis(hydroxyethylpolyoxyethylene)-4-nitrosoaniline (II, n=50) in was mixed with 1.3 g malononitrile and 0.5 g morpholine and heated to 90° C. for one hour. The reaction was then vacuum stripped to remove the water and the morpholine. The orange tint was then cut the desired absorbency and bottled.
EXAMPLE 26
Synthesis of N,N-bis(hydroxyethylpolyoxyethylene)-4-aminoaniline-3-nitrobenzylidene Tint (XXVI) ##STR26##
A solution of 90 g N,N-bis(hydroxyethylpolyoxyethylene)-4-aminoaniline (IV, n=50) and 32 ml water was mixed with 3.0 g 3-nitrobenzaldehyde and 0.5 g morpholine and heated to 90° C. for one hour. The reaction was then vacuum stripped to remove the water and the morpholine. The yellow tint was then cut the desired absorbency and bottled.
EXAMPLE 27
Synthesis of N,N,O-tris(hydroxyethylpolyoxyethylene, polyoxypropylene, polyglycidol)-4-amino-3-hydroxyanilinedi(ethylformate)methine Tint (XXVII) ##STR27##
A solution of l70 g (XX, n=29.5, m=0.8, p =1.7) was mixed with 1.6 g diethylmalonate and 0.5 g morpholine and heated to 90° C. for one hour. The reaction was then vacuum stripped to remove the water and the morpholine. The yellow tint was then cut the desired absorbency and bottled.
EXAMPLE 28
Synthesis of N,N-bis(hydroxyethylpolyoxyethylene, polyglycidol)-4-aminoaniline dicyanomethine Tint (XXVIII) ##STR28##
A solution of 110 g N,N-bis(hydroxyethylpolyoxyethylene, polyglycidol)-4-nitrosoaniline (XIV, n=16.7, m=2) cut to a 55.6% solution in water, was mixed with 0.6 g malononitrile and 0.5 g morpholine and heated to 90° C. for one hour. The reaction was then vacuum stripped to remove the water and the morpholine. The orange tint was then cut the desired absorbency and bottled.
EXAMPLE 29
Synthesis of N,N,O-tris(hydroxyethylpolyoxyethylene, polyoxypropylene, polyglycidol)-4-amino-3-hydroxyaniline-cyano-2-cyanobenzylidene Tint (XXIX) ##STR29##
A solution of 170 g XX, n=25, m=0.8, p=1.7) with 44.6% water was mixed with 1.4 g 2'-cyano-o-tolunitrile and 0.5 g morpholine and heated to 90° C. for one hour. The reaction was then vacuum stripped to remove the water and the morpholine. The red tint was then cut the desired absorbency and bottled.
EXAMPLE 30
Synthesis of N,N-bis(hydroxyethylpolyoxyethylene, polyglycidol)-4-aminoaniline benzoylnitromethine Tint (XXX) ##STR30##
A solution of 110 g N,N-bis(hydroxyethylpolyoxyethylene, polyglycidol)-4-nitrosoaniline (XIV, n=33.3, m=2) cut to a 55.6% solution in water, was mixed with 1.7 g benzolynitromethane and 2 ml morpholine and heated to 110° C. for one hour. The reaction was then vacuum stripped to remove the water and the morpholine. The yellow tint was then cut the desired absorbency and bottled.
EXAMPLE 31
Synthesis of N,N-bis(hydroxyethylpolyoxyethylene, polyoxypropylene, polyglycidol)-4-amino-m-anisidine-4-nitrophenylcyanomethine Tint (XXXI) ##STR31##
A solution of 100 g (XVIII, n=35.3, m=1, p=2) was mixed with 1.6 g 4-nitrophenylacetonitrile and 2 ml morpholine and heated to 60° C. for one hour. The reaction was then vacuum stripped to remove the water and the morpholine. The purple tint was then cut the desired absorbency and bottled.
EXAMPLE 32
Synthesis of N,N-bis(hydroxyethylpolyoxyethylene, polyoxypropylene, polyglycidol)-4-amino-m-toluidine-4-nitrophenylcyanomethine Tint (XXXII) ##STR32##
A solution of 177.5 g (XVI, n=33.3, m=1, p=2, 55% solids) was mixed with 1.6 g 4-nitrophenylacetonitrile and 2 ml morpholine and heated to 60° C. for one hour. The reaction was then vacuum stripped to remove the water and the morpholine. The purple tint was then cut the desired absorbency and bottled.
EXAMPLE 33
Synthesis of N,N-bis(hydroxyethylpolyoxyethylenepolyoxypropyleneoxyethylene)-4-aminoaniline 5-hydroxynaphthylidene Tint (XXXIII) ##STR33##
A solution (50% solids in water) of 76 g bis(hydroxyethylpolyoxyethylenepolyoxypropyleneoxyethylene)-4-nitrosoaniline (XI, n=35, m=15, p=1) was mixed with 1.6 g 1,5-naphthalenediol and 2 ml morpholine and stirred at room temperature for one hour. The reaction was then vacuum stripped to remove the water and the morpholine. The blue tint was then cut the desired absorbency and bottled.
EXAMPLE 34
Synthesis of N,N-bis(hydroxyethylpolyoxyethylenepolyoxypropylene)-4-aminoaniline dicyanomethine Tint (XXXIV) ##STR34##
A charge of 287 g N,N-bis(hydroxyethylpolyoxyethylenepolyoxypropylene)-4-nitrosoaniline (XII, n=15, m=15) was cut to a 55.6% solution in water, was mixed with 6.6 g malononitrile and 20.0 ml morpholine and heated to 50° C. for one hour. The reaction was then vacuum stripped to remove the water and the morpholine. The orange tint was then cut the desired absorbency and bottled.
EXAMPLE 35
Synthesis of N,N-bis(hydroxyethylpolyoxyethylene)-4-amino-m-toluidine 2-cyano-2'-cyanobenzylidene Tint (XXXV) ##STR35##
A solution of 177.5 g of 55% N,N-bis(hydroxyethylpolyoxyethylene)-4-nitroso-m-toluidine (VI, n=100) in water was mixed with 1.4 g 2-cyano-o-tolunitrile and 2 ml morpholine and heated to 75° C. for two hours. The reaction was then vacuum stripped to remove the water and the morpholine. The red tint was then cut the desired absorbency and bottled.
EXAMPLE 36
Fugitivity Testing of Acid Labile Tints
A test was constructed which would simulate actual processing conditions that textile materials would encounter during heat setting, tufting, and continuous dying in order to make carpet. This test was used to determine the fugitivity of various tints when they were subjected to these conditions.
First, 4 inch by 4 inch undyed squares of nylon carpet were cut, and the level of color on them was determined using a Hunter Labscan Colorimeter. The samples were then sprayed with a tint solution such that around 0.5% by weight tint was applied to the carpet square. The samples were allowed to dry overnight and were then read on the colorimeter again. The samples were then heat set in an autoclave, read again on the colorimeter, and allowed to age for one week. They were then dipped in an acid solution (pH 5) for 30 seconds and then vacuumed. They were dipped in a more acidic solution (pH 2.2) and allowed to drain. Both acid solutions were at room temperature. The samples were sprayed twice with water and vacuumed. They were then steamed and vacuumed a final time. The wet samples were dried in a convection oven and read one last time on a colorimeter. The results of this last color measurement were compared to the second. A five point scale was developed in which a score of 5.00 indicates that the tint was 100% fugitive, and the carpet square returned to its completely white shade. The results for the Acid Labile Tints were then compare to the Versatint commercial tints which currently represent the state of the art for fugitive tints. (Table 1)
TABLE 1______________________________________Tint Score______________________________________YellowsVersatint Yellow II 2.56Structure XXVII 4.08Structure XXI 3.14Structure XXX 3.24RedsVersatint Red II 1.74Structure XXII 3.14Structure XXX 3.60OrangesVersatint Orange II 2.36Structure XXIV 4.27Structure XXV 2.76Structure XXVIII 3.88PurplesVersatint Purple II 1.39Structure XXXI 2.35Structure XXXII 2.29BluesVersatint Blue II 1.25Structure XXIII 1.91______________________________________
EXAMPLE 37
Test for Application as an Acid Labile Ink
Five parts of the colorants listed below, 15 parts glycerin and, 80 parts deionized water were weighed into a container and mixed. Using a syringe 2 ml of each ink were placed into the transorb of an assembled pen. The end caps were placed on the pens and the pens were inverted in the writing position. After setting for 0.5 hours the pens were used to make a series of stripes on white 8.5"×1141 paper. The paper was allowed to dry. Using a cotton tipped swab, a 5% sulfuric acid solution was striped over portions of the stripes and the results were noted.
______________________________________Defined ColorantStructure Mark on Paper After Acid Contact______________________________________Example # XXIX Red ColorlessExample # XXXV Red ColorlessExample # XXII Red ColorlessExample # XXV Orange No Effect______________________________________
There are, of course, many obvious modifications and alternate embodiments of the invention which are intended to be included within the scope of the following claims.
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An article may be temporarily colored by application of an aqueous solution of a polyoxyalkylene substituted chromophore characterized by a N═pair with an electron withdrawing group bonded to one element of the pair and an electron donating group bonded to the opposite element. The polyoxyalkylene substituent imparts solubility to the colorant and bulk to prevent penetration into interstices in the article being colored. The colorant may be subsequently decolorized in hydrolysis when an aqueous acid solution is applied to the colorant.
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BACKGROUND OF THE PRESENT INVENTION
[0001] 1. Field of Invention
[0002] The present invention relates to a reluctance motor, and more particularly to a poly-phase reluctance motor.
[0003] 2. Description of Related Arts
[0004] A conventional multi-phase permanent magnet synchronous motor is disclosed in FIG. 1 of the drawings of which the armature winding is a distributed winding which requires a large number of coils to build the winding, the end wires of each winding intersect with each other, the end wires are long and the copper loss is great, and the insulation of the winding is complex and the manufacturing cost is high. Because there exists magnetic coupling between separate phases, the mutual inductance will adversely affect the precision on current control. On the other hand, the magnetic flux generated by the winding in each phase will pass through a relative long flux path, therefore the stator iron loss is relatively great and further increase of motor efficiency is restricted. Also, the permanent magnet is positioned on the stator and the structural strength and allowable temperature rise of the stator are restricted, hence the application of electric motor is limited.
SUMMARY OF THE PRESENT INVENTION
[0005] An object of the present invention is to provide a poly-phase reluctance electric motor with transverse magnetic flux in order to solve the problem of conventional multi-phase permanent magnet synchronous motor in which the precision level in current control which is adversely affected by the existence of magnetic coupling between different phases.
SOLUTION
Technical Solution
[0006] According to the present invention, the foregoing and other objects and advantages are attained by a multi-phase reluctance electric motor with transverse magnetic flux, comprising: a stator and a rotor; wherein a gas partition channel is defined between the stator and the rotor; wherein the rotor comprises a rotor frame unit 4 and a plurality of rotor teeth 5 ; wherein the plurality of rotor teeth 5 are uniformly distributed along the outer circumferential portion of the rotor frame unit 4 ; wherein the rotor frame unit 4 and the rotor teeth 5 have an integrated structure; wherein the stator comprises a housing 1 and an armature unit with m number of phases defining m number of single-phase armature members, where m is the number of phases of the electric motor and m is equal to or greater than 3; wherein the housing 1 has a cylindrical structure; wherein the m number of armature members of the armature unit are sequentially arranged along an axial direction inside the housing, and the single-phase armature members are sequentially staggered along an circumferential direction at an electrical angle of 360°/m; wherein each of the single-phase armature member comprises an armature iron core, an armature coil 2 and 2n number of permanent magnet 3 ; wherein n is a positive integer; wherein the armature iron core comprises a first iron core segment 6 , a second iron core segment 7 and a third iron core segment 8 in which all of the first, second and third iron core segments have a ring-shaped structure defining an axial direction, a central axis along the axial direction, an outer diameter and an inner diameter respectively, wherein the outer diameter of each of the first, the second and the third iron core segments are the same; wherein the first, the second and the third iron core segments are sequentially and tightly arranged along the axial direction inside the housing 1 , and the central axis of the first, the second and the third iron core segments are the same; wherein the second iron core segment 7 is positioned between the first iron core segment 6 and the third iron core segment 8 and the inner diameter of the second iron core segment 7 is greater than that of the first iron core segment 6 and the inner diameter of the third iron core segment 8 ; wherein the inner diameter of the first iron core segment 6 and the inner diameter of the third iron core segment 8 are the same; wherein the armature coil 2 has an annular coil structure and the armature coil 2 is embedded within an annular space formed between the first iron core segment, the second iron core segment and the third iron core segments; wherein the 2n number of permanent magnets 3 utilizes permanent magnet having a tile-shaped structure which is radial magnetized or parallel magnetized; wherein the 2n number of permanent magnet 3 are divided equally into 2 groups to define a first permanent magnet group and a second permanent magnet group; wherein the permanent magnets of the first permanent magnet group are sequentially and alternately aligned according to a N-pole and a S-pole of each of the permanent magnets along a circumferential direction at an inner surface of the first segment 6 ; wherein the permanent magnets 3 of the second permanent magnet group are sequentially and alternately aligned according to a S-pole and a N-pole of each of the permanent magnet 3 along a circumferential direction at an inner surface of the third segment 8 ; wherein the permanent magnets 3 in the first segment 6 and the permanent magnets in the third segment 8 are arranged in opposite polarities and symmetrically along the axis of symmetry of the cross-section of the second segment 7 ; wherein a polar distance τ m is defined as a distance between each two adjacently positioned permanent magnets in the same iron core segment in which the permanent magnets are aligned along the circumferential direction of the corresponding iron core segment, a pitch τ p of the rotor teeth ( 5 ) is defined as a distance between two tooth which are aligned along the circumferential direction, and a relation between the polar distance and the pitch fulfills the equation 2 τ m =τ p .
[0007] The multi-phase reluctance electric motor with transverse magnetic flux according to another preferred embodiment of the present invention comprises a stator and a rotor; wherein a gas partition channel is defined between the stator and the rotor; wherein the rotor comprises a rotor frame unit 4 and a plurality of rotor teeth 5 ; wherein the plurality of rotor teeth 5 are uniformly distributed along the outer circumferential portion of the rotor frame unit 4 ; wherein the rotor frame unit 4 and the rotor teeth 5 have an integrated structure; wherein the stator comprises a housing 1 and an armature unit with m number of phases defining m number of single-phase armature members, where m is the number of phases of the electric motor and m is equal to or greater than 3; wherein the housing 1 has a cylindrical structure; wherein the m number of armature members of the armature unit are sequentially arranged along an axial direction inside the housing, and the single-phase armature members are sequentially staggered along an circumferential direction at an electrical angle of 360°/m; wherein each of the single-phase armature member comprises an armature iron core, an armature coil 2 and 2n number of permanent magnet 3 ; wherein n is a positive integer; wherein the armature iron core comprises a first iron core segment 6 , a second iron core segment 7 and a third iron core segment 8 in which all of the first, second and third iron core segments have a ring-shaped structure defining an axial direction, a central axis along the axial direction, an outer diameter and an inner diameter respectively, wherein the outer diameter of each of the first, the second and the third iron core segments are the same; wherein the first, the second and the third iron core segments are sequentially and tightly arranged along the axial direction inside the housing 1 , and the central axis of the first, the second and the third iron core segments are the same; wherein the second iron core segment 7 is positioned between the first iron core segment 6 and the third iron core segment 8 and the inner diameter of the second iron core segment 7 is greater than that of the first iron core segment 6 and the inner diameter of the third iron core segment 8 ; wherein the inner diameter of the first iron core segment 6 and the inner diameter of the third iron core segment 8 are the same; wherein the armature coil 2 has an annular coil structure and the armature coil 2 is embedded within an annular space formed between the first iron core segment, the second iron core segment and the third iron core segments; wherein a plurality of axial slots for permanent magnet are uniformly provided along the circumferential direction at an inner circumferential surface of the first iron core segment 6 and at an inner circumferential surface of the third iron core segment 8 respectively; wherein a number of the axial slots in the first iron core segment 6 is the same as a number of the axial slots in the third iron core segment 8 ; wherein the 2n number of permanent magnets 3 utilizes permanent magnet having a tile-shaped structure which is radial magnetized or parallel magnetized; wherein the 2n number of permanent magnet 3 are divided equally into 2 groups to define a first permanent magnet group and a second permanent magnet group; wherein each of the permanent magnets of the first permanent magnet group are secured into position at one of the axial slot of the first iron core segment 6 ; wherein each of the permanent magnets of the second permanent magnet group are secured into position at one of the axial slots of the third iron core segment 8 ; wherein a magnetization direction of each of the permanent magnets which is positioned in the first iron core segment 6 are the same, and the magnetization direction of the permanent magnets in the first iron core segment 6 is pointing to or away from the center; wherein a magnetization direction of each of the plurality of permanent magnets in the third iron core segment 8 are the same, and the magnetization direction of the permanent magnets in the third iron core segment 8 is pointing to or away from the center; wherein the permanent magnets in the first iron core segment 6 and the permanent magnets in the third iron core segment 8 are arranged in opposite polarities and symmetrically along the axis of symmetry of the cross-section of the second iron core segment 7 ; wherein a polar distance τ m is defined as a distance between each two adjacently positioned permanent magnets in the same iron core segment in which the permanent magnets are aligned along the circumferential direction of the corresponding iron core segment, a pitch τ p of the rotor teeth ( 5 ) is defined as a distance between two tooth which are aligned along the circumferential direction, and a relation between the polar distance and the pitch fulfills the equation τ m =τ p .
[0008] The multi-phase reluctance electric motor with transverse magnetic flux according to another preferred embodiment of the present invention comprises a stator and a rotor; wherein a gas partition channel is defined between the stator and the rotor; wherein the rotor comprises a rotor frame unit 4 and a plurality of rotor teeth 5 ; wherein the plurality of rotor teeth 5 are uniformly distributed along the outer circumferential portion of the rotor frame unit 4 ; wherein the rotor frame unit 4 and the rotor teeth 5 have an integrated structure; wherein the stator comprises a housing 1 and an armature unit with m number of phases defining m number of single-phase armature members, where m is the number of phases of the electric motor and m is equal to or greater than 3; wherein the housing 1 has a cylindrical structure; wherein the m number of armature members of the armature unit are sequentially arranged along an axial direction inside the housing, and the single-phase armature members are sequentially staggered along an circumferential direction at an electrical angle of 360°/m; wherein each of the single-phase armature member comprises an armature iron core, an armature coil 2 and 2n number of permanent magnet 3 ; wherein n is a positive integer; wherein the armature iron core comprises a first iron core segment 6 , a second iron core segment 7 and a third iron core segment 8 in which all of the first, second and third iron core segments have a ring-shaped structure defining an axial direction, a central axis along the axial direction, an outer diameter and an inner diameter respectively, wherein the outer diameter of each of the first, the second and the third iron core segments are the same; wherein the first, the second and the third iron core segments are sequentially and tightly arranged along the axial direction inside the housing 1 , and the central axis of the first, the second and the third iron core segments are the same; wherein the second iron core segment 7 is positioned between the first iron core segment 6 and the third iron core segment 8 and the inner diameter of the second iron core segment 7 is greater than that of the first iron core segment 6 and the inner diameter of the third iron core segment 8 ; wherein the inner diameter of the first iron core segment 6 and the inner diameter of the third iron core segment 8 are the same; wherein the armature coil 2 has an annular coil structure and the armature coil 2 is embedded within an annular space formed between the first iron core segment, the second iron core segment and the third iron core segments; wherein a plurality of axial slots for permanent magnet are uniformly provided along the circumferential direction at an inner circumferential surface of the first iron core segment 6 and at an inner circumferential surface of the third iron core segment 8 respectively; wherein a number of the axial slots in the first iron core segment 6 is the same as a number of the axial slots in the third iron core segment 8 ; wherein a rotation difference of positions between the axial slots of the first iron core segment 6 and the axial slots of the third iron core segment 8 along the circumferential direction is equal to half of a pitch τ p /2, where a pitch τ p of the rotor teeth 5 is defined as a distance between two tooth which are aligned along the circumferential direction; wherein the 2n number of permanent magnets 3 utilizes permanent magnet having a tile-shaped structure which is radial magnetized or parallel magnetized; wherein the 2n number of permanent magnet 3 are divided equally into 2 groups to define a first permanent magnet group and a second permanent magnet group; wherein each of the permanent magnets of the first permanent magnet group are secured into position at one of the axial slot of the first iron core segment 6 ; wherein each of the permanent magnets of the second permanent magnet group are secured into position at one of the axial slots of the third iron core segment 8 ; wherein a magnetization direction of each of the permanent magnets which is positioned in the first iron core segment 6 are the same, and the magnetization direction of the permanent magnets in the first iron core segment 6 is pointing to or away from the center; wherein a magnetization direction of each of the plurality of permanent magnets in the third iron core segment 8 are the same, and the magnetization direction of the permanent magnets in the third iron core segment 8 is pointing to or away from the center; wherein the permanent magnets in the first iron core segment 6 and the permanent magnets in the third iron core segment 8 are arranged in the same polarities; wherein a polar distance τ m is defined as a distance between each two adjacently positioned permanent magnets in the same iron core segment in which the permanent magnets are aligned along the circumferential direction of the corresponding iron core segment, and a relation between the polar distance and the pitch fulfills the equation τ m =τ p .
[0009] The multi-phase reluctance electric motor with transverse magnetic flux according to another preferred embodiment of the present invention comprises a stator and a rotor; wherein a gas partition channel is defined between the stator and the rotor; wherein the rotor comprises a rotor frame unit 4 and a plurality of rotor teeth 5 ; wherein the plurality of rotor teeth 5 are uniformly distributed along the outer circumferential portion of the rotor frame unit 4 ; wherein the rotor frame unit 4 and the rotor teeth 5 have an integrated structure; wherein the stator comprises a housing 1 and an armature unit with m number of phases defining m number of single-phase armature members, where m is the number of phases of the electric motor and m is equal to or greater than 3; wherein the housing 1 has a cylindrical structure; wherein the m number of armature members of the armature unit are sequentially arranged along an axial direction inside the housing, and the single-phase armature members are sequentially staggered along an circumferential direction at an electrical angle of 360°/m; wherein each of the single-phase armature member comprises an armature iron core, an armature coil 2 and 2n number of permanent magnet 3 ; wherein n is a positive integer; wherein each of the armature iron cores comprises n number of iron core poles and each one of the iron core poles comprises one first iron core segment 6 , one second iron core segment 7 and one third iron core segment 8 fittingly arranged together, while n number of axial slots are uniformly provided along the circumferential direction at an inner surface of the housing 1 and each of the axial slots has a bottom portion having an arc-shaped structure and two side panels which are parallel to each other; wherein the number of axial slots is the same as the number of iron core poles of the armature iron core in the same armature iron core, the n number of iron core poles of each of the armature iron core are sequentially positioned in the axial slots along the circumferential direction respectively, and each of the iron core pole are fittingly in direct contact with the bottom portion and the two side panels of the axial slot corresponding to the particular iron core pole; wherein a height of the first iron core segment 6 along a radial direction is the same as a height of the third iron core segment 8 along the radial direction, a height of the second iron core segment 7 along the radial direction is smaller than the height of the first iron core segment 6 along the radial direction, each of the iron core poles define one gas partition side panel adjacent to the gas partition channel and has one winding groove provided on the gas partition side panel, and all of the winding grooves of the n number of iron core poles of the same armature iron core have the same axial position; wherein the armature coil 2 is an annular armature coil and the armature coil 2 is embedded in the winding grooves of the n number of iron core poles of the armature iron core corresponding to the same armature iron core; wherein the 2n number of permanent magnet 3 utilizes radial magnetized or parallel magnetized tile-shaped permanent magnet; wherein the 2n number of permanent magnets 3 are positioned at an inner surface of the first iron core segment 6 and at an inner surface of the third iron core segment 8 of the n number of iron core poles respectively; wherein each of the two adjacently positioned permanent magnets 3 belonging to the same particular iron core pole are arranged in opposite polarities and each of the two adjacently positioned permanent magnets 3 along the circumferential direction are also arranged in opposite polarities; wherein a polar distance τ m is defined as a distance between the two adjacently positioned permanent magnets aligned along the circumferential direction, a pitch τ p is defined as a distance between two tooth of the rotor teeth 5 which are aligned along the circumferential direction, and a relation between the polar distance and the pitch fulfills the equation 2 τ m =τ p .
[0010] The multi-phase reluctance electric motor with transverse magnetic flux according to another preferred embodiment of the present invention comprises a stator and a rotor; wherein a gas partition channel is defined between the stator and the rotor; wherein the rotor comprises a rotor frame unit 4 and a plurality of rotor teeth 5 ; wherein the plurality of rotor teeth 5 are uniformly distributed along the outer circumferential portion of the rotor frame unit 4 ; wherein the rotor frame unit 4 and the rotor teeth 5 have an integrated structure; wherein the stator comprises a housing 1 and an armature unit with m number of phases defining m number of single-phase armature members, where m is the number of phases of the electric motor and m is equal to or greater than 3; wherein the housing 1 has a cylindrical structure; wherein the m number of armature members of the armature unit are sequentially arranged along an axial direction inside the housing, and the single-phase armature members are sequentially staggered along an circumferential direction at an electrical angle of 360°/m; wherein each of the single-phase armature member comprises an armature iron core, an armature coil 2 and 2n number of permanent magnet 3 ; wherein n is an even number; wherein the armature iron core comprises a first iron core segment 61 , a second iron core segment 71 and a third iron core segment 81 , all of the first, the second and the third iron core segments have a ring-shaped structure, each of which defines a central axis, an outer diameter and an inner diameter respectively, the first, the second and the third iron core segments are sequentially and tightly arranged along an axial direction inside the housing 1 , the central axis of the first, the second and the third iron core segments are the same, the outer diameter of the first, the second and the third segments are the same, the second iron core segment 7 is positioned between the first iron core segment 6 and the third iron core segment 8 , the inner diameter of the second iron core segment 7 is greater than the inner diameter of the first iron core segment 7 , and the inner diameter of the first iron core segment 6 and the inner diameter of the third iron core segment 8 are the same; wherein the armature coil 2 is an annular armature coil and the armature coil 2 is embedded within an annular space formed between the first iron core segment 6 , the second iron core segment 7 and the third iron core segment 8 ; wherein each of the 2n number of permanent magnets 3 has a flat-shaped structure and is tangential magnetized; wherein the 2n number of permanent magnets 3 are divided equally into 2 groups to define a first permanent magnet group and a second permanent magnet group; wherein the n number of permanent magnets 3 of the first permanent magnet group are uniformly embedded inside the first iron core segment 6 of the armature iron core along the circumferential direction and are aligned to forming a first radial alignment pattern along the radial direction; wherein the n number of permanent magnets 3 of the second permanent magnet group are uniformly embedded inside the third iron core segment 8 of the armature iron core along the circumferential direction and are aligned to forming a second radial alignment pattern along the radial direction, while each of the permanent magnets 3 are fittingly in direct contact with the housing 1 ; wherein a length of each of the permanent magnets 3 of the first iron core segment 6 and a length of each of the permanent magnets 3 of the third iron core segment 8 along the axial direction are the same; the first iron core segment 6 embedded with the permanent magnets 3 and the third iron core segment 8 embedded with the permanent magnets 3 have the same structural construction in which each of the two adjacently positioned permanent magnets 3 along the circumferential direction are arranged in opposite polarities and each of the two adjacently positioned permanent magnets 3 along the axial direction are arranged in opposite polarities; wherein a polar distance τ m is defined as a distance between the two adjacently positioned permanent magnets aligned along the circumferential direction, a pitch τ p is defined as a distance between two tooth of the rotor teeth 5 which are aligned along the circumferential direction, and a relation between the polar distance and the pitch fulfills the equation 2 τ m =τ p .
[0011] The multi-phase reluctance electric motor with transverse magnetic flux according to another preferred embodiment of the present invention comprises a stator and a rotor; wherein a gas partition channel is defined between the stator and the rotor; wherein the rotor comprises a rotor frame unit 4 and a plurality of rotor teeth 5 ; wherein the plurality of rotor teeth 5 are uniformly distributed along the outer circumferential portion of the rotor frame unit 4 ; wherein the rotor frame unit 4 and the rotor teeth 5 have an integrated structure; wherein the stator comprises a housing 1 and an armature unit with m number of phases defining m number of single-phase armature members, where m is the number of phases of the electric motor and m is equal to or greater than 3; wherein the housing 1 has a cylindrical structure; wherein the m number of armature members of the armature unit are sequentially arranged along an axial direction inside the housing, and the single-phase armature members are sequentially staggered along an circumferential direction at an electrical angle of 360°/m; wherein each of the single-phase armature member comprises an armature iron core, an armature coil 2 and a plurality number of permanent magnets 3 ; wherein each of the armature iron cores comprises a plurality number of iron core poles in which each one of the iron core poles comprises one first iron core segment 6 , one second iron core segment 7 and one third iron core segment 8 fittingly arranged together, while a plurality number of axial slots which have the same structural construction are uniformly provided along the circumferential direction at an inner surface of the housing 1 and are aligned to form a radial pattern along the radial direction, and each of the axial slots has a bottom portion having an arc-shaped structure and two side panels extended from two sides of the bottom portion; wherein the number of axial slots is the same as the number of iron core poles of the armature iron core belonging to the same armature iron core; wherein each of the iron core poles of each one of the armature iron core is fittingly positioned in one of the axial slots, and each of the iron core poles is fittingly in direct contact with the bottom portion and the two side panels of the axial slot receiving the particular iron core pole; wherein the second iron core segment 7 is positioned between the first iron core segment 6 and the third iron core segment 8 , a height of the first iron core segment 6 along the radial direction is the same as a height of the third iron core segment 8 along the radial direction, a height of the second iron core segment 7 along the radial direction is smaller than the height of the first iron core segment 6 along the radial direction, each of the iron core poles defines one gas partition side panel adjacent to the gas partition channel and has one winding groove provided on the gas partition side panel, and all of the winding grooves of each of the iron core poles of the same armature iron core has the same axial position; wherein the armature coil 2 is an annular armature coil and the armature coil 2 is embedded in the winding grooves of the iron core poles of the armature iron core corresponding to the same armature iron core; wherein each of the plurality number of permanent magnet 3 has a flat-shaped structure and is tangential magnetized; wherein along the circumferential direction, one piece of permanent magnet 3 is embedded into the center of the first iron core segment 6 of each of the iron core pole, and one piece of permanent magnet 3 is embedded into the center of the third iron core segment 8 of each of the iron core pole; wherein each of the two adjacently positioned permanent magnets 3 along the circumferential direction are arranged in opposite polarities and each of the two adjacently positioned permanent magnets 3 along the axial direction are arranged in opposite polarities; wherein a polar distance τ m is defined as a distance between the two adjacently positioned permanent magnets aligned along the circumferential direction, a pitch τ p is defined as a distance between two tooth of the rotor teeth 5 which are aligned along the circumferential direction, and a relation between the polar distance and the pitch fulfills the equation 2 τ m =τ p .
[0012] According to the multi-phase reluctance electric motor with transverse magnetic flux of the present invention, the multi-phase reluctance electric motor with transverse magnetic flux comprises: a stator and a rotor; wherein a gas partition channel is defined between the stator and the rotor; wherein the rotor comprises a rotor frame unit 4 and a plurality of rotor teeth 5 ; wherein the plurality of rotor teeth 5 are uniformly distributed along the outer circumferential portion of the rotor frame unit 4 ; wherein the rotor frame unit 4 and the rotor teeth 5 have an integrated structure; wherein the stator comprises a housing 1 and an armature unit with m number of phases defining m number of single-phase armature members, where m is the number of phases of the electric motor and m is equal to or greater than 3; wherein the housing 1 has a cylindrical structure; wherein the m number of armature members of the armature unit are sequentially arranged along an axial direction inside the housing, and the single-phase armature members are sequentially staggered along an circumferential direction at an electrical angle of 360°/m; wherein each of the single-phase armature member comprises an armature iron core, an armature coil 2 and 2n number of permanent magnet 3 ; wherein n is a positive integer; wherein the armature iron core comprises a first iron core segment 6 , a second iron core segment 7 and a third iron core segment 8 in which all of the first, second and third iron core segments have a ring-shaped structure defining an axial direction, a central axis along the axial direction, an outer diameter and an inner diameter respectively, wherein the outer diameter of each of the first, the second and the third iron core segments are the same; wherein the first, the second and the third iron core segments are sequentially and tightly arranged along the axial direction inside the housing 1 , and the central axis of the first, the second and the third iron core segments are the same; wherein the second iron core segment 7 is positioned between the first iron core segment 6 and the third iron core segment 8 and the inner diameter of the second iron core segment 7 is greater than that of the first iron core segment 6 and the inner diameter of the third iron core segment 8 ; wherein the inner diameter of the first iron core segment 6 and the inner diameter of the third iron core segment 8 are the same; wherein the armature coil 2 has an annular coil structure and the armature coil 2 is embedded within an annular space formed between the first iron core segment, the second iron core segment and the third iron core segments; wherein the 2n number of permanent magnets 3 utilizes permanent magnet having a tile-shaped structure which is radial magnetized or parallel magnetized; wherein the 2n number of permanent magnet 3 are divided equally into 2 groups to define a first permanent magnet group and a second permanent magnet group; wherein the permanent magnets of the first permanent magnet group are sequentially and alternately aligned according to a N-pole and a S-pole of each of the permanent magnets along a circumferential direction at an inner surface of the first segment 6 ; wherein the permanent magnets 3 of the second permanent magnet group are sequentially and alternately aligned according to a S-pole and a N-pole of each of the permanent magnet 3 along a circumferential direction at an inner surface of the third segment 8 ; wherein the permanent magnets 3 in the first segment 6 and the permanent magnets in the third segment 8 are arranged in opposite polarities and symmetrically along the axis of symmetry of the cross-section of the second segment 7 ; wherein a polar distance τ m is defined as a distance between each two adjacently positioned permanent magnets in the same iron core segment in which the permanent magnets are aligned along the circumferential direction of the corresponding iron core segment, a pitch τ p of the rotor teeth 5 is defined as a distance between two tooth which are aligned along the circumferential direction, and a relation between the polar distance and the pitch fulfills the equation 2 τ m =τ p .
[0013] According to the multi-phase reluctance electric motor with transverse magnetic flux of the present invention, the multi-phase reluctance electric motor with transverse magnetic flux comprises: a stator and a rotor; wherein a gas partition channel is defined between the stator and the rotor; wherein the rotor comprises a rotor frame unit 4 and a plurality of rotor teeth 5 ; wherein the plurality of rotor teeth 5 are uniformly distributed along the outer circumferential portion of the rotor frame unit 4 ; wherein the rotor frame unit 4 and the rotor teeth 5 have an integrated structure; wherein the stator comprises a housing 1 and an armature unit with m number of phases defining m number of single-phase armature members, where m is the number of phases of the electric motor and m is equal to or greater than 3; wherein the housing 1 has a cylindrical structure; wherein the m number of armature members of the armature unit are sequentially arranged along an axial direction inside the housing, and the single-phase armature members are sequentially staggered along an circumferential direction at an electrical angle of 360°/m; wherein each of the single-phase armature member comprises an armature iron core, an armature coil 2 and 2n number of permanent magnet 3 ; wherein n is a positive integer; wherein the armature iron core comprises a first iron core segment 6 , a second iron core segment 7 and a third iron core segment 8 in which all of the first, second and third iron core segments have a ring-shaped structure defining an axial direction, a central axis along the axial direction, an outer diameter and an inner diameter respectively, wherein the outer diameter of each of the first, the second and the third iron core segments are the same; wherein the first, the second and the third iron core segments are sequentially and tightly arranged along the axial direction inside the housing 1 , and the central axis of the first, the second and the third iron core segments are the same; wherein the second iron core segment 7 is positioned between the first iron core segment 6 and the third iron core segment 8 and the inner diameter of the second iron core segment 7 is greater than that of the first iron core segment 6 and the inner diameter of the third iron core segment 8 ; wherein the inner diameter of the first iron core segment 6 and the inner diameter of the third iron core segment 8 are the same; wherein the armature coil 2 has an annular coil structure and the armature coil 2 is embedded within an annular space formed between the first iron core segment, the second iron core segment and the third iron core segments; wherein a plurality of axial slots for permanent magnet are uniformly provided along the circumferential direction at an inner circumferential surface of the first iron core segment 6 and at an inner circumferential surface of the third iron core segment 8 respectively; wherein a number of the axial slots in the first iron core segment 6 is the same as a number of the axial slots in the third iron core segment 8 ; wherein the 2n number of permanent magnets 3 utilizes permanent magnet having a tile-shaped structure which is radial magnetized or parallel magnetized; wherein the 2n number of permanent magnet 3 are divided equally into 2 groups to define a first permanent magnet group and a second permanent magnet group; wherein each of the permanent magnets of the first permanent magnet group are secured into position at one of the axial slot of the first iron core segment 6 ; wherein each of the permanent magnets of the second permanent magnet group are secured into position at one of the axial slots of the third iron core segment 8 ; wherein a magnetization direction of each of the permanent magnets which is positioned in the first iron core segment 6 are the same, and the magnetization direction of the permanent magnets in the first iron core segment 6 is pointing to or away from the center; wherein a magnetization direction of each of the plurality of permanent magnets in the third iron core segment 8 are the same, and the magnetization direction of the permanent magnets in the third iron core segment 8 is pointing to or away from the center; wherein the permanent magnets in the first iron core segment 6 and the permanent magnets in the third iron core segment 8 are arranged in opposite polarities and symmetrically along the axis of symmetry of the cross-section of the second iron core segment 7 ; wherein a polar distance τ m is defined as a distance between each two adjacently positioned permanent magnets in the same iron core segment in which the permanent magnets are aligned along the circumferential direction of the corresponding iron core segment, a pitch τ p of the rotor teeth 5 is defined as a distance between two tooth which are aligned along the circumferential direction, and a relation between the polar distance and the pitch fulfills the equation τ m =τ p .
[0014] According to the multi-phase reluctance electric motor with transverse magnetic flux of the present invention, the multi-phase reluctance electric motor with transverse magnetic flux comprises: a stator and a rotor; wherein a gas partition channel is defined between the stator and the rotor; wherein the rotor comprises a rotor frame unit 4 and a plurality of rotor teeth 5 ; wherein the plurality of rotor teeth 5 are uniformly distributed along the outer circumferential portion of the rotor frame unit 4 ; wherein the rotor frame unit 4 and the rotor teeth 5 have an integrated structure; wherein the stator comprises a housing 1 and an armature unit with m number of phases defining m number of single-phase armature members, where m is the number of phases of the electric motor and m is equal to or greater than 3; wherein the housing 1 has a cylindrical structure; wherein the m number of armature members of the armature unit are sequentially arranged along an axial direction inside the housing, and the single-phase armature members are sequentially staggered along an circumferential direction at an electrical angle of 360°/m; wherein each of the single-phase armature member comprises an armature iron core, an armature coil 2 and 2n number of permanent magnet 3 ; wherein n is a positive integer; wherein the armature iron core comprises a first iron core segment 6 , a second iron core segment 7 and a third iron core segment 8 in which all of the first, second and third iron core segments have a ring-shaped structure defining an axial direction, a central axis along the axial direction, an outer diameter and an inner diameter respectively, wherein the outer diameter of each of the first, the second and the third iron core segments are the same; wherein the first, the second and the third iron core segments are sequentially and tightly arranged along the axial direction inside the housing 1 , and the central axis of the first, the second and the third iron core segments are the same; wherein the second iron core segment 7 is positioned between the first iron core segment 6 and the third iron core segment 8 and the inner diameter of the second iron core segment 7 is greater than that of the first iron core segment 6 and the inner diameter of the third iron core segment 8 ; wherein the inner diameter of the first iron core segment 6 and the inner diameter of the third iron core segment 8 are the same; wherein the armature coil 2 has an annular coil structure and the armature coil 2 is embedded within an annular space formed between the first iron core segment, the second iron core segment and the third iron core segments; wherein a plurality of axial slots for permanent magnet are uniformly provided along the circumferential direction at an inner circumferential surface of the first iron core segment 6 and at an inner circumferential surface of the third iron core segment 8 respectively; wherein a number of the axial slots in the first iron core segment 6 is the same as a number of the axial slots in the third iron core segment 8 ; wherein a rotation difference of positions between the axial slots of the first iron core segment 6 and the axial slots of the third iron core segment 8 along the circumferential direction is equal to half of a pitch τ p /2, where a pitch τ p of the rotor teeth 5 is defined as a distance between two tooth which are aligned along the circumferential direction; wherein the 2n number of permanent magnets 3 utilizes permanent magnet having a tile-shaped structure which is radial magnetized or parallel magnetized; wherein the 2n number of permanent magnet 3 are divided equally into 2 groups to define a first permanent magnet group and a second permanent magnet group; wherein each of the permanent magnets of the first permanent magnet group are secured into position at one of the axial slot of the first iron core segment 6 ; wherein each of the permanent magnets of the second permanent magnet group are secured into position at one of the axial slots of the third iron core segment 8 ; wherein a magnetization direction of each of the permanent magnets which is positioned in the first iron core segment 6 are the same, and the magnetization direction of the permanent magnets in the first iron core segment 6 is pointing to or away from the center; wherein a magnetization direction of each of the plurality of permanent magnets in the third iron core segment 8 are the same, and the magnetization direction of the permanent magnets in the third iron core segment 8 is pointing to or away from the center; wherein the permanent magnets in the first iron core segment 6 and the permanent magnets in the third iron core segment 8 are arranged in the same polarities; wherein a polar distance τ m is defined as a distance between each two adjacently positioned permanent magnets in the same iron core segment in which the permanent magnets are aligned along the circumferential direction of the corresponding iron core segment, and a relation between the polar distance and the pitch fulfills the equation τ m =τ p .
[0015] According to the multi-phase reluctance electric motor with transverse magnetic flux of the present invention, the multi-phase reluctance electric motor with transverse magnetic flux comprises: a stator and a rotor; wherein a gas partition channel is defined between the stator and the rotor; wherein the rotor comprises a rotor frame unit 4 and a plurality of rotor teeth 5 ; wherein the plurality of rotor teeth 5 are uniformly distributed along the outer circumferential portion of the rotor frame unit 4 ; wherein the rotor frame unit 4 and the rotor teeth 5 have an integrated structure; wherein the stator comprises a housing 1 and an armature unit with m number of phases defining m number of single-phase armature members, where m is the number of phases of the electric motor and m is equal to or greater than 3; wherein the housing 1 has a cylindrical structure; wherein the m number of armature members of the armature unit are sequentially arranged along an axial direction inside the housing, and the single-phase armature members are sequentially staggered along an circumferential direction at an electrical angle of 360°/m; wherein each of the single-phase armature member comprises an armature iron core, an armature coil 2 and 2n number of permanent magnet 3 ; wherein n is a positive integer; wherein each of the armature iron cores comprises n number of iron core poles and each one of the iron core poles comprises one first iron core segment 6 , one second iron core segment 7 and one third iron core segment 8 fittingly arranged together, while n number of axial slots are uniformly provided along the circumferential direction at an inner surface of the housing 1 and each of the axial slots has a bottom portion having an arc-shaped structure and two side panels which are parallel to each other; wherein the number of axial slots is the same as the number of iron core poles of the armature iron core in the same armature iron core, the n number of iron core poles of each of the armature iron core are sequentially positioned in the axial slots along the circumferential direction respectively, and each of the iron core pole are fittingly in direct contact with the bottom portion and the two side panels of the axial slot corresponding to the particular iron core pole; wherein a height of the first iron core segment 6 along a radial direction is the same as a height of the third iron core segment 8 along the radial direction, a height of the second iron core segment 7 along the radial direction is smaller than the height of the first iron core segment 6 along the radial direction, each of the iron core poles define one gas partition side panel adjacent to the gas partition channel and has one winding groove provided on the gas partition side panel, and all of the winding grooves of the n number of iron core poles of the same armature iron core have the same axial position; wherein the armature coil 2 is an annular armature coil and the armature coil 2 is embedded in the winding grooves of the n number of iron core poles of the armature iron core corresponding to the same armature iron core; wherein the 2n number of permanent magnet 3 utilizes radial magnetized or parallel magnetized tile-shaped permanent magnet; wherein the 2n number of permanent magnets 3 are positioned at an inner surface of the first iron core segment 6 and at an inner surface of the third iron core segment 8 of the n number of iron core poles respectively; wherein each of the two adjacently positioned permanent magnets 3 belonging to the same particular iron core pole are arranged in opposite polarities and each of the two adjacently positioned permanent magnets 3 along the circumferential direction are also arranged in opposite polarities; wherein a polar distance τ m is defined as a distance between the two adjacently positioned permanent magnets aligned along the circumferential direction, a pitch τ p is defined as a distance between two tooth of the rotor teeth 5 which are aligned along the circumferential direction, and a relation between the polar distance and the pitch fulfills the equation 2 τ m =τ p .
[0016] According to the multi-phase reluctance electric motor with transverse magnetic flux of the present invention, the multi-phase reluctance electric motor with transverse magnetic flux comprises: a stator and a rotor; wherein a gas partition channel is defined between the stator and the rotor; wherein the rotor comprises a rotor frame unit 4 and a plurality of rotor teeth 5 ; wherein the plurality of rotor teeth 5 are uniformly distributed along the outer circumferential portion of the rotor frame unit 4 ; wherein the rotor frame unit 4 and the rotor teeth 5 have an integrated structure; wherein the stator comprises a housing 1 and an armature unit with m number of phases defining m number of single-phase armature members, where m is the number of phases of the electric motor and m is equal to or greater than 3; wherein the housing 1 has a cylindrical structure; wherein the m number of armature members of the armature unit are sequentially arranged along an axial direction inside the housing, and the single-phase armature members are sequentially staggered along an circumferential direction at an electrical angle of 360°/m; wherein each of the single-phase armature member comprises an armature iron core, an armature coil 2 and 2n number of permanent magnet 3 ; wherein n is an even number; wherein the armature iron core comprises a first iron core segment 61 , a second iron core segment 71 and a third iron core segment 81 , all of the first, the second and the third iron core segments have a ring-shaped structure, each of which defines a central axis, an outer diameter and an inner diameter respectively, the first, the second and the third iron core segments are sequentially and tightly arranged along an axial direction inside the housing 1 , the central axis of the first, the second and the third iron core segments are the same, the outer diameter of the first, the second and the third segments are the same, the second iron core segment 7 is positioned between the first iron core segment 6 and the third iron core segment 8 , the inner diameter of the second iron core segment 7 is greater than the inner diameter of the first iron core segment 7 , and the inner diameter of the first iron core segment 6 and the inner diameter of the third iron core segment 8 are the same; wherein the armature coil 2 is an annular armature coil and the armature coil 2 is embedded within an annular space formed between the first iron core segment 6 , the second iron core segment 7 and the third iron core segment 8 ; wherein each of the 2n number of permanent magnets 3 has a flat-shaped structure and is tangential magnetized; wherein the 2n number of permanent magnets 3 are divided equally into 2 groups to define a first permanent magnet group and a second permanent magnet group; wherein the n number of permanent magnets 3 of the first permanent magnet group are uniformly embedded inside the first iron core segment 6 of the armature iron core along the circumferential direction and are aligned to forming a first radial alignment pattern along the radial direction; wherein the n number of permanent magnets 3 of the second permanent magnet group are uniformly embedded inside the third iron core segment 8 of the armature iron core along the circumferential direction and are aligned to forming a second radial alignment pattern along the radial direction, while each of the permanent magnets 3 are fittingly in direct contact with the housing 1 ; wherein a length of each of the permanent magnets 3 of the first iron core segment 6 and a length of each of the permanent magnets 3 of the third iron core segment 8 along the axial direction are the same; the first iron core segment 6 embedded with the permanent magnets 3 and the third iron core segment 8 embedded with the permanent magnets 3 have the same structural construction in which each of the two adjacently positioned permanent magnets 3 along the circumferential direction are arranged in opposite polarities and each of the two adjacently positioned permanent magnets 3 along the axial direction are arranged in opposite polarities; wherein a polar distance τ m is defined as a distance between the two adjacently positioned permanent magnets aligned along the circumferential direction, a pitch τ p is defined as a distance between two tooth of the rotor teeth 5 which are aligned along the circumferential direction, and a relation between the polar distance and the pitch fulfills the equation 2 τ m =τ p .
[0017] According to the multi-phase reluctance electric motor with transverse magnetic flux of the present invention, the multi-phase reluctance electric motor with transverse magnetic flux according to another preferred embodiment of the present invention comprises a stator and a rotor; wherein a gas partition channel is defined between the stator and the rotor; wherein the rotor comprises a rotor frame unit 4 and a plurality of rotor teeth 5 ; wherein the plurality of rotor teeth 5 are uniformly distributed along the outer circumferential portion of the rotor frame unit 4 ; wherein the rotor frame unit 4 and the rotor teeth 5 have an integrated structure; wherein the stator comprises a housing 1 and an armature unit with m number of phases defining m number of single-phase armature members, where m is the number of phases of the electric motor and m is equal to or greater than 3; wherein the housing 1 has a cylindrical structure; wherein the m number of armature members of the armature unit are sequentially arranged along an axial direction inside the housing, and the single-phase armature members are sequentially staggered along an circumferential direction at an electrical angle of 360°/m; wherein each of the single-phase armature member comprises an armature iron core, an armature coil 2 and a plurality number of permanent magnets 3 ; wherein each of the armature iron cores comprises a plurality number of iron core poles in which each one of the iron core poles comprises one first iron core segment 6 , one second iron core segment 7 and one third iron core segment 8 fittingly arranged together, while a plurality number of axial slots which have the same structural construction are uniformly provided along the circumferential direction at an inner surface of the housing 1 and are aligned to form a radial pattern along the radial direction, and each of the axial slots has a bottom portion having an arc-shaped structure and two side panels extended from two sides of the bottom portion; wherein the number of axial slots is the same as the number of iron core poles of the armature iron core belonging to the same armature iron core; wherein each of the iron core poles of each one of the armature iron core is fittingly positioned in one of the axial slots, and each of the iron core poles is fittingly in direct contact with the bottom portion and the two side panels of the axial slot receiving the particular iron core pole; wherein the second iron core segment 7 is positioned between the first iron core segment 6 and the third iron core segment 8 , a height of the first iron core segment 6 along the radial direction is the same as a height of the third iron core segment 8 along the radial direction, a height of the second iron core segment 7 along the radial direction is smaller than the height of the first iron core segment 6 along the radial direction, each of the iron core poles defines one gas partition side panel adjacent to the gas partition channel and has one winding groove provided on the gas partition side panel, and all of the winding grooves of each of the iron core poles of the same armature iron core has the same axial position; wherein the armature coil 2 is an annular armature coil and the armature coil 2 is embedded in the winding grooves of the iron core poles of the armature iron core corresponding to the same armature iron core; wherein each of the plurality number of permanent magnet 3 has a flat-shaped structure and is tangential magnetized; wherein along the circumferential direction, one piece of permanent magnet 3 is embedded into the center of the first iron core segment 6 of each of the iron core pole, and one piece of permanent magnet 3 is embedded into the center of the third iron core segment 8 of each of the iron core pole; wherein each of the two adjacently positioned permanent magnets 3 along the circumferential direction are arranged in opposite polarities and each of the two adjacently positioned permanent magnets 3 along the axial direction are arranged in opposite polarities; wherein a polar distance τ m is defined as a distance between the two adjacently positioned permanent magnets aligned along the circumferential direction, a pitch τ p is defined as a distance between two tooth of the rotor teeth 5 which are aligned along the circumferential direction, and a relation between the polar distance and the pitch fulfills the equation 2 τ m =τ p .
Advantageous Effect
[0018] According to the preferred embodiments of the present invention, unique armature structure is employed to construct the multi-phase reluctance electric motor with transverse magnetic flux such that the mutual inductance between phase transition is eliminated, the control precision in motor current and electromagnetic torque as well as the dynamic characteristics of the system are increased; and the quantity requirement of armature coil 2 is small, the processing procedure is simple, the cost is low, the copper loss is small, and the efficiency is high. The electric motor according to the preferred embodiment of the present invention is simple in design and is easy to increase the torque, therefore modularization can be realized. Meanwhile, because the permanent magnets are positioned on the stator, therefore the reliability and safety of the electric motor are improved and its field of applicability is increased.
[0019] Still further objects and advantages will become apparent from a consideration of the ensuing description and drawings.
[0020] These and other objectives, features, and advantages of the present invention will become apparent from the following detailed description, the accompanying drawings, and the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] FIG. 1 is the structural illustration of a conventional multi-phase permanent magnet synchronous motor;
[0022] FIG. 2 is the longitudinal sectional view of a one-phase armature member of a multi-phase reluctance electric motor with transverse magnetic flux according to the embodiment 1 of the present invention;
[0023] FIG. 3 is an A-A illustration of FIG. 2 ;
[0024] FIG. 4 is a right end view of the one-phase armature member of a multi-phase reluctance electric motor with transverse magnetic flux according to the embodiment 1 of the present invention;
[0025] FIG. 5 is the longitudinal sectional view of a one-phase armature member of a multi-phase reluctance electric motor with transverse magnetic flux according to the embodiment 2 of the present invention;
[0026] FIG. 6 is an B-B illustration of FIG. 5 ;
[0027] FIG. 7 is a right end view of the one-phase armature member of a multi-phase reluctance electric motor with transverse magnetic flux according to the embodiment 2 of the present invention;
[0028] FIG. 8 is the longitudinal sectional view of a one-phase armature member of a multi-phase reluctance electric motor with transverse magnetic flux according to the embodiment 3 of the present invention;
[0029] FIG. 9 is a right end view of the one-phase armature member of a multi-phase reluctance electric motor with transverse magnetic flux according to the embodiment 2 of the present invention;
[0030] FIG. 10 is a right end view of the one-phase armature member of a multi-phase reluctance electric motor with transverse magnetic flux according to the embodiment 2 of the present invention;
[0031] FIG. 11 is the longitudinal sectional view of a one-phase armature member of a multi-phase reluctance electric motor with transverse magnetic flux according to the embodiment 4 of the present invention;
[0032] FIG. 12 is a C-C illustration of FIG. 9 ;
[0033] FIG. 13 is a right end view of the one-phase armature member of a multi-phase reluctance electric motor with transverse magnetic flux according to the embodiment 4 of the present invention;
[0034] FIG. 14 is the longitudinal sectional view of a one-phase armature member of a multi-phase reluctance electric motor with transverse magnetic flux according to the embodiment 5 of the present invention;
[0035] FIG. 15 is a D-D illustration of FIG. 12 ;
[0036] FIG. 16 is a right end view of the one-phase armature member of a multi-phase reluctance electric motor with transverse magnetic flux according to the embodiment 5 of the present invention;
[0037] FIG. 17 is a left end view of the one-phase armature member of a multi-phase reluctance electric motor with transverse magnetic flux according to the embodiment 5 of the present invention;
[0038] FIG. 18 is a left end view of the one-phase armature member of a multi-phase reluctance electric motor with transverse magnetic flux with an alternative structural construction according to the embodiment 5 of the present invention;
[0039] FIG. 19 is the longitudinal sectional view of a one-phase armature member of a multi-phase reluctance electric motor with transverse magnetic flux according to the embodiment 6 of the present invention;
[0040] FIG. 20 is an E-E illustration of FIG. 16 ;
[0041] FIG. 21 is a right end view of the one-phase armature member of a multi-phase reluctance electric motor with transverse magnetic flux according to the embodiment 6 of the present invention; and
[0042] FIG. 22 is a left end view of the one-phase armature member of a multi-phase reluctance electric motor with transverse magnetic flux according to the embodiment 6 of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0043] Embodiment 1: The multi-phase reluctance electric motor with transverse magnetic flux according to this preferred embodiment of the present invention is illustrated in FIG. 2 , FIG. 3 and FIG. 4 of the drawings. The multi-phase reluctance electric motor with transverse magnetic flux according to this preferred embodiment of the present invention comprises a stator and a rotor; wherein a gas partition channel is defined between the stator and the rotor; wherein the rotor comprises a rotor frame unit 4 and a plurality of rotor teeth 5 ; wherein the plurality of rotor teeth 5 are uniformly distributed along the outer circumferential portion of the rotor frame unit 4 ; wherein the rotor frame unit 4 and the rotor teeth 5 have an integrated structure; wherein the stator comprises a housing 1 and an armature unit with m number of phases defining m number of single-phase armature members, where m is the number of phases of the electric motor and m is equal to or greater than 3; wherein the housing 1 has a cylindrical structure; wherein the m number of armature members of the armature unit are sequentially arranged along an axial direction inside the housing, and the single-phase armature members are sequentially staggered along an circumferential direction at an electrical angle of 360°/m; wherein each of the single-phase armature member comprises an armature iron core, an armature coil 2 and 2n number of permanent magnet 3 ; wherein n is a positive integer; wherein the armature iron core comprises a first iron core segment 6 , a second iron core segment 7 and a third iron core segment 8 in which all of the first, second and third iron core segments have a ring-shaped structure defining an axial direction, a central axis along the axial direction, an outer diameter and an inner diameter respectively, wherein the outer diameter of each of the first, the second and the third iron core segments are the same; wherein the first, the second and the third iron core segments are sequentially and tightly arranged along the axial direction inside the housing 1 , and the central axis of the first, the second and the third iron core segments are the same; wherein the second iron core segment 7 is positioned between the first iron core segment 6 and the third iron core segment 8 and the inner diameter of the second iron core segment 7 is greater than that of the first iron core segment 6 and the inner diameter of the third iron core segment 8 ; wherein the inner diameter of the first iron core segment 6 and the inner diameter of the third iron core segment 8 are the same; wherein the armature coil 2 has an annular coil structure and the armature coil 2 is embedded within an annular space formed between the first iron core segment, the second iron core segment and the third iron core segments; wherein the 2n number of permanent magnets 3 utilizes permanent magnet having a tile-shaped structure which is radial magnetized or parallel magnetized; wherein the 2n number of permanent magnet 3 are divided equally into 2 groups to define a first permanent magnet group and a second permanent magnet group; wherein the permanent magnets of the first permanent magnet group are sequentially and alternately aligned according to a N-pole and a S-pole of each of the permanent magnets along a circumferential direction at an inner surface of the first segment 6 ; wherein the permanent magnets 3 of the second permanent magnet group are sequentially and alternately aligned according to a S-pole and a N-pole of each of the permanent magnet 3 along a circumferential direction at an inner surface of the third segment 8 ; wherein the permanent magnets 3 in the first segment 6 and the permanent magnets in the third segment 8 are arranged in opposite polarities and symmetrically along the axis of symmetry of the cross-section of the second segment 7 ; wherein a polar distance τ m is defined as a distance between each two adjacently positioned permanent magnets in the same iron core segment in which the permanent magnets are aligned along the circumferential direction of the corresponding iron core segment, a pitch τ p of the rotor teeth ( 5 ) is defined as a distance between two tooth which are aligned along the circumferential direction, and a relation between the polar distance and the pitch fulfills the equation 2 τ m =τ p .
[0044] Embodiment 2: The multi-phase reluctance electric motor with transverse magnetic flux according to this preferred embodiment of the present invention is illustrated in FIG. 5 , FIG. 6 and FIG. 7 of the drawings. The multi-phase reluctance electric motor with transverse magnetic flux according to this preferred embodiment of the present invention comprises a stator and a rotor; wherein a gas partition channel is defined between the stator and the rotor; wherein the rotor comprises a rotor frame unit 4 and a plurality of rotor teeth 5 ; wherein the plurality of rotor teeth 5 are uniformly distributed along the outer circumferential portion of the rotor frame unit 4 ; wherein the rotor frame unit 4 and the rotor teeth 5 have an integrated structure; wherein the stator comprises a housing 1 and an armature unit with m number of phases defining m number of single-phase armature members, where m is the number of phases of the electric motor and m is equal to or greater than 3; wherein the housing 1 has a cylindrical structure; wherein the m number of armature members of the armature unit are sequentially arranged along an axial direction inside the housing, and the single-phase armature members are sequentially staggered along an circumferential direction at an electrical angle of 360°/m; wherein each of the single-phase armature member comprises an armature iron core, an armature coil 2 and 2n number of permanent magnet 3 ; wherein n is a positive integer; wherein the armature iron core comprises a first iron core segment 6 , a second iron core segment 7 and a third iron core segment 8 in which all of the first, second and third iron core segments have a ring-shaped structure defining an axial direction, a central axis along the axial direction, an outer diameter and an inner diameter respectively, wherein the outer diameter of each of the first, the second and the third iron core segments are the same; wherein the first, the second and the third iron core segments are sequentially and tightly arranged along the axial direction inside the housing 1 , and the central axis of the first, the second and the third iron core segments are the same; wherein the second iron core segment 7 is positioned between the first iron core segment 6 and the third iron core segment 8 and the inner diameter of the second iron core segment 7 is greater than that of the first iron core segment 6 and the inner diameter of the third iron core segment 8 ; wherein the inner diameter of the first iron core segment 6 and the inner diameter of the third iron core segment 8 are the same; wherein the armature coil 2 has an annular coil structure and the armature coil 2 is embedded within an annular space formed between the first iron core segment, the second iron core segment and the third iron core segments; wherein a plurality of axial slots for permanent magnet are uniformly provided along the circumferential direction at an inner circumferential surface of the first iron core segment 6 and at an inner circumferential surface of the third iron core segment 8 respectively; wherein a number of the axial slots in the first iron core segment 6 is the same as a number of the axial slots in the third iron core segment 8 ; wherein the 2n number of permanent magnets 3 utilizes permanent magnet having a tile-shaped structure which is radial magnetized or parallel magnetized; wherein the 2n number of permanent magnet 3 are divided equally into 2 groups to define a first permanent magnet group and a second permanent magnet group; wherein each of the permanent magnets of the first permanent magnet group are secured into position at one of the axial slot of the first iron core segment 6 ; wherein each of the permanent magnets of the second permanent magnet group are secured into position at one of the axial slots of the third iron core segment 8 ; wherein a magnetization direction of each of the permanent magnets which is positioned in the first iron core segment 6 are the same, and the magnetization direction of the permanent magnets in the first iron core segment 6 is pointing to or away from the center; wherein a magnetization direction of each of the plurality of permanent magnets in the third iron core segment 8 are the same, and the magnetization direction of the permanent magnets in the third iron core segment 8 is pointing to or away from the center; wherein the permanent magnets in the first iron core segment 6 and the permanent magnets in the third iron core segment 8 are arranged in opposite polarities and symmetrically along the axis of symmetry of the cross-section of the second iron core segment 7 ; wherein a polar distance τ m is defined as a distance between each two adjacently positioned permanent magnets in the same iron core segment in which the permanent magnets are aligned along the circumferential direction of the corresponding iron core segment, a pitch τ p of the rotor teeth ( 5 ) is defined as a distance between two tooth which are aligned along the circumferential direction, and a relation between the polar distance and the pitch fulfills the equation τ m =τ p .
[0045] Embodiment 3: The multi-phase reluctance electric motor with transverse magnetic flux according to this preferred embodiment of the present invention is illustrated in FIG. 8 , FIG. 9 and FIG. 10 of the drawings. The multi-phase reluctance electric motor with transverse magnetic flux according to this preferred embodiment of the present invention comprises a stator and a rotor; wherein a gas partition channel is defined between the stator and the rotor; wherein the rotor comprises a rotor frame unit 4 and a plurality of rotor teeth 5 ; wherein the plurality of rotor teeth 5 are uniformly distributed along the outer circumferential portion of the rotor frame unit 4 ; wherein the rotor frame unit 4 and the rotor teeth 5 have an integrated structure; wherein the stator comprises a housing 1 and an armature unit with m number of phases defining m number of single-phase armature members, where m is the number of phases of the electric motor and m is equal to or greater than 3; wherein the housing 1 has a cylindrical structure; wherein the m number of armature members of the armature unit are sequentially arranged along an axial direction inside the housing, and the single-phase armature members are sequentially staggered along an circumferential direction at an electrical angle of 360°/m; wherein each of the single-phase armature member comprises an armature iron core, an armature coil 2 and 2n number of permanent magnet 3 ; wherein n is a positive integer; wherein the armature iron core comprises a first iron core segment 6 , a second iron core segment 7 and a third iron core segment 8 in which all of the first, second and third iron core segments have a ring-shaped structure defining an axial direction, a central axis along the axial direction, an outer diameter and an inner diameter respectively, wherein the outer diameter of each of the first, the second and the third iron core segments are the same; wherein the first, the second and the third iron core segments are sequentially and tightly arranged along the axial direction inside the housing 1 , and the central axis of the first, the second and the third iron core segments are the same; wherein the second iron core segment 7 is positioned between the first iron core segment 6 and the third iron core segment 8 and the inner diameter of the second iron core segment 7 is greater than that of the first iron core segment 6 and the inner diameter of the third iron core segment 8 ; wherein the inner diameter of the first iron core segment 6 and the inner diameter of the third iron core segment 8 are the same; wherein the armature coil 2 has an annular coil structure and the armature coil 2 is embedded within an annular space formed between the first iron core segment, the second iron core segment and the third iron core segments; wherein a plurality of axial slots for permanent magnet are uniformly provided along the circumferential direction at an inner circumferential surface of the first iron core segment 6 and at an inner circumferential surface of the third iron core segment 8 respectively; wherein a number of the axial slots in the first iron core segment 6 is the same as a number of the axial slots in the third iron core segment 8 ; wherein a rotation difference of positions between the axial slots of the first iron core segment 6 and the axial slots of the third iron core segment 8 along the circumferential direction is equal to half of a pitch τ p /2, where a pitch τ p of the rotor teeth ( 5 ) is defined as a distance between two tooth which are aligned along the circumferential direction; wherein the 2n number of permanent magnets 3 utilizes permanent magnet having a tile-shaped structure which is radial magnetized or parallel magnetized; wherein the 2n number of permanent magnet 3 are divided equally into 2 groups to define a first permanent magnet group and a second permanent magnet group; wherein each of the permanent magnets of the first permanent magnet group are secured into position at one of the axial slot of the first iron core segment 6 ; wherein each of the permanent magnets of the second permanent magnet group are secured into position at one of the axial slots of the third iron core segment 8 ; wherein a magnetization direction of each of the permanent magnets which is positioned in the first iron core segment 6 are the same, and the magnetization direction of the permanent magnets in the first iron core segment 6 is pointing to or away from the center; wherein a magnetization direction of each of the plurality of permanent magnets in the third iron core segment 8 are the same, and the magnetization direction of the permanent magnets in the third iron core segment 8 is pointing to or away from the center; wherein the permanent magnets in the first iron core segment 6 and the permanent magnets in the third iron core segment 8 are arranged in the same polarities; wherein a polar distance τ m is defined as a distance between each two adjacently positioned permanent magnets in the same iron core segment in which the permanent magnets are aligned along the circumferential direction of the corresponding iron core segment, and a relation between the polar distance and the pitch fulfills the equation τ m =τ p .
[0046] Embodiment 4: The multi-phase reluctance electric motor with transverse magnetic flux according to this preferred embodiment of the present invention is illustrated in FIG. 11 , FIG. 12 and FIG. 13 of the drawings. The multi-phase reluctance electric motor with transverse magnetic flux according to this preferred embodiment of the present invention comprises a stator and a rotor; wherein a gas partition channel is defined between the stator and the rotor; wherein the rotor comprises a rotor frame unit 4 and a plurality of rotor teeth 5 ; wherein the plurality of rotor teeth 5 are uniformly distributed along the outer circumferential portion of the rotor frame unit 4 ; wherein the rotor frame unit 4 and the rotor teeth 5 have an integrated structure; wherein the stator comprises a housing 1 and an armature unit with m number of phases defining m number of single-phase armature members, where m is the number of phases of the electric motor and m is equal to or greater than 3; wherein the housing 1 has a cylindrical structure; wherein the m number of armature members of the armature unit are sequentially arranged along an axial direction inside the housing, and the single-phase armature members are sequentially staggered along an circumferential direction at an electrical angle of 360°/m; wherein each of the single-phase armature member comprises an armature iron core, an armature coil 2 and 2n number of permanent magnet 3 ; wherein n is a positive integer; wherein each of the armature iron cores comprises n number of iron core poles and each one of the iron core poles comprises one first iron core segment 6 , one second iron core segment 7 and one third iron core segment 8 fittingly arranged together, while n number of axial slots are uniformly provided along the circumferential direction at an inner surface of the housing 1 and each of the axial slots has a bottom portion having an arc-shaped structure and two side panels which are parallel to each other; wherein the number of axial slots is the same as the number of iron core poles of the armature iron core in the same armature iron core, the n number of iron core poles of each of the armature iron core are sequentially positioned in the axial slots along the circumferential direction respectively, and each of the iron core pole are fittingly in direct contact with the bottom portion and the two side panels of the axial slot corresponding to the particular iron core pole; wherein a height of the first iron core segment 6 along a radial direction is the same as a height of the third iron core segment 8 along the radial direction, a height of the second iron core segment 7 along the radial direction is smaller than the height of the first iron core segment 6 along the radial direction, each of the iron core poles define one gas partition side panel adjacent to the gas partition channel and has one winding groove provided on the gas partition side panel, and all of the winding grooves of the n number of iron core poles of the same armature iron core have the same axial position; wherein the armature coil 2 is an annular armature coil and the armature coil 2 is embedded in the winding grooves of the n number of iron core poles of the armature iron core corresponding to the same armature iron core; wherein the 2n number of permanent magnet 3 utilizes radial magnetized or parallel magnetized tile-shaped permanent magnet; wherein the 2n number of permanent magnets 3 are positioned at an inner surface of the first iron core segment 6 and at an inner surface of the third iron core segment 8 of the n number of iron core poles respectively; wherein each of the two adjacently positioned permanent magnets 3 belonging to the same particular iron core pole are arranged in opposite polarities and each of the two adjacently positioned permanent magnets 3 along the circumferential direction are also arranged in opposite polarities; wherein a polar distance τ m is defined as a distance between the two adjacently positioned permanent magnets aligned along the circumferential direction, a pitch τ p is defined as a distance between two tooth of the rotor teeth 5 which are aligned along the circumferential direction, and a relation between the polar distance and the pitch fulfills the equation 2 τ m =τ p .
[0047] Embodiment 5: The multi-phase reluctance electric motor with transverse magnetic flux according to this preferred embodiment of the present invention is illustrated in FIG. 14 to FIG. 18 of the drawings. The multi-phase reluctance electric motor with transverse magnetic flux according to this preferred embodiment of the present invention comprises a stator and a rotor; wherein a gas partition channel is defined between the stator and the rotor; wherein the rotor comprises a rotor frame unit 4 and a plurality of rotor teeth 5 ; wherein the plurality of rotor teeth 5 are uniformly distributed along the outer circumferential portion of the rotor frame unit 4 ; wherein the rotor frame unit 4 and the rotor teeth 5 have an integrated structure; wherein the stator comprises a housing 1 and an armature unit with m number of phases defining m number of single-phase armature members, where m is the number of phases of the electric motor and m is equal to or greater than 3; wherein the housing 1 has a cylindrical structure; wherein the m number of armature members of the armature unit are sequentially arranged along an axial direction inside the housing, and the single-phase armature members are sequentially staggered along an circumferential direction at an electrical angle of 360°/m; wherein each of the single-phase armature member comprises an armature iron core, an armature coil 2 and 2n number of permanent magnet 3 ; wherein n is an even number; wherein the armature iron core comprises a first iron core segment 61 , a second iron core segment 71 and a third iron core segment 81 , all of the first, the second and the third iron core segments have a ring-shaped structure, each of which defines a central axis, an outer diameter and an inner diameter respectively, the first, the second and the third iron core segments are sequentially and tightly arranged along an axial direction inside the housing 1 , the central axis of the first, the second and the third iron core segments are the same, the outer diameter of the first, the second and the third segments are the same, the second iron core segment 7 is positioned between the first iron core segment 6 and the third iron core segment 8 , the inner diameter of the second iron core segment 7 is greater than the inner diameter of the first iron core segment 7 , and the inner diameter of the first iron core segment 6 and the inner diameter of the third iron core segment 8 are the same; wherein the armature coil 2 is an annular armature coil and the armature coil 2 is embedded within an annular space formed between the first iron core segment 6 , the second iron core segment 7 and the third iron core segment 8 ; wherein each of the 2n number of permanent magnets 3 has a flat-shaped structure and is tangential magnetized; wherein the 2n number of permanent magnets 3 are divided equally into 2 groups to define a first permanent magnet group and a second permanent magnet group; wherein the n number of permanent magnets 3 of the first permanent magnet group are uniformly embedded inside the first iron core segment 6 of the armature iron core along the circumferential direction and are aligned to forming a first radial alignment pattern along the radial direction; wherein the n number of permanent magnets 3 of the second permanent magnet group are uniformly embedded inside the third iron core segment 8 of the armature iron core along the circumferential direction and are aligned to forming a second radial alignment pattern along the radial direction, while each of the permanent magnets 3 are fittingly in direct contact with the housing 1 ; wherein a length of each of the permanent magnets 3 of the first iron core segment 6 and a length of each of the permanent magnets 3 of the third iron core segment 8 along the axial direction are the same; the first iron core segment 6 embedded with the permanent magnets 3 and the third iron core segment 8 embedded with the permanent magnets 3 have the same structural construction in which each of the two adjacently positioned permanent magnets 3 along the circumferential direction are arranged in opposite polarities and each of the two adjacently positioned permanent magnets 3 along the axial direction are arranged in opposite polarities; wherein a polar distance τ m is defined as a distance between the two adjacently positioned permanent magnets aligned along the circumferential direction, a pitch τ p is defined as a distance between two tooth of the rotor teeth 5 which are aligned along the circumferential direction, and a relation between the polar distance and the pitch fulfills the equation 2 τ m =τ p .
[0048] Embodiment 6: The multi-phase reluctance electric motor with transverse magnetic flux according to this preferred embodiment of the present invention is illustrated in FIG. 19 to FIG. 22 of the drawings. The multi-phase reluctance electric motor with transverse magnetic flux according to this preferred embodiment of the present invention comprises a stator and a rotor; wherein a gas partition channel is defined between the stator and the rotor; wherein the rotor comprises a rotor frame unit 4 and a plurality of rotor teeth 5 ; wherein the plurality of rotor teeth 5 are uniformly distributed along the outer circumferential portion of the rotor frame unit 4 ; wherein the rotor frame unit 4 and the rotor teeth 5 have an integrated structure; wherein the stator comprises a housing 1 and an armature unit with m number of phases defining m number of single-phase armature members, where m is the number of phases of the electric motor and m is equal to or greater than 3; wherein the housing 1 has a cylindrical structure; wherein the m number of armature members of the armature unit are sequentially arranged along an axial direction inside the housing, and the single-phase armature members are sequentially staggered along an circumferential direction at an electrical angle of 360°/m; wherein each of the single-phase armature member comprises an armature iron core, an armature coil 2 and a plurality number of permanent magnets 3 ; wherein each of the armature iron cores comprises a plurality number of iron core poles in which each one of the iron core poles comprises one first iron core segment 6 , one second iron core segment 7 and one third iron core segment 8 fittingly arranged together, while a plurality number of axial slots which have the same structural construction are uniformly provided along the circumferential direction at an inner surface of the housing 1 and are aligned to form a radial pattern along the radial direction, and each of the axial slots has a bottom portion having an arc-shaped structure and two side panels extended from two sides of the bottom portion; wherein the number of axial slots is the same as the number of iron core poles of the armature iron core belonging to the same armature iron core; wherein each of the iron core poles of each one of the armature iron core is fittingly positioned in one of the axial slots, and each of the iron core poles is fittingly in direct contact with the bottom portion and the two side panels of the axial slot receiving the particular iron core pole; wherein the second iron core segment 7 is positioned between the first iron core segment 6 and the third iron core segment 8 , a height of the first iron core segment 6 along the radial direction is the same as a height of the third iron core segment 8 along the radial direction, a height of the second iron core segment 7 along the radial direction is smaller than the height of the first iron core segment 6 along the radial direction, each of the iron core poles defines one gas partition side panel adjacent to the gas partition channel and has one winding groove provided on the gas partition side panel, and all of the winding grooves of each of the iron core poles of the same armature iron core has the same axial position; wherein the armature coil 2 is an annular armature coil and the armature coil 2 is embedded in the winding grooves of the iron core poles of the armature iron core corresponding to the same armature iron core; wherein each of the plurality number of permanent magnet ( 3 ) has a flat-shaped structure and is tangential magnetized; wherein along the circumferential direction, one piece of permanent magnet 3 is embedded into the center of the first iron core segment 6 of each of the iron core pole, and one piece of permanent magnet 3 is embedded into the center of the third iron core segment 8 of each of the iron core pole; wherein each of the two adjacently positioned permanent magnets 3 along the circumferential direction are arranged in opposite polarities and each of the two adjacently positioned permanent magnets 3 along the axial direction are arranged in opposite polarities; wherein a polar distance τ m is defined as a distance between the two adjacently positioned permanent magnets aligned along the circumferential direction, a pitch τ p is defined as a distance between two tooth of the rotor teeth 5 which are aligned along the circumferential direction, and a relation between the polar distance and the pitch fulfills the equation 2 τ m =τ p .
[0049] Embodiment 7: The multi-phase reluctance electric motor with transverse magnetic flux according to this preferred embodiment of the present invention is different from the above embodiments 1, 2, 3, 4, 5 or 6 in that the rotor teeth 5 utilizes rotor teeth with high magnetic permeability. All other elements and connection of elements are the same as the above embodiments 1, 2, 3, 4, 5 or 6.
[0050] Embodiment 8: The multi-phase reluctance electric motor with transverse magnetic flux according to this preferred embodiment of the present invention is different from the above embodiments 1, 2, 3, 4, 5 or 6 in that the rotor frame unit utilizes magnetic rotor frame unit or non-magnetic rotor frame unit. That is the rotor frame unit is magnetized or is made of non-magnetic materials. All other elements and connection of elements are the same as the above embodiments 1, 2, 3, 4, 5 or 6.
[0051] Embodiment 9: The multi-phase reluctance electric motor with transverse magnetic flux according to this preferred embodiment of the present invention is different from the above embodiments 1, 2, 3, 4, 5 or 6 in that the first iron core segment 6 , the second iron core segment 7 and the third iron core segment 8 are integral in structure or separate (non-integral) in structure. All other elements and connection of elements are the same as the above embodiments 1, 2, 3, 4, 5 or 6.
[0052] Embodiment 10: The multi-phase reluctance electric motor with transverse magnetic flux according to this preferred embodiment of the present invention is different from the above embodiments 1, 2, 3, 4, 5 or 6 in that a thickness of each of the permanent magnets defined along the tangential direction of a side of the housing is greater than or equal to a thickness of the permanent magnets 3 defined along the gas partition side panel. All other elements and connection of elements are the same as the above embodiments 1, 2, 3, 4, 5 or 6.
[0053] Embodiment 10: The multi-phase reluctance electric motor with transverse magnetic flux according to this preferred embodiment of the present invention is different from the above embodiments 1, 2, 3, 4, 5 or 6 in that each of the iron core poles has a laminated structure comprising a plurality of silicon steel sheets compressed together to form the laminated structure which defines a lamination direction along a tangential direction. All other elements and connection of elements are the same as the above embodiments 1, 2, 3, 4, 5 or 6.
[0054] According to the above preferred embodiments of the present invention, the permanent magnet which has a tile-shaped structure is radial magnetized or parallel magnetized, wherein radial magnetized refers to that the permanent magnet is magnetized along the direction of the radius, while parallel magnetized refers to that the center of the permanent magnet is magnetized along the direction of the radius, and the remaining portion of the permanent magnet is magnetized in parallel direction with respect to the magnetized direction of the center of the permanent magnet in which the center of the permanent magnet is magnetized along the direction of the radius.
[0055] One skilled in the art will understand that the embodiment of the present invention as shown in the drawings and described above is exemplary only and not intended to be limiting.
[0056] It will thus be seen that the objects of the present invention have been fully and effectively accomplished. It embodiments have been shown and described for the purposes of illustrating the functional and structural principles of the present invention and is subject to change without departure from such principles. Therefore, this invention includes all modifications encompassed within the spirit and scope of the following claims.
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Disclosed is a poly-phase reluctance electric motor with transverse magnetic flux, which electric motor is composed of a stator and a rotor. The stator is composed of a housing ( 1 ) and a number m of phase armature units which are arranged within the housing ( 1 ) along the axial direction successively, with each of the phase armature units being staggered at an electrical angle of 360°/m along the circumferential direction. Each phase armature unit is composed of a unit armature iron core, an armature coil ( 2 ) and permanent magnets ( 3 ), with the unit armature iron core being composed of a first annular iron core segment ( 6 ), a second annular iron core segment ( 7 ) and a third annular iron core segment ( 8 ). The armature coil ( 2 ) is embedded within an annular space formed among the first to the third annular iron core segments ( 6, 7, 8 ). The permanent magnets ( 3 ) are fixedly arranged on the inner surfaces of the first and the third annular iron core segments ( 6, 8 ) along the circumferential direction in a manner of the N pole and the S pole spaced successively. The pole distance τm between every two adjacent permanent magnets ( 3 ) on the same annular iron core segment and the tooth distance τp between the rotor teeth ( 5 ) arranged along the circumferential direction fulfil 2τm=τp. The electric motor eliminates the mutual inductance between phases, improving the precision with which the current and electromagnetic torque of the electric motor can be controlled and the dynamic characteristics of the system, and improving the reliability and safety of the motor as a result of the permanent magnets ( 3 ) being located on the stator.
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CROSS-REFERENCE TO PRIORITY APPLICATION
[0001] The present application claims the benefit of U.S. Provisional Application Ser. No. 60/461,414 filed Apr. 10, 2003, which is hereby incorporated herein by reference in its entirety.
FIELD OF THE INVENTION
[0002] The present invention relates to a facial mask with an integral cushion and forehead piece used to supply breathable gas to a wearer's airways.
[0003] The invention has been developed primarily for use in supporting a nasal mask used in Continuous Positive Airway Pressure (CPAP) treatment of, for example, Obstructive Sleep Apnea (OSA) and other ventilation assistance treatments such as Non-Invasive Positive Pressure Ventilation (NIPPV) and will be described hereinafter with reference to this application. However, it will be appreciated that the invention is not limited to these particular uses.
BACKGROUND OF THE INVENTION
[0004] CPAP treatment is a common ameliorative treatment for breathing disorders including OSA. CPAP treatment, as described in U.S. Pat. No. 4,944,310, provides pressurized air or other breathable gas to the entrance of a patient's airways at a pressure elevated above atmospheric pressure, typically in the range of 4-20 cm H 2 O. It is also known for the level of treatment pressure to vary during a period of treatment in accordance with patient need, that form of CPAP being known as automatically adjusting nasal CPAP treatment, as described in U.S. Pat. No. 5,245,995.
[0005] NIPPV is another form of treatment for breathing disorders that can involve a relatively higher pressure of gas being provided in the patient mask during the inspiratory phase of respiration and a relatively lower pressure or atmospheric pressure being provided in the patient mask during the expiratory phase of respiration. In other NIPPV modes, the pressure can be made to vary in a complex manner throughout the respiratory cycle. For example, the pressure at the mask during inspiration or expiration can be varied through the period of treatment.
[0006] Typically, the ventilation assistance for CPAP or NIPPV treatment is delivered to the patient by way of a nasal mask. Alternatively, a mouth mask full-face mask or nasal prongs can be used.
[0007] In this specification, any reference to CPAP treatment is to be understood as embracing all of the above-described forms of ventilation treatment or assistance.
[0008] A CPAP apparatus broadly includes a flow generator for supplying a continuous source of pressurized air or other breathable gas. Such a flow generator is typically a stand-alone unit having an electric motor driving a blower and is typically controlled by a servo-controller under the control of a microcontroller unit. Alternatively, other supplies of pressurized gas can be used. The flow generator is connected to the mask by a gas supply conduit or tube to supply the pressurized gas to an interior of the mask. The mask or gas supply conduit generally includes a venting system to vent exhalation gases from the interior of the mask to the atmosphere. The mask is normally secured to the wearer's head by a headgear or straps. The straps are adjusted with sufficient tension to achieve a gas-tight seal between the mask and the wearer's face. The mask generally includes a forehead support to rest against the user's forehead to support and stabilize the mask with respect to the user's face and prevent the mask from exerting undue pressure on the user's nose when the straps are tensioned. Examples of nasal masks are shown in U.S. Pat. Nos. 4,782,832 and 5,243,971.
[0009] One problem that arises with the use of masks is that a single shape of mask must be utilized for a large variety of users having differently shaped and sized heads and facial regions. Therefore, it is desirable for the forehead support to be adjustable to alter an extension between a forehead contacting portion of the forehead support and the mask frame, thereby accommodating a variety of users with a single mask configuration, while maintaining a comfortable fit and gas-tight seal for each user. Additionally, an adjustable forehead support can be adjusted to position the gas supply conduit in a desired position with respect to the user, such as to prevent the gas supply conduit from contacting the wearer's forehead or face and causing discomfort to the user.
[0010] Adjustable forehead supports are known. See, for example, the adjustable forehead supports disclosed in U.S. Pat. No. 6,119,693 to Kwok et al. and PCT International Patent Application Publication No. WO 00/78384 to Kwok et al., both assigned to the assignee of the present application. Both references disclose effective, durable forehead support mechanisms. However, these mechanisms require several components that increase the expense of manufacturing such mechanisms and make the mechanisms more appropriate for masks that will be used over an extended period of time, generally 3-6 months. Such mechanisms are relatively costly to use with masks intended for single or short-term use.
[0011] There are circumstances where an inexpensive, disposable short-term use mask is appropriate. For instance, such a mask might be appropriate under CPAP testing conditions where the testing is expected to last only a few days or weeks. Such a mask might also be used for patients admitted to hospitals for short-term stays. Extended use masks require periodic disassembly, cleaning and disinfecting, and reassembly to maintain sanitary conditions. The use of a disposable mask can eliminate such mask maintenance during extended treatment. Instead of performing the mask maintenance at the periodic intervals, a user can just dispose the disposable mask at the proper intervals and use a new disposable mask. However, for it to be generally desirable to use a disposable mask in such extended term treatment, the cost of the mask must be sufficiently low so as to compare favorably economically with the overall cost of an extended use mask, including the cost of the extended use mask, as well as the time required and nuisance of the periodic maintenance of the extended use mask.
[0012] Thus, there is a need for an inexpensive short-term use mask for providing breathable gases to a patient, as during CPAP treatment. To accommodate a large variety of users comfortably with a single mask configuration and maintain a gas-tight seal for each user, the mask should include a simple, easy to use adjustable forehead support mechanism. The mask should be inexpensive enough to be disposable during extended term CPAP treatment while comparing favorably economically to the use of an extended term mask. The mask should also be inexpensive enough to justify single-use. It is an object of the present invention to provide such a mask.
SUMMARY OF THE INVENTION
[0013] The present invention addresses the above needs by providing a respiratory mask with an adjustable forehead support that is constructed with few moving parts, and with as many parts as possible molded as one piece or co-molded together in a single process. The present invention provides a mask that is not only low in cost, but also is easy to adjust due to the simplicity of the adjustable forehead support.
[0014] A respiratory mask is provided having a mask frame, a mask cushion attached to the frame and a forehead support member integrally formed with the mask frame. A plurality of strap attachment portions are provided on the mask frame for attaching straps to the respiratory mask to secure the respiratory mask to a head and facial region of a user. The forehead support includes a forehead pad having a bore mounted over a forehead support member. The support pad bore has a number of sides, and the outer surface of the forehead support member has a cross-section with a corresponding number of sides, such that the support pad can be mounted over the forehead support member in a number of distinct angular positions corresponding to the number of sides of the support pad bore. An exterior surface of the support pad has a number of sides corresponding to the number of sides of the support pad bore, each exterior side preferably having a different spacing to an axis of the forehead support member than the other sides. In this manner, a number of different extensions between a forehead-contacting portion of the support pad and the mask frame can be provided by changing the angular position of the support pad with respect to the forehead support member.
[0015] An alternative embodiment of the mask includes a mask frame, molded in a flat configuration, having a cushion supporting portion, an air inlet portion and a forehead support portion. A mask cushion is attached to the mask frame cushion supporting portion. The forehead support portion and mask frame air inlet members are connected to the mask frame cushion supporting portion by hinges such that the air inlet portion can be folded over the cushion supporting portion and the forehead support portion can be folded over the air inlet portion with a cooperative locking mechanism on the mask frame interlocking the components in a final folded configuration ready for wearing. The forehead support portion includes a pair of forehead support adjustment mechanisms adjustable as to height to adjust the extension of a forehead support pad relative to the interlocked mask frame and mask cushion. The mask frame also includes portions for attaching to headgear or straps to secure the mask to the head and facial region of the user.
[0016] A method of manufacturing a respiratory mask is provided including molding integrally in a generally flat configuration, a mask frame having a cushion supporting portion, an air inlet portion and a forehead support portion, with the forehead support portion and mask frame air inlet members being connected to the mask frame cushion supporting portion by hinges such that the air inlet portion can be folded over the cushion supporting portion and the forehead support portion can be folded over the air inlet portion and locked in a final wearable configuration. A mask cushion is also molded to or otherwise attached to the mask frame cushion supporting portion.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] Preferred embodiments of the invention will now be described, by way of examples only, with reference to the accompanying drawings in which:
[0018] FIG. 1 is a front perspective view of a first embodiment of a mask according to the invention;
[0019] FIG. 2 is a rear perspective view of the mask shown in FIG. 1 ;
[0020] FIG. 3 a is an enlarged perspective view of the forehead support of the mask according to the first embodiment of the invention;
[0021] FIG. 3 b is an exploded view of the forehead support of the mask according to the first embodiment of the invention;
[0022] FIG. 3 c is a top plan view of the forehead pad of the mask according to the first embodiment of the invention;
[0023] FIGS. 4 a - d are top plan views of the forehead support according to the first embodiment in each of four adjustable positions;
[0024] FIGS. 5 a - d are side elevational views of the forehead support according to the first embodiment in each of the four adjustable positions on a user's forehead;
[0025] FIG. 6 is a top plan view of an alternative embodiment of the forehead pad;
[0026] FIG. 7 is a side elevational view of the mask according to the first embodiment secured to a user;
[0027] FIGS. 8 a - c are schematic drawings depicting the interaction between the cushion and a user's facial region;
[0028] FIG. 9 is a front perspective view of an alternative embodiment of a mask according to the invention;
[0029] FIG. 10 is a rear perspective view of the mask shown in FIG. 9 ;
[0030] FIG. 11 is a rear perspective schematic view of an alternative embodiment of the present invention;
[0031] FIG. 12 is a rear elevational view of an alternative embodiment of the present invention;
[0032] FIGS. 13 a - d are partial schematic top plan views of an alternative embodiment of a forehead support of the present invention;
[0033] FIGS. 14 a - d are partial schematic top plan views of an alternative embodiment of a forehead pad of the present invention;
[0034] FIGS. 15 a - c are partial elevational views of an alternative embodiment of the forehead support of the present invention;
[0035] FIGS. 16 a and 16 b are partial side elevational schematic views of an alternative embodiment of the forehead support of the present invention;
[0036] FIG. 17 is a front perspective view of another embodiment of the invention, in a flat, unfolded state, wherein the respiratory mask is molded as a single piece in a generally flat configuration to be folded together for assembly;
[0037] FIG. 17 a is a rear perspective view of the embodiment configuration of FIG. 17 ;
[0038] FIG. 18 is a rear perspective view of the embodiment of FIG. 17 wherein the air inlet portion has been folded onto the cushion supporting portion;
[0039] FIGS. 19 a - c show top perspective detail views of a forehead support adjustment mechanism of the embodiment of FIG. 17 with progressive stages of positioning of the forehead support adjustment mechanism;
[0040] FIGS. 20 a - c show bottom perspective detail views corresponding to FIGS. 19 a - c;
[0041] FIG. 21 is a rear perspective view of the embodiment of FIG. 17 with the forehead support adjustment mechanisms assembled;
[0042] FIG. 22 is a rear perspective view of the embodiment of FIG. 21 with the forehead support adjustment mechanisms folded onto the forehead support portion;
[0043] FIG. 23 is a front perspective view of the embodiment of FIG. 17 in a fully assembled state (less straps and air hose);
[0044] FIGS. 24 a - b are side elevational views of the embodiment of FIG. 17 showing two different forehead support adjustments;
[0045] FIG. 25 is a side elevational view of a further embodiment of the present invention incorporating the folding frame design of FIGS. 17-24 and the forehead support of FIGS. 1-16 ;
[0046] FIG. 26 is a front, top perspective view of the embodiment of FIG. 25 ;
[0047] FIG. 27 is a rear, bottom perspective view of the embodiment of FIG. 26 .
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0048] In the included figures a nasal mask is depicted, but the current invention is not intended to be limited to nasal masks. The aspects of the current invention are equally applicable to a mouth or full-face mask.
[0049] FIGS. 1 and 2 show front and rear perspective views of an embodiment of the present invention. A nasal mask 10 has a mask frame 20 , strap attachment portions 30 , a forehead support 40 including a forehead support member 42 and a forehead pad 50 , and a mask cushion 60 . The mask also has a single air inlet tube 70 mounted on the mask frame 20 for supplying pressurized gas to an interior of the mask 10 . Pressurized gas is supplied to the mask 10 by an air supply conduit (not shown) connected between the air inlet tube 70 and a pressurized air supply (not shown). As is known, an exhaust vent can be provided on the mask 10 or air supply conduit for exhausting exhalation gases from an interior of the mask. Other embodiments may have vents, elbows, pressure ports, or other attachments for items such as a sense tube or oxygen supply port as further options. There may also be further attachment portions for straps or other types of headgear.
[0050] FIG. 3 a is an enlarged perspective view of the forehead pad 50 and FIG. 3 b is an exploded view of the mask frame 20 , forehead support member 42 and the forehead pad 50 . In this embodiment, forehead support member 42 , is attached to and extends upwardly from mask frame 20 . Forehead support member 42 includes a lower supporting surface 43 , an upper supporting surface 44 and an upright column 46 positioned between the supporting surfaces 43 and 44 having four exterior sides 45 . Two upper strap attachment portions 49 are mounted on opposing sides of an upper portion of the forehead support member 42 and are reinforced by brace member 47 attached to and extending between an upper portion of the upper strap attachment portions 49 and the upper portion of the forehead support member 42 . A position indicating marker 48 is attached to the brace member 47 . In the preferred embodiment, upright column 46 is solid to add strength to the forehead support member 42 . In alternative embodiments, the upright column 46 can be hollow or can have a strengthening insert molded therein.
[0051] In this embodiment, the forehead pad 50 is an elastomeric pad, having four exterior sides 52 , denoted individually as sides 521 , 522 , 523 and 524 , and an off-center bore 56 . The off-center square bore 56 is defined by four inner surfaces 561 , 562 , 563 , and 564 , corresponding to sides 521 , 522 , 523 and 524 , respectively. The bore 56 is configured and sized so as to be able to mount over the upright column 46 in a mating fashion. Upper supporting surface 44 and lower supporting surface 43 are sized to be somewhat larger than the size of bore 56 so that when the forehead pad is mounted over the forehead support member 42 , the upper and lower supporting surfaces will retain the forehead pad in place on the forehead support member 42 . The elasticity of the forehead pad 50 allows the forehead pad 50 to pass over the larger upper supporting surface 44 when installing or removing the forehead pad 50 with respect to the forehead support member 42 .
[0052] Since the bore 56 is off-center, a distance between an axis of the bore 56 and the exterior sides 52 is different for each side 521 , 522 , 523 , and 524 , which in the embodiment shown, increases from side 521 to side 522 to side 523 to side 524 . See FIG. 3 c , which shows a distance d4 for side 524 greater than a distance d3 for side 523 greater than a distance d2 for side 522 greater than a distance d1 for side 521 . In this embodiment, the forehead pad can be mounted on the forehead support member in four different angular positions. In each angular position, a different side 52 will be facing toward the user to contact the user's forehead. Since the distance between each side 52 and the axis of the bore 56 is different, changing the angular position of the forehead pad 50 with respect to the forehead support member will alter the distance between the forehead support member 42 and the user's forehead, allowing the forehead support 40 to be adjusted as desired for each user.
[0053] Each exterior side 52 has a corresponding position indicator 54 , denoted individually as position indicators 541 , 542 , 543 and 544 , corresponding to sides 521 , 522 , 523 and 524 , respectively. These position indicators 54 are depicted as rounded projections, which provide a visual and tactile indicator of the position of the forehead pad 50 when mounted on the forehead support member. As shown, position indicator 541 includes one raised projection, position indicator 542 includes two raised projections, position indicator 543 includes three raised projections and position indicator 544 includes four raised projections. Alternatively, the position indicators can be in the form of printed markings, notches, labels or other forms of visual and/or tactile indicators. The user is able to determine which angular position the forehead pad is in by determining which position indicator 54 is aligned with the position indicating marker 48 .
[0054] The bore 56 need not be of continuous cross-section, and need not extend from one end of the forehead pad 50 to the other, but rather may be open at only one end. Its configuration may also be tapered or have other provisions in order to effectively lock the forehead pad 50 to the mask 10 so that it will resist moving from the chosen position when in use. Such locking effect may include the provision of stepped configuration along the forehead support member 42 or the bore 56 such that there is engagement and interference between the two components. Alternative mechanisms for locking the adjusted forehead pad 50 to the forehead support member 42 can also be used.
[0055] FIGS. 4 a, b, c , and d are top plan view of the mask 10 and FIGS. 5 a, b, c and d are side elevational views of the mask 10 positioned on a user, respectively illustrating the four angular positions of the forehead pad according to this embodiment of the invention. FIGS. 4 a and 5 a illustrate the first angular position, appropriate for a user having a protuberant forehead. The forehead pad 50 has been rotated counterclockwise from the first position to the second position illustrated in FIGS. 4 b and 5 b . This position is appropriate for a less protuberant forehead than in position 1 . The forehead pad 50 has been further rotated counterclockwise from the second position to the third position illustrated in FIGS. 4 c and 5 c . This position is appropriate for a slightly receding forehead. Finally, the forehead pad has been rotated counterclockwise from the third position to the fourth position illustrated in FIGS. 4 d and 5 d . This position is appropriate for users having a more receding forehead than illustrated in FIG. 5 c . Although only four positions are shown, fewer or greater than four positions can be provided by suitably altering the number of sides 45 , 52 and 56 , with a distance between each side 52 and an axis of the forehead support member 42 being different.
[0056] In an alternative embodiment shown in FIG. 6 , the forehead pad 50 can be cam-shaped and have a toothed off-center bore 56 adapted to engage a similarly toothed forehead support member 42 to provide a greater resolution of adjustment, Alternatively, if pad 50 is retained to support 42 by press fit, a generally continuously variable adjustability of the distance from the forehead contacting surface of the pad 50 to the mask frame 20 .
[0057] FIG. 7 illustrates a nasal mask 10 of the present invention being worn by a user. Mounting straps 32 are attached to the strap attachment portions 30 , to attach the nasal mask to the user's head. The forehead pad 50 contacts the forehead. The mask cushion 60 seals the mask frame 20 to the facial region of the user. The mask cushion 60 is shaped to substantially conform to the facial region of the user. However, the shape of the facial regions of different users varies and the adjustable position of the forehead pad 50 may not be optimal for all users. Therefore, it is desirable for the mask cushion 60 to be flexible and resilient to seal the mask frame 20 to the facial regions of a variety of users.
[0058] FIGS. 8 a , 8 b and 8 c are schematic diagrams depicting the accordionate configuration and behavior of the mask cushion 60 . Cushion 60 includes a face contacting portion 66 connected to a main body 68 of the cushion 60 by cushion hinged portions 62 and 64 . If a portion of the mask frame 20 is close to the facial region of the user, the included angles of the two hinged portions 62 , 64 will decrease, allowing the face contacting portion 66 to draw closer to the mask frame without causing discomfort to the user. If a portion of the mask frame 20 is not close to the facial region of the user, the included angles of the two hinged portions 62 , 64 will increase, allowing the face contacting portion 66 to extend from the mask frame while continuing to maintain a seal with the facial region of the user. FIG. 8 a depicts a condition in which the angle between the mask frame 20 and the facial region of the user is substantially optimized. FIG. 8 b depicts a condition in which the upper portion of the mask frame 20 is closer to the facial region of the user than the lower portion, and the upper portion of the face contacting portion 66 of the cushion is closer to the cushion main body 68 than the lower portion of the face contacting portion 66 to accommodate for this. FIG. 8 c depicts a condition opposite to the condition in FIG. 8 b in which the lower portion of the mask frame 20 is closer to the facial region of the user than the upper portion, and the lower portion of the face contacting portion 66 of the cushion is closer to the cushion main body 68 than the upper portion of the face contacting portion 66 to accommodate for this.
[0059] FIGS. 9 and 10 show front and rear perspective views of an alternative embodiment of the present invention. The nasal mask 10 of this embodiment is similar to the embodiment shown in FIGS. 1 and 2 but has a mask frame 20 having a slightly different shape and configuration to improve moldability of the frame, as well as to improve the aesthetic appearance of the frame. This embodiment also has strap attachment portions 30 , a forehead support 40 including a forehead support member 42 and a forehead pad 50 , a mask cushion 60 and a single air inlet tube 70 mounted on the mask frame 20 for supplying pressurized gas to an interior of the mask 10 .
[0060] FIG. 11 is a rear perspective schematic view of an alternative embodiment of the present invention. In the nasal mask 10 of this embodiment, an air inlet tube 72 is mounted to the top of the mask frame 20 and has a square outer cross-section so as to act as the forehead support member 42 of the previous embodiments. As with the previous embodiments, the forehead pad 50 can be placed over the air inlet tube in a plurality of different angular positions to alter a distance between the air inlet tube/forehead support member 72 and allow the mask to be adjusted for each user.
[0061] FIG. 12 is a rear elevational view of an alternative embodiment of the present invention.
[0062] FIGS. 13 a - d are partial schematic top plan views of an alternative embodiment of the forehead support 40 . In this embodiment, the forehead support member 42 is configured to have a U-shaped cross-section. An open end of the U-shaped cross-section is shown as facing toward the user but can be oriented away from the user as well. The U-shape can reduce material required for the forehead support member 42 while retaining the necessary strength. FIGS. 13 a - d show the different angular positions of the forehead pad 50 corresponding respectively to the positions shown in FIGS. 4 a - d and 5 a - d.
[0063] FIGS. 14 a - d are partial schematic top plan views of an alternative embodiment of the forehead pad 50 positioned on the forehead support member 42 of the embodiment shown in FIGS. 13 a - d . The forehead pad 50 of this embodiment is not shaped as a rectangle with flat exterior sides. Rather, each exterior side 52 of the forehead pad is generally U-shaped in cross-section with the open end facing outward. Although the bore 56 is positioned generally in a center of a central portion 59 of the forehead pad 50 , the two legs 58 of the U-shaped cross-section of each exterior side 52 have a different height. Because of this configuration, the adjustment of the forehead support 40 can be altered as described above by changing the angular orientation of the forehead pad 50 on the forehead support member 42 . FIGS. 14 a - d show the different angular positions of the forehead pad 50 corresponding respectively to the positions shown in FIGS. 4 a - d , 5 a - d and 15 a - d . This configuration of forehead pad 50 can reduce the amount of material required to make the pad and can also minimize an area of contact of the forehead pad 50 with the user to increase the comfort of the user.
[0064] FIGS. 15 a - c are partial elevational views of an alternative embodiment of the forehead support 40 . In this embodiment, the forehead support member 42 (or air inlet tube 72 ) has an extended height to provide for a plurality of different elevational positions for the forehead pad 50 . In the embodiment shown, the forehead support member 42 includes three separate elevational adjustment positions 120 bounded on each side by position retaining flanges 122 . The forehead pad can be moved to any one of the elevational adjustment positions 120 to provide a desired elevational position of the forehead pad 50 on the nasal mask 10 with respect to the user. The position retaining flanges 122 are larger than the bore 56 in the forehead pad 50 to prevent the forehead pad 50 from moving undesirably up and down the forehead support member 42 once it has been adjusted but due to the flexibility of the forehead pad 50 , it can be moved over a position retaining flange 122 by applying sufficient force to the forehead pad 50 . The force required to move the forehead pad to a different elevational adjustment position can be altered by altering the size of the position retaining flanges 122 with respect to the bore 56 and/or by changing the flexibility of the forehead pad 50 . Three elevational positions of the forehead pad 50 are shown respectively in FIGS. 15 a , 15 b and 15 c . The number of elevational adjustment positions 120 can be altered as desired. In a modified version of this embodiment, retaining flanges can be positioned on the forehead pad 50 to engage grooves or other structure on the forehead support member 42 .
[0065] FIGS. 16 a and 16 b are partial side elevational schematic views of an alternative embodiment of the forehead support 40 . In this embodiment, the forehead support member 42 is tapered along its length. Because the forehead pad 50 is flexible, it can be moved to a desired position along the forehead support member and the forehead support member will correspondingly expand the bore 56 of the flexible forehead pad 50 , creating a friction fit between the forehead pad 50 and the forehead support member 42 that will retain the forehead pad 50 in the adjusted position. FIG. 16 a shows the forehead pad 50 in an elevated position with respect to the forehead support member 42 where there is a minimal friction fit and FIG. 16 b shows the forehead pad 50 in a lowered position with respect to the forehead support member 42 where there is an increased frictional fit. Thus, this embodiment allows infinite elevational positioning of the forehead pad 50 along a given range of the forehead support member 42 , as opposed to the discrete positioning provided by the embodiment of FIGS. 15 a - c . The magnitude of retaining force of the friction fit between the forehead pad 50 and the forehead support member 42 can be altered by altering the size and shape of the bore 56 , the flexibility, material or surface finish of the forehead pad 50 , or the taper, size, shape, material or surface finish of the forehead member 42 . In one embodiment, a retaining flange can be provided at a bottom portion of the forehead support member 42 to provide a positive bottom stop to the elevational adjustment of the forehead pad 50 .
[0066] FIGS. 17-24 illustrate another embodiment of the invention. In this embodiment, the respiratory mask is molded as a single piece in a generally flat configuration and folded together for assembly. FIG. 17 is a front perspective view of the mask frame in the flat, unfolded state. The mask frame 20 includes a cushion supporting portion 80 , an air inlet portion 90 and a forehead support portion 100 . An integral hinge 92 , also called a “living hinge”, is molded between the cushion supporting portion 80 and the air inlet portion 90 . An integral hinge 102 is molded between the cushion supporting portion 80 and the forehead support portion 102 . In this manner, both the air inlet portion 90 and the forehead support portion 102 can be folded with respect to the cushion supporting portion 80 . A sealing member 82 (see FIG. 17 a ) is provided around a periphery of the cushion supporting member 80 and adapted to sealingly engage the air inlet portion 90 such that when the air inlet portion 90 is folded over onto the cushion supporting portion 80 , a gas-tight seal is formed between those two portions to seal an interior of the mask 10 . A latch mechanism 94 is attached to a distal edge of the air inlet portion 90 and is adapted to engage a lip 84 on the cushion supporting portion when the two components are folded together to latch the two components in the folded position. See FIG. 18 , which is a rear perspective view of the mask 10 wherein the air inlet portion 90 has been folded onto the cushion supporting portion 80 and latched in place.
[0067] The forehead support portion 100 has a main body portion 104 and a forehead pad mounting portion 108 interconnected by an offset portion 106 to offset the forehead pad 110 with respect to the main body portion 104 . The degree of offset, if any, can be altered as desired for the specific application. Rib 109 between the main body portion 104 and the offset portion 106 adds strength to the forehead support portion 100 .
[0068] The forehead support portion 100 can utilize the forehead support mechanism 40 discussed above, as shown in FIGS. 25-27 and discussed in more detail below. Alternatively, a nonadjustable forehead pad 110 can be attached to the forehead support portion 100 using methods described herein or molded integrally therewith. In such an embodiment, it is desirable to provide an alternative mechanism for adjusting the forehead pad with respect to the mask frame 20 . In one such embodiment, the forehead support portion 100 is provided with a pair of forehead support adjustment mechanisms 130 . Each forehead support adjustment mechanism 130 is preferably molded integrally with the forehead support portion 100 , although this is not required, and includes an elongated adjustment channel member 132 attached at one end to the forehead support portion 100 by hinge 134 . A foldable adjustable height member 138 is attached at another end of the adjustment channel member 132 by hinge 136 . The adjustable height member 138 preferably, though not necessarily, includes a side segment 140 , top segment 144 and side segment 148 connected together by hinges 142 and 146 , respectively, so as to be foldable with respect to one another. See FIGS. 17-18 . Alternatively, top member 144 and hinge 146 can be omitted so that side segment 140 is directly connected to side segment 148 by hinge 142 . See FIGS. 19-24 . An adjustment tab 152 is connected to side member 148 by hinge 150 and is configured and arranged for adjustable engagement with adjustment channel member 132 . See FIGS. 19 a - c , which show top perspective detail views of the forehead support adjustment mechanism 130 with progressive stages of positioning of the forehead support adjustment mechanism 130 , and 20 a - c , which show corresponding bottom perspective detail views thereof.
[0069] Each elongated adjustment channel member 132 includes a channel 154 including a tab insertion portion 156 and an adjustment portion 158 . The adjustment portion 158 of channel 154 includes a pair of sets of uniformly spaced opposed detent slots 160 extending from side walls of the channel 154 inward toward one another. The adjustment tab 152 includes a top retaining portion 162 connected to an adjustment fixing portion 164 connected to a bottom retaining portion 166 . See FIGS. 19 and 20 . The bottom retaining portion 166 can be grooved (see FIGS. 19 a and 20 b ), ridged or otherwise textured, as can top retaining portion 162 to increase a user's grip on the adjustment tab 152 during adjustment. The adjustment fixing portion 164 includes a pair of sets of outwardly facing detent lugs 168 spaced, configured and dimensioned so as to be able to uniformly engage the detent slots 160 of channel 154 in a temporarily fixed adjustment position until sufficient force is applied to move the detent lugs 168 with respect to the detent slots 160 .
[0070] In a preferred embodiment, a width of the bottom retaining portion 166 of the adjustment tab 152 is less than or equal to a width of the tab insertion portion 156 of the channel 154 and a width of the top retaining portion 162 of the adjustment tab 152 is greater than a width of the tab insertion portion 156 of the channel 154 so as to permit insertion of the adjustment tab 152 into the tab insertion portion 156 (see FIGS. 19 a and 20 a ) until the top retaining portion 162 of the adjustment tab 152 contacts the adjustment channel member 132 to prevent further insertion (see FIGS. 19 b and 20 b ). On the other hand, the width of the bottom retaining portion 166 of the adjustment tab is greater than a minimum width between the opposing sets of detent slots 160 of channel 154 so that when the adjustment tab 152 is moved along the length of the channel 154 from out of the tab insertion portion 156 into the adjustment portion 158 (see FIGS. 19 c and 20 c ), the detent slots 160 engage the bottom retaining portion 166 of adjustment tab 152 to retain adjustment tab 152 in the channel 154 until the adjustment tab 152 is again moved lengthwise along the channel 154 back into the tab insertion portion 156 (see FIGS. 19 b and 20 b ). Adjusting the position of the adjustment tab 152 along the length of the channel 154 allows the overall height of the adjustable height member 138 to be altered with respect to the adjustment channel member 132 and thus, the forehead support portion 100 of the mask, to adjust the height of the forehead support pad, as will be discussed below in further detail. FIG. 21 is a rear perspective view of the mask of this embodiment, with the adjustment tabs 152 positioned in the adjustment portions 158 of the channels 154 , respectively.
[0071] A minimum inner width between the closest portions of opposed sets of the detent slots 160 of the channel 154 is somewhat smaller than a maximum exterior width of opposed sets of the detent lugs 168 of the adjustment tab 152 so that engagement between the detent slots 160 of channel 154 and the detent lugs 168 of the adjustment tab 152 will temporarily fix the adjustment tab 152 in a desired lengthwise position in the adjustment portion 158 of the channel 154 until sufficient force is applied to overcome such engagement. The force required is determined by a trade-off between balancing the minimum force required to maintain the adjustment tab 152 in a desired adjusted position in the channel 154 when the mask is being worn by the user with the maximum force desired to allow the user the change the adjustment of the adjustment tab 152 . These forces can be altered by altering the magnitude of the engagement between opposing detent slots/detent lugs of the channel 154 and adjustment tab 152 , respectively, by altering dimensions of the respective detent slot/detent lugs and altering the number and/or shape of the respective detent slots/detent lugs, as well as by altering the material and/or rigidity of the respective detent slots/detent lugs. The positioning of the detent slots and detent lugs on the respective components can be reversed and alternative detent configurations can be used.
[0072] FIG. 22 is a rear perspective view of the mask of this embodiment where the forehead support adjustment mechanisms 130 , through hinges 134 , have been folded down onto a rear surface of the forehead support portion 100 of mask frame 20 . Forehead support portion 100 can include stabilizing portions 170 (see FIG. 21 ), such as raised ridges or walls, slots or other structure, to engage the adjustment channel members 132 or other portions of the forehead support adjustment mechanisms 130 to provide lateral and other support to the mechanisms 130 when they are in their final folded position. At this point, the cushion supporting portion 80 /air inlet portion 90 folded subassembly can be folded toward the forehead support portion 100 of the mask until subassembly comes into contact with the upstanding portion of the adjustable height members 138 , with the adjustable height members 138 positioned on opposing sides of the cushion supporting portion 80 /air inlet portion 90 folded subassembly and between the forehead support portion 100 and the cushion supporting portion 80 /air inlet portion 90 folded subassembly. See FIGS. 23-24 . In the shown embodiment, the adjustable height members 138 are shown as contacting a surface 96 of the air inlet portion 90 , although this can be altered as desired so that the adjustable height members 138 contact other portions of the cushion supporting portion 80 /air inlet portion 90 folded subassembly.
[0073] By altering the lengthwise positions of the adjustment tabs 152 in the adjustment portions 158 of the channels 154 , the height of the adjustable height members 138 can be adjusted with respect to the forehead support portion 100 , thereby altering an angle θ (at hinge 102 ) between the forehead support portion 100 and the cushion supporting portion 80 /air inlet portion 90 folded subassembly, and thus, altering a corresponding relative height between the forehead pad 110 and the cushion 60 . Compare FIGS. 24 a and 24 b . The height of adjustable height member 138 is higher in FIG. 24 a because the adjustment tab 152 is positioned in the adjustment portion 158 of channel 154 nearer hinge 136 in FIG. 24 a , thereby resulting in the forehead pad 110 being relatively positioned more toward the front of the mask than in FIG. 24 b to better accommodate a user having a more protuberant forehead. For instance, the adjustment shown in FIG. 24 a corresponds more with a user as shown in FIG. 5 b while the adjustment shown in FIG. 24 b corresponds more with a user as shown in FIG. 5 c . The user can easily adjust the relative position of the forehead pad 110 through manual adjustment of the height of the adjustable height member 138 by moving the adjustment tab 152 in the channel 154 . In this embodiment, the angle of the forehead pad 110 will change with respect to the user within the range of adjustment provided. However, this is accommodated by the resiliency of the forehead pad and can be altered within certain parameters by altering the angle of upright portion 46 , and/or a user-contacting portion of the forehead pad 110 with respect to a plane of forehead support portion 100 . Alternatively, hinge 102 can be replaced by a double hinge to minimize relative angle changes in the forehead pad 110 as the relative height of the forehead pad is adjusted. Alternatively, the forehead pad can have a cylindrical surface to accommodate varying angles of contact with the forehead.
[0074] Strap attachment portions 49 and 30 are provided on the forehead support portion 100 and the cushion supporting portion 80 or air inlet portion 90 for attaching to headgear or straps to secure the mask to the head and facial region of the user. Although the adjustment mechanisms 130 are shown as being attached to the forehead support portion 100 , alternative embodiments can be constructed by attaching the adjustment mechanisms to the cushion support portion 80 and/or the air inlet portion 90 and contacting against the forehead support portion 100 . Alternatively, the use of a single adjustment mechanism or three or more adjustment mechanisms is contemplated, as well as the use of separately molded adjustment mechanisms.
[0075] FIGS. 25-27 show a further embodiment of the present invention incorporating aspects from the mask of FIGS. 17-24 and the forehead support of FIGS. 1-16 . In this embodiment, the forehead support portion supports a forehead support member 42 and forehead pad similar to the embodiments shown in FIGS. 1-16 . This embodiment also shows use of the mask frame and forehead adjustment mechanisms of the embodiment shown in FIGS. 17-24 . Thus, this embodiment gives a wider range of forehead pad adjustability than either of the other two groups of mask embodiments alone. In a modification of this embodiment, the forehead support adjustment mechanisms 130 could be removed or replaced by generally fixed members to combine the one-piece, disposable frame aspects of FIGS. 17-24 with the forehead pad adjustment of FIGS. 1-16 .
[0076] In order to enable the mask to be molded as one piece, allowance must be made for variation in the desirable characteristics of the different sections of the molding. For example, the mask frame 20 must be rigid, but the mask cushion 60 must be flexible enough to provide comfort and good sealing properties while the forehead support member 42 must be resilient. To make the mask out of one material, such as polypropylene, while providing the differing levels of flexibility desired in the various components, the molding process can provide a changing gradient of material density, as can be achieved by forms of gas assisted injection molding, resulting in a change in rigidity. Another option, which could be used in addition to the changing gradient of material density, is the use of a continuous gradient of material thickness or by stepped contours or introduction of ribbing to provide reinforcement in certain areas where more rigidity is required.
[0077] An alternative construction can involve the incorporation of a separate mask cushion 60 to the mask frame 20 . The mask cushion 60 can be made of material different to the mask frame 20 or can be made of the same material and may be attached by using any of the methods known in the art, such as friction fit, strapping, clips, or adhesive. Alternatively, the mask cushion 60 can be overmolded onto the mask frame or co-molded with the mask frame 20 in accordance with methods known in the art of molding. In such examples, placement of appropriate channeling in the mask frame 20 allows for bleed-through of cushion molding material so as to achieve enhanced attachment of the mask cushion 60 to the mask frame 20 . This can be especially desirable if the mask cushion 60 is made of a material that does not readily form a chemical bond with the material of the mask frame 20 . This technique may also be used to provide even softer material between the mask frame 20 and the user at certain contact points, a decorative effect, or visually vivid and tactile labeling. The key polymers capable of incorporating living hinges and which would be suited to this application are polypropylene and styrene-butadiene copolymers such as K-Resin®.
[0078] It is intended that various features of the various embodiments described above can be combined to create different embodiments of the nasal mask of the present invention. The embodiments describe above are exemplary only and are not exhaustive of the scope of the invention. It is also intended that changes and modifications can be made to the embodiments described above without departing from the scope of the invention.
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A respiratory mask has an adjustable forehead support member that is simple and inexpensive to manufacture. The forehead support member may be adjusted by rotating a forehead pad about an off-center bore or by bending an angular adjustment beam. The mask has a mask cushion with an accordionate membrane having at least two hinged portions. The mask may be constructed with a mask frame, the mask cushion, and the forehead support member molded as one piece.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation-in-part of U.S. application Ser. No. 11/382,586, entitled “Method for Treating Periodontal Disease,” filed May 10, 2006, which claims the benefit of U.S. Provisional Application No. 60/689,365, filed Jun. 10, 2005.
FIELD OF THE INVENTION
[0002] The present invention relates to the field of treatment of periodontal disease and, more particularly, relates to treating periodontal disease with a laser and chemical combination.
BACKGROUND OF INVENTION
[0003] Periodontal disease is a pathogenic infection of the gums which is common among all humans and animals. The disease provides a major pathway to the loss of teeth and oral bone throughout every society, leading to extreme personal discomfort among the afflicted. Given the prevalence of the disease and related costs, effective treatments of the disease and prevention strategies are continually being pursued.
[0004] A major contributor to periodontal disease concerns the oral environment. The oral environment provides a warm moist cavity that is full of nutrients, making it an excellent location to incubate microbes. It is not surprising, therefore, that pathogens readily ingress into periodontal pockets where the infection occurs. In the milder forms of periodontal disease—commonly referred to as gingivitis—the gums redden, swell and bleed easily. Gingivitis is limited to the soft tissue surrounding the tooth and does not typically result in bone loss. This stage of the disease is reversible with treatment and proper oral care. On the other hand, uncontrolled or rampant periodontal infection leads to advanced stages of the disease called periodontitis. Left untreated, periodontitis causes progressive bone loss around teeth that ultimately results in the teeth becoming loose from their sockets. There are few if any characteristic stages of progression, as the driving actions underlying the disease are the same—e.g., accumulation of bacteria at the gum line leading to the formation of dental plaque. A specific treatment of the disease depends primarily on the extent of the disease—e.g., the extent of the infection or the formation of plaque.
[0005] Some common characteristics of the disease are as follows. First, there occurs an accumulation of bacteria at the gum line that forms bacterial or dental plaque. Bacterial plaque later calcifies to form calculus, which can exist both above and below the gum line. At the same time, there occurs a sustained dramatic change in the normal micro flora existing below the gum line in the region between the gum and tooth—typically referred to as the gingival margin. Disease causing microbes find a safe home in the gingival margin, where they are safe from the tongue and major saliva pathways, thereby upsetting the balance of micro flora. The rogue microbes begin to emit enzymes that destroy the connective tissue between teeth and gums which creates a “periodontal pocket.” Because the mouth acts as an incubator with a good supply of nutrition, microbes flourish in the periodontal pockets. Dentists use a tool called a periodontal probe to measure pocket depths of individual patients. This provides a measure of the depth the rogue microbes have eaten the connective tissue away. The deeper the periodontal pocket goes, the more difficult it is to treat. When the pockets are near the surface (say about less than 3 mm) the pocket can in some cases be treated with a sulcular disinfection regime as disclosed in commonly owned U.S. patent application Ser. No. 11/382,586. An appropriate disinfection regime can bring back into balance the normal micro flora and allow healing to occur.
[0006] There are two different issues a clinician must address in order to cure periodontal disease. The first obviously is the restoration of the normal micro flora, while the second is to restore the pocket to its normal state, at least to the extent possible. If the periodontal pocket is greater than 3 mm, then sulcular disinfection will not work because it only addresses one part of the problem—the microbes. This presents a major problem with periodontal pockets—even though you disinfect them, rogue microbes can easily migrate back into the deep protective pockets and start where they left off. One can continuously treat deep pockets and slow down the disease with a disinfection regime, but one will rarely restore the pockets to their pre-infection condition. Deep pockets provide too big a space for microbes and therefore require a different procedure in order to have some chance of success.
[0007] The laser curettage treatment described herein provides certain advantages that will advance the treatment and prognosis for patients suffering advanced stages of the disease—i.e., to the point where deep pockets have developed. Curettage is a procedure used by many periodontists, and consists of using small hand instruments to physically scrape away the diseased lining of epithelial cells from the bottom of the pocket. The idea is to scrape away the diseased tissue and, at the same time, cause a slight wound. The wound is key to decreasing pocket depth. And if there are insufficient interfering microbes the new gingival tissue will grow back higher on the tooth. Through multiple curettage treatments it is possible to eliminate the pocket entirely.
[0008] The curettage procedure described above has been used successfully on many patients. As described and disclosed below, the present invention dispenses with the use of hand instruments to destroy the diseased epithelial lining and, instead, uses a laser and a powerful disinfection regime. Specifically, while standard curettage comprises a physical scraping of tissue, the present invention achieves that result through the process of laser ablation of tissue combined with flooding the pocket with an anti-microbial solution. While lasers have been used in the treatment of periodontal disease, such treatments appear generally limited to photodynamic therapies, as disclosed, for example, in U.S. Patent Application Publication 2004/0259053 (Bekov et al.).
[0009] Recently, lasers have been used to treat periodontal disease by using a fiber-optic guide to direct laser energy into periodontal pockets to kill bacteria. One approach using this technique is disclosed, for example, in U.S. Pat. No. 6,663,386 (Moelsgaard). This less invasive and painful form of treatment does have its limitations, however, in that the laser is limited by the relative size of the guide and the ability to adequately control its direction. As such, areas needing treatment may not be adequately treated or can be missed entirely. What is needed is a method to improve upon the use of the laser treatment of periodontal disease for maximum coverage and disinfection of the treated area.
BRIEF SUMMARY OF THE INVENTION
[0010] In view of the foregoing disadvantages inherent in the known types of treatment of periodontal disease, this invention provides a new and improved method of treatment merging the benefits of laser ablation and chemical treatment. As such, the present invention's general purpose is to provide a new and improved method that is both safe and efficient, providing a broader treatment area than that obtained through use of a laser guide alone or in conjunction with a cooling spray of water or water and air with minimal resulting discomfort to the patient.
[0011] The present invention provides an improved method for treating periodontal disease. The method comprises the use of a laser or radiant energy source that is tuned to ablate the cells and tissue comprising the gingival margin in the periodontal pocket below and in the region of the gum line. The laser light is applied to infected periodontal pockets with the intention of destroying through ablation the infected cells and tissue that make up the diseased epithelial lining, together with any susceptible pathogens. The periodontal pocket is then flushed with an anti-microbial substance with the intention to destroy any residual susceptible pathogens. The advantage of the flushing is that any residual organisms have been already weakened by the applied laser light and the use of a liquid anti-microbial substance will reach areas missed by the direction of the guide.
[0012] The more important features of the invention have thus been outlined in order that the more detailed description that follows may be better understood and in order that the present contribution to the art may better be appreciated. Additional features of the invention will be described hereinafter and will form the subject matter of the claims that follow.
[0013] Many objects of this invention will appear from the following description and appended claims, reference being made to the accompanying drawings forming a part of this specification wherein like reference characters designate corresponding parts in the several views.
[0014] 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 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.
[0015] As such, those skilled in the art will appreciate that the conception, upon which this disclosure is based, may readily be utilized as a basis for the designing of other structures, methods and systems for carrying out the several purposes of the present invention. It is important, therefore, that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] FIG. 1 is a partial sectional view of a normal tooth and surrounding tissue.
[0017] FIG. 2 is the tooth and surrounding tissue of FIG. 1 having developed an early stage of gingivitis.
[0018] FIG. 3 is the tooth and surrounding tissue of FIG. 2 having developed advanced periodontal disease.
[0019] FIG. 4 is the tooth and surrounding tissue of FIG. 3 , being treated by a fiber optic guide through which laser light is being transmitted.
[0020] FIG. 5 is tooth and surrounding tissue of FIG. 4 being flushed with an anti-microbial substance by the means of a slender tip attached to a syringe.
[0021] FIG. 6 illustrates a laser apparatus of the present invention being used to ablate infected tissue from the pocket region of a tooth exhibiting periodontitis.
DETAILED DESCRIPTION OF THE INVENTION
[0022] With reference now to the drawings, the preferred embodiment of the method of periodontal treatment is herein described. It should be noted that the articles “a”, “an” and “the”, as used in this specification, include plural referents unless the content clearly dictates otherwise. With reference to FIG. 1 , a healthy tooth 2 rests in a bony socket 4 in the jaw 6 . The entire area is covered by the gingiva 10 , or “gums.” Over time, if left without proper oral care, tartar 12 will build up against tooth 2 (shown in FIG. 2 ), causing the gums 10 to recede away from the tooth and exposing the root 3 of the tooth 2 in a condition called “gingivitis.” FIG. 3 illustrates a condition further deteriorated from gingivitis, or the so-called peridontitis. Where periodontitis has occurred, the gums 10 have receded to the point of forming an open pocket 20 around the tooth 2 and its root system 3 . The pocket 20 is filled with inflamed tissue 22 and infectious matter 24 . If left untreated the tooth 2 and socket 4 may deteriorate, causing loss of the tooth 2 .
[0023] Treatment of the condition is shown in FIGS. 4 and 5 . The method harnesses the benefits of a radiant energy source that is of sufficient strength to ablate the cells and tissue that comprise the lining of the open pocket 20 and the inflamed tissue 22 . The process of ablation is coupled with flooding the pocket region with anti-microbial agents that are chemically lethal to a wide variety of pathogens. The combined effect of ablation by radiant energy and flooding with anti-microbial agents is intended to provide a “wound” to the epithelial lining through ablation of cells and tissue and, at the same time, to destroy a broad spectrum of pathogens, such that remaining pathogens can eventually be controlled by the normal functions of the immune system. The healing process of the wound creates a healthy tissue that reduces pocket size, thereby restoring the gum region to its pre-periodontitis state.
[0024] The method warrants a radiant energy source with sufficient energy to become not only lethal to pathogens, but to destroy through ablation the cells and tissue that comprise the epithelial lining or the lining of the open pocket 20 and the inflamed tissue 22 . The radiant energy can be produced from sources such as a diode laser, examples of which are the gallium nitride, aluminum gallium arsenide diode laser and the like. The radiant energy can be produced from sources such as high intensity light from incandescent, halogen or plasma arc devices. The radiant energy can be produced from sources such as solid state lasers, examples of which are neodymium YAG, titanium sapphire, thulium YAG, ytterbium YAG, Ruby, holmium YAG lasers and the like. The radiant energy can be produced from sources such as EB or electron beam devices. The radiant energy can be produced from sources such as gas lasers, examples of which include carbon dioxide gas, argon gas, xenon gas, nitrogen gas, helium-neon gas, carbon monoxide gas, and hydrogen fluoride gas lasers and the like. There are also many dye lasers that utilize a radiant energy source that pass through or are absorbed by various dyes or stains to achieve various incident energies or flux densities at specific wavelengths. Dye lasers are also within the scope of this method.
[0025] The method also warrants an anti-microbial substance that is capable of destroying pathogens. There are numerous substances with anti-microbial or anti-pathogenic activity. Any substance that is capable of destroying or stemming the growth of a pathogen is within the scope of this method. A few possible examples of antimicrobial substances include: ethanol, isopropanol, methyl paraben, ethyl paraben, butyl paraben, propyl paraben, hydrogen peroxide, carbamide peroxide, eugenol, sodium chlorite, chlorhexidine, chlorhexidine gluconate, sodium chlorite, thymol, cetyl pyridinium chloride, chloroxylenol, iodine, hexachlorophene, triclosan, quaternary ammonium compounds, sodium hypochlorite, calcium hypochlorite, or any like substance that is capable of destroying or limiting the reproduction of pathogens.
[0026] Many of these antimicrobial agents are a dry powder in their raw form and would benefit by being dissolved into a solvent. Liquid antimicrobial agents are able to migrate easier into difficult areas, thus having an advantage over powders. A few examples of possible solvents include: water, propylene glycol, glycerin, polysorbates, liquid polyethylene glycols, ethanol or any solvent capable of dissolving or liquefying an antimicrobial substance.
[0027] Optionally, the antimicrobial agent can contain additional components that would improve patient comfort such as a flavor, sweetener or anesthetic. A few possible substances that would aid in patient comfort include: sodium saccharin, phenylalanine, benzocaine, lidocaine, dyclonine hydrochloride, peppermint oil, spearmint oil, methyl salicylate and any like substance.
[0028] Numerous formulas are capable of being produced during the practice of this method. Compositions may be made in any combination according to the following Table A, dependant upon the desired agents used and overall effect.
[0000] TABLE A Percentage by Rinse Component Total Weight Function Antimicrobial agent 0.01%-100% Kill bacteria Solvent 0%-99.99% Allows the rinse to be a fluid that will easily flow into a periodontal pocket. Flavoring 0%-5% Make the rinse palatable. Anesthetic 0%-30% Reduce patient discomfort.
A few specific examples include:
Formula #1
[0030] 6.0%—chlorhexidine gluconate 20% aqueous
[0031] 94.0%—Water
Formula #2
[0033] 1%—chlorhexidine
[0034] 99.0%—Water
Formula #3
[0036] 5.0%—sodium hypochlorite
[0037] 95.0%—Water
Formula #4
[0039] 1.0%—calcium chlorite
[0040] 99.0%—Water
Formula #5
[0042] 0.5%—sodium chlorite
[0043] 99.5.0%—Water
Formula #6
[0045] 10.0%—chlorhexidine gluconate 20% aqueous
[0046] 73.4%—Water
[0047] 0.3%—peppermint oil
[0048] 15.0%—ethanol
[0049] 0.3%—Phenylalanine
[0050] 1.0%—dyclonine hydrochloride
Formula #7
[0052] 3.0%—hydrogen peroxide
[0053] 55.4%—glycerin
[0054] 0.3%—peppermint oil
[0055] 40.0%—water
[0056] 0.3%—Phenylalanine
[0057] 1.0%—benzocaine
Formula #8
[0059] 1.0%—methyl paraben
[0060] 25.0%—Water
[0061] 0.3%—methyl salicylate
[0062] 25.0%—ethanol
[0063] 0.3%—sodium saccharin
[0064] 1.0%—lidocaine
[0065] 47.4%—propylene glycol
[0000] The above example formulas are sufficiently adequate over one or multiple applications to destroy or limit the growth of pathogens in the oral environment.
[0066] A typical procedure of events during a routine periodontal treatment regime would be to first identify areas of greatest infection. These areas would be selected for greatest exposure to radiant energy. Referring to FIG. 4 , the radiant energy source would be focused into these infected pockets by means of a thin fiber optic guide 40 , the fiber optic guide being small enough to be directed between the teeth and gums. The periodontal pocket 20 is then radiated with radiant energy while the optical fiber 40 is moved in increments around the gums 10 . As illustrated in FIG. 5 , once the treatment of the gums by radiant energy is complete, the periodontal pocket 20 is flushed with an antimicrobial fluid 46 by means of a small tip 42 attached to a syringe 44 . The treatment regime may include multiple treatments, the number of which depends on the degree of infection present. The treatment regime usually continues until the pocket 20 has filled in substantially from its state of periodontitis. Following the filling in of the pocket 20 , a regime of sulcular disinfection may be continued until swelling and redness of infected gums is no longer apparent and only pink healthy gums persist.
[0067] The treatment regime can also begin by flushing the periodontal pockets with antimicrobial agents, followed by radiating with radiant energy. This would allow any additional anisthetic contained in the antimicrobial agent to anesthetize the working area prior to receiving radiant energy, and may prove particularly helpful and beneficial where substantial or repetitive ablation occurs during the process of laser curettage.
[0068] In yet a further embodiment of the present invention, a 1% chlorhexidine gluconate irrigation solution is used in conjunction with an 810 nm diode laser. The solution may contain a mild anesthetic and, if desired, be flavored. The solution is delivered using a syringe having a capacity of about 1 cc, although larger or smaller syringes may be used. The above described irrigation solution is designed for irrigation into the periodontal pockets prior to their being irradiated with the 810 nm laser light. The synergistic application of this broad-spectrum anti-microbial solution in conjunction with 810 nm laser light provides an excellent treatment in the control of early-stage periodontal disease—e.g., the gingivitis stage. Indeed, independent research by the inventors indicates that when treatment of early-stage periodontal disease using the combined irrigation solution and 810 nm laser is performed, the combination provides an increase in the kill rate of an isolated strain of bacterium—e.g., streptococcus mutans —by 11% over chlorhexidine solution alone.
[0069] In a yet further embodiment of the present invention—referred to herein as laser curettage—the following steps are performed leading to successful treatment of early-stage periodontal disease. First, the pocket depths are established using a periodontal probe. The pockets are then flooded throughout the entire pocket arch using the irrigation solution above described. Excess solution is then removed using a typical dental suction apparatus. The pockets are then irradiated with an 810 nm diode laser apparatus having a power output set from between about 1.0 to about 5.0 Watts or, more preferably, from between about 2.0 to about 4.0 Watts. Referring now to FIG. 6 , in one embodiment, the laser apparatus 100 includes a fiber optic cable 101 surrounded by a cladding layer 102 . A length 104 of the cladding layer 102 about 1-2mm greater than the measured pocket depth is then stripped and cleaved from the fiber of the laser apparatus 100 to form a bare fiber optic portion 106 . The stripped and cleaved portion 106 of the fiber 101 is then inserted into the periodontal pocket, where the bare fiber optic portion 106 lightly contacts the sulcus lining just inside the crest of the gingiva 108 while resting against a tooth 110 . Using very light pressure, the lasing commences using short paint brush-like strokes around the circumference of the tooth with the laser energy being directed at infected or inflamed tissue 115 with sufficient intensity to ablate the infected or inflamed tissue.
[0070] This process will create a small trough between the tooth and gingiva. The suction apparatus or sterile cotton gauze or the like is then used to remove or extricate tissue from the treatment area or tissue that attaches to the fiber. The treatment is repeated over the entire arch. Upon completion, the pockets of entire arch are again flooded with the irrigation solution. The treatment may be repeated on a monthly basis until recovery is complete. In a yet further embodiment, patients with advanced periodontal disease are treated with an interim sulcular disinfection treatment, one embodiment of which is described below, which is performed intermittently between periodic treatments using the laser curettage routine.
[0071] In an even further embodiment of the present invention—referred to herein as sulcular disinfection—the following steps are performed leading to successful treatment of early-stage periodontal disease. In a further embodiment, the same or similar steps may be performed intermittently with or following treatment by laser curettage. First, the pocket depths are established using a periodontal probe. The pockets are then flooded throughout the entire pocket arch using the irrigation solution above described. The pockets are then irradiated with an 810 nm laser apparatus having a power output set from between about 0.1 to about 0.5 Watts or, more preferably, from between about 0.2 to about 0.4 Watts. Referring now to FIG. 7 , in one embodiment, the laser apparatus 200 includes a fiber optic cable 201 surrounded by a cladding layer 202 . A length 204 of the cladding layer 202 approximately equal to the measured pocket depth is then stripped and cleaved from the fiber optic cable 201 of the laser apparatus 200 to form a bare fiber optic portion 206 . The stripped and cleaved portion of the fiber is then inserted into the periodontal pocket, where the bare fiber optic portion 206 lightly contacts the sulcus lining just inside the crest of the gingiva 208 while resting against the tooth 210 . Using very light pressure, the lasing commences using short paint brush-like strokes around the circumference of the tooth, with the laser energy being directed at infected or inflamed tissue 215 with sufficient intensity to destroy pathogens. Each tooth should receive an average of 15 seconds of laser treatment time. Problematic areas may be lased for longer treatment times. Areas of increased infection may be lased for 20-25 seconds per tooth. The treatment just described is repeated over the entire arch. Upon completion, the pockets over the entire arch are flooded again with the irrigation solution. The treatment is preferably repeated on a bimonthly to monthly regimen. If the patient overall shows little to no periodontal improvement within 3-4 scheduled treatments then the following additional embodiment of treatment should be performed.
[0072] Although the present invention has been described with reference to preferred embodiments, numerous modifications and variations can be made and still the result will come within the scope of the invention. No limitation with respect to the specific embodiments disclosed herein is intended or should be inferred.
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Laser ablation is used in curettage to treat periodontal disease. After an initial step of ablating afflicted tissues, an anti-microbial rinse is applied. A flexible fiber optic guide is the preferred means of directing radiant energy to the afflicted tissues. Sulcular disinfection may also be achieved by similar associated processes. Various anti-microbial agents and laser sources are disclosed.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to automatic identification of articles by means of attached tags, enabling non-contact automatic identification. In particular, the invention relates to identification of probe cards in a semiconductor integrated circuit manufacturing environment.
2. Discussion of the Related Art
In a factory environment, tracking the progress of product lots is often required in order to know where a particular lot is and what processing has been performed on that lot. An example is in the processing of lots of semiconductor wafers into integrated circuits.
Preferably, this tracking is computer controlled, and performed automatically. Systems exist whereby all processing machinery is connected by a communications link to a central computer, which then stores information on the process steps that have been performed on each product lot. Data on lot progress may be entered by a machine operator. Alternatively, and preferably, a system of automatically identifying lots using tags is used. For example, radio transponder tags may be encapsulated into boxes containing semiconductor wafers. Although commonly known as `radio transponder tags`, communication to and from the tags is performed using a modulated magnetic field, rather than radio transmission.
Boxes containing the transponder tags are passed in proximity to magnetic coupling antennae, which read information from the tags.
FIG. 1 shows such a system. A box 10 containing wafers 20 has arrived at a work location 25, such as an oven 30. A transponder tag 40 is integrated into the box. The tag is normally a cylindrical glass capsule, about 20 mm×4 mm×4 mm, which contains a non-volatile memory, holding an identification symbol, a small magnetic coupling antenna and control circuitry. The tag is powered by an externally applied magnetic field. The non-volatile memory is typically EEPROM. The ;control circuitry allows reading and, possibly, writing of the memory contents.
Upon arrival at the work location 25, the box 10 passes in proximity to a magnetic coupling antenna 50. The arrival of the box may be automatically detected, or signaled by operator input. A master controller 60 causes an interrogating signal to be emitted by antenna 50. In response to the interrogating signal, the transponder tag 40 emits an identification signal, containing the identification symbol. The identification signal is received by antenna 50, decoded by the master controller 60, and transmitted over a communications network 70 to a central computer 80. The master controller 60 may also emit an identification symbol of its own to the central computer, in the same transmission. The transponder tag's identification symbol typically contains a sequence of, for example, 8 bytes, indicating that the tag is in a box, and including a box identification number. The central computer 80 is programmed with a relationship between each box identification number and the lot number of the wafers 20 in the corresponding box. Thus, the central computer receives a message such as "Box 153A6 at work location 25", which it easily interprets as "Product type ST16243, Lot No. AG94, arrived at oven 30". Similar arrangements are made at other work locations 85,. 95, 105. Several antennae may be installed on one machine, all connected to a same master controller, to monitor the progress of a lot through the machine.
Optionally, at each work location, an operator input/output data terminal 106 may be installed, and connected to master controller 60. The machine operator may wear a badge 108 or a bracelet 109, carrying a transponder tag. This will be read by master controller 60, using antenna 50, to ensure that the person about to operate the machine is a qualified operator.
It is thus easy for computer 80 to control the progress of product lots through the factory.
In a semiconductor manufacturing environment, many different types of integrated circuits are produced concurrently. All are produced on identically sized wafers, contained in boxes of identical appearance. It is imperative that the correct processing is applied to each lot of wafers, corresponding to the required integrated circuit product. As the central computer knows which lot is awaiting processing on which machine, it can automatically load processing instructions customized to that particular lot onto that machine. If a lot arrives at a work location out of sequence, or has already been processed at that location, an alarm may be activated.
Such lot monitoring systems for semiconductor fabrication applications are marketed, by Fluoroware Inc., under the name `Fluorotrac`, which includes an identification system from Texas Instruments sold under the name `TIRIS`. Typically, in such applications, the communications are performed in a frequency band just below 150 kHz, although other frequencies could be used.
Identifiers other than transponder tags may be used, but have drawbacks. Bar-code and optical character recognition (OCR) systems allow cheap tags to be used, but require careful orientation of the tag on an object, and of the object itself, to allow reading. Readers of bar-codes, and OCR readers are bulky. Such bar-code and OCR tags may become illegible after long service life.
Infra-red emitters require a battery to be included in the tag, which needs to be replaced at regular intervals.
Small, electrically powered modules may be used, but these require direct electrical connection to be made to read the identification symbol. The orientation of the object during read operations becomes critical. Corrosion of exposed electrical contacts is also likely in an industrial environment.
The transponder tag is relatively omnidirectional, and so is indifferent to object orientation. The transponder tags are sealed, and usually embedded in the objects which they identify, require no maintenance, and should not degrade with time or exposure to harsh environments. They do not require a battery.
FIG. 2 shows a probing work location. This may correspond to work location 105 of FIG. 1. Here, completed or partially completed wafers are electrically tested.
A prober, controlled by a host computer (not shown) comprises test instruments (also not shown), connected to a test head 110 and a platen 120 which defines the range of movement of a chuck 130, provided with wheels 132 or propelled by a linear motor. The chuck carries a wafer under test 140. Above the platen 120, a support 150 includes a hole 152. At the lower extremity of hole 152, a support ring160 protrudes into the hole 152. A probe card 170 is supported by the support ring 160. The probe card itself may have a circular hole 172 in its center, with probe pins 180 protruding down through hole 172. Alternatively, the probe card 170 may have no hole, and have probe pins 180 suitably attached to the underside of the probe card. The chuck 130 moves the wafer under test 140 horizontally and vertically, to bring selected contact pads on the wafer into electrical contact with probe pins 180.
An annular sprung contact ring 190 is placed above the probe card 170, and is held *in place by an annular clamping ring 200. The test head 110 is above, and brought into proximity with the sprung contact ring l90. Sprung contact pins 205 are embedded in the sprung contact ring 190. These sprung contact pins 205 protrude from each planar surface of the sprung contact ring 190. Pairs of sprung contact pins 205, placed directly opposite each other, one on each planar surface of the sprung contact ring 190, are electrically connected together. These pairs of sprung contact pins 205 serve to electrically connect together pads on the probe card 170 and corresponding pads on the test head 110, to allow test signals to be passed to the wafer under test 140, under control of the host computer.
When a probe card with a hole is in use, the hole in the sprung contact ring 190 allows a visual check of the alignment of probepins 180 to contact pads on the wafer under test 140 to be made, using a microscope 207 installed through the test head 110. Use of probe cards with no hole requires arrangements to be made to view the probes from below the probe card.
As described above, a lot of wafers 20 arriving at the probe work location 105 is identified by tag 40 in the box 10, by master controller 60, using antenna 50.
During probing operations, the probe pins 180 are brought repeatedly into contact with the wafer under test. This causes wear to the probe pins, which are very fine. Each probe card must therefore be serviced after a certain number of wafers have been tested.
As different integrated circuits are of different sizes, the number of test operations per wafer will depend on what integrated circuit is present on the wafer. Each different integrated circuit requires a specific test program, to test the specific functions of that circuit. The pattern of contact pads may be specific to the circuit under test.
Thus, before attempting to test a wafer, one must be sure that:
1. the correct probe card 170 is installed on the prober;
2. the correct test program is about to be run; and
3. the probe card 170 is not yet due for servicing.
At least the first and third of.these requirements are usually checked by an operator, who enters data into the host computer indicating the type of integrated circuit to be tested, and a probe card identification, as written on the probe card 170. This system is imperfect, as it is often difficult to read the card identification when the card is already installed on the machine. Operators may erroneously enter a particular card identification, even though a different card may actually be installed.
Outfitting existing probers with the alternative identification apparatus to transponder tags described above has drawbacks:
the infra red emitters and the required receivers are relatively bulky, and so will not fit into the available space; they require batteries to be included, which need to be regularly replaced (although it could be possible to provide a power supply via certain sprung contact pins 205);
electrically powered modules require relatively complex reading arrangements, may require modifications to be made to the prober and/or the test head, and may be too large to fit in the available space;
bar code and optical character recognition systems, although providing inexpensive tags, require large readers which will not fit into the available space.
Although transponder tags 40 are very small, the magnetic coupling antennae 50 required are relatively large. An antenna cannot be placed at a distance from the probe card, as the card is encased by test head 110 and support 150, which. are typically metal, and which would block a modulated magnetic field. There is also not enough space under support 150 to install an antenna, as this would risk collision with the moving chuck 130.
It is therefore desired to devise an automatic probe card identification system. This would operate in conjunction with the above described, known, system for identifying boxes.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a system for identifying probe cards, using transponder tags attached to the probe cards, and which requires no substantial modification to existing probers.
Another object of the present invention is to provide a magnetic coupling antenna usable in conjunction with existing probers and transponder tags to enable the automatic identification of probe cards, in a manner compatible with known transponder tag based lot identification systems.
Another object of the current invention is to provide such a system which is relatively inexpensive to implement.
Another object of the present invention is to provide an automatically identifiable probe card, compatible with such systems.
Another object of the present invention is to provide such a system which is compatible with existing transponder tag based systems.
Accordingly, the invention provides a system for identifying probe cards, including a prober which accepts a number of interchangeable probe cards, including: a probe card carrying a transponder tag; a magnetic coupling antenna supported above the probe card when it is in use, the transponder tag being substantially located within a magnetic field generated by the magnetic coupling antenna; and circuitry connected to the magnetic coupling antenna for receiving signals emitted by the transponder tag, for deriving data therefrom, and for communicating-the data to a central computer which holds information on the probe cards in a memory.
According to an embodiment of the invention the magnetic coupling antenna comprises a coil of wire wound onto an armature, shaped as a partial toroid, having two ends and a gap between the two ends.
According to an embodiment of the invention, the prober also includes a sprung contact ring held vertically above the probe card, the antenna being retained within a magnetically inert carrier, supported in a hole in the sprung contact ring.
According to an embodiment of the invention, the antenna comprises an armature in the form of a partial toroid, having a coil of wire wound thereon.
BRIEF DESCRIPTION OF THE DRAWINGS
Particular embodiments of the present invention are explained below, by way of example only, with reference to the accompanying drawings, wherein:
FIG. 1 shows an automatic lot control system of the prior art;
FIG. 2 shows a prober of the prior art used in conjunction with the system of FIG. 1;
FIGS. 3A and 3B show a probe card, modified according to one aspect of the invention, in plan and elevation. respectively;
FIG. 4A shows an antenna, according to an aspect of the invention;
FIG. 4B shows a cross section of a sprung contact ring, modified according to an aspect of the invention, to include the antenna of FIG. 4A;
FIGS. 5A and 5B show the prober of FIG. 2, modified according to the invention; and
FIG. 6 shows an alternative embodiment of the invention, as applied to the prober of FIG. 2.
DETAILED DESCRIPTION
As can be appreciated from FIG. 2, the space available for installing apparatus in proximity to probe card 170 is very limited.
Referring to FIG. 2, sprung contact ring 190 is annular. It contains a cylindrical hole 192, shaded in the diagram. This hole is typically 50 to 80 mm in diameter, and the sprung contact ring 190 is typically about 20 to 30 mm thick. The total distance between the test head 110 and the probe card is typically about 30 to 50 mm.
FIGS. 3A and 3B show, in plan and elevation, respectively, a probe card 170, modified according to an aspect of the invention to carry a transponder. tag 40'. The probe card has a circular hole 172 at its center, which is concentric with the hole in the sprung contact ring 190, when the card is in use. The probe pins 180 are soldered to the upper surface of the probe card, around hole 172. To allow efficient communication, the transponder tag 40' is placed away from metallic objects, such as the probe pins. This is achieved by mounting a small carrier 220 across hole 172 in probe card 170, and attaching the tag 40' thereto. The carrier 220 is typically a small piece of thin board, such as epoxy or bakelite, held by pins 222 attached at one end to probe card 170, and at the other end to carrier 220. The pattern of these pins may be specific to each probe card, to prevent transponder tags from being moved from one probe card to another during servicing. The use of carrier 220 allows the transponder tag to protrude into the hole in sprung contact ring 190, when the probe card 170 is installed in the prober.
For probe cards having no hole, the transponder tag may be mounted on the top side of the probe card, either directly, or on a carrier.
FIG. 4A shows a magnetic coupling antenna 230 according to an aspect of the invention. It comprises a coil 231 of wire, wound onto a ferrite or metallic armature 232 shaped as a partial toroid. This is contained within a suitable support 235, such as a cylindrical tube of plastic, or other magnetically inert material. The two extremities of the coil 231, 240, 245 are kept free. The antenna 230 is designed to operate efficiently as a transmitter and receiver of a modulated magnetic field at the frequency required by transponder tag 40'. The shape of the armature 232 is designed to channel a magnetic field generated by coil 231 to produce an optimum coupling and energy transfer from the coil 231 to the transponder tag 40'. The exact nature of the material of the armature will be selected according to the frequency operating range. The external diameter, of the support 235 is less than the diameter of the cylindrical hole in the sprung contact ring 190.
FIG. 4B shows a cross-section of a sprung contact ring modified according to the invention. The support 235 of FIG. 4A is enclosed within the cylindrical hole 192 of the sprung contact ring 190. The height of the support 235 may extend beyond the thickness of sprung contact ring 190. The support 235 preferably extends beyond the coil 231 and armature 232 to facilitate handling and storage. A filling 250 of epoxy resin or other suitable adhesive may be used to retain the support 235 within the sprung contact ring 190. Arrangements may be made to connect the extremities of the wire 240, 245 to two of the sprung contact pins 205.
FIGS. 5A and 5B show the probe Work location 105 of FIG. 2, with the prober modified according to the present invention. Probe card 170 carrying transponder tag 40' is installed below sprung contact ring 190, itself carrying a magnetic coupling antenna 230. The radio transponder tag 40' lies within or below the gap in the armature 232. The extremities of wire 240, 245 may be brought out directly to communicate with a master controller in the same way as a standard antenna 50, as shown in FIG. 5A, or (preferably), two sprung. contact pins 205a, 205b are dedicated to connecting the antenna coil 231 to the test head 110, and further connections are made from the test head 110 to the master controller 60, as shown in FIG. 5B. The small carrier 220 raises the transponder tag 40' into the magnetic field of the armature 232, itself mounted on sprung contact ring 190, to ensure a good magnetic coupling between the coil 231 and the tag 40'.
FIG. 6 shows an alternative arrangement using a, probe card with no hole. Probe pins 180 may themselves be attached to a small carrier 255, attached to the underside of the probe card 170. As in FIGS. 3A and 3B, the transponder tag 40' is attached to a carrier 220 on pins 222. The transponder tag 40' is then held within the magnetic field of the armature 232.
No modifications need to be made to the prober or the probe card 170, other than attaching the support 222 and the tag 40' as described. This may be simply done using epoxy resin or other suitable adhesive.
Using the probe card and the sprung contact ring described above, the system of FIG. 1 may be extended to control the supply and servicing of probe cards. The transponder tag 40' on the probe card 170 may be programmed to contain an identifier that it is a probe card, and a unique identification code. Alternatively, it may just contain a number, and the fact that it is a probe card will be known to the master controller 60 by the fact that its identification symbol is read by antenna 230. As with box identifiers, the central computer 80 is programmed with the correspondence between the identification code in the tag and the actual probe card name. Alternatively, the actual probe card name may be directly programmed into the tag.
When a lot of wafers 20 arrives at the probe work location 105, the arrival of the box 10 is signaled automatically or manually to master controller 60. The master controller then sends interrogation signals to antennae 50 and 230 (and maybe others). As before, it will receive back from the tag in the box 10 "Box 153A6", an identifier for the machine operator if a provision for operator identification is made (Such as "Operator 2725"), and an identifier from probe card 170, as received by antenna 230, such as "Probe Card A167"
These identifiers, are transmitted to the central computer 80 by master controller 60, which adds its own identifier "Work location 105". The central computer easily interprets this as "John Smith is about to load lot No. AG94 of product ST16243 onto probe station 105, using probe card ST16--3".
Thus, the central computer can ensure that the correct test program is loaded into the prober's host computer, that the correct probe card is installed, and it can count the number of times the card has been used since it was last serviced. If the card is due for a service soon, this may be communicated to the machine operator by means of a data terminal, a lamp or audible alarm. If the card's service becomes overdue, the central computer can forbid the prober to work with that probe card.
The factory's maintenance department will have access to a data entry terminal where they can update the servicing records, and allow the probe card to be used again, after being serviced. Similarly, if a probe card becomes damaged in use, this data can be entered to the central computer, and the card be forbidden for use until it has been serviced.
Thus, the present invention achieves the objectives, of:
providing a system for identifying probe cards, using transponder tags attached to the probe cards, which requires no substantial modification to existing probers;
providing such a system which is relatively inexpensive to implement;
providing an automatically identifiable probe card, compatible with such a system;
providing a magnetic coupling antenna usable in conjunction with existing probers; and
providing such a system which is compatible with an existing transponder tag based lot control system.
Other types of probers are in use, which use probe cards with edge connectors. In such cases, no sprung contact ring is present. However, the advantages of the invention may also be achieved in such cases by ensuring that the gap in the armature of the antenna is located above a transponder tag installed on the probe card. Again, the use of a hollow cylindrical support has the advantage of fitting easily into the prober. Use of a partially toroidal armature allows uninterrupted visual alignment checking, using a microscope. Other types of coil support may be used, or the coil and its armature may be directly attached to the prober.
Having thus described at least one illustrative embodiment of the invention, various alterations, modifications, and improvements will readily occur to those skilled in the art. Such alterations, modifications, and improvements are intended to be within the spirit and scope of the invention. Accordingly, the foregoing description is by way of example only and is not intended as limiting. The invention is limited only as defined in the following claims and the equivalents thereto.
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A system for identifying probe cards including a prober which accepts a number of interchangeable probe cards, each carrying a transponder tag; a magnetic coupling antenna supported above the probe card when it is in use, the transponder tag being substantially located within a magnetic field generated by the magnetic coupling antenna; and circuitry connected to the magnetic coupling antenna for receiving signals emitted by the transponder tag, for deriving data therefrom, and for communicating the data to a central computer which holds information on the probe cards in a memory.
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This application is a continuation-in-part of my prior-filed copending application Ser. No. 073,908, filed Sept. 10, 1979, now U.S. Pat. No. 4,298,614, issued Nov. 3, 1981.
BACKGROUND OF THE INVENTION
1. Field of the Invention
Chemical compounds, photochemotherapy, compounds having an enhanced combination of photosensitizing properties for use in photochemotherapy, selective photosensitizing agents.
2. Prior Art
Psoralens have been used for years as dermal photosensitizing agents, e.g., in the treatment of vitiligo. Their topical and/or oral application, followed by irradiation with light, results in stimulation of melanin, thus producing a tanning effect. They have accordingly also been used for such cosmetic purpose. More recently, psoralens have been found useful in the photochemotherapeutic treatment of psoriasis, in which case they are administered orally or topically to the subject, whose skin is subsequently exposed to controlled ultraviolet radiation, as in Psoralite (TM) apparatus. A high percentage of emissions of this disease have been effected in such manner.
The effectiveness of a psoralen for such uses and for such purpose has in the past related to its ability to produce erythema upon the skin upon irradiation. Psoralens also have other uses, and their uses, as well as underlying rationale and theory, are partially elucidated in U.S. Pat. Nos. 4,124,598 and 4,130,568, and are otherwise well-known in the art from various preexisting publications.
Rather recently, it has been found that the erythema, produced upon the skin of a patient or animal upon irradiation with ultraviolet light "A" in a so-called PUVA evaluation or application, after administration of psoralen to the subject, is associated with the linear structure of psoralens. This makes it possible for psoralens to engage in photocycloaddition reactions with double bonds of pyrimidine bases of macromolecules, such as present in the complementary strands of DNA (deoxyribonucleic acid), in a manner such that two double bonds of the psoralen compound react so as to produce two (2) cycloadditions with two (2) separate molecules of the pyrimidine base, as present in the complementary strands of DNA, thereby forming an interstrand crosslinkage. Such interstrand crosslinkages occur in photoreactions between highly erythematic linear psoralens and DNA. On the other hand, some psoralens, because of their angular structure, can engage, for geometric reasons, only one of the two photoreactive sites, thus effecting a single cycloaddition to only one of the two complementary strands of DNA with consequent production of a monofunctional adducts. In other words, psoralen compounds in the photoreaction with DNA can form either or both of monofunctional and bifunctional adducts, and this capacity varies with the type of psoralen compound involved, some compounds forming essentially only monofunctional adducts, whereas other compounds form solely or a preponderance of bifunctional adducts or interstrand crosslinkages. The ability or capacity to form only monofunctional and not bifunctional adducts, or at least minimization of bifunctional cycloaddition or bifunctional adduct formation, is now considered desirable from the standpoint that the consequences deriving from bifunctional damage are considered to be more serious from a biological repair standpoint than the consequences deriving from monofunctional cycloaddition or adduct effects. This means that it is at least no longer considered necessary that a compound exhibit strong bifunctional effects, as evidenced by a high degree of erythema in usual test procedures, for it to be useful in photochemotherapy, but that it is even preferred for it to produce monofunctional adducts or a single cycloaddition without interstrand crosslinkage to DNA. Psoralen compounds which produce monofunctional adducts only, or at least in preponderance, have been found effective in the treatment of psoriasis and in producing other desirable effects, such as tanning, even though they do not cause interstrand crosslinkages and consequent erythema. Such unique properties therefore constitute desirable and much sought after criteria or desideratum in the evaluation of photosensitizing compounds but, as already stated, up until the present time such psoralen compounds as produce monofunctional DNA adducts have been angular in their nature, such as some isopsoralens (or angelicins). However, the compounds of the present invention, despite their linear structure, for unknown reasons, are characterized by inability to crosslink DNA molecules and cause erythema, while nevertheless possessing ability to cause DNA monoaddition and production of monofunctional adducts, a totally unpredictable combination of characteristics for linear psoralen compounds. Further, linear psoralens are also characterized by established and recognized reactivity with ribonucleic acids (RNA), and accordingly the new psoralen compounds find use in the study of secondary structures of nucleic acids, as inhibitors of RNA replication, and in the inactivation of viruses, as well as in the photochemotherapy of psoriasis and in suntanning, all important uses.
The standard tests and test procedures, and their significance, are fully elucidated in the following publications: F. Dall'Acqua, S. Marciani, G. Rodighiero: Interstrand crosslinkages occurring in the photoreaction between psoralen and DNA. FEBS letters 9, 121 (1970); F. Dall'Acqua, S. Marciani, L. Ciavatta, G. Rodighiero: Formation of interstrand cross-linkings in the photoreactions between furocoumarins and DNA. Zeitschrift Naturforsch. 26b, 561 (1971); Baccichetti et al., Z. Naturforsch. 34c, 811-814 (1979); Bordin et al., Biochimica et Biophysica Acta 447, 249-259 (1976); Baccichetti et al., Experientia 35, 183 (1979); and see U.S. Pat. Nos. 4,124,598 and 4,130,568, as well as Hearst et al., Nucleic Acids Res. 1977, 4(5), 1339-1347; Isaacs et al., Biochemistry 1977, 16(6), 1058-1064; Shen et al., J. Mol. Biol. 1977, 116(4), 661-679; and Johnson et al., Science 1977, 197(4306), 906-908.
The unique linear psoralen compounds of the present invention then, which possess the characteristic, when employed in PUVA therapy, of forming only monofunctional adducts or essentially so, without concurrent interstrand DNA crosslinkages or erythema, thus finding employment and use in the foregoing manners, particularly in the photochemotherapy of tanning and psoriasis, should be welcome additions to the physicians' armamentarium of useful drugs.
OBJECTS OF THE INVENTION
It is an object of the invention to provide novel psoralen compounds. It is a further object to provide novel psoralen compounds of unique structure which have a beneficial or enhanced combination of characteristics when compared with psoralen compounds of similar but different structure. It is an additional object to provide novel psoralen compounds having beneficial or enhanced photosensitizing characteristics in accord with the foregoing stated criteria. It is a still further object to provide novel psoralen compounds having beneficial or enhanced photosensitizing characteristics, relatively low toxicity, and of a structure differing essentially from known psoralen compounds, the beneficial combination of properties of which could not be predicted on a basis of known structure-activity relationships. Still other objects will be apparent to one skilled in the art and still additional objects will become apparent hereinafter from the following description and claims.
SUMMARY OF THE INVENTION
The present invention relates to 5'-aminoalkyl-4'-alkylpsoralens having beneficial or enhanced photosensitizing activity, especially oral activity, as well as low toxicity, when compared with psoralens of similar but different structure. It is particularly concerned with 5'-primaryaminoloweralkyl-4'-loweralkylpsoralens, and especially 5'-aminomethyl-4'-methylpsoralen and salts thereof. It is to be noted that the compounds of this invention have no eight (8) carbon atom methyl or methoxy substituent as in the prior art compounds trisoralen (4,5',8-trimethylpsoralen), 8-methoxypsoralen, or the compounds of U.S. Pat. Nos. 4,124,598 or 4,130,568. Despite this fact, and the fact that they are characterized by essential absence of DNA crosslinking and/or erythematic photosensitization activity, they are characterized by DNA-binding (monocyloaddition or monofunctional adduct production) which approaches that of 8-methoxypsoralen, a widely-recognized and commonly-employed photosensitizing agent. These new compounds are therefore characterized by surprising and unpredictable selective photosensitization activity, i.e., DNA-binding activity without concurrent erythematic activity, according to the aforesaid criteria, as well as a relatively low toxicity.
The compounds of the invention have the formula ##STR1## 5'-primaryaminoloweralkyl-4'-loweralkylpsoralen, wherein loweralkyl is preferably methyl.
DETAILED DESCRIPTION OF THE INVENTION
The following Preparations and Examples are given by way of illustration only and are not to be construed as limiting.
The appropriate starting 7-hydroxycoumarin is a well-known compound which can be prepared in known manner and converted to psoralens by known procedure (MacLeod and Worth, Tetrahedron Lett., 237-240(1972)). Variations in the alkylhalomethyl ketone reactant produces variations in the alkyl group at position 4' of the resulting psoralen as will appear more fully hereinafter, especially from the Examples which follow. Chloroalkylation with a selected chloroalkyl methyl ether introduces a desired chloroalkyl group into the 5' position of the 4'-alkylpsoralen nucleus, whereafter reaction with potassium phthalimide followed by cleavage with hydrazine acetate yields the desired 5'-aminoalkyl-4'-alkylpsoralen, in which the various alkyl groups correspond to those in the reactants employed in converting the starting 7-hydroxycoumarin, namely, the alkylhalomethyl-ketone (4' position) and the chloroalkylating agent (5' position) employed. Alternatively, the haloalkylation may be effected according to Olah and Kuhn, J. Org. Chem. 29, 2317 (1964) or Friedel-Crafts and Related Reactions, Vol. II, Part 2, G. A. Olah, ed., Interscience, New York, New York, 1964, page 749. The structure of the final 5'-aminoalkyl-4'-alkylpsoralen is confirmed by nuclear magnetic resonance spectra, using a Perkin-Elmer Model R-24B.
Thin layer chromatography (TLC) was performed on Silica Gel GF 254 glass-backed slides, 250 microns thick, manufactured by Analtech, Inc. The eluent was benzene:2-butanone::17:3 unless otherwise indicated. NMR spectra were run on Perkin-Elmer Model R-24B. Melting points were taken on either a Fisher Digital Melting Point Analyzer, Model 355, or on a Thomas Hoover Capillary Melting Point Apparatus. All melting points are uncorrected.
5'-AMINOMETHYL-4'-METHYLPSORALEN
7-Acetonyloxycoumarin.
A mixture of potassium iodide (1.0 g, 6 mmol), chloroacetone (28.43 mL, 33.03 g, 0.357 mole) and reagent grade acetone (400 mL., dried over K 2 CO 3 ) was allowed to stand overnight. 7-Hydroxycoumarin (50.0 g, 0.308 mol), anhyd. K 2 CO 3 (49.34 g, 0.357 mole), and dry reagent grade acetone (1 L) were added and the mixture was refluxed for about 24 hours with overhead stirring and protection from atmospheric moisture (Drierite-TM tube). The hot reaction mixture was filtered and the precipitate was washed with two portions (200 mL) of dry reagent grade acetone. The filtrate and washes were combined and evaporated in vacuo to obtain a first crop. A mixture of the precipitate and water (1 L) was extracted with two portions (700 mL) of trichloromethane, which were combined, dried (MgSO 4 ), and evaporated in vacuo to obtain more product. A trichloromethane (CHCl 3 ) solution (3 L) of the two crops was washed once with 5% aqueous NaOH (1 L), and then three times with water (1 L), dried (MgSO 4 ), and evaporated, in vacuo to obtain crude 7-acetonyloxycoumarin (64.65 g, 96%), mp 168.2°-169.9° C., which was suitable for use in the next step. Recrystallization of a portion from 95% ethanol gave a purer sample (85.3% recovery, 82% yield), mp 174.6°-174.8° C. (previous run: mp 166.9°-167.1° C.) The NMR (CDCl 3 ) spectrum was identical to that obtained in the previous run.
4'-Methylpsoralen.
A stirred (overhead) mixture of 7-acetonyloxycoumarin (crude, 61.92 g, 0.284 mole) and 0.1 N aqueous potassium hydroxide (3.3 L) was heated under gentle reflux for six hours, allowed to cool to room temperature, and acidified with 1.0 N hydrochloric acid (about 500 mL). A yellow precipitate was collected by filtration, washed with water until free of acid, and placed in CHCl 3 (3 L). After removal of a brown, NaHCO 3 -soluble solid, the CHCl 3 solution was washed with two portions (2 L) of saturated aqueous NaHCO 3 , once with water (2 L), and dried (MgSO 4 ). Evaporation in vacuo yielded crude 4'-methylpsoralen (36.09 g, 63.5%), mp 187.4°-189.1° C. Recrystallization gave a purer product (78% recovery, 50% yield), mp 194.3°-195.2° C. (previous run: 187.1°-187.7° C.). NMR (CDCl 3 ) δ2.25 (d, 3, J≅1 Hz, 4'-CH 3 ), 6.26 (d, 1, J=9 Hz, C 3 H), 7.27 (s, 1, C 8 H), 7.36 (d, 1, J≅1 Hz, C 5 , H), 7.47 (s, 1, C 5 H), 7.70 (d, 1, J=9 Hz, C 4 H).
5'-Chloromethyl-4'-methylpsoralen.
Chloromethyl methyl ether (75 mL, 988 mmol) was added to a solution of 4'-methylpsoralen (8.612 g, 43 mmol) in glacial acetic acid (600 mL) and the solution was stirred at room temperature for 24 hours. Another portion (75 mL) of chloromethyl methyl ether was added and stirring was allowed to continue for another forty hours, although crystallization began to occur after a total reaction time of about forty hours. Water (3.75 L) was added and a cream-colored precipitate was collected by suction filtration, washed with water, and dried in vacuo to obtain 5'-chloromethyl-4'-methylpsoralen (7.60 g, 71%), mp 181.7°-182.9° C. An analytical sample of colorless needles, mp 183.9°-184.8° C., was obtained from a further run by filtering the reaction mixture before diluting it with water. NMR (CDCl 3 ) δ2.3 (s, 3, 4'-CH 3 ), 4.7 (s, 2, CH 2 Cl), 6.35 (d, 1, J=9 Hz, C 3 H), 7.35 (s, 1, C 8 H), 7.50 (s, 1, C 5 H), 7.75 (d, 1, J=9 Hz, C 4 H).
Anal. Calcd. for C 13 H 9 O 3 Cl: C, 62.79; H, 3.65; Cl, 14.26. Found: C, 63.07; H, 3.72; Cl, 14.23.
4'-Methyl-5'-phthalimidomethylpsoralen.
A mixture of 5'-chloromethyl-4'-methylpsoralen (7.618 g, 30.6 mmol), potassium phthalimide (6.80 g, 36 mmol), and dimethylformamide (500 mL) was stirred and heated at 100° C. for six hours. It was concentrated in vacuo to a cream-colored paste, diluted with water (400 mL), and filtered, the filtration rate being too slow to wash the precipitate. The slurry of precipitate and wash water was extracted with three portions (1 L) of CHCl 3 , which were dried (MgSO 4 ) and concentrated in vacuo to obtain 4'-methyl-5'-phthalimidomethylpsoralen (9.35 g, 85%). A fourth CHCl 3 extract (200 mL) yielded more product (0.663 g) after drying (MgSO 4 ) and evaporation in vacuo. The total yield was 10.013 g (91%), mp 261.5°-265.8° C., of material suitable for use in the next step. An analytical sample, mp 270°-270.5° C., was prepared by recrystallization from glacial acetic acid.
Anal. Calcd. for C 21 H 13 O 5 N: C, 70.19: H, 3.65; N, 3.90. Found: C, 69.88; H, 3,86; N, 3.73.
5'-aminomethyl-4'-methylpsoralen (E-120).
A mixture of 4'-methyl-5'-phthalimidomethylpsoralen (6.0 g; 16.7 mmol), absolute ethanol (1.2 L, not dried), glacial acetic acid (15.24 mL, 266 mmol), and 85% hydrazine hydrate (7.63 mL, 133 mmol) was heated under reflux for six hours and concentrated in vacuo to an off-white solid. HCl (1 F, 500 mL) was added, followed by NaHCO 3 (s) until the pH was ca. 8.0, and the mixture was extracted with three portions (500 mL) of CHCl 3 , which were dried (Na 2 SO 4 ), and concentrated in vacuo to obtain 5'-aminomethyl-4'-methylpsoralen (E-120) (2.945 g, 77%), mp 153.1°-156.3° C. Recrystallization from a benzene-ligroin (bp 94°-105°) solvent pair gave an analytical sample (73% recovery), mp 154.1°-156.1° C. NMR (CDCl 3 ) δ1.7 (br, s, 2, NH 2 , exchangeable with D 2 O), 2.25 (s, 3, 4'-CH 3 ), 3.95 (s, 2, CH 2 ), 6.31 (d, 1, J=9 Hz, C 3 H), 7.32 (s, 1, C 8 H), 7.46 (s, 1, C 5 H), 7.75 (d, 1, J=9 Hz, C 4 H).
Anal. Calcd. for C 13 H 11 O 3 N: C, 68.11; H, 4.84; N, 6.11. Found: C, 67.94; H, 4.85; N, 5.82.
5'-AMINOETHYL-4'-ETHYLPSORALEN.
In the same manner as given in the foregoing, but using ethylchloromethyl ketone and chloroethyl methyl ether in Steps 1 and 3, respectively, in place of chloroacetone and chloromethyl methyl ether, the title compound is produced.
5'-AMINOMETHYL-4'-PROPYLPSORALEN.
In the same manner as given in the foregoing, but using propylchloromethyl ketone in Step 1 instead of chloroacetone, the title compound is produced.
In the same manner as given in the foregoing, other variations in selection of starting materials are productive of still other 5'-aminoloweralkyl-4'-loweralkylpsoralens within the scope of the invention in which one or both of the loweralkyl groups present in the compound are varied. As used herein, the term "loweralkyl" comprehends such straight or branched radicals or groups having one to eight carbon atoms, preferably one to four carbon atoms, inclusive, such as methyl, ethyl, propyl, isopropyl, butyl, and the like.
When isolating compounds of the invention in the form of an acid addition salt, the acid is preferably selected so as to contain an anion which is non-toxic and pharmacologically acceptable, at least in usual therapeutic doses. Representative salts which are included in this preferred group are the hydrochlorides, hydrobromides, sulphates, acetates, phosphates, nitrates, methanesulphonates, ethanesulphonates, lactates, citrates, tartartes or bitartrates, and maleates. Other acids are likewise suitable and may be employed if desired. For example, fumaric, benzoic, ascorbic, succinic, salicylic, bismethylenesalicylic, propionic, gluconic, malic, malonic, mandelic, cinnamic, citraconic, stearic, palmitic, itaconic, glycolic, benzenesulphonic, and sulphamic acids may also be employed as acid addition salt-forming acids.
PHARMACOLOGY
The biophotosensitization activity of the compounds of the invention is minimal in the erythemal response test according to the procedure of Pathak and Fitzpatrick, J. Invest. Dermatol. 32, 509-518 (1959), entitled "Bioassay of Natural and Synthetic Furocoumarins (Psoralens)", and usually employed standard modifications thereof. As "biophotosensitization activity" is employed herein, however, as well as "photochemical sensitivity on the skin of a mammal", and "photosensitizing" or "photosensitization", as well as "photochemotherapy", the compounds of the invention are active biophotosensitizing agents inasmuch as they produce solely or at best a preponderance of monoaddition or monofunctional addition in the standard tests for DNA photoreactivity, said monofunctional addition being opposed to interstrand cross-linking, as explained in the foregoing. The compounds are thus clearly useful in the further study of reactions and secondary structures of nucleic acids and as inhibitors of RNA replication, and are indicated for employment in the inactivation of viruses as well as in the photochemotherapy of psoriasis and/or tanning by the PUVA procedure, in which they are found to be equally as effective as numerous previously-employed psoralen compounds, without the production of excessive erythema, if any, which is of course dependent upon numerous factors, such as amount of irradiation employed, dosage of the photosensitizing agent, mode of employment (whether topical or oral), and individual skin sensitivities of the mammal subjected to the PUVA therapy, including of course human beings, with respect to which psoriasis is a unique malady. The compounds are accordingly useful for all of the foregoing purposes, but particularly for effecting photochemical sensitivity on the skin of a mammal, these terms as employed herein not being restricted to the production of erythema thereon. They are effective both orally and topically, and the method of effecting photochemical-sensitivity on the skin of a mammal merely comprises the step of orally or topically administering to the said mammal an effective photosensitizing dose of a compound of the invention. When the subject is then exposed to ultraviolet radiation, more particularly ultraviolet "A", in the non-burning range, monofunctional adducts are formed, tanning occurs, and psoriasis is mitigated in human patients, as aforesaid. Other uses of the compounds of the present invention are also set forth in the foregoing.
ERYTHEMA
The erythematic activity of the compounds of the present invention was determined by visual grading of erythemal response according to a modification of the procedure of Pathak and Fitzpatrick, J. Invest. Dermatol. 32, 509-518 (1959), entitled "Bioassay of Natural and Synthetic Furocoumarins (Psoralens)". (The psoralens are of course "linear" isomers of the furocoumarin family.) According to this bioassay, erythema production on albino guinea pig skin is measured visually and the response accorded a gradation definition according to a 0, ∓, 1, 2, 3, and 4 scale. The modification employed involved variation of the time between administration of the test compound and exposure to ultraviolet light, thereby enabling measurement of times of onset and decline of the induced erythematic photosensitivity effect.
PROTOCOLS--ERYTHEMA
Each drug is tested orally by administering a dosage of forty (40) mgm/kgm of body weight to groups of fifteen female Hartley albino guinea pigs. The appropriate dosage for each animal is packed into a gelatin capsule and placed far back in the animal's pharynx. Swallowing is assisted by syringe delivery of one to three milliliters of water. The animals are not allowed to eat or drink six hours before and after administration of each product. The exposure of ultraviolet "A" radiation is for two (2) minutes at a dose of 1.14 joules per square centimeter at different times after administration, e.g., 10, 20, 30, 45, 60, 90, 120, 180, 240 minutes after administration. Readings and evaluations are carried out 48 hours post ingestion. Irradiations were made on depiliated regions of the mid-dorsal area of the back in discrete areas (0.5 cm 2 ) using adhesive tape templates. The rest of the animal was covered in black paper.
Gradation: Responses are graded as follows:
0 No response, ± faint erythema; 1+ erythema; 2+ erythema and slight edema; 3+ erythema and intense edema; and 4+ vesiculobullous reaction.
RESULTS--ERYTHEMA
The compounds of the invention show no oral erythematic activity as read at 48 hours. The compound 5'-aminomethyl-4'-methylpsoralen (E-120), made from 7-hydroxycoumarin as in the foregoing, shows no such erythematic photosensitizing response orally at any post-ingestion time, as read at 48 hours after ingestion for UVA applications at ten (10) through 240 minutes after ingestion, and a low order of oral toxicity at the dosage level tested. In contrast, the control methoxsalen (8-methoxypsoralen), at the same dose level, exhibits a 48-hour after ingestion erythema reading as follows, with the UVA application being at 10, 20, 30, 45, 60, 90, 120, 180 and 240 minutes after ingestion: 0, 0, 1+, 3+, 3+, 3+, 4+, 3+, 2+. The compound E-120 is therefore essentially inactive erythemically.
RESULTS--DNA BINDING
However, in the standard DNA-binding test (references given herein under "Prior Art"), identical amounts of the compound E-120 and 8-methoxypsoralen (8-MOP) exhibited substantially equivalent DNA-binding activity as follows:
______________________________________E-120 0.83 ± 0.48-MOP 1 (arbitrarily assigned as standard)______________________________________
PROTOCOLS--DNA BINDING TEST
Results--Erythema vs. DNA-monoaddition
According to this DNA unwinding test, stock solutions of the test compounds are prepared and dissolved in absolute ethanol. These stock solutions are used to determined specific absorption coefficients in terms of absorption per microgram of the test compound. Ethanol volumes are kept as low as possible to eliminate the possibility of alteration of the DNA structure. Concentrations of the concentrated, sometimes "saturated", stock solutions are determined by dilution into water and using the specific absorption coefficients determined on the standardized solutions prepared as first-above set forth. All of the absorption spectra are taken in de-ionized water with an ethanol concentration of four percent (4%) or less.
Each sample is then irradiated at a minimum of four (4) ratios of drug to DNA with two (2) irradiation times at each ratio. The irradiation intensity is 1.5 mW/cm 2 using black light bulbs (F 20 T 12 BLB-GE). Weight ratios of test compound to DNA are varied over three (3) orders of magnitude for each test compound, and the irradiation times are two (2) hours and twenty (20) hours. Irradiations are performed at 4° C.
Agarose gel electrophoresis is employed to analytically separate linear DNA molecules on a basis of molecular weight, lower molecular weight fragments migrating faster on the gel. Agarose can, under appropriate conditions, also resolve molecules of identical molecular weight, but having different conformations. In fact, supercoiled (Form I), nicked-circular (Form II), and linear (Form III) DNA molecules can be resolved, and this capacity for separation or resolving molecules of identical molecular weight but with different conformations is the basis for the psoralen unwinding assay.
The starting DNA sample consists of a mixture of supercoiled (Form I) (fast-running major band) and nicked-circular (Form II) (slower-running, less intense band). Under the conditions employed, full-length linear DNA migrates between supercoiled and nicked-circular DNA. The less intense, slowest-moving bands, are simply dimer and trimer length molecules which repeat the monomer distribution.
Upon photo-reaction with typical psoralen derivatives, according to the foregoing protocol, the DNA helix unwinds proportionately to the extent of photo-reaction. The unwinding of the DNA helix reduces the super-helical density of the DNA, causing the DNA to migrate more slowly on the agarose gel. Thus, any photo-reaction which causes DNA unwinding, DNA nicking, or DNA fragmentation, can be readily detected with the foregoing agarose gel assay.
In the foregoing psoralen DNA unwinding test procedure, the figure 0.83±0.4 determined for the compound E-120 is definitely indicative of monoaddition of monofunctional DNA-binding activity, as opposed to cross-linking activity. In contrast thereto, for example, highly erythemic compounds which cause extremely strong erythemic reactions upon exposure to identical irradiation conditions show a DNA-binding activity in this test as great as 8±4, which is clearly indicative of cross-linking, a conclusion which is also supported by their highly erythemic activity in the usual erythema test, which is fully discussed in the foregoing.
Therefore, according to the DNA-binding test, the compound E-120 exhibits the same order of effectiveness as does the compound 8-methoxypsoralen, a commonly-employed and widely-recognized photosensitizing agent, without however exhibiting the erythema which is concurrent upon the employment thereof.
COMPOSITIONS AND METHOD OF TREATING
The pharmaceutical compositions according to the present invention are suitable for use in effecting photochemical sensitivity on the skin of a mammal, particularly a human patient or subject, and comprise an effective amount of a compound of the invention in association with a pharmaceutically-acceptable carrier or diluent. Such compositions are well-known in the art, and reference may again be made to U.S. Pat. Nos. 4,124,598 and 4,130,568 for representative examples and disclosure concerning the same. The procedure for preparation of such compositions is conventional in the art. For tanning or oral treatment of psoriasis, the active ingredient is generally formulated in tablets or in gelatin capsules. In such case the diluent may, if desired, be eliminated, although it is generally present. For topical application, solutions or ointments may be prepared and employed. These may be formulated with any one of a number of pharmaceutically-acceptable carriers, as is well known in the art. Administration may be, for example, in the form of tablets, capsules, powders, syrups, or solutions, or as already stated in the form of ointments, creams, or solutions for topical use. For tablet preparation, the usual tablet adjuvants such as cornstarch, potato starch, talcum, magnesium stearate, gelatin, lactose, gums, or the like may be employed, but any other pharmaceutical tableting adjuvants may also be used, provided only that they are compatible with the active ingredient. In general, an oral dosage regimen will include about 10 mg. to about 50 mg. per kg. of body weight, with a dose in the neighborhood of about 20 mg. per kg. generally being preferred. Such administration and selection of dosage and unit dosage will of course have to be determined according to established medical principles and under the supervision of the physician in charge of the PUVA therapy involved. For topical use, only an effective amount of the active ingredient per unit area is involved, and this will illustratively be in the form of a one percent solution, suspension, or ointment thereof, illustratively applied on the order of one-tenth milliliter per square centimeter, in association with a suitable carrier, e.g., ethanol, or other carriers of the type already mentioned.
It is to be understood that the invention is not to be limited to the exact details of operation or exact compounds, compositions, methods, or procedures shown and described, as obvious modifications and equivalents will be apparent to one skilled in the art.
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The invention relates to 5'-aminoalkyl-4'-alkylpsoralens, having essentially no erythematic photosensitizing activity but at the same time having substantial DNA-binding photosensitizing activity, making them of especial interest from the standpoint of suntanning and psoriasis treatment, characteristics which are unpredictable when the compounds are compared with psoralens of similar but different structure.
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BACKGROUND OF THE INVENTION
This application is a continuation-in-part of prior copending application Ser. No. 236,047, filed Feb. 19, 1981, which is expressly incorporated herein by reference, and the benefit of the filing date of which is hereby claimed under 35 USC 120.
The present invention relates to methods for separating bitumen from bitumen-bearing materials, and more particularly to the separation of bitumen in situ from bitumen-bearing deposits.
Bitumen-bearing sand deposits commonly referred to as "tar sands" or "oil sands" occur in North and South America, principally in the United States, Canada, and Venezuela. These bitumen-bearing deposits have a bitumen content ranging from seven to twelve percent by weight and in high-grade sands, higher than twelve percent by weight. The remainder of the bitumen-bearing sand constitutes water and siliceous and other organic materials. The bitumen in many sand deposits comprises alkane, cycloalkanes, light aromatics, heavy resins (for example, C 16 hydrocarbons), and asphaltenes. Bitumen, also commonly referred to as petroleum, is also trapped in other subterranean formations. Some of these formations are of the type that can be tapped by conventional drilling methods. However, much of the bitumen in these formations is too viscous to be economically pumped from the geologic strata in which it is trapped. The bitumen therefore must be separated by other methods from the formations or deposits.
Many methods have been suggested to remove bitumen from bitumen-bearing sands and other deposits. Among these are the so-called "thermal recovery" and "solvent recovery" processes and combinations of the two. The solvent and thermal recovery rocesses have been suggested both for removing bitumen from tar sands and for enhancing the recovery from wells from which bitumen recovery has been exhausted by conventional methods. The primary drawback of the thermal and solvent recovery processes is the relatively high expense and less than desirable efficiency. The prior art thermal systems require the generation of and addition of heat to the bitumen-bearing deposits, for example, by the injection of steam or hot water. Thermal generation requires the expenditure of substantial amounts of energy and thus reduces the overall efficiency of thermally based recovery processes. Similarly, known solvent recovery methods either require the addition of heat to the solvent or require expensive pretreatment and posttreatment steps to insure economic solvent and bitumen recovery. Again, the high cost of the addition of heat or the additional treatment steps renders prior art solvent recovery processes either uneconomical or environmentally undesirable. Furthermore, the solvents that have been suggested for use in the solvent recovery systems are either incompatible with water that naturally occurs in the bitumen-bearing substrates, forming undesirable emulsions, or are not universal solvents for the bitumen and other hydrocarbon mateerials occurring in the deposits. For example, the asphaltenes in the bitumen will precipitate out of most conventional solvents that have been suggested for use with solvent recovery processes and, thus, are not recoverable from the deposit.
It is therefore a broad object of the present invention to provide an in situ solvent recovery system for separating bitumen from bitumen-bearing deposits. It is a further object of the present invention to provide a solvent recovery system that does not require the addition of external heat. A further object is to provide a solvent for use in a solvent recovery system that is both compatible with water occurring in the bitumen-bearing substrate, as well as being capable of functioning as a universal solvent for all of the bitumen and bitumen-related materials. It is further an object of the present invention to provide a solvent for such an in situ solvent recovery system that virtually can be completely recovered from the subterranean deposit. It is an additional object of the present invention to provide an economically and environmentally desirable in situ solvent recovery system.
SUMMARY OF THE INVENTION
The foregoing objects and other objects that will become apparent to one of ordinary skill after reading the following specification are provided by the present method for in situ removal of bitumen from subterranean bitumen-bearing deposits. The method is effected by first injecting into the bitumen-bearing deposit a solvent composition having an inverse critical solution (ICS) temperature in a two-phase system with water. The composition is injected into the deposit in an amount sufficient to dissolve substantially all of the bitumen in the deposit. The composition and the dissolved bitumen thereby form a mixture. The mixture is then removed from the deposit and thermally separated into a bitumen component and a solvent composition component. The solvent is selected from a member of or mixtures of members of the groups of amines having the formula: ##STR1## wherein:
R 1 is a hydrogen or an alkyl radical,
R 2 and R 3 are alkyl radicals having from 1 to 6 carbon atoms or alkenyl radicals having from 2 to 6 carbon atoms,
the total number of carbon atoms in the amine molecule being in the range of from 3 to 7, inclusive.
DETAILED DESCRIPTION OF THE INVENTION
In accordance with a broad aspect of the present invention, a solvent composition having an inverse critical solution (ICS) point, more completely defined below, is injected into a subterranean deposit bearing or comprising bitumen (which term encompasses what is commonly referred to as petroleum). The present invention can be employed with a variety of subterranean bitumen-bearing deposits. The process is especially effective in tar sand deposits. Additionally, the present invention can be employed with other petroleum-bearing strata to remove bitumen that cannot economically or otherwise be extracted by conventional methods. For example, the present invention can be employed as a recovery enhancement system for obtaining additional petroleum from wells that are no longer naturally pressurized or that can no longer be economically pumped. The bitumen-bearing deposit does, however, have to be sufficiently porous so that the solvent composition can pass through and contact the bitumen held captive therein.
The solvent utilized with the present invention is one that exhibits an ICS point in a two-phase system with water. Preferably, the composition exhibits this point at or near atmospheric pressure and prevailing ambient temperature. Below the ICS point water and the solvent composition are completely miscible in all proportions. Above the ICS point the solvent composition and water will separate into two distinct liquid phases. One phase will comprise primarily the solvent composition with a small amount of water in solution therewith; the other phase will comprise primarily water with a small amount of the solvent composition dissolved therein. One class of compounds that exhibits an ICS point is certain of the secondary and tertiary amines. These amines can be used by themselves or in admixture with each other in the process of the present invention. By choosing one amine or a mixture of two or more amines the solvent composition can be tailored to appropriately suit the optimum process parameters for a given set of bitumen separation conditions.
A particularly useful and preferred class of amines that can be used with the present invention is those amines which comprise a member of or mixtures of members of the group having the formula ##STR2## wherein R 1 can be hydrogen or alkyl and R 2 and R 3 can be independently selected from alkyl radicals having from one to six carbon atoms and alkenyl radicals having from two to six carbon atoms, the total number of carbon atoms in the amine molecule being in the range of from 3 to 7, inclusive, the amine exhibiting an ICS temperature in a two-phase system with water. Examples of compounds within this class that can be used in accordance with the present invention are triethylamine and diisopropylamine.
Triethylamine (TEA) presently is preferred as the solvent composition since it exhibits its ICS temperature at about 18.7° C. at a pressure of 760 mm. of Hg. This temperature is very near average atmospheric ambient operating conditions in North America (approximately 23° C.). Thus, only a relatively small amount of energy is required to raise a triethylamine-water system to a temperature above the ICS temperature so that the water and solvent components can easily be separated after the bitumen extraction.
The process of the present invention does not require that heat be added to the solvent composition prior to its injection into the bitumen-bearing deposit. The preferred class of amines, and especially triethylamine and diisopropylamine are effective solvents for bitumen at ordinary ground temperatures on the order of 45° to 65° F. Additionally, most of these amines will function as excellent bitumen solvents at the even higher temperatures encountered in very deep subterranean structures. Once the solvent composition has entered the bitumen-bearing substrate and contacts the bitumen in the substrate, the bitumen is quickly dissolved into the solvent composition. Any water present in the system will also be dissolved into the solvent composition, thus eliminating the formation of troublesome emulsions.
Although not critical, the amount of solvent composition pumped through a given deposit need be no greater than about one part solvent per one part by weight of material through which the solvent is being pumped. A greater solvent-to-material ratio can be employed; however, a greater solvent-to-deposit ratio may result in less efficient removal of the bitumen from the bitumen-bearing deposit.
The bitumen/solvent mixtures can be removed from the subterranean deposit by any of a variety of conventional methods, as shown and suggested for example in U.S. Pat. Nos. 3,811,506; 3,822,748; 3,838,737; 3,838,738; and 3,840,073. Among the simplest of the prior art processes for injecting a solvent into a subterranean deposit and removing that solvent is the procedure whereby the solvent is injected at a first location into a deposit. The solvent is withdrawn at a second location spaced from the first location. The solvent can be driven to the second location by injecting water or other nonpolluting liquid at the first location following the solvent injection. The second liquid tends to drive the solvent toward the second withdrawal location. A variety of other methods, of course, is also available.
A surprisingly large percentage of the solvent can be recovered from the bitumen-bearing substrate by pumping water through the deposit following injection of the solvent composition. It has been found that greater than 99% of the solvent can be recovered in this manner. Solvent recovery can be enhanced even further by pretreatment or posttreatment with dilute aqueous alkaline solution. A suggested solution is a 0.1% by weight aqueous sodium hydroxide solution. Such a solution can be pumped through the deposit in advance of injection of the solvent composition or subsequent to removal of the solvent composition. In either event, it has been found that less than one-tenth of one percent of the solvent remains after such pretreatment or posttreatment procedures. In addition to the alkaline posttreatment procedures, solvent recovery can also be enhanced by the injection of steam or hot water into the deposit. The stream or hot water posttreatment steps can also be combined with each other and/or with the aqueous alkaline posttreatment just described.
Once the mixture of bitumen and solvent composition has been withdrawn from the bitumen-bearing deposit, the bitumen and solvent can be thermally separated from the bitumen by, for example, distillation techniques. The liquid fraction, for example, can be flashed into a distillation column, heated by steam or other heat source. The solvent will boil off the liquid fraction as a water-solvent azeotropic vapor and can be recondensed and forwarded to a decanter explained in more detail below. Any additional water is also removed in the solvent still and is condensed and recycled to the decanter along with the solvent. The bottoms from the distillation substantially comprise the bitumen that has been extracted from the tar sands. The bitumen is forwarded to a second processing location for further refinement into petroleum products that can be utilized in the ordinary channels of consumption. If desired, however, a fractionating column can be substituted for the simple distillation column just described. If a fractionating column is employed, not only can the solvent and water be removed at the upper level of the column, but also the bitumen can be separated into its several primary components, including alkanes and cycloalkanes, light aromatics, resins, and asphaltenes. These components can then be further refined as necessary or desired.
As previously mentioned, ground water occurring in the bitumen-bearing deposit is also taken into solution in the solvent composition. The solvent can be reclaimed from the solvent/water composition by raising the temperature of the solvent above the ICS temperature, causing it to separate into liquid phases, one comprising primarily solvent and the other comprising primarily water. The solvent phase can be decanted and recycled directly to a holding tank awaiting reinjection into the bitumen-bearing substrate. The water phase taken from the decanter can be introduced into a water still in which any residual solvent in the water can be flashed off, recondensed, and reintroduced into the decanter. The water thus produced is substantially pure and can be returned to the environment. Alternatively, the water containing a very minor proportion of solvent can be utilized to flush the bitumen-bearing deposit after injection of the solvent composition.
EXAMPLES
The present invention has thus far been broadly described in relation to a preferred embodiment and alternatives thereto. The following Examples are intended to be instructive to one of ordinary skill in the art so that he will readily be able to make and use the invention. The Examples are also intended to be illustrative of the unique advantages of the invention over prior in situ bitumen separation methods. The Examples are not, however, intended to delimit in any way the protection accorded by Letters Patent hereon.
EXAMPLE I
A laboratory simulation of in situ bitumen extraction conditions was constructed by packing a glass column having a diameter of 0.88 inches was packed with 72 grams of bitumen-bearing tar sand to a depth of six inches. Triethylamine in a ratio of one part by weight (72 grams), solvent to one part by weight sand was fed into the top of the glass column and elutriated through the sand using gravity as the only driving force. The sand was then washed by adding water to the column at the same 1:1 weight ratio and elutriating it through the column. All elutriating was conducted at room temperature (between 65° F. and 70° F.). The original bitumen content of the tar sand was about 7.5% by weight based on the original bitumen-bearing tar sand. The residual bitumen in the sand was analyzed to be 0.074%, thus indicating a bitumen removal efficiency of greater than 99%. The water-wet sand remaining in the column was analyzed for triethylamine and found to contain 0.65 milligrams TEA per gram of sand.
EXAMPLE II
A glass column similar to that utilized in Example I was packed with tar sand containing about 7.5% by weight bitumen based on the total tar sand and bitumen. 72 grams of 0.1% by weight aqueous sodium hydroxide were then elutriated through the column with the assist of a vacuum on the receiving flask. Thereafter, 72 grams of TEA were elutriated through the column with a vacuum assist. The column was then washed with 72 grams of water. The residual bitumen in the sand was analyzed at 0.07%. The residual TEA in the wet sand was analyzed at 0.4 milligrams per gram.
The present invention has been described in relation to a preferred embodiment. One of ordinary skill after reading the foregoing specification may be able to effect various changes, substitutions of equivalents, and other alterations without departing from the broad concepts disclosed herein. It is therefore intended that the scope of protection granted by Letters Patent hereon be limited only by the definition contained in the appended claims and equivalents thereof.
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A method for in situ separation of bitumen from bitumen-bearing subterranean deposits includes the step of injecting a solvent composition into the deposit. The solvent composition must have an inverse critical solution temperature in a two-phase system with water and be selected from a particular group of amines that includes triethylamine and diisopropylamine. When the solvent composition contacts the bitumen in the deposit, the bitumen is dissolved by the solvent. Thereafter, the bitumen/solvent mixture is removed and separated into a bitumen component and a solvent component. The bitumen is thereafter processed to yield a usable petroleum product.
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BACKGROUND OF THE INVENTION
[0001] 1. Technical Field
[0002] The present invention concerns assays for determining presence, and for quantitation, of species sources of DNA. More specifically, the invention concerns assay methods for detecting and quantitating ruminant-source material in animal feed and pork material in foods. In addition, the invention extends to assay methods for detecting and quantitating beef and chicken material in foods of mixed or complex sources, and to products used in performing the foregoing methods. In addition, the invention extends to detecting and quantitating ruminant-source, pork-source, beef-source, and chicken-source material in cosmetics and other substances, which may be ingested by humans.
[0003] 2. Related Art
Animal Species Involved
[0004] With the exception of the chicken assay disclosed hereinafter, all of the assays described herein are directed to hoofed mammals of the order Artiodactyla. Within that order, two suborders are of interest here: Suiforms and Ruminantia. Within Suiforms the family Suidae is of interest because it includes the common pig, Sus scrofa. The Ruminantia (“cud-chewing” animals) as a whole are of interest, because of governmental disease-control guidelines and regulations discussed hereinafter. Within Ruminantia, the family of principal interest is Bovidae, which includes cattle (cows), sheep, and goats. Within Bovidae the principal species of interest is Bos taurus, whose meat (beef) is widely consumed; the species Ovis aries is also of some interest because its meat (lamb) is also widely consumed. Deer ( Odocoileus virginianus, in Cervidae family) and antelope ( Antilocarpa americana in Bovidae family) are also among the Ruminantia whose meat is consumed to some extent. The assays specifically described hereinafter involve animals used as food.
Mad Cow Disease
[0005] Bovine spongiform encephalopathy (BSE), commonly referred to as “mad cow disease,” has a human form termed vCJD that is a variant of Creutzfeldt-Jakob disease, a fatal neurodegenerative disease that has caused many deaths in the United Kingdom. See P. Brown, Bovine spongiform encephalophathy and variant Creutzfeldt-Jakob disease, Br. Med. J. 322 (2001) 841-844. In response to the BSE epidemic in Europe, the United States Food and Drug Administration (FDA) imposed strict guidelines in 1997, prohibiting the use of ruminant-derived protein in the manufacture of animal feed intended for cows or other ruminants. It is widely believed that the practice of utilizing ruminant carcasses in animal feed for livestock is responsible for the spread of BSE to epidemic proportions. See P. Brown (2001), supra. As a result, the need for sensitive detection of ruminant species remains in animal feed is a paramount agricultural issue.
Pork and Beef Avoidance
[0006] The risk associated with infectious transmissible spongiform encephalopathy in humans has discouraged many individuals around the globe from consuming beef. Hindu populations also choose not to eat beef, while Jewish and Muslim populations choose to avoid consumption of pork, even in minute quantities, due to their religious beliefs. Many consumers prefer to include more chicken in their diet instead of beef or pork. In addition to concerns about infectious disease and religious concerns, many individuals are altering their eating behavior to include more chicken simply to reduce dietary fat intake in accordance with health trends. Other consumers, however, may avoid chicken because of fear of Salmonella infection. Any conceivable ambiguity in the labeling practices of commercial suppliers or grocery stores is unacceptable to these consumer subsets. The need for sensitive detection and quantitation of bovine, porcine, and chicken species in food and mixed-food products is critical in response to this consumer demand.
Prior Detection Methods
[0007] The quantitative detection of meat species sources in mixed food samples has been approached using a variety of different systems. Early approaches to identify species-specific components within mixed samples involved the use of high-performance liquid chromatography. See E. O. Espinoza, M. A. Kirms, M. S. Filipek, Identification and quantitation of source from hemoglobin of blood and blood mixtures by high performance liquid chromatography, J. Forensic Sci. 41 (1996) 804-811; H. I. Inoue, H. F. Takabe, O. Takenaka, M. Iwasa, Y. Maeno, Species identification of blood and blood-stains by high-performance liquid chromatography, Int. J. Legal Med. 104 (1990) 9-12. These methods have proven useful for the identification of many different animal species, but the detection limits using these approaches are restrictive. The detection of nuclear DNA sequences has also been useful in this regard, but is limited as a result of their generally low copy number. See R. Meyer, U. Candrian, J. Luthy, Detection of pork in heated meat products by the polymerase chain reaction, J. AOAC Int. 77 (1994) 617-622. Meat species identification using enzyme-linked immunosorbent assays, see F. C. Chen, Y. H. Hsieh, Detection of pork in heat-processed meat products by monoclonal antibody-based ELISA, J. AOAC Int. 83 (2000) 79-85, and protein profiles, see H. J. Skarpeid, K. Kvaal, K. I. Hildrum, Identification of animal species in ground meat mixtures by multivariate analysis of isoelectric focusing protein profiles, Electrophoresis 19 (1998) 3103-3109, have also been used.
[0008] But assays based on the polymerase chain reaction (PCR) are currently the method of choice for species identification. See J. H. Calvo, P. Zaragoza, R. Osta, A quick and more sensitive method to identify pork in processed and unprocessed food by PCR amplification of a new specific DNA fragment, J. Anim. Sci. 79 (2001) 2108-2112. PCR analysis of species-specific mitochondrial DNA sequences is the most common method currently used for identification of meat species in food, see B. L. Herman, Determination of the animal origin of raw food by species-specific PCR, J. Dairy Res. 68 (2001) 429-436; T. Matsunaga, K. Chikuni, R. Ranabe, S. Muroya, K. Shibata, J. Yamada, Y. Shinmura, A quick and simple method for the identification of meat species and meat products by PCR assay, Meat Sci. 51 (1999) 143-148; R. Meyer, C. Hofelein, J. Luthy, U. Candrian, Polymerase chain reaction-restriction fragment length polymorphism analysis: A simple method for species identification in food, J. AOAC Int. 78 (1995) 1542-1551; S. Lahiff, M. Glennon, L. O'Brien, J. Lyng, T. Smith, M. Maher, N. Shilton, Species-specific PCR for the identification of bovine, porcine and chicken species in meat and bone meal (IBM), Mol. Cell. Probes 15 (2001) 27-35; L. Partis, D. Croan, Z. Guo, R. Clark, T. Coldham, J. Murby, Evaluation of a DNA fingerprinting method for determining the species origin of meats, Meat Sci. 54 (2000) 11 369-376; J. F. Montiel-Sosa, E. Ruiz-Pesini, J. Montoya, P. Roncales, M. J. Lopez-Perez, A. Perez-Martos, Direct and highly species-specific detection of pork meat and fat in meat products by PCR amplification and mitochondrial DNA, J. Agric. Food Chem. 48 (2000) 2829-2832, and animal feedstuffs, see F. Bellagamba, V. M. Moretti, S. Comincini, F. Valfre, Identification of species in animal feedstuffs by polymerase chain reaction-restriction fragment length polymorphism analysis of mitochondrial DNA, J. Agric. Food Chem. 49 (2001); 3775-3781; M. Tartaglia, E. Saulle, S. Pestalozza, L. Morelli, G. Antonucci, P. A. Battaglia, Detection of bovine mitochondrial DNA in ruminant feeds: a molecular approach to test for the presence of bovine-derived materials, J. Food Prot. 61 (1998) 513-518; P. Krcmar, E. Rencova, Identification of bovine-specific DNA in feedstuffs, J. Food Prot. 64 (2001) 117-119.
[0009] The advantage of mitochondrial-based DNA analyses derives from the fact that there are many mitochondria per cell and many mitochondrial DNA molecules within each mitochondrion, making mitochondrial DNA a naturally amplified source of genetic variation. Recently, PCR-based methods have been reported that use multi-copy nuclear DNA sequences such as satellite DNA, see Z. Guoli, Z. Mingguang, Z. Zhijiang, O. Hongsheng, L. Qiang, Establishment and application of a polymerase chain reaction for the identification of beef, Meat Sci. 51 (1999) 233-236; J. H. Calvo, C. Rodellar, P. Zaragoza, R. Osta, Beef- and bovine-derived material identification in processed and unprocessed food and feed by PCR amplification, J. Agric. Food Chem. 50 (2002) 5262-5264, and repetitive elements, see J. H. Calvo, P. Zaragoza, R. Osta, A quick and more sensitive method to identify pork in processed and unprocessed food by PCR amplification of a new specific DNA fragment, J. Anim. Sci. 79 (2001) 2108-2112; K. Tajima, O. Enishi, M. Amari, M. Mitsumori, H. Kajikawa, M. Kurihara, S. Yanai, H. Matsui, H. Yasue, T. Mitsuhashi, T. Kawashima, M. Matsumoto, PCR detection of DNAs of animal origin in feed by primers based on sequences of short and long interspersed repetitive elements, Biosci. Biotechnol. Biochem. 66 (2002) 2247-2250. Like mitochondrial-based systems, these nuclear PCR-based assays take advantage of multiple target amplification sites in the genome of interest. However, many of these systems require additional procedural steps (such as endonuclease digestion) and at least 1-250 pg of starting DNA template for species detection. See J. H. Calvo, P. Zaragoza, R. Osta, A quick and more sensitive method to identify pork in processed and unprocessed food by PCR amplification of a new specific DNA fragment, J. Anim. Sci. 79 (2001) 2108-2112; J. H. Calvo, C. Rodellar, P. Zaragoza, R. Osta, Beef- and bovine-derived material identification in processed and unprocessed food and feed by PCR amplification, J. Agric. Food Chem. 50 (2002) 5262-5264. Also, Tajima and co-workers, see K. Tajima, O. Enishi, M. Amari, M. Mitsumori, H. Kajikawa, M. Kurihara, S. Yanai, H. Matsui, H. Yasue, T. Mitsuhashi, T. Kawashima, M. Matsumoto, PCR detection of DNAs of animal origin in feed by primers based on sequences of short and long interspersed repetitive elements, Biosci. Biotechnol. Biochem. 66 (2002) 2247-2250, recently reported the development of PCR assays for the detection of ruminant-, pig-, and chicken-derived materials based on sequences of short and long interspersed repetitive elements.
[0010] These assays exceed the detection limits of previously reported assays. See T. Matsunaga, K. Chikuni, R. Ranabe, S. Muroya, K. Shibata, J. Yamada, Y. Shinmura, A quick and simple method for the identification of meat species and meat products by PCR assay, Meat Sci. 51 (1999) 143-148; S. Lahiff, M. Glennon, L. O'Brien, J. Lyng, T. Smith, M. Maher, N. Shilton, Species-specific PCR for the identification of bovine, porcine and chicken species in meat and bone meal (MBM), Mol. Cell. Probes. 15 (2001) 27-35; M. Tartaglia, E. Saulle, S. Pestalozza, L. Morelli, G. Antonucci, P. A. Battaglia, Detection of bovine mitochondrial DNA in ruminant feeds: a molecular approach to test for the presence of bovine-derived materials, J. Food Prot. 61 (1998) 513-518. However, there are several limitations to their methods. Primarily, the detection of PCR products is exclusively gel based and thus non-quantitative. In addition, the relatively large size of the PCR amplicons for the assays (179-201 bp) reported by Tajima and co-workers, see K. Tajima, O. Enishi, M. Amari, M. Mitsumori, H. Kajikawa, M. Kurihara, S. Yanai, H. Matsui, H. Yasue, T. Mitsuhashi, T. Kawashima, M. Matsumoto, PCR detection of DNAs of animal origin in feed by primers based on sequences of short and long interspersed repetitive elements, Biosci. Biotechnol. Biochem. 66 (2002) 2247-2250, may limit their utility for testing trace materials that contain degraded DNA (or truncated sequences).
Cosmetics and Other Materials
[0011] Inedible remnants of cows, sheep, and other animals are rendered into fat (or “tallow”) as well as meat-and-bone meal. The fat “is used in an amazing array of products (such as soap, lipstick, linoleum, and glue).” See Trying to Keep “Mad Cow Disease” Out of U.S. Herds, http://www.fda.gov/fdac/features/2001/201_cow.html. Some of these products, such as lipstick and glue, may be ingested by human users. Considerations similar to those applying to meat may therefore apply to potentially ingested products such as lipstick that may contain ruminant-source, pork-source, or beef-source fat. Such products are thus a potential vector for BSE or religious issues. In addition, it is well known that the Sepoy Mutiny of 1857 was at least in part triggered by rumors that new British Enfield rifle cartridges were greased with animal fat from cows and pigs, thus offending both Hindus and Moslems. Hence, some consumers may wish to avoid such animal-fat products.
SINEs
[0012] Short interspersed elements (SINEs) reside within almost every genome that has been studied to date. Most SINEs have amplified in the past 65 million years and are thought to have been spread throughout each genome via an RNA-mediated duplication process termed retroposition. P. L. Deininger, M. A. Batzer, Evolution of retroposons, Evol. Biol. 27 (1993) 157-196. Because each of the SINE families within the different genomes was derived independently, every mammalian order has a significant number (in excess of 100,000) of characteristic mobile elements.
PCR Terminology
[0013] In a polymerase chain reaction (PCR), a predetermined DNA sequence (of a genome) from a DNA sample is multiplied (“amplified”) many times to produce a resultant product in which the concentration of the predetermined sequence is greatly increased relative to the concentration in the original DNA sample. This process facilitates detection of the presence of the predetermined DNA sequence (also referred to hereinafter at times as the “sequence of interest”). The amplified sequence in PCR typically contains the DNA sequence of interest flanked at each end by another short sequence. The total amplified sequence is termed an amplicon. The amplicon may be represented as A-X-B-Y-C, where B=the sequence of interest, A=a flanking sequence, C=another flanking sequence, and X and Y are nucleotide sequences. Sequences complementary to A and C, i.e., A′ and C′, are known as primers; A′ is the “forward” primer and C′ is the “reverse” primer. The sequence of regions A through C is chosen so that the region B can be amplified using the primers A′ and C′ having sequences complementary to regions A and C. At times hereinafter, when the sequence of interest B is a SINE, such an amplicon A-B-C is said to be representative of SINE B.
[0014] A primer is a reagent that facilitates PCR. Primers are short segments of DNA which are complementary to the two segments of DNA within a strand of DNA that flank the DNA sequence which is to be copied from the strand of DNA (i.e., amplified); in PCR they bind (“anneal”) to the DNA sequence which is to be copied. Primers can be specific for a known DNA sequence or can be nonspecific in which case they bind to many genetic sequences. The present invention is concerned primarily with specific primers. More than one primer set can usually be designed for a given sequence of interest. Various constraints and trade-offs govern design and selection of primers.
[0015] The copy number is a measure of the number of copies of a given DNA sequence found in a given kind of DNA sample. When the copy number is high, a PCR will produce a higher concentration of the given DNA sequence than when the copy number is low. Detection of a sequence with a high copy number is therefore easier.
[0016] The size (length) of an amplicon is measured in terms of base pairs (bp). When a DNA sequence is degraded or truncated, PCR may be unsuccessful. It has been shown that selection of a smaller amplicon, if possible, helps to address this problem, since PCR product yield is inversely correlated to amplicon length. See A. K. Lindqvist, P. K. Magnusson, J. Balciuniene, C. Wadelius, E. Lindholm, M. E. Alarcon-Riquelme, U. B. Gyllensten, Chromosome-specific panels of tri- and tetranucleotide microsatellite markers for multiplex fluorescent detection and automated genotyping: evaluation of their utility in pathology. Genome Res. (1996) 6:1170-1176; A. Beckmann, U. Vogt, N. Huda, K. S. Zänker, B. H. Brandt, Direct-Double-Differential PCR for Gene Dosage Quantification of c-myc, Clin. Chem. (1999) 45:141-143.
SUMMARY OF THE INVENTION
[0017] Accordingly, it is an object of the present invention to provide assay methods for both detecting qualitatively and also quantitating ruminant-source material in animal feed and pork material in foods.
[0018] It is a further object of the present invention to provide assay methods for both detecting qualitatively and also quantitating beef and chicken material in foods of mixed or complex sources. Additionally, it is an object of the invention to provide assay methods applicable to lipsticks and other materials that may contain material from an objectionable or undesired species source.
[0019] It is a further object of the present invention to provide primers, probes, and other products adapted to carrying out the foregoing assay methods.
[0020] It is a further object of the present invention to provide assay methods for the foregoing purposes that do not require additional processing steps beyond PCR, for example, restriction endonuclease digestion or hybridization for scoring, as in the previously cited assays of Meyer et al. (1995), Bellagamba et al. (2001), and Tartaglia et al. (1998). In addition, it is an object to avoid need for special expertise and expensive special equipment, such as automated DNA sequencers, as in the previously cited assays of Partis et al. (2000) and Bellagamba et al. (2001). It is an object to minimize the cost of performing the assays and to permit laboratories with only average resources to be able to perform the assays.
[0021] It is a further object of the present invention to improve the low range detection limits of the assays by at least one order of magnitude over that of previously reported assays in this field.
[0022] It is a further object of the present invention to provide assays using less starting DNA template materials than previously reported assays and assays less sensitive to degraded DNA templates than previously reported assays in this field.
[0023] These and other objects of the invention are realized by a family of assays based on PCR amplification of short interspersed elements (SINEs) and agarose gel electrophoresis, with probes and primers specially developed for use in these assays. The assays use SINEs as markers to identify the DNA from the species, genus, family, or order of interest, thereby providing specific genomic tags that can be used in conjunction with PCR to amplify specific subsets of genomic sequences unique to the genome or species of interest from mixed-DNA sources. During intra-SINE PCR, primers developed for the assays act within the core body of the SINE to amplify multiple copies of the element of interest and generate a homogeneous product composed entirely of the repeat core unit DNA sequences characteristic of the genome being amplified. The primers were designed and selected with a view to obtaining short-length amplicons to improve accuracy of detection, especially with degraded samples containing a low copy number of DNA sequences of interest.
[0024] First, qualitative analyses were performed by inspection of the results of electrophoresis on agarose gel containing ethidium bromide. Second, SYBR Green UV fluorescence detection was used in conjunction with the species-specific intra-SINE PCR to provide a highly quantitative analysis. Third, TaqMan chemistry was used for quantitation instead of SYBR Green-based detection. While fluorescence detection is a preferred mode of quantitation, other forms of tagging the SINE of interest can be used for such detection (e.g., radioactive tagging).
[0025] In each case, the assay comprises four basic steps: First, a DNA-containing sample of feed or food to be analyzed is provided. Second, the DNA is extracted or isolated using standard (i.e., conventional) means. Third, PCR amplification of predetermined genomic DNA sequences occurs. The sequences are selected to accomplish the objects of the invention, as described in greater detail below. The sequences selected are SINEs unique to the animal species or family, etc. of interest. The primers are selected to provide small amplicons. The third step results in an amplified DNA product. Fourth, the amplified DNA product is compared with a reference, first using electrophoresis on agarose gel containing ethidium bromide. This provides a qualitative or screening test to detect the DNA of interest. Then SYBR Green fluorescence detection is used where quantitation is required. TaqMan quantitation is also described hereinafter.
[0026] Three species-specific assays are described: cow, pig, and chicken; an assay for ruminant species (the various species that are members of the sub-order Ruminata) as a whole is also described. Using SYBR Green-based detection, the minimum effective quantitation levels were 0.1, 0.01, 5, and 1 pg of starting DNA template using the bovine, porcine, chicken, and ruminant species-specific SINE-based PCR assays of the invention, respectively. Background cross-amplification with DNA templates derived from 14 other species was negligible. Species specificity of the PCR amplicons was further tested and demonstrated by measuring the ability of the assays to accurately detect trace quantities of species-specific DNA from mixed (complex) sources. Bovine DNA was detected at 0.005% (0.5 pg), porcine DNA was detected at 0.0005% (0.05 pg), and chicken DNA was detected at 0.05% (5 pg) in a 10-ng mixture of bovine, porcine, and chicken DNA templates. Six commercially purchased meat products were also tested using these assays. The SINE-based PCR methods reported here were shown to be species-specific, and highly sensitive.
[0027] Kits are also described for assaying food and feed samples in accordance with the foregoing processes. The kits comprise a polymerase and buffer, and primers suitable for a PCR on the pertinent amplicon.
BRIEF DESCRIPTION OF DRAWINGS
[0028] FIG. 1 is a chromatography display for the assays of the invention, showing UV fluorescence visualization of results of gel chromatography of: (A) the bovine-specific assay, (B) the porcine-specific assay, (C) the chicken-specific assay, and (D) the ruminant species assay.
[0029] FIG. 2 shows the quantitation range for the four assays of the invention: (A) the bovine-specific assay, (B) the porcine-specific assay, (C) the chicken-specific assay, and (D) the ruminant species assay.
[0030] FIG. 3 shows cross amplification of DNA templates derived from 14 species for the four assays of the invention: (A) the bovine-specific assay, (B) the porcine-specific assay, (C) the chicken-specific assay, and (D) the ruminant species assay.
[0031] FIG. 4 shows DNA detection showing UV fluorescence visualization of results of gel chromatography of the ruminant assay of the invention as applied to mixed DNA samples containing 1%: (A) bovine DNA, and (B) sheep DNA.
[0032] FIG. 5 illustrates UV fluorescence visualization of results of gel chromatography of eight complex meat sample mixtures, using the four assays of the invention: (A) the bovine-specific assay, (B) the porcine-specific assay, (C) the chicken-specific assay, and (D) the ruminant species assay.
[0033] FIG. 6 shows quantitative PCR analysis of complex mixtures from six meat products, using the four assays of the invention: (A) the bovine-specific assay, (B) the porcine-specific assay, (C) the chicken-specific assay, and (D) the ruminant species assay.
DETAILED DESCRIPTION
The SINEs of Interest
[0034] As previously indicated, the SINEs to be amplified by PCR are selected to uniquely identify the species, genus, etc. of interest, i.e., the subject of the assay. That is, each SINE of interest is selected from a genomic subset common to members of the particular type of animal that is the target of the given assay. But this SINE is one not found in genomes of other types of animal that are non-targets of the given assay.
[0035] Bovine SINE families such as Bov-tA, Bov-A, and Bov-B are common to all ruminant members of the order Artiodactyla such as shown when using the invention's Bov-tA2 ruminant assay (illustrated in FIG. 1D ). See C. Jobse, J. B. Buntjer, N. Haagsma, H. J. Breukelman, J. J. Beintema, J. A. Lenstra, Evolution and recombination of the bovine DNA repeats, J. Mol. Evol. 41 (1995) 277-283. But these elements have also undergone recombination events throughout bovine evolution such that some sequence variants have formed satellites of the original SINE families. Some of these satellites, such as the 1.711B bovine repeat (Gen-Bank No. V00116) used in the bovine (beef) assay of the present invention, emerged after the radiation of the Bovidae approximately 5-15 million years ago and are absent from other ruminant species (see FIG. 1A ). See Jobse et al. (1995). Therefore, such elements can advantageously be used to distinguish beef samples from other ruminant-derived samples. The 1.711B bovine repeat is thought to occupy 7.1% of the bovine genome. R. E. Streeck, A multicopy insertion sequence in the bovine genome with structural homology to the long terminal repeats of retroviruses, Nature 298 (1982) 767-768.
[0036] The porcine SINE PRE-1 used in the porcine assay of the invention (GenBank No. Y00104) is present in the common domestic pig, Sus scrofa, and other members of the Suidae family, but is absent from other genomes (see FIG. 1B ). The PRE-1 SINE sequence reportedly diversified at least 43.2 million years ago and has about 100,000 copies per genome. See D. S. Singer, L. J. Parent, R. Ehrlich, Identification and DNA sequence of an interspersed repetitive DNA element in the genome of the miniature swine, Nucleic Acids Res. 15 (1987) 2780; H. Yasue, Y. Wada, A swine SINE (PRE-1 sequence) distribution in swine-related animal species and its phylogenetic analysis in swine genome, Anim. Genet. 27 (1996) 95-98. Although, technically speaking, this assay detects members of the Suidae family, rather than just the common domestic pig Sus scrofa, the distinction is immaterial since only the common domestic pig is used for commercial meat purposes and, also, any member of the Suidae family is an “unclean” animal proscribed by the Bible (because, although hoofed, they do not chew the cud).
[0037] The CR1 family of SINEs reportedly has six sub-families designated A through F. See T. L. Vandergon, M. Reitman, Evolution of chicken repeat 1 (CR1) elements: evidence for ancient subfamilies and multiple progenitors, Mol. Biol. Evol. 11 (1994) 886-898. The chicken assay of this invention was designed in the CR1 SINE subfamily “C” (Gen-Bank No. X03517). This SINE is present in the chicken genome, but it is absent from other avian genomes such as duck (see FIG. 1C ) and dove. See W. E. Stumph, P. Kristo, M. Tsai, B. W. O'Malley, A chicken middle-repetitive DNA sequence which shares homology with mammalian ubiquitous repeats, Nucleic Acids Res. 9 (1981); T. L. Vandergon, M. Reitman, Evolution of chicken repeat 1 (CR1) elements: evidence for ancient subfamilies and multiple progenitors, Mol. Biol. Evol. 11 (1994)886-898.
Primer Design and PCR Amplification
[0038] DNA sequences from bovine, see C. Jobse, J. B. Buntjer, N. Haagsma, H. J. Breukelman, J. J. Beintema, J. A. Lenstra, Evolution and recombination of the bovine DNA repeats, J. Mol. Evol. 41 (1995) 277-283; S. Kostia, M. Ruohonen-Lehto, R. Vainola, S. L. Varvio, Phylogenetic information in inter-SINE and inter-SSR fingerprints of the artiodactyla and evolution of the Bov-tA SINE, Heredity 84 (2000) 3745; R. E. Streeck, A multicopy insertion sequence in the bovine genome with structural homology to the long terminal repeats of retroviruses, Nature 298 (1982) 767-768; porcine, see D. S. Singer, L. J. Parent, R. Ehrlich, Identification and DNA sequence of an interspersed repetitive DNA element in the genome of the miniature swine, Nucleic Acids Res. 15 (1987) 2780; H. Yasue, Y. Wada, A swine SINE (PRE-1 sequence) distribution in swine-related animal species and its phylogenetic analysis in swine genome, Anim. Genet. 27 (1996) 95-98; and chicken, see W. E. Stumph, P. Kristo, M. Tsai, B. W. O'Malley, A chicken middle-repetitive DNA sequence which shares homology with mammalian ubiquitous repeats, Nucleic Acids Res. 9 (1981) 5383-5397; T. L. Vandergon, M. Reitman, Evolution of chicken repeat 1 (CR1) elements: evidence for ancient subfamilies and multiple progenitors, Mol. Biol. Evol. 11 (1994) 886-898, genomes were subjected to computational analysis. This was done using the Repeat Masker server at the University of Washington to identify SINEs contained within those genomes. See http://ftp.genome.washington.edu/cgi-bin/RepeatMasker.
[0039] Oligonucleotides were designed using either Primer3 software (Whitehead Institute for Biomedical Research, Cambridge, Mass.) or Primer Express software (Applied Biosystems, Inc.) and purchased from MWG Biotech, Inc., or Sigma-Genosys, Inc. Each primer pair was evaluated for species specificity and sensitivity using standard PCR and agarose gel electrophoresis. Only those oligonucleotide pairs meeting the previously discussed (see objects of invention) criteria were selected for further analysis (see Tables 1 and 2). The SYBR Green PCR core reagent kit was purchased from Applied Biosystems, Inc. (SYBR is a registered trademark of Molecular Probes,Inc.).
[0040] Those skilled in the art will appreciate that some variations or molecular manipulations of the primers described will also serve effectively in a PCR of the SINEs of interest. For example, adding or deleting one or a few bases from the primer or shifting its position slightly relative to the SINE of interest will provide an equivalent of the described primer. Thus, subsets and supersets of the sequences identified for primer use should be considered equivalents thereof, as should substantially overlapping sets. It is considered that the invention extends to such modifications of the primers described herein.
[0000]
TABLE 1
Repetitive elements and amplicon sizes for intra-SINE PCR detection assays
Genus, species
Common name
Order
Family
size (bp)
Repeat element
PCR amplicon
Cow
Artiodactyla
Bovidae
Bos taurus
1.711B bov. rpt.
98
Pig
Artiodactyla
Suidae
Sus scrofa
PRE-1 SINE
134
Chicken
Galliformes
Phasianidae
Gallus gallus
CR1 SINE, subf. “C”
169
Ruminants
Artiodactyla
N/A
N/A
Bov-tA2 SINE
100
[0000]
TABLE 2
Oligonuclotide primers for intra-
SINE-based PCR detection assays
Assay
Forward primer
Reverse primer
Bovine
5′ TTTCTTGTTATAGCCCAC
5′ TTTCTCTAAAGGTGGT
CACAC 3′
TGGTCAG 3′
Porcine
5′ GACTAGGAACCATGAGGT
5′ AGCCTACACCACAGCC
TGCG 3′
ACAG 3′
Chicken
5′ CTGGGTTGAAAAGGACCA
5′ GTGACGCACTGAACAG
CAGT 3′
GTTG 3′
Ruminants
5′ CAGTCGTGTCCGACTCTT
5′ AATGGCAACACGCTTC
TGT 3′
AGTATT 3′
[0041] PCR conditions were optimized for each assay with regard to annealing temperature and concentrations of MgCl 2 and oligonucleotide primers. Quantitative PCRs were carried out in 50 μl using 1× SYBR Green buffer, 1 mM dNTPs, 3.0 mM MgCl 2 , and 1.25 units AmpliTaq Gold® DNA polymerase as recommended by the supplier (Applied Biosystems, Norwalk, Conn.). The concentrations of oligonucleotide primers used were 0.3 μM for the bovine assay and 0.2 μM each for the porcine, chicken, and ruminant PCR-based assays. Each sample was subjected to an initial denaturation of 12 min at 95° C. to activate the AmpliTaq Gold, followed by 40 amplification cycles of denaturation at 95° C. for 20 s and either 55° C. to anneal for 45 s and 30 s of extension at 60° C. (bovine, chicken, and ruminant assays) or 63° C. for 1 min to anneal and extend (porcine assay). Each reaction contained 49 μl of PCR reagent mix (master mix) and 1 μl of DNA template. Quantitative PCR experiments were performed using an ABI Prism 7000 sequence detection system (Applied Biosystems, Inc.).
[0042] Conventional PCRs for agarose gel detection were carried out in 25 μl using 2 ng of DNA template, 1× PCR buffer II (Applied Biosystems, Inc.), 0.2 mM dNTPs, 1.5 mM MgCl 2 , 1 unit Taq DNA polymerase, and the same oligonucleotide concentrations as described above. Each sample was subjected to an initial denaturation of 1 min at 95° C., followed by 30 amplification cycles of denaturation at 95° C. for 30 s and either 55° C. to anneal for 30 s and 30 s of extension at 72° C. (bovine, chicken, and ruminant assays) or 63° C. for 1 min to anneal and extend (porcine assay). In the porcine assay, using “hot-start PCR” (automatic with AmpliTaq Gold) and an annealing/extension temperature of 63° C. or higher was critical to assay specificity.
DNA Samples
[0043] DNAs from cow ( Bos taurus ), horse ( Equus caballus ), sheep ( Ovis aries ), antelope ( Antilocapra americana ), dog ( Canis familiaris ), cat ( Felis catus ), and rabbit ( Oryctolagus cuniculus ) were obtained by tissue and blood extraction using the Wizard Genomic DNA Purification kit (Promega) and from samples provided by the Louisiana State University School of Veterinary Medicine. Chicken ( Gallus gallus ) DNA was extracted from blood using the QIAamp DNA Blood Mini Kit (Qiagen, Inc.). DNAs from pig ( Sus scrofa ), deer ( Odocoileus virginianus ), duck ( Anas discors ), rat ( Rattus norvegicus ), and mouse ( Mus musculus ), and from commercial food products were prepared from tissue with proteinase K digestion followed by phenol:chloroform extraction and ethanol precipitation. See W. M. Strauss, in: Current Protocols in Molecular Biology, Wiley, New York, 1998, pp. 2.2.1-2.2.3. Human DNA (HeLa cell line ATCC CCL2) isolations were performed using Wizard genomic DNA purification (Promega). Extracted DNA was stored in 10 mM Tris/0.1 mM EDTA (TLE), quantified spectrophotometrically, and then serially diluted 10-fold in TLE such that concentrations from 10 ng to 0.01 pg were assayed in triplicate using PCR.
Assays
Verification Tests
[0044] First a series of assays was performed to determine the quantitation range for each of the four SINEs of Table 1, and these results are shown in FIGS. 2A through 2D . Then a series of assays was performed to determine the cross-amplification of DNA templates derived from each of these and various other species. These results are shown in FIGS. 3A through 3D .
[0045] For the purpose of these tests, a number of multi-species DNA mixtures were prepared, as shown in Table 3.
[0000]
TABLE 3
Composition of Mixed DNA Samples
Bovine
Porcine
Chicken
Total template
DNA ng
(%)
DNA ng
(%)
DNA ng
(%)
DNA ng
(%)
Bovine mix
1
5
(50)
5
(50)
0
(0)
10
(100)
2
1
(10)
0*
(0)
0*
(0)
10*
(100)
3
0.05
(0.5)
7
(70)
2.95
(29.5)
10
(100)
4
0.005
(0.05)
7
(72)
2.795
(27.95)
10
(100)
5
0.0005
(0.005)
7.22
(72.2)
2.7795
(27.795)
10
(100)
Porcine Mix
1
5
(50)
5
(50)
0
(0)
10
(100)
2
4.5
(45)
1
(10)
4.5
(45)
10
(100)
3
4.5
(45)
0.5
(5)
5
(50)
10
(100)
4
4.95
(49.5)
0.1
(1)
4.95
(49.5)
10
(100)
5
4.95
(49.5)
0.05
(0.5)
5
(50)
10
(100)
6
4.995
(49.95)
0.005
(0.05)
5
(50)
10
(100)
7
4.9995
(49.995)
0.0005
(0.005)
5
(50)
10
(100)
8
4.99995
(49.9995)
0.00005
(0.0005)
5
(50)
10
(100)
Chick. mix
1
2.5
(25)
2.5
(25)
5
(50)
10
(100)
2
4.5
(45)
4.5
(45)
1
(10)
10
(100)
3
4.75
(47.5)
4.75
(47.5)
0.5
(5)
10
(100)
4
4.95
(49.5)
4.95
(49.5)
0.1
(1)
10
(100)
5
4.9925
(49.925)
4.9925
(49.925)
0.015
(0.15)
10
(100)
6
4.9975
(49.975)
4.9975
(49.975)
0.005
(0.05)
10
(100)
*Ovine and deer DNA at 4.5 ng each (45% each).
Bovine Assay Quantitation Range and Cross-Amplification
[0046] After 30 cycles of conventional PCR, amplicons were chromatographed on a 2% agarose gel that contained ethidium bromide and then visualized using UV fluorescence. The results appear in FIG. 1A , where Lane 1 is a 100 bp ladder and Lane 2 is the cow DNA. The empty lanes (lanes without any bands for PCR product) are lanes: (3) pig, (4) chicken, (5) horse, (6) sheep, (7) deer, (8) antelope, (9) rabbit, (10) duck, (11) dog, (12) cat, (13) rat, (14) mouse, (15) human, (16) NTC (no-template control). The empty lanes show the insensitivity of this assay to various non-bovine species.
[0047] FIG. 2A shows the quantification range for the assay, using SYBER Green fluorescence detection. The PCR cycle at which the fluorescent signal crosses the baseline is considered to be the threshhold cycle plotted on the y axis. A tenfold dilution series of the bovine DNA was carried out. Then the fluorescent signal produced by the tenfold dilution series was plotted by means of three replicates±1 standard deviation. The R 2 value is 99-100%. Analyses of the species in the DNA mixtures of Table 3 are plotted as open triangles in FIG. 2A along the standard curve as the mean of three replicates±1 standard deviation.
[0048] The bovine assay based on the 1.711B bovine repeat had a linear quantitation range of 10 to 0.0001 ng (0.1 pg), or 10 6 , as shown by the standard curve (see FIG. 2A ). The mean value of the negative template control (NT) was 29.1±0.1 and was not significantly different from the lowest value tested (0.00001 ng or 0.01 pg). This assay detected the known values of bovine DNA within mixed-DNA samples from 50% (5 ng) to 0.005% (0.5 pg) as indicated by the triangles on the standard curve. A total of 10 ng of DNA template was used in each test. Background cross-amplification was detected in trace amounts only from rabbit ( Or. cuniculus ) and dog ( C. familiaris ) DNA templates, following 26 cycles of PCR when tested with an equivalent amount of DNA (2 ng) (see FIG. 3A ). Therefore, cross-species amplification does not limit the effective quantitation range of this assay when testing DNA samples from complex (mixed) sources.
[0049] The criterion that the PCR cycle at which the fluorescent signal crosses the baseline is considered to be the threshhold cycle plotted on the y axis, as described above, is used for all quantitative assays described hereinafter. That concept of threshhold cycle is used as the quantification measure for all of the quantitative PCR assays of the invention, and also in the claims.
Porcine Assay Quantitation Range and Cross-Amplification
[0050] After 30 cycles of conventional PCR, amplicons were chromatographed on a 2% agarose gel that contained ethidium bromide and then visualized using UV fluorescence. The results appear in FIG. 1B , where Lane 1 is a 100 bp ladder and Lane 3 is the pig DNA. The empty (no band) or substantially empty (very faint band) lanes are lanes: (2) cow, (4) chicken, (5) horse, (6) sheep, (7) deer, (8) antelope, (9) rabbit, (10) duck, (11) dog, (12) cat, (13) rat, (14) mouse, (15) human, (16) NTC (no-template control). The empty lanes show the insensitivity of this assay to various non-porcine species.
[0051] FIG. 2B was developed to show the quantitation range for the intra-PRE-1 SINE of the porcine-specific assay in a manner similar to that described above for the bovine assay. The porcine intra-PRE-1 SINE-based PCR assay had a linear quantitation range of 10 to 0.00001 ng (0.01 pg), or 10 7 , as shown by the standard curve (see FIG. 2B ). The mean value of the negative control was 34.2±0.3 and was significantly different from 31.3±0.6 at the 0.01 pg level (p=0.0037). This assay detected the known values of porcine DNA within mixed-DNA samples from 50% (5 ng) to 0.0005% (0.05 pg) as indicated by the triangles on the standard curve.
[0052] Background amplification was detected in trace amounts only from duck ( Anas discors ) and rat ( R. norvegicus ) following 29 cycles of PCR when tested with an equivalent amount of DNA template (2 ng) (see FIG. 3B ). Therefore, cross-species amplification limits the effective quantitation range of this porcine intra-SINE PCR assay to 0.1 pg when equivalent amounts of duck or rat DNA may be present in the samples. However, when DNA samples derived from most complex sources were tested the effective minimum quantitation range was 0.01 pg. The complex sources of principal interest here include pork, beef, lamb, and chicken, which are the most common meat animals in the United States; horse may be of some lesser interest; duck and rat are not of significant interest as likely adulterants of meat products in the United States.
Chicken Assay Quantitation Range and Cross-Amplification
[0053] After 30 cycles of conventional PCR, amplicons were chromatographed on a 2% agarose gel that contained ethidium bromide and then visualized using UV fluorescence. The results appear in FIG. 1C , where Lane 1 is a 100 bp ladder and Lane 4 is the chicken DNA. The empty lanes (no bands) are lanes: (2) cow, (3) pig, (5) horse, (6) sheep, (7) deer, (8) antelope, (9) rabbit, (10) duck, (11) dog, (12) cat, (13) rat, (14) mouse, (15) human, (16) NTC (no-template control). The empty lanes show the insensitivity of this assay to various non-chicken species.
[0054] FIG. 2C was developed to show the quantitation range for the chicken intra-CR1. Subfamily “C” SINE-based PCR assay in a manner similar to that described above for the bovine assay. The chicken intra-CR1 SINE-based PCR assay had a linear quantitation range of 10-0.005 ng, or 2000-fold, as shown by the standard curve (see FIG. 2C ). The mean value of the negative control was 32.9±0.5 and was not significantly different from the lowest value tested (0.001 ng). This assay detected the known values of chicken DNA within mixed-DNA samples from 50% (5 ng) to 0.05% (5 pg),as indicated by the triangles on the standard curve. No amplification was detected from any of the other species tested, making this assay absolutely chicken-specific within its quantitation range (see FIG. 3C ).
Ruminant Assay Quantitation Range and Cross-Amplification
[0055] FIG. 1D is based on the same methodology as FIGS. 1A-C , and shows that the intra-Bov-t-A2 SINE-based PCR ruminant assay, carried out by the same procedure as the preceding cases, detects cow (Lane 2), sheep (Lane 6), deer (Lane 7, and antelope (Lane 8). Lane 1 is a 100 bp ladder and the empty lanes are lanes: (3) pig, (5) horse, (9) rabbit, (10) duck, (11) dog, (12) cat, (13) rat, (14) mouse, (15) human, (16) NTC (no-template control). FIG. 1D thus shows the sensitivity of this assay to four ruminant species and its insensitivity to numerous non-ruminant species.
[0056] FIG. 2D was developed to show the quantitation range for the intra-Bov-tA2 SINE-based PCR assay for detection of multiple ruminant species in a manner similar to that described above for the bovine assay. The intra-Bov-tA2 SINE-based PCR assay has a linear quantitation range of 10-0.001 ng (10 4 ) using bovine DNA as shown by the standard curve and also using ovine DNA shown by the triangles superimposed along the standard curve (see FIG. 2D ). The combined mean value of the negative control (not shown) was 34.8±0.4 and was significantly different from 30.9±0.5 at the 0.001 ng level (p=0.02). PCR amplification was detected from all ruminant species tested (cow, sheep, deer, and antelope) and no signal was detected from other species (see FIG. 3D ). The intra-Bov-tA2 SINE-based PCR assay thus allows sensitive simultaneous quantitation (down to 1 pg of starting DNA template) of DNA derived from various ruminant species in a single assay.
[0057] FIG. 4 shows ruminant DNA detection using the intra-Bov-tA2 SINE-based PCR assay at concentrations from 10 ng to 1 pg. Following 30 cycles of conventional PCR using the intra-Bov-tA2 SINE oligonucleotide primers, amplicons were chromatographed on a 2% agarose gel stained with ethidium bromide. Using ruminant DNA standards from both bovine and ovine genomes, the assay detected 100 pg of ruminant DNA, corresponding to 1% in a 10-ng mixed-DNA sample of starting template. This assay thus permits detection, at 100 pg, and rough quantitative estimates to be performed by simple, inexpensive agarose gel electrophoresis as an initial screening tool. It is considered that the data shown in FIG. 4 indicates the utility of the instant ruminant assay for purposes of testing feed material for compliance with government regulations against use of ruminant source protein in feed.
[0058] Assay specificity was further evaluated by testing the ability of the assays to accurately detect known trace quantities of species-specific DNA from complex (mixed) templates containing other DNAs. Bovine DNA was detected at 0.005% (0.5 pg), porcine DNA was detected at 0.0005% (0.05 pg), and chicken DNA was detected at 0.05% (5 pg) in a 10-ng mixture of bovine, porcine, and chicken DNA.
Tests on Commercial Meat Samples
[0059] After verification of the quantification range of the assays and their specificity, a series of assays were performed on six different meat products purchased at random from local stores. These were ground meat or sausage, as shown in Table 4.
[0000]
TABLE 4
Contents of six commercially purchased meat samples
Meat Product 1
Ingredients (per package label)
a.
Ground beef
73% ground beef; 27% fat
b.
Ground pork
Fresh ground pork; 28% fat
c.
Ground lamb
Fresh ground lamb; 28% fat
d.
Pork sausage
Pork, water, green onions, salt, sugar, spices,
paprika, granulated garlic, natural flavors
e.
Chicken sausage
Chicken, green onions, salt, red pepper,
black pepper, garlic powder, sugar, paprika
f.
Mixed pork and
Pork, beef, salt, red pepper, black pepper,
beef sausage
garlic powder, sugar, paprika
Example 1
Agarose Gel Fluorescence Meat Assays
[0060] 30 cycles of conventional PCR were carried out using 2 ng of template DNA (extracted by conventional means) from six different commercially purchased meat products. The amplified products were chromatographed on a 2% agarose gel stained with ethidium bromide. The detection was performed in the visualization of FIG. 5A with bovine DNA using the 1.711B bovine repeat assay. The detection was performed in the visualization of FIG. 5B with porcine DNA using the intra-PRE-1 SINE assay. The detection was performed in the visualization of FIG. 5C with chicken DNA using the intra-CR1, subfamily “C” SINE assay. The detection was performed in the visualization of FIG. 5D with ruminant DNA using the intra-Bov-t-A2 assay.
[0061] Lanes: (1) 100 bp DNA ladder; (2) negative control; (3) positive control DNA (A, bovine; B, porcine; C, chicken; and D, ovine); (4) ground beef; (5) ground pork; (6) ground lamb; (7) pork sausage; (8) chicken sausage; (9) mixed beef and pork sausage.
[0062] As appears from FIGS. 5A-D , each positive control was visualized and no negative control was visualized. Beef showed, as was to be expected, in the ground beef sample and the mixed beef-pork sausage sample. Beef also showed to a slight extent in the chicken sausage sample. Pork showed, as was to be expected, in the ground pork sample and pork sausage, as well as in mixed beef-pork sausage. It also showed in chicken sausage. Chicken showed, as was to be expected, in the chicken sausage. It also showed slightly in the mixed beef-pork sausage. Ruminant showed, as was to be expected, in ground beef, ground lamb, and mixed-beef pork sausage. The agarose gel ethidium bromide assays showed significant contamination (pork) only in the chicken sausage, and showed slight contamination (beef) in the chicken sausage.
[0063] Restating the same data in terms of the different meat samples, rather than on an DNA-assay-by-DNA-assay basis, leads to the following conclusions: The ground beef sample contained only beef ( FIGS. 5A-D , lane 4). The ground pork sample contained only pork ( FIGS. 5A-D , lane 5). The ground lamb contained DNA from a ruminant species and did not contain beef, chicken, or pork ( FIGS. 5A-D , lane 6). The pork sausage contained only pork and no beef, chicken, or ruminant species ( FIGS. 5A-D , lane 7). The chicken sausage contained chicken, but also appeared to have some beef and pork components ( FIGS. 5A-D , lane 8). The mixed sausage contained beef and pork as labeled and also trace amounts of chicken ( FIGS. 5A-D , lane 9).
Example 2
Quantitative PCR Meat Assays
[0064] Quantitative PCR analysis was undertaken for six meat samples, using the same primers and SYBR Green fluorescence detection. Results are shown in FIG. 6 . (The Applied Biosystems Web page at http://www.appliedbiosystems.com/catalog/myab/StoreCatalog/products/CategoryDetails.jsp?hierarchyID=101&category3rd=112235&trail=no provides information about SYBR® Green PCR Master Mix. Sigma-Aldrich has provided further information on SYBR Green chemistry at http://www.sigmaaldrich.com/Area_of_Interest/Life_Science/Life_Science_Quarterly/Winter — 2002/SYBR_Green_Feature_Article.html.)
[0065] In FIGS. 6A through 6D , the six products were labeled as follows: (a) ground beef—open triangles; (b) ground pork—open squares; (c) ground lamb—open circles; (d) pork sausage—filled triangles; (e) chicken sausage—filled squares; (f) mixed beef and pork sausage—filled circles. The PCR cycle at which the fluorescent signal crosses baseline is considered to be the threshold cycle, plotted on the y axis. The fluorescent signal produced by a 10-fold dilution series of (A) bovine, (B) porcine, (C) chicken, or (D) bovine and ovine DNA is plotted as the mean of duplicates±1 standard deviation, to form a standard curve. DNA (10 ng) from each meat sample was analyzed in duplicate using each of the four quantitative assays. Values were calculated using the standard curves and plotted as the mean with x and y error bars equal to 1 standard deviation. Values significantly different from the no template control are marked with an asterisk (*p=0.05).
[0066] The results from Example 2 indicated that both the ground beef sample and the ground lamb sample contained trace amounts of pork, 0.17±0.10 pg (˜0.002%) and 0.40±0.00 pg (˜0.004%), respectively (see FIG. 6B ). These calculated values were in both cases significantly different from the negative control (p=0.05). The mixed sausage sample contained beef and pork in almost equal amounts as indicated on the product label (see FIGS. 6A , 6 B and 6 D) and did not contain any chicken DNA within the quantitative range of the assay (see FIG. 6C ), contrary to the indications of the initial gel-based screening. The chicken sausage contained significant levels of both beef and pork, 5.6±0.0 pg (˜0.06%) and 0.77±0.09 ng (˜7.7%), respectively, as suggested by the gel-based assay (see FIGS. 6A and 6B ).
TaqMan Chemistry
[0067] TaqMan chemistry involves use of a probe in PCR as well as use of primers as previously described. The first stage in assay design is to design a suitable primer and probe. The primer is a short piece of genetic material that allows Taq polymerase, an enzyme that catalyses the replication of DNA/RNA, to attach to the DNA segment of interest (such as, here, porcine PRE-SINE 1) and is specific to that sequence (the target). The probe is a specific DNA sequence that will only stick to the piece of target material. Attached to opposite ends of the probe are two fluorescent dye molecules; one is a reporter molecule, the other a quencher molecule. The reporter emits fluorescent light at a specific wavelength, and the quencher absorbs this light. (A typical reporter dye is 6-carboxyfluorescein (FAM), which has its emission spectra quenched due to the spatial proximity of a second fluorescent dye, 6-carboxy-tetramethyl-rhodamine (TAMRA).) This means that when the two molecules are in close proximity, such as at either end of the probe, no light is seen. However, if the two molecules are separated, the reporter molecule will emit light, which will be detected by the machine.
[0068] At the beginning of the detection steps, samples are introduced to the TaqMan® equipment, as are the specific primers and probes. If there are regions of sequences present that are specifically detectable by the primers and probe, the primer and probe will attach to the genetic material at respective positions, allowing amplification to occur. The DNA polymerase enzyme recognizes the region where primer is annealed and then continues to make new DNA using the sequence as a template. Once it reaches the point where the probe is annealed, it cleaves the chemical bond between the reporter dye and probe, releasing the reporter molecules. This leads to an increase in the light output, which is detected by the Taqman equipment. As the PCR cycles increase in number, the light intensity increases, too. During the entire amplification process this light emission intensity increases exponentially, the final level being measured by spectrophotometry after termination of the PCR. Because increase of the fluorescence intensity of the reporter dye is achieved only when probe hybridization and amplification of the target sequence has occurred, the TaqMan assay provides a sensitive method to determine the presence or absence of specific sequences. Therefore, TaqMan chemistry has been widely used in diagnostic applications. As previously indicated, however, other forms of tagging are also well known and are capable of use in the assay. For example, other fluorescent dyes exist besides SYBR Green and, also, radioactive tagging can be used here instead of using a fluorescent tag.
Example 3
Taq Man Pork Assay
[0069] A TaqMan probe for the PRE-1 intra-SINE porcine detection assay was designed: 5′ FAM-TTTGATCCCTGGCCTTGCTCAGTGG-TAMRA 3′. The assay of FIG. 6B was then performed with this probe and the results were compared with the SYBR Green-based pork assay of Example 2 and FIG. 6B . The assay sensitivity was, unexpectedly, almost the same. It appears that at least the 5′-FAM reporter molecule typically used with TaqMan-based detection chemistry is not significantly different from SYBR Green in sensitivity.
[0070] A second TaqMan probe (using a non-TAMRA quencher) and primer set was designed for a PRE-1 intra-SINE assay. This detection system was approximately as sensitive as the SYBR Green-based detection system in terms of linear quantitation of a pig DNA sample. But this detection system is considered a less preferred mode than SYBR Green-based detection because of cross-species amplification leading to a higher background signal from other species with mixed samples. While this detection system has some utility, it is considered less preferable than the system of Ex. 3. This second TaqMan porcine assay used the following primers and probe:
[0000]
Forward primer:
5′ GGCCTTGCTCAGTGGGTTAA 3′
Reverse primer:
5′ GGGATCCAAGCCACATCTGT 3′
Probe:
5′ FAM-ACAGCTCACGGCAACGCCGG-BHQ1 3′
Example 4
TaqMan Beef, Ruminant, Chicken Assays
[0071] TaqMan probes are designed for the 1.711B bovine repeat, Bov-tA2, and CR1 subf. “C” SINEs, respectively. The assays of FIGS. 6A , C, and D are performed with these probes and the results are compared with the SYBR Green-based assays of Ex. 2 and FIGS. 6A , C, and D. The assay sensitivity is approximately the same.
[0072] An implementation of these assays, in conjunction with the TaqMan chemistry assay of Ex. 3, is designed for a multicolor multiplex assay of beef, pork, and chicken. The uniformity of each species-specific amplicon in conjunction with fluorophor-specific TaqMan probes makes the combined assays amenable to a multicolor multiplex detection, which is not available with SYBR Green-based detection.
[0073] It is considered that the ruminant assays of meat samples of FIGS. 5D and 6D provide proxies for a ruminant assay of cattle feed samples, indicating the utility of the ruminant assays for testing compliance with current guidelines and regulations intended to prevent spread of BSE.
Example 5
Cattle Feed Assay
[0074] Samples A and B of cattle feed containing 25% protein of unknown origin are subjected to the procedures of Example 1. Sample A shows results comparable to those of FIG. 5D . Sample B shows all lanes empty except positive control. It is concluded that sample A contains ruminant-source material, contrary to government regulations, and sample B does not.
Example 6
Lipstick Assay
[0075] A commercially available lipstick tube containing a lipstick of unknown content is subjected to DNA extraction and the procedures of Example 1. The lipstick shows the presence of material derived from a ruminant species, based on results comparable to those of FIG. 5D .
Evaluation of Data from Verification Tests and Assay Ex. 1-2
[0076] First, the assays of Examples 1 and 2 met the objectives of the invention of not requiring process steps such as endonuclease digestion or hybridization for scoring, and they could be performed by simple agarose gel analysis as an initial screening tool. The cost was moderate and no expensive special equipment (such as an automated DNA sequencer) was needed. Addition of SYBR Green-based detection made possible accurate quantitation, as did use of TaqMan chemistry. The assays thus satisfied the object of the invention to provide assays that lent themselves both to inexpensive gel agarose qualitative tests for screening purposes and also to quantitation. The assays also met the objects of short amplicon length, to improve accuracy (especially for degraded DNA templates), and high copy number. It is believed that no other reported assays meet all of these objectives of this invention.
Bovine Assay
[0077] The quantitation range of the bovine detection assay was approximately 10 6 , with a minimum effective quantitation level of 0.1 pg of DNA. The detection limits using previously reported methods range from 2.5 pg, see J. H. Calvo, C. Rodellar, P. Zaragoza, R. Osta, Beef- and bovine-derived material identification in processed and unprocessed food and feed by PCR amplification, J. Agric. Food Chem. 50 (2002) 5262-5264, to 250 pg, see T. Matsunaga, K. Chikuni, R. Ranabe, S. Muroya, K. Shibata, J. Yamada, Y. Shinmura, A quick and simple method for the identification of meat species and meat products by PCR assay, Meat Sci. 51 (1999) 143-148; M. Tartaglia, E. Saulle, S. Pestalozza, L. Morelli, G. Antonucci, P. A. Battaglia, Detection of bovine mitochondrial DNA in ruminant feeds: a molecular approach to test for the presence of bovine-derived materials, J. Food Prot. 61 (1998) 513-518; P. Krcmar, E. Rencova, Identification of bovine-specific DNA in feedstuffs, J. Food Prot. 64 (2001) 117-119, of bovine DNA. Thus, the low range detection limit of the intra-SINE-based quantitative bovine PCR assay of this invention exceeds the previously reported assays by a minimum of 25-fold.
[0078] Moreover, the previously reported assays do not meet other objectives of the present invention. Thus, Z. Guoli et al. (1999) and J. H. Calvo et al. (2002) reported PCR assays based on the bovine 1.709 satellite. But both assays were qualitative (gel based) and not quantitative. Furthermore, the 1.709 repeat is estimated to occupy 4.3% of the bovine genome, see C. Jobse et al. (1995), whereas the instant assay uses the 1.711 repeat which is estimated to occupy 7.1% of the bovine genome, and thus has a much higher copy number. The bovine assay of this invention is believed to be the only reported quantitative assay based on genomic repetitive sequences.
Porcine Assay
[0079] The intra-SINE-based porcine quantitative PCR assay proved to be even more sensitive than the bovine assay, with a quantitative range of 10 7 and a minimum effective quantitation level of 0.01 pg. The detection limits previously reported using other methods ranged from 1 pg (0.005% in 20 ng), see Calvo et al. (2001); Tajima et al. (2002), to 250 pg, as in Matsunaga et al. (1999). Thus, the low range detection limit of the instant porcine intra-SINE-based quantitative PCR assay exceeds the currently available assay methods by a minimum of 100-fold.
Chicken Assay
[0080] A comparison of the chicken intra-SINE-based quantitative PCR assay to previously reported methods was difficult because the previous studies describing chicken-specific PCR-based quantification assays either did not report a detection limit for poultry, as in Lahiff et al. (2000), or reported a minimum detection limit of 250 pg, as in Matsunaga et al. (1999). The quantitative range of the chicken intra-SINE PCR assay of this invention was approximately 2000-fold, with a minimum effective quantitation level of 5 pg of template, an improvement by a factor of 50 over prior PCR quantitations.
Ruminant Assay
[0081] The quantitative range of the ruminant species intra-SINE detection assay of this invention was approximately 10 4 , with a minimum effective quantitation level of 1 pg. The detection limits of previously reported assays for ruminant species detection are similar to those previously reported for bovine detection assays, so that the ruminant assay of this invention exceeds the detection limits of previously reported assays by more than an order of magnitude.
Amplicon Size and DNA Degradation
[0082] The size of the PCR amplicons used to detect ruminant, porcine, and chicken DNA in the instant intra-SINE-based quantitative PCR assays are 81 bp (45%), 45 bp (25%), and 32 bp (16%) shorter than those reported by Tajima et al. (2002). The latter assays appear to be based on the next shortest reported PCR amplicons for quantitative assays based on detection of a repetitive genomic sequence. See Table 4. J. H. Calvo et al. (2002) reported a PCR beef assay with an amplicon of 84 bp in length, but the assay was a qualitative gel based assay only, and was based on the 1.709 repeat, which as previously indicated has a much lower copy number than the amplicon of the beef assay of the instant invention. J. H. Calvo et al. (2001) reported a 161 bp amplicon for a pork assay based on an unspecified DNA sequence, which is somewhat shorter in length than the 179 bp amplicon of Tajima, see Table 4, but the Calvo assay was not quantitative. The present quantitative assays therefore should be highly useful contributions to the art as assays for the analysis of samples that contain degraded DNA templates.
[0000]
TABLE 4
Amplicon Sizes (bp)
Assay Type
Assay of Invention
Other Assay (min.)
Pork
134
179
Beef
98
None reported
Ruminant
100
181
Chicken
169
201
Kits
[0083] It is considered that the scope of the invention extends to kits used to practice the assays of the invention. Thus, it is contemplated that the invention would be exploited by marketing kits for DNA quantitation of unknown biological samples, using the principles and procedures described hereinabove. A DNA quantitation kit comprises reagents and DNA control materials. The control contains a predetermined amount of DNA sample of the animal source of interest, suspended in an appropriate salt solution. The reagent mix, often termed a Primer Mix, contains the primers, salts, and other chemicals such as dNTPs, in proportions suitable to obtain the desired results. The following examples illustrate representative kits for practicing embodiments of the invention.
Example 7
Kit for Quantitative Assay of Meat for Pork Content
[0084] A kit suitable for performing asingle assay to quantitate pork presence in a ground meat sample believed to contain some pork comprises PCR tubes, sterile water, sterile TLE, SYBR® Green core reagent kit and porcine DNA controls, and a pair of primers (forward, 5′ GACTAGGAACCATGAGGTTGCG 3′; reverse, 5′ AGCCTACACCACAGCCACAG 3′) that are adapted for amplification of the Pre-1 SINE of the porcine-specific assay of the invention, or else a TaqMan probe that is designed to be so adapted (e.g., 5′ FAM-TTTGATCCCTGGCCTTGCTCAGTGG-TAMRA 3′). The concentrations of each reagent are selected depending on the intended use of the kit. Since the detection range of the porcine assay is 10 7 —from 0.01 pg—dilutions within this range should be selected that bracket the anticipated concentration of porcine DNA in the sample.
[0085] It is useful to analyze more than one concentration of the unknown DNA sample. Stock primers are reconstituted in sterile TLE to a concentration of 100 μM. Then, 0.5 ml of working solution of each primer at 10 μM is made by diluting 50 μl of each stock with 450 μl of TLE. This represents a 10× working concentration of each primer for the quantitative PCR assay. PCR tubes, strips or plate as needed are prepared, and a template showing the location of the negative control (TLE), the positive controls (A 10-fold serial dilution of porcine control DNA from 10 ng/μl). 1 μl of DNA template is pipetted into each appropriate well. Then a master mix of all remaining PCR reagents is prepared. 49 μl of master mix is pipetted into each well and is pipetted to make a final PCR reaction volume of 50 μl, as recommended by the manufacturer (SYBR® Green PCR core reagent kit). PCR tubes or plate is placed into the Z-PCR machine. PCR is performed as in Example 2. The amplification analysis is performed using an ABI prism 7,000 sequence detection system (Applied Biosystems, Inc.) or a Bio-Rad i-cycler iQ real-time PCR detection system. A calibration curve is generated from the results for the standard DNA samples.
[0086] As used in the claims, determining the presence of a SINE or amplicon representative of the SINE comprises qualitative determination or quantitative determination of such presence, or both. As used in the claims ordinary agarose gel electrophoresis means electrophoresis on an agarose gel without any additional procedural steps, such as endonuclease digestion. As used in the claims, insensitive to presence of material from a given type of animal as source means that the amount (weight, e.g., in pg) detected (or putatively detected) from that type of animal source is not significantly greater than the amount detected for the negative control in the assay.
[0087] While the invention has been described in connection with specific and preferred embodiments thereof, it is capable of further modifications without departing from the spirit and scope of the invention. This application is intended to cover all variations, uses, or adaptations of the invention, following, in general, the principles of the invention and including such departures from the present disclosure as come within known or customary practice within the art to which the invention pertains, or as are obvious to persons skilled in the art, at the time the departure is made.
[0088] For example, it is known to use other fluorescent dyes instead of ethidium bromide, and substitution of one of them for ethidium bromide should be considered the substitution of an equivalent. Other forms of tags and tagging (also known as labeling), besides fluorescent dyes, can also be substituted—for example, biotin, a chemiluminescer, enzyme, or a radioisotope. A fluorescent tag can be incorporated into a PCR product by using either a labeled primer or a labeled dUTP, and the two expedients should be considered equivalent. Also, it is known to substitute polyacrylamide gel for agarose gel. In principle, SYBR Green-based or TaqMan chemistry can be used to carry out a qualitative or screening test, but it is considered impractical to do so, at least at present, because of cost considerations and added complexity, relative to gel electrophoresis. At this time, work is being done on other DNA amplification processes to supplement PCR. It is considered that, if and when such further amplification processes become commercially available, they will provide equivalents to use of PCR in this invention.
[0089] It should be appreciated that the scope of this invention is not limited to the detailed description of the invention hereinabove, which is intended merely to be illustrative, but rather comprehends the subject matter defined by the following claims.
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A family of PCR assays is disclosed for determining, both qualitatively and quantitatively, presence of material from a predetermined species source and for quantifying the amount of such material. The assays are based respectively on SINEs uniquely characteristic of pig species, cow species, chicken species, and ruminant sub-order, and having a high copy number. The assays disclosed permit rapid, inexpensive evaluation of meat samples to facilitate elimination from their diet of pork or beef by persons desiring to avoid such food sources; as well as the assay of cattle feed to determine presence therein of ruminant-source proteins, which are a potential source of bovine spongiform encephalopathy (BSE), commonly referred to as “mad cow disease.” The assays amplify the predetermined unique SINEs and the resulting amplified mixture is then evaluated qualitatively by electrophoresis on gel containing ethidium bromide or quantitatively by SYBR Green-based detection or TaqMan chemistry. The invention also extends to kits, primers, and other products used in connection with the assays. The amplicons are selected to be from about 100 to 170 bp long.
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CROSS-REFERENCE TO RELATED APPLICATIONS
METHOD FOR CONTROLLING A SPRYTE RENDERING PROCESSOR; U.S. Pat. No. 5,596,693, issued Jan. 21, 1997, based on application Ser. No. 08/509,674, filed Jul. 31, 1995, which is a File Wrapper Continuation application of application Ser. No. 7/970,278 filed Nov. 2, 1992; Inventors: David L. Needle, Robert J. Mical
RESOLUTION ENHANCEMENT FOR VIDEO DISPLAY USING MULTI-LINE INTERPOLATION; U.S. Pat. No. 5,481,275, issued Jan. 2, 1996, based on application Ser. No. 7/970,287 filed Nov. 2, 1992; Inventors: Robert J. Mical, David L. Needle, Teju J. Khubchandani, Stephen H. Landrum
DIGITAL SIGNAL PROCESSOR ARCHITECTURE; application Ser. No. 08/501,163, filed Jul. 11, 1995, which is a File Wrapper Continuation application of application Ser. No. 8/001,463 filed Jan. 6, 1993, now abandoned; Inventors: Donald M. Gray, III, David L. Needle
AUDIO/VIDEO COMPUTER ARCHITECTURE; application Ser. No. 08/591,952, filed Jul. 23, 1996, now abandoned, which is a File Wrapper Continuation application of application Ser. No. 08/442,634, filed May 17, 1995, now abandoned, which is a File Wrapper Continuation application of application Ser. No. 7/970,308 filed Nov. 2, 1992; Inventors: Robert J. Mical, David L. Needle
IMPROVED METHOD AND APPARATUS FOR PROCESSING IMAGE DATA; U.S. Pat. No. 5,572,235, issued Nov. 5, 1996, based on application Ser. No. 7/970,083 filed Nov. 2, 1992; Inventors: Robert J. Mical, David L. Needle
SPRYTE RENDERING SYSTEM WITH IMPROVED CORNER CALCULATING ENGINE AND IMPROVED POLYGON-PAINT ENGINE; application Ser. No. 7/970,289 filed Nov. 2, 1992, now abandoned; Inventors: David L. Needle, Robert J. Mical, Stephen H. Landrum, Donald M. Gray, III
METHOD AND APPARATUS FOR UPDATING A CLUT DURING HORIZONTAL BLANKING; application Ser. No. 08/300,867, filed Sep. 2, 1994, which is a File Wrapper Continuation of application Ser. No. 7/969,994 filed Nov. 2, 1992, now abandoned; Inventors: Robert J. Mical, David L. Needle, Teju J. Khubchandani
DISPLAY LIST MANAGEMENT MECHANISM FOR REAL-TIME CONTROL OF BY-THE-LINE MODIFIABLE VIDEO DISPLAY SYSTEM; U.S. Pat. No. 5,502,462, issued Mar. 26, 1996, based on application Ser. No. 8/146,505 filed Nov. 1, 1993; Inventors: Robert J. Mical, David L. Needle, Stephen H. Landrum, Teju J. Khubchandani
EXPANSION BUS; application Ser. No. 08/302,380, filed Sep. 8, 1994, now abandoned, which is a File Wrapper Continuation application of application Ser. No. 8/001,070 filed Jan. 6, 1993, now abandoned; Inventors: Richard B. Tompane, Dean M. Drako, David L. Needle
Each of these patent applications is assigned to the assignee of the present invention and is specifically incorporated by reference into the present application.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to the delivery, selection and communication of information in an interactive format, and specifically to the delivery and selection of information delivered to a television user over a cable television system.
2. Description of the Related Art
Television has traditionally been a broadcast medium of entertainment. Service providers, such as television stations and networks, broadcast entertainment and information programming via a communications medium, such as a television network or cable system from the head-end of the communications system to a client or individual user at the receiving end of the system. While in the early days of television, this meant transmission of the broadcast signals through the air, more recently, cable networks have become commonplace. Transmission of the broadcast signals through the cable network provides a much wider signal transmission bandwidth and opens the possibility for the transmission of data in large quantities to the user. Bandwidth is defined as the information capacity of a particular transmission system. This traditional model of one-way communication between the service provider and the user has recently begun to change with the proliferation of interactive communication between the client and the service provider.
The television and cable network communication medium is a particularly advantageous way to transmit a great volume of information from the service providers to the end users, the viewers, and to provide an interactive mechanism for the viewer to utilize services such as video on demand, home shopping, interactive games, and home banking using the television as the interface. However, using television as the mechanism for correspondence between the service provider and the end user requires extensive modification of existing communication hardware to provide one or more of the following: greater signal bandwidth, more powerful head-end servers, and more powerful end-user receivers.
As shown in FIG. 1, a typical cable television system comprises four main elements: the head-end 10, a central originating point of all signals carried, where signals are received from service providers (television networks, special channels, etc.) in process; a trunk system 12, the main artery carrying signals through a community; a distribution system (including trunk bridging amplifiers 14), which is bridged from the trunk system and carries signals to individual neighborhoods for distribution to subscribers; and subscriber drops 16, including individual lines 18 to subscribers' television sets fed from taps (Area 1, Area 2 . . . Area X) in the distribution system. The head-end may include a satellite antenna system, tape processing, live programming cameras, signal-processing equipment, pilot carrier generators, combining networks, and equipment for bi-directional interactive services. The subscriber equipment may comprise end-user terminals, converters, de-scramblers, teletext decoding equipment, and the like, depending on the particular service in place and the sophistication in bandwidth of the given system. The trunk system may be physically composed of open air broadcasts, fiber optic lines, coaxial lines, or a combination of each.
In addition to providing video and music programming, in an interactive system, a significant quantity of information must be transmitted to the viewer as part of the interactive service environment. For example, the interactive environment may include several different interface screens utilizing a "multi-media" format (combining several different types of data, video, and audio), and a pointer or other means (such as a control pad-controlled cursor) for interacting with each of the data, audio, and video elements on the interface screen. As yet, no standard transmission or interaction format for the distribution system has been settled upon, and a number of standards are currently under development by television, telephone, or other communications providers.
A number of commercial services currently exist which provide broadcast programming along with data to a home viewer. Perhaps the most basic of these is commonly referred to as "Teletext," and provides cyclical digital data inserted in the vertical blanking interval of a video signal. (The vertical blanking interval is a standard interspersed period in a video signal which is approximately the black level of the signal, used to accommodate retrace periods of display scanning.) The amount of data which may be supported and transmitted by the Teletext system is limited by the bandwidth of the vertical blanking interval. As such, the data capacity is limited and the net result is usually the provision of this format of a few lines of text at the base of a television screen in the user's home. Teletext services can provide a viewer with a wide variety of useful information which can be program oriented, or completely independent of the program. The viewer uses a remote control key pad to select television images, teletext pages, or a combination of both. Some forms of two-way teletext exist, but these systems usually include an entry keyboard and a return link, via a telephone line, to a database.
A second commercial service to provide data over television transmissions is known as the "Sega Channel." The objective of the Sega Channel is to allow users of the Sega video game system to download software games directly from a broadcast channel for use on the game system rather than requiring the individual user to go to a retail store to purchase game cartridges. The Sega Channel broadcasts game program data on a standard cable channel via a cable network, in a continuous data stream of software games which the user may desire to download. Each game is broadcast at a different time, and broadcast information includes game identification information which is decoded by the game system in the user's home and which identifies the game to the system for downloading. The game system shows the individual user a selection menu on the user's television from which the user can select the particular game he or she wishes to download. When the game is transmitted over the broadcast medium at the appointed broadcast time, the game will be downloaded into the game system and the user may then play the game in the game unit. The Sega channel transmission scheme does not include any provision for "backchannel" information from the user to the information service provider.
Another commercial broadcast system which does provide some backchannel communication, but is limited to smaller broadcast environments, is commercially known as "Spectravision." Spectravision is generally set up in small environments such as hotels, resorts, or other limited areas, and the viewer is provided with one or more screens of information for video on demand, and hotel services such as in-room checkout, room service, and billing queries. The user, through an end-user box and accompanying remote control interface, can request in-room movies through the video on demand interface, request account information, or perform a check out, all through the Spectravision interface. Information which must be transmitted to the user in this system includes the complete video on demand menu (several screens of data), customer services menus and summaries of account information on the customer's charges during the stay in the hotel, and menus which the consumer may scroll through on demand and select to perform such services. This usually represents a fair amount of textual information, however, the backchannel communication for such a system is minimal, thereby limiting user response and choice. A local server for the particular small area which Spectravision services is all that is required. Spectravision also provides the viewer with the ability to switch between dedicated Spectravision services and regular full broadcast television services.
In providing interactive services in larger cable network applications, the main problem which arises is that of server and communications overhead. Allowing each subscriber to browse and navigate through all available services, (such as an electronic program guide for video-on-demand services,) creates substantial processing overhead on the head-end server. This, in turn, requires that the speed and capacity of the head-end server be increased for the system as a whole to be commercially effective, which increases the cost of the system.
As shown in FIG. 2, an interactive delivery system requires a physical delivery system which provides backchannel communication. An attempt to provide a fully interactive television interface on a larger scale will be made by U.S. West, Inc., a telecommunications company, which will conduct a trial of an interactive system in Omaha, Nebr. In the U.S. West example, the network configuration will comprise a broad-band network to provide video and data services. The broadband network is comprised of a head-end broadcasting server 20 providing transmission to a plurality of video switches 24 and nodes 26. The video switch will transmit packets of data continuously or in bursts through the broad-band network. The video switch 24 will deliver signals to a node 26 that will serve from 200 to 2,000 homes. From the video node, dual co-axial cables A,B will be used for distributing video signals to a pedestal that will contain video distribution equipment, video interaction equipment, and an optical network unit. As shown in FIG. 3B, the video portion of the network is a dual co-axial cable design, with a sub-split design "A" cable providing 650 mhz of bandwidth to support 77 analog channels, up to 136 digital channels, and 25 mhz of shared upstream (or backchannel) capacity. The spectrum "B" cable provides 500 mhz of bandwidth to support up to 664 digital channels and 107 mhz of shared backchannel capacity. The split design allows for channel frequency compatibility of the analog channels with existing cable-ready TV sets, while the "B" channel provides backchannel capacity anticipated for the more interactive services expected to use digital channels. A spectrum of the transmission bandwidth of approximately 1 GHz is shown in FIG. 3A. This U.S. West embodiment illustrates how the aforementioned problems will result. The communications overhead on the head-end which will result from backchannel communications and viewer demand, even in the limited service area of the experiment, is quite significant.
When a user is browsing or merely viewing the possible selections available from the head-end, communication with the head-end server is required; however, no revenue for the service provider is created during the browsing events. Thus, activities such as browsing increase the cost for all revenue-generating activity. It would therefore be desirable to reduce the load on the head-end server which is required for any such non-revenue generating activity.
In the aforementioned prior art transmission schemes, the bandwidth allocated from the head-end to the home user is quite large in comparison to the backchannel band-width allocated for viewer communication to the server. Because the total amount of bandwidth through the backchannel which will be required at the head-end at any given time will fluctuate with the use pattern of the subscribers (the number of subscribers making demands on the head end at a given time and the activities of those subscribers), such fluctuation will place unpredictable communication latencies on the system. It is important to determine all communication latencies on the backchannel to determine operating parameters for a commercially viable system and for service providers to configure their programming so that the user is not unduly burdened during the periods of maximum latency in the system.
Additional processing overhead is required during handshaking. Handshaking comprises the interaction with all communications to the server involving a response mechanism to the user which ensures reliable communications between the server and the user. A simplified communications model that does not require, or at least minimize, server intervention in handshaking is desirable.
Congestion within the communications pipeline resulting from large bursts of backchannel communication can impair the quality of service to viewers by resulting in a large latency period. A large volume of backchannel communication or a "connection storm" can occur when large numbers of viewers simultaneously request service, as at the start or end of a popular event, or after a power outage when the users are attempting to re-establish service. This again can result in unpredictable latency times.
Each server has a finite bandwidth, and congestion will occur at the server as the number of requests it must handle increases. Indeed, in large scale implementations, a network of servers will be required to distribute requests and balance the load on the network infrastructure, also increasing the expense of providing service to users.
Any one or more of the aforementioned difficulties could result in the interactive viewing experience being less seamless than the viewer currently experiences with analog television signals. For any system which utilizes digital communication technology to transmit data to a viewer to be commercially viable, the system must make the viewing experience appear as seamless as the viewer's current viewing experience. Viewers have come to expect a minimum level of broadcast quality in television viewing, thereby requiring any new system be comparable to current systems in the manner in which programming and information is presented to the viewer.
Thus, it is desirable to provide an interactive system which will overcome the aforesaid deficiencies in a broadcast communications medium.
One means of disseminating a large amount of data over a network and is the "Data Cycle" proposal and research set forth by Bellcore (Bell Communications Research, Inc.). The data cycle is a proposal for a distributed, shared memory database implemented through use of a storage pump which continuously broadcasts the entire contents of the database over a ring network to a series of access managers which control, for example, SQL-type application access to the data which is broadcast on the network. In the embodiments described in a paper entitled "The Datacycle Architecture: A Database Broadcast System", authors Bowen, et al., a data rate of 52 megabytes per second is supported such that a 32 megabyte database stored on a single storage pump is entirely broadcast every 0.6 seconds. A user seeking to extract data from the database initiates a query through an access manager via one of any suitable number of applications. The access manager then extracts the data and provides it to the application and ultimately the user. The database is continually broadcast over the broadcast channel at a repeating rate, and therefore may be updated via an update manager coupled to the access managers and the storage pump.
As described in the Bowen, et al. paper, the system is useful, for example, in providing a directory assistance database which may be continually updated and provided to the directory assistance operators of a given telephone network.
In consideration of the aforesaid problems, a communications system which reduces the overall overhead at the head-end and still provides complete interactivity and a large quantity of information to the user is therefore desirable.
SUMMARY OF THE INVENTION
It is therefore an object of the invention to provide an information delivery system for use with a communications medium which reduces the overall overhead of the system and yet provide full interactivity for the end user.
A further object of the invention is to provide an information delivery system which operates independently of the physical network to which it is applied and thus may be used on a variety of different networks.
Yet another object of the invention is to provide an information delivery system which can be utilized on current communications networks in use throughout the country.
A further object of the invention is to provide the aforesaid objects using conventional signal and compression schemes currently in place.
A further object of the invention is to provide a standard user interface which is intuitive to use and based on current viewing habits, which provides a viewer access to the services available on the information system, and which may be updated as new and different service providers broadcast on the system.
These and other objects of the invention are provided in an information delivery system having a number of inventive aspects. A first aspect of the invention comprises an information delivery system. The system includes a head end broadcasting a data stream of media objects, the head end being coupled to a broadcast television interface and at least one information service provider, and including an encoder for encoding information in the media object. A programming guide delineating programming information available on the information delivery system may be provided in one or more media objects in the data stream in an encoded fashion by the encoder. A user terminal is coupled to the head-end and receives the media objects. The user terminal has an output and includes a decoder for decoding information in the media objects. Also provided is a user interface, at least partially stored in the user-terminal, which selects a user-defined subset of media objects for provision to the output of the user terminal.
The system allows the reduction of head-end server overhead and predictable system latencies, and one can customize the data stream for individual purposes, or provide additional data streams in hybrid systems using both digital and analog signals.
A second aspect of the invention comprises an encoding structure for an information delivery system. The structure makes use of a dictionary library containing terms and common phrases of the information to be encoded. A listing array is provided which includes a set of listing offsets to the terms and phrases in the dictionary library, and a plurality of listing vectors provide offsets into the listing array. A sorting vector contains sorted offsets into the listing vector and can be used to perform queries of the encoded material while the material is encoded.
The encoding structure provides an improvement over conventional coding structures by optimizing the encoded data structure for decoding by the end user terminal in the information delivery system, and gives greater compression ratios than found in currently-employed techniques.
In yet a third aspect of the invention, an information navigation system for an information delivery system is provided. The navigation system includes an electronic program guide, the electronic program guide comprising a listing of programming available on the information delivery system. The navigation system also includes a user interface having a plurality of object representations (such as icons) of various functions of the system, and including a broadcast television interface. The navigation system also includes a smart service navigator which interacts with the user interface and the electronic program guide to provide an output to the user.
The information navigation system works in conjunction with the delivery system and the encoding structure to deliver to the user a seamless, realistic, real-time interactive viewing experience, while minimizing such problems as communications overhead, transmission congestion, unpredictable system latencies, and finite server bandwidths. In addition, the navigation system provides information to the transmission and service providers which allows the providers to optimize use of the network and services.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be described with respect to the particular embodiments thereof. Other objects, features, and advantages of the invention will become apparent with reference to the specification and drawings in which:
FIG. 1 is a block diagram of a conventional cable television network.
FIG. 2 is a block diagram of a communications medium suitable for use with the information delivery system of the present invention.
FIG. 3A is a diagram of a bi-directional trunk system shown in FIG. 2.
FIG. 3B is a diagram of the subdivision of the bi-directional trunk system shown in FIG. 3A.
FIG. 3C is a diagram of the frequency spectrum of the sub-divided bi-directional trunk system shown in FIG. 3B.
FIG. 4 is a representation of an exemplary interface screen which may be provided by an end-user terminal to a user.
FIG. 5 is a table representing media object type, size and bit requirements.
FIG. 6 is a table representing the type and number of media objects suitable for use in a user interface in accordance with the present invention.
FIG. 7 is a block diagram showing the interaction between the MPEG2 transport layer and a network interface in a user terminal.
FIG. 8 is a table representing the bandwidth and space requirements of the objects shown in FIG. 6.
FIG. 9 is a depiction of the encoding scheme for the electronic program guide of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
The interactive information delivery system of the present invention will be described with reference to FIGS. 2-9. Although the system of the present invention will be described with reference to a particular hardware embodiment, and specifically the network embodiment publicly disclosed for the U.S. West trial for Omaha, Nebr., it should be understood that the invention is not limited to any particular hardware configuration. Indeed, a feature of the invention is that the system is designed to be utilized on any number of different communication hardware schemes which may be currently in existence or hereafter developed.
Generally, the invention utilizes a broadcast streaming approach to information delivery through a conventional television distribution network. Through this approach, full motion video, still images, artwork, music, information and other data can be provided to the end-user and used as an information guide to all information sources available on the network to minimize the problems which attend implementing an interactive television system. A single broadcast data stream of such information is repeated at a pre-determined rate, with a "smart" end-user terminal decoding the data stream, thus providing a pre-determined and consistent latency period. The data stream may be broadcast on a single 6 mhz broadcast channel, available on any number of commercial cable television networks (including the U.S. West embodiment set forth above). It should be noted that the particular transmission provider is not critical to the invention.
A unique advantage of this system is that information provided through this format can comprise information which would be considered non-revenue generating, but overhead intensive on the head end. Thus, the overhead on the head-end is reduced without any loss of information to the user. In addition, one or more data streams may be utilized, with each stream serving a particular service provider's special requirements. Thus, the service provider may customize both the individual objects which the provider contributes to a common stream transmitted by, for example, a cable network operator, or may generate an exclusive stream of its own to provide exclusive information to its own broadcast stream.
The information is provided to the end-user terminal in the form of media objects. A second feature of the invention is the digital compression and de-compression of the data. Through the use of MPEG-2 data transport, the data, text, video, and other signals in the broadcast data stream can be sent through the normal broadcast channel and contain enough information to supply the "smart" terminal with program and service information to make the output at the user-end appear to be completely interactive, allowing the user to interact with the data without placing undue burdens on the head-end of the system. The stress and sophistication of interactivity on the end-user of the system can be dependent on the hardware in use at the user-end of the system. As hereinafter described, by using video modulation, a 6 mhz channel will support a bandwidth of 30 Mbps when modulated at 64 quadrature-amplitude modulation (QAM). This yields an effective bandwidth of 27 Mbps for the delivery of media objects, after accounting for transport level error correction coding.
An additional feature of the invention is a user interface and service navigator which generally comprises two components. A first component will be resident at the user-end, in the end-user terminal, and includes the ability to compensate for transmission system latencies. A second component of the user interface will allow the particular service provider at the head-end to program a variety of situation-based responses for the user interface to enact when any communication latencies occur. The provision of these situation-based responses is possible because of the known values for the maximum latency of the repeating broadcast data stream, which is the maximum latency for the system. An overview for the user interface provides a programming navigation format through which the service provider can implement customized menus particular to the broadcast data stream.
Yet another component of the user-interface allows for the recording and storage of user-preferences based on repeated inquiries to the system.
Through use of the broadcast streaming feature, data compression and the service navigator, the user is provided with a fully interactive experience while the stress on the head-end and communication overhead is limited. Hence, the number of video servers required at the head-end is reduced, while the latency of the system is made predictable. Thus, the system of the present invention provides superior navigation to television viewers as they cope with the great number of choices available to them while reducing the hardware overhead required for system navigation.
Additionally, while using digital media objects transmitted in a compressed format, the user is provided with a seamless viewing experience nearly equivalent to that presently experienced with analog signals. A plurality of such objects may be provided to the end user, thereby increasing the quantity of information that a user is exposed to, while allowing the presentation of such information to be manipulated in a common format and into a highly optimized manner for both the user and service providers. This advantage is provided through the use of a "smart" user end terminal, the user interface, and a "smart" service navigator, as will be hereinafter described. The system of the present invention therefore presents a commercially viable improvement to existing interactive television approaches.
In the transmission system shown in FIG. 2, the head-end server 20 is utilized to encode and transmit a plurality of media objects into the data stream into the trunk system. Each media object conforms to a specific model representing composition of various media types, such as video, still pictures, background artwork, music or text. Using each of the media objects, complicated structures can be built from easy to manipulate and simple to define components. Each media object embodies a broad set of functionality requiring minimal effort to construct useful visual, auditory, and sensory output for the user interface.
Each object can comprise data which is provided to the "smart" terminal to define the information which is to be placed in the user interface and displayed to the user, information for the user interface as to how the object should be depicted by the user interface, any information regarding elements for controlling the object (such as buttons, visual gauges, etc.), and code which controls the behavior of the object in the form of scripts or embedded code contained by the object.
Each media object may comprise, for example, an electronic program guide, a short video clip of a video on demand program, or other information which is designed to be a control mechanism for other objects. In such a delivery system, the communications load on the system relies substantially in the transmission of data and images to the network, thereby minimizing backchannel communication.
FIGS. 3A-3C show a block representation of the bi-directional trunk system in use in the U.S. West trial. As shown in FIG. 3B, the trunk system is divided into a uni-directional, analog "A" cable and a bi-directional, digital "B" cable. As shown in FIG. 3C, each cable includes a number of 6 mhz channels which transport the data utilized in the system of the present invention.
The novel user interface and service navigational scheme of the present invention will be described with reference to FIG. 4. FIG. 4 shows components of the user interface, comprising an overview of an interactive interface screen with various different media objects placed thereon. As shown in FIG. 4, typical media objects represent icons for a "media valet," a TV guide (an electronic program guide), a video on demand guide, and a navigation guide. Standard broadcast television can also be provided in a window with a media object used to overlay the picture with current information about the program.
The user interface is designed to provide viewers with optimum choice, but not to overload the user with too many choices which will drive the user to avoid using the interface because he/she is overwhelmed. The interface is designed to leverage itself off what the viewing public currently experiences--integrating new experiences around viewers' existing experiences. The user interface of the present invention uses the predictable response times of the broadcast data stream to offer interactivity to the services offered by the information providers through a consistent look and feel.
The user interface of the present invention is highly visual. The interface items are depicted by representations of themselves. For example, movies can be represented by poster art, and services can be represented by the service logo. As such, the viewer can instantly comprehend the hierarchy and array of items available.
The interface incorporates graphics, music and transition effects which have a quality similar to or equal that of a television picture. By animating the visual display, the display is never idle when waiting for viewer input. Furthermore, the interface provides a navigation platform that may be utilized across different service providers. A standard paradigm provides a singular visual understanding of the categories and hierarchy of items which are available. In one embodiment, the paradigm comprises an organization wherein one moves vertically on the screen to choose between higher level categories, while one moves horizontally to select within the category. As such, more than one menu can be displayed at a given time, and the viewer is less likely to get caught in layer upon layer of menus.
Furthermore the interface is designed to be expandable, so that as more services become available and more programming is offered, they can be easily added to the interface by adding different media objects to the data stream.
A further unique aspect of the interface is the provision of a smart service navigator or "media valet." Through the use of intelligent filtering and weighting algorithms, the interface can be personalized for each viewer household. The media valet acts to record viewer preferences based upon any number of algorithms which can not only record preferences, but make suggestions to the user for programs which the user may find similar or interesting, based upon the viewers recorded viewing habits. For example, the service navigator may note that the viewer tends to view movies in a particular genre with a particular movie star. When a new listing of a movie which fits a similarity profile becomes available, the valet may suggest this option to the user.
The service navigator may be programmed by the user for specific preferences, however a unique aspect of the invention is the that the navigator make such interpretations without any more user input than that required by the user in selecting programming. Such suggestions by the navigator may be automated so that the navigator provides suggestions each time the system is activated, or the suggestions may be provided by a specific user request.
The navigator may be implemented in a manner currently similar to conventional "agency" software. For example, certain types of searching tools currently available for the internet utilize a vector analysis technique wherein a vector map is calculated for each item which a particular user selects as part of a search. Thereafter, when a search for similar items is desired, the software calculates a vector map of the search items and compares this map with the map representing the average of the user's past selected preferences. Only those search items which fall within a certain limited variance from the user preference map are then presented to the user. Applying this technique to the present invention, the service navigator would read and calculate a vector map for each of the selected items which a user views over a given period of time. Thereafter, each time the selection guide is loaded into the "smart" terminal, the navigator can perform an automatic or user-prompted search for similar items, and provide those items to the user.
Yet another aspect of the interface and navigator is to provide interactive programming accessibility through an electronic program guide. The electronic program guide can be made to show the interactive services, such as home shopping and video on demand, as regular broadcast channels in the television line-up, and thus a coherent paradigm is maintained for all services.
An example of how each of the objects shown in FIG. 4 would be used is as follows.
In the television window, the normal broadcast channels may be scanned in a conventional manner by using channel-up and channel-down buttons on a conventional or customized remote control. An advantage of the transmission system of the present invention is that information regarding the station, the length of the program, and the title of the program, can be overlaid on the television broadcast picture using media objects supplying such information which are provided in the data stream.
The overlay can also display tie-ins to other interactive services in the program.
The navigation field can display media objects such as a rotating globe (or any other visual representation), having different categories shown thereon which represent the different programming areas available from the service providers. In one example, the globe could rotate to show different menu items, and posters of each of the particular broadcast or service choices. In this example, the broadcast and service choices could be video objects of the actual images being broadcast at that time on the system. A preview clip of movies and shows can also be shown by directing a pointing mechanism and clicking on the appropriate indicator, and further information regarding each of the services is thereafter provided to the viewer on demand by downloading one or more additional media objects from the data stream. A similar interface can be provided for the video on demand menus. Posters can be shown for the different titles, a preview clip can be requested, and an interactive "buy" button tie-in used to allow the user to purchase a particular video.
The program guide interface can display programs in the current time period, and other time periods, again using a globe or other suitable graphical representation for an interface. The TV guide offers an alternative to scanning channels to find a particular program. Scanning can be incorporated into the guide and customized to implement scanning by time period, or by other additional information available for each program (or service), such as length of running time and/or program stars.
A second aspect of the invention, the broadcast streaming approach provision of data to the end-user, will now be described with reference to FIGS. 5-8.
The broadcast data stream contains all information that the end-user terminal needs to provide basic services for interactive video delivery service. Such basic services could include the electronic program guide (including up-to-date programming information for all available video programming from the head-end); a service navigation system (the "media valet"); and the user interface overview, to provide consistent look and feel across each of the various available services. It should be noted that not all of the information in the broadcast data stream will be required by the end-user terminal at any given time. Indeed, the repetition of the broadcast data stream allows the end-user terminal to select whatever information is needed at a given time. The end-user terminal contains means to decode and decompress the signal, and provide the signal to the user interface. An end-user terminal suitable for use with the information delivery system of the present invention is disclosed in co-pending U.S. patent application Ser. No. 7/970,308 entitled Audio/Video computer architecture, and commercially available as the "REAL 3DO Multi-player System" developed by The 3DO Company and manufactured by Matsushita.
The aforementioned end-user terminal includes a cache memory (see FIG. 7) to which components of the broadcast data stream may be downloaded. The structure of the data broadcast stream is well defined to allow the end-user terminal to cache information as required and remove information from the cache in a seamless manner. Information is then retrieved from the end-user terminal's memory cache, or the broadcast stream, before any request is made to the head-end server on the backchannel. By using a sophisticated end-user terminal, such as the 3DO Multiplayer, in conjunction with the broadcast stream, the viewer can manipulate basic services, such as scrolling through program guide, to determine what programming from the head-end server the individual subscriber desires to view at any given time. The server is therefore not required to continually respond to requests from a number of different subscribers at any given time to conduct repetitive, high-overhead, non-revenue generating activity. The broadcast data stream contains all the necessary information to allow the viewer to utilize the basic services without placing any overhead, other than that required to generate and maintain the broadcast stream, on the server.
In a further aspect of the invention, the broadcast data stream may also include boot code for the end-user terminal. Where the boot code is included in the broadcast data stream, connection storms can be eliminated in the situation which, for example, occurs after resumption of service after a power outage where a number of users will simultaneously request services at the same time. Upon re-initiation of the broadcast data stream, the boot code is provided as a component of the stream to the end-user terminals, and there is thus no requirement for immediate backchannel communication from each user on the system to the head-end server.
General technical assumptions for various particular media objects are shown in FIG. 5. Each assumption defines the average size and bit requirement for each particular object. As shown in FIG. 5, seven types of media objects are contemplated: object code (for the boot code), text, music, still photos, animation, fonts, and short video. Thus, all of the object data could be repeated within the stream with a less than one second period of latency.
FIG. 6 represents the media objects which are required for the user interface and which must be provided to the end-user terminal. The data stream contains media objects for each portion user interface that makes up a set of services which, in a given embodiment, may be considered basic interactive services. As shown in FIG. 6, these basic service interfaces should comprise: a Help And Tours interface; a Video On Demand interface; a Pay-Per-View (PPV) Events interface; the Electronic Program Guide (EPG) interface; a User Preferences interface; a Check Reservations interface; and an Advertising interface. In alternative embodiments, an "expanded" set of services would include additional interface objects, such as a Bulletin Board interface; a Guest Services interface; a Games interface; an Education interface; and a Reference Materials interface.
FIG. 6 shows the number of media objects required for interfaces to basic services and for additional services, and the amount of storage required by all media objects. As an example, consider the electronic program guide media object defined in FIG. 6. The electronic program guide requires one code module, one background photo, one piece of animation, one thousand text objects, one background music object, and one specialized font object for the EPG interface. It should be noted that objects for the additional services could be provided on the same broadcast stream as data stream, or may be provided on a separate, alternative 6 mhz channel. These interfaces are included in FIG. 6 to demonstrate the feasibility of using a broadcast stream with a 6 mhz channel including those interfaces for both the basic services and additional services.
FIG. 7 is a depiction of the interaction of the MPEG transport layer, the end-user terminal 100 and a network interface 110 in the end-user terminal. The user terminal 100 includes the network interface 110, data cache 120 and a communications manager 130. In operation, the output of the head-end for the broadcast stream would use the MPEG-2 transport layer to transmit the media objects to the end-user terminals 100. The network interface module 110 within the user terminal 100 is used to parse the broadcast data stream for desired information. Media object calls are utilized to request information which is read by the network interface 100 and deposited into memory hardware 120 within the user terminal.
The MPEG-2 transport layer uses the model of sending programs or program information description ("PID") packs. In this model, programs are treated as related groups of elementary streams. In the U.S. West test, transport layer hardware (manufactured by Scientific Atlanta) supports four elementary streams per program. These streams are designated for video, audio, and two private data channels, as illustrated in FIG. 7. Each elementary stream is assigned a program information descriptor (PID). Each PID is referenced by a number PID n . PID 0 is reserved and contains a directory of all programs. Each program is referenced by a number PRG n and a two-stage mapping through PID 0 and the program map PID is done to obtain the information contained within the program.
The program reference number PRG 0 contains a directory used to map the naming convention used to request a specific interface to a particular PRG n . The format of the data in the PRG c is completely independent from formats used by the MPEG transport layer or PID 0 .
When the user terminal 100 is brought on-line, such as at power up or by a specific selection by the user, the boot code contained in the data stream is provided to the user terminal. The end-user terminal 100 will interpret the boot code, and initiate a boot process to start the terminal. Once the booting process is completed, a digital tuner (not shown) in the user terminal 100 will tune-in to a pre-selected, default frequency of the broadcast data stream. The particular frequency can be embedded in the boot code, or can be provided in a separate function call to a "Level 2" server which is providing the broadcast data stream. Alternatively, the control channel with the broadcast data stream could be used to request a continuous feed session from the communications manager, and the digital frequency for the broadcast data stream would be returned during the session initiation. This allows the location of the broadcast data stream to be moved dynamically or requested on demand.
The system reserved program reference number PRG c is then read to obtain the directory of the program information descriptor (PID) packs that describe the location, within the broadcast data stream, of the different user interfaces defined by the service providers. The PID packs may follow the hardware standard set forth by the hardware provider (Scientific Atlanta hardware in the U.S. West embodiment), and may be designed to follow any particular hardware of the particular communications network in use. The system reserved program reference number PRG c is then stored in the user terminal's internal memory.
Changes to the user interface are supported by dynamically changing the PIDs for an interface during transmission of the broadcast data stream. These changes should occur after user terminal 100 has stored PRG c . Thus, during idle periods, user terminal 100 re-reads PRG c to obtain any changes in the PID mapping. Alternatively, a well-known mapping scheme between a particular PRG n and the user interface could be used, therefore not requiring PRG c to be read during each idle period. This alternative approach sacrifices making dynamic changes to the PIDs.
The user interface can also include transition effects, which allow seamless transition between different user menus and interfaces. A media object for the transition effects, PRM tc , is located within PRG c and a request is made to network interface 110 to load the PID pack. The transition effects are stored in user terminal 100 in anticipation that the viewer will require use of these effects first.
A media object for the electronic program guide, PRM epg , is located within PRG c , and a request is made to the network interface to load the PID pack. Within 2.3 seconds, the average latency time as noted above, the EPG interface is loaded into the user terminal 100 and may be presented to the viewer. When the viewer requests either the EPG or the necessary information will already be loaded into user terminal 100 for provision to the user.
Note that user terminal 100 may utilize the transition effects between screens during the latency period. In essence, the viewer sees a seamless interface transmission, and to the viewer it appears that the system is interacting with the host to obtain the information requested by the viewer. Thus, the latency period is less noticeable to the viewer as the particular transition effects provide video, audio, or other information to occupy the viewer during the latency period.
A session with the broadcast data stream will remain active until the digital tuner is required for other purposes.
An example of the response of the system to a particular user request using the example of a user request to a main menu screen is as follows. When a viewer wants the main services menu, a media object PRM main menu is located within PRG c . The digital tuner, if tuned to an alternative digital frequency as discussed above, can be retuned to the data stream. A request is made to the network interface in the end-user terminal to load the main menu PID pack. A graphic or animation object is then used as a transition to the new interface, thus masking the latency and the potential re-tuning to the broadcast data stream. Within an average of 2.3 seconds, the interface is ready to be presented to the viewer. The previous EPG data is held in memory cache 120 in user terminal 100 as long as possible before being expunged from memory. Alternatively, the information for the main menu could have been located in memory cache 120 if it had previously been used, thus avoiding the data stream access.
Should the viewer want video on demand data, the operation would be similar as that described to the main menu function. The media object for the video on demand, PRM vod , is located within PRG c . The digital tuner, if necessary, would be re-tuned to the broadcast data stream, and a request made to the network interface to load the video on demand PID pack. When a selection is made by the user based on the information provided in the PID pack, the digital tuner can tune to an alternative channel where the video on demand will occur.
Such media objects for VOD can include PRM vod posters, which can include a set of posters representing the different movies available on video on demand. The media object can also include PRM vod previews which can include a short video clip of the movie which is available in the video on demand service.
Bandwidth management and selection of media objects from the MPEG-2 data stream are handled by calls to network interface 110. The throughput from the network interface should be sufficient to handle the data rate for the PID packs for the user interfaces. Likewise, the data requirement from the PID packs from the interfaces should not exceed the range of the network interface. (Both criteria are met using the aforementioned 3DO Multiplayer as the end-user terminal.)
The potential does exist for data to be missed by the end-user terminal. In such cases, because there is no communication from the end-user terminal to the head-end server, the end-user terminal must delay for the worst case latency period until the missing data appears in the data stream.
The service system models set forth above give rise to a number of variations which are considered to be within the scope of the invention.
In some embodiments, interactive services which will utilize even greater degrees of backchannel communication to the host head-end, can also be included. Nevertheless, even in embodiments where significant backchannel is required to provide information to the head-end, one or more alternative streams can be provided by the head-end server to include such information as, for example, the Sears, Roebuck & Company catalog. Again, such a broadcast channel would operate under the same principles set forth herein, wherein all the information which is required by the user to browse through the particular selections can be provided continuously on a repeating data stream. The user terminal will then extract from the data stream based on the interfaces supplied by the service provider, in this case Sears, Roebuck & Company. In such instances, again, the backchannel is reduced to that required for ordering specific components from the service provider. In the Sears, Roebuck example, the only overhead which is required by the service provider is the provision of the transmission bandwidth and the overhead at the server.
While the interface shown in FIG. 4 represents one example of a user interface screen which may be incorporated as part of the present invention and utilized with the broadcast streaming approach, other types of interface screens, which do not use iconic representations of media objects, may be utilized within the context of the present invention. The system includes the capability to incorporate real time images as part of the viewing experience. For example, service providers whose main business consists of retail clothing sales may wish to display goods available for retail purchase in a representation which presents the user with an example of how such goods would appear in a real world situation. A clothing manufacturer may wish to show off a new collection by, for example, showing a scene where the clothes are worn by individuals at a social function, such as a cocktail party, allowing the viewer to see how the clothes appear in one environment in which the clothes might be used. If the user wanted further information on a particular item, the user could direct a cursor (using, for example, a remote control) to "click" on the particular item of interest and additional information about the item could be displayed. The foregoing example is merely one of the many types of interactive means a service provider might utilize with the interface of the present invention. Since the media objects may be manipulated by the service providers, the appearance of the interface may be customized for individual service providers on a desired basis.
Another example of the contemplated uses of the interface in conjunction with the broadcast streaming approach include the provision of a "barker" mode in which advertising objects can be inserted into the stream and displayed to the user without user interaction. (A "barker" is a person who advertises by hawking at the entrance to a show.) In this case, the barker mode could be active and utilized with either the user interface discussed with respect to FIG. 4 or the real-world interface example set forth above. In either case, the advertisement can be output to the viewing screen as a tease to the viewer regarding a particular product or service.
The barker mode can be tied into the smart service navigator. For example, the service navigator can record the types of products and services which the viewer purchases through on-line services, and/or the advertisements or products which the viewer may select, over a period of time, to view more information on. This file may be sold by the cable provider to service providers, or may be user controlled, so that the user has the opportunity to sell access to the viewer's own preferences to the transmission provider or the service providers. The barker mode could also be viewer controlled to prohibit such advertisements from appearing on the viewer's individualized user interface. The information gathered by the service navigator could also be utilized by the service providers to provide viewer or group specific programming.
Still further variations of the system of the present invention exist with respect to the smart service navigator. For example, the service navigator itself need not be limited to a service navigator which is provided by any one source, such as the transmission provider. Second source providers could develop customized, field optimized navigators for particular fields of interest, such as movies, commerce, or television.
In addition, in a further variation on the information gathering concept set forth above with respect to the commercial service providers, the navigator may gather general information feedback on viewer habits, and such information can be used by the service providers to optimize system broadcast performance. For example, if the service providers know that viewer demand for a particular program is greatest during a particular period, the provider can adjust program scheduling accordingly. This information could also be used to assess the number of viewers utilizing a particular service, and the frequency of such use, when determining revenue issues between the transmission provider and the service provider. Thus, the system of the present invention provides a mechanism wherein the broadcast system can be optimize information transmission by compensating for heavy load demands on the head end of the system.
Still another variation on the use of the service navigator includes allowing the navigator to continue operating in the background, while the viewer is engaged in viewing a currently running program, or while the viewer's television is off, while the viewer is away from the home, etc. In this mode, the smart navigator may be acting on behalf of the user, selecting, sorting and queuing information for the viewer when the viewer returns. As will be readily understood, this mode of the smart navigator could be combined with a "barker" mode wherein when the viewer returns to view the system, those programs of interest can be relayed to the viewer.
Other variations of the various examples set forth herein are contemplated for use with the present invention, and are considered to be within the scope of the invention.
It should be noted that the particular user terminal which is required for use in the system is also independent of the system architecture. While the architecture described herein has been set forth with respect to the interactive game system produced by The 3DO Company, the system would work equally as well with hardware from various vendors, and personal computers such as the Macintosh and PC-compatible computers. With each different embodiment of hardware, different data types would comprise the different media objects, each data type being specific to the particular platform.
FIG. 8 shows the size requirements, overall bandwidth requirements, and transmission times, for each user interface, and the worst case latency (equal to the total period for repetition of the data stream) for the system as a whole. As shown therein, the total required bandwidth (basic and additional services) is 93.2 megabits, or 3.84 seconds. Thus, 3.84 seconds defines the worst case latency for the system, with the average access time required to obtain a particular piece of information being 1.92 seconds. The interfaces beyond those of the basic services account for 37.0 megabits of data or 1.5 seconds latency.
Thus, for a stream that supports only the base services, and given the 27 Mbps bandwidth of the U.S. West environment, the bit requirement on such a system would be 56.2 Mb, or a worst case latency of 2.3 seconds. This means that an average access time to information would be half of 2.3 seconds, or 1.15 seconds.
In the embodiment set forth above where the end-user terminal 100 contains a cache memory 120, information could be cached in the end-user terminal for one or more previously-used interfaces to provide rapid access without using the broadcast stream. It should be noted that the system of the present invention may be utilized in combination with any amount of backchannel communication from the user terminal, for example, for use in selecting different services such as pay-per-view, home shopping, and interactive games. However, the data stream includes all necessary media objects which are required by the subscriber to obtain information about the various services available from the service provider. Once the viewer decides upon a particular service or program, the viewer can make a selection, and only at that time does the viewer make use of the backchannel to the head-end. Note that the function selected can be provided on a separate, 6 mhz broadcast channel, and that the user interface can include the necessary instructions to have the user terminal re-tune to a different broadcast channel to access the service. Alternatively, additional broadcast data streams can be provided on other broadcast channels, with objects for specific services on that channel, the user interface and terminal can begin decoding in a manner that is transparent to the viewer.
In still another embodiment of the invention, the system can be utilized with low bandwidth transmission systems. A storage medium can be provided at the user-end of the system, and information which might otherwise be provided as media objects in the stream can be stored on the disk and accessed by calls from objects in the stream. In this variation, the amount of information provided in the stream versus the amount of information provided on the storage medium can vary, depending on the particular application. The storage medium could comprise, for example, a computer's hard disk, or a CD ROM. In a practical example, a catalog distributer of retail items may desire to provide a separate broadcast data stream, but the amount of information necessary to input into the stream may be prohibitive. In such a case, the distributor could store on a CD ROM a number of the media objects normally input into the stream, such as particular items of clothing which the distributor will carry for a long period of time, or other presentation objects such as backgrounds, music, and animation, which the distributor will use on a repeated basis to present items to the viewer/consumer. The information on the CD ROM can be updated periodically, by distributing additional disks, but the information on how the stored data is to be manipulated can be dynamically updated almost instantly from the data stream. The data stream can also include price information, special sale information, and "barker" instructions. In this embodiment, significantly less bandwidth is required to provide the user with a great deal of information.
A further aspect of the present invention is the manner in which the information provided via the broadcast data stream is manipulated by the end-user terminal in the system. FIG. 9 is a representation of a novel method of encoding information for use with the end-user terminal in the system of the present invention.
Certain end-user terminals suitable for use with the present invention will have a limited memory capacity. In such cases, some form of compression or encoding of the data to be stored in the memory is desirable, however such compression or encoding should not adversely affect the response time of the system.
As noted above, one feature of the system is to provide superior navigation to television viewers. In accordance with this object, superior use of the information database provided by the service providers may be made in the system by providing additional information infused with the information from the service providers. In one aspect, each service provider's database can be extended with additional fields and information licensed from other providers, which then can be integrated with the information provided from the service provider. Such information can include demographic information, ratings, etc. Further, through the use of encoding techniques and delivery protocols, the end-user terminal can be instructed to store user databases and memory and perform efficient searches without access to the server or via a backchannel communication scheme. Information captured from viewers while using the information system is used to provide assistance to the viewer in the future. As noted above, the "media valet" can provide choices to the viewer that are tailored to past interests and habits.
In accordance with these objects, it is extremely desirable to store the EPG and other databases in the user terminal for use on an "as-needed" basis. This guarantees predictable and rapid response to requests made by the viewer in the situations where the viewer is watching television and requests information, the viewer scrolling through the EPG, or the viewer is browsing through pay-per-view and video on demand listings.
In storing the essential databases for use with the system of the present invention, the electronic program guide, the video on demand database, and the pay-per-view database, an understanding of the storage demands of such databases is required.
As an example of the encoding scheme of the present invention, the electronic program guide database specification and requirements are hereinafter described.
The amount of data used to represent seven days of electronic program guide listings is approximately 1.70 megabytes depending upon the programming appearing during the week. These are the storage requirements for data supplied by the Tribune Media Company for programming in the San Francisco Bay Area.
The electronic program guide and video on demand data includes the following information: start time; duration; title; channel; description; subtitle; part sequence; actors and directors; genre; year; rating; warning; category; short movie description; and long movie description. The specification of 1.70 megabytes of data is a specification for raw text with embedded tags to designate different data fields. Indexing and searching structure is not included in the text size. 1.7 megabytes of text is approximately equal to 8,761 program listings at 193 bytes per listing. An index for the electronic program guide is larger than the electronic program guide itself, occupying 1.96 megabytes. This full text index is used to search arbitrarily for words in the electronic program guide. This also assumes 48 cable channels: comprised of 21 network channels and 27 cable channels. The cable channels, while having more bytes per listing than network channels, have fewer listings due to generally longer program times. As a result, the total memory requirement to store searchable, weekly electric program guide is 3.7 megabytes.
Because this may be beyond the memory capacity of many of the user terminals suitable for use with the system of the present invention, an encoding scheme may be utilized to reduce the storage requirement for the electronic program guide data set.
Several alternatives for this encoding scheme exist. The first alternative is to reduce the amount of information used in the electronic program guide. For example, the minimal electronic program guide could comprise data for the start time, duration, title, and channel. This reduces the memory requirement, but sacrifices most of the descriptive information and would limit the amount and quality of the information provided to the viewer in the media valet. A second alternative is to create an algorithm that stores the reduced data set from the first alternative in the user terminal and simultaneously generates a request to the Level 2 service provider's gateway for more detailed information. This provides a limited yet rapid response to the viewer's request with the gateway providing the detailed information. This creates a multi-mode situation in the interface, where the user would have an immediate response with limited information, with detailed information appearing later depending on the response time of the gateway.
Another alternative is to use a smaller data set. A window of time can be chosen in which sub-sets of the entire electronic program guide (i.e., a daily electronic program guide or an hourly electronic program guide) are saved to memory. This would give the user full information immediately for the current time window, but sacrifice the viewing and potential recording of future programming without first accessing the server or communication channel.
Still another alternative is to use a single communication channel to query a server resident database. This places all the database information on the server and frees memory space in the end-user terminal. However, the network must now handle more traffic for browsing activity done by the viewer. It also requires a response from a Level 2 gateway that is timely and consistent to provide rapid response to viewer requests.
Still another alternative is to store a compressed version of the electronic program guide in the end-user terminal. Using LZW compression (a common compression technique) on the electronic program guide, the data size of the electronic program guide can be reduced from 1.7 megabytes to 509 kilobytes. At these data sizes, a conventional end-user terminal suitable for use with the system of the present invention could store the data, but neither of the techniques allows selective decoding to access only a portion of the information. The entire electronic program guide would have to be decompressed before the data could be accessed. This decompression time would add to the overall system latency and would require the end-user terminal to store the decompressed data.
Finally, the electronic program guide information can be encoded into a data structure that uses a dictionary format and which relies on the redundancy of T.V. data to reduce its overall size. This would remove the redundant use of words and phrases from the electronic program guide to achieve storage savings. The dictionary format could provide sufficient savings to store the electronic program guide and a searching structure within a limited storage capacity available on such conventional end-user terminals. Ideally, the savings achieved by encoding this information would rival the savings achieved by the LZW compression.
However, unlike the compressed formats, the encoded format can be used directly to create text displays and perform searches.
An encoding scheme in accordance with the present invention is shown in FIG. 9. The program listing contains an array of offsets to the dictionary of terms utilized to build the EPG. A listing vector contains offsets to the program listing structure for each program listing. The offsets are 4 bytes that allow 4 gigabytes of data to be referenced. The vector has a maximum of 65,535 entries that can be referenced by using 2-byte offsets into that vector. A sort vector contains sorted 2-byte offsets to the listing vector. There may be many sort vectors constructed from fields in each program listing, for example, by sorting by title, sorting by channel and time, etc. A binary search (a common searching technique) can be used to locate the particular program listing through the appropriate sort vector. The sort vector shares with the listing vector the same maximum of 65,535 entries that allows all listing vector entries to be referenced.
As shown, the Program Listing structure is comprised of a listing/header and Run Length encoded fields. Some electronic program guide information that is common to all listings will be quantized into the listing header. All other information appearing in the program listing will be represented by a field I.D., a length, and a series of 2-byte offsets to the dictionary vector. To locate a particular field I.D., the listing headers would be traversed until the field I.D. is located.
Finally, a dictionary is shown which contains all the words found in the electronic program guide. Frequent phrases are also encoded into the dictionary to take advantage of the redundant use of program titles and descriptions. The case of the words is maintained in the dictionary, and punctuation is also entered with the words. This allows the dictionary to faithfully recreate a line of text with proper case and punctuation. However, original word spacing is not maintained. The dictionary is made up of two structures. The dictionary word table contains all the words, while the dictionary vector contains 4-byte offsets to the dictionary word table. This implies a maximum of 65,535 entries in the dictionary, and 4 gigabytes of dictionary data. Sort vectors can also be associated with the dictionary vector. (These maximum values are purely representative of this particular example.)
Using the proposed technique to encode the aforementioned electronic program guide for the San Francisco Bay Area, seven days of data can be encoded to a data space of 438 kilobytes including search indexes. Seven days of data now also comprises 8,761 program listings occupying a total space of 50 bytes per listing. The keyed search index necessary to create the electronic program guide display is 18 kilobytes. Each additional keyed index requires only 18 kilobytes. The index used to locate program listings where a given word appears would be an additional 289 kilobytes. This would be equivalent to the full text index described above at 1.96 megabytes. This index would answer such inquiries as searching for all movies by a particular actor, or all movies in a particular movie category type, such as comedies. The proposed encoded format is therefore a competitive one compared with the results achieved with the LZW compression on the original EPG text.
Additional improvements of the proposed format can achieve additional savings over the estimated 438 kilobytes. For example, were one to identify and remove additional redundant information, such as short and long movie descriptions which are essentially the same, would reduce the storage requirement by approximately 4% to 421 kilobytes at 48 bytes per listing.
In addition, one could reduce the information used in the electronic program guide. As set forth above, the minimal required electronic program guide information would be the start time, duration, title, and channel. This would reduce the storage requirement by 64% to 156 kilobytes at 17 bytes per listing. The time window concept described above as a stored alternative could also be used. A daily window would require approximately 22 kilobytes per day. To add back the description of information, the mixture of EPG information would become start time, duration, title, channel, description, short movie description and long movie description. This reduces the storage requirement by about 22% to 342 kilobytes at 39 bytes per listing. Using short movie descriptions instead achieves 26% savings to 325 kilobytes at 37 bytes per listing.
In addition, one could restrict the text used to build the full text index. Only those fields deemed important (i.e. titles, descriptions, actors) would be utilized. This would reduce the additional 286 kilobytes required for this index. Finally, the format used for encoding the electronic program guide can be matched with the algorithm used for compression. If data compression is used on the encoded format to reduce the electronic program guide bandwidth requirement, the format for the encoding could produce redundancies that the delivery impression algorithm could locate. This would produce better compression and result in additional time savings during delivery.
The video on demand and pay-per-view databases could be encoded using the same technique for similar storage savings. A sample from the video on demand data covering titles beginning with the letters "e" and "f" is used as an example. This would represent 2,837 listings or 1.3 megabytes of data at 442 bytes per listing. The proposed encoded format set forth above with respect to the electronic program guide reduces the storage requirement by 54% to 461 kilobytes at 162 bytes per listing. Extrapolating from the listings for the letters "e" and "f" to the full alphabet results in approximately 44,000 listings or about 7.2 megabytes of data. This memory estimate includes a single search index which could be assigned to any field comprising the video on demand data set. Each additional search index would require 88 kilobytes.
The intelligence of the user terminal could therefore completely relieve the Level 2 server from the task of database searching for the electronic program guide and video on demand database. If the Level 2 gateway instead sent those databases entirely through the broadcast data stream, the end-user terminal could perform the searches with predictable response times. If the video on demand database were encoded into a separate data stream, the delivery time for the video on demand information would be 2.1 seconds (assuming a 7.2 megabyte database transmitted at 27 Mbps).
The user interface is designed to provide viewers with optimum choice, but not to overload the user with a too many choices which will drive the user to avoid using the interface because they are overwhelmed. The interface is designed to leverage itself off what the viewing public already experiences--integrating new experiences around viewers' existing experiences.
The user interface of the present invention uses the predictable response times of he broadcast data stream to offer interactivity to the services offered by the information providers through a consistent look and feel.
First, the interface is highly visual, as shown in FIG. 4. The interface items are depicted by representations of themselves. For example, movies can be represented by poster art, and services can be represented buy the service logo. As such, the viewer can instantly comprehend the hierarchy and array of items available.
The interface incorporates graphics, music and transition effects which have a quality similar to or equal that of a television picture. By animating the visual display, the display is never idle when waiting for viewer input. Furthermore, the interface provides a navigation platform that may be utilized across different service providers. A standard paradigm provides a singular visual understanding of the categories and hierarchy of items which are available. In one embodiment, the paradigm comprises an organization wherein one moves vertically on the screen to choose between higher level categories, while one moves horizontally to select within the category. As such, more than one menu can be displayed at a given time, and the viewer is less likely to get caught in layer upon layer of menus.
Furthermore the interface is designed to be expandable, so that as more services become available and more programming is offered, they can be easily added to the interface. In a further aspect, the interface can be provided in a unique, real-world representative mode. Through customization of various media objects, service providers can add or change the interface based on the provider's particular applications or needs.
A unique aspect of the interface is the provision of a "smart" media "valet". Through the use of intelligent filtering and weighting algorithms, the interface can be personalized for each viewer household. The valet can operate in a foreground or background mode, can gather information about the user for the benefit of the user and service providers, and increases the efficiency of the viewing experience for the viewer.
Yet another aspect of the interface is to provide interactive programming accessibility through the EPG. The EPG can be made to show the interactive services, such as home shopping and video on demand as regular channels in the television line-up, and thus a coherent paradigm is maintained for all services.
The various objects and advantages of the present invention will be apparent to those skilled in the art. Numerous modifications to the system, and variations to the means for distributing data over a communication medium, will be obvious to those of average skill in the art. For example, the information system is independent of the particular communications medium upon which it is used. Furthermore, the system is not limited to a single broadcast stream, but may include many different broadcast streams for transmitting data. Various methods of providing the media objects to the user, either entirely through the stream, or with a portion stored in the user's terminal, are contemplated. As an additional example, the system is not limited to the use of any particular end-user terminal, but may be utilized with any number of different end-user terminals. Such modifications are intended to be within the scope of the invention as disclosed in the instant written description, the figures, and the following claims.
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An information delivery system including a head end broadcasting a data stream of media objects, the head end being coupled to a broadcast television interface and at least one information service provider and including an encoder for encoding information in the media object is disclosed. The system may deliver and implement a programming guide delineating programming information available on the information delivery system in one or more media objects in the data stream in an encoded fashion by the encoder. A user terminal is coupled to the head-end and receives the media objects. The user terminal has an output and includes a decoder for the media objects. Also provided in one aspect is a user interface, at least partially stored in the user-terminal, which selects a user-defined subset of media objects for provision to the output of the user terminal. Further, an information navigation system for an information delivery system is provided. The navigation system functions with the electronic program guide and includes a user interface having a plurality of icon representations of various functions of the system, and including a broadcast television interface. The navigation system also includes a smart service navigator which interacts with the user interface and the electronic program guide to provide an output to the user.
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BACKGROUND OF THE INVENTION
This invention relates to shock absorbers and, more particularly, to a hydraulic shock absorber for use in protecting the drill bit and drill string from shocks produced by the vibrational energy developed in rotary drilling through rough and broken formations.
BRIEF DESCRIPTION OF THE PRIOR ART
Many different types of shock absorbers have been designed for use in rotary drilling operations. Most of the prior devices have a trapped gas located inside a variable volume container. By reducing the volume of the container with upward movement of a lower component through a lower sub, the trapped gas is compressed thereby increasing the resistance to the upward movement within a telescoping component. Likewise, when the lower component moves downward from the telescoping component, the volume of the trapped gas increases thereby offering less resistance to upward movement within the telescoping component. The movement within the telescoping component is normally initiated by forces on the drilling bit.
Other types of shock absorbers used in rotary drilling include an elastomeric substance located between telescoping elements of the shock absorber. The elastomeric substance is unsuitable in high temperature and certain chemical environments and life is relatively short for this type of device.
Still another type of shock absorbing device is disclosed in U.S. Pat. No. 3,382,936 and consists of an air bag filled with pressurized air with the volume of the air bag being changed in response to telescoping movement of the lower element inside a casing. The problem with using a pressurized bag of air in a shock absorber becomes apparent when the downweight on the drilling bit is substantially varied. Since the shock absorber must be preset with a predetermined air pressure for a given drilling condition, when drilling conditions change the shock absorber will be considerably less effective.
SUMMARY OF THE INVENTION
The present invention is directed to a hydraulic shock absorber comprising an upper sub connected to the upper end of a casing enclosing a plurality of axially aligned hollow pistons slidably mounted therein, the casing being connected at its lower end to a lower sub enclosing an anvil slidably mounted therein. Drilling fluid flows through the string of drilling pipe, into the upper sub and through the hollow pistons before leaving the shock absorber via the anvil. Each piston is comprised of a radially extending flange for sealing against the casing and a sleeve extending downwardly through a seating ring connected inside said casing. Pressure outside the casing feeds through holes in the casing to an annulus between the flange and the seating ring. The sleeve is held downward by a force equal to the pressure differential between the pressure inside the casing and the pressure outside the casing times the pressure differential area of the piston.
As downweight on the drill bit reaches a predetermined level, the anvil will slidably move upward inside the casing until it abuts the bottom piston. Further increases in the downweight will move the anvil and bottom piston into abutting engagement with the next adjacent piston. If the downweight on the drill bit is further increased to overcome the downward force on the second piston, the second piston will move upward with the first piston and anvil until the second piston abuts a third piston located thereabove. The procedure may be repeated for as many piston stages as are contained in the hydraulic shock absorber. A predetermined number of slidable pistons will be in abutting relationship depending upon the pressure differential, differential pressure areas of the respective pistons, and the downweight on the drill bit.
Assume for example that a predetermined downweight is being applied to a drill bit, and the anvil has reached its optimum position by successive abutments of a predetermined number of pistons. Thereafter, if the downweight is suddenly decreased by any action, such as the drill bit breaking through a hard formation, the number of pistons acting in successive abutting relationship against the anvil will be decreased by movement of the anvil in the lower sub. The vibration caused by the sudden change in operating conditions of the drill bit will be substantially attenuated by the hydraulic shock absorber.
It is important that sufficient flow exist from outside the casing to the annulus formed between each respective seating ring and flange, and from the center flow passage of the piston to the annulus formed below each respective seating ring so that each stage of the shock absorber will have a fast reaction time to allow fast response to changing conditions on the bottom of the hole.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is an elongated cross sectional view of the hydraulic shock absorber with the anvil partially retracted in the casing.
FIG. 2 is an elongated cross sectional view of the hydraulic shock absorber with the anvil fully extended from the casing.
FIG. 3 is an elongated cross sectional view of the hydraulic shock absorber with the anvil fully retracted inside the casing.
FIG. 4 is a cross sectional view of FIG. 1 along section lines 4--4.
FIG. 5 is a cross sectional view of FIG. 1 along section lines 5--5.
FIG. 6 is a cross sectional view of FIG. 1 along section lines 6--6.
FIG. 7 is an enlarged view of a portion of the hydraulic shock absorber depicting the first stage piston.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIG. 1 of the drawings, there is shown the hydraulic shock absorber represented generally by the reference numeral 10. The hydraulic shock absorber 10 has an upper sub 12 for connection in a string of drilling pipe by means of threads 14. A center flow passage 16 extends through the upper sub 12 for receiving drilling fluid from the string of drilling pipe. The upper sub 12 is connected to a casing 18 by means of threads 20. A lower sub 22 is connected to the bottom of casing 18 by means of threads 24.
Inside of lower sub 22 is mounted an anvil 26 by means of a spline connection 28 as can be seen in more detail in FIG. 6. By means of the spline connection 28, the anvil 26 is free to slide along the longitudinal axis of the hydraulic shock absorber 10 between limited stops. The lower stop of the anvil 26 is controlled by split ring 30. The split ring 30 is formed from two identical halves of a cylinder split along the longitudinal axis which halves are in an abutting relationship. The split ring 30 encircles the upper portion of anvil 26. An inwardly directed flange 32 of split ring connection 30 is received in undercut 34 of anvil 26. If anvil 26 were to move downward inside of lower sub 22 to its lowermost position, the bottom 36 of the split ring connection 30 would come to rest against the top 38 of the lower sub 22 to prevent further downward movement. V-slots 40 (See FIG. 5) extend the entire length of the split ring connection 30 to prevent drilling fluid from being trapped in annulus 42 thereby impeding longitudinal movement of the anvil 26. The construction of the split ring connection 30 can be seen in FIG. 5 in combination with FIG. 1.
Below the spline connection 28 are sloping cross bores 44 connecting to a center flow passage 46 of the anvil 26. The sloping cross bores 44 prevent fluid wash along the spline connection 28. Seals 48 between anvil 26 and lower sub 22 prevent the leakage of drilling fluid therebetween. The pressure outside the hydraulic shock absorber 10 (represented by the symbol P O ) is less than the pressure inside the hydraulic shock absorber (represented by the symbol P I ) by an amount substantially equal to the pressure drop across the drill bit (not shown). The anvil 26 is normally connected to a drill bit (not shown) by means of threads 54. Upward movement of the anvil 26, as will be subsequently described in more detail, is limited by the upper stop formed from an abutment of shoulder 50 with the bottom 52 of the lower sub 22.
Inside the casing 18 are located a plurality of hollow pistons, designated as first stage piston 121, second stage piston 122, third stage piston 123, fourth stage piston 124 and fifth stage piston 125. The pistons have similar components consisting of flanges respectively designated as 82, 98, 100, 102 and 104 and downwardly extending sleeves respectively designated as 70, 90, 92, 94 and 96. The sleeves are slideably received in seating rings designated respectively as 56, 106, 108, 110 and 112 which are connected to the casing by means of hollow screws 58 having passages 64 communicating through casing 18.
In the unloaded condition as illustrated in FIG. 2, each of said pistons is separated from the adjacent piston by a finite distance in order that they will be sequentially activated upon upward movement of the anvil.
Referring now to FIG. 7, a detailed description of the pistons and seating rings will be given for the first stage piston 121. The arrangement and function of each of the pistons is identical. It is also to be noted that in the preferred embodiment, the casing is described as a unitary member, however, it may be desirable to construct the casing in segments, each segment housing a single piston with the seating ring forming an integral part of the casing segment.
A seating ring 56 is held in position by hollow screws 58 above anvil 26. The seating ring 56 seals with casing 18 by means of seal 60. The screws 58 have a passage 64 communicating from outside the casing 18, to an annulus 68 formed between the seating ring 56 and sleeve 70 of first stage piston 121. The sleeve 70 is slidably received inside of the seating ring 56. The sleeve 70 is slidably seated with the seating ring 56 by means of seal 72. The bottom 74 of sleeve 70 has a series of cross slots 76 to allow fluid pressure through sleeve flow passage 78 to act across the entire bottom 74 of the sleeve 70 and the top 80 of anvil 26. Also, cross slots 76 allow fluid to pass in and out of chamber 75.
The piston 121 has a radially extending flange 82 that slidably seals with casing 18 by means of seal 84. As can be seen from the drawings, the surface area 86 below the radially extending flange 82 is subject to pressure P O via annulus 68 and passage 64. The pressure P I is acting on the upper surface area 88 and bottom surface 74 of piston 121. The pressure P O is acting on the surface area 86. The net downward force acting on piston 121 is the pressure P I minus P O times surface area 86.
METHOD OF OPERATION
Referring now to FIG. 2 of the drawings, the hydraulic shock absorber 10, previously described in conjunction with FIG. 1, is shown with the anvil 26 in the fully extended position with the bottom 36 of the split ring connection 30 resting against the top 38 of the lower sub 22. The maximum distance is separating shoulder 50 from bottom 52 of lower sub 22. By referring to each successive stage above anvil 26, it can be seen that the pistons 121, 122, 123, 124, and 125 are in the full down position, therefore, each of the pistons has a net downward force thereon equal to P I minus P O times the pressure differential area of each respective piston, namely the area of surface 86. It should be understood that the primary differential area of each piston can be varied by varying the cross sectional area of the sleeve.
As a typical illustration concerning the use of the hydraulic shock absorber 10, assume that the pressure drop across the drill bit is approximately 850 psi, therefore, P I minus P O is approximately equal to 850 psi. If the effective area of the anvil 26, as defined by seals 48, is approximately 21.6 in. sq., the downward force caused by the pressure drop is equal to 850 psi times 21.6 in. sq., or 18,360 lbs. of force tending to move the anvil 26 to its lowermost position. Therefore, during normal drilling operations a total of 18,360 lbs. of downweight must be exerted on the drill bit to overcome the downward force on the anvil 26. Once the downweight exceeds 18,360 lbs., the anvil 26 will slide upward in the spline connection 28 until it abuts the bottom 74 of piston 121.
The piston 121 forms the first stage of the hydraulic shock absorber 10. Piston 121 is held down by a force equal to P I minus P O (850 lbs.) times the surface area 86 of the flange 82. Assume the surface area 86 is approximately equal to 11.4 in. sq. Then, the downward force acting on the first stage is equal to 850 lbs. times 11.4 in. sq. which equals 9,690 lbs. Once the downweight on the drill bit has increased by an additional 9,690 lbs. so that it now exceeds 28,050 lbs., both the anvil 26 and the first stage will move upward until the first stage abuts the second stage.
Assuming the surface area below flange 98 of piston 122 is 11.4 in. sq., the downweight on the drill bit must increase by an additional 9,690 lbs. to a total that exceeds 37,740 lbs. downweight on the drill bit before any subsequent upward movement of the anvil 26 occurs. Any downweight in excess of 37,740 lbs. will move the anvil 26, the first stage and the second stage of the hydraulic shock absorber 10 upward until the second stage abuts piston 123.
Assume now that the surface area below flange 100 of sleeve 92 is approximately 12.5 in. sq., then the additional force necessary to raise the third stage is equal to 10,650 lbs. for a total downweight in excess of 48,365 lbs. When the downweight on the drill bit exceeds 48,365 lbs., the anvil 26 and the first, second and third stages will move upward until the third stage abuts the fourth stage piston 124.
Assuming that the effective surface area of both remaining stages are also 12.5 in. sq., then downweights of 58,990 lbs. and 69,615 lbs., respectively, will be required to displace these stages.
Once the total design limitation of the hydraulic shock absorber 10 has been exceeded by the 69,615 lbs. downweight given in this illustration, the shoulder 50 of the anvil 26 will abut bottom 52 of lower sub 22. Any additional downweight will be transmitted directly through the casing 18 from the string of drilling pipe (not shown) to the drilling bit (not shown). A typical example of the hydraulic shock absorber 10 which has exceeded its design limitation is shown in FIG. 3 wherein each stage of the hydraulic shock absorber 10 has been raised from its respective seating block, and shoulder 50 of anvil 26 abuts bottom 52 of lower sub 22. FIG. 1 illustrates a typical operating condition wherein stages one, two and three have been raised from their respective seating blocks 56, 106 and 108. The third stage is abutting the bottom of the fourth stage; however, the additional downward force of the fourth stage has not been exceeded.
Due to change in the formations being drilled, the downweight on the drill bit is subject to rapid changes. The previously described stages of the hydraulic shock absorber 10, which have been described at typical operating pressures and downweights, will act to attenuate the shock effect of variations in the downweight on the drill bit. Otherwise, the shock effect would be reflected through the string of drilling pipe.
It will be obvious to one skilled in the art that the response rate of the shock absorber assembly is determined by the size of the flow passages 64 in hollow screws 58, and notches 76.
It should also be realized that the downward force exerted by each stage of the hydraulic shock absorber 10 may be varied by varying the pressure drop across the bit. Pressure drop across the bit can be varied by varying the flow rate at the surface or by a change in restriction to flow in the bit. A common method of further restricting the flow through the bit would be the insertion of a ball, commonly called a "frac ball", at the surface. The ball would flow through the string of drilling pipe and the hydraulic shock absorber 10 to the drilling bit and seat in one of a plurality of restricted passages in the drill bit. By restricting or stopping flow through one of the passages of the drill bit, the pressure drop across the drill bit is increased significantly. Since the force exerted by each stage is directly dependent upon the pressure drop across the drill bit, the force required to overcome the down force of each succeeding stage of the hydraulic shock absorber 10 has been directly increased.
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An hydraulic shock absorber for protecting the drill bit and drill pipe in rotary earth drilling consists of a casing with an upper sub mounted in its one end for connection to a string of drill pipe. An anvil is slidably mounted on the other end. A plurality of hollow pistons are slidably mounted inside the casing. The pistons each have a hollow sleeve portion extending in sealing relationship through seating rings mounted on the inside of said casing. The pistons also have a radial flange portion at their upper end slidably sealing with the walls of the casing and a fluid passage extends through the wall of the casing between the flange portion and the seating ring.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is a continuation of U.S. patent application Ser. No. 14/373,844 filed on Jul. 22, 2014, which is a U.S. National phase of International Application No. PCT/US2013/022696, filed on Jan. 23, 2013, which claims priority to U.S. Provisional Application No. 61/590,089, filed Jan. 24, 2012, the disclosures of which are incorporated herein by reference in their entirety.
TECHNICAL FIELD
[0002] The various embodiments disclosed herein relate to viral vaccines. In particular, the various embodiments relate to viral vaccines for the treatment of cancer.
BACKGROUND
[0003] Some viruses, such as papilloma viruses (e.g., HPV16, HPV18), retroviruses (e.g., HTLV, feline leukemia virus), herpes viruses (e.g., Epstein Barr Virus), and hepatitis viruses (e.g., HBV), are known to cause cancer in humans and other animals. While vaccines, which utilize viral coat proteins or virus-like particles, are often successful at preventing infection, there is a need for therapies that treat established disease and virally-associated cancers.
SUMMARY
[0004] In some embodiments, an isolated polynucleotide is provided. The isolated polynucleotide can include a first nucleotide sequence encoding a first antigenic polypeptide, where the first antigenic polypeptide comprises an amino acid sequence having at least 70% sequence identity to the amino acid sequence of a first oncogenic viral polypeptide, is capable of initiating an immune response to the first oncogenic viral polypeptide in an immune-competent host, and is non-oncogenic in the immune-competent host. In some embodiments, the polynucleotide includes a second nucleotide sequence encoding a second antigenic polypeptide, where the second antigenic polypeptide comprises an amino acid sequence having at least 70% sequence identity to the amino acid sequence of a second oncogenic viral polypeptide, is capable of initiating an immune response to the second oncogenic viral polypeptide in the immune-competent host, and is non-oncogenic in the immune-competent host.
[0005] The virus can be a human papilloma virus. The first oncogenic viral polypeptide can be E6 and the second oncogenic viral polypeptide can be E7.
[0006] The first nucleotide sequence can encode SEQ ID NO:2 having a specific mutation, e.g., a point mutation or deletion at L50, a point mutation or deletion at E148, a point mutation or deletion at T149, a point mutation or deletion at Q150, or a point mutation or deletion at L151. The first nucleotide sequence can encode SEQ ID NO:29.
[0007] The second nucleotide sequence can encode SEQ ID NO:4 having a specific mutation, e.g., a point mutation or deletion at H2, a point mutation or deletion at C24, a point mutation or deletion at E46, or a point mutation or deletion at L67. The second nucleotide sequence can encode SEQ ID NO:30.
[0008] In some embodiments, a composition is provided. The composition comprises a pharmaceutically acceptable carrier and a polynucleotide provided herein. The polynucleotide can include a first nucleotide sequence encoding a first antigenic polypeptide, where the first antigenic polypeptide comprises an amino acid sequence having at least 70% sequence identity to the amino acid sequence of a first oncogenic viral polypeptide, is capable of initiating an immune response to the first oncogenic viral polypeptide in an immune-competent host, and is non-oncogenic in the immune-competent host. In some embodiments, the polynucleotide includes a second nucleotide sequence encoding a second antigenic polypeptide, where the second antigenic polypeptide comprises an amino acid sequence having at least 70% sequence identity to the amino acid sequence of a second oncogenic viral polypeptide, is capable of initiating an immune response to the second oncogenic viral polypeptide in the immune-competent host, and is non-oncogenic in the immune-competent host.
[0009] The virus in the provided compositions can be a human papilloma virus. In the provided compositions, the first oncogenic viral polypeptide can be E6 and the second oncogenic viral polypeptide can be E7.
[0010] The first nucleotide sequence in the provided compositions can encode SEQ ID NO:2 having a specific mutation, e.g., a point mutation or deletion at L50, a point mutation or deletion at E148, a point mutation or deletion at T149, a point mutation or deletion at Q150, or a point mutation or deletion at L151. The first nucleotide sequence in the provided compositions can encode SEQ ID NO:29.
[0011] The second nucleotide sequence in the provided compositions can encode SEQ ID NO:4 having a specific mutation, e.g., a point mutation or deletion at H2, a point mutation or deletion at C24, a point mutation or deletion at E46, or a point mutation or deletion at L67. The second nucleotide sequence in the provided compositions can encode SEQ ID NO:30.
[0012] In some embodiments of the provided compositions, the pharmaceutically acceptable carrier in the provided compositions can be an adenovirus envelope.
[0013] In some embodiments, a method for killing a cell expressing a first oncogenic viral polypeptide in a subject is provided. The method includes administering to the subject a composition in an amount sufficient to initiate an immune response against the first oncogenic viral peptide, where the composition comprises a pharmaceutically acceptable carrier and a polynucleotide provided herein and the immune response is effective to cause a cytotoxic effect in the cell. The polynucleotide can include a first nucleotide sequence encoding a first antigenic polypeptide, where the first antigenic polypeptide comprises an amino acid sequence having at least 70% sequence identity to the amino acid sequence of a first oncogenic viral polypeptide, is capable of initiating an immune response to the first oncogenic viral polypeptide in an immune-competent host, and is non-oncogenic in the immune-competent host. In some embodiments, the polynucleotide includes a second nucleotide sequence encoding a second antigenic polypeptide, where the second antigenic polypeptide comprises an amino acid sequence having at least 70% sequence identity to the amino acid sequence of a second oncogenic viral polypeptide, is capable of initiating an immune response to the second oncogenic viral polypeptide in the immune-competent host, and is non-oncogenic in the immune-competent host.
[0014] In the provided methods, the virus can be a human papilloma virus. In the provided methods, the first oncogenic viral polypeptide can be E6 and the second oncogenic viral polypeptide can be E7.
[0015] In the provided methods, the first nucleotide sequence can encode SEQ ID NO:2 having a specific mutation, e.g., a point mutation or deletion at L50, a point mutation or deletion at E148, a point mutation or deletion at T149, a point mutation or deletion at Q150, or a point mutation or deletion at L151. In the provided methods, the first nucleotide sequence can encode SEQ ID NO:29.
[0016] In the provided methods, the second nucleotide sequence can encode SEQ ID NO:4 having a specific mutation, e.g., a point mutation or deletion at H2, a point mutation or deletion at C24, a point mutation or deletion at E46, or a point mutation or deletion at L67. In the provided methods, the second nucleotide sequence can encode SEQ ID NO:30.
[0017] In some embodiments of the provided methods, the pharmaceutically acceptable carrier can be an adenovirus envelope.
[0018] In some embodiments of the provided methods, the cell can be part of a neoplasia. In some embodiments of the provided methods, the cell can be part of a malignant neoplasia.
[0019] While multiple embodiments are disclosed, still other embodiments will become apparent to those skilled in the art from the following detailed description, which shows and describes illustrative embodiments of the invention. Accordingly, the drawings and detailed description are to be regarded as illustrative in nature and not restrictive.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] FIG. 1 is a schematic showing mutations in HPV16 E6 and E7.
[0021] FIG. 2 shows tumor suppressor protein expression (A), HPV16 E6/E7 expression (B), and relative telomerase activity (RTA) (C) in cells infected with a control retrovirus, a retrovirus encoding wild type E6/E7, and a retrovirus encoding a mutant E6/E7.
[0022] FIG. 3 shows the growth characteristics of cells infected with a control retrovirus (A), a retrovirus encoding wild type E6/E7 (B), and a retrovirus encoding a mutant E6/E7 (C).
[0023] FIG. 4 shows the growth rate (A) and p53 expression of cells infected with a control retrovirus (LXSN), a retrovirus encoding wild type E6/E7, and a retrovirus encoding a mutant E6/E7 (B).
[0024] FIG. 5 shows the growth rate of cells infected with an control adenovirus, an adenovirus encoding wild type E6/E7, and an adenovirus encoding a mutant E6/E7.
[0025] FIG. 6 shows the interferon gamma response of splenocytes from mice immunized with buffer control, control adenovirus (vector control), or adenovirus encoding mutant E6/E7 exposed to the indicated antigen.
[0026] FIG. 7 shows the IL-2 response of splenocytes from mice immunized with buffer control, control adenovirus (vector control), or adenovirus encoding mutant E6/E7 exposed to the indicated antigen.
[0027] FIG. 8 shows HPV+ tumor growth in mice vaccinated with (A) control adenovirus (vector control), (B) adenovirus encoding mutant E6/E7, or (C) adenovirus encoding wild type E6/E7. Each line indicates tumor growth in an individual mouse.
[0028] FIG. 9 shows survival in mice implanted with HPV+ cancer cells and vaccinated with control adenovirus (Ad5 [E1-,E2b-]-null), or adenovirus encoding mutant E6/E7 (Ad5 [E1-,E2b-]-E6 Δ /E7 Δ ).
DETAILED DESCRIPTION
[0029] The various embodiments disclosed herein relate to an antigenic polypeptide that initiates an immune response to an oncogenic viral polypeptide in an immune-competent host, but is non-oncogenic in the immune-competent host. Also provided herein are polynucleotides comprising a sequence encoding such an antigenic polypeptide, compositions comprising such polynucleotides, and methods of use.
[0030] As used herein, an oncogenic viral polypeptide is a polypeptide encoded by a viral genome that, when expressed in a host cell, transforms the cell. Oncogenic viral polypeptides include, without limitation, HPV (human papilloma virus)16 E6, HPV16 E7, HPV18 E6, HPV18 E7, HBV (hepatitis B virus) HBXAg, HCV (hepatitis C virus) core protein, HCV NS5A, HTLV (human T-cell lymphotropic virus) TAX, EBV (Epstein-Barr virus) EBNA, and EBV LMP-1. In some embodiments, an oncogenic viral polypeptide (e.g., HPV E6) is sufficient to transform a host cell alone. In other embodiments, an oncogenic viral polypeptide transforms a host cell only in the presence of one or more additional specific cofactors (e.g., other viral oncogenes, host cell gene mutations). For example, HPV E6 can immortalize cells that have a mutation in ErbB2, which can induce invasive growth in some cells.
[0031] As used herein, an antigenic polypeptide is a polypeptide that elicits an immune response when present in an immune-competent host. As used herein, an immune-competent host is an animal capable of producing an immune response that results in cytotoxicity (e.g., cytotoxic T-cell-mediated cytotoxicity or antibody-mediated cytotoxicity).
[0032] The antigenic polypeptides provided herein are derived from oncogenic viral polypeptides and contain at least one mutation (e.g., a substitution, deletion, or addition of one or more amino acid) as compared to the oncogenic viral polypeptides from which they are derived. An antigenic polypeptide provided herein contains at least one mutation that renders it non-oncogenic under the same conditions under which the oncogenic viral polypeptide from which it is derived transforms a host cell. Mutations that render an oncogenic viral polypeptide non-oncogenic include those that inactivate oncogenic functions, such as, but not limited to, disrupting binding to tumor suppressor proteins, disrupting activation domains, and disrupting binding to DNA. For example, an antigenic polypeptide derived from HPV16 E6 can include a mutation that disrupts a p53 binding site, a telomerase activation site, a PDZ binding domain, or a combination thereof. In another example, an antigenic polypeptide derived from HPV16 E7 can include a mutation that disrupts an Rb protein binding site, an Mi2β binding site, or a combination thereof.
[0033] An antigenic polypeptide provided herein has at least 70% sequence identity (e.g., at least 72%, at least 75%, at least 80%, at least 85%, at least 95%, at least 96%, at least 98%, at least 99%, at least 99.5%, or at least 99.7% sequence identity, or from 70% to 99%, from 75% to 99%, from 80% to 99%, or from 88% to 99.9% sequence identity) to an oncogenic viral polypeptide and elicits a cytotoxic immune response to a cell that expresses the oncogenic viral polypeptide. In some embodiments, an antigenic polypeptide and the oncogenic viral polypeptide from which it is derived are about 95.9% identical, about 96.7% identical, about 96.9% identical, about 97.2% identical, about 97.9% identical, about 98.6% identical, about 99% identical, or about 99.3% identical. Examples of antigenic polypeptides include SEQ ID NO:23, SEQ ID NO:24, SEQ ID NO:25, SEQ ID NO:26, SEQ ID NO:27, SEQ ID NO:28, SEQ ID NO:29, SEQ ID NO:30, and SEQ ID NO:31.
[0034] “Percent sequence identity” refers to the degree of sequence identity between any given oncogenic viral polypeptide sequence, e.g., SEQ ID NO:2 or SEQ ID NO:4, and an antigenic polypeptide sequence derived therefrom. An antigenic polypeptide typically has a length that is from 70% to 130% percent of the full length of the oncogenic viral polypeptide from which it is derived, e.g., 71%, 74%, 75%, 77%, 80%, 82%, 85%, 87%, 89%, 90%, 93%, 95%, 97%, 99%, 100%, 105%, 110%, 115%, 120%, or 130% of the full length of the oncogenic viral polypeptide from which it is derived. A percent identity for any antigenic polypeptide relative to the oncogenic viral polypeptide from which it is derived can be determined as follows. An oncogenic viral polypeptide (e.g., SEQ ID NO:2 or SEQ ID NO:4) is aligned to one or more candidate sequences using the computer program available under the commercial name ClustalW (version 1.83, default parameters), which allows alignments of nucleic acid or polypeptide sequences to be carried out across their entire length (global alignment). Chema et al., Nucleic Acids Res., 31(13):3497-500 (2003).
[0035] ClustalW calculates the best match between a reference (e.g., an oncogenic viral polypeptide) and one or more candidate sequences (e.g., an antigenic polypeptide derived from an oncogenic viral polypeptide), and aligns them so that identities, similarities and differences can be determined. Gaps of one or more residues can be inserted into a reference sequence, a candidate sequence, or both, to maximize sequence alignments. For fast pairwise alignment of nucleic acid sequences, the following default parameters are used: word size: 2; window size: 4; scoring method: percentage; number of top diagonals: 4; and gap penalty: 5. For multiple sequence alignment of nucleic acid sequences, the following parameters are used: gap opening penalty: 10.0; gap extension penalty: 5.0; and weight transitions: yes. For fast pairwise alignment of protein sequences, the following parameters are used: word size: 1; window size: 5; scoring method: percentage; number of top diagonals: 5; gap penalty: 3. For multiple alignment of protein sequences, the following parameters are used: weight matrix: blosum; gap opening penalty: 10.0; gap extension penalty: 0.05; hydrophilic gaps: on; hydrophilic residues: Gly, Pro, Ser, Asn, Asp, Gln, Glu, Arg, and Lys; residue-specific gap penalties: on. The ClustalW output is a sequence alignment that reflects the relationship between sequences. ClustalW can be run, for example, at the European Bioinformatics Institute site on the World Wide Web (ebi.ac.uk/Tools/msa/clustalw2/), or downloaded from, for example, the Clustal.org site on the World Wide Web (clustal.org/clustal2/).
[0036] To determine percent identity of an antigenic polypeptide to an oncogenic viral polypeptide, the sequences are aligned using ClustalW, the number of identical matches in the alignment is divided by the length of the reference sequence, and the result is multiplied by 100. It is noted that the percent identity value can be rounded to the nearest tenth. For example, 78.11, 78.12, 78.13, and 78.14 are rounded down to 78.1, while 78.15, 78.16, 78.17, 78.18, and 78.19 are rounded up to 78.2.
[0037] Polynucleotides provided herein (e.g., SEQ ID NO:34) include double stranded or single stranded, linear or circular DNA or RNA that comprise a nucleotide sequence encoding an antigenic polypeptide provided herein. In some embodiments, a polynucleotide provided herein includes more than one nucleotide sequence, each encoding an antigenic polypeptide. In some embodiments, a polynucleotide can comprise a concatamer of nucleotide sequences encoding the same antigenic polypeptide.
[0038] The polynucleotides provided herein also comprise one or more nucleotide sequences operatively linked to a nucleotide sequence encoding an antigenic polypeptide that promotes expression of protein from the antigenic polypeptide nucleotide sequence(s) contained therein. Such sequences include, without limitation, promoters, enhancers, RNA stabilization sequences, internal ribosomal entry sites (IRES), and protein stabilization sequences. Promoters suitable for use in the provided polynucleotides include, without limitation, SV40 early promoter, CMV immediate early promoter, retroviral long terminal repeats (LTRs), regulatable promoters (e.g., tetracycline or IPTG responsive promoters), and RSV promoter.
[0039] When a plurality of nucleotide sequences encoding antigenic polypeptides are included in a polynucleotide provided herein, the polypeptides expressed therefrom can be expressed as separate proteins, e.g., via separate promoters or through the use of an IRES, or they can be expressed as fused proteins.
[0040] In some embodiments, a polynucleotide provided herein includes a nucleotide sequence that encodes a protein tag (e.g., myc tag or FLAG tag) operatively linked to antigenic polypeptide nucleotide sequence such that the tag is attached to the antigenic polypeptide when expressed. As used herein, a protein tag is not included in the antigenic polypeptide sequence for the purposes of determining percent sequence identity to the oncogenic viral polypeptide from which it is derived.
[0041] In some embodiments, the polynucleotides provided herein include marker sequences that facilitate the detection of the polynucleotides and/or protein expression from the polynucleotides. In some embodiments, a marker sequence can encode a marker protein, such as a fluorescent marker (e.g., GFP, RFP, or YFP) to facilitate detection of protein expression from the polynucleotide. In other embodiments, a marker sequence does not encode a protein, but can be detected using nucleic acid detection techniques, such as polymerase chain reaction. In some embodiments, a marker sequence can be used to disrupt a region in an oncogenic viral polypeptide that contributes to oncogenic activity of the oncogenic viral polypeptide to produce an antigenic polypeptide. In such cases, the marker sequence is not included in the antigenic polypeptide sequence for the purposes of determining percent sequence identity to the oncogenic viral polypeptide from which it is derived, and the remaining sequence can retain 100% sequence identity to the oncogenic viral polypeptide from which it is derived.
[0042] A polynucleotide provided herein can be produced using known methods, such as site directed mutagenesis of an oncogenic viral polypeptide-encoding polynucleotide (e.g., SEQ ID NO:1, SEQ ID NO:3, and SEQ ID NO:5).
[0043] Any of the polynucleotides provided herein can be incorporated into a pharmaceutically acceptable carrier. Appropriate pharmaceutically acceptable carriers include, without limitation, viral envelopes, cationic lipid carriers, autologous cells, plasmid vectors, and viral vectors. When a polynucleotide provided herein is incorporated into a viral envelope, it may include one or more packaging sequences that support incorporation into the envelope.
[0044] In certain implementations, a composition comprising a polynucleotide provided herein and a pharmaceutically acceptable carrier is formulated for introduction (e.g., enterally, transdermally, intravenously, subcutaneously, or intramuscularly) into an immune-competent host. In use, the composition is administered to an immune-competent host at risk of infection by a virus whose genome encodes an oncogenic viral polypeptide. In some embodiments, the composition is administered to an immune-competent host that has already been infected with such a virus, or has cells (e.g., cancer cells) that express an oncogenic viral polypeptide.
[0045] When administered to an immune-competent host, according to one embodiment, a composition provided herein elicits a cytotoxic immune response to a cell expressing an oncogenic viral polypeptide. In some embodiments, administration of a composition provided herein can be used to treat, ameliorate, and/or prevent cancer associated with the expression of an oncogenic viral polypeptide in a subject. In some embodiments, administration of a composition provided herein can result in a reduction in a population of cells expressing an oncogenic viral polypeptide. A reduction in a population of cells expressing an oncogenic viral polypeptide can be measured using any appropriate means, such as, for example, measuring a change in size of a tumor comprising cells expressing the oncogenic viral polypeptide, or measuring a change in the number of circulating cancer cells expressing the oncogenic viral polypeptide. In some embodiments, administration of a composition provided herein to a population of subjects with a cancer associated with the expression of an oncogenic viral polypeptide can result in a longer average survival as compared to a control population that has been similarly treated, but without the administration of a composition provided herein.
[0046] In some embodiments, the compositions provided herein can be used in combination with one or more standard therapies (e.g., radiation, surgery, or chemotherapy) to treat a subject having a cancer associated with the expression of an oncogenic viral polypeptide. When used in combination with a standard therapy, the compositions provided herein can be administered before, during, or after the administration of the standard therapy. In some embodiments, the timing of administration of a composition provided herein and/or a standard therapy can be adjusted to increase the efficacy of one or both of the composition or the standard therapy. For example, a composition provided herein can be administered as an initial dose followed over time with additional booster doses to increase immune response. In another example, a composition provided herein can be administered before chemotherapy or after immune recovery from chemotherapy to increase the likelihood of a sufficient immune response.
[0047] The compositions provided herein can be dosed in an amount sufficient to elicit a cytotoxic immune response. The dose can be adjusted in order to elicit an immune response, yet not induce a systemic adverse reaction to a carrier in the composition. For example, when using an adenoviral carrier, an appropriate dosage can be in the range of about 10 8 to 10 12 particles per dose. In some embodiments, the dose amount and/or number of doses can be adjusted depending on the type of sequences used to promote expression of the encoded antigenic polypeptide, the strength of the immune response in the subject, or the type of pharmaceutically acceptable carrier used.
[0048] The compositions provided herein can be packaged as premixed formulations or as separate components that can be mixed prior to use. In some embodiments, the compositions provided herein can be packaged in individual doses. In other embodiments, the compositions provided herein can be packaged in containers containing multiple dosages that are measured prior to administration. In some embodiments, the compositions provided herein can be formulated as a concentrate that is diluted before administration. In yet other embodiments, the compositions provided herein can be produced by mixing the separate components prior to administration. Packaging can further include appropriate documentation, labeling, and the like.
[0049] It is to be understood that the following examples are not intended to limit the scope of the invention.
EXAMPLES
Example 1
Mutagenesis of HPV16 E6/E7 and Viral Construction
[0050] HPV16 E6/E7 mutagenesis. Six mutations in HPV16 E6 and E7 were introduced into a wild type E6/E7 encoding nucleic acid as shown in FIG. 1 using in vitro site-directed mutagenesis. For the mutation designated L50G, a leucine to glycine mutation was made at position 50 in E6 within a p53 binding and telomerase activation site domain. For the mutation designated PDZ, the C-terminal PDZ binding domain of E6 at residues 146-151 was substituted with four alanine residues. For the mutation designated H2P, a histidine residue was substituted with a proline residue within an Rb binding site in E7 at position 2. For the mutation designated C24G, a cysteine residue was replaced with a glycine residue within an Rb binding site in E7 at position 24. For the mutation designated E46A, a glutamic acid residue was changed to alanine within an Rb binding site in E7 at position 46. For the mutation designated L67R, leucine to arginine mutation was made within an Mi2β binding region of E7 at position 67. Site-directed mutagenesis was performed on a nucleic acid encoding HPV16 E6 and E7 (SEQ ID NO:5) as per manufacturer directions (Agilent Technologies #200521) using the primers listed in Table 1.
[0000]
TABLE 1
Mutation
Forward primer
Reverse primer
L50G
GACTATTTTGCTTT
CCCATCTCTATATAC
TCGGGATGGATG
TATGCATCCATC
(SEQ ID NO: 7)
(SEQ ID NO: 8)
PDZ
GAACTCGTAGAGCA
GTGTATCTCCATGCA
GCCGCGGCGTA
TGATTACGCCG
(SEQ ID NO: 9)
(SEQ ID NO: 10)
H2P
CAGCCGCGGCGTAAT
GCAATGTAGGTGTAT
CATGCCTGGA
CTCCAGGCATG
(SEQ ID NO: 11)
(SEQ ID NO: 12)
C24G
CCAGAGACAACTGA
GCTGTCATTTAATTG
TCTCTACGGTTA
CTCATAACCGTA
(SEQ ID NO: 13)
(SEQ ID NO: 14)
E46A
GGTCCAGCTGGACA
GTAATGGGCTCTGTC
AGCAGCACCGG
CGGTGCTGCTT
(SEQ ID NO: 15)
(SEQ ID NO: 16)
L67R
CGTGTGTGCTTTGT
GTGTGACTCTACGCT
ACGCACCTCCGA
TCGGAGGTGC
(SEQ ID NO: 17)
(SEQ ID NO: 18)
[0051] The mutated construct was cloned into an adenoviral shuttle vector Ad5 VQ. Fidelity of the final construct was verified by direct DNA sequencing.
[0052] Viral construction. E1 and E2b deficient Ad5 CMV vectors (empty vector designated [E1-, E2b-]) containing mutant E6/E7 (designated [E1-, E2b-]mut-E6/E7) and wildtype E6/E7 (designated [E1-, E2b-]wt-E6/E7) were constructed and produced as previously described (Amalfitano et al. (1998) J. Virol. 72(2):926-33). Briefly, the wildtype and mutant E6/E7 sequences were sub-cloned into the E1 region of the Ad5 [E1-, E2b-] vector using a homologous recombination-based approach. The replication deficient virus was propagated in the E.C7 packaging cell line, CsCl 2 purified, and titered. Viral infectious titer was determined as plaque forming units (PFU) on an E.C7 cell monolayer. The viral particle (VP) concentration was determined by sodium dodecyl sulfate (SDS) disruption and spectrophotometry at 260 nm and 280 nm. The ratio of VP to plaque forming units (PFU) was 36.7/1 VP/PFU. The mut-E6/E7 insert as well as wt-E6/E7 were then cut and ligated into the retroviral vector pLXSN using EcoRI and BamHI restriction sites. Retrovirus particles were generated in the Phoenix A cell line according to recommended methods (Nolan Lab, Stanford University, California) with polybrene (Sigma H9268) added to a final concentration of 8 μg/ml.
Example 2
Effect of E6/E7 Mutations on Oncogenesis
[0053] Oncogenesis in a human adenocarcinoma alveolar basal epithelium cell line. To determine whether the mutated E6/E7 promoted oncogenesis, A549 cells (human adenocarcinoma alveolar basal epithelium cell line) were infected with a retrovirus containing wt-E6/E7 (SEQ ID NO:6), mut-E6/E7 (SEQ ID NO:31), or control vector, and were ring cloned. Clones were analyzed by western blot. FIG. 2A shows that expression of wt-E6/E7 decreases PTPN13, pRb, and p53 protein expression while PTPN13, pRb, and p53 expression levels are similar to control in mut-E6/E7 expressing cells. PCR analysis of clones confirmed that mut-E6/E7 was expressed at levels similar to wt-E6/E7 ( FIG. 2B ) suggesting that the changes evident by western blot were a consequence of altered E6/E7 function rather than expression levels and confirm an oncogenic loss-of-function in the mut-E6/E7 construct. Telomerase activity was also examined in these clones. The mut-E6/E7 and vector control showed significantly less relative telomerase activity (RTA) compared to the wt-E6/E7 ( FIG. 2C ). Because wt-E6/E7 induces morphological mesenchymal type changes, the morphological characteristics of clones were also examined. FIG. 3 shows that control and mut-E6/E7 grow in tight colonies, while wt-E6/E7 expression induces a mesenchymal-like change in morphology and cells grow in a non-adherent manner. Together, these data suggest that, unlike expression of wt-E6/E7, stable expression of mut-E6/E7 does not induce the biochemical or morphological changes associated with cellular transformation.
[0054] Transformation in primary human epithelial cells. To further show that mut-E6/E7 does not transform cells, primary human tonsil epithelia (HTE) were infected with retrovirus containing wt-E6/E7, mut-E6/E7, or empty vector (LXSN). Uninfected HTE cells (HTE052) served as an additional control. Expression of wt-E6/E7 results in cellular immortalization. However, HTEs expressing mut-E6/E7 and as well as controls, did not immortalize ( FIG. 4A ). These results demonstrate that stable expression of the mut-E6/E7, even expressed from an integrating retrovirus, does not result in cellular immortalization.
[0055] To determine whether wt-E6/E7 or mut-E6/E7 in a non-replicative adenoviral viral vector infection of primary human tonsillar keratinocytes can result in transformation, HTE were infected with [E1-, E2b-] expressing GFP, [E1-, E2b-]mut-E6/E7, or [E1-, E2b-]wt-E6/E7. Wt-E6/E7 was able to induce loss of p53 ( FIG. 4B ) however neither wt-E6/E7 or mut-E6/E7 were able to immortalize primary tonsil epithelial cells after infection ( FIG. 5 ). To determine if this was due to viral loss with replication we examine persistence of viral DNA with cell growth. Q-PCR was performed and demonstrated that, as cells replicated, viral DNA was lost at a similar rate with all inserts, suggesting the viral genes did not integrate into the host cell DNA. Therefore HPV genes in the [E1-, E2b-] adenoviral vector does not persist with division and that transient expression of wt-E6/E7 from a replication-deficient adenoviral vector is not sufficient to transform primary cells.
[0056] Cell culture. A549 cells were grown in Dulbecco's Modified Eagle Medium (Thermo Fisher #SH30022.01) supplemented with 10% Fetal Bovine Serum (Thermo Fisher #SH3007103). Primary human tonsil epithelial cells (HTE) were isolated from surgical tonsillectomy of consented patients under institutional IRB approval using known techniques (Williams et al. (2009) Head Neck. 31(7):911-8). Primary HTE were maintained in Keratinocyte SFM media (KSFM, Invitrogen #17005-042).
[0057] Retroviral infection. HTE and A549 cells were infected with retroviral supernatant containing wt-E6/E7, mut-E6/E7, or empty vector retrovirus and incubated at 37° C. with 5% CO 2 overnight. Media was aspirated 24 hours post-infection and fresh media supplemented with neomycin (RPI #G64000) for selection. Individual colonies were ring cloned and put under selection at 800 ug/ml neomycin. Data shown using retrovirally infected clones is representative of multiple clones tested. Due to their density dependence for cell growth, HTE cell lines were not placed under antibiotic selection but maintained in KSFM until cell death or immortalization.
[0058] Standard PCR was done to analyze mRNA in stable cell lines expressing LXSN, LXSN wt-E6/E7, or LXSN mut-E6/E7 to validate that the changes made in mut-E6/E7 did not affect E6/E7 transcription rate. PCR was performed using E6/E7 forward primer 5′-CAAACCGTTGTGTGATTTGTTAATTA-3′ (SEQ ID NO:19) and E6/E7 reverse primer 5′-GCTTTTTGTCCAGATGTCTTTGC-3′ (SEQ ID NO:20), and expression levels were normalized to GADPH levels using GAPDH forward primer 5′-GGGAAGGTGAAGGTCGGAGT-3′ (SEQ ID NO:21) and GAPDH reverse primer 5′-TGGAAGATGGTGATGGGATTTC-3′ (SEQ ID NO:22). All primer concentrations were 450 nM. Preincubation was 94° C. for 10 min. Cycling conditions were 94° C. for 40 sec, 55° C. for 40 sec, and 72° C. for 1 min for a total of 30 cycles.
[0059] Adenoviral infection. Primary human tonsil epithelial cells grown to 80% confluency were infected with [E1-, E2b-]null, [E1-, E2b-]wt-E6/E7, [E1-, E2b-]mut-E6/E7 or Ad GFP at an MOI of 100 for 24 hours. DNA was collected at passages 4, 5 and 6 post-infection. Cells were trypsinized, rinsed and resuspended in 1× Phosphate Buffered Saline. DNA extraction was performed using standard animal tissue spin-column protocol from DNeasy DNA Blood and Tissue Kit (Qiagen #69504).
[0060] Q-PCR. Quantitative real-time polymerase chain reaction was performed to assay for HPV16 copy number using HPV16 primer set 520 5′-TTGCAGATCATCAAGAACACGTAGA-3′ (SEQ ID NO:32) and 671 5′-CTTGTCCAGCTGGACCATCTATTT-3′ (SEQ ID NO:33). An 18S primer set from Applied Biosystems was used as a control. The amplification reaction included SyberGreen Universal Master Mix (Applied Biosystems), 250 nM (HPV16 primer set) or 100 nM (18S primer set) of each primer, and 25 ng template. Cycling conditions were 95° C. for 10 minutes with 40 cycles at 95° C. for 15 seconds and 60° C. for 60 seconds using the Stratagene Mx3000P thermocycler.
[0061] Western blot analysis. Stable cell lines A549 wt-E6/E7, A549 mut-E6/E7 and parental A549 cells were grown to 80-90% confluency, rinsed with PBS and harvested with lysis solution (50 mM Tris HCl pH 7.5; 150 mM NaCl; 5 mM EDTA; 2 mM Na 3 VO 4 ; 100 mM NaF; 10 mM NaPPi; 10% glycerol; 1% Triton; 1× Halt Protease Inhibitors; 17.4 μg/μl PMSF). Membranes were pelleted by centrifugation (10,000 rpm at 4° C.) and soluble proteins collected. Total protein was quantified using the BCA protein assay kit as per the manufacturer's directions (Pierce) and equal total protein was analyzed by western blot. Briefly, proteins were separated by SDS-PAGE, transferred to PVDF-membranes (Immobilon-P), blocked with either 5% bovine serum albumin (MP Biomedicals) or non-fat dry milk, and visualized by chemiluminescence on film or via UVP bioimaging system (Upland, Calif.). Membranes were incubated with the following antibodies: FAP-1 (1:500, Santa Cruz sc15356), p53 (1:500, Calbiochem OP43), pRb (1:250, BD Biosciences 554136) and GAPDH (1:5000, Ambion #Am4300)
Example 3
HPV Specific Cell Mediated Immune Response
[0062] Cell mediated immunity in response to mutant E6/E7. To determine whether the mutations in E6/E7, rendering them non-oncogenic, alter the ability to mount an HPV-specific immune response in the context of the [E1-, E2b-] adenoviral vector in vitro, spleens were harvested from control and immunized mice and the ability of splenocytes to secrete IFN-γ and IL-2 when stimulated by E6/E7 or lysates from cells immortalized with E6/E7 was examined. Cell mediated immunity (CMI) responses were determined in control non-vaccinated and vaccinated mice by assessing the numbers of IFN-γ and IL-2 secreting cells in splenocytes harvested from groups of individual mice using enzyme-linked immunospot (ELISpot) analysis. As shown in FIGS. 6 and 7 , CMI responses were detected in mice immunized with Ad5 [E1-, E2b-]mut-E6/E7. This was demonstrated by significantly elevated levels of IFN-γ ( FIG. 6 ) and IL-2 ( FIG. 7 ) spot forming cells (SFC) induced in immunized mice but not control mice injected with buffer solution or Ad5 [E1-, E2b-]null. Although the IL-2 SFC responses were consistently lower than those observed for IFN-γ, they were significantly elevated above control values. The specificity of the CMI responses was demonstrated by a lack of reactivity when splenocytes from all groups were exposed to irrelevant antigens HIV-gag or CMV. The presence of functionally active splenocytes in all groups of mice was verified by positive responses to concanavalin A (ConA). These results indicate that the non-oncogenic mut-E6/E7 is immunogenic and induces a HPV specific E6/E7 immune response at or above the level of that induced by wt-E6/E7 when expressed from an adenoviral vector.
[0063] Animal immunizations. All animal studies were performed under approval by the institutional animal care and use review. Male C57Bl/6 mice 8 to 10 weeks old were injected three times subcutaneously at 7 day intervals with a buffer solution (N=4), 10 10 VP Ad5 [E1-, E2b-] null, or 10 10 VP Ad5 [E1-, E2b-] mut-E6/E7. A fourth immunization 2 weeks following the third immunization served as an additional boost injection. Two weeks after the last injection/immunization, all mice were sacrificed and spleens harvested. Splenocytes were isolated for ELISpot testing. Serum from each mouse was collected and stored at 20° C. until testing.
[0064] Cell culture. Mouse tonsil epithelial cells expressing HPV16 E6, E7, Ras, and luciferace (mEERL) (Williams et al. (2009) Head. Neck. 31(7):911-8) were maintained in DMEM supplemented with 22.5% Hams F-12 medium, 10% heat inactivated FCS, 100 U/mL penicillin, 100 μg/mL streptomycin, 0.5 μg/mL hydrocortisone, 0.0084 μg/mL cholera toxin, 5 μg/mL transferrin, 5 μg/mL insulin, 0.00136 μg/mL tri-iodo-thyronine, and 5 μg/mL EGF.
[0065] HPV+ cell lysate preparation. HPV+ (mEERL) cells were grown in two T125 flask until confluent, after which cells were aseptically scraped off the plastic surface, washed three times with sterile PBS, and re-suspended in 1 mL of sterile PBS. Cells were lysed by freeze-thawing 3 times and cellular debris removed by centrifugation. Soluble protein was brought to a final volume of 2 mL with sterile PBS. The presence of HPV-E7 in the lysate was confirmed by western blot analysis performed as described elsewhere (Gabitzsch et al. (2009) Immunol. Lett. 122(1):44-51).
[0066] ELISpot analysis. HPV16-E6 and E7 specific IFN-γ and IL-2 production from splenocytes isolated from individual mice following immunizations was detected by ELISpot as described elsewhere (Gabitzsch et al. (2009) Vaccine. 27(46):6394-8). Briefly, cells were stimulated with HPV16 E6 and E7 peptides (15-mer peptide complete sets for each; JPT Peptide Technologies, Berlin, Germany). Peripheral blood mononuclear cells (PBMC) were used at a concentration of 2×10 5 cells/well and reported as the number of spot forming cells (SFC) per 10 6 cells per well. All E6 peptides were combined and tested as a single pool. Similarly, all E7 peptides were combined and tested as a single pool. Each peptide pool was tested in duplicate. To test for specificity, splenocytes were exposed to an HIV-gag peptide pool and a cytomegalovirus (CMV) peptide pool. Peptides were utilized at 0.1 μg of each peptide/well. To test for reactivity to mEERL cell lysate, 25 μL of lysate was added to test wells in duplicate. In all ELISpot assays, cells stimulated with concanavalin A (ConA) at a concentration of 1 μg/well served as positive controls. Colored SFC were counted using an Immunospot ELISpot plate reader (Cellular Technology, Shaker Heights, Ohio) and responses considered positive if, 1) 50 SFC were detected/10 6 cells after subtraction of the negative control or 2) SFC were at least 2-fold greater than those in the negative control wells and significantly elevated.
[0067] Statistical analysis. Statistically significant differences in the mean immune responses between groups of animals were determined by Student's t-test with a P-value of 0.05 or lower being considered significant, using GraphPad Prism® (GraphPad Software, Inc.).
Example 4
Survival in an HPV+ Tumor Model
[0068] To test whether an immune response to non-oncogenic mut-E6/E7 would synergize with chemoradiation as wt-E6/E7 has been demonstrated to do in an adenovirus background, a mouse model of HPV+ related HNSCC was used. HPV+ tumors were generated in wildtype mice which then received intranasal immunization with adenovirus expressing mut-E6/E7 (Ad5 [E1-, E2b-]-E6 Δ /E7 Δ ) or adenovirus control (Ad5 [E1-,E2b-]-null) in conjunction with cisplatin and radiation (cisplatin/xrt). Mice receiving only cisplatin/xrt (historical data) or cisplatin/xrt+[E1-, E2b-] vector control (Ad empty) had similar tumor growth and long term survival. However, mice receiving mut-E6/E7 or wt-E6/E7 had significantly improved survival. The mut-E6/E7 mice showed the best overall control of tumor growth and survival ( FIGS. 8 and 9 ). These data confirm that mut-E6/E7 enhances immune related clearance in vivo during standard therapy for HPV related cancer.
[0069] Cell culture. mEERL were maintained as described in Example 3.
[0070] HPV+ cell preparation. HPV+ (mEERL) cells were grown in a single T125 flask until confluent, after which cells were scraped off the plastic surface and washed.
[0071] Tumor models. Male C57BlJ/6 mice were obtained from the Jackson Labs and maintained by Sanford Research LARF in accordance with USDA guidelines. All experiments were approved by Sanford Research IACUC and performed within institutional guidelines. Briefly, using a 23-gauge needle 1×10 6 mEERL cells were implanted subcutaneously in the right hind flank of mice. After palpable tumors were present, on days 7, 14, and 21, mice were given 10 10 viral particles adenovirus control (Ad5 [E1-,E2b-]-null), or adenovirus encoding mut-E6/E7 (Ad5 [E1-, E2b-]-E6 Δ /E7 Δ ) intranasally. Cisplatin was dissolved in bacteriostatic 0.9% sodium chloride (Hospira Inc. Lake Forest, Ill.) at 20 mg/m 2 and administered intraperitoneally at 13, 20, and 27 days post tumor implantation. Mice were treated with 8Gy X-ray radiation therapy (RadSource RS2000 irradiator, Brentwood, Tenn.) concurrently with cisplatin treatment. Growth of tumors was monitored weekly using caliper measurements and tumor volume calculated using the following formula, volume=(width 2 )(depth). Mice were euthanized when tumors reached 1.5 cm in any dimension, the animal became emaciated, or demonstrated functional leg impairment. Long-term survival was followed for greater than 70 days.
Example 5
Other Oncogenic Viral Polypeptides
[0072] The approach outlined in Examples 1-4 can be used to produce polypeptides derived from other oncogenic viral polypeptides that are effective for initiating an immune response to the respective oncogenic viral polypeptide.
[0073] In an example, one or both of EBV oncogenes LMP and EBNA are altered to make them non-oncogenic. Such altered EBV oncogenes are used as a therapy, either alone or in combination with cisplatin and/or radiation, for nasopharyngeal cancer.
[0074] In another example, an HPV oncogene is altered in order to treat Kaposi's Sarcoma.
[0075] Various modifications and additions can be made to the exemplary embodiments discussed without departing from the scope of the present invention. For example, while the embodiments described above refer to particular features, the scope of this invention also includes embodiments having different combinations of features and embodiments that do not include all of the above described features.
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This document relates to polynucleotides encoding antigenic polypeptides to induce an immune response to oncogenic viral polypeptides. Also provided are compositions comprising polynucleotides encoding antigenic polypeptides, and methods of use. In the provided methods, the virus can be a human papilloma virus. In some embodiments, a method for killing a cell expressing a first oncogenic viral polypeptide in a subject is provided. The method includes administering to the subject a composition in an amount sufficient to initiate an immune response against the first oncogenic viral peptide, where the composition comprises a pharmaceutically acceptable carrier and a polynucleotide provided herein and the immune response is effective to cause a cytotoxic effect in the cell. In some embodiments, the polynucleotide includes a second nucleotide sequence encoding a second antigenic polypeptide. The first oncogenic viral polypeptide can be E6 and the second oncogenic viral polypeptide can be E7.
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BACKGROUND OF INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a method for detecting an unbalanced disc by means of a compact disc (CD) drive, and more particularly, to a method that detects a central error (CE) signal of the CD drive when the vibration frequency is approximately a resonance frequency of a coil of a pick-up head of the CD drive so as to detect the unbalanced disc when the CD drive operates at low rotary speed.
[0003] 2. Description of the Prior Art
[0004] As technologies of manufacturing optical storage devices improve, both the reading speed and writing speed of CD drives have made impressive progress. Since the high reading and writing speed performance of CD drive requires a high rotary speed motor, the vibration of the CD drive inevitably becomes acute while the rotary speed of the motor increases. Also, the mechanical limitations of the CD drive tend to generate resonance between the pick-up head and the motor, thereby deteriorating the performance of the CD drive. In addition, an optical disc of poor quality influences performance of the CD drive as well. Normally, optical discs of poor quality are classified into two kinds: unbalanced discs and vertical discs. Unbalanced discs have an unequally coated pigment thereon, and therefore the weight distribution of the unbalanced disc is not even. Vertical discs are warped due to unequal injection when such discs are fabricated.
[0005] An unbalanced disc is similar to a car that has four unbalanced tires. This car may go smoothly in low speed. While the speed gets higher, however, the car begins to vibrate. Similarly, an unbalanced disc vibrates strongly at high rotary speed. The vibration of the unbalanced disc seriously affects performance of the CD drive. In a worse situation, the vibration causes a permanent damage to the bearing of the motor.
[0006] When a CD drive reads an optical disc, a focus error (FE) signal and a track error (TE) signal are frequently used to adjust the position of the pick-up head so as to correctly read or write data on the optical disc. The focus error signal represents the accuracy of the laser beam that is emitted from the pick-up head and focused onto the optical disc, while the track error signal indicates whether the laser beam can precisely orient tracks of the optical disc.
[0007] Conventionally, the method of detecting an unbalanced optical disc is to input the FE signal or TE signal through a bandpass filter, and then to compare the output FE signal or TE signal with a predetermined threshold voltage. If the FE signal or TE signal is larger than the threshold voltage, the optical disc is determined as an unbalanced optical disc. However, the conventional method is practicable only when the rotary speed of the CD drive is high. As long as the optical disc is considered as an unbalanced optical disc, the rotary speed is lowered so as to correctly read data of the optical disc. In addition, the conventional method fails to distinguish an unbalanced disc from a vertical disc. This further inhibits a CD drive to correctly read data of an optical disc.
[0008] Consequently, if an unbalanced disc can be detected at low rotary speed, it becomes easier to improve the reading efficiency of the CD drive and to overcome the control difficulty of the CD drive.
SUMMARY OF INVENTION
[0009] It is therefore a primary objective of the claimed invention to provide a method of detecting an unbalanced disc for overcoming the above problems.
[0010] According to the claimed invention, a method for detecting an unbalanced disc by means of a CD drive is disclosed. The CD drive includes a pick-up head for reading data of an optical disc, and a motor for rotating the optical disc. The method comprises the following steps:
(a) adjusting a rotary speed of the motor so that a vibration frequency of the CD drive is approximately a resonance frequency of a coil of the pick-up head; (b) when the vibration frequency of the CD drive is approximately the resonance frequency of the coil of the pick-up head, detecting if a voltage value of a central error (CE) signal is larger than a threshold voltage; and (c) determining if the optical disc is an unbalanced disc according to a result of step (b).
[0014] These and other objectives of the present invention will no doubt become obvious to those of ordinary skill in the art after having read the following detailed description of the preferred embodiment that is illustrated in the various figures and drawings.
BRIEF DESCRIPTION OF DRAWINGS
[0015] FIG. 1 is a schematic diagram of a CD drive of the present invention.
[0016] FIG. 2 to FIG. 4 are schematic diagrams illustrating how the central error signal is received.
[0017] FIG. 5 is a flowchart illustrating the method for detecting an unbalanced disc according to the present invention.
DETAILED DESCRIPTION
[0018] Please refer to FIG. 1 to FIG. 4 . FIG. 1 is a schematic diagram of a CD drive 10 of the present invention; FIG. 2 to FIG. 4 are schematic diagrams illustrating how the central error signal is received. The CD drive 10 includes a pick-up head 12 , a first lens 14 , a spectroscope 16 , an object lens 18 , a second lens 22 , and a photoelectric sensor 24 . The pick-up head 12 emits a laser beam. The laser beam is equalized by the first lens 14 , passed through the spectroscope 16 , and sent to the object lens 18 so as to focus on an optical disc 20 . Accordingly, the laser beam is reflected by the optical disc 22 , passes through the spectroscope 16 , and arrives at the photoelectric sensor 24 . Therefore, the reflected laser beam is received by the photoelectric sensor 24 and converted into a voltage signal. The photoelectric sensor 24 is connected to different control circuits for the purpose of generating different voltage signals, such as a FE signal or a TE signal. According to the present invention, the photoelectric sensor 24 is connected to a control circuit 26 for generating a central error (CE) signal. As shown in FIG. 2 to FIG. 4 , the illuminated face of the photoelectric sensor 24 is clockwise divided into four areas A, B, C, and D. The CE signal is the intensity difference between the left half region and the right half region of the photoelectric sensor 24 . Therefore, the CE signal can be briefly described by the following equation CE=k[(A+D)−(B+C)], where k is a coefficient. Therefore, by calculating the CE signal the deviation of the pick-up head 12 relative to the central position of the optical disc is perceived when reading the optical disc 20 . In a normal condition, the reflected laser beam is supposed to be located in the central position of the photoelectric sensor 24 , as shown in FIG. 2 . However, if the reflected laser beam approaches the central position of the optical disc 20 , the left half region (areas A and D) will receive more reflected laser beam as shown in FIG. 3 . According to the definition of CE, a larger voltage signal will be generated. On the other hand, if the laser beam reflects away from the central position of the optical disc 20 , the right half region (areas B and C) will receive more reflected laser beam as shown in FIG. 4 . Similarly, a larger voltage signal will be generated in this case.
[0019] Please refer to FIG. 5 . FIG. 5 is a flowchart illustrating the method for detecting an unbalanced disc according to the present invention. The CD drive 10 controls the pick-up head 12 via a coil, and the vibration of the CD drive 10 leads to a resonance of the coil. If the vibration frequency of the coil is less than the first resonance frequency, the vibration breadth of the pick-up head 12 will augment as the vibration frequency of the coil increases. Since the pick-up head 12 is a part of the CD drive 10 , the vibration breadth of CD drive 10 is proportional to that of the pickup head 12 . While the vibration frequency of the coil equals the first resonance frequency, the vibration breadth of the pick-up head 12 will reach its maximum. Nevertheless, while the vibration frequency of the coil exceeds the first resonance frequency, the vibration breadth of the pick-up head 12 will diminish as the vibration frequency of the coil increases. Presently, the vibration breadth of the CD drive 10 can be maintained in a steady state in a certain frequency range. Normally, the first resonance frequency of the coil is located in this range where the vibration breadth of the CD drive 10 remains steady. On the basis of this character, the CD drive 10 reads the optical disc 20 at a frequency which approximates the first resonance frequency of the coil. In such case, the CE signal of an unbalanced disc is obviously larger than that of a normal disc.
[0020] The method for detecting an unbalanced disc includes the following steps:
Step 210 : start detecting the optical disc 20 ; Step 220 : adjust the rotary speed of the motor to a frequency which is approximately the first resonance frequency of the coil of the pick-up head 12 , so that the vibration frequency of the CD drive 10 is approximately the first resonance frequency of the coil of the pick-up head 12 ; Step 230 : measure the voltage value of the CE signal V pp ; Step 240 : determine if V pp is larger than a predetermined threshold voltage V th , if yes, then execute step 241 , otherwise, execute step 242 ; Step 241 : determine the optical disc 20 as an unbalanced disc; Step 242 : determine the optical disc 20 as a normal disc; Step 250 : end.
[0028] An illustrative example is listed as follows to show how to detect an unbalanced disc according to the present invention. Assume the vibration breadth of the CD drive 10 can be maintained between 20 Hz and 150 Hz while the vibration frequency increases, and the first resonance frequency of the coil of the pick-up head 12 is approximately 40 Hz. While the rotary speed of the motor of the CD drive 10 reaches 2400 rpm, the vibration frequency of the CD drive 10 will become approximately the first resonance frequency of the coil. In such case, since the rotary speed of the motor is not very high, the CD drive 10 is able to determine if the optical disc 20 is an unbalanced disc or not according to the voltage value of the CE signal V pp . Substantially, the CE signal of a normal disc is 400 mv, while the CE signal of an unbalanced reaches 1500 mv in most cases. Once the optical disc 20 is marked as an unbalanced disc, a different method is adopted to read the optical disc 20 so as to improve the efficiency of the CD drive 20 . It is to be noted that the CE signal is selected, instead of the TE signal, because the error range of CE signal is much greater than that of TE signal.
[0029] Briefly described, while the CD drive 10 reads an unbalanced disc and a normal disc in the first resonance frequency of the coil of the pick-up head 12 , the CE signals of the unbalanced disc and the normal disc are remarkably different. Therefore, according to the present invention, the rotary speed of the motor is adjusted to a low speed so that the vibration frequency of the CD drive 10 is approximately the first resonance frequency of the coil of the pick-up head 12 . Then the CE signal is detected, and if the CE signal is greater than a predetermined threshold value, the optical disc 20 is determined as an unbalanced disc. In such case, the CD drive 10 can adopt a different method for improving the efficiency of reading the optical disc 20 .
[0030] In comparison with the prior art, an unbalanced disc can be detected when the rotary speed of the CD drive is low. Thus, it becomes easier to improve the reading efficiency of the CD drive and to overcome control difficulties of the CD drive. In addition, vertical discs can be detected in the art when the rotary speed is low, thus the method of the present invention is able to distinguish unbalanced discs from vertical discs at low rotary speed.
[0031] Those skilled in the art will readily appreciate that numerous modifications and alterations of the device may be made without departing from the scope of the present invention. Accordingly, the above disclosure should be construed as limited only by the metes and bounds of the appended claims.
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A CD drive has a pick-up head for reading data of an optical disc, and a motor for rotating the optical disc. The method first adjusts the rotary speed of the motor so that the vibration frequency of the CD drive is approximately the resonance frequency of a coil of the pick-up head. Then, when the vibration frequency of the CD drive is approximately the resonance frequency of the coil of the pick-up head, the method detects if the voltage of a central error (CE) signal of the CD drive is greater than a threshold voltage. Finally, the method determines if the optical disc is an unbalanced disc according to the comparison result.
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RELATED APPLICATIONS
This is a divisional of application Ser. No. 09/708,878, entitled Easily Stackable Safety Delineators, filed on Nov. 8, 2000, and now abandoned, which is a continuation of application Ser. No. 09/258,058, entitled Easily Stackable Safety Delineators, filed on Feb. 26, 1999, now U.S. Pat. No. 6,186,699, which is a continuation of application Ser. No. 08/916,552, entitled Stackable Vertical Panel, filed on Aug. 22, 1997, now U.S. Pat. No. 6,095,716, which is a continuation of application Ser. No. 08/503,264, entitled Stackable Vertical Panel, filed on Jul. 18, 1995, now U.S. Pat. No. 5,749,673, which is a continuation-in-part of application Ser. No. 08/195,119, entitled Safety Delineators, filed on Feb. 10, 1994, now U.S. Pat. No. 5,560,732.
BACKGROUND OF THE INVENTION
This application relates to traffic safety delineators, and more particularly to an improved vertical panel which is fixedly mounted to a traffic safety delineator having a conical structure, thereby having a unique capability of being easily stacked and transported.
Traffic safety delineators are extensively used at the present time to mark potential driving hazards, such as construction zones, potholes, etc., as well as to channelize traffic past such hazards. They are often used, as well, on sidewalks, bicycle paths, parking lots, indoor shopping malls, and the like to alert passersby to potential dangers, whatever the mode of transportation.
Vertical panels are well known in the prior art for use as barrel delineators when lack of space is an issue, being typically mounted on metallic stands and the like. They are most usually fabricated of polyethylene sheeting and have a minimum frontal surface area of 270 square inches as required by U.S. government standards, the front surface comprising alternating contrasting stripes (typically orange and white contrasting stripes) arranged in a diagonal pattern. This configuration has been shown to assist motorists in guiding their vehicles through the demarcated zone.
Traffic safety delineators having a conical structure are particularly widely used, and are commonly referred to as traffic safety cones. Although they may comprise only a freestanding conical body portion, they more typically include an integral weighted base as well, in order that the body portion may be stably supported in the wind gusts which are typically generated by high speed traffic, as well as by natural weather patterns. Prior art bases are typically fabricated of a solid material, such as rubber or plastic, in order to provide adequate weight to anchor the delineator body, which is typically molded of a resilient plastic.
Both traffic safety cones and vertical panels are designed to be temporary and portable, so are frequently lifted and transported from place to place, either within a single construction site as the construction project progresses, or between different sites. Thus, it is important that the temporary markers be easy and convenient to pick up. Unfortunately, however, neither prior art cones nor vertical panels typically provide means for being conveniently gripped, and are usually just lifted by attempting to grab some portion of the body portion of the cone or vertical panel itself. Both the cone and the vertical panel can be quite heavy and awkward to pick up, particularly with the supporting structure attached.
Several prior art designs have been developed to attempt to provide a handle for picking up traffic safety cones and the like. For example, a traffic safety cone having a bail handle, like that of a pail, extending from the top thereof is known in the prior art. Also, traffic safety cones and tubes are presently available which have a T-top handle extending from the top thereof. Such a handle may be used to carry the tube or cone by grasping the T-top with one's fingers. However, neither type of handle is fully satisfactory in providing a convenient means for easily grasping and picking up a delineator, since they do not permit a comfortable, full hand grip, and tend to pinch and cramp the user's fingers over time.
Another problem with traffic safety cones results from the common practice of stacking the cones when storing or transporting them. Obviously, stacking the cones is advantageous because of the space which is saved and because of the increased number of cones which may be transported at one time. However, as one cone is dropped downwardly over another one in a stacking relationship, they tend to stick and jam together, because of the interfering contact between their respective sidewalls. This problem is aggravated in warm weather, when the cone sidewall material tends to expand and increase the interfering contact. Once jammed, they can be very difficult to separate, and the tedious process of doing so can be labor intensive and result in downtime and frustration for the construction crew.
Because of their non-uniform construction and typically metallic supporting stands, vertical panels are even more difficult to transport and store. Since they are not stackable, they tend to be stowed singly in a storage yard or truck in a somewhat haphazard manner, wasting space and increasing clutter.
What is needed, therefore, is a vertical panel having a supporting structure which permits convenient stacking of a plurality of vertical panels, as well as a handle for providing a convenient means for gripping the vertical panel, in order to transport it to a new location. Furthermore, an improved traffic safety cone is needed, including a contoured gripping means which permits a comfortable full hand grip of the cone.
SUMMARY OF THE INVENTION
The present invention solves the aforementioned problems of the prior art by providing a safety delineator having a conical body portion to which is attached one or more vertical panels. A new and improved handle feature permits easy and comfortable full hand gripping of the delineator and also prevents sticking and jamming together of a plurality of the delineators when they are stacked. The delineators may be stacked with the vertical panels attached thereto, since each vertical panel is particularly designed to wrap around the conical body portion to which it is attached as another vertical delineator slides over it.
More particularly, a safety delineator is provided which comprises a body portion having a top end and a base end, wherein the base end includes a horizontal support element for supporting the body portion in an upstanding position. A handle, which is adapted to permit convenient generally full hand gripping of the safety delineator, is integrally molded with the body portion and comprises a shaft portion axially oriented and extending axially upwardly from the body portion top end. A knob portion extends axially upwardly from the shaft portion. Preferably the handle is at least three inches long, and more preferably at least 5½ inches long so that the shaft portion has a sufficient length to permit all of the fingers of an average adult hand to be wrapped thereabout. One or more vertical panels are preferably fixedly attached to the body portion.
In another aspect of the invention, a safety delineator is provided which comprises a conical body portion constructed of a resilient plastic material and having a top end and a base end. The base end includes a horizontal support element for supporting the body portion in an upstanding position and one or more vertical panels fixedly attached to the body portion. Each vertical panel is preferably attached to its corresponding conical body using one or more mechanical fasteners, such as metal tubular rivets (plastic push rivets could be used as well), and is generally rectangular in shape, having two upper corners and two lower corners. The two upper corners of the vertical panel preferably have a rounded configuration to facilitate wrapping of the vertical panel about the circumference of the body portion to which it is attached when another delineator is stacked thereatop in a nesting fashion.
In yet another aspect of the invention, a method of storing or transporting a plurality of vertical panel delineators, wherein each delineator comprises a conical body portion having at least one vertical panel attached thereto, is disclosed. The method comprises the steps of standing a first one of said delineators in an upright position and stacking a second one of the delineators over the first delineator in a nesting fashion such that the vertical panel attached to the first delineators wraps about the conical body portion thereof as the second delineator slides over the first vertical panel.
The invention, together with additional features and advantages thereof, may best be understood by reference to the following description taken in conjunction with the accompanying illustrative drawing.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a perspective view illustrating a conical safety delineator (traffic safety cone) having vertical panels attached thereto, constructed in accordance with the present invention;
FIG. 2 is a fragmentary view, partially in cross-section, of the top handle portion of the delineator illustrated in FIG. 1;
FIG. 3 is a cross-sectional view taken along lines 3 — 3 of FIG. 2;
FIG. 4 is a cross-sectional view taken along lines 4 — 4 of FIG. 1, illustrating a preferred means for attaching the vertical panels to the conical safety delineator; and
FIG. 5 is a cross-sectional view illustrating two stacked conical safety delineators of the type shown in FIG. 1 .
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawing, FIG. 1 illustrates a vertical panel delineator 10 constructed in accordance with the invention. The delineator 10 comprises a highway safety cone 12 having a conical body portion 14 , which includes a top end 16 and a base end 18 . The conical body portion 14 has a minimum diameter at the top end 16 and expands conically to a maximum diameter at the bottom end 18 . At the bottom end, a lip portion 20 (FIG. 5) flares outwardly to form a horizontal support base for the cone body 14 , and to provide a means for assembling the cone 12 to a weighted support base (gravity anchor) 22 . The illustrated support base 22 is constructed of a solid dense material, preferably rubber, but could also comprise a hollow plastic ballasted member, as is discussed in the co-pending parent application Ser. No. 08/195,119 entitled Safety Delineators, and filed on Feb. 10, 1994. Both such bases are available commercially from the assignee of the present application. The cone body 14 itself, between the top end 16 and the lip portion 20 , is conventional in construction and is preferably fabricated of a resilient plastic using known molding techniques.
An advantageous and important feature of the invention is the addition of a handle 24 to the cone 12 , which enables a user to quickly and easily grip the cone in order to transport it between locations. The handle 24 is preferably molded to be integral with the cone body 14 , extending upwardly from the top end 16 , and is configured to generally resemble a doorknob. In its preferred configuration, the handle includes a first transition fillet 26 , a necked down generally cylindrical shaft portion 28 , and a generally hemispherical knob portion 30 . The first fillet 26 transitions the handle 24 between the diameter of the top end 16 (approximately 4 inches in the preferred embodiment) and that of the cylindrical shaft 28 . The diameter of the shaft 28 is small enough to be comfortably gripped by the hand of an average adult (approximately 1¼ inches in the preferred embodiment). A second transition fillet 32 (FIG. 2) transitions the handle 24 between the diameter of the shaft 28 and the diameter of the knob 30 , which in the preferred embodiment is about 2¾ inches. The purpose of the knob is primarily to prevent a user's hand from slipping off of the end of the shaft 28 . Of course, the actual configuration and dimensions of the handle 24 may be varied in accordance with particular design and manufacturing considerations, as long as it functions to permit easy and convenient gripping of the cone.
Preferably, the handle shaft portion 28 includes a plurality of spaced circumferential ribs 34 (FIGS. 1 and 2 ), which primarily function to improve a user's grip on the shaft by preventing slipping of his or her hand thereon. In the preferred embodiment, they are blended out at the mold parting line for ease of fabrication (not shown). Any number of ribs may be employed, but they may also be eliminated if desired, or replaced by an alternate non-skid surface, such as rubberized tape or the like.
Still another desirable feature is the employment of a plurality of cicumferentially spaced stiffeners 36 , best seen in FIG. 3, of which there are preferably four, although a different number may be used. The stiffeners 36 , which are molded protrusions, extend axially through the first transition fillet 26 , functioning to reinforce it and to prevent it from buckling because of downward pressure on the handle 24 , which is commonly applied in the ordinary course of utilizing the cone 12 .
A key feature of the present invention is the use of the safety cone 12 as a convenient platform for supporting one or more vertical panels 38 . The vertical panels 38 are conventional, in that they are rectangular in configuration, preferably fabricated of polyethylene sheeting or some other flexible, weather-resistant material, and preferably have a minimum frontal surface area of 270 square inches, in order to meet current governmental regulations. In a preferred embodiment, they are approximately 8 inches in width and 36 inches in length. The frontal surface of each panel 38 (only one of which is shown) has a plurality of alternating contrasting stripes 40 and 42 , which are preferably orange and white, respectively. Each vertical panel 38 is preferably attached to the body portion 14 of the safety cone 12 using metal tubular rivets 44 (best seen in FIG. 4 ), in combination with low profile washers 45 (FIG. 4 ). Alternatively, plastic push rivets could be utilized. The tubular rivet is pushed through a corresponding hole 46 in the body portion 14 , as well as through the vertical panel 38 . Once fully through both pieces, the washer 45 secures the attachment, the head 50 of the rivet being flush with the vertical panel 38 . In the preferred embodiment, four such tubular rivets 44 are employed to secure each vertical panel 38 . Of course a different number of rivets could be employed if desired, or other known fastening means could be alternatively utilized.
The use of the safety cone 12 as a standardized supporting platform for the vertical panels 38 greatly increases the versatility and functionality of the vertical panels. The cone 12 , when used in combination with the weighted support base 22 , easily withstands gusts caused by high speed traffic and prevailing weather conditions to remain in position. Furthermore, because of the handle 24 on the cone 12 , the vertical panels 38 are conveniently carried by a worker for placement in a desired location. The cones 12 are more durable and lighter than the supporting platforms typically used for vertical panels in the prior art, many of which are metallic, because of their resilient plastic construction. Finally, and perhaps most significantly, the use of standardized cones 12 as platforms for the vertical panels 38 enables the panels 38 to be much more easily transported and stored, because of their stacking ability.
As discussed above in the Background of the Invention portion of the specification, safety cones of the type herein disclosed, as well as many other types of traffic safety delineators and channelizers, are typically stacked for compact storage and for ease of transportability between locations. However, the prior art cones generally available in the prior art tend to stick and jam together when stacked, thereby making it difficult to separate them for use. This invention solves that problem because of the unique handle configuration at the top of each cone 12 , which makes the cones self-spacing. Thus, when two or more cones are stacked together, as shown in FIG. 5, the top of the knob portion 30 of the lower cone abuts the interior surface 52 of the transition fillet 26 of the upper cone, thereby creating a stop which prevents further relative stacking motion between the two cones, i.e. further collapsing of the upper cone onto the lower one. Advantageously, the relative stacking motion is stopped by the abutment of the lower cone knob 30 on the upper cone interior surface 52 before the upper cone has descended onto the lower cone sufficiently to create a jamming or sticking problem.
As illustrated in the drawing, the cones 12 may be stacked with the vertical panels 38 attached thereto; i.e. the vertical panel delineators 10 may be stacked without removing the vertical panels. This is possible because the vertical panels 38 are made of a flexible material (preferably polyethylene sheeting), so that as the upper cone 12 descends onto the lower one during the stacking process, the vertical panel 38 on the lower cone merely rolls about the circumference of the lower cone, as illustrated, so that substantially all of the reverse side of the vertical panel contacts the circumferential surface of the cone. In other words, the vertical panel 38 wraps around the cone as the upper cone slides over it. In order to enhance this “rolling” or “wrapping” action, the two upper corners 54 and 56 of each vertical panel 38 are preferably rounded. The rounding of the corners 54 and 56 causes them to better engage the inner surface of the upper cone as it descends, so that they “plow in”, thereby enhancing the desired “rolling” or “wrapping” action. Thus, even when the vertical panels are attached, the stacked delineators do not stick and are rotatable about one another.
Accordingly, although exemplary embodiments of the invention have been shown and described, it is to be understood that all the terms used herein are descriptive rather than limiting, and that many changes, modifications, and substitutions may be made by one having ordinary skill in the art without departing from the spirit and scope of the invention.
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A safety delineator is provided which includes a conical body portion and an upstanding handle portion. The handle has a substantially increased length relative to prior art delineators to permit full hand gripping of the delineator and also to assist in preventing sticking and jamming together of a plurality of the delineators when they are stacked in a nesting fashion.
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[0001] The present application claims the benefit of U.S. Provisional Application Ser. No. 62/278,853 filed on Jan. 14, 2016.
FIELD OF THE INVENTION
[0002] The invention relates to a manufacture of patterned textiles, and more particularly the design and manufacture of tufted patterned textiles having optimized yarn consumption.
BACKGROUND OF THE INVENTION
[0003] In the manufacture of patterned textiles, and particularly in the manufacture of tufted textile products, designs are created for fabrics in a pixel-mapped format where each pixel in a graphic representation corresponds to a separate tuft or bight of yarn that is displayed on the surface of the tufted carpet. Pixel-mapped designs became prevalent as a result of the evolution of tufting machines to possess the capability of placing a particular color of yarn at virtually any location in a given pattern. In the field of broadloom tufting machines, this capability was present in the mid to late 1990s with computer controlled needle bar shifters, servo motor driven backing feeds, and servo motor driven yarn feed pattern controls. However, even decades earlier simple patterns could be tufted in a similar fashion as typified by Hammel, U.S. Pat. No. 3,103,187 using photo-electric cells to read instructions for actuation of electromagnetic clutch operated yarn feeds.
[0004] Other types of tufting machines such as hollow needle machines manufactured by Tapistron, or the Colortron machines manufactured by Tuftco Corp. have the ability to place any color of yarn in any location of the backing fabric. Independent control needle (“ICN”) machines typified by Cobble's ColorTec machines, also could place any color yarn at any position on backing fabric from about 1994.
[0005] Tufted textile fabrics may be manufactured from a single color of yarn threaded in all the needles of a tufting machine. However, in commercial and hospitality markets, it is much more common that patterns will have between about three to six colors of yarn, and in some cases, even more. When using multiple colors of yarn in a pattern, it often happens that some colors are utilized more heavily than others and particular needles on the tufting machine may utilize more of one color yarn than is utilized by a different needle tufting even the same color. These variations in yarn consumption can lead to inefficiencies.
[0006] The production of completed tufted textiles generally involves several distinct steps. First is the selection or creation of a pattern. Second is the tufting of a fabric by placing the yarns in a backing fabric according to the pattern. Finally, there are finishing steps to remove irregularities, to lock the tufted yarns in place with the application of a secondary backing, and to trim any uneven margins as the fabric is cut to size.
[0007] The creation of tufted fabric involves feeding yarns to needles on a tufting machine, and reciprocating the needles to insert the yarns through the backing fabric. By controlling operations such as the shifting of needles, the feeding of the backing fabric, the amounts of yarn fed to specific needles, the types of knives and gauge parts operating to seize or cut yarns carried through the backing fabric, and in the case of ICN tufting machines, the selection of needles to penetrate the backing fabric, almost any design can be created on a properly configured and threaded tufting machine.
[0008] It can be seen that the inputs necessary to create the tufted fabric include labor, yarn, backing fabric and the typically multi-million dollar investment in a tufting machine and yarn creel. Such tufting machines, while built on a chassis not unlike those from the last century, now include sophisticated electronics and software in addition to the many precision reciprocating and electronically driven parts that operate to move the yarns and backing as required.
[0009] With the evolution of tufting machines, the possibilities for patterns have evolved from solids, textures, geometrics, repeated graphics, and copies of woven textiles, to encompass nearly photographic representations of a wide range of images. Furthermore, patterns may now be over 1000 positions in both width and length, leading to designs with over a million individual pixel-mapped positions. In modern designs, carpet patterns that have organic or natural aspects, perhaps with the appearance of fallen leaves or similar designs inspired by nature or entropy, have emerged as desirable for many large spaces.
[0010] Since a tufting machine is a sizable fixed investment that should justify its cost over several years of production, the opportunities to minimize the overall cost of creating tufted fabrics must focus on the labor and materials consumed in that production. Labor is involved in creating designs and in configuring tufting machines for each individual pattern to be run, especially the threading of yarns to the individual needles and positioning of yarn cones in a yarn creel or the winding of beams to feed the yarns to the needles.
[0011] In addition, there is wasted yarn when patterns do not utilize similar amounts of colors of yarn fed to needles across the width of the tufting machine. This leads to two inefficiencies. First, if for example a red yarn is fed to a needle on the right side of the tufting machine and will consume a three pound yarn cone over the course of production of a pattern while a red yarn fed to a needle in the center of that machine will consume a four pound yarn cone, some compromise must be made. Either four pound yarn cones are placed in all positions on the creel for red yarns or three pound and four pound yarn cones must be prepared and positioned in appropriate places on the creel to feed yarns to the appropriate needle. In the former case, an extra pound of yarn will be left on the cones that were associated with needles only using three pounds of red yarn and that yarn will need to be salvaged. In the latter case, additional labor, with increased possibilities of improper configuration of the yarn creel, is injected into the configuration process.
SUMMARY OF THE INVENTION
[0012] Since it may take several weeks to manually calculate and balance yarn consumption across large patterns, it is desirable to utilize software to automate the calculation of information about the yarn consumed on a per-needle per-color basis for use by designers. It is also desirable to provide tools to facilitate the balancing of yarn consumption over the course of a pattern or over a series of patterns using the same color palette. To provide these features, design software can be operated to calculate the yarn consumption by color and needle. In addition, software can apply algorithmic modifications to a pattern to balance yarn consumption while altering the appearance of the pattern in selected ways, perhaps to minimize the appearance of alteration, for instance, leading to the more efficient creation of tufted fabrics.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] The particular features and advantages of the invention as well as other objects will become apparent from the following description taken in connection with the accompanying drawings in which:
[0014] FIG. 1A is a perspective view of a tufting machine and creel;
[0015] FIG. 1B is a simplified diagrammatic illustration of a tufting machine showing operative components;
[0016] FIG. 2 is a flow diagram illustrating exemplary steps presently used in designing and manufacturing tufted fabric;
[0017] FIG. 3 is a flow diagram of exemplary steps in practicing a yarn balancing method in connection with designing patterns to manufacturing tufted fabrics;
[0018] FIG. 4 is a pixel representation of a fabric design that is suitable for tufting;
[0019] FIG. 5 is an exemplary control screen display for the input of design and tufting parameters, and especially a needle bar shift profile;
[0020] FIG. 6 is an exemplary control screen display for inputting a pattern and tufting parameters and specifically yarn assignments and yarn feed increments;
[0021] FIG. 7 is an exemplary control screen illustrating controls that can be utilized to apply a balancing algorithm to a design;
[0022] FIG. 8 is an exemplary control screen showing modifications in the appearance of a pixel-mapped design as a balancing algorithm is applied.
[0023] FIG. 9 is a graphic representation of Von Neuman and Moore Neighborhood points.
DETAILED DESCRIPTION OF THE INVENTION
[0024] Turning then to FIG. 1A , a general depiction of the tufting machine 10 with take up rolls 19 for the tufted fabric and two story creel 14 to hold cones of yarn is illustrated. It should be understood that the invention can be practiced on a wide variety of tufting machines, not simply the broadloom machine 10 depicted in FIG. 1A . For instance, ColorTec ICN machines and Colortron hollow needle tufting machines also have the capability to place yarns in individual pixel locations according to a pattern and thus are suitably adapted to utilize with the invention. In addition, the yarn creel set up is exemplary and yarns could be supplied to the tufting machine from a single story creel or from beams that are wound for use in supplying yarns. In the typical case there will be hundreds of separate yarns fed from the creel, most frequently between about 600 and 1800 yarns and most commonly between about 1100 and 1700 yarns, although some machine and pattern combinations, such as relatively narrow hollow needle machines tufting patterns with a limited number of colors, could operate with a smaller number. A sample machine would typically have a substantially smaller tufting width and a smaller number of yarns would be fed into the pattern. The yarns will often be fed independently of other yarns using single end pattern control yarn feed devices. However, yarn optimization is also practical on tufting machines using double end or quadruple end yarn feeds, or even servo scroll yarn feed devices that carry larger pluralities of yarns that are typically distributed across the width of the tufting machine by a tube bank, or other yarn feed arrangements with an array of independent yarn feed drives. There will preferably be more than 72 independent yarn feed drives in the array and most commonly more than 300 independent yarn feed drives.
[0025] The tufting machine 10 disclosed in FIG. 1B includes a rotary needle shaft or main drive shaft 11 driven by stitch drive mechanism 12 from a drive motor or other conventional means. Rotary eccentric mechanism 15 mounted upon rotary needle shaft 11 is adapted to reciprocally move the vertical push rod 16 for vertically and reciprocally moving the needle bar slide holder 17 and needle bar 18 . The needle bar 18 supports a plurality of uniformly spaced tufting needles 20 in a longitudinal row, or staggered longitudinal rows, extending transversally of the feeding direction of the backing fabric or material 22 . The backing fabric 22 is moved longitudinally in direction 21 through the tufting machine 10 by the backing fabric feed mechanism 23 and across a backing fabric support with needle plate and needle plate fingers.
[0026] Yarns 25 are fed from the creel 14 to the pattern control yarn feed 26 to the respective needles 20 . As each needle 20 carries a yarn 25 through the backing fabric 22 , a hook is reciprocally driven by the looper drive 29 to cross each corresponding needle 20 and hold the corresponding yarn end 25 to form loops. Cut pile tufts are formed by cutting the loops with knives. A cut/loop or Level Cut Loop (LCL) apparatus may also be employed, and may have its own controller, just as do the yarn feed, needle bar or backing shifter, and backing feed apparatus.
[0027] The needle bar shifting apparatus 32 is designed to laterally or transversely shift the needle bar 18 relative to the needle bar holder 17 a predetermined transverse distance equal to the needle gauge or multiple of the needle gauge, and in either transverse direction from its normal central position, relative to the backing fabric 22 , and for each stroke of the needles 20 . Alternatively, a jute or backing shifter may move the backing fabric laterally with respect to a stationary needle bar.
[0028] In order to generate input encoder signals for the needle bar shifting apparatus 32 corresponding to each stroke of the needles 20 , an encoder 34 may be mounted upon a stub shaft 35 , or in another suitable location, and communicate positional information from which a tufting machine controller can determine the position of the needles in the tufting cycle. Alternatively, drive motors may use commutators to indicate the motor positions from which the positions of the associated driven components may be extrapolated by the controller. Operator controls 24 also interface with the tufting machine controllers to provide necessary pattern information to the storage associated with the various tufting machine controllers before machine operation.
[0029] On a broadloom tufting machine, these components can be operated in a fashion to provide pixel-addressed yarn placement as described in various prior patents such as U.S. Pat. Nos. 6,439,141; 7,426,895; and 8,359,989 and continuations thereof. Pixel controlled yarn placement in connection with ICN machines is described in U.S. Pat. Nos. 5,382,723 and 5,143,003; while pixel controlled placement of yarns utilizing hollow needle tufting machines is described in U.S. Pat. Nos. 4,549,496 and 5,738,030. All these patents are incorporated herein by reference. Software to facilitate such pixel mapped designs has been available from NedGraphics since at least about 2004 in the form of its Texcelle and Tuft programs, from Tuftco Corp. in the form of its Tuftco Design System, and from Yamaguchi in the form of its design system for similar lengths of time.
[0030] Turning then to the existing process of designing and manufacturing tufted fabric as reflected in FIG. 2 , the first step 28 is the creation of a graphic design to be tufted. The design can be created by an artist or adapted from a photograph or preexisting image. In either case, the image should be created or processed to limit the color palette to a manageable number of yarn colors, preferably between two and twelve, and most commonly three to six colors. Preferably, this design process is executed on a design workstation running Texcelle or Tuftco Design software although sometimes automated design features can be included in the Operator Interface of a tufting machine.
[0031] For illustrative purposes, a two color pattern 38 a has been prepared in FIG. 4 in the general configuration of black and white “zebra” stripes. The pattern is enlarged sufficiently that the right angles indicating individual black or white pixels or yarn tufts can be observed.
[0032] The next step 30 is to load the image into a tufting machine having a controller running an operator interface software such as the iTuft system sold by Tuftco Corp. and to process the pattern graphics to create machine instructions. The tufting machine should be threaded with appropriate yarns 31 . When using the iTuft system, there are two principal steps prior to creating machine instructions. One step 33 (in FIG. 2 ), carried out as reflected in FIG. 5 , is to assign a shift pattern or step pattern 41 to the needle bar 37 (shown in FIG. 2 ) and a stitch rate to the pattern. In the case of a two color pattern, it is quite practical to use a very simple stepping pattern of over and back so that the needle bar merely moves from dead center 42 to a position offset by one gauge unit 43 and then repeats. In this case, the repeat length 44 is only two steps. In the event that a four color pattern were being tufted, a typical stepping pattern could involve two steps to the right, four steps to the left, and two steps to the right. Variations of the shift profile for other numbers of colors utilized on a broadloom tufting machine are well known and easily computed. It can also be seen that the stitch rate 45 may be specified which can affect the density of yarn bights and the weight of the resulting tufted fabrics.
[0033] In addition to entering the stepping pattern in FIG. 5 , in the iTuft system the yarns and yarn feed increments are assigned to the colors in the graphic pattern 37 (in FIG. 2 ) using the operator controls in FIG. 6 . In this example, the threadup 51 is only A and B yarns, or two colors 52 , and the white yarns “A” are assigned 53 to needle 1 and odd needles, and black yarns “B” are assigned 54 to needle 2 and even needles, and tufting heights 55 , 56 are set. In the prior art, at this point the pixel-mapped design can be translated into tufting machine instructions 39 . Tufting machines instructions in the form of a yarn feed pattern array for the yarn feed drives, a shift pattern array for each shifter moving the needle bars or backing fabric, a backing feed instruction (or array in the event of varied stitch rates), and a cut/loop array if operating an LCL type apparatus are transferred from the computer running the iTuft operator interface system to storage accessible by the controllers for the yarn feed, shifter, backing feed, and LCL apparatus and the tufting machine 10 operated to produce a tufted fabric of the design 40 .
[0034] Using the yarn optimization techniques of the invention requires some modifications to the prior art process. The pixel-mapped design is created as before 28 but then the design file is loaded into a tufting machine, or more typically a desk top simulator, 30 . Then the shift pattern and stitch rate are set 33 and yarn feed increments assigned to colors in the design 37 . After the pattern has been associated with yarns, yarn feed increments, and a stepping pattern, it is then possible to compute the yarn consumption for each needle 71 as shown in FIG. 3 . This calculation involves combining the lengths of yarn that are utilized in shifting yarns from one position to another in addition to the lengths of yarn that are actually fed and tufted into the backing fabric and at least NedGraphics and Tuftco have provided this functionality in their design software. In the case where a single yarn drive feeds multiple yarns or in a hollow needle type machine where several yarns are selectively fed through a single needle, the calculation may be performed for the yarn fed by a single yarn feed drive.
[0035] After calculating yarn consumption for each needle on the tufting machine, information regarding yarn consumption is provided to the operator or designer. For instance, in FIG. 7 , it can be seen that the minimum yarn consumption 61 per pattern repeat on needle 42 [A] which is tufting white yarn is over 14 inches less than average while the maximum yarn consumption 62 on needle 41 [B] which is tufting black yarn is about 18.5 inches above average. In the event that the operator wishes to balance yarn consumption, the “balance” control 64 provides for the application of an algorithm to adjust the pattern.
[0036] As depicted in the flow diagram of FIG. 3 , each needle is analyzed sequentially. For instance, while the needles in the first and last threadup repeats on a broadloom machine are generally excluded (since those needles are only over the sewing area about half the time and would greatly distort average yarn consumption figures), at some location relatively near the edge—often the fourth needle or so, the needle in position n is analyzed to determine whether it is tufting a greater or lower than average amount of yarn over the course of the pattern. The needle is then classified 72 into a group of high feed needles or low feed needles, and optionally also a group of reasonably optimally fed needles, then the algorithm passes to the needle n+1.
[0037] Then either the high feed group or low feed group of needles is selected for adjustment 73 and a particular algorithm may be selected 74 in the event the system is programmed with a plurality of algorithms. So if low feed needles are selected, each needle is tufting a lower than the average amount, and an analysis is conducted to determine the possible locations that additional tufts of the yarn carried by low feed needle n may be advantageously placed. In a pattern with a long repeat, such as hundreds or thousands of stitches, it is not practical to calculate every possible variation, and it is most efficient to select a subset of candidate stitch locations 75 for a particular needle and analyze that subset for locations that are likely favorable for the placement of an additional bight of yarn carried by the examined needle. So, for instance in a pattern having a stitch length of 1000, it is entirely feasible to perform calculations for only about 15 to 45 candidate stitch locations (depth) for each needle in the group.
[0038] Among the algorithms that can be advantageously used to determine likely suitability for placement of an additional bight of a particular color are cell automata algorithms such as Von Neumann and Moore neighborhood algorithms as represented in their simplest forms in FIG. 9 . In unmodified form, these algorithms determine in which candidate locations there are already the highest concentration of yarns of the same color as that being tufted by needle n and from that group of highly ranked locations conducts a lottery to pick a single location and applies rules to determine where to place an additional tuft of yarn on needle n. Rules for instance would require that the new tuft of yarn on needle n not be replacing a yarn that is on a needle that is underfeeding or optimally feeding. Additional rules may be implemented as desired to affect the appearance of the resulting balanced pattern. After determining stitches for substitution with yarn from needles in the group, the graphic display is updated as are the yarn feed calculations and groupings for the affected needles.
[0039] Additional variable algorithm characteristics may also be set by the designer 76 . A single iteration across the tufting machine is unlikely to resolve the total out of balance situation so that a large number of iterations 63 on the order of 100 or more may be needed to carry out the balancing process. Some rigidly efficient algorithms may make suitable adjustments in only dozens of iterations, however, more subtle algorithms and severely out of balance yarn quantities may result in thousands of iterations being applied to completely optimize a pattern. When the algorithm is applied 77 , preferably the graphic display of the pattern 38 a is shown 78 during the balancing process, with a graphical progress indicator. In the event that the operator determines the pattern graphic 38 b in FIG. 8 is becoming unreasonably distorted, the balancing operation can be stopped 80 using a stop button on the progress indicator, not shown. If the pattern appearance changes too much, the process may be cancelled 65 and the parameters modified and restarted. In addition, at an intermediate point where the balancing is stopped, the partially balanced pattern can be exported 66 and again utilized in a graphic design setting. This allows modifications to be made to return a partially balanced carpet design to suitable appearance with the balancing process then repeated 81 , and this combination of artistic intervention and automated balancing can continue until a balanced and aesthetically suitable design results. Once the design is balanced and is aesthetically suitable, the balanced pattern can be applied 67 (corresponding to translating the pixel-mapped design into Tufting Machine Instructions 39 in FIG. 3 ) and stored in the tufting machine.
[0040] FIG. 8 illustrates the appearance of the pattern 38 b of FIG. 4 after balancing has been applied to correct substantially all of the below average fed yarns 61 b and substantially reduce the amount that yarns are fed in excess of average 62 b. The zebra stripe pattern has been modified 38 b but still retains an organic appearance.
[0041] In a pattern with additional colors, it is possible to lock 68 some colors so that they are not adjusted during the balancing process. In addition, the number of candidate locations for stitch replacement can be specified in the candidate depth 69 field. The complexities in graphic visualization of the balancing process are quite extraordinary since in patterns a single color yarn can be tufted at a variety of different heights. For instance, a yarn might be tufted at a tacking stitch height where it is essentially embedded in the backing fabric, it might be tufted at a low height where the stitch is practically hidden by adjacent stitches, it might be tufted at an intermediate height where the stitch is partially visible, it might be tufted at a high height where the stitch is entirely visible relative to adjacent stitches, and it might be tufted at an even higher height with the intention that the stitch will be tip sheared after the fabric is tufted. For yarn consumption calculation purposes, these yarn feed amounts are combined with variations to compensate for transition stitches (yarn feed amounts change when stitch heights adjust from high to low or vice-versa), and various lateral shifting and stitch rate distance adjustments. For graphic display purposes, each of these intended distinct heights may be represented by different colors though the stitches are all associated with the same color yarn carried by the same needle. Optionally, the display can be modified to show yarns of the same color in a single color and in 3D. In addition, patterns may be tufted on graphics tufting machines that have front and rear needle bars (or front and rear lateral rows of needles on a single staggered needle bar) that can be shifted in unison or independently and stitches from one needle bar are offset from stitches of the other needle bar by a stitch offset quantity so that the patterns tufted by the front needle bar align with the pattern tufted by the rear needle bar.
[0042] In the simple cellular automata shown in FIG. 9 , the Moore Neighborhood comprises the eight cells surrounding a central cell P on a 2-dimensional square lattice and the Von Neumann Neighborhood comprises the four cells orthogonally surrounding a central cell. If a point P is selected for analysis, weights are assigned to the pixels corresponding to the surrounding cells based upon similarities (or dissimilarities) to the yarn that can be placed by the analyzed needle at point P. For instance, if same color adjacent cells are assigned to value=1 and different color adjacent cells are assigned value=0, then candidates points P with a value of 8 would be the most preferred in a Moore Neighborhood analysis searching for similarity. However, values may be assigned in a large variety of ways with greater weight given to various characteristics, for instance, vertically aligned cells N, S may be weighted more heavily than horizontally aligned cells W, E. Locked yarn colors may be assigned differing or negative weights and weights may be assigned based upon yarn heights and textures in addition to color.
[0043] Algorithms may be implemented that tend to either create or break up clumps of color, or that tend to either extend the length or fragment lines of color for instance. Designers will appreciate that different algorithms may be best suited for balancing different styles of patterns with preferred results.
[0044] Numerous alterations of the structure herein disclosed will suggest themselves to those skilled in the art. However, it is to be understood that the present disclosure relates to the preferred embodiment of the invention which is for purposes of illustration only and not to be construed as a limitation of the invention. All such modifications which do not depart from the spirit of the invention are intended to be included within the scope of the appended claims.
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A method is provided for optimizing the yarn consumption in patterned textiles by applying cell automata algorithms to bitmapped-type pattern designs including operator selected rules to influence the general appearance of the pattern design.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to the field of paving roads and specifically to reducing fumes from asphalt during paving.
2. Description of the Related Art
Asphalt, comprising tar and an aggregate, such as stone, has long been used as a paving material for roads, parking lots, sidewalks and other surfaces. Hot asphalt is transported to a paving site where it is spread on a graded base surface, such as soil, sand, gravel or old pavement. The asphalt is then leveled or shaped to a desirable configuration in which it cools and hardens to provide a durable paved surface.
In laying asphalt pavement roadways and the like, it is a widespread practice to employ so-called floating screed paving machines. These machines include a tractor-like main frame having an engine for propulsion and for material distributing functions. Typically, there is a material receiving hopper at the front of the paver arranged to receive hot asphalt material from a truck as the paving machine advances along the roadbed. Slat conveyors or the like are provided to convey the material from the hopper, at the front of the machine, toward the floating screed, at the back of the machine. Immediately in front of the screed, there is typically provided a distributing auger, which receives the raw asphalt material from the slat conveyor and conveys it laterally so as to distribute the material along the front edge of the screed. As the machine advances along the prepared roadbed, the raw asphalt material flows under the screed, which levels, smoothes and compacts it to provide a continuous, level pavement mat.
The paving material comprises an aggregate and a bituminous material. The bituminous material is generally asphalt derived from petroleum. The asphalt is composed of hydrocarbons and heterocyclic compounds containing nitrogen, sulfur, and oxygen. Typically these are pre-mixed and transported to the paving site, but they may be mixed on-site or as a part of the paving process. The mixture is sometimes referred to as asphalt or blacktop. A related bitumen, tar, is sometimes used in the same manner as the asphalt or is sprayed onto a surface covered with aggregate. Some of the materials in the asphalt or tar exhale gasses or fumes which are irritating or potentially harmful to persons, plants and animals near the paving operation. In particular, a "screed operator" is typically positioned near the screed and a "paver operator" rides atop the paver as the asphalt is being distributed and leveled. The gasses include undesirable benzine or benzene rings.
It would be desirable to contain the fumes so as to isolate the screed operator and others from the fumes. It would further be desirable to process the fumes so as to remove or reduce the undesirable effects of the components of the fumes before discharging the fumes to the atmosphere.
SUMMARY OF THE INVENTION
The present invention provides an apparatus for conveying paving material. The apparatus includes a paving material conveyance and a fume processor for removing noxious components of fumes exhaled by the paving material. A fume conduit directs the fumes from the conveyance to the processor.
The conveyance may be a paving apparatus and the processor and conduit are preferably carried on board the conveyance. The fume processor includes a heating element for heating the fumes, such as an engine of the paving material conveyance. The fume conduit is connected to an input of the engine so as to burn the fumes in the engine.
Preferably, the fume conduit includes a separator for directing part of the fumes to an intake of the engine and another part of the fumes to an exhaust flow from the engine. The processor may include a filter or a scrubber. A suction means is provided for urging the fumes toward the processor. The suction can be created by the engine. The fume conduit includes a duct for directing the fumes to the processor. The fume conduit also includes a hood for containing and collecting the fumes. The conduit may be a flexible screen at least partly covering the conveyance.
The paving material conveyance may include a screed for levelling the paving material. In such a case, the fume conduit includes a screen over the screed for collecting the fumes around an inlet of the hood. When the screed is extendable, the screen comprises a roll of film having one end attached to the conveyance and another end attached to the screed so as to be extendable therewith. Clamps on the screed releasably attach the screen thereto.
A method of reducing fumes exhaled from paving material carried in a paving material conveyance is also disclosed. The steps include collecting the fumes in a fume conduit; directing the fumes to an intake of an engine of the paving material conveyance; and burning the fumes in the engine. Part of the fumes may be separated and directed to an exhaust flow of the engine.
The description herein focuses on asphalt based paving materials, but could apply to any paving material or coating which exhales harmful or undesirable fumes. Also, the apparatus described is a paver, but could be another conveyance, such as a vehicle.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a partially cut away side elevational view of a paver equipped with a fume collection system according to the invention;
FIG. 2 shows a rear elevational view of the paver with its screed removed;
FIG. 3 shows a detailed perspective view of the rear part of the paver and a fume collection hood disposed thereon; and
FIG. 4 shows a detailed perspective view of a paver having an extendable screed equipped with a fume collection screen according to the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1, a paving material conveyance, such as a paver 10 or a dump truck, is adapted to hold or transport paving material. As discussed above, the paving material typically comprises an aggregate and a bituminous material, commonly referred to as asphalt. The paver 10 shown is represenatative of a wide variety of paving material conveyances having different construction and features well known in the art. The paver 10 is powered by an engine 12, preferably of an internal combustion type. The engine has an air intake 13 for air used in the combustion process. Byproducts or waste from the combustion process are exhausted through an exhaust system which includes a muffler 15 and an exhaust pipe 17. The engine 12 drives wheels or a track 14 to move the paver 10 over a surface, such as a roadbed 16 on which the paving material is to be distributed.
A hopper 18 on the paver 10 is adapted to receive paving material from a dump truck, for example. A slat type conveyor (not shown) moves the paving material from the hopper 18 toward the back of the paver 10 through the middle of the paver. A rotating auger 20 distributes the paving material toward sides of the paver 10. A screed 22 is disposed behind the auger 20 for further distributing and levelling the paving material distributed by the auger. The screed 22 is pulled by a pair of tow arms 24 secured to the paver so as to permit the screed to "float," thereby providing a smoothly paved surface despite irregularities in the roadbed 16. The screed 22 includes end gates 26 which prevent paving material from spilling beyond the ends of the screed. One or more control stations 28 are equipped to accommodate an operator who controls operation of the paver and the screed. To this point, the paver 10 and associated apparatus described are well known in the art.
According to a preferred embodiment of the invention, the paver is equipped with a hood 30 disposed above the auger 20. The hood 30 is also shown in FIGS. 2 and 3. The hood 30 is made of fiberglass, steel, or other suitable material which is not substantially degraded by fumes from the paving material or other environmental conditions. The hood 30 may be rigid or flexible. As will become apparent, the hood 30 should be shaped and located so as to contain and collect substantially all of the fumes from the paving material as the paving material is distributed by the auger 20.
Returning to FIG. 1, a duct 32 is in communication with the hood 30. The duct 32 is preferably a rigid pipe of galvanized metal or other suitable material. As shown, the duct 32 extends forwardly from the hood 30 through the paver 10, however the duct may follow any suitable path as will become apparent. The forward end of the duct 32 or conduit communicates with an input of an air cleaner 34, such as a filter and/or an activated charcoal scrubber. The air cleaner 34 is suitable for removing particulate matter or other components from the fumes flowing in the duct 32. One output of the the air cleaner 34 is connected to communicate with the air intake 13 of the engine 12. Another output of the air cleaner is connected to communicate with the exhaust flow from the engine 12, preferably at the exhaust pipe 17, by means of a hose 36, for example. The air cleaner serves as an air separator to direct part of the fumes to the engine 12 and part of the fumes to the exhaust pipe 17. Alternative embodiments could eliminate the air cleaner and use only a separator or all of the fumes could be directed to the engine with or without the air cleaner.
The air cleaner 34, engine 12, and exhaust serve as a fume processor for removing noxious components from the fumes of the paving material. The hood and duct define a conduit for directing the fumes to the fume processor. The fumes are burned in the combustion process in the engine, thereby eliminating or reducing noxious components of the fumes, such as benzine or benzene rings. The engine is preferred as the fume processor since it has been found to be effective and is readily available on pavers and other paving material conveyances. However, a separate fume processor could be used in addition to or in place of the engine. For example, a separately fueled combustion chamber, a series of filters, or a chemical treatment plant could be used.
The suction required for proper flow of the fumes into the fume processor through the hood and the duct is achieved by the natural vacuum created by the engine. This flow is augmented by connecting an output of the air cleaner 34 to the exhaust pipe 17, as shown in FIG. 1. If necessary, additional suction may be generated by a fan, for example. In addition, fumes may be directed toward the conduit or hood by a blower disposed near the screed 22, for example.
In a preferred embodiment, the air cleaner separates the flow to its two outputs shown by quantity. It might also be desirable to separate the flow by quality, for example, where disparate fume processors are used to treat different components of the fumes.
Referring to FIG. 4, the screed 22 is of an extendable type, as is known in the art and described, for example, in U.S. Pat. No. 4,379,653 to Brown, which is incorporated herein by reference. During transport of the paver 10 on a trailer, for example, the screed is retracted. During paving the screed 22 can be extended laterally so as to permit paving of an area wider than the width of the paver 10.
A screen 38 is provided on a roll diposed in a case 40. The case 40 is mounted on the tow arm 24 above the screed 22. The case may be removably mounted on the tow arm or the roll may be removably mounted in the case. A smooth bar 42, such as a rigid rod, is disposed on a non-extending part of the screed and is generally parallel with the case 40. The screen 38 is unrolled from the case, wrapped partly around the bar 42, and pulled over the screed. A leading end of the screen is fastened on or near the end gate by means of clamps 44. The screen 38 forms an extension of the conduit to cover the screed and contain fumes exhaled by the paving material within the extended screed. The screen and screed cooperate with the hood to direct the fumes into the duct 32 by means of the suction created by the engine 12. The roll of screen material should be spring biased to return to the case when the screed is retracted.
Preferably, the screen is made of 0.020 thick welding curtain, and may be transparent or opaque. The screen can be made from any flexible sheet material which is rollable and sufficiently resistant to heat and fumes from the paving operation. Ideally the screen is inexpensive and disposable. The roll should include surplus screen so that damaged screen can be unclamped and discarded and new screen can be pulled from the case and clamped to the end gate. An exhausted roll of screen material can be replaced.
The screen contains fumes from the paving material and facilitates conveyance of the fumes to the fume processor. The screen can be adapted for other stationary or movable parts in which paving material is to be contained. The necessary combination and configuration of one or more hoods, screens, and ducts will be apparent from the structure of the paver or other conveyance. For example, the conveyance could comprise a dump truck having a retractable screen over the dump body. The duct could be flexible so as to remain connected during dumping. The apparatus need not entirely enclose the paving material, so long as sufficient suction is generated to contain the desired amount of fumes.
The present disclosure describes several embodiments of the invention, however, the invention is not limited to these embodiments. Other variations are contemplated to be within the spirit and scope of the invention and appended claims.
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A paver or other apparatus used to convey paving material is provided with a conduit including a hood and a duct for directing fumes from the paving material to a fume processor. A paver having an extendable screed or other moving parts is equipped with a roll of screen material. The screen material is unrolled and fastened over the extended screed to contain and direct the fumes to the conduit. The fumes are burned in an engine of the paver or otherwise processed to remove or reduce noxious components thereof.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to U.S. Provisional Application No. 61/723,113, filed Nov. 6, 2012, the entirety of which is incorporated by reference herein.
FIELD OF INVENTION
[0002] Novel compositions are disclosed for topical application and delivery of hydrophilic, biologically-active agents in a microemulsion to and through the protective outer layer of a biological surface, wherein a biological surface includes those of humans, animals, viruses, protozoa, fungi, and bacteria. More specifically, hydrophilic, polar, biologically active agents that are solubilized by a reverse emulsion surfactant into a microemulsion, with or without added polymer, in non-stinging, volatile, hydrophobic solvents are disclosed. Transdermal delivery is augmented by the addition of a penetration enhancer.
BACKGROUND OF THE INVENTION
[0003] The delivery of biologically-active agents through a biological surface is a well-recognized method of treatment in controlled drug delivery. Such compounds are often delivered from a device to a skin surface, with transdermal delivery through the skin.
[0004] The treatment of the skin of humans and animals with topical drugs, antibiotics, antimicrobial agents, anti-infective agents, and pain-relieving agents is well known. In recent years transdermal delivery of biologically active substances has gained favor because of the controlled release of a minimalized concentration of the active agent. The initial systems for transdermal delivery pertained to patches containing small, lipophilic drugs, such as scopolamine, nicotine, estradiol, fentanyl, lidocaine and testosterone, as well as combination patches containing drugs for contraception and hormone replacement. Following the initial patch studies, transdermal chemical enhancers were studied, as well as non-cavitational ultrasound and iontophoresis. More recent developments for penetrating the stratum corneum of the skin involve microneedles, thermal ablation, microdermabrasion, electroporation, and cavitational ultrasound. Since the inception of transdermal drug delivery patches, it is believed that more than one billion transdermal patches are manufactured each year. However, it has been difficult to exploit the transdermal route to deliver hydrophilic drugs (M. R. Prausnitz and R. Langer, Nat. Biotechnol., November, 26(11), 1261-1268 (2008)).
[0005] A commercially successful application for the use of a non-stinging, volatile, hydrophobic solvent on human and veterinary skin has been in the area of liquid adhesive bandages. These bandages are prepared from siloxy-containing hydrophobic and amphiphilic polymers admixed with volatile liquid polydimethylsiloxanes and volatile liquid alkanes (U.S. Pat. No. 4,987,893, U.S. Pat. No. 5,103,812, U.S. Pat. No. 6,383,502, and U.S. Pat. No. 8,263,720, the entireties of which are incorporated herein by reference). They have been reported to provide non-stinging, non-irritating liquid bandage coating materials after solvent evaporation that allow body fluid evaporation while protecting the body surface from further contamination and desiccation. Over time, these polymer coatings self-remove from the skin as healing occurs. Certain hydrophobic drugs, such as isopropyl xanthic disulfide, a fungicide, can dissolve directly in these hydrophobic, volatile solvents (U.S. Pat. No. 5,103,812) without the use of any additives. However, hydrophilic (e.g., polar or ionic) biologically-active agents, such as pharmaceutical drugs, antimicrobial agents, anti-infective agents, and pain-relieving agents are not soluble in the hydrophobic volatile solvents.
SUMMARY
[0006] A composition for transdermal delivery of biologically-active agents in a hydrophobic, volatile solvent containing a reverse emulsion surfactant that gives a water-in-oil microemulsion (w/o) of the biologically-active agents solubilized in the volatile, non-polar solvent is described. The composition can provide transdermal delivery of biologically-active substances that are inherently insoluble in the volatile, hydrophobic solvent by solubilizing them in a reverse microemulsion. The biologically active agents can be hydrophilic (e.g., polar or ionic) and be solubilized in the hydrophobic, volatile solvent via a reverse microemulsion.
[0007] As used herein, “biologically-active agents” has its standard meaning and includes chemical substances or formulations that beneficially affect human, animals, or plants or is intended for use in the cure, mitigation, treatment, prevention, diagnosis of infection or disease, or is destructive to or inhibits the growth of microorganisms. The phrases “biologically-active agents” and “active agents” are used interchangeably herein.
[0008] As used herein, “biological surface” has its standard meaning and includes the surface or outer layer of bacteria, fungi, protozoa, viruses, plants, animals, and humans.
[0009] As used herein, “surfactant” has its standard meaning and includes emulsifying agents, emulsifiers, and surface-active agents.
[0010] As used herein, “microemulsion” is has its standard meaning and includes thermodynamically stable mixtures of oil, water (and/or hydrophilic compound) and surfactant. Microemulsions include three basic types: direct (oil dispersed in water, o/w), reverse (water dispersed in oil, w/o) and bicontinuous. Microemulsions are optically clear because the dispersed micelles have a diameter that is less than the wavelength of visible light (e.g., less than 380 nanometers, less than 200 nanometers, or less than 100 nanometers) in diameter. In the absence of opacifiers, microemulsions are optically clear, isotropic liquids.
[0011] As used herein, “reverse microemulsion” refers to a microemulsion comprising a hydrophilic phase suspended in a continuous oil phase. A reverse microemulsion can include droplets of a hydrophilic phase (e.g., water, alcohol, or a mixture of both) stabilized in an oil phase by a reverse emulsion surfactant. In such instances, a hydrophilic active agent can be solubilized in the droplets. However, in other instances, the reverse microemulsion can be free of water and/or alcohol, and the hydrophilic active agent can be directly solubilized in the oil phase by the reverse emulsion surfactant.
[0012] As used herein, “hydrophilic” has its standard meaning and includes compounds that have an affinity to water and are usually charged or has polar groups in its structure that attract water. For example, hydrophilic compounds can be miscible in water.
[0013] As used herein, “free of water and/or alcohol” means that the composition includes less than 3 wt-% water and C 1 -C 4 alkyl alcohols combined, or less than 2 wt-%, or less than 1 wt-%, or less than 0.5 wt-%, or less than 0.1 wt-%.
[0014] As used herein, “non-stinging” means that the formulation does not cause a sharp, irritatingly or smarting pain as a result of contact with a biological surface.
[0015] As used herein, “non-burning” means that the formulation does not cause a biological surface to increase in temperature.
[0016] The compositions described herein are particularly helpful for transdermal delivery of biologically-active agents, particularly those of a hydrophilic or polar nature, from a non-stinging, volatile solvent capable of penetrating the stratum corneum of the skin and other biological surfaces in order to rapidly provide the biological agent to a targeted area. Such a solvent is advantageous over other transdermal procedures because of the ease of percutaneous penetration, painless application, the extent of the surface area that can be covered, including all areas that flex or stretch, and the speed with which the biologically-active agent can penetrate the skin.
[0017] The solvent for solubilization of biologically-active agents is preferably volatile and hydrophobic, and more preferentially the solvent is non-stinging and non-burning to intact skin or to an open wound. Such solvents are particularly useful because they can be applied without causing discomfort to the patient and the low surface tension facilitates flow into crevices and difficult to reach areas. Furthermore, rapidly volatilize because of their low heat of vaporizations, which deposits the biologically-active substances solubilized in the volatile, hydrophobic solvent in a desired location. Preferred non-stinging, non-burning hydrophobic solvents include hexamethyldisiloxane (HMDS) (heat of vaporization 34.8 KJ/mol) and isooctane (heat of vaporization 33.26 kJ/mol), which can be used in spray-on applications on biological surfaces, many drugs are difficulty soluble or insoluble in these solvents. Silicone solvents are most preferred on the skin because they are non-stinging and give excellent lubrication and comfort. Of all the silicone fluids, hexamethyldisiloxane possesses the fastest evaporation rate, the lowest viscosity, and the lowest surface tension, with the highest spreadability. Additionally, unlike other volatile fluids, hexamethyldisiloxane does not heat, burn, or sting the skin as it evaporates, and only slight cooling is observed. Although these attributes make silicone solvents beneficial for topical treatment to skin, few biologically-active organic or inorganic substances dissolve in them without the microemulsion system described herein.
[0018] The hydrophobic, volatile liquid is preferably non-stinging and non-irritating, and comprises a low molecular weight polydimethylsiloxane, such as hexamethyldisiloxane, octamethyltrisiloxane, or an alkylmethyltrisiloxane; a low molecular weight cyclic siloxane, such as hexamethylcyclotrisiloxane or octamethylcyclotetrasiloxane; cyclomethicones, a linear, branched or cyclic alkane, such as propane, butane, and isobutane (under pressure), pentane, hexane, heptane, octane, isooctane, and isomers thereof, petroleum distillates, volatile vegetable hydrocarbons, cyclopentane or cyclohexane; a chlorofluorocarbon, such as trichloromonofluoromethane, dichlorodifluoromethane, and dichlorotetrafluoroethane; a fluorocarbon, such as tetrafluoroethane, heptafluoropropane, 1,1-difluoroethane, pentafluoropropane, perfluoroheptane, perfluoromethylcyclohexane, hydrofluoroalkanes such as 1,1,1,2,-tetrafluoroethane and 1,1,1,2,3,3,3-heptafluoropropane, combinations thereof and the like; a volatile gas under pressure, such as liquid carbon dioxide; or a mixture thereof. As will be understood, when stored under high pressure, carbon dioxide can be present in the form of a liquid at room temperature. The volatile solvent can be hexamethyldisiloxane, isooctane, and mixtures thereof. Preferentially, the volatile solvent is hexamethyldisiloxane.
[0019] As used herein, “volatile” has its standard meaning, that is, it can evaporate rapidly at normal temperatures and pressures. For example, a solvent is volatile if one drop (0.05 mL) of the solvent will evaporate completely between 20-25° C. within 5 minutes, or within 4 minutes, or within 3 minutes, or within 2 minutes, or within 1 minute, or within 30 seconds, or within 15 seconds.
[0020] The biologically-active agents can be solubilized in the hydrophobic volatile liquid by the addition of a reverse emulsion surfactant, such that a reverse microemulsion is formed. A reverse emulsion, also termed an inverse emulsion, results from the aggregation of surfactant molecules in a nonpolar solvent, wherein water is incorporated into the surfactant core, such that a water-in-oil emulsion is formed. Reverse emulsion surfactants with HLB numbers from 3 to 11 are generally used, where HLB is the hydrophile-lipophile balance. The HLB value of the reverse emulsion surfactants can range from 5 to 11 or 7 to 10. The higher the HLB number, the more water-soluble the surfactant, while a low HLB number indicates a lower aqueous solubility and a higher affinity for the non-polar phase.
[0021] In some embodiment, the compositions described herein can be active antimicrobial agents against at least one microbe selected from the group consisting of Gram negative bacteria, Gram positive bacteria, and fungi. In some embodiment, the compositions described herein can be active antimicrobial agents against at least two microbes selected from the group consisting of Gram negative bacteria, Gram positive bacteria, and fungi, while the compositions can be active antimicrobial agents against Gram negative bacteria, Gram positive bacteria, and fungi in other embodiments.
[0022] It is also possible to have a double emulsion, such as a water-in-oil-in-water emulsion or an oil-in-water-in-oil emulsion. Unless otherwise specified, “reverse emulsion” includes double emulsions. Reverse emulsion can be water-in-oil emulsions, except for double emulsions.
[0023] The ratio of drug to volatile liquid to surfactant to water can be such that the resulting solution remains optically clear. The reverse emulsion surfactant can have inherent solubility in the hydrophobic, volatile liquid and can solubilize water and/or the active agent into the reverse micelle, yielding an overall clear, transparent solution. When a soluble polymer is added to the composition, solution clarity is maintained, as is the clarity of the resulting polymer film which, after solvent evaporation adsorbs the surfactant encapsulated biologically-active agent in water and acts as the substrate for sustained, transdermal delivery. In certain instances, the addition of water is not necessary for solubilization of biologically-active agents by a reverse emulsion surfactant in a volatile, hydrophobic solvent.
[0024] Suitable reverse emulsion surfactants include sodium bis(2-ethylhexyl)sulfosuccinate, sodium bis(tridecyl)sulfosuccinate, bis(dialkyl)sulfosuccinate salts, copolymers of polydimethylsiloxane and polyethylene/polypropylene-oxide, polyoxypropylene (12) dimethicone, cetyl PEG/PPG-10/1 dimethicone, hexyl laurate and polyglyceryl-4-isostearate, PEG-10 dimethicone, sorbitan monolaurate, sorbitan monooleate, polyoxyethylenesorbitan trioleate, polyoxyethylene octyl phenyl ether, polyoxyethylene 10 cetyl ether, polyoxyethylene 20 cetyl ether, polyethylene glycol tert-octylphenyl ether, sodium di(2-ethylhexyl)phosphate, sodium di(oleyl)phosphate, sodium di(tridecyl)phosphate, sodium dodecylbenzenesulfonate, sodium 3-dodecylaminopropanesulfonate, sodium 3-dodecylaminopropionate, sodium N-2-hydroxydodecyl-N-methyltaurate, lecithin, sucrose fatty acid esters, 2-ethylhexylglycerin, caprylyl glycol, long chain hydrophobic vicinal diols of monoalkyl glycols, monoalkyl glycerols, or monoacyl glycerols, polyoxyl castor oil derivatives, polyethylene glycol hydrogenated castor oil, tetraethylene glycol dodecyl ether, potassium oleate, sodium oleate, cetylpyridynium chloride, alkyltrimethylammonium bromides, benzalkonium chloride, didodecyldimethylammonium bromide, trioctylmethylammonium bromide, cetyltrimethylammonium bromide, cetyldimethylethylammonium bromide, and the like, with or without added alkanols such as isopropanol, 1-butanol, and 1-hexanol, and combinations thereof. The reverse emulsion surfactants can be dialkylsulfosuccinate salts, such as sodium bis(2-ethylhexyl)sulfosuccinate.
[0025] Sodium bis(2-ethylhexyl)sulfosuccinate (Aerosol AOT, also called AOT, docusate sodium, DSS, Aerosol OT, and sodium 1,4-bis(2-ethylhexoxy)-1,4-dioxobutane-2-sulfonate) is a well-studied surfactant, which forms reverse micelles of well-defined structure in organic solvents (T. K. De, A. Maitra, Adv. Colloid Interface Sci. 59, 95 (1995)). It is a versatile double-tailed medicinal surfactant (S. N. Malik, D. H. Canaham, M. W. Gouda, J. Pharm. Sci. 64, 987 (1975)). It is the most widely used surfactant in reverse micelle encapsulation studies (P. F. Flynn, Prog. Nucl. Magn. Reson. Spectrosc. 45, 31-51 (2004)) and is a common ingredient in consumer products. AOT microemulsions generally give “inverted” micelles filled with water in a weakly polar oil consisting of alkanes (cyclohexane, isooctane, etc.) or aromatic molecules (J. R. Lalanne, B. Pouligny, and E. Sein, J. Phys. Chem., 87, 696-707 (1983)). The chemical structure of AOT imparts a well-balanced hydrophilic-lipophilic property. This unique feature of AOT allows the formation of alcohol-free reverse micellar and normal micellar aggregates in non-aqueous and aqueous media, respectively, without using any co-surfactant. AOT dissolves a considerable amount of water in oil and forms a stable reverse micellar system that is also known as water-in-oil microemulsion (R. R. Gupta, S. K. Jain, M. Varshney, Colloids and Surfaces B: Biointerfaces, 41, 25-32 (2005)). It interacts with penetration enhancers, as a non-volatile oil phase, for transdermal delivery of many biologically active agents (M. Varshney, T. Khanna, M. Changez, Colloids & Surfaces B 13, 1-11 (1999)). Also, AOT microemulsions have been reported to act as safe transdermal carriers (M. Changez and M. Varshney, Drug Devel. Industrial Phar., 26(5), 507-512 (2000)). AOT (also called docusate sodium) has been reported to have a HLB value of 10, a value supporting microemulsion formation (Pharmaceutical Suspensions: From Formulation Development to Manufacturing, A. K. Kulshreshtha, O. N. Singh, G. M. Wall, eds., “Pharmaceutical Development of Suspension Dosage Form, Y Ali, et al., 2009, Table 4.3, page 112).
[0026] Dialkylsulfosuccinates, such as sodium bis(2-ethylhexy)sulfosuccinate (AOT), have also been demonstrated to have antibacterial (against Gram positive microorganisms), anti-fungal and anti-viral properties (U.S. Pat. Nos. 4,717,737, 4,719,235 and 4,885,310). This effect would be expected to enhance the antimicrobial and anti-infective properties of the compositions described herein.
[0027] The biologically-active agents that can be incorporated into the surfactant reverse micelles include: antibiotics, antiseptics, anti-infective agents, antimicrobial agents, antibacterial agents, antifungal agents, antiviral agents, antiprotozoal agents, sporicidal agents, antiparasitic agents, peripheral neuropathy agents, neuropathic agents, analgesic agents, anti-inflammatory agents, anti-allergic agents, anti-hypertension agents, mitomycin-type antibiotics, polyene antifungal agents, antiperspirant agents, decongestants, anti-kinetosis agents, central nervous system agents, wound healing agents, anti-VEGF agents, anti-tumor agents, escharotic agents, anti-psoriasis agents, anti-diabetic agents, anti-arthritis agents, anti-itching agents, antipruritic agents, anesthetic agents, anti-malarial agents, dermatological agents, anti-arrhythmic agents, anticonvulsants, antiemetic agents, anti-rheumatoid agents, anti-androgenic agents, anthracyclines, anti-smoking agents, anti-acne agents, anticholinergic agents, anti-aging agents, antihistamines, anti-parasitic agents, hemostatic agents, vasoconstrictors, vasodilators, anticlotting agents, cardiovascular agents, angina agents, erectile dysfunction agents, sex hormones, growth hormones, immunomodulators, tumor necrosis factor alpha, anti-cancer agents, antineoplastic agents, anti-depressant agents, antitussive agents, anti-neoplastic agents, narcotic antagonistics, anti-hypercholesterolaemia agents, apoptosis-inducing agents, birth control agents, sunless tanning agents, emollients, alpha-hydroxyl acids, matrix metalloproteinases, topical retinoids, hormones, tumor-specific antibodies, antisense oligonucleotides, small interfering RNA (siRNA), anti-VEGF RNA aptamer, nucleic acids, DNA, vitamins, essential oils, silver salts, zinc salts, salicylic acid, benzoyl peroxide, 5-fluorouracil, nicotinic acid, nitroglycerin, clonidine, estradiol, testosterone, nicotine, motion sickness agents, scopolamine, fentanyl, diclofenac, buprenorphine, bupivacaine, ketoprofen, opiods, cannabinoids, enzymes, enzyme inhibitors, oligopeptides, cyclopeptides, polypeptides, proteins, prodrugs, protease inhibitors, cytokines, hyaluronic acid, chondroitin sulfate, dermatan sulfate, parasympatholytic agents, chelating agents, hair growth agents, lipids, glycolipids, glycoproteins, endocrine hormones, growth hormones, growth factors, heat shock proteins, immunological response modifiers, saccharides, polysaccharides, insulin and insulin derivatives, steroids, corticosteroids, and non-steroidal anti-inflammatory drugs or similar materials, in either their salt form or their neutral form, either being inherently hydrophilic or encapsulated within a hydrophilic microparticle or nanoparticle. Such biologically-active agents could be in either of the (R)-, (R,S)-, or (S)-configuration, or a combination thereof.
[0028] The non-stinging, hydrophobic volatile liquid can be a low molecular weight polydimethylsiloxane, such as hexamethyldisiloxane or octamethyltrisiloxane; a low molecular weight cyclic siloxane, such as hexamethylcyclotrisiloxane or octamethylcyclotetrasiloxane; a linear, branched or cyclic alkane, such as propane, butane, and isobutane (under pressure), pentane, hexane, heptane, octane, isooctane, petroleum distillates, or cyclohexane; a chlorofluorocarbon such as trichloromonofluoromethane, dichlorodifluoromethane, and dichlorotetrafluoroethane; a fluorocarbon such as tetrafluoroethane, heptafluoropropane, 1,1-difluoroethane, pentafluoropropane, perfluoroheptane, perfluoromethylcyclohexane, hydrofluoroalkanes such as 1,1,1,2,-tetrafluoroethane and 1,1,1,2,3,3,3-heptafluoropropane, combinations thereof and the like; a volatile gas under pressure, such as liquid carbon dioxide; or a mixture thereof. As will be understood, when stored under high pressure, carbon dioxide can be present in the form of a liquid at room temperature. The volatile solvent can be hexamethyldisiloxane, isooctane, and mixtures thereof. Preferably, the volatile solvent is hexamethyldisiloxane.
[0029] More hydrophilic solvents, such as ethanol, isopropanol, glycerin, propylene glycol, and poly(ethylene glycol) can be added in small amounts (10 weight % or less) to the reverse emulsion surfactant in the volatile, hydrophobic solvent in order to enhance solubility of the biologically active agent or any other added material, but these polar solvents should not interfere with the overall solvent composition being non-stinging to a user. The hydrophilic solvents can include ethanol, isopropanol, glycerin and mixtures thereof. Other hydrophilic solvents, such as methanol, acetone, dioxane, ethyl acetate, tetrahydrofuran, N-methylpyrrolidone, N,N-dimethylacetamide, tetraethylene glycol, dimethyl sulfoxide and mixtures thereof can also be used. The composition can be free of added hydrophilic solvents.
[0030] Chemical penetration enhancers are known to significantly enhance the transdermal delivery of drugs through the skin strata to the dermis. The penetration enhancer can function to enhance transdermal delivery of the biologically-active agent through the stratum corneum to the dermis, as well as potentially facilitating penetration of an antibiotic or antimicrobial agent through the outer wall of a microorganism (e.g., bacteria, mold, yeast, or protozoa), thus enhancing biocidal activity. Such penetration enhancers include, but are not limited, fatty acids such as branched and linear C 6 -C 18 saturated acids, unsaturated acids, such as C 14 to C 22 , oleic acid, cis-9-octadecenoic acid, linoleic acid, linolenic acid, fatty alcohols, such as saturated C 8 -C 18 terpenes, such as d-limonene, alpha-pinene, 3-carene, menthone, fenchone, pulegone, piperitone, eucalyptol, chenopodium oil, carvone, menthol, alpha-terpineol, terpinen-4-ol, carveol, limonene oxide, pinene oxide, cyclopentane oxide, triacetin, cyclohexane oxide, ascaridole, 7-oxabicylco[2,2,1]heptane, 1,8-cineole, glycerol monoethers, glycerol monolaurate, glycerol monooleate, isostearyl isostearate pyrrolidones, such as 2-pyrrolidone, N-methyl-2-pyrrolidone, 1-ethyl-2-pyrrolidone, 5-methyl-2-pyrrolidone, 1,5-dimethyl-2-pyrrolidone, 2-pyrrolidone-5-carboxylic acid, N-hexyl-2-pyrrolidone, N-lauryl-2-pyrrolidone, 1-dodecylazacycloheptan-2-one, 4-decyloxazolidin-2-one, N-dodecylcaprolactam, and 1-methyl-3-dodecyl-2-pyrrolidone, cationic surfactants such as alkyltrimethylammonium halides, alkyldimethylbenzylammonium halides and alkylpyridinium halides, anionic surfactants, such as sodium lauryl sulfate and sodium laureth sulfate, and nonionic surfactants, such as polysorbates 20, 21, 80 and 81, Pluronic F127, Pluronic F68, N-n-butyl-N-n-dodecylacetamide, N,N-di-n-dodecylacetamide, N-cycloheptyl-N-n-dodecylacetamide and N,N-di-n-propyldodecanamide, urea, 1-dodecylurea, 1,3-didodecylurea, 1,3-diphenylurea, dimethyl sulfoxide, decylmethyl sulfoxide, tetradecylmethyl sulfoxide, hydrophobic esters such as methyl laureate, isopropyl lanolate, isopropyl myristate, isopropyl palmitate, and cyclodextrins. Also effective penetration enhancers include 1-alkyl-2-piperidinones, 1-alkyl-2-azacycloheptanones, such as 1-dodecyazacycloheptan-2-one, 1,2,3-alkanetriols, such as 1,2,3-nonanetriol, 1,2-alkanediols, n-alkyl-β-D-glucopyranosides, 2-(1-alkyl)-2-methyl-1,3-dioxolanes, oxazolidinones, such as 4-decyloxazolidin-2-one, N,N-dimethylalkanamides, 1,2-dihydroxypropyl alkanoates, such as 1,2-dihydroxypropyl decanoate, 1,2-dihydroxypropyl octanoate, sodium deoxycholate, trans-3-alken-1-ols, cis-3-alken-1-ols, and trans-hydroxyproline-N-alkanamide-C-ethylamide. A more complete list of penetration enhancers is given in “A Listing of Skin Penetration Enhancers Cited in the Technical Literature,” D. W. Osborne, J. J. Henke, Pharmaceutical Technology, 21 (11), 58-66 (1997), the entirety of which is incorporated herein by reference. The penetration enhancers can include hydrophobic esters isopropyl myristate and isopropyl palmitate and non-ionic surfactants of polysorbate.
[0031] As a substrate carrier for the sustained release of the biologically-active agents incorporated within the reverse emulsion surfactant, with or without other additives, polymers utilized in non-stinging, liquid adhesive bandages are preferred. In some embodiments, liquid adhesive bandages are prepared from siloxy-containing hydrophobic polymers admixed with volatile liquid polydimethylsiloxanes and volatile liquid alkanes (U.S. Pat. No. 4,987,893, U.S. Pat. No. 5,103,812, and U.S. Pat. No. 8,263,720, the entireties of which are incorporated herein by reference, and U.S. Pat. No. 6,383,502) that provide non-stinging, non-irritating liquid bandage coating materials after solvent evaporation. Such coating materials are oxygen permeable and allow body fluid evaporation while protecting the body surface from further contamination and desiccation.
[0032] Additionally, amphiphilic siloxy-containing polymers have also been reported as liquid adhesive bandages in volatile, hydrophobic solvents (U.S. Pat. No. 7,795,326, the entirety of which is incorporated herein by reference), wherein the hydrophobic siloxysilane monomer is copolymerized with a hydrophilic nitrogen-containing monomer. Other siloxy-containing polymers include block copolymers of polydimethylsiloxane and polyurethane, and block copolymers of polydimethylsiloxane and poly(ethylene glycol). Still, other polymers soluble in the volatile, hydrophobic solvents include block copolymers of polystyrene and ethylene/butylene, block copolymers of polystyrene and polyisobutylene, block copolymers of polystyrene and polyisoprene, block copolymers of polystyrene and polybutadiene, block copolymers of polydimethylsiloxane and polyurethanes, polymers of C 4 -C 18 acrylates and methacrylates, butyl rubber, polyisobutylene, and combinations thereof.
[0033] The preferred siloxy-containing monomer for both the hydrophobic and amphiphilic liquid adhesive bandages of the above mentioned patents is based upon the siloxy monomer, 3-methacryloyloxypropyltris(trimethylsiloxy)silane (TRIS). TRIS can be used in combination with both hydrophilic comonomers, such as N-isopropylacrylamide (NIPAM), or hydrophobic comonomers, such as methyl methacrylate, such that the resulting copolymers are soluble in a volatile, non-stinging, hydrophobic solvent.
[0034] Similarly, other polymer substrates could be based upon adhesive-type polymers from hydrophobic monomers such as isooctyl acrylate (ISO), such that they are soluble in volatile, non-stinging solvent.
[0035] In reference to the sustained release described herein, it is notable that certain diseases, such as peripheral neuropathy, are difficult to control because of the pain generated and the difficulty in predicting the extent to which a systemic drug would be effective. Current oral or systemic treatments for neuropathic pain include over-the-counter pain killers; tricyclic antidepressants, such as nortriptyline and amitriptyline; anticonvulsants, such as gabapentin, pregabalin, and carbamazepine; serotonin-norepinephrine reuptake inhibitors, such as duloxetine and venlafaxine; opiates such as oxycodone and tramadol; cannabinoids such as nitinol; and topical medications, such as the lidocaine patch and capsaicin cream. Although the over-the-counter pain killers and topical medications have minimal side effects, they also show limited ability to reduce neuropathic pain. Opiates are most effective and relatively inexpensive; however, they have a higher risk of addiction and induce tolerance and hyperalgesia with long-term use; hence, they are only used when other medications fail. Tricyclic antidepressants (TCAs) are effective and inexpensive, but could cause severe morbidity and mortality due to cardiovascular and neurological toxicity. Pregabalin and duloxetine are the only two drugs that are currently approved by the FDA for treatment of diabetic peripheral neuropathy. Although these drugs are relatively expensive, they are effective with fewer side effects, lower risk of abuse and drug tolerance, and fewer drug interactions compared to TCAs and opiates (T. J. Lindsay, B. C. Rodgers, V. Savath, K. Hettinger, Am. Fam. Physician, 82(2), 151-8 (2010)), although they may still have serious side effects.
[0036] Another important method of topical drug delivery is treating motion sickness through the use of a scopolamine transdermal patch, which is normally applied behind the ear. It has been reported that scopolamine delivered transdermally is associated with considerably fewer side effects than when administered by other routes (http://www.drugs.com/sfx/scopolamine-side-effects.html).
[0037] In the treatment of microbial infection on the skin by aerobic microorganisms or under the skin by anaerobic microorganisms, treatment is either by the utilization of antibiotics, predominantly through oral application, or by the use of topical antimicrobial agents or anti-infective agents, such as liquids, creams, or ointments. An antimicrobial agent is defined as a substance that kills microorganisms or inhibits their growth or replication, while an anti-infective agent is defined as a substance that counteracts infection by killing infectious agents, such as microorganisms, or preventing them from spreading. Often, the two terms are used interchangeably.
[0038] In general, antimicrobial agents (or anti-infective agents) such as chlorhexidine, poly(hexamethylene biguanide), alexidine, benzalkonium chloride, benzethonium chloride, cetyltrimethylammonium chloride, cetylpyridynium chloride, alkyltrimethylammonium bromides, neomycin, bacitracin, polymyxin B, miconazole, clotrimazole, peroxides, salicylic acid, salicylates, silver, silver salts, zinc salts, N-halo compounds and the like are utilized in topical formulations. A major problem for microbial infection on the surface of the skin surface or inside the body is the presence of a microbial biofilm, wherein the biofilm is an aggregate of microorganisms that are adhered to each other on a surface through an extracellular polymeric matrix. Biofilms are difficult to eradicate, and targeted delivery of an antimicrobial, biologically active substance will greatly increase its concentration to facilitate the biofilm's eradication.
[0039] Currently used transdermal delivery patches have a number of difficult issues associated with them due to long-term skin occlusion. These side effects include contact dermatitis, growth of bacteria and yeast, and painful removal of patches (Hogan, D. J., Maibach, H. I., “Adverse dermatologic reactions to transdermal drug delivery systems,” J. Am. Acad. Dermatol., 22, 811-4 (1990)). Patches also have reduced efficacy due to issues with adhesion; temperature changes, perspiration, bathing, and movement, which cause patches to wrinkle or fall off the patient. Adhesion is a critical factor for successful drug delivery (Wokovich, A. M., Prodduturi, S., Doub, W. H., Hussain, A. S., Buhse, L. F., Eur. J. Pharm. Biopharm. 64, 1-8 (2006)).
[0040] The spray-on and paint-on coatings described herein (e.g., the compositions including soluble polymers) can alleviate a number of the difficulties with transdermal patches described above by providing a conformal coating with improved drug release consistency and efficiency as compared to current patch products. In addition, unlike microneedles and other methods of topical application, a spray-on application from a volatile, non-stinging solvent is less invasive and minimizes pain associated with application and delivery of biologically-active agents to the skin.
[0041] One of the benefits of the compositions described herein is that they can include a polymeric substrate for adsorption of the biologically-active agent which, after evaporation of the volatile solvent, provides sustained release of the biologically active agent to the biological surface on which it is deposited. In addition, the water-in-oil microemulsions of the compositions described herein exhibit slow release of the water-soluble biologically-active agents (Martin Malmsten, Surfactants and Polymers in Drug Delivery, 2002, Marcel Dekker, Inc. New York, Chapter 5, Microemulsions).
[0042] It is an object of the invention to provide delivery of biologically-active agents from a hydrophobic, volatile solvent to a biological surface.
[0043] It is a further object of this invention to provide a surfactant capable of solubilizing a biologically-active agent into a hydrophobic, volatile solvent.
[0044] It is a further object of this invention to provide a hydrophobic, volatile solvent that is non-stinging to a biological surface.
[0045] It is a further object of this invention to provide a reverse emulsion surfactant that also has antimicrobial properties.
[0046] It is a further object of the invention to provide transdermal delivery of biologically-active agents that are inherently insoluble in the hydrophobic, volatile solvent and are solubilized in a reverse emulsion.
[0047] It is a further object of the invention to provide transdermal delivery of biologically-active agents that can penetrate the skin surface to the epidermis.
[0048] It is a further object of the invention to provide transdermal delivery of biologically-active agents that can penetrate the skin surface to the dermis.
[0049] It is a further object of the invention to provide transdermal delivery of biologically-active agents that can penetrate the skin surface to the muscle.
[0050] It is a further object of the invention to provide transdermal delivery of biologically-active agents that can penetrate the skin surface to the bloodstream.
[0051] It is a further object of the invention that the volatile, hydrophobic solvent is non-stinging and non-irritating to skin.
[0052] It is a further object of the invention to provide a surfactant to solubilize biologically-active substances into a volatile, hydrophobic solvent.
[0053] It is an additional object to form a reverse microemulsion through the combination of a surfactant, a nonpolar solvent, and water to solubilize a biologically active agent.
[0054] It is an additional object to form a reverse microemulsion through the combination of a surfactant and a nonpolar solvent to solubilize a biologically active agent.
[0055] In another aspect of the invention, the reverse emulsion contains one or more solubilized polymers capable of forming an adherent coating on a biological surface after solvent evaporation.
[0056] In another aspect of the invention, the reverse emulsion contains a solubilized polymer incorporating the biologically active agent and reverse emulsion surfactant, which is capable of forming an adherent coating on a biological surface after solvent evaporation.
[0057] In another aspect of the invention, the reverse emulsion contains one or more percutaneous penetration enhancers.
[0058] In another aspect of the invention, the reverse emulsion contains one or more antimicrobial agents.
[0059] In another aspect of the invention, the reverse emulsion contains one or more anti-infective agents.
[0060] In another aspect of the invention, the reverse emulsion contains one or more peripheral neuropathy agents.
[0061] In another aspect of the invention, the reverse emulsion contains one or more motion sickness agents.
[0062] In another aspect of the invention, polymer coatings are provided that are useful for protecting biological surfaces against microbial contamination and form conformal, adhesive films after solvent evaporation.
[0063] In another aspect, the polymer coating functions as the substrate for sustained release of the biologically active agents.
[0064] In another aspect, a polymer coating is provided that is adherent under flex stress, including bending, twisting, and stretching.
[0065] It is a further object of the invention to provide a coating that, after application to skin and in the absence of a covering product, releases from that surface gradually over time without requiring externally applied solvents or other removal methods.
[0066] It is a further object of this invention to provide a coating that is water insoluble but is water vapor permeable.
[0067] It is a further object of this invention to provide a coating that is oxygen permeable.
[0068] It is a further object of the invention to provide a low surface tension polymer solution that will flow readily into confined spaces.
[0069] It is a further object to provide a polymer coating that can be cast upon the skin, mucous membranes, or internal organs.
[0070] In another aspect, a polymer coating is provided that remains adherent to a surface when exposed to external water, soaps, detergents, and most skincare products.
[0071] In another aspect, a polymer coating is provided that remains adherent to a surface when exposed to varying external humidity and temperature conditions.
[0072] In another aspect, a transparent polymer coating is provided that reduces pain and inflammation when applied to damaged or irritated skin or tissue.
[0073] In a further aspect of the invention, transdermal delivery of a drug for peripheral neuropathy is provided.
[0074] In a further aspect of the invention, transdermal delivery of an antibiotic is provided.
[0075] In a further aspect of the invention, transdermal delivery of an antimicrobial agent is provided.
[0076] In a further aspect of the invention, transdermal delivery of an antiseptic agent is provided.
[0077] In a further aspect of the invention, transdermal delivery of an anti-infective agent is provided.
[0078] In a further aspect of the invention, transdermal delivery of a pain-relieving agent is provided.
[0079] In a further aspect of the invention, transdermal delivery of an anti-inflammatory agent is provided.
[0080] In a further aspect of the invention, transdermal delivery of an anti-tumor agent is provided.
[0081] In a further aspect of the invention, transdermal delivery of a cardiovascular agent is provided.
[0082] In a further aspect of the invention, transdermal delivery of a diabetic agent is provided.
[0083] In a further aspect of the invention, transdermal delivery of a Parkinson's disease agent is provided.
[0084] In a further aspect of the invention, transdermal delivery of an Alzheimer's disease agent is provided.
[0085] In a further aspect of the invention, transdermal delivery of an attention deficit hyperactivity disorder agent is provided.
[0086] In a further aspect of the invention, transdermal delivery of insulin or an insulin derivative is provided.
[0087] In a further aspect of the invention, transdermal delivery of an opioid or cannabinoid is provided.
[0088] In a further aspect of the invention, transdermal delivery of a skin cancer agent is provided.
[0089] In a further aspect of the invention, transdermal delivery of an anti-cancer agent is provided.
[0090] In a further aspect of the invention, transdermal delivery of a dermatological agent is provided.
[0091] In a further aspect of the invention, transdermal delivery of a wound healing agent is provided.
[0092] In a further aspect of the invention, transdermal delivery of an anti-smoking agent is provided.
[0093] In a further aspect of the invention, transdermal delivery of an anti-psoriasis agent is provided.
[0094] In a further aspect of the invention, transdermal delivery of steroids, corticosteroids, and non-steroidal anti-inflammatory drugs is provided.
[0095] In a further aspect of the invention, transdermal delivery of an anti-diabetic agent is provided.
[0096] In a further aspect of the invention, transdermal delivery of an anti-allergic agent is provided.
[0097] In a further aspect of the invention, transdermal delivery of an antipruritic agent is provided.
[0098] In a further aspect of the invention, transdermal delivery of an anti-rheumatoid agent is provided.
[0099] In a further aspect of the invention, transdermal delivery of an erectile dysfunction agent is provided.
[0100] In a further aspect of the invention, transdermal delivery of an female sexual dysfunction agent is provided.
[0101] In a further aspect of the invention, transdermal delivery of a post-menopausal bone loss agent is provided.
[0102] In a further aspect of the invention, transdermal delivery of a urinary incontinence agent is provided.
[0103] In a further aspect of the invention, transdermal delivery of a vitamin, essential oil, or essential fatty acid is provided.
[0104] In a further aspect of the invention, transdermal delivery of a combination of one or more biologically-active agents is provided.
DETAILED DESCRIPTION
[0105] Transdermal drug delivery systems are typically systemically noninvasive, can be self-administered, can provide controlled extended release, and can improve patient compliance (M. R. Prausnitz, and R. Langer, Nat. Biotechnol., November, 26(11), 1261-1268 (2008)). However, currently used transdermal delivery patches have a number of issues associated with them due to long-term skin occlusion. These side effects include contact dermatitis, growth of bacteria and yeast, and painful removal of patches (Hogan, D. J., and Maibach, H. I., 1990, J. A. Acad. Dermat., 22, 811-814 (1990)). Patches also have reduced efficacy due to issues with loss of adhesion caused by temperature changes, perspiration, bathing, movement, skin lotions, and the like, which cause patches to wrinkle or fall off the patient (Wokovich, A. M., Prodduturi, S., Doub, W. H., Hussain, A. S., and Buhse, L. F., Eur. J. Pharm. Biopharm., 64, 1-8 (2006)). The spray-on or paint-on application of the compositions described herein provides a conformal coating that exhibits improved drug release consistency and efficiency as compared to current patch products.
[0106] Transdermal delivery of biologically-active agents from non-stinging, volatile solvents to and through the protective outer layer of a biological surface has surprisingly not been reported. An advantage of this method over other methods of transdermal drug delivery is that skin penetration can occur quickly because all active ingredients are solubilized into liquid form using a reverse emulsion surfactant that has the ability to coat and penetrate a biological surface.
[0107] The composition described herein is a unique liquid delivery system that can be brushed on, sprayed on, painted on, or used as a dipping solution; hence, allowing for the most skin surface coverage while minimizing additional pain inflicted during application. The hydrophobic portion of the delivery system preferably includes hexamethyldisiloxane (HMDS), a non-stinging, non-burning, quickly-evaporating hydrophobic solvent. The use of a volatile hydrophobic solvent enables an intimately conformal coating, which is particularly useful on peripheral and mobile areas such as fingers and toes. Unlike a patch, the intimately conformal coating may provide more consistent delivery of the biologically active substance over a larger area.
[0108] The biologically-active agents incorporated into the compositions described herein can include, but are not limited to, antimicrobial agents, anti-infective agents, antibacterial drug agents, antifungal drug agents, antiviral drug agents, anti-parasitic drugs, and pain medications. Antimicrobial and anti-infective agents can be incorporated in to the compositions. The antimicrobial and anti-infective agents include, but are not limited to, biguanides, such as poly(hexamethylene biguanide) (PHMB) hydrochloride and related salts, alexidine hydrochloride and related salts, chlorhexidine digluconate, chlorhexidine diacetate and related salts, nanosilver, colloidal silver, silver sulfadiazine, silver nitrate, hydrogen peroxide, benzoyl peroxide, peracetic acid, lactic acid, fatty acids, ethanol, isopropanol, long-chain alcohols, branched and long-chain glycols and glycerol ethers and esters, essential oils, benzalkonium chloride, benzethonium chloride, methylbenzethonium chloride, cetyltrimethylammonium bromide, cetylpyridinium chloride, honey, boric acid, benzoic acid, povidone-iodine, poloxamer-iodine, iodine, salicylic acid, zinc salts, tin salts, aluminum sulfate, bismuth subsalicylate, clotrimazole, miconazole nitrate, ketoconazole, fluconazole, oxiconazole nitrate, methyl salicylate, triethanolamine salicylate, phenyl salicylate, acetylsalicylic acid, thymol, eucalyptol, menthol, eugenol, peppermint oil, sage oil, chloroxlyneol, cloflucarban, hexylresorcinol, triclocarban, hexachlorophene, pyrithione zinc, chlorobutanol, capsaicin, warfarin, bacitracin, neomycin sulfate, polymyxin b sulfate, aloe vera, glutaraldehyde, formaldehyde, ethylene oxide, chloroamines, Dakin's solution, dilute bleach, polyquaternium-1, polyquaternium-10, ionene polymers, pyridinium polymers, imidazolium polymers, diallyldimethylammonium polymers, acryloyl-, methacryloyl-, and styryl-trimethylammonium polymers, acrylamido- and methacrylamido-trimethylammonium polymers, and antimicrobial peptides. The antimicrobial agents can include PHMB and its salts, alexidine and its salts, chlorhexidine and its salts, branched and long-chain glycols and glycerol ethers and esters, benzalkonium chloride, benzethonium chloride, cetyltrimethylammonium bromide, miconazole nitrate, and neomycin sulfate. The antimicrobial agents can be PHMB and its salts, chlorhexidine and its salts, miconazole nitrate, polymyxin b sulfate and neomycin sulfate.
[0109] Antibacterial drug agents that can be incorporated into the surfactant reverse micelles include, but are not limited to, penicillin-related compounds including beta-lactam antibiotics, broad spectrum penicillins, and penicillinase-resistant penicillins (such as ampicillin, ampicillin-sublactam, nafcillin, amoxicillin, cloxacillin, methicillin, oxacillin, dicloxacillin, azocillin, bacampicillin, cyclacillin, carbenicillin, carbenicillin indanyl, mezlocillin, penicillin G, penicillin V, ticarcillin, piperacillin, aztreonam and imipenem, cephalosporins (such as cephapirin, cefaxolin, cephalexin, cephradine and cefadroxil, cefamandole, cefoxitin, cefaclor, cefuroxime, cefuroxime axetil, cefonicid, cefotetan, ceforanide, cefotaxime, ceftizoxime, ceftriaxone, cefoperazone and ceftazidime), tetracyclines (such as tetracycline hydrochloride, demeclocytetracycline, doxycycline, methacycline, minocycline and oxytetracycline), beta-lactamase inhibitors (such as clavulanic acid), aminoglycosides (such as amikacin, gentamicin C, kanamycin A, neomycin B, netilmicin, streptomycin and tobramycin), chloramphenicol, erythromycin, clindamycin, spectinomycin, vancomycin, bacitracin, isoniazid, rifampin, ethambutol, aminosalicylic acid, pyrazinamide, ethionamide, cycloserine, dapsone, sulfoxone sodium, clofazimine, sulfonamides (such as sulfanilamide, sulfamethoxazole, sulfacetamide, sulfadiazine, and sulfisoxazole), trimethoprim-sulfamethoxazole, quinolones (such as nalidixic acid, cinoxacin, norfloxacin and ciprofloxacin), methenamine, nitrofurantoin and phenazopyridine. Pharmaceutical antimicrobial drug agents include agents active against protozoal infections, such as chloroquine, emetine or dehydroemetine, 8-hydroxyquinolines, metronidazole, quinacrine, melarsoprol, nifurtimox, and pentamidine.
[0110] Antifungal pharmaceutical and non-pharmaceutical drug agents that can be incorporated into the surfactant reverse micelles include, but are not limited to, amphotericin-B, flucytosine, ketoconazole, miconazole, itraconazole, griseofulvin, clotrimazole, econazole, terconazole, butoconazole, terbinafine, ciclopirox olamine, haloprogin, toinaftate, naftifine, nystatin, natamycin, anidulafungin, caspofungin, griseofulvin, Iodoquinol, undecylenic acid, benzoic acid, salicylic acid, propionic acid and caprylic acid.
[0111] Antiviral drug agents that can be incorporated into the surfactant reverse micelles include, but are not limited to, zidovudine, acyclovir, ganciclovir, vidarabine, idoxuridine, trifluridine, foxcarnet, amantadine, rimantadine, tee tree oil, and ribavirin.
[0112] Anti-parasitic drugs that can be incorporated into the surfactant reverse micelles include, but are not limited to, metronidiazole, mebendazole, albendazole, milbemycin, ivermectin, praziquantel, artemisinin, quinine, chloroquine, halofantrine, mefloquine, lumefantrine, amodiaquine, pyronaridine, piperaquine, primaquine, tafenoquine, atovaquone, artemether, artesunate, dihydroartemisinin, artemisinin, proguanil, tetracyclines, pentamidine, suramin, melarsoprol, amphotericin, eflornithine, benznidazole, and aminosidine,
[0113] Pain medications that can be incorporated into the surfactant reverse micelles include, but are not limited to, nortriptyline and amitriptyline; anticonvulsants such as gabapentin, pregabalin, and carbamazepine; serotonin-norepinephrine reuptake inhibitors such as duloxetine and venlafaxine; opiates such as oxycodone and tramadol; cannabinoids such as nitinol; and topical medications such as the lidocaine patch and capsaicin cream.
[0114] The solubilities of the above described drugs in water can be enhanced by salt formation, or by encapsulation within a hydrophilic matrix, such as a microparticle or nanoparticle utilizing a hydrophilic polymer covering. While not necessary for practicing the invention, when cationic, biologically-active agents are utilized in a volatile, hydrophobic solvent with a reverse emulsion surfactant such as sodium bis(2-ethylhexyl)sulfosuccinate (AOT), it is believed that a complex first forms between the cationic portion of the biologically-active agent and the anion of bis(2-ethylhexyl)sulfosuccinate, which complex is then encapsulated by dissolution into an AOT reverse micelle. Similarly, if an anionic biologically active agent is employed, a cationic reverse emulsion surfactant could generate an analogous complex. If a neutral reverse emulsion surfactant is used, either cationic, neutral, or anionic biologically active agents can be encapsulated into the reverse emulsion micelle, presumably without an ionic complex formation. Furthermore, anionic biologically active agents can also be encapsulated into an anionic reverse emulsion surfactant such as sodium bis(2-ethylhexyl)sulfosuccinate (AOT) without an insoluble complex first forming.
[0115] The reverse emulsion surfactants can be dialkylsulfosuccinates and salts thereof, with or without added water or alcohol. The dialkylsulfosuccinate salts range in hydrocarbon chain length of each alkyl group from 6 carbon atoms to 18 carbon atoms in length, and contain one or two identical or different, straight-chain and/or branched-chain, saturated or unsaturated alkyl groups. Exemplary, dialkylsulfosuccinates include, but are not limited to, sodium bis(2-ethylhexyl)sulfosuccinate (Aerosol AOT or AOT) and sodium bis(tridecyl)sulfosuccinate (Aerosol TR or TR). The anionic surfactant sodium bis(2-ethylhexyl)sulfosuccinate can form stable microemulsions consisting of water, AOT, and a bulk organic solvent (C. L. Kitchens, D. P. Bossev, and C. B. Roberts, J. Phys. Chem. B, 110, 20392-20400 (2006)).
[0116] In this invention, if water is needed, typically the amount of water forming the water-in-oil emulsion is between from about 0 to about 10 weight %, preferably between from about 0.001 to about 7.5 wt %, and more preferably from 0.01 to about 5 wt %. A minimum amount of water is most preferred to allow faster evaporation of the solvent. If an alcohol, such as ethanol, is added as a cosolvent, the alcohol concentration is 10% or less of the hydrophilic liquid (e.g., water plus alcohol). Alcohol can be used to enhance the solubility of the biologically-active agent in water for encapsulation by the reverse emulsion surfactant. In certain instances, the biologically-active agent may dissolve directly into the reverse emulsion surfactant in the volatile, non-polar solvent, even though the agent is inherently insoluble in the volatile, hydrophobic solvent.
[0117] The reverse emulsion surfactant can be present in an amount from 0.10 to 50 weight percent (wt %), or between 0.20 to 20 wt %, or between 0.40 to 10 wt % of the composition, or any combination thereof (e.g., 0.10-0.40 wt-% and 0.20-10 wt-%).
[0118] The biologically-active agent component of the formulation can be present in amounts ranging from 0.00001 to 10 wt %, or from 0.0001 to 7.5 wt %, or from 0.001 to 5 wt %, or from 0.01 to 2.5 wt %, or from 0.1 to 1 wt % of the composition, or any combinations thereof (e.g., 0.01-1 wt-% or 1-5 wt-%).
[0119] The volatile, hydrophobic solvent of the formulation can be present from 40 to 99.99 wt %, or from 45 to 99 wt %, or from 50 to 90 weight %, or from 55 to 80 weight percent of the composition, or any combination thereof (e.g., 40-55 wt-% or 45-80 wt-%).
[0120] The polar solvent (e.g., water and/or C 1 -C 4 alkyl alcohols combined) can be present from 0 to 3 wt % or 0.01 to 3 wt %, or less than 2 wt %, or less than 1 wt %, or less than 0.5 wt %, or less than 0.1 wt %.
[0121] The added polymer, to form a substrate for the sustained release of the biologically-active agent over time, and which forms a coating on a biological surface after the evaporation of the volatile solvent, can be present in an amount ranging from 0 to 20 wt %, or from 1 to 15 wt %, or from 2 to 10 wt % of the composition, or any combination thereof (e.g., 2-15 wt % or 1-2 wt %).
[0122] The composition can include from 50-99.5 wt % volatile, hydrophobic solvent, 0.25 to 50 wt % reverse emulsion surfactant, from 0.00001 to 5 wt % of biologically active agent, and from 0 to 20 wt % polymer substrate. The composition can include from 0 to 5 wt % of a hydrophilic solvent (e.g., water and C 1 -C 4 alkyl alcohols). The polymer substrate can be present in an amount that it is completely soluble in the composition and/or completely soluble in the volatile, hydrophobic solvent. The composition can be optically clear.
[0123] The following ingredients and their abbreviations are used in this invention:
ALEX: Alexidine Dihydrochloride, 1,1′-hexamethylenebis[5-(2-ethylhexyl)biguanide]dihydrochloride, Toronto Research Chemicals. AgNO 3 : Silver Nitrate, Alfa Aesar. AOT: Aerosol AOT, sodium bis(2-ethylhexyl)sulfosuccinate, docusate sodium, Fisher Scientific. Cavilon: 3M™ Cavilon™ No-Sting Barrier Film, composed of HMDS (65-90%), ISO (8-12%), Acrylate Terpolymer (3-12%), and polyphenylmethylsiloxane copolymer (0.1-5%). CHG: Chlorhexidine Digluconate, Spectrum Chemicals. CHG-P: Chlorhexidine powder, from neutralization and drying of chlorhexidine digluconate. DULOX: Duloxetine, (+)-(S)—N-methyl-3-(naphthalen-1-yloxy)-3-(thiophen-2-yl)propan-1-amine, SST Corporation, and converted to the hydrochloride salt. ETOH: Ethanol, VWR International. G 67: Gransurf 67, PEG-10 dimethicone, Grant Industries. G W9: Gransurf W9, Cetyl PEG/PPG-10/1 Dimethicone, hexyl laurate and polyglyceryl-4-isostearate, Grant Industries. GML: Glycerol Monolaurate, Lauricidin®, Med-Chem Laboratories. HMDS: Hexamethyldisiloxane, Dow Corning. IOA: Isooctyl Acrylate, Sartomer. IOA:NIPAM: 4:1 wt % Copolymer of IOA and NIPAM prepared by free radical polymerization (uncrosslinked); Table 1, US Patent Application Publication 2012/0208974. IPM: Isopropyl Myristate, Alzo International Incorporated IPP: Isopropyl Palmitate, Alzo International Incorporated. ISO: Isooctane, VWR International. Kraton: Kraton G1657 M, Kraton Performance Polymers, a linear triblock copolymer of styrene and ethylene/butylene, with a polystyrene content of 13%. LIDO: Lidocaine Hydrochloride, 2-(diethylamino)-N-(2,6-dimethylphenyl)acetamide hydrochloride, Midcoast Environment. MICON, Miconazole Nitrate, Sigma Aldrich. MMA: Methyl Methacrylate, Alfa Aesar. NEO: Neomycin Trisulfate, Sigma Aldrich. Neosporin: Bacitracin, Neomycin, and Polymyxin B, Johnson & Johnson. NIPAM: N-isopropylacrylamide, Jarchem. PHMB: Poly(hexamethylene biguanide) Hydrochloride, Cosmocil™ CQ, Arch Chemical. POLYMYX: Polymyxin B Trisulfate, Sigma Aldrich. PREG: Pregablin, SST Corporation; converted to pregabalin hydrochloride; (S)-3-(aminomethyl)-5-methylhexanoic acid hydrochloride. Roccal: Roccal®-D PLUS, Pfizer: a mixture of alkyldimethylbenzyl ammonium chloride, didecyldimethylammonium chloride, benzylcocoalkyldimethylammonium chlorides, and tributyltin oxide. R-Surf: Reverse emulsion surfactant. SC 50: Sensiva® SC 50, glycerol 1-(2-ethylhexyl) ether), Schülke & Mayr. SCOP: Scopolamine Hydrochloride, Enzo Biochem. SL: Sodium Laurate, sodium dodecanoate, Sigma Aldrich. SORB: Sorbic Acid, 2,4-hexadienoic acid, Alfa Aesar. TR: Aerosol TR, sodium bis(tridecyl)sulfosuccinate, Cytec Industries. TRIS (containing 0.3% TRIS-D): 3-Methacryloxypropyltris(trimethylsiloxy)silane, Silar Laboratories. TRIS dimer (TRIS-D): 1,3-Bis(3-methacryloxypropyl)-1,1,3,3-tetrakis(trimethylsiloxy)disiloxane, Gelest. TRIS:MMA: 9:1 wt % copolymer of TRIS and MMA. TRIS:NIPAM: 3:1 wt % copolymer of TRIS and NIPAM; U.S. Pat. No. 7,795,326. Water: (Purified, USP), Ricca Chemical Company. XL-TRIS: polymer of TRIS and MMA crosslinked with TRIS-D, TRIS/MMA/TRIS-D=60/20/20 wt % (U.S. Pat. No. 8,263,720). Zn(OAc) 2 : Zinc Acetate, Alfa Aesar.
Examples
[0165] For all formulations in the following Examples, each biologically-active agent was inherently insoluble in the non-polar, hydrophobic solvents tested, namely, isooctane (ISO) and hexamethyldisiloxane (HMDS). Solubility occurred in the presence of a reverse emulsion surfactant, with or without the presence of added water, to give optically clear, homogeneous solutions. Since the concentrations of the biologically-active agents (Active) were considerably less than that of the solvent used, the data in the Tables pertaining to all ingredients were rounded-off to the next highest number.
[0166] Table 1 lists the compositions of formulations in weight percent (wt %) of various antimicrobial agents often used in over-the-counter formulations solubilized as optically clear, transparent solutions in the non-stinging, volatile solvents of hexamethyldisiloxane (HMDS) and isooctane (ISO), with Aerosol AOT (AOT, HLB 10) as the reverse emulsion surfactant and water. The antimicrobial agents include three biguanides, poly(hexamethylene biguanide) hydrochloride (PHMB), alexidine dihydrochloride (ALEX), and chlorhexidine digluconate (CHG), as well as neomycin trisulfate (NEO), an aminoglucoside antibiotic, polymyxin B trisulfate (POLYMYX), a cyclic peptide antibiotic, and two antimicrobial salts, silver nitrate and zinc acetate. In addition, an ALEX formulation also included ethanol as a hydrophilic co-solvent with water because of the limited solubility of alexidine dihydrochloride in water.
[0167] All the hydrophilic, ionic, polar antimicrobial agents studied are inherently insoluble in ISO and HMDS. The antimicrobial activity of each of these agents is dependent upon their cationic form, and each is insoluble in the non-polar solvents of ISO and HMDS. However, these non-polar solvents containing AOT dissolve antimicrobial compounds that are soluble in water or alcohol. For the studied compounds of PHMB, CHG, ALEX, NEO, silver nitrate, zinc acetate, and POLYMYX, when these compounds were mixed with a higher concentration of AOT in HMDS or isooctane, a white precipitate initially formed, which then dissolved to form a clear solution upon increasing AOT content. Presumably, the cationic, biologically active agent formed a bis(2-ethylhexyl)sulfosuccinate salt with the AOT anion, which was then solubilized by Aerosol AOT into a reverse emulsion.
[0168] The amount of biologically active agent that can be incorporated appears to depend on the amount of water that can be dissolved in the AOT reverse emulsion in HMDS and ISO, which appears related to its solubility in water. For example, the water solubility of alexidine HCl (ALEX, 0.1% soluble in water) is much lower than CHX digluconate (CHG, 20% soluble in water). Thus, less ALEX can be solubilized in a reverse emulsion into the non-polar solvents with AOT. However, since ALEX is more soluble in ethanol than in water, adding ethanol increased its solubility in isooctane with AOT (Table 1).
[0169] Table 1 demonstrates that homogeneous, transparent (optically clear), stable solutions can be prepared from the various cationic antimicrobial agents studied in a reverse emulsion with the surfactant AOT in volatile, hydrophobic solvents. If said formulations are applied to a biological surface, after solvent evaporation the active agent would be transported to a biological surface.
[0170] From Table 1 it is seen that the weight percent of volatile solvent in each case was above 90%, with the amount of AOT ranging from approximately 0.5% to 5% of the formulation. Table 1 also includes two ratios, AOT/Active, where the active represents the cationic antimicrobial agent, and AOT/water. The ratio of AOT to active ranged from 10 to 1000, and the ratio of AOT to water ranged from 1 to approximately 5. In terms of molar amounts of AOT/active, these range from approximately a low value of a 20 molar excess (using CHG and NEO as examples) to that of a 4,500 molar excess (using PHMB as an example). The AOT/active ratio is consistent with additional Aerosol AOT needed to first form a sulfosuccinate salt of the cationic antimicrobial, followed by its dissolution into a sodium bis(2-ethylhexyl)sulfosuccinate (AOT) reverse micelle.
[0171] Whereas the biologically-active agents in Table 1 are active through their cationic ion and then solubilized into the anionic bis(2-ethylhexyl)sulfosuccinate reverse micelle, a related study was done with the anionic fatty acid salt sodium laurate (SL) in place of the cationic, biologically-active agents, with anionic AOT as the surfactant. Sodium laurate, the sodium salt of lauric acid, the latter of which is a fatty acid with antibacterial properties, was investigated for its solubility in ISO, a solvent in which it is insoluble, with AOT and water. Solubility of the anionic surfactant occurred giving a clear, homogeneous microemulsion. The ratio of ISO/SL/AOT/H 2 O investigated was 92.57/2.78×10 −2 /4.63/2.78, with an AOT/SL ratio of 16.7 and an AOT/H 2 O ratio of 1.67, all values consistent with those of Table 1. AOT, an anionic, reverse emulsion surfactant was able to solubilize an anionic, water-soluble fatty acid salt into a microemulsion into the hydrophobic solvent isooctane, thus indicating that both cationic and anionic biological species can be solubilized into a water-in-oil microemulsion.
[0000]
TABLE 1
Antimicrobial Agents in Isooctane and HMDS, With Aerosol AOT, Water and Ethanol
%
Active
Active
Active
Active
Active
Active
Active
R-Surf
AOT/
AOT/
Solvent
Solvent
PHMB
ALEX
CHG
NEO
AgNO 3
Zn(OAc) 2
POLYMYX
AOT
H20
EtOH
Active
H2O
ISO
93.41
4.67 ×
4.67
1.87
100
2.5
10−2
ISO
98.31
0.199 ×
0.497
0.198
2500
2.5
10−3
ISO
98.68
0.987 ×
0.493
0.493
0.326
50
1
10−2
HMDS
99.40
4.97 ×
0.497
0.099
1000
5
10−4
HMDS
94.34
4.72 ×
4.72
0.943
1000
5
10−3
HMDS
91.57
0.183
4.58
3.66
25
1.25
HMDS
99.21
4.96 ×
0.495
0.248
10
2
10−2
HMDS
93.41
4.67 ×
4.67
1.87
100
2.5
10−2
HMDS
92.48
0.116
4.62
2.78
40
1.66
HMDS
92.37
0.231
4.63
2.77
20
1.67
HMDS
93.37
9.34 ×
4.67
1.87
50
2.5
10−2
[0172] Table 2 includes other reverse emulsion surfactants that can solubilize the biguanides PHMB and CHG as clear solutions in isooctane or HMDS. These surfactants include Sensiva SC 50 (SC 50, HLB 7.5), Gransurf W9 (G W9, HLB 4.5), and Aerosol TR (TR, HLB 4-7). The amount of surfactant needed to form optically clear, reverse emulsions in ISO and HMDS was substantially higher than that of Table 1, thus reducing the amount of volatile solvent, the latter of which ranged from approximately 48 wt % to 82 wt %. Aerosol TR appeared more effective than Gransurf W9 and Sensiva SC 50, but less effective than Aerosol AOT. The ratio of surfactant to active biguanide agent ranged from 400 to 2000, with a surfactant to water ratio of 10 to 21.
[0000]
TABLE 2
Antimicrobial Agents in ISO and HMDS with Various Reverse Emulsion Surfactants and Water
%
Active
Active
R-Surf
R-Surf
R-Surf
Solvent
Solvent
PHMB
CHG
G W9
TR
SC 50
H20
R-Surf/Active
R-Surf/H2O
ISO
48.78
9.76 × 10−2
48.78
2.34
500
21
HMDS
48.78
9.76 × 10−2
48.78
2.34
500
21
HMDS
81.93
4.10 × 10−2
16.39
1.64
400
10
HMDS
47.61
2.38 × 10−2
47.61
4.76
2000
10
[0173] Table 3 lists three solid cationic antimicrobial agents (CHG-P, MICON, and GML) and one solid anionic antimicrobial agent (SORB) (anionic at pH above its pK a of 4.76, http://en.wikipedia.org/wiki/Sorbic_acid) in water that are solubilized in HMDS and ISO with a reverse emulsion surfactant and without added water. Chlorhexidine powder (CHG-P) was prepared by the neutralization of chlorhexidine digluconate (CHG), while miconazole nitrate (MICON) and glycerol monolaurate (GML) were used as received. Miconazole is an imidazole-based antifungal agent, and glycerol monolaurate is a monoglyceride with antimicrobial properties. Sorbic acid and its salts are used as preservatives in foods, drugs and preserved solutions, with antimicrobial properties against mold, yeast, and fungi. These biologically active agents were not soluble in isooctane or hexamethyldisiloxane, but were solubilized to give optically clear solutions when four different reverse emulsion surfactants were added (AOT, G W9, G 67(HLB 4.5), and SC 50) to ISO and HMDS. Sorbic acid, a carboxylic acid preservative, was solubilized by Aerosol AOT, an anionic reverse emulsion surfactant, with no difficulty. The solvent concentrations ranged from about 50 to 95 wt %. Although no water was added to the formulations in Table 3, the ratios of surfactant to biologically active agent were similar to those of Tables 1 and 2, ranging from 5 to 500. It is conceivable that trace quantities of water were present in the various components of Table 3 to enhance solubilization.
[0000]
TABLE 3
Antimicrobial Agents In ISO and HMDS with Various Reverse Emulsion Surfactants and No Added Water
%
Active
Active
Active
Active
R-Surf
R-Surf
R-Sur
R-Sur
R-Surf/
Solvent
Solvent
% CHG-P
% MICON
% GML
% SORB
% AOT
% GW9
% G67
% SC 50
Active
HMDS
95.23
9.52 × 10−2
4.76
50
HMDS
90.83
9.08 × 10−2
9.08
100
HMDS
95.15
9.51 × 10−2
4.76
50
HMDS
49.95
9.99 × 10−2
49.95
500
ISO
95.15
9.51 × 10−2
4.76
50
ISO
95.15
9.51 × 10−2
4.76
50
ISO
49.95
9.99 × 10−2
49.95
500
ISO
49.95
9.99 × 10−2
49.95
500
ISO
94.34
0.943
4.72
5
ISO
95.15
9.52 × 10−2
4.76
50
[0174] The formulation of a polymer substrate for controlled release of a biologically active agent from a volatile, non-stinging hydrophobic solvent is illustrated in Table 4. The solvents used were ISO and HMDS, with the antimicrobial agents of PHMB, CHG, NEO, and silver nitrate, in addition to lidocaine hydrochloride, a local anesthetic and antiarrhythmic drug, often used topically to relieve pruritus, burning and pain. The reverse emulsion surfactants included AOT and SC 50.
[0175] The polymer substrates used in Table 4 include (1) IOA:NIPAM, a non-crosslinked copolymer of 4:1 parts by weight of isooctyl acrylate (IOA) and N-isopropylacrylamide (NIPAM) monomers; (2) TRIS:MMA, a copolymer of 9:1 parts by weight of 3-methacryloyloxypropyltris(trimethylsiloxy)silane (TRIS) and methyl methacrylate (MMA); (3) Kraton, a commercial elastomer containing block polymers of styrene and ethylene/butylene; (4) Cavilon, 3M™ Cavilon™ No-Sting Barrier Film, a commercial liquid bandage comprised of a proprietary acrylate polymer with polyphenylmethylsiloxane in a volatile solvent of HMDS and ISO; and (5) XL-TRIS, a solubilized, crosslinked polymer of TRIS and methyl methacrylate.
[0176] Three polymer-containing solutions were found to not need added water to produce optically clear, homogeneous compositions with the TRIS:NIPAM and Cavilon polymers, while the remaining formulations had ratios of surfactant to water similar to that of Table 1.
[0177] Table 4 shows the percent loading of the biologically active agent in the polymer as the volatile solvent has evaporated (′)/0 Active in Polymer). These values ranged from 0.01 to 1 wt %.
[0000]
TABLE 4
Biologically-Active Agents in a Polymer Matrix with Aerosol AOT and Sensiva SC 50 as Surfactants with and Without Water
R-
R-
%
%
Active
Active
Active
Active
Active
Surf
Surf
R-
R-
Active
%
Poly-
Poly-
%
%
%
%
Active
%
%
%
%
Surf/
Surf/
in
Solvent
Solvent
mer
mer
PHMB
CHG
MICON
NEO
AgNO 3
LIDO
AOT
SC 50
H2O
Active
H2O
Polymer
ISO
89.25
IOA:
4.46
4.46 ×
4.46
1.78
100
2.5
1
NIPAM
10−2
ISO
89.25
TRIS:
4.46
4.46 ×
4.46
1.78
100
2.5
1
MMA
10−2
ISO
89.25
Kraton
4.46
4.46 ×
4.46
1.78
100
2.5
1
10−2
ISO
94.92
TRIS:
4.75
2.37 ×
0.237
9.49 ×
100
2.5
0.05
NIPAM
10−3
10−2
ISO
94.60
Cavilon
4.73
4.73 ×
0.473
0.189
100
2.5
0.1
10−3
ISO
94.60
TRIS:
4.73
4.73 ×
0.473
0.189
100
2.5
0.1
NIPAM
10−3
ISO/
92.44
Cavilon
6.96
9.94 ×
0.398
0.199
400
2
0.01
HMDS
10−4
HMDS
94.86
TRIS:
4.74
1.897 ×
0.379
0
20
NA
0.4
NIPAM
10−2
ISO/
92.53
Cavilon
6.96
9.95 ×
0.497
0
50
NA
0.1
HMDS
10−3
ISO/
86.11
Cavilon
6.48
0.463
4.63
2.31
10
2
7
HMDS
ISO/
86.87
Cavilon
6.54
4.67 ×
4.67
1.87
100
2.5
0.7
HMDS
10−2
ISO/
86.83
Cavilon
6.54
9.34 ×
4.67
1.87
50
2.5
1
HMDS
10−2
HMDS
94.61
TRIS:
4.73
2.37 ×
0.473
0.167
20
2.8
0.5
NIPAM
10−2
HMDS
94.86
TRIS:
4.74
1.90 ×
0.379
0
20
NA
0.4
NIPAM
10−2
HMDS
94.61
XL-
4.73
4.73 ×
0.473
0.142
10
3.33
1
TRIS
10−2
HMDS
94.61
Cavilon
4.73
4.73 ×
0.473
0.142
10
3.33
1
10−2
[0178] Table 5 includes compositions related to Table 4, and provides the solubilities of a combination of antimicrobial agents, CHG and MICON, and PHMB and MICON, in a Cavilon solution solubilized by AOT with water. The ratios of the reverse emulsion surfactant to actives and to water were similar to the other Tables, as was the % loading of the combined antimicrobials in the Cavilon polymer. The compositions of Table 5 were optically clear.
[0000]
TABLE 5
Combinations of Antimicrobial Agents in a Polymer Matrix with AOT and Water
%
%
Active
Active
Active
R-Surf
%
AOT/
AOT/
% Actives
Solvent
Solvent
Polymer
Polymer
% PHMB
% CHG
% MICON
% AOT
H2O
Actives
H2O
in Polymer
HMDS/ISO
92.34
Cavilon
6.95
9.93 × 10−3
9.93 × 10−3
0.496
0.199
25
2.5
0.29
HMDS/ISO
92.23
Cavilon
6.91
9.62 × 10−4
9.93 × 10−3
0.474
0.384
45
1.2
0.15
[0179] Table 6 lists three compositions that include different medications used in pain therapy: (1) lidocaine (LIDO), (2) pregabalin (PREG), an anticonvulsant drug used for neuropathic pain and anxiety disorders, particularly fibromyalgia and spinal cord injuries, and (3) duloxetine (DULOX), a serotonin-norepinephrine reuptake inhibitor, for peripheral neuropathy, particularly diabetic neuropathy, fibromyalgia, and depressive and anxiety disorders. The solvents were ISO and HMDS, with AOT as the reverse emulsion surfactant with water. The ratios of the surfactant to active and surfactant to water were consistent with other results. The compositions of Table 6 were optically clear.
[0000]
TABLE 6
Pain Medictions in Isooctane and HMDS, with Aerosol AOT and Water
%
Active
Active
Active
R-Surf
Solvent
Solvent
LIDO
PREG
DULOX
AOT
H2O
AOT/Active
AOT/H2O
ISO
93.37
9.34 × 10−2
4.67
1.87
50
2.5
HMDS
93.46
0.467
4.67
1.4
10
3.33
HMDS
93.37
9.34 × 10−2
4.67
1.87
50
2.5
[0180] Table 7 shows formulations that include skin penetration enhancers (PE) of isopropyl myristate (IPM) and isopropyl palmitate (IPP), using AOT as the reverse emulsion surfactant in ISO and HMDS containing water, with PHMB and LIDO. Two polymer matrices were studied, XL-TRIS and Cavilon. One formulation had no polymer matrix. The ratios of surfactant to active and surfactant to water were consistent with other Tables. In addition, the ratios of AOT to the penetration enhancers were also studied, and these values show that the penetration enhancer can be used in greater quantity than the reverse emulsion surfactant. The ratio of the penetration enhancer to the active was twice that of the surfactant to the active. The loading of the active in the solvent dried polymer was from 0.025 to 1%. The compositions of Table 7 were optically clear.
[0000]
TABLE 7
Lidocaine Hydrochloride and PHMB Hydrochloride with a Penetration Enhancer, Aerosol AOT and a Polymer Matrix
%
%
Active
Active
R-Surf
PE
PE
AOT/
AOT/
AOT/
PE/
% Active
Solvent
Solvent
Polymer
Polymer
PHMB
LIDO
AOT
IPM
IPP
H2O
Active
H2O
PE
Active
in Polymer
HMDS
93.72
XL-TRIS
4.69
4.69 × 10−2
0.469
0.937
0.141
10
3.33
0.5
20
1
HMDS
93.72
XL-TRIS
4.69
4.69 × 10−2
0.469
0.937
0.141
10
3.33
0.5
20
1
HMDS
92.85
XL-TRIS
4.62
4.64 × 10−2
0.464
0.929
0.929
0.139
10
3.34
0.25
40
1
ISO
98.13
2.45 × 10−3
0.491
0.98
0.393
200
1.25
0.5
400
NA
ISO
89.36
Cavilon
8.94
2.23 × 10−3
0.447
0.893
0.357
200
1.25
0.5
400
0.025
ISO
93.54
Cavilon
4.68
2.34 × 10−3
0.468
0.935
0.374
200
1.25
0.5
400
0.05
[0181] Table 8 shows formulations of scopolamine hydrochloride (SCOP) in reverse emulsion surfactants of AOT in ISO or HMDS with water. Scopolamine is a tropane alkaloid drug with muscarinic antagonist effects. It is often used in controlled release patches to prevent nausea and vomiting from motion sickness. The ratios of surfactant to active and surfactant to water are consistent with other Tables. The compositions of Table 8 were optically clear.
[0000]
TABLE 8
Scopolamine in ISO and HMDS with AOT and Water
%
Active
R-Surf
AOT/
AOT/
Solvent
Solvent
SCOP
AOT
H2O
SCOP
H2O
ISO
93.46
0.467
4.67
1.4
10
3.34
HMDS
93.46
0.467
4.67
1.4
10
3.34
[0182] In Tables 1-8, the HLB values of all reverse emulsion surfactants were within the range of 4-10, a range found for microemulsion reverse surfactants.
[0183] The data in the above Tables illustrate that hydrophilic, ionic, polar biologically-active agents can be incorporated into a volatile hydrophobic solvent, which could also include a polymeric substrate for controlled release of the biologically active agent, such that the agent can be transported to and through a surface after evaporation of the volatile solvent. To further demonstrate the delivery properties of biologically-active agents in non-polar, volatile, hydrophobic solvents described herein, antimicrobial analysis by zones of inhibition (ZOI) were undertaken with the Gram positive bacteria, methicillin-resistant Staphylococcus aureus (Table 9), the Gram negative bacteria, Pseudomonas aeruginosa (Table 10), and the yeast (fungi), Candida albicans (Table 11) as a function of time over three days, with various antimicrobials added to Cavilon solution containing AOT. All microbiological testing was done by INCELL Corporation, San Antonio, Tex. All zones of inhibition data were measured in mm.
[0184] The zones of inhibition testing for methicillin-resistant Staphylococcus aureus and Pseudomonas aeruginosa were performed as described below. The bacteria were purchased from ATCC and expanded in Tryptic soy broth overnight. Each of the bacteria cultures was then spread onto Tryptic soy agar (TSA) plates. Sterile cloning cylinders containing the biologically-active agent in a volatile, hydrophobic solvent (0.1 mL per cylinder) were placed on the TSA plates and allowed to air dry for 1 h at room temperature. Neosporin was used as a positive control. The TSA plates were observed and photographed after 24 h, 48 h, and 72 h. Images were used to measure zone of inhibition or areas of clearing surrounding the delivered material.
[0185] The zones of inhibition testing was also performed with Candida albicans , purchased from ATCC and expanded in Tryptic soy broth overnight. This fungi culture was diluted to 0.1 OD 600 units and spread onto TSA plates. Sterile cloning cylinders were placed on the TSA plates, charged with the biologically-active agent in a volatile, hydrophobic solvent (0.1 mL per cylinder) and allowed to air dry for 1 h at room temperature. A 1% Roccal solution was used as a positive control. The TSA plates were observed and photographed after 24 h, 48 h, and 72 h. Images were used to measure zone of inhibition or areas of clearing surrounding the delivered material.
[0186] The polymer substrate chosen for the sustained release studies of biologically-active antimicrobial over time was Cavilon. The Cavilon solution is composed of a proprietary acrylate polymer and a smaller amount of polyphenylmethylsiloxane in HMDS and ISO. This was used as a negative control for all zone of inhibition studies (Tables 8-10).
[0187] Table 9 shows the zones of inhibition results for methicillin-resistant Staphylococcus aureus , ATCC 700787, with Aerosol AOT, PHMB with AOT, CHX with AOT, NEO with AOT, and silver nitrate with AOT, all in the solids of the Cavilon polymer, determined over a three day period. Similarly, Table 10 provides zones of inhibition results for Pseudomonas aeruginosa , ATCC 27853, with Aerosol AOT, PHMB with AOT, CHX with AOT, NEO with AOT, all in the solids of the Cavilon polymer, determined over a three day period. Previously, it was reported that Aerosol AOT (called docusate sodium) was investigated as an antibacterial agent, an antiviral agent, and an antifungal agent. As an antibacterial agent, it was reported active against Gram positive bacteria such as Staphylococcus aureus , but was inactive against Gram negative bacteria such as Pseudomonas aeruginosa (G. N. Kern, U.S. Pat. No. 4,717,737). As an antifungal agent, AOT was reported effective against Candida albicans (G. N. Kern, U.S. Pat. No. 4,885,310).
[0188] The ZOI behavior of AOT in Table 9 against methicillin-resistant Staphylococcus aureus indicates that AOT in the Cavilon polymer is indeed active against this bacterium, and it was considerably more effective than the Neosporin positive control. In addition, as shown in Table 10, AOT in the Cavilon polymer was considerably more effective against Pseudomonas aeruginosa than Neosporin. This behavior is contrary to that expected in view of G. N. Kern (U.S. Pat. No. 4,717,737), whose patent indicated a lack of biocidal activity against Gram negative bacteria, including Pseudomonas aeruginosa . Combining AOT with PHMB in the Cavilon polymer substrate significantly enhanced the overall biocidal activity, as its zones of inhibition were significantly greater than AOT alone. Combining AOT with CHG in the Cavilon polymer substrate produced exceptional results, being substantially greater than either the positive control (neomycin) or AOT. This enhanced effect may be due to the higher solubility of CHG in AOT than that of PHMB in AOT, which results in a greater concentration of active in the Cavilon polymer for sustained release. Similarly, silver nitrate and NEO at polymer loadings greater than that of PHMB were also highly effective sustained release antimicrobial agents over the three day period.
[0000]
TABLE 9
Zone of Inhibition of Staphylococcus aureus with Antimicrobials in AOT and Cavilon
R-
%
%
PC
Active
Active
Active
Surf
Active
%
Poly-
Neo-
%
%
Active
%
%
%
AOT/
AOT/
in
ZOI
ZOI
ZOI
Solvent
Solvent
mer
sporin
PHMB
CHG
AgNO 3
NEO
AOT
H2O
Active
H2O
Polymer
24 h
48 h
72 h
HMDS/
93
7
0
0
0
ISO
HMDS/
92.54
6.97
0.498
5.34
6.3
5.32
ISO
HMDS/
92.17
6.94
9.91 ×
0.496
0.396
496
1.25
0.014
9.54
9.98
8.16
ISO
10−4
HMDS/
92.26
6.94
4.96 ×
0.496
0.248
10
2
0.71
8.95
8.94
9.71
ISO
10−2
HMDS/
92.34
6.95
9.93 ×
0.496
0.199
50
0.2
0.14
11.53
11.03
11.67
ISO
10−3
HMDS/
92.35
6.95
4.97 ×
0.497
0.199
100
2.5
0.49
8.16
9
8.18
ISO
10−3
100 μL
3.38
3
3.19
[0189] Table 10 shows the zones of inhibition results for Pseudomonas aeruginosa . These results show the Cavilon polymer with AOT is a highly effective antibacterial agent over time and substantially better than the Neosporin positive control. This was also found for PHMB and for NEO in AOT and Cavilon polymer. CHG in AOT and Cavilon, however, was less effective, in marked contrast to its activity against Staphylococcus aureus (Table 9).
[0000]
TABLE 10
Zone of Inhibition of Pseudomonas aeruginosa with Antimicrobials in AOT and Cavilon
Active
Active
Active
R-Surf
%
%
%
PC
%
%
%
%
%
AOT/
AOT/
Active in
ZOI
ZOI
ZOI
Solvent
Solvent
Polymer
Neosporin
PHMB
CHG
NEO
AOT
H2O
Active
H20
Polymer
24 h
48 h
72 h
HMDS/ISO
93
7
0
0
0
HMDS/ISO
92.54
6.97
0.498
8.18
8.22
11.2
HMDS/ISO
92.17
6.94
9.91 ×
0.496
0.396
500
1.25
0.014
10.1
9.6
9.15
10−4
HMDS/ISO
92.34
6.95
9.93 ×
0.496
0.199
50
2.5
0.14
2.77
0
0
10−3
HMDS/ISO
92.26
6.94
4.96 ×
0.497
0.199
10
2.5
0.71
7.43
6.41
7.61
10−2
100 μL
2.09
1.74
1.45
[0190] Table 11 shows zones of inhibition results against of Candida albicans , ATCC 10231, for PHMB and MICON in AOT and Cavilon, compared to 1 wt % Roccal as the positive control and Cavilon as the negative control. For the miconazole nitrate formulation, no added water was necessary to solubilize this antifungal agent in AOT. The positive control was superior to all other formulations, perhaps because of its higher concentration. For these data PHMB in AOT appeared slightly less effective than AOT itself. However, MICON with AOT was superior to that of AOT by itself and PHMB with AOT. The ratios of AOT/active and AOT/water were similar to those of other Tables.
[0000]
TABLE 11
Zone of Inhibitions of Candida Albicans with Antimicrobials in AOT and Cavilon
%
%
Active
Active
PC
R-Surf
Active
%
Poly-
%
%
%
%
%
AOT/
AOT/
in
ZOI
ZOI
ZOI
Solvent
Solvent
mer
PHMB
MICON
Roccal
AOT
H2O
Active
H20
Polymer
24 h
48 h
72 h
HMDS/ISO
93
7
0
0
0
0
0
HMDS/ISO
92.54
6.97
0.498
0
12.7
12.4
13.3
HMDS/ISO
92.17
6.94
9.91 × 10−4
0.496
0.396
500
1.25
0.014
12.1
11.2
11.1
HMDS/ISO
92.53
6.96
9.95 × 10−3
0.497
0
50
0.143
16.5
14.9
15
1
24.1
24
23.3
[0191] Also of consideration for application to animal and human skin is the potential of toxicity to mammalian cells for reverse emulsion surfactants such as AOT. It has been reported that in water solution, at a concentration as low as 0.002 wt %, AOT is cytotoxic to mammalian cells such as fibroblasts, kidney cells, and cancer cells (G. N. Kern, U.S. Pat. No. 4,885,310). This can be undesirable considering mammalian cells such as fibroblast are needed for wound repair. However, the prior art does not indicate whether AOT is cytotoxic in a volatile, hydrophobic solvent containing polymers for controlled delivery. Therefore, a cytotoxicity studied was conducted using Cavilon solution containing 0.5 wt % AOT, which is a similar concentration to that used in all the above antibacterial and antifungal studies (Tables 9-11). Cavilon solution without AOT was used as a negative control.
[0192] The toxicity study was conducted by Toxikon Corporation, Bedford, Mass., and the data is given in Table 12. The biological reactivity of L929 mouse fibroblast cell in response to the AOT Cavilon solution was determined. The monolayer of fibroblasts was cultured in an agar plate, and the cell viability was evaluated using a vital dye (neutral red). The AOT Cavilon solution was applied directly to the surface of the agar. Positive (Buna-N-Rubber) and negative (Negative Control Plastic, Cavilon solution) control articles were prepared to verify the proper functioning of the test system. The cultures were incubated at 37±1° C., in a humidified atmosphere containing 5±1% carbon dioxide. Zone of inhibition was measured, and biological reactivity (cellular degeneration and malformation) was rated on a scale from Grade 0 (No reactivity) to Grade 4 (Severe reactivity) at 24 and 48 hours. The experiment was run in triplicate. The results indicate that AOT Cavilon solution with a Grade of zero, although effective in killing gram positive bacteria, gram negative bacteria, and fungi, is not toxic to mammalian cells.
[0000]
TABLE 12
Cytotoxicity Testing of 0.5 wt % AOT in Cavilon
0.05 wt % AOT
Positive
Negative
Disc
in Cavilon
Control
Control
Control
Zone
Zone
Zone
Zone
Size
Size
Size
Size
Time
(cm)
Grade
(cm)
Grade
(cm)
Grade
(cm)
Grade
24 hours
0
0
0.3
3
0
0
0
0
48 hours
0
0
0.3
3
0
0
0
0
[0193] Another concern with the use of a reverse emulsion surfactant for its application to mammalian skin is its potential to cause skin irritation. It has been reported that in water solution AOT can be irritating to skin (M. Changez and M. Varshney, Drug Development and Industrial Pharmacy, 26(5), 507-512 (2000)). To test if AOT is skin-irritating when used in a volatile, hydrophobic solvent with the presence of polymer, an animal skin-irritation study was conducted by Toxikon Corporation, Cavilon solution containing 0.5 wt % AOT was examined, and Cavilon solution was used as a negative control.
[0194] Three albino rabbits were used for the skin irritation study. The application sites were prepared by clipping the skin of the trunk free of hair within 24 h before application of the test and control substances. The animals were treated by applying an AOT-containing Cavilon solution and the Cavilon negative control (0.5 mL) directly onto skin over a skin area of approximate 6 cm 2 . The test solution was applied to the skin on the left side of the spine and the control solution was applied to the skin on the right side of the spine. The AOT solution and the negative control were each applied sequentially to three sites, and observed at 6, 24, 48, and 72 h for signs of erythema and edema. Observations were scored according to the Draize Scale for Scoring. None of the AOT solution sites presented any signs of erythema or edema at any of the observation points. None of the control sites of any animal at any of the observation periods showed signs of erythema or edema. Therefore, the tested AOT Cavilon solution was considered a non-irritant.
Other Embodiments
[0195] While the above specification contains many specifics, these should not be construed as limitations on the scope of the invention, but rather as examples of preferred embodiments thereof. Many other variations are possible. Accordingly, the scope of the invention should be determined not by the embodiments illustrated, but by the appended claims and their legal equivalents.
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A composition and method adapted for delivery of hydrophilic, biologically-active agents are disclosed. The composition can include a reverse microemulsion formed from at least one hydrophilic, biologically-active agent solubilized by a hydrophobic reverse emulsion surfactant in a non-stinging, volatile, hydrophobic solvent. The non-stinging, volatile, hydrophobic solvent is selected from the group consisting of volatile linear and cyclic siloxanes, volatile linear, branched, and cyclic alkanes, volatile fluorocarbons and chlorofluorocarbons, liquid carbon dioxide under pressure, and combinations thereof. The reverse microemulsion can be an optically clear solution.
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[0001] The present invention relates to a frame for casings, doors or windows and the like, particularly but not exclusively for outdoor use.
[0002] In particular, the present invention can be applied to casings and to the corresponding sashes of windows, doors, doors with door frame, entrance doors, sliding doors or windows, center-hung sashes, shutters of various types such as matchboard shutters, Venetian-style shutters, open/closed slat shutters, et cetera.
BACKGROUND OF THE INVENTION
[0003] Currently, the door and window market is becoming orientated toward the choice of component materials that achieve high performance in terms of durability without having to perform any maintenance.
[0004] Particular attention is paid to the materials that compose doors or windows and corresponding casings for outdoor use.
[0005] These are in fact most affected by early aging, both because they are exposed to the effects of weather and because of the chemical attacks caused by pollution.
[0006] Casings are formed by a frame that can be fixed to the jambs of the openings to be closed and is provided with an inward side and an outward side with respect to the building in which the frame is applied.
[0007] Likewise, the corresponding doors or windows are also formed by a frame, which can be fixed to the casing and is provided with an inward side and an outward side.
[0008] The outward sides of the frames are the ones exposed to the effects of weather and to the highest concentration of pollutants and therefore are the ones that deteriorate more rapidly.
[0009] The most widespread type of door or window and casing is substantially based on a structure that is entirely made of wood.
[0010] Wood deteriorates rapidly and periodically needs maintenance, including stripping and repainting, especially on the outward side of the frame.
[0011] In order to obviate these drawbacks, frames made of metallic material such as aluminum are currently known and used.
[0012] However, these aluminum frames have a distinctly higher production cost than equivalent wood frames, due both to the structural complexity of the profiled elements that form them and to the particular operations for assembling their components.
[0013] Moreover, their users often perceive them negatively, since they are considered cold and unaesthetic.
SUMMARY OF THE INVENTION
[0014] The aim of the present invention is to provide a frame for casings, doors or windows and the like, particularly for outdoor use, that solves the drawbacks noted above in known types.
[0015] Within this aim, an object of the present invention is to provide a frame for casings, doors or windows and the like, particularly for outdoor use, that withstands the deterioration caused by the atmospheric environment and by pollutants and has low production costs.
[0016] Another object of the present invention is to provide a frame for casings, doors or windows and the like, particularly for outdoor use, that has a high-value finish.
[0017] Another object of the present invention is to provide a frame for casings, doors or windows and the like, particularly for outdoor use, that is strong and stable from a geometric and structural standpoint.
[0018] Another object of the present invention is to provide a frame for casings, doors or windows and the like, particularly for outdoor use, that can be manufactured with known systems and technologies.
[0019] This aim and these and other objects that will become better apparent hereinafter are achieved by a frame for casings, doors or windows and the like, particularly for outdoor use, comprising a base framework constituted by at least one laminated wood layer, characterized in that it comprises a metal skin for facing and outward protection and means for the adhesion of said skin to said framework.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] Further characteristics and advantages of the present invention will become better apparent from the following detailed description of a preferred but not exclusive embodiment thereof, illustrated by way of non-limiting example in the accompanying drawings, wherein:
[0021] [0021]FIG. 1 is a sectional axonometric view, taken along a transverse plane, of the lower cross-members of a pair of frames according to the invention, respectively of a window sash and of a window casing;
[0022] [0022]FIG. 2 is a sectional axonometric view, taken along a transverse plane, of the lateral posts of a pair of frames according to the invention, respectively of a window sash and of a window casing;
[0023] [0023]FIG. 3 is a sectional axonometric view, taken along a transverse plane, of a portion of the lower cross-members of a pair of frames, in a second embodiment according to the invention, respectively of a window sash and of a window casing;
[0024] [0024]FIG. 4 is a sectional axonometric view, taken along a transverse plane, of a portion of the lateral posts of a pair of frames, in a second embodiment according to the invention, respectively of a window sash and of a window casing;
[0025] [0025]FIG. 5 is a cutout axonometric view of a frame of a vertical matchboard shutter according to the invention;
[0026] [0026]FIG. 6 is a front view of a frame of a slat shutter according to the invention;
[0027] [0027]FIG. 7 is a sectional side view of a portion of the slat shutter frame of FIG. 6;
[0028] [0028]FIG. 8 is a sectional perspective view, taken along a transverse plane, of a perimetric portion of another embodiment of the frame according to the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0029] With reference to FIGS. 1 to 4 , a first frame related to a window sash, according to the invention, is generally designated by the reference numeral 10 .
[0030] Likewise, a second frame of a complementary casing, according to the invention, is generally designated by the reference numeral 100 .
[0031] The first sash frame 10 and the second casing frame 100 are substantially composed of the same components; for the sake of simplicity, therefore, the first sash frame 10 will be described mostly hereinafter.
[0032] When the complementary components of the second frame 100 are described, they will be designated by the same name as the first frame 10 but with progressive, generally corresponding, numerals increased by one hundred.
[0033] The first sash frame 10 comprises a perimetric base framework 11 that is constituted in this case by four laminated wood layers that are mutually bonded by gluing: respectively, an outward layer 12 , two central layers 13 a and 13 b, and an inward layer 14 .
[0034] The outward layer 12 protrudes, parallel to the plane of the window, with a portion 15 with respect to the other three layers 13 a, 13 b and 14 , and acts as an abutment for a double-glazing unit 16 .
[0035] The double-glazing unit 16 is sandwiched between the portion 15 and a rim 17 that is fixed to the inward layer 14 .
[0036] An exposed finishing veneer 19 , made of high-value wood (for example oak, chestnut, birch, rift-sawn fir, larch or mahogany, et cetera) or very high-value wood (for example teak, rosewood, et cetera), is applied to the side of the framework 11 that is directed toward the inside of the building to which the frame 10 is applied, in practice on the inward face 18 of the inward layer 14 .
[0037] The thickness of said veneer can be for example 3-4 mm, and the veneer is cold- or high frequency-bonded and pressed.
[0038] The inward layer 14 protrudes toward the second frame 100 of the casing in the opposite direction with respect to the protrusion of the portion 15 of the outward layer 12 with a part 20 with respect to the other two layers 13 and 14 .
[0039] The protruding part 20 acts as an internal closure element of the window, abutting against the inward side of the second frame 100 (in particular against the exposed finishing veneer 119 of the inward layer 114 ).
[0040] A slot 21 is provided on the protruding part 20 of the inward layer 14 of the sash frame 10 and accommodates a fixing portion 22 of a first L-shaped gasket 23 that is interposed between the frames 10 and 100 when the window is closed.
[0041] A metallic facing skin 30 is made to adhere, by way of adhesion means specified hereinafter, to the side of the framework 11 that is directed toward the outside of the building to which the first frame 10 is applied, in practice on the entire visible outward face 24 of the outward layer 12 .
[0042] The outward layer 12 forms an acute-angled recess 12 a together with the adjacent central layer 13 a, and the metallic facing skin 30 also adheres to the portion of the central layer 13 a that is formed by the recess 12 a.
[0043] The metallic skin 30 has, for example, a thickness comprised between 0.1 mm and 0.35 mm and is preferably made of aluminum alloy, for example alloy types 3005 or 8011, in one of the following physical states: H14, H16, H34.
[0044] As an alternative, the metallic skin 30 can be made of materials or alloys such as copper, brass, bronze, steel, et cetera.
[0045] In the case of brass and copper, these materials are in the soft or annealed physical state.
[0046] The metallic skin 30 has an external finish provided by means of a heat-sealing lacquer.
[0047] The means for the adhesion of the metallic skin 30 to the outward layer 12 comprise, for example, an adhesive of the reactive hot-melt type based on polyurethane with post-crosslinking.
[0048] As an alternative, said adhesion means can comprise a thermal bonding film that is interposed between the metallic facing skin 30 and the outward layer 12 .
[0049] Consider now the second casing frame 100 ; the materials of the corresponding components of the first sash frame 10 and of the second casing frame 100 are substantially the same.
[0050] The base framework 111 of the second frame 100 is composed of an outward laminated layer 112 , a central laminated layer 113 , and an inward laminated layer 114 , which are respectively bonded to each other by means of adhesive.
[0051] An exposed finishing veneer 119 , made of valuable or highly valuable wood, adheres to the inward face 118 of the inward layer 114 .
[0052] A metallic finishing skin 130 adheres to the entire exposed outward face 124 of the outward layer 112 .
[0053] In particular, the outward layer 112 protrudes in the opposite direction with respect to the protrusion of the part 20 of the first frame 10 that abuts against the veneer 119 with a portion 120 with respect to the other two layers 113 and 114 .
[0054] The portion 120 of the outward layer 112 acts as an abutment for the outward side of the first frame 10 when the window is closed.
[0055] A slot 121 is provided on the portion 120 of the outward layer 112 of the first frame 10 and accommodates a portion 122 for fixing a second L-shaped gasket 123 that is interposed between the frames 10 and 100 when the window is closed.
[0056] With reference to FIG. 1, which is a sectional view of the lower cross-members of the first sash frame 10 and of the second casing frame 100 of a window, the outward layer 12 surmounts, when the window is closed, the region occupied by the second gasket 123 , so as to protect the outer closure region of the window against the rain, like a shelter, thus reducing possible infiltrations of water between the first frame 10 and the second frame 100 .
[0057] With reference to FIGS. 3 and 4, an alternative embodiment of the invention comprises a base framework 11 of the first sash frame 10 that is provided by means of only three laminated layers; the outward layer 12 , the central layer 13 , and the inward layer 14 .
[0058] With reference to FIG. 3, which is a sectional view of a portion of the lower cross-members of the first sash frame 10 and of the casing frame 100 of a window, a metallic profiled element 40 is fixed to the metallic skin 30 of the first frame 10 and is constituted by a central plate 41 , which is inclined toward the lower part of the window (and therefore toward the second frame 100 ), and by two parallel wings 42 , which protrude on opposite sides with respect to the plate 41 .
[0059] The metallic profiled element 40 is fixed by means of one of said wings 42 and surmounts, when the window is closed, the region occupied by the second gasket 123 , so as to protect against the rain, like a shelter, the outward closure region of the window, thus reducing possible infiltrations of water between the first frame 10 and the second frame 100 .
[0060] With reference again to both embodiments, when the window is closed, a gap 50 is formed between the first frame 10 and the second frame 100 .
[0061] In particular, the second casing frame 100 has a groove 151 that is formed at the base of the protruding portion 120 of the outward layer 112 .
[0062] The groove 151 is covered on its sides by a portion of metallic film 130 a that is similar to the metallic skin 130 that adheres to the visible outward face 124 .
[0063] With reference to the lower cross-member of the window (and therefore to FIGS. 1 and 3), the groove 151 corresponds to a channel for accumulating condensation and has a channel 152 for discharging externally said condensation that passes within the laminated layers.
[0064] Within the gap 50 , the frame 10 has a first longitudinal recess 51 , which is formed proximate to the coupling of the metallic skin 30 , and a second longitudinal recess 52 , which is larger than said first recess 51 and is formed centrally between the laminated layers.
[0065] The sash frame 10 and the casing frame 100 further comprise means 60 for ventilating the wood portion of said framework proximate to said metallic skin; said means are constituted for example by regions 61 that are not covered by the metallic skin 30 and are adjacent to the peripheral end portion of said metallic skin.
[0066] The ventilation means 60 can also comprise a plurality of microperforations, not shown in the figures, provided in series on the metallic skin 30 ; the dimensions of said microperforations are such that water finds it difficult to enter them but are sufficient to ventilate the underlying wood.
[0067] In particular, said microperforations are used for shutters or doors or otherwise for casings with extensive wood surfaces, which accordingly have central parts that are difficult to ventilate from the peripheral region.
[0068] With reference to FIG. 5, an embodiment of the invention is designated by the reference numeral 200 and corresponds to a frame of a matchboard shutter.
[0069] As before, said shutter frame 200 comprises a base framework 211 , which is constituted for example by four laminated wood layers that are mutually bonded by gluing: respectively, an outward layer 212 , two central layers 213 a and 213 b, and an inward layer 214 .
[0070] The metallic facing skin 230 adheres both to the outward layer 212 and to the inward layer 214 .
[0071] Both the outward layer 212 and the inward layer 214 have vertical grooves 215 that the skin 230 follows completely.
[0072] With reference to FIGS. 6 and 7, another embodiment of the invention is designated by the reference numeral 300 and corresponds to a slat shutter frame.
[0073] As described earlier, said slat shutter frame 300 comprises a perimetric base framework 311 , which is constituted for example by four laminated wood layers that are mutually bonded by gluing: respectively, an outward layer 312 , two central layers 313 a and 313 b, and an inward layer 314 .
[0074] The metallic facing skin 330 adheres to the outward layer 312 , to the inward layer 314 , to the inward and outward edge portions 315 and 316 of the base framework 311 .
[0075] The slats 317 , provided in an inward layer 414 and an outward layer 412 that are mutually bonded by adhesive, also have a metallic facing skin 430 that adheres directly to their entire surface, both on the outward layer 412 and on the inward layer 414 .
[0076] In particular, on each slat 317 the skin 430 is provided in two parts that are respectively fixed to the outward layer 412 and to the inward layer 414 and end by folding onto the head 418 of the slat and inside the groove 419 formed on the bottom 420 of said slat.
[0077] The groove 419 is suitable for coupling to the head of a corresponding contiguous slat.
[0078] Alternative embodiments of the invention relate to frames for doors, front doors, et cetera, and respective door frames, are substantially similar to the preceding ones and are characterized in that they comprise said metallic facing skin for outward protection of said means for the adhesion of said skin to said framework.
[0079] For example, the frame of a door (not shown in the figures) comprises a base framework that is composed of a plurality of laminated layers that are respectively mutually bonded by adhesive.
[0080] An exposed finishing veneer, made of valuable or extremely valuable wood, is made to adhere to the face of the inward layer.
[0081] Said metallic facing skin is applied by adhesion to the entire visible outward surface of the door.
[0082] Optionally, said metallic skin may adhere to both faces of the door.
[0083] With reference to FIG. 8, a frame according to the invention is generally designated by the reference numeral 500 .
[0084] In this embodiment, said frame relates to a shutter, for example of the matchboard type.
[0085] The frame 500 comprises a base framework 511 , which is constituted in this embodiment by a single laminated wood layer 112 ; as an alternative, said framework may be constituted by a plurality of wood layers.
[0086] A metallic facing skin 515 for outward protection adheres to the base framework 511 on the side 513 of the framework 511 that is directed toward the outside of the building to which the frame is applied (with reference to the case of a closed casing on the building) and on the corresponding inward side 514 .
[0087] The metallic skin 515 has, for example, a thickness comprised between 0.1 mm and 0.35 mm and is preferably made of aluminum alloy, for example alloy types 3005 or 8011, in one of the following physical states: H14, H16, H34.
[0088] As an alternative, the metallic skin 515 can be made of copper, brass, bronze, steel, et cetera and can have an external finish provided by means of a thermal bonding lacquer.
[0089] In order to make the metallic skin 515 adhere to the wood layer 512 , it is possible to use for example an adhesive of the reactive hot-melt type based on polyurethane with post-crosslinking; as an alternative, it is possible to interpose a thermal bonding film.
[0090] In this embodiment, the perimetric edge 516 of the base framework 511 , delimited on the outer side 513 and on the inner side 514 (except for the portion related to the hinges of the sash) is formed by a step-like portion 516 a for abutment during closure of the sash onto a corresponding casing portion (not shown).
[0091] A metallic protective lamina 517 is fixed along the step-like portion 516 a and substantially duplicates its step-like configuration.
[0092] In particular, in this embodiment the metallic lamina 517 is an extruded aluminum profile.
[0093] At the outer edge 518 and at the inner edge 519 of the framework 511 , the metallic lamina 517 has a region 517 a that gradually decreases in thickness until it ends with a wider rim 520 that has a substantially circular transverse cross-section.
[0094] The metallic lamina 517 is coupled to the perimetric edge 516 by way of fixing means 521 , constituted by two longitudinal tabs 522 that each protrude at right angles from a respective one of the two parallel surfaces 517 b of the metallic lamina 517 that duplicate the step-like portion 516 a.
[0095] The tabs 522 are inserted within corresponding slots 523 formed in the layer 512 .
[0096] In particular, the longitudinal tabs 522 are sawtooth-shaped on opposite sides and are inserted with interference in the slots 523 , which have a rectangular cross-section.
[0097] Advantageously, the fixing means 521 comprise silicone 526 (or an equivalent material having the same waterproofing and adhesiveness characteristics), which is arranged between the lamina 517 and the layer 512 , as described hereinafter.
[0098] At the outer edge 518 and at the inner edge 519 , the framework 511 has a bevel 524 .
[0099] The bevel 524 and the thinner region 517 a of the lamina 517 form a cavity 525 for retaining the silicone 526 .
[0100] The metallic skin that adheres to the outward and inward sides of the framework allows to protect the wood against the effects of weather acting directly on said sides.
[0101] In practice it has been found that the invention thus described solves the problems noted in known types of frame for casings, doors or windows and the like, particularly for outdoor use; in particular, the present invention provides a frame for casings, doors or windows and the like, particularly for outdoor use, that withstands deterioration caused by the atmospheric environment and by polluting agents.
[0102] The metallic skin that adheres to the outward side of the frame in fact allows to protect the wood from the effects of weather and requires no maintenance.
[0103] Moreover, the present invention provides a frame for casings, doors or windows and the like, particularly for outdoor use, that has a high-value finish.
[0104] The use of an exposed finishing veneer of high-value wood on the inward side of the frame in fact makes the casing and the door or window aesthetically appreciable.
[0105] The possibility to apply lacquer to the metallic skin further allows to obtain a luxury finish with an extremely vast color range.
[0106] Moreover, it should be noted that the ventilation means spare the wood from rotting due to humidity, since the metallic skin tends to not allow paths for the escape of moisture particles.
[0107] The metallic lamina that is fixed to the perimetric edges of the framework also allows indirect protection of the door or window, avoiding for example contact with the rain that infiltrates between the door or window and the casing when the door is closed.
[0108] The fixing of the metallic lamina to the perimetric edges of the framework provides an optimum seal and is easy and quick to perform.
[0109] The invention thus conceived is susceptible of numerous modifications and variations, all of which are within the scope of the appended claims; all the details may further be replaced with other technically equivalent elements.
[0110] In practice, the materials employed, so long as they are compatible with the specific use, as well as the dimensions, may be any according to requirements and to the state of the art.
[0111] The disclosures in Italian Patent Application No. PD2003A000073 and in Italian Utility Model Application No. PD2003U000061 from which this application claims priority are incorporated herein by reference.
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A frame for casings, doors or windows and the like, particularly but not exclusively for outdoor use, applicable to casings and corresponding sashes of windows, doors, front doors, sliding sashes, center-hung sashes, matchboard shutters, Venetian-style shutters, open/closed slat shutters. The frame has a base framework of one or more laminated wood layers, an exposed finishing veneer adhered to the inside side and a metal skin for facing and protection, adhered to the framework; the metallic skin provides a frame with aesthetic finish and weather protection.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application No. 60/262,304, filed Jan. 12, 2001.
BACKGROUND OF THE INVENTION
[0002] 1. Technical Field
[0003] The present invention relates generally to air compressors and, more particularly, to a portable air compressor having individual high and low pressure output ports.
[0004] 2. Discussion
[0005] Construction workers and other professionals often times have a need for a portable compressed air source. Specifically, workers within the rough construction industry have found certain tools such as air nailers and air staple guns useful in their trade. To operate these devices in the field, a portable source of compressed air is required. Additionally, it should be appreciated that many construction sites do not include a source of electrical power. Accordingly, a portable air compressor with its own source of compressing power is preferred.
[0006] In the past, portable air compressors have been equipped with at least one storage tank having a pressure switch to define the pressure within the tank and a regulator to limit the pressure released at an output port or ports. Typically, the operating range of the output pressure regulator is from 0 to 200 PSI. This corresponds to the operating range of standard air nailers and air staple guns.
[0007] Recently, a new line of pneumatic hand tools has been introduced. Some air nailers and staple guns now operate at a pressure of approximately 425 PSI. Designers of these new tools have been able to drastically decrease the size and weight of the air nailers using the higher operating pressure. As would be expected, workers in the field prefer lighter weight, less cumbersome tools if performance is not sacrificed.
[0008] However, many existing air tools currently require regulated pressures ranging from 35 TO 90 PSI. Such devices include paint spray guns and impact wrenches. Accordingly, a need exists for a portable air compressor having a low pressure output port and a high pressure output port.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] [0009]FIG. 1 is an exploded perspective view of a high pressure portable air compressor constructed in accordance with the teachings of the present invention;
[0010] [0010]FIG. 2 is a partial exploded perspective view of a first panel assembly of the present invention;
[0011] [0011]FIG. 3 is a partial exploded perspective view of a second panel assembly of the present invention; and
[0012] [0012]FIG. 4 is an exploded perspective view of an alternative compressor embodiment.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0013] With reference to the figures, a high pressure portable air compressor constructed in accordance with the teachings of the present invention is generally depicted at reference numeral 100 . Air compressor 100 includes a motor 102 , a compressor 104 , a storage tank 106 , a deck 108 , a first panel assembly 110 and a second panel assembly 112 . Deck 108 is coupled to storage tank 106 and includes mounting provisions for motor 102 and compressor 104 .
[0014] Deck 108 is a generally “U” shaped member having a mounting plate portion 114 positioned between a pair of downwardly extending side walls 116 . Mounting plate portion 114 includes a plurality of apertures 118 for receipt of fasteners (not shown) used to couple motor 102 and compressor 104 to deck 108 . Once mounted to deck 108 , motor 102 is drivingly coupled to compressor 104 via a belt 119 . During operation, rotation of motor 102 causes rotation of compressor 104 thereby initiating a supply of compressed air to an intake port 120 located on storage tank 106 . It should be appreciated that motor 102 may be an electrically powered AC or DC motor, an internal combustion engine or any other suitable power generating device.
[0015] With reference to FIG. 2, first panel assembly 110 includes a panel 122 coupled to deck 108 . Panel 122 includes a pair of apertures 124 for receipt of a first gage 126 and a second gage 128 . Panel 122 further includes an aperture 130 for receipt of a pressure regulator assembly 132 . A pair of apertures 134 are each adapted to receive a quick coupler 136 . Each quick coupler 136 is a normally closed valve which opens upon interconnection with a mating hose coupler (not shown). Each quick coupler 136 includes a right-hand NPT thread at one end and an automotive type quick connect fitting at the opposite end. Each quick coupler 136 is coupled to a manifold 138 downstream of regulator 132 . Therefore, the output pressure from each quick coupler 136 substantially matches the regulated air pressure.
[0016] Manifold 138 includes an input 140 receiving pressurized air directly from storage tank 106 . First gage 126 directly receives air stored in storage tank 106 as well. Accordingly, first gage 126 displays storage tank internal pressure. Second gage 128 is also plumbed to manifold 138 but receives regulated pressure downstream of regulator 132 . As such, second gage 128 displays the pressure output from regulator 132 . A pressure relief valve (not shown) is coupled to manifold 138 to assure that only relatively low pressure is available to quick coupler 136 .
[0017] A pilot valve 142 is also coupled to panel 122 and manifold 138 . Pilot valve 142 is useful to vent compressed air to atmosphere once the target tank pressure is met. It should be appreciated that pilot valve 142 may be alternatively coupled directly to tank 106 . Pilot valve 142 is typically used only when compressor 100 is equipped with an internal combustion motor to allow the internal combustion motor to operate in a constant-run mode. If an electric motor is used, compressor 100 operates in start-stop mode where a pressure limit switch shuts off the motor once the desired tank pressure is reached.
[0018] A dual control system may also be used in conjunction with an electric motor. The dual control system includes a pressure limit switch and a pilot valve. With dual control, a user may select to operate the compressor in the start-stop mode or the constant-run mode to conserve electricity.
[0019] In the embodiment depicted in FIG. 3, a dual pressure limit switch 143 is included to allow a user to select a desired maximum tank pressure. If a maximum pressure of 200 PSI is desired, the user simply moves switch 143 to position A. If high pressure tools are to be used, the user moves switch 143 to position B thereby directing motor 102 to compress air until approximately 425 PSI is generated. Therefore, air is compressed to the full 425 PSI only when necessary to avoid undue motor and compressor loading.
[0020] With reference to FIG. 4, second panel assembly 112 includes a manifold 144 having an input 146 in communication with the interior volume of storage tank 106 . A burst hose 148 is plumbed between manifold 144 and storage tank 106 to prevent gross over-pressure situations. Specifically, burst hose 148 is designed to provide a pressure relief for tank 106 when internal pressure is greater than approximately 900 PSI.
[0021] Second panel assembly 112 includes a regulator assembly 150 , a gage 152 and a pair of high pressure quick couplers 154 . Gage 152 is positioned downstream of regulator 150 and displays the regulated output pressure. It should be appreciated that second panel assembly 112 is preferably a high pressure panel assembly. As such, pressure gage 152 is capable of measuring pressures up to 450 PSI or greater, if so desired. First gage 126 is therefore the low pressure gage and includes a dial face indicating that pressures from 0-200 PSI are available.
[0022] With reference to FIG. 1, deck 108 includes a plurality of apertures 155 for receipt of pressure regulator 150 , pressure gage 152 and quick couplers 154 . Each quick coupler 154 includes left-hand NPT threads and preferably includes quick connect fittings of a smaller size than quick couplers 136 to assure that a user connects to the appropriate air pressure source. Manifold 144 is coupled to deck 108 and preferably positioned between the deck and storage tank 106 . In this manner, the high pressure fitting interconnections are not easily disturbed.
[0023] A second embodiment high pressure air compressor 156 having alternative tank, deck and motor configurations is depicted in FIG. 5. Air compressor 156 includes a pair of tanks 158 positioned adjacent one another to provide a low-profile assembly. Tanks 158 are plumbed in communication with one another and are charged to the same pressure. Handles 160 are coupled to the tank to assist a user when transporting the air compressor. A wheel 162 is rotatably coupled to tanks 158 to further facilitate movement of the unit. An internal combustion engine 164 is used to drive compressor 104 via drive belts 166 . One skilled in the art will appreciate that a high pressure portable air compressor may be constructed using some or all of the exemplary components depicted in FIG. 5 without departing from the scope of the present invention.
[0024] The foregoing discussion discloses and describes merely exemplary embodiments 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 may be made therein without department from the spirit and scope of the invention as defined in the following claims:
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A portable air compressor includes a frame, a motor mounted to the frame,a storage tank coupled to the frame and a compression mechanism in communication with the storage tank. The motor drivingly engages the compression mechanism. The compressor includes a first regulator coupled to the storage tank for defining a first pressure at a first outlet port. A second regulator is coupled to the storage tank for defining a second pressure output at a second outlet port.
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BACKGROUND
[0001] The present disclosure relates to a toilet. More particularly, the present disclosure relates to a toilet including a ventilation system for exhausting odorous air therefrom.
[0002] It is apparent that numerous innovations for toilets have been provided in the prior art that are adapted to be used. Furthermore, even though these innovations may be suitable for the specific individual purposes to which they address, however, they would not be suitable for the purposes of the present disclosure as heretofore described.
BRIEF SUMMARY
[0003] The present disclosure provides a method for exhausting odorous air from a toilet that avoids the disadvantages of the prior art and is simple to use.
[0004] The present disclosure provides a toilet for exhausting odorous air therefrom, comprising a bowl, a trap, a self-contained ventilation system, a water tank, and a water supply line. The bowl has a rim therearound wherein the bowl communicates with the rim. The bowl is for receiving human waste that produces the odorous air. The main trap is contained in the bowl, wherein the trap is for communicating the contents in the bowl with a drain conduit so as to provide a passageway from the bowl to a drain stack. The ventilation system includes an exhaust blower having a blower inlet and a blower outlet. The blower inlet is in communication with air space between the contents in the bowl and the rim. The blower outlet is in communication with the drain conduit downstream from the trap. The exhaust blower further including a check valve between the blower outlet and the drain conduit for preventing the odorous air from flowing upstream from the drain stack into the blower outlet. The check valve is spring biased to a closed position and when closed blocks the odorous air from the drain conduit to the blower outlet. The check valve is selectively biased to an open position when the exhaust blower is activated at a pressure at the blower outlet thereby opening the check valve to allow odorous air to flow from the blower outlet to the drain conduit; and, wherein the exhaust blower includes a cutoff switch for deactivating the exhaust blower during a flush of the toilet
[0005] The present disclosure further provides a toilet for exhausting odorous air therefrom, comprising a bowl, a trap, a self-contained ventilation system, a water tank, and a water supply line. The bowl has a rim therearound wherein the bowl communicates with the rim. The bowl is for receiving human waste that produces the odorous air. The main trap is contained in the bowl wherein the trap is for communicating the contents in the bowl with a drain conduit so as to provide a passageway from the bowl to a drain stack. The ventilation system includes an exhaust blower having a blower inlet and a blower outlet. The blower inlet is in communication with air space between the contents in the bowl and the rim. The blower outlet is in communication with the drain conduit downstream from the trap. The exhaust blower including a cut-off switch for deactivating the exhaust blower during a flush. The shut-off switch comprising a float switch operably deactivated when a float drops during a flush and operably activates when the float rises when a level of the water in the tank moves down and up, respectively. The cut-off switch interrupts power temporarily to the exhaust blower during a flush while the float drops and rises, and resumes power to the exhaust blower when the float reaches a select water level in the tank.
[0006] The novel features which are considered characteristic of the present disclosure are set forth in the appended claims. The disclosure itself, however, both as to its construction and its method of operation, together with additional objects and advantages thereof, will be best understood from the following description of the specific embodiments when read and understood in connection with the accompanying drawing.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] The figures of the drawing are briefly described as follows:
[0008] FIG. 1 is an enlarged diagrammatic cross sectional view of a toilet assembly;
[0009] FIG. 2 is an enlarged cross sectional view of a portion of a toilet bowl and rim;
[0010] FIG. 2A is an enlarged cross sectional view of a portion of the toilet bowl and rim;
[0011] FIG. 3 is a cross sectional side view of a toilet tank;
[0012] FIG. 4 is a cross sectional front view of the toilet tank; and,
[0013] FIG. 5 is an electrical circuit schematic according to the present disclosure.
DETAILED DESCRIPTION
[0014] Referring now to the figures, in which like numerals indicate like parts, and particularly to FIG. 1 , which is a diagrammatic cross sectional view of the present disclosure, the toilet assembly of the present disclosure is shown generally at 10 for exhausting odorous air (not shown) therefrom.
[0015] The configuration of the toilet assembly 10 can best be seen in FIG. 1 , which is a diagrammatic cross sectional view of the toilet 10 , and as such, will be discussed with reference thereto.
[0016] It will be understood that each of the elements described above, or two or more together, may also find a useful application in other types of constructions differing from the types described above.
[0017] While the disclosure has been illustrated and described as embodied in a toilet for exhausting odorous air therefrom, however, it is not limited to the details shown, since it will be understood that various omissions, modifications, substitutions and changes in the forms and details of the device illustrated and its operation can be made by those skilled in the art without departing in any way from the spirit of the present disclosure.
[0018] Without further analysis, the foregoing will so fully reveal the gist of the present disclosure that others can, by applying current knowledge, readily adapt it for various applications without omitting features that, from the standpoint of prior art, fairly constitute characteristics of the generic or specific aspects of this disclosure.
[0019] The present development relates to a self-contained ventilated toilet assembly 10 as illustrated in FIGS. 1 , 2 , 2 A, and 3 - 5 . The toilet 10 includes a bowl 14 defined as part of a pedestal base 18 . The pedestal base 18 defines a drain conduit 22 . The drain conduit 22 begins at a waste outlet 26 that communicates with the bowl 14 and extends to a stack outlet 30 that is adapted to communicate with a conventional drain stack of a house or other structure (not shown) in which the toilet is installed. The drain conduit 22 comprises a trap 34 that collects a volume of water to block flow of sewage gases from the drain stack into the bowl 14 by way of the drain conduit 22 . A ring or U-shaped toilet seat 38 is pivotally connected to the pedestal base 18 by a hinge 42 and generally conforms to the dimensions of a rim 46 of the bowl so as to provide a seating location for a user of the toilet 10 .
[0020] The pedestal base 18 defines a neck 50 that extends horizontally outward from the rim 46 of the bowl 14 at the rear of the rim/bowl. A tank 54 is supported on/above the neck 50 and is adapted to contain a volume of water 58 that is selectively communicated to the bowl 14 for supplying water and flushing waste from the bowl through waste outlet 26 , into the drain conduit 22 , and out of the drain conduit 22 via stack outlet 30 into the drain stack. More particularly, the rim 46 of the bowl defines an internal rim conduit 62 as shown in FIGS. 1 and 2 . A lower region of the rim conduit 62 includes a plurality of apertures 66 that communicate with the bowl. During a flush of the toilet 10 , water 58 from the tank 54 flows into a neck conduit 52 of the neck 50 which communicates with the rim conduit 62 such that the water 58 flows from the neck conduit 52 into the rim conduit 62 . Water flowing in the rim conduit 62 flows out of the apertures 66 into the bowl 14 such that the contents of the bowl 14 are flushed into the drain conduit 22 via waste outlet 26 .
[0021] As shown in FIGS. 3 and 4 , the tank 54 comprises a flush opening 70 that is in fluid communication with the neck conduit 52 (which is in fluid communication with the rim conduit 62 ). A flush valve 74 is located in the tank and normally seats over the flush opening 70 to block same. The flush valve 74 (e.g., a flapper or other type of valve) is selectively unseated by user manipulation of a flush handle 70 , which is connected to the flush valve 74 by a linkage such as a chain 82 or other member(s). When the flush valve 74 is unseated, water 58 in the tank 54 flows by gravity into the flush opening 70 , neck conduit 52 , rim conduit 62 and rim apertures 66 for flushing the bowl 14 as described above. When the user releases the handle 78 , the flapper or other flush valve 74 is normally re-seated over the flush opening 70 to block same.
[0022] As shown in FIG. 4 , the tank 54 is connected to a water supply line 86 , and a float valve 90 is located in the tank 54 and controls the flow of water 58 into the tank 54 to refill same after a flush. In particular, the float valve 90 comprises a float 94 that moves up and down with the level of water 58 in the tank 54 . When the level of water 58 in the tank drops during a flush, the float 94 drops and opens the float valve 90 to allow flow of water into the tank 54 from the supply line 86 . When the flush valve 74 closes and the level of the water 58 in the tank 54 rises to a select level, the float 94 is elevated sufficiently to close the float valve 90 to stop the flow of water into the tank via supply line 86 .
[0023] Unlike a conventional toilet, the toilet 10 comprises a self-contained ventilation system to evacuate noxious gases from the bowl 14 . In the illustrated embodiment, the self-contained ventilation system can be automatically activated when a user of the toilet 10 is seated on the toilet seat 38 , but alternative activation systems are contemplated, such as a manual on/off switch connected to the toilet 10 . The toilet 10 comprises an exhaust blower 98 housed in the pedestal base 18 (or alternatively mounted outside the pedestal base). The exhaust blower 98 is electrically connected to a low-voltage source of electrical power. In one example, the low-voltage source of electrical power comprises a rechargeable battery 102 (e.g., 12 volts) that can be also housed in the pedestal base 18 . The battery 102 can be removable for recharging and/or can be adapted to be recharged by selectively connecting the pedestal base 18 to a source of electrical power. In another example, the toilet 10 comprises a DC power supply 106 (alone or in combination with the battery) that is connected to a conventional wall outlet for input of AC electrical power and output of DC electrical power, e.g., 9 to 12 volts DC to the exhaust blower 98 . In either case, when the exhaust blower 98 is activated, it draws air and other gases into its blower inlet 110 and exhausts same through its blower outlet 114 .
[0024] According to the present development, the blower inlet 110 is in communication with the interior of the bowl 14 (i.e., generally the space in the bowl 14 between the top of the rim 46 (above) and any water or other contents of the bowl (below), and the blower outlet 114 is in communication with the drain conduit 22 downstream from the trap 34 (i.e., at a location in the drain conduit 22 preferably between the trap 34 and stack outlet 30 where gases flowing into the drain conduit 22 from the blower outlet 114 will not be able to flow back to the bowl 14 via the drain conduit 22 ). In one embodiment as shown in FIG. 2A , a nozzle 122 is connected to the rim 46 and is located in the bowl 14 between the top of the rim 46 and the contents of the bowl 14 . The nozzle 122 is in communication with the blower inlet 110 through a hose or other conduit/path 126 such that noxious fumes and odors F are drawn from the bowl 14 into the nozzle 122 and flow to the blower inlet 110 and then to the blower outlet 114 when the exhaust blower 98 is active. In another embodiment as shown in FIG. 2 , the blower inlet 110 is in communication with the rim conduit 62 (directly or via the neck conduit 52 ). In such case, the blower inlet 110 is in communication with the interior of the bowl 14 through a rim conduit hose 127 and the rim conduit apertures 66 such that noxious fumes and odors F are drawn from the bowl 14 into the apertures 66 and rim conduit 62 (and optionally also the neck conduit 52 depending upon the location where the blower inlet 110 is connected to the rim conduit 62 and/or neck conduit 52 ) and flow to the blower inlet 110 and then to the blower outlet 114 when the exhaust blower 98 is active.
[0025] During periods when the exhaust blower 98 is inactive, to prevent noxious sewer gases from flowing upstream from the drain stack and drain conduit 22 into the blower outlet 114 , through the exhaust blower 98 and into the bowl 14 by way of the blower inlet 110 , the toilet 10 further comprises a check valve 130 located between the blower outlet 114 and the drain conduit 22 . The check valve 130 is spring biased to its closed position and, when closed, blocks flow of sewer gases from the drain conduit 22 to the blower outlet 114 . When the exhaust blower 98 is activated, pressure at the blower outlet 114 opens the check valve 130 such that air and odors can flow from the blower outlet 114 into the drain conduit 22 . In one example, the check valve 130 opens in response to a predeterminable pounds per square inch (PSI) of air pressure. When the blower 98 is deactivated, the check valve 130 automatically returns to its normally closed condition.
[0026] The exhaust blower 98 can be connected to a toggle switch or other manually activated switch 138 located on the toilet or elsewhere. It is preferred, however, that the exhaust blower 98 be automatically activated when a user is seated on the toilet seat 38 . As such, the toilet comprises at least one and preferably first and second seat switches 134 , 136 (see also FIG. 5 ) that are connected to the rim 46 and that are located between the rim 46 and toilet seat 38 . If multiple switches are used, they are preferably located on opposite lateral sides of the bowl 14 or are otherwise distributed about the rim 46 . The switches 134 , 136 are adapted to be activated (closed) by pressure upon a user being seated on the toilet seat 38 . The seat switches 134 , 136 are preferably spring-loaded and are deactivated (opened) when the user is unseated from the toilet seat 38 . The exhaust blower 98 is activated when at least one of the seat switches 134 , 136 is closed, and is deactivated when both seat switches 134 , 136 are opened. Alternatively, the toilet 10 can comprise one or more contact or non-contact sensors that are activated by the presence of a user near the toilet and/or seated on the toilet seat 38 , such that the exhaust blower 98 is activated only when the sensors are activated.
[0027] The exhaust blower 98 is preferably water-compatible and/or submersible such that it is capable of drawing water into the blower inlet 110 and exhausting same via blower outlet 114 . Nonetheless, for the embodiment of FIG. 2 (where the blower inlet 110 is in communication with the neck conduit 52 and rim conduit 62 ), it has been deemed desirable to deactivate the exhaust blower 98 during a flush of the toilet 10 , to minimize noise and the possibility of drawing water from the rim conduit 62 into the blower inlet 110 . In such embodiment, the toilet 10 comprises a cut-off switch for deactivating the exhaust blower 98 during a flush. For example, as shown, the toilet 10 comprises a float switch 140 ( FIGS. 4 and 5 ) that is deactivated (opened) when the float 94 drops during a flush and that is activated (closed) when the float 94 is elevated when the level of water 58 in the tank 54 rises (which indicates that the flush valve 74 is closed and the flush has ended). When the float switch 140 is opened during a flush, electrical power to the exhaust blower 98 is interrupted and the exhaust blower 98 is temporarily deactivated, until the float switch 140 closes when the tank 54 is sufficiently re-filled.
[0028] As shown in FIG. 1 , the blower inlet 110 can be directly connected to the rim conduit and/or neck conduit 52 through a hose or other path, e.g., through a conduit defined in the porcelain or other material from which the pedestal 18 and/or bowl 14 are defined/fabricated. Alternatively, as shown in FIGS. 4 and 5 , the blower inlet 110 is connected through a hose or other conduit 144 to an open upper portion of an overflow tube 148 that is located in the tank 54 . Unlike a conventional overflow tube, the overflow tube 148 includes first and second openings 150 , 152 , one of which 150 functions as a conventional overflow tube opening (to drain excess water 58 from the tank 54 around the flush valve 74 to the neck conduit 52 ) and the other of which 152 is connected to the blower inlet 110 through the hose or other conduit 144 (shown in broken lines). Because the overflow tube 148 is in communication with the neck conduit 52 , the blower inlet 110 will also be in communication with the neck conduit 52 and rim conduit 62 and rim conduit apertures 66 .
[0029] As noted above, any hose or other conduit or path or part thereof referred to herein can be defined as an integral and/or one-piece construction with the bowl 14 and/or pedestal 18 and/or tank 54 of the toilet, i.e., the conduit or path can be defined entirely or partly by an opening defined in the toilet 10 , itself, and need not be a separate hose, pipe, etc.
[0030] FIG. 5 shows one example of a suitable electrical circuit for the toilet 10 . The battery and/or power supply 102 , 106 is connected to a relay 156 that is connected to the exhaust blower 98 and that selectively supplies electrical power to the exhaust blower 98 . In particular, the relay 156 supplies electrical power to the exhaust blower 98 only when the float switch (if present) is closed and when at least one of the seat switches 134 , 136 (or the single seat switch if only one is used) is closed. The switches 134 , 136 , 138 , 140 can be in a low voltage/amperage path (e.g., at or below a predeterminable limit (volts, amps, etc.) to maximize their life and prevent burn-out of same as could would occur without the relay.
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The present disclosure further provides a toilet for exhausting odorous air therefrom, comprising a bowl, a trap, a housing, a self-contained ventilation system, a water tank, and a water supply line. The bowl has a rim therearound wherein the bowl communicates with the rim. The main trap is contained in the bowl wherein the trap is for communicating the contents in the bowl with a drain conduit so as to provide a passageway from the bowl to a drain stack. The ventilation system includes an exhaust blower having a blower inlet and a blower outlet. The blower inlet is in communication with air space between the contents in the bowl and the rim. The blower outlet is in communication with the drain conduit downstream from the trap. The exhaust blower including a cut-off switch for deactivating the exhaust blower during a flush.
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[0001] This is a continuation of application Ser. No. 11/280,948 filed Nov. 16, 2005. That application was related to and claimed priority to U.S. Provisional Patent application No. 60/629,024 filed Nov. 18, 2004. Application Ser. Nos. 11/280,948 and 60/629,024 are hereby incorporated by reference.
BACKGROUND
[0002] 1. Field of the Invention
[0003] The present invention relates generally to the field of drywall construction and installation and more particularly to an edge clip to capture and hold adjoining edges of sheet rock or drywall.
[0004] 2. Description of the Prior Art
[0005] Non-Horizontal, or vaulted, ceilings are common in all construction. Also, building framing many times settles with time after construction due to shrinkage or expansion of framing materials or their foundations, particularly in wood framed structures. It is common to hang sheet rock and to tape the joints before a frame has settled. This causes the taped joints between adjoining sheets of sheet rock to be damaged (pop, delaminate, etc.). This damage has to be fixed. This is particularly evident and common at the apex of vaulted or non-horizontal ceilings. When a frame settles, the angle between sheets can change and/or the sheets can move relative to one another.
[0006] It would be advantageous to have a clip the would capture and hold adjoining edges of sheet rock or drywall.
SUMMARY OF THE INVENTION
[0007] The present invention relates to a drywall edge clip that holds drywall edge joints together that has an elongated top member, a stem attached to the top member at a proximal end, the stem being approximately perpendicular to the top member, and a pair of tabs attached to a distal end of the stem, the tabs being of approximately equal length having a hinge between them so that they can take any angle between being parallel to the top member to being perpendicular to it. The device can be metal or plastic or any other rigid or semi-rigid material. An embodiment of the invention can have serrations along the length of the stem to act as a wire-tie, where the tabs slide along the serrated stem with a locking device that only allows the tabs to move toward the top member (being tightened). In this embodiment, the unused tail of the stem can be broken off using a side to side movement. This breaking process can be facilitated by having additional serrations on the side of the stem.
DESCRIPTION OF THE FIGURES
[0008] FIGS. 1A , 1 B and 1 C show an embodiment of the edge clip of the present invention.
[0009] FIG. 2 shows embodiments of the present invention installed in a vaulted ceiling.
[0010] FIG. 3 shows embodiments of the present invention installed in a conventional vertical wall seam.
[0011] FIG. 4A shows a first enlarged edge view of a typical vaulted ceiling.
[0012] FIG. 4B shows a second enlarged view of a typical vaulted ceiling.
[0013] FIGS. 5A-5C show an alternative embodiment of the present invention.
[0014] FIGS. 6A-6C show a wire-tie embodiment of the present invention.
[0015] Several drawings and illustrations have been presented to aid in the understanding of the present invention. The scope of present invention is not limited to what is shown in the figures.
DESCRIPTION OF THE INVENTION
[0016] The present invention is related to a specially designed clip to capture and hold adjoining edges of sheet rock (drywall), particularly at the apex, or top joint of a vaulted ceiling. The adjoining sheets of sheet rock may not be screwed to the frame along the edge of each adjoining sheet that form the joint between sheets at the apex of the vaulted, or angled, ceiling. The clips of the present invention can be put in place to capture adjoining edges of each sheet and hold them relative to one another. With the edge of the sheet at the apex of the ceiling free of the frame and joined to the adjacent sheet at the apex joint, the two adjoining edges can be held together relative to one another and stay together even if frame settling occurs. Also, because the edges are normally held firmly together at the apex they will not be able to droop or sag. Being mutually attached the edges will mutually support each other in a manner similar to how an arch supports itself. The remainder of the sheet can be attached to the building frame as is currently specified. The numbers of nails or screws and their location will need to be determined to completely support the sheet while allowing the apex joint to move free of the building frame.
[0017] FIG. 1A shows a front view of a first embodiment of the edge clip of the present invention. Flexible tabs 1 can be molded plastic, spring steel, or other flexible material that can be deflected without permanent deformation, an elastic material with memory. In this case the flexible tabs 1 can be temporarily bent by hand in the direction of the arrows and will be inclined to return to their original shape. The stem 2 connects the flexible tabs 1 to the cross member 3 .
[0018] The tabs 1 can angle downward and outward and can bend on a hinge 10 that allows insertion between drywall sheets. The hinge 20 is optional; the present invention can be made without any hinge. After insertion, the stem 2 runs through the seam with the back 3 pulling against the tabs 1 to hold the seem together. The optional hinge 10 can be made in the tabs by placing a slot or groove between the tabs.
[0019] FIG. 1B shows a side view of the edge clip of FIG. 1A as projected from the right side of FIG. 1A . Again the flexible tabs 1 , the stem 2 and the cross member 3 can be seen.
[0020] FIG. 1C shows a isometric view of the edge clip of FIG. 1A . In this view you can see the flexible tabs 1 are shown deflected as they might be during a normal installation. Also shown are the stem 2 and the cross member 3 .
[0021] FIG. 2 shows a typical room vaulted ceiling arrangement viewed from above the ceiling as though the roof was removed and one could see the top side of a room ceiling. The rafters 4 are shown coming to an apex forming the raised (or vaulted) ceiling. Sheet rock 5 is shown as it would normally be screwed to the rafters 4 . At the apex 6 of the ceiling, where the two edges of the sheet rock 5 meet, one can see that the cross member 3 of the edge clips as they would be installed.
[0022] FIG. 3 shows a typical room vaulted ceiling arrangement viewed from inside of the room looking up at the ceiling. No walls are shown in this view and therefore one can still see the rafters 4 . The sheet rock 5 can be seen as it would normally be screwed to the rafters 4 . The screws 7 can be seen in a typical pattern used to attach the sheet rock 5 to the rafters 4 except that the screws 7 have not been installed at the apex 6 of the ceiling where the sheet rock 5 edges meet. This is done so as the wood the rafters 4 shrinks or settles the two edges of the sheet rock 5 that meet at the apex 6 will be held together relative to one another by the edge clip cross member 3 , not shown, and the edge clip flexible tabs 1 , which can be seen in this view. This keeps the drywall corner finishing material from delaminating, peeling or otherwise loosing its bond to the drywall.
[0023] FIG. 4A shows a edge on view of a typical vaulted ceiling arrangement blown up so the details of how the edge clip flexible tabs 1 , stem 2 , and cross member 3 capture the edge of the sheet rock 5 at the apex 6 of the ceiling. The rafters 4 can also be seen. One of the rafters 4 has been hidden so the complete edge clip can be seen. The flexible tabs 1 normally try to return to their original shape and so push against the sheet rock 5 which causes the sheet rock 5 to be captured between the flexible tabs 1 and the cross member 3 .
[0024] FIG. 4B shows a edge on view of a typical vaulted ceiling arrangement blown up so the details of how the edge clip flexible tabs 1 , stem 2 , and cross member 3 hold the matching edges of the sheet rock 5 at the apex 6 after the wood rafters 4 have shrunk or settled. As the wood rafters 4 shrink the angle formed at the apex 6 increases causing the edges of the sheet rock 5 at the apex 6 to move away from one another. This typically causes the finishing tape to delaminate or peel away from the sheet rock 5 since it is typically screwed to the rafters 4 . Using the edge clip rather than screws to secure the sheet rock 5 edge at the apex 6 of the rafters 4 allows the sheet rock 5 to flex away from the rafter 4 . This view shows the drywall screws 7 set back from the apex 6 an appropriate distance to allow the sheet rock 5 to flex. This keeps the finished corner from intact and structurally sound even if after the rafters 4 shrink or settle.
[0025] FIGS. 5A-5C show an embodiment of the present invention similar to the edge clip shown in FIG. 1A-1C except it may be made of metal components. Features and usage of this embodiment are similar to those of previously described embodiments.
[0026] FIGS. 6A-6C show a zip-tie embodiment of the present invention. In this embodiment, the stem of the clip can be serrated in the same manner as a plastic cable tie. Tabs 1 can slide along the stem 2 of the device to pull the edges of the sheet rock together. The edge clip of this embodiment can be zipped tight since the serrations do not allow motion of the tabs 1 in a direction that would loosen the seam. When the desired tightness is reached, the remaining tail of the clip can be broken off by moving it in the direction of the arrows 9 in FIG. 6A . The breaking off of the tail can be facilitated by having addition serrations on the side of the stem. This process is further described in our related U.S. patent application Ser. No. 11/070,825 filed Mar. 1, 2005. Application Ser. No. 11/070,825 is hereby incorporated by reference.
[0027] Several descriptions and illustrations have been provided to better aid in the understanding of the present invention. One skilled in the art will understand that many changes and variations are possible without departing from the spirit of the invention. Each of these changes and variations is within the scope of the present invention.
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A drywall or sheet rock edge clip device that can hold joints of drywall together at the apex of vaulted ceilings or at any other drywall seam at any angle. The device can include tabs and a head or cross member coupled by a stem that fits through the seam or joint and pulls and holds it together. A wire-tie version of the invention can have serrations along the stem and pull up and tighten like a wire-tie. The unused tail section can be broken off by bending it from side to side.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part of copending U.S. patent application Ser. No. 09/307,056, filed on May 7, 1999, to Epstein et al, now issued U.S. Pat. No. 6,475,183, the subject matter of which is hereby incorporated by reference. This application discloses subject matter related to our U.S. patent application Ser. No. 08/838,078, now issued U.S. Pat. No., 6,331,172, and Ser. No. 08/839,614, now issued U.S. Pat. No. 5,971,956, both filed Apr. 14, 1997, to patent application Ser. No. 08/946,364 filed Oct. 7, 1997, now issued U.S. Pat. No. 6,007,515, and to patent application Ser. No. 09/037,160 filed Mar. 9, 1998, now issued U.S. Pat. No. 6,063,055, all naming Gordon H. Epstein as first inventor. The disclosures of the aforementioned United States patent applications, “the above applications” are hereby incorporated herein by reference thereto.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a filling device for an applicator which applies multiple fluid sealant components to a work surface and is particularly, although not exclusively, useful for applying tissue sealant components to biological tissue to effect hemostasis or achieve other therapeutic results. More particularly, it relates to a dual compartment enclosed direct filling device for a hand-held applicator.
2. Description of Related Art Including Information Disclosed under 37 CFR 1.97 and 37 CFR 1.98
Use of tissue sealants and other biological materials is an important emerging surgical technique, well adapted for the operating room or field environments such as the doctor's office or mobile medical units. Preferred sealants include fibrin sealants which are formed from blood plasma components and comprise, on the one hand, a first component containing fibrinogen and Factor XIII and on the other hand a second component which usually includes thrombin, and calcium ions. The fibrinogen is capable of a polymerizing and being cross-linked to form a solid fibrin clot when the components are mixed. The necessary additional factors to simulate relevant portions of the natural blood coagulation cascade are suitably distributed between the fibrinogen and thrombin components.
Antanavich et al. U.S. Pat. No. 5,585,007, whose disclosure and references are hereby incorporated herein by reference thereto, provides an extensive discussion of the literature relating to fibrinogen sealant preparation (column 1, line 20 to column 4, line 62) and applicators column 4 line 62 to column 5, line 14), as well as a bibliography, (columns 6–10) and is a helpful guide to the teachings of prior workers in the field.
Depending upon the potency of the particular formulations employed, coagulation of the sealant may take place very rapidly, yielding a gel within perhaps 10 or 20 seconds. Though often very desirable for surgical reasons, such fast-acting properties present potential problems of fouling or clogging. These problems must be overcome in devising suitable applicators, methods of application and devices suitable for filling said applicators.
A popular manually operable applicator for such two-component sealants employs a dual syringe construction wherein two syringes, connected by a yoke, each provide a reservoir for one of the components. In most prior devices, the sealant components are discharged in separate streams and mixed externally of the applicator. Such applicators are similar in principle to household epoxy glue applicators commonly available in hardware stores.
Until May of 1998, when the FDA first approved such products, fibrin sealant was not commercially available in the US, therefore use of fibrin sealant was limited to supplies produced within the clinic, which are not subject to FDA control.
Current methods of filling biological glue applicators can be complicated and time consuming. As taught in Epstein U.S. Pat. No. 5,266,877 and in our assignee's international application PCT/US98/07846, components of the sealant can be placed in separate compartments in a flat filler tray for transfer to an applicator. Though useful as a device to permit rapid and reliable filling of a dual syringe applicator at the point of use, such filler trays are not suitable for external storage of the sealant components. This process can be time consuming and it requires a significant degree of care to efficiently transfer the sealant to the applicator. Also, a small amount of sealant will be left in the tray, and it is thus wasted. Furthermore the transfer of sealant components to multiple storage containers raises the likelihood in which the sealants will gather bio-burden, and bacteria, which can threaten the sterility of the sealant.
After FDA approval, however, fibrin sealant is now commercially available in the US. This availability has created a need for an effective and efficient device useful for transferring the components of the sealant, from commercially available or standardized, bottle-like storage containers, into an applicator.
There is accordingly a need for a device which can effectively deliver, in a sterile environment, multiple sealant components directly from their storage containers to an applicator.
SUMMARY OF THE INVENTION
The present invention solves the problem of effectively delivering multiple sealant components directly from commercially available or standardized storage containers, for example, bottles, to an applicator while allowing the use of the entire fill device within a sterile field.
In one aspect, the invention provides a direct dual filling device for the multiple sealant components of a liquid sealant, at least two of said components being complementary one to the other and polymerize when mixed, the direct filling device comprising a body having a plurality of inlet ports connected to drawing tubes which pierce the protective covering of commercially available bottles, the bottles containing the sealant components. The device also having a hood which snaps onto a base thereby enclosing the bottles. within the structure, allowing the device to be brought into a sterile field. The base having slanted bottle supports which hold the bottles in a tilted position. This feature allows the drawing tubes to extract virtually all of the fluid contained within the bottles. The device can be attached to an applicator with keying such that when the plunger of the applicator is retracted, fluid is drawn from each respective bottle to the proper reservoir contained within the applicator. Applications are disclosed for use with single vials.
The invention enables multiple sealant components to be directly delivered from their commercially available containers into an applicator without significant risk of contamination of the sealant components, and with minimal wasting of the sealant components. The different sealant components are delivered directly from their containers into separate individual reservoirs, thereby preventing coagulation of the sealant components. Once the hood of the device is guided onto the bottles and snapped onto the base, the entire device can be brought into the sterile environment.
BRIEF DESCRIPTION OF THE DRAWINGS
One way of carrying out the invention is described in detail below with reference to the drawings which illustrate one or more specific embodiments of the invention and in which:
FIG. 1 is a side elevational view of a direct dual filling device connected to an applicator according to the present invention;
FIG. 2 is an enlarged side elevational view of the present invention;
FIG. 3 is a view of the present invention along section lines 3 — 3 of FIG. 2 ;
FIG. 3A is a view similar to FIG. 3 showing an alternate embodiment wherein the hood includes a locking member which comprises an o-ring.
FIG. 4 is a top view of the present invention;
FIG. 5 is a perspective view of the present invention;
FIG. 6 is a perspective view of a direct dual filling device connected to an applicator according to an alternative embodiment of the present invention;
FIG. 7 is an exploded view of an alternative embodiment of the present invention;
FIG. 8 is an elevational section view of an alternative embodiment of the present invention;
FIG. 9 is an elevational view of an alternative embodiment of the present invention;
FIG. 10 is an elevational view of an alternative embodiment of the present invention;
FIG. 10 a is a partial elevational view depicting the vial support;
FIG. 11 is an elevational view of an alternative embodiment of the present invention;
FIG. 12 is a cut away view showing the hood being lowered onto the base during assembly;
FIG. 13 is a cut away view showing the drawing tube held in place by the guide
FIG. 14 is an exploded view showing an alternative embodiment of the hood;
FIG. 15 is an elevational section view of the embodiment shown in FIG. 14 ;
FIG. 16 is a cut away view showing the hood of the embodiment shown in FIG. 14 being lowered onto the base during assembly;
FIG. 17 is a partial cross-sectional view of the embodiment shown in FIG. 14 ;
FIG. 18 is a frontal view showing a cover of an alternative embodiment of the invention for use with a single vial;
FIG. 19 is a frontal view showing the vial of the embodiment shown in FIG. 18 ;
FIG. 20 is a frontal view showing the base of the embodiment shown in FIG. 18 ;
FIG. 21 is a frontal view showing the assembled system of the embodiment shown in FIG. 18 before engagement;
FIG. 22 is a frontal view showing the assembled system of the embodiment shown in FIG. 18 after engagement;
FIG. 22A is an enlarged side elevational view of the embodiment shown in FIG. 22 , with portions of the device cut away.
FIG. 23 is a frontal view showing the assembled system without the cover of an alternative embodiment of a single vial system of the invention;
FIG. 24 is a frontal view showing the system with the cover of the embodiment shown in FIG. 23 ;
FIG. 25 is a frontal view showing the assembled system of an alternative embodiment of a single vial system of the invention;
FIG. 26 is a frontal view showing a detailed view of the cover and needle assembly of the embodiment shown in FIG. 25 ; and
FIG. 27 is a frontal view showing the assembled system of an alternative embodiment of a single vial system of the invention;
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIGS. 1 and 2 of the drawings, the direct dual filling device 10 comprises a body 12 , a hood 14 and a collar 16 which is adapted to fit an applicator 18 . The inventive device is preferably constructed out of a clear thermoplastic material such as polycarbonate, polystyrene, polypropylene, polytetrafluoroethylene, acrylonitrile butadiene-styrene or acrylic, however any suitable material may be used.
Applicator 18 preferably has at least two fluid reservoirs for separately holding and controllably dispensing reactable fluids, each of the fluid reservoirs being connected to a syringe by a fluid conduit. The applicator is of the type primarily used for applying multiple fluid sealant components to biological tissue to effect hemostasis or achieve other therapeutic results.
However the inventive filling device can be adapted to fit applicators having a wide variety of uses which require the direct filling of fluids into separate reservoirs located within an applicator.
Located within body 12 are inlet ports 20 and 21 which are adapted to receive syringes 22 and 23 of applicator 18 . Rubber O-rings 34 and 35 are positioned within inlet ports 20 and 21 respectively, such that an air tight seal is formed. Inlet ports 20 and 21 are connected to drawing tubes 24 and 25 by transverse channels 26 and 27 respectively, which drawing tubes 24 and 25 extend into bottles 28 and 29 .
Drawing tubes 24 and 25 should have sufficient length to extract substantially all the liquid contained within the bottle, or conversely they should have a length such that when the system is inverted substantially all of the liquid can be extracted. Drawing tubes 24 and 25 are preferably configured with pointed ends 30 and 31 which have the ability to pierce the protective packaging found on standard medical fluid bottles 28 and 29 and form a seal. Drawing tubes 24 and 25 are preferably formed out of a metallic material, however any suitable material such as thermoplastic may be used. The tubes can also have the ability to be removed from support sleeves 32 and 33 for replacement.
Channel 26 allows the fluid contained within right bottle 28 to be drawn through tube 24 and into syringe 22 for deposit within the proper receptacle located within applicator 18 without coming into contact with the fluid contained within bottle 29 . Similarly, channel 27 allows the fluid contained within left bottle 29 to be drawn through tube 25 and into syringe 23 for deposit within the proper receptacle located within applicator 18 without coming into contact with the fluid contained within bottle 28 . This allows the simultaneous filling of both sides of the applicator directly from the commercially available containers. Channels 26 and 27 can be formed out of thermoplastic tubing or molded directly into body 12 of the direct filling device 10 .
In order to fill applicator 18 directly from bottles 28 and 29 , hood 14 is placed over said bottles such that pointed tips 30 and 31 are approximately centered on the protective seal covering the bottles. The contoured shape of hood 14 guides the inventive device as the bottles are seated and snap into place within hood 14 by locking members 40 . As clearly shown in FIG. 3 , locking members 40 are located within hood 14 such that they move apart when cap 42 of its respective bottle passes by during the insertion of the bottle, then once the bottle has reached the proper location locking members 40 retract under bottle cap 42 to lock or “seat” the bottles in place. Once the bottles have been seated the system may be inverted to ensure that all of the fluid is draw out of the bottles. In FIG. 3A , an alternate locking member 40 A is illustrated showing the locking members comprising an o-ring which extends radially inward from the hood.
The plunger 19 of applicator 18 is then retracted thereby drawing the fluid contained within bottles 28 and 29 through their respective drawing tubes and channels into the syringes of applicator 18 for deposit within a reservoir.
The direct filling device 10 , as shown in FIG. 4 , is connected to applicator 18 by a pair of snap fit members 36 . Applicator 18 is placed over the filling device such that the syringes are approximately centered over inlet ports 22 and 23 , then pressed down until locked in place by snap fit members 36 . The novel shaping of the collar 16 allows filling device 10 to mate with applicator 18 in only one orientation, thereby “keying” the fill device to the applicator. The general pentagon shape precisely fits to the applicator body in the same manner as interchangeable applicator tips or heads, which are used for droplet or spray dispensing of sealant. This feature of keying the filling device collar to the applicator ensures the proper fibrin components are delivered to their respective reservoirs without significant risk of cross-contamination, particularly when refilling. The agent bottles can only fit into the fill device hood 14 one way and the applicator can
As depicted in FIG. 5 , bottle 29 is inserted into hood 14 until seated by locking members 40 . As can be clearly seen, hood 14 has a recess 44 which aides the user in removal of the bottles. Recess 44 is also useful, if hood 14 is opaque, to view any labels present on the bottle so it can be verified that the proper components are delivered into the proper reservoirs. Also shown is the contoured shape of hood 14 . The shape can be varied to allow use of different types and shapes of bottles. The hood can also be modified so that each side allows insertion of a different shaped bottle, thereby keying the bottles to the fill device. This in conjunction with the novel shape of the collar is important in ensuring that the proper components are delivered to the proper reservoirs within the applicator.
The direct dual filling device embodiment shown in FIGS. 6–11 is a more detailed embodiment of the invention which includes most of the features shown in the embodiment of FIGS. 1–5 and is suitable for manufacturing from injected molded plastics components. As will be described, several of the parts of the direct dual filling device shown in FIGS. 6–11 embody similar construction and functionality to the components of the embodiment shown in FIGS. 1–5 .
Many individual structural features of the components of the direct dual filling device can be seen from the exploded view of FIG. 7 , while FIGS. 8–13 show additional structural features and relationships of the internal components and FIG. 6 shows the overall external appearance of the direct tool filling device while in use.
Referring to FIG. 7 , the direct dual filling device 100 , shown in exploded view, comprises a hood 102 , having a first half 104 and a second half 106 , a pair of drawing tubes 108 and 110 , a pair of fluid conduits 112 and 114 , and a base 116 . First-half 104 and second half 102 , of hood 102 have a pair of drawing tube guides 118 and 120 , and a pair of recesses 122 and 124 . Base 116 has a pair of vial supports 126 and 128 which are configured to support vials 130 and 132 . Additionally, each of the vial supports 126 and 128 have a vial support surface 134 .
Hood 102 can be contoured to resemble the shape of the filling device when assembled with agent vials. The shape can also vary to allow use of different types and shapes of bottles. The hood can be modified so that each side allows insertion of a different shaped bottle, thereby keying the bottles to the fill device. This in conjunction with the novel shape of the collar is important in ensuring that the proper components are delivered to the proper reservoirs within the applicator.
In preferred embodiments, hood 102 and base 116 are essentially rigid, injected molded components having limited resilience in their thinner sections. Hood 102 is also preferably formed from a clear plastic such as polycarbonate or SAN. In contrast, fluid conduits 112 and 114 are preferably fabricated from a distinctly elastomeric, resilient molding material such as silicone rubber.
Once assembled hood 102 is configured to snap into the base by use of snap fit members 111 . Hood 102 and base 116 are configured such that they may only be assembled in one direction, so in use, the operator cannot assemble the device incorrectly. Base 116 and hood 102 are also color-coded to indicate which side is for the thrombin vial in which side is for the fibrinogen vial. Furthermore, base 116 is labeled with a “T” indicating the side for thrombin, and an “F” indicating the side for fibrinogen once hood 102 is snapped onto base 116 , bottles 108 and 110 can be brought into the sterile field.
When assembled, the upper portions of first-half 104 and second half 106 combine to form a collar 136 , embodying features of collar 16 . A pair of channels 137 having inlet ports 140 and 142 are also defined within hood 102 . Channels 137 are configured to retain fluid conduits 112 and 114 .
Fluid conduits 112 and 114 comprise a cylindrical cup 144 and a tubular arm 146 , which fits suitably within channel 137 . Cups 144 are internally configured to be pressed into tight sealing engagement, when so mounted to syringes 22 and 23 of applicator 18 , with the ends of sealant components syringes mounted in a mating applicator body, to receive liquid components therefrom. Tubular arms 146 of fluid conduits 112 and 114 are flexible and can readily be manipulated during assembling of filling device 102 . The ends of tubular arms 146 are configured to be fitted with the ends of drawing tubes 108 and 110 respectively. This configuration allows liquid components to be drawn through tube 108 into fluid conduit 112 and stored within the respective reservoir located within applicator 18 . Similarly, liquid component may be drawn through tube 110 into fluid conduit 114 and stored within the other reservoir located within applicator 18 without significant risk of contamination. When assembled, the filling device provides an airtight interface from the drawing tubes to the applicator reservoir.
Drawing tubes 108 and 110 should have sufficient length to extract substantially all the liquid contained within the corresponding vial. Drawing tubes 108 and 110 are preferably configured with a pointed end which has the ability to pierce the protective seal found on standard medical fluid bottles thereby forming a seal. Drawing tubes 108 and 110 generally resemble a needle, and are preferably formed out of a metallic material, however any suitable material such as thermoplastic may be used. Both of the tubes may be of similar diameter, however the tube diameter may differ to accommodate liquids having differing viscosities.
Drawing tube guides 118 and 120 are hinged within recesses 122 and 124 so that they may be housed within the recesses when the filling device used in use. FIG. 13 illustrates the manner in which drawing to 108 is held in place by drawing tube guides 118 . Each of the guides has a forked end 119 which when used in conjunction with one another will hold drawing tube 118 in a vertical position. Recesses 122 and 124 should be of suitable size to allow for variations in the position of the guide, when it is being stored.
Collar 136 is connected to an applicator 18 by a pair of snap fit members 138 . Applicator 18 is placed over direct dual filling device 100 such that the syringes of applicator 18 are approximately centered over inlet ports 140 and 142 , then pressed down until in place by snap fit members 138 . Alternatively, collar 136 may be configured without snap fit members 138 . Due to the stability of the device when assembled, applicator 18 can be held in place by a combination of gravity and the friction generated by the tight nature of the seal formed between the syringes and the fluid conduits. The novel shaping of collar 136 allows direct dual filling device 100 to mate with applicator 18 in only one orientation, thereby “keying” the fill device to the applicator. The general pentagon shape precisely fits the applicator body in the same manner as interchangeable applicator tips or heads, which are used for droplet or spray dispensing of sealant. This feature of keying the filling device collar to the applicator insures the proper fibrin components are delivered to their respective reservoirs without significant risk of cross-contamination, and the resulting loss of materials caused by the cross-contamination.
As shown in FIG. 8 , first-half 104 of hood 102 has a central divider 148 which divides the hood into two compartments 150 and 152 , which when hood 102 is assembled, house vials 130 and 132 respectively. Compartment 150 has an upper surface 154 which is slanted from its lowest point at divider 148 to its highest point at outer wall 156 . Similarly, compartment 152 has an upper surface and 158 which is slanted from its lowest point at divider 148 to its highest point at outer wall 160 .
Vial supports 126 and 128 are separated by divider slot 162 which is configured to receive central divider 148 of hood 102 . Vial support surface 134 has a slanted outer portion 164 , a level central portion 166 , and an inner slanted U-shaped surface 168 . The angle at which the inner and outer portions of vial support surface 134 is constructed, is substantially parallel to slanted upper surface 154 and 158 of hood 102 . Vial support surface 134 has a width which allows vials 130 and 132 to be suspended by their necks as shown in FIG. 8 .
The assembly of the components of filling device 100 can take place at a factory or other such manufacturing facility prior to use of the inventive device. Drawing tubes 108 and 110 are mated with tubular arms 146 of fluid conduits 112 and 114 . The assembly is then snugly fitted within channel 137 such that drawing tubes 108 and 110 all are held by guides 118 and 120 respectively. Preferably, one half of channel 137 is of sufficient proportion to accommodate a greater portion of fluid conduits 112 and 114 . This allows the fluid conduits to be placed within the larger channel prior to be two halves being assembled, thereby allowing for greater restraint of the conduits prior to assembling the two halves of hood 102 .
Once the drawing tubes and fluid conduits are in place, first-half 104 and second-half 106 , of hood 102 are configured to be assembled together by snap fit members 105 . Alternatively, ultrasonic welding, glue, press fitting or any other method of assembly may be used. All of the components of the inventive device are then sterilized. When it is desired to use the inventive filling device the operator need only insert the vials and mate the hood onto the base.
Generally, the agent vials are not sterilized and are unable to be brought into a sterile environment without risk of contamination. However, when the agent vials are shrouded within the inventive filling device the assembly may be brought into a sterile environment for use.
The operator assembles the device by sliding the agent vials onto vial supports 126 and 128 such that the necks of the two agent vials are resting on vial support surface 134 . The angle at which the outer portion 164 of vial support surface 134 is configured, will cause the two agent vials to slide down into place resting on level central portion 166 of vial support surface 134 . The angle is such that friction will not stop the bottle from fully seating on level central portion 166 . As shown and FIG. 10 a vial 130 is properly seated within vial support 126 when the center line 180 of vial 130 is positioned at a point on level central portion 166 further out than pivot fulcrum 182 . Pivot fulcrum 182 occurs at the point where level portion 166 transforms into inner support surface 168 . This positioning allows vial 130 to be firmly held in place by support 126 , while still allowing vile 130 to pivot in the direction of arrow 184 . By allowing vial 130 to fully seat within vial support surface 134 , vial 130 will maintain a level position during the first part of the insertion of the drawing tube. This allows the needle to properly align with the target area of the vials septum. Since the vials septum has a thin portion in be center which allows needles to puncture, it is desirable to align the drawing tube with this target area, thereby assuring a good seal.
Once the vials are properly seated, the hood assembly is placed over the base assembly such that divider 148 is positioned to engage within divider slot 162 as shown in FIG. 9 . As the hood assembly is lowered onto the base in the direction of arrow 170 , divider 148 and divider slot 162 act to align drawing tubes 108 and 110 with the target area of agent vials 130 and 132 .
As the hood assembly is further lowered onto the base in the direction of arrow 170 , drawing tubes 108 and 110 puncture the septa of the agent vials creating an airtight interface. As indicated earlier the drawing tubes should be held vertical by their guides and the agent vials positioned correctly by the vial support face so that the drawing tubes puncture the target area of the septa.
As illustrated in FIG. 12 , when guides 118 and 120 come into contact with the top portion of agent vials 130 and 132 they all are folded up and out of the way into recesses 122 and 124 .
FIG. 10 depicts the point at which the top portion of vials 130 and 132 comes into contact with upper surfaces 154 and 158 . As the housing moves onto the base in the direction of arrow 170 , the slanted configuration of upper surface 154 causes agent vial 130 to tilt in the direction of arrow 172 . Similarly, the slanted configuration of upper surface 158 causes agent vial 132 to tilt in the direction of arrow 174 . The vials are tilted because the top slanted inner surface of the housing vial cavities are forced down onto the lid of each vial, causing them to tilt to the same angle as the top of the inner cavity.
Simultaneously with the tilting of agent viles 130 and 132 , drawing tubes 108 and 110 are driven into the bottom corner of their respective viles. Ideally, the sharpened tips of the drawing tubes are shaped such that they conform to the shape of the bottom corner of the agent vials so that as much fluid as possible is drawn up.
Once the hood assembly has been completely lowered onto the base into the fully engaged position of FIG. 11 , it may be locked into place by snap fittings 111 . Agent vials 130 and 132 are tilted in such a manner that drawing tubes 108 and 110 are forced into the bottom corner of each respective vial, which has now become the low point for the agent to pool into. This configuration along with the shaping of the drawing tubes allows for minimal waste of the agent contained within the vials.
Once the inventive filling device is assembled, it may be brought into a sterile field. Although, the agent vials are generally not sterile and therefore would not be allowed within a sterile environment for risk of contamination, the hood and base assembly has effectively shrouded the vials within a sterile environment so that they may be brought into a sterile field.
FIGS. 14–17 show an alternative embodiment of the inventive device. Referring to FIGS. 14 and 15 , hood 102 comprises compliant upper arms 103 and 107 which act as compliant tipping arms. Arms 103 and 107 are vertically positioned and have a resilient flexibility to engage and tip vials 130 and 132 as hood 102 is lowered before the needles bottom out on the vials' convexity and hold vials 130 and 132 in tilted position so as to optimize evacuation of the contents of vials 130 and 132 . Base 116 comprises modified vial supports 126 ′ and 128 ′ which are open on either side of vials 130 and 132 . Thus, a nurse or other user may load a device without touching the base thus avoiding contaminating the sterile field.
Referring to FIG. 16 which shows a view similar to that shown in FIG. 12 , hood 102 is provided internally with rounded jaws 131 and 133 (not shown) which firmly clasp the tops of vials 130 and 132 . Jaws 131 and 133 suspend vials 130 and 132 in carved rounded recesses 135 and 139 (not shown). The inside of the jaw has a part circular horizontal ledge where the bottle can sit vertically. Jaws 130 and 132 and recesses 135 and 139 maintain vials 130 and 132 in a vertical position prior to tilting as recesses 135 and 139 prevent tilting until the bottom of each vial is above the recesses. Arms 103 and 107 are vertically positioned and have a resilient flexibility to engage and tip vials 130 and 132 and the vials tilt after the hood clasps the bottoms of the vials. Base 116 is shaped to provide visual guides 117 and 121 to assist the user in visually matching the round and square portion of hood 102 and base 116 for alignment and proper orientation. Once assembled hood 102 is configured to snap into the base by use of snap fit members 111 .
When using the inline body, fibrinogen and thrombin typically take up only a small portion of the volume of the vial. With most of the vial being empty, depressurization is not a problem. Therefore, venting is not usually necessary. However, most medical personnel are used drawing out a desired volume of liquid from a vial by first injecting the same volume of sterile air into the vial. Then the syringe automatically withdraws the same amount of liquid volume to equalize the pressure in the vial. However such pressurization may cause problems in that fluids may back up into the needles prematurely. Additionally, this method also causes air bubbles and inaccurate dosages. Accordingly, venting is desirable to prevent such undesired pressurization and release unwanted air while maintaining the sterile field. To address this issue, an oversized piece of hypo tube can be used to provide a collar over the needle which has an inner diameter of 0.002 in greater than the outer diameter of the needle. When the needle pushes against the collar, it makes a gap allowing air to escape between the needle and collar. Alternatively as shown in FIG. 17 , a pair of dagger-like molded inserts 113 and 115 alongside each needle which is against drawing tubes 108 and 110 which allow air to escape within the sterile field. If desired inserts 113 and 115 may be provided with sharply pointed tips or cutting edges to create a hole alongside the needles which stays open after piercing. The hole allows air but not liquid to escape.
Although only two bottles are depicted for use with the inventive filling device, adaptation can be easily made to allow the use of three or more, which can directly fill three or more reservoirs contained within the applicator. This adaptation can be accomplished by expanding the hood and adding another inlet port, transverse channel and drawing tube.
During surgery, it is desirable to have access to variable doses of intravenous drugs. However, due to the limitations of the operating theater, syringes are often pre-filled in a separate room under a hood which maintains the sterile field. Current practice for dispensing local anesthetic or saline during surgery is to reach in and out of the sterile field to get more fluids or to dump the fluid into a sterile bowl inside the sterile field. This practice raises the risk of needle sticks, contamination or misuse of a non-labeled fluid in the sterile field.
Referring to FIGS. 18 to 22 , an alternative embodiment of the inventive device is shown in the form of a single vial, direct filling device 200 having a cover 210 which snaps onto a base 216 thereby enclosing the vial 214 within the structure, allowing device 200 to be brought into a sterile field. This device provides needleless filling of fluids from non-sterile vials inside the sterile field with reduced waste, while maintaining label visibility for application safety. The device consists of a base or bag, cover and a needle. With this device the vial is completely shrouded and can be moved into the sterile field. The device is for single use, but multiple fillings. It is understood that the system may come with a needle, tube, and/or other structures for mating with the syringe such as in accordance with one of the embodiments described above, with one example being shown in FIG. 22A which, where indicated, identifies similar structures with identical numbers as used with previous embodiments, or, alternatively, the syringe may be attached to a needle retracted within a protective cover so that the needle is only exposed within the sterile environment of the system.
Cover 210 has a hole 211 which receives needle 212 and has a tilted side portion 213 which accommodates vial 214 tilting. Base 216 has a curved notch 217 where the neck of vial 214 rests. Vial 214 may be any standard size vial which is used for intravenous medication. Vial 214 is loaded into the device and is suspended by its neck. This arrangement accommodates multiple vial sizes and tilting of vial 214 . FIG. 21 shows the assembled system 200 with vial 214 sitting in base 216 in vertical position. Rib 218 is tilted before engagement. FIG. 22 shows the device after it is fully assembled and with rib 218 fully engaged. Cover 210 has a feature that tilts the vial 214 for maximum fluid removal. This can be achieved while device 200 is sitting on a table in an upright position. When fully assembled the non-sterile vial 214 is shrouded and can be brought inside the sterile field providing a revisitable supply of medical fluid to the user. Both cover 210 and base 216 are preferably clear to allow for visual inspection of the vial label and fluid level.
FIGS. 23 & 24 show an alternative embodiment of filler device 200 where the syringe can be filled in an upright position while sitting on a table. Filler device 200 does not tilt vial 214 , but instead has needle 212 extending completely to the bottom of vial 214 . More specifically, FIG. 23 shows the inventive device before cover 210 is assembled to it. As shown in FIG. 24 , in preferred embodiments, the inventive device 200 further comprises locking rings 219 and mating receptacles 220 to accommodate different vial sizes.
FIGS. 25 & 26 show an alternative embodiment of the device shown in FIGS. 23 and 24 . Needle 212 is a short needle which extends just past the septum into vial 214 . The device is then inverted for filling the syringe. This embodiment would be useful for withdrawing small volumes of fluid as a longer needle extending to the bottom of the vial may withdraw air instead of liquid. Inversion of the vial is often desirable for withdrawing suspensions.
FIG. 27 shows an alternative embodiment of the device shown in FIGS. 25 and 26 . However, in this embodiment, a plastic bag is used as base 216 . More specifically the base 216 comprises a plastic bag that is attached to the cover 210 . When vial 214 is assembled the bag is unrolled and sealed with an adhesive strip. Cover 210 locks vial 214 into place.
While illustrative embodiments of the invention have been described above, it is, of course, understood that various modifications will be apparent to those of ordinary skill in the art. Many such modifications are contemplated as being within the spirit and scope of the invention.
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A filling device and method, particularly for two-component sealants such as fibrin sealants, which enables two fluids to be separately and directly filled to the reservoirs of a dual syringe fluid applicator from two storage containers, which can be standardized, sealed, sterilized bottles. The device has a connector which engages with the fluid applicator, is keyed to orient the applicator's fluid reservoirs in a predetermined manner and holds the containers in side-by-side alignment with the applicator. Two fluid conduits whose downward ends may be pointed to pierce seals on the bottles, extend between the applicator and the bottles and can each have a transverse reach to accommodate the girth of the bottles. The bottles may be tilted by the device to enable the conduits to draw maximal fluid from a lowermost point of the bottle. Tilting can be effected by a downward movement of the device supporting the applicator which movement can introduce the fluid conduits into the bottles. A shroud can enclose and seal the bottles and permit the apparatus complete with fluid applicator to be introduced into a sterile environment. Additionally embodiments for use with a single vial are also disclosed.
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This application is a Division of application Ser. No. 09/252,816 filed on Feb. 19, 1999, now U.S. Pat. No. 6,265,633.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to nucleic acids comprising a gene specifically expressed in lupulin glands of hops and to regulatory sequences thereof.
2. Discussion of the Background
Plants produce and store a wide variety of low molecular weight organic compounds including terpenoids, alkaloids, phenolics, saponins, etc. Since, formerly, these compounds were not considered to be directly involved in supporting living matter having only minor biological functions, they were conventionally called “secondary metabolic products”.
Now, however, it has been elucidated that these secondary metabolic products function for promoting cellular differentiation and protecting cells from external harmful factors, and, furthermore, these secondary metabolic products formed by plants have been utilized and applied in a wide field of popular foods, medicaments, dyes, etc.
These secondary metabolic products have been paid so much attention with respect to their usefulness that the production pathways thereof in plant cells have been successively elucidated, indicating that these compounds are produced via a complicated biosynthetic cascade involving a number of enzymes. Most of these compounds biosynthesized via a cascade of enzymatic reactions can be isolated by directly extracting plant materials, but such a direct extraction from plants not only does not meet the demand for production on a large scale, but also is generally expensive. Therefore, the development of methods for synthesizing these compound in vitro using cultured cells, etc. has been under way.
On the one hand, it has been elucidated that hops, a major material for rendering a refreshing bitterness and flavor to beer, secrete a variety of secondary metabolic products in lupulin glands on the cones, contributing a great deal to the bitterness and flavor of beer.
Based on these circumstances, hops have been subjected to various breeding attempts focused on secondary metabolic products accumulated in lupulin glands such as bitter substance, essential oils, etc. in addition to the improvement of their agricultural properties.
However, hops are a dioecious plant, and especially the male plant bears no cones, materials for beer, is not commercially appreciated, and accordingly has not been actively studied so that its genetic properties useful for beer brewing have hardly been elucidated at all. Therefore, at present, hop breeding by conventional crossing relies largely on breeders' experience and intuition, and no prediction can be made especially on the quality of fermentation products at all till the time of the actual bearing of cones.
On the other hand, these days, breeding methods using genetic engineering such as a transformation technique and marker assisted selection have become available for various plants. In these methods, a more objective breeding can be performed compared with those conventional breeding methods that largely depend on breeders' experience and intuition. The transformation technique is a technique for directly introducing a desired character by transferring and expressing a foreign gene in plant cells. The expression of a foreign gene can be performed by linking a desired structural gene and a terminator capable of functioning in plant cells to a gene expression regulating promoter which is capable of functioning also in plant cells, and transferring the resulting transformed promoter into plant cells. Promoters frequently used in experiments are exemplified by CaMV 35S capable of expressing a transferred gene in regardless of any tissues of relatively numerous varieties of plants, and the promoter for the nopaline synthetase gene (Sanders, P. R., et al., Nucleic Acid Res., 15 (1987) 1543-1558). Furthermore, in the practical aspect of genetic transformation, the transferred gene might be harmful for the plant growth, etc. Therefore, there has been also a demand for promoters capable of expressing a foreign gene in a desired tissue, desired period, and desired quantity. The advantage of the breeding method using the transformation technique over the conventional traditional breeding method is that the former method is capable of transducing a desired character to plants regardless of their species with a relatively high accuracy in a short time. Also in the case of hops, since they can be proliferated by root-planting, the procedure for fixing the transduced character is not required. Therefore, the breeding method using the transformation technique is especially effective for hops.
Marker assisted selection is an example of a breeding method using the DNA marker such as RFLP (Restriction Fragment Length Polymorphism) marker, and have been put into practical use, especially for rice and wheat. It has been generally agreed that transformation techniques are capable of transducing a character regulated by a single gene, but incapable of transducing a character regulated by multiple genes. Marker assisted selection is capable of compensating for these defects of transformation techniques.
A prerequisite for such a breeding method using gene technology is to elucidate genes related with the desired character and those regulating those genes. Especially, from the viewpoint of hops as the beer material as well as the source of effective drug ingredient, if genes related to the biosynthesis of secondary metabolic products secreted from lupulin glands contained in the cones of female plants are elucidated, these genes can be applied to the hop breeding method using the gene technology, and, furthermore, also to the field of medical treatment.
SUMMARY OF THE INVENTION
Therefore, in order to elucidate genes specifically expressed in lupulin glands and facilitate their practical application, it is an object of the present invention to isolate, purify and provide such genes, as well as regulatory sequences thereof, such as promoters, for these genes.
As described above, nucleic acids isolated and purified in the present invention comprise genes specifically expressed in the lupulin glands of hops, promoters specifically functioning in lupulin glands, and portions thereof.
Using these nucleic acids, the conventional method for breeding hops wholly dependent on the breeders experience and intuition can be converted to a more objective method using genetic engineering. As described above, since important secondary metabolic products, such as beer materials and effective drug ingredients, are secreted exclusively in lupulin glands on the hop cones, genes specifically expressed to function in lupulin glands are likely related to the biosynthesis of these secondary metabolic products. Thus, by utilizing genes capable of participating in the biosynthesis of secondary metabolic products as a marker, an improved marker assisted selection can be developed for the breeding of hops which will contribute significantly to the food and drug industries. In addition, by transferring the above-described genes to hops using a transformation technique, breeding of industrially useful cultivar can be accomplished. That is, by breeding hops using a genetic engineering technique with these nucleic acids, the composition of secondary metabolic products accumulating in lupulin glands can be regulated. Furthermore, the nucleic acids of the present invention enable the maintenance and improvement of hop quality for beer brewing, and the use of hops for drug production.
A more complete appreciation of the invention and many of the attendant advantages thereof will be readily obtained as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 : diagram representing the procedure of inverse PCR in the case of isolation of the regulatory sequence in the lupulin-specific gene.
FIG. 2 : results of Northern blot analysis of RNAs which have been recovered from lupulin-rich fraction and lupulin-poor fraction and electrophoresed using a lupulin-specific gene as the probe. The analytical results indicate the specificity of lupulin-specific gene expression in lupulin glands.
DETAILED DESCRIPTION OF THE INVENTION
By the above-described expression “specifically expressed” or “specifically functions,” it is meant that the genes are expressed or functioning not only in lupulin glands alone but also doing so more in these glands as compared to other organs. That is, whether the genes are expressed or functioning “specifically” in lupulin glands or not can be determined by their expression amount and function intensity in lupulin glands compared with other organs.
Furthermore, by the expression “specifically expressed” or “specifically functions” it is not only meant that the genes are as specific as defined above throughout the entire developing period, etc. but also that the expression and function of the genes are more highly elevated by the specific developing period or external influences compared with other organs.
The above-described nucleic acids comprise both DNA and RNA. Also, the type of “genes” coded in the above-described nucleic acids includes any types such as genomic DNA, cDNA and mRNA.
Further, portions of the above-described nucleic acids are also included in the present invention. In some applications, even a partial sequence thereof alone is capable of functioning without a whole length thereof being required, i.e., use of a fragment having the desired functional property of the full-length sequence. For example, in the case of application of these nucleic acids to the breeding method by the marker assisted selection based on RFLP, molecules are identified by hybridization and PCR, wherein the size of probes and PCR primers used is sufficient if they comprise a portion of the above-described specific nucleic acids derived from lupulin glands, for example, a partial continuous sequence of several tens to several hundreds bp long.
Furthermore, in the present invention, the above-described genes specifically expressed in lupulin glands feature that the genes encode proteins related to the biosynthesis of secondary metabolic products generated in lupulin glands.
Proteins herein used include, for example, the amino acid sequence described in SEQ ID NO:1. Genes encoding the protein include those having the base sequence described in SEQ ID NO:2, and also those having the base sequence partially different from that of SEQ ID NO:2 but reserving the very base sequence encoding the above-described amino acid sequence. In the case of the use of this base sequence as probes and PCR primers, it can be modified to a certain extent so far as the resulting sequence retains the desired functional capability. All amino acid sequences encoding the above-described amino acid sequences are within the scope of the present invention. Specific nucleic acid sequences other than those described above are readily determined by using the well-established genetic code for codons which encode the amino acid residues of the proteins described above. The genetic code is set forth in L. Stryer, Biochemistry , Third Edition, 1988, W.H. Freeman and Co., incorporated herein by reference in its entirety.
Also, isolated and purified nucleic acids of the present invention comprise the gene encoding chalcone synthetase. This chalcone synthetase is the enzyme related to the metabolism of phenylalanine and tyrosine, and, more specifically, has been determined to catalyze the conversion of 1 mole of coumaroyl CoA and 3 moles of malonyl CoA to 4,2,4,6-tetrahydroxychalcone (naringenin-chalcone) in the biosynthesis of flavonoids. Therefore, the above-described nucleic acids can be used to regulate the metabolic system involved in the biosynthesis of flavonoids in plants, and also as a gene marker for characters related to flavonoids. Furthermore, recently, it has been indicated that a chalcone synthetase-like enzyme possibly has a valerophenone synthetase activity which catalyzes the biosynthesis of phlorisovalerophenone and phlorisobutyrophenone, the precursors of bitter substance, α-acid and β-acid (European Brewery Convention, Proceedings of the 26th Congress, p. 215 (1997)). These facts indicate that the protein encoded by the gene isolated in the present invention functions as the valerophenone synthetase participating in the biosynthesis of bitter substance. Accordingly, the above-described nucleic acids can be used for the regulation of the metabolic system concerning the biosynthesis of bitter substance in hops and also as the gene marker for the character related to bitter substance.
Nucleic acids isolated and purified in the present invention also include a regulatory sequence for the specific expression of the gene in lupulin glands, and the sequence contains a promoter which is activated in lupulin glands. Such a sequence includes, for example, one having the base sequence described in SEQ ID NO:7. This regulatory sequence specific in lupulin glands can be used to facilitate the expression of genes linked downstream thereof in lupulin glands.
Furthermore, it is an object of the present invention to provide a vector containing a gene specifically expressed in lupulin glands or a regulatory sequence specifically regulating the expression of gene in lupulin glands.
Breeding of plants such as hops can be achieved by transforming plants including hops using a vector bearing a gene specifically expressible in the above-described lupulin glands. Especially, such a vector becomes effective for the breeding by the elevation/suppression of the production of secondary metabolic products. Furthermore, this vector can be used not only for the plant breeding but also the production of secondary metabolic products by expressing the gene related to the biosynthesis the secondary metabolic products in cultured cells. If the production of secondary metabolic products becomes possible in cultured cells, the isolation of the secondary metabolic products can be easily performed.
Also, the above-described vector bearing a regulatory sequence can be used not only for the expression of the specific genes but also for the specific expression of a desired gene in hop lupulin glands by linking a gene derived from hops or different plant species downstream of the regulatory sequence. By doing so, any desired gene in lupulin glands can be expressed.
In addition, the present invention also includes plant cells transformed by the above-described vector. Herein, plant cells can include, without any limitations in their morphology or growing stages, various types of cells such as cultured cells, callus, protoplasts, plant, etc. This invention can also include not only plant cells of the first generation but also plants generated from the first generation plant cells.
The above-described transformed plant enables the expression of desired genes including those encoding secondary metabolic products by the transfer of the above-described vector, increasing the usefulness of plants as materials for foods and drugs.
In the following description, the present invention will be described in detail with reference to preferred embodiments.
1. Isolation of Nucleic Acids Comprising Hop Lupulin Gland-specific Gene and the Expression Regulatory Sequence Thereof
(1) Preparation of Total RNA and mRNA
Total RNA can be prepared by the existing method, for example, a method described in “Protocols of Plant PCR Experiment”, Shujun-sha, p. 56 (1995), incorporated herein by reference. The preparation of mRNA from the total RNA can be carried out by the existing method, for example, according to the protocol attached to “Oligotex-dT30 <Super>” available from Takara-Shuzo.
(2) Preparation of cDNA Library
cDNA library can be prepared from mRNA by the existing method. cDNA can be prepared, for example, according to the protocol attached to “cDNA synthesis module”, Amersham. Also, the formation of a library of cDNA thus prepared can be performed according to protocols attached to “cDNA rapid adaptor ligation module” and “cDNA rapid cloning module” both from Amersham, and “GIGAPACK II Plus Packaging Extract”, Stratogene. All of the above-cited publications are incorporated herein by reference.
(3) Preparation of Lupulin-specific Probes
By lupulin-specific probes is meant gene fragments complementary to genes specifically expressed in lupulin glands. In the present preferred embodiment, the lupulin-specific probes can be obtained by the following method.
Cones approximately 15 days after blooming are divided into a fraction comprising mainly lupulin glands and the bracteole base dense with lupulin glands (lupulin-rich fraction) and a fraction comprising mainly the stipular bract containing few lupulin glands (lupulin-poor fraction), respectively. A group of genes expressed in the lupulin-rich fraction has subtracted from it a group of genes also expressed in the lupulin-poor fraction, and a group of remaining genes are considered to be the ones specifically expressed in lupulin glands with a high probability.
Such a subtraction of a group of genes expressed also in the lupulin-poor fraction from a group of genes expressed in the lupulin-rich fraction can be carried out by the existing method, conveniently, for example, according to the protocol attached to a “Subtractor Kit” from Invitrogen.
(4) Isolation of Lupulin-specific cDNA
By “lupulin-specific cDNA” is meant cDNA derived from the gene specifically expressed in lupulin glands. Isolation of lupulin-specific cDNA can be performed by screening cDNA library prepared from the lupulin-rich fraction using the lupulin-specific probes. This screening can be carried out by the existing method, for example, by a method described in the “User's guide for performing the hybridization using DIG system” (Boehringer Mannheim, p. 37 (1995)), incorporated herein by reference.
Labeling of lupulin-specific probes can be also carried out by the existing method, for example, according to the protocol attached to “DIG-High Prime”, Boehringer Mannheim.
(5) Preparation of Hop Genomic DNA
Preparation of hop genomic DNA can be performed by the existing method, for example, a method described in “Protocols for plant PCR experiment” (Shu-jun Sha, p. 54 (1995)), incorporated herein by reference.
(6) Isolation of Nucleic Acid Comprising a Regulatory Region for the Lupulin-specific Gene Expression
By “nucleic acid comprising a regulatory region for the lupulin-specific gene expression” is meant nucleic acid comprising a regulatory region containing the promoter specifically functioning in lupulin glands. The nucleic acid can be isolated by the existing method using the reverse PCR with the DNA sequence of lupulin-specific cDNA as the primer, for example, methods described in “Protocols for plant PCR experiment” (Shu-jun Sha, p. 69 (1995)), incorporated herein by reference.
(7) DNA Sequencing
DNA sequence thus isolated can be determined by the existing method, for example, according to the protocol attached to an “ABI PRISM Dye Primer Cycle Sequencing Ready Reaction Kit” (Perkin-Elmer), incorporated herein by reference. The DNA sequence thus decided can be examined for the homology to that of existing genes in other plant species.
(8) Northern Hybridization Analysis (Hereinafter Referred to as Northern Analysis)
Whether the lupulin-specific gene thus isolated is actually expressed specifically in lupulin glands and whether the nucleic acid thus isolated comprising the lupulin-specific expression regulatory region regulating the gene actually functions specifically in lupulin glands can be confirmed by carrying out Northern analysis with the isolated lupulin-specific gene as the probe. Northern analysis can be performed by the existing method, for example, based on the methods described in “Protocols for non-isotope experiments-DIG hybridization (Shu-Jun Sha, p. 45 (1994)) and “User's guide for performing the hybridization using DIG system” (Boehringer Mannheim, p. 40 (1995)), both incorporated herein by reference.
2. Preparation of Vectors Bearing the Above-isolated Lupulin-specific Gene or Lupulin-specific Expression Regulatory Sequence
Lupulin-specific gene the specificity of which in lupulin glands has been confirmed as described above can be expressed, according to the existing method, by inserting the gene downstream of the expression regulatory sequence in a suitable vector bearing the expression regulatory sequence followed by transferring the transformed vector to appropriate cells. There are no limitations on the type of vectors bearing the expression regulatory sequence, and a vector described below bearing lupulin-specific expression regulatory sequence and a commercially available expression vector (for example, pBI121 (CLONTECH) can be used.
Also, the construction of vector bearing the lupulin-specific expression regulatory sequence can be similarly achieved by selecting an appropriate vector from existing plasmids according to the purpose and inserting the above-described expression regulatory sequence, for example, SEQ ID NO:7 to it. In this case, the cloning region having various restriction sites for linking structural genes may be optionally included downstream of the expression regulatory sequence.
3. Applications
Since secondary metabolic products are abundantly secreted in hop lupulin glands, the lupulin-specific genes isolated above are highly likely to be the gene related to the biosynthesis of the secondary metabolic products. Therefore, the application of genes obtained above to the transformation technique and marker assisted selection enables, for example, hop breeding based on the improvement of secondary metabolic products formed in lupulin glands. For the above-described transformation technique, well-known methods can be used.
Having generally described this invention, a further understanding can be obtained by reference to certain specific examples which are provided herein for purposes of illustration only and are not intended to be limiting unless otherwise specified.
EXAMPLES
Example 1
Preparation of Lupulin-rich and Lupulin-poor Fractions
Hop cones were harvested 15 days after blooming, and frozen in liquid nitrogen. These frozen cones were dissected on dry-ice, and divided using a dissection forceps into a fraction comprising mainly lupulin glands and the endocyte base with dense lupulin glands, and a fraction comprising mainly the endocyst with few lupulin glands. These fractions were referred to as the lupulin-rich fraction and lupulin-poor fraction, respectively, and stored at −80° C.
Example 2
Preparation of Total RNA and mRNA from Lupulin-rich and Lupulin-poor Fractions
Total RNA and mRNA of lupulin-rich fraction and lupulin-poor fraction were prepared as follows. Each fraction was frozen and pulferized in liquid nitrogen, suspended in a 2% CTAB solution (consisting of 2% cetyltrimethylammonium bromide, 0.1 M Tris (pH 9.5), 20 mM EDTA, 1.4 M NaCl and 1% β-mercaptoethanol), and incubated at 65 for 30 min. After the suspension was extracted twice with chloroform/isoamyl alcohol (24:1), a three quarters volume of isopropanol was added to the extract to precipitate DNA and RNA. After DNA and RNA thus precipitated were dissolved in water, a ⅓ volume of 10 M lithium chloride was added, and the resulting mixture was allowed to stand at −20° C. overnight, and then centrifuged at 15,000 rpm for 10 min. Precipitates thus obtained were washed with 70% ethanol and dissolved in a DNase reaction buffer (consisting of 100 mM sodium acetate (pH 5.2) and 5 mM magnesium chloride). To this mixture was added DNase, and the resulting mixture was incubated at 37° C. to decompose DNA. To the incubation mixture was added a ⅓ volume of 10 M lithium chloride, and the mixture was allowed to stand at −20° C. overnight, then centrifuged at 15,000 rpm for 10 min. Precipitates thus obtained were dissolved in water, and the resulting solution was purified by the extraction with phenol-chloroform, and subjected to the ethanol precipitation. Precipitates thus obtained were dissolved in water and used as the total RNA preparation, from which mRNA was prepared using an “Oligotex-dT30<Super>” (Takara-Shuzo) according to the protocol attached thereto.
Example 3
Preparation of Lupulin-specific Probes
Herein, lupulin-specific probes were prepared by subtracting mRNA present also in the lupulin-poor fraction from mRNA in the lupulin-rich fraction. More specifically, the lupulin-specific probes were prepared using a “Subtractor Kit” (Invitrogen) and according to the protocol attached to the Kit.
First, cDNA was synthesized from mRNA of the lupulin-rich fraction. Also, mRNA in the lupulin-poor fraction was labelled with biotin. Then, cDNA of the lupulin-rich fraction thus prepared was mixed with the biotinized mRNA in the lupulin-poor fraction to form a hybrid, to which was then added streptoavidin to combine with the biotinized mRNA in the hybrid. Then, the removal of the biotinized mRNA by extracting the hybrid with phenol-chloroform resulted in the depletion of cDNA derived from mRNA present also in the lupulin-poor fraction from the cDNA of the lupulin-rich fraction. As a result, cDNA derived only from the lupulin-rich fraction was obtained to be used as the probe. Lupulin-specific probes thus obtained were labelled with digoxigenin using a “DIG-High Prime” (Boehringer Mannheim).
Example 4
Isolation of Lupulin-specific cDNA
A cDNA library was prepared from mRNA in the lupulin-rich fraction using a “cDNA synthesis module”, “cDNA rapid adaptor ligation module” and “cDNA rapid cloning module—MOSSlox” (Amersham), and “GIGAPACK Plus Packaging Extract” (Stratagene) with—MOSSlox as the vector. This library was screened by the hybridization method using lupulin-specific probes labelled with digoxigenin.
More specifically, each plaque derived from the above-described cDNA library was transferred to membrane filter, and blocked in a hybridization buffer (containing 5×SSC, 100 mM phosphate buffer, 7% SDS, 2% blocking agent, 0.1% N-lauroyl sarcosine, 50% formamide and 50 g/ml fish sperm DNA). Then, to the hybridization buffer was added the above-described probe, and the membrane was incubated in the resulting mixture at 42° C. overnight. Then, the membrane was washed twice with a rinsing solution (containing 1% SDS and 2×SSC) at 56° C. for 5 min, and further twice with a rinsing solution (containing 0.1% SDS and 0.1×SSC) at 68° C. for 5 min. Then, by detecting the positive plaque, the lupulin-specific cDNA was isolated.
Example 5
Determination of DNA Sequence of Lupulin-specific cDNA and Amino Acid Sequence of Translation Products
The DNA sequence of gene fragments containing the lupulin-specific cDNA and lupulin-specific promoter thus obtained was then determined. For sequencing, each gene fragment was subcloned into the pUC vector or pBluescript vector. Sequencing was performed using a “ABI PRISM Dye Primer Cycle Sequencing Ready Reaction Kit” and a DNA sequencer (ABI373S model) (Perkin-Elmer).
The DNA sequence of the lupulin-specific cDNA thus determined is shown in SEQ ID NO:2. Also, the putative amino acid sequence of the translation product derived from the DNA sequence is shown in SEQ ID NO:1. In this case, the amino acid sequence of SEQ ID NO:1 corresponds to the DNA sequence from the initiation codon (ATG), position 36-38 to the termination codon (TAA), position 1218-1220 in SEQ ID NO:2.
Example 6
Preparation of Hop Genomic DNA
Hop genomic DNA was prepared as follows. Leaves or cones of hops were frozen and pulferized in liquid nitrogen, suspended in a 2% CTAB solution (containing 2% cetyltrimethylammonium bromide, 0.1 M Tris (pH 9.5), 20 mM EDTA, 1.4 M NaCl and 1% β-mercaptoethanol), and incubated at 65° C. for 30 min. The suspension was extracted twice with chloroform-isoamylalcohol (24:1), and added with a ¾ volume of isopropanol to precipitate DNA and RNA. DNA and RNA thus precipitated were dissolved in a high salt TE buffer (containing 1 M NaCl, 10 mM Tris (pH 8.0) and 1 mM EDTA), added with RNase, and the mixture was incubated at 60° C. to decompose RNA. To the reaction mixture was added 2 volumes of isopropanol to precipitate DNA, which was washed with 70% ethanol, and then dissolved in water to obtain a genomic DNA sample.
Example 7
Isolation of the Expression Regulatory Sequence for the Lupulin-specific Gene
Isolation of the expression regulatory sequence for the lupulin-specific gene was carried out using the inverse PCR method as follows. FIG. 1 is a diagram representing the procedures in this Example 7.
First, hop genomic DNA obtained in Example 6 was digested with a restriction enzyme Xho I (S1 and S2). Xho I digests were subjected to self circularization according to the protocol attached to a “DNA Ligation Kit Ver. 1” (Takara-Shuzo) (S3).
Next, the flanking region containing the promoter for lupulin-specific gene was amplified by PCR using primers having the sequence within the lupulin-specific cDNA with a portion of this ligation reaction mixture as the template (S4). Sequences of a pair of primers herein used are represented in SEQ ID NO:3 (primer 1) and NO:4 (primer 2). Herein, SEQ ID NO:3 is a sequence complementary to that from position 137 to 166 and SEQ ID NO:4 is a sequence from position 303 to 332 of SEQ ID NO:2, respectively.
The above-described PCR was performed using an “Expand High-Fidelity PCR System” (Boehringer-Mannheim) according to the protocol attached thereto, incorporated herein by reference. The reaction conditions were as follows: after 30 cycles of the incubations at 94° C. for 1 min, 55° C. for 1 min and 68° C. for 4 min, the mixture was further incubated at 72° C. for 6 min.
The reaction solution thus obtained was electrophoresed for the identification of PCR products. Since, in addition to the amplified fragment 1 , non-specific amplified fragments might be contained in the above PCR products, a selective amplification of only the desired fragment was further attempted using different primers (S5). That is, in order to selectively amplify only DNA segment comprising the lupulin-specific promoter, PCR was performed with a portion of the above-described PCR solution as the template using primer 3 (SEQ ID NO:5) complementary to the sequence further upstream of the lupulin-specific gene than primer 1 and the above-described primer 2 (S6). The primer 3 (SEQ ID NO:5) comprises the sequence complementary to that from Nos. 114 to 143 of the lupulin-specific cDNA (SEQ ID NO:2). PCR was carried out using the same conditions and apparatus as described above. Then, the DNA sequence was determined using the PCR-amplified fragment obtained using these primers 2 and 3.
Example 8
DNA Sequence Determination of the Expression Regulatory Sequence for the Lupulin-specific Gene
Base sequence of the above-described amplified fragment 2 was determined similarly as in Example 5 described above by subcloning the amplified fragment to the pUC vector or pBluescript vector and using an ABI PRISM Dye Primer Cycle Sequencing Ready Reaction Kit and a DNA sequencer (ABI373S type) (Perkin-Elmer). Results are shown in SEQ ID NO:6.
Since this amplified fragment was obtained by the inverse PCR method, it is expected that the amplified fragment contains the expression regulatory sequence such as that of the promoter within the lupulin-specific gene (a portion thereof). Therefore, in order to identify this expression regulatory sequence, the DNA fragment thus amplified was compared with DNA sequence of the lupulin-specific cDNA. These comparisons revealed that the DNA fragment herein amplified (SEQ ID NO:6) contained the promoter sequence in the lupulin-specific cDNA. More specifically, the sequence position 1-690 of SEQ ID NO:6 corresponded to the sequence position 303-992 of the lupulin-specific cDNA (SEQ ID NO:2), and the sequence position 3296-3438 of SEQ ID NO:6 corresponded to the sequence Nos. 1-143 of the lupulin-specific cDNA (SEQ ID NO:2), respectively. Therefore, it has been indicated that the expression regulatory region such as the promoter for the lupulin-specific gene is included in the region position 691-3295 of SEQ ID NO: 6, which is shown in SEQ ID NO:7.
Example 9
Northern Blot Analysis of the Lupulin-specific cDNA and the Expression Regulatory Sequence of the Lupulin-specific Gene
Whether the above-described lupulin-specific cDNA was actually expressed in lupulin glands and whether the promoter for the above-described lupulin-specific gene actually functioned in lupulin glands were examined by the Northern blot analysis for the total RNAs extracted from the lupulin-rich and lupulin-poor fractions, respectively, using labelled DNAs prepared based on the lupulin-specific cDNA (SEQ ID NO:2) in Example 5.
First, the total RNAs from the lupulin-rich and lupulin-poor fractions were prepared by a similar method as in Example 2, and fractionated by denaturing agarose gel electrophoresis (1% agarose, 18% formaldehyde, 20 mM MOPS, 5 mM sodium acetate and 1 mM EDTA (pH 7)). RNAs thus fractionated in the agarose gel were transferred to nylon membrane, and subjected to hybridization using cDNA obtained above as the probe according to the Users guide for hybridization with DIG System (Boehringer-Mannheim, p.40 (1995)), incorporated herein by reference.
Hybridization was performed under the following conditions. The above-described membrane was blocked using a hybridization buffer of the same constituents as in Example 4. To the above-described hybridization buffer was added the lupulin-specific cDNA labelled with digoxigenin as the probe, the blocked membrane was soaked into this mixture, and incubated at 50° C. overnight. Then, the membrane was rinsed twice at 56° C. for 10 min with a washing solution (containing 1% SDS and 2×SSC), further twice at 68° C. for 30 min with a washing solution (containing 0.1% SDS and 0.1×SSC), and then searched for bands fused with the probe. Results are shown in FIG. 2 .
As represented in FIG. 2, although a few mRNAs for the gene obtained above were also present in the lupulin-poor fraction, they were clearly present in abundance in the lupulin-rich fraction, indicating the strong expression of this gene specifically in lupulin glands. The expression of this gene is controlled by the nucleic acid comprising the expression regulatory region containing the promoter localized upstream of the structural gene in the genomic DNA, and the nucleic acid comprising the expression regulatory region is the one isolated and identified in the above-described example, indicating a specifically strong function of the above-described isolated nucleic acid comprising the expression regulatory region in lupulin glands. Signal bands detected in the low molecular side were thought to be decomposed products of mRNA of the gene obtained above.
Example 10
Homology Examination
The putative amino acid sequence derived from the DNA sequence of the lupulin-specific cDNA thus obtained was compared for homology with the existing amino acid sequences. As a result, the gene had a high homology with the gene for chalcone synthetase catalyzing the synthesis of nalingenin concerned to the biosynthesis of flavonoids in plants. More specifically, in comparison with chalcon synthetases from other plants such as Arabidopsis (Plant J., 8 (5), 659-671 (1995)), barley (Plant Mol. Biol. 16:1103-1106 (1991)), pea (EMBL/GenBank/DDBJ databases X80007), petunia (J. Biotechnol., 11 (2), 131-135 (1995) and rye (EMBL/GenBank/DDBJ databases X92547), the hop enzyme showed 65-70% homology in the DNA level and 70-75% homology in the amino acid level.
Recently, chalcone synthetase has been indicated to have the activity of valerophenone synthetase catalyzing phlorisovalerophenone and phlorisobutylophenone, precursors of bitter substance, α-acid and β-acid (European Brewery Convention, Proceedings of the 26th Congress, p. 215 (1997)), indicating a possibility for the translation product of the gene obtained above to participate in the biosynthesis of bitter substance as valerophenone synthetase.
Therefore, in the event that the gene specifically expressed in lupulin glands encodes chalcone synthetase, this nucleic acid can be used for improving flavonoids in plants. Also, in the case that this gene encodes valerophenone synthetase, this nucleic acid can be used for improving bitter substance in hops. Furthermore, since hop bitter substance, α-acid and β-acid, have pharmacological activity (Biosci. Biotech. Biochem. 61 (1), 158 (1997)), it is possible for the above-described nucleic acid to be applied to drug production.
Industrial Applicability
As described above, nucleic acids comprising genes specifically expressed in hop lupulin glands enable the breeding of hops by genetic engineering techniques focused on secondary metabolic products expressed in lupulin glands. Also, in the case of the use of vectors bearing the above-described lupulin-specific genes, it is expected that the production of secondary metabolic products can be achieved outside of plants, such as in cultured cells. Since such secondary metabolic products include important materials such as foods and drugs, and also since chalcone synthetase is involved in the biosynthesis of flavonoids, and valerophenone synthetase is involved in the biosynthesis of bitter substance, the present invention is expected to greatly contribute to the development and improvement of materials for foods and medicines.
Furthermore, the lupulin-specific promoter in the present invention can be utilized for the improvement of secondary metabolic products such as essential oil constituents and bitter substance accumulated in lupulin glands by inserting the gene of interest downstream of the promoter. The promoter can also be used for introducing novel other characters to hops.
Obviously, numerous modifications and variations of the present invention are possible in light of the above teachings. It is therefore to be understood that within the scope of the appended claims, the invention may be practiced otherwise than as specifically described herein.
This application is based on Japanese Patent Application Ser. No. Hei 10-37266, filed on filed on Feb. 19, 1998, and Japanese Patent Application Ser. No. Hei 10-174235, filed on filed on Jun. 22, 1998, both of which are incorporated herein by reference in their entirety.
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<223> OTHER INFORMATION: polynucleotide
<400> SEQUENCE: 5
agcttggttg aaacagttgg caggaacggc
#
# 30
<210> SEQ ID NO 6
<211> LENGTH: 3439
<212> TYPE: DNA
<213> ORGANISM: Humulus lupulus
<400> SEQUENCE: 6
gcaccatctc tgaacacacg ccaagacatg ttggtggttg aagttcccaa gc
#ttgggaag 60
gaggctgcaa tcaatgccat caaagaatgg ggccaaccca agtccaagat ca
#cccatctc 120
atcttctgca ccggctcctc catcgacatg ccaggagccg attaccaatg cg
#ccaagctt 180
ctcggcctcc gaccctcggt gaagcgagtg atgctgtatc aactcggctg tt
#atgccggt 240
ggaaaagttc ttcgcatagc caaggacata gcagagaaca acaagggcgc ta
#gagttctc 300
attgtgtgct ctgagatcac agcttgtatc tttcgcgggc cctcggagaa ac
#atttggat 360
tgcttggtgg ggcaatctct gttcggagac ggggcatctt cggtcatcgt tg
#gtgccgac 420
cctgatgcct cggtaggcga gcggccgatc ttcgagttgg tttcagctgc gc
#agacgatt 480
ttgcctaact cggatggagc catagccggg cacgtaacgg aagccgggct ga
#catttcac 540
ttgctgaggg acgtgccagg gttgatctcc caaaacattg agaagagctt ga
#ttgaggcc 600
ttcactccga ttgggattaa tgactggaac aacatattct ggattgcaca tc
#ccggtgga 660
cctgccattc tggacgagat agaggccaag ctcgaggagt ttggagactg tc
#cgaggtcc 720
ttctcctagg gtgatcacca gctcgatagt ccctatagcc gttgatcctt ct
#cccgaaaa 780
accgcacagc atcatggagg tcgccttcag ctcggcgaca gtcaaaccca tc
#ttctccaa 840
cgtggaccgg aatagaaggt ttaccgagct cccattatcg atcaacaccc tc
#ctaaccct 900
ccgaatagcg agctgaactg ctacgaccag agggtcgtta tgagggaact gg
#acatggcc 960
cgcatcttct tctgtaaaaa tgatcggttg cctctccaat cgctgctgct tt
#ggcagacg 1020
ctgctccggg acgaactcta ctccattatg cgccttgagt tcgtttacgt at
#ctcttttg 1080
ggcaccccta ctcacgctag ctaaatgcgg acctccagag attgtggata tc
#tctcctcc 1140
aatcactgga ggagggacgt cttgatctat ccgagaccca gaaatctata ca
#aaaaaaaa 1200
actatgtata aggttcataa acacattata ttcattaatt taaccttaaa at
#taaaaaaa 1260
atgaaaaaaa ctcaccaaaa ttggtctagg aagtcggaga cgccgctagt tc
#ttgggaga 1320
aaacctaagt tttgaatttg ggagaatgaa gggcttgggg tcgatggctg ag
#atttaata 1380
ctgggtgcac tgtttgcgtt agtgggcaac tgacgctaac ggcttgtttg ca
#tcagtgcc 1440
aaactgacgc aaacacaccg ttagcgttag ttgcccactg acgcaaacgg tg
#cattaaga 1500
gcatcagttg gccactgacg caaacttcac caattaacag tgtcagtgtt at
#cactgatg 1560
caaatgcccc tgaatttgtg gtagtactca acttccacaa atgctgattc tc
#ggtcaacg 1620
gcgtcagtca actgtgttga gtgacgcgtt tgactgacac aaaataagta tt
#ttggtgta 1680
gtggaagatt aactaagaag gtaaaattgg aggttattgt tatcactcct tc
#atcattta 1740
taaaagtaga aatacgttcc atttaatata ctaaccaacc ttgctgccac at
#atcccctg 1800
aaaaaaataa aacaacaaca acctttctac cataaaatta ggcatatgat ga
#tatataac 1860
ctaactataa cacaaaatta ggcatatgat gatatatata acctaactat aa
#cacaaaat 1920
taggcatata tatatacact cacaaatagt ggctgctata cccaacacct ta
#attaatta 1980
atagttaatg ctcctctaga agactggacg agatcaagtg ctattatgcg ga
#atcaagat 2040
ctcctatcaa aaaaagatgt cccagcctat gtttagaaaa tgttaaatca aa
#ttctgtta 2100
actaatttct atatttctca tccctactcc ttttttttta acaatcaaca at
#tcattgaa 2160
aataatcaaa atgtaataca actaataata agatgatata tatagtaact at
#ccatacaa 2220
gttcattatc cactctaagt gcatgcacaa ttcatgaacg gccttattgg cc
#aaacgtca 2280
aacacaaatt agagatacct tagaaaaatt ggataataaa cttgttatat tt
#tctaacaa 2340
agaccctaat tcattactac tccattaaat gacgtgtatc tttcattttt tt
#ttaaaaat 2400
tttagaaact aatagagtat ggattgatgc tgcattataa gaaatcgatc ac
#accttcag 2460
ttatgaactt tccggctaag caccatcggg catctatgtc ctcctctttt gc
#cacattat 2520
catatgaaat accactgttt tcctcctctt ccaagcttat ggtcaagacc gg
#ccctgaac 2580
taaggtgggt tagacccacg cctagggcct attttttttt acatttcttt ta
#aaaatact 2640
ataaattttt aaaaagtttt tacaaaaagg gcccctaatc accaattttt cc
#taaggctc 2700
aaaactcttc agggccagcc ctgcctatgg tagcatatct agattctaaa tc
#ttgcttat 2760
gagaactgct cgatgccata acttccttcg ccaccaagac taataacaca aa
#caatagag 2820
aacgaacaca ccaatagcaa tacaaaacac cttacgtcaa ctgacccaac ag
#agagctac 2880
catgtcaaaa gacaatacta gtttgagact tcaccactgt caaaattcta gt
#tctcaaca 2940
ctagcaaaaa aaaaagtgtt aaacaccatc aatcacataa cgacatactt ct
#tggccata 3000
ttttttttcc catgtaatca tgtaaaaggt ggggaaaata aatcaataca ca
#taaagaac 3060
aatgaaaaaa taaataaaca agtcaaatta ttataattta acattaataa aa
#agttgaga 3120
atcacaaaca ttggtacgta ggtattaggg ttggtgttta cacatattat cc
#ataggcca 3180
tgcacacctt acctaaccca tgcaccactt tgtacatatt atatatataa ct
#ccaatttg 3240
gctttgcatt tcaacacttg taatcattac actatatttg tgtatatagt gt
#aagttttc 3300
acagtactac tagctatata tatatcaggt aatggcgtcc gtaactgtag ag
#caaatccg 3360
aaaggctcag cgagctgaag gtccggccac catcctcgcc attggcaccg cc
#gttcctgc 3420
caactgtttc aaccaagct
#
# 343
#9
<210> SEQ ID NO 7
<211> LENGTH: 2606
<212> TYPE: DNA
<213> ORGANISM: Humulus lupulus
<400> SEQUENCE: 7
ctcgaggagt ttggagactg tccgaggtcc ttctcctagg gtgatcacca gc
#tcgatagt 60
ccctatagcc gttgatcctt ctcccgaaaa accgcacagc atcatggagg tc
#gccttcag 120
ctcggcgaca gtcaaaccca tcttctccaa cgtggaccgg aatagaaggt tt
#accgagct 180
cccattatcg atcaacaccc tcctaaccct ccgaatagcg agctgaactg ct
#acgaccag 240
agggtcgtta tgagggaact ggacatggcc cgcatcttct tctgtaaaaa tg
#atcggttg 300
cctctccaat cgctgctgct ttggcagacg ctgctccggg acgaactcta ct
#ccattatg 360
cgccttgagt tcgtttacgt atctcttttg ggcaccccta ctcacgctag ct
#aaatgcgg 420
acctccagag attgtggata tctctcctcc aatcactgga ggagggacgt ct
#tgatctat 480
ccgagaccca gaaatctata caaaaaaaaa actatgtata aggttcataa ac
#acattata 540
ttcattaatt taaccttaaa attaaaaaaa atgaaaaaaa ctcaccaaaa tt
#ggtctagg 600
aagtcggaga cgccgctagt tcttgggaga aaacctaagt tttgaatttg gg
#agaatgaa 660
gggcttgggg tcgatggctg agatttaata ctgggtgcac tgtttgcgtt ag
#tgggcaac 720
tgacgctaac ggcttgtttg catcagtgcc aaactgacgc aaacacaccg tt
#agcgttag 780
ttgcccactg acgcaaacgg tgcattaaga gcatcagttg gccactgacg ca
#aacttcac 840
caattaacag tgtcagtgtt atcactgatg caaatgcccc tgaatttgtg gt
#agtactca 900
acttccacaa atgctgattc tcggtcaacg gcgtcagtca actgtgttga gt
#gacgcgtt 960
tgactgacac aaaataagta ttttggtgta gtggaagatt aactaagaag gt
#aaaattgg 1020
aggttattgt tatcactcct tcatcattta taaaagtaga aatacgttcc at
#ttaatata 1080
ctaaccaacc ttgctgccac atatcccctg aaaaaaataa aacaacaaca ac
#ctttctac 1140
cataaaatta ggcatatgat gatatataac ctaactataa cacaaaatta gg
#catatgat 1200
gatatatata acctaactat aacacaaaat taggcatata tatatacact ca
#caaatagt 1260
ggctgctata cccaacacct taattaatta atagttaatg ctcctctaga ag
#actggacg 1320
agatcaagtg ctattatgcg gaatcaagat ctcctatcaa aaaaagatgt cc
#cagcctat 1380
gtttagaaaa tgttaaatca aattctgtta actaatttct atatttctca tc
#cctactcc 1440
ttttttttta acaatcaaca attcattgaa aataatcaaa atgtaataca ac
#taataata 1500
agatgatata tatagtaact atccatacaa gttcattatc cactctaagt gc
#atgcacaa 1560
ttcatgaacg gccttattgg ccaaacgtca aacacaaatt agagatacct ta
#gaaaaatt 1620
ggataataaa cttgttatat tttctaacaa agaccctaat tcattactac tc
#cattaaat 1680
gacgtgtatc tttcattttt ttttaaaaat tttagaaact aatagagtat gg
#attgatgc 1740
tgcattataa gaaatcgatc acaccttcag ttatgaactt tccggctaag ca
#ccatcggg 1800
catctatgtc ctcctctttt gccacattat catatgaaat accactgttt tc
#ctcctctt 1860
ccaagcttat ggtcaagacc ggccctgaac taaggtgggt tagacccacg cc
#tagggcct 1920
attttttttt acatttcttt taaaaatact ataaattttt aaaaagtttt ta
#caaaaagg 1980
gcccctaatc accaattttt cctaaggctc aaaactcttc agggccagcc ct
#gcctatgg 2040
tagcatatct agattctaaa tcttgcttat gagaactgct cgatgccata ac
#ttccttcg 2100
ccaccaagac taataacaca aacaatagag aacgaacaca ccaatagcaa ta
#caaaacac 2160
cttacgtcaa ctgacccaac agagagctac catgtcaaaa gacaatacta gt
#ttgagact 2220
tcaccactgt caaaattcta gttctcaaca ctagcaaaaa aaaaagtgtt aa
#acaccatc 2280
aatcacataa cgacatactt cttggccata ttttttttcc catgtaatca tg
#taaaaggt 2340
ggggaaaata aatcaataca cataaagaac aatgaaaaaa taaataaaca ag
#tcaaatta 2400
ttataattta acattaataa aaagttgaga atcacaaaca ttggtacgta gg
#tattaggg 2460
ttggtgttta cacatattat ccataggcca tgcacacctt acctaaccca tg
#caccactt 2520
tgtacatatt atatatataa ctccaatttg gctttgcatt tcaacacttg ta
#atcattac 2580
actatatttg tgtatatagt gtaagt
#
# 2606
|
An isolated and purified nucleic acid comprising a gene specifically expressed in hop lupulin glands. Hops are dioecious, and only female plants bear cones, the lupulin glands of which contain secondary metabolic products which provide bitterness and flavor to beer. These secondary metabolic products contain some pharmacologically effective compounds. In order to breed a more useful cultivar of hops by manipulating the constituent of such useful secondary metabolic products relying on genetic engineering techniques, this invention provides an isolated and purified nucleic acid comprising a gene specifically expressed in hop lupulin glands. By using this nucleic acid, it is possible to develop a novel method for breeding hops with transformation techniques and molecular selection techniques. Furthermore, the present invention also provides a nucleic acid comprising the regulatory region for specifically expressing genes in lupulin glands. This nucleic acid can be used also for hop breeding.
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BACKGROUND OF THE INVENTION
Field of the Invention
The invention relates to an adjusting device for adjusting, a sheet transport cylinder in a sheet-fed rotary printing machine, depending upon various thicknesses of printing material.
Such an adjusting device is described in the published German Patent Document DE 39 02 923 A1, wherein an outer cylindrical or jacket surface of the sheet transport cylinder is provided with an outer or jacket film or foil, the outer diameter of which is variable by a variable-height element disposed under the outer film or foil and on a surface of the sheet transport cylinder. The outer film or foil is fixed by an adjusting device to at least one clamping point of the sheet transport cylinder so that a change in the outer diameter of the outer film or foil is effected by the adjusting device. The adjusting device can be operated manually or by a servodrive, for example, a pneumatic servodrive. In the case of a sheet-fed rotary printing machine having many printing units and therefore many sheet transport cylinders, an unacceptably long machine stoppage and refitting time is needed to change the outer diameter of the sheet transport cylinders manually. Although the refitting times can be shortened by using the servodrive, it would have to be integrated into the rotating sheet transport cylinder. This is firstly very complicated to implement in construction terms with regard to the power supply, for example, of a compressed air connection to the servodrive, and secondly is not possible at all in certain cases, for example, because the installation space needed in the sheet transport cylinder for the integration of the servodrive is not available.
Diagonal register adjusting devices described in German Patent DE 465 246 and German Patent Documents DE 34 00 652 C2 and DE 40 13 003 A1 represent only further prior art, and do not correspond to the generic type of adjusting device mentioned in the introduction hereto, and, in these devices, the axis of rotation of the sheet transport cylinder is adjusted to a following position which is skewed with respect to the initial position.
SUMMARY OF THE INVENTION
It is accordingly an object of the invention, therefore, to provide an adjusting device for a sheet-fed rotary printing machine wherein the adjustment is dependent upon various printing-material thicknesses, the adjusting device providing improved construction preconditions for remote operation.
With the foregoing and other objects in view, there is provided, in accordance with one aspect of the invention, an adjusting device for adjusting a sheet transport cylinder in a sheet-fed rotary printing machine, depending upon various printing-material thicknesses, comprising a mounting support for mounting the sheet transport cylinder so that a rotational axis of the sheet transport cylinder is adjustable from a first axial position, which corresponds to a given printing-material thickness, to a second axial position, which corresponds to another printing-material thickness and is axially parallel to the first axial position.
In accordance with another feature of the invention, the mounting support comprises at least one eccentric bearing having an eccentricity.
In accordance with a further feature of the invention, a movement path described by an axis of rotation during an adjustment thereof from the first to the second axial position corresponds to a line which determines a change in cylinder nips, which, in terms of size, is effected at least approximately to the same mutual extent, the nips being formed by the sheet transport cylinder together with adjacent cylinders.
In accordance with an added feature of the invention, the sheet transport cylinder is disposed between another sheet transport cylinder and an impression cylinder.
In accordance with an additional feature of the invention, the rotational axis of the sheet transport cylinder, both in the first and in the second axial position thereof, extends axially parallel to an axis of rotation of an adjacent impression cylinder.
In accordance with yet another feature of the invention, adjusting directions lie at least approximately on a bisector of an angle determined by the axis of rotation of the sheet transport cylinder and axes of rotation of other sheet transport cylinders adjacent to the first-mentioned sheet transport cylinder.
In accordance with a concomitant aspect of the invention, there is provided a sheet-fed rotary printing machine having at least one adjusting device for adjusting a sheet transport cylinder, depending upon various printing-material thicknesses, comprising a mounting support for the sheet transport cylinder so that a rotational axis of the sheet transport cylinder is mounted so that it is adjustable from a first axial position, which corresponds to a given printing-material thickness, into a second axial position, which corresponds to another printing-material thickness and is axially parallel to the first axial position.
The sheet transport cylinder is thus mounted so that the rotational axis thereof can be adjusted from a first axial position (initial position), which corresponds to one printing-material thickness, into a second axial position (following position), which corresponds to another printing-material thickness and is axially parallel to the first axial position.
The adjusting device according to the invention is particularly well suited for remote operation, because if an actuating drive is used to operate the adjusting device, the actuating drive can be arranged in a stationary manner and externally to the sheet transport cylinder. In the case wherein the actuating drive is constructed as a pneumatic operating cylinder, fixing it to a frame of the sheet-fed rotary printing machine arranged beside the sheet transport cylinder is advantageous, because an operating cylinder arranged in this way can be connected to a compressed air source in a straightforward manner via hose lines.
Other features which are considered as characteristic for the invention are set forth in the appended claims.
Although the invention is illustrated and described herein as embodied in an adjusting device for a sheet-fed rotary printing machine, it is nevertheless not intended to be limited to the details shown, since various modifications and structural changes may be made therein without departing from the spirit of the invention and within the scope and range of equivalents of the claims.
The construction and method of operation of the invention, however, together with additional objects and advantages thereof will be best understood from the following description of specific embodiments when read in connection with the accompanying drawings, wherein:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a fragmentary diagrammatic side elevational view of a sheet-fed rotary printing machine; and
FIG. 2 is an enlarged fragmentary view of FIG. 1 showing a sheet transport cylinder and an adjusting device according to the invention for the sheet-fed rotary printing machine.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings and first, particularly, to FIG. 1 thereof, there is shown therein a sheet-fed rotary printing machine assembled from a plurality of printing units 1 to 3 in in-line construction. The printing unit 2 includes a printing-form cylinder 4 , which carries an offset printing form, a rubber blanket cylinder 5 and an impression cylinder 6 . As viewed in the transport direction of a sheet of printing material through the sheet-fed rotary printing machine, sheet transport cylinders 7 and 8 are arranged upline of the impression cylinder 6 , and sheet transport cylinders 9 and 10 are arranged downline therefrom. The impression cylinder 6 is mounted in a side frame of the sheet-fed rotary printing machine by stationary rotary bearings. The sheet transport cylinder 9 is disposed between the cylinders 6 and 10 . A sum formed from the addition of the radii of the cylinders 6 and 10 and the diameter of the sheet transport cylinder 9 is greater than a center spacing between axes of rotation 11 and 12 of the cylinders 6 and 10 , respectively.
An axis of rotation 13 (note FIG. 2) of the sheet transport cylinder 9 is mounted so that it can be adjusted by an adjusting device 14 into various axial positions 13 a and 13 b and continuously into all the axial positions lying between these axial positions 13 a and 13 b . The sheet transport cylinder 9 , together with the rotational axis 13 thereof, is mounted so that it can be adjusted in an adjusting direction represented by the arrow A for the purpose of adapting the size of cylinder nips or gaps 15 and 16 to a printing-material thickness of the sheets of printing material to be processed, which is increased when compared with the preceding print job, and so that it can be adjusted in the opposite adjusting direction represented by the arrow B for the purpose of adapting to a reduced printing-material thickness.
In FIG. 2, the sheet transport cylinder 9 is illustrated in phantom in a position thereof resulting from the axial position 13 a , and with a solid line in the position thereof resulting from the axial position 13 b . As a result of adjusting the rotational axis 13 in the adjusting direction B from the axial position 13 a into the axial position 13 b towards the rotational axes 11 and 12 , both the width of the cylinder nip 15 between the cylinders 6 and 9 , and the width of the cylinder nip 16 between the sheet transport cylinders 9 and 10 can be reduced in size. By an oppositely directed adjustment of the rotational axis 13 in the adjusting direction A away from the rotational axes 11 and 12 , the cylinder nips 15 and 16 can be increased in size. The cylinder nips 15 and 16 can be increased or decreased in size, by the adjustments of the sheet transport cylinder 9 and the rotational axis 13 thereof in the adjusting directions A, B carried out by the adjusting device 14 , to an extent which is at least approximately equal with respect to one another and which corresponds to the thickness of the printing material of the sheets of printing material, respectively, to be processed.
The adjusting device 14 includes two eccentric bearings, i.e., one each for each of the two axle journals of the sheet transport cylinder 9 . Each of the eccentric bearings is constructed as a pretensioned three-ring bearing, the inner ring of which is formed by a rolling-contact bearing seated on the axle journal of the sheet transport cylinder 9 . The rolling-contact bearing is plugged into a central ring, specifically a setting ring that can be rotated about the mid-axis 17 thereof by an actuating drive, for example, a pneumatic operating cylinder. Between the mid-axis 17 and the rolling-contact bearing, and therefore the rotational axis 13 , there is an eccentricity e of the eccentric bearing. The central setting ring is plugged into an outer ring of the three-ring bearing so that it can be rotated about the mid-axis 17 thereof. A pivoting angle α of the rotational axis 13 between the axial position 13 a corresponding to a maximum printing-material thickness and the axial position 13 b corresponding to a minimum printing material thickness is so small that an arcuate movement path described by the rotational axis 13 as it is adjusted from one of the axial positions 13 a , 13 b to the other can be assumed to be a quasi straight line 18 . The line 18 guarantees the change in the cylinder nips 15 and 16 , which, in terms of size, is carried out at least approximately to the same mutual extent, and which change is effected by the adjustment of the rotational axis 13 .
Each of the cylinders 6 , 9 and 10 has a gearwheel assigned thereto, which is arranged coaxially with the respective cylinder and firmly connected to the latter so as to rotate therewith. The mutually engaged gearwheels form a gear mechanism via which the cylinders 6 , 9 and 10 can be driven in rotation. Tooth play, which changes as a result of the adjustment of the sheet transport cylinder 9 and, therefore, of the gearwheel thereof into one of the setting positions A, B, between teeth on the gearwheel of the sheet transport cylinder 9 , and teeth of the adjacent cylinders 6 and 10 can automatically be compensated for by an anti-backlash gear mechanism. For example, an anti-backlash gear or so-called auxiliary gearwheel can be assigned coaxially to the gearwheel of the sheet transport cylinder 9 , likewise meshes with the gearwheels of the cylinders 6 and 10 and is biased in the circumferential direction relative to the gearwheel of the sheet transport cylinder 9 by at least one spring. Instead of assigning the auxiliary wheel to the sheet transport cylinder 9 , such an auxiliary wheel can also be assigned to the cylinders 6 and 10 , respectively, so that each second gearwheel of the gear mechanism connecting the cylinders 6 , 9 and 10 is biased.
The cylinders 6 , 9 and 10 are equipped with grippers to clamp the printing-material sheet firmly. In order to control the periodic opening and closing of the grippers of the sheet transport cylinder 9 , there is assigned to the latter a gripper control cam, which is coupled to the adjusting device 14 , so that the gripper control cam can be adjusted synchronously with the sheet transport cylinder 9 in the adjusting direction A or B. As a result of adjusting the gripper control cam by the amount corresponding to the adjustment of the sheet transport cylinder 9 , the correctness of the gripper closing times is ensured even after the adjustment of the sheet transport cylinder 9 . Furthermore, it is conceivable to take into account an angle which changes as a result of the adjustment between an opening point and a closing point of the grippers of the sheet transport cylinder 9 , by subdividing the gripper control cam into a gripper opening cam and a gripper closing cam which, for example, are arranged coaxially with one another. By rotating the gripper opening cam relative to the gripper closing cam, or the latter relative to the former, compensation for the angle which changes as a result of the adjustment of the sheet transport cylinder 9 is possible.
By driving the cylinders 6 , 9 and 10 in rotation via the gearwheels of the gear mechanism, the drive being performed with mutually equal circumferential surface speeds of the cylinders 6 , 9 and 10 , both sides of the printing-material sheet have the same speed while the printing-material sheet is transported through the cylinder nip 15 or 16 , so that no displacement is to be feared, relative to the circumferential surface, of the side of the sheet resting on the circumferential or jacket surface of the sheet transport cylinder 9 and provided with a fresh imprint in the printing units 1 and 2 , and therefore no smearing of the imprint is to be feared.
Both in the axial positions 13 a and 13 b and in every intermediate position lying between these axial positions 13 a and 13 b , the rotational axis 13 extends axially parallel to the rotational axes 11 and 12 of the cylinders 6 and 10 , respectively. Expressed in other words: when the rotational axis 13 is in the axial position 13 a , the rotational axis 13 extends parallel to that of the line perpendicular to the plane of FIG. 2, along which the rotational axis 13 extends when the rotational axis 13 is in the axial position 13 b.
The pneumatic operating cylinder which rotates the central setting ring and functions as an actuating drive in the adjusting device 14 is fitted to the side frame of the sheet-fed rotary printing machine in a stationary manner, for example, by a rotary joint. The supply of power to the actuating drive, i.e., the compressed-air supply to the operating cylinder, is completely uncomplicated. The supply of compressed air is carried out via hoses fixed to the operating cylinder by hose couplings. Advantageously, no rotary valves or rotary lead-throughs are required for the compressed air.
Differing from the illustrated exemplary embodiment, the adjusting device 14 can also include a linear guide, along which the rotational axis 13 can be adjusted into the axial positions 13 a and 13 b . The movement path described by the rotational axis 13 during the adjustment thereof along the linear guide into the adjusting position A or B corresponds to an ideal straight line which is the bisector of an angle formed by a first leg, determined by the rotational axis 13 and the rotational axis 11 , and by a second leg, determined by the rotational axis 13 and the rotational axis 12 . In other words, the rotational axis 13 forms the center of this obtuse angle, and a mid-point center line of the rotational axes 11 and 13 forms the first leg, and a mid-point center line of the rotational axes 12 and 13 forms the second leg.
The bisector would be exactly congruent with the adjusting directions A, B shown in FIG. 2 .
The sheet transport cylinder 8 likewise has an adjusting device assigned thereto which, in constructive and functional terms, corresponds to the adjusting device 14 .
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An adjusting device for adjusting a sheet transport cylinder in a sheet-fed rotary printing machine, depending upon various printing-material thicknesses, includes a mounting support for mounting the sheet transport cylinder so that a rotational axis of the sheet transport cylinder is adjustable from a first axial position, which corresponds to a given printing-material thickness, to a second axial position, which corresponds to another printing-material thickness and is axially parallel to the first axial position.
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FIELD OF THE INVENTION
[0001] The invention relates to fungicide, pesticide, and acaricide. Specifically to a novel substituted pyrimidine compounds and uses thereof.
BACKGROUND OF THE INVENTION
[0002] Compounds represented by following general formula and specific compound (No. 47 compound in Patent EP0370704 and No. A compound in Patent JP2009161472) were reported in Patent EP0370704 and JP2009161472, some compounds have some fungicidal and insecticidal activities. Known as a developed commercial fungicide, its English general name is diflumetorim, and Chinese name is Fumijunan. Specific compound (No. 5 compound in the literature) was also reported effective to wheat rust and barley powdery mildew in Pesticide Science. 1999, 55: 896-902.
[0000]
[0003] The preparation method of specific compound (No. 7 compound in Patent JP11012253) were reported in Patent JP11012253, JP11049759 and EP0665225, and its English general name is flufenerim, and Chinese name is Michongan.
[0000]
[0004] The preparation method of specific pyrimidinamine compounds represented by following general formula CK1, CK2, CK3 and CK4 (No. 83, 87, 101 and 41 compounds in Patent EP0665225) were reported in Patent EP0665225, JP10036355 and U.S. Pat. No. 5,498,612, their fungicidal, insecticidal and acricidal activities were also reported.
[0000]
[0005] Compounds represented by following general formula and specific compound (No. 447 compound) were reported in U.S. Pat. No. 5,925,644, some compounds have some fungicidal, acricidal and nematicidal activities.
[0000]
[0006] Disclosed in Patent EP264217, DE3786390, U.S. Pat. No. 4,895,849, U.S. Pat. No. 4,985,426 and JP63225364 are substituted pyrimidine benzylamine compounds having a structure as represented by following formula and the specific compound CK6 and CK7 (No. 77 and 74 compounds in Patent EP264217) applied as fungicide, insecticide and acricide.
[0000]
[0007] Disclosed in Patent WO9507278 is the compound having a structure as represented by following formula with application as fungicide, acricide and/or insecticide. Thereinto, the specific compound CK8, CK9 and CK10 were listed in No. 209 line of Table 1 without any biological activity reported.
[0000]
[0008] Disclosed in U.S. Pat. No. 5,227,387 are the compound having a structure as represented by following formula and the specific compound CK11 (No. 81 compound in the patent) applied as nematicide.
[0000]
[0009] Compound represented by following formula and the specific compound CK12 (No. 29 compound in the patent) with application as fungicide and insecticide were disclosed in U.S. Pat. No. 5,326,766.
[0000]
[0010] Compound represented by following formula and the specific compound CK13 (No. 98 compound in the patent), CK14 (No. 271 compound in the patent) and CK15 (No. 117 compound in the patent) with application as fungicide and insecticide were disclosed in Patent EP534341.
[0000]
[0011] Compound represented by following general formula and the specific compound CK16 (No. 26 compound in the patent) applied as fungicide, insecticide and acricide were disclosed in Patent WO9728133.
[0000]
[0012] Compound represented by following general formula and the specific compound CK17 (No. 2.50 compound in U.S. Pat. No. 5,468,751) with application as fungicide, insecticide and acricide were disclosed in U.S. Pat. No. 5,468,751 and EP470600.
[0000]
[0013] Compound represented by following general formula with application as inhibitor to treat HIV-1 was disclosed in Literature Bioorganic & Medicinal Chemistry Letters, 2007. 17: 260-265.
[0000]
[0014] The following compound CK18 (No. 46 compound in the patent) and CK19 (No. 49 compound in the patent) were reported with good insecticidal activity at the concentration of 50 ppm and good fungicidal activity at the concentration of 400 and 100 ppm.
[0000]
[0015] The following compound CK20 (CAS No 0.203734-18-3) and CK21 (CAS No. 203734-22-9) were retrieved via Scifinder database without both specific literature and biological activity disclosed.
[0000]
[0016] However, substituted pyrimidine compounds represented by general formula PY of the present invention have not been reported in prior literature.
SUMMARY OF THE INVENTION
[0017] The object of the present invention is to provide a novel substituted pyrimidine compounds, which can be used to prepare fungicides, pesticides, and acaricides against harmful fungus, bacteria, insects, and mites in agricultural or other fields.
[0018] Detailed descriptions of the invention are as follows:
[0019] The present invention provides a kind of substituted pyrimidine compounds having a structure as represented by general formula PY:
[0000]
[0020] Wherein:
[0021] R 1 is selected from H, halo, cyano, C 1 -C 12 alkyl, C 3 -C 12 cycloalkyl, haloC 1 -C 12 alkyl, cyanoC 1 -C 12 alkyl, cyanoC 1 -C 12 alkoxy, C 2 -C 12 alkenyl, haloC 2 -C 12 alkenyl, C 2 -C 12 alkynyl, haloC 2 -C 12 alkynyl, C 1 -C 12 alkoxyC 1 -C 12 alkyl, haloC 1 -C 12 alkoxyC 1 -C 12 alkyl, C 1 -C 12 alkoxycarbonylC 1 -C 12 alkyl, C 1 -C 12 alkylaminocarbonylC 1 -C 12 alkyl or di(C 1 -C 12 alkyl)aminocarbonylC 1 -C 12 alkyl;
[0022] R 2 is selected from H, halo, cyano, C 3 -C 12 cycloalkyl, C 1 -C 12 alkyl, C 1 -C 12 alkoxy or haloC 1 -C 12 alkoxy;
[0023] R 3 , R 4 may be the same or different, selected respectively from H, halo, OH, amino, C 1 -C 12 alkyl, C 1 -C 12 alkoxy, C 3 -C 12 cycloalkyl, C 2 -C 12 alkenyl, C 2 -C 12 alkynyl, haloC 2 -C 12 alkenyl, haloC 2 -C 12 alkynyl, C 1 -C 12 alkoxyC 1 -C 12 alkyl, unsubstituted or further substituted arylC 1 -C 6 alkyl or heteroarylC 1 -C 6 alkyl by 1 to 5 following groups: halo, C 1 -C 6 alkyl, haloC 1 -C 6 alkyl, C 1 -C 6 alkoxy or haloC 1 -C 6 alkoxy; or R 3 , R 4 and conjoint carbon can also form a C 3 -C 8 cycle;
[0024] R 5a , R 5b , R 5c may be the same or different, selected respectively from H, halo, OH, NO 2 , cyano, C 1 -C 12 alkyl, haloC 1 -C 12 alkyl, C 3 -C 12 cycloalkyl, C 1 -C 12 alkoxy, haloC 1 -C 12 alkoxy, C 1 -C 12 alkylthio, haloC 1 -C 12 alkylthio, C 2 -C 12 alkenyl, haloC 2 -C 12 alkenyl, C 2 -C 12 alkynyl, haloC 2 -C 12 alkynyl, C 3 -C 12 alkenoxy, haloC 3 -C 12 alkenoxy, C 3 -C 12 alkynoxy, haloC 3 -C 12 alkynoxy, C 1 -C 12 alkylsulfinyl, haloC 1 -C 12 alkylsulfinyl, C 1 -C 12 alkylsulfonyl, haloC 1 -C 12 alkylsulfonyl, C 1 -C 12 alkylcarbonyl, haloC 1 -C 12 alkylcarbonyl, C 1 -C 12 alkylcarbonyloxy, C 1 -C 12 alkylcarbonylamino, C 1 -C 12 alkylsulfonyloxy, C 1 -C 12 alkoxycarbonyl, C 1 -C 12 alkoxycarbonylC 1 -C 12 alkyl, C 1 -C 12 alkoxycarbonylamino, C 1 -C 12 alkoxyC 1 -C 12 alkoxy or C 1 -C 12 alkoxycarbonylC 1 -C 12 alkoxy;
[0025] X 1 is selected from N or CR 6 ; X 2 is selected from N or CR 7 ; X 3 is selected from N or CR 8 ; X 4 is selected from N or CR 9 ; X 5 is selected from N or CR 10 ; X 6 is selected from N or CR 11 ; however, X 2 , X 3 , X 4 , X 5 , X 6 are not simultaneously selected from N;
[0026] R 6 , R 7 , R 8 , R 9 , R 10 , R 11 may be the same or different, selected respectively from H, halo, OH, cyano, HO(C═O), amino, NO 2 , C 1 -C 12 alkyl, haloC 1 -C 12 alkyl, C 1 -C 12 alkoxy, haloC 1 -C 12 alkoxy, C 3 -C 12 cycloalkyl, C 2 -C 12 alkenyl, C 2 -C 12 alkynyl, C 2 -C 12 alkenoxy, haloC 2 -C 12 alkenoxy, C 2 -C 12 alkynoxy, haloC 2 -C 12 alkynoxy, C 1 -C 12 alkylthio, haloC 1 -C 12 alkylthio, C 1 -C 12 alkoxyC 1 -C 12 alkyl, haloC 1 -C 12 alkoxyC 1 -C 12 alkyl, C 1 -C 12 alkylthioC 1 -C 12 alkyl, haloC 1 -C 12 alkylthioC 1 -C 12 alkyl, C 1 -C 12 alkylsulfinyl, haloC 1 -C 12 alkylsulfinyl, C 1 -C 12 alkylsulfonyl, haloC 1 -C 12 alkylsulfonyl, C 1 -C 12 alkylaminosulfonyl, C 1 -C 12 alkylamino, haloC 1 -C 12 alkylamino, di(C 1 -C 12 alkyl)amino, halo di(C 1 -C 12 alkyl)amino, C 1 -C 12 alkylcarbonyl, haloC 1 -C 12 alkylcarbonyl, C 1 -C 12 alkoxycarbonyl, haloC 1 -C 12 alkoxycarbonyl, di(C 1 -C 12 alkyl)amino(C 1 -C 12 alkyl), CONH 2 , CONHNH 2 , CON(C 1 -C 12 alkyl)NH 2 , CONHNH(C 1 -C 12 alkyl), CONHN(di(C 1 -C 12 alkyl)), CONHNHCO(C 1 -C 12 alkyl), CONHNHCO 2 (C 1 -C 12 alkyl), CONHNH(phenyl), C 1 -C 12 alkylaminocarbonyl, di(C 1 -C 12 alkyl)aminocarbonyl, halo di(C 1 -C 12 alkyl)aminocarbonyl, C 1 -C 12 alkylsulfonylamino, C 1 -C 12 alkylsulfonyl(C 1 -C 12 alkyl)amino, haloC 1 -C 12 alkylsulfonylamino, C 1 -C 12 alkoxyamino, C 1 -C 12 alkoxycarbonylamino, C 1 -C 12 alkoxyaminocarbonyl, cyanoC 1 -C 12 alkyl, cyanoC 1 -C 12 alkoxy, C 1 -C 12 alkoxycarbonylC 1 -C 12 alkyl, haloC 1 -C 12 alkoxycarbonylC 1 -C 12 alkyl, C 1 -C 12 alkylaminocarbonylC 1 -C 12 alkyl, di(C 1 -C 12 alkyl)aminocarbonylC 1 -C 12 alkyl, C 1 -C 12 alkylthiocarbonylC 1 -C 12 alkyl, haloC 1 -C 12 alkylthiocarbonylC 1 -C 12 alkyl, C 1 -C 12 alkylcarbonyloxy, haloC 1 -C 12 alkylcarbonyloxy, C 1 -C 12 alkoxycarbonyloxy, haloC 1 -C 12 alkoxycarbonyloxy, C 1 -C 12 alkylaminocarbonyloxy, haloC 1 -C 12 alkylaminocarbonyloxy, C 1 -C 12 alkylsulfonyloxy, haloC 1 -C 12 alkylsulfonyloxy, C 1 -C 12 alkoxyC 1 -C 12 alkoxy, haloC 1 -C 12 alkoxyC 1 -C 12 alkoxy, C 1 -C 12 alkoxycarbonylC 1 -C 12 alkoxy or haloC 1 -C 12 alkoxycarbonylC 1 -C 12 alkoxy;
[0027] W is selected from H, halo, C 1 -C 12 alkyl, C 1 -C 12 alkoxy, C 1 -C 12 alkylthio or C 1 -C 12 alkylsulfonyl;
[0028] A is selected from O, S or NR 12 ;
[0029] B is selected from —CH 2 — or —CH 2 CH 2 —;
[0030] R 12 is selected from H, OH, H(C)═O, C 1 -C 12 alkyl, haloC 1 -C 12 alkyl, C 1 -C 12 alkoxy, haloC 1 -C 12 alkoxy, C 3 -C 12 cycloalkyl, C 1 -C 12 alkylthio, C 2 -C 12 alkenylthio, C 2 -C 12 alkenyl, C 2 -C 12 alkynyl, haloC 2 -C 12 alkenyl, haloC 2 -C 12 alkynyl, C 1 -C 12 alkoxyC 1 -C 12 alkyl, haloC 1 -C 12 alkoxyC 1 -C 12 alkyl, C 1 -C 12 alkylthioC 1 -C 12 alkyl, haloC 1 -C 12 alkylthioC 1 -C 12 alkyl, C 1 -C 12 alkylsulfinyl, haloC 1 -C 12 alkylsulfinyl, C 1 -C 12 alkylsulfonyl, haloC 1 -C 12 alkylsulfonyl, C 1 -C 12 alkylaminosulfonyl, di(C 1 -C 12 alkyl)aminosulfonyl, C 1 -C 12 alkylsulfonylaminocarbonyl, C 1 -C 12 alkylcarbonylaminosulfonyl, C 3 -C 12 cycloalkyloxycarbonyl, C 1 -C 12 alkylcarbonyl, haloC 1 -C 12 alkylcarbonyl, C 1 -C 12 alkoxycarbonyl, haloC 1 -C 12 alkoxycarbonyl, C 1 -C 12 alkylcarbonylC 1 -C 12 alkyl, C 1 -C 12 alkoxycarbonylC 1 -C 12 alkyl, C 1 -C 12 alkylaminocarbonyl, di(C 1 -C 12 alkyl)aminocarbonyl, C 2 -C 12 alkenoxycarbonyl, C 2 -C 12 alkynoxycarbonyl, C 1 -C 12 alkoxyC 1 -C 12 alkoxycarbonyl, C 1 -C 12 alkylaminothio, di(C 1 -C 12 alkyl)aminothio, unsubstituted or further substituted (hetero)arylcarbonylC 1 -C 6 alkyl, (hetero)arylcarbonyl, (hetero)aryloxycarbonyl, (hetero)arylC 1 -C 6 alkyloxycarbonyl or (hetero)arylC 1 -C 6 alkyl by 1 to 5 following groups: halo, NO 2 , cyano, C 1 -C 6 alkyl, haloC 1 -C 6 alkyl, C 1 -C 6 alkoxy or haloC 1 -C 6 alkoxy;
[0031] Or the salts or complexes formed from the compounds represented by general formula PY.
[0032] The technical scheme of the present invention can be further subdivided into three optimization of technical schemes.
[0033] The first optimization of technical schemes is: the compounds represented by formula PY, wherein, X 1 is selected from CR 6 , X 2 is selected from N or CR 7 , X 3 is selected from N or CR 8 , X 4 is selected from CR 9 , X 5 is selected from CR 10 , X 6 is selected from N or CR 11 , within X 2 , X 3 and X 6 , at least one of which is selected from N, other substituents are defined as above, the compound having a structure as represented by formula I is as fellows.
[0034] The second optimization of technical schemes is: the compounds represented by formula PY, wherein, X 1 is selected from CR 6 , X 2 is selected from CR 7 , X 3 is selected from CR 8 , X 4 is selected from CR 9 , X 5 is selected from CR 10 , X 6 is selected from CR 11 , other substituents are defined as above, the compound having a structure as represented by formula II is as fellows.
[0035] The third optimization of technical schemes is: the compounds represented by formula PY, wherein, X 1 is selected from N, X 2 is selected from N or CR 7 , X 3 is selected from N or CR 8 , X 4 is selected from N or CR 9 , X 5 is selected from CR 10 , X 6 is selected from N or CR 11 , within X 2 , X 3 , X 4 and X 6 , at least one of which is selected from N, other substituents are defined as above, the compound having a structure as represented by formula III is as fellows.
[0000]
[0036] Detailed descriptions of three technical schemes of present invention are respectively disclosed.
[0037] The first optimization of technical schemes is:
[0038] the compounds having a structure as represented by formula I are as fellows.
[0000]
[0039] Wherein:
[0040] R 1 is selected from cyano, C 3 -C 12 cycloalkyl, C 1 -C 12 alkyl, halomethyl, cyanoC 1 -C 12 alkyl, cyanoC 1 -C 12 alkoxy, C 1 -C 12 alkoxycarbonylC 1 -C 12 alkyl, C 1 -C 12 alkylaminocarbonylC 1 -C 12 alkyl or di(C 1 -C 12 alkyl)aminocarbonylC 1 -C 12 alkyl;
[0041] R 2 is selected from halo, cyano, C 3 -C 12 cycloalkyl, C 1 -C 12 alkyl or C 1 -C 12 alkoxy;
[0042] R 3 , R 4 may be the same or different, selected respectively from H, halo, OH, amino, C 1 -C 12 alkyl or C 1 -C 12 alkoxy;
[0043] R 5a , R 5b , R 5c may be the same or different, selected respectively from H, halo, OH, C 1 -C 12 alkyl or C 1 -C 12 alkoxy;
[0044] X 2 is selected from N or CR 7 , X 3 is selected from N or CR 8 , X 6 is selected from N or CR 11 , within X 2 , X 3 , X 6 , at least one substituent is selected from N;
[0045] R 9 is selected from H, halo, OH, cyano, HO(C═O), amino, NO 2 , C 1 -C 12 alkyl, haloC 1 -C 12 alkyl, C 1 -C 12 alkoxy, haloC 1 -C 12 alkoxy, C 3 -C 12 cycloalkyl, C 2 -C 12 alkenyl, C 2 -C 12 alkynyl, C 2 -C 12 alkenoxy, haloC 2 -C 12 alkenoxy, C 2 -C 12 alkynoxy, haloC 2 -C 12 alkynoxy, C 1 -C 12 alkylthio, haloC 1 -C 12 alkylthio, C 1 -C 12 alkoxyC 1 -C 12 alkyl, haloC 1 -C 12 alkoxyC 1 -C 12 alkyl, C 1 -C 12 alkylthioC 1 -C 12 alkyl, haloC 1 -C 12 alkylthioC 1 -C 12 alkyl, C 1 -C 12 alkylsulfinyl, haloC 1 -C 12 alkylsulfinyl, C 1 -C 12 alkylsulfonyl, haloC 1 -C 12 alkylsulfonyl, C 1 -C 12 alkylaminosulfonyl, C 1 -C 12 alkylamino, haloC 1 -C 12 alkylamino, di(C 1 -C 12 alkyl)amino, C 1 -C 12 alkoxycarbonyl, di(C 1 -C 12 alkyl)amino(C 1 -C 12 alkyl), haloC 1 -C 12 alkoxycarbonyl, CONH 2 , CONHNH 2 , CON(C 1 -C 12 alkyl)NH 2 , CONHNH(C 1 -C 12 alkyl), CONHN(di(C 1 -C 12 alkyl)), CONHNHCO(C 1 -C 12 alkyl), CONHNHCO 2 (C 1 -C 12 alkyl), CONHNH(phenyl), C 1 -C 12 alkylaminocarbonyl, di(C 1 -C 12 alkyl)aminocarbonyl, C 1 -C 12 alkylsulfonylamino, C 1 -C 12 alkylsulfonyl(C 1 -C 12 alkyl)amino, haloC 1 -C 12 alkylsulfonylamino, C 1 -C 12 alkoxyamino, C 1 -C 12 alkoxycarbonylamino, C 1 -C 12 alkoxyaminocarbonyl, cyanoC 1 -C 12 alkyl, cyanoC 1 -C 12 alkoxy, C 1 -C 12 alkoxycarbonylC 1 -C 12 alkyl, C 1 -C 12 alkylaminocarbonylC 1 -C 12 alkyl or di(C 1 -C 12 alkyl)aminocarbonylC 1 -C 12 alkyl;
[0046] R 6 , R 7 , R 8 , R 10 , R 11 may be the same or different, selected respectively from H, halo, OH, cyano, HO(C═O), amino, NO 2 , C 1 -C 12 alkyl, haloC 1 -C 12 alkyl, C 1 -C 12 alkoxy, haloC 1 -C 12 alkoxy, C 3 -C 12 cycloalkyl, C 2 -C 12 alkenyl, C 2 -C 12 alkynyl, C 2 -C 12 alkenoxy, haloC 2 -C 12 alkenoxy, C 2 -C 12 alkynoxy, haloC 2 -C 12 alkynoxy, C 1 -C 12 alkylthio, haloC 1 -C 12 alkylthio, C 1 -C 12 alkoxyC 1 -C 12 alkyl, haloC 1 -C 12 alkoxyC 1 -C 12 alkyl, C 1 -C 12 alkylthioC 1 -C 12 alkyl, haloC 1 -C 12 alkylthioC 1 -C 12 alkyl, C 1 -C 12 alkylsulfinyl, haloC 1 -C 12 alkylsulfinyl, C 1 -C 12 alkylsulfonyl, haloC 1 -C 12 alkylsulfonyl, C 1 -C 12 alkylamino, haloC 1 -C 12 alkylamino, di(C 1 -C 12 alkyl)amino, C 1 -C 12 alkoxycarbonyl, CONH 2 , C 1 -C 12 alkylaminocarbonyl or di(C 1 -C 12 alkyl)aminocarbonyl;
[0047] W is selected from H or C 1 -C 12 alkyl;
[0048] A is selected from O, S or NR 12 ;
[0049] B is selected from —CH 2 — or —CH 2 CH 2 —;
[0050] R 12 is selected from H, OH, H(C)═O, C 1 -C 12 alkyl, haloC 1 -C 12 alkyl, C 1 -C 12 alkoxy, haloC 1 -C 12 alkoxy, C 3 -C 12 cycloalkyl, C 1 -C 12 alkylthio, C 2 -C 12 alkenylthio, C 2 -C 12 alkenyl, C 2 -C 12 alkynyl, haloC 2 -C 12 alkenyl, haloC 2 -C 12 alkynyl, C 1 -C 12 alkoxyC 1 -C 12 alkyl, haloC 1 -C 12 alkoxyC 1 -C 12 alkyl, C 1 -C 12 alkylthioC 1 -C 12 alkyl, haloC 1 -C 12 alkylthioC 1 -C 12 alkyl, C 1 -C 12 alkylsulfinyl, haloC 1 -C 12 alkylsulfinyl, C 1 -C 12 alkylsulfonyl, haloC 1 -C 12 alkylsulfonyl, C 1 -C 12 alkylaminosulfonyl, di(C 1 -C 12 alkyl)aminosulfonyl, C 1 -C 12 alkylsulfonylaminocarbonyl, C 1 -C 12 alkylcarbonylaminosulfonyl, C 3 -C 12 cycloalkyloxycarbonyl, C 1 -C 12 alkylcarbonyl, haloC 1 -C 12 alkylcarbonyl, C 1 -C 12 alkoxycarbonyl, haloC 1 -C 12 alkoxycarbonyl, C 1 -C 12 alkylcarbonylC 1 -C 12 alkyl, C 1 -C 12 alkoxycarbonylC 1 -C 12 alkyl, C 1 -C 12 alkylaminocarbonyl, di(C 1 -C 12 alkyl)aminocarbonyl, C 2 -C 12 alkenoxycarbonyl, C 2 -C 12 alkynoxycarbonyl, C 1 -C 12 alkoxyC 1 -C 12 alkoxycarbonyl, C 1 -C 12 alkylaminothio, di(C 1 -C 12 alkyl)aminothio, unsubstituted or further substituted (hetero)arylcarbonylC 1 -C 6 alkyl, (hetero)arylcarbonyl, (hetero)aryloxycarbonyl, (hetero)arylC 1 -C 6 alkyloxycarbonyl or (hetero)arylC 1 -C 6 alkyl by 1 to 5 following groups: halo, NO 2 , cyano, C 1 -C 6 alkyl, haloC 1 -C 6 alkyl, C 1 -C 6 alkoxy or haloC 1 -C 6 alkoxy;
[0051] Or the salts or complexes formed from the compounds represented by general formula I.
[0052] The preferred compounds represented by general formula I of this invention are:
[0053] R 1 is selected from cyano, C 3 -C 6 cycloalkyl, C 1 -C 6 alkyl, halomethyl, cyanoC 1 -C 6 alkyl, cyanoC 1 -C 6 alkoxy, C 1 -C 6 alkoxycarbonylC 1 -C 6 alkyl, C 1 -C 6 alkylaminocarbonylC 1 -C 6 alkyl or di(C 1 -C 6 alkyl)aminocarbonylC 1 -C 6 alkyl;
[0054] R 2 is selected from halo, cyano, C 3 -C 6 cycloalkyl, C 1 -C 6 alkylorC 1 -C 6 alkoxy;
[0055] R 3 , R 4 may be the same or different, selected respectively from H, halo, OH, amino, C 1 -C 6 alkyl or C 1 -C 6 alkoxy;
[0056] R 5a , R 5b , R 5c may be the same or different, selected respectively from H, halo, OH, C 1 -C 6 alkyl or C 1 -C 6 alkoxy;
[0057] X 2 is selected from N or CR 7 , X 3 is selected from N or CR 8 , X 6 is selected from N or CR 11 , within X 2 , X 3 , X 6 , at least one substituent is selected from N;
[0058] R 7 is selected from H, halo, cyano or C 1 -C 6 alkyl;
[0059] R 6 , R 8 may be the same or different, selected respectively from H, halo, cyano, C 1 -C 6 alkyl or C 1 -C 6 alkoxy;
[0060] R 9 is selected from H, halo, OH, cyano, HO(C═O), amino, NO 2 , C 1 -C 6 alkyl, haloC 1 -C 6 alkyl, C 1 -C 6 alkoxy, haloC 1 -C 6 alkoxy, C 3 -C 6 cycloalkyl, C 2 -C 6 alkenyl, C 2 -C 6 alkynyl, C 2 -C 6 alkenoxy, haloC 2 -C 6 alkenoxy, C 2 -C 6 alkynoxy, haloC 2 -C 6 alkynoxy, C 1 -C 6 alkylthio, haloC 1 -C 6 alkylthio, C 1 -C 6 alkoxyC 1 -C 6 alkyl, haloC 1 -C 6 alkoxyC 1 -C 6 alkyl, C 1 -C 6 alkylthioC 1 -C 6 alkyl, haloC 1 -C 6 alkylthioC 1 -C 6 alkyl, C 1 -C 6 alkylsulfinyl, haloC 1 -C 6 alkylsulfinyl, C 1 -C 6 alkylsulfonyl, haloC 1 -C 6 alkylsulfonyl, C 1 -C 6 alkylaminosulfonyl, C 1 -C 6 alkylamino, haloC 1 -C 6 alkylamino, di(C 1 -C 6 alkyl)amino, C 1 -C 6 alkoxycarbonyl, CONH 2 , C 1 -C 6 alkylaminocarbonyl, di(C 1 -C 6 alkyl)aminocarbonyl, cyanoC 1 -C 6 alkoxy, C 1 -C 6 alkoxycarbonylC 1 -C 6 alkyl, C 1 -C 6 alkylaminocarbonylC 1 -C 6 alkyl or di(C 1 -C 6 alkyl)aminocarbonylC 1 -C 6 alkyl;
[0061] R 10 is selected from H, halo, OH, cyano, HO(C═O), amino, NO 2 , C 1 -C 6 alkyl, haloC 1 -C 6 alkyl, C 1 -C 6 alkoxy, haloC 1 -C 6 alkoxy, C 3 -C 6 cycloalkyl, C 2 -C 6 alkenyl, C 2 -C 6 alkynyl, C 2 -C 6 alkenoxy, haloC 2 -C 6 alkenoxy, C 2 -C 6 alkynoxy, haloC 2 -C 6 alkynoxy, C 1 -C 6 alkylthio, haloC 1 -C 6 alkylthio, C 1 -C 6 alkoxyC 1 -C 6 alkyl, haloC 1 -C 6 alkoxyC 1 -C 6 alkyl, C 1 -C 6 alkylthioC 1 -C 6 alkyl, haloC 1 -C 6 alkylthioC 1 -C 6 alkyl, C 1 -C 6 alkylsulfinyl, haloC 1 -C 6 alkylsulfinyl, C 1 -C 6 alkylsulfonyl, haloC 1 -C 6 alkylsulfonyl, C 1 -C 6 alkylamino, haloC 1 -C 6 alkylamino, di(C 1 -C 6 alkyl)amino, C 1 -C 6 alkoxycarbonyl, CONH 2 , C 1 -C 6 alkylaminocarbonyl or di(C 1 -C 6 alkyl)aminocarbonyl;
[0062] R 11 is selected from H, halo, OH, cyano, HO(C═O), amino, NO 2 , C 1 -C 6 alkyl, haloC 1 -C 6 alkyl, C 1 -C 6 alkoxy, haloC 1 -C 6 alkoxy, C 1 -C 6 alkoxycarbonyl, CONH 2 , C 1 -C 6 alkylaminocarbonyl or di(C 1 -C 6 alkyl)aminocarbonyl;
[0063] W is selected from H or C 1 -C 6 alkyl;
[0064] A is selected from O, S or NR 12 ;
[0065] B is selected from —CH 2 — or —CH 2 CH 2 —;
[0066] R 12 is selected from H, OH, H(C)═O, C 1 -C 6 alkyl, C 1 -C 6 alkylcarbonyl or C 1 -C 6 alkylsulfonyl;
[0067] Or the salts formed from the compounds represented by general formula I with hydrochloric acid, sulfuric acid, nitric acid, phosphoric acid, formic acid, acetic acid, trifluoroacetic acid, oxalic acid, methylsulfonic acid, p-toluenesulfonic acid, benzoic acid, alizaric acid, maleic acid, sorbic acid, malic acid or citric acid.
[0068] In the general formula I, the preferred compounds represented by general formula I-A, I-B, I-C, I-D, I-E, I-F, I-G or I-H of this invention are:
[0000]
[0069] Wherein:
[0070] R 1 is selected from cyano, C 1 -C 4 alkyl or halomethyl;
[0071] R 2 is selected from halo, cyano, C 3 -C 4 cycloalkyl, C 1 -C 4 alkyl or C 1 -C 4 alkoxy;
[0072] R 3 , R 4 may be the same or different, selected respectively from H, halo, OH, amino, C 1 -C 4 alkyl or C 1 -C 4 alkoxy;
[0073] R 5b is selected from H, halo, OH, C 1 -C 4 alkyl or C 1 -C 4 alkoxy;
[0074] R 7 is selected from H, halo, cyano or C 1 -C 4 alkyl;
[0075] R 8 is selected from H, halo, cyano, C 1 -C 4 alkyl or C 1 -C 4 alkoxy;
[0076] R 9 is selected from H, halo, OH, cyano, HO(C═O), amino, NO 2 , C 1 -C 4 alkyl, haloC 1 -C 4 alkyl, C 1 -C 4 alkoxy, haloC 1 -C 4 alkoxy, C 1 -C 4 alkylthio, haloC 1 -C 4 alkylthio, C 1 -C 4 alkoxyC 1 -C 4 alkyl, haloC 1 -C 4 alkoxyC 1 -C 4 alkyl, C 1 -C 4 alkylthioC 1 -C 4 alkyl, haloC 1 -C 4 alkylthioC 1 -C 4 alkyl, C 1 -C 4 alkylsulfinyl, haloC 1 -C 4 alkylsulfinyl, C 1 -C 4 alkylsulfonyl, haloC 1 -C 4 alkylsulfonyl, C 1 -C 4 alkylaminosulfonyl, C 1 -C 4 alkylamino, haloC 1 -C 4 alkylamino, di(C 1 -C 4 alkyl)amino, C 1 -C 4 alkoxycarbonyl, CONH 2 , C 1 -C 4 alkylaminocarbonyl, di(C 1 -C 4 alkyl)aminocarbonyl, cyanoC 1 -C 4 alkoxy, C 1 -C 4 alkoxycarbonylC 1 -C 4 alkyl, C 1 -C 4 alkylaminocarbonylC 1 -C 4 alkyl or di(C 1 -C 4 alkyl)aminocarbonylC 1 -C 4 alkyl;
[0077] R 10 is selected from H, halo, OH, cyano, HO(C═O), amino, NO 2 , C 1 -C 4 alkyl, haloC 1 -C 4 alkyl, C 1 -C 4 alkoxy, haloC 1 -C 4 alkoxy, C 3 -C 4 cycloalkyl, C 2 -C 4 alkenyl, C 2 -C 4 alkynyl, C 2 -C 4 alkenoxy, haloC 2 -C 4 alkenoxy, C 2 -C 4 alkynoxy, haloC 2 -C 4 alkynoxy, C 1 -C 4 alkylthio, haloC 1 -C 4 alkylthio, C 1 -C 4 alkoxyC 1 -C 4 alkyl, haloC 1 -C 4 alkoxyC 1 -C 4 alkyl, C 1 -C 4 alkylthioC 1 -C 4 alkyl, haloC 1 -C 4 alkylthioC 1 -C 4 alkyl, C 1 -C 4 alkylsulfinyl, haloC 1 -C 4 alkylsulfinyl, C 1 -C 4 alkylsulfonyl, haloC 1 -C 4 alkylsulfonyl, C 1 -C 4 alkylamino, haloC 1 -C 4 alkylamino, di(C 1 -C 4 alkyl)amino, C 1 -C 4 alkoxycarbonyl, CONH 2 , C 1 -C 4 alkylaminocarbonyl or di(C 1 -C 4 alkyl)aminocarbonyl;
[0078] R 11 is selected from H, halo, OH, cyano, HO(C═O), amino, NO 2 , C 1 -C 4 alkyl, haloC 1 -C 4 alkyl, C 1 -C 4 alkoxy, haloC 1 -C 4 alkoxy, C 1 -C 4 alkoxycarbonyl, CONH 2 , C 1 -C 4 alkylaminocarbonyl or di(C 1 -C 4 alkyl)aminocarbonyl;
[0079] Or the salts formed from the compounds represented by general formula I-A, I-B, I-C, I-D, I-E, I-F, I-G or I-H with hydrochloric acid, sulfuric acid, nitric acid, phosphoric acid, acetic acid, trifluoroacetic acid, oxalic acid, methylsulfonic acid, p-toluenesulfonic acid, benzoic acid, maleic acid, sorbic acid, malic acid or citric acid.
[0080] In the general formula I, further more, the preferred compounds represented by general formula I-A, I-B, I-C, I-D, I-E, I-F, I-G or I-H of this invention are:
[0081] R 1 is selected from cyano, CH 3 , C 2 H 5 , n-C 3 H 7 , i-C 3 H 7 , n-C 4 H 9 , s-C 4 H 9 , i-C 4 H 9 , t-C 4 H 9 , CH 2 Cl, CHCl 2 , CH 2 F, CHF 2 , CClF 2 , CCl 3 or CF 3 ;
[0082] R 2 is selected from F, Cl, Br, cyano, CH 3 , C 2 H 5 , OCH 3 or OC 2 H 5 ;
[0083] R 3 , R 4 may be the same or different, selected respectively from H, Cl, Br, OH, amino, CH 3 , C 2 H 5 , OCH 3 or OC 2 H 5 ;
[0084] R 5b is selected from H, Cl, Br, OH, CH 3 , C 2 H 5 , OCH 3 or OC 2 H 5 ;
[0085] R 7 is selected from H, Cl or cyano;
[0086] R 8 is selected from H, Cl, Br, cyano, CH 3 or OCH 3 ;
[0087] R 9 is selected from H, F, Cl, Br, cyano, HO(C═O), amino, NO 2 , CH 3 , C 2 H 5 , CF 3 , CClF 2 , OCH 3 , OC 2 H 5 , OCF 3 , COOCH 3 , COOC 2 H 5 , CONH 2 , CONHCH 3 , CONHC 2 H 5 , CON(CH 3 ) 2 , SO 2 CH 3 or SO 2 NHCH 3 ;
[0088] R 10 is selected from H, Cl, cyano, CH 3 , C 2 H 5 , OCH 3 or OC 2 H 5 ;
[0089] R 11 is selected from H, F, Cl, Br, cyano, HO(C═O), amino, NO 2 , CH 3 , C 2 H 5 , CF 3 , CClF 2 , OCH 3 , OC 2 H 5 , OCF 3 , COOCH 3 , COOC 2 H 5 , CONH 2 , CONHCH 3 , CONHC 2 H 5 or CON(CH 3 ) 2 ;
[0090] Or the salts formed from the compounds represented by general formula I-A, I-B, I-C, I-D, I-E, I-F, I-G or I-H with hydrochloric acid, sulfuric acid, nitric acid, phosphoric acid, acetic acid, trifluoroacetic acid, oxalic acid, methylsulfonic acid, p-toluenesulfonic acid, maleic acid or benzoic acid.
[0091] Even more preferred compounds represented by general formula I of this invention are:
[0092] In the general formula I-A,
[0093] R 1 is selected from CH 3 , C 2 H 5 , CH 2 Cl, CHF 2 , CClF 2 , CCl 3 or CF 3 ;
[0094] R 2 is selected from Cl, Br or cyano;
[0095] R 3 , R 4 , R 10 is selected from H;
[0096] R 5b is selected from H, Cl, Br or OCH 3 ;
[0097] R 8 is selected from H or Cl;
[0098] R 9 is selected from H, Cl, cyano, CF 3 , CClF 2 , COOCH 3 , COOC 2 H 5 or CONH 2 ;
[0099] R 11 is selected from H, Cl, NO 2 , CF 3 , COOCH 3 or CONHCH 3 ;
[0100] Or, in the general formula I-B,
[0101] R 1 is selected from CH 3 , C 2 H 5 or CHF 2 ;
[0102] R 2 is selected from Cl, Br or cyano;
[0103] R 9 is selected from Cl, Br, cyano or CF 3 ;
[0104] R 3 , R 4 , R 5b , R 10 , R 11 is selected from H;
[0105] Or, in the general formula I-C,
[0106] R 1 is selected from CH 3 , C 2 H 5 or CHF 2 ;
[0107] R 2 is selected from Cl, Br or cyano;
[0108] R 3 , R 4 , R 5b , R 9 is selected from H;
[0109] R 8 , R 10 is selected from CH 3 or OCH 3 ;
[0110] Or, in the general formula I-E,
[0111] R 1 is selected from CH 3 , C 2 H 5 or CHF 2 ;
[0112] R 2 is selected from Cl, Br or cyano;
[0113] R 3 , R 4 , R 5b , R 8 , R 10 is selected from H;
[0114] R 9 is selected from H, Cl, cyano, CF 3 , COOCH 3 , COOC 2 H 5 or CONH 2 ;
[0115] R 11 is selected from H, Cl or CF 3 ;
[0116] Or the salts formed from the compounds represented by general formula I-A, I-B, I-C or I-E with hydrochloric acid, sulfuric acid, nitric acid, phosphoric acid, acetic acid, trifluoroacetic acid, oxalic acid, methylsulfonic acid, p-toluenesulfonic acid, maleic acid or benzoic acid.
[0117] Most preferred compounds represented by general formula I of this invention are:
[0118] In the general formula I-A,
[0119] R 1 is selected from CH 3 , C 2 H 5 , CH 2 Cl, CHF 2 or CF 3 ;
[0120] R 2 is selected from Cl, Br or cyano;
[0121] R 3 , R 4 , R 5b , R 10 is selected from H;
[0122] R 9 is selected from Cl, cyano or CF 3 ;
[0123] R 8 , R 11 is selected from H or Cl;
[0124] Or, in the general formula I-B,
[0125] R 1 is selected from CH 3 , C 2 H 5 or CHF 2 ;
[0126] R 2 , R 9 is selected from Cl, Br or cyano;
[0127] R 3 , R 4 , R 5b , R 10 , R 11 is selected from H;
[0128] Or the salts formed from the compounds represented by general formula I-A or I-B with hydrochloric acid, sulfuric acid, nitric acid, phosphoric acid, acetic acid, trifluoroacetic acid, oxalic acid, methylsulfonic acid, p-toluenesulfonic acid, maleic acid or benzoic acid.
[0129] The second optimization of technical schemes is:
[0130] The compounds having a structure as represented by formula II are as fellows.
[0000]
[0131] Wherein:
[0132] R 1 is selected from C 1 -C 12 alkyl, C 3 -C 8 cycloalkyl or halomethyl;
[0133] R 2 is selected from halo, cyano or C 1 -C 4 alkoxy;
[0134] R 3 , R 4 may be the same or different, selected respectively from H, halo, C 1 -C 12 alkyl, C 1 -C 12 alkoxy or C 3 -C 12 cycloalkyl; or R 3 , R 4 and conjoint carbon can also form a C 3 -C 8 cycle;
[0135] R 5a , R 5b , R 5c may be the same or different, selected respectively from H, halo, OH, C 1 -C 12 alkyl or C 1 -C 12 alkoxy;
[0136] R 6 , R 7 , R 8 , R 9 , R 10 , R 11 may be the same or different, selected respectively from H, halo, OH, amino, cyano, NO 2 , C 1 -C 12 alkyl, haloC 1 -C 12 alkyl, C 1 -C 12 alkoxy, haloC 1 -C 12 alkoxy, C 3 -C 12 cycloalkyl, C 1 -C 12 alkylamino, haloC 1 -C 12 alkylamino, di(C 1 -C 12 alkyl)amino, halo di(C 1 -C 12 alkyl)amino, C 1 -C 12 alkylaminocarbonyl, di(C 1 -C 12 alkyl)aminocarbonyl, halo di(C 1 -C 12 alkyl)aminocarbonyl, CONH 2 , C 1 -C 12 alkylthio, haloC 1 -C 12 alkylthio, C 2 -C 12 alkenyl, C 2 -C 12 alkynyl, C 2 -C 12 alkenoxy, haloC 2 -C 12 alkenoxy, C 2 -C 12 alkynoxy, haloC 2 -C 12 alkynoxy, C 1 -C 12 alkylsulfonyl, haloC 1 -C 12 alkylsulfonyl, C 1 -C 12 alkylcarbonyl, haloC 1 -C 12 alkylcarbonyl, C 1 -C 12 alkoxycarbonyl, haloC 1 -C 12 alkoxycarbonyl, C 1 -C 12 alkoxyC 1 -C 12 alkyl, haloC 1 -C 12 alkoxyC 1 -C 12 alkyl, C 1 -C 12 alkylthioC 1 -C 12 alkyl, haloC 1 -C 12 alkylthioC 1 -C 12 alkyl, C 1 -C 12 alkoxycarbonylC 1 -C 12 alkyl, haloC 1 -C 12 alkoxycarbonylC 1 -C 12 alkyl, C 1 -C 12 alkylthiocarbonylC 1 -C 12 alkyl, haloC 1 -C 12 alkylthiocarbonylC 1 -C 12 alkyl, C 1 -C 12 alkylcarbonyloxy, haloC 1 -C 12 alkylcarbonyloxy, C 1 -C 12 alkoxycarbonyloxy, haloC 1 -C 12 alkoxycarbonyloxy, C 1 -C 12 alkylaminocarbonyloxy, haloC 1 -C 12 alkylaminocarbonyloxy, C 1 -C 12 alkylsulfonyloxy, haloC 1 -C 12 alkylsulfonyloxy, C 1 -C 12 alkoxyC 1 -C 12 alkoxy, haloC 1 -C 12 alkoxyC 1 -C 12 alkoxy, C 1 -C 12 alkoxycarbonylC 1 -C 12 alkoxy or haloC 1 -C 12 alkoxycarbonylC 1 -C 12 alkoxy;
[0137] W is selected from H or C 1 -C 12 alkyl;
[0138] A is selected from NR 12 ;
[0139] B is selected from —CH 2 or —CH 2 CH 2 —;
[0140] R 12 is selected from H, OH, H(C)═O, haloC 1 -C 12 alkyl, C 1 -C 12 alkoxy, haloC 1 -C 12 alkoxy, C 3 -C 12 cycloalkyl, C 1 -C 12 alkylthio, C 2 -C 12 alkenylthio, C 2 -C 12 alkenyl, C 2 -C 12 alkynyl, haloC 2 -C 12 alkenyl, haloC 2 -C 12 alkynyl, C 1 -C 12 alkoxyC 1 -C 12 alkyl, haloC 1 -C 12 alkoxyC 1 -C 12 alkyl, C 1 -C 12 alkylthioC 1 -C 12 alkyl, haloC 1 -C 12 alkylthioC 1 -C 12 alkyl, C 1 -C 12 alkylsulfinyl, haloC 1 -C 12 alkylsulfinyl, C 1 -C 12 alkylsulfonyl, haloC 1 -C 12 alkylsulfonyl, C 1 -C 12 alkylaminosulfonyl, di(C 1 -C 12 alkyl)aminosulfonyl, C 1 -C 12 alkylsulfonylaminocarbonyl, C 1 -C 12 alkylcarbonylaminosulfonyl, C 3 -C 12 cycloalkyloxycarbonyl, C 1 -C 12 alkylcarbonyl, haloC 1 -C 12 alkylcarbonyl, C 1 -C 12 alkoxycarbonyl, haloC 1 -C 12 alkoxycarbonyl, C 1 -C 12 alkylcarbonylC 1 -C 12 alkyl, C 1 -C 12 alkoxycarbonylC 1 -C 12 alkyl, C 1 -C 12 alkylaminocarbonyl, di(C 1 -C 12 alkyl)aminocarbonyl, C 2 -C 12 alkenoxycarbonyl, C 2 -C 12 alkynoxycarbonyl, C 1 -C 12 alkoxyC 1 -C 12 alkoxycarbonyl, C 1 -C 12 alkylaminothio, di(C 1 -C 12 alkyl)aminothio, unsubstituted or further substituted (hetero)arylcarbonylC 1 -C 6 alkyl, (hetero)arylcarbonyl, (hetero)aryloxycarbonyl, (hetero)arylC 1 -C 6 alkyloxycarbonyl or (hetero)arylC 1 -C 6 alkyl by 1 to 5 following groups: halo, NO 2 , cyano, C 1 -C 6 alkyl, haloC 1 -C 6 alkyl, C 1 -C 6 alkoxy or haloC 1 -C 6 alkoxy;
[0141] Or the salts or complexes formed from the compounds of general formula II.
[0142] The preferred compounds represented by general formula II of this invention are:
[0143] R 1 is selected from C 1 -C 6 alkyl, C 3 -C 6 cycloalkyl or halomethyl;
[0144] R 2 is selected from halo, cyano or C 1 -C 4 alkoxy;
[0145] R 3 , R 4 may be the same or different, selected respectively from H, halo, C 1 -C 6 alkyl, C 1 -C 6 alkoxy or C 3 -C 6 cycloalkyl; or R 3 , R 4 and conjoint carbon can also form a C 3 -C 8 cycle;
[0146] R 5a , R 5b , R 5c , R 6 may be the same or different, selected respectively from H, halo, OH, C 1 -C 6 alkyl or C 1 -C 6 alkoxy;
[0147] R 7 , R 8 , R 9 , R 10 , R 11 may be the same or different, selected respectively from H, halo, OH, amino, cyano, NO 2 , C 1 -C 6 alkyl, haloC 1 -C 6 alkyl, C 1 -C 6 alkoxy, haloC 1 -C 6 alkoxy, C 3 -C 6 cycloalkyl, C 1 -C 6 alkylamino, haloC 1 -C 6 alkylamino, di(C 1 -C 6 alkyl)amino, halo di(C 1 -C 6 alkyl)amino, C 1 -C 6 alkylaminocarbonyl, di(C 1 -C 6 alkyl)aminocarbonyl, halo di(C 1 -C 6 alkyl)aminocarbonyl, CONH 2 , C 1 -C 6 alkylthio, haloC 1 -C 6 alkylthio, C 2 -C 6 alkenyl, C 2 -C 6 alkynyl, C 2 -C 6 alkenoxy, haloC 2 -C 6 alkenoxy, C 2 -C 6 alkynoxy, haloC 2 -C 6 alkynoxy, C 1 -C 6 alkylsulfonyl, haloC 1 -C 6 alkylsulfonyl, C 1 -C 6 alkylcarbonyl, haloC 1 -C 6 alkylcarbonyl, C 1 -C 6 alkoxycarbonyl, haloC 1 -C 6 alkoxycarbonyl, C 1 -C 6 alkoxyC 1 -C 6 alkyl, haloC 1 -C 6 alkoxyC 1 -C 6 alkyl, C 1 -C 6 alkylthioC 1 -C 6 alkyl, haloC 1 -C 6 alkylthioC 1 -C 6 alkyl, C 1 -C 6 alkoxycarbonylC 1 -C 6 alkyl, haloC 1 -C 6 alkoxycarbonylC 1 -C 6 alkyl, C 1 -C 6 alkylthiocarbonylC 1 -C 6 alkyl, haloC 1 -C 6 alkylthiocarbonylC 1 -C 6 alkyl, C 1 -C 6 alkylcarbonyloxy, haloC 1 -C 6 alkylcarbonyloxy, C 1 -C 6 alkoxycarbonyloxy, haloC 1 -C 6 alkoxycarbonyloxy, C 1 -C 6 alkylaminocarbonyloxy, haloC 1 -C 6 alkylaminocarbonyloxy, C 1 -C 6 alkylsulfonyloxy, haloC 1 -C 6 alkylsulfonyloxy, C 1 -C 6 alkoxyC 1 -C 6 alkoxy, haloC 1 -C 6 alkoxyC 1 -C 6 alkoxy, C 1 -C 6 alkoxycarbonylC 1 -C 6 alkoxy or haloC 1 -C 6 alkoxycarbonylC 1 -C 6 alkoxy;
[0148] W is selected from H or C 1 -C 3 alkyl;
[0149] A is selected from NR 12 ;
[0150] B is selected from —CH 2 — or —CH 2 CH 2 —;
[0151] Rig is selected from H, OH, H(C)═O, C 1 -C 6 alkyl, C 1 -C 6 alkylsulfonyl or C 1 -C 6 alkylcarbonyl;
[0152] Or the salts formed from the compounds represented by general formula II with hydrochloric acid, sulfuric acid, nitric acid, phosphoric acid, formic acid, acetic acid, trifluoroacetic acid, oxalic acid, methylsulfonic acid, p-toluenesulfonic acid, benzoic acid, alizaric acid, maleic acid, sorbic acid, malic acid or citric acid.
[0153] Furthermore, the preferred compounds represented by general formula II of this invention are:
[0154] R 1 is selected from C 1 -C 4 alkyl, C 3 -C 4 cycloalkyl or halomethyl;
[0155] R 2 is selected from F, Cl, Br or cyano;
[0156] R 3 , R 4 may be the same or different, selected respectively from H, halo, C 1 -C 4 alkyl, C 1 -C 4 alkoxy or C 3 -C 6 cycloalkyl; or R 3 , R 4 and conjoint carbon can also form a C 3 -C 8 cycle;
[0157] R 5a , R 5b , R 5c , R 6 may be the same or different, selected respectively from H, halo, OH, C 1 -C 4 alkyl or C 1 -C 4 alkoxy;
[0158] R 7 , R 8 , R 9 , R 10 , R 11 may be the same or different, selected respectively from H, halo, OH, amino, cyano, NO 2 , C 1 -C 4 alkyl, haloC 1 -C 4 alkyl, C 1 -C 4 alkoxy, haloC 1 -C 4 alkoxy, C 3 -C 4 cycloalkyl, C 1 -C 4 alkylamino, haloC 1 -C 4 alkylamino, di(C 1 -C 4 alkyl)amino, halo di(C 1 -C 4 alkyl)amino, C 1 -C 4 alkylaminocarbonyl, di(C 1 -C 4 alkyl)aminocarbonyl, halo di(C 1 -C 4 alkyl)aminocarbonyl, CONH 2 , C 1 -C 4 alkylthio, haloC 1 -C 4 alkylthio, C 2 -C 4 alkenyl, C 2 -C 4 alkynyl, C 2 -C 4 alkenoxy, haloC 2 -C 4 alkenoxy, C 2 -C 4 alkynoxy, haloC 2 -C 4 alkynoxy, C 1 -C 4 alkylsulfonyl, haloC 1 -C 4 alkylsulfonyl, C 1 -C 4 alkylcarbonyl, haloC 1 -C 4 alkylcarbonyl, C 1 -C 4 alkoxycarbonyl, haloC 1 -C 4 alkoxycarbonyl, C 1 -C 4 alkoxyC 1 -C 4 alkyl, haloC 1 -C 4 alkoxyC 1 -C 4 alkyl, C 1 -C 4 alkylthioC 1 -C 4 alkyl, haloC 1 -C 4 alkylthioC 1 -C 4 alkyl, C 1 -C 4 alkoxycarbonylC 1 -C 4 alkyl, haloC 1 -C 4 alkoxycarbonylC 1 -C 4 alkyl, C 1 -C 4 alkylthiocarbonylC 1 -C 4 alkyl, haloC 1 -C 4 alkylthiocarbonylC 1 -C 4 alkyl, C 1 -C 4 alkylcarbonyloxy, haloC 1 -C 4 alkylcarbonyloxy, C 1 -C 4 alkoxycarbonyloxy, haloC 1 -C 4 alkoxycarbonyloxy, C 1 -C 4 alkylaminocarbonyloxy, haloC 1 -C 4 alkylaminocarbonyloxy, C 1 -C 4 alkylsulfonyloxy, haloC 1 -C 4 alkylsulfonyloxy, C 1 -C 4 alkoxyC 1 -C 4 alkoxy, haloC 1 -C 4 alkoxyC 1 -C 4 alkoxy, C 1 -C 4 alkoxycarbonylC 1 -C 4 alkoxy or haloC 1 -C 4 alkoxycarbonylC 1 -C 4 alkoxy;
[0159] W is selected from H or CH 3 ;
[0160] A is selected from NR 12 ;
[0161] B is selected from —CH 2 — or —CH 2 CH 2 —;
[0162] R 12 is selected from H, OH, H(C)═O, C 1 -C 4 alkyl, C 1 -C 4 alkylsulfonyl or C 1 -C 4 alkylcarbonyl;
[0163] Or the salts formed from the compounds represented by general formula II with hydrochloric acid, sulfuric acid, nitric acid, phosphoric acid, acetic acid, trifluoroacetic acid, oxalic acid, methylsulfonic acid, p-toluenesulfonic acid, benzoic acid, maleic acid, sorbic acid, malic acid or citric acid.
[0164] Even more preferred compounds represented by formula II of this invention are:
[0165] R 1 is selected from CH 3 , C 2 H 5 , n-C 3 H 7 , i-C 3 H 7 , n-C 4 H 9 , s-C 4 H 9 , i-C 4 H 9 , t-C 4 H 9 , cyclopropyl, cyclobutyl, CF 3 , CCl 3 , CH 2 F, CH 2 Cl, CH 2 Br, CClF 2 , CCl 2 F, CHF 2 or CHCl 2 ;
[0166] R 2 is selected from F, Cl, Br or cyano;
[0167] R 3 , R 4 may be the same or different, selected respectively from H, F, Cl, Br, I, CH 3 , C 2 H 5 , n-C 3 H 7 , i-C 3 H 7 , n-C 4 H 9 , s-C 4 H 9 , i-C 4 H 9 , t-C 4 H 9 , OCH 3 , OC 2 H 5 , OC 3 H 7 -n, OC 3 H 7 -i, OC 4 H 9 -n, OC 4 H 9 -s, OC 4 H 9 -i or OC 4 H 9 -t;
[0168] R 5a , R 5b , R 5c , R 6 may be the same or different, selected respectively from H, F, Cl, Br, I, OH, CH 3 , C 2 H 5 , n-C 3 H 7 , i-C 3 H 7 , n-C 4 H 9 , s-C 4 H 9 , i-C 4 H 9 , t-C 4 H 9 , OCH 3 , OC 2 H 5 , OC 3 H 7 -n, OC 3 H 7 -i, OC 4 H 9 -n, OC 4 H 9 -s, OC 4 H 9 -i or OC 4 H 9 -t;
[0169] R 7 , R 8 , R 9 , R 10 , R 11 may be the same or different, selected respectively from H, F, Cl, Br, I, cyano, amino, NO 2 , CH 3 , C 2 H 5 , n-C 3 H 7 , i-C 3 H 7 , n-C 4 H 9 , s-C 4 H 9 , i-C 4 H 9 , t-C 4 H 9 , CF 3 , CCl 3 , CClF 2 , CCl 2 F, CHCl 2 , CH 2 F, CHF 2 , OCH 3 , OC 2 H 5 , OC 3 H 7 -n, OC 3 H 7 -i, OC 4 H 9 -n, OC 4 H 9 -s, OC 4 H 9 -i, OC 4 H 9 -t, OCF 3 , OCH 2 CF 3 , COOCH 3 , COOC 2 H 5 , CONH 2 , CONHCH 3 , CONHC 2 H 5 , CONH(CH 3 ) 2 , methylsulfonyl or trifluoromethylsulfonyl;
[0170] W is selected from H or CH 3 ;
[0171] A is selected from NR 12 ;
[0172] B is selected from —CH 2 — or —CH 2 CH 2 —;
[0173] R 12 is selected from H;
[0174] Or the salts formed from the compounds represented by general formula II with hydrochloric acid, sulfuric acid, nitric acid, phosphoric acid, acetic acid, trifluoroacetic acid, oxalic acid, methylsulfonic acid, p-toluenesulfonic acid, maleic acid or benzoic acid.
[0175] Even further more preferred compounds represented by formula II of this invention are:
[0176] R 1 is selected from CH 3 , C 2 H 5 , n-C 3 H 7 , i-C 3 H 7 , n-C 4 H 9 , s-C 4 H 9 , i-C 4 H 9 , t-C 4 H 9 , cyclopropyl, cyclobutyl, CH 2 Cl, CHCl 2 , CH 2 F, CHF 2 , CClF 2 , CCl 3 or CF 3 ;
[0177] R 2 is selected from F, Cl, Br or cyano;
[0178] R 3 , R 4 may be the same or different, selected respectively from H, F, Cl, Br, I, CH 3 , C 2 H 5 , n-C 3 H 7 , i-C 3 H 7 , OCH 3 , OC 2 H 5 , OC 3 H 7 -n or OC 3 H 7 -i;
[0179] R 5a , R 5b , R 5c , R 6 may be the same or different, selected respectively from H, F, Cl, Br or OCH 3 ;
[0180] R 7 , R 8 , R 9 , R 10 , R 11 may be the same or different, selected respectively from H, F, Cl, Br, I, cyano, NO 2 , CH 3 , C 2 H 5 , n-C 3 H 7 , i-C 3 H 7 , n-C 4 H 9 , s-C 4 H 9 , i-C 4 H 9 , t-C 4 H 9 , OCH 3 , OCF 3 , CF 3 , CCl 3 , CClF 2 , CCl 2 F, CHCl 2 , CH 2 F, CHF 2 , methylsulfonyl or trifluoromethylsulfonyl;
[0181] W is selected from H or CH 3 ;
[0182] A is selected from NH;
[0183] B is selected from —CH 2 — or —CH 2 CH 2 —;
[0184] Or the salts formed from the compounds of general formula II with hydrochloric acid, sulfuric acid, nitric acid, phosphoric acid, acetic acid, trifluoroacetic acid, oxalic acid, methylsulfonic acid, p-toluenesulfonic acid, maleic acid or benzoic acid.
[0185] Most preferred compounds represented by formula II of this invention are:
[0186] R 1 is selected from CH 3 , C 2 H 5 , CHF 2 or CF 3 ;
[0187] R 2 is selected from Cl or cyano;
[0188] R 3 , R 4 is selected from H;
[0189] R 5a , R 5b , R 5c , R 6 may be the same or different, selected respectively from H, F, Cl, Br or OCH 3 ;
[0190] W is selected from H or CH 3 ;
[0191] R 7 , R 8 , R 9 , R 10 , R 11 may be the same or different, selected respectively from H, F, Cl, cyano, NO 2 , CH 3 , OCH 3 , OCF 3 , CF 3 or methylsulfonyl;
[0192] A is selected from NH;
[0193] B is selected from —CH 2 — or —CH 2 CH 2 —;
[0194] Or the salts formed from the compounds represented by general formula II with hydrochloric acid, sulfuric acid, nitric acid, phosphoric acid, acetic acid or trifluoroacetic acid.
[0195] The third optimization of technical schemes is:
[0196] the compounds having a structure as represented by formula III are as fellows.
[0000]
[0197] R 1 is selected from halo, C 1 -C 12 alkyl, C 3 -C 12 cycloalkyl, haloC 1 -C 12 alkyl, C 2 -C 12 alkenyl, haloC 2 -C 12 alkenyl, C 2 -C 12 alkynyl, haloC 2 -C 12 alkynyl, C 1 -C 12 alkoxyC 1 -C 12 alkyl or haloC 1 -C 12 alkoxyC 1 -C 12 alkyl;
[0198] R 2 is selected from halo, cyano, C 1 -C 12 alkyl, C 1 -C 12 alkoxy or haloC 1 -C 12 alkoxy;
[0199] W is selected from H, halo, C 1 -C 12 alkyl, C 1 -C 12 alkoxy, C 1 -C 12 alkylthio or C 1 -C 12 alkylsulfonyl;
[0200] R 3 , R 4 may be the same or different, selected respectively from H, C 1 -C 12 alkyl, C 3 -C 12 cycloalkyl, C 2 -C 12 alkenyl, C 2 -C 12 alkynyl, haloC 2 -C 12 alkenyl, haloC 2 -C 12 alkynyl, C 1 -C 12 alkoxyC 1 -C 12 alkyl, unsubstituted or further substituted arylC 1 -C 6 alkyl or heteroarylC 1 -C 6 alkyl by 1 to 5 following groups: halo, C 1 -C 6 alkyl, haloC 1 -C 6 alkyl, C 1 -C 6 alkoxy or haloC 1 -C 6 alkoxy; or R 3 , R 4 and conjoint carbon can also form a C 3 -C 8 cycle;
[0201] R 5a , R 5b , R 5c may be the same or different, selected respectively from H, halo, NO 2 , cyano, C 1 -C 12 alkyl, haloC 1 -C 12 alkyl, C 3 -C 12 cycloalkyl, C 1 -C 12 alkoxy, haloC 1 -C 12 alkoxy, C 1 -C 12 alkylthio, haloC 1 -C 12 alkylthio, C 2 -C 12 alkenyl, haloC 2 -C 12 alkenyl, C 2 -C 12 alkynyl, haloC 2 -C 12 alkynyl, C 3 -C 12 alkenoxy, haloC 3 -C 12 alkenoxy, C 3 -C 12 alkynoxy, haloC 3 -C 12 alkynoxy, C 1 -C 12 alkylsulfinyl, haloC 1 -C 12 alkylsulfinyl, C 1 -C 12 alkylsulfonyl, haloC 1 -C 12 alkylsulfonyl, C 1 -C 12 alkylcarbonyl, haloC 1 -C 12 alkylcarbonyl, C 1 -C 12 alkylcarbonyloxy, C 1 -C 12 alkylcarbonylamino, C 1 -C 12 alkylsulfonyloxy, C 1 -C 12 alkoxycarbonyl, C 1 -C 12 alkoxycarbonylC 1 -C 12 alkyl, C 1 -C 12 alkoxycarbonylamino, C 1 -C 12 alkoxyC 1 -C 12 alkoxy or C 1 -C 12 alkoxycarbonylC 1 -C 12 alkoxy;
[0202] X 2 is selected from N or CR 7 ;
[0203] X 3 is selected from N or CR 8 ;
[0204] X 4 is selected from N or CR 9 ;
[0205] X 6 is selected from N or CR 11 ; however, X 2 , X 3 , X 4 , X 6 are not simultaneously selected from N;
[0206] R 7 , R 8 , R 9 , R 11 may be the same or different, selected respectively from H, halo, OH, cyano, HO(C═O), amino, NO 2 , C 1 -C 12 alkyl, haloC 1 -C 12 alkyl, C 1 -C 12 alkoxy, haloC 1 -C 12 alkoxy, C 1 -C 12 alkoxycarbonyl, CONH 2 , C 1 -C 12 alkylaminocarbonyl, di(C 1 -C 12 alkyl)aminocarbonyl, C 1 -C 12 alkylsulfonyl or haloC 1 -C 12 alkylsulfonyl;
[0207] R 10 is selected from H, halo, OH, cyano, HO(C═O), amino, NO 2 , C 1 -C 12 alkyl, haloC 1 -C 12 alkyl, C 1 -C 12 alkoxy, haloC 1 -C 12 alkoxy, C 3 -C 12 cycloalkyl, C 2 -C 12 alkenyl, C 2 -C 12 alkynyl, C 2 -C 12 alkenoxy, haloC 2 -C 12 alkenoxy, C 2 -C 12 alkynoxy, haloC 2 -C 12 alkynoxy, C 1 -C 12 alkylthio, haloC 1 -C 12 alkylthio, C 1 -C 12 alkoxyC 1 -C 12 alkyl, haloC 1 -C 12 alkoxyC 1 -C 12 alkyl, C 1 -C 12 alkylthioC 1 -C 12 alkyl, haloC 1 -C 12 alkylthioC 1 -C 12 alkyl, C 1 -C 12 alkylsulfinyl, haloC 1 -C 12 alkylsulfinyl, C 1 -C 12 alkylsulfonyl, haloC 1 -C 12 alkylsulfonyl, C 1 -C 12 alkylaminosulfonyl, C 1 -C 12 alkylamino, haloC 1 -C 12 alkylamino, di(C 1 -C 12 alkyl)amino, C 1 -C 12 alkoxycarbonyl, CONH 2 , C 1 -C 12 alkylaminocarbonyl, di(C 1 -C 12 alkyl)aminocarbonyl, cyanoC 1 -C 12 alkoxy, C 1 -C 12 alkoxycarbonylC 1 -C 12 alkyl, C 1 -C 12 alkylaminocarbonylC 1 -C 12 alkyl or di(C 1 -C 12 alkyl)aminocarbonylC 1 -C 12 alkyl;
[0208] A is selected from O, S or NR 12 ;
[0209] B is selected from is selected from —CH 2 — or —CH 2 CH 2 —;
[0210] R 12 is selected from H, OH, H(C)═O, C 1 -C 12 alkyl, haloC 1 -C 12 alkyl, C 1 -C 12 alkoxy, haloC 1 -C 12 alkoxy, C 3 -C 12 cycloalkyl, C 1 -C 12 alkylthio, C 2 -C 12 alkenylthio, C 2 -C 12 alkenyl, C 2 -C 12 alkynyl, haloC 2 -C 12 alkenyl, haloC 2 -C 12 alkynyl, C 1 -C 12 alkoxyC 1 -C 12 alkyl, haloC 1 -C 12 alkoxyC 1 -C 12 alkyl, C 1 -C 12 alkylthioC 1 -C 12 alkyl, haloC 1 -C 12 alkylthioC 1 -C 12 alkyl, C 1 -C 12 alkylsulfinyl, haloC 1 -C 12 alkylsulfinyl, C 1 -C 12 alkylsulfonyl, haloC 1 -C 12 alkylsulfonyl, C 1 -C 12 alkylaminosulfonyl, di(C 1 -C 12 alkyl)amino sulfonyl, C 1 -C 12 alkylsulfonylaminocarbonyl, C 1 -C 12 alkylcarbonylaminosulfonyl, C 3 -C 12 cycloalkyloxycarbonyl, C 1 -C 12 alkylcarbonyl, haloC 1 -C 12 alkylcarbonyl, C 1 -C 12 alkoxycarbonyl, haloC 1 -C 12 alkoxycarbonyl, C 1 -C 12 alkylcarbonylC 1 -C 12 alkyl, C 1 -C 12 alkoxycarbonylC 1 -C 12 alkyl, C 1 -C 12 alkylaminocarbonyl, di(C 1 -C 12 alkyl)aminocarbonyl, C 2 -C 12 alkenoxycarbonyl, C 2 -C 12 alkynoxycarbonyl, C 1 -C 12 alkoxyC 1 -C 12 alkoxycarbonyl, C 1 -C 12 alkylaminothio, di(C 1 -C 12 alkyl)aminothio, unsubstituted or further substituted (hetero)arylcarbonylC 1 -C 6 alkyl, (hetero)arylcarbonyl, (hetero)aryloxycarbonyl, (hetero)arylC 1 -C 6 alkyloxycarbonyl or (hetero)arylC 1 -C 6 alkyl by 1 to 5 following groups: halo, NO 2 , cyano, C 1 -C 6 alkyl, haloC 1 -C 6 alkyl, C 1 -C 6 alkoxy or haloC 1 -C 6 alkoxy;
[0211] Or the salts or complexes formed from the compounds represented by general formula III.
[0212] The preferred compounds represented by general formula III of this invention are:
[0213] R 1 is selected from halo, C 1 -C 8 alkyl, C 3 -C 8 cycloalkyl, haloC 1 -C 8 alkyl, C 2 -C 8 alkenyl, haloC 2 -C 8 alkenyl, C 2 -C 8 alkynyl, haloC 2 -C 8 alkynyl, C 1 -C 8 alkoxyC 1 -C 8 alkyl or haloC 1 -C 8 alkoxyC 1 -C 8 alkyl;
[0214] R 2 is selected from halo, cyano, C 1 -C 8 alkyl, C 1 -C 8 alkoxy or haloC 1 -C 8 alkoxy;
[0215] W is selected from H, halo, C 1 -C 8 alkyl, C 1 -C 8 alkoxy, C 1 -C 8 alkylthio or C 1 -C 8 alkylsulfonyl;
[0216] R 3 , R 4 may be the same or different, selected respectively from H, C 1 -C 8 alkyl, C 3 -C 8 cycloalkyl, C 2 -C 8 alkenyl, C 2 -C 8 alkynyl, haloC 2 -C 8 alkenyl, haloC 2 -C 8 alkynyl, C 1 -C 8 alkoxyC 1 -C 8 alkyl, unsubstituted or further substituted arylC 1 -C 4 alkyl or heteroarylC 1 -C 4 alkyl by 1 to 3 following groups: halo, C 1 -C 4 alkyl, haloC 1 -C 4 alkyl, C 1 -C 4 alkoxy or haloC 1 -C 4 alkoxy; or R 3 , R 4 and conjoint carbon can also form a C 3 -C 8 cycle;
[0217] R 5a , R 5b , R 5c may be the same or different, selected respectively from H, halo, NO 2 , cyano, C 1 -C 8 alkyl, haloC 1 -C 8 alkyl, C 3 -C 6 cycloalkyl, C 1 -C 8 alkoxy, haloC 1 -C 8 alkoxy, C 1 -C 8 alkylthio, haloC 1 -C 8 alkylthio, C 2 -C 8 alkenyl, haloC 2 -C 8 alkenyl, C 2 -C 8 alkynyl, haloC 2 -C 8 alkynyl, C 3 -C 8 alkenoxy, haloC 3 -C 8 alkenoxy, C 3 -C 8 alkynoxy, haloC 3 -C 8 alkynoxy, C 1 -C 8 alkylsulfinyl, haloC 1 -C 8 alkylsulfinyl, C 1 -C 8 alkylsulfonyl, haloC 1 -C 8 alkylsulfonyl, C 1 -C 8 alkylcarbonyl, haloC 1 -C 8 alkylcarbonyl, C 1 -C 8 alkylcarbonyloxy, C 1 -C 8 alkylcarbonylamino C 1 -C 8 alkylsulfonyloxy, C 1 -C 8 alkoxycarbonyl, C 1 -C 8 alkoxycarbonylC 1 -C 8 alkyl, C 1 -C 8 alkoxycarbonylamino C 8 -C 8 alkoxyC 1 -C 8 alkoxy or C 1 -C 8 alkoxycarbonylC 1 -C 8 alkoxy;
[0218] X 2 is selected from N or CR 7 ;
[0219] X 3 is selected from N or CR 8 ;
[0220] X 4 is selected from N or CR 9 ;
[0221] X 6 is selected from N or CR 11 ; however, X 2 , X 3 , X 4 , X 6 are not simultaneously selected from N;
[0222] R 7 , R 8 , R 9 , R 11 may be the same or different, selected respectively from H, halo, OH, cyano, HO(C═O), amino, NO 2 , C 1 -C 8 alkyl, haloC 1 -C 8 alkyl, C 1 -C 8 alkoxy, haloC 1 -C 8 alkoxy, C 1 -C 8 alkoxycarbonyl, CONH 2 , C 1 -C 8 alkylaminocarbonyl, di(C 1 -C 8 alkyl)aminocarbonyl, C 1 -C 8 alkylsulfonyl or haloC 1 -C 8 alkylsulfonyl;
[0223] R 10 is selected from H, halo, OH, cyano, HO(C═O), amino, NO 2 , C 1 -C 8 alkyl, haloC 1 -C 8 alkyl, C 1 -C 8 alkoxy, haloC 1 -C 8 alkoxy, C 3 -C 8 cycloalkyl, C 2 -C 8 alkenyl, C 2 -C 8 alkynyl, C 2 -C 8 alkenoxy, haloC 2 -C 8 alkenoxy, C 2 -C 8 alkynoxy, haloC 2 -C 8 alkynoxy, C 1 -C 8 alkylthio, haloC 1 -C 8 alkylthio, C 1 -C 8 alkoxyC 1 -C 8 alkyl, haloC 1 -C 8 alkoxyC 1 -C 8 alkyl, C 1 -C 8 alkylthioC 1 -C 8 alkyl, haloC 1 -C 8 alkylthioC 1 -C 8 alkyl, C 1 -C 8 alkylsulfinyl, haloC 1 -C 8 alkylsulfinyl, C 1 -C 8 alkylsulfonyl, haloC 1 -C 8 alkylsulfonyl, C 1 -C 8 alkylaminosulfonyl, C 1 -C 8 alkylamino, haloC 1 -C 8 alkylamino, di(C 1 -C 8 alkyl)amino, C 1 -C 8 alkoxycarbonyl, CONH 2 , C 1 -C 8 alkylaminocarbonyl, di(C 1 -C 8 alkyl)aminocarbonyl, cyanoC 1 -C 8 alkoxy, C 1 -C 8 alkoxycarbonylC 1 -C 8 alkyl, C 1 -C 8 alkylaminocarbonylC 1 -C 8 alkyl or di(C 1 -C 8 alkyl)aminocarbonylC 1 -C 8 alkyl;
[0224] A is selected from O, S or NR 12 ;
[0225] B is selected from is selected from —CH 2 — or —CH 2 CH 2 —;
[0226] R 12 is selected from H, OH, H(C)═O, C 1 -C 8 alkyl, haloC 1 -C 8 alkyl, C 1 -C 8 alkoxy, haloC 1 -C 8 alkoxy, C 3 -C 8 cycloalkyl, C 1 -C 8 alkylthio, C 2 -C 8 alkenylthio, C 2 -C 8 alkenyl, C 2 -C 8 alkynyl, haloC 2 -C 8 alkenyl, haloC 2 -C 8 alkynyl, C 1 -C 8 alkoxyC 1 -C 8 alkyl, haloC 1 -C 8 alkoxyC 1 -C 8 alkyl, C 1 -C 8 alkylthioC 1 -C 8 alkyl, haloC 1 -C 8 alkylthioC 1 -C 8 alkyl, C 1 -C 8 alkylsulfinyl, haloC 1 -C 8 alkylsulfinyl, C 1 -C 8 alkylsulfonyl, haloC 1 -C 8 alkylsulfonyl, C 1 -C 8 alkylaminosulfonyl, di(C 1 -C 8 alkyl)amino sulfonyl, C 1 -C 8 alkylsulfonylaminocarbonyl, C 1 -C 8 alkylcarbonylaminosulfonyl, C 3 -C 8 cycloalkyloxycarbonyl, C 1 -C 8 alkylcarbonyl, haloC 1 -C 8 alkylcarbonyl, C 1 -C 8 alkoxycarbonyl, haloC 1 -C 8 alkoxycarbonyl, C 1 -C 8 alkylcarbonylC 1 -C 8 alkyl, C 1 -C 8 alkoxycarbonylC 1 -C 8 alkyl, C 1 -C 8 alkylaminocarbonyl, di(C 1 -C 8 alkyl)aminocarbonyl, C 2 -C 8 alkenoxycarbonyl, C 2 -C 8 alkynoxycarbonyl, C 1 -C 8 alkoxyC 1 -C 8 alkoxycarbonyl, C 1 -C 8 alkylaminothio, di(C 1 -C 8 alkyl)aminothio, unsubstituted or further substituted (hetero)arylcarbonylC 1 -C 6 alkyl, (hetero)arylcarbonyl, (hetero)aryloxycarbonyl, (hetero)arylC 1 -C 6 alkyloxycarbonyl or (hetero)arylC 1 -C 6 alkyl by 1 to 3 following groups: halo, NO 2 , cyano, C 1 -C 4 alkyl, haloC 1 -C 4 alkyl, C 1 -C 4 alkoxy or haloC 1 -C 4 alkoxy;
[0227] Or the salts formed from the compounds represented by general formula III.
[0228] Furthermore, the preferred compounds represented by general formula III of this invention are:
[0229] R 1 is selected from halo, C 1 -C 4 alkyl, C 3 -C 6 cycloalkyl, haloC 1 -C 4 alkyl, C 2 -C 4 alkenyl, haloC 2 -C 4 alkenyl, C 2 -C 4 alkynyl, haloC 2 -C 4 alkynyl, C 1 -C 4 alkoxyC 1 -C 4 alkyl or haloC 1 -C 4 alkoxyC 1 -C 4 alkyl;
[0230] R 2 is selected from halo or cyano;
[0231] W is selected from H or CH 3 ;
[0232] R 3 , R 4 is selected from H, CH 3 or C 2 H 5 ;
[0233] R 5a , R 5b , R 5c may be the same or different, selected respectively from H, halo, NO 2 , cyano, C 1 -C 4 alkyl, haloC 1 -C 4 alkyl, C 3 -C 6 cycloalkyl, C 1 -C 4 alkoxy, haloC 1 -C 4 alkoxy, C 1 -C 4 alkylthio, haloC 1 -C 4 alkylthio, C 2 -C 4 alkenyl, C 2 -C 4 alkynyl, C 1 -C 4 alkylsulfinyl, C 1 -C 4 alkylsulfonyl, C 1 -C 4 alkylcarbonyl or C 1 -C 4 alkoxyC 1 -C 4 alkoxy;
[0234] X 2 is selected from N or CR 7 ;
[0235] X 3 is selected from N or CR 8 ;
[0236] X 4 is selected from N or CR 9 ;
[0237] X 6 is selected from N or CR 11 ; however, X 2 , X 3 , X 4 , X 6 are not simultaneously selected from N;
[0238] R 7 , R 8 , R 9 , R 11 may be the same or different, selected respectively from H, halo, OH, cyano, HO(C═O), amino, NO 2 , C 1 -C 4 alkyl, haloC 1 -C 4 alkyl, C 1 -C 4 alkoxy, haloC 1 -C 4 alkoxy, C 1 -C 4 alkoxycarbonyl, CONH 2 , C 1 -C 4 alkylaminocarbonyl, di(C 1 -C 4 alkyl)aminocarbonyl or C 1 -C 4 alkylsulfonyl or haloC 1 -C 4 alkylsulfonyl;
[0239] R 10 is selected from H, halo, OH, cyano, HO(C═O), amino, NO 2 , C 1 -C 4 alkyl, haloC 1 -C 4 alkyl, C 1 -C 4 alkoxy, haloC 1 -C 4 alkoxy, C 3 -C 4 cycloalkyl, C 2 -C 4 alkenyl, C 2 -C 4 alkynyl, C 2 -C 4 alkenoxy, haloC 2 -C 4 alkenoxy, C 2 -C 4 alkynoxy, haloC 2 -C 4 alkynoxy, C 1 -C 4 alkylthio, haloC 1 -C 4 alkylthio, C 1 -C 4 alkoxyC 1 -C 4 alkyl, haloC 1 -C 4 alkoxyC 1 -C 4 alkyl, C 1 -C 4 alkylthioC 1 -C 4 alkyl, haloC 1 -C 4 alkylthioC 1 -C 4 alkyl, C 1 -C 4 alkylsulfinyl, haloC 1 -C 4 alkylsulfinyl, C 1 -C 4 alkylsulfonyl, haloC 1 -C 4 alkylsulfonyl, C 1 -C 4 alkylaminosulfonyl, C 1 -C 4 alkylamino, haloC 1 -C 4 alkylamino, di(C 1 -C 4 alkyl)amino, C 1 -C 4 alkoxycarbonyl, CONH 2 , C 1 -C 4 alkylaminocarbonyl, di(C 1 -C 4 alkyl)aminocarbonyl, cyanoC 1 -C 12 alkoxy, C 1 -C 4 alkoxycarbonylC 1 -C 4 alkyl, C 1 -C 4 alkylaminocarbonylC 1 -C 4 alkyl or di(C 1 -C 4 alkyl)aminocarbonylC 1 -C 4 alkyl;
[0240] A is selected from O, S or NH;
[0241] B is selected from —CH 2 — or —CH 2 CH 2 —;
[0242] Or the salts formed from the compounds represented by general formula III with hydrochloric acid, sulfuric acid, phosphoric acid, formic acid, acetic acid, trifluoroacetic acid, oxalic acid, methylsulfonic acid, p-toluenesulfonic acid, benzoic acid, alizaric acid, maleic acid, sorbic acid, malic acid or citric acid.
[0243] In the general formula III, even more preferred compounds represented by general formula III-A, III-B, III-C, III-D, III-E, III-F, III-G, III-H, III-I or III-J of this invention are:
[0000]
[0244] Wherein:
[0245] R 1 is selected from F, Cl, Br, I, C 1 -C 4 alkyl, C 3 -C 6 cycloalkyl, haloC 1 -C 4 alkyl, C 2 -C 4 alkenyl, C 2 -C 4 alkynyl, C 1 -C 4 alkoxyC 1 -C 4 alkyl or haloC 1 -C 4 alkoxyC 1 -C 4 alkyl;
[0246] R 2 is selected from halo or cyano;
[0247] W is selected from H or CH 3 ;
[0248] R 3 , R 4 is selected from H, CH 3 or C 2 H 5 ;
[0249] R 5a , R 5b , R 5c may be the same or different, selected respectively from H, F, Cl, Br, I, NO 2 , cyano, C 1 -C 4 alkyl, haloC 1 -C 4 alkyl, C 1 -C 4 alkoxy, haloC 1 -C 4 alkoxy or C 1 -C 4 alkylcarbonyl;
[0250] R 7 , R 8 , R 9 , R 11 may be the same or different, selected respectively from H, F, Cl, Br, I, cyano, HO(C═O), NO 2 , C 1 -C 4 alkyl, haloC 1 -C 4 alkyl, C 1 -C 4 alkoxy, haloC 1 -C 4 alkoxy, C 1 -C 4 alkoxycarbonyl, C 1 -C 4 alkylaminocarbonyl, di(C 1 -C 4 alkyl)aminocarbonyl, C 1 -C 4 alkylsulfonyl or haloC 1 -C 4 alkylsulfonyl;
[0251] R 10 is selected from H, F, Cl, Br, I, cyano, NO 2 , C 1 -C 4 alkyl, haloC 1 -C 4 alkyl, C 1 -C 4 alkoxy, haloC 1 -C 4 alkoxy, C 1 -C 4 alkylsulfonyl or haloC 1 -C 4 alkylsulfonyl;
[0252] A is selected from O, S or NH;
[0253] Or the salts formed from the compounds represented by general formula III-A, III-B, III-C, III-D, III-E, III-F, III-G, III-H, III-I or III-J with hydrochloric acid, sulfuric acid, phosphoric acid, formic acid, acetic acid, trifluoroacetic acid, oxalic acid, methylsulfonic acid, p-toluenesulfonic acid, benzoic acid, alizaric acid, maleic acid, sorbic acid, malic acid or citric acid.
[0254] Even further more preferred compounds represented by formula III of this invention are:
[0255] R 1 is selected from Cl, CH 3 , C 2 H 5 , CHCl 2 , CCl 3 , CH 2 F, CClF 2 , CHF 2 or CF 3 ;
[0256] R 2 is selected from halo or cyano;
[0257] W is selected from H or CH 3 ;
[0258] R 3 , R 4 is selected from H;
[0259] R 5a , R 5c is selected from H;
[0260] R 5b is selected from H, F, Cl, Br or OCH 3 ;
[0261] R 7 , R 8 , R 9 , R 11 may be the same or different, selected respectively from H, F, Cl, Br, cyano, NO 2 , C 1 -C 4 alkyl, haloC 1 -C 4 alkyl, C 1 -C 4 alkoxy, haloC 1 -C 4 alkoxy, C 1 -C 4 alkoxycarbonyl, C 1 -C 4 alkylaminocarbonyl, di(C 1 -C 4 alkyl)aminocarbonyl, C 1 -C 4 alkylsulfonyl or haloC 1 -C 4 alkylsulfonyl;
[0262] R 10 is selected from H, F, Cl, Br, I, cyano, NO 2 , methylsulfonyl, C 1 -C 4 alkyl, haloC 1 -C 4 alkyl, C 1 -C 4 alkoxy or haloC 1 -C 4 alkoxy;
[0263] A is selected from NH;
[0264] Or the salts formed from the compounds represented by general formula III-A with hydrochloric acid, sulfuric acid, phosphoric acid, formic acid, acetic acid, trifluoroacetic acid, oxalic acid, methylsulfonic acid, p-toluenesulfonic acid, benzoic acid, alizaric acid, maleic acid, sorbic acid, malic acid or citric acid.
[0265] Most preferred compounds represented by formula III of this invention are:
[0266] In the general formula III-A,
[0267] R 1 is selected from Cl, CH 3 , C 2 H 5 , CHF 2 or CF 3 ;
[0268] R 2 is selected from Cl or cyano;
[0269] W is selected from H or CH 3 ;
[0270] R 3 , R 4 is selected from H;
[0271] R 5a , R 5c is selected from H;
[0272] R 5b is selected from H, Cl or OCH 3 ;
[0273] R 7 , R 8 , R 9 , R 11 may be the same or different, selected respectively from H, F, Cl, CH 3 , cyano, NO 2 , CF 3 , CClF 2 , CCl 3 , OCH 3 , OCF 3 , OCH 2 CF 3 , methylsulfonyl or trifluorosulfonyl;
[0274] R 10 is selected from H, F, Cl, CH 3 , cyano, NO 2 , methylsulfonyl, CF 3 , CClF 2 , OCH 3 , OCF 3 or OCH 2 CF 3 ;
[0275] A is selected from NH;
[0276] Or the salts formed from the compounds represented by general formula III-A with hydrochloric acid, sulfuric acid, phosphoric acid, formic acid, acetic acid, trifluoroacetic acid, oxalic acid, methylsulfonic acid, p-toluenesulfonic acid, benzoic acid, alizaric acid, maleic acid, sorbic acid, malic acid or citric acid.
[0277] The terms of substitutes used above to definite the compounds represented by general formula PY are as follows:
[0278] The “halogen” or “halo” is fluorine, chlorine, bromine or iodine.
[0279] The “alkyl” stands for straight or branched chain alkyl, such as methyl, ethyl, propyl, isopropyl or tert-butyl.
[0280] The “cycloalkyl” is substituted or unsubstituted cyclic alkyl, such as cyclopropyl, cyclopentyl or cyclohexyl. The substitute(s) is(are) methyl, halogen, etc.
[0281] The “haloalkyl” stands for straight or branched chain alkyl, in which hydrogen atoms can be all or partly substituted with halogen, such as chloromethyl, dichloromethyl, trichloromethyl, fluoromethyl, difluoromethyl, trifluoromethyl, etc.
[0282] The “alkoxy” refers to straight or branched chain alkyl, which is linked to the structure by oxygen atom. The “haloalkoxy” refers to straight or branched chain alkoxy, in which hydrogen atoms may be all or partly substituted with halogen, such as chloromethoxy, dichloromethoxy, trichloromethoxy, fluoromethoxy, difluoromethoxy, trifluoromethoxy, chlorofluoromethoxy, trifluoroethoxy, etc. The “alkylthio” refers to straight or branched chain alkyl, which is linked to the structure by sulfur atom. The “haloalkylthio” refers to straight or branched chain alkylthio, in which hydrogen atoms may be all or partly substituted with halogen, such as chloromethylthio, dichloromethylthio, trichloromethylthio, fluoromethylthio, difluoromethylthio, trifluoromethylthio, chlorofluoromethylthio, etc.
[0283] The “cyanoalkyl” refers to straight or branched chain alkyl, in which hydrogen atoms may be all or partly substituted with cyano, such as —CH 2 CN, —CH 2 CH 2 CN, —CH 2 C(CH 3 ) 2 CN, —CH 2 CH(CN) 2 , etc. The “cyanoalkoxy” refers to alkoxy, in which hydrogen atoms may be all or partly substituted with cyano, such as —OCH 2 CN. The “haloalkylamino” refers to straight or branched chain alkylamino, in which hydrogen atoms may be all or partly substituted with halogen. The “dialkylamino” such as —N(CH 3 ) 2 , —N(CH 3 CH 2 ) 2 . The “dihaloalkylamino” such as —N(CF 3 ) 2 , —N(CH 2 CCl 3 ) 2 . The “dialkylaminoalkyl” such as —CH 2 N(CH 3 ) 2 .
[0284] The “alkenyl” refers to straight or branched chain alkenyl, such as ethenyl, 1-propenyl, 2-propenyl and different isomer of butenyl, pentenyl and hexenyl. Alkenyl also includes polyene, such as propa-1,2-dienyl and hexa-2,4-dienyl. The “haloalkenyl” stands for straight or branched chain alkenyl, in which hydrogen atoms can be all or partly substituted with halogen. The “alkynyl” refers to straight or branched chain alkynyl, such as ethynyl, 1-propynyl, 2-propynyl and different isomer of butynyl, pentynyl and hexynyl. Alkynyl also includes groups including more than one triple bonds, such as hexa-2,5-diynyl. The “haloalkynyl” stands for straight or branched chain alkynyl, in which hydrogen atoms can be all or partly substituted with halogen.
[0285] The alkenoxyl refers to straight or branched chain alkynes is linked to the structure by oxygen, The haloalkenoxyl stands for a straight-chain or branched alkenoxyl, in which hydrogen atoms may be all or partly substituted with halogen. The alkynoxyl refers to straight or branched chain alkynes is linked to the structure by oxygen. The haloalkynoxyl stands for a straight-chain or branched alkynoxyl, in which hydrogen atoms may be all or partly substituted with halogen.
[0286] The “alkylsulfinyl” means a straight-chain or branched alkyl is linked to the structure by (—SO—), such as methylsulfinyl.
[0287] The “haloalkylsulfinyl” stands for a straight-chain or branched alkylsulfinyl, in which hydrogen atoms may be all or partly substituted with halogen.
[0288] The “alkylsulfonyl” means a straight-chain or branched alkyl is linked to the structure by (—SO 2 —), such as methylsulfonyl.
[0289] The “haloalkylsulfonyl” stands for a straight-chain or branched alkylsulfonyl, in which hydrogen atoms may be all or partly substituted with halogen.
[0290] The “alkylcarbonyl” means alkyl is linked to the structure by carbonyl, such as —COCH 3 , —COCH 2 CH 3 . The “haloalkylcarbonyl” stands for a straight-chain or branched alkylcarbonyl, in which hydrogen atoms may be all or partly substituted with halogen, such as —COCF 3 . The “alkoxyalkyl” means alkyl-O-alkyl-, such as —CH 2 OCH 3 . The “haloalkoxyalkyl” refers to alkoxyalkyl, in which hydrogen atom may be all or partyl substituted with halogen, such as —CH 2 OCH 2 CH 2 Cl. The “alkylthioalkyl” means alkyl-S-alkyl-, such as —CH 2 SCH 3 . The “haloalkylthioalkyl” refers to alkylthioalkyl, in which hydrogen atom may be all or partyl substituted with halogen, such as —CH 2 SCH 2 CH 2 Cl, —CH 2 SCH 2 CF 3 .
[0291] The “alkoxycarbonyl” means alkoxy is linked to the structure by carbonyl. such as —COOCH 3 , —COOCH 2 CH 3 . The “haloalkoxycarbonyl” refers to straight or branched chain alkoxycarbonyl, in which hydrogen atoms can be all or partly substituted with halogen. The “alkylaminocarbonyl” means alkyl-NH—CO—, such as —CONHCH 3 , —CONHCH 2 CH 3 . The “dialkylaminocarbonyl” such as —CON(CH 3 ) 2 , —CON(CH 2 CH 3 ) 2 . The “halodialkylaminocarbonyl” such as —CON(CF 3 ) 2 , —CON(CH 2 CCl 3 ) 2 .
[0292] The “alkoxycarbonylalkyl” such as —CH 2 COOCH 3 , —CH 2 COOCH 2 CH 3 . The “haloalkoxycarbonylalkyl” such as —CH 2 COOCF 3 , —CH 2 COOCH 2 CF 3 .
[0293] The “alkoxycarbonylamino” such as —NHCOOCH 3 , —NHCOOCH 2 CH 3 . The “alkoxyaminocarbonyl” such as —CONHOCH 3 , —CONHOCH 2 CH 3 . The “alkylaminocarbonylalkyl” such as —CH 2 CONHCH 3 , —CH 2 CONHCH 2 CH 3 . “dialkylaminocarbonylalkyl” such as —CH 2 CON(CH 3 ) 2 , —CH 2 CON(CH 2 CH 3 ) 2 .
[0294] The “alkenylthio” refers to straight or branched chain alkenyl, which is linked to the structure by sulfur atom. Such as —SCH 2 CH═CH 2 . The “cycloalkyloxycarbonyl” means cyclopropyloxycarbonyl, cyclohexyloxycarbonyl, etc.
[0295] The “alkenoxylcarbonyl” means CH 2 ═CHCH 2 OCO—. The “alkynoxylcarbonyl” means —COOCH 2 C≡CH. The “alkoxyamino”: such as —NHOCH 3 . The “alkoxyalkoxycarbonyl”: such as —COOCH 2 CH 2 OCH 3 , etc. The “alkylaminothio” refers to —SNHCH 3 , —SNHC 2 H 5 . The “dialkylaminothio” refers to —SN(CH 3 ) 2 , —SN(C 2 H 5 ) 2 .
[0296] The “alkylcarbonylalkyl” refers to alkyl-CO-alkyl-. The “alkylsulfonylamino” refers to alkyl-SO 2 —NH—. The “haloalkylsulfonylamino” refers to straight or branched chain alkylsulfonylamino, in which hydrogen atoms can be all or partly substituted with halogen. The “alkylsulfonylalkylamino” refers to alkyl-SO 2 -alkyl-NH—. The “alkylaminosulfonyl” refers to alkyl-NH—SO 2 —. The“alkylcarbonylaminosulfonyl” refers to alkyl-CO—NH—SO 2 —. The “dialkylaminosulfonyl” refers to (alkyl) 2 -N—SO 2 —.
[0297] The “alkylthiocarbonylalkyl” refers to —CH 2 COSCH 3 , —CH 2 COSCH 2 CH 3 . The “haloalkylthiocarbonylalkyl” refers to —CH 2 COSCF 3 , —CH 2 COSCH 2 CF 3 .
[0298] The “alkylcarbonyloxy” such as —OCOCH 3 . The “haloalkylcarbonyloxy” such as —OCOCF 3 .
[0299] The “alkoxycarbonyloxy” such as —OCOOCH 3 . The “haloalkoxycarbonyloxy” such as —OCOOCF 3 . The “alkoxyalkoxy” stands for —OCH 2 OCH 3 . The “haloalkoxyalkoxy” stands for —OCH 2 OCF 3 . The “alkoxycarbonylalkoxy” stands for —OCH 2 COOCH 3 . The “alkylsulfonylaminocarbonyl” refers to alkyl-SO 2 —NH—CO—.
[0300] The “alkylcarbonylamino” refers to alkyl-CO—NH—. The “cycloalkyloxycarbonyl” means cyclopropyloxycarbonyl, cyclohexyloxycarbonyl. The “alkoxycarbonylalkoxy” stands for —OCH 2 COOCF 3 . The “alkylsulfonyloxy” such as alkyl-O—SO 2 CH 3 . The “haloalkylsulfonyloxy” such as —O—SO 2 CF 3 . The “alkylaminocarbonyloxy” such as —O—CONHCH 3 . The “haloalkylaminocarbonyloxy” such as —O—CONHCF 3 .
[0301] The “aryl” in (hetero)arylcarbonylalkyl, (hetero)arylcarbonyl, (hetero)aryloxycarbonyl, (hetero)arylalkyloxycarbonyl and (hetero)arylalkyl includes phenyl or naphthyl etc. The “heteroaryl” stands for five member ring or six member ring containing one or more N, O, S hetero atoms, such as furyl, pyrazolyl, thiazolyl, pyridinyl, pyrimidinyl, pyrazinyl, pyridazinyl, triazinyl, quinolinyl, etc.
[0302] (Hetero)arylcarbonylalkyl refers to —CH 2 COPh, etc. (Hetero)aryloxycarbonyl such as phenoxycarbonyl, p-chlorophenoxycarbonyl, p-nitrophenoxycarbonyl, naphthyloxycarbonyl, etc. Arylalkyloxycarbonyl means benzyloxycarbonyl, p-chlorobenzyloxycarbonyl, p-trifluoromethylbenzyloxycarbonyl, etc.
[0303] (Hetero)arylcarbonyl refers to benzoyl, 4-Cl-benzoyl, etc. (Hetero)arylalkyloxycarbonyl refers to —COOCH 2 Ph, —COOCH 2 —4-Cl-Ph, etc. (Hetero)arylalkyl means benzyl, phenylethyl, 4-chloro-benzyl, 2-chloro-5-picolyl, 2-chloro-5-methylthiazole, etc.
[0304] The present invention is also explained by the following compounds having a structure as represented by formula I listed in Table 1 to Table 118, but without being restricted thereby.
[0305] Table 1: in general formula I-A, R 1 =CH 3 , R 2 =Cl, R 3 =R 4 =R 5b =R 8 =R 10 =R 11 =H, the substituent R 9 refers to Table 1, the representative compounds are coded as I-1 I-58.
[0000]
[0000]
TABLE 1
No.
R 9
I-1
H
I-2
F
I-3
Cl
I-4
Br
I-5
I
I-6
CH 3
I-7
Et
I-8
n-Pr
I-9
i-Pr
I-10
n-Bu
I-11
s-Bu
I-12
t-Bu
I-13
CH 2 F
I-14
CH 2 Cl
I-15
CH 2 Br
I-16
CHF 2
I-17
CHCl 2
I-18
CHBr 2
I-19
CClF 2
I-20
CCl 3
I-21
CBr 3
I-22
CF 3
I-23
CN
I-24
CH 2 OCH 3
I-25
CH 2 OCH 2 CF 3
I-26
CH 2 N(CH 3 ) 2
I-27
CH 2 CN
I-28
OCH 3
I-29
OCF 3
I-30
OCH 2 CF 3
I-31
SCH 3
I-32
SO 2 CH 3
I-33
CO 2 H
I-34
CO 2 CH 3
I-35
CO 2 C 2 H 5
I-36
CO 2 CH 2 CF 3
I-37
CO 2 -t-Bu
I-38
CONH 2
I-39
CONHCH 3
I-40
CON(CH 3 ) 2
I-41
CON(CH 3 ) 2
I-42
CONHNHCH 3
I-43
CONHN(CH 3 ) 2
I-44
CONHOCH 3
I-45
CONHNH 2
I-46
CON(CH 3 )NH 2
I-47
CONHNHCOCH 3
I-48
CONHNHCO 2 CH 3
I-49
CONHNH-Ph
I-50
NO 2
I-51
NH 2
I-52
NHCH 3
I-53
NHCH 2 CH 3
I-54
NHCOCH 3
I-55
NHCO 2 CH 3
I-56
NHSO 2 CH 3
I-57
NHSO 2 CF 3
I-58
N(CH 3 )SO 2 CH 3
[0306] Table 2: in general formula I-A, R 1 =CH 3 , R 2 =R 5b =Cl, R 3 =R 4 =R 8 =R 10 =R 11 =H, the substituent R 9 are consistent with those in Table 1 and corresponding to I-1-I-58 in table 1 in turn, the representative compounds are coded as I-59-I-116.
[0307] Table 3: in general formula I-A, R 1 =CH 3 , R 2 =Cl, R 5b =Br, R 3 =R 4 =R 8 =R 10 =R 11 =H, the substituent R 9 are consistent with those in Table 1 and corresponding to I-1-I-58 in table 1 in turn, the representative compounds are coded as I-117-I-174.
[0308] Table 4: in general formula I-A, R 1 =CH 3 , R 2 =Cl, R 5b =OCH 3 , R 3 =R 4 =R 8 =R 10 =R 11 =H, the substituent R 9 are consistent with those in Table 1 and corresponding to I-1-I-58 in table 1 in turn, the representative compounds are coded as I-175-I-232.
[0309] Table 5: in general formula I-A, R 1 =C 2 H 5 , R 2 =Cl, R 3 =R 4 =R 5b =R 8 =R 10 =R 11 =H, the substituent R 9 are consistent with those in Table 1 and corresponding to I-1-I-58 in table 1 in turn, the representative compounds are coded as I-233-I-290.
[0310] Table 6: in general formula I-A, R 1 =C 2 H 5 , R 2 =R 5b =Cl, R 3 =R 4 =R 8 =R 10 =R 11 =H, the substituent R 9 are consistent with those in Table 1 and corresponding to I-1-I-58 in table 1 in turn, the representative compounds are coded as I-291-I-348.
[0311] Table 7: in general formula I-A, R 1 =C 2 H 5 , R 2 =Cl, R 5b =Br, R 3 =R 4 =R 8 =R 10 =R 11 =H, the substituent R 9 are consistent with those in Table 1 and corresponding to I-1-I-58 in table 1 in turn, the representative compounds are coded as I-349-I-406.
[0312] Table 8: in general formula I-A, R 1 =C 2 H 5 , R 2 =Cl, R 5b =OCH 3 , R 3 =R 4 =R 8 =R 10 =R 11 =H, the substituent R 9 are consistent with those in Table 1 and corresponding to I-1-I-58 in table 1 in turn, the representative compounds are coded as I-407-I-464.
[0313] Table 9: in general formula I-A, R 1 =CH 3 , R 2 =R 11 =Cl, R 3 =R 4 =R 5b =R 8 =R 10 =H, the substituent R 9 are consistent with those in Table 1 and corresponding to I-1-I-58 in table 1 in turn, the representative compounds are coded as I-465-I-522.
[0314] Table 10: in general formula I-A, R 1 =CH 3 , R 2 =Cl, R 11 =NO 2 , R 3 =R 4 =R 5b =R 8 =R 10 =H, the substituent R 9 are consistent with those in Table 1 and corresponding to I-1-I-58 in table 1 in turn, the representative compounds are coded as I-523-I-580.
[0315] Table 11: in general formula I-A, R 1 =C 2 H 5 , R 2 =R 11 =Cl, R 3 =R 4 =R 5b =R 8 =R 10 =H, the substituent R 9 are consistent with those in Table 1 and corresponding to I-1-I-58 in table 1 in turn, the representative compounds are coded as I-581-I-638.
[0316] Table 12: in general formula I-A, R 1 =C 2 H 5 , R 2 =Cl, R 11 =NO 2 , R 3 =R 4 =R 5b =R 8 =R 10 =H, the substituent R 9 are consistent with those in Table 1 and corresponding to I-1-I-58 in table 1 in turn, the representative compounds are coded as I-639-I-696.
[0317] Table 13: in general formula I-A, R 1 =CH 3 , R 2 =R 8 =R 11 =Cl, R 3 =R 4 =R 5b =R 10 =H, the substituent R 9 are consistent with those in Table 1 and corresponding to I-1-I-58 in table 1 in turn, the representative compounds are coded as I-697-I-754.
[0318] Table 14: in general formula I-A, R 1 =CH 3 , R 2 =R 8 =R 10 =R 11 =Cl, R 3 =R 4 =R 5b =H, the substituent R 9 are consistent with those in Table 1 and corresponding to I-1-I-58 in table 1 in turn, the representative compounds are coded as I-755-I-812.
[0319] Table 15: in general formula I-A, R 1 =C 2 H 5 , R 2 =R 8 =R 11 =Cl, R 3 =R 4 =R 5b =R 10 =H, the substituent R 9 are consistent with those in Table 1 and corresponding to I-1-I-58 in table 1 in turn, the representative compounds are coded as I-813-I-870.
[0320] Table 16: in general formula I-A, R 1 =C 2 H 5 , R 2 =R 8 =R 10 =R 11 =Cl, R 3 =R 4 =R 5b =H, the substituent R 9 are consistent with those in Table 1 and corresponding to I-1-I-58 in table 1 in turn, the representative compounds are coded as I-871-I-928.
[0321] Table 17: in general formula I-A, R 1 =CH 3 , R 2 =Cl, R 11 =CF 3 , R 3 =R 4 =R 5b =R 8 =R 10 =H, the substituent R 9 are consistent with those in Table 1 and corresponding to I-1-I-58 in table 1 in turn, the representative compounds are coded as I-929-I-986.
[0322] Table 18: in general formula I-A, R 1 =C 2 H 5 , R 2 =Cl, R 11 =CF 3 , R 3 =R 4 =R 5b =R 8 =R 10 =H, the substituent R 9 are consistent with those in Table 1 and corresponding to I-1-I-58 in table 1 in turn, the representative compounds are coded as I-987-I-1044.
[0323] Table 19: in general formula I-A, R 1 =CH 3 , R 2 =Cl, R 11 =CO 2 CH 3 , R 3 =R 4 =R 5b =R 8 =R 10 =H, the substituent R 9 are consistent with those in Table 1 and corresponding to I-1-I-58 in table 1 in turn, the representative compounds are coded as I-1045-I-1102.
[0324] Table 20: in general formula I-A, R 1 =CH 3 , R 2 =Cl, R 11 =CONH 2 , R 3 =R 4 =R 5b =R 8 =R 10 =H, the substituent R 9 are consistent with those in Table 1 and corresponding to I-1-I-58 in table 1 in turn, the representative compounds are coded as I-1103-I-1160.
[0325] Table 21: in general formula I-A, R 1 =CH 3 , R 2 =Cl, R 11 =CONHCH 3 , R 3 =R 4 =R 5b =R 8 =R 10 =H, the substituent R 9 are consistent with those in Table 1 and corresponding to I-1-I-58 in table 1 in turn, the representative compounds are coded as I-1161-I-1218.
[0326] Table 22: in general formula I-A, R 1 =C 2 H 5 , R 2 =Cl, R 11 =CO 2 CH 3 , R 3 =R 4 =R 5b =R 8 =R 10 =H, the substituent R 9 are consistent with those in Table 1 and corresponding to I-1-I-58 in table 1 in turn, the representative compounds are coded as I-1219-I-1276.
[0327] Table 23: in general formula I-A, R 1 =C 2 H 5 , R 2 =Cl, R 11 =CONH 2 , R 3 =R 4 =R 5b =R 8 =R 10 =H, the substituent R 9 are consistent with those in Table 1 and corresponding to I-1-I-58 in table 1 in turn, the representative compounds are coded as I-1277-I-1334.
[0328] Table 24: in general formula I-A, R 1 =C 2 H 5 , R 2 =Cl, R 11 =CONHCH 3 , R 3 =R 4 =R 5b =R 8 =R 10 =H, the substituent R 9 are consistent with those in Table 1 and corresponding to I-1-I-58 in table 1 in turn, the representative compounds are coded as I-1335-I-1392.
[0329] Table 25: in general formula I-A, R 1 =CH 3 , R 2 =R 5b =R 11 =Cl, R 3 =R 4 =R 8 =R 10 =H, the substituent R 9 are consistent with those in Table 1 and corresponding to I-1-I-58 in table 1 in turn, the representative compounds are coded as I-1393-I-1450.
[0330] Table 26: in general formula I-A, R 1 =C 2 H 5 , R 2 =R 5b =R 11 =Cl, R 3 =R 4 =R 8 =R 10 =H, the substituent R 9 are consistent with those in Table 1 and corresponding to I-1-I-58 in table 1 in turn, the representative compounds are coded as I-1451-I-1508.
[0331] Table 27: in general formula I-A, R 1 =CH 3 , R 2 =R 11 =Cl, R 5b =Br, R 3 =R 4 =R 8 =R 10 =H, the substituent R 9 are consistent with those in Table 1 and corresponding to I-1-I-58 in table 1 in turn, the representative compounds are coded as I-1509-I-1566.
[0332] Table 28: in general formula I-A, R 1 =C 2 H 5 , R 2 =R 11 =Cl, R 5b =Br, R 3 =R 4 =R 8 =R 10 =H, the substituent R 9 are consistent with those in Table 1 and corresponding to I-1-I-58 in table 1 in turn, the representative compounds are coded as I-1567-I-1624.
[0333] Table 29: in general formula I-A, R 1 =CH 3 , R 2 =R 11 =Cl, R 5b =OCH 3 , R 3 =R 4 =R 8 =R 10 =H, the substituent R 9 are consistent with those in Table 1 and corresponding to I-1-I-58 in table 1 in turn, the representative compounds are coded as I-1625-I-1682.
[0334] Table 30: in general formula I-A, R 1 =C 2 H 5 , R 2 =R 11 =Cl, R 5b =OCH 3 , R 3 =R 4 =R 8 =R 10 =H, the substituent R 9 are consistent with those in Table 1 and corresponding to I-1-I-58 in table 1 in turn, the representative compounds are coded as I-1683-I-1740.
[0335] Table 31: in general formula I-A, R 1 =CH 3 , R 2 =Br, R 3 =R 4 =R 5b =R 8 =R 10 =R 11 =H, the substituent R 9 are consistent with those in Table 1 and corresponding to I-1-I-58 in table 1 in turn, the representative compounds are coded as I-1741-I-1798.
[0336] Table 32: in general formula I-A, R 1 =C 2 H 5 , R 2 =Br, R 3 =R 4 =R 5b =R 8 =R 10 =R 11 =H, the substituent R 9 are consistent with those in Table 1 and corresponding to I-1-I-58 in table 1 in turn, the representative compounds are coded as I-1799-I-1856.
[0337] Table 33: in general formula I-A, R 1 =CH 3 , R 2 =Br, R 11 =Cl, R 3 =R 4 =R 5b =R 8 =R 10 =H, the substituent R 9 are consistent with those in Table 1 and corresponding to I-1-I-58 in table 1 in turn, the representative compounds are coded as I-1857-I-1914.
[0338] Table 34: in general formula I-A, R 1 =C 2 H 5 , R 2 =Br, R 11 =Cl, R 3 =R 4 =R 5b =R 8 =R 10 =H, the substituent R 9 are consistent with those in Table 1 and corresponding to I-1-I-58 in table 1 in turn, the representative compounds are coded as I-1915-I-1972.
[0339] Table 35: in general formula I-A, R 1 =CH 3 , R 2 =Br, R 5b =Cl, R 3 =R 4 =R 8 =R 10 =R 11 =H, the substituent R 9 are consistent with those in Table 1 and corresponding to I-1-I-58 in table 1 in turn, the representative compounds are coded as I-1973-I-2030.
[0340] Table 36: in general formula I-A, R 1 =C 2 H 5 , R 2 =Br, R 5b =Cl, R 3 =R 4 =R 8 =R 10 =R 11 =H, the substituent R 9 are consistent with those in Table 1 and corresponding to I-1-I-58 in table 1 in turn, the representative compounds are coded as I-2031-I-2088.
[0341] Table 37: in general formula I-A, R 1 =CH 3 , R 2 =R 5b =Br, R 3 =R 4 =R 8 =R 10 =R 11 =H, the substituent R 9 are consistent with those in Table 1 and corresponding to I-1-I-58 in table 1 in turn, the representative compounds are coded as I-2089-I-2146.
[0342] Table 38: in general formula I-A, R 1 =C 2 H 5 , R 2 =R 5b =Br, R 3 =R 4 =R 8 =R 10 =R 11 =H, the substituent R 9 are consistent with those in Table 1 and corresponding to I-1-I-58 in table 1 in turn, the representative compounds are coded as I-2147-I-2204.
[0343] Table 39: in general formula I-A, R 1 =CH 3 , R 2 =Br, R 5b =OCH 3 , R 3 =R 4 =R 8 =R 10 =R 11 =H, the substituent R 9 are consistent with those in Table 1 and corresponding to I-1-I-58 in table 1 in turn, the representative compounds are coded as I-2205-I-2262.
[0344] Table 40: in general formula I-A, R 1 =C 2 H 5 , R 2 =Br, R 5b =OCH 3 , R 3 =R 4 =R 8 =R 10 =R 11 =H, the substituent R 9 are consistent with those in Table 1 and corresponding to I-1-I-58 in table 1 in turn, the representative compounds are coded as I-2263-I-2320.
[0345] Table 41: in general formula I-A, R 1 =CF 2 H, R 2 =Cl, R 3 =R 4 =R 5b =R 8 =R 10 =R 11 =H, the substituent R 9 are consistent with those in Table 1 and corresponding to I-1-I-58 in table 1 in turn, the representative compounds are coded as I-2321-I-2378.
[0346] Table 42: in general formula I-A, R 1 =CF 2 H, R 2 =R 5b =Cl, R 3 =R 4 =R 8 =R 10 =R 11 =H, the substituent R 9 are consistent with those in Table 1 and corresponding to I-1-I-58 in table 1 in turn, the representative compounds are coded as I-2379-I-2436.
[0347] Table 43: in general formula I-A, R 1 =CF 2 H, R 2 =Cl, R 5b =OCH 3 , R 3 =R 4 =R 8 =R 10 =R 11 =H, the substituent R 9 are consistent with those in Table 1 and corresponding to I-1-I-58 in table 1 in turn, the representative compounds are coded as I-2437-I-2494.
[0348] Table 44: in general formula I-A, R 1 =CF 2 H, R 2 =Cl, R 5b =Br, R 3 =R 4 =R 8 =R 10 =R 11 =H, the substituent R 9 are consistent with those in Table 1 and corresponding to I-1-I-58 in table 1 in turn, the representative compounds are coded as I-2495-I-2552.
[0349] Table 45: in general formula I-A, R 1 =CF 2 H, R 2 =R 11 =Cl, R 3 =R 4 =R 5b =R 8 =R 10 =H, the substituent R 9 are consistent with those in Table 1 and corresponding to I-1-I-58 in table 1 in turn, the representative compounds are coded as I-2553-I-2610.
[0350] Table 46: in general formula I-A, R 1 =CF 2 H, R 2 =Cl, R 11 =NO 2 , R 3 =R 4 =R 5b =R 8 =R 10 =H, the substituent R 9 are consistent with those in Table 1 and corresponding to I-1-I-58 in table 1 in turn, the representative compounds are coded as I-2611-I-2668.
[0351] Table 47: in general formula I-A, R 1 =CF 2 H, R 2 =R 11 =Cl, R 5b =OCH 3 , R 3 =R 4 =R 8 =R 10 =H, the substituent R 9 are consistent with those in Table 1 and corresponding to I-1-I-58 in table 1 in turn, the representative compounds are coded as I-2669-I-2726.
[0352] Table 48: in general formula I-A, R 1 =CF 3 , R 2 =Cl, R 3 =R 4 =R 5b =R 8 =R 10 =R 11 =H, the substituent R 9 are consistent with those in Table 1 and corresponding to I-1-I-58 in table 1 in turn, the representative compounds are coded as I-2727-I-2784.
[0353] Table 49: in general formula I-A, R 1 =CF 3 , R 2 =R 11 =Cl, R 3 =R 4 =R 5b =R 8 =R 10 =H, the substituent R 9 are consistent with those in Table 1 and corresponding to I-1-I-58 in table 1 in turn, the representative compounds are coded as I-2785-I-2842.
[0354] Table 50: in general formula I-A, R 1 =CF 3 , R 2 =Cl, R 11 =NO 2 , R 3 =R 4 =R 5b =R 8 =R 10 =H, the substituent R 9 are consistent with those in Table 1 and corresponding to I-1-I-58 in table 1 in turn, the representative compounds are coded as I-2843-I-2900.
[0355] Table 51: in general formula I-A, R 1 =CH 2 Cl, R 2 =Cl. R 3 =R 4 =R 5b =R 8 =R 10 =R 11 =H, the substituent R 9 are consistent with those in Table 1 and corresponding to I-1-I-58 in table 1 in turn, the representative compounds are coded as I-2901-I-2958.
[0356] Table 52: in general formula I-A, R 1 =CH 2 Cl, R 2 =Cl, R 11 =NO 2 , R 3 =R 4 =R 5b =R 8 =R 10 =H, the substituent R 9 are consistent with those in Table 1 and corresponding to I-1-I-58 in table 1 in turn, the representative compounds are coded as I-2959-I-3016.
[0357] Table 53: in general formula I-A, R 1 =CH 2 Cl, R 2 =R 11 =Cl, R 3 =R 4 =R 5b =R 8 =R 10 =H, the substituent R 9 are consistent with those in Table 1 and corresponding to I-1-I-58 in table 1 in turn, the representative compounds are coded as I-3017-I-3074.
[0000]
[0358] Table 54: in general formula I-B, R 1 =CH 3 , R 2 =Cl, R 3 =R 4 =R 5b =R 10 =R 11 =H, the substituent R 9 are consistent with those in Table 1 and corresponding to I-1-I-58 in table 1 in turn, the representative compounds are coded as I-3075-I-3132.
[0359] Table 55: in general formula I-B, R 1 =CH 3 , R 2 =R 5b =Cl, R 3 =R 4 =R 10 =R 11 =H, the substituent R 9 are consistent with those in Table 1 and corresponding to I-1-I-58 in table 1 in turn, the representative compounds are coded as I-3133-I-3190.
[0360] Table 56: in general formula I-B, R 1 =CH 3 , R 2 =Cl, R 5b =Br, R 3 =R 4 =R 10 =R 11 =H, the substituent R 9 are consistent with those in Table 1 and corresponding to I-1-I-58 in table 1 in turn, the representative compounds are coded as I-3191-I-3248.
[0361] Table 57: in general formula I-B, R 1 =CH 3 , R 2 =Cl, R 5b =OCH 3 , R 3 =R 4 =R 10 =R 11 =H, the substituent R 9 are consistent with those in Table 1 and corresponding to I-1-I-58 in table 1 in turn, the representative compounds are coded as I-3249-I-3306.
[0362] Table 58: in general formula I-B, R 1 =C 2 H 5 , R 2 =Cl, R 3 =R 4 =R 5b =R 10 =R 11 =H, the substituent R 9 are consistent with those in Table 1 and corresponding to I-1-I-58 in table 1 in turn, the representative compounds are coded as I-3307-I-3364.
[0363] Table 59: in general formula I-B, R 1 =C 2 H 5 , R 2 =R 5b =Cl, R 3 =R 4 =R 10 =R 11 =H 5 the substituent R 9 are consistent with those in Table 1 and corresponding to I-1-I-58 in table 1 in turn, the representative compounds are coded as I-3365-I-3422.
[0364] Table 60: in general formula I-B, R 1 =C 2 H 5 , R 2 =Cl, R 5b =Br, R 3 =R 4 =R 10 =R 11 =H, the substituent R 9 are consistent with those in Table 1 and corresponding to I-1-I-58 in table 1 in turn, the representative compounds are coded as I-3423-I-3480.
[0365] Table 61: in general formula I-B, R 1 =C 2 H 5 , R 2 =Cl, R 5b =OCH 3 , R 3 =R 4 =R 10 =R 11 =H, the substituent R 9 are consistent with those in Table 1 and corresponding to I-1-I-58 in table 1 in turn, the representative compounds are coded as I-3481-I-3538.
[0366] Table 62: in general formula I-B, R 1 =CH 3 , R 2 =R 11 =Cl, R 3 =R 4 =R 5b =R 10 =H 5 the substituent R 9 are consistent with those in Table 1 and corresponding to I-1-I-58 in table 1 in turn, the representative compounds are coded as I-3539-I-3596.
[0367] Table 63: in general formula I-B, R 1 =CH 3 , R 2 =Cl, R 11 =NO 2 , R 3 =R 4 =R 5b =R 10 =H, the substituent R 9 are consistent with those in Table 1 and corresponding to I-1-I-58 in table 1 in turn, the representative compounds are coded as I-3597-I-3654.
[0368] Table 64: in general formula I-B, R 1 =C 2 H 5 , R 2 =R 11 =Cl, R 3 =R 4 =R 5b =R 10 =H 5 the substituent R 9 are consistent with those in Table 1 and corresponding to I-1-I-58 in table 1 in turn, the representative compounds are coded as I-3655-I-3712.
[0369] Table 65: in general formula I-B, R 1 =C 2 H 5 , R 2 =Cl, R 11 =NO 2 , R 3 =R 4 =R 5b =R 10 =H, the substituent R 9 are consistent with those in Table 1 and corresponding to I-1-I-58 in table 1 in turn, the representative compounds are coded as I-3713-I-3770.
[0370] Table 66: in general formula I-B, R 1 =CH 3 , R 2 =R 10 =Cl, R 3 =R 4 =R 5b =R 11 =H 5 the substituent R 9 are consistent with those in Table 1 and corresponding to I-1-I-58 in table 1 in turn, the representative compounds are coded as I-3771-I-3828.
[0371] Table 67: in general formula I-B, R 1 =CH 3 , R 2 =R 10 =R 11 =Cl, R 3 =R 4 =R 5b =H 5 the substituent R 9 are consistent with those in Table 1 and corresponding to I-1-I-58 in table 1 in turn, the representative compounds are coded as I-3829-I-3886.
[0372] Table 68: in general formula I-B, R 1 =C 2 H 5 , R 2 =R 11 =Cl, R 3 =R 4 =R 5b =R 10 =H 5 the substituent R 9 are consistent with those in Table 1 and corresponding to I-1-I-58 in table 1 in turn, the representative compounds are coded as I-3887-I-3944.
[0373] Table 69: in general formula I-B, R 1 =C 2 H 5 , R 2 =R 10 =R 11 =Cl, R 3 =R 4 =R 5b =H, the substituent R 9 are consistent with those in Table 1 and corresponding to I-1-I-58 in table 1 in turn, the representative compounds are coded as I-3945-I-4002.
[0374] Table 70: in general formula I-B, R 1 =CH 3 , R 2 =Cl, R 11 =CF 3 , R 3 =R 4 =R 5b =R 10 =H, the substituent R 9 are consistent with those in Table 1 and corresponding to I-1-I-58 in table 1 in turn, the representative compounds are coded as I-4003-I-4060.
[0375] Table 71: in general formula I-B, R 1 =C 2 H 5 , R 2 =Cl, R 11 =CF 3 , R 3 =R 4 =R 5b =R 10 =H, the substituent R 9 are consistent with those in Table 1 and corresponding to I-1-I-58 in table 1 in turn, the representative compounds are coded as I-4061-I-4118.
[0376] Table 72: in general formula I-B, R 1 =CH 3 , R 2 =Br, R 3 =R 4 =R 5b =R 10 =R 11 =H, the substituent R 9 are consistent with those in Table 1 and corresponding to I-1-I-58 in table 1 in turn, the representative compounds are coded as I-4119-I-4176.
[0377] Table 73: in general formula I-B, R 1 =C 2 H 5 , R 2 Br, R 3 =R 4 =R 5b =R 10 =R 11 =H, the substituent R 9 are consistent with those in Table 1 and corresponding to I-1-I-58 in table 1 in turn, the representative compounds are coded as I-4177-I-4234.
[0000]
[0378] Table 74: in general formula I-C, R 1 =CH 3 , R 2 =Cl, R 3 =R 4 =R 5b =R 8 =R 10 =H, the substituent R 9 are consistent with those in Table 1 and corresponding to I-1-I-58 in table 1 in turn, the representative compounds are coded as I-4235-I-4292.
[0379] Table 75: in general formula I-C, R 1 =CH 3 , R 2 =R 5b =Cl, R 3 =R 4 =R 8 =R 10 =H, the substituent R 9 are consistent with those in Table 1 and corresponding to I-1-I-58 in table 1 in turn, the representative compounds are coded as I-4293-I-4350.
[0380] Table 76: in general formula I-C, R 1 =CH 3 , R 2 =Cl, R 5b =Br, R 3 =R 4 =R 8 =R 10 =H, the substituent R 9 are consistent with those in Table 1 and corresponding to I-1-I-58 in table 1 in turn, the representative compounds are coded as I-4351-I-4408.
[0381] Table 77: in general formula I-C, R 1 =CH 3 , R 2 =Cl, R 5b =Br, R 3 =R 4 =R 8 =R 10 =H, the substituent R 9 are consistent with those in Table 1 and corresponding to I-1-I-58 in table 1 in turn, the representative compounds are coded as I-4409-I-4466.
[0382] Table 78: in general formula I-C, R 1 =C 2 H 5 , R 2 =Cl, R 3 =R 4 =R 5b =R 8 =R 10 =H, the substituent R 9 are consistent with those in Table 1 and corresponding to I-1-I-58 in table 1 in turn, the representative compounds are coded as I-4467-I-4524.
[0383] Table 79: in general formula I-C, R 1 =C 2 H 5 , R 2 =R 5b =Cl, R 3 =R 4 =R 8 =R 10 =H, the substituent R 9 are consistent with those in Table 1 and corresponding to I-1-I-58 in table 1 in turn, the representative compounds are coded as I-4525-I-4582.
[0384] Table 80: in general formula I-C, R 1 =C 2 H 5 , R 2 =Cl, R 5b =Br, R 3 =R 4 =R 8 =R 10 =H, the substituent R 9 are consistent with those in Table 1 and corresponding to I-1-I-58 in table 1 in turn, the representative compounds are coded as I-4583-I-4640.
[0385] Table 81: in general formula I-C, R 1 =C 2 H 5 , R 2 =Cl, R 5b =OCH 3 , R 3 =R 4 =R 8 =R 10 =H, the substituent R 9 are consistent with those in Table 1 and corresponding to I-1-I-58 in table 1 in turn, the representative compounds are coded as I-4641-I-4698.
[0386] Table 82: in general formula I-C, R 1 =CH 3 , R 2 =Cl, R 3 =R 4 =R 5b =H, R 8 =R 10 =CH 3 , the substituent R 9 are consistent with those in Table 1 and corresponding to I-1-I-58 in table 1 in turn, the representative compounds are coded as I-4699-I-4756.
[0387] Table 83: in general formula I-C, R 1 =CH 3 , R 2 =Cl, R 3 =R 4 =R 5b =H, R 8 =R 10 =OCH 3 , the substituent R 9 are consistent with those in Table 1 and corresponding to I-1-I-58 in table 1 in turn, the representative compounds are coded as I-4757-I-4814.
[0388] Table 84: in general formula I-C, R 1 =CH 3 , R 2 =Cl, R 3 =R 4 =R 5b =H, R 8 =R 10 =Cl, the substituent R 9 are consistent with those in Table 1 and corresponding to I-1-I-58 in table 1 in turn, the representative compounds are coded as I-4815-I-4872.
[0389] Table 85: in general formula I-C, R 1 =CH 3 , R 2 =Cl, R 3 =CH 3 , R 4 =R 5b =R 8 =R 10 =H, the substituent R 9 are consistent with those in Table 1 and corresponding to I-1-I-58 in table 1 in turn, the representative compounds are coded as I-4873-I-4930.
[0390] Table 86: in general formula I-C, R 1 =CH 3 , R 2 =Cl, R 3 =CH 3 , R 4 =R 5b =H, R 8 =R 10 =CH 3 , the substituent R 9 are consistent with those in Table 1 and corresponding to I-1-I-58 in table 1 in turn, the representative compounds are coded as I-4931-I-4988.
[0391] Table 87: in general formula I-C, R 1 =CH 3 , R 2 =Cl, R 3 =CH 3 , R 4 =R 5b =H, R 8 =R 10 =OCH 3 , the substituent R 9 are consistent with those in Table 1 and corresponding to I-1-I-58 in table 1 in turn, the representative compounds are coded as I-4989-I-5046.
[0392] Table 88: in general formula I-C, R 1 =CH 3 , R 2 =Cl, R 3 =CH 3 , R 4 =R 5b =H, R 8 =R 10 =Cl, the substituent R 9 are consistent with those in Table 1 and corresponding to I-1-I-58 in table 1 in turn, the representative compounds are coded as I-5047-I-5104.
[0393] Table 89: in general formula I-C, R 1 =C 2 H 5 , R 2 =Cl, R 3 =CH 3 , R 4 =R 5b =R 8 =R 10 =H, the substituent R 9 are consistent with those in Table 1 and corresponding to I-1-I-58 in table 1 in turn, the representative compounds are coded as I-5105-I-5162.
[0394] Table 90: in general formula I-C, R 1 =C 2 H 5 , R 2 =Cl, R 3 =R 4 =R 5b =H, R 8 =R 10 =CH 3 , the substituent R 9 are consistent with those in Table 1 and corresponding to I-1-I-58 in table 1 in turn, the representative compounds are coded as I-5163-I-5220.
[0395] Table 91: in general formula I-C, R 1 =C 2 H 5 , R 2 =Cl, R 3 =R 4 =R 5b =H, R 8 =R 10 =OCH 3 , the substituent R 9 are consistent with those in Table 1 and corresponding to I-1-I-58 in table 1 in turn, the representative compounds are coded as I-5221-I-5278.
[0396] Table 92: in general formula I-C, R 1 =C 2 H 5 , R 2 =Cl, R 3 =R 4 =R 5b =H, R 8 =R 10 =Cl, the substituent R 9 are consistent with those in Table 1 and corresponding to I-1-I-58 in table 1 in turn, the representative compounds are coded as I-5279-I-5336.
[0397] Table 93: in general formula I-C, R 1 =CH 3 , R 2 =R 8 =Cl, R 3 =R 4 =R 5b =R 10 =H, the substituent R 9 are consistent with those in Table 1 and corresponding to I-1-I-58 in table 1 in turn, the representative compounds are coded as I-5337-I-5394.
[0398] Table 94: in general formula I-C, R 1 =CH 3 , R 2 =Cl, R 8 =CH 3 , R 3 =R 4 =R 5b =R 10 =H, the substituent R 9 are consistent with those in Table 1 and corresponding to I-1-I-58 in table 1 in turn, the representative compounds are coded as I-5395-I-5452.
[0399] Table 95: in general formula I-C, R 1 =CH 3 , R 2 =Cl, R 8 =OCH 3 , R 3 =R 4 =R 5b =R 10 =H, the substituent R 9 are consistent with those in Table 1 and corresponding to I-1-I-58 in table 1 in turn, the representative compounds are coded as I-5453-I-5510.
[0400] Table 96: in general formula I-C, R 1 =C 2 H 5 , R 2 =R 8 =Cl, R 3 =R 4 =R 5b =R 10 =H, the substituent R 9 are consistent with those in Table 1 and corresponding to I-1-I-58 in table 1 in turn, the representative compounds are coded as I-5511-I-5568.
[0401] Table 97: in general formula I-C, R 1 =C 2 H 5 , R 2 =Cl, R 8 =CH 3 , R 3 =R 4 =R 5b =R 10 =H, the substituent R 9 are consistent with those in Table 1 and corresponding to I-1-I-58 in table 1 in turn, the representative compounds are coded as I-5569-I-5626.
[0402] Table 98: in general formula I-C, R 1 =C 2 H 5 , R 2 =Cl, R 8 =OCH 3 , R 3 =R 4 =R 5b =R 10 =H, the substituent R 9 are consistent with those in Table 1 and corresponding to I-1-I-58 in table 1 in turn, the representative compounds are coded as I-5627-I-5684.
[0000]
[0403] Table 99: in general formula I-D, R 1 =CH 3 , R 2 =Cl, R 3 =R 4 =R 5b =R 7 =R 10 =R 11 =H, the substituent R 9 are consistent with those in Table 1 and corresponding to I-1-I-58 in table 1 in turn, the representative compounds are coded as I-5685-I-5742.
[0404] Table 100: in general formula I-D, R 1 =CH 3 , R 2 =R 5b =Cl, R 3 =R 4 =R 7 =R 10 =R 11 =H, the substituent R 9 are consistent with those in Table 1 and corresponding to I-1-I-58 in table 1 in turn, the representative compounds are coded as I-5743-I-5800.
[0405] Table 101: in general formula I-D, R 1 =CH 3 , R 2 =Cl, R 5b =Br, R 3 =R 4 =R 7 =R 10 =R 11 =H, the substituent R 9 are consistent with those in Table 1 and corresponding to I-1-I-58 in table 1 in turn, the representative compounds are coded as I-5801-I-5858.
[0406] Table 102: in general formula I-D, R 1 =CH 3 , R 2 =Cl, R 5b =OCH 3 , R 3 =R 4 =R 7 =R 10 =R 11 =H, the substituent R 9 are consistent with those in Table 1 and corresponding to I-1-I-58 in table 1 in turn, the representative compounds are coded as I-5859-I-5916.
[0407] Table 103: in general formula I-D, R 1 =C 2 H 5 , R 2 =Cl, R 3 =R 4 =R 5b =R 7 =R 10 =R 11 =H, the substituent R 9 are consistent with those in Table 1 and corresponding to I-1-I-58 in table 1 in turn, the representative compounds are coded as I-5917-I-5974.
[0408] Table 104: in general formula I-D, R 1 =C 2 H 5 , R 2 =R 5b =Cl, R 3 =R 4 =R 7 =R 10 =R 11 =H, the substituent R 9 are consistent with those in Table 1 and corresponding to I-1-I-58 in table 1 in turn, the representative compounds are coded as I-5975-I-6032.
[0409] Table 105: in general formula I-D, R 1 =C 2 H 5 , R 2 =Cl, R 5b =Br, R 3 =R 4 =R 7 =R 10 =R 11 =H, the substituent R 9 are consistent with those in Table 1 and corresponding to I-1-I-58 in table 1 in turn, the representative compounds are coded as I-6033-I-6090.
[0410] Table 106: in general formula I-D, R 1 =C 2 H 5 , R 2 =Cl, R 5b =OCH 3 , R 3 =R 4 =R 7 =R 10 =R 11 =H, the substituent R 9 are consistent with those in Table 1 and corresponding to I-1-I-58 in table 1 in turn, the representative compounds are coded as I-6091-I-6148.
[0411] Table 107: in general formula I-D, R 1 =CH 3 , R 2 =R 11 =Cl, R 3 =R 4 =R 5b =R 7 =R 10 =H, the substituent R 9 are consistent with those in Table 1 and corresponding to I-1-I-58 in table 1 in turn, the representative compounds are coded as I-6149-I-6206.
[0412] Table 108: in general formula I-D, R 1 =CH 3 , R 2 =Cl, R 11 =NO 2 , R 3 =R 4 =R 5b =R 7 =R 10 =H, the substituent R 9 are consistent with those in Table 1 and corresponding to I-1-I-58 in table 1 in turn, the representative compounds are coded as I-6207-I-6264.
[0413] Table 109: in general formula I-D, R 1 =C 2 H 5 , R 2 =R 11 =Cl, R 3 =R 4 =R 5b =R 7 =R 10 =H, the substituent R 9 are consistent with those in Table 1 and corresponding to I-1-I-58 in table 1 in turn, the representative compounds are coded as I-6265-I-6322.
[0414] Table 110: in general formula I-D, R 1 =C 2 H 5 , R 2 =Cl, R 11 =NO 2 , R 3 =R 4 =R 5b =R 7 =R 10 =H, the substituent R 9 are consistent with those in Table 1 and corresponding to I-1-I-58 in table 1 in turn, the representative compounds are coded as I-6323-I-6380.
[0415] Table 111: in general formula I-D, R 1 =CH 3 , R 2 =R 7 =R 11 =Cl, R 3 =R 4 =R 5b =R 10 =H, the substituent R 9 are consistent with those in Table 1 and corresponding to I-1-I-58 in table 1 in turn, the representative compounds are coded as I-6381-I-6438.
[0416] Table 112: in general formula I-D, R 1 =CH 3 . R 2 =R 7 =R 10 =R 11 =Cl, R 3 =R 4 =R 5b =H, the substituent R 9 are consistent with those in Table 1 and corresponding to I-1-I-58 in table 1 in turn, the representative compounds are coded as I-6439-I-6496.
[0417] Table 113: in general formula I-D, R 1 =C 2 H 5 , R 2 =R 7 =R 11 =Cl, R 3 =R 4 =R 5b =R 10 =H, the substituent R 9 are consistent with those in Table 1 and corresponding to I-1-I-58 in table 1 in turn, the representative compounds are coded as I-6497-I-6554.
[0418] Table 114: in general formula I-D, R 1 =C 2 H 5 , R 2 =R 7 =R 10 =R 11 =Cl, R 3 =R 4 =R 5b =H, the substituent R 9 are consistent with those in Table 1 and corresponding to I-1-I-58 in table 1 in turn, the representative compounds are coded as I-6555-I-6612.
[0419] Table 115: in general formula I-D, R 1 =CH 3 , R 2 =Cl, R 11 =CF 3 , R 3 =R 4 =R 5b =R 7 =R 10 =H, the substituent R 9 are consistent with those in Table 1 and corresponding to I-1-I-58 in table 1 in turn, the representative compounds are coded as I-6613-I-6670.
[0420] Table 116: in general formula I-D, R 1 =C 2 H 5 , R 2 =Cl, R 11 =CF 3 , R 3 =R 4 =R 5b =R 7 =R 10 =H, the substituent R 9 are consistent with those in Table 1 and corresponding to I-1-I-58 in table 1 in turn, the representative compounds are coded as I-6671-I-6728.
[0421] Table 117: the salts of some compounds having a structure as represented by formula I of the present invention are listed in Table 117, but without being restricted thereby.
[0000]
TABLE 117
the salts of some compounds
No.
structure
I-6729
I-6730
I-6731
I-6732
I-6733
I-6734
I-6735
I-6736
I-6737
I-6738
I-6739
I-6740
I-6741
I-6742
I-6743
I-6744
I-6745
I-6746
I-6747
I-6748
I-6749
I-6750
I-6751
I-6752
I-6753
I-6754
I-6755
I-6756
I-6757
I-6758
I-6759
I-6760
I-6761
I-6762
I-6763
I-6764
I-6765
I-6766
I-6767
I-6768
I-6769
I-6770
I-6771
I-6772
I-6773
I-6774
I-6775
I-6776
I-6777
I-6778
I-6779
I-6780
I-6781
I-6782
[0422] Some compounds represented by general formula I-E, I-F, I-G and I-H of the present invention are listed in Table 118, but without being restricted thereby.
[0000]
TABLE 118
No.
structure
I-6783
I-6784
I-6785
I-6786
I-6787
I-6788
I-6789
I-6790
I-6791
I-6792
I-6793
I-6794
I-6795
I-6796
I-6797
I-6798
I-6799
I-6800
I-6801
I-6802
I-6803
I-6804
I-6805
I-6806
I-6807
I-6808
I-6809
I-6810
I-6811
I-6812
I-6813
I-6814
I-6815
I-6816
I-6817
I-6818
I-6819
I-6820
I-6821
I-6822
I-6823
I-6824
I-6825
I-6826
I-6827
I-6828
I-6829
I-6830
I-6831
I-6832
I-6833
I-6834
I-6835
I-6836
I-6837
I-6838
I-6839
I-6840
I-6841
I-6842
I-6843
I-6844
I-6845
I-6846
[0423] In the general formula I, A=NR 12 , R 12 ≠H, part of preferred substituents of R 12 are listed in table 119, but without being restricted thereby. The present invention is also explained by the following compounds in the general formula I listed in Table 120, but without being restricted thereby.
[0000]
TABLE 119
R 12 substituents
R 12
OH
C 2 H 5
i-C 4 H 9
CHF 2
CHCl 2
OC 2 H 5
OCH 2 CF 3
SCH 3
CH 2 CH═CH 2
CH 2 C≡C—I
CH 2 CH 2 OCH 2 CH 3
CH 2 SCH 3
CH 2 SCH 2 Cl
SOC 2 H 5
SO 2 C 2 H 5
SO 2 NHCH 3
COC 2 H 5
CO-i-C 4 H 9
COOCH 3
COOCF 3
CH 2 COOC 2 H 5
CONHC 2 H 5
COOCH 2 CH═CH 2
SNHCH 3
—C(═O)H
n-C 3 H 7
t-C 4 H 9
CHBr 2
CCl 3
OCH(CH 3 ) 2
OCF 2 CF 3
SC 2 H 5
CH 2 CH═CCl 2
CH 2 OCH 3
CH 2 OCH 2 Cl
CH 2 SCH 2 CH 3
CH 2 SCH 2 CH 2 Cl
SOCF 3
SO 2 CF 3
SO 2 N(CH 3 ) 3
CO-n-C 3 H 7
CO-t-C 4 H 9
COOC 2 H 5
COOCH 2 CH 2 Cl
CH 2 COCH 3
CONH-t-C 4 H 9
COOCH 2 C≡CH
SNHC 2 H 5
CBr 3
i-C 3 H 7
CI 3
CF 3
CH 2 F
OC(CH 3 ) 3
OCH 2 F
SCH 2 CH═CH 2
C≡CH
CH 2 OCH 2 CH 3
CH 2 OCH 2 CH 2 Cl
CH 2 CH 2 SCH 3
CH 2 CH 2 SCH 2 Cl
SOCH 2 CF 3
SO 2 CH 2 CF 3
CONHSO 2 CH 3
CO-i-C 3 H 7
COCF 3
COO-n-C 3 H 7
COOCH 2 CF 3
CH 2 COC 2 H 5
CON(CH 3 ) 2
COOCH 2 OCH 3
SN(CH 3 ) 2
CH 3
n-C 4 H 9
CH 2 Br
CH 2 Cl
OCH 3
OCF 3
OCHF 2
CH═CH 2
CH 2 C≡CH
CH 2 CH 2 OCH 3
CH 2 CH 2 OCH 2 Cl
CH 2 CH 2 SCH 2 CH 3
SOCH 3
SO 2 CH 3
SO 2 NHCOCH 3
COCH 3
CO-n-C 4 H 9
COCH 2 Cl
COO-t-C 4 H 9
CH 2 COOCH 3
CONHCH 3
CON(C 2 H 5 ) 2
COOCH 2 CH 2 OCH 3
SN(C 2 H 5 ) 2
[0000]
TABLE 120
No.
structure
I-6847
I-6848
I-6849
I-6850
I-6851
I-6852
I-6853
I-6854
I-6855
I-6856
I-6857
I-6858
I-6859
I-6860
I-6861
I-6862
I-6863
I-6864
I-6865
I-6866
I-6867
I-6868
I-6869
I-6870
I-6871
I-6872
I-6873
I-6874
I-6875
I-6876
I-6877
I-6878
I-6879
I-6880
I-6881
I-6882
I-6883
I-6884
I-6885
I-6886
I-6887
I-6888
I-6889
I-6890
I-6891
I-6892
I-6893
I-6894
[0424] In the general formula II, part of preferred substituents of R 1 , R 2 , R 3 (R 4 ), R 5a (R 5b , R 5c ), R 6 (R 7 , R 8 , R 9 , R 10 , R 11 ) and R 12 are separately listed in table 121, table 122, table 123, table 124, table 125 and table 126, but without being restricted thereby.
[0000]
[0000]
TABLE 121
R 1 substituents
R 1
CH 3
n-C 4 H 9
CF 3
CH 2 Br
CF 2 H
C 2 H 5
s-C 4 H 9
CCl 3
CClF 2
CBr 2 H
n-C 3 H 7
i-C 4 H 9
CH 2 F
CFCl 2
CBr 3
i-C 3 H 7
t-C 4 H 9
CH 2 Cl
CCl 2 H
CClBr 2
[0000]
TABLE 122
R 2 substituents
R 2
R 2
R 2
R 2
F
Cl
Br
I
CN
OCH 3
OC 2 H 5
OC 3 H 7 -n
OC 3 H 7 -i
OC 4 H 9 -n
OC 4 H 9 -i
OC 4 H 9 -t
[0000]
TABLE 123
R 3 (R 4 ) substituents
R 3 (R 4 )
H
i-C 3 H 7
F
t-C 4 H 9
OCH 3
CH 3
n-C 4 H 9
Cl
OC 2 H 5
C 2 H 5
s-C 4 H 9
Br
OC 3 H 7 -n
n-C 3 H 7
i-C 4 H 9
I
OC 3 H 7 -i
CR 3 (R 4 )
[0000]
TABLE 124
R 5a (R 5b , R 5c ) substituents
R 5a (R 5b , R 5c )
R 5a (R 5b , R 5c )
R 5a (R 5b , R 5c )
R 5a (R 5b , R 5c )
H
CH 3
i-C 4 H 9
OC 4 H 9 -n
F
C 2 H 5
t-C 4 H 9
OC 4 H 9 -i
Cl
n-C 3 H 7
OCH 3
OC 4 H 9 -t
Br
i-C 3 H 7
OC 2 H 5
OCF 3
I
n-C 4 H 9
OC 3 H 7 -n
OCH 2 CF 3
OH
s-C 4 H 9
OC 3 H 7 -i
OCF 2 CF 3
[0000]
TABLE 125
R 6 (R 7 , R 8 , R 9 , R 10 , R 11 ) substituents
R 6 (R 7 , R 8 ,
R 9 , R 10 ,
R 6 (R 7 , R 8 ,
R 6 (R 7 , R 8 , R 9 ,
R 6 (R 7 , R 8 , R 9 ,
R 11 )
R 9 , R 10 , R 11 )
R 10 , R 11 )
R 10 , R 11 )
R 6 (R 7 , R 8 , R 9 , R 10 , R 11 )
H
4-CH 3
3-CH 2 OCH 3
2,6-2Cl-4-CONH 2
2-CF 3 -4-Br-6-NO 2
2-F
2,3-2CH 3
4-CH 2 OCH 3
2,4-2Cl-6-NO 2
3-NO 2 -4-CF 3
3-F
2,4-2CH 3
2-OCOCH 3
2,4-2Cl-6-CN
2-NO 2 -4-CN-5-CF 3
4-F
2,5-2CH 3
3-OCOCH 3
2,4-2Cl-6-CF 3
2-NO 2 -4-CF 3 -5-CN
2,3-2F
2,6-2CH 3
4-OCOCH 3
2,4-2F-6-NO 2
4-OCF 3 -2,6-2Br
2,4-2F
3,4-2CH 3
2-OCOCH 2 CH 3
2,6-2F-4-NO 2
2-CH 3 -4-Cl-5-CH 2 CO 2 C 2 H 5
2,5-2F
3,5-2CH 3
3-OCOCH 2 CH 3
2-NO 2 -4-F
2,4-2Cl-3-CH 3
2,6-2F
2-C 2 H 5
4-OCOCH 2 CH 3
2-NO 2 -4-Br
2,4-2Cl-3-CH 3 -6-NO 2
3,4-2F
3-C 2 H 5
2-OCO 2 CH 3
2-NO 2 -4-CF 3
2-Cl-3-CH 3
3,5-2F
4-C 2 H 5
3-OCO 2 CH 3
2-NO 2 -4-CN
2-CH 3 -3-Cl
2,3,4-3F
2-CF 3
4-OCO 2 CH 3
2-NO 2 -4-COCH 3
2-CH 3 -3-Cl-4,6-2NO 2
2,3,5-3F
3-CF 3
2-OCH 2 OCH 3
2-NO 2 -4-CONH 2
2-CH 3 -3-Cl-4-NO 2
2,4,5-3F
4-CF 3
3-OCH 2 OCH 3
2-NO 2 -4-CH 3
2-CH 3 -3-Cl-6-NO 2
2,3,6-3F
2-OCH 3
4-OCH 2 OCH 3
2-NO 2 -4-OCH 3
2-Cl-3-CH 3 -4,6-2NO 2
2,4,6-3F
3-OCH 3
2-OCF 2 OCF 3
2-NO 2 -4-SCH 3
2-Cl-3-CH 3 -4-NO 2
3,4,5-3F
4-OCH 3
3-OCF 2 OCF 3
2-NO 2 -4-NCH 3
2-Cl-3-CH 3 -6-NO 2
2-Cl
2-SCH 3
4-OCF 2 OCF 3
2-F-4-NO 2
2-Br-4-NO 2 -6-CN
3-Cl
3-SCH 3
2-COPh
2-Br-4-NO 2
3-Cl-4-CF 3 -2,6-2NO 2
4-Cl
4-SCH 3
3-COPh
2-CF 3 -4-NO 2
2NO 2 -4,5-2Cl
2,3-2Cl
2-OCF 3
4-COPh
2-CN-4-NO 2
2-NO 2 -3,5-2Cl
2,4-2Cl
3-OCF 3
2-COCH 2 Ph
2-COCH 3 -4-NO 2
2,5-2Cl-4-NO 2
2,5-2Cl
4-OCF 3
3-COCH 2 Ph
2-CONH 2 -4-NO 2
2,5-2Cl-6-NO 2
2,6-2Cl
2-SCF 3
4-COCH 2 Ph
2-CH 3 -4-NO 2
2,3-2Cl-4-NO 2
3,4-2Cl
3-SCF 3
2-NHPh
2-Cl-4-F-6-NO 2
2,3-2Cl-6-NO 2
3,5-2Cl
4-SCF 3
3-NHPh
2-Cl-4-Br-6-NO 2
3,4-2Cl-2,6-2NO 2
2,3,4-3Cl
2-OC 2 H 5
4-NHPh
2-Cl-4-CH 3 -6-NO 2
2,5-2Cl-4,6-2NO 2
2,3,5-3Cl
3-OC 2 H 5
2-OPh
2-Cl-4-CF 3 -6-NO 2
2,4,5-3Cl-6-NO 2
2,4,5-3Cl
4-OC 2 H 5
3-OPh
2-Cl-4,6-2NO 2
2,3,4-3Cl-5-NO 2
2,3,6-3Cl
2-NHCH 3
4-OPh
2-Cl-4-CN-6-NO 2
2,3,4-3Cl-6-NO 2
2,4,6-3Cl
3-NHCH 3
2-CONHPh
2-Cl-4-OCF 3 -6-NO 2
2,3,5-3Cl-4,6-2CN
3,4,5-3Cl
4-NHCH 3
3-CONHPh
2-F-4-Cl-6-NO 2
2,5-2Cl-4-OCF 2 OCF 3
2-Br
2-N(CH 3 ) 2
4-CONHPh
2-Br-4-Cl-6-NO 2
2,6-2Br-4-NO 2
3-Br
3-N(CH 3 ) 2
2-CO 2 Ph
2-CH 3 -4-Cl-6-NO 2
2-F-4-NO 2 -6-Cl
4-Br
4-N(CH 3 ) 2
3-CO 2 Ph
2-CF 3 -4-Cl-6-NO 2
2-Cl-4-NO 2 -6-SCN
2,3-2Br
2-COCH 3
4-CO 2 Ph
4-Cl-2,6-2NO 2
2-Br-4-NO 2 -6-Cl
2,4-2Br
3-COCH 3
2-CONH 2
2-F-4-CN
2-Cl-4-NO 2 -6-OCH 3
2,5-2Br
4-COCH 3
3-CONH 2
2-CN-4-CF 3
2-Cl-4-NO 2 -6-SCH 3
2,6-2Br
2-COC 2 H 5
4-CONH 2
4-CF 3 -2,6-2NO 2
2-Cl-4-NO 2 -6-NHCH 3
3,4-2Br
3-COC 2 H 5
2-Cl-4-F
4-CN-2,6-2NO 2
2-Cl-4-NO 2 -6-SO 2 CH 3
3,5-2Br
4-COC 2 H 5
2-Cl-4-Br
4-CH 3 -2,6-2NO 2
2-Cl-4-SO 2 CH 3
2,3,4-3Br
2-SO 2 CH 3
2-Cl-4-CH 3
4-OCF 3 -2,6-2NO 2
2,6-2Cl-4-SO 2 CH 3
2,3,5-3Br
3-SO 2 CH 3
2-Cl-4-CF 3
4-OCH 3 -2,6-2NO 2
2,6-2Cl-4-CH 3
2,4,5-3Br
4-SO 2 CH 3
2-Cl-4-NO 2
4-SCH 3 -2,6-2NO 2
2,6-2Cl-4-CO 2 CH 3
2,3,6-3Br
2-OCHF 2
2-Cl-4-CN
4-NHCH 3 -2,6-2NO 2
2,6-2Cl-4-CONHCH 3
2,4,6-3Br
3-OCHF 2
2-Cl-4-OCF 3
4-F-2,6-2NO 2
2,6-2Cl-4-CON(CH 3 ) 2
3,4,5-3Br
4-OCHF 2
2-F-4-Cl
2-CF 3 -4,6-2NO 2
2,6-2Cl-4-CF(CF 3 ) 2
2-CN
2-SO 2 C 2 H 5
2-Br-4-Cl
2-CN-4,6-2NO 2
2-Cl-4-CF(CF 3 ) 2 -6-Br
3-CN
3-SO 2 C 2 H 5
2-CH 3 -4-Cl
2-CH 3 -4,6-2NO 2
2-F-4-CF(CF 3 ) 2 -6-Br
4-CN
4-SO 2 C 2 H 5
2-CF 3 -4-Cl
2-F-4,6-2NO 2
2-F-4-CF(CF 3 ) 2 -6-Cl
2-NO 2
2-CO 2 CH 3
2-NO 2 -4-Cl
2-OCF 3 -4,6-2NO 2
2,4,5-3Cl-3,6-2CN
3-NO 2
3-CO 2 CH 3
2-CN-4-Cl
2-CF 3 -4-Br
2,3,5-3F-4,6-2CN
4-NO 2
4-CO 2 CH 3
2-OCF 3 -4-Cl
3-CF 3 -4-NO 2
2-SO 2 NH 2
2,4-2NO 2
2-CO 2 C 2 H 5
2,6-2Cl-4-NO 2
2-CN-4-Cl-6-NO 2
3-SO 2 NH 2
2,4,6-3NO 2
3-CO 2 C 2 H 5
2,6-2Cl-4-CF 3
2-OCF 3 -4-Cl-6-NO 2
4-SO 2 NH 2
2-CH 3
4-CO 2 C 2 H 5
2,6-2Cl-4-CN
3-CF 3 -4-CN
3-CH 3
2-CH 2 OCH 3
2,6-2Cl-4-COCH 3
3-CN-4-CF 3
[0000]
TABLE 126
R 12 substituents
R 12
R 12
R 12
R 12
H
OH
CH 3
C 2 H 5
n-C 3 H 7
i-C 3 H 7
n-C 4 H 9
s-C 4 H 9
i-C 4 H 9
t-C 4 H 9
HCO
CH 3 CO
CH 3 CH 2 CO
n-C 3 H 7 CO
i-C 3 H 7 CO
CH 3 SO 2
CH 3 CH 2 SO 2
n-C 3 H 7 SO 2
n-C 4 H 9 SO 2
[0425] The present invention is also explained by the following compounds having a structure as represented by formula II listed in Table 127 to Table 202, Compounds having a structure as represented by formula II-A are listed in Table 127 to Table 190, Compounds having a structure as represented by formula II-B are listed in Table 191 to Table 201, but without being restricted thereby.
[0000]
[0426] In general formula II-A, W=H, R 1 =CH 3 , R 2 =Cl, R 3 =R 4 =R 5b =H, the substituents R 7 , R 8 , R 9 , R 10 and R 11 refer to Table 127, the representative compounds are coded as II-1-II-278.
[0000]
TABLE 127
No.
R 7
R 8
R 9
R 10
R 11
II-1
H
H
H
H
H
II-2
F
H
H
H
H
II-3
H
F
H
H
H
II-4
H
H
F
H
H
II-5
F
F
H
H
H
II-6
F
H
F
H
H
II-7
F
H
H
F
H
II-8
F
H
H
H
F
II-9
H
F
F
H
H
II-10
H
F
H
F
H
II-11
F
F
F
H
H
II-12
F
F
H
F
H
II-13
F
H
F
F
H
II-14
F
F
H
H
F
II-15
F
H
F
H
F
II-16
H
F
F
F
H
II-17
Cl
H
H
H
H
II-18
H
Cl
H
H
H
II-19
H
H
Cl
H
H
II-20
Cl
Cl
H
H
H
II-21
Cl
H
Cl
H
H
II-22
Cl
H
H
Cl
H
II-23
Cl
H
H
H
Cl
II-24
H
Cl
Cl
H
H
II-25
H
Cl
H
Cl
H
II-26
Cl
Cl
Cl
H
H
II-27
Cl
Cl
H
Cl
H
II-28
Cl
H
Cl
Cl
H
II-29
Cl
Cl
H
H
Cl
II-30
Cl
H
Cl
H
Cl
II-31
H
Cl
Cl
Cl
H
II-32
Br
H
H
H
H
II-33
H
Br
H
H
H
II-34
H
H
Br
H
H
II-35
Br
Br
H
H
H
II-36
Br
H
Br
H
H
II-37
Br
H
H
Br
H
II-38
Br
H
H
H
Br
II-39
H
Br
Br
H
H
II-40
H
Br
H
Br
H
II-41
Br
Br
Br
H
H
II-42
Br
Br
H
Br
H
II-43
Br
H
Br
Br
H
II-44
Br
Br
H
H
Br
II-45
Br
H
Br
H
Br
II-46
H
Br
Br
Br
H
II-47
CN
H
H
H
H
II-48
H
CN
H
H
H
II-49
H
H
CN
H
H
II-50
NO 2
H
H
H
H
II-51
H
NO 2
H
H
H
II-52
H
H
NO 2
H
H
II-53
NO 2
H
NO 2
H
H
II-54
NO 2
H
NO 2
H
NO 2
II-55
CH 3
H
H
H
H
II-56
H
CH 3
H
H
H
II-57
H
H
CH 3
H
H
II-58
CH 3
CH 3
H
H
H
II-59
CH 3
H
CH 3
H
H
II-60
CH 3
H
H
CH 3
H
II-61
CH 3
H
H
H
CH 3
II-62
H
CH 3
CH 3
H
H
II-63
H
CH 3
H
CH 3
H
II-64
C 2 H 5
H
H
H
H
II-65
H
C 2 H 5
H
H
H
II-66
H
H
C 2 H 5
H
H
II-67
CF 3
H
H
H
H
II-68
H
CF 3
H
H
H
II-69
H
H
CF 3
H
H
II-70
OCH 3
H
H
H
H
II-71
H
OCH 3
H
H
H
II-72
H
H
OCH 3
H
H
II-73
SCH 3
H
H
H
H
II-74
H
SCH 3
H
H
H
II-75
H
H
SCH 3
H
H
II-76
OCF 3
H
H
H
H
II-77
H
OCF 3
H
H
H
II-78
H
H
OCF 3
H
H
II-79
SCF 3
H
H
H
H
II-80
H
SCF 3
H
H
H
II-81
H
H
SCF 3
H
H
II-82
OC 2 H 5
H
H
H
H
II-83
H
OC 2 H 5
H
H
H
II-84
H
H
OC 2 H 5
H
H
II-85
NHCH 3
H
H
H
H
II-86
H
NHCH 3
H
H
H
II-87
H
H
NHCH 3
H
H
II-88
N(CH 3 ) 2
H
H
H
H
II-89
H
N(CH 3 ) 2
H
H
H
II-90
H
H
N(CH 3 ) 2
H
H
II-91
COCH 3
H
H
H
H
II-92
H
COCH 3
H
H
H
II-93
H
H
COCH 3
H
H
II-94
COC 2 H 5
H
H
H
H
II-95
H
COC 2 H 5
H
H
H
II-96
H
H
COC 2 H 5
H
H
II-97
SO 2 CH 3
H
H
H
H
II-98
H
SO 2 CH 3
H
H
H
II-99
H
H
SO 2 CH 3
H
H
II-100
OCHF 2
H
H
H
H
II-101
H
OCHF 2
H
H
H
II-102
H
H
OCHF 2
H
H
II-103
SO 2 C 2 H 5
H
H
H
H
II-104
H
SO 2 C 2 H 5
H
H
H
II-105
H
H
SO 2 C 2 H 5
H
H
II-106
CO 2 CH 3
H
H
H
H
II-107
H
CO 2 CH 3
H
H
H
II-108
H
H
CO 2 CH 3
H
H
II-109
CO 2 C 2 H 5
H
H
H
H
II-110
H
CO 2 C 2 H 5
H
H
H
II-111
H
H
CO 2 C 2 H 5
H
H
II-112
CH 2 OCH 3
H
H
H
H
II-113
H
CH 2 OCH 3
H
H
H
II-114
H
H
CH 2 OCH 3
H
H
II-115
OCOCH 3
H
H
H
H
II-116
H
OCOCH 3
H
H
H
II-117
H
H
OCOCH 3
H
H
II-118
OCOCH 2 CH 3
H
H
H
H
II-119
H
OCOCH 2 CH 3
H
H
H
II-120
H
H
OCOCH 2 CH 3
H
H
II-121
OCO 2 CH 3
H
H
H
H
II-122
H H
OCO 2 CH 3
H
H
H
II-123
H
H
OCO 2 CH 3
H
H
II-124
OCH 2 OCH 3
H
H
H
H
II-125
H
OCH 2 OCH 3
H
H
H
II-126
H
H
OCH 2 OCH 3
H
H
II-127
OCF 2 OCF 3
H
H
H
H
II-128
H
OCF 2 OCF 3
H
H
H
II-129
H
H
OCF 2 OCF 3
H
H
II-130
COPh
H
H
H
H
II-131
H
COPh
H
H
H
II-132
H
H
COPh
H
H
II-133
COCH 2 Ph
H
H
H
H
II-134
H
COCH 2 Ph
H
H
H
II-135
H
H
COCH 2 Ph
H
H
II-136
NHPh
H
H
H
H
II-137
H
NHPh
H
H
H
II-138
H
H
NHPh
H
H
II-139
OPh
H
H
H
H
II-140
H
OPh
H
H
H
II-141
H
H
OPh
H
H
II-142
CONHPh
H
H
H
H
II-143
H
CONHPh
H
H
H
II-144
H
H
CONHPh
H
H
II-145
CO 2 Ph
H
H
H
H
II-146
H
CO 2 Ph
H
H
H
II-147
H
H
CO 2 Ph
H
H
II-148
CONH 2
H
H
H
H
II-149
H
CONH 2
H
H
H
II-150
H
H
CONH 2
H
H
II-151
Cl
H
F
H
H
II-152
Cl
H
Br
H
H
II-153
Cl
H
CH 3
H
H
II-154
Cl
H
CF 3
H
H
II-155
Cl
H
NO 2
H
H
II-156
Cl
H
CN
H
H
II-157
Cl
H
OCF 3
H
H
II-158
F
H
Cl
H
H
II-159
Br
H
Cl
H
H
II-160
CH 3
H
Cl
H
H
II-161
CF 3
H
Cl
H
H
II-162
NO 2
H
Cl
H
H
II-163
CN
H
Cl
H
H
II-164
OCF 3
H
Cl
H
H
II-165
Cl
H
NO 2
H
Cl
II-166
Cl
H
CF 3
H
Cl
II-167
Cl
H
CN
H
Cl
II-168
Cl
H
COCH 3
H
Cl
II-169
Cl
H
CONH 2
H
Cl
II-170
Cl
H
Cl
H
NO 2
II-171
Cl
H
Cl
H
CN
II-172
Cl
H
Cl
H
CF 3
II-173
F
H
F
H
NO 2
II-174
F
H
NO 2
H
F
II-175
NO 2
H
F
H
H
II-176
NO 2
H
Br
H
H
II-177
NO 2
H
CF 3
H
H
II-178
NO 2
H
CN
H
H
II-179
NO 2
H
COCH 3
H
H
II-180
NO 2
H
CONH 2
H
H
II-181
NO 2
H
CH 3
H
H
II-182
NO 2
H
OCH 3
H
H
II-183
NO 2
H
SCH 3
H
H
II-184
NO 2
H
NCH 3
H
H
II-185
F
H
NO 2
H
H
II-186
Br
H
NO 2
H
H
II-187
CF 3
H
NO 2
H
H
II-188
CN
H
NO 2
H
H
II-189
COCH 3
H
NO 2
H
H
II-190
CONH 2
H
NO 2
H
H
II-191
CH 3
H
NO 2
H
H
II-192
Cl
H
F
H
NO 2
II-193
Cl
H
Br
H
NO 2
II-194
Cl
H
CH 3
H
NO 2
II-195
Cl
H
CF 3
H
NO 2
II-196
Cl
H
NO 2
H
NO 2
II-197
Cl
H
CN
H
NO 2
II-198
Cl
H
OCF 3
H
NO 2
II-199
F
H
Cl
H
NO 2
II-200
Br
H
Cl
H
NO 2
II-201
CH 3
H
Cl
H
NO 2
II-202
CF 3
H
Cl
H
NO 2
II-203
NO 2
H
Cl
H
NO 2
II-204
F
H
CN
H
H
II-205
CN
H
CF 3
H
H
II-206
NO 2
H
CF 3
H
NO 2
II-207
NO 2
H
CN
H
NO 2
II-208
NO 2
H
CH 3
H
NO 2
II-209
NO 2
H
OCF 3
H
NO 2
II-210
NO 2
H
OCH 3
H
NO 2
II-211
NO 2
H
SCH 3
H
NO 2
II-212
NO 2
H
NHCH 3
H
NO 2
II-213
NO 2
H
F
H
NO 2
II-214
CF 3
H
NO 2
H
NO 2
II-215
CN
H
NO 2
H
NO 2
II-216
CH 3
H
NO 2
H
NO 2
II-217
F
H
NO 2
H
NO 2
II-218
OCF 3
H
NO 2
H
NO 2
II-219
CF 3
H
Br
H
H
II-220
H
CF 3
NO 2
H
H
II-221
CN
H
Cl
H
NO 2
II-222
OCF 3
H
Cl
H
NO 2
II-223
H
CF 3
CN
H
H
II-224
H
CN
CF 3
H
H
II-225
CF 3
H
Br
H
NO 2
II-226
H
NO 2
CF 3
H
H
II-227
NO 2
H
CN
CF 3
H
II-228
NO 2
H
CF 3
CN
H
II-229
Br
H
OCF 3
H
Br
II-230
CH 3
H
Cl
CH 2 CO 2 C 2 H 5
H
II-231
Cl
CH 3
Cl
H
OCF 2 OCF 3
II-232
Cl
CH 3
Cl
H
NO 2
II-233
Cl
CH 3
H
H
H
II-234
CH 3
Cl
H
H
H
II-235
CH 3
Cl
NO 2
H
NO 2
II-236
CH 3
Cl
NO 2
H
H
II-237
CH 3
Cl
H
H
NO 2
II-238
Cl
CH 3
NO 2
H
NO 2
II-239
Cl
CH 3
NO 2
H
H
II-240
Cl
CH 3
H
H
NO 2
II-241
Br
H
NO 2
H
CN
II-242
NO 2
Cl
CF 3
H
NO 2
II-243
NO 2
H
Cl
Cl
H
II-244
NO 2
Cl
H
Cl
H
II-245
Cl
H
NO 2
Cl
H
II-246
Cl
H
H
Cl
NO 2
II-247
Cl
Cl
NO 2
H
H
II-248
Cl
Cl
H
H
NO 2
II-249
NO 2
Cl
Cl
H
NO 2
II-250
Cl
H
NO 2
Cl
NO 2
II-251
Cl
H
Cl
Cl
NO 2
II-252
Cl
Cl
Cl
NO 2
H
II-253
Cl
Cl
Cl
H
NO 2
II-254
Cl
Cl
CN
Cl
CN
II-255
Cl
H
OCF 2 OCF 3
Cl
H
II-256
Br
H
NO 2
H
Br
II-257
F
H
NO 2
H
Cl
II-258
Cl
H
NO 2
H
SCN
II-259
Br
H
NO 2
H
Cl
II-260
Cl
H
NO 2
H
OCH 3
II-261
Cl
H
NO 2
H
SCH 3
II-262
Cl
H
NO 2
H
NHCH 3
II-263
Cl
H
NO 2
H
SO 2 CH 3
II-264
Cl
H
SO 2 CH 3
H
H
II-265
Cl
H
SO 2 CH 3
H
Cl
II-266
Cl
H
CH 3
H
Cl
II-267
Cl
H
CO 2 CH 3
H
Cl
II-268
Cl
H
CONHCH 3
H
Cl
II-269
Cl
H
CON(CH 3 ) 2
H
Cl
II-270
Cl
H
CF(CF 3 ) 2
H
Cl
II-271
Cl
H
CF(CF 3 ) 2
H
Br
II-272
F
H
CF(CF 3 ) 2
H
Br
II-273
F
H
CF(CF 3 ) 2
H
Cl
II-274
Cl
CN
Cl
Cl
CN
II-275
F
F
CN
F
CN
II-276
SO 2 NH 2
H
H
H
H
II-277
H
SO 2 NH 2
H
H
H
II-278
H
H
SO 2 NH 2
H
H
[0427] Table 128: in general formula II-A, W=H, R 1 =C 2 H 5 , R 2 =Cl, R 3 =R 4 =R 5b =H, the substituents R 7 , R 8 , R 9 , R 10 and R 11 are consistent with those in Table 127 and corresponding to II-1-II-278 in table 127 in turn, the representative compounds are coded as II-279-II-556.
[0428] Table 129: in general formula II-A, W=H, R 1 =CH 3 , R 2 =R 5b =Cl, R 3 =R 4 =H 5 the substituents R 7 , R 8 , R 9 , R 10 and R 11 are consistent with those in Table 127 and corresponding to II-1-II-278 in table 127 in turn, the representative compounds are coded as II-557-II-834.
[0429] Table 130: in general formula II-A, W=H, R 1 =C 2 H 5 , R 2 =R 5b =Cl, R 3 =R 4 =H 5 the substituents R 7 , R 8 , R 9 , R 10 and R 11 are consistent with those in Table 127 and corresponding to II-1-II-278 in table 127 in turn, the representative compounds are coded as II-835-II-1112.
[0430] Table 131: in general formula II-A, W=H, R 1 =CH 3 , R 2 =Cl, R 3 =R 4 =H, R 5b =Br, the substituents R 7 , R 8 , R 9 , R 10 and R 11 are consistent with those in Table 127 and corresponding to II-1-II-278 in table 127 in turn, the representative compounds are coded as II-1113-II-1390.
[0431] Table 132: in general formula II-A, W=H, R 1 =C 2 H 5 , R 2 =Cl, R 3 =R 4 =H, R 5b =Br, the substituents R 7 , R 8 , R 9 , R 10 and R 11 are consistent with those in Table 127 and corresponding to II-1-II-278 in table 127 in turn, the representative compounds are coded as II-1391-II-1668.
[0432] Table 133: in general formula II-A, W=H, R 1 =CH 3 , R 2 =Cl, R 3 =R 4 =H, R 5b =OCH 3 , the substituents R 7 , R 8 , R 9 , R 10 and R 11 are consistent with those in Table 127 and corresponding to II-1-II-278 in table 127 in turn, the representative compounds are coded as II-1669-II-1946.
[0433] Table 134: in general formula II-A, W=H, R 1 =C 2 H 5 , R 2 =Cl, R 3 =R 4 =H, R 5b =OCH 3 , the substituents R 7 , R 8 , R 9 , R 10 and R 11 are consistent with those in Table 127 and corresponding to II-1-II-278 in table 127 in turn, the representative compounds are coded as II-1947-II-2224.
[0434] Table 135: in general formula II-A, W=H, R 1 =CH 3 , R 2 =Cl, R 3 =R 5b =H, R 4 =CH 3 , the substituents R 7 , R 8 , R 9 , R 10 and R 11 are consistent with those in Table 127 and corresponding to II-1-II-278 in table 127 in turn, the representative compounds are coded as II-2225-II-2502.
[0435] Table 136: in general formula II-A, W=H, R 1 =C 2 H 5 , R 2 =Cl, R 3 =R 5b =H, R 4 =CH 3 , the substituents R 7 , R 8 , R 9 , R 10 and R 11 are consistent with those in Table 127 and corresponding to II-1-II-278 in table 127 in turn, the representative compounds are coded as II-2503-II-2780.
[0436] Table 137: in general formula II-A, W=H, R 1 =CH 3 , R 2 =Cl, R 3 =H, R 4 =CH 3 , R 5b =Cl, the substituents R 7 , R 8 , R 9 , R 10 and R 11 are consistent with those in Table 127 and corresponding to II-1-II-278 in table 127 in turn, the representative compounds are coded as II-2781-II-3058.
[0437] Table 138: in general formula II-A, W=H, R 1 =C 2 H 5 , R 2 =Cl, R 3 =H, R 4 =CH 3 , R 5b =Cl, the substituents R 7 , R 8 , R 9 , R 10 and R 11 are consistent with those in Table 127 and corresponding to II-1-II-278 in table 127 in turn, the representative compounds are coded as II-3059-II-3336.
[0438] Table 139: in general formula II-A, W=H, R 1 =CH 3 , R 2 =Cl, R 3 =H, R 4 =CH 3 , R 5b =Br, the substituents R 7 , R 8 , R 9 , R 10 and R 11 are consistent with those in Table 127 and corresponding to II-1-II-278 in table 127 in turn, the representative compounds are coded as II-3337-II-3614.
[0439] Table 140: in general formula II-A, W=H, R 1 =C 2 H 5 , R 2 =Cl, R 3 =H, R 4 =CH 3 , R 5b =Br, the substituents R 7 , R 8 , R 9 , R 10 and R 11 are consistent with those in Table 127 and corresponding to II-1-II-278 in table 127 in turn, the representative compounds are coded as II-3615-II-3892.
[0440] Table 141: in general formula II-A, W=H, R 1 =CH 3 , R 2 =Cl, R 3 =H, R 4 =CH 3 , R 5b =OCH 3 , the substituents R 7 , R 8 , R 9 , R 10 and R 11 are consistent with those in Table 127 and corresponding to II-1-II-278 in table 127 in turn, the representative compounds are coded as II-3893-II-4170.
[0441] Table 142: in general formula II-A, W=H, R 1 =C 2 H 5 , R 2 =Cl, R 3 =H, R 4 =CH 3 , R 5b =OCH 3 , the substituents R 7 , R 8 , R 9 , R 10 and R 11 are consistent with those in Table 127 and corresponding to II-1-II-278 in table 127 in turn, the representative compounds are coded as II-4171-II-4448.
[0442] Table 143: in general formula II-A, W=CH 3 , R 1 =CH 3 , R 2 =Cl, R 3 =R 4 =R 5b =H, the substituents R 7 , R 8 , R 9 , R 10 and R 11 are consistent with those in Table 127 and corresponding to II-1-II-278 in table 127 in turn, the representative compounds are coded as II-4449-II-4726.
[0443] Table 144: in general formula II-A, W=CH 3 , R 1 =C 2 H 5 , R 2 =Cl, R 3 =R 4 =R 5b =H, the substituents R 7 , R 8 , R 9 , R 10 and R 11 are consistent with those in Table 127 and corresponding to II-1-II-278 in table 127 in turn, the representative compounds are coded as II-4727-II-5004.
[0444] Table 145: in general formula II-A, W=CH 3 , R 1 =CH 3 , R 2 =R 5b =Cl, R 3 =R 4 =H, the substituents R 7 , R 8 , R 9 , R 10 and R 11 are consistent with those in Table 127 and corresponding to II-1-II-278 in table 127 in turn, the representative compounds are coded as II-5005-II-5282.
[0445] Table 146: in general formula II-A, W=CH 3 , R 1 =C 2 H 5 , R 2 =R 5b =Cl, R 3 =R 4 =H, the substituents R 7 , R 8 , R 9 , R 10 and R 11 are consistent with those in Table 127 and corresponding to II-1-II-278 in table 127 in turn, the representative compounds are coded as II-5283-II-5560.
[0446] Table 147: in general formula II-A, W=CH 3 , R 1 =CH 3 , R 2 =Cl, R 3 =R 4 =H, R 5b =Br, the substituents R 7 , R 8 , R 9 , R 10 and R 11 are consistent with those in Table 127 and corresponding to II-1-II-278 in table 127 in turn, the representative compounds are coded as II-5561-II-5838.
[0447] Table 148: in general formula II-A, W=CH 3 , R 1 =C 2 H 5 , R 2 =Cl, R 3 =R 4 =H, R 5b =Br, the substituents R 7 , R 8 , R 9 , R 10 and R 11 are consistent with those in Table 127 and corresponding to II-1-II-278 in table 127 in turn, the representative compounds are coded as II-5839-II-6116.
[0448] Table 149: in general formula II-A, W=CH 3 , R 1 =CH 3 , R 2 =Cl, R 3 =R 4 =H, R 5b =OCH 3 , the substituents R 7 , R 8 , R 9 , R 10 and R 11 are consistent with those in Table 127 and corresponding to II-1-II-278 in table 127 in turn, the representative compounds are coded as II-6117-II-6394.
[0449] Table 150: in general formula II-A, W=CH 3 , R 1 =C 2 H 5 , R 2 =Cl, R 3 =R 4 =H, R 5b =OCH 3 , the substituents R 7 , R 8 , R 9 , R 10 and R 11 are consistent with those in Table 127 and corresponding to II-1-II-278 in table 127 in turn, the representative compounds are coded as II-6395-II-6672.
[0450] Table 151: in general formula II-A, W=CH 3 , R 1 =CH 3 , R 2 =Cl, R 3 =R 5b =H, R 4 =CH 3 , the substituents R 7 , R 8 , R 9 , R 10 and R 11 are consistent with those in Table 127 and corresponding to II-1-II-278 in table 127 in turn, the representative compounds are coded as II-6673-II-6950.
[0451] Table 152: in general formula II-A, W=CH 3 , R 1 =C 2 H 5 , R 2 =Cl, R 3 =R 5b =H, R 4 =CH 3 , the substituents R 7 , R 8 , R 9 , R 10 and R 11 are consistent with those in Table 127 and corresponding to II-1-II-278 in table 127 in turn, the representative compounds are coded as II-6951-II-7228.
[0452] Table 153: in general formula II-A, W=CH 3 , R 1 =CH 3 , R 2 =Cl, R 3 =H, R 4 =CH 3 , R 5b =Cl, the substituents R 7 , R 8 , R 9 , R 10 and R 11 are consistent with those in Table 127 and corresponding to II-1-II-278 in table 127 in turn, the representative compounds are coded as II-7229-II-7506.
[0453] Table 154: in general formula II-A, W=CH 3 , R 1 =C 2 H 5 , R 2 =Cl, R 3 =H, R 4 =CH 3 , R 5b =Cl, the substituents R 7 , R 8 , R 9 , R 10 and R 11 are consistent with those in Table 127 and corresponding to II-1-II-278 in table 127 in turn, the representative compounds are coded as II-7507-II-7784.
[0454] Table 155: in general formula II-A, W=CH 3 , R 1 =CH 3 , R 2 =Cl, R 3 =H, R 4 =CH 3 , R 5b =Br, the substituents R 7 , R 8 , R 9 , R 10 and R 11 are consistent with those in Table 127 and corresponding to II-1-II-278 in table 127 in turn, the representative compounds are coded as II-7785-II-8062.
[0455] Table 156: in general formula II-A, W=CH 3 , R 1 =C 2 H 5 , R 2 =Cl, R 3 =H, R 4 =CH 3 , R 5b =Br, the substituents R 7 , R 8 , R 9 , R 10 and R 11 are consistent with those in Table 127 and corresponding to II-1-II-278 in table 127 in turn, the representative compounds are coded as II-8063-II-8340.
[0456] Table 157: in general formula II-A, W=CH 3 , R 1 =CH 3 , R 2 =Cl, R 3 =H, R 4 =CH 3 , R 5b =OCH 3 , the substituents R 7 , R 8 , R 9 , R 10 and R 11 are consistent with those in Table 127 and corresponding to II-1-II-278 in table 127 in turn, the representative compounds are coded as II-8341-II-8618.
[0457] Table 158: in general formula II-A, W=CH 3 , R 1 =C 2 H 5 , R 2 =Cl, R 3 =H, R 4 =CH 3 , R 5b =OCH 3 , the substituents R 7 , R 8 , R 9 , R 10 and R 11 are consistent with those in Table 127 and corresponding to II-1-II-278 in table 127 in turn, the representative compounds are coded as II-8619-II-8896.
[0458] Table 159: in general formula II-A, W=H, R 1 =CHF 2 , R 2 =Cl, R 3 =R 4 =R 5b =H, the substituents R 7 , R 8 , R 9 , R 10 and R 11 are consistent with those in Table 127 and corresponding to II-1-II-278 in table 127 in turn, the representative compounds are coded as II-8897-II-9174.
[0459] Table 160: in general formula II-A, W=H, R 1 =CF 3 , R 2 =Cl, R 3 =R 4 =R 5b =H, the substituents R 7 , R 8 , R 9 , R 10 and R 11 are consistent with those in Table 127 and corresponding to II-1-II-278 in table 127 in turn, the representative compounds are coded as II-9175-II-9452.
[0460] Table 161: in general formula II-A, W=H, R 1 =CHF 2 , R 2 =R 5b =Cl, R 3 =R 4 =H, the substituents R 7 , R 8 , R 9 , R 10 and R 11 are consistent with those in Table 127 and corresponding to II-1-II-278 in table 127 in turn, the representative compounds are coded as II-9453-II-9730.
[0461] Table 162: in general formula II-A, W=H, R 1 =CF 3 , R 2 =R 5b =Cl, R 3 =R 4 =H, the substituents R 7 , R 8 , R 9 , R 10 and R 11 are consistent with those in Table 127 and corresponding to II-1-II-278 in table 127 in turn, the representative compounds are coded as II-9731-II-10008.
[0462] Table 163: in general formula II-A, W=H, R 1 =CHF 2 , R 2 =Cl, R 3 =R 4=14 , R 5b =Br, the substituents R 7 , R 8 , R 9 , R 10 and R 11 are consistent with those in Table 127 and corresponding to II-1-II-278 in table 127 in turn, the representative compounds are coded as II-10009-II-10286.
[0463] Table 164: in general formula II-A, W=H, R 1 =CF 3 , R 2 =Cl, R 3 =R 4 =H, R 5b =Br, the substituents R 7 , R 8 , R 9 , R 10 and R 11 are consistent with those in Table 127 and corresponding to II-1-II-278 in table 127 in turn, the representative compounds are coded as II-10287-II-10564.
[0464] Table 165: in general formula II-A, W=H, R 1 =CHF 2 , R 2 =Cl, R 3 =R 4 =H, R 5b =OCH 3 , the substituents R 7 , R 8 , R 9 , R 10 and R 11 are consistent with those in Table 127 and corresponding to II-1-II-278 in table 127 in turn, the representative compounds are coded as II-10565-II-10842.
[0465] Table 166: in general formula II-A, W=H, R 1 =CF 3 , R 2 =Cl, R 3 =R 4 =H, R 5b =OCH 3 , the substituents R 7 , R 8 , R 9 , R 10 and R 11 are consistent with those in Table 127 and corresponding to II-1-II-278 in table 127 in turn, the representative compounds are coded as II-10843-II-11120.
[0466] Table 167: in general formula II-A, W=H, R 1 =CHF 2 , R 2 =Cl, R 3 =R 5b =H, R 4 =CH 3 , the substituents R 7 , R 8 , R 9 , R 10 and R 11 are consistent with those in Table 127 and corresponding to II-1-II-278 in table 127 in turn, the representative compounds are coded as II-11121-II-11398.
[0467] Table 168: in general formula II-A, W=H, R 1 =CF 3 , R 2 =Cl, R 3 =R 5b =H, R 4 =CH 3 , the substituents R 7 , R 8 , R 9 , R 10 and R 11 are consistent with those in Table 127 and corresponding to II-1-II-278 in table 127 in turn, the representative compounds are coded as II-11399-II-11676.
[0468] Table 169: in general formula II-A, W=H, R 1 =CHF 2 , R 2 =Cl, R 3 =H, R 4 =CH 3 , R 5b =Cl, the substituents R 7 , R 8 , R 9 , R 10 and R 11 are consistent with those in Table 127 and corresponding to II-1-II-278 in table 127 in turn, the representative compounds are coded as II-11677-II-11954.
[0469] Table 170: in general formula II-A, W=H, R 1 =CF 3 , R 2 =Cl, R 3 =H, R 4 =CH 3 , R 5b =Cl, the substituents R 7 , R 8 , R 9 , R 10 and R 11 are consistent with those in Table 127 and corresponding to II-1-II-278 in table 127 in turn, the representative compounds are coded as II-11955-II-12232.
[0470] Table 171: in general formula II-A, W=H, R 1 =CHF 2 , R 2 =Cl, R 3 =H, R 4 =CH 3 , R 5b =Br, the substituents R 7 , R 8 , R 9 , R 10 and R 11 are consistent with those in Table 127 and corresponding to II-1-II-278 in table 127 in turn, the representative compounds are coded as II-12233-II-12510.
[0471] Table 172: in general formula II-A, W=H, R 1 =CF 3 , R 2 =Cl, R 3 =H, R 4 =CH 3 , R 5b =Br, the substituents R 7 , R 8 , R 9 , R 10 and R 11 are consistent with those in Table 127 and corresponding to II-1-II-278 in table 127 in turn, the representative compounds are coded as II-12511-II-12788.
[0472] Table 173: in general formula II-A, W=H, R 1 =CHF 2 , R 2 =Cl, R 3 =H, R 4 =CH 3 , R 5b =OCH 3 , the substituents R 7 , R 8 , R 9 , R 10 and R 11 are consistent with those in Table 127 and corresponding to II-1-II-278 in table 127 in turn, the representative compounds are coded as II-12789-II-13066.
[0473] Table 174: in general formula II-A, W=H, R 1 =CF 3 , R 2 =Cl, R 3 =H, R 4 =CH 3 , R 5b =OCH 3 , the substituents R 7 , R 8 , R 9 , R 10 and R 11 are consistent with those in Table 127 and corresponding to II-1-II-278 in table 127 in turn, the representative compounds are coded as II-13067-II-13344.
[0474] Table 175: in general formula II-A, W=CH 3 , R 1 =CHF 2 , R 2 =Cl, R 3 =R 4 =R 5b =H, the substituents R 7 , R 8 , R 9 , R 10 and R 11 are consistent with those in Table 127 and corresponding to II-1-II-278 in table 127 in turn, the representative compounds are coded as II-13345-II-13622.
[0475] Table 176: in general formula II-A, W=CH 3 , R 1 =CF 3 , R 2 =Cl, R 3 =R 4 =R 5b =H, the substituents R 7 , R 8 , R 9 , R 10 and R 11 are consistent with those in Table 127 and corresponding to II-1-II-278 in table 127 in turn, the representative compounds are coded as II-13623-II-13900.
[0476] Table 177: in general formula II-A, W=CH 3 , R 1 =CHF 2 , R 2 =R 5b =Cl, R 3 =R 4 =H, the substituents R 7 , R 8 , R 9 , R 10 and R 11 are consistent with those in Table 127 and corresponding to II-1-II-278 in table 127 in turn, the representative compounds are coded as II-13901-II-14178.
[0477] Table 178: in general formula II-A, W=CH 3 , R 1 =CF 3 , R 2 =R 5b =Cl, R 3 =R 4 =H 5 the substituents R 7 , R 8 , R 9 , R 10 and R 11 are consistent with those in Table 127 and corresponding to II-1-II-278 in table 127 in turn, the representative compounds are coded as II-14179-II-14456.
[0478] Table 179: in general formula II-A, W=CH 3 , R 1 =CHF 2 , R 2 =Cl, R 3 =R 4 =H, R 5b =131; the substituents R 7 , R 8 , R 9 , R 10 and R 11 are consistent with those in Table 127 and corresponding to II-1-II-278 in table 127 in turn, the representative compounds are coded as II-14457-II-14734.
[0479] Table 180: in general formula II-A, W=CH 3 , R 1 =CF 3 , R 2 =Cl, R 3 =R 4 =H, R 5b =Br, the substituents R 7 , R 8 , R 9 , R 10 and R 11 are consistent with those in Table 127 and corresponding to II-1-II-278 in table 127 in turn, the representative compounds are coded as II-14735-II-15012.
[0480] Table 181: in general formula II-A, W=CH 3 , R 1 =CHF 2 , R 2 =Cl, R 3 =R 4 =H, R 5b =OCH 3 , the substituents R 7 , R 8 , R 9 , R 10 and R 11 are consistent with those in Table 127 and corresponding to II-1-II-278 in table 127 in turn, the representative compounds are coded as II-15013-II-15290.
[0481] Table 182: in general formula II-A, W=CH 3 , R 1 =CF 3 , R 2 =Cl, R 3 =R 4 =H, R 5b =OCH 3 , the substituents R 7 , R 8 , R 9 , R 10 and R 11 are consistent with those in Table 127 and corresponding to II-1-II-278 in table 127 in turn, the representative compounds are coded as II-15291-II-15568.
[0482] Table 183: in general formula II-A, W=CH 3 , R 1 =CHF 2 , R 2 =Cl, R 3 =R 5b =H, R 4 =CH 3 , the substituents R 7 , R 8 , R 9 , R 10 and R 11 are consistent with those in Table 127 and corresponding to II-1-II-278 in table 127 in turn, the representative compounds are coded as II-15569-II-15846.
[0483] Table 184: in general formula II-A, W=CH 3 , R 1 =CF 3 , R 2 =Cl, R 3 =R 5b =H, R 4 =CH 3 , the substituents R 7 , R 8 , R 9 , R 10 and R 11 are consistent with those in Table 127 and corresponding to II-1-II-278 in table 127 in turn, the representative compounds are coded as II-15847-II-16124.
[0484] Table 185: in general formula II-A, W=CH 3 , R 1 =CHF 2 , R 2 =Cl, R 3 =H, R 4 =CH 3 , R 5b =Cl, the substituents R 7 , R 8 , R 9 , R 10 and R 11 are consistent with those in Table 127 and corresponding to II-1-II-278 in table 127 in turn, the representative compounds are coded as II-16125-II-16402.
[0485] Table 186: in general formula II-A, W=CH 3 , R 1 =CF 3 , R 2 =Cl, R 3 =H, R 4 =CH 3 , R 5b =Cl, the substituents R 7 , R 8 , R 9 , R 10 and R 11 are consistent with those in Table 127 and corresponding to II-1-II-278 in table 127 in turn, the representative compounds are coded as II-16403-II-16680.
[0486] Table 187: in general formula II-A, W=CH 3 , R 1 =CHF 2 , R 2 =Cl, R 3 =H, R 4 =CH 3 , R 5b =Br, the substituents R 7 , R 8 , R 9 , R 10 and R 11 are consistent with those in Table 127 and corresponding to II-1-II-278 in table 127 in turn, the representative compounds are coded as II-16681-II-16958.
[0487] Table 188: in general formula II-A, W=CH 3 , R 1 =CF 3 , R 2 =Cl, R 3 =H, R 4 =CH 3 , R 5b =Br, the substituents R 7 , R 8 , R 9 , R 10 and R 11 are consistent with those in Table 127 and corresponding to II-1-II-278 in table 127 in turn, the representative compounds are coded as II-16959-II-17236.
[0488] Table 189: in general formula II-A, W=CH 3 , R 1 =CHF 2 , R 2 =Cl, R 3 =H, R 4 =CH 3 , R 5b =OCH 3 , the substituents R 7 , R 8 , R 9 , R 10 and R 11 are consistent with those in Table 127 and corresponding to II-1-II-278 in table 127 in turn, the representative compounds are coded as II-17237-II-17514.
[0489] Table 190: in general formula II-A, W=CH 3 , R 1 =C 2 H 5 , R 2 =Cl, R 3 =H, R 4 =CH 3 , R 5b =OCH 3 , the substituents R 7 , R 8 , R 9 , R 10 and R 11 are consistent with those in Table 127 and corresponding to II-1-II-278 in table 127 in turn, the representative compounds are coded as II-17515-II-17792.
[0000]
[0490] In general formula II-B, R 1 =CH 3 , R 2 =Cl, R 7 =R 8 =R 10 =R 11 =H, R 9 =CF 3 , the substituent R 12 refers to Table 191, the representative compounds are coded as II-17793-II-17932.
[0000]
TABLE 191
No.
R 12
II-17793
S-i-C 3 H 7
II-17794
OH
II-17795
—C(═O)H
II-17796
CBr 3
II-17797
CH 3
II-17798
C 2 H 5
II-17799
n-C 3 H 7
II-17800
i-C 3 H 7
II-17801
n-C 4 H 9
II-17802
i-C 4 H 9
II-17803
t-C 4 H 9
II-17804
CI 3
II-17805
CH 2 Br
II-17806
CHF 2
II-17807
CHBr 2
II-17808
CF 3
II-17809
CH 2 Cl
II-17810
CHCl 2
II-17811
CCl 3
II-17812
CH 2 F
II-17813
OCH 3
II-17814
OC 2 H 5
II-17815
OCH(CH 3 ) 2
II-17816
OC(CH 3 ) 3
II-17817
OCF 3
II-17818
OCH 2 CF 3
II-17819
OCH 2 F
II-17820
OCHF 2
II-17821
SCH 3
II-17822
SC 2 H 5
II-17823
SCH 2 CH═CH 2
II-17824
CH═CH 2
II-17825
CH 2 CH═CH 2
II-17826
CH 2 CH═CCl 2
II-17827
C≡CH
II-17828
CH 2 C≡CH
II-17829
CH 2 C≡C—I
II-17830
CH 2 OCH 3
II-17831
CH 2 OCH 2 CH 3
II-17832
CH 2 CH 2 OCH 3
II-17833
CH 2 CH 2 OCH 2 CH 3
II-17834
CH 2 OCH 2 Cl
II-17835
CH 2 OCH 2 CH 2 Cl
II-17836
CH 2 CH 2 OCH 2 Cl
II-17837
CH 2 SCH 3
II-17838
CH 2 SCH 2 CH 3
II-17839
CH 2 CH 2 SCH 3
II-17840
CH 2 CH 2 SCH 2 CH 3
II-17841
CH 2 SCH 2 Cl
II-17842
CH 2 SCH 2 CH 2 Cl
II-17843
CH 2 CH 2 SCH 2 Cl
II-17844
SOCH 3
II-17845
SOC 2 H 5
II-17846
SOCF 3
II-17847
SOCH 2 CF 3
II-17848
SO 2 CH 3
II-17849
SO 2 C 2 H 5
II-17850
SO 2 CF 3
II-17851
SO 2 CH 2 CF 3
II-17852
SO 2 NHCOCH 3
II-17853
SO 2 NHCH 3
II-17854
SO 2 N(CH 3 ) 3
II-17855
CONHSO 2 CH 3
II-17856
COCH 3
II-17857
COC 2 H 5
II-17858
CO—n-C 3 H 7
II-17859
CO—i-C 3 H 7
II-17860
CO—n-C 4 H 9
II-17861
CO—i-C 4 H 9
II-17862
CO—t-C 4 H 9
II-17863
COCF 3
II-17864
COCH 2 Cl
II-17865
COOCH 3
II-17866
COOC 2 H 5
II-17867
COO—n-C 3 H 7
II-17868
COO—t-C 4 H 9
II-17869
COOCF 3
II-17870
COOCH 2 CH 2 Cl
II-17871
COOCH 2 CF 3
II-17872
CH 2 COOCH 3
II-17873
CH 2 COOC 2 H 5
II-17874
CH 2 COCH 3
II-17875
CH 2 COC 2 H 5
II-17876
CONHCH 3
II-17877
CONHC 2 H 5
II-17878
CONH—t-C 4 H 9
II-17879
CON(CH 3 ) 2
II-17880
CON(C 2 H 5 ) 2
II-17881
COOCH 2 CH═CH 2
II-17882
COOCH 2 C≡CH
II-17883
COOCH 2 OCH 3
II-17884
COOCH 2 CH 2 OCH 3
II-17885
SNHCH 3
II-17886
SNHC 2 H 5
II-17887
SN(CH 3 ) 2
II-17888
SN(C 2 H 5 ) 2
II-17889
II-17890
II-17891
II-17892
II-17893
II-17894
II-17895
II-17896
II-17897
II-17898
II-17899
II-17900
II-17901
II-17902
II-17903
II-17904
II-17905
II-17906
II-17907
II-17908
II-17909
II-17910
II-17911
II-17912
II-17913
II-17914
II-17915
II-17916
II-17917
II-17918
II-17919
II-17920
II-17921
II-17922
II-17923
II-17924
II-17925
II-17926
II-17927
II-17928
II-17929
II-17930
II-17931
II-17932
[0491] Table 192: in general formula II-B, R 1 =C 2 H 5 , R 2 =Cl, R 7 =R 8 =R 10 =R 11 =H, R 9 =CF 3 , the substituent R 12 are consistent with those in Table 191 and corresponding to II-17793-II-17932 in table 191 in turn, the representative compounds are coded as II-17933-II-18072.
[0492] Table 193: in general formula II-B, R 1 =CH 3 , R 2 =R 9 =Cl, R 7 =R 8 =R 10 =R 11 =H, the substituent R 12 are consistent with those in Table 191 and corresponding to II-17793-II-17932 in table 191 in turn, the representative compounds are coded as II-18073-II-18212.
[0493] Table 194: in general formula II-B, R 1 =C 2 H 5 , R 2 =R 9 =Cl, R 7 =R 8 =R 10 =R 11 =H, the substituent R 12 are consistent with those in Table 191 and corresponding to II-17793-II-17932 in table 191 in turn, the representative compounds are coded as II-18213-II-18352.
[0494] Table 195: in general formula II-B, R 1 =CH 3 , R 2 =R 7 =R 9 =Cl, R 8 =R 10 =R 11 =H, the substituent R 12 are consistent with those in Table 191 and corresponding to II-17793-II-17932 in table 191 in turn, the representative compounds are coded as II-18353-II-18492.
[0495] Table 196: in general formula II-B, R 1 =C 2 H 5 , R 2 =R 7 =R 9 =Cl, R 8 =R 10 =R 11 =H, the substituent R 12 are consistent with those in Table 191 and corresponding to II-17793-II-17932 in table 191 in turn, the representative compounds are coded as II-18493-II-18632.
[0496] Table 197: in general formula II-B, R 1 =CH 3 , R 2 =R 7 =R 11 =Cl, R 8 =R 10 =H, R 9 =NO 2 , the substituent R 12 are consistent with those in Table 191 and corresponding to II-17793-II-17932 in table 191 in turn, the representative compounds are coded as II-18633-II-18772.
[0497] Table 198: in general formula II-B, R 1 =C 2 H 5 , R 2 =R 7 =R 11 =Cl, R 8 =R 10 =H, R 9 =NO 2 , the substituent R 12 are consistent with those in Table 191 and corresponding to II-17793-II-17932 in table 191 in turn, the representative compounds are coded as II-18773-II-18912.
[0498] Table 199: in general formula II-B, R 1 =CHF 2 , R 2 =R 9 =Cl, R 7 =R 8 =R 10 =R 11 =H, the substituent R 12 are consistent with those in Table 191 and corresponding to II-17793-II-17932 in table 191 in turn, the representative compounds are coded as II-18913-II-19052.
[0499] Table 200: in general formula II-B, R 1 =CHF 2 , R 2 =Cl, R 7 =R 8 =R 10 =R 11 =H, R 9 =CF 3 the substituent R 12 are consistent with those in Table 191 and corresponding to II-17793-II-17932 in table 191 in turn, the representative compounds are coded as II-19053-II-19192.
[0500] Table 201: in general formula II-B, R 1 =CHF 2 , R 2 =R 7 =R 9 =Cl, R 8 =R 10 =R 11 =H, the substituent R 12 are consistent with those in Table 191 and corresponding to II-17793-II-17932 in table 191 in turn, the representative compounds are coded as II-19193-II-19332.
[0501] The salts of some compounds having a structure as represented by formula II of the present invention are listed in Table 202, but without being restricted thereby.
[0000]
TABLE 202
the salts of some compounds
No.
structure
II-19333
II-19334
II-19335
II-19336
II-19337
II-19338
II-19339
II-19340
II-19341
II-19342
II-19343
II-19344
II-19345
II-19346
II-19347
II-19348
II-19349
II-19350
II-19351
II-19352
II-19353
II-19354
II-19355
II-19356
II-19357
II-19358
II-19359
II-19360
II-19361
II-19362
II-19363
II-19364
II-19365
II-19366
II-19367
II-19368
II-19369
II-19370
II-19371
II-19372
II-19373
II-19374
II-19375
II-19376
II-19377
II-19378
II-19379
II-19380
II-19381
II-19382
II-19383
II-19384
II-19385
II-19386
II-19387
II-19388
II-19389
II-19390
II-19391
II-19392
II-19393
II-19394
II-19395
II-19396
II-19397
II-19398
II-19399
II-19400
II-19401
II-19402
II-19403
II-19404
II-19405
II-19406
II-19407
II-19408
II-19409
II-19410
II-19411
II-19412
II-19413
II-19414
II-19415
II-19416
II-19417
II-19418
II-19419
II-19420
II-19421
II-19422
II-19423
II-19424
II-19425
II-19426
II-19427
II-19428
II-19429
II-19430
II-19431
II-19432
II-19433
II-19434
II-19435
II-19436
[0502] In the general formula III, part of preferred substituents of R 1 , R 2 , W, R 3 and R 4 are separately listed in table 203 to table 206, but without being restricted thereby. The definitions of other substituents are defined as above.
[0000]
TABLE 203
R 1 substituents
R 1
H
F
Cl
Br
I
CH 3
C 2 H 5
n-C 3 H 7
i-C 3 H 7
n-C 4 H 9
i-C 4 H 9
t-C 4 H 9
CH 2 Cl
CHCl 2
CH 2 CH═CH 2
CCl 3
CHF 2
CHBr 2
CF 3
CH(CH 3 )F
CH(CH 3 )Cl
CH(CH 3 )Br
C(CH 3 ) 2 F
OCH 3
OC 2 H 5
OCF 3
OCH 2 CH═CH 2
OCH 2 CH═CHCl
OCH 2 C≡CH
OCH 2 C≡C—I
OCH 2 C≡CCH 3
OSO 2 CH 3
CH 2 C≡CH
SCH 3
SOCH 3
SO 2 CH 3
COOH
COOCH 3
COOC 2 H 5
CONH 2
CONHCH 3
CONHCN
CONHCH 2 CN
CON(CH 3 ) 2
NH 2
NHCH 3
NHC 2 H 5
N(CH 3 ) 2
N(C 2 H 5 ) 2
NHCH 2 CN
CH 2 OCH 2 Cl
NHOCH 3
NHOC 2 H 5
NHCOCH 3
NHCOC 2 H 5
NHCOOCH 3
NHCOOC 2 H 5
N(CH 3 )NH 2
NHN(CH 3 ) 2
CH 2 OCH 3
CH 2 OCH 2 CH 3
CH 2 CH 2 OCH 3
CH 2 CH 2 OCH 2 CH 3
CH(CH 3 )SCH 3
CH(CH 3 )SOCH 3
CH(CH 3 )SO 2 CH 3
CH(CH 3 )OH
CH(CH 3 )OCOCH 3
CH 2 OCH 2 CH 2 Cl
[0000]
TABLE 204
R 2 substituents
R 2
R 2
R 2
R 2
H
NO 2
t-C 4 H 9
OC 4 H 9 -i
F
CH 3
OCH 3
OC 4 H 9 -t
Cl
C 2 H 5
OC 2 H 5
OCH 2 F
Br
n-C 3 H 7
OC 3 H 7 -n
OCHF 2
I
i-C 3 H 7
OC 3 H 7 -i
OCF 3
CN
n-C 4 H 9
OC 4 H 9 -n
OCH 2 CF 3
[0000]
TABLE 205
W substituents
W
H
F
Cl
Br
I
CH 3
C 2 H 5
n-C 3 H 7
i-C 3 H 7
n-C 4 H 9
t-C 4 H 9
CHCl 2
CCl 3
CHF 2
CHBr 2
CF 3
CH(CH 3 )F
CH(CH 3 )Cl
CH(CH 3 )Br
CH(n-C 4 H 9 )F
C(CH 3 ) 2 F
OCH 3
OC 2 H 5
OC 3 H 7 -n
OC 3 H 7 -i
OC 4 H 9 -n
OC 4 H 9 -i
OC 4 H 9 -t
OCF 3
OCH 2 CF 3
SCH 3
SC 2 H 5
SC 3 H 7 -n
SC 3 H 7 -i
SC 4 H 9 -n
SC 4 H 9 -i
SC 4 H 9 -t
[0000]
TABLE 206
R 3 (R 4 )substituents
R 3 (R 4 )
H
CH 3
C 2 H 5
n-C 3 H 7
i-C 3 H 7
n-C 4 H 9
i-C 4 H 9
t-C 4 H 9
CH═CH 2
C≡CH
CH 2 CH═CH 2
CH 2 C≡CH
CH 2 CH═CCl 2
CH 2 C≡C—I
CH 2 OCH 3
CH 2 OCH 2 CH 3
CH 2 CH 2 OCH 3
CH 2 CH 2 OCH 2 CH 3
CR 3 R 4
[0503] The present invention is also explained by the following compounds having a structure as represented by formula III listed in Table 207 to Table 304, but without being restricted thereby. The compounds having a structure as represented by formula III-A, III-B, III-C, III-D, III-E, III-F, III-G and III-H refer to Table 207 to Table 304, R 5a =R 5c =H.
[0504] In general formula III-A,
[0000]
[0505] A=NH, R 1 =CH 3 , R 2 =Cl, W=R 3 =R 4 =R 5b =H, the substituents R 7 , R 8 , R 9 , R 10 and R 11 refer to Table 207, the representative compounds are coded as III-1-III-180.
[0000]
TABLE 207
No.
R 7
R 8
R 9
R 10
R 11
III-1
H
H
H
H
H
III-2
F
H
H
H
H
III-3
H
F
H
H
H
III-4
H
H
F
H
H
III-5
Cl
H
H
H
H
III-6
H
Cl
H
H
H
III-7
H
H
Cl
H
H
III-8
Br
H
H
H
H
III-9
H
Br
H
H
H
III-10
H
H
Br
H
H
III-11
I
H
H
H
H
III-12
H
I
H
H
H
III-13
H
H
I
H
H
III-14
CH 3
H
H
H
H
III-15
H
CH 3
H
H
H
III-16
H
H
CH 3
H
H
III-17
OCH 3
H
H
H
H
III-18
H
OCH 3
H
H
H
III-19
H
H
OCH 3
H
H
III-20
CF 3
H
H
H
H
III-21
H
CF 3
H
H
H
III-22
H
H
CF 3
H
H
III-23
OCF 3
H
H
H
H
III-24
H
OCF 3
H
H
H
III-25
H
H
OCF 3
H
H
III-26
NO 2
H
H
H
H
III-27
H
NO 2
H
H
H
III-28
H
H
NO 2
H
H
III-29
CN
H
H
H
H
III-30
H
CN
H
H
H
III-31
H
H
CN
H
H
III-32
CH(CH 3 ) 2
H
H
H
H
III-33
H
CH(CH 3 ) 2
H
H
H
III-34
H
H
CH(CH 3 ) 2
H
H
III-35
H
H
t-Bu
H
H
III-36
SCH 3
H
H
H
H
III-37
H
SCH 3
H
H
H
III-38
H
H
SCH 3
H
H
III-39
SCF 3
H
H
H
H
III-40
H
SCF 3
H
H
H
III-41
H
H
SCF 3
H
H
III-42
COCH 3
H
H
H
H
III-43
H
COCH 3
H
H
H
III-44
H
H
COCH 3
H
H
III-45
SOCH 3
H
H
H
H
III-46
H
SOCH 3
H
H
H
III-47
H
H
SOCH 3
H
H
III-48
SO 2 CH 3
H
H
H
H
III-49
H
SO 2 CH 3
H
H
H
III-50
H
H
SO 2 CH 3
H
H
III-51
OCHF 2
H
H
H
H
III-52
H
OCHF 2
H
H
H
III-53
H
H
OCHF 2
H
H
III-54
CO 2 CH 3
H
H
H
H
III-55
H
CO 2 CH 3
H
H
H
III-56
H
H
CO 2 CH 3
H
H
III-57
N(CH 3 ) 2
H
H
H
H
III-58
H
N(CH 3 ) 2
H
H
H
III-59
H
H
N(CH 3 ) 2
H
H
III-60
N(C 2 H 5 ) 2
H
H
H
H
III-61
H
N(C 2 H 5 ) 2
H
H
H
III-62
H
H
N(C 2 H 5 ) 2
H
H
III-63
NHCOCH 3
H
H
H
H
III-64
H
NHCOCH 3
H
H
H
III-65
H
H
NHCOCH 3
H
H
III-66
NHSO 2 CH 3
H
H
H
H
III-67
H
NHSO 2 CH 3
H
H
H
III-68
H
H
NHSO 2 CH 3
H
H
III-69
OCH 2 CH═CH 2
H
H
H
H
III-70
H
OCH 2 CH═CH 2
H
H
H
III-71
H
H
OCH 2 CH═CH 2
H
H
III-72
OCH 2 C≡CH
H
H
H
H
III-73
H
OCH 2 C≡CH
H
H
H
III-74
H
H
OCH 2 C≡CH
H
H
III-75
F
F
H
H
H
III-76
F
H
F
H
H
III-77
F
H
H
F
H
III-78
F
H
H
H
F
III-79
H
F
F
H
H
III-80
H
F
H
F
H
III-81
Cl
Cl
H
H
H
III-82
Cl
H
Cl
H
H
III-83
Cl
H
H
Cl
H
III-84
Cl
H
H
H
Cl
III-85
H
Cl
Cl
H
H
III-86
H
Cl
H
Cl
H
III-87
NO 2
H
NO 2
H
H
III-88
NO 2
H
H
NO 2
H
III-89
NO 2
H
H
H
NO 2
III-90
H
NO 2
H
NO 2
H
III-91
CN
H
CN
H
H
III-92
CN
H
H
CN
H
III-93
CN
H
H
H
CN
III-94
H
CN
H
CN
H
III-95
CH 3
CH 3
H
H
H
III-96
CH 3
H
CH 3
H
H
III-97
CH 3
H
H
CH 3
H
III-98
CH 3
H
H
H
CH 3
III-99
H
CH 3
CH 3
H
H
III-100
H
CH 3
H
CH 3
H
III-101
CF 3
H
CF 3
H
H
III-102
CF 3
H
H
CF 3
H
III-103
CF 3
H
H
H
CF 3
III-104
H
CF 3
H
CF 3
H
III-105
OCF 3
H
OCF 3
H
H
III-106
OCF 3
H
H
OCF 3
H
III-107
OCF 3
H
H
H
OCF 3
III-108
H
OCF 3
H
OCF 3
H
III-109
CH 3
Cl
H
H
H
III-110
CH 3
H
Cl
H
H
III-111
H
Cl
CH 3
H
H
III-112
Cl
H
CH 3
H
H
III-113
CH 3
H
H
Cl
H
III-114
CH 3
H
H
H
Cl
III-115
Br
CH 3
H
H
H
III-116
H
CH 3
Cl
H
H
III-117
CH 3
NO 2
H
H
H
III-118
CH 3
H
NO 2
H
H
III-119
CH 3
H
OCH 3
H
H
III-120
CH 3
H
H
NO 2
H
III-121
Cl
H
CF 3
H
H
III-122
Cl
H
H
CF 3
H
III-123
Cl
H
NO 2
H
H
III-124
Cl
H
H
NO 2
H
III-125
CF 3
H
Br
H
H
III-126
CF 3
H
NO 2
H
H
III-127
H
CF 3
NO 2
H
H
III-128
H
CF 3
Cl
H
H
III-129
CF 3
H
CN
H
H
III-130
Cl
H
CN
H
H
III-131
NO 2
H
CN
H
H
III-132
NO 2
H
CH 3
H
H
III-133
NO 2
H
CF 3
H
H
III-134
NO 2
H
Cl
H
H
III-135
NO 2
H
H
Cl
H
III-136
H
NO 2
CH 3
H
H
III-137
H
NO 2
Cl
H
H
III-138
CN
F
H
H
H
III-139
CN
H
NO 2
H
H
III-140
CN
H
Cl
H
H
III-141
CN
H
H
CH 3
H
III-142
Cl
Cl
Cl
H
H
III-143
Cl
Cl
H
Cl
H
III-144
Cl
H
Cl
Cl
H
III-145
Cl
H
Cl
H
Cl
III-146
H
Cl
Cl
Cl
H
III-147
CH 3
H
CH 3
H
CH 3
III-148
OCH 3
H
OCH 3
H
OCH 3
III-149
Cl
Cl
Br
H
H
III-150
F
H
F
H
Cl
III-151
CH 3
H
Br
H
Br
III-152
CF 3
H
Cl
H
Cl
III-153
CF 3
H
Br
H
Br
III-154
F
H
Cl
H
Br
III-155
Cl
H
NO 2
H
Cl
III-156
Br
H
NO 2
H
Br
III-157
Cl
H
CN
H
Cl
III-158
Cl
H
CF 3
H
Cl
III-159
Br
H
CF 3
H
Br
III-160
Cl
CH 3
H
H
Cl
III-161
Cl
H
CONH 2
H
Cl
III-162
Cl
H
CO 2 CH 3
H
Cl
III-163
Cl
H
NHCOCH 3
H
Cl
III-164
Cl
H
OCF 3
H
Cl
III-165
Br
H
F
H
Br
III-166
Br
H
CH 3
H
Br
III-167
Cl
H
COCH 3
H
Cl
III-168
Cl
H
NO 2
Cl
H
III-169
F
H
F
H
Cl
III-170
Cl
H
CF 3
H
Br
III-171
CH 3
H
NO 2
H
Cl
III-172
CH 3
H
NO 2
H
Br
III-173
CH 3
H
Cl
H
NO 2
III-174
CH 3
H
Br
H
NO 2
III-175
NO 2
H
CF 3
H
Cl
III-176
NO 2
H
CF 3
H
Br
III-177
F
H
Br
H
Br
III-178
CN
H
Cl
H
Cl
III-179
CN
H
Br
H
Br
III-180
F
H
CN
H
H
[0506] Table 208: A=NH, R 1 =C 2 H 5 , R 2 =Cl, W=R 3 =R 4 =R 5b =H, the substituents R 7 , R 8 , R 9 , R 10 and R 11 are consistent with those in Table 207 and corresponding to III-1 III-180 in table 207 in turn, the representative compounds are coded as III-181 III-360.
[0507] Table 209: A=NH, R 1 =CF 3 , R 2 =Cl, W=R 3 =R 4 =R 5b =H, the s substituents R 7 , R 8 , R 9 , R 10 and R 11 are consistent with those in Table 207 and corresponding to III-1 III-180 in table 207 in turn, the representative compounds are coded as III-361 III-540.
[0508] Table 210: A=NH, R 1 =CHF 2 , R 2 =Cl, W=R 3 =R 4 =R 5b =H, the substituents R 7 , R 8 , R 9 , R 10 and R 11 are consistent with those in Table 207 and corresponding to III-1 III-180 in table 207 in turn, the representative compounds are coded as III-541-III-720.
[0509] Table 211: A=NH, R 1 =CH 3 , R 2 =Cl, W=R 3 =R 4 =H, R 5b =Cl, the substituents R 7 , R 8 , R 9 , R 10 and R 11 are consistent with those in Table 207 and corresponding to III-1-III-180 in table 207 in turn, the representative compounds are coded as III-721-III-900.
[0510] Table 212: A=NH, R 1 =C 2 H 5 , R 2 =Cl, W=R 3 =R 4 =H, R 5b =Cl, the substituents R 7 , R 8 , R 9 , R 10 and R 11 are consistent with those in Table 207 and corresponding to III-1-III-180 in table 207 in turn, the representative compounds are coded as III-901-III-1080.
[0511] Table 213: A=NH, R 1 =CF 3 , R 2 =Cl, W=R 3 =R 4 =H, R 5b =Cl, the substituents R 7 , R 8 , R 9 , R 10 and R 11 are consistent with those in Table 207 and corresponding to III-1-III-180 in table 207 in turn, the representative compounds are coded as III-1081-III-1260.
[0512] Table 214: A=NH, R 1 =CHF 2 , R 2 =Cl, W=R 3 =R 4 =H, R 5b =Cl, the substituents R 7 , R 8 , R 9 , R 10 and R 11 are consistent with those in Table 207 and corresponding to III-1-III-180 in table 207 in turn, the representative compounds are coded as III-1261-III-1440.
[0513] Table 215: A=NH, R 1 =CH 3 , R 2 =Cl, W=CH 3 , R 3 =R 4 =R 5b =H, the substituents R 7 , R 8 , R 9 , R 10 and R 11 are consistent with those in Table 207 and corresponding to III-1-III-180 in table 207 in turn, the representative compounds are coded as III-1441-III-1620.
[0514] Table 216: A=NH, R 1 =C 2 H 5 , R 2 =Cl, W=CH 3 , R 3 =R 4 =R 5b =H, the substituents R 7 , R 8 , R 9 , R 10 and R 11 are consistent with those in Table 207 and corresponding to III-1-III-180 in table 207 in turn, the representative compounds are coded as III-1621-III-1800.
[0515] Table 217: A=NH, R 1 =CF 3 , R 2 =Cl, W=CH 3 , R 3 =R 4 =R 5b =H, the substituents R 7 , R 8 , R 9 , R 10 and R 11 are consistent with those in Table 207 and corresponding to III-1-III-180 in table 207 in turn, the representative compounds are coded as III-1801-III-1980.
[0516] Table 218: A=NH, R 1 =CHF 2 , R 2 =Cl, W=CH 3 , R 3 =R 4 =R 5b =H, the substituents R 7 , R 8 , R 9 , R 10 and R 11 are consistent with those in Table 207 and corresponding to III-1-III-180 in table 207 in turn, the representative compounds are coded as III-1981-III-2160.
[0517] Table 219: A=NH, R 1 =CH 3 , R 2 =Cl, W=CH 3 , R 3 =R 4 =H, R 5b =Cl, the substituents R 7 , R 8 , R 9 , R 10 and R 11 are consistent with those in Table 207 and corresponding to III-1-III-180 in table 207 in turn, the representative compounds are coded as III-2161-III-2340.
[0518] Table 220: A=NH, R 1 =C 2 H 5 , R 2 =Cl, W=CH 3 , R 3 =R 4 =H, R 5b =Cl, the substituents R 7 , R 8 , R 9 , R 10 and R 11 are consistent with those in Table 207 and corresponding to III-1-III-180 in table 207 in turn, the representative compounds are coded as III-2341-III-2520.
[0519] Table 221: A=NH, R 1 =Cl, R 2 =Cl, W=CH 3 , R 3 =R 4 =R 5b =H, the substituents R 7 , R 8 , R 9 , R 10 and R 11 are consistent with those in Table 207 and corresponding to III-1-III-180 in table 207 in turn, the representative compounds are coded as III-2521-III-2700.
[0520] Table 222: A=NH, R 1 =CHF 2 , R 2 =Cl, W=CH 3 , R 3 =R 4 =H, R 5b =Cl, the substituents R 7 , R 8 , R 9 , R 10 and R 11 are consistent with those in Table 207 and corresponding to III-1-III-180 in table 207 in turn, the representative compounds are coded as III-2701-III-2880.
[0521] Table 223: A=NH, R 1 =CH 3 , R 2 =Cl, W=R 4 =R 5b =H, R 3 =CH 3 , the substituents R 7 , R 8 , R 9 , R 10 and R 11 are consistent with those in Table 207 and corresponding to III-1-III-180 in table 207 in turn, the representative compounds are coded as III-2881-III-3060.
[0522] Table 224: A=NH, R 1 =C 2 H 5 , R 2 =Cl, W=R 4 =R 5b =H, R 3 =CH 3 , the substituents R 7 , R 8 , R 9 , R 10 and R 11 are consistent with those in Table 207 and corresponding to III-1-III-180 in table 207 in turn, the representative compounds are coded as III-3061-III-3240.
[0523] Table 225: A=NH, R 1 =CH 3 , R 2 =Cl, W=R 4 =H, R 3 =CH 3 , R 5b =Cl, the substituents R 7 , R 8 , R 9 , R 10 and R 11 are consistent with those in Table 207 and corresponding to III-1-III-180 in table 207 in turn, the representative compounds are coded as III-3241-III-3420.
[0524] Table 226: A=NH, R 1 =C 2 H 5 , R 2 =Cl, W=R 4 =H, R 3 =CH 3 , R 5b =Cl, the substituents R 7 , R 8 , R 9 , R 10 and R 11 are consistent with those in Table 207 and corresponding to III-1-III-180 in table 207 in turn, the representative compounds are coded as III-3421-III-3600.
[0525] Table 227: A=NH, R 1 =CH 3 , R 2 =Cl, W=R 5b =H, R 3 =R 4 =CH 3 , the substituents R 7 , R 8 , R 9 , R 10 and R 11 are consistent with those in Table 207 and corresponding to III-1-III-180 in table 207 in turn, the representative compounds are coded as III-3601-III-3780.
[0526] Table 228: A=NH, R 1 =C 2 H 5 , R 2 =Cl, W=R 5b =H, R 3 =R 4 =CH 3 , the substituents R 7 , R 8 , R 9 , R 10 and R 11 are consistent with those in Table 207 and corresponding to III-1-III-180 in table 207 in turn, the representative compounds are coded as III-3781-III-3960.
[0527] Table 229: A=NH, R 1 =CH 3 , R 2 =Cl, W=H, R 3 =R 4 =CH 3 , R 5b =Cl, the substituents R 7 , R 8 , R 9 , R 10 and R 11 are consistent with those in Table 207 and corresponding to III-1-III-180 in table 207 in turn, the representative compounds are coded as III-3961-III-4140.
[0528] Table 230: A=NH, R 1 =C 2 H 5 , R 2 =Cl, W=H, R 3 =R 4 =CH 3 , R 5b =Cl, the substituents R 7 , R 8 , R 9 , R 10 and R 11 are consistent with those in Table 207 and corresponding to III-1-III-180 in table 207 in turn, the representative compounds are coded as III-4141-III-4320.
[0529] Table 231: A=O, R 1 =CH 3 , R 2 =Cl, W=R 3 =R 4 =R 5b =H, the substituents R 7 , R 8 , R 9 , R 10 and R 11 are consistent with those in Table 207 and corresponding to III-1-III-180 in table 207 in turn, the representative compounds are coded as III-4321-III-4500.
[0530] Table 232: A=O, R 1 =C 2 H 5 , R 2 =Cl, W=R 3 =R 4 =R 5b =H, the substituents R 7 , R 8 , R 9 , R 10 and R 11 are consistent with those in Table 207 and corresponding to III-1-III-180 in table 207 in turn, the representative compounds are coded as III-4501-III-4680.
[0531] Table 233: A=O, R 1 =CH 3 , R 2 =Cl, W=R 3 =R 4 =H, R 5b =Cl, the substituents R 7 , R 8 , R 9 , R 10 and R 11 are consistent with those in Table 207 and corresponding to III-1-III-180 in table 207 in turn, the representative compounds are coded as III-4681-III-4860.
[0532] Table 234: A=O, R 1 =C 2 H 5 , R 2 =Cl, W=R 3 =R 4 =H, R 5b =Cl, the substituents R 7 , R 8 , R 9 , R 10 and R 11 are consistent with those in Table 207 and corresponding to III-1-III-180 in table 207 in turn, the representative compounds are coded as III-4861-III-5040.
[0533] Table 235: A=S, R 1 =CH 3 , R 2 =Cl, W=R 3 =R 4 =R 5b =H, the substituents R 7 , R 8 , R 9 , R 10 and R 11 are consistent with those in Table 207 and corresponding to III-1-III-180 in table 207 in turn, the representative compounds are coded as III-5041-III-5220.
[0534] Table 236: A=S, R 1 =C 2 H 5 , R 2 =Cl, W=R 3 =R 4 =R 5b =H, the substituents R 7 , R 8 , R 9 , R 10 and R 11 are consistent with those in Table 207 and corresponding to III-1-III-180 in table 207 in turn, the representative compounds are coded as III-5221-III-5400.
[0535] Table 237: A=S, R 1 =CH 3 , R 2 =Cl, W=R 3 =R 4 =H, R 5b =Cl, the substituents R 7 , R 8 , R 9 , R 10 and R 11 are consistent with those in Table 207 and corresponding to III-1-III-180 in table 207 in turn, the representative compounds are coded as III-5401-III-5580.
[0536] Table 238: A=S, R 1 =C 2 H 5 , R 2 =Cl, W=R 3 =R 4 =H, R 5b =Cl, the substituents R 7 , R 8 , R 9 , R 10 and R 11 are consistent with those in Table 207 and corresponding to III-1 III-180 in table 207 in turn, the representative compounds are coded as III-5581-III-5760.
[0537] In general formula III-B,
[0000]
[0538] A=NH, R 1 =CH 3 , R 2 =Cl, W=R 3 =R 4 =R 5b =H, the substituents R 8 , R 9 , R 10 and R 11 refer to Table 239, the representative compounds are coded as III-5761-III-5802.
[0000]
TABLE 239
No.
R 8
R 9
R 10
R 11
III-5761
H
H
H
H
III-5762
H
H
H
F
III-5763
H
H
H
Cl
III-5764
H
H
H
Br
III-5765
H
H
Cl
H
III-5766
H
Cl
H
H
III-5767
H
Br
H
H
III-5768
Cl
H
H
H
III-5769
H
H
H
NO 2
III-5770
H
H
NO 2
H
III-5771
H
NO 2
H
H
III-5772
H
CN
H
H
III-5773
H
OCF 3
H
H
III-5774
H
H
H
CH 3
III-5775
H
H
CH 3
H
III-5776
H
CH 3
H
H
III-5777
CH 3
H
H
H
III-5778
H
H
H
CF 3
III-5779
H
H
CF 3
H
III-5780
H
CF 3
H
H
III-5781
H
H
H
OCH 3
III-5782
H
H
OCH 3
H
III-5783
H
OCH 3
H
H
III-5784
OCH 3
H
H
H
III-5785
H
Cl
H
Cl
III-5786
Cl
H
Cl
H
III-5787
H
NO 2
H
Cl
III-5788
H
CN
H
Cl
III-5789
H
CF 3
H
Cl
III-5790
H
NO 2
H
Br
III-5791
H
H
Cl
NO 2
III-5792
H
Cl
H
NO 2
III-5793
H
CN
H
CH 3
III-5794
H
Br
CH 3
H
III-5795
H
NO 2
CH 3
H
III-5796
CH 3
H
CH 3
H
III-5797
H
Cl
H
CF 3
III-5798
Cl
H
H
CF 3
III-5799
CH 3
Cl
CH 3
Cl
III-5800
Cl
Cl
H
Cl
III-5801
Cl
CF 3
H
Br
III-5802
H
Br
CH 3
Br
[0539] Table 240: A=NH, R 1 =C 2 H 5 , R 2 =Cl, W=R 3 =R 4 =R 5b =H, the substituents R 8 , R 9 , R 10 and R 11 are consistent with those in Table 239 and corresponding to III-5761-III-5802 in table 239 in turn, the representative compounds are coded as III-5803-III-5844.
[0540] Table 241: A=NH, R 1 =CF 3 , R 2 =Cl, W=R 3 =R 4 =R 5b =H, the substituents R 8 , R 9 , R 10 and R 11 are consistent with those in Table 239 and corresponding to III-5761-III-5802 in table 239 in turn, the representative compounds are coded as III-5845-III-5886.
[0541] Table 242: A=NH, R 1 =CHF 2 , R 2 =Cl, W=R 3 =R 4 =R 5b =H, the substituents R 8 , R 9 , R 10 and R 11 are consistent with those in Table 239 and corresponding to III-5761-III-5802 in table 239 in turn, the representative compounds are coded as III-5887-III-5928.
[0542] Table 243: A=NH, R 1 =CH 3 , R 2 =Cl, W=R 3 =R 4 =H, R 5b =Cl, the substituents R 8 , R 9 , R 10 and R 11 are consistent with those in Table 239 and corresponding to III-5761-III-5802 in table 239 in turn, the representative compounds are coded as III-5929-III-5970.
[0543] Table 244: A=NH, R 1 =C 2 H 5 , R 2 =Cl, W=R 3 =R 4 =H, R 5b =Cl, the substituents R 8 , R 9 , R 10 and R 11 are consistent with those in Table 239 and corresponding to III-5761-III-5802 in table 239 in turn, the representative compounds are coded as III-5971-III-6012.
[0544] Table 245: A=NH, R 1 =CH 3 , R 2 =Cl, W=CH 3 , R 3 =R 4 =R 5b =H, the substituents R 8 , R 9 , R 10 and R 11 are consistent with those in Table 239 and corresponding to III-5761-III-5802 in table 239 in turn, the representative compounds are coded as III-6013-III-6054.
[0545] Table 246: A=NH, R 1 =C 2 H 5 , R 2 =Cl, W=CH 3 , R 3 =R 4 =R 5b =H, the substituents R 8 , R 9 , R 10 and R 11 are consistent with those in Table 239 and corresponding to III-5761-III-5802 in table 239 in turn, the representative compounds are coded as III-6055-III-6096.
[0546] Table 247: A=NH, R 1 =C 2 H 5 , R 2 =Cl, W=CH 3 , R 3 =R 4 =R 5b =H, the substituents R 8 , R 9 , R 10 and R 11 are consistent with those in Table 239 and corresponding to III-5761-III-5802 in table 239 in turn, the representative compounds are coded as III-6097-III-6138.
[0547] Table 248: A=O, R 1 =C 2 H 5 , R 2 =Cl, W=R 3 =R 4 =R 5b =H, the substituents R 8 , R 9 , R 10 and R 11 are consistent with those in Table 239 and corresponding to III-5761-III-5802 in table 239 in turn, the representative compounds are coded as III-6139-III-6180.
[0548] Table 249: A=S, R 1 =CH 3 , R 2 =Cl, W=R 3 =R 4 =R 5b =H, the substituents R 8 , R 9 , R 10 and R 11 are consistent with those in Table 239 and corresponding to III-5761-III-5802 in table 239 in turn, the representative compounds are coded as III-6181-III-6222.
[0549] Table 250: A=S, R 1 =C 2 H 5 , R 2 =Cl, W=R 3 =R 4 =R 5b =H, the substituents R 8 , R 9 , R 10 and R 11 are consistent with those in Table 239 and corresponding to III-5761-III-5802 in table 239 in turn, the representative compounds are coded as III-6223-III-6264.
[0550] In general formula III-C,
[0000]
[0551] A=NH, R 1 =CH 3 , R 2 =Cl, W=R 3 =R 4 =R 5b =H, the substituents R 7 , R 9 , R 10 and R 11 refer to Table 251, the representative compounds are coded as III-6265 III-6282.
[0000]
TABLE 251
No.
R 7
R 9
R 10
R 11
III-6265
H
H
H
H
III-6266
Cl
H
H
H
III-6267
OCH 3
H
H
H
III-6268
OCH 2 CF 3
H
H
H
III-6269
H
H
H
CH 3
III-6270
H
H
H
CF 3
III-6271
H
Br
H
H
III-6272
H
CF 3
H
H
III-6273
H
OCH 3
H
H
III-6274
Cl
H
Cl
H
III-6275
Cl
Cl
H
H
III-6276
H
Cl
Cl
H
III-6277
Cl
H
H
CH 3
III-6278
Cl
H
CH 3
H
III-6279
Cl
CH 3
H
H
III-6280
Cl
Cl
H
CF 3
III-6281
H
NHCH 3
Cl
H
III-6282
H
SO 2 CH 3
Cl
H
[0552] Table 252: A=NH, R 1 =C 2 H 5 , R 2 =Cl, W=R 3 =R 4 =R 5b =H, the substituents R 7 , R 9 , R 10 and R 11 are consistent with those in Table 251 and corresponding to III-6265 III-6282 in table 251 in turn, the representative compounds are coded as III-6283 III-6300.
[0553] Table 253: A=NH, R 1 =CH 3 , R 2 =Cl, W=R 3 =R 4 =H, R 5b =Cl, the substituents R 7 , R 9 , R 10 and R 11 are consistent with those in Table 251 and corresponding to III-6265-III-6282 in table 251 in turn, the representative compounds are coded as III-6301-III-6318.
[0554] Table 254: A=NH, R 1 =C 2 H 5 , R 2 =Cl, W=R 3 =R 4 =H, R 5b =Cl, the substituents R 7 , R 9 , R 10 and R 11 are consistent with those in Table 251 and corresponding to III-6265-III-6282 in table 251 in turn, the representative compounds are coded as III-6319-III-6336.
[0555] Table 255: A=NH, R 1 =CH 3 , R 2 =Cl, W=CH 3 , R 3 =R 4 =R 5b =H, the substituents R 7 , R 9 , R 10 and R 11 are consistent with those in Table 251 and corresponding to III-6265-III-6282 in table 251 in turn, the representative compounds are coded as III-6337-III-6354.
[0556] Table 256: A=NH, R 1 =C 2 H 5 , R 2 =Cl, W=CH 3 , R 3 =R 4 =R 5b =H, the substituents R 7 , R 9 , R 10 and R 11 are consistent with those in Table 251 and corresponding to III-6265-III-6282 in table 251 in turn, the representative compounds are coded as III-6355-III-6372.
[0557] In general formula III-D,
[0000]
[0558] A=NH, R 1 =CH 3 , R 2 =Cl, W=R 3 =R 4 =R 5b =H, the substituents R 7 , R 8 , R 10 and R 11 refer to Table 257, the representative compounds are coded as III-6373 III-6380.
[0000]
TABLE 257
No.
R 7
R 8
R 10
R 11
III-6373
H
H
Cl
H
III-6374
H
H
H
Br
III-6375
Cl
H
H
Cl
III-6376
H
H
OCH 3
H
III-6377
H
OCH 3
OCH 3
H
III-6378
H
Cl
OCH 3
H
III-6379
H
Cl
NHCH 3
H
III-6380
Cl
Cl
Cl
Cl
[0559] Table 258: A=NH, R 1 =C 2 H 5 , R 2 =Cl, W=R 3 =R 4 =R 5b =H, the substituents R 7 , R 8 , R 10 and R 11 are consistent with those in Table 257 and corresponding to III-6373 III-6380 in table 257 in turn, the representative compounds are coded as III-6381-III-6388.
[0560] Table 259: A=NH, R 1 =CH 3 , R 2 =Cl, W=R 3 =R 4 =H, R 5b =Cl, the substituents R 7 , R 8 , R 10 and R 11 are consistent with those in Table 257 and corresponding to III-6373-III-6380 in table 257 in turn, the representative compounds are coded as III-6389-III-6396.
[0561] Table 260: A=NH, R 1 =C 2 H 5 , R 2 =Cl, W=R 3 =R 4 =H, R 5b =Cl, the substituents R 7 , R 8 , R 10 and R 11 are consistent with those in Table 257 and corresponding to III-6373-III-6380 in table 257 in turn, the representative compounds are coded as III-6397-III-6404.
[0562] Table 261: A=NH, R 1 =CH 3 , R 2 =Cl, W=CH 3 , R 3 =R 4 =R 5b =H, the substituents R 7 , R 8 , R 10 and R 11 are consistent with those in Table 257 and corresponding to III-6373-III-6380 in table 257 in turn, the representative compounds are coded as III-6405-III-6412.
[0563] Table 262: A=NH, R 1 =C 2 H 5 , R 2 =Cl, W=CH 3 , R 3 =R 4 =R 5b =H, the substituents R 7 , R 8 , R 10 and R 11 are consistent with those in Table 257 and corresponding to III-6373-III-6380 in table 257 in turn, the representative compounds are coded as III-6413-III-6420.
[0564] In general formula III-E,
[0000]
[0565] A=NH, R 1 =CH 3 , R 2 =Cl, W=R 3 =R 4 =R 5b =H, the substituents R 8 , R 9 , R 10 and R 11 refer to Table 263, the representative compounds are coded as III-6421-III-6424.
[0000]
TABLE 263
No.
R 8
R 9
R 10
III-6421
H
H
H
III-6422
CH 3
H
CH 3
III-6423
OCH 3
H
OCH 3
III-6424
CO 2 C 2 H 5
H
CF 3
[0566] Table 264: A=NH, R 1 =C 2 H 5 , R 2 =Cl, W=R 3 =R 4 =R 5b =H, the substituents R 8 , R 9 , R 10 and R 11 are consistent with those in Table 263 and corresponding to III-6421 III-6424 in table 263 in turn, the representative compounds are coded as III-6425-III-6428.
[0567] Table 265: A=NH, R 1 =CH 3 , R 2 =Cl, W=R 3 =R 4 =H, R 5b =Cl, the substituents R 8 , R 9 , R 10 and R 11 are consistent with those in Table 263 and corresponding to III-6421-III-6424 in table 263 in turn, the representative compounds are coded as III-6429-III-6432.
[0568] Table 266: A=NH, R 1 =C 2 H 5 , R 2 =Cl, W=R 3 =R 4 =H, R 5b =Cl, the substituents R 8 , R 9 , R 10 and R 11 are consistent with those in Table 263 and corresponding to III-6421-III-6424 in table 263 in turn, the representative compounds are coded as III-6433-III-6436.
[0569] Table 267: A=NH, R 1 =CH 3 , R 2 =Cl, W=CH 3 , R 3 =R 4 =R 5b =H, the substituents R 8 , R 9 , R 10 and R 11 are consistent with those in Table 263 and corresponding to III-6421-III-6424 in table 263 in turn, the representative compounds are coded as III-6437-III-6440.
[0570] Table 268: A=NH, R 1 =C 2 H 5 , R 2 =Cl, W=CH 3 , R 3 =R 4 =R 5b =H, the substituents R 8 , R 9 , R 10 and R 11 are consistent with those in Table 263 and corresponding to III-6421-III-6424 in table 263 in turn, the representative compounds are coded as III-6441-III-6444.
[0571] In general formula III-F,
[0000]
[0572] A=NH, R 1 =CH 3 , R 2 =Cl, W=R 3 =R 4 =R 5b =H, the substituents R 8 , R 10 and R 11 refer to Table 269, the representative compounds are coded as III-6445-III-6448.
[0000]
TABLE 269
No.
R 8
R 10
R 11
III-6445
H
H
H
III-6446
H
Cl
H
III-6447
CH 3
Cl
H
III-6448
H
Cl
Cl
[0573] Table 270: A=NH, R 1 =C 2 H 5 , R 2 =Cl, W=R 3 =R 4 =R 5b =H, the substituents R 8 , R 10 and R 11 are consistent with those in Table 269 and corresponding to III-6445 III-6448 in table 269 in turn, the representative compounds are coded as III-6449 III-6452.
[0574] Table 271: A=NH, R 1 =CH 3 , R 2 =Cl, W=R 3 =R 4 =H, R 5b =Cl, the substituents R 8 , R 10 and R 11 are consistent with those in Table 269 and corresponding to III-6445 III-6448 in table 269 in turn, the representative compounds are coded as III-6453-III-6456.
[0575] Table 272: A=NH, R 1 =C 2 H 5 , R 2 =Cl, W=R 3 =R 4 =H, R 5b =Cl, the substituents R 8 , R 10 and R 11 are consistent with those in Table 269 and corresponding to III-6445 III-6448 in table 269 in turn, the representative compounds are coded as III-6457 III-6460.
[0576] Table 273: A=NH, R 1 =CH 3 , R 2 =Cl, W=CH 3 , R 3 =R 4 =R 5b =H, the substituents R 8 , R 10 and R 11 are consistent with those in Table 269 and corresponding to III-6445 III-6448 in table 269 in turn, the representative compounds are coded as III-6461 III-6464.
[0577] Table 274: A=NH, R 1 =C 2 H 5 , R 2 =Cl, W=CH 3 , R 3 =R 4 =R 5b =H, the substituents R 8 , R 10 and R 11 are consistent with those in Table 269 and corresponding to III-6445 III-6448 in table 269 in turn, the representative compounds are coded as III-6465 III-6468.
[0578] In general formula III-G,
[0000]
[0579] A=NH, R 1 =CH 3 , R 2 =Cl, W=R 3 =R 4 =R 5b =H, the substituents R 7 , R 9 and R 10 refer to Table 275, the representative compounds are coded as III-6469-III-6470.
[0000]
TABLE 275
No.
R 7
R 9
R 10
III-6469
H
H
H
III-6470
H
H
Cl
[0580] Table 276: A=NH, R 1 =C 2 H 5 , R 2 =Cl, W=R 3 =R 4 =R 5b =H, the substituents R 7 , R 9 and R 10 are consistent with those in Table 275 and corresponding to III-6469 III-6470 in table 275 in turn, the representative compounds are coded as III-6471 III-6472.
[0581] Table 277: A=NH, R 1 =CH 3 , R 2 =Cl, W=R 3 =R 4 =H, R 5b =Cl, the substituents R 7 , R 9 and R 10 are consistent with those in Table 275 and corresponding to III-6469 III-6470 in table 275 in turn, the representative compounds are coded as III-6473 III-6474.
[0582] Table 278: A=NH, R 1 =C 2 H 5 , R 2 =Cl, W=R 3 =R 4 =H, R 5b =Cl, the substituents R 7 , R 9 and R 10 are consistent with those in Table 275 and corresponding to III-6469 III-6470 in table 275 in turn, the representative compounds are coded as III-6475 III-6476.
[0583] Table 279: A=NH, R 1 =CH 3 , R 2 =Cl, W=CH 3 , R 3 =R 4 =R 5b =H, the substituents R 7 , R 9 and R 10 are consistent with those in Table 275 and corresponding to III-6469-III-6470 in table 275 in turn, the representative compounds are coded as III-6477 III-6478.
[0584] Table 280: A=NH, R 1 =C 2 H 5 , R 2 =Cl, W=CH 3 , R 3 =R 4 =R 5b =H, the substituents R 7 , R 9 and R 10 are consistent with those in Table 275 and corresponding to III-6469 III-6470 in table 275 in turn, the representative compounds are coded as III-6479 III-6480.
[0585] In general formula III-H,
[0000]
[0586] A=NH, R 1 =CH 3 , R 2 =Cl, W=R 3 =R 4 =R 5b =H, the substituents R 9 , R 10 and R 11 refer to Table 281, the representative compounds are coded as III-6481-III-6482.
[0000]
TABLE 281
No.
R 9
R 10
R 11
III-6481
H
H
H
III-6482
Cl
H
H
[0587] Table 282: A=NH, R 1 =C 2 H 5 , R 2 =Cl, W=R 3 =R 4 =R 5b =H, the substituents R 9 , R 10 and R 11 are consistent with those in Table 281 and corresponding to III-6481-III-6482 in table 281 in turn, the representative compounds are coded as III-6483-III-6484.
[0588] Table 283: A=NH, R 1 =CH 3 , R 2 =Cl, W=R 3 =R 4 =H, R 5b =Cl, the substituents R 9 , R 10 and R 11 are consistent with those in Table 281 and corresponding to III-6481-III-6482 in table 281 in turn, the representative compounds are coded as III-6485-III-6486.
[0589] Table 284: A=NH, R 1 =C 2 H 5 , R 2 =Cl, W=R 3 =R 4 =H, R 5b =Cl, the substituents R 9 , R 10 and R 11 are consistent with those in Table 281 and corresponding to III-6481-III-6482 in table 281 in turn, the representative compounds are coded as III-6487-III-6488.
[0590] Table 285: A=NH, R 1 =CH 3 , R 2 =Cl, W=CH 3 , R 3 =R 4 =R 5b =H, the substituents R 9 , R 10 and R 11 are consistent with those in Table 281 and corresponding to III-6481-III-6482 in table 281 in turn, the representative compounds are coded as III-6489-III-6490
[0591] Table 286: A=NH, R 1 =C 2 H 5 , R 2 =Cl, W=CH 3 , R 3 =R 4 =R 5b =H, the substituents R 9 , R 10 and R 11 are consistent with those in Table 281 and corresponding to III-6481-III-6482 in table 281 in turn, the representative compounds are coded as III-6491-III-6492.
[0592] In general formula III-A, A=NR 12 , R 1 =CH 3 , R 2 =Cl, W=R 3 =R 4 =R 5b =R 7 =R 8 =R 10 =R 11 =H, R 9 =Cl, the substituents R 12 refer to Table 287, the representative compounds are coded as III-6493-III-6632.
[0000]
TABLE 287
No.
R 12
III-6493
S—i-C 3 H 7
III-6494
OH
III-6495
—C(═O)H
III-6496
CBr 3
III-6497
CH 3
III-6498
C 2 H 5
III-6499
n-C 3 H 7
III-6500
i-C 3 H 7
III-6501
n-C 4 H 9
III-6502
i-C 4 H 9
III-6503
t-C 4 H 9
III-6504
CI 3
III-6505
CH 2 Br
III-6506
CHF 2
III-6507
CHBr 2
III-6508
CF3
III-6509
CH 2 Cl
III-6510
CHCl 2
III-6511
CCl 3
III-6512
CH 2 F
III-6513
OCH 3
III-6514
OC 2 H 5
III-6515
OCH(CH 3 ) 2
III-6516
OC(CH 3 ) 3
III-6517
OCF 3
III-6518
OCH 2 CF 3
III-6519
OCH 2 F
III-6520
OCHF 2
III-6521
SCH 3
III-6522
SC 2 H 5
III-6523
SCH 2 CH═CH 2
III-6524
CH═CH 2
III-6525
CH 2 CH═CH 2
III-6526
CH 2 CH═CCl 2
III-6527
C≡CH
III-6528
CH 2 C≡CH
III-6529
CH 2 C≡C—I
III-6530
CH 2 OCH 3
III-6531
CH 2 OCH 2 CH 3
III-6532
CH 2 CH 2 OCH 3
III-6533
CH 2 CH 2 OCH 2 CH 3
III-6534
CH 2 OCH 2 Cl
III-6535
CH 2 OCH 2 CH 2 Cl
III-6536
CH 2 CH 2 OCH 2 Cl
III-6537
CH 2 SCH 3
III-6538
CH 2 SCH 2 CH 3
III-6539
CH 2 CH 2 SCH 3
III-6540
CH 2 CH 2 SCH 2 CH 3
III-6541
CH 2 SCH 2 Cl
III-6542
CH 2 SCH 2 CH 2 Cl
III-6543
CH 2 CH 2 SCH 2 Cl
III-6544
SOCH 3
III-6545
SOC 2 H 5
III-6546
SOCF 3
III-6547
SOCH 2 CF 3
III-6548
SO 2 CH 3
III-6549
SO 2 C 2 H 5
III-6550
SO 2 CF 3
III-6551
SO 2 CH 2 CF 3
III-6552
SO 2 NHCOCH 3
III-6553
SO 2 NHCH 3
III-6554
SO 2 N(CH 3 ) 3
III-6555
CONHSO 2 CH 3
III-6556
COCH 3
III-6557
COC 2 H 5
III-6558
CO—n-C 3 H 7
III-6559
CO—i-C 3 H 7
III-6560
CO—n-C 4 H 9
III-6561
CO—i-C 4 H 9
III-6562
CO—t-C 4 H 9
III-6563
COCF 3
III-6564
COCH 2 Cl
III-6565
COOCH 3
III-6566
COOC 2 H 5
III-6567
COO—n-C 3 H 7
III-6568
COO—t-C 4 H 9
III-6569
COOCF 3
III-6570
COOCH 2 CH 2 Cl
III-6571
COOCH 2 CF 3
III-6572
CH 2 COOCH 3
III-6573
CH 2 COOC 2 H 5
III-6574
CH 2 COCH 3
III-6575
CH 2 COC 2 H 5
III-6576
CONHCH 3
III-6577
CONHC 2 H 5
III-6578
CONH—t-C 4 H 9
III-6579
CON(CH 3 ) 2
III-6580
CON(C 2 H 5 ) 2
III-6581
COOCH 2 CH═CH 2
III-6582
COOCH 2 C≡CH
III-6583
COOCH 2 OCH 3
III-6584
COOCH 2 CH 2 OCH 3
III-6585
SNHCH 3
III-6586
SNHC 2 H 5
III-6587
SN(CH 3 ) 2
III-6588
SN(C 2 H 5 ) 2
III-6589
III-6590
III-6591
III-6592
III-6593
III-6594
III-6595
III-6596
III-6597
III-6598
III-6599
III-6600
III-6601
III-6602
III-6603
III-6604
III-6605
III-6606
III-6607
III-6608
III-6609
III-6610
III-6611
III-6612
III-6613
III-6614
III-6615
III-6616
III-6617
III-6618
III-6619
III-6620
III-6621
III-6622
III-6623
III-6624
III-6625
III-6626
III-6627
III-6628
III-6629
III-6630
III-6631
III-6632
[0593] Table 288: in general formula III-A, A=NR 12 , R 1 =CH 3 , R 2 =Cl, W=R 3 =R 4 =R 5b =R 8 =R 10 =R 11 =H, R 7 =R 9 =Cl, the substituent R 12 are consistent with those in Table 287 and corresponding to III-6493-III-6632 in table 287 in turn, the representative compounds are coded as III-6633-III-6772.
[0594] Table 289: in general formula III-A, A=NR 12 , R 1 =CH 3 , R 2 =Cl, W=R 3 =R 4 =R 5b =R 7 =R 8 =R 10 =R 11 =H, R 9 =CF 3 , the substituent R 12 are consistent with those in Table 287 and corresponding to III-6493-III-6632 in table 287 in turn, the representative compounds are coded as III-6773-III-6912.
[0595] Table 290: in general formula III-B, A=NR 12 , R 1 =CH 3 , R 2 =Cl, W=R 3 =R 4 =R 5b =R 8 =R 10 =R 11 =H, R 9 =Cl, the substituent R 12 are consistent with those in Table 287 and corresponding to III-6493-III-6632 in table 287 in turn, the representative compounds are coded as III-6913-III-7052.
[0596] Table 291: in general formula III-B, A=NR 12 , R 1 =CH 3 , R 2 =Cl, W=R 3 =R 4 =R 5b =R 8 =R 10 =R 11 =H, R 9 =CF 3 , the substituent R 12 are consistent with those in Table 287 and corresponding to III-6493-III-6632 in table 287 in turn, the representative compounds are coded as III-7053-III-7192.
[0597] Table 292: in general formula III-B, A=NR 12 , R 1 =CH 3 , R 2 =Cl, W=R 3 =R 4 =R 5b =R 8 =R 10 =H, R 9 =CF 3 , R 11 =Cl, the substituent R 12 are consistent with those in Table 287 and corresponding to III-6493-III-6632 in table 287 in turn, the representative compounds are coded as III-7193-III-7332.
[0598] Table 293: in general formula III-B, A=NR 12 , R 1 =CH 3 , R 2 =Cl, W=R 3 =R 4 =R 5b =R 8 =R 10 =H, R 9 =R 11 =Cl, the substituent R 12 are consistent with those in Table 287 and corresponding to III-6493-III-6632 in table 287 in turn, the representative compounds are coded as III-7333-III-7472.
[0599] Table 294: in general formula III-C, A=NR 12 , R 1 =CH 3 , R 2 =Cl, W=R 3 =R 4 =R 5b =R 9 =R 10 =R 11 =H, R 7 =Cl, the substituent R 12 are consistent with those in Table 287 and corresponding to III-6493-III-6632 in table 287 in turn, the representative compounds are coded as III-7473-III-7612.
[0600] Table 295: in general formula III-D, A=NR 12 , R 1 =CH 3 , R 2 =Cl, W=R 3 =R 4 =R 5b =R 7 =R 11 =H, R 8 =R 10 =Cl, the substituent R 12 are consistent with those in Table 287 and corresponding to III-6493-III-6632 in table 287 in turn, the representative compounds are coded as III-7613-III-7752.
[0601] Table 296: in general formula III-E, A=NR 12 , R 1 =CH 3 , R 2 =Cl, W=R 3 =R 4 =R 5b =R 9 =H, R 8 =R 10 =OCH 3 , the substituent R 12 are consistent with those in Table 287 and corresponding to III-6493-III-6632 in table 287 in turn, the representative compounds are coded as III-7753-III-7892.
[0602] Table 297: in general formula III-E, A=NR 12 , R 1 =C 2 H 5 , R 2 =Cl, W=R 3 =R 4 =R 5b =R 9 =H, R 8 =R 10 =CH 3 , the substituent R 12 are consistent with those in Table 287 and corresponding to III-6493-III-6632 in table 287 in turn, the representative compounds are coded as III-7893-III-8032.
[0603] Table 298: in general formula III-F, A=NR 12 , R 1 =CH 3 , R 2 =Cl, W=R 3 =R 4 =R 5b =R 8 =H, R 10 =CH 3 , R 11 =Cl, the substituent R 12 are consistent with those in Table 287 and corresponding to III-6493-III-6632 in table 287 in turn, the representative compounds are coded as III-8033-III-8172.
[0604] Table 299: in general formula III-G, A=NR 12 , R 1 =CH 3 , R 2 =Cl, W=R 3 =R 4 =R 5b =R 7 =R 9 =H, R 10 =Cl, the substituent R 12 are consistent with those in Table 287 and corresponding to III-6493-III-6632 in table 287 in turn, the representative compounds are coded as III-8173-III-83122.
[0605] Table 300: in general formula III-H, A=NR 12 , R 1 =CH 3 , R 2 =Cl, W=R 3 =R 4 =R 5b =R 10 =R 11 =H, R 7 =Cl, the substituent R 12 are consistent with those in Table 287 and corresponding to III-6493-III-6632 in table 287 in turn, the representative compounds are coded as III-8313-III-8452.
[0606] The salts of some compounds having a structure as represented by formula III of the present invention are listed in Table 301, but without being restricted thereby.
[0000]
TABLE 301
the salts of some compounds
No.
structure
III-8453
III-8454
III-8455
III-8456
III-8457
III-8458
III-8459
III-8460
III-8461
III-8462
III-8463
III-8464
III-8465
III-8466
III-8467
III-8468
III-8469
III-8470
III-8471
III-8472
III-8473
III-8474
III-8475
III-8476
III-8477
III-8478
III-8479
III-8480
III-8481
III-8482
III-8483
III-8484
III-8485
III-8486
III-8487
III-8488
III-8489
III-8490
III-8491
III-8492
III-8493
III-8494
III-8495
III-8496
[0607] The compounds represented by general formula PY of the invention can be prepared according to three schemes in which Substituent A can be defined as different substituents the definitions of each substituent is defined as above:
[0608] Scheme 1 to prepare the compounds represented by general formula PY: when A=NH, the compounds represented by general formula PY-1 can be prepared according to the following two schemes.
[0609] Method 1: the compounds represented by general formula PY-1 can be prepared by reaction of intermediates i and ii in the presence of proper base, the preparation methods are shown as follows.
[0000]
[0610] The reaction was carried out in proper solvent and the proper solvent mentioned may be selected from benzene, toluene, xylene, acetone, butanone, methylisobutylketone, tetrahydrofuran, acetonitrile, 1,4-dioxane, DMF, N-methyl pyrrolidone, DMSO, pyridine, dichloromethane, chloroform, dichloroethane, methyl acetate or ethyl acetate and so on.
[0611] The reaction above can be carried out in the presence or absence of base, the reaction is promoted in the presence of base. Proper base mentioned may be selected from alkali metal hydride such as sodium hydride; alkali metal hydroxides such as sodium hydroxide or potassium hydroxide; alkali metal carbonate such as sodium carbonate or potassium carbonate; organic amine such as pyridine or triethylamine.
[0612] The proper temperature mentioned is from room temperature to boiling point of the solvent, normal temperature is from 20 to 100° C.
[0613] The reaction time is in the range of 30 minutes to 20 hours, generally being I-10 hours.
[0614] The detailed operation refers to the methods described in EP0370704, EP0356158, EP0264217, EP0665225, JP10036355 or U.S. Pat. No. 4,985,426.
[0615] Intermediates I are commercially available, or prepared according to the methods described in JP2000007662, U.S. Pat. No. 4,977,264, U.S. Pat. No. 6,090,815, US20040092402, JP09124613, U.S. Pat. No. 5,468,751, U.S. Pat. No. 4,985,426, U.S. Pat. No. 4,845,097 , Recueil des Travaux Chimiques des Pays - Bas (1978), 97 (11), Pages 288-92, Journal of the American Chemical Society, 79, 1455 (1957) or Journal of Chemical Society, p. 3478-3481 (1955).
[0616] Intermediates ii are commercially available, or prepared according to the methods described in U.S. Pat. No. 4,895,849, JP10036355, EP665225, US20070093498, WO2007046809, U.S. Pat. No. 5,783,522A, WO02083647A1, CN1927860A, WO9404527, US20110054173, WO2011025505, WO2004093800A, WO 2012075917, US20050648509, US2002082454, Organic Syntheses, Coll. Vol. 10, p. 501 (2004); Vol. 75, p. 61 (1998) or Organic Syntheses, Coll. Vol. 10, p. 102 (2004); Vol. 75, p. 53 (1998).
[0617] Method 2: the compounds represented by general formula iv can be prepared by reaction of intermediates i and iii in proper solvent, then the compounds represented by general formula PY-1 can be prepared by reaction of intermediates iv and v in the presence of proper base, the preparation methods are shown as follows. Wherein, L is a leaving group, selected from halogen, boric acid, methyl methanesulfonate or p-toluenesulfonates.
[0000]
[0618] The reaction was carried out between the intermediates represented by general formula i and iii in proper solvent and the proper solvent mentioned may be selected from benzene, toluene, xylene, acetone, butanone, methylisobutylketone, tetrahydrofuran, acetonitrile, 1,4-dioxane, DMF, N-methyl pyrrolidone, DMSO, pyridine, dichloromethane, chloroform, dichloroethane, methyl acetate or ethyl acetate and so on. The reaction above can be carried out in the presence or absence of base, the reaction is promoted in the presence of base. Proper base mentioned may be selected from alkali metal hydride such as sodium hydride; alkali metal hydroxides such as sodium hydroxide or potassium hydroxide; alkali metal carbonate such as sodium carbonate or potassium carbonate; organic amine such as pyridine or triethylamine.
[0619] The proper temperature mentioned is from room temperature to boiling point of the solvent, normal temperature is from 20 to 100° C. The reaction time is in the range of 30 minutes to 20 hours, generally being I-10 hours.
[0620] The reaction was carried out between the intermediates represented by general formula iv and v in proper solvent and the proper solvent mentioned may be selected from benzene, toluene, xylene, acetone, butanone, methylisobutylketone, tetrahydrofuran, acetonitrile, 1,4-dioxane, DMF, N-methyl pyrrolidone, DMSO, pyridine, dichloromethane, chloroform, dichloroethane, methyl acetate or ethyl acetate and so on. The reaction above can be carried out in the presence of base. Proper base mentioned may be selected from alkali metal hydride such as sodium hydride; alkali metal hydroxides such as sodium hydroxide or potassium hydroxide; alkali metal carbonate such as sodium carbonate or potassium carbonate; organic amine such as pyridine or triethylamine.
[0621] The proper temperature mentioned is from room temperature to boiling point of the solvent, normal temperature is from 20 to 200° C. The reaction time is in the range of 30 minutes to 20 hours, generally being I-10 hours.
[0622] The detailed operation refers to the methods described in JP11049759, EP0370704, EP0196524 or U.S. Pat. No. 4,895,849.
[0623] Other materials, such as the compounds represented by general formula iii and v, used to prepare the compounds represented by general formula PY-1, are commercially available.
[0624] The intermediate represented by general formula ii is one of key intermediate, some compounds are commercially available, or are prepared according to the known method described above, also can be prepared according to the following two schemes in which Substituent X 1 can be defined as different substituents.
[0625] Method 1: when X 1 =CR 6 , the intermediate ii used to prepare the compounds represented by the general formula I and II (wherein A=NH) can be prepared according to the following two schemes. Relevant intermediates are commercially available, or prepared according to the methods described in U.S. Pat. No. 4,895,849, JP10036355, EP665225, US20070093498, WO2007046809, U.S. Pat. No. 5,783,522A, WO02083647A1, CN1927860A, Organic Syntheses, Coll. Vol. 10, p. 501 (2004); Vol. 75, p. 61 (1998) or Organic Syntheses, Coll. Vol. 10, p. 102 (2004); Vol. 75, p. 53 (1998).
[0626] (1) Reduction of Cyano:
[0000]
[0627] Wherein, L is a leaving group, selected from halogen, boric acid, methyl methanesulfonate or p-toluenesulfonates. B is a alkyl chain with one more carbon than M.
[0628] The compounds represented by general formula ii-c can be prepared by reaction of intermediates ii-a and ii-b in proper solvent in the presence of proper base. The detailed operation refers to the methods described in US2002082454 and Fine Chemicals, 2005, 22 (12): 944-960. The proper temperature mentioned is from room temperature to boiling point of the solvent, normal temperature is from 20 to 100° C. The reaction time is in the range of 30 minutes to 20 hours, generally being I-10 hours. The proper solvent mentioned may be selected from acetone, butanone, tetrahydrofuran, acetonitrile, toluene, xylene, benzene, DMF, DMSO, methanol or ethanol and so on. Proper base mentioned may be selected from potassium hydroxide, sodium hydroxide, sodium carbonate, potassium carbonate, sodium bicarbonate, triethylamine, pyridine or sodium hydride.
[0629] When L refers to boric acid group, the compounds represented by general formula ii-c can also be prepared by reaction of intermediates ii-a and ii-b at 0-100° C. in proper solvent in the presence of proper base and catalyst. The proper solvent mentioned may be selected from benzene, toluene, xylene, chloroform, dichloromethane, acetone, butanone, tetrahydrofuran, acetonitrile, 1,4-dioxane, DMF, N-methyl pyrrolidone or DMSO and so on. Proper base mentioned may be selected from pyridine or triethylamine and so on. Proper catalyst mentioned may be selected from copper acetate, copper chloride or copper sulfate and so on.
[0630] The intermediates represented by general formula ii-1 can be prepared by reaction of intermediates represented by general formula ii-c and ammonia water in the presence of proper catalyst by using hydrogenation reduction. The detailed operation refers to the methods described in J. Am. Chem. Soc, 70, 3788 (1948); 82, 681 (1960); 82, 2386 (1960); Can. J. Chem, 49, 2990 (1971); J. Org. Chem, 37, 335 (1972); Organic Syntheses, Coll. Vol. 3, p. 229, p. 720 (1955), Vol. 23, p. 71 (1943) or Vol. 27, p. 18 (1947). The proper temperature mentioned is from room temperature to boiling point of the solvent, normal temperature is from 20 to 100° C. The reaction time is in the range of 30 minutes to 20 hours, generally being I-10 hours. The proper solvent mentioned may be selected from methanol, ethanol, isopropanol, benzene, toluene, xylene, acetone, butanone, methylisobutylketone, chloroform, dichloroethane, methyl acetate, ethyl acetate, tetrahydrofuran, 1,4-dioxane, DMF, N-methyl pyrrolidone or DMSO, etc. The proper catalysts mentioned may be selected from Raney-nickel, palladium carbon or platinum oxide, etc.
[0631] (2) The Method to Prepare the Substituted Amine and its Salts by Reaction of the Substituted 4-Hydroxyphenylalkyl Amine
[0000]
[0632] Wherein, Boc 2 O refers to di-tert-butyl dicarbonate.
[0633] Firstly, the compounds represented by general formula ii-e can be prepared by reaction of intermediates ii-d and di-tert-butyl dicarbonate at 0-100° C. in proper solvent in the presence of proper base. The preferred temperature is 0-50° C. The reaction time is in the range of 30 minutes to 20 hours, generally being 0.5-10 hours. The proper solvent mentioned may be selected from benzene, toluene, xylene, chloroform, dichloromethane, tetrahydrofuran, acetonitrile, 1,4-dioxane, DMF, N-methyl pyrrolidone or DMSO and so on. Proper base mentioned may be selected from alkali metal carbonate such as sodium carbonate, sodium bicarbonate, potassium carbonate or potassium bicarbonate.
[0634] Then the compounds represented by general formula ii-f can be prepared by reaction of intermediates ii-e and ii-b at 0-100° C. in proper solvent in the presence of proper base. The reaction time is in the range of 30 minutes to 20 hours, generally being 0.5-10 hours. The proper solvent mentioned may be selected from benzene, toluene, xylene, chloroform, dichloromethane, acetone, butanone, tetrahydrofuran, acetonitrile, 1,4-dioxane, DMF, N-methyl pyrrolidone or DMSO and so on. Proper base mentioned may be selected from alkali metal hydride such as sodium hydride; alkali metal hydroxides such as sodium hydroxide or potassium hydroxide; alkali carbonate such as sodium carbonate or potassium carbonate; organic amine such as pyridine or triethylamine.
[0635] When L refers to boric acid group. The method to prepare the compounds represented by general formula ii-f refers to the method to prepare the compounds represented by general formula ii-c with method of cyano reduction.
[0636] The salts represented by general formula ii-g can be prepared by deprotection reaction of intermediates represented by general formula ii-f and proper acid in proper solvent, and then alkalized to obtain ii-1. The preferred temperature is 0-50° C. The reaction time is in the range of 30 minutes to 20 hours, generally being 0.5-10 hours. The proper solvent mentioned may be selected from ethyl acetate, methyl acetate, methyl formate, benzene, toluene, xylene, chloroform, dichloromethane, water, tetrahydrofuran, acetonitrile, 1,4-dioxane, DMF, N-methyl pyrrolidone or DMSO and so on. the proper acid mentioned may be selected from hydrochloric acid, trifluoroacetic acid, sulfuric acid, acetic acid, propionic acid, butyric acid, oxalic acid, adipic acid, dodecanedioic acid, lauric acid, stearic acid, fumaric acid, maleic acid, benzoic acid or phthalic acid, etc. the proper base mentioned may be selected from alkali metal hydride such as sodium hydride; alkali metal hydroxides such as sodium hydroxide or potassium hydroxide; alkali carbonate, such as sodium carbonate or potassium carbonate; organic amine, such as pyridine or triethylamine. The detailed operation refers to the methods described in WO2004093800A and US20050096485.
[0637] Other materials mentioned above, such as the compounds represented by general formula ii-a, ii-b, ii-d and Boc 2 O, used to prepare the compounds represented by general formula ii-1, are commercially available.
[0638] Method 2: when X 1 =N, the intermediate ii used to prepare the compounds represented by the general formula III (wherein A=NH) can be prepared according to the following two schemes in which B is selected from different substituent.
[0639] (1) When B=—CH 2 —, the detailed operation refers to the methods described in WO9404527, US20110054173 or WO2011025505. The compounds also can be prepared according to the following method.
[0000]
[0640] Wherein, U is a leaving group, selected from halogen or hydroxy, etc.
[0641] The intermediates represented by general formula ii-j can be prepared by reaction of intermediates represented by general formula ii-h and ii-i in proper solvent and temperature in the presence of proper base. The reaction time is in the range of 30 minutes to 20 hours, generally being 0.5-10 hours. The intermediates represented by general formula ii-k can be prepared by reduction reaction of intermediates represented by general formula ii-j and Red-Al, the detailed operation refers to the methods described in EP1840128. The intermediates represented by general formula ii-L can be prepared by reaction of intermediates represented by general formula ii-k and sulfoxide chloride according to known methods. The intermediates represented by general formula ii-m can be prepared by reaction of intermediates represented by general formula ii-L and sodium cyanide according to the methods described in WO2007045989 and WO2009115257. According to the methods described in Journal of Organic Chemistry, 71 (21), 8023-8027; 2006, Synthesis, (24), 4242-4250, 2010, Heterocycles, 56 (I-2), 443-455, 2002 or ARKIVOC (Gainesville, Fla., United States) [online computer file], (10), 40-51, 2002, The intermediates represented by general formula ii-n can be prepared via intermediate ii-m. Finally, the intermediates represented by general formula ii-2 can be prepared by reaction of intermediates represented by general formula ii-n and ammonia water in the presence of proper catalyst by using hydrogenation reduction. The detailed operation refers to the methods described in J. Am. Chem. Soc, 70, 3788 (1948); 82, 681 (1960); 82, 2386 (1960); Can. J. Chem, 49, 2990 (1971); J. Org. Chem, 37, 335 (1972); Organic Syntheses, Coll. Vol. 3, p. 229, p. 720 (1955), Vol. 23, p. 71 (1943) or Vol. 27, p. 18 (1947). The proper catalysts mentioned may be selected from Raney-nickel, palladium carbon or platinum oxide, etc.
[0642] The sources of intermediates are as follows: the intermediate represented by general formula ii-h and ii-I are commercially available, or can be prepared according to the conventional method.
[0643] The proper base mentioned may be selected from potassium hydroxide, sodium hydroxide, sodium carbonate, potassium carbonate, sodium bicarbonate, triethylamine, pyridine, sodium methoxide, sodium ethoxide, sodium hydride, potassium tert-butoxide or sodium tert-butoxide and so on.
[0644] The reaction was carried out in proper solvent and the proper solvent mentioned may be selected from tetrahydrofuran, 1,4-dioxane, acetonitrile, toluene, xylene, benzene, DMF, N-methyl pyrrolidone, DMSO, acetone or butanone and so on.
[0645] The proper temperature mentioned is from room temperature to boiling point of the solvent, normal temperature is from 20 to 100° C.
[0646] The reaction time is in the range of 30 minutes to 20 hours, generally being I-10 hours.
[0647] (2) When B=—CH 2 CH 2 —, the preparation method is as follows:
[0000]
[0648] The compounds represented by general formula ii-o can be prepared by reaction of the compounds represented by general formula ii-n according to the methods described in Synthesis, (9), 727-9; 1983 or Tetrahedron Letters, 39 (51), 9455-9456; 1998; the compounds having general formula ii-3 can be prepared by reaction of the compounds having general formula ii-o according to the methods in which B=—CH 2 —.
[0649] The second method to prepare the compounds represented by general formula PY: when A=NR 12 (R 12 ≠H), the compounds represented by general formula PY-2 can be prepared by reaction of the compounds represented by general formula PY-1 with U-R1 according to the conventional method (U defined as above); or can be prepared according to the methods described in JP08269021, JP3543411, JP1995-72621, JP1995-96669, JP3511729, JP08291149, EP530149, WO9208704 and WO2004093800A.
[0650] The third method to prepare the compounds represented by general formula PY: when A=O or S, the compounds represented by general formula PY-3, PY-4 can be prepared according to the methods described in WO2012075917 and EP534341.
[0651] The structural formula of the compounds represented by general formula PY-2, PY-3 and PY-4 are shown as follows
[0000]
[0652] In general formula PY, the corresponding salts represented by general formula PY-5A can be prepared by reaction of the compounds represented by general formula PY-5 (when A=NR 12 ) with corresponding organic acids or inorganic acids, as shown in the following.
[0000]
[0653] In addition, in general formula PY, the salts can also formed based on nitrogen atom of pyrimidine ring, the preparation method refers to DE19647317, JP2001504473, U.S. Pat. No. 5,925,644, WO9822446 and ZA9710187, etc.
[0654] The reaction forming salts of compounds represented by general formula PY-5 with organic acids or inorganic acids can be carried out at room temperature to boiling point of the solvent, normal temperature is from 20 to 100° C. The reaction time is in the range of 30 minutes to 20 hours, generally being I-10 hours. The proper solvent mentioned may be selected from water, methanol, ethanol, isopropanol, benzene, toluene, xylene, acetone, ethyl methyl ketone, methyl isobutyl ketone, chloroform, dichloromethane, methyl acetate, ethyl acetate, tetrahydrofuran, 1,4-dioxane, DMF, N-methyl pyrrolidone or DMSO and so on.
[0655] The acids, which can be used to form salts with compounds represented by general formula PY-5, includes carboxylic acid, such as formic acid, acetic acid, propanoic acid, butyric acid, oxalic acid, trifluoroacetic acid, adipic acid, dodecanedioic acid, lauric acid, stearic acid, fumaric acid, maleic acid, sorbic acid, malic acid, citric acid, benzoic acid, p-toluylic acid or phthalic acid, etc. sulfonic acid, such as methanesulfonic acid, 1,3-propylene sulfonic acid, p-toluenesulfonic acid or dodecylbenzene sulfonic acid, etc. inorganic acid, such as hydrochloric acid, sulphuric acid, nitric acid, phosphorous acid or carbonic acid, etc. The further preferred acids are hydrochloric acid, sulphuric acid, nitric acid, phosphorous acid, acetic acid, trifluoroacetic acid, oxalic acid, methanesulfonic acid, p-toluenesulfonic acid or benzoic acid.
[0656] Although the compounds represented by general formula PY and some compounds reported in prior art are both belong to substituted pyrimidine compounds, there are still some obvious differences in structure between them. It is due to these differences in structure that lead to compounds of present invention with better fungicidal and/or insecticidal/acaricidal activities.
[0657] The compounds represented by general formula PY show excellent activity against both many plant pathogens/diseases in agricultural and other fields, and insects/mites. Therefore the technical scheme of the present invention also includes the uses of the compounds represented by general formula PY or their salts/complexes to prepare fungicides, insecticides/acaricides in agricultural, forestry or public health fields. The further preferred technical scheme of the present invention also includes the uses of the compounds represented by general formula I, II or III or their salts/complexes to prepare fungicides, insecticides/acaricides in agricultural, forestry or public health fields.
[0658] The present invention is explained by the following examples of plant disease and insect pests, but without being restricted thereby.
[0659] The compounds represented by general formula PY can be used to control these plant diseases: Oomycete diseases, such as downy mildew (cucumber downy mildew, rape downy mildew, soybean downy mildew, downy mildew of beet, downy mildew of sugarcane, tobacco downy mildew, pea downy mildew, vegetable sponge downy mildew, chinese wax gourd downy mildew, muskmelon downy mildew, chinese cabbage downy mildew, spinach downy mildew, radish downy mildew, grape downy mildew, onion downy mildew), white rust (rape white rust, chinese cabbage white rust), damping-off disease (rape damping-off, tobacco damping-off, tomato damping-off, pepper damping-off, eggplant damping-off, cucumber damping-off, cotton damping-off), pythium rot (pepper soft stale disease, vegetable sponge cottony leak, chinese wax gourd cottony leak), blight (broad bean phytophthora blight, cucumber phytophthora blight, pumpkin phytophthora rot, chinese wax gourd phytophthora blight, watermelon phytophthora blight, muskmelon phytophthora blight, pepper phytophthora blight, chinese chives phytophthora blight, carlic phytophthora blight, cotton phytophthora blight), late blight (potato late blight, tomato late blight) and so on; diseases caused by Deuteromycotina, such as wilt disease (sweet potato fusarium wilt, cotton fusarium wilt disease, sesame wilt disease, fusarium wilt disease of costarbean, tomato fusarium wilt, bean fusarium wilt, cucumber fusarium wilt, vegetable sponge fusarium wilt, pumpkin fusarium wilt, chinese wax gourd fusarium wilt, watermelon fusarium wilt, muskmelon fusarium wilt, pepper fusarium wilt, broad bean fusarium wilt, fusarium wilt disease of rape, fusarium wilt disease of soybean), root rot (pepper root rot, eggplant root rot, bean fusarium root-rot, cucumber fusarium root rot, balsam pear fusarium root rot, cotton black root rot, broad bean thielaviopsis root rot), drooping disease (cotton soreshin, sesame soreshin, pepper rhizoctonia rot, cucumber rhizoctonia rot, chinese cabbage rhizoctonia rot), anthracnose (sorghum anthracnose, cotton anthracnose, kenaf anthracnose, jute anthracnose, flax anthracnose, tobacco anthracnose, mulberry anthracnose, pepper anthracnose, eggplant anthracnose, bean anthracnose, cucumber anthracnose, balsam pear anthracnose, summer squash anthracnose, chinese wax gourd anthracnose, watermelon anthracnose, muskmelon anthracnose, litchi anthracnose), verticillium wilt (cotton verticillium wilt, verticillium wilt of sunflower, tomato verticillium wilt, pepper verticillium wilt, eggplant verticillium wilt), scab (summer squash scab, chinese wax gourd scab, muskmelon scab), gray mold (cotton boll gray mold, kenaf gray mold, tomato gray mold, pepper gray mold, bean gray mold, celery gray mold, spinach gray mold, kiwi fruit gray mold rot), brown spot (cotton brown spot, jute brown spot, beet sercospora leaf spot, peanut brown spot, pepper brown leaf spot, chinese wax gourd corynespora leaf spot, soybean brown spot, sunflower brown spot, pea ascochyta blight, broad bean brown spot), black spot (flax black spot, rape alternaria leaf spot, sesame black spot, sunflower alternaria leaf spot, costarbean alternaria leaf spot, tomato nail head spot, pepper black fruit spot, eggplant black spot, bean leaf spot, cucumber alternaria blight, celery alternaria black leaf spot, carrot alternaria black rot, carrot leaf blight, apple alternaria rot, peanut brown spot), spot blight (tomato septoria leaf spot, pepper septoria leaf spot, celery late blight), early blight (tomato early blight, pepper early blight, eggplant early blight, potato early blight, celery early blight), ring spot (soybean zonate spot, sesame ring spot, bean zonate spot), leaf blight (sesame leaf blight, sunflower leaf blight, watermelon alternaria blight, muskmelon alternaria spot), basal stem rot (tomato basal stem rot, bean rhizoctonia rot), and others (corn northern leaf spot, kenaf damping-off, rice blast, millet black sheath, sugarcane eye spot, cotton aspergillus boll rot, peanut crown rot, soybean stem blight, soybean black spot, muskmelon alternaria leaf blight, peanut web blotch, tea red leaf spot, pepper phyllosticta blight, chinese wax gourd phyllosticta leaf spot, celery black rot, spinach heart rot, kenaf leaf mold, kenaf brown leaf spot, Jute stem blight, soybean cercospora spot, sesame leaf spot, costarbean gray leaf spot, tea brown leaf spot, eggplant cercospora leaf spot, bean cercospora leaf spot, balsam pear cercospora leaf spot, watermelon cercospora leaf spot, jute dry rot, sunflower root and stem rot, bean charcoal rot, soybean target spot, eggplant corynespora leaf spot, cucumber corynespora target leaf spot, tomato leaf mold, eggplant fulvia leaf mold, broad bean chocolate spot) and so on; diseases caused by Basidiomycete, such as rust (wheat stripe rust, wheat stem rust, wheat leaf rust, peanut rust, sunflower rust, sugarcane rust, chinese chives rust, onion rust, millet rust, soybean rust), smut (corn head smut, corn smut, sorghum silk smut, sorghum loose kernel smut, sorghum hard smut, sorghum smut, millet kernel smut, sugarcane smut, bean rust), and others (for example, wheat sheath blight and rice sheath blight) and so on; diseases caused by Ascomycete, such as powdery mildew (wheat powdery mildew, rape powdery mildew, powdery mildew of sesame, powdery mildew of sunflower, beet powdery mildew, eggplant powdery mildew, pea powdery mildew, vegetable sponge powdery mildew, pumpkin powdery mildew, summer squash powdery mildew, chinese wax gourd, muskmelon powdery mildew, grape powdery mildew, broad bean powdery mildew), sclerotinia rot (flax sclertiniose, rape sclertiniose, soybean sclertiniose, peanut sclertiniose, tobacco sclerotinia rot, pepper sclerotinia rot, eggplant sclerotinia rot, bean sclerotinia rot, pea sclerotinia rot, cucumber sclerotinia rot, balsam pear sclerotinia rot, chinese wax gourd sclerotinia rot, watermelon sclerotinia disease, celery stem rot), scab (apple scab, pear scab) and so on. Especially, the compounds of the present invention exhibit very good control against corn southern rust, rice blast, cucumber gray mold and cucumber downy mildew at very low doses.
[0660] The compounds represented by general formula PY can be used to control these insect pests: Coleoptera, such as Acanthoscelides spp., Acanthoscelides obtectus, Agrilus planipennis, Agriotes spp., Anoplophora glabripennis, Anthonomus spp., Anthonomus grandis, Aphidius spp., Apion spp., Apogonia spp., Atacnius sprctulus, Atomaria linearis , pygmy mangold beetle, Aulacophore spp., Bothynoderes punctiventris, Bruchus spp., Bruchus pisorum, Cacoesia, Cacoesia spp., Callosobruchus maculatus, Carpophilus hemipteras, Cassida vittata, Ccrostcrna spp., Ccrotoma, Ccrotoma spp., Cerotoma trifur cata, Ceutorhynchus spp., Ceutorhynchus assimilis , cabbage seedpod weevil, Ceutorhynchus napi , cabbage curculio, Chaetocnema spp., Colaspis spp., Conoderus scalaris, Conoderus stigmosus, Conotrachelus nenuphar, Cotinus nitidis , Green June beetle, Crioceris asparagi, Cryptolestes ferrugincus , rusty grainbeetle, Cryptolestes pusillus, Cryptolestes turcicus Turkish grain beetle, Ctenicera spp., Curculio spp., Cyclocephala spp., Cylindrocpturus adspersus , sunflower stem weevil, Deporaus marginatus , mango leaf-cutting weevil, Dermestes lardarius, Dermestes maculates, Diabrotica spp., Epilachna varivcstis , raustinus cubae, Hylobius pales , pales weevil, Hypera spp., Hypera postica, Hyperdoes spp., Hyperodes weevil, Hypothenemus hampei, Ips spp., engravers, Lasioderma serricorne, Leptinotarsa decemlineata, Liogenys fuscus, Liogenys suturalis, Lissorhoptrus oryzophilus, Lyctus spp., powder post beetles, Maecolaspis joliveti, Megascelis spp., Melanotus communis, Meligethes spp., Meligethes aeneus , blossom beetle, Melolontha melolontha, Oberea brevis, Oberea linearis , Oryctes rhinoceros, date palm beetle, Oryzaephilus mercator , merchant grain beetle, Oryzaephilus surinamensis , sawtoothed grain beetle, Otiorhynchus spp., Oulema melanopus , cereal leafbeetle, Oulema oryzae, Pantomorus spp., Phyllophaga spp., Phyllophaga cuyabana, Phyllotreta spp., Phynchites spp., Popillia japonica, Prostephanus truncates , larger grain borer, Rhizopertha dominica , lesser grain borer, Rhizotrogus spp., Eurpoean chafer, Rhynchophorus spp., Scolytus spp., Shenophorus spp. Sitona lincatus, pca leaf weevil, Sitophilus spp., Sitophilus granaries, granary weevil, Sitophilus oryzae , rice weevil, Stegobium paniceum, drugstore beetle, Tribolium spp., Tribolium castaneum , red flour beetle, Tribolium confusum , confused flour beetle, Trogoderma variabile , warehouse beetle and Zabrus tenebioides.
[0661] Dermaptera.
[0662] Dictyoptera, such as Blattella germanica , German cockroach, Blatta orientalis, Parcoblatta pennylvanica, Periplaneta americana , American cockroach, Periplaneta australoasiae , Australian cockroach, Periplaneta brunnca , brown cockroach, Periplaneta fuliginosa , smokybrown cockroach, Pyncoselus suninamensis , Surinam cockroach and Supella longipalpa , brownbanded cockroach.
[0663] Diptera, such as Aedes spp., Agromyza frontella , alfalfa blotch leafminer, Agromyza spp., Anastrepha spp., Anastrepha suspensa , Caribbean fruit fly, Anopheles spp., Batrocera spp., Bactrocera cucurbitae, Bactrocera dorsalis, Ceratitis spp., Ceratitis capitata, Chrysops spp., Cochliomyia spp., Contarinia spp., Culex spp., Dasineura spp., Dasineura brassicae, Delia spp., Delia platura , seedcorn maggot, Drosophila spp., Fannia spp., Fannia canicularis , little house fly, Fannia scalaris, Gasterophilus intestinalis, Gracillia perseae, Haematobia irritans, Hylemyia spp., root maggot, Hypoderma lineatum , common cattle grub, Liriomyza spp., Liriomyza brassica , serpentine leafminer, Melophagus ovinus, Musca spp., muscid fly, Musca autumnalis , face fly, Vusca domestica , house fly, Oestrus ovis , sheep bot fly, Oscinella frit, Pegomyia betae , beet leafminer, Phorbia spp., Psila rosae , carrotrust fly, Rhagoletis cerasi , cherry fruit fly, Rhagoletis pomonella , apple maggot, Sitodiplosis mosellana , orange wheat blossom midge, stomoxys calcitruns , stable fly, Tahanus spp. and Tipula spp.
[0664] Hemiptera, such as Acrosternum hilare , green stink bug, Blissus leucopterus , chinch bug, Calocoris norvegicus , potato mirid, Cimex hemipterus , tropical bed bug, Cimex lectularius , bed hug, Daghertus fasciatus, Dichelops furcatus, Dysdercus suturellus , cotton stainer, Edessa meditabunda, Eurygaster maura , cereal bug, Euschistus heros, Euschistus servus , brown stink bug, Helopeltis antonii, Helopeltis theivora , tea blight plantbug, Lagynotomus spp., Leptocorisa oratorius, Leptocorisa varicorni, Lygus spp., plant bug, Lygus hesperus , western tarnished plant bug, Maconellicoccus hirsutus, Neurocolpus longirostris, Nezara viridula , southern green stink bug, PhyLocoris spp., Phytocoris californicus, Phytocoris relativus, Piezodorus guildingi, Poecilocapsus lineatus , fourlined plant bug, Psallus vaccinicola, Pseudacysta perseae, Scaptocoris castanea and Triatoma spp., bloodsucking conenose bug, kissing bug.
[0665] Homoptera, such as Acrythosiphonpisum, pea aphid, Adelges spp., adelgids, Aleurodes proletella, Aleurodicus disperses, Aleurothrixus flccosus , woolly whitefly, Aluacaspis spp., Amrasca bigutella bigutella, Aphrophora spp., leafhopper, Aonidiella aurantii , California red scale, Aphis spp., Aphis gossypii , cotton aphid, Aphis pomi , apple aphid, Aulacorthitm solan , foxglove aphid, Bemisia spp., Bemisia argentifolii, Bemisia tabaci , sweetpotato whitefly, Brachycolus noxius , Russian aphid, Brachycorynclia asparagi , asparagus aphid, Brevennia rehi, Brevicoryne brassicae, Ceroplastes spp., Ceroplastes rubens , red wax scale, Chionaspis spp., Chrysomphalus spp., Coccus spp., Dysaphis plantaginea , rosy apple aphid, Empoasca spp., Eriosoma lanigerum , woolly apple aphid, Icerya purchasi , cottony cushion scale, Idioscopus nitidulus , mango leafhopper, Laodelphax striatellus , smaller brown planthopper, Lepidosaphes spp., Macrosiphum spp., Macrosiphum euphorbiae , potato aphid, Macrosiphum granarium , English grain aphid, Macrosiphum rosae , rose aphid, Macrosteles quadrilineatus , aster leafhopper, Mahanarva frimbiolata, Metopolophium dirhodum , rose grain aphid, Midis longicornis, Myzus persicae , green peach aphid, Nephotettix spp., Nephotettix cinctipes , green leafhopper, Nilaparvata lugens , brown planthopper, Parlatoria pergandii , chaff scale, Parlatoria ziziphi , ebony scale, Peregrinus maidis , corn delphacid, Philaenus spp., Phylloxera vitifoliae , grape phylloxera, Physokermes piceae , spruce bud scale, Planococcus spp., Pseudococcus spp., Pseudococcus brevipes , pine apple mealybug, Quadraspidiotus perniciosus , San Jose scale, Rhapalosiphum spp., Rhapalosiphum maida , corn leaf aphid, Rhapalosiphum padi , oatbird-cherry aphid, Saissetia spp., Saissetia oleae, Schizaphis graminum , greenbug, Sitobion avenge, Sogatella furcifera , white-backed planthopper, Therioaphis spp., Toumeyella spp., Toxoptera spp., Trialeurodes spp., Trialeurodes vaporariorum , greenhouse whitefly, Trialeurodes abutiloneus , bandedwing whitefly, Unaspis spp., Unaspis yanonensis , arrowhead scale and Zulia entreriana.
[0666] Hymenoptera, such as Acromyrrmex spp., Athalia rosae, Atta spp., leafcutting ants, Camponotus spp., carpenter ant, Diprion spp., sawfly, Formica spp., Iridomyrmex humilis, Argentineant, Monomorium ssp., Monomorium minumum, little black ant, Monomorium pharaonis , haraoh ant, Neodiprion spp., Pogonomyrmex spp., Polistes spp., paper wasp, Solenopsis spp., Tapoinoma sessile , odorous house ant, Tetranomorium spp., pavement ant, Vespula spp., yellow jacket and Xylocopa spp., carpenter bee.
[0667] Isoptera, such as Coptotermes spp., Coptotermes curvignathus, Coptotermes frenchii, Coptotermes formosanus , Formosan subterranean termite, Cornitermes spp., nasute termite, Cryptotermes spp., Heterotermes spp., desert subterranean termite, Ileterotermes aureus, Kalotermes spp., Incistitermes spp., Macrotermes spp., fungus growing termite, Marginitermes spp., Microcerotermes spp., harvester termite, Microtermes obesi, Procornitermes spp., Reticulitermes spp., Reticuliterme banyulensis, Reticulitermes grassei, Reticulitermes flavipes, Reticulitermes hageni, Reticulitermes hesperus, Reticulitermes santonensis, Reticulitermes speratus, Reticulitermes tibialis, Reticulitermes virginicus, Schedorhinotermes spp. and Zootermopsis spp.
[0668] Lepidoptera, such as Achoea janata, Adoxophyes spp., Adoxophyes orana, Agrotis spp., Agrotis ipsilon, Alabama argillacea , cotton leafworm, Amorbia cuneana, Amyelosis transitella , navel orangeworm, Anacamptodes defectaria, Anarsia lineatella , peach twig borer, Anomis sabulijera , jute looper, Anticarsia gemmatalis , velvetbean caterpillar, Archips argyrospila )(fruit tree leafroller, Archips rosana , rose leaf roller, Argyrotaenia spp., tortricid moths, Argyrotaenia citrana , orange tortrix, Autographa gamma, Bonagota cranaodes, Borbo cinnara , rice leaf folder, Bucculatrix thurberiella , cotton leafperforator, Caloptilia spp., Capua reticulana, Carposina niponensis , peach fruit moth, Chilo spp., Chlumetia transversa , mango shoot borer, Choristoneura rosaceana , oblique banded leaf roller, Chrysodeixis spp., Cnaphalocerus medinalis , grass leafroller, Colias spp., Conpomorpha cramerella, Cossus cossus, Crambus spp., Sod webworms, Cydia funebrana , plum fruit moth, Cydia molesta , oriental fruit moth, Cydia nignicana , pea moth, Cydia pomonella , codling moth, Darna diducta, Diaphania spp., stem borer, Diatraea spp., stalk borer, Diatraea saccharalis , sugarcane borer, Diatraea graniosella , southwester corn borer, Earias spp., Earias insulata , Egyptian bollworm, Earias vitella , rough northern bollworm, Ecdytopopha aurantianum, Elasmopalpus lignosellus , lesser cornstalk borer, Epiphysias postruttana , light brown, apple moth, Ephestia spp., Ephestia cautella , almond moth, Ephestia elutella , tobbaco moth, Ephestia kuehniella, Mediterranean flour moth, Epimeces spp, Epinotia aporema, Erionota thrax , banana skipper, Eupoecilia ambiguella , grape berry moth, Euxoa auxiliaris , army cutworm, Feltia spp., Gortyna spp., Grapholita molesta , oriental fruit moth, Hedylepta indicata , bean leaf webber, Helicoverpa spp., Helicoverpa armigera , cotton bollworm, Helicoverpa zea, Heliothis spp., Heliothis virescens , tobacco budworm, Hellula undalis , cabbage webworm, Indarbela spp. Keiferia lycopersicella , tomato pinworm, Leucinodes orbonalis , eggplant fruit borer, Leucoptera malifoliella, Lithocollectis spp., Lobesia botrana , grape fruit moth, Loxagrotis spp., Loxagrotis albicosta , western bean cutworm, Lymantria dispar , gypsy moth, Lyonetiaclerkella , apple leafminer, Mahasena corbetti , oil palm bagworm, Malacosoma spp., tent caterpillars, Mamestra brassicae , cabbage armyworm, Maruca testulalis, Metisa plana, Mythimna unipuncta , true armyworm, Neoleucinodes elegantalis , small tomato borer, Nymphula depunctalis , rice caseworm, Operophthera brumata , winter moth, Ostrinia nubilalis , European corn borer, Oxydia vesulia, Pandemis cerasana , common currant tortrix, Pandemis heparana , brown apple tortrix, Papilio demodocus, Pectinophora gossypiella , pink bollworm, Peridroma spp., Peridroma saucia , variegated cutworm, Perileucoptera coffeella , white coffee leafminer, Phthorimaea operculella , potato tuber moth, Phyllocnisitis citrella, Phyllonorycter spp., Pieris rapae , imported cabbageworm, Plathypena scabra, Plodia interpunctella , Indian meal moth, Plutella xylostella , diamondback moth, Polychrosis viteana , grape berry moth, Prays endocarps, Prsys oleae , olive moth, Pseudaletia spp., Pseudaletia unipunctata, Pseudoplusia includens , soybean looper, Rachiplusia nu, Scirpophaga incertulas, Sesamia spp., Sesamia inferens , pink rice stemborer, Sesamia nonagrioides, Setora nitens, Sitotroga cerealella , Angoumois grain moth, Sparganothis pilleriana, Spodoptera spp., Spodoptera exigua , beet armyworm, Spodoptera fugiperda , fall armyworm, Spodoptera oridania , southern armyworm, Synanthedon spp., Thecla basilides, Thermisia gemmatalis, Tineola bisselliella , webbing clothes moth, Trichoplusia ni , cabbage looper, Tuts absoluta, Yponomeuta spp., Zeuzeracoffeae , red branch borer and Zeuzera pyrina , eopard moth.
[0669] Mallophaga, chewing lice, such as Bovicola ovis , sheep biting louse, Menacanthus stramineus , chicken body louse and Menopon gallinea , common hen house,
[0670] Orthoptera, such as Anabrus simplex, Mormon cricket, Gryllotalpidae, mole cricket, Locusta migratoria, Melanoplus spp., Microcentrum retinerve , angular winged katydid, Pterophylla spp., histocerca gregaria, Scudderia furcata , fork tailed bush katydid and Valanga nigricorni , sucking louse, such as Haematopinus spp., Linognathus ovillus , sheep louse, Pediculus humanus capitis, Pediculus humanus humanus and Pthirus pubis , crab louse.
[0671] Siphonaptera, such as Ctenocephalides canis , dog flea, Ctenocephalides felis , cat flea and Pulex irritanshuman flea.
[0672] Thysanoptera, such as Frankliniella fusca , tobacco thrip, Frankliniella occidentalis , western flower thrips, Frankliniella shultzei, Frankliniella williamsi , corn thrip, Heliothrips haemorrhaidalis , greenhouse thrip, Riphiphorothrips cruentatus, Scirtothrips spp, Scirtothrips cirri , citrus thrip, Scirtothrips dorsalis , yellow tea thrips, Taeniothrips rhopalantennalis and Thrips spp.
[0673] Thysanura, bristletail, such as Lepisma spp, silverfish and Thermobia spp.
[0674] Acarina, mite and tick, such as Acarapsis woodi , tracheal mite of honeybee, Acarus spp., Acarus siro , grain mite, Aceria mangiferae , mango bud mite, Aculops spp., Aculops lycopersici , tomato russet mite, Aculops pelekasi, Aculus pelekassi, Aculus schlechtendali , apple rust mite, Amblyomma amcricanum , lone star tick, Boophilus spp., Brevipalpus obovatus , privet mite, Brevipalpus phoenicis , red and black flat mite, Demodex spp., mange mites, Dermacentor spp., Dermacentor variabilis , american dog tick, Dermatophagoides pteronyssinus , house dust mite, Eotetranycus spp., Eotetranychus carpini , yellow spider mite, Epitimerus spp., Eriophyes spp., Iodes spp., Metatetranycus spp., Notoedres cati, Oligonychus spp., Oligonychus coffee, Oligonychus ilicus , southernred mite, anonychus spp., Panonychus cirri , citrus red mite, Panonychus ulmi , European red mite, Phyllocoptruta oleivora , citrus rust mite, Polyphagotarsonemun latus , broad mite, Rhipicephalus sanguineus , brown dog tick, Rhizoglyphus spp., bulb mite, Sarcoptes scabiei , itch mite, Tegolophus perseaflorae, Tetranychus spp., Tetranychus urticae , twospotted spider mite and Varroa destructor.
[0675] Nematoda, such as Aphelenchoides spp., bud and leaf & pine wood nematode, Belonolaimus spp., sting nematodes, Criconemella spp., ring nematodes, Dirofilaria immitis , dog heartworm, Ditylenchus spp., Heterodera spp., cyst nematode, Heterodera zeae , corn cyst nematode, Hirschmanniella spp., root nematodes, Hoplolaimus spp., lance nematodes, Meloidogyne spp., Meloidogyne incognita, Onchocerca volvulus , hook-tail worm, PraLylenchus spp., lesion nematode, Radopholus spp., burrowing nematode and Rotylenchus reniformis , kidney-shaped nematode.
[0676] Symphyla, such as Scutigerella immaculata.
[0677] Especially, the compound represented by the present invention provides great control effects against peach aphid, diamondback moth, armyworm, and carmine spider mite, and acquires great effects at a minimal dosage.
[0678] Due to their positive characteristics, the compounds mentioned above can be advantageously used in protecting crops of farming and gardening, domestic and breeding animals, as well as environments frequented by human beings, from pathogens, insects and pest mites.
[0679] In order to obtain desired effect, the dosage of the compound to be applied can vary with various factors, for example, the used compound, the protected crop, the type of harmful organism, the degree of infestation, the climatic conditions, the application method and the adopted formulation.
[0680] The dosage of compounds in the range of 10 g to 5 kg per hectare can provide a sufficient control.
[0681] A further object of the present invention also includes fungicidal, insecticidal/acaricidal compositions containing the compounds having general formula PY as active ingredient, and the weight percentage of the active ingredient in the composition is 0.1-99%. The fungicidal, insecticidal/acaricidal compositions also include the carrier being acceptable in agriculture, forestry, public health.
[0682] Especially, a preferred object of the present invention also includes fungicidal, insecticidal/acaricidal compositions containing the compounds and its salts/complexes having general formula I, II or III as active ingredient, wherein the weight percentage of the active ingredient in the composition is 0.1-99%.
[0683] The compositions of the present invention can be used in the form of various formulations. Usually, the compounds having general formula PY as active ingredient can be dissolved in or dispersed in carriers or made to a formulation so that they can be easily dispersed as an fungicide or insecticide. For example: these chemical formulations can be made into wettable powder, oil miscible flowable, aqueous suspension, aqueous emulsion, aqueous solution or emulsifiable concentrates. Therefore, in these compositions, at least a liquid or solid carrier is added, and usually suitable surfactant(s) can be added when needed.
[0684] Still also provided by the present invention are the application methods for controlling phytopathogenic fungi, insects, pest mites: which is to apply the compositions of the present invention to the phytopathogenic fungi, insects, pest mites as mentioned above or their growing loci. The suitable effective dosage of the compounds of the present invention is usually within a range of 10 g/ha to 1000 g/ha, preferably from 20 g/ha to 500 g/ha. For some applications, one or more other fungicides, insecticides/acaricides, herbicides, plant growth regulators or fertilizer can be added into the fungicidal, insecticidal/acaricidal compositions of the present invention to make additional merits and effects.
[0685] It should be noted that variations and changes are permitted within the claimed scopes in the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0686] The present invention is illustrated by the following examples, but without being restricted thereby. (All raw materials are commercially available unless otherwise specified.)
PREPARATION EXAMPLES
Example 1
The preparation of intermediate 4,5-dichloro-6-methylpyrimidine
1) The preparation of 4-hydroxyl-5-chloro-6-methylpyrimidine
[0687]
[0688] 8.80 g (0.16 mol) of CH 3 ONa in methanol was added slowly to a solution of 11.30 g (0.11 mol) of formimidamide in 50 mL of methanol at room temperature under stirring, the mixture was stirred for another 2 hrs after addition at room temperature. Followed by addition of 11.17 g (0.068 mol) of ethyl 2-chloro-3-oxobutanoate, the mixture was continued stirring for another 5-7 hrs at room temperature. After the reaction was over by Thin-Layer Chromatography monitoring, the reaction mixture was concentrated under reduced pressure and pH was adjusted to 5-6 with HCl, and then filtered to afford orange-yellow solid, the water phase was extracted with ethyl acetate (3×50 mL), dried over anhydrous magnesium sulfate, filtered and then concentrated under reduced pressure. The residue was dissolved to 50 ml of ethyl acetate, stand overnight to obtain 6.48 g as orange-yellow solid with yield of 66%. m.p. 181˜184° C.
2) The preparation of intermediate 4,5-dichloro-6-methylpyrimidine
[0689]
[0690] 50 ml of POCl 3 was added dropwise to a solution of 14.5 g (0.1 mol) of 4-hydroxyl-5-chloro-6-methylpyrimidine in 50 mL of toluene, the mixture was refluxed for 5-7 hrs after addition. After the reaction was over by Thin-Layer Chromatography monitoring, the reaction mixture was concentrated under reduced pressure to remove toluene and extra POCl 3 , and then poured into ice water. The water phase was extracted with ethyl acetate (3×50 mL), the organic phases were emerged, dried over anhydrous magnesium sulfate, filtered and then concentrated under reduced pressure. The residue was purified through silica column to give 14.43 g as yellow liquid with yield of 88.5%.
Example 2
The preparation of intermediate 4,5-dichloro-6-(difluoromethyl)pyrimidine
1) The preparation of 2-dichloro-4,4-difluoro-3-oxobutanoate
[0691]
[0692] 177.46 g (1.33 mol) of sulfonyl chloride in 200 mL dichloromethane was added slowly to a solution of 200.00 g (1.20 mol) of ethyl 4,4-difluoro-3-oxobutanoate in 300 mL of dichloromethane at room temperature under stirring for 3 hrs, then a lot of gas released out after addition. the mixture was continued stirring for another 5-7 hrs at room temperature. After the reaction was over by Thin-Layer Chromatography monitoring, the excess solvent and sulfonyl chloride were concentrated under reduced pressure to obtain 240 g as faint yellow liquid.
2) The preparation of 4-hydroxyl-5-chloro-6-(difluoromethyl)pyrimidine
[0693]
[0694] A solution of 71.9 g (0.70 mol) of formimidamide in 150 mL of methanol was stirred at 5-10° C., 64.6 g (1.20 mol) of CH 3 ONa in methanol prepared and cooled to room temperature ahead of time was added slowly to the above solution under stirring, followed by addition of 100 g (0.50 mol) of ethyl 2-chloro-4,4-difluoro-3-oxobutanoate in 100 ml of methanol, the mixture was continued stirring for another 3-4 hrs at room temperature. After the reaction was over by Thin-Layer Chromatography monitoring, the reaction mixture was concentrated under reduced pressure and pH was adjusted to 5-6 with HCl, and then filtered to afford 65 g as white solid with yield of 73%. m.p. 204-206° C.
3) The preparation of 4,5-dichloro-6-(difluoromethyl)pyrimidine
[0695]
[0696] 100 ml of POCl 3 was added dropwise to a solution of 65.0 g (0.36 mol) of 4-hydroxyl-5-chloro-6-(difluoromethyl)pyrimidin in 150 mL of toluene, the mixture was refluxed for 3-5 hrs after addition. After the reaction was over by Thin-Layer Chromatography monitoring, the reaction mixture was concentrated and er reduced pressure to remove toluene and extra POCl 3 , and then poured into ice water. The water phase was extracted with ethyl acetate (3×50 mL), the organic phases were emerged, washed with saturated sodium bicarbonate, dried over anhydrous magnesium sulfate, filtered and then concentrated under reduced pressure. The residue was purified through silica column to give 64.5 g as yellow liquid, cooled to be solid in refrigerator with yield of 90%.
Example 3
The preparation of 2-(4-(5-(trifluoromethyl)pyridin-2-yloxy)phenyl)ethanamine
1) The preparation of 2-(4-(5-(trifluoromethyl)pyridin-2-yloxy)phenyl)acetonitrile
[0697]
[0698] To a solution of 2-chloro-5-(trifluoromethyl)pyridine 18.15 g (0.1 mol) and 2-(4-hydroxyphenyl)acetonitrile 15.96 g (0.12 mol) in 200 mL butanone was added potassium carbonate 27.60 g (0.2 mol). The reaction mixture was continued stirring and heating to reflux for 4-10 hrs, and monitored by TLC (Thin-Layer Chromatography) until the reaction was over, the excessive solvent was evaporated under reduced pressure. Then the mixture was poured into 200 mL of ethyl acetate to separate the organic layer, the organic phase was washed with 50 mL of 5% aqueous solution of NaOH, and 50 mL of brine successively, dried and evaporated under reduced pressure, the residual was purified via silica column (ethyl acetate/petroleum ether (boiling point range 60-90° C.)=1:5, as an eluent) to obtain 22.50 g target intermediate as white solid with yield of 81.5%, m.p. 48-490.
2) The preparation of 2-(4-(5-(trifluoromethyl)pyridin-2-yloxy)phenyl)ethanamine
[0699]
[0700] To a solution of 2-(4-(5-(trifluoromethyl)pyridin-2-yloxy)phenyl)acetonitrile 2.78 g (0.01 mol), Raney nickel (1.0 g) and 10 mL of 25% aqueous ammonia in 50 mL ethanol was filled with hydrogen, then the reaction mixture was continued stirring at room temperature for 3-15 hrs and monitored by TLC until the reaction was over, Raney nickel was filtered, the solution was concentrated under reduced pressure to give sticky oil cooled to obtain 2.20 g target intermediate as white solid with yield of 78%, m.p. 82-83° C.
Example 4
The preparation of 4-(2-(5-chloro-6-methylpyrimidin-4-ylamino)ethyl)phenol
[0701]
[0702] To a solution of 4-(2-aminoethyl)phenol 1.13 g (0.01 mol) and triethylamine 2.02 g (0.02 mol) in 50 mL toluene was dropwise added 4,5-dichloro-6-methylpyrimidine 1.63 g (0.01 mol). The reaction mixture was continued stirring for 4-10 hrs, and monitored by TLC (Thin-Layer Chromatography) until the reaction was over, the excessive solvent was evaporated under reduced pressure. then the mixture was poured into (3×50 mL) of ethyl acetate to separate the organic layer, the organic phase was washed with 50 mL of brine, dried and evaporated under reduced pressure, the residual was purified via silica column (ethyl acetate/petroleum ether (boiling point range 60-90° C.)=1:3, as an eluent) to obtain 2.10 g target intermediate as white solid with yield of 88%, m.p. 177-179° C.
Example 5
The preparation of intermediate 2-(4-(3,5,6-trichloropyridin-2-yloxy)phenyl)ethanamine
1) tert-butyl 4-hydroxyphenethylcarbamate
[0703]
[0704] To a solution of 4-(2-aminoethyl)phenol 11.3 g (0.1 mol) and sodium bicarbonate 10.08 g (0.12 mol) in 80 mL tetrahydrofuran was dropwise added di-tert-butyl dicarbonate 21.80 g (0.1 mol) at room temperature, then the reaction mixture was continued stirring for 4-10 hrs, and monitored by TLC (Thin-Layer Chromatography) until the reaction was over, the excessive solvent was evaporated under reduced pressure. Then the mixture was poured into (3×50 mL) of ethyl acetate to separate the organic layer, the organic phase was washed with 50 mL of brine, dried and evaporated under reduced pressure, the residual was purified via silica column (ethyl acetate/petroleum ether (boiling point range 60-90° C.)=1:4, as an eluent) to obtain 17.15 g target intermediate as white solid with yield of 81%, m.p. 48-49° C.
2) The preparation of tert-butyl 4-(3,5,6-trichloropyridin-2-yloxy)phenethylcarbamate
[0705]
[0706] To a solution of tert-butyl 4-hydroxyphenethylcarbamate 2.37 g (0.01 mol) and 2,3,5,6-tetrachloropyridine 2.17 g (0.01 mol) in 50 mL butanone was added potassium carbonate 2.76 g (0.02 mol). The reaction mixture was continued stirring and heating to reflux for 4-10 hrs, and monitored by TLC (Thin-Layer Chromatography) until the reaction was over, the excessive solvent was evaporated under reduced pressure. then the mixture was poured into (3×50 mL) of ethyl acetate to separate the organic layer, the organic phase was washed with 50 mL of brine, dried and evaporated under reduced pressure, the residual was purified via silica column (ethyl acetate/petroleum ether (boiling point range 60-90° C.)=1:5, as an eluent) to obtain 3.55 g target intermediate as white solid with yield of 82%, m.p. 48-49° C.
3) The preparation of 2-(4-(3,5,6-trichloropyridin-2-yloxy)phenyl)ethanamine hydrochloride
[0707]
[0708] To a solution of tert-butyl 4-(3,5,6-trichloropyridin-2-yloxy)phenethylcarbamate 4.17 g (0.01 mol) in 50 mL ethyl acetate was dropwise added 15 mL concentrated hydrochloric acid. The reaction mixture was Gradually dissolved and continued stirring for 4-5 hrs, then a large amount of solid was precipitated and filtered, the filter cake was washed with 50 mL ethyl acetate to obtain 3.0 g target intermediate as white solid with yield of 88%, m.p. 48-49° C.
Example 6
The Preparation of Compound I-22
[0709]
[0710] To a solution of 4,5-dichloro-6-methylpyrimidine 1.63 g (0.01 mol) and 2-(4-(5-(trifluoromethyl)pyridin-2-yloxy)phenyl)ethanamine 2.82 g (0.01 mol) in 50 mL toluene was added triethylamine 2.02 g (0.02 mol) after the reaction mixture was dissolved. The reaction mixture was continued stirring and heating to reflux for 4-10 hours, and monitored by TLC (Thin-Layer Chromatography) until the reaction was over, the excessive solvent was evaporated under reduced pressure. then the mixture was poured into (3×50 mL) of ethyl acetate to separate the organic layer, the organic phase was washed with 50 mL of brine, dried and evaporated under reduced pressure, the residual was purified via silica column (ethyl acetate/petroleum ether (boiling point range 60-90° C.)=1:3, as an eluent) to obtain 3.25 g compound I-22 as white solid with yield of 80%, m.p. 98-99° C.
[0711] 1 H-NMR (300 MHz, internal standard TMS, solvent CDCl 3 ) δ(ppm): 2.46 (3H, s), 2.97 (2H, t), 3.79 (2H, q), 5.47 (1H, t), 7.01 (1H, d), 7.12 (2H, d), 7.29 (2H, d), 7.90 (1H, d), 8.40 (1H, d), 8.44 (1H, s).
Example 7
The Preparation of Compound I-254
[0712]
[0713] To a solution of 1.77 g (0.01 mol) 4,5-dichloro-6-ethylpyrimidine (the preparation refers to Example 1, the difference is replacing ethyl 2-chloro-3-oxobutanoate to ethyl 2-chloro-3-oxopentanoate) and 2-(4-(5-(trifluoromethyl)pyridin-2-yloxy)phenyl)ethanamine 2.82 g (0.01 mol) in 50 mL toluene was added triethylamine 2.02 g (0.02 mol). The reaction mixture was heated to reflux for 4-10 hours, and monitored by TLC (Thin-Layer Chromatography) until the reaction was over, the excessive solvent was evaporated under reduced pressure. then the mixture was poured into (3×50 mL) of ethyl acetate to separate the organic layer, the organic phase was washed with 50 mL of brine, dried and evaporated under reduced pressure, the residual was purified via silica column (ethyl acetate/petroleum ether (boiling point range 60-90° C.)=1:3, as an eluent) to obtain 3.56 g compound I-254 as white solid with yield of 83%, m.p. 76˜78° C.
[0714] 1 H-NMR (300 MHz, internal standard TMS, solvent CDCl 3 ) δ(ppm): 1.26 (3H, t), 2.79 (2H, q), 2.77 (4H, m), 2.97 (2H, t), 3.79 (2H, q), 5.51 (1H, t), 7.00 (1H, d), 7.11 (2H, d), 7.29 (2H, d), 7.89 (1H, d), 8.44 (2H, m).
Example 8
The Preparation of Compound I-483
[0715]
[0716] To a solution of 4-(2-(5-chloro-6-methylpyrimidin-4-ylamino)ethyl)phenol 2.64 g (0.01 mol) and 2-(4-(5-(trifluoromethyl)pyridin-2-yloxy)phenyl)ethanamine 2.33 g (0.01 mol) in 30 mL N,N-dimethyl formamide was added potassium carbonate 2.76 g (0.02 mol). The reaction mixture was heated to reflux for 4-10 hours, and monitored by TLC (Thin-Layer Chromatography) until the reaction was over, the excessive solvent was evaporated under reduced pressure. then the mixture was poured into (3×50 mL) of ethyl acetate to separate the organic layer, the organic phase was washed with 50 mL of brine, dried and evaporated under reduced pressure, the residual was purified via silica column (ethyl acetate/petroleum ether (boiling point range 60-90° C.)=1:4, as an eluent) to obtain 3.77 g compound I-483 as colorless oil with yield of 82%.
[0717] 1 H-NMR (300 MHz, internal standard TMS, solvent CDCl 3 ) δ(ppm): 2.45 (3H, s), 2.96 (2H, t), 3.72-3.84 (2H, q), 5.45 (1H, t), 7.13 (2H, d), 7.29 (2H, d), 7.99 (1H, d), 8.27 (1H, s), 8.40 (1H, s).
Example 9
The Preparation of Compound I-583
[0718]
[0719] To a solution of 2.78 g (0.01 mol) 4-(2-(5-chloro-6-ethylpyrimidin-4-ylamino)ethyl)phenol (the preparation refers to Example 3, the difference is replacing 4,5-dichloro-6-methylpyrimidine to 4,5-dichloro-6-ethylpyrimidine) and 2,3,5-trichloropyridine 1.83 g (0.01 mol) in 30 mL N,N-dimethyl formamide was added potassium carbonate 2.76 g (0.02 mol). The reaction mixture was heated to reflux for 4-10 hours, and monitored by TLC (Thin-Layer Chromatography) until the reaction was over, the excessive solvent was evaporated under reduced pressure. then the mixture was poured into (3×50 mL) of ethyl acetate to separate the organic layer, the organic phase was washed with 50 mL of brine, dried and evaporated under reduced pressure, the residual was purified via silica column (ethyl acetate/petroleum ether (boiling point range 60-90° C.)=1:3, as an eluent) to obtain 3.50 g compound I-583 as colorless oil with yield of 83%, m.p. 53-54° C.
[0720] 1 H-NMR (300 MHz, internal standard TMS, solvent CDCl 3 ) δ(ppm): 1.26 (3H, t), 2.79 (2H, q), 2.96 (2H, q), 3.77 (2H, q), 5.47 (1H, t), 7.11 (2H, d), 7.28 (2H, d), 7.77 (1H, s), 8.45 (1H, s).
Example 10
The Preparation of Compound I-2342
[0721]
[0722] To a solution of 4,5-dichloro-6-(difluoromethyl)pyrimidine 1.99 g (0.01 mol) and 2-(4-(5-(trifluoromethyl)pyridin-2-yloxy)phenyl)ethanamine 2.82 g (0.01 mol) in 50 mL toluene was added triethylamine 2.02 g (0.02 mol) after the reaction mixture was dissolved. The reaction mixture was continued stirring and heating to reflux for 4-10 hours, and monitored by TLC (Thin-Layer Chromatography) until the reaction was over, the excessive solvent was evaporated under reduced pressure. then the mixture was poured into (3×50 mL) of ethyl acetate to separate the organic layer, the organic phase was washed with 50 mL of brine, dried and evaporated under reduced pressure, the residual was purified via silica column (ethyl acetate/petroleum ether (boiling point range 60-90° C.)=1:4, as an eluent) to obtain 3.82 g compound I-2342 as white solid with yield of 86%, m.p. 102-103° C.
[0723] 1 H-NMR (300 MHz, internal standard TMS, solvent CDCl 3 ) δ(ppm): 8.581 (s, 1H, pyrimidine-H), 8.439 (s, 1H, pyridine-6-H), 7.891-7.927 (d, 1H, pyridine-4-H), 7.008-7.037 (d, 1H, pyridine-3-H), 7.111-7.310 (dd, 4H, Ar—H), 6.547-6.904 (t, 1H, F 2 C—H, 5.747 (s, 1H, NH), 3.815-3.882 (q, 2H, N—CH 2 —C), 2.964-3.010 (t, 2H, C—CH 2 —Ar).
Example 11
The Preparation of Compound I-2574
[0724]
[0725] To a solution of 1.99 g (0.01 mol) 4,5-dichloro-6-(difluoromethyl)pyrimidine and 2.82 g (0.01 mol) 2-(4-(5-(trifluoromethyl)pyridin-2-yloxy)phenyl)ethanamine (the preparation refers to Example 3) in 50 mL toluene was added triethylamine 2.02 g (0.02 mol) after the reaction mixture was dissolved. The reaction mixture was heated to reflux for 4-10 hours, and monitored by TLC (Thin-Layer Chromatography) until the reaction was over, the excessive solvent was evaporated under reduced pressure. then the mixture was poured into (3×50 mL) of ethyl acetate to separate the organic layer, the organic phase was washed with 50 mL of brine, dried and evaporated under reduced pressure, the residual was purified via silica column (ethyl acetate/petroleum ether (boiling point range 60-90° C.)=1:4, as an eluent) to obtain 4.16 g compound I-2574 as white solid with yield of 84%.
[0726] 1 H-NMR (300 MHz, internal standard TMS, solvent CDCl 3 ) δ(ppm): δ 8.577 (s, 1H, pyrimidine-H), 8.270 (s, 1H, pyridine-6-H), 7.981-7.987 (d, 1H, pyridine-4-H), 7.128-7.319 (dd, 4H, Ar—H), 6.716 (t, 1H, F 2 C—H), 3.843-3.864 (q, 2H, N—CH 2 —C), 2.970-3.016 (t, 2H, C—CH 2 —Ar).
Example 12
The Preparation of Compound I-2748
[0727]
[0728] To a solution of 2.17 g (0.01 mol) 4,5-dichloro-6-(trifluoromethyl)pyrimidine (the preparation refers to Example 1) and 3.19 g (0.01 mol) 2-(4-(5-(trifluoromethyl)pyridin-2-yloxy)phenyl)ethanamine in 50 mL toluene was added triethylamine 2.02 g (0.02 mol). The reaction mixture was heated to reflux for 4-10 hours, and monitored by TLC (Thin-Layer Chromatography) until the reaction was over, the excessive solvent was evaporated under reduced pressure. then the mixture was poured into (3×50 mL) of ethyl acetate to separate the organic layer, the organic phase was washed with 50 mL of brine, dried and evaporated under reduced pressure, the residual was purified via silica column (ethyl acetate/petroleum ether (boiling point range 60-90° C.)=1:4, as an eluent) to obtain 4.07 g compound I-2748 as white solid with yield of 88%, m.p. 96-97° C.
[0729] 1 H-NMR (300 MHz, internal standard TMS, solvent CDCl 3 ) δ(ppm): 8.577 (s, 1H, pyrimidine-H), 8.436 (s, 1H, pyridine-6-H), 7.892-7.920 (d, 1H, pyridine-4-H), 7.010-7.039 (d, 1H, pyridine-3-H), 7.115-7.313 (dd, 4H, Ar—H), 5.898 (s, 1H, NH), 3.825-3.890 (q, 2H, N—CH 2 —C), 2.966-3.014 (t, 2H, C—CH 2 —Ar).
Example 13
The Preparation of Compound I-3309
[0730]
[0731] To a solution of 1.77 g (0.01 mol) 4,5-dichloro-6-ethylpyrimidine and 2.50 g (0.01 mol) 2-(4-(6-chloropyridazin-3-yloxy)phenyl)ethanamine (the preparation refers to Example 3, the difference is replacing 2-chloro-5-(trifluoromethyl)pyridine to 3,6-dichloropyridazine) in 50 mL toluene was added 2.02 g (0.02 mol)triethylamine after the reaction mixture was dissolved. The reaction mixture was heated to reflux for 4-10 hours, and monitored by TLC (Thin-Layer Chromatography) until the reaction was over, the excessive solvent was evaporated under reduced pressure. then the mixture was poured into (3×50 mL) of ethyl acetate to separate the organic layer, the organic phase was washed with 50 mL of brine, dried and evaporated under reduced pressure, the residual was purified via silica column (ethyl acetate/petroleum ether (boiling point range 60-90° C.)=1:3, as an eluent) to obtain 3.40 g compound I-3309 as white solid with yield of 87%, m.p. 138-140° C.
[0732] 1 H-NMR (300 MHz, internal standard TMS, solvent CDCl 3 ) δ(ppm): 1.25 (3H, t), 2.79 (2H, q), 2.96 (2H, t), 3.78 (2H, q), 5.50 (1H, s), 7.16 (3H, m), 7.26 (2H, m), 7.50 (1H, d), 8.45 (1H, s).
Example 14
The Preparation of Compound I-4757
[0733]
[0734] To a solution of 1.63 g (0.01 mol) 4,5-dichloro-6-methylpyrimidine and 2.75 g (0.01 mol) 2-(4-(4,6-dimethoxypyrimidin-2-yloxy)phenyl)ethanamine (the preparation refers to Example 3, the difference is replacing 2-chloro-5-(trifluoromethyl)pyridine to 4,6-dimethoxy-2-(methylsulfonyl)pyrimidine) in 50 mL toluene was added 2.02 g (0.02 mol)triethylamine after the reaction mixture was dissolved. The reaction mixture was heated to reflux for 4-10 hours, and monitored by TLC (Thin-Layer Chromatography) until the reaction was over, the excessive solvent was evaporated under reduced pressure. then the mixture was poured into (3×50 mL) of ethyl acetate to separate the organic layer, the organic phase was washed with 50 mL of brine, dried and evaporated under reduced pressure, the residual was purified via silica column (ethyl acetate/petroleum ether (boiling point range 60-90° C.)=1:4, as an eluent) to obtain 3.24 g compound I-4757 as white solid with yield of 81%, m.p. 119-120° C.
[0735] 1 H-NMR (300 MHz, internal standard TMS, solvent CDCl 3 ) δ(ppm): 2.46 (3H, s), 2.95 (2H, t), 3.82 (2H, m), 3.84 (6H, s), 5.43 (1H, s), 5.78 (1H, s), 7.26 (4H, m), 8.40 (1H, s).
Example 15
The Preparation of Compound I-6730
[0736]
[0737] To a solution of compound I-22 0.41 g (0.01 mol) in 20 mL ethanol was dropwise added 10 mL of concentrated hydrochloric acid at room temperature, The reaction mixture was heated to reflux for 4-10 hours, and monitored by TLC (Thin-Layer Chromatography) until the reaction was over, the excessive solvent was evaporated under reduced pressure. the brown residue was washed with (3×50 mL) of acetone to obtain 0.33 g compound I-6730 as white solid with yield of 75%, m.p. 108-110° C.
[0738] 1 H-NMR (300 MHz, internal standard TMS, solvent CDCl 3 ) δ(ppm): 2.49 (3H, s), 2.88 (2H, t), 3.64 (2H, m), 7.08 (2H, d), 7.17 (1H, d), 7.35 (2H, d), 7.37 (1H, m), 8.16 (1H, d), 8.25 (1H, s), 8.50 (1H, s).
Example 16
The preparation of 2-(4-(2-chloro-4-(trifluoromethyl)phenoxy)phenyl)ethanamine
1) The preparation of 2-(4-(2-chloro-4-(trifluoromethyl)phenoxy)phenyl)acetonitrile
[0739]
[0740] To a solution of 150 mL N,N-dimethyl formamide was added 1,2-dichloro-4-(trifluoromethyl)benzene 25.8 g (0.12 mol), 2-(4-hydroxyphenyl)acetonitrile 13.3 g (0.1 mol) and potassium carbonate 27.60 g (0.2 mol). The reaction mixture was continued stirring and heating to reflux overnight, and monitored by TLC (Thin-Layer Chromatography) until the reaction was over, the excessive solvent was evaporated under reduced pressure. Then the mixture was poured into 300 mL of ethyl acetate to separate the organic layer, the organic phase was washed with 50 mL of 5% aqueous solution of NaOH, and 50 mL of brine successively, dried and evaporated under reduced pressure, the residual was purified via silica column (ethyl acetate/petroleum ether (boiling point range 60-90° C.)=1:4, as an eluent) to obtain 14.55 g target intermediate as white solid with yield of 46.2%, m.p. 66.2° C.
2) The preparation of 2-(4-(2-chloro-4-(trifluoromethyl)phenoxy)phenyl)ethanamine hydrochloride
[0741]
[0742] To a solution of 2-(4-(2-chloro-4-(trifluoromethyl)phenoxy)phenyl)acetonitrile 3.12 g (0.01 mol), Raney nickel (1.0 g) and 10 mL of 25% aqueous ammonia in 50 mL ethanol was filled with hydrogen at high pressure, then the reaction mixture was continued stirring at room temperature for 3 hours and monitored by TLC until the reaction was over, Raney nickel was filtered, the solution was concentrated under reduced pressure to give sticky liquid. To a solution of the residue was dropwise added 5 mL of concentrated hydrochloric acid and stirred for half an hour at room temperature until target intermediate precipitated, filtered to obtain 3.45 g white solid with yield of 97.9%, m.p. 155.7° C.
Example 17
The preparation of 2-(4-(2,6-dichloro-4-nitrophenoxy)phenyl)ethanamine hydrochloride
1) The preparation of tert-butyl 4-(2,6-dichloro-4-nitrophenoxy)phenethylcarbamate
[0743]
[0744] To a solution of tert-butyl 4-hydroxyphenethylcarbamate 2.10 g (0.01 mol) and 1,3-dichloro-2-fluoro-5-nitrobenzene 2.33 g (0.01 mol) in 50 mL butanone was added potassium carbonate 2.76 g (0.02 mol). The reaction mixture was continued stirring and heating to reflux for 4-10 hours, and monitored by TLC (Thin-Layer Chromatography) until the reaction was over, the excessive solvent was evaporated under reduced pressure. then the mixture was poured into (3×50 mL) of ethyl acetate to separate the organic layer, the organic phase was washed with 50 mL of brine, dried and evaporated under reduced pressure, the residual was purified via silica column (ethyl acetate/petroleum ether (boiling point range 60-90° C.)=1:4, as an eluent) to obtain 3.73 g target intermediate as white solid with yield of 87.3%, m.p. 149-151° C.
2) The preparation of 2-(4-(2,6-dichloro-4-nitrophenoxy)phenyl)ethanamine
[0745]
[0746] To a solution of tert-butyl 4-(2,6-dichloro-4-nitrophenoxy)phenethylcarbamate 4.27 g (0.01 mol) in 50 mL ethyl acetate was dropwise added 6 mL trifluoroacetic acid until the solid was dissolved at room temperature for 4-5 hours, and monitored by TLC (Thin-Layer Chromatography) until the reaction was over, the excessive solvent was evaporated under reduced pressure. then the mixture was poured into (3×50 mL) of ethyl acetate to separate the organic layer, the organic phase was washed with 50 mL of brine, dried and evaporated under reduced pressure to give 3.03 g target intermediate as white solid with yield of 92.8%, m.p. 107-109° C.
Example 18
The preparation of 2-(4-(4-(trifluoromethyl)phenoxy)phenyl)ethanamine
1) The preparation of tert-butyl 4-(4-(trifluoromethyl)phenoxy)phenethylcarbamate
[0747]
[0748] To a solution of 4-(trifluoromethyl)phenylboronic acid 4.56 g (0.024 mol) in 50 mL dichloromethane was added 4 Å molecular sieve powder, Cupric Acetate Anhydrous 3.82 g (0.021 mol), triethylamine 10.1 g (0.1 mol), and pyridine 7.9 g (0.1 mol) successively; The reaction mixture was continued to react overnight, and monitored by TLC (Thin-Layer Chromatography) until the reaction was over, filtered and the excessive solvent was evaporated under reduced pressure. then the mixture was poured into (3×50 mL) of ethyl acetate to separate the organic layer, the organic phase was washed with 50 mL of brine, dried and evaporated under reduced pressure, the residual was purified via silica column (ethyl acetate/petroleum ether (boiling point range 60-90° C.)=1:4, as an eluent) to obtain 5.95 g target intermediate as white solid with yield of 65.1%.
2) The preparation of 2-(4-(4-(trifluoromethyl)phenoxy)phenyl)ethanamine hydrochloride
[0749]
[0750] To a solution of tert-butyl 4-(4-(trifluoromethyl)phenoxy)phenethylcarbamate 3.81 g (0.01 mol) in 50 mL ethyl acetate was dropwise added 12 mL concentrated hydrochloric acid. The reaction mixture was continued to stir for 4-5 hours, and monitored by TLC (Thin-Layer Chromatography) until the reaction was over, the excessive solvent was evaporated under reduced pressure. then the mixture was poured into (3×50 mL) of ethyl acetate to react for half an hour and filtered to give 2.92 g target intermediate as white solid with yield of 91.9%.
Example 19
The Preparation of Compound II-69
[0751]
[0752] To a solution of 1.63 g (0.01 mol) 4,5-dichloro-6-methylpyrimidine and 3.18 g (0.01 mol) 2-(4-(4-(trifluoromethyl)phenoxy)phenyl)ethanamine hydrochloride in 50 mL toluene was added 4.45 g (0.022 mol)triethylamine. The reaction mixture was continued stirring and heating to reflux for 4-10 hours, and monitored by TLC (Thin-Layer Chromatography) until the reaction was over, the excessive solvent was evaporated under reduced pressure. then the mixture was poured into (3×50 mL) of ethyl acetate to separate the organic layer, the organic phase was washed with 50 mL of brine, dried and evaporated under reduced pressure, the residual was purified via silica column (ethyl acetate/petroleum ether (boiling point range 60-90° C.)=1:2, as an eluent) to obtain 2.76 g compound II-69 as colourless oil with yield of 72.6%.
[0753] 1 H-NMR (300 MHz, internal standard TMS, solvent CDCl 3 ) δ(ppm): 2.46 (3H, s), 2.94 (2H, t), 3.77 (2H, q), 5.42 (1H, s), 702 (4H, m), 7.25 (2H, m), 7.56 (2H, d), 8.39 (1H, s).
Example 20
The Preparation of Compound II-165
[0754]
[0755] To a solution of 1.63 g (0.01 mol) 4,5-dichloro-6-methylpyrimidine and 3.26 g (0.01 mol) 2-(4-(2,6-dichloro-4-nitrophenoxy)phenyl)ethanamine in 50 mL toluene was added 4.45 g (0.022 mol)triethylamine. The reaction mixture was continued stirring and heating to reflux for 4-10 hours, and monitored by TLC (Thin-Layer Chromatography) until the reaction was over, the excessive solvent was evaporated under reduced pressure. Then the mixture was poured into (3×50 mL) of ethyl acetate to separate the organic layer, the organic phase was washed with 50 mL of brine, dried and evaporated under reduced pressure, the residual was purified via silica column (ethyl acetate/petroleum ether (boiling point range 60-90° C.)=1:2, as an eluent) to obtain 3.23 g compound II-165 as rufous solid with yield of 71.2%, m.p. 118-120° C.
[0756] 1 H-NMR (300 MHz, internal standard TMS, solvent CDCl 3 ) δ(ppm): 2.45 (3H, s), 2.91 (2H, t), 3.70-3.85 (2H, q), 5.42 (1H, t), 6.80 (2H, d), 7.18 (2H, d), 8.31 (2H, s), 8.38 (1H, s).
Example 21
The Preparation of Compound II-297
[0757]
[0758] To a solution of 1.77 g (0.01 mol) 4,5-dichloro-6-ethylpyrimidine (the preparation refers to Example 1, the difference is replacing ethyl 2-chloro-3-oxobutanoate to ethyl 2-chloro-3-oxopentanoate) and 2.84 g (0.01 mol) 2-(4-(4-chlorophenoxyl)phenyl)ethanamine hydrochloride (the preparation refers to Example 18, the difference is replacing 4-(trifluoromethyl)phenylboronic acid to 4-chlorophenylboronic acid) in 50 mL toluene was added 4.45 g (0.022 mol)triethylamine. The reaction mixture was continued stirring and heating to reflux for 4-10 hours, and monitored by TLC (Thin-Layer Chromatography) until the reaction was over, the excessive solvent was evaporated under reduced pressure. then the mixture was poured into (3×50 mL) of ethyl acetate to separate the organic layer, the organic phase was washed with 50 mL of brine, dried and evaporated under reduced pressure, the residual was purified via silica column (ethyl acetate/petroleum ether (boiling point range 60-90° C.)=1:2, as an eluent) to obtain 3.16 g compound II-297 as rufous solid with yield of 81.6%, m.p. 84.7° C.
[0759] 1 H-NMR (300 MHz, internal standard TMS, solvent CDCl 3 ) δ(ppm): 1.26 (3H, t), 2.78 (2H, dd), 2.92 (2H, t), 3.75 (2H, dd), 5.45 (1H, t), 6.84-7.00 (4H, m), 7.20 (2H, d), 7.29 (2H, d), 8.44 (1H, s).
Example 22
The Preparation of Compound II-303
[0760]
[0761] To a solution of 1.77 g (0.01 mol) 4,5-dichloro-6-ethylpyrimidine and 3.19 g (0.01 mol) 2-(4-(3,5-dichlorophenoxyl)phenyl)ethanamine hydrochloride (the preparation refers to Example 18, the difference is replacing 4-(trifluoromethyl)phenylboronic acid to 3,5-dichlorophenylboronic acid) in 50 mL toluene was added 4.45 g (0.022 mol)triethylamine. The reaction mixture was continued stirring and heating to reflux for 4-10 hours, and monitored by TLC (Thin-Layer Chromatography) until the reaction was over, the excessive solvent was evaporated under reduced pressure. then the mixture was poured into (3×50 mL) of ethyl acetate to separate the organic layer, the organic phase was washed with 50 mL of brine, dried and evaporated under reduced pressure, the residual was purified via silica column (ethyl acetate/petroleum ether (boiling point range 60-90° C.)=1:2, as an eluent) to obtain 3.17 g compound II-303 as pale rufous oil with yield of 75.1%.
[0762] 1 H-NMR (300 MHz, internal standard TMS, solvent CDCl 3 ) δ(ppm): 1.26 (3H, t), 2.78 (2H, dd), 2.95 (2H, t), 3.72-3.84 (2H, q), 5.45 (1H, t), 6.85 (2H, d), 7.00 (2H, d), 7.25 (2H, d), 8.45 (1H, s).
Example 23
The Preparation of Compound II-347
[0763]
[0764] To a solution of 1.77 g (0.01 mol) 4,5-dichloro-6-ethylpyrimidine and 3.18 g (0.01 mol) 2-(4-(4-(trifluoromethyl)phenoxy)phenyl)ethanamine hydrochloride in 50 mL toluene was added 4.45 g (0.022 mol)triethylamine. The reaction mixture was continued stirring and heating to reflux for 4-10 hours, and monitored by TLC (Thin-Layer Chromatography) until the reaction was over, the excessive solvent was evaporated under reduced pressure. then the mixture was poured into (3×50 mL) of ethyl acetate to separate the organic layer, the organic phase was washed with 50 mL of brine, dried and evaporated under reduced pressure, the residual was purified via silica column (ethyl acetate/petroleum ether (boiling point range 60-90° C.)=1:2, as an eluent) to obtain 3.15 g compound II-347 as white solid with yield of 74.8%, m.p. 52.6° C.
[0765] 1 H-NMR (300 MHz, internal standard TMS, solvent CDCl 3 ) δ(ppm): 1.27 (3H, t), 2.78 (2H, q), 2.95 (2H, t), 3.78 (2H, q), 5.42 (1H, s), 7.01 (4H, m), 7.24 (2H, m), 7.58 (2H, d), 8.45 (1H, s).
Example 24
The Preparation of Compound II-8915
[0766]
[0767] To a solution of 1.98 g (0.01 mol) 4,5-dichloro-6-(difluoromethyl)pyrimidine (the preparation refers to Example 1, the difference is replacing ethyl 2-chloro-3-oxobutanoate to ethyl 2-chloro-4,4-difluoro-3-oxobutanoate) and 2.84 g (0.01 mol) 2-(4-(4-chlorophenoxyl)phenyl)ethanamine hydrochloride in 50 mL toluene was added 4.45 g (0.022 mol)triethylamine. The reaction mixture was continued stirring and heating to reflux for 4-10 hours, and monitored by TLC (Thin-Layer Chromatography) until the reaction was over, the excessive solvent was evaporated under reduced pressure. then the mixture was poured into (3×50 mL) of ethyl acetate to separate the organic layer, the organic phase was washed with 50 mL of brine, dried and evaporated under reduced pressure, the residual was purified via silica column (ethyl acetate/petroleum ether (boiling point range 60-90° C.)=1:2, as an eluent) to obtain 2.89 g compound II-8915 as white solid with yield of 70.5%, m.p. 98.5° C.
[0768] 1 H-NMR (300 MHz, internal standard TMS, solvent CDCl 3 ) δ(ppm): 2.94 (2H, t), 3.76-3.86 (2H, q), 5.71 (1H, s), 6.72 (1H, t), 6.90-7.05 (4H, m), 7.17-7.32 (4H, m), 8.57 (1H, s).
Example 25
The Preparation of Compound II-10583
[0769]
[0770] m), To a solution of 1.98 g (0.01 mol) 4,5-dichloro-6-(difluoromethyl)pyrimidine (the preparation refers to Example 1, the difference is replacing ethyl 2-chloro-3-oxobutanoate to ethyl 2-chloro-4,4-difluoro-3-oxobutanoate) and 3.14 g (0.01 mol) 2-(4-(4-chlorophenoxy)-3-methoxyphenyl)ethanamine hydrochloride in 50 mL toluene was added 4.45 g (0.022 mol)triethylamine. The reaction mixture was continued stirring and heating to reflux for 4-10 hours, and monitored by TLC (Thin-Layer Chromatography) until the reaction was over, the excessive solvent was evaporated under reduced pressure. then the mixture was poured into (3×50 mL) of ethyl acetate to separate the organic layer, the organic phase was washed with 50 mL of brine, dried and evaporated under reduced pressure, the residual was purified via silica column (ethyl acetate/petroleum ether (boiling point range 60-90° C.)=1:2, as an eluent) to obtain 2.89 g compound II-10583 as rufous oil with yield of 76.8%.
[0771] 1 H-NMR (300 MHz, internal standard TMS, solvent CDCl 3 ) δ(ppm): 2.95 (2H, t), 3.80-3.92 (5H, m), 5.72 (1H, s), 6.72 (1H, t), 6.75-6.97 (5H, m), 7.20-7.26 (2H, m), 8.58 (1H, s).
Example 26
The Preparation of Compound II-19334
[0772]
[0773] To a solution of compound II-347 0.42 g (0.01 mol) in 20 mL ethanol was dropwise added 10 mL of concentrated hydrochloric acid at room temperature. The reaction mixture was heated to reflux for 4-10 hours, and monitored by TLC (Thin-Layer Chromatography) until the reaction was over, the excessive solvent was evaporated under reduced pressure. the brown residue was washed with (3×10 mL) of ethyl acetate to obtain 0.36 g compound II-19334 as white solid with yield of 78.1%, m.p. 120.5° C.
[0774] 1 H-NMR (300 MHz, internal standard TMS, solvent CDCl 3 ) δ(ppm): 1.27 (3H, t), 2.80-3.09 (4H, m), 3.80 (2H, d), 6.92-7.18 (4H, d), 7.31 (2H, d), 7.67 (2H, d), 8.71 (1H, d), 9.28 (1H, s).
Example 27
The preparation of 2-(6-(4-chlorophenoxyl)pyridin-3-yl)ethanamine
1) The preparation of methyl 6-(4-chlorophenoxyl)nicotinate
[0775]
[0776] To a solution of 25.6 g (0.2 mol) 4-chlorophenol in 350 mL N,N-dimethylformamide was added 70% sodium hydride 103 g (3.0 mol) in batches. The reaction mixture was stirred for 4 hours at room temperature, then 34.2 g (0.2 mol) methyl 6-chloronicotinate was added in batches, then the reaction temperature was raised to 100° C. to react for 10 hours, and monitored by TLC (Thin-Layer Chromatography) until the reaction was over, the solution was poured into water, extracted with ethyl acetate, the organic phase was washed with water, saturated brine successively, dried, filtered and evaporated under reduced pressure, the cooled residual was filtered and washed with petroleum ether, to obtain 42.0 g air dried target intermediate as brown solid, m.p. 64-66° C. 1 H-NMR (300 MHz, internal standard TMS, solvent CDCl 3 ) δ(ppm): 3.92 (3H, s), 6.75 (1H, d), 6.96 (1H, d), 7.11 (2H, d), 7.37 (2H, d), 8.30 (1H, d), 8.81 (1H, s).
2) The preparation of (6-(4-chlorophenoxyl)pyridin-3-yl)methanol
[0777]
[0778] To a solution of 52.6 g (0.2 mol) methyl 6-(4-chlorophenoxyl)nicotinate in 500 mL anhydrous ether was dropwise added 65% Red-Al 74.5 g (0.24 mol) in toluene at 0. then the reaction mixture was stirred for 4 hours at room temperature, then at 0.10% sodium hydroxide solution prepared beforehand was dropwise added until the reaction solution was clarified, then the reaction temperature was raised to 35 to react for 2 hours, and monitored by TLC (Thin-Layer Chromatography) until the reaction was over, the solution was poured into water, extracted with ethyl acetate, the organic phase was washed with water, saturated brine successively, dried, filtered and evaporated under reduced pressure, the residual was purified via silica column (ethyl acetate/petroleum ether (boiling point range 60-90° C.)=1:3, as an eluent) to obtain 42.2 g target intermediate as white solid, m.p. 100-102° C. 1 H-NMR (300 MHz, internal standard TMS, solvent CDCl 3 ) δ(ppm): 3.20 (1H, bs), 4.56 (2H, s), 6.87 (1H, d), 7.04 (2H, d), 7.33 (2H, d), 7.69 (1H, d), 8.06 (1H, s).
3) The preparation of 5-(chloromethyl)-2-(4-chlorophenoxyl)pyridine
[0779]
[0780] To a solution of 23.5 g (0.1 mol) (6-(4-chlorophenoxyl)pyridin-3-yl)methanol in 350 mL dichloromethane was dropwise added 17.9 g (0.15 mol) sulfoxide chloride at 0° C. then the reaction mixture was stirred for 4 hours at room temperature, and monitored by TLC (Thin-Layer Chromatography) until the reaction was over, the excessive sulfoxide chloride was evaporated and the residual was poured into water, extracted with ethyl acetate, the organic phase was washed with water, saturated sodium bicarbonate solution, and saturated brine successively, dried, filtered and evaporated under reduced pressure, to obtain 22.8 g target intermediate as white solid, m.p. 78-80° C. 1 H-NMR (300 MHz, internal standard TMS, solvent CDCl 3 ) δ(ppm): 4.55 (2H, s), 6.94 (1H, d), 7.09 (2H, d), 7.36 (2H, d), 7.75 (1H, d), 8.15 (1H, s).
4) The preparation of 2-(6-(4-chlorophenoxyl)pyridin-3-yl)acetonitrile
[0781]
[0782] To a solution of 2.69 g (55 mmol) sodium cyanide dissolved in 300 mL dimethyl sulfoxide was added 13.9 g (50 mmol) 5-(chloromethyl)-2-(4-chlorophenoxyl)pyridine and the catalytic amount of 18-Crown-6 at 40° C. then the reaction mixture was raised to 80° C. to react for 2 hours, and monitored by TLC (Thin-Layer Chromatography) until the reaction was over, the residual was poured into water, extracted with toluene, the organic phase was washed with water, and saturated brine successively, dried, filtered and evaporated under reduced pressure, the residual was purified via silica column (ethyl acetate/petroleum ether (boiling point range 60-90° C.)=1:3, as an eluent) to obtain 11.2 g target intermediate as white solid, m.p. 100-102° C. 1 H-NMR (300 MHz, internal standard TMS, solvent CDCl 3 ) δ(ppm): 3.70 (2H, s), 6.97 (1H, d), 7.08 (2H, d), 7.37 (2H, d), 7.71 (1H, d), 8.10 (1H, s).
5) The preparation of 2-(6-(4-chlorophenoxy)pyridin-3-yl)ethanamine
[0783]
[0784] To a solution of 2-(6-(4-chlorophenoxyl)pyridin-3-yl)acetonitrile 2.44 g (0.01 mol), Raney nickel (1.0 g) and 10 mL of 25% aqueous ammonia in 50 mL ethanol was filled with hydrogen, then the reaction mixture was continued stirring at room temperature for 3-15 hours and monitored by TLC until the reaction was over, Raney nickel was filtered, the solution was concentrated under reduced pressure to give 2.30 g jade-green sticky liquid with yield of 95.0%, colourless oil. 1 H-NMR (300 MHz, internal standard TMS, solvent CDCl 3 ) δ(ppm): 1.46 (2H, bs), 2.70 (2H, t), 2.94 (2H, t), 6.87 (1H, d), 7.07 (2H, dd), 7.34 (2H, dd), 7.55 (1H, dd), 8.02 (1H, d).
Example 28
The Preparation of Compound III-7
[0785]
[0786] To a solution of 0.25 g (1.0 mmol) 2-(6-(4-chlorophenoxyl)pyridin-3-yl)ethanamine and 0.21 g (1.5 mmol) potassium carbonate in 10 mL N, N-dimethylformamide was added 0.16 g (1.0 mmol) 4,5-dichloro-6-methylpyrimidine. then the reaction mixture was raised to 80° C. to react for 2 hours, and monitored by TLC (Thin-Layer Chromatography) until the reaction was over, the residual was poured into water, extracted with ethyl acetate, the organic phase was washed with water, and saturated brine successively, dried, filtered and evaporated under reduced pressure, the residual was purified via silica column (ethyl acetate/petroleum ether (boiling point range 60-90° C.)=1:4, as an eluent) to obtain 0.28 g compound III-7 as colourless oil. 1 H-NMR (300 MHz, internal standard TMS, solvent CDCl 3 ) δ(ppm): 2.46 (3H, t), 2.91 (2H, t), 3.75 (2H, m), 5.43 (1H, bs), 6.89 (1H, d), 7.07 (2H, d), 7.35 (2H, d), 7.58 (1H, dd), 8.03 (1H, d), 8.39 (1H, s).
Example 29
The Preparation of Compound III-202
[0787]
[0788] To a solution of 0.28 g (1.0 mmol) 2-(6-(4-(trifluoromethyl)phenoxy)pyridin-3-yl)ethanamine (the preparation refers to Example 27, the difference is replacing 4-chlorophenol to 4-(trifluoromethyl)phenol) and 0.21 g (1.5 mmol) potassium carbonate in 10 mL N,N-dimethylformamide was added 0.18 g (1.0 mmol) 4,5-dichloro-6-ethylpyrimidine (the preparation refers to Example 1, the difference is replacing ethyl 2-chloro-3-oxobutanoate to ethyl 2-chloro-3-oxopentanoate). then the reaction mixture was raised to 80° C. to react for 2 hours, and monitored by TLC (Thin-Layer Chromatography) until the reaction was over, the residual was poured into water, extracted with ethyl acetate, the organic phase was washed with water, and saturated brine successively, dried, filtered and evaporated under reduced pressure, the residual was purified via silica column (ethyl acetate/petroleum ether (boiling point range 60-90° C.)=1:4, as an eluent) to obtain 0.30 g compound III-202 as colourless oil. 1 H-NMR (300 MHz, internal standard TMS, solvent CDCl 3 ) δ(ppm): 1.28 (3H, t), 2.78 (2H, m), 2.93 (2H, t), 3.76 (2H, m), 5.43 (1H, bs), 6.96 (1H, d), 7.20-7.23 (2H, m), 7.61-7.66 (3H, m), 8.06 (1H, d), 8.44 (1H, s).
Example 30
The Preparation of Compound III-622
[0789]
[0790] To a solution of 0.28 g (1.0 mmol) 2-(6-(2,4-dichlorophenoxyl)pyridin-3-yl)ethanamine (the preparation refers to Example 27, the difference is replacing 4-chlorophenol to 2,4-dichlorophenol) and 0.21 g (1.5 mmol) potassium carbonate in 10 mL N,N-dimethylformamide was added 4,5-dichloro-6-(difluoromethyl)pyrimidine 0.20 g (1.0 mmol). then the reaction mixture was raised to 80° C. to react for 2 hours, and monitored by TLC (Thin-Layer Chromatography) until the reaction was over, the residual was poured into water, extracted with ethyl acetate, the organic phase was washed with water, and saturated brine successively, dried, filtered and evaporated under reduced pressure, the residual was purified via silica column (ethyl acetate/petroleum ether (boiling point range 60-90° C.)=1:4, as an eluent) to obtain 0.32 g compound III-622 as colourless oil. 1 H-NMR (300 MHz, internal standard TMS, solvent CDCl 3 ) δ(ppm): 2.92 (2H, t), 3.80 (2H, m), 5.72 (1H, bs), 6.54, 6.72, 6.90 (1H, t), 6.89 (1H, s), 6.98 (1H, d), 7.14 (1H, d), 7.27-7.31 (2H, m), 7.48 (1H, d), 7.61 (1H, dd), 7.98 (1H, d), 8.56 (1H, s).
Example 31
The Preparation of Compound III-2630
[0791]
[0792] To a solution of 0.26 g (1.0 mmol) 2-(6-(4-chloro-2-methylphenoxy)pyridin-3-yl)ethanamine (the preparation refers to Example 27, the difference is replacing 4-chlorophenol to 4-chloro-2-methylphenol) and 0.21 g (1.5 mmol) potassium carbonate in 10 mL N,N-dimethylformamide was added 0.18 g (1.0 mmol) 4,5,6-trichloropyrimidine (the preparation refers to Example 1, the difference is replacing ethyl 2-chloro-3-oxobutanoate to diethyl 2-chloromalonate). then the reaction mixture was raised to 80° C. to react for 2 hours, and monitored by TLC (Thin-Layer Chromatography) until the reaction was over, the residual was poured into water, extracted with ethyl acetate, the organic phase was washed with water, and saturated brine successively, dried, filtered and evaporated under reduced pressure, the residual was purified via silica column (ethyl acetate/petroleum ether (boiling point range 60-90° C.)=1:4, as an eluent) to obtain 0.32 g compound III-2630 as colourless oil. 1 H-NMR (300 MHz, internal standard TMS, solvent CDCl 3 ) δ(ppm): 2.15 (3H, s), 2.89 (2H, t), 3.73-3.79 (2H, m), 5.62 (1H, bs), 6.87 (1H, d), 6.98 (1H, d), 7.18-7.22 (2H, m), 7.54 (1H, dd), 8.00 (1H, d), 8.29 (1H, s).
[0793] Other compounds represented by the general formula PY of the present invention were prepared according to the above examples.
[0794] Physical properties and 1 HNMR spectrum ( 1 HNMR, 300 MHz, internal standard: TMS, ppm) of some compounds of this invention are as follows:
[0795] Compound I-23: m.p. 147.5° C. δppm 2.46 (3H, s), 2.97 (2H, t), 3.78 (2H, q), 5.42 (1H, m), 7.01 (1H, d), 7.10 (2H, d), 7.30 (2H, d), 7.92 (1H, d), 8.40 (1H, s), 8.47 (1H, s).
[0796] Compound I-34: m.p. 109.0° C. δppm 2.46 (3H, s), 2.96 (2H, t), 3.79 (2H, q), 3.92 (3H, s), 5.43 (1H, m), 6.94 (1H, d), 7.12 (2H, d), 7.28 (2H, d), 8.28 (1H, d), 8.40 (1H, s), 8.82 (1H, s).
[0797] Compound I-35: yellow oil. δppm 1.38 (3H, t), 2.46 (3H, s), 2.96 (2H, t), 3.79 (2H, q), 4.38 (2H, q), 5.43 (1H, m), 6.93 (1H, d), 7.12 (2H, d), 7.28 (2H, d), 8.28 (1H, d), 8.40 (1H, s), 8.83 (1H, s).
[0798] Compound I-80: δppm 2.47 (3H, s), 2.95 (2H, t), 3.79 (2H, q), 5.55 (1H, m), 7.09 (1H, d), 7.18 (2H, m), 7.37 (1H, s), 7.93 (1H, m), 8.41 (2H, m).
[0799] Compound I-196: δppm 2.46 (3H, t), 2.96 (2H, t), 3.75 (3H, s), 3.80 (2H, dd), 5.49 (1H, t), 6.87 (2H, s), 7.02 (1H, d), 7.09 (1H, d), 7.88 (1H, d), 8.41 (2H, s).
[0800] Compound I-255: yellow oil. δppm 1.27 (3H, t), 2.79 (2H, q), 2.97 (2H, t), 3.80 (2H, q), 5.48 (1H, m), 7.02 (1H, d), 7.10 (2H, d), 7.30 (2H, d), 7.92 (1H, d), 8.46 (1H, s), 8.47 (1H, s).
[0801] Compound I-266: m.p. 102.2° C. δppm 1.26 (3H, t), 2.79 (2H, q), 2.97 (2H, t), 3.79 (2H, q), 3.92 (3H, s), 5.44 (1H, m), 6.94 (1H, d), 7.12 (2H, d), 8.29 (2H, d), 8.27 (1H, d), 8.45 (1H, s), 8.82 (1H, s).
[0802] Compound I-267: yellow oil. δppm 1.26 (3H, t), 1.38 (3H, t), 2.79 (2H, t), 2.98 (2H, t), 3.79 (2H, q), 4.38 (2H, q), 5.43 (1H, m), 6.93 (1H, d), 7.12 (2H, d), 7.29 (2H, d), 8.27 (1H, d), 8.45 (1H, s), 8.83 (1H, s).
[0803] Compound I-312: δppm 1.27 (3H, t), 2.80 (3H, q), 2.96 (2H, t), 3.80 (2H, q), 5.51 (1H, m), 7.09 (1H, d), 7.18 (2H, m), 7.37 (1H, s), 7.93 (1H, m), 8.40 (1H, s), 8.46 (1H, s).
[0804] Compound I-428: δppm 1.26 (3H, t), 2.79 (2H, dd), 2.96 (2H, t), 3.75 (3H, s), 3.81 (2H, dd), 5.50 (1H, t), 6.87 (2H, d), 7.02 (1H, d), 7.10 (1H, d), 7.88 (1H, s), 8.40 (1H, s), 8.45 (1H, s).
[0805] Compound I-467: m.p. 102-103° C. δppm 2.46 (3H, s), 2.96 (2H, t), 3.78 (2H, q), 5.43 (1H, s), 7.11 (2H, d), 7.27 (2H, d), 7.78 (1H, s), 7.97 (1H, s), 8.40 (1H, s).
[0806] Compound I-486: m.p. 92-93° C. δppm 2.47 (3H, s), 2.98 (2H, t), 3.80 (2H, q), 5.44 (1H, s), 7.13 (2H, d), 7.30 (2H, d), 7.98 (1H, s), 8.28 (1H, s), 8.41 (1H, s).
[0807] Compound I-502: m.p. 128.5° C. δppm 2.49 (3H, s), 2.89 (2H, t), 3.63 (2H, q), 5.34 (1H, m), 7.06 (2H, d), 7.28 (2H, d), 7.72 (2H, s), 8.24 (1H, s), 8.38 (1H, s), 8.46 (1H, s).
[0808] Compound I-602: colourless oil. Δppm 2.88 (2H, t), 4.06 (2H, q), 5.49 (s, 1H), 7.21 (4H, m,), 8.28 (1H, d), 8.28 (1H, s), 68.450 (1H, s).
[0809] Compound I-618: m.p. 168.9° C. δppm 1.26 (3H, t), 2.79 (2H, q), 2.97 (2H, t), 3.80 (2H, q), 5.47 (1H, m), 5.83 (2H, s), 7.13 (2H, d), 7.30 (2H, d), 8.28 (1H, s), 8.40 (1H, s), 8.44 (1H, s).
[0810] Compound I-699: m.p. 146-147° C. δppm 2.45 (3H, s), 2.96 (2H, t), 3.78 (2H, q), 5.45 (1H, s), 7.11 (2H, d), 7.28 (2H, d), 7.84 (1H, s), 8.41 (1H, s).
[0811] Compound I-815: m.p. 98-100° C. δppm 1.26 (3H, t), 2.79 (2H, q), 2.96 (2H, t), 3.79 (2H, q), 5.43 (1H, s), 7.11 (2H, d), 7.27 (2H, d), 7.84 (1H, s), 8.46 (1H, s).
[0812] Compound I-929: yellow oil. δppm 2.46 (3H, s), 2.96 (2H, t), 3.87 (2H, q), 5.47 (1H, m), 7.09 (1H, m), 7.14 (2H, d), 7.28 (2H, d), 7.98 (1H, d), 8.29 (1H, d), 8.40 (1H, s).
[0813] Compound I-987: yellow oil. δppm 1.26 (3H, t), 2.79 (2H, q), 2.96 (2H, t), 3.78 (2H, q), 5.46 (1H, m), 7.13 (1H, q), 7.15 (2H, d), 7.29 (2H, d), 8.00 (1H, d), 8.30 (1H, d), 8.45 (1H, s).
[0814] Compound I-1045: m.p. 80-83° C. δppm 1.39 (3H, t), 2.46 (3H, s), 2.94 (2H, t), 3.77 (2H, q), 5.47 (1H, s), 7.06 (1H, m), 7.12 (2H, d), 7.26 (2H, d), 8.27 (1H, m), 8.40 (1H, s).
[0815] Compound I-1199: m.p. 147-149° C. δppm 2.47 (3H, s), 2.97 (2H, t), 3.06 (3H, d), 3.62-3.79 (2H, q), 5.50 (1H, t), 7.12 (2H, d), 7.16 (1H, dd), 7.32 (2H, d), 7.86 (1H, s), 8.20 (1H, dd), 8.41 (1H, s), 8.64 (1H, dd).
[0816] Compound I-1219: m.p. 113-114° C. δppm 1.39 (3H, t), 2.79 (3H, s), 2.95 (2H, t), 3.78 (2H, q), 4.41 (2H, q), 5.49 (1H, t), 7.09 (3H, m), 7.27 (2H, m), 8.26 (2H, m), 8.45 (1H, s).
[0817] Compound I-1414: δppm 2.47 (3H, s), 2.96 (2H, t), 3.80 (2H, q), 5.46 (1H, m), 7.20 (2H, s), 7.37 (1H, s), 8.00 (1H, d), 8.24 (1H, d), 8.41 (1H, s).
[0818] Compound I-1472: δppm 1.27 (3H, t), 2.80 (2H, q), 2.97 (2H, t), 3.80 (2H, q), 5.47 (1H, m), 7.21 (2H, s), 7.37 (1H, s), 8.00 (1H, d), 8.25 (1H, d), 8.46 (1H, s).
[0819] Compound I-1646: δppm 2.46 (3H, t), 2.96 (2H, t), 3.74 (3H, s), 3.81 (2H, dd), 5.48 (1H, t), 6.89 (2H, t), 7.11 (1H, d), 7.96 (1H, d), 8.23 (1H, t), 8.41 (1H, s).
[0820] Compound I-1704: δppm 1.26 (3H, t), 2.79 (2H, dd), 2.96 (2H, t), 3.73 (3H, s), 3.79 (2H, dd), 5.48 (1H, t), 6.88 (2H, d), 7.12 (1H, d), 7.96 (1H, d), 8.23 (1H, s), 8.45 (1H, s).
[0821] Compound I-1762: δppm 2.50 (3H, s), 2.96 (2H, t), 3.78 (2H, q), 5.54 (1H, m), 7.01 (1H, d), 7.12 (1H, d), 7.30 (2H, d), 7.90 (1H, m), 8.41 (1H, s), 8.44 (1H, s).
[0822] Compound I-1820: δppm 1.26 (3H, t), 2.81 (3H, q), 2.97 (2H, t), 3.78 (2H, q), 5.55 (1H, m), 7.01 (1H, d), 7.11 (2H, d), 7.30 (2H, d), 7.90 (1H, m), 8.44 (1H, s).
[0823] Compound I-1878: δppm 2.50 (3H, s), 2.97 (2H, t), 3.79 (2H, q), 5.53 (1H, m), 7.14 (2H, d), 7.30 (3H, m), 7.99 (1H, s), 8.27 (1H, s), 8.40 (1H, s).
[0824] Compound I-1936: δppm 1.26 (3H, t), 2.81 (3H, q), 2.97 (2H, t), 3.79 (2H, q), 5.54 (1H, m), 7.13 (2H, d), 7.31 (2H, d), 7.98 (1H, m), 8.27 (1H, s), 8.44 (1H, s).
[0825] Compound I-2052: δppm 1.30 (3H, t), 2.83 (2H, q), 2.95 (2H, t), 3.79 (2H, q), 5.61 (1H, m), 7.09 (1H, d), 7.18 (2H, m), 7.33 (1H, s), 7.93 (1H, m), 8.43 (1H, d).
[0826] Compound I-2400: δppm 2.98 (3H, t), 3.85 (2H, q), 5.77 (1H, m), 6.73 (1H, m), 7.10 (1H, d), 7.19 (2H, m), 7.38 (1H, s), 7.94 (1H, m), 8.40 (1H, s), 8.59 (1H, s).
[0827] Compound I-2458: δppm 2.98 (2H, t), 3.75 (3H, s), 3.87 (2H, dd), 5.77 (1H, t), 6.72 (1H, t), 6.89 (2H, t), 7.03 (1H, d), 7.10 (1H, t), 7.88 (1H, dd), 8.40 (1H, s), 8.59 (1H, s).
[0828] Compound I-2555: brown oil. δppm 8.576 (s, 1H, pyrimidine-H), 7.965-7.972 (d, 1H, pyridine-6-H), 7.776-7.783 (d, 1H, pyridine-4-H), 7.128-7.294 (dd, 4H, Ar—H), 6.726-7.100 (t, 1H, F 2 C—H), 3.828-3.849 (q, 2H, N—CH 2 —C), 2.951-2.999 (t, 2H, C—CH 2 -Ar).
[0829] Compound I-2611: m.p. 156-157° C. δppm 8.583 (s, 1H, pyrimidine-H), 8.337-8.393 (m, 3H, pyridine-H), 7.164-7.322 (dd, 4H, Ar—H), 6.550-6.909 (t, 1H, F 2 C—H), 5.739 (s, 1H, NH), 3.816-3.883 (q, 2H, N—CH 2 —C), 2.968-3.015 (t, 2H, C—CH 2 —Ar).
[0830] Compound I-2690: δppm 2.98 (2H, t), 3.74 (3H, s), 3.86 (2H, dd), 5.76 (1H, t), 6.72 (1H, t), 6.88 (2H, d), 7.13 (1H, d), 7.96 (1H, d), 8.23 (1H, s), 8.58 (1H, s).
[0831] Compound I-2787: δppm 8.575 (s, 1H, pyrimidine-H), 7.965-7.972 (d, 1H, pyridine-6-H), 7.775-7.782 (d, 1H, pyridine-4-H), 7.105-7.295 (dd, 4H, Ar—H), 5.882 (s, 1H, NH), 3.815-3.881 (q, 2H, N—CH 2 —C), 2.955-3.001 (t, 2H, C—CH 2 —Ar).
[0832] Compound I-2843: m.p. 123-124° C. δppm 8.577 (s, 1H, pyrimidine-H), 8.336-8.394 (m, 3H, pyridine-H), 7.152-7.325 (dd, 4H, Ar—H), 5.917 (s, 1H, NH), 3.826-3.917 (q, 2H, N—CH 2 —C), 2.972-3.020 (t, 2H, C—CH 2 —Ar).
[0833] Compound I-3077: m.p. 130-132° C. δppm 2.46 (3H, s), 2.95 (2H, t), 3.77 (2H, q), 5.50 (1H, s), 7.16 (3H, m), 7.27 (2H, m), 7.48 (1H, d), 8.40 (1H, s).
[0834] Compound I-4121: δppm 2.50 (3H, s), 2.95 (2H, t), 3.77 (2H, q), 5.57 (1H, m), 7.16 (3H, m), 7.29 (2H, m), 7.49 (1H, d), 8.40 (1H, s).
[0835] Compound I-5221: m.p. 121-124° C. δppm 1.26 (3H, t), 2.78 (2H, q), 2.95 (2H, t), 3.78 (2H, m), 3.84 (6H, s), 5.44 (1H, s), 5.78 (1H, s), 7.20 (4H, m), 8.45 (1H, s).
[0836] Compound I-6729: m.p. 102.8° C. δppm 2.49 (3H, s), 2.88 (2H, t), 3.81 (2H, m), 7.11 (2H, d), 18 (1H, d), 7.30 (2H, d), 7.52 (1H, d), 8.17 (1H, d), 8.50 (1H, s), 8.78 (1H, s), 9.40 (1H, s).
[0837] Compound I-6731: m.p. 148.6° C. δppm 2.30 (3H, s), 2.49 (3H, s), 2.93 (2H, t), 3.81 (2H, m), 7.27-7.05 (8H, m), 7.29 (2H, d), 7.51 (1H, d), 8.14 (1H, d), 8.47 (1H, s), 8.77 (1H, s), 9.33 (1H, s).
[0838] Compound I-6732: m.p. 164.6° C. δppm 2.50 (3H, s), 2.94 (2H, t), 3.81 (2H, m), 7.09 (2H, d), 7.18 (1H, d), 7.30 (2H, d), 8.18 (1H, d), 8.50 (1H, s), 8.81 (1H, s), 9.28 (1H, s).
[0839] Compound I-6733: m.p. 113.7° C. δppm 2.35 (3H, s), 2.89 (2H, t), 3.64 (2H, m), 7.09 (2H, d), 7.16 (1H, d), 7.30 (2H, d), 7.37 (1H, m), 8.15 (1H, d), 8.19 (1H, s), 8.51 (1H, s).
[0840] Compound I-6734: m.p. 56.9° C. δppm 2.37 (3H, s), 2.90 (2H, t), 3.66 (2H, m), 7.09 (2H, d), 7.16 (1H, d), 7.29 (2H, d), 7.49 (1H, m), 8.16 (1H, d), 8.30 (1H, s), 8.50 (1H, s).
[0841] Compound I-6735: m.p.>300° C. δppm 2.35 (3H, s), 2.88 (2H, t), 3.62 (2H, m), 7.08 (2H, d), 7.15 (1H, d), 7.36 (1H, m), 8.15 (1H, d), 7.32 (2H, d), 8.20 (1H, s), 8.48 (1H, s).
[0842] Compound I-6790: δppm 1.23 (3H, t), 2.51 (3H, s), 2.74 (2H, q), 2.94 (2H, t), 3.77 (2H, q), 5.40 (1H, m), 7.11 (2H, d), 7.26 (2H, d), 7.84 (1H, s).
[0843] Compound I-6791: yellow oil. δppm 1.23 (3H, t), 2.50 (3H, s), 2.74 (2H, q), 2.96 (2H, t), 3.79 (2H, q), 5.39 (1H, m), 5.83 (2H, s), 7.13 (2H, d), 7.30 (2H, d), 8.26 (1H, s), 8.40 (1H, s).
[0844] Compound I-6793: m.p. 116.0° C. δppm 1.23 (3H, t), 2.51 (3H, s), 2.74 (2H, q), 2.94 (2H, t), 3.77 (2H, q), 5.40 (1H, m), 7.10 (1H, m), 7.14 (2H, d), 7.29 (2H, d), 8.00 (1H, d), 8.31 (1H, d).
[0845] Compound I-6795: yellow oil. δppm 1.24 (3H, t), 2.46 (3H, s), 2.74 (2H, q), 2.96 (2H, t), 3.78 (2H, q), 5.40 (1H, m), 7.01 (1H, d), 7.10 (2H, d), 7.30 (2H, d), 7.91 (1H, d), 8.47 (1H, s).
[0846] Compound I-6796: m.p. 90.8° C. δppm 1.23 (3H, t), 1.38 (3H, t), 2.51 (3H, s), 2.74 (2H, q), 2.95 (2H, t), 3.78 (2H, q), 4.38 (2H, q), 5.38 (1H, m), 6.93 (1H, d), 7.11 (2H, d), 7.29 (2H, d), 8.28 (1H, d), 8.83 (1H, s).
[0847] Compound I-6797: yellow oil. δppm 1.23 (3H, t), 2.49 (3H, s), 2.74 (2H, q), 2.95 (2H, t), 3.78 (2H, q), 3.92 (3H, s), 5.39 (1H, m), 6.93 (1H, d), 7.11 (2H, d), 7.29 (2H, d), 8.28 (1H, d), 8.82 (1H, s).
[0848] Compound I-6806: δppm 1.24 (3H, t), 2.51 (3H, s), 2.75 (2H, q), 2.94 (2H, t), 3.79 (2H, q), 5.40 (1H, m), 7.09 (1H, d), 7.17 (2H, m), 7.33 (1H, s), 7.93 (1H, m), 8.41 (1H, s).
[0849] Compound II-19: δppm 2.52 (3H, s), 2.92 (2H, t), 3.75 (2H, dd), 5.43 (1H, t), 6.81-7.01 (4H, m), 7.19 (2H, d), 7.28 (2H, d), 8.39 (1H, s).
[0850] Compound II-21: δppm 2.46 (3H, s), 2.92 (2H, t), 3.75 (2H, dd), 5.42 (1H, t), 6.89 (1H, d), 6.92 (2H, d), 7.15-7.22 (3H, m), 7.47 (1H, d), 8.39 (1H, s).
[0851] Compound II-25: δppm 2.45 (3H, s), 2.95 (2H, t), 3.70-3.83 (2H, q), 5.44 (1H, t), 6.84 (2H, d), 7.00 (2H, d), 7.06 (1H, s), 7.26 (2H, d), 8.40 (1H, s).
[0852] Compound II-53: m.p. 140-142° C. δppm 2.65 (3H, s), 3.13 (2H, t), 3.65-3.76 (2H, q), 6.93 (1H, d), 7.17 (2H, d), 7.35 (2H, d), 8.31 (1H, d), 8.47 (1H, s), 8.62 (1H, t), 9.14 (1H, d).
[0853] Compound II-154: δppm 2.46 (3H, s), 2.95 (2H, t), 3.77 (2H, dd), 5.42 (1H, t), 6.92 (1H, d), 7.00 (2H, d), 7.25 (2H, d), 7.43 (1H, d), 7.75 (1H, s), 8.39 (1H, s).
[0854] Compound II-204: δppm 2.47 (3H, s), 2.96 (2H, t), 3.77 (2H, dd), 5.43 (1H, t), 6.93 (1H, t), 7.02 (2H, d), 7.26 (2H, d), 7.37 (1H, dd), 7.48 (1H, dd), 8.40 (1H, s).
[0855] Compound II-235: m.p. 140-142° C. δppm 1.25 (3H, s), 2.45 (3H, s), 2.86 (2H, t), 3.72 (2H, q), 5.41 (1H, s), 6.79 (2H, d), 7.08 (2H, d), 8.39 (2H, m).
[0856] Compound II-236: δppm 2.25 (3H, s), 2.45 (3H, s), 2.90 (2H, t), 3.62-3.81 (2H, q), 5.43 (1H, t), 6.74 (2H, d), 7.14 (2H, d), 7.40 (1H, d), 7.77 (1H, d), 8.38 (1H, s).
[0857] Compound II-254: m.p. 183-185° C. δppm 2.45 (3H, s), 2.86 (2H, t), 3.66-3.83 (2H, q), 5.43 (1H, t), 6.80 (2H, d), 7.08 (2H, d), 8.39 (1H, s).
[0858] Compound II-274: m.p. 130-132° C. δppm 2.929-2.953 (t, 2H), 3.744-3.765 (q, 2H), 5.65 (s, 1H), 6.830-7.230 (dd, 4H), 8.392 (s, 1H).
[0859] Compound II-299: δppm 1.23 (3H, t), 2.78 (2H, dd), 2.92 (2H, t), 3.75 (2H, dd), 5.44 (1H, t), 6.85 (1H, d), 6.91 (2H, d), 7.17-7.23 (3H, m), 7.46 (1H, d), 8.44 (1H, s).
[0860] Compound II-432: δppm 1.26 (3H, t), 2.78 (2H, dd), 2.95 (2H, t), 3.77 (2H, dd), 5.44 (1H, t), 6.92 (1H, d), 7.00 (2H, d), 7.25 (2H, d), 7.42 (1H, d), 7.73 (1H, s), 8.44 (1H, s).
[0861] Compound II-443: m.p. 101.0° C. δppm 1.25 (3H, t), 2.77 (2H, dd), 2.92 (2H, t), 3.74 (2H, dd), 5.42 (1H, t), 6.79 (2H, d), 7.18 (2H, d), 8.32 (2H, s), 8.43 (1H, s).
[0862] Compound II-482: δppm 1.26 (3H, t), 2.78 (2H, dd), 2.98 (2H, t), 3.78 (2H, dd), 5.44 (1H, t), 6.93 (1H, t), 7.08 (2H, d), 7.27 (2H, d), 7.37 (1H, dd), 7.48 (1H, dd), 8.44 (1H, s).
[0863] Compound II-1687: δppm 2.46 (3H, s), 2.93 (2H, t), 3.75-3.96 (5H, m), 5.43 (1H, t), 6.77-6.87 (4H, m), 6.93 (1H, d), 7.23 (2H, d), 8.40 (1H, s).
[0864] Compound II-1737: δppm 2.47 (3H, s), 2.95 (2H, t), 3.75-3.91 (5H, m), 5.42 (1H, t), 6.80-7.04 (5H, m), 7.53 (2H, d), 8.41 (1H, s).
[0865] Compound II-1965: δppm 1.26 (3H, t), 2.79 (2H, dd), 2.95 (2H, t), 3.72-3.95 (5H, m), 5.45 (1H, t), 6.78-6.90 (4H, m), 6.94 (1H, d), 7.24 (2H, d), 8.45 (1H, s).
[0866] Compound II-2015: δppm 1.26 (3H, t), 2.79 (2H, dd), 2.95 (2H, t), 3.75-3.95 (5H, m), 5.48 (1H, t), 6.80-6.88 (2H, q), 6.93 (2H, d), 7.01 (1H, d), 7.53 (2H, d), 8.45 (1H, s).
[0867] Compound II-8917: m.p. 93.3° C. δppm 2.94 (2H, t), 3.81 (2H, dd), 5.70 (1H, t), 6.72 (1H, t), 6.90-6.97 (3H, q), 7.16-7.23 (3H, q), 7.47 (1H, d), 8.57 (1H, s).
[0868] Compound II-8921: m.p. 106-107° C. δppm 2.945-2.992 (2H, t), 3.797-3.864 (2H, q), 5.717 (1H, s), 6.549-6.848 (1H, t), 6.854-7.237 (7H, m), 8.583 (1H, s).
[0869] Compound II-8965: m.p. 109-110° C. δppm 2.944-2.990 (2H, t), 3.798-3.865 (2H, q), 5.717 (1H, s), 6.542-6.900 (1H, t), 7.010-7.588 (8H, m), 8.574 (1H, s).
[0870] Compound II-9058: δppm 2.938-2.984 (2H, t), 3.790-3.858 (2H, q), 6.545-6.903 (1H, t), 6.992-7.458 (4H, dd), 6.930-6.959 (1H, d), 7.478-7.487 (1H, d), 7.952-7.960 (1H, s), 8.571 (1H, s).
[0871] Compound II-9073: m.p. 77-78° C. δppm 2.970-3.016 (2H, t), 3.812-3.878 (2H, q), 5.738 (1H, s), 6.549-6.906 (1H, t), 7.061-7.319 (4H, dd), 7.005-7.035 (1H, d), 7.698-7.727 (1H, d), 8.233 (1H, s), 8.575 (1H, s).
[0872] Compound II-9170: m.p. 154-158° C. δppm 2.951-2.975 (2H, t), 3.800-3.821 (2H, q), 6.714-6.874 (1H, t), 6.844-7.233 (4H, dd), 8.569 (1H, s).
[0873] Compound II-9336: m.p. 130-131° C. δppm 2.942-2.989 (2H, t), 3.799-3.866 (2H, q), 6.994-7.459 (4H, dd), 6.936-6.965 (1H, d), 7.480-7.488 (1H, d), 7.593-7.961 (1H, d), 8.571 (1H, s).
[0874] Compound II-9351: m.p. 128-129° C. δppm 2.975-3.021 (2H, t), 3.820-3.887 (2H, q), 5.875 (1H, s), 7.066-7.322 (4H, dd), 7.009-7.039 (1H, d), 7.704-7.731 (1H, d), 8.238 (1H, s), 8.580 (1H, s).
[0875] Compound II-10633: δppm 2.98 (2H, t), 3.79 (3H, t), 3.86 (2H, dd) 5.74 (1H, s), 6.72 (1H, t), 6.84-7.05 (5H, m), 7.53 (2H, d), 8.58 (1H, s).
[0876] Compound III-1: colourless oil. δppm 2.50 (3H, s), 2.88 (2H, t), 3.74 (2H, m), 5.45 (1H, bs), 6.87 (1H, d), 7.09-7.22 (3H, m), 7.36-7.42 (2H, m), 7.56 (1H, dd), 8.05 (1H, d), 8.38 (1H, s).
[0877] Compound III-5: colourless oil.
[0878] Compound III-6: colourless oil. δppm 2.46 (3H, s), 2.92 (2H, t), 3.75 (2H, m), 5.42 (1H, bs), 6.90 (1H, d), 7.03 (1H, dd), 7.13-7.18 (2H, m), 7.29 (1H, d), 7.59 (1H, dd), 8.05 (1H, d), 8.39 (1H, s).
[0879] Compound III-16: colourless oil. δppm 2.35 (3H, s), 2.52 (3H, s), 2.88 (2H, t), 3.70-3.77 (2H, m), 5.42 (1H, bs), 6.85 (1H, d), 7.01 (2H, d), 7.19 (2H, d), 7.53 (1H, dd), 8.03 (1H, d), 8.38 (1H, s).
[0880] Compound III-19: colourless oil. δppm 2.46 (3H, s), 2.89 (2H, t), 3.70-3.77 (2H, m), 3.82 (3H, s), 5.42 (1H, bs), 6.83 (1H, d), 6.92 (2H, d), 7.06 (2H, d), 7.53 (1H, dd), 8.03 (1H, d), 8.38 (1H, s).
[0881] Compound III-21: colourless oil.
[0882] Compound III-22: colourless oil. δppm 2.46 (3H, t), 2.93 (2H, t), 3.76 (2H, m), 5.43 (1H, bs), 6.95 (1H, d), 7.20-7.28 (2H, m), 7.60-7.66 (3H, m), 8.06 (1H, d), 8.39 (1H, s).
[0883] Compound III-82: colourless oil. δppm 2.46 (3H, s), 2.90 (2H, t), 3.74 (2H, m), 5.42 (1H, bs), 6.97 (1H, d), 7.14 (1H, d), 7.28 (1H, d), 7.49 (1H, d), 7.62 (1H, dd), 7.97 (1H, d), 8.38 (1H, s).
[0884] Compound III-83: colourless oil. δppm 2.46 (3H, s), 2.91 (2H, t), 3.75 (2H, m), 5.42 (1H, bs), 6.97 (1H, d), 7.16 (1H, dd), 7.22 (1H, d), 7.40 (1H, d), 7.61 (1H, dd), 7.99 (1H, d), 8.39 (1H, s).
[0885] Compound III-110: colourless oil. δppm 2.14 (3H, t), 2.46 (3H, t), 2.89 (2H, t), 3.73 (2H, m), 5.42 (1H, bs), 6.86 (1H, d), 6.97 (1H, d), 7.17-7.25 (2H, m), 7.56 (1H, dd), 7.99 (1H, d), 8.38 (1H, s).
[0886] Compound III-121: colourless oil.
[0887] Compound III-181: colourless oil. δppm 1.26 (3H, t), 2.78 (2H, m), 2.90 (2H, t), 3.75 (2H, m), 5.45 (1H, bs), 6.87 (1H, d), 7.11-7.22 (3H, m), 7.36-7.42 (2H, m), 7.56 (1H, dd), 8.05 (1H, d), 8.43 (1H, s).
[0888] Compound III-185: colourless oil. δppm 1.26 (3H, t), 2.78 (2H, m), 2.88 (2H, t), 3.74 (2H, m), 5.43 (1H, bs), 6.94 (1H, d), 7.20 (2H, d), 7.28-7.32 (1H, m), 7.47 (1H, d), 7.59 (1H, dd), 8.00 (1H, d), 8.43 (1H, s).
[0889] Compound III-186: colourless oil. δppm 1.26 (3H, t), 2.75-2.83 (2H, m), 2.89-2.96 (2H, m), 3.72-3.79 (2H, m), 5.47 (1H, bs), 6.91 (1H, d), 7.03 (1H, d), 7.13-7.19 (2H, m), 7.29-7.34 (1H, m), 7.60 (1H, dd), 8.06 (1H, s), 8.44 (1H, s).
[0890] Compound III-187: colourless oil. δppm 1.26 (3H, t), 2.79 (2H, m), 2.91 (2H, t), 3.75 (2H, m), 5.43 (1H, bs), 6.89 (1H, d), 7.07 (2H, d), 7.35 (2H, d), 7.58 (1H, dd), 8.03 (1H, dd), 8.43 (1H, s).
[0891] Compound III-196: colourless oil. δppm 1.23 (3H, t), 2.35 (3H, s), 2.74-2.91 (5H, m), 3.70-3.77 (2H, m), 5.46 (1H, bs), 6.85 (1H, d), 6.99 (2H, d), 7.19 (2H, d), 7.54 (1H, dd), 8.03 (1H, d), 8.43 (1H, s).
[0892] Compound III-199: colourless oil. δppm 1.26 (3H, t), 2.75-2.82 (2H, m), 2.88 (2H, t), 3.70-3.77 (2H, m), 3.82 (3H, s), 5.42 (1H, bs), 6.83 (1H, d), 6.92 (2H, d), 7.06 (2H, d), 7.54 (1H, dd), 8.03 (1H, d), 8.43 (1H, s).
[0893] Compound III-201: colourless oil.
[0894] Compound III-262: colourless oil. δppm 1.26 (3H, t), 2.79 (2H, m), 2.90 (2H, t), 3.74 (2H, m), 5.42 (1H, bs), 6.97 (1H, d), 7.14 (1H, d), 7.29 (1H, d), 7.48 (1H, d), 7.61 (1H, dd), 7.97 (1H, d), 8.43 (1H, s).
[0895] Compound III-263: colourless oil. δppm 1.26 (3H, t), 2.81 (2H, m), 2.91 (2H, t), 3.75 (2H, m), 5.43 (1H, bs), 6.98 (1H, d), 7.14-7.22 (2H, m), 7.40 (2H, d), 7.63 (1H, dd), 7.99 (1H, s), 8.44 (1H, s).
[0896] Compound III-290: colourless oil. δppm 1.26 (3H, t), 2.14 (3H, s), 2.78 (2H, m), 2.89 (2H, t), 3.74 (2H, m), 5.42 (1H, bs), 6.86 (1H, d), 6.97 (1H, d), 7.19 (1H, dd), 7.25 (1H, d), 7.57 (1H, dd), 8.00 (1H, d), 8.43 (1H, s).
[0897] Compound III-301: colourless oil.
[0898] Compound III-541: colourless oil. δppm 2.91 (2H, t), 3.81 (2H, m), 5.73 (1H, bs), 6.54, 6.71, 6.83 (1H, t), 6.88 (1H, d), 7.09-7.18 (2H, m), 7.22 (1H, t), 7.36-7.42 (2H, m), 7.56 (1H, dd), 8.07 (1H, d), 8.56 (1H, s).
[0899] Compound III-545: colourless oil. δppm 2.92 (2H, t), 3.80 (2H, m), 5.71 (1H, bs), 6.53, 6.71, 6.89 (1H, t), 6.95 (1H, d), 7.18-7.32 (3H, m), 7.47 (1H, d), 7.59 (1H, dd), 8.00 (1H, d), 8.56 (1H, s).
[0900] Compound III-546: colourless oil. δppm 2.94 (2H, t), 3.77-3.82 (2H, m), 5.74 (1H, bs), 6.54, 6.72, 6.89 (1H, t), 6.91 (1H, d), 7.02 (1H, d), 7.13-7.18 (2H, m), 7.29-7.35 (1H, m), 7.61 (1H, dd), 8.06 (1H, d), 8.61 (1H, s).
[0901] Compound III-547: colourless oil. δppm 2.93 (2H, t), 3.80 (2H, m), 5.72 (1H, bs), 6.53, 6.72, 6.89 (1H, t), 6.92 (1H, d), 7.07 (2H, d), 7.35 (2H, d), 7.58 (1H, dd), 8.03 (1H, s), 8.56 (1H, s).
[0902] Compound III-556: colourless oil. δppm 2.35 (3H, t), 2.91 (2H, t), 3.76-3.84 (2H, m), 5.73 (1H, bs), 6.54, 6.72, 6.84 (1H, t), 6.89 (1H, d), 7.01 (1H, d), 7.19 (1H, d), 7.55 (1H, dd), 8.04 (1H, d), 8.56 (1H, s).
[0903] Compound III-559: colourless oil. δppm 2.91 (2H, t), 3.76-3.81 (5H, m), 5.73 (1H, bs), 6.54, 6.72, 6.84 (1H, t), 6.91 (1H, d), 6.94 (1H, dd), 7.06 (1H, dd), 7.54 (1H, dd), 8.03 (1H, d), 8.56 (1H, s).
[0904] Compound III-561: colourless oil. δppm 2.95 (2H, t), 3.81 (2H, m), 5.74 (1H, bs), 6.54, 6.72, 6.89 (1H, t), 6.95 (1H, d), 7.32 (1H, d), 7.39 (1H, s), 7.44-7.54 (2H, m), 7.62 (1H, dd), 8.05 (1H, d), 8.57 (1H, s).
[0905] Compound III-562: colourless oil. δppm 2.95 (2H, t), 3.81 (2H, m), 5.74 (1H, bs), 6.54, 6.72, 6.89 (1H, t), 6.97 (1H, d), 7.21-7.24 (2H, m), 7.61-7.67 (3H, m), 8.06 (1H, d), 8.57 (1H, s).
[0906] Compound III-623: colourless oil. δppm 2.92 (2H, t), 3.80 (2H, m), 5.72 (1H, bs), 6.54, 6.72, 6.89 (1H, t), 6.91 (1H, s), 6.99 (1H, d), 7.15-7.22 (2H, m), 7.40 (1H, d), 7.61 (1H, dd), 8.00 (1H, d), 8.57 (1H, s).
[0907] Compound III-650: colourless oil. δppm 2.13 (3H, s), 2.91 (2H, t), 3.79 (2H, m), 5.66 (1H, bs), 6.53, 6.72, 6.86 (1H, t), 6.89 (1H, s), 6.97 (1H, d), 7.17-7.25 (2H, m), 7.57 (1H, dd), 8.01 (1H, d), 8.56 (1H, s).
[0908] Compound III-661: colourless oil.
[0909] Compound III-2521: colourless oil. δppm 2.90 (2H, t), 3.74-3.81 (2H, m), 5.60 (1H, bs), 6.83-6.89 (1H, m), 7.09-7.11 (2H, m), 7.13-7.22 (1H, m), 7.37-7.42 (2H, m), 7.49-7.56 (1H, m), 8.15 (1H, d), 8.29 (1H, s).
[0910] Compound III-2526: colourless oil. δppm 2.92 (2H, t), 3.74-3.81 (2H, m), 5.62 (1H, bs), 6.91 (1H, d), 7.02 (1H, d), 7.14-7.18 (2H, m), 7.29-7.34 (1H, m), 7.57-7.60 (1H, m), 8.05 (1H, d), 8.32 (1H, s).
[0911] Compound III-2527: colourless oil. δppm 2.91 (2H, t), 3.74-3.81 (2H, m), 5.60 (1H, bs), 6.90 (1H, d), 7.07 (2H, dd), 7.35 (2H, dd), 7.54 (1H, dd), 8.03 (1H, d), 8.29 (1H, s).
[0912] Compound III-2536: colourless oil. δ(CDCl 3 ): 2.36 (3H, s), 2.89 (2H, t), 3.73-3.79 (2H, m), 5.62 (1H, bs), 6.85 (1H, d), 6.98-7.02 (2H, m), 7.20 (2H, d), 7.54 (1H, dd), 8.03 (1H, d), 8.29 (1H, s).
[0913] Compound III-2539: colourless oil. δppm 2.89 (2H, t), 3.73-3.79 (2H, m), 3.81 (3H, t), 5.61 (1H, bs), 6.83 (1H, d), 6.92 (2H, dd), 7.05 (2H, dd), 7.52 (1H, dd), 8.03 (1H, d), 8.29 (1H, s).
[0914] Compound III-2541: colourless oil. δppm 2.93 (2H, t), 3.75-3.82 (2H, m), 5.62 (1H, bs), 6.94 (1H, d), 7.32 (1H, d), 7.40-7.51 (3H, m), 7.60 (1H, dd), 8.04 (1H, d), 8.30 (1H, s).
[0915] Biological Testing
[0916] The compounds of the present invention exhibit both excellent fungicidal activity against many fungi in agricultural field and better insecticidal and acaricidal activities.
[0917] Except for the controls CK1-CK21 (known compounds illustrated in background technology) listed in following Table 303-310, according to the prior art, the following compounds CK22-CK84, diflumetorim and flufenerim were also prepared as controls, all the controls were self-made, they are listed in Table 302.
[0000]
TABLE 302
the structure of controls
No.
Structure
CK22
CK23
CK24
CK25
CK26
CK27
CK28
CK29
CK30
CK31
CK32
CK33
CK34
CK35
CK36
CK37
CK38
CK39
CK40
CK41
CK42
CK43
CK44
CK45
CK46
CK47
CK48
CK49
CK50
CK51
CK52
CK53
CK54
CK55
CK56
CK57
CK58
CK59
CK60
CK61
CK62
CK63
CK64
CK65
CK66
CK67
CK68
CK69
CK70
CK71
CK72
CK73
CK74
CK75
CK76
CK77
CK78
CK79
CK80
CK81
CK82
CK83
CK84
Example 32
Fungicidal Testing
[0918] (1) The Determination of Protectant Activity In Vivo
[0919] The method is as followed: The whole plant is used in this test. The compound is dissolved in a proper solvent to get mother solution. The proper solvent is selected from acetone, methanol, DMF and so on according to their dissolving capability to the sample. The volume rate of solvent and testing solution (v/v) is equal to or less than 5%. The mother solution is diluted with water containing 0.1% tween-80 to get the testing solution whose concentration is designed. The testing solution is sprayed to the host plant by a special plant sprayer. The plant is inoculated with fungus after 24 hours. According to the infecting characteristic of fungus, the plant is stored in a humidity chamber and then transferred into greenhouse after infection is finished. And the other plants are placed in greenhouse directly. The activity of compound is obtained by eyeballing after 7 days in common.
[0920] The protectant activities in vivo of some compounds are as follows:
[0921] The protectant activity against cucumber downy mildew in vivo:
[0922] At the dosage of 400 ppm, the protectant activity of compounds I-22, I-35, I-254, I-255, I-467, I-483, I-486, I-502, I-583, I-602, I-699, I-815, I-987, I-1762, I-1878, I-2555, I-2574, I-2748, I-2611, I-3077, I-3309, I-4757, I-5221, I-6730, I-6732, I-6740, I-6765, I-6790, I-6796, II-21, II-25, II-69, II-154, II-204, II-236, II-254, II-297, II-299, II-303, II-347, II-432, II-482, II-1687, II-1965, II-8915, II-8917, II-8921, II-8965, II-9058, II-10583, III-1, III-5, III-7, III-16, III-19, III-22, III-82, III-110, III-121, III-181, III-187, III-196, III-199, III-201, III-202, III-262, III-263, III-290, III-301, III-541, III-547, III-556, III-562, III-622, III-623, III-650, III-2521, III-2526, III-2527, III-2536, III-2539, III-2541, III-2630 and so on was 100%, the protectant activity of compounds I-618, I-1199, I-2787, I-2843, I-6793, I-6797, II-235, II-274, II-9073, II-9170, II-9336, II-19334 and so on was between 80%-99%;
[0923] At the dosage of 100 ppm, the protectant activity of compounds I-22, I-254, I-255, I-467, I-583, I-602, I-699, I-987, I-1199, I-2748, I-3077, I-4757, I-6730, I-6732, I-6740, I-6765, II-21, II-204, II-236, II-297, II-299, II-482, II-1687, II-8915, II-8917, II-8921, II-8965, II-10583, III-1, III-5, III-7, III-16, III-19, III-22, III-82, III-110, III-121, III-181, III-187, III-196, III-199, III-201, III-202, III-262, III-263, III-301, III-541, III-547, III-556, III-562, III-622, III-623, III-650, III-2521, III-2526, III-2527, III-2536, III-2539, III-2541 and so on was 100%, the protectant activity of compounds I-35, I-502, I-987, I-2555, I-2611, I-3309, I-5221, I-6790, I-6796, II-25, II-69, II-303, II-347, II-9058, III-290, III-2630 and so on was between 80%-99%;
[0924] At the dosage of 50 ppm, the protectant activity of compounds I-22, I-254, I-255, I-467, I-2748, I-3077, I-6730, I-6765, II-21, II-204, II-236, II-297, II-482, II-1687, II-8917, II-8965, III-1, III-5, III-7, III-16, III-19, III-22, III-82, III-110, III-121, III-181, III-187, III-196, III-201, III-202, III-262, III-263, III-301, III-541, III-547, III-556, III-562, III-622, III-623, III-650, III-2521, III-2526, III-2527, III-2536, III-2539, III-2541 and so on was 100%, the protectant activity of compounds I-583, I-602, I-699, I-987, I-1199, I-2611, I-3309, I-5221, I-6790, I-6796, II-25, II-299, II-8915, II-8921, II-9058, II-10583, III-199, III-2630 and so on was between 80%-99%;
[0925] At the dosage of 25 ppm, the protectant activity of compounds I-22, I-255, I-467, I-583, I-699, I-3077, I-6730, I-6732, I-6765, II-204, II-236, II-297, II-482, II-8917, III-1, III-5, III-7, III-16, III-19, III-22, III-82, III-110, III-121, III-181, III-187, III-196, III-201, III-202, III-262, III-263, III-301, III-541, III-547, III-556, III-562, III-622, III-623, III-2521, III-2526, III-2527, III-2539 and so on was 100%, the protectant activity of compounds I-602, I-699, I-3309, I-6790, II-25, II-1687, II-8915, II-8921, II-8965, II-10583, III-199, III-650, III-2536, III-2541 and so on was between 80%-99%;
[0926] At the dosage of 12.5 ppm, the protectant activity of compounds I-22, III-1, III-7, III-16, III-22, III-187, III-202, III-301, III-541, III-556, III-562, III-622, III-2521, III-2527 and so on was 100%, the protectant activity of compounds I-255, I-3077, I-6765, II-204, II-482, II-8915, II-8917, II-10583, III-19, III-82, III-196, III-201, III-263, III-623, III-650, III-2536, III-2539 and so on was between 80%-99%;
[0927] At the dosage of 6.25 ppm, the protectant activity of compounds I-22, III-7, III-16, III-22, III-187, III-202, III-301, III-541, III-562 and so on was 100%, the protectant activity of compounds I-6765, II-8915, II-8917, II-10583, III-19, III-196, III-556, III-622 and so on was between 80%-99%.
[0928] The protectant activity against wheat powdery mildew in vivo:
[0929] At the dosage of 400 ppm, the protectant activity of compounds I-22, I-23, I-34, I-35, I-254, I-255, I-266, I-267, I-467, I-486, I-502, I-602, I-815, I-929, I-987, I-1219, I-1414, I-1472, I-1762, I-2342, I-2555, I-2574, I-3309, I-4121, I-4757, I-6729, I-6730, I-6731, I-6732, I-6733, I-6734, I-6735, I-6739, I-6740, I-6741, I-6742, I-6756, I-6757, I-6758, I-6763, I-6765, I-6790, I-6793, I-6795, I-6796, II-19, II-25, II-69, II-154, II-204, II-297, II-299, II-303, II-347, II-432, II-482, II-1687, II-1965, II-8917, II-8921, II-8965, II-9058, II-9073, II-10583, II-19334, III-1, III-5, III-6, III-7, III-16, III-19, III-21, III-22, III-82, III-83, III-110, III-121, III-181, III-185, III-186, III-187, III-196, III-199, III-201, III-202, III-262, III-263, III-301, III-541, III-545, III-546, III-547, III-556, III-559, III-561, III-562, III-622, III-623, III-650, III-2536, III-2541 and so on was 100%; compounds I-483, I-583, I-2748, I-2787, I-2922, I-3077, I-5221, I-6797, II-53, II-9351, III-2539 and so on was between 80%-99%.
[0930] At the dosage of 100 ppm, the protectant activity of compounds I-22, I-254, I-255, I-267, I-467, I-486, I-602, I-987, I-1414, I-1472, I-2342, I-2555, I-2574, I-6729, I-6730, I-6739, I-6740, I-6741, I-6742, I-6756, I-6757, I-6758, I-6763, I-6765, I-6793, II-154, II-204, II-297, II-303, II-347, II-432, II-482, II-1687, II-8921, II-8965, II-10583, II-19334, III-121, III-202, III-301 and so on was 100%; compounds I-23, I-483, I-502, I-583, I-6731, I-6732, I-6733, I-6735, II-19, II-25, II-299, II-8917, II-9058, II-9073, III-1, III-5, III-7, III-22, III-82, III-110, III-181, III-541, III-545, III-562, III-2541 and so on was between 80%-99%.
[0931] At the dosage of 25 ppm, the protectant activity of compounds I-22, I-254, I-255, I-2342, I-2555, I-2574, I-6730, I-6739, I-6740, I-6742, I-6765, I-6793, II-204, II-297, II-303, II-347, II-432, II-482, II-1687, II-8921, II-10583, II-19334, III-202 and so on was 100%; compounds I-23, I-254, I-502, I-602, I-987, I-6729, I-6731, I-6732, I-6733, I-6735, I-6756, I-6763, II-19, II-299, II-8917, II-8965, II-9058, II-9073, III-121, III-301 and so on was between 80%-99%.
[0932] At the dosage of 6.25 ppm, the protectant activity of compounds I-22, I-2342, I-2574, I-6765, II-204, II-432, II-10583 and II-19334 and so on was 100%; compounds I-23, I-255, I-502, I-2555, I-6730, I-6739, I-6742, II-19, II-297, II-303, II-482, II-1687, II-8921, III-202 and so on was between 80%-99%.
[0933] The protectant activity against corn rust in vivo:
[0934] At the dosage of 400 ppm, the protectant activity of compounds I-22, I-35, I-254, I-266, I-267, I-467, I-483, I-486, I-583, I-815, I-929, I-987, I-1045, I-1199, I-1219, I-1472, I-1762, I-1878, I-2342, I-2555, I-2574, I-2922, I-3077, I-4121, I-4757, I-5221, I-6729, I-6730, I-6731, I-6732, I-6733, I-6734, I-6735, I-6739, I-6740, I-6741, I-6742, I-6756, I-6757, I-6758, I-6763, I-6765, I-6790, I-6791, I-6793, I-6795, I-6796, II-19, II-21, II-53, II-69, II-154, II-165, II-204, II-297, II-299, II-303, II-347, II-432, II-482, II-1687, II-1965, II-8915, II-8917, II-8921, II-8965, II-10583, II-19334, III-1, III-6, III-7, III-16, III-19, III-21, III-82, III-83, III-110, III-181, III-185, III-186, III-196, III-199, III-201, III-202, III-262, III-301, III-541, III-545, III-546, III-547, III-556, III-559, III-561, III-622, III-623, III-661, III-2521, III-2526, III-2536, III-2539, III-2630 and so on was 100%; compounds I-1627, I-2748, II-25, II-236, II-254, III-5, III-22, III-650, III-2527, III-2541 and so on was between 80%-99%.
[0935] At the dosage of 100 ppm, the protectant activity of compounds I-22, I-35, I-254, I-467, I-486, I-583, I-987, I-2342, I-2574, I-2922, I-4757, I-5221, I-6729, I-6731, I-6732, I-6733, I-6734, I-6735, I-6739, I-6740, I-6741, I-6742, I-6756, I-6757, I-6758, I-6763, I-6765, I-6796, II-21, II-69, II-154, II-204, II-297, II-299, II-303, II-347, II-432, II-482, II-1687, II-8915, II-8917, II-8965, II-10583, III-6, III-7, III-21, III-110, III-201, III-202, III-262, III-301, III-545, III-546, III-559, III-561, III-622, III-661 and so on was 100%; compounds I-267, I-815, I-1199, I-1219, I-3077, I-3309, I-6730, I-6791, II-19, II-165, II-8921, II-19334, III-19, III-82, III-181, III-185, III-186, III-196, III-199, III-547, III-556, III-623, III-2526 and so on was between 80%-99%.
[0936] At the dosage of 25 ppm, the protectant activity of compounds I-22, I-254, I-583, I-2342, I-6729, I-6742, II-69, II-154, II-204, II-303, II-432, II-482, II-8915, II-8917, II-8965, III-7, III-262, III-561, III-622 and so on was 100%; compounds I-35, I-266, I-467, I-987, I-1219, I-2574, I-4757, I-5221, I-6730, I-6731, I-6732, I-6733, I-6734, I-6735, I-6739, I-6740, I-6765, I-6757, I-6796, II-21, II-297, II-299, II-347, II-8921, II-10583, III-199, III-201, III-545, III-546, III-559 was between 80%-99%.
[0937] At the dosage of 6.25 ppm, the protectant activity of compounds I-22, I-254, I-2342, I-6742, II-154, II-303, II-432, II-482, II-8915, II-8917 and so on was 100%; compounds I-266, I-987, I-2574, I-6732, I-6733, I-6796, II-21, II-204, II-297, II-299, II-347, II-8921, II-8965, III-262, III-559, III-561, III-622 was between 80%-99%.
[0938] (2) Determination of Fungicidal Activity In Vitro
[0939] The method is as followed: High Through Put is used in the test. The compound is dissolved in a proper solvent to become a testing solution whose concentration is designed. The solvent is selected from acetone, methanol, DMF and so on according to their dissolving capability to the sample. In a no animalcule condition, the testing solution and pathogens suspension are added into the cells of 96 cells culture board, which then should be placed in the constant temperature box. 24 hours later, pathogen germination or growth can be investigated by eyeballing, and the activity in vitro of the compound is evaluated based on germination or growth of control treatment.
[0940] The activities in vitro (inhibition rate) of some compounds are as follows:
[0941] The inhibition rate against rice blast:
[0942] At the dosage of 25 ppm, the inhibition rate of compounds I-22, I-483, I-929, I-987, I-1762, I-2574, I-2922, I-6757, I-6758, I-6763, II-53, II-165, II-274, II-1965, III-7, III-121, III-301, III-661 and so on was 100%; compounds I-23, I-35, I-254, I-255, I-266, I-618, I-1199, I-1219, I-1878, I-2342, I-3077, I-3309, I-4121, I-4757, I-5221, I-6729, I-6730, I-6731, I-6732, I-6733, I-6734, I-6735, I-6742, I-6758, I-6791, I-6793, I-6795, I-6796, I-6797, II-19, II-25, II-69, II-204, II-347, II-482, II-1687, II-9336, II-10583, III-1, III-5, III-6, III-7, III-16, III-19, III-21, III-22, III-82, III-83, III-110, III-181, III-186, III-187, III-196, III-199, III-201, III-202, III-262, III-541, III-545, III-546, III-547, III-556, III-559, III-561, III-562, III-622, III-623, III-661, III-2521, III-2526, III-2536, III-2539, III-2541, III-2630 was between 80%-99%. contrast compounds CK4, CK5, CK6, CK10, CK20, CK32, CK33, CK35, CK37, CK40, CK41, CK43, CK46, CK47, CK48, CK49, CK50, CK55, CK56 and CK58 was less than 50%, contrast compounds CK1, CK2, CK3, CK7, CK11, CK13, CK15, CK16, CK21, CK38, CK39, CK44, CK45, CK59, CK60, CK61 and CK63 was all 0;
[0943] At the dosage of 8.3 ppm, the inhibition rate of compounds I-483, I-2574, I-2922, II-53, II-165, III-7, III-661 and so on was 100%; compounds I-22, I-929, I-987, I-6758 and II-274 was between 80%-99%. contrast compound CK17 was 50%; contrast compounds CK5, CK6, CK14, CK18, CK19, CK46, CK47, CK48, CK49, CK50, CK51, CK52 and diflumetorim was all 0;
[0944] At the dosage of 2.8 ppm, the inhibition rate of compounds I-483, I-2922, II-53, II-165, III-7 and so on was 100%; compound II-274 was between 80%-99%. contrast compound CK17 was 0;
[0945] At the dosage of 0.9 ppm, the inhibition rate of compounds I-483, I-2922, II-53, II-165, III-7 and so on was 100%;
[0946] At the dosage of 0.3 ppm, the inhibition rate of compounds I-483, I-2922, II-53, II-165 and III-7 was 100%;
[0947] At the dosage of 0.1 ppm, the inhibition rate of compounds I-483, I-2922, II-165 and III-7 was 100%;
[0948] The inhibition rate against cucumber gray mold:
[0949] At the dosage of 25 ppm, the inhibition rate of compounds I-486, I-1045, I-2342, I-4757, II-303, II-1965, II-8921, III-82 and so on was 100%; compounds I-1199, I-3309, II-69, II-347, III-7, III-199, III-202, III-262, III-545, III-547, III-559, III-622 was between 80%-99%. contrast compounds CK20, CK21, CK24, CK25, CK44, CK45, CK56, CK57, CK62 was less than 50%, contrast compounds CK1, CK2, CK3, CK4, CK6, CK7, CK8, CK9, CK10, CK13, CK14, CK15, CK16, CK17, CK22, CK26, CK32, CK33, CK34, CK35, CK46, CK47, CK48, CK51, CK52, CK53, CK54, CK55, CK58, CK59, CK60, CK61, CK63, CK67, CK68, CK70, CK73, CK74, CK75, CK76, CK77, CK78, CK79, CK80, CK81, CK82, CK83, CK84, diflumetorim and flufenerim was all 0;
[0950] (2) The Contrastive Test Results of Some Compounds and Contrasts
[0951] Contrastive tests were carried out between some compounds and contrasts. The test results are listed in table 303-table 305 (“///” in the following tables means no test).
[0000]
TABLE 303
The comparative test of protectant activity against cucumber
downy mildew
control effect against cucumber downy mildew (%)
Compound
400
100
50
25
12.5
6.25
3.125
No.
mg/L
mg/L
mg/L
mg/L
mg/L
mg/L
mg/L
I-22
100
100
100
100
100
100
85
I-3309
100
90
90
90
70
60
50
II-236
100
100
100
100
///
///
///
II-297
100
100
100
100
///
///
///
II-8915
100
100
100
99
95
90
20
II-8917
100
100
100
100
95
85
///
II-10583
100
100
100
95
95
95
///
III-1
100
100
100
100
100
///
///
III-5
100
100
100
100
///
///
///
III-7
100
100
100
100
100
100
100
III-16
100
100
100
100
100
100
///
III-19
100
100
100
100
98
95
///
III-22
100
100
100
100
100
100
///
III-82
100
100
100
100
98
///
///
III-110
100
100
100
100
///
///
///
III-121
100
100
100
100
///
///
///
III-181
100
100
100
100
///
///
///
III-187
100
100
100
100
100
100
///
III-196
100
100
100
100
85
85
///
III-201
100
100
100
100
98
///
///
III-202
100
100
100
100
100
100
///
III-262
100
100
100
100
///
///
///
III-263
100
100
100
100
98
70
///
III-301
100
100
100
100
100
100
///
III-541
100
100
100
100
100
100
95
III-547
100
100
100
100
///
///
///
III-556
100
100
100
100
100
95
///
III-562
100
100
100
100
100
100
///
III-622
100
100
100
100
100
98
///
III-623
100
100
100
100
98
70
///
III-650
100
100
100
98
95
///
///
III-2521
100
100
100
100
100
///
///
III-2527
100
100
100
100
100
75
///
III-2536
100
100
100
98
90
///
///
III-2539
100
100
100
100
85
///
///
CK1
100
100
100
100
50
30
20
CK3
80
///
///
///
///
///
///
CK6
70
///
///
///
///
///
///
CK7
70
30
0
0
///
///
///
CK8
98
95
80
75
///
///
///
CK9
100
98
90
70
///
///
///
CK10
100
82
40
20
///
///
///
CK11
85
30
0
0
///
///
///
CK13
85
25
0
0
///
///
///
CK14
98
40
0
0
///
///
///
CK15
95
15
0
0
///
///
///
CK16
85
///
///
///
///
///
///
CK17
100
40
10
0
///
///
///
CK20
100
10
0
0
///
///
///
CK22
100
98
75
60
///
///
///
CK23
100
0
0
0
///
///
///
CK25
100
0
0
0
///
///
///
CK26
100
60
40
0
///
///
///
CK27
100
0
0
0
///
///
///
CK28
100
40
20
0
///
///
///
CK29
98
98
90
25
///
///
///
CK32
60
///
///
///
///
///
///
CK33
0
///
///
///
///
///
///
CK34
85
///
///
///
///
///
///
CK35
60
///
///
///
///
///
///
CK37
100
20
10
0
///
///
///
CK42
100
100
100
20
0
0
0
CK43
100
40
20
0
///
///
///
CK52
100
98
90
70
///
///
///
CK53
100
90
85
60
///
///
///
CK54
100
90
80
65
///
///
///
CK55
100
0
0
0
///
///
///
CK56
100
10
0
0
///
///
///
CK57
50
///
///
///
///
///
///
CK58
0
///
///
///
///
///
///
CK59
80
///
///
///
///
///
///
CK60
100
10
0
0
///
///
///
CK61
100
90
85
30
///
///
///
CK62
80
///
///
///
///
///
///
CK63
70
///
///
///
///
///
///
CK65
0
///
///
///
///
///
///
CK66
0
///
///
///
///
///
///
CK67
100
60
20
0
///
///
///
CK68
0
///
///
///
///
///
///
CK69
100
100
98
50
///
///
///
CK70
100
60
30
0
///
///
///
CK71
80
///
///
///
///
///
///
CK72
100
100
40
20
///
///
///
CK73
98
98
95
60
///
///
///
CK74
50
///
///
///
///
///
///
CK75
60
///
///
///
///
///
///
CK76
0
///
///
///
///
///
///
CK77
0
///
///
///
///
///
///
CK78
0
///
///
///
///
///
///
CK79
85
///
///
///
///
///
///
CK80
85
///
///
///
///
///
///
CK83
100
100
98
85
///
///
///
CK84
100
100
100
85
///
///
///
diflumetorim
100
100
100
70
15
0
///
flufenerim
0
///
///
///
///
///
///
[0000]
TABLE 304
The comparative test of protectant activity against wheat
powdery mildew
control effect against wheat powdery mildew (%)
Compound
400
100
25
6.25
1.6
0.4
No.
mg/L
mg/L
mg/L
mg/L
mg/L
mg/L
I-22
100
100
100
100
15
///
I-254
100
100
100
100
20
///
I-2342
100
100
100
100
95
60
I-2574
100
100
100
100
75
20
I-6765
100
100
100
100
///
///
II-204
100
100
100
100
///
///
II-297
100
100
100
90
40
30
II-303
100
100
100
90
80
25
II-432
100
100
100
100
80
50
II-482
100
100
100
98
///
///
II-8921
100
100
100
90
40
///
II-10583
100
100
100
100
///
///
II-19334
100
100
100
100
60
///
III-1
100
98
98
98
///
///
III-202
100
100
100
95
///
///
CK1
100
100
100
80
///
///
CK2
100
100
80
0
///
///
CK4
40
0
///
///
///
///
CK6
100
100
90
85
0
0
CK8
0
///
///
///
///
///
CK9
100
0
0
0
///
///
CK10
50
///
///
///
///
///
CK11
100
60
40
0
///
///
CK12
80
30
0
0
///
///
CK13
40
0
0
0
///
///
CK14
85
10
0
0
///
///
CK15
95
85
10
0
///
///
CK16
70
///
///
///
///
///
CK17
100
75
70
50
///
///
CK19
50
0
///
///
///
///
CK20
100
30
0
0
///
///
CK21
0
///
///
///
///
///
CK22
100
90
50
0
///
///
CK23
100
0
0
0
///
///
CK24
0
0
///
///
///
///
CK25
0
///
///
///
///
///
CK26
70
///
///
///
///
///
CK27
80
///
///
///
///
///
CK29
100
80
50
40
///
///
CK30
100
80
20
0
///
///
CK31
0
0
0
0
///
///
CK32
0
///
///
///
///
///
CK33
0
///
///
///
///
///
CK34
0
///
///
///
///
///
CK35
0
///
///
///
///
///
CK36
100
80
60
0
///
///
CK37
0
///
///
///
///
///
CK41
100
70
50
0
///
///
CK42
100
70
60
50
///
///
CK43
20
///
///
///
///
///
CK44
0
///
///
///
///
///
CK45
0
///
///
///
///
///
CK48
30
0
0
0
///
///
CK51
100
80
40
0
///
///
CK53
100
80
0
0
///
///
CK52
0
///
///
///
///
///
CK55
60
///
///
///
///
///
CK56
70
///
///
///
///
///
CK57
0
///
///
///
///
///
CK58
0
///
///
///
///
///
CK59
0
///
///
///
///
///
CK60
0
///
///
///
///
///
CK61
70
///
///
///
///
///
CK63
50
///
///
///
///
///
CK65
0
///
///
///
///
///
CK66
0
///
///
///
///
///
CK67
0
///
///
///
///
///
CK68
0
///
///
///
///
///
CK69
100
0
0
0
///
///
CK70
98
0
0
0
///
///
CK71
100
///
///
///
///
///
CK72
100
70
60
50
///
///
CK73
40
///
///
///
///
///
CK74
0
///
///
///
///
///
CK75
0
///
///
///
///
///
CK76
75
///
///
///
///
///
CK77
100
100
80
70
///
///
CK78
0
///
///
///
///
///
CK79
0
///
///
///
///
///
CK80
100
80
0
0
///
///
CK81
40
///
///
///
///
///
CK82
100
80
0
0
///
///
CK83
100
100
70
40
///
///
diflumetorim
100
95
95
90
///
///
[0000]
TABLE 305
The comparative test of protectant activity against corn rust
control effect against corn rust (%)
Compound
400
100
25
6.25
1.6
0.4
No.
mg/L
mg/L
mg/L
mg/L
mg/L
mg/L
I-22
100
100
100
100
50
20
I-254
100
100
100
100
95
40
II-154
100
100
100
100
50
///
II-303
100
100
100
100
80
50
II-432
100
100
100
100
75
15
II-482
100
100
100
100
///
///
II-8915
100
100
100
100
80
30
II-8917
100
100
100
100
60
10
II-8965
100
100
100
95
85
30
III-7
100
100
100
///
///
///
III-262
100
100
100
90
90
60
III-561
100
100
100
95
80
40
CK2
100
100
100
85
///
///
CK4
0
0
///
///
///
///
CK5
95
98
40
30
///
///
CK6
100
100
100
80
30
0
CK8
50
///
///
///
///
///
CK9
100
100
20
0
///
///
CK10
50
///
///
///
///
///
CK12
100
100
85
75
///
///
CK13
100
0
0
0
///
///
CK14
100
20
0
0
///
///
CK15
95
85
30
0
///
///
CK16
0
///
///
///
///
///
CK17
100
0
0
0
////
///
CK18
80
30
0
///
///
///
CK19
70
0
///
///
///
///
CK20
100
70
0
0
///
///
CK21
85
///
///
///
///
///
CK22
100
100
40
0
///
///
CK23
100
0
0
0
///
///
CK24
100
50
20
0
///
///
CK25
0
///
///
///
///
///
CK26
100
0
0
0
///
///
CK27
100
100
90
30
///
///
CK28
100
100
100
95
0
0
CK29
100
95
85
30
///
///
CK30
0
0
0
0
///
///
CK31
0
0
0
0
///
///
CK33
0
///
///
///
///
///
CK34
0
///
///
///
///
///
CK35
0
///
///
///
///
///
CK36
100
60
40
0
///
///
CK37
0
///
///
///
///
///
CK38
0
///
///
///
///
///
CK39
100
100
80
50
10
0
CK40
100
100
90
70
30
0
CK41
100
100
90
80
20
0
CK42
70
///
///
///
///
///
CK43
85
///
///
///
///
///
CK44
85
///
///
///
///
///
CK45
80
///
///
///
///
///
CK46
40
0
0
0
///
///
CK47
80
30
0
0
///
///
CK48
60
20
0
0
///
///
CK49
85
30
0
0
///
///
CK50
80
0
0
0
///
///
CK51
80
20
0
0
///
///
CK52
85
///
///
///
///
///
CK53
0
///
///
///
///
///
CK54
100
60
30
0
///
///
CK55
0
///
///
///
///
///
CK56
70
///
///
///
///
///
CK57
0
///
///
///
///
///
CK58
0
///
///
///
///
///
CK59
0
///
///
///
///
///
CK60
0
///
///
///
///
///
CK61
0
///
///
///
///
///
CK63
100
30
0
0
///
///
CK65
0
///
///
///
///
///
CK66
0
///
///
///
///
///
CK67
0
///
///
///
///
///
CK68
0
///
///
///
///
///
CK69
100
90
50
0
///
///
CK70
100
30
10
0
///
///
CK71
0
///
///
///
///
///
CK72
100
80
20
0
///
///
CK73
100
90
10
0
///
///
CK74
100
100
90
85
///
///
CK75
0
///
///
///
///
///
CK76
70
///
///
///
///
///
CK77
100
60
40
0
///
///
CK78
0
///
///
///
///
///
CK79
0
///
///
///
///
///
CK80
100
85
20
0
///
///
CK81
80
///
///
///
///
///
CK82
100
30
0
0
///
///
CK83
30
///
///
///
///
///
CK84
100
90
60
0
///
///
diflumetorim
100
80
10
0
///
///
Example 33
Bioactivity Test Against Insects and Mites
[0952] Determination of insecticidal activity of compounds of the present invention against a few insects were carried out by the following procedures:
[0953] Compounds were dissolved in mixed solvent (acetone:methanol=1:1), and diluted to required concentration with water containing 0.1% of tween 80.
[0954] Diamond back moth, armyworm, peach aphid and carmine spider mite were used as targets and the method of spraying by airbrush was used for determination of insecticidal biassays.
[0955] (1) Bioactivity Test Against Diamond Back Moth
[0956] (1) Determination of Insecticidal Activity Against Diamond Back Moth
[0957] The method of spraying by airbrush: The cabbage leaves were made into plates of 2 cm diameter by use of punch. A test solution (0.5 ml) was sprayed by airbrush at the pressure of 0.7 kg/cm 2 to both sides of every plate. 10 Second instar larvae were put into the petri-dishes after the leaf disc air-dried and 3 replicates were set for each treatment. Then the insects were maintained in observation room (25° C., 60˜70% R.H.). Scores were conducted and mortalities were calculated after 72 hrs.
[0958] Part of test results against diamond back moth:
[0959] At the dosage of 600 ppm, compounds I-22, I-254, I-255, I-467, I-583, I-815, I-3077, I-3309, I-4121, I-6729, I-6731, I-6732, I-6733, I-6734, I-6735, I-6739, I-6740, I-6742, I-6756, I-6757, I-6758, I-6765, II-19, II-154, II-204, II-297, II-347, II-482, II-1687, II-1965, II-8915, II-8965, II-10583, II-19334, III-1, III-6, III-7, III-16, III-19, III-21, III-22, III-110, III-181, III-185, III-187, III-196, III-199, III-201, III-202, III-541, III-546, III-547, III-556, III-559, III-562, III-622 and III-2527 showed 100% control against carmine spider mite; compounds II-21, II-274, II-303, II-432, II-8917, II-9170, III-83, III-262, III-545, III-561, III-2526 and III-2539 showed 80%-99% control.
[0960] At the dosage of 100 ppm, compounds I-254, I-255, I-6739, I-6740, I-6742, I-6756, I-6757, I-6758, I-6765, I-3309, II-19, II-204, II-482, II-19334, III-196, III-546, III-547 and III-556 showed 100% control against carmine spider mite; compounds II-1965, II-8965, II-9170, III-7, III-22, III-187 and III-202 showed 80%-99% control.
[0961] (2) Bioactivity Test Against Armyworm
[0962] The method of spraying by airbrush: The corn leaves were made into plates of 2 cm diameter by use of punch. A test solution (0.5 ml) was sprayed by airbrush at the pressure of 0.7 kg/cm 2 to both sides of every plate. 10 Second instar larvae were put into the petri-dishes after the leaf disc air-dried and 3 replicates were set for each treatment. Then the insects were maintained in observation room (25□, 60˜70% R.H.). Scores were conducted and mortalities were calculated after 72 h.
[0963] Part of test results against armyworm:
[0964] At the dosage of 600 ppm, compounds I-255, I-467, I-486, I-583, I-1472, I-2342, I-3309, I-4121, I-6729, I-6731, I-6732, I-6733, I-6734, I-6735, I-6739, I-6740, I-6741, I-6756, I-6757, I-6758, I-6763, I-6765, II-19, II-21, II-69, II-204, II-297, II-299, II-347, II-482, II-1965, II-8915, II-8917, II-8965, II-10583, II-19334, III-1, III-6, III-7, III-16, III-19, III-21, III-22, III-181, III-187, III-196, III-199, III-201, III-202, III-541, III-546, III-547, III-556, III-559, III-561, III-562 and III-2527 showed 100% control against carmine spider mite; compounds I-254, I-1762, I-2748, I-6742, II-303, II-432, III-110, III-650 and III-2541 showed 80%-99% control.
[0965] At the dosage of 100 ppm, compounds I-255, I-3309, I-6739, I-6740, I-6741, I-6756, I-6757, I-6758, I-6763, I-6765, II-204, II-482, II-8965, III-22, III-187, III-199, III-202, III-547, III-559, III-561 and III-562 showed 100% control against carmine spider mite; compounds I-1472, II-69, II-297, II-1965, II-8915, II-19334, III-196, III-201 and III-650 showed 80%-99% control.
[0966] At the dosage of 10 ppm, compounds II-482, III-187, III-547 and III-562 showed 80%-99% control.
[0967] (3) Bioactivity Test Against Green Peach Aphid
[0968] Method: Filter papers were put in culture dishes (Diameter=6 cm), and water was dripped on filter papers for preserving moisture. Green peach aphids ( Myzus Persicae Sulzer) were maintained on cabbage. Leaves (Diameter=3 cm) of approximately 15-30 aphids were put in the culture dishes. Bioactivity tests were used the method of Airbrush Foliar Spray, pressure=10 psi (0.7 kg/cm2), spray volume=0.5 mL. The studies were conducted at three constant temperatures 25±1 C in incubator cabinets with 60±5% RH. Survey the survival aphids after 48 hrs and calculate the death rates.
[0969] Part of test results against Green Peach Aphid:
[0970] At the dosage of 600 ppm, compounds I-22, I-23, I-34, I-35, I-254, I-255, I-266, I-267, I-467, I-483, I-486, I-502, I-583, I-602, I-815, I-929, I-987, I-1414, I-1472, I-1762, I-1878, I-2342, I-2555, I-2748, I-3077, I-3309, I-4121, I-6729, I-6730, I-6731, I-6732, I-6733, I-6734, I-6735, I-6739, I-6740, I-6741, I-6742, I-6756, I-6757, I-6758, I-6763, I-6765, I-6790, I-6793, I-6795, I-6796, I-6797, II-19, II-21, II-25, II-69, II-154, II-204, II-236, II-297, II-299, II-303, II-347, II-432, II-443, II-482, II-1687, II-1965, II-8915, II-8917, II-8921, II-8965, II-9073, II-10583, II-19334, III-1, III-5, III-6, III-7, III-16, III-19, III-21, III-22, III-82, III-83, III-110, III-121, III-181, III-185, III-186, III-187, III-196, III-199, III-201, III-202, III-262, III-263, III-301, III-541, III-545, III-546, III-547, III-556, III-559, III-561, III-562, III-622, III-623, III-650, III-661, III-2527, III-2536 and III-2539 showed 100% control against carmine spider mite; compounds I-699, I-1199, I-5221, III-2526 and III-2541 showed 80%-99% control.
[0971] At the dosage of 100 ppm, compounds I-22, I-23, I-34, I-35, I-254, I-255, I-266, I-267, I-483, I-486, I-583, I-602, I-815, I-987, I-1414, I-1472, I-1762, I-1878, I-2342, I-2555, I-3077, I-3309, I-4121, I-6729, I-6731, I-6732, I-6733, I-6734, I-6735, I-6739, I-6740, I-6741, I-6742, I-6756, I-6757, I-6758, I-6763, I-6765, I-6793, I-6796, I-6797, II-19, II-69, II-154, II-204, II-297, II-299, II-303, II-347, II-432, II-443, II-482, II-1687, II-1965, II-8915, II-8917, II-8965, II-10583, II-19334, III-7, III-16, III-22, III-110, III-121, III-181, III-185, III-186, III-187, III-196, III-199, III-201, III-202, III-262, III-301, III-541, III-547, III-556, III-559, III-561, III-562, III-650 and III-661 showed 100% control against carmine spider mite; compounds I-467, I-5221, II-21, II-25, II-8921, II-9073, III-1, III-5, III-6, III-21, III-545 and III-546 showed 80%-99% control.
[0972] At the dosage of 10 ppm, compounds I-22, I-34, I-35, I-254, I-255, I-266, I-267, I-987, I-1472, I-1762, I-1878, I-2342, I-3309, I-4121, I-6729, I-6731, I-6732, I-6733, I-6734, I-6735, I-6739, I-6740, I-6741, I-6742, I-6756, I-6757, I-6758, I-6763, I-6765, I-6796, II-19, II-69, II-204, II-297, II-347, II-482, II-1687, II-1965, II-8915, II-8917, II-8965, II-10583, II-19334, III-22, III-181, III-187, III-202, III-301, III-547 and III-562 showed 100% control against carmine spider mite; compounds I-23, I-583, I-602, I-3077, I-6793, I-6797, II-21, II-299, III-7, III-186, III-196 and III-541 showed 80%-99% control.
[0973] At the dosage of 5 ppm, compounds I-254, I-1762, I-6731, I-6735, I-6739, I-6740, I-6741, I-6742, I-6756, I-6757, I-6758, I-6763, I-6765, II-69, II-204, II-297, II-347, II-482 and II-8915 showed 100% control against carmine spider mite; compounds II-299, II-8917, II-8965 and II-19334 showed 80%-99% control.
[0974] At the dosage of 2.5 ppm, compounds I-254, I-6739, I-6756, I-6757, I-6758, I-6765, II-297, II-347, II-482 and II-8915 showed 100% control against carmine spider mite; compounds II-69, II-204 and II-19334 showed 80%-99% control.
[0975] (4) Bioactivity Test Against Carmine Spider Mite
[0976] The method: Broadbean shoots with two true leaves in pot were taken, the healthy adults of carmine spider mite were inoculated to the leaves. The adults were counted and then sprayed with airbrush at the pressure of 0.7 kg/cm 2 and at dose of 0.5 ml. 3 replicates were set for each treatment. And then they were maintained in standard observation room. Scores were conducted and mortalities were calculated after 72 hrs.
[0977] Parts of the test results against carmine spider mite are as follows:
[0978] At the dosage of 600 ppm, compounds I-22, I-23, I-254, I-255, I-266, I-267, I-483, I-583, I-602, I-929, I-987, I-1472, I-1762, I-2342, I-6729, I-6730, I-6731, I-6732, I-6733, I-6734, I-6735, I-6739, I-6740, I-6741, I-6742, I-6756, I-6757, I-6758, I-6763, I-6765, I-6795, I-6797, II-19, II-21, II-69, II-154, II-204, II-297, II-299, II-303, II-347, II-432, II-443, II-482, II-1687, II-1965, II-8915, II-8917, II-8965, II-10583, II-19334, III-1, III-5, III-7, III-16, III-19, III-21, III-22, III-110, III-181, III-185, III-187, III-196, III-199, III-201, III-202, III-541, III-545, III-547, III-556, III-559, III-561, III-562 and III-2539 showed 100% control against carmine spider mite; compounds I-1414, I-2555, I-3077, I-3309, I-6796, II-165, III-83, III-546 and III-623 showed 80%-99% control.
[0979] At the dosage of 100 ppm, compounds I-22, I-254, I-255, I-266, I-987, I-1762, I-2342, I-6729, I-6731, I-6732, I-6733, I-6734, I-6735, I-6739, I-6740, I-6741, I-6756, I-6757, I-6758, I-6763, I-6765, I-6795, I-6797, II-19, II-21, II-69, II-154, II-204, II-297, II-299, II-347, II-432, II-443, II-482, II-1965, II-8915, II-8917, II-8965, II-19334, III-7, III-16, III-22, III-181, III-187, III-199, III-202, III-547, III-556, III-559 and III-562 showed 100% control against carmine spider mite; compounds I-23, I-483, I-602, I-3309, III-1, III-19, III-196, III-541 and III-2539 showed 80%-99% control.
[0980] At the dosage of 10 ppm, compounds I-254, I-6739, I-6756, I-6765, II-204, II-347, II-482, II-8965 and II-19334 showed 100% control against carmine spider mite; compounds I-6740, I-6741, I-6757, I-6758, II-69, II-443, III-199 and III-562 showed 80%-99% control.
[0981] At the dosage of 5 ppm, compounds II-482 and II-19334 showed 100% control against carmine spider mite; compounds II-204, II-347 and II-8965 showed 80%-99% control.
[0982] At the dosage of 2.5 ppm, compounds II-482, II-8965 and II-19334 showed 80%-99% control.
[0983] (5) The Contrastive Test Results of Some Compounds and Contrasts
[0984] Contrastive tests were carried out between some compounds and contrasts. The test results are listed in table 306 to table 310 (“///” in the following tables means no test).
[0000]
TABLE 306
contrastive tests against diamond back moth
Insecticidal activity against
diamond back moth (%)
Compound No.
600 mg/L
100 mg/L
10 mg/L
I-255
100
100
43
I-3309
100
100
60
I-6733
100
68
40
I-6734
100
52
40
I-6742
100
75
47
II-19
100
100
50
II-204
100
100
20
II-347
100
70
65
II-482
100
100
60
II-8965
100
80
40
III-196
100
100
///
III-546
100
100
///
III-547
100
100
57
III-556
100
100
77
CK4
0
///
///
CK6
86
16
0
CK7
85
16
0
CK8
33
///
///
CK9
100
45
25
CK10
33
///
///
CK11
86
55
5
CK12
100
35
0
CK13
67
16
0
CK14
67
10
0
CK15
17
15
0
CK16
0
///
///
CK17
0
///
///
CK20
57
///
///
CK21
80
25
10
CK22
0
///
///
CK23
0
///
///
CK25
0
///
///
CK26
0
///
///
CK27
0
///
///
CK28
0
///
///
CK29
0
///
///
CK30
0
///
///
CK32
0
///
///
CK33
29
///
///
CK34
0
///
///
CK35
0
///
///
CK36
20
0
0
CK37
0
///
///
CK38
100
21
5
CK39
80
20
0
CK40
100
29
13
CK41
86
53
0
CK42
0
///
///
CK43
0
///
///
CK44
80
25
10
CK45
86
12
0
CK46
100
10
0
CK48
40
///
///
CK51
57
///
///
CK52
20
///
///
CK53
0
///
///
CK55
0
///
///
CK56
0
///
///
CK57
0
///
///
CK58
0
///
///
CK59
57
///
///
CK60
86
25
15
CK61
0
///
///
CK63
57
///
///
CK65
86
35
5
CK66
0
///
///
CK67
14
///
///
CK68
14
///
///
CK69
100
5
0
CK70
0
///
///
CK71
0
///
///
CK72
0
///
///
CK74
0
///
///
CK75
0
///
///
CK76
0
///
///
CK77
0
///
///
CK78
0
///
///
CK79
0
///
///
CK80
0
///
///
CK81
0
///
///
CK82
17
///
///
CK83
17
///
///
CK84
0
///
///
diflumetorim
0
///
///
[0000]
TABLE 307
contrastive tests against armyworm
Insecticidal activity against
armyworm (%)
Compound No.
600 mg/L
100 mg/L
10 mg/L
I-255
100
100
25
I-3309
100
100
60
I-6756
100
100
28
I-6757
100
100
28
II-204
100
100
47
II-297
100
95
30
II-482
100
100
80
II-8915
100
95
44
II-8965
100
100
69
II-19334
100
84
44
III-22
100
100
71
III-187
100
100
95
III-199
100
100
64
III-202
100
100
65
III-547
100
100
95
III-556
100
75
45
III-562
100
100
83
CK4
40
///
///
CK5
100
56
0
CK6
29
///
///
CK7
100
0
0
CK8
17
///
///
CK9
40
///
///
CK10
0
///
///
CK11
29
///
///
CK12
86
20
0
CK13
86
0
0
CK14
0
///
///
CK15
0
///
///
CK16
0
///
///
CK17
0
///
///
CK18
100
43
14
CK19
86
25
7
CK20
///
///
0
CK21
0
///
///
CK22
0
///
///
CK23
0
///
///
CK24
///
///
0
CK25
0
///
///
CK26
0
///
///
CK27
29
///
///
CK28
29
///
///
CK29
14
///
///
CK30
57
///
///
CK32
0
///
///
CK33
100
0
0
CK34
0
///
///
CK35
0
///
///
CK36
0
///
///
CK37
0
///
///
CK38
0
///
///
CK39
0
///
///
CK40
43
6
0
CK41
100
0
0
CK42
0
///
///
CK43
0
///
///
CK44
0
///
///
CK45
0
///
///
CK46
71
0
0
CK47
86
25
0
CK48
50
///
///
CK49
17
///
///
CK51
43
///
///
CK52
0
///
///
CK53
0
///
///
CK54
67
///
///
CK55
0
///
///
CK56
0
///
///
CK57
0
///
///
CK58
0
///
///
CK59
14
///
///
CK60
0
///
///
CK61
0
///
///
CK63
71
///
///
CK64
0
///
///
CK65
0
///
///
CK66
0
///
///
CK67
0
///
///
CK68
0
///
///
CK70
0
///
///
CK71
86
///
///
CK72
71
///
///
CK73
100
50
0
CK74
0
///
///
CK75
0
///
///
CK76
0
///
///
CK77
0
///
///
CK78
0
///
///
CK79
0
///
///
CK80
0
///
///
CK81
14
///
///
CK82
0
///
///
CK83
29
///
///
CK84
0
///
///
diflumetorim
0
///
///
[0000]
TABLE 308
contrastive tests against peach aphid
Insecticidal activity against peach aphid (%)
Compound
600
100
10
5
2.5
1.25
No.
mg/L
mg/L
mg/L
mg/L
mg/L
mg/L
I-22
100
100
100
100
100
100
I-254
100
100
100
100
100
100
I-3309
100
100
100
100
96
48
I-6731
100
100
100
100
93
60
I-6735
100
100
100
100
80
67
I-6739
100
100
100
100
100
100
I-6756
100
100
100
100
100
100
I-6757
100
100
100
100
100
100
I-6758
100
100
100
100
100
89
I-6765
100
100
100
100
100
84
II-19
100
100
100
///
///
///
II-69
100
100
100
100
81
///
II-204
100
100
100
100
97
60
II-297
100
100
100
100
100
93
II-347
100
100
100
100
100
81
II-482
100
100
100
100
100
100
II-1687
100
100
100
///
///
///
II-1965
100
100
100
///
///
///
II-8915
100
100
100
100
100
100
II-8917
100
100
100
83
///
///
II-8965
100
100
100
91
///
///
II-10583
100
100
100
///
///
///
II-19334
100
100
100
96
83
67
III-7
100
100
90
88
///
///
III-22
100
100
100
100
98
67
III-181
100
100
100
///
///
///
III-187
100
100
100
///
///
///
III-202
100
100
100
100
100
94
III-301
100
100
100
///
///
///
III-547
100
100
100
///
///
///
III-562
100
100
100
///
///
///
CK2
100
100
95
37
23
0
CK4
100
100
64
41
0
///
CK6
100
76
0
///
///
///
CK7
100
100
59
///
///
///
CK8
0
///
///
///
///
///
CK9
100
79
23
///
///
///
CK10
100
91
23
///
///
///
CK11
100
98
85
25
0
///
CK12
100
100
73
///
///
///
CK13
100
98
83
0
///
///
CK14
100
70
0
///
///
///
CK15
69
40
0
///
///
///
CK16
64
///
///
///
///
///
CK17
0
///
///
///
///
///
CK18
100
71
51
7
0
///
CK19
100
86
33
///
///
///
CK21
100
98
35
19
0
///
CK22
0
///
///
///
///
///
CK23
0
///
///
///
///
///
CK24
100
100
89
28
0
///
CK25
0
///
///
///
///
///
CK26
100
48
45
///
///
///
CK27
0
///
///
///
///
///
CK28
100
100
43
///
///
///
CK29
0
///
///
///
///
///
CK30
93
50
0
///
///
///
CK32
0
///
///
///
///
///
CK33
0
///
///
///
///
///
CK34
65
///
///
///
///
///
CK35
0
///
///
///
///
///
CK36
90
14
0
///
///
///
CK37
100
16
0
///
///
///
CK38
100
24
0
///
///
///
CK39
100
86
2
0
///
///
CK40
100
100
72
27
0
///
CK41
100
97
23
15
0
///
CK42
100
67
20
17
0
///
CK43
0
///
///
///
///
///
CK44
100
98
35
19
0
///
CK45
100
98
55
39
26
0
CK46
100
5
0
///
///
///
CK48
100
87
0
///
///
///
CK51
100
50
0
///
///
///
CK52
88
0
0
///
///
///
CK53
84
66
34
///
///
///
CK54
100
100
34
///
///
///
CK55
0
///
///
///
///
///
CK56
100
0
0
///
///
///
CK57
61
///
///
///
///
///
CK58
100
0
0
///
///
///
CK59
75
15
0
///
///
///
CK60
81
0
0
///
///
///
CK61
88
0
0
///
///
///
CK63
100
0
0
///
///
///
CK65
0
///
///
///
///
///
CK66
0
///
///
///
///
///
CK67
86
54
0
///
///
///
CK68
0
///
///
///
///
///
CK69
100
100
70
///
///
///
CK70
81
0
0
///
///
///
CK72
55
///
///
///
///
///
CK73
100
100
0
///
///
///
CK74
100
100
26
///
///
///
CK75
100
0
0
///
///
///
CK76
52
///
///
///
///
///
CK77
72
///
///
///
///
///
CK78
0
///
///
///
///
///
CK79
100
16
0
///
///
///
CK80
87
40
16
///
///
///
CK81
75
///
///
///
///
///
CK82
86
130
0
///
///
///
CK83
100
100
11
///
///
///
CK84
100
43
7
///
///
///
diflumetorim
100
35
0
///
///
///
flufenerim
100
100
100
100
90
37
[0000]
TABLE 309
contrastive tests against carmine spider mite
Insecticidal activity against
Compound
carmine spider mite (% )
No.
600 mg/L
100 mg/L
10 mg/L
I-22
100
100
74
I-254
100
100
97
I-255
100
100
85
I-987
100
100
80
I-6729
100
100
87
I-6734
100
100
82
I-6757
100
100
97
I-6758
100
100
99
I-6739
100
100
100
I-6756
100
100
100
I-6741
100
100
85
I-6765
100
100
100
I-6740
100
100
85
II-69
100
100
90
II-204
100
100
100
II-297
100
100
74
II-299
100
100
72
II-347
100
100
100
II-432
100
100
76
II-443
100
100
83
II-482
100
100
100
II-8965
100
100
100
II-19334
100
100
100
III-7
100
100
///
III-16
100
100
///
III-22
100
100
72
III-181
100
100
///
III-199
100
100
87
III-547
100
100
///
III-556
100
100
///
III-559
100
100
///
III-562
100
100
88
CK2
100
100
32
CK4
75
///
///
CK6
100
53
5
CK7
100
96
36
CK8
54
///
///
CK12
100
41
///
CK13
100
0
0
CK14
100
33
6
CK15
59
0
0
CK16
0
///
///
CK17
40
///
///
CK20
100
72
///
CK21
0
///
///
CK23
64
///
///
CK24
100
100
85
CK25
0
///
///
CK26
0
///
///
CK27
100
100
18
CK28
100
100
22
CK30
100
100
28
CK32
91
22
0
CK33
41
///
///
CK34
0
///
///
CK35
0
///
///
CK36
0
///
///
CK37
0
///
///
CK38
99
37
14
CK39
100
37
16
CK41
100
99
0
CK43
74
29
16
CK44
0
///
///
CK45
0
///
///
CK46
100
63
28
CK52
44
///
///
CK53
100
100
12
CK55
0
///
///
CK56
32
25
0
CK57
33
///
///
CK58
0
///
///
CK59
0
///
///
CK60
0
///
///
CK61
0
///
///
CK62
0
///
///
CK63
0
///
///
CK64
56
///
///
CK65
0
///
///
CK66
0
///
///
CK67
61
///
///
CK68
4
///
///
CK69
100
100
4
CK70
13
///
///
CK72
13
///
///
CK73
100
85
24
CK74
0
///
///
CK75
0
///
///
CK76
41
///
///
CK77
56
///
///
CK78
17
///
///
CK79
27
///
///
CK80
6
///
///
CK81
0
///
///
CK82
23
///
///
CK84
100
0
0
diflumetorim
100
100
73
flufenerim
100
100
72
[0985] Further contrastive tests were carried out between the compounds with better activities, such as compound I-22, I-254, I-255, I-6729, I-6734, I-6739, I-6756, I-6757, I-6758, II-204, II-347, II-482, II-8965 and II-19334, and the contrast CK24 at a low dosage. The test results are listed in table 310.
[0000]
TABLE 310
Insecticidal activity
against carmine
spider mite (%)
Compound No.
5 mg/L
2.5 mg/L
I-22
59
///
I-254
93
79
I-255
84
72
I-6729
78
64
I-6734
57
51
I-6739
93
76
I-6756
88
71
I-6757
80
75
I-6758
82
79
II-204
80
60
II-347
90
75
II-482
100
93
II-8965
92
82
II-19334
100
87
CK24
15
5
|
Disclosed is a substituted pyrimidine compound having a structure as represented by formula PY.
See the description for the definition of each substituent in the formula. The compound of the present invention provides broad-spectrum bactericidal, pesticidal, and acaricidal activities, provides great control effects against plant diseases such as cucumber downy mildew, corn rust, wheat powdery mildew, rice blast, and cucumber gray mold, specifically provides improved control effects against cucumber downy mildew, corn rust, wheat powdery mildew, and rice blast, provides great control effects against aphid, carmine spider mite, diamondback moth, and armyworm, and acquires great effects at a minimal dosage. The compound of the present invention also provides characteristics such as a simplified preparation method.
| 2
|
FIELD OF THE INVENTION
[0001] The present invention relates to a method for operating an actuator having a capacitative element, an ohmic resistance being connected in parallel with the capacitative element and the value of the ohmic resistance being sensed at specific points in time.
BACKGROUND INFORMATION
[0002] A method is referred to in Published Patent Application No. DE 199 58 406 A1, which describes a piezoactuator that is used, for example, in a fuel injector. The piezoactuator behaves similarly to a capacitative element in electrical terms, and is therefore itself often referred to as a capacitative element. The capacitative element is longer or shorter depending on its charge state. The change in length of the capacitative element is transferred to a valve element of the fuel injector.
[0003] In the event of an interruption in activation of the capacitative element, or a malfunction of one of the components, it may happen that the capacitative positioner remains continuously in one specific position because it can no longer be discharged. In a context of use in a fuel injector, the result of this may be, for example, that the latter remains in the open position for a long period of time, and fuel is continuously injected into the combustion chamber of the internal combustion engine. This may result in severe damage to the internal combustion engine.
[0004] The ohmic resistance is provided to prevent such a situation. It enables discharging of the capacitative element even when the actual control line is interrupted, e.g. due to a cable break or a contact fault. The value of the ohmic resistance is dimensioned such that the time constant resulting from the capacitative element and the ohmic resistance is so great that no significant discharge of the capacitative element occurs within the usual activation time period that is usual for fault-free injection. On the other hand, the time constant is set so that the capacitative element is sufficiently discharged within the maximum time available before the valve must definitely be closed in order not to damage the internal combustion engine.
[0005] German Published Patent Application No. 199 58 406 proposes to sense the value of the ohmic resistance at specific points in time, and to draw conclusions therefrom as to the nature and/or the temperature of the capacitative element. The temperature dependence of the capacitative element may thereby be corrected.
SUMMARY OF THE INVENTION
[0006] The present invention may enhance operating reliability when a capacitative element is used.
[0007] This may be achieved, in the context of a method of the kind cited initially, in that correct functioning of the ohmic resistance is monitored, and a fault signal is outputted upon detection of a malfunction.
[0008] An exemplary method according to the present invention may monitor the functionality of the ohmic resistance representing a safety device in order to detect states in which that safety device can no longer perform the function assigned to it. This in turn may make it possible, for example, to seek out in timely fashion a maintenance facility that can repair the safety device, i.e. the ohmic resistance, and thus restore the operating reliability of, for example, an internal combustion engine.
[0009] In a first exemplary embodiment, the value of the ohmic resistance may be sensed and compared with a limit value. A corresponding exemplary method for sensing the value of the ohmic resistance is described in German Published Patent Application No. 199 58 406. Sensing the value of the ohmic resistance and comparing the sensed value with a limit value may be simple and reliable capability for checking the functionality of the ohmic resistance. This is because if the ohmic resistance loses contact with the capacitative element, e.g. as a result of a poor solder joint, the value of the ohmic resistance rises sharply. This may be unequivocally detected by way of the claimed comparison with a limit value. It may also be possible to monitor whether the value of the ohmic resistance is within a tolerance band.
[0010] In another exemplary embodiment, the value of the ohmic resistance may be sensed during a startup phase of a control unit with which the capacitative element is activated, and/or during a shutdown phase of the control unit when the latter is being switched off. The above-claimed sensing of the value of the ohmic resistance may not be possible in every case during normal operation of the capacitative element. This is because in order to sense the value of the ohmic resistance (in accordance with the exemplary method indicated in German Published Patent Application No. 199 58 406), it may be necessary to charge the capacitative element to a certain voltage and to sense the discharge curve through the ohmic resistance. A sufficiently high voltage may be important in this context, since the error may become too great at excessively low voltages. This may not be achievable during normal operation of the capacitative element.
[0011] Prior to actual operation of the capacitative element, however, there exist a startup phase of the control unit that activates the capacitative element. During this startup phase of the control unit, for example, a self-test may be executed and certain initial values are set. The same also applies to the shutdown phase of the control unit, which may be necessary for controlled shutoff of the capacitative element and of the device in which the capacitative element is being used. During these phases, the capacitative element is not yet being used as intended, so that charging and discharging for test purposes produce no interference here.
[0012] The capacitative element may be used in an injector of an internal combustion engine, and the value of the ohmic resistance may be sensed during a coasting mode of the internal combustion engine. No fuel is usually injected into the internal combustion engine while the internal combustion engine is in coasting mode. It may therefore be appropriate to use this operating state in order to sense the value of the ohmic resistance.
[0013] In an exemplary embodiment of a method according to the present invention, correct functioning of the capacitative element may be monitored. A corresponding exemplary method therefor is described in European Patent Application No. 1 138 905. With this exemplary method according to the present invention, therefore, on the one hand correct functioning of the capacitative element may be monitored, i.e. a determination may be made as to whether activation from the control unit to the capacitative element is OK (cable break, loose connector, etc.); and on the other hand, correct functioning of the ohmic resistance, i.e. the safety device of the capacitative element, may be monitored. A high level of safety may thus be achieved with this exemplary embodiment of the method according to the present invention.
[0014] According to an exemplary embodiment, a first fault signal may be outputted when it is determined that the ohmic resistance is working correctly and the capacitative element not correctly, or when it is determined that the capacitative element is working correctly and the ohmic resistance not correctly. The user of the capacitative element may be, in this fashion, given concrete information regarding that specific malfunction. He or she may thus react accordingly, i.e. seek out a maintenance facility.
[0015] In this context, the capacitative element may be used in an injector of an internal combustion engine, and the first fault signal may cause a reduction in the maximum permitted torque of the internal combustion engine. The internal combustion engine is thus shifted into a “safety mode” in which it may continue to be operated, but only in such a manner that no permanent damage to the internal combustion engine occurs.
[0016] In this context a second fault signal may be outputted when it is determined that on the one hand the ohmic resistance and on the other hand the capacitative element are not working correctly. The result is to create a graduated fault message that informs the user not only of the existence of a malfunction, but also about the nature and severity of the malfunction. The user may thus react to the reported malfunctions in particularly effective and specific fashion. It is understood in this context that the second fault signal indicates a more serious malfunction than the first fault signal. This is because if on the one hand the ohmic resistance and on the other hand the capacitative element are not working correctly, this means that the risk of damage to the apparatus being operated with the capacitative element may be particularly high.
[0017] If the capacitative element is used in an injector of an internal combustion engine, the second fault signal should cause the affected cylinder to be shut off, the fuel pressure to be reduced, and/or the internal combustion engine to be shut down. These actions may reduce the risk of permanent damage to the internal combustion engine, or may entirely rule out such a risk.
[0018] It may also be desired if the first and/or the second fault signal result(s) in an input into a fault memory and/or the triggering of a specific alarm signal. This may facilitate diagnosis at the maintenance facility and appropriate reaction by the user.
[0019] The present invention also relates to a computer program to carry out the aforesaid exemplary method when it is executed on a computer. In this context, the computer program may be stored on a memory, in particular on a flash memory.
[0020] The present invention further relates to an open- and/or closed-loop control unit for operating an internal combustion engine. In this context, such an open- and/or closed-loop control unit may encompass a memory on which a computer program of the aforesaid kind is stored.
[0021] Also the subject matter of the present invention may include an internal combustion engine having a combustion chamber, having at least one injector that encompasses a capacitative element as actuator and that encompasses an ohmic resistance connected in parallel with the latter. To enhance the operating reliability of the internal combustion engine, it is proposed that it encompass an open- and/or closed-loop control device of the aforesaid kind.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] FIG. 1 schematically depicts an internal combustion engine having an injector that encompasses a piezoactuator.
[0023] FIG. 2 shows a detail of the piezoactuator of FIG. 1 and a control unit for activating it.
[0024] FIG. 3 is a flow chart of an exemplary method operating the piezoactuator of FIG. 1 .
[0025] FIG. 4 is a flow chart of a further exemplary method for operating the piezoactuator of FIG. 1 .
DETAILED DESCRIPTION
[0026] In FIG. 1 , an internal combustion bears in its entirety the reference character 10 . It encompasses a combustion chamber 12 into which fresh air is introduced through an inlet valve 14 and an intake duct 16 . The hot combustion gases are discharged from combustion chamber 12 through an outlet valve 18 and an exhaust duct 20 .
[0027] Fuel is introduced directly into combustion chamber 12 through an injector 22 that is activated by a control unit 24 and receives fuel under high pressure from a fuel system 26 . Injector 22 encompasses a valve needle (not depicted in FIG. 1 ) that is actuated by a piezoactuator 28 . The fuel/air mixture present in combustion chamber 12 after an injection is ignited by a spark plug 30 (note in this context that the use of injector 22 is not confined to gasoline internal combustion engines, but that it may also be used in diesel internal combustion engines).
[0028] As is evident from FIG. 2 , piezoactuator 28 encompasses a multi-layer piezo positioner 32 whose length depends on its electrical charge state. Since a multi-layer piezo positioner of this kind has electrical properties similar to those of a capacitative element, it may also itself be referred to as a capacitative element. An ohmic resistance 34 is connected in parallel with multi-layer piezo positioner 32 . Multi-layer piezo positioner 32 and ohmic resistance 34 thus constitute an RC element.
[0029] Piezoactuator 28 may be connected, for example via a hydraulic coupler (not depicted), to the valve needle of injector 22 , and may influence the position of the valve needle depending on the voltage present at multi-layer piezo positioner 32 . In an exemplified embodiment that is not depicted, the piezoactuator actuates a hydraulic control valve that causes a motion of the valve needle by way of a pressure change in a control chamber.
[0030] Multi-layer piezo positioner 32 and ohmic resistance 34 are, via their one terminal, on the one hand grounded (reference character 36 ) and on the other hand connected to an evaluation block 38 that is part of open- and closed-loop control unit 24 and is discussed in greater detail below. At their other terminal, multi-layer piezo positioner 32 and ohmic resistance 34 are on the one hand again connected to evaluation block 38 and on the other hand connected to an output stage switch 40 . As once again discussed in detail below, the manner of connection of evaluation block 38 makes it possible to sense, by means thereof, the voltage drop occurring through RC element 32 , 34 .
[0031] Output stage switch 40 is activated by a control block 42 that receives and processes different input signals, also including signals from evaluation block 38 . Multi-layer piezo positioner 32 and ohmic resistor 34 can be connected via output stage switch 40 to an energy source 44 . Additionally disposed between output stage switch 40 and energy source 44 is a monitoring device 46 whose exact function will once again be discussed in detail below.
[0032] Control block 42 additionally activates a further output stage switch 48 that may ground (reference character 50 ) the other terminal of capacitative element 32 and of ohmic resistance 34 . Piezoactuator 28 is connected to open- and closed-loop control unit 24 via a line 52 and a connector 54 .
[0033] During normal operation of internal combustion engine 10 , injector 22 with multi-layer piezo positioner 32 works as follows: When fuel is to be injected by injector 22 into combustion chamber 12 of internal combustion engine 10 , first output stage switch 40 is closed by control block 42 , and second output stage switch 48 is opened. Multi-layer piezo positioner 32 is thus connected to energy source 44 . The voltage now present at capacitative element 32 causes an elongation of the capacitative element which, as already indicated above, causes valve needle of injector 22 to lift off from a corresponding valve seat and open a passage for fuel from fuel source 26 into combustion chamber 12 .
[0034] When the injection of fuel into combustion chamber 12 is to be terminated, output stage switch 48 is closed by control block 42 (output stage switch 40 having been opened again immediately after the end of the charging operation). Both terminals of multi-layer piezo positioner 32 are thus grounded (reference characters 36 and 50 ), so that multi-layer piezo positioner 32 discharges again and becomes correspondingly shorter. As a result, the valve needle of injector 22 once again comes into contact against the corresponding valve seat so that communication between fuel system 26 and combustion chamber 12 is again interrupted.
[0035] Reliable operation of capacitative element 32 may be important for the overall operating reliability of the internal combustion engine. Without corresponding countermeasures, it may happen that, for example in the event of a break in cable 52 or a loose connector 54 , multi-layer piezo positioner 32 is no longer connected to open- and closed-loop control device 24 and thus may no longer be activated. If the connection between multi-layer piezo positioner 32 and open- and closed-loop control device 24 is interrupted while multi-layer piezo positioner 32 is charged, i.e. while an injection of fuel into combustion chamber 12 of internal combustion engine 10 is occurring, then without corresponding countermeasures, that injection may not be terminated. This may result in severe damage to internal combustion engine 10 .
[0036] To prevent this, ohmic resistance 34 is connected in parallel with multi-layer piezo positioner 32 . This resistance is dimensioned so that the time constant resulting from multi-layer piezo positioner 32 and ohmic resistance 34 (which constitute an RC element) is so great that no significant discharge of capacitative element 32 occurs within the usual activation time period that is necessary and usual for a fault-free injection of fuel into combustion chamber 12 . On the other hand, the time constant is set so that multi-layer piezo positioner 32 is sufficiently discharged within the maximum time available before injector 22 must definitely be closed in order not to damage internal combustion engine 10 . When appropriately dimensioned, ohmic resistor 34 therefore acts as a so-called “bleeder resistance.”
[0037] If a break in line 52 or a detachment of connector 54 occurs while injector 22 is open, multi-layer piezo positioner 32 is therefore discharged through ohmic resistance 34 , and injector 22 is thus closed again. Ohmic resistance 34 is therefore an important safety device of injector 22 . The knowledge that this safety device is functional may thus enhance the overall operating reliability of internal combustion engine 10 . The functionality of ohmic resistance 34 is determined, during a coasting mode of the internal combustion engine, during startup and during shutdown of open- and closed-loop control device 24 , as follows (see FIG. 3 ):
[0038] The exemplary method depicted in FIG. 3 begins with a Start block 56 . After this, in block 58 multi-layer piezo positioner 32 is charged to a defined voltage U. Simultaneously, a time counter t is set to zero. The subsequent query in block 60 checks whether the value of time counter t is greater than or equal to a time threshold t 1 . If that is not the case, the time counter is then incremented in 62 , and the query in block 60 is made again. If time counter t is greater than or equal to time threshold t 1 , the voltage U 1 at that time t 1 is then measured in block 64 .
[0039] The next step 66 queries whether the content of time counter t is greater than or equal to a second time threshold t 2 . If that is not the case, the time counter is then incremented in block 68 . If it is the case, the value U 2 of the voltage at time t 2 is then ascertained in block 70 .
[0040] The voltage in the RC element constituted by multi-layer piezo positioner 32 and ohmic resistance 34 decreases over time according to an exponential function, the exponential function being determined substantially by a time constant. By measuring voltage U 1 at time t 1 and voltage U 2 at time t 2 , the time constant may be determined and, if the capacitance of capacitative element 32 is known, therefore the value R of ohmic resistance 34 . This calculation of the value R is performed in block 72 .
[0041] Block 74 then queries whether the value R is greater than a limit value G. If the response to the query in block 74 if No, this indicates that ohmic resistance 34 is working correctly (block 76 ). If, however, a solder joint with which ohmic resistance 34 is connected to multi-layer piezo positioner 32 is defective, for example, the value R of ohmic resistance 34 rises sharply and exceeds limit value G. In this case the response to the query in 74 is Yes, and that logical signal is further processed in block 78 in a manner depicted below in detail. The checking of the functionality of ohmic resistance 34 ends in an End block 80 .
[0042] FIG. 4 depicts the processing in processing block 78 in detail. That processing contains substantially a combination of the logical Yes result of query block 74 with the logical results of the diagnosis of the functionality of capacitative element 32 by way of monitoring block 46 (see FIG. 2 ). Block 82 queries whether multi-layer piezo positioner 32 is or is not functional. If a defect is present, a bit B 2 =1 is set at the output of block 82 . If no defect is present, bit B 2 =0 is set at the output of block 82 . Analogously, a bit B 1 =1 is set at the output of query 74 if the value R of ohmic resistance 34 is greater than the limit value G, i.e. if there is a defect in ohmic resistance 34 . The same bit B 1 is set to zero when ohmic resistance 34 is working in fault-free fashion.
[0043] The respective outputs of queries 74 and 82 are fed into three logical AND blocks 84 , 86 , and 88 . The output of query block 74 is inverted in block 90 before being fed into block 84 , and the output of query block 82 is inverted in block 92 before being fed into block 86 . The two AND blocks 84 and 86 are connected on the output side to an OR element 94 whose output is again connected to an OR element 96 . The output of AND block 88 leads directly to an OR element 98 .
[0044] OR elements 96 and 98 ensure that the exemplary method described in FIG. 4 is performed for all the cylinders 1 through i of internal combustion engine 10 . The output of OR element 96 leads to an alarm block 100 , and the output of OR element 98 to a second alarm block 102 .
[0045] If both bits B 1 and B 2 are equal to zero (capacitative element 32 and ohmic resistance 34 are each working correctly), a bit =0 is also present at the respective outputs of AND blocks 84 , 86 , and 88 , so that ultimately neither alarm block 100 nor alarm block 102 is activated. If, however, bit B 1 =1 (ohmic resistance 34 is defective), and bit B 2 =0 (capacitative element 32 is working correctly), this results in a bit=1 at the output of AND block 86 , so that ultimately alarm block 100 is activated.
[0046] The same also applies to the case in which bit B 1 =0 (ohmic resistance 34 is working correctly), but bit B 2 =1 (capacitative element 32 is defective). In this case a logical value of 1 is present at the output of AND block 84 , once again ultimately resulting, via OR element 94 , in the activation of alarm block 100 . Lastly, if bit B 1 =1 (ohmic resistance 34 is defective) and bit B 2 =1 (capacitative element 32 is defective), this then results in a bit=1 at the output of AND block 88 , which ultimately causes the activation of alarm block 102 .
[0047] Alarm block 100 causes an input into a fault memory and the illumination of a warning light. In addition, the maximum torque that may be generated by internal combustion engine 10 is reduced. Upon activation of alarm block 102 , on the other hand, the affected cylinder is shut down, fuel pressure is reduced and, if applicable, the entire internal combustion engine 10 is shut down. The exemplary method depicted in FIG. 4 thus permits a graduated reaction, depending on whether only piezo positioner 32 or only ohmic resistance 34 , or both piezo positioner 32 and ohmic resistance 34 simultaneously, are defective.
|
A positioner includes a capacitative element with which an ohmic resistance is connected in parallel. The value of the ohmic resistance is sensed at specific points in time. To enhance operating reliability during operation of the positioner, correct functioning of the ohmic resistance is monitored, and a fault signal is outputted upon detection of a malfunction.
| 5
|
This invention pertains to humidifiers and more particularly to improved means for automatically controlling and regulating the humidity of an enclosed atmosphere.
BACKGROUND OF THE INVENTION
In the art of baking breads and like bakery goods, it is time honored practice to hold the dough having a rising agent, for a period of time to enable the dough to properly rise prior to baking. In commercial bakeries this evolution is usually carried out in a so called "proofing-box" or cabinet having an enclosed atmosphere in which the temperature and humidity are regulated to insure uniform consistency and quality in the baked end products.
Generally, past practice has employed steam, generated in a heated open tray or pan and circulating air to humidify the proofing box atmosphere. Problems arise with this approach, however, due to the inability to accurately control the steaming cycle, particularly as to the time required to start and stop steam generation and its release into the atmosphere. Consequently, automatic humidity control and regulation under the prior art has been relatively inaccurate.
One typical attempt at resolving this difficulty is demonstrated in U.S. Pat. No. 3,456,598, issued July 22, 1969, wherein a cover is placed over an open steaming tray having an immersed heater; the cover being manually adjustable to regulate release of steam into the atmosphere.
In a related field of development, U.S. Pat. No. 3,895,215, issued July 15, 1975, utilizes heated moving air streams into which water vapor is released for humidifying the atmosphere of a food holding and warming cabinet.
SUMMARY OF THE INVENTION
This invention is directed to an improved system for automatically controlling the humidity of an enclosed atmosphere in contravention of the difficulties and shortcomings of the prior art.
In brief, the invention includes a control system comprising a heater in intimate heat transfer relation with an open top cast metal steamer tray, a time regulated water control valve having a selectively operable time delay for regulating the open time of the valve, a thermal responsive means reactive to the temperature of the tray casting and in control relation with the tray heater and water control valve, and a humidity responsive means controlling operation of the thermal responsive means. The control arrangement is such that when the humidity responsive means demands humidity, the thermal responsive means is actuated to energize the steamer heater. When the tray casting reaches a predetermined high temperature, the the heater is deactivated and the water control valve supplies water to the heated tray for a set time interval. The water evaporates rapidly and cools the heated tray casting until it reaches a preset low temperature whereupon the heater is again activated to evaporate any water remaining in the tray and reheat the casting until it reaches its upper temperature limit; this cycle is repeated until the humidistat is satisfied and the steamer heater thermostat is deenergized. In a preferred embodiment the control system is electrically powered.
It is an important object of this invention to provide an improved system for controlling the humidity of an enclosed atmosphere.
It is another important object of this invention to provide an improved steam generating means and means for controlling its operation to produce relatively constant humidity levels in an enclosed atmosphere.
It is a further object of this invention to provide a humidifier for enclosed atmospheres which utilizes a steam generating means that is rapidly responsive to humidity requirements.
It is still another important object of this invention to provide an improved steam generating means for a humidifier system which utilizes an electrical heater embedded in a cast metal steamer tray and thermostatic switch means which respond to the temperature of the tray casting for controlling the heater.
Another important object of this invention is to provide a system for automatically regulating the humidity levels of an enclosed atmosphere which comprises a thermostatically controlled heater and water supply means arranged so that water is periodically supplied to a heated cast metal steamer tray in small time measured quantities at predetermined temperatures of the tray casting to generate and release limited quantities of steam into the atmosphere.
Having described this invention the above and further objects, features and advantages thereof will be recognized by those familiar with the art from the following detailed description of a preferred embodiment thereof, illustrated in the accompanying drawings, and representing the best mode presently contemplated for enabling those with skill in the art to practice this invention.
IN THE DRAWINGS
FIG. 1 is a perspective view of a dough proof box embodying the feature of this invention;
FIG. 2 is a side elevation, with parts broken away of an improved steamer tray of this invention; and
FIG. 3 is a schematic diagram of an electrical control circuit according to this invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
With reference to the drawings, the features of a preferred embodiment of this invention, will be described.
As shown in FIG. 1, a typical dough proofing box, is indicated generally at 10. Box 10 comprises an insulated upright cabinet 11 equipped with a hingedly mounted front door 12 providing access to the cabinet's interior in which dough is to be held in an environment of controlled temperature and humidity. Suitable temperature and humidity operating controls 13 are located at the upper end of the cabinet along with air circulating ducts, blowers and heaters for supplying heated air to a distribution duct 14 located along one side of the cabinet's interior. An improved steamer tray assembly 15, of this invention is mounted adjacent the outlet end of the air supply duct 14. Water and electricity are supplied to the tray 15 and controls 13, respectively, as will appear presently.
With special reference to FIG. 2, the tray assembly 15 comprises an open top tray 20, preferably cast of aluminum or other material capable of good heat conduction. The tray is elongated, of generally rectangular configuration and has an open top tank chamber 21 extending inwardly of its upper side for reception of water from a supply fitting 22 attached to bracket 23 fixed to one end of the tray.
A tray support bracket 25, comprising a large planar body 26 formed with a right angularly related support flange 27 along its lower edge is adapted to be attached to an interior wall of the cabinet 11 as by sheet metal screws (not shown) receptive in mounting openings 28 in body 26. Bolts 29 extend through shelf or flange 27 into the underside of the tray body to fix the tray to bracket 25.
Internally the tray casting contains one or more electrical calrod type heating elements 30, preferably cast with the body of the tray. A thermal probe 31 also extends into the tray casting to sense the latter's temperature. Probe 31 fits into a bore socket adjacent heater element 30 and may be removed for repair or replacement as needed. Electrical leads for heater element 30 and probe 31, extend through a cylindrical boss 34 formed at one end of the tray and provided with external threads. Internally threaded sleeve 35 thread over the boss 34 and a connector fitting 36 fixed to a junction box 37 (shown uncovered). Conduit 38 carries electrical conductors (not shown) to a terminal plate 39 to which the electrical leads from the tray heater element and thermal probe are also joined.
With reference to FIG. 3, the features of an electrical control system according to this invention for controlling the internal environment of the dough proofing box 10 of FIG. 1 will now be described.
As there indicated line conductors L 1 and L 2 and neutral conductor N are supplied from a normal 208/240V or greater, 60 Hz supply source.
An air heating element 40, in series circuit with relay contacts 1R 1 and 1R 2 is connected between conductors L 1 and L 2 . Element 40 works in conjunction with blower motor 41 in series with manual control switch 42 and protective fuse 43 connected across L 1 and N to energize heater 40 and circulate air within the proofing box cabinet 11. A ready light 44 in parallel circuit with motor 41 indicates the "on" or energized state of the motor circuit.
An air heater thermostat 45 having a heater coil 46 and thermal responsive switch contacts 47 controls relay 1R 1 ; closure of switch 47 serving to energize relay contacts 1R and 1R 2 to energize heater 40. Thermostat 45 is energized with the motor circuit via a normally closed thermally responsive switch 48 set to open at a predetermined high temperature limit for the air heater element 40. Opening of switch 48 serves to energize an alarm light 49 to indicate the overheated condition of the heater element as would occur if relay 1R failed to open contacts 1R 1 and 1R 2 in response to the supervising operation of thermostat 45. A ready light 50 in parallel circuit with relay 1R indicates that heater 40 is "on".
Humidity is regulated by a steamer control circuit in series relation with the motor and heater control circuit above described; such being conditioned for operation upon closure of the manual heat control switch 42.
More specifically, as indicated in FIG. 3, a manually operated switch 55 in series with a humidistat 56 exercises overall control of steamer thermostat 57. A ready light 58 is in circuit with switch 55 to indicate the "on" condition of switch 55. This advises the operator that humidity is demanded. The steamer thermostat 57 is activated in response to closure of the humidistat 56 which is capable of being selectively adjusted to "open" at desired humidity levels. Thus when the atmospheric humidity is lower than the desired level, switch 56 is closed and remains so until its set humidity level is attained. With switch 56 closed the steamer thermostat is activated to respond to the temperature of the steamer tray 20 as sensed by the temperature probe 31 described heretofore. The thermostat is set to "close" at sensed temperatures below a selected low temperature, such as 220° F., and to "open" at a preset high temperature of 230° F., by way of illustration.
The closed condition of the thermally responsive switch 57, as indicated in FIG. 3, energizes relay 2R which closes contacts 2R 1 and 2R 2 in circuit with the steamer heating element 30 to energize the same. It will be noted that element 30 is guarded by a manually resettably, thermally responsive switch 59 set to open at a preset high temperature of the steamer tray. Opening operation of switch 59 deenergizes the steamer heating element in the event of failure of relay 2R, thereby guarding element 30 from overheating.
When the steamer tray temperature reaches a preset high limit (in the order of 230° F. in the illustrated case), relay 2R is deenergized by operation of the thermostatic switch 57. Opening operation of the thermostat serves to energize a water control circuit by moving the thermostat's switch arm from primary contact 60 to a secondary contact 61. At the same time the heating element 30 is deenergized with opening operation of relay contacts 2R 1 and 2R 2 .
Energization of the secondary thermostat contact 61 serves to energize a timer 62, such as a digital time delay circuit module commercially available from INFITEC, INC., Syracuse, N.Y. Timer 62 in turn serves to operate a water control valve 63 to "open" for a preset time interval (in the order of 3 seconds) to supply a limited quantity of water to the hot steamer tray 20. Typically an electrically operated solenoid operated valve is ideal for the purpose. A ready light 64 turns on and off with energization and deenergization of relay 2R to indicate the status of the humidity control circuit.
Water introduced into the hot steamer tray rapidly generates steam into the heated air supplied by duct 14. This humidifies the atmosphere and cools the steamer tray to below the 220° F. thermostat setting, causing the latter to reenergize the tray heating element 30 and deenergize timer 62 and water supply valve 63.
Any water remaining in tray 20 is steamed off and when the tray is dry its temperature rises until it again reaches the "high" temperature of 230° F. The tray heater is again deenergized, water is added to the tray and the cycle repeats until the required humidity demanded by humidistat 56 is satisfied.
While the circuit described and shown in FIG. 3, embodies only one tray heating element 30, more than one such element may be employed as required to rapidly heat the steamer tray.
In light of the foregoing it is believed those of skill in the art will readily recognize the improved advancement of this invention over the prior art. Further, while the invention has been described in relation to a preferred embodiment thereof, such is readily susceptible to modification, change and substitution of equivalents without departing from the scope of the invention as defined in the following appended claims.
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An electrical control system for regulating the humidity of an enclosed atmosphere in a dough proof box or the like, comprising a cast metal steamer tray, incorporating an electrical heating element operable to heat the tray between selected upper and lower temperature limits determined by a thermostat responsive to temperatures of the tray casting. A time controlled valve supplies water to the tray for selected time intervals when the thermostat senses the tray's upper temperature. A humidistat controls operation of the thermostat. As a result, the steamer tray is heated between high and low limits and supplied with measured amounts of water to effect rapid generation of limited quantities of steam to satisfy the humidity levels demanded by the humidistat.
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FIELD OF THE INVENTION
The present invention relates to integrated circuit packages, and in particular to a solder interconnection ball joint for ball grid array packages.
BACKGROUND OF THE INVENTION
Integrated circuit die are typically housed in closed packages. The packages include internal and external structures for electrically connecting the die in the package to external circuitry, e.g., a circuit board. One known type of package is a ball grid array ("BGA") package.
BGA packages characteristically have an array of solder interconnection balls, sometimes described as "bumps", in a selected pattern on a bottom external portion of the package. The interconnection balls are placed on metallic portions of an external circuit board, heated, and upon re-solidifying, form conductive, metal-to-metal bonds with metallization or metal traces the circuit board.
BGA packages typically have a flat, insulating substrate base having first and second surfaces. The integrated circuit die enclosed in the package is above an interior first surface of the substrate. The substrate has a plurality of through-holes drilled between its interior (i.e., within the package) first surface and exterior second surface. The circumference of each drilled through-hole is lined throughout its entire length with metal, so that a conductive metallized via is formed between the interior and exterior surfaces of the substrate. The hole at the center of the via may become filled with epoxy solder mask material as a result of manufacturing steps which apply layers of epoxy solder mask material onto the surfaces of the substrate.
Metal conductive structures within the package, such as metal traces on the interior first surface of the substrate and bond wires, electrically connect the metal lining of each of the vias to contact pads on the die. At an opposite end of each via, at the exterior second surface of the substrate, the metal of the via is electrically connected to metal lines or traces on the exterior surface of the substrate. These metal traces extend laterally away from the via to a flat metal interconnection ball land on the exterior surface of the substrate. Hence, the land is displaced from the metallized via.
A heated solder interconnection ball is placed on the exposed metal surface of the land. Upon re-solidification of the solder, an interconnection ball joint is formed at the intersection of the interconnection ball and the metal surface of the land. The metal-to-metal bond between the interconnection ball and the land at the joint is uninterrupted, with no purposeful discontinuities or voids.
BGA packages having such uninterrupted metal-to-metal bonding at their interconnection ball joints are prone to electrical connectivity failures. Applicants have discovered, for example, in packages where solder interconnection balls are in an uninterrupted metal-to-metal bond with a nickel layer of an interconnection ball land, that the nickel layer tends to crack, causing a failure in the electrical connection between the interconnection ball and the package.
Accordingly, there is a need for a package, which may be readily manufactured and is not susceptible, or is less susceptible, to failure by cracking at the metal-to-metal joint between a land on the package substrate and the interconnection ball.
SUMMARY OF INVENTION
Embodiments of an improved interconnection ball joint for a ball grid array ("BGA") integrated circuit package are disclosed. The joint has improved cracking resistance compared to the interconnection ball joints on conventional BGA packages.
The package has a substrate base. The substrate has a first surface and an opposite second surface. The integrated circuit die is affixed, such as by a conventional adhesive, to the first surface of the substrate. A metal-lined via extends through the substrate from the first surface to the second surface of the substrate. This metallized via has a central hole, i.e., within the metal plating that lines the walls of the via. The hole extends throughout the length of the via, i.e., through the substrate from the first surface to the second surface of the substrate.
A planar metallic interconnection ball land is formed on the second surface of the substrate. The land is integral with the metal lining of the metallized via. The land is adjacent to and formed around the via and the hole.
The central hole within the metal lining of the via contains, at least adjacent to the land, a plug of a flexible nonconductive material, such as epoxy solder mask material. In the example, the plug of nonconductive material within the via extends throughout the entire length the hole through the substrate.
A metallic solder interconnection ball is placed symmetrically and accurately on the planar surface of the land, forming an interconnection ball joint. At the joint, the interconnection ball is centered on and opposite the metallized via and the plug of nonconductive material in the central hole of the via. The interconnection ball forms a metal-to-metal annular bond with the land around the plug of nonconductive material in the central hole of the via.
In contrast with the interconnection ball joints of conventional BGA packages, which have uninterrupted metal-to-metal bonds at the joints between the interconnection balls and lands, joints in accordance with the present invention have a discontinuity in their metal-to-metal bonds. In the embodiments described herein, the metal-to-metal bonding at the joint occurs around the approximately circular surface of the plug of nonconductive material in the central hole of the metallized via.
Joints in accordance with the present invention unexpectedly demonstrate superior shearing strengths and cracking resistance, compared to conventional interconnection ball joints, due to the presence of such discontinuities in the metal-to-metal bonding at the joint. This reduces the risk of electrical failure due to cracking at the joint. Moreover, the embodiments described herein achieve this result in a manner which allows miniaturization of the package itself, because the interconnection balls are placed directly below the conductive vias through the substrate, eliminating the need for some or all metal traces on the external lower substrate surface.
A example package employs a plurality of such interconnection ball joints. The integrated circuit die within the package is electrically connected to the interconnection balls by a conductive path that extends through the metallized vias and the interconnection ball lands. The die and the other structures on the first surface of the substrate are encapsulated in a conventional encapsulating material, such as plastic.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a cross-sectional side view of a portion of a BGA package, before encapsulation of the die and bond wires, which displays a single interconnection ball land prior to placement of an interconnection ball on the land.
FIG. 2 is a top view of an interconnection ball land on the bottom external surface of a BGA package.
FIG. 3 is a cross-sectional side view of a portion of a BGA package, before encapsulation of the die and bond wires, which displays a single interconnection ball joint.
FIG. 4 is a cross-sectional side view of an integrated circuit package showing a plurality of interconnection ball joints.
DETAILED DESCRIPTION
FIG. 1 shows relevant portions of an exemplary BGA package in accordance with the present invention, before an interconnection ball is placed on the package and before encapsulation of the die and bond wires. Substrate 11 is a substantially planar sheet of a nonconductive material. Substrate 11 forms an insulating base of the BGA package.
Substrate 11 has an upper first surface 12. Inside the package, integrated circuit die 10 rests on and is affixed to upper first surface 12. Substrate 11 has a lower second surface 13, which is opposite upper first surface 12. Lower second surface 13 forms the external underside of the BGA package. Portions of upper first surface 12 and lower second surface 13 of substrate 11 are covered by layers 14 of a non-conductive epoxy solder masking material.
In this embodiment, substrate 11 is formed of a flat non-conductive laminate. An example thickness of substrate 11 is 0.36 mm to 0.56 mm, but the thickness may vary depending on the package application. Examples of suitable laminates include Mitsubishi-BT, Arlon 45N, and Nellco BT. Alternatively, substrate 11 may be ceramic or insulated metal.
Metallized via 15 of FIG. 1 is a metal-lined, epoxy-filled circular drill hole that extends though substrate 11, from upper first surface 12 to lower second surface 13. Lining the circumferential walls of via 15, throughout its length and about its entire circumference, is conductive metal plating 16. Within the metallized walls of via 15, throughout its length and adjacent to plating 16, is plug 17. Plug 17 fills the central hole within metal lining 16 of via 15.
Plug 17 is formed of a compliant, non-conductive material. In the example of FIG. 1, plug 17 is formed of epoxy solder mask material like layers 14. However, the material of plug 17 does not necessarily have to be the same as the material of layers 14.
Metallized via 15 of FIG. 1 may be formed by, first, drilling a circular hole through substrate 11. An example drill hole diameter is approximately 0.3 mm. Then, metal plating 16 is deposited on the walls of the drill hole, throughout its length and about its entire circumference, forming a conductive path through substrate 11. Metal plating 16 may be a layer of copper that is 0.0025 mm thick that is deposited by a conventional PTH copper plating process.
After the metal plating step, there is an unfilled hole at the approximate center of via 15, within metal plating 16. This central hole extends the length of via 15, from upper first surface 12 to lower second surface 13 of substrate 11. Plug 17 is formed in this central hole of via 15. Plug 17 may be formed during the formation of layers 14, or by a separate step particularly aimed at filling the hole within via 15.
The shape, dimensions, and materials of via 15 may vary, depending on the packaging application. For example, the diameter of via 15 may be larger or smaller. If larger interconnection balls are used, then via 15 may have a larger diameter, and vice versa. The desired size of the package and the reliability and electrical requirements of the package are also considerations in determining the size of via 15. As another example, instead of copper, metal plating 16 may be another metal, such as gold. As a final example, instead of epoxy solder mask material, plug 17 can be formed of a different material that is compliant, non-conductive, and does not form a bond with the metal of the land or interconnection ball. An alternative material for plug 17 is silicone, which is readily obtainable from the Dow Corning Company, among other sources.
At the intersection of via 15 and upper first surface 12 of substrate 11, via 15 is electrically connected to a conductive metal trace denoted as metallization 18, which extends laterally away from via 15 on upper first surface 12 of substrate 11. An opposite second end of metallization 18 is electrically connected to a conductive metal contact 19, which in turn is connected by a conductive bond wire 20 to a conductive bonding pad on die 10. Thus, there is a conductive path between die 10 and metal plating 16 of via 15. There are a variety of alternative, conventional ways to effect such an electrical connection, such as with tape automated bonding or a flip-chip configuration.
Returning to FIG. 1, a conductive approximately planar metal interconnection ball land 21 is formed around via 15, at the intersection of via 15 with lower second surface 13 of substrate 11. The metal of land 21 is integral with metal lining 16 of via 15, ensuring electrical connectivity, and is around plug 17. In the embodiment of FIG. 1, land 21 is formed of substantially planar layers of three different metals. Beginning at lower second surface 13 of substrate 11, these metal layers include: an underlying first metal layer 23, which is connected to plating 16 of via 15; an intermediate second metal layer 24; and a topmost third metal layer 25.
As examples, layer 23 may be copper that is approximately 0.019 mm to 0.038 mm thick; intermediate layer 24 may be nickel that is approximately 0.005 mm thick; and topmost layer 25 may be gold that is approximately 0.0005 mm thick. Each of these copper, nickel, and gold layers may be deposited on substrate 11 by conventional electroplating methods, such as the Learonal method.
In FIG. 1, the metal plane of land 41 has a discontinuity, specifically a circular hole, at its center. The hole is the center portion of via 15, which is adjacent to land 21 and filled with nonconductive epoxy solder mask material (i.e., plug 17). The exposed surface of plug 17, near lower second surface 13 of substrate 11 and adjacent to land 21, is substantially planar across via 15 and is approximately flush with the adjacent layer 25 of land 21. In an alternative embodiment, the exposed surface of plug 17 may be slightly below the adjacent metal surface of layer 25 of land 21.
FIG. 2 is a top view of land 21 of FIG. 1. Land 21 is depicted as having an overall circular shape, although it may have other shapes, such as a square shape, depending on the application. The exposed surface of plug 17 of via 15 is adjacent to and at the approximate center of the metal surface of land 21. Layer 25 of land 21 is exposed in this view. Land 21 surrounds plug 17, and is electrically connected to metal plating 16 of via 15. Accordingly, there is a conductive path between land 21 and die 10 through metal plating 16 of via 15.
FIG. 3 shows an embodiment, in accordance with the present invention, of an interconnection ball joint 30, which was formed by the placement of a solder interconnection ball onto land 21 of FIGS. 1 and 2. Annular joint 30 is formed at the intersection of interconnection ball 22, interconnection ball land 21, and nonconductive plug 17. A conductive metal-to-metal annular bond forms around the circular plug 17 of nonconductive epoxy solder mask material, which is contained within via 15, near lower second surface 13 of substrate 11 and adjacent to land 21. A conductive path exists between interconnection ball 22 and die 10 through land 21, via 15, and the other conductive structures described above. The shape of the perimeter of the annular joint and bond may vary, for example, according to the shape of the interconnection ball. For example, the outer periphery of the resultant annular joint may be rectilinear, and the inner periphery of the annular joint may be circular.
Interconnection ball 22 serves as a conductive connection point between the BGA package and an external circuit board (not shown).
In the embodiment of FIG. 3, interconnection ball 22 is formed of eutectic 63/37 tin/lead solder. Alternatively, other solders may be used to form interconnection ball 22, such as non-eutectic tin/lead solder, non-lead solders, or other low melting point solders formed of a metal or an alloy of metals.
In the example of FIG. 3, the eutectic solder of interconnection ball 22 is shaped, heated, and placed onto land 21. Upon re-solidification of the solder, a metal-to-metal annular bond is formed about circular plug 17 between interconnection ball 22 and land 21 (see FIG. 2).
Where metal layers 23, 24, and 25 of land 21 are copper, nickel, and gold, respectively, as in the example described above, the metal-to-metal bond at joint 30 is primarily between the nickel intermediate layer 24 and the eutectic tin/lead solder of interconnection ball 22, because all or most of gold layer 25 dissolves into the solder. Accordingly, FIG. 3 does not show gold layer 25.
Joint 30 of FIG. 3 does not have an uninterrupted metal-to-metal bond like the interconnection ball joints of the conventional BGA packages described above. Circular plug 17 in via 15 is at the approximate center of land 21 (see FIG. 2) and joint 30. Because of this epoxy-filled circular hole in the metal horizontal plane of land 21, there is a circular discontinuity in the metal-to-metal bonding at joint 30. Interconnection ball 22 forms a metal-to-metal annular bond with the planar metal surface of land 21 about plug 17, but does not bond with the nonconductive surface of plug 17.
Applicants have discovered that interconnection ball joints, such as the example of FIG. 3, having a discontinuity in the metal-to-metal bonding between the interconnection ball and the metal land demonstrate significantly higher shearing strengths than the uninterrupted metal-to-metal joints of conventional BGA packages. This result is unexpected, assuming similar size interconnection ball lands, because the area of the metal-to-metal bond of the interconnection ball joint is smaller. Applicants hypothesize that the discontinuity in the metal-to-metal bond (i.e., the central hole of via 15, which is filled with plug 17 of a non-conductive material) functions like a hole drilled in a glass automobile windshield at the tip of a propagating crack. The hole stops the crack from propagating further. In the case of FIG. 1, joint 30 reduces the risk of electrical connectivity failures due to, for example, cracking of nickel layer 24.
The embodiment of FIG. 3 is particularly suited for current and future BGA packaging applications, because of its efficient, compact design. By placing interconnection ball 22 onto land 21, opposite and directly below via 15 and plug 17, and by using via 15 as the discontinuity in land 21, metal traces on the lower surface of the BGA package can be eliminated. This reduces the package's surface area and cost.
FIG. 4 is a cross-sectional side view of an exemplary integrated circuit package 40 employing interconnection ball joints in accordance with the present invention. FIG. 4 includes components described above with respect to FIGS. 1--3. For clarity, FIG. 4 only shows two of bond wires 20, contacts 19, metal traces 18, vias 15, interconnection balls 22, and joints 30, although many more of these structure may exist in a typical package, depending on the particular packaging application. Also for clarity, layers 14 and plug 17 are not shown.
FIG. 4 shows encapsulating material 41, which covers and seals die 10, bond wires 20, contacts 19, metal trace 18, and the remainder of first surface 12 of substrate 11 within package 40. Encapsulating material 41 may be, for example, plastic, such as an epoxy resin or other resin conventionally used in semiconductor packages for encapsulation.
The above-described embodiments are exemplary. Other embodiments, within the scope of the claims below, will be apparent to those skilled in the art.
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An improved interconnection ball joint for a ball grid array integrated circuit package includes a substrate base having a first surface to which an integrated circuit die is affixed, and an opposite second surface. A metallized via extends through the substrate. The via has a central hole which extends through the substrate. The hole is plugged with a flexible nonconductive material, such as epoxy solder mask material. A metallic interconnection ball land is on the second surface of the substrate, integral with the metallized via and adjacent to the hole and the plug of nonconductive material. A solder interconnection ball is formed on the land, opposite the via and the plug of nonconductive material. A metal-to-metal annular bond is formed at the joint between the interconnection ball and the land around the plug of nonconductive material in the center of the via. The joint has an unexpectedly high shearing strength, and resists cracking, which reduces risks of a electrical connectivity failure at the joint. Location of the interconnection ball directly opposite the via allows miniaturization of the package.
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