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BACKGROUND OF THE INVENTION
The present invention relates to an automatic transmission for a vehicle which uses a belt type continuously-variable speed transmission system (hereinafter referred to as "CVT").
The CVT includes an input pulley, an output pulley and an endless belt extended between the pulleys. The input pulley and the output pulley each includes a fixed sheave secured to a rotational shaft and a movable sheave mounted movably in an axial direction of the rotational shaft by means of a servo motor, and the movable sheave can be displaced axially to thereby change the ratio of rotational speed of the output pulley relative to that of the input pulley in the range of approximately 0.5 to 2.0.
When the CVT is used as the transmission for a vehicle, a first rotational shaft having the input pulley of the CVT mounted thereon is connected to an output shaft of an engine through a coupling means, and between a second rotational shaft having the output pulley of the CVT mounted thereon and a differential device are provided with a planetary gear mechanism, a forward-reverse changeover mechanism. A low-high speed changeover mechanism is provided in the planetary gear mechanism, if necessary. Generally speaking, the forward-reverse changeover mechanism and the low-high speed changeover mechanism are necessary to provide with a clutch for connecting specific elements of the planetary gear mechanism or a brake adapted to connect a specific element of the planetary gear mechanism in a stationary position. However, when a wet multiple-disc type clutch or brake is employed as the aforementioned clutch or brake, it is difficult to load the transmission on a small automobile because the diameter of a frictional engaging element of said wet multiple-disc type clutch or brake is large, resulting in a large dimension of the whole transmission for a vehicle.
What is needed is an automatic transmission for a vehicle wherein a forward-reverse changeover gear mechanism or a low-high speed changeover gear mechanism, which is provided between the rotational shaft having the output pulley of the CVT mounted thereon and a transmission output shaft for a vehicle, is miniaturized and light-weighted.
SUMMARY OF THE INVENTION
Generally speaking, in accordance with the present invention, an automatic transmission for a vehicle especially suitable for a small size, front-engine front-drive automobile provided with a belt type continuously-variable speed transmission system (CVT) and a planetary gear mechanism, is provided. The CVT includes an input pulley mounted on a first shaft, an output pulley mounted on a second shaft and an endless belt extended between the input pulley and output pulley to transmit power. The first shaft is disposed coaxially with and coupled to an output shaft of a coupling means, and the second shaft is disposed parallel with the first shaft. The input pulley and output pulley each includes a fixed sheave and a movable sheave which is well known.
The planetary gear mechanism has its input shaft and output shaft disposed coaxially with the second shaft of the CVT and includes at least one forward speed range and one reverse range.
The planetary gear mechanism according to the present invention is of the type in which a first element thereof is braked and held in a stationary position by means of brake means thereby establishing the forward range whereas a second element is braked and held in a stationary position by means of brake means thereby establishing the reverse range. To this end, one end of a first intermediate shaft is connected to the first element whereas one end of a second intermediate shaft is connected to the second element, the first and second intermediate shafts being selectively held by the forward-reverse changeover mechanism. The brake means includes a sleeve which is disposed coaxially with and slidably movable but non-rotatable with respect to the rotational axis of the input shaft of the planetary gear mechanism and having splines adapted to selectively mesh with splines formed on the first and second intermediate shafts, whereby the outer diameter of the brake means is reduced as compared with a wet multiple-disc type brake means and the braking effect of the brake means is not impaired.
According to the present invention, a low-high speed changeover mechanism is further provided in the planetary gear mechanism. This low-high speed changeover mechanism includes a first and a second discs disposed perpendicularly and rotatably with respect to a rotational axis of an output shaft of the planetary gear mechanism, a sleeve which is movable axially of the rotational axis and rotatable integrally with a third element of the planetary gear mechanism and a shift lever having one end placed in engagement with the sleeve, the first and second discs being formed with splines, and the sleeve being formed with splines selectively engageable with the splines formed on the first and second discs. When the sleeve is shifted by the shift lever to a position where the sleeve is selectively connected to the first disc, the first element of the planetary gear mechanism is connected to the third element to form the forward range gear train whereas when the sleeve is shifted by the shift lever to a position where the sleeve is selectively connected to the second disc, the third element of the planetary gear mechanism is connected to a fourth element of the planetary gear mechanism to form another forward range gear train.
Accordingly, it is a primary object of the present invention to provide an improved and compact automatic transmission having a CVT and a planetary gear mechanism which automatic transmission is capable of establishing a forward range gear train when a first element of the planetary gear mechenism is selectively held in a stationary position by means of brake means and of establishing a reverse range gear train when a second element of the planetary gear mechanism is selectively held in a stationary position by means of brake means.
Another object of the present invention is to provide an improved and compact automatic transmission having a CVT and a planetary gear mechanism in which the planetary gear mechanism includes the first element, the second element, a first intermediate shaft connected to the first element, a second intermediate shaft connected to the second element and the brake means including splines formed on the first and second intermediate shafts, respectively, and a sleeve having splines adapted to selectively mesh with the splines formed on the first intermediate shaft to hold the first element in the stationary position and to selectively mesh with the splines formed on the second intermediate shaft to hold the second element in the stationary position, whereby the outer diameter of the brake means is reduced in compared with that of a wet multiple-disc type brake means.
A further object of the present invention is to provide an improved and compact automatic transmission having a CVT and a planetary gear mechanism in which the planetary gear mechanism includes the first element, the second element, the third element, a fourth element, brake means selectively holds the first element and the second element in the stationary position, respectively, and clutch means disposed between the third element and the fourth element and adapted to establish another forward range gear train when the third element is connected to the fourth element by means of the clutch means.
Still other objects and advantages of the invention will in part be obvious and will in part be apparent from the specification.
The invention accordingly comprises the features of construction, combinations of elements and arrangement of parts which will be exemplified in the constructions hereinafter set forth, and the scope of the invention will be indicated in the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
For a fuller understanding of the invention, reference is had to the following description taken in connection with the accompanying drawings, in which:
FIG. 1 is a schematic sectional view of an automatic transmission in accordance with an embodiment of the present invention, and
FIG. 2 is a schematic sectional view of an automatic transmission in accordance with another embodiment of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows an embodiment in which the present invention is applied to an automatic transmission for a vehicle of the front-engine front-drive system. This automatic transmission comprises a coupling means 15, a belt type continuously-variable speed transmission system (CVT) 3, a planetary gear mechanism 8, a differential device 2 and a transmission housing 70 for accommodating these elements and fixedly mounted on an engine 1. The housing 70 is partially shown in FIG. 1.
The coupling means 15 is shown in form of a fluid coupling including an input shaft 16 connected coaxially with an output shaft (not shown) of the engine 1 and an output shaft 17 disposed coaxially with the input shaft 16. Other automatic clutch means such as a torque converter, a centrifugal clutch, a magnetic clutch, etc. can be used in place of the fluid coupling 15.
The CVT 3 comprises an input pulley 31 mounted on a first shaft 4, an output pulley 32 mounted on a second shaft 5, and an endless belt 33 extended between the pulleys 31 and 32 to transmit power. The pulleys 31, 32 each has fixed sheaves 31A, 32A secured to the shafts 4, 5, and movable sheaves 31B, 32B mounted slidably axially on the shafts 4, 5, respectively. Each of the movable sheaves 31B, 32B is operated by hydraulic servomotor mounted on the shafts 4, 5, respectively. The first shaft 4 is disposed coaxially with the output shaft 17 of the coupling means 15 and coupled thereto. The second shaft 5 is formed in the form of a tubular shaft, which rotational axis is arranged parallel with the rotational axis of the first shaft 4.
The planetary gear mechanism 8 has an input shaft 51 and an output shaft 52 disposed coaxially with the rotational axis of the second shaft 5 of the CVT 3 and has two sets of planetary gear set. The first planetary gear set comprises a first sun gear 81 fixed concentrically with the input shaft 51, a first ring gear 82 arranged concentrically with the sun gear 81, at least one first planetary gear 83 meshing with the sun gear 81 and ring gear 82 and a first planetary carrier 84 for rotatably supporting the planetary gear 83 thereon. The second planetary gear set comprises a second sun gear 85 arranged concentrically with the rotational axis of the output shaft 52, a second ring gear 86 arranged concentrically with the sun gear 85, at least one second planetary gear 87 meshing with the sun gear 85 and ring gear 86 and a second planetary carrier 88 for roratably supporting the planetary gear 87 thereon. The first ring gear 82 and second sun gear 85 are connected to one end of a first intermediate shaft 53 disposed concentrically with the rotational axis of the input shaft 51 and are rotated integrally therewith, and the first planetary carrier 84 and second ring gear 86 are connected to one end of a second intermediate shaft 54 disposed concentrically with the rotational axis of the input shaft 51 and are rotated integrally therewith. The second planetary carrier 88 is connected to one end of the output shaft 52. In the planetary gear mechanism 8, when the first intermediate shaft 53 is braked and held in a stationary position and the second intermediate shaft 54 is rotated freely, a forward range gear train is formed for transmitting rotation in the same direction as that of the input shaft 51 to the output shaft 52, whereas when the second intermediate shaft 54 is braked and held in a stationary position and the first intermediate shaft 53 is rotated freely, a reverse range gear train is formed for transmitting rotation in the direction opposite to that of the input shaft 51 to the output shaft 52.
The output shaft 52 is formed in the form of a tubular shaft, the other end thereof is connected to a gear casing 21 of a differential device 2 concentrically with the rotational axis thereof. This differential device 2 comprises differential gears 22, 23 secured to a shaft supported on the casing 21 perpendicularly to the rotational axis of the casing 21 and output gears 24, 25 rotatably supported on the casing 21 with respect to the rotational axis of the casing 21, and meshed with said output gears 24, 25, respectively. Output shafts 28, 29 are connected to said output gears 24, 25, respectively, for connection with an axle (not shown) used to drive front wheels.
The transmission housing, which is not totally shown in FIG. 1 but partly indicated at 70, is secured to the engine 1. The fluid coupling 15 and input pulley 31 of the CVT 3 are rotatably supported on the housing 70 by means of the first shaft 4 and the output pulley 32 of the CVT 3, planetary gear mechanism 8 and differential device 2 are rotatably supported on the housing 70 by means of the second shaft 5 and output shaft 52.
A forward-reverse changeover mechanism 7 is formed between the output pulley 32 of the CVT 3 and the planetary gear mechanism 8. The mechanism 7 includes splines 74, 75 which are formed on the outer circumference of the other end of the first intermediate shaft 53 and on the outer circumference of the other end of the second intermediate shaft 54, respectively, a sleeve 72 which is disposed concentrically with and movable axially of the rotational axis of the input shaft 51 of the planetary gear mechanism 8, splines 73 formed on the inner circumference of the sleeve 72 and selectively engageable with the splines 74, 75, and a shift lever 71 one end of which is engaged with the sleeve 72 through a shift ring 79. The sleeve 72 has a key 76 formed axially and integrally therewith, said key is fitted into a groove 77 formed in the housing 70, and cannot be rotated with respect to the rotational axis of the input shaft 51. When the shift lever 71 is operated to move the sleeve 72 in a direction as indicated by the arrow D shown in FIG. 1 in the direction of the rotational axis, he splines 73 formed on the inner circumference of the sleeve 72 comes to mesh with the spline 74 formed on the outer circumference of the first intermediate shaft 53 to hold the first intermediate shaft 53 in the stationary position so that the second intermediate shaft 54 can be rotated freely, and hence the forward range gear train is formed. When the sleeve 72 is moved in a direction of arrow R which is opposite the arrow D, the splines 73 formed on the inner circumference of the sleeve 72 comes to mesh with the splines 75 formed on the outer circumference of the second intermediate shaft 54 to hold the second intermediate shaft at the stationary position so that the first intermediate shaft can be rotated freely, and hence the reverse range gear train is formed. The other end of the shift lever 71 projects beside the driver's seat of the vehicle.
The embodiment of the present invention shown in FIG. 1 operates as follows. The engine 1 of the vehicle is started and the lever 71 projecting besides the driver's seat is positioned to the forward or reverse position to move the shift ring by a driver. If the engine 1 is in the idling mode, engine torque generated by the engine 1 may not be transmitted to the input pulley 31 of the CVT 3 through the fluid coupling 15, and therefore, the sleeve 72 of the forward-reverse changeover mechanism 7 is readily spline-coupled with the first intermediate shaft 53 of or second intermediate shaft 54 of the planetary gear mechanism 8 to hold the first intermediate shaft 53 or second intermediate shaft 54 in the stationary position. Next, an accelerator pedal is pressed down by the driver, the engine torque is transmitted to the input shaft 4 of the CVT 3 by means of the fluid coupling 15 when the throttle opening of the engine 1 exceeds a predetermined value, and the vehicle starts to move. As is known, the CVT 3 continuously varies the ratio of rotational speed between the input shaft 4 and output shaft 5. The engine torque transmitted to the output shaft 5 of the CVT 3 is transmitted to the front wheels through the planetary gear mechanism 8, differential device 2 and output shafts 28, 29.
In the above-described transmission, the changing-over of the forward range drive and reverse range drive of the planetary gear mechanism 8 is achieved in such a way that the splines 73 formed on the sleeve 72 of the forward-reverse changeover mechanism 7 is selectively meshed with the splines 74 formed on the first intermediate shaft 53 or the splines 75 formed on the second intermediate shaft 54 to selectively hold the intermediate shafts 53, 54 in the stationary position, and therefore, the dimension of the outer circumference of the forward-reverse changeover mechanism 7 can be considerably reduced and the force for braking the first intermediate shaft 53 or second intermediate shaft 54 can be considerably increased.
FIG. 2 shows another embodiment of the present invention in which a low-high speed changeover mechanism 9 is further provided in the planetary gear mechanism 8 shown in FIG. 1. Accordingly, detailed explanations for parts common to those of the embodiment shown in FIG. 1 will be omitted.
The low-high speed changeover mechanism 9 includes a first and a second discs 93, 94 formed on the inner circumferences thereof with splines 96, 97, respectively, a second sleeve 92 disposed concentrically with respect to the rotational axis of the output shaft 52 of the planetary gear mechanism 8 and formed on the outer circumference thereof with splines 98, 99 for selectively meshing with the splines 96, 97 formed on the two discs 93, 94, respectively, and at least one guide pin 95 loosely supported on the sleeve 92. The first disc 93 is connected to the first ring gear 82 of the planetary gear mechanism 8, the second disc 94 is connected to the second planetary gear 88, and each of the first and second discs 93, 94 is rotatable concentrically with respect to the rotational axis of the output shaft 52 and has a mean plane thereof in a plane vertical to the rotational axis of the output shaft 52 of the planetary gear mechanism 8. The second sleeve 92 is spline-coupled axially slidably to the second sun gear 85 of the planetary gear mechanism 8 and is rotatable integrally with the sun gear 85. A shift ring 91 is relatively rotatably engaged with a groove formed on the outer circumference of the second sleeve 92 and is operated by means of a shift lever 100 directly or indirectly associated with the shift lever 71 to shift the sleeve 92 in a direction of L or H, which is indicated by the arrow in FIG. 2. When the sleeve 92 is shifted in the direction of the arrow L, the splines 98 formed on the sleeve 92 comes to mesh with the splines 96 formed on the first disc 93 to connect the first ring gear 82 with the second sun gear 85 whereby the second disc 94 may be rotated freely thereby the same forward range gear train as that of the planetary gear mechanism 8 shown in FIG. 1 is formed. When the sleeve 92 is shifted in the direction of arrow H, the splines 98 formed on the sleeve 92 is moved away from the splines 96 formed on the first disc 93 to rotate the first disc 93 and the first ring gear 82 freely and the splines 99 formed on the sleeve 92 comes to mesh with the splines 97 formed on the second disc 94 to connect the second carrier 88 to the second sun gear 85 of the planetary gear mechanism 8 thereby the second planetary gear set is interlocked, and hence a forward range high-speed gear train is formed. The guide pin 95 is disposed between opposed surfaces of the first and second discs 93, 94 with the lengthwise direction thereof being parallel with the rotational axis of the output shaft 52. When the sleeve 92 is shifted in the direction of arrow L or H, one end of the guide pin 95 comes to abut with either the first disc 93 or the second disc 94 whereby the rotational speed of the disc is synchronized with the rotational speed of the sleeve 92 to facilitate the spline-coupling between the sleeve 92 and the first disc 93 or the second disc 94. That is, the low-high speed changeover mechanism 9 corresponds to a dog clutch having the function of a synchronizer.
In the embodiment shown in FIG. 2, the upshift from the forward range low-speed gear train to the forward range high-speed gear train or the downshift from the forward range high-speed gear train to the forward range low-speed gear train is carried out by moving the second sleeve 92 in its axial direction through the shift lever 100 or shift ring 91. In this operation, one end of the guide pin 95 loosely supported on the second sleeve 92 comes into contact with one surface of the first disc 93 or second disc 94 to thereby synchronize the rotational speed of the disc in contact with the guide pin 95 with the rotational speed of the second sleeve, and thereafter, the splines formed on the second sleeve 92 is brought into engagement with the splines 96 formed on the first disc 93 or the splines 99 formed on the second sleeve 92 into engagement with the splines 97 formed on the second disc 94. Therefore, the engagement between these splines is extremely easily and positively effected.
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An automatic transmission for a front-engine front-drive vehicle including a fluid coupling, a belt type continuously-variable speed transmission (CVT), a planetary gear mechanism, a forward-reverse changeover mechanism and a differential device. The forward-reverse changeover mechanism includes a brake disposed between the planetary gear mechanism and the output of CVT. The planetary gear mechanism is provided with a low-high speed changeover mechanism. Each of the clutch and the brake is provided with recesses in one part thereof and are provided with projections in the other part which can be fitted into the recesses, and the dimension of the outer diameter thereof is small as compared with that of clutches or brakes of the wet multiple-disc type.
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BACKGROUND OF THE INVENTION
The present invention relates to the field of closures, more particularly to a two-piece plastic construction for a cabinetry door. In one embodiment of the invention, the two-piece plastic construction may be used as a transparency viewer. A preferred use of the cabinetry door and transparency viewer of the invention in dental operatory settings.
The variety of door types and constructions is too great to discuss in detail. Materials such as wood, glass, metal, and thick sheets of plastic have all been used for cabinetry doors in the past. In many instances, the weight of such doors has been a problem due to the thickness required for maintaining structual rigidity and for receiving attachment hardware.
Another problem that has remained unsolved until the present invention has been the need for a separate unit for reading transparencies, for example, an X-ray viewer in a dental operatory. Such units take up counter or shelf space in the operatory that could otherwise be used as working surfaces. Also, the electrical requirements of such units limit their positionability and storage when not in use. An object of the present invention is to provide a two-piece, hollow construction for a cabinetry door.
Another object of the invention is to provide a lightweight cabinetry door that can swing up and be slid back into a cabinet.
Yet another object of the invention is to provide a lightweight cabinetry door that is partially transparent to provide partial visibility for the contents of the cabinet from the outside without opening the door.
The further object of the invention is to provide a two-piece plastic cabinetry door that is easy and inexpensive to manufacture, lightweight, structurally rigid, and is somewhat transparent for viewing contents of a cabinet.
Another object of the invention is to provide a transparency viewer that can be lifted up and slid under a cabinet or shelf to be out of the way.
Still another object of the invention is to provide a transparency viewer that may be attached to the bottom of a shelf or cabinet to be lifted up and slid out of the way when not in use, and also serve as a task light for a work surface under it when it is in the stored position.
A still further object of the invention is to provide a cabinet door and transparency viewer.
Yet another object of the invention is to provide a cabinet door and transparency viewer wherein said door may serve as a transparency viewer when in the down position and may serve as a task light or cabinet light when in the up position.
Other objects, advantages and features of the present invention will become apparent with reference to the following description of the preferred embodiments and the appended claims and drawings.
SUMMARY OF THE INVENTION
A cabinetry door includes two members. A first member has a planar main surface with a top surface, a bottom surface, a right side surface and a left side surface forming a peripheral lip around the main surface. The second member has a planar main surface, also with a peripheral lip. A top parallel surface, bottom parallel surface, right side parallel surface and left side parallel surface form a peripheral flange about the second member's peripheral lip. The flange is received by the planar main surface in the first member. Securing means connect the second member to the first member.
In a transparency viewer embodiment of the invention, the first member has a light-transmitting portion associated with its planar main surface. Holding members are provided to hold transparencies against the light-transmitting portion. A light source is disposed between the first and second members, the second member being provided with an access opening having a removable cover.
DESCRIPTION OF THE DRAWINGS
In the drawings:
FIG. 1 is a front elevational view of a cabinetry door embodying the principles of the present invention;
FIG. 2 is a back elevational view of a cabinetry door embodying the principles of the present invention;
FIG. 3 is side elevational view of a cabinetry door embodying the principles of the present invention, taken in section along line 3--3 in FIG. 2;
FIG. 4 is an elevational view of a cabinetry door embodying the principles of the present invention, taken in section along line 4--4 in FIG. 2.
FIG. 5 is a sectional elevational view of a cabinetry door embodying the principles of the present invention illustrated installed in a cabinet and shown in the down position;
FIG. 6 is an enlarged section of the attachment portion (illustrated within the circle in FIG. 5) of a cabinetry door embodying the principles of the present invention;
FIG. 7 is a front elevational view of a cabinetry door and transparency viewer embodying the principles of the present invention;
FIG. 8 is a back elevation view of a cabinetry door and transparency viewer embodying the principles of the present invention, a portion of the back cover being broken away to better illustrate the lighting means;
FIG. 9 is a sectional view of a cabinetry door and transparency viewer embodying the principles of the present invention, taken along line 9--9 in FIG. 7;
FIG. 10 is a sectional view of a cabinetry door and transparency viewer embodying the principles of the present invention, taken along line 10--10 in FIG. 7.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
A cabinetry door 20 in accordance with the present invention has a front member 22 and a back member 24. Both the front and back members may be made of a moldable plastic material (such as lexan) and are preferably vacuum formed to their respective shapes. As shown in FIG. 1, front member 22 has the general shape of a shallow rectangular tub, having a planar front surface 30, and a peripheral lip formed by a slanted top surface 32, a slanted bottom surface 34, a slanted right side surface 36 and a slanted left side surface 38. The outside (front) surface of front member 22 preferably has a roughened, scratch-resistant finish. Referring to FIGS. 2, 3 and 4, back member 24 has a back planar surface 40, a top perpendicular surface 42, a top parallel surface 44, a bottom perpendicular surface 46, a bottom parallel surface 38, a right side perpendicular surface 50, a right side parallel surface 52, a left side perpendicular surface 54 and a left side parallel surface 56. An extended portion 60 of back planar surface 24 is provided with a securing member 62 such as the plate for a magnetic catch, or a portion of a mechanical latch.
The perpendicular surfaces 42, 46, 50 and 54 form a peripheral lip. The parallel surfaces 44, 48, 52 and 56 form a peripheral flange around the back member which corresponds to the peripheral area of front surface 30, so that the back member 24 may be placed within the front member 22 and secured to it by means such as an adhesive 68, double-sided tape, glue, cement, velcro, or a mechanical fastener. It is preferred to use double-sided tape.
Two pairs of openings 64 and 66 are provided at the top right and left corners of back planar surface 40 for the attachment of hinges 70 by attachment means 72 such as a nut and bolt, a molly, or preferably an expanding bolt such as the "Plus-Nut" (sold by B. F. Goodrich). The hinge (as illustrated in FIGS. 5 and 6 ) has two portions, a first portion 74 that is attached to the back member 24, and a second portion 76 that is received within a track 78 affixed inside a cabinet 80 in which the door 20 is installed. The door 20 is thus movable from its lowered position as shown in FIG. 5 to a stored or open position by swinging the door up parallel to the cabinet top and sliding it back along the track 78.
A cabinetry door and transparency viewer 100 of the present invention, as illustrated in FIGS. 7-10, is similar both in construction and mounting to the cabinetry door 20. The door and viewer 100 may be used as a cabinet closure, such as the door 20, or may be used as a separate device suspended from beneath a cabinet to provide task lighting when in the up or stored position and to view transparencies such as X-rays when in the down position.
Front member 122 and back member 124 are secured together in the same fashion as are front member 22 and back member 24, by use of securing means such as an adhesive 168, double-sided tape, glue, cement, velcro or a mechanical fastener.
Front member 122 has a front surface 130, a slanted top surface 132, a slanted bottom surface 134 having two recessed end portions 135, a slanted right side surface 136, and a slanted left side surface 138.
Back member 124 has a back planar surface 140, a top perpendicular surface 142, a top parallel surface 144, a bottom perpendicular surface 146, a bottom parallel surface 148, a right side perpendicular surface 150, a right side parallel surface 152, a left side perpendicular surface 154 and a left side parallel surface 156. Back planar surface 140 also has an extended portion 160 for a securing member 162, and has two pair of hinge openings 164 and 166 at the upper right and left corners, respectively.
Front member 122 has a cutaway portion 170 in front planar surface 130, which is provided with a protruding portion 172 at the bottom of cutaway portion 170 to serve as a transparency holder. A light-transmitting portion has a translucent panel 174 disposed behind front planar surface 130 and surrounding cutaway portion 170; the translucent panel is adhered to the back of front member 122 by securing means 168, smilar to the means used for attachment of back member 124.
The back planar surface of back member 124 also has a cutaway portion 180 which is covered by a light transmitting panel 182, the panel being attached by members 184, such as screws, which are received in openings 186 disposed in back planar surface 140. A replaceable bulb 190 and its associated fixture 192 are disposed between front member 122 and back member 124, as, by example, by fastening to the front surface of back member 124. The fixture is provided with wiring 194 leading to a switch 196 disposed in recessed portion 135 and to a power source (not shown).
To those skilled in the art to which this invention relates, many changes in construction and widely differeing embodiments and applications of the invention will suggest themselves without departing from the spirit and scope of the invention. For example, changes in the overall shape of the door, its size, and the materials from which it is constructed are easily made and are intended to be covered as part of the present invention. The disclosure and descriptions herein are purely illustrative and are not intended to be in any sense limiting.
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A cabinetry door including a first member having a backwardly extending peripheral border and a second member having a forwardly extending peripheral border with a peripheral flange, wherein the peripheral flange of the second member is attached to the first member within its peripheral border. In a transparency viewer embodiment, the first member includes an light-transmitting portion and a transparency holder, and a light source is disposed between the first and second members.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention is broadly concerned with novel nanoscale polymetallic composite particles, as well as magnetic recording media (e.g., flexible tapes and rigid disks) and integrated circuits using polymetallic nanoscale particles. More particularly, the invention pertains to such composite particles and end products wherein, in preferred forms, the nanoscale composite particles have an average diameter of from about 5-500 nm with an elemental metal core surrounded by a metal-containing shell material.
2. Description of the Prior Art
U.S. Pat. Nos. 4,588,708 and 4,877,647 describe catalyst and metallic coatings made by the Solvated Metal Atom Dispersion (SMAD) process. This method utilizes metal vapors (i.e., atoms) that are produced by heating pieces of elemental metal in a high temperature crucible up to the vaporization point of the metal while under vacuum. The metal vapor is condensed on the inside walls of the vacuum vessel which is cooled to a very low temperature. At the same time the vapors of an organic solvent are codeposited with the metal vapor on the low temperature vessel wall, forming a frozen matrix. After the codeposition, the frozen matrix contains metal atoms, atomic oligomers such as dimers, trimers and small metal clusters. Upon warming, the atoms and oligomers begin to migrate and bond to each other to form metal particles of various sizes, dependent upon the concentration of the metal atoms in the solvent, the chemical structure of the solvent, warm-up rate, and other parameters. Two important facets of this process are: (1) as the clusters grow they become heavier and less mobile, and (2) as the clusters grow solvent binds to the cluster surface and tends to slow further growth. Thus, the SMAD process yields metal clusters/particles in a solvent medium free of extraneous reagents.
It has also been known to employ SMAD processes for the fabrication of core/shell metallic composite particles where elemental metal particles are encapsulated within a metallic shell material. For example, metastable Fe-Mg core/shell composite particles are described by Klabunde et al. (Chem. Mater., Vol. 6, No. 6, 1994). Additionally, codeposition of Fe and Ag has been attempted, but the method failed to yield core/shell particles, resulting mainly in separate Se and Ag particles (Easom et al., Polyhedron, Vol. 13, No. 8, 1994). The key to producing metallic core/shell composites is to choose combinations of metals that are not normally thermodynamically miscible. The SMAD process forces atoms of the immiscible elements to combine at low temperatures, so that metastable alloy composite particles form. Upon heating of these particles, controlled phase segregation can be accomplished since there is a natural tendency for the two elements to separate. Although it cannot be predicted which metal will nucleate and form the core, and which will form the shell, experience has shown that the metal possessing the stronger metal-metal bonds will generally form the core material.
A major driving force behind the study of nanoscale ferromagnetic particles is the search for improved magnetic recording materials useful in magnetic recording and the like. In such applications, the ferromagnetic particles should be a single domain unit that possess two stable opposite magnetic poles along a preferred axis. The switching field is the minimum magnetic field needed to switch the magnetic poles in the single domain particles. The size of the switch units (single domain particles) is important in the performance of the recording medium. They should be small enough to allow recording of the intended magnetization pattern and to provide a high signal-to-noise ratio, which requires the use of small switch units that are partially independent, so that one unit is not strongly affected by the magnetization of the other units. Additionally, a magnetic recording medium must be chemically stable under the conditions of use. For this reason, metallic Fe, Co, or Ni, being extremely oxophilic in ultrafine particle form, are generally not useful. Instead, iron oxide, chromium oxide, barium ferrite and cobalt-enhanced iron oxide are most commonly employed. However, such metal oxides have relatively low magnetization intensities and are therefore not optimum for recording materials. On the other hand, elemental iron has a magnetization intensity of 1700 emu/cm 3 , which is several times that of the oxides. Accordingly, elemental iron would be admirably suited for use in recording media if the oxophilic properties thereof could be appropriately controlled.
SUMMARY OF THE INVENTION
The present invention overcomes the problems outlined above and provides novel polymetallic (especially bimetallic) composite particles having an average diameter of from about 5-500 nm (more preferably from about 10-100 nm and most preferably from about 15-60 nm) with an elemental metal core surrounded by a metal-containing shell material; the core and shell material are thermodynamically immiscible and each is evaporable at a temperature of up to about 2000° C. under a vacuum. The shell material is preferably non-magnetic and selected from the group consisting of In, Nd and metal salts; in many instances, the metal moiety of such salts is different than the core metals. Preferred metal salts are the metal oxides and halides, particularly the fluorides.
In preferred forms, the core fraction of the composite particles is present at a level of at least about 30% by weight, more preferably from about 30-90% by weight, most preferably from about 50-70% by weight. Correspondingly, the shell material is present at a level of up to about 70% by weight, more preferably from about 10-70% by weight, and most preferably from about 30-50% by weight. Core metals are normally selected from the group consisting of the transition metals, and especially Fe, Al, Mg, Cr, Co, Ni, Pd, Au, Cu, and Ag. The shell material may be an elemental metal such as an alkaline earth metal, or a metal salt; the metal salts are normally selected from the group consisting of the metal oxides, sulfides and halides, especially the metal fluorides. The composites are preferably formed by co-condensation of vapors of the core elemental metal and the metallic shell material, followed by heating of the condensate. A conventional SMAD reactor can be used for this purpose. Generally speaking, the core metal and metallic shell material are heated to their respective vaporization temperatures in individual crucibles within the SMAD reactor under a vacuum of at least about 10-3 Torr. The exterior walls of the SMAD reactor are typically cooled to a temperature of about -100° C. and lower.
The magnetic recording media of the invention are generally flexible tape or rigid disk media. The tapes comprise an elongated web of synthetic resin substrate material having a magnetic coating applied to at least one face thereof. The magnetic coating includes a synthetic resin binder with magnetizable particles dispersed therein, the particles being of the type described above with an elemental core surrounded by a metal-containing shell material. The core and shell material are thermodynamically immiscible and each is evaporable at a temperature of up to about 2000° C. under a vacuum. The magnetizable particles have two stable opposite magnetic poles switchable under the influence of an externally applied magnetic field.
In this context, the core metal is preferably selected from the group consisting of Ni, Fe, Cr, and Co, whereas the metallic shell material is selected from the group consisting of non-magnetic elemental metals and metal salts (e.g., elemental lithium, magnesium and gold, and magnesium fluoride). Advantageously, the shell material should be more oxophilic than the elemental core metal so that any trace oxygen is scavenged. Moreover, the shell material should be inert and essentially impermeable to oxygen and other environmental gases. This enables the core metal to remain purely metallic in use and inhibits formation of deleterious oxides.
In the fabrication of flexible magnetic recording media, the substrates can be selected from a wide variety of materials such as polyethylene terephthalates, polyethylene napthalates, aramids and polyimids. These substrates would typically have a thickness of from about 1-10 thousandths of an inch. The magnetic coatings applied to the substrates are fabricated by mixing the magnetic particles in synthetic resin binders such as those selected from the group consisting of the polystyrenes, vinyl chloride copolymers, vinylidene chloride copolymers, polyvinyl acetate resins, acrylate and methacrylate resins, polyurethane elastomers, modified cellulose derivatives, epoxy and phenoxy resins, polyamids and combinations of polyethers with --OH groups with polyesters and polyisocyanates. Such magnetic coatings can have from about 1-80% by weight loading of magnetic particles, more preferably from about 3-60% by weight, and most preferably from about 5-30% by weight.
Rigid magnetic disks may be prepared by applying a coating made up of a synthetic resin (for example, phenol-formaldehyde, urea-formaldehyde, epoxy, polyvinyl acetate and silicone resins) with the above described magnetic particles to a rigid disk (e.g., made of aluminum or other suitable material); the particle loading in such coatings are the same as used in the fabrication of flexible web media.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a powder X-ray diffraction pattern for Fe--In SMAD particles (Fe:In molar ratio=1:1) heat treated at (A) 400° C., (B) 600° C. and (C) 700° C. for 2 hrs. followed by oxidative passivation;
FIG. 2 is a powder X-ray diffraction pattern of iron crystallite sizes and transmission electron micrograph (TEM) overall particle sizes of Fe--In samples (Fe:In molar ratio=1:1);
FIG. 3 is a room temperature Mossbauer spectrum of the Fe--In SMAD particles (Fe:In molar ratio=1:1) heat treated at 400° C., followed by oxidative passivation;
FIG. 4 is a graph illustrating saturation magnetization values of Fe--In SMAD particles (Fe:In molar ratio=1:1) versus different Fe crystallite sizes for the particles;
FIG. 5 is a powder X-ray diffraction pattern of heat treated and passivated Fe--Nd SMAD particles heat treated at (A) 450° C., (B) 325° C., and (C) 225° C.;
FIG. 6 is a graph of saturation magnetization values versus temperature for non-heat treated fresh and exposed Fe--Nd SMAD particles;
FIG. 7 is a graph of coercivity versus temperature for non-heat treated fresh and exposed Fe--Nd SMAD particles;
FIG. 8 is a graph of saturation magnetization versus Fe crystallite size for passivated Fe--Nd SMAD particles;
FIG. 9 is a powder X-ray diffraction pattern of fresh and passivated Fe--Mg F 2 SMAD particles (Fe:Mg F 2 molar ratio=1:2) wherein the particles are (A) fresh, as prepared, (B) heat treated at 200° C. and passivated, (C) heat treated at 400° C. and passivated and (D) heat treated at 600° C. and passivated;
FIG. 10 is a powder X-ray diffraction pattern of different Fe crystallite sizes in Fe--Mg F 2 SMAD particles heat treated at different particles;
FIG. 11 is a TEM photo of Fe--Mg F 2 SMAD particles heat treated at 500° C. for 2 hrs.;
FIG. 12 is a graph of saturation magnetization values versus Fe crystallite size for passivated Fe--Mg F 2 SMAD particles (percentage of Fe bulk value, 220 emu/g of Fe);
FIG. 13 is a schematic representation illustrating the encapsulation of Fe core metal within Mg F 2 shell material;
FIG. 14 is a powder X-ray diffraction pattern of fresh and passivated CO--Mg F 2 SMAD particles: (A) fresh, as prepared; (B) heat treated at 200° C. and passivated; (C) heat treated at 400° C. and passivated; and (D) heat treated at 700° C. and passivated;
FIG. 15 is a TEM photo of Co--Mg F 2 SMAD particles heat treated at 400° C. for 2 hrs.;
FIG. 16 is a TEM photo of Co--Mg F 2 SMAD particles heat treated at 600° C. for 2 hrs.;
FIG. 17 is a graph of Co crystallite size versus heat treatment temperature for Co--Mg F 2 SMAD particles heat treated at different temperatures;
FIG. 18 is a graph of saturation magnetization values versus Co crystallize size for passivated Co--Mg F 2 SMAD particles;
FIG. 19 is a graph of magnetic coercivity versus Co crystallite size for passivated Co--Mg F 2 SMAD particles;
FIG. 20 is a schematic representation illustrating the encapsulation of Co core metal within Mg F 2 shell material;
FIG. 21 is a powder X-ray diffraction pattern of fresh and passivated Ni--Mg F 2 SMAD particles: (A) fresh, as prepared; (B) (B) heat treated at 200° C. and passivated; (C) heat treated at 400° C. and passivated; and (D) heat treated at 700° C. and passivated;
FIG. 22 is a graph of saturation magnetization values versus Ni crystallize size for passivated Ni--Mg F 2 SMAD particles; and
FIG. 23 is a graph of magnetic coercivity versus Ni crystallite size for passivated Ni--Mg F 2 SMAD particles.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The following examples set forth preferred methods in accordance with the invention. It is to be understood, however, that these examples are provided by way of illustration and nothing therein should be taken as a limitation upon the overall scope of the invention. In these examples, the following preferred method is used for preparation and determination of the characteristics of the samples therein:
Methods and Materials
A. Equipment
1. X-ray powder diffraction: SCINTAG 3000 XRD diffractometer
X-ray powder diffraction (XRD) was used to study the chemical compositions and structures of the powders. For samples with a fresh surface, degassed mineral oil was applied to coat the sample for temporary protection from oxidation by forming a powder/oil paste in an argon-filled dry-box. XRD analysis (which lasts for about one hour) was carried out immediately after the coating because the protection from mineral oil was effective for only a few hours. For samples with passivated surfaces, no such precaution was taken.
X-ray powder diffraction was also used to estimate the crystallite sizes of the core metal particles. This was achieved with the aid of the Scherrer formula:
t=0.91λ/B.sub.χ oσθ.sub.B
where λ is the X-ray wavelength, t is the crystallite diameter in Å, B is the width of the peak at half height, and θ B is the half value of the peak position in degrees.
2. BET Surface Area: Micrometrics Flowsorb II 2300 BET
The direct information from BET measurement is the surface area of the particles. Under assumed conditions, such as the particles were spherically shaped and individually spaced, the average size of the particles were calculated from the specific surface area data, as follows: Given a group of spherical particles N with the total mass of M, the average specific area of these particles is:
S=(N)(4πR.sup.2)/M
where R is the average radius of these particles. Since M is equal to N(4/3)πR 3 ρ where ρ is the average density of the particles, the term (4/3)πR 3 ρ is the average mass of the particles. Thus,
S=N(4πR.sup.2)/N(4/3)πR.sup.3 ρ
S=3/Rρ
and R=3/Sρ,
therefore, the average BET size t of the particles is:
t=2r=6/Sρ.
3. Transmission Electron Microscopy (TEM)
Both the overall particle sizes and the core metal crystallite sizes were estimated from TEM studies. 3-5 mg of each sample was placed in a sample vial containing toluene, and agitated for 3-5 minutes in a sonicator thereby forming a suspension of the particles. One drop of the test suspension was transferred onto a carbon-coated copper grid as the sample holder. After evaporation of the solvent, the sample was ready for TEM study. To avoid sintering of the particles caused by the heat generated by the electron beam, liquid nitrogen was used to cool the sample chamber (-196° C.).
4. Mossbauer Spectroscopy
The Mossbauer spectra were obtained on a Ranger Scientific Inc. MS-1200 Mossbauer spectrometer. Mossbauer spectroscopy was used to study the oxidation states and the fine structures (e.g., core metal crystallite size, surface/interface effect on the Mossbauer parameters of the core metal) of core metal species in the samples. Approximately 5-10 mg of elemental core metal was required to obtain Mossbauer spectra for each sample. Thus, the corresponding amount of sample required in each study was estimated based on the mass balance of the sample. Like the XRD studies, samples with fresh surfaces were protected with mineral oil before being transferred into the sample chamber. Mossbauer spectra were taken at both room temperature (298 K) and liquid nitrogen temperature (77 K).
5. SQUID Magnetometry
Magnetic properties of the samples were taken from a MPMS2 (Magnetic Property Measurement System) SQUID (Superconducting Quantum Interference Device) magnetometer designed by Quantum Design. The field range of the equipment was ±55,000 Oe, with a sensitivity of 10 -8 emu. Fresh samples were protected in mineral oil in a gel capsule during the measurement. Magnetization curves of these samples were taken at different temperatures between 10 K and 300 K in fields up to 55,000 Oe.
B. Solvated-Metal-Atom-Dispersion (SMAD) Method with Immiscible Metals
This method involved the codeposition of a metallic shell material (e.g., In or MgF 2 ) with a core metal (such as Fe) as well as the simultaneous deposition at 77 K of an excess of a hydrocarbon diluent (solvent) as described by Klabunde et al., J Am. Chem. Soc., 98 (1979), Free Atoms, Clusters, and Nanoscale Particles, Academic Press (1994), Active Metals--Preparation, Characterization, Applications, VCH Publ., 237 (1996), incorporated by reference herein. Briefly, the SMAD apparatus comprises a vacuum flask provided with ajacket for liquid nitrogen cooling. The center of the flask is equipped with electric crucibles independently controlled for vaporizing the core metal and the metallic shell material, and with an inlet for the solvent. In the operation of the apparatus, the solvent vaporizes on entry, and then condenses on the inner walls of the flask together with the vaporized core metal and metallic shell material atoms. This condensation and cooling generates a frozen matrix of core metal, metallic shell material atoms and solvent which collects on the walls of the flask. Upon completion of the condensate formation, the liquid nitrogen cooling is discontinued. The flask can then be warmed to spur kinetic growth of the bimetallic particles. The metastable particles are then isolated and heat treated to cause phase segregation into core/shell composite particles. In order to be successful, the metallic shell material must be inert toward the core metal atoms and growing clusters, and be capable of protecting the encapsulate core metal clusters from air oxidation.
C. Preparation of Materials
Prior to the evaporation of a core metal and a metallic shell material, pentane was pre-dried by refluxing over Na/K with benzophenone. Before being deposited on the SMAD reactor, the dried pentane (held in a Schlenk tube) was degassed on a vacuum line with liquid nitrogen. The crucibles used were tungsten baskets obtained from R. D. Mathis Company. The tungsten baskets were coated with a water based alumina cement (Zircar Alumina Cement) obtained from Zircar Products, Inc. The Zircar Alumina Cement consisted of 70% alumina in a combination of milled fibers and sub-micro particles. Alumina cement is mildly acidic (pH 5) and forms a strong bond on removal of the water solvent. Prior to use, the coated crucibles were heated at about 100° C. in air for two hours and then heated to red hot in vacuum (10 -3 Torr) at increments of about 200° C. for two hours at each temperature, up to about 1,650° C. in order to eliminate the volatiles as well as avoid cracking of the alumina coating.
D. Preparation of Samples
Although several metals were co-evaporated in the following examples, each of the evaporations were carried out as follows:
Prior to the evaporation, the crucibles that contained the core metal (such as Fe) and the metallic shell material (such as In or MgF 2 ) were warmed up at increments of about 100° C. for about two hours at each increment to a temperature about 100-200° C. below the boiling points of the starting materials. This slow heating process effectively outgassed the starting materials, and minimized sudden vaporization surges during deposition. After the crucibles were heated, approximately 40-50 ml of pentane was deposited on the walls of the reactor. The evaporation of the core metal was initiated after a steady evaporation of the metallic shell material was achieved. The heating of the core metal was carefully controlled by slowly increasing the voltage to the crucible to prevent pressure surges in the reactor. In the whole evaporation process, a constant evaporation of the metallic shell material and a constant deposition of pentane at a rate of 2-3 ml per minute were ensured prior, during, and after the core metal evaporation. About one gram of core metal was evaporated in each experiment and about 100 ml of pentane was used. After the evaporation, an additional 40-50 ml of pentane was deposited to cover the product (about 200 ml total of liquid pentane).
After the final coating of pentane was finished, the reactor was closed off from the vacuum line. The liquid nitrogen dewar was removed to allow the reactor to warm to room temperature. Then the vacuum was re-applied to transfer the pentane to a cold trap and a black powder was obtained. The reactor was closed off from the vacuum line again and filled with argon to normal pressure. The lower part of the reactor containing the final product was quickly removed, covered with an aluminum foil, and carefully transferred into an argon-filled dry-box.
Heat treatments at various temperatures were applied to the collected SMAD particles to increase the sizes of the core metal crystallites within these particles. A certain amount of the sample, usually 70-100 mg, was transferred into a Pyrex glass tube in the argon-filled dry-box. The glass tube filled with argon was then sealed on a hydrogen/oxygen flame. After the sample was heated at the desired temperature over the desired time period, the sample tube was cut open in the dry-box and stored in a sample vial.
After the bimetallic powder sample was heat-treated, carefully controlled exposure to air (oxygen) was required to stabilize the surfaces of these particles against further oxidation (passivation). Thus, a slow oxidation procedure was used in which a sample vial containing 50 to 100 mg of the fresh SMAD sample (heat-treated or as-prepared) was transferred from the dry-box into open air. The cap was then slightly opened to allow slow diffusion of air into the vial. After a 12 to 24 hour period, the cap was removed and the sample was found to be stable against further oxidation. In some cases, the color of the sample changed slightly during this process.
EXAMPLE 1
In this example, using the preferred method described above, a sample was prepared using iron as the core metal and indium as the metallic shell material. The properties of Fe and In are shown in Table 1 as follows:
TABLE 1______________________________________Properties of Iron and Indium Units Iron (∝-Fe) Indium______________________________________Density g/cm.sup.3 7.87 7.31Melting Point K 1,808 429.6Boiling Point K 3,023 2,285Crystal Structure bcc tetrPauling Electronegativity 1.83 1.7Valency 2,3,4 2 or 3______________________________________
About 2.6 grams of In and 1.3 grams of Fe (Fe:In molar ratio of 1:1) were co-evaporated in the presence of pentane at 77 K and 10 -3 torr. After the evaporation, about 3 grams of dark powder was collected from the SMAD reactor. X-ray powder diffraction of the as-prepared sample showed a weak signal for indium, but no crystalline form of iron could be detected. A second Fe--In sample, with an Fe to In molar ratio of 2:1, was also studied. XRD of the as-prepared sample of this ratio showed iron and indium, both being nearly amorphous. It was desirable to have indium equal to or in excess of Fe in order for the indium metal to protect iron from oxidation beyond the formation of a nearly homogeneous Fe--In amorphous alloy. Therefore, the 1:1 ratio was chosen for further study.
The as-prepared sample of the Fe:In=1:1 molar ratio system was divided into several portions and transferred into Pyrex glass tubes in an argon atmosphere. After the tubes were sealed, they were heated in a tube furnace at 200° C., 300° C., 350° C., 400° C., 600° C., or 700° C. for two hours. The powders were transferred into small vials, slowly passivated, and analyzed by XRD. In the sample heated at 200° C., a strong In signal was detected while only a weak Fe signal could be seen. Although neither iron oxide nor indium oxide were present, a small peak at 2θ of 41.5° suggested the presence of α-Fe 2 O 3 . After being heated at 300° C., the sample showed signals for Fe, In, α-Fe 2 O 3 , and In 2 O 3 . For the 350° C. sample, a similar pattern was evident. In the 300° C. and 350° C. samples, the In signals and the signals of indium oxide were about the same strength.
In the case of the sample heated to 400° C., the peaks of iron became much sharper, the signals of indium oxide also appeared stronger than the samples heat-treated at lower temperatures (FIG. 1A), and there was still a weak peak for α-Fe 2 O 3 at about 41.5° of 2θ. After these particles were heated at 600° C. and 700° C., no iron oxide signals could be found even after extended exposure to air (FIGS. 1B and 1C). In the Fe--In=2:1 molar ratio system, XRD results of the heat-treated samples showed similar results.
Since Fe and In were both susceptible to oxidation, at high heat treatment temperatures more Fe atoms were driven into the center of the particles and were protected by In atoms that moved to the surfaces of the particles. During this process, the In reduced the iron oxides as well as scavenged any adventitious oxygen traces that might have been present.
XRD and TEM gave the overall sizes and Fe crystallite sizes of these core/shell composite particles. These results are summarized in FIG. 2 and Table 2.
TABLE 2______________________________________Overall Particle Sizes and Fe Crystallite Sizes of Fe-InSMAD particles obtained from TEM and XRD studies XRDSample Molar Heat Treatment TEM Particle Fe CrystalliteRatio (Fe:In) Temperature (°C.) Size (nm) Size (nm)______________________________________1:1 Fresh, as-prepared 31:1 200 12 71:1 300 23 161:1 350 30 211:1 400 70 312:1 Fresh, as-prepared 42:1 200 20 72:1 300 30 112:1 400 80 29______________________________________
A room temperature Mossbauer spectrum of the Fe/In (2:1) particles is shown in FIG. 3. After the particles were heated at 400° C., the iron in the sample was much better protected and only a small amount was oxidized.
The magnetic properties of these samples were obtained on a SQUID magnetometer. In a mixture of Fe/In/α-Fe 2 O 3 /In 2 O 3 , only Fe was strongly magnetic with a saturation magnetization value of 220 emu/gram. α-Fe 2 O 3 was only slightly magnetic with a saturation magnetization value of 0.6 emu/gram, and neither In nor In 2 O 3 was magnetic. SQUID can only provide the overall magnetization value of the sample therefore it was necessary to translate the SQUID data into the magnetization values of metallic iron. If the samples did not take up any oxygen during the passivation process, the chemical compositions of these samples would have been very close to those of the starting materials. For example, for the Fe:In=1:1 system, the chemical composition of the samples would have contained 33% Fe by mass and 67% In by mass. Based on XRD and Mossbauer data, about 50% by mass of the In was in the form of In 2 O 3 after the passivation procedure. This translated into a mass balance of 30% by mass for Fe° in the Fe:In=1:1 molar ratio system. For the Fe:In=2:1 molar ratio system, the Fe° mass balance would be 46% by mass. These values were used in calculation of the saturation magnetization per gram of iron values (emu/g of Fe) as shown in Table 3.
TABLE 3______________________________________Saturation Magnetization Values (emu/g of iron) for Fe:In samplesFe:In Molar Heat Treatment Fe XRD SizeRatio Temperature (nm) 10K 150K 300K______________________________________1:1 Fresh, as-prepared 3 99 89 741:1 200° C. 7 104 102 981:1 300° C. 16 115 113 1101:1 350° C. 21 119 117 1131:1 400° C. 31 150 148 1451:1 600° C. 50 214 211 2061:1 700° C. 55 213 209 2072:1 Fresh, as-prepared 4 163 155 1402:1 200° C. 7 152 148 1452:1 300° C. 11 172 170 1672:1 400° C. 29 192 189 1872:1 600° C. 50 221 216 2132:1 700° C. 60 219 215 212______________________________________
The coercivity values of the Fe:In samples are shown in Table 4, and FIG. 4 plots the M s values opposite Fe° crystallite sizes.
TABLE 4______________________________________Coercivity values in Oersteds of Fe:In samplesFe:In Molar Heat TreatmentRatio Temperature 10K 77K 150K 220K 300K______________________________________1:1 Fresh, as-prepared 5 10 27 48 1901:1 200° C. 250 100 60 45 201:1 300° C. 235 100 75 40 301:1 350° C. 50 35 20 20 101:1 400° C. 35 17 20 140 1001:1 600° C. 10 5 5 5 52:1 Fresh, as-prepared 300 175 107 75 452:1 200° C. 145 120 110 100 1052:1 300° C. 150 113 105 105 1052:1 400° C. 85 55 35 50 30______________________________________
EXAMPLE 2
In this example, the evaporation of iron and neodymium was carried out using the preferred method described above. Fe was evaporated out of an alumina-coated tungsten crucible and Nd from a boron nitride crucible placed in a tungsten basket with alumina coating on the outside in the presence of pentane at 77 K and 10 -3 torr. Several reactions were carried out using a Fe:Nd 1:1 molar ratio system. In a typical reaction in which about 0.56 g of Fe (10.0 mmole) and 1.50 g of Nd (10.4 mmole) were used, 1.6 g of black pyrophoric powder was collected. Elemental analysis of the powder gave 25.1% and 69.3% by weight Fe and Nd, respectively.
The pyrophoric fresh Fe--Nd powders were then heat-treated under argon at different temperatures ranging from 250° C. to 750° C. for two hours. After the heat treatments, these powders were slowly passivated in air allowing a layer of metal oxides to form on the surfaces of these powders. No evident physical changes were observed on the stabilized powders after they had been stored in sample vials for six months.
A X-ray powder diffraction pattern of the fresh Fe--Nd SMAD powder showed only one broad peak due to metallic iron. The XRD patterns of heat-treated and passivated powders showed that the iron began to crystallize at very low temperature (FIG. 5), but clear signals for Nd 2 O 3 were not observed until the heat treatment temperature reached 500° C. In addition, no clear signals for iron oxides or metallic Nd could be seen after any of the heat treatments. A weak signal for the Fe--Nd intermetallic compound Fe 2 Nd was observed for samples heated at 500° C. and above. The average XRD α-Fe crystallite sizes, estimated with the Scherrer formula, are listed in Table 5 along with the BET surface area data and the estimated sample densities. The BET overall particle sizes listed in this table were estimated from the BET surface area data and the sample densities under the assumption that all the particles had a spherical shape. For comparison, the estimated TEM sizes of these particles are also listed in Table 5.
TABLE 5______________________________________XRD, TEM, and BET Surface Area Data on Fe:Nd (Molar Ratio 1:1)Samples BET XRD Specific TEM Fe BET Surface Size Size Size Area DensitySample (nm) (nm3) (nm).sup.a (m.sup.2 /gram) (g/cm.sup.3).sup.b______________________________________Fresh, as-prepared 2 93 8.7 7.4Heated at 225° C. 12 8 32 28 6.8and passivatedHeated at 325° C. 14 29 30 6.9and passivatedHeated at 450° C. 19 25 34 7.1and passivatedHeated at 600° C. 30 26 7.2and passivatedHeated at 750° C. 35 29 25 34 7.1and passivated______________________________________ a. Assuming all the particles had a spherical shape b. Estimation was based on the information obtained from XRD and Mossbaue studies on the concentrations of Fe, Fe.sub.2 O.sub.3 and Nd.sub.2 O.sub.3.
To determine the valence states of Fe atoms in these samples, Mossbauer spectra were taken. When exposed to air, all the Fe atoms in the as-prepared particles were oxidized to α-Fe 2 O 3 . The heat-treated and passivated Fe--Nd samples showed a gradual increase of the percentage of metallic Fe (as the α-Fe sextet) upon increase of the heat treatment temperature. These changes together with the Mossbauer data on the metallic α-Fe phase (sextet) in these powders are summarized in Table 6.
TABLE 6______________________________________Room Temperature Mossbauer Data on Fe-Nd SamplesSample Heat IsomerTreatment Shift (IS) Quadruple Split- HyperfineTemperature (mm/ ting (QS) Field (H.sub.f) % of Fe as(°C.) second) (mm/second) (Koe) α-Fe sextet______________________________________Fresh, -0.01 0.02 323.2as-prepared225, passivated 0.02 0.04 332.8 54325, passivated -0.01 -0.03 332.7 59450, passivated 0.06 0.09 329.6 71500, passivated -0.01 -0.01 332.1 70600, passivated 0.06 0.04 330.5 74750, passivated -0.02 -0.02 333.41 68Not heated, 0.24 0.96 0 to 10passivated(mainlyα-Fe.sub.2 O.sub.3doublets)______________________________________
The Mossbauer data indicated the presence of pure α-Fe, while the rest of the signal was assigned to α-Fe 2 O 3 and Fe 2 Nd. Since the signals of α-Fe 2 O 3 and Fe 2 Nd. Since the signals of α-Fe 2 O 3 and Fe 2 Nd (each as a doublet) overlap with each other, their relative abundance could not be assessed.
The hyperfine field of the fresh, unexposed Fe--Nd powder (324 KOe) was slightly lower than the standard value (333 KOe). This indicated a close-range electronic interaction between iron (electronegativity 1.8) and Nd (electronegativity 1.1) atoms that enabled Fe atoms to withdraw some electron density from the surrounding Nd atoms.
The Mossbauer data showed that when the samples were heat-treated at temperatures higher than 450° C., at least 70% by mass of the iron atoms were protected from further oxidation (as α-Fe) after the powders were stabilized by oxidative passivation of the surfaces. However, a Mossbauer spectrum of the sample heat-treated at 750° C. showed a slightly lower content of the α-Fe phase because more Fe atoms formed Fe 2 Nd at this high temperature. Also, the extensive sintering of the surface layer led to shrinking of the protecting shell resulting in the exposure of the Fe crystallite core to oxygen.
Magnetic studies of these Fe--Nd bimetallic particles allowed examination of the saturation magnetization and coercivity values of these powders. Based on the XRD patterns, none of the exposed samples had metallic Nd as a component. Thus, all Nd was assigned as Nd 2 O 3 in the exposed particles, and all the Fe atoms were considered as metallic Fe when the mass balance of the passivated samples was calculated. This gave an estimated Fe mass balance of 25% for all the passivated samples with a starting Fe/Nd molar ratio of 1:1. For fresh, unexposed Fe--Nd bimetallic powders, only metallic Fe atoms and metallic Nd atoms were considered as the components, and for the Fe:Nd=1:1 molar ratio system, the theoretical mass balance for Fe was about 28%. The comparison between the saturation magnetization values of the fresh, unexposed Fe--Nd sample (not heated) and the as-prepared, exposed Fe--Nd sample (not heated) is illustrated in FIG. 6, and the comparison of their coercivities is given in FIG. 7. FIG. 6 demonstrates that the saturation magnetization value of the fresh, as-prepared Fe--Nd sample had a strong temperature dependence. The saturation magnetization value of this sample was about 162 emu/g of Fe at 10 K, and gradually decreased to about 85 emu/g of Fe at 300 K. Because there was no oxygen in this sample, the lower M s values of this sample compared with that of the bulk Fe were due to the formation of Fe--Nd alloys on the surfaces of the iron crystallites. The exposed Fe--Nd particles (not heated) had very low M s values confirming that most of the iron atoms in this sample were oxidized to α-Fe 2 O 3 during the exposure to air as indicated by the room temperature Mossbauer data. The coercivity values of the fresh and exposed particles were also quite different. The high coercivities of the fresh, as-prepared Fe--Nd particles indicated that this sample contained ferromagnetic metallic iron clusters, whereas the very low coercivities of the exposed Fe--Nd sample were due to amorphous α-Fe 2 O 3 (FIG. 7).
Although no information on the magnetic properties of Nd 2 O 3 was found in the literature, it was reasonable to believe that Nd 2 O 3 had a very low magnetic moment. Therefore, the contribution of Nd 2 O 3 to the saturation magnetization values of the passivated Fe--Nd particles was omitted. Furthermore, α-Fe 2 O 3 had a saturation magnetization value of 0.6 emu/g as compared to the pure Fe saturation magnetization value of 220 emu/g, thus the magnetic moment of these samples came only from metallic Fe. Based on the estimated mass balance of these samples, the magnetization values of the passivated Fe--Nd particles were calculated and are illustrated in FIG. 8 opposite the Fe crystallite sizes.
Passivated Fe--Nd particles, especially the sample not receiving heat treatment, had reduced saturation magnetization values due to oxidation upon passivation. However, the formation of Fe--Nd alloys on the surfaces of the Fe clusters was also taken into consideration. For samples heated at lower temperatures (small Fe crystallites), the oxidation effect predominates, whereas, for samples heated at higher temperatures, less Fe was oxidized and more Fe formed alloys with Nd. The low M s value of the 750° C. sample (compared with the 600° C. sample) was due to the extensive formation of Fe 2 Nd in this sample.
The passivated Fe--Nd particles demonstrated very low coercivities of 12.6-105 Oe at 300 K. For α-Fe crystallites with an iron oxide outside coating, room-temperature coercivity values can be as high as 1,050 Oe. These Fe--Nd powders must therefore be considered soft magnetic materials and consist of Fe° clusters protected by Fe 2 Nd and Nd 2 O 3 coatings.
EXAMPLE 3
The Fe--MgF 2 system studied in this example using the preferred method described above had a Fe to MgF 2 molar ratio of 1:2 where 0.80 g of Fe (14.3 mmole) and 1.78 g MgF 2 (28.6 mmole) were co-evaporated and deposited at 77 K with pentane vapor. The evaporation temperature of MgF 2 under the normal SMAD reactor pressure (about 10 -3 torr) was 1100° C. About 2 g of the product was collected. FIG. 9 gives the XRD patterns of the as-prepared samples as well as the heat-treated and passivated Fe--MgF 2 (molar ratio 1:2) powders. In the as-prepared sample, signals of MgF 2 and Fe were both present, and the estimated Fe crystallite size was about 9 nm. The XRD patterns of the heat-treated and passivated samples showed only the signals of Fe and MgF 2 , and no signals for iron oxides were visible. The estimated XRD sizes of the Fe crystallites for each of the heat-treatment temperatures are given in Table 7. A graphic version of the information provided in this table is given in FIG. 10 .
TABLE 7______________________________________XRD Fe Sizes of Fe-MgF.sub.2 ParticlesHeat Treatment Temperature (°C.) XRD Fe Crystallite Size (nm)______________________________________Room Temperature, as-prepared 9.0200 12.0300 15.0350 18.0400 22.0600 60.0______________________________________
TEM photos of these particles are shown in FIG. 11. The TEM measured sizes of the particles and the α-Fe crystallite sizes are listed in Table 8.
TABLE 8______________________________________TEM Sizes Fe-MgF.sub.2 ParticlesHeat Treatment TEM Overall TEM α-Fe TEM α-FeTemperature Particle Size Crystallite Crystallite(°C.) (nm) (I).sup.a Size (nm) (II).sup.b Size (nm)______________________________________Room Temperature,as-prepared200 12-15300 17-19400 22-25500 50-100 10-15600 50-150 10-15______________________________________ a. Large Fe Crystallites b. Isolated Small Fe Crystallites
The TEM photos show that, after being heated at lower temperatures, the Fe--MgF 2 particles still had a near single-phase structure with the Fe crystallites embedded in a matrix of MgF 2 demonstrating that the Fe crystallites grew very little. When the temperature reached 500° C., severe phase separation occurred. Most of the Fe clusters aggregated into very large Fe particles (50 to 100 nm), and only a small number of the smaller Fe crystallites remained. In the 500° C. and 600° C. samples, there were actually two groups of Fe crystallites. One group included the large Fe particles with a size range of around 100 nm, and the other group contained the smaller 10-15 nm Fe crystallites. The large Fe particles accounted for more than 90% of the total mass of the Fe in these materials whereas the small Fe crystallites represented less than 10% of the total Fe mass. After heat-treatments at the temperatures of 500° C. and 600° C., the MgF 2 crystals also grew into large pieces with a size range of a few hundred nanometers.
The magnetic properties ofthese Fe--MgF 2 particles were studied using a SQUID magnetometer. Although a small portion of the Fe atoms in these materials were actually oxidized during the passivation process, the magnetization values per gram of Fe were calculated without consideration of the mass change caused by the oxidation of Fe atoms because the extent of the oxidation was very hard to estimate, and also because the oxidation of Fe caused only a small change in the mass balance of these materials. The calculated magnetization values of these Fe--MgF 2 materials are listed in Table 9, and the coercivity values are given in Table 10. FIG. 12 gives the percentage of the bulk magnetization value (220 emu/g of Fe) at 300 K versus Fe crystallite sizes in these particles.
TABLE 9______________________________________Magnetization Values of Passivated Fe-MgF.sub.2 ParticlesHeat α-Fe Magnetization (emu/g of Fe) at DifferentTreatment Size Temperatures (K)Temp (°C.) (nm) 10K 77K 150K 220K 300K______________________________________Fresh, as-prepared 9 187 183 177 170 158200 12 135 134 132 129 125300 15 203 198 193 185 172400 22 209 205 200 193 184600 50-100 219 215 210 205 194______________________________________
TABLE 10______________________________________Magnetic Coercivity Values of Fe-MgF.sub.2 ParticlesHeat α-Fe Magnetic Coercivity (Oe) at DifferentTreatment Size Temperatures (K)Temp (°C.) (nm) 10K 77K 150K 220K 300K______________________________________Fresh, as-prepared 9 420 270 215 170 105200 12 955 475 240 179 159300 15 320 120 120 95 72400 22 580 370 265 200 130600 50-100 180 140 90 72 56______________________________________
The magnetization data in Table 9 and the information provided in FIG. 12 show that after being heated at temperatures of 400° C. and above, more than 85% of the Fe atoms were protected when these particles were exposed to air. A schematic illustration for the formation of encapsulated Fe clusters in a MgF 2 matrix using the SMAD method is shown in FIG. 13.
EXAMPLE 4
In this example, the evaporation of Co and MgF 2 followed the preferred method as described above. The Co--MgF 2 system had a molar ratio of 1:2 in which 0.80 g of cobalt (13.6 mmole) and 1.69 g of MgF 2 (27.2 mmole) were co-evaporated in the presence of pentane at 77 K. Co vaporized at about 1300° C. under the SMAD reactor pressure (10 -3 torr). FIG. 14 gives the XRD patterns of the fresh, as-prepared Co--MgF 2 powders as well as the heat-treated and passivated samples. The average size of the Co crystallites of the fresh, as-prepared sample was estimated at about 4.5 nm by using the Scherrer formula for XRD broadening. All the XRD patterns showed metallic cobalt and MgF 2 , and no clear signals of cobalt oxides could be observed. The estimated XRD asizes and the estimated TEM sizes of cobalt crystallites in these samples are listed in Table 11. TEM photos of these particles are given in FIGS. 15 and 16.
TABLE 11______________________________________Estimated Co Crystallite Sizes in the Co-MgF.sub.2 ParticlesHeat Treatment XRD Co TEM CoTemperature (°C.) Crystallite Size (nm) Particle Size (nm)______________________________________Fresh, as-prepared 4.5200 5.9300 7.2 5-10400 10.0 10-15500 12.2 15-20600 13.6 15-25700 16.0 20-30______________________________________
A graphic version of the heat-treatment temperature-Co crystallite size relationship is given in FIG. 17. From a comparison of Table 11 and FIG. 18, it will be appreciated that the XRD Co sizes were generally smaller than the sizes estimated from the TEM photos because, in the XRD patterns of the Co--MgF 2 particles, the Co line (2θ=44.2°) by which the Co crystallite sizes were calculated with the Scherrer formula, partially overlaps with a MgF 2 line which is at about 39.8° of 2θ. As a result, the calculated XRD Co sizes were smaller than they should have been, thus the TEM sizes were more accurate. The magnetic properties of these Co--MgF 2 particles are listed in Tables 12 and 13 and also shown in FIGS. 18 and 19.
TABLE 12______________________________________Saturation Magnetization Values of Co-MgF.sub.2 ParticlesHeatTreatment XRD Saturation Magnetization Values (emu/gTemper- Co Size TEM Co of Co) at Different Temperatures (K)ature (°C.) (nm) Size (nm) 10K 77K 150K 220K 300K______________________________________Fresh, as- 4.5 113 111 109 107 106prepared200 5.9 102 101 100 99 98300 7.2 5-10 105 104 103 101 100400 10.0 10-15 107 104 103 101 100500 12.2 15-20 120 118 117 116 115600 13.6 15-25 131 129 129 128 128700 16.0 20-30 134 132 131 131 130______________________________________
TABLE 13______________________________________Magnetic Coercivity Values of Co-MgF.sub.2 ParticlesHeat Treatment Coercivity Values (Oe) atTemperature XRD Co TEM Co Different Temperatures (K)(°C.) Size (nm) Size (nm) 10K 150K 300K______________________________________Fresh, as-prepared 4.5 500 239 71200 5.9 267 84 35300 7.2 5-10 515 82 74400 10.0 10-15 585 118 78500 12.2 15-20 466 174 92600 13.6 15-25 420 210 140700 16.0 20-30 509 206 177______________________________________
Cobalt had a bulk magnetization value of 162.5 emu/g of Co and, thus, at least 80% of the cobalt atoms were protected so long as these particles were heated at temperatures higher than 500° C. before they were exposed to air as illustrated in Table 12 and FIG. 18. The Co--MgF 2 system had a much narrower Co size distribution, therefore, a simplified schematic illustration of the encapsulation of Co particles in the MgF 2 matrix is given in FIG. 20.
EXAMPLE 5
The evaporation of Ni and MgF 2 also followed the preferred method as described above. Ni vaporized at about 1400° C. under the SMAD reactor pressure of about 10 -3 torr. The Ni--MgF 2 system had a molar ratio of 1:2 in which 0.80 g of Ni (13.6 mmole) and 1.69 g of MgF 2 (27.2 mmole) were co-evaporated in the presence of pentane at 77 K. FIG. 21 gives the XRD patterns of the fresh, as-prepared and the heat-treated and passivated Ni--MgF 2 particles. The average size of the Ni crystallites was estimated at 5.8 nm in the fresh, as-prepared sample. In all the XRD patterns of the heat-treated and passivated samples, only the signals of Ni and MgF 2 were clearly visible. No signs of nickel oxides were detected. The estimated XRD sizes and TEM sizes of the Ni crystallites are listed in Table 14.
TABLE 14______________________________________XRD and TEM Sizes of Ni Crystallites in Ni-MgF.sub.2 ParticlesHeat TreatmentTemperature XRD Ni Crystallite TEM Ni Crystallite Size(°C.) Size (nm) (nm)______________________________________Fresh, as-prepared 5.8200 7.5 7300 8.5 5-10400 11.0 10500 13.6 10-15600 19.0 15-25______________________________________
From the above comparison it will be appreciated that the XRD and TEM sizes correspond with one another. The magnetic properties of these materials are listed in Tables 15 and 16, and FIGS. 22 and 23 also illustrate these results.
TABLE 15______________________________________Saturation Magnetization Values of Ni-MgF.sub.2 ParticlesHeat XRD TEMTreatment Ni Ni Saturation Magnetization Values (emu/gTemper- Size Size of Ni) at Different Temperatures (K)ature (°C.) (nm) (nm) 10K 77K 150K 220K 300K______________________________________Fresh, as- 5.8 25.8 22.2 20.6 19.2 17.4prepared200 7.5 7 24.0 21.2 18.7 17.1 16.2300 8.5 5-10 31.0 26.5 24.8 23.3 21.4400 11.0 10 39.2 37.2 35.8 34.4 32.1500 13.6 10-15 46.5 45.1 44.0 42.7 40.6600 19.0 15-25 50.0 48.3 47.5 46.3 44.4______________________________________
TABLE 16______________________________________Magnetic Coercivities of Ni-MgF.sub.2 Particles Coercivity Values (Oe) ofHeat Treatment Ni-MgF.sub.2 Particles atTemperature XRD Ni TEM Ni Different Temperatures (K)(°C.) Size (nm) Size (nm) 10K 150K 300K______________________________________Fresh, as-prepared 5.8 149 23 5.0200 7.5 7 100 40 10300 8.5 5-10 70 10 5.0400 11.0 10 62 20 7.0500 13.6 10-15 76 9.0 3.0600 19.0 15-25 194 16 17______________________________________
EXAMPLE 6
A sample of 0.5 g polystyrene resin (plastic) was dissolved in 15 mL of toluene in a 25 mL beaker and 0.3 g of Fe--Mg composite particles (50-60 nm diameter overall size, iron crystallite size 16 nm) was added with stirring (37% by weight composite particle loading) followed by 3 minutes of sonication in a conventional sonicator-cleaner. Some of the toluene evaporated at room temperature until the slurry became viscous. Then the mixture was poured into an approximately 3" diameter circular mold, and the toluene allowed to evaporate completely leaving a black, thin disk having a thickness of about 10 thousandths of an inch. The resulting disk was rigid if left in contact with the mold. However, it could be peeled off giving a flexible disk and cut into lengths of tape.
After magnetization with a hand-held permanent magnet, the magnetized tape was studied using a Hall probe. A 400-1000 milliGauss signal was detected. The magnetization direction was reversed, and again a 400-1000 milliGauss signal was detected.
For a comparison, a normal commercial magnetic tape was measured for remnant magnetization, which showed a signal of about 500 milliGauss.
In another series of tests, several magnet tapes were fabricated by encapsulating Fe--Mg magnetic particles in accordance with the invention in polystyrene binder, as described above. The composite particle loading ranged from 5-40% by weight. For example, a 5% loading yielded a 40-80 milliGauss reading on the Hall probe.
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Composite nanoparticles comprising an elemental metal core surrounded by a metal-containing shell material are described wherein the particles have an average diameter of from about 5-500 nm; the core metal is preferably selected from the group consisting of the transition metals and especially Fe, Co and Ni, whereas the shell material is advantageously a metal such as an alkaline earth metal, or a metal salt such as a metal oxide or metal halide. The shell material is preferably more oxophilic than the elemental core material, enabling the core metal to remain purely metallic. These core/shell composite particles can be used to fabricate magnetizable recording media such as tapes and disks.
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TECHNICAL FIELD
[0001] The invention relates to an underwater location device such as may be used for controlling the launch, positioning or recovery of a tidal turbine or other underwater equipment. It should be noted that the example of a tidal turbine is used herein but the invention is not limited to such uses.
BACKGROUND ART
[0002] Tidal currents offer a considerable source of sustainable energy at various sites throughout the world, usually within easy reach of land and in relatively shallow waters. Tidal currents are created by movement of the tides around the earth producing a varying sea level, dependent on the phases of the moon and sun. As the sea levels vary, so the waters attempt to maintain equilibrium subject to gravitational forces, thus inducing flow from one area of sea to another. This flow is modified by a number of factors such as, the Coriolis forces due to the earth rotation, earth/moon/sun alignment, local topography, atmospheric pressure and temperature and salinity gradients. The major advantage of tidal power generation is its regularity, which can be predicted for years in advance.
[0003] According to a study by the ETSU (Energy Technology Support Unit) the United Kingdom may obtain up to 20 percent of its total electricity by using these systems to collect energy from fast moving tidal currents that exist in channels and offshore areas. Similar resources have been noted to exist elsewhere such as in the Straits of Messina, between Sicily and mainland Italy.
[0004] The most powerful flows tend to occur in areas of restriction, either by width or depth, but for the same reasons are not suitable for widespread exploitation by large, fixed devices which require a minimum rotor area, and therefore water depth, to justify the costs of installation and maintenance. It is assumed from the outset that new tidal barrage systems are unlikely ever to be pursued due to their inherent properties of high cost, delayed financial return, and serious environmental consequences.
[0005] The considerable size of the available resource has attracted various proposals for its exploitation.
[0006] The following represents the existing systems within the field of tidal current energy extraction. It is assumed that power transmission problems will be equal for any system, and that all systems will require some form of non-toxic anti-fouling agent.
[0007] There also exist operational environmental impacts common to all methods of tidal power generation, such as, an inherent risk of collision damage to fish and marine mammals, redirection of currents and the sediments and food particles contained within them, and shipping, particularly fishing.
[0008] A first type of tidal current energy extraction system encountered on the market is the Monopile system. This technology is well known and understood by contractors familiar with the offshore oil industry. It consists of twin axial flow turbines, each turbine driving a generator via a gearbox, mounted on streamlined cantilevers either side of a circular section, vertical steel monopile. It is anticipated that a number of structures will be grouped together in ‘farms’. The planning of such a tidal ‘farm’ would need to be accurately modelled for wake effects, as once installed, the monopile is expensive to re-site. In addition, operational depth is restricted to the 20 m-35 m range. Concerning the installation and maintenance, monopile systems require a hole to be drilled in suitable bedrock and the base of the turbine tower is secured within the socket so produced. Existing monopile support mechanisms for presenting a tidal turbine to the tidal currents are expensive, thus making only a few sites economically viable for power generation and requiring considerable sub sea engineering expertise.
[0009] The current monopile systems permit raising the turbines above water level for maintenance and repair, which is beneficial, but the long-term (i.e. 20 years) reliability and corrosion resistance of the necessary mechanism must be questionable. The protrusion of the piles above sea level would reduce the likelihood of impact with passing vessels.
[0010] Concerning the environmental and decommissioning issues, the impact of installation would be considerable, especially to the benthic flora and fauna, but subsequently the piles may become areas of shelter and therefore, populated. To minimise the danger to shipping and fishing, decommissioning would require complete removal of the piles, which would disturb the benthic population once again.
[0011] A second type of tidal current energy extraction system that exists in the prior art is the floating tether. This floating tether device is anchored to the seabed with a mooring cable and suspended clear of the seabed using a flotation buoy. The axial flow tidal current turbine is free to position itself into the direction of the tidal flow, which obviates the need for a yaw mechanism.
[0012] Several prototypes have already been developed including a 10-kilowatt device tested in Scotland in 1994. At present, the arrangement is unlikely to be suitable for large power output installations due to the relative sizes of anchor, turbine and float. On occasions of relatively high velocity tidal streams (e.g. spring tides), if the anchor holds, the turbine will be dragged lower in the water with the unwanted potential to collide with the seabed.
[0013] Concerning the installation of the floating tether system, it is relatively quick and inexpensive. However, visual inspection would need to be frequent as the structure is likely to be subject to storm damage and fatigue loading of the cable, leading to possible loss of the supporting float and subsequent sinking of the device, or loss of anchorage and subsequent drifting. Once sunk, the device would be open to damage by the oscillating tidal currents and could prove difficult to recover, whilst a drifting device would potentially cause damage to any other moored turbines in its path.
[0014] Due to the length of tether required and the random positioning of the device at any one time, this arrangement is not suitable for closely grouped tidal farms and a safe spread would fail to make economical use of the power available in a given area. For the same reasons, this type of arrangement would present a hazard to all forms of shipping, large and small. It would, however present a possible solution to a one-off, small scale installation in areas such as the mouth of a sea loch. Concerning the environmental impacts of installation and decommissioning of the floating tether systems, it will be minimal, leaving no footprint on removal.
[0015] A third type of tidal current energy extraction system that also exists in the prior art is the oscillating hydroplane system. In that system, a central post mounted on five legs supports a complex mechanism comprising two interconnected symmetrical hydrofoils. These hydrofoils are used to pump high-pressure oil, which drives an electrical generator via a hydraulic motor. At the end of each stroke, the hydrofoils are tilted to give the required angle of attack to produce the return stroke, thus creating an oscillating motion.
[0016] Concerning the installation and maintenance, at present, the oscillating hydroplane system does not yet possess a launch and recovery mechanism. As a result of the constant oscillations and considerable number of moving parts, it is probable that this device will be subject to high dynamic loading and subsequent fatigue stress. The upward stroke of the hydrofoils will tend to lift the device off the seabed and hence increase the possibility of it being washed away at high tidal stream velocities.
[0017] Concerning the environmental impacts of installation and decommissioning of the oscillating hydroplane systems, they are expected to be minimal, leaving no footprint on removal. However, this cannot be confirmed until a launch/recovery mechanism is proposed. Using high pressure oil as a means of power transmission does however introduce the possibility of pollution in the event of leakage.
[0018] Some ‘tidal’ energy extraction systems can also be used in freshwater applications such as rivers.
[0019] With these existing systems and designs, it is a problem that their instabilities during operations as well as during launch and recovery, if possible, might cause damage. In addition, since these systems are becoming larger and larger, the frequent installation and maintenance operations will become more and more difficult and expensive.
SUMMARY OF THE INVENTION
[0020] It is an object of the present invention to obviate or mitigate the problems of controlling underwater equipment in a flowstream.
[0021] In a first aspect, the invention described herein relates to an apparatus for controlling underwater equipment comprising:
attachment means for attaching underwater equipment to the apparatus; and at least one member for generating positive or negative lift.
[0025] Preferably, the at least one member is adapted to create a negative lift due to fluid flow in a first direction and is adapted to create a negative lift due to fluid flow in a second, different, direction.
[0026] Preferably, the first and second directions are generally opposite to each other.
[0027] Preferably, the apparatus is adapted to anchor the underwater equipment to a sea- or river-bed.
[0028] Preferably, the attachment means is adapted to attach the underwater equipment in close proximity to the centre of gravity of the apparatus.
[0029] Preferably, the space frame is mounted on a number of feet equipped with slippage prevention means, which may be an arrangement of spikes or the like, to typically resist slipping by shear force rather than relying on friction alone such that, in use, the negative lift will preferably tend to force said slippage prevention means into a sea- or river-bed thus resisting the drag forces acting on the space frame tangentially to the seabed.
[0030] Preferably, the at least one member comprises at least one hydrofoil.
[0031] Typically, differences in pressure acting on opposing surfaces of each of the at least one member due to a predetermined angle of attack causes said at least one member to generate negative or positive lift.
[0032] Preferably, the apparatus is adapted to control the launch and/or recovery of the underwater equipment attached to it.
[0033] In a preferred embodiment, the at least one members are rotatable to any position and even more preferably in the region of 160° to 200° about a longitudinal axis of the respective member.
[0034] Preferably, the hydrofoils are symmetrical.
[0035] Said at least one members preferably comprise at least one hydrofoils which are more preferably self-rectifying static hydrofoils, which may be capable of passive rotation about an axis such that each hydrofoil maintains alignment with a periodically reciprocating rectilinear flow.
[0036] Moreover, the at least one members are preferably moveable between a first configuration in which they are capable of generating positive lift and a second configuration in which they are capable of generating negative lift.
[0037] Preferably, the at least one member has a variable actuating means to vary the positive or negative lift generated by the member.
[0038] Preferably, said actuating means comprises a motor which may be a hydraulic, pneumatic or electric actuated motor. Preferably, a shaft member is actuated when a change between first and second configurations is required, said actuation typically causing the shaft member to rotate through a predetermined angle, which may be in the region of 180°.
[0039] Preferably, said apparatus comprises a support framework which is typically composed of sub frameworks, where a number of shaft members are connected to the framework and on which said symmetrical hydrofoils are coupled. Preferably, the at least one hydrofoils are coupled to the support framework by a respective bearing member connected to the hydrofoil. The bearing member of the hydrofoil is typically coupled to the shaft member of the framework, the bearing member and shaft member combining to provide a rotation enabling portion and a rotation prevention portion. Preferably, the bearing member is substantially cylindrical. The rotation prevention portion typically comprises at least one stop members (which may be in the form of lugs mounted on the shaft member) and which are adapted to engage with at least one respective stop members (which may also be lugs) mounted on the respective bearing member of each hydrofoil. Typically, the bearing member comprises a pair of stop members which are spaced apart around its inner circumference, typically being spaced apart by approximately 180°.
[0040] Typically, the shaft member comprises a pair of stop members which are spaced apart around its outer circumference, typically being spaced apart by approximately 180°. Preferably, one of the bearing stop members is engageable with a respective shaft stop member to define the first negative configuration and the other of the bearing stop members is engageable with the other of the shaft stop members to define the second negative configuration.
[0041] Preferably, said apparatus is a multi-legged, self-levelling space frame equipped with a plurality of hydrofoils, typically at different heights.
[0042] In alternative embodiments, the at least one member is rigidly connected to a support framework and is unsymmetrical. Preferably, the at least one member comprises a disc shaped member which, in use, is adapted to produce positive or negative lift regardless of the direction of flow of fluid thereby. Preferably, the disc shaped member produces negative lift.
[0043] According to a second aspect of the invention, there is provided a method of controlling underwater equipment; the method comprising:
providing an apparatus having at least one member for generating positive or negative lift; attaching the apparatus to underwater equipment; releasing the apparatus into a fluid; allowing fluid to flow past the at least one member to generate positive or negative lift.
[0048] Preferably, the method according to the second aspect of the invention is performed using the apparatus according to the first aspect of the invention.
[0049] Preferably, the apparatus is placed in a flow of water.
[0050] Preferably, the underwater equipment is a turbine.
[0051] According to a further aspect of the present invention, there is provided an apparatus for maintaining underwater equipment within a sea or river tidal current location, the apparatus comprising at least one moveable members capable of generating negative lift, where said at least one members are moveable between a first configuration in which they create a negative lift due to flow in a first direction, and a second configuration in which they create a negative lift due to flow in a second, different, direction.
[0052] The invention also provides energy extracting apparatus for extracting energy from fluid flow, said energy extracting apparatus comprising:
a turbine; at least one member, which in use, generates positive or negative lift.
BRIEF DESCRIPTION OF THE DRAWINGS
[0055] Embodiments of the present invention will now be described, by way of example only, with reference to the accompanying drawings, in which:—
[0056] FIG. 1 shows a side view of a space frame in accordance with the present invention, showing a tubular frame allowing the positioning of the hydrofoils at differing heights;
[0057] FIGS. 2 a to 2 d show the passive reversing of the hydrofoils in response to a change in flow direction whilst FIGS. 2 e to 2 h show the different movements of hydrofoils of FIG. 1 actuated by hydraulic motors to create positive and negative lifts during launch, recovery and transitional operations according to the present invention;
[0058] FIGS. 2 i to 2 m show the passive reversing of the hydrofoils in response to a change in flow direction;
[0059] FIG. 3 in its upper half shows a first side view, and in its lower half shows an opposite side view, illustrating the fundamental geometry of the passive reversing mechanism;
[0060] FIG. 3 a in its upper half shows a first side view, and in its lower half shows an opposite side view, illustrating the fundamental geometry of the passive reversing mechanism;
[0061] FIG. 3 b is a third side view showing the fundamental geometry of the passive reversing mechanism;
[0062] FIG. 4 shows in detail the assemblage of hydrofoils onto the space frame of FIG. 1 ;
[0063] FIG. 5 a is a side view of a second embodiment of an apparatus in accordance with the present invention and an attached canister;
[0064] FIG. 5 b is a front view of the FIG. 5 a apparatus with the attached canister;
[0065] FIG. 5 c is a plan view of the FIG. 5 a apparatus with the attached canister; and,
[0066] FIGS. 5 d - 5 f are a series of views of an attachment ring which forms part of the FIG. 5 a apparatus.
DETAILED DESCRIPTION OF THE INVENTION
[0067] According to the present invention, the apparatus for launching an underwater device from a vessel, securing the underwater device whilst in operation on the seabed and permitting recovery to a vessel, for maintenance and repair should be as simple as possible without involving any sophisticated and specialised equipment. A first embodiment of the invention is shown in FIG. 1 and utilises passive, self-rectifying static hydrofoils, the central shaft (see FIG. 3 ) of which can be rotated through 180° to generate positive or negative lift as required.
[0068] As is shown in FIG. 1 , the apparatus 1 for controlling the launch, secure positioning and recovery of an underwater device comprises a space frame 10 for attaching to any desired underwater device such as power extraction equipment which may comprise a tidal turbine (not shown), a hydrofoil support frame to accommodate the self rectifying hydrofoil mechanisms 12 and hydraulically operated legs 11 for levelling of the apparatus 1 . The feet 14 are equipped with spikes or similar serrated attachments (not shown) to initiate grip on the sea or river bed.
[0069] The hydrofoils 12 are inclined in such a way as to generate a significant downforce as a result of the stream flow over their surfaces. This downforce will push the apparatus 1 into the seabed, and, since the actual applied force will be proportional to the square of the velocity of the fluid passing over them, the apparatus 1 will be more securely fixed as the streamflow velocity increases. By this means the apparatus can overcome overturning moments applied to the underwater device that it supports.
[0070] The space frame 10 is shown as arched tubing but is not restricted to shape since any frame configuration offering different levels of mounting point for the hydrofoils 12 will suffice. The apparatus 1 as shown has multiple hydrofoils 12 but any number of hydrofoils 12 will suffice. As is shown in FIGS. 2 a to 2 h , each hydrofoil 12 is mounted on a central shaft 48 such that it may rotate upwards from horizontal (or any angle of inclination above horizontal) through vertical to any angle above horizontal but now pointing in the opposite direction. The angle of attack of the hydrofoils 12 is governed by the relative size and positioning of lugs 46 attached to the central shaft 48 and the corresponding lobes 44 attached to an outer shaft (not shown) which is itself fixed to the hydrofoil 12 .
[0071] In a preferred embodiment, the apparatus 1 according to the present invention comprises a multi-legged, self-levelling space frame 10 equipped with a number of hydrofoils 12 at different heights with any underwater device, such as a tidal turbine, it supports, situated as close as practicable to the centre of gravity of the apparatus 1 .
[0072] It is anticipated that the space frame 10 will be mounted on a number of feet 14 equipped with spikes (not shown) to resist slipping of the apparatus 1 with respect to the river bed (not shown) by shear force rather than relying on friction alone. The number of feet 14 A, 14 B required will depend on the weight of the apparatus 1 ; however, the location and the shape of these supporting feet 14 A, 14 B aim at holding the apparatus 1 in the orientation shown in FIG. 1 upwards against the current and thus ensuring the stability of the space frame 10 . The negative lift (arrow A) will tend to force these spikes into the sea or river bed (not shown in FIG. 1 ) thus resisting the drag forces acting on the space frame 10 tangentially to the sea or river bed.
[0073] The drag forces acting on the underwater device (such as the tidal turbine) attached to the apparatus 1 will naturally tend to apply an overturning moment to the space frame 10 about its rearmost feet 14 B, with respect to the direction of flow (arrow F). These forces will however be overcome by positioning the hydrofoils 12 at stations such that the negative lift (arrow A), created by the foremost or upstream (those at the left hand side of the space frame 10 as shown in FIG. 1 ) hydrofoils 12 acting over the length of the space frame 10 , is arranged to exceed the overturning moment.
[0074] Thus, the space frame 10 is symmetrical about its midpoint M with the hydrofoils 12 being coupled to the space frame 10 in a manner, to be subsequently detailed in a discussion of FIGS. 2 a to 2 h , which allows them to passively reverse with stream flow F to maintain compressive forces in a downwards direction A and restraining moments regardless of tidal stream direction.
[0075] During operation of the apparatus 1 , the hydrofoils 12 are free to rotate (shown as clockwise in FIGS. 2 a to 2 d and 2 I to 2 m ) in response to the change in tidal stream flow F direction in a manner which is shown from left to right in FIGS. 2 a to 2 d to create a negative lift (arrow A) so as to push the apparatus 1 into the seabed.
[0076] When the apparatus 1 is to be installed on the seabed or is to be recovered from the seabed for e.g. maintenance of the apparatus 1 , as shown in the FIGS. 2 a to 2 d , hydraulic motors 30 , via a suitable gearing mechanism such as a worm and wheel arrangement 32 (as shown in FIG. 3 ) or chain type mechanism (not shown), are utilised to rotate (shown as anticlockwise in FIGS. 2 e to 2 h ) the longitudinal axes (i.e. the horizontal axes perpendicular to the stream flow 12 ) of the hydrofoils 12 through the required angle until the hydrofoils 12 have reached the configuration shown FIG. 2 h ; for the configuration shown in FIGS. 2 e to 2 h , this angle is approximately 180°. It should be kept in mind that the hydraulic motors 30 can be replaced by pneumatic or electric motors. In other words, if the apparatus 1 is towed, e.g. by a boat or other vessel or installation at the surface, the hydrofoils 12 will produce positive lift (arrow B) as shown in FIGS. 2 e to 2 h . For launch and recovery, this positive lift can be utilised to raise or lower the space frame 10 within the tidal stream. If required, this action could be augmented by forming air tanks within the space frame 10 that can be ‘blown’ with compressed air to improve the buoyancy of the apparatus 1 . If the hydraulic motors 30 use the worm and wheel mechanism 32 form of drive, the hydrofoil 12 positions can be altered over a range of positions, thus permitting the apparatus 1 to be ‘flown’ in the water. Hydraulic connections (and pneumatic connections if required) can be affixed to a supporting marker buoy (not shown) for ease of access.
[0077] FIG. 3 shows the mechanism and assemblage of hydrofoils 12 , hydraulic motors 30 and worm and wheel drive shaft mechanisms 32 in more detail. The hydrofoils 12 are free to rotate about a central shaft 48 , through an included angle of say 160° which will maintain an angle of 10° to the horizontal. The 10° angle effectively becomes an angle of attack when the tidal stream flow F reverses. Thus as the tidal stream 10 reciprocates, the hydrofoils 12 will maintain an angle of 10°, creating a negative lift (arrow A), which will therefore push the spikes 16 into the seabed and immobilise the space frame 10 . As will be described subsequently, positioning lugs 46 mounted on a central shaft 48 provided a stop for locating lobes 44 of the hydrofoil 12 , such that the hydrofoil 12 cannot rotate further than the 160° shown in FIGS. 2 a to 2 d.
[0078] By rotating the central shaft 48 through slightly greater than 180° (say 200°), the negative lift becomes positive lift (arrow B) and the space frame 10 will rise through the water so that the tidal turbine 90 can be recovered on the vessel (not shown).
[0079] FIG. 4 shows in more detail the mechanical assemblage of hydrofoils 12 with space frame 10 . The hydraulic motor 30 for actuating the positioning gear is equipped with a drive shaft 32 that is utilised for rotating an indented positioning gear 42 or a toothed gear wheel. The positioning gear 42 is solidly attached to a central shaft 48 which passes through a bore provided in the larger end of each hydrofoil 12 , a section of which is show on FIG. 4 . The bore of the hydrofoil 12 is provided with a pair of diametrically opposed and inwardly projecting hydrofoil locating lobes 44 . The central shaft 48 has a pair of diametrically opposed and outwardly projecting positioning lugs 46 , each one of which selectively co-operates with one of the respective pair of diametrically opposed hydrofoil locating lobes 44 .
[0080] Thus, by rotating the drive shaft 32 , the hydraulic motor 30 actuates or rotates the position gear 42 which in turn rotates the central shaft 48 . The positioning lugs 46 will contact the locating lobes 44 and carry them 44 (and the hydrofoil 12 ) about the rotational axis of the central shaft 48 until the hydrofoil 12 is in the desired configuration, this being through an angle of approximately 160° until the hydrofoil 12 is in the configuration shown in FIG. 2 h . At this point, the motor 30 is de-actuated and the positioning lugs 46 will hold the hydrofoil 12 locked in this configuration. The rotation of 160° enables the hydrofoil 12 to maintain an angle of 10° to the horizontal in order to provide an angle of attack when the tidal stream F reverses.
[0081] Conversely, the rotation of the central shaft 48 by 180° drives the hydrofoils 12 to create a positive lift and in which case, the space frame 10 will rise through water. FIG. 3 a shows how the attitude of the hydrofoil 12 is changed by a simple 180° clockwise rotation of the central shaft 48 .
[0082] The apparatus according to the present invention, can be launched and recovered by a non-specialist vessel, using non-specialist equipment. Indeed if the vessel is large enough, a number of apparatus 1 may be launched or recovered in a day without the need to return to port. This will also permit easy access for maintenance and repair. Since apparatus 1 possesses few moving parts and no complex mechanisms, it should be inherently reliable.
[0083] A second embodiment of an apparatus in accordance with the present invention is shown in FIGS. 5 a - 5 d . The apparatus 100 comprises a tripod support frame 110 , a bottom ring or stand 126 , a disc-shaped hydrofoil 112 , support brackets 120 and an attachment ring 122 with bolts 123 . The apparatus 100 is attached to an ADCP canister 124 via the attachment ring 122 and bolts 123 . Other subsea equipment may also be attached to the apparatus 100 in place of the canister 124 .
[0084] The hydrofoil 112 is rigidly connected to the frame 110 via the support brackets 120 and its plane is generally parallel to the main plane defined by the bottom ring 126 such that the hydrofoil 122 will be generally parallel to the seabed in use. A central aperture 119 is provided within the hydrofoil 112 . A lower face 113 of the hydrofoil 112 faces the stand 126 and is of a generally flat surface, whereas its opposite, upper, face 115 faces away from the stand 126 and gradually curves upwards away from the main plane of the hydrofoil as it approaches the central aperture 119 to form a raised lip portion 117 . This can be achieved by the assembly of a plurality of smaller hydrofoils 112 s to produce a multi-faceted hydrofoil 112 . The hydrofoil 112 thus has rotational symmetry around a central axis 118 but is not symmetrical on either side of its main plane.
[0085] Thus when a flow of water passes over each face 113 , 115 of the hydrofoil 112 , the reaction force of the water on the raised lip 117 pushes the hydrofoil 112 along with the other components of the apparatus 100 and ADCP canister 124 in a downwards direction—that is “negative lift” results.
[0086] Thus in use, the hydrofoil helps to direct the apparatus 100 and attached equipment towards the seabed and once in position, the hydrofoil maintains the apparatus and equipment on the seabed.
[0087] The apparatus 100 may be attached to a line (not shown) and the line attached at its other end to a buoy. If the apparatus needs to be recovered, the apparatus may be pulled in by the line.
[0088] An advantage of certain embodiments of the present invention, such as the second embodiment, is that they continue to perform their function of providing negative lift regardless of the direction of flow of the water.
[0089] An advantage of the second embodiment of the invention is that it includes no moving parts and so is reliable and requires minimal maintenance.
[0090] The embodiments described herein may also be provided with an integral turbine or other underwater equipment rather than attaching such equipment to the apparatus before use.
[0091] Although reference is made to employing the apparatus 1 , 100 in a tidal current and in certain embodiments using a tidal turbine, it is to be understood that the apparatus 1 , 100 may be placed in any flow of liquid such as rivers and are not limited to their use tidal areas.
[0092] An advantage of certain embodiments of the present invention is that they permit the launch and recovery of underwater equipment to be carried out using a non-specialist but suitably equipped vessel.
[0093] Concerning the primary environmental impact of embodiments of apparatus 1 according to the present invention, it would have some impact upon the benthic flora and fauna, and, although the positioning and retrieval of apparatus 1 would be relatively frequent (at least once every year is anticipated), nothing more than temporary localised disturbance is anticipated. There exists some potential for hydraulic oil leakage, but the system contents are minimal so, even in the event of complete system evacuation, any oil contamination would be minor. Operational environmental hazards are in common with the other forms of tidal energy extraction and decommissioning would leave no footprint.
[0094] Improvements and modifications in terms of dimensions and locations of the different parts described above may be incorporated to the hereinbefore described apparatus for controlling the launch and recovery of a tidal turbine without departing from the scope of the present invention.
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The apparatus may include a space frame on which is mounted at least one hydrofoil for generating positive or negative lift. The frame is attachable to underwater equipment such as a turbine. The hydrofoils are adapted to produce negative lift when a flow of liquid passes over them and so in use cause the apparatus and attached equipment to sink to the seabed. The flow of water over the hydrofoils continue to produce negative life and so maintain the apparatus on the seabed. In certain embodiments, the hydrofoils can typically be set to a passive configuration in which they flip over when the current flow changes direction. Furthermore, the hydrofoils are selectively rotatable to provide an angle of attack such that they may be adapted to provide positive lift when it is necessary to remove the apparatus from the water.
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FIELD OF THE INVENTION
[0001] The present invention is related to a catalyst composition for selective hydrogenations, for example for the selective hydrogenation of acetylene in the gaseous phase, comprising a heterogeneous catalyst with a BET surface area of ≦9 m 2 /g and an ionic liquid applied to the surface of the same. The catalyst composition has improved characteristics such as, for example, improved selectivity in favor of the desired product and better thermal stability.
BACKGROUND OF THE INVENTION
[0002] Ethylene and propylene are important monomers for the production of plastics, such as for example polyethylene or polypropylene. Ethylene and propylene are primarily derived from petroleum and petroleum products by means of thermal or catalytic cracking of hydrocarbons. The ethylene or propylene derived with the aid of the cracking process does, however, contain an undesirably high proportion of acetylenic compounds such as acetylene or methyl acetylene (propyne), which can negatively influence downstream ethylene or propylene polymerization. Therefore prior to polymerization the ethylene or propylene must be freed from acetylenic compounds as far as possible.
[0003] Typically for the polymerization of ethylene the acetylene concentration must, for example, be reduced to a value of below 1 ppm. For this the acetylene is selectively hydrogenated into ethylene. High requirements are placed on the catalyst and the hydrogenation process. On the one hand, the acetylene must be removed as completely as possible by transformation into ethylene, while the hydrogenation of ethylene into ethane must be prevented, hence the term “selective hydrogenation”. In order to ensure this result, the hydrogenation is carried out within a temperature range that is delimited by the so-called “clean-up” temperature and the so-called “run-away” temperature. In the present context the “clean-up” temperature is understood as the temperature from which an appreciable hydrogenation of acetylene into ethylene is observed, while “run-away” temperature is understood as the temperature at which an appreciable hydrogenation of ethylene into ethane commences. The said temperatures can be determined in that the hydrogen consumption of a defined gas mixture containing acetylene, ethylene, and hydrogen is, for example, measured depending on the temperature.
[0004] Palladium shell catalysts, often using silver as a promoter, are primarily used as commercial catalysts for the selective hydrogenation of acetylene into ethylene in hydrocarbon streams. The palladium and the silver are supported on an inert, temperature-resistant substrate. The production of these catalysts is carried out in such a way that suitable salts of palladium and silver, for example palladium nitrate and silver nitrate, are applied to a substrate in form of an aqueous solution (impregnation). The impregnation can take place during separate steps with a palladium compound solution and a silver compound solution. It is, however, also possible to apply the solution of palladium compounds and the solution of silver compounds to the substrate simultaneously during a single impregnation step. The impregnated substrate is then calcined to transform the silver into silver oxide, or the palladium into palladium oxide, and is then subjected to a reduction in order to transfer the catalyst into the active form. During the reaction the silver and palladium are assumed to be transferred into the oxidation state “zero”.
[0005] DE 31 19 850 A1 describes a method for the selective hydrogenation of a diolefin with at least 4 carbon atoms in a hydrocarbon mixture. Hydrogenation takes place with hydrogen on a catalyst containing palladium and silver. The silver/palladium weight ratio of the catalyst is 0.7:1 to 3:1. The production of the catalyst is by way of co-impregnation of a substrate with an aqueous solution of palladium and silver salts.
[0006] U.S. Pat. No. 5,648,576 A describes a method for the selective gaseous phase hydrogenation of acetylenic hydrocarbons (C 2 -C 3 ) into the corresponding ethylenic hydrocarbons. The production of the catalyst is realized by co-impregnating the substrate with an aqueous solution of the respective metal salts.
[0007] EP 0 064 301 A1 offers a catalyst for the selective gaseous phase hydrogenation of acetylene. The production of the catalyst is realized by means of a two-step application of palladium and silver.
[0008] EP 0 780 155 A1 describes the production of hydrogenation catalysts, whereby solutions of palladium nitrate and silver nitrate in a nitrogenous acid are used for the impregnation of the substrate.
[0009] Apart from the Pd/Ag catalysts described above, a number of further palladium based catalyst are described, which also provide improved selectivity and sometimes also improved activity; the same include Pd/Zn, Pd/Cd, Pd/Ga and Pd/Au. The latter catalyst family is characterized primarily by a high “run-away” temperature.
[0010] According to the definition of Wasserscheid and Keim in “Angewandte Chemie” 2000, 112, pages 3926-3945, ionic liquids are salts, i.e. compounds of anions and cations that are externally neutral, which melt at low temperatures, usually at temperatures of below 100° C. Ionic liquids are therefore already liquid at low temperatures. In addition they are generally not flammable and have an extremely low vapor pressure. Due to the high variation range of the structure of their cations and anions, their physical and chemical characteristics can be varied over a broad range.
[0011] The concept of coating heterogeneous catalysts with small quantities of an ionic liquid has already been described by Jess et al. and Claus et al. [U. Kernchen, B. Etzold, W. Korth, A. Jess, Chem. Eng. Technol. 2007, 30, 985-994; J. Arras, M. Steffan, Y. Shayeghi, P. Claus, Chem. Commun. 2008, 4058-4060]. In both cases an improved selectivity towards the desired product in the target reaction of the hydrogenation of citral or the hydrogenation of diolefins could be achieved than is possible with the uncoated catalyst. This catalyst family has also been named as SCILL—Solid Catalyst with Ionic Liquid Layer—catalysts by the authors.
[0012] US 2008/0269533 A1 describes the selective mono-hydrogenation of conjugated dienes with the aid of supported Pd nanoparticles coated with ionic liquids.
[0013] International patent application WO2007/124 896 relates to heterogeneous catalysts having a BET surface area of preferably 10 to 300 m 2 /g. These catalysts may be covered with an ionic liquid and are used for the selective hydrogenation of unsaturated cyclic compounds.
[0014] A catalyst system for the selective hydrogenation of acetylene in the simultaneous presence of ethylene comprising a heterogeneous catalyst coated with ionic liquid has also already been described [M. Ruta, G. Laurenczy, P. J. Dyson, L. Kiwi-Minsker, J. Phys. Chem. C 2008, 112, 17814-17819]. However, these catalysts are prepared with support materials that are not suitable for industrial use, as the production of the same is too costly. The described turnovers are also far from realizable.
[0015] With all of the examples described so far support materials with a high specific surface area and a suitable pore volume were used. In order to achieve an even coating of the entire catalyst surface, and thus the best possible effect (selectivity increase etc.) a relatively large quantity of ionic liquid is required (10-17 wt. % in relation to the initial weight of the heterogeneous catalyst). This often results in a substantial pore filling of the catalyst and the reduced activity connected with the same. Ionic liquids are also expensive, which results in substantial additional costs for the overall catalyst formulation.
SUMMARY OF THE INVENTION
[0016] There remains a need for further improving the selectivity of Pd/promoter catalysts for the hydrogenation of acetylenic hydrocarbons, while maintaining or even increasing catalyst activity.
[0017] It is therefore the object of this invention to provide a catalyst with high selectivity and activity for the hydrogenation of acetylenic hydrocarbons.
[0018] Surprisingly it has been found that conventional heterogeneous catalysts with a BET surface area of ≦9 m 2 /g which are coated with a small amount of an ionic liquid have improved characteristics, such as improved selectivity in the hydrogenation of unsaturated hydrocarbons while retaining high activity.
[0019] With the catalyst system of the invention, known pre-formulated catalysts for the transformation of acetylene into ethylene with a BET surface area of ≦9 m 2 /g are coated with one (or more) ionic liquid(s). The resulting catalyst formulations have a very high selectivity during the hydrogenation of acetylene in ethylene rich gas streams and are further surprisingly characterized by a higher “run-away” temperature. The catalyst formulations of the invention further may use very small quantities of ionic liquid (in the range of 3% by weight of the catalyst) to achieve these advantageous effects. The loss of catalyst activity is very small.
DETAILED DESCRIPTION OF THE INVENTION
[0020] The pre-formulated catalysts used for coating are, as already described above, supported palladium shell catalysts which preferably comprise at least one further promoter such as for example silver, gold, zinc, tin, lead, gallium, cadmium, copper, bismuth, or potassium. Preferred promoters are Ag, Au and Zn. Preferred metal or metal-alloy shell thicknesses are between 100 and 500 μm. The Pd metal content in relation to the total weight of the catalyst is between 10 and 1000 ppm, preferably between 50 and 500 ppm. For the desired target reaction the catalysts are used either as shaped bodies such as for example tablets, rings, tri-holes, extrudates etc., or as a granulate or powder. The mass ratio of palladium to promoter metal for example lies within a range of 1:5 to 3:1, preferably within a range of 1:4 to 2:1, and particularly preferably within a range of 1:3 to 1:1.
[0021] Suitable carrier substrates are Al 2 O 3 , SiO 2 , alumo silicates, TiO 2 , ZrO 2 , ZnO, MgO, Fe 2 O 3 and CeO 2 , or mixtures thereof. In order to increase activity or selectivity the substrates can further be doped with at least one of the following elements: Li, Na, K, Rb, Cs, Be, Mg, Ca, Sr and/or Ba. Na, K and/or Ca are particularly suitable.
[0022] The BET surface area of the uncoated catalyst is ≦9 m 2 /g, and more preferably ≦8 m 2 /g, particularly preferably ≦6 m 2 /g. The determination of the surface area may be carried out in accordance with ASTM D3663, Standard Test Method for Surface Area of Catalysts and Catalyst Carriers.
[0023] The integral pore volume of the catalyst (determined according to DIN 66134 of February 1998 (N 2 adsorption)) without the IL-coating preferably is in the range of 0.005 to 0.07 ml/g, more preferably in the range of 0.007 to 0.04 ml/g and particularly preferably within a range of 0.009 to 0.02 ml/g.
[0024] Suitable pre-formulated catalysts for use in preparing supported ionic liquid phase catalyst compositions of the invention include any commercially-available supported Pd or Pd/Ag catalysts supplied by, for example Sud-Chemie, AG, Munich, Germany, BASF, Johnson-Mathey, etc.
[0025] For the production of a catalyst composition of the invention a pre-formulated catalyst is loaded with ionic liquid. The ionic liquid to be used for this is not particularly restricted, and in principle, all known ionic liquids suitable for this purpose can be used. Preferred ionic liquids for use with this invention are compounds with the formula (I):
[0000] [A] n + [Y] n − (I),
[0026] wherein:
[0027] n=1 or 2;
[0028] [Y] n − is selected from the group consisting of tetrafluoroborate ([BF 4 ] − ), hexafluorophosphate ([PF 6 ] − ), dicyanamide ([N(CN) 2 ] − ), halides (Cl − , Br − , F − , I − ), hexafluoroantimonate ([SbF 6 ] − ), nitrate ([NO 3 ] − ), nitrite ([NO 2 ] − ), anionic metal complexes such as for example [CuCl 4 ] 2− , [PdCl 4 ] 2− or [AuCl 4 ] − , acetate ([CH 3 COO] − ), trifluoracetate ([F3CCOO] − ), hexafluoroarsenate ([AsF 6 ] − ), sulfate ([SO 4 ] 2 − ), alkyl sulfates ([R′—SO 4 ] − ), tosylate ([C 7 H 7 SO 3 ] − ), triflate ([CF 3 SO 3 ] − ), nonaflate ([C 4 F 9 SO 3 ] − ), triperfluoroethylene trifluorophosphate ([PF 3 (C 2 F 5 ) 3 ] − ), tricyanomethide ([C(CN) 3 ] − ), tetracyanoborate ([B(CN) 4 ] − , thiocyanate ([SCN] − ), carbonate ([CO 3 ] 2 − ), carboxylates ([R′—COO] − ), sulfonates ([R′SO 3 ] − ), dialkylphosphates ([R′PO 4 R″] − ), alkyl phosphonates ([R′HPO 3 ] − ) and bissulfonylimides ([(R′—SO 2 ) 2 N] − ), such as bis(trifluormethylsulfonyl)imide,
[0029] wherein R′ and R″ are the same or different, and each represents a linear or branched, 1 to 12 carbon atom-containing aliphatic or alicyclic alkyl group or a C 5 -C 18 -aryl, C 5 -C 18 -aryl-C 1 -C 6 -alkyl, or C 1 -C 6 -alkyl-C 5 -C 18 -aryl group that can be substituted with halogen atoms; and
[0030] [A] + is selected from the group consisting of quaternary ammonium cations with the formula [NR 1 R 2 R 3 R] + , phosphonium cations with the formula [PR 1 R 2 R 3 R] + , sulfonium cations with the formula [SR 1 R 2 R] + , guadinium cations with the formula (II):
[0000]
[0031] imidazolium cations with the formula (III)
[0000]
[0000] wherein the imidazole core may additionally be substituted with one or more groups selected from C 1 -C 6 -alkyl, C 1 -C 6 -alkoxy, C 1 -C 6 -aminoalkyl, C 5 -C 12 -aryl, and C 5 -C 12 -aryl-C 1 -C 6 -alkyl groups,
[0032] pyridinium cations with the formula (IV)
[0000]
[0000] wherein the pyridine core may additionally be substituted with one or more groups selected from C 1 -C 6 -alkyl, C 1 -C 6 -alkoxy, C 1 -C 6 -aminoalkyl, C 5 -C 12 -aryl, and C 5 -C 12 -aryl-C 1 -C 6 -alkyl groups,
[0033] pyrazolium cations with the formula (V)
[0000]
[0000] wherein the pyrazole core may additionally be substituted with one or more groups selected from C 1 -C 6 -alkyl, C 1 -C 6 -alkoxy, C 1 -C 6 -aminoalkyl, C 5 -C 12 -aryl, and C 5 -C 12 -aryl-C 1 -C 6 -alkyl groups,
[0034] triazolium cations with the formula (VI)
[0000]
[0000] wherein the triazole core may additionally be substituted with one or more groups selected from C 1 -C 6 -alkyl, C 1 -C 6 -alkoxy, C 1 -C 6 -aminoalkyl, C 5 -C 12 -aryl, and C 5 -C 12 -aryl-C 1 -C 6 -alkyl groups,
[0035] and pyrrolidinium cations with the formula (VII)
[0000]
[0000] wherein the pyrrolidinium core may additionally be substituted with one or more groups selected from C 1 -C 6 -alkyl, C 1 -C 6 -alkoxy, C 1 -C 6 -aminoalkyl, C 5 -C 12 -aryl, and C 5 -C 12 -aryl-C 1 -C 6 -alkyl groups,
[0036] wherein R 1 , R 2 , and R 3 are selected independently from each other from the group consisting of: hydrogen; linear or branched, saturated or unsaturated, aliphatic or alicyclic alkyl groups with 1 to 20 carbon atoms, which may be interrupted by one or two of NH, O and/or S; heteroaryl groups with 3 to 8 carbon atoms and at least one hetero atom selected from N, O and S, wherein the heteroaryl groups can be substituted with one or more groups selected from C 1 -C 6 -alkyl groups and halogen atoms; heteroaryl-C 1 -C 6 -alkyl groups with 3 to 8 carbon atoms and at least one hetero atom selected from N, O and S in the heteroaryl portion, wherein the heteroaryl portion can be substituted with at least one group selected from C 1 -C 6 -alkyl groups and halogen atoms; polyethers with the formula [—CH 2 CH 2 O] n R a with n=1 to 50,000, wherein R a is selected from the group consisting of linear or branched, saturated or unsaturated, aliphatic or alicyclic alkyl groups with 1 to 20 carbon atoms; aryl groups with 5 to 12 carbon atoms, which may be substituted with one or more C 1 -C 6 -alkyl groups and/or halogen atoms; aryl-C 1 -C 6 -alkyl groups with 5 to 12 carbon atoms in the aryl portion, which may be substituted with one or more C 1 -C 6 -alkyl groups and/or halogen atoms, and
[0037] wherein R is selected from the group consisting of: linear or branched, saturated or unsaturated, aliphatic or alicyclic alkyl groups with 1 to 20 carbon atoms; heteroaryl-C 1 -C 6 -alkyl groups with 4 to 8 carbon atoms and at least one hetero atom selected from N, O and S in the heteroaryl portion, which may be substituted with one or more C 1 -C 6 -alkyl groups and/or halogen atoms; and aryl-C 1 -C 6 -alkyl groups with 4 to 12 carbon atoms in the aryl portion, which may be substituted with one or more C 1 -C 6 -alkyl groups and/or halogen atoms.
[0038] Further preferred ionic liquids for use with this invention are compounds with the formula (I):
[0000] [A] n + [Y] n − (I),
[0000] wherein:
[0039] n and [Y] n − are as defined above, and
[0040] [A] + is selected from the group consisting of quaternary ammonium cations with the formula [NR 1 R 2 R 3 R] + , imidazolium cations with the formula (III)
[0000]
[0000] pyridinium cations with the formula (IV)
[0000]
[0000] and pyrrolidinium cations with the formula (VII)
[0000]
[0041] wherein R, R 1 , R 2 and R 3 are selected independently from each other from the group consisting of hydrogen; linear or branched C 1 -C 12 -alkyl groups; linear or branched (C 1 -C 6 -alkyloxy)-C 1 -C 6 -alkyl groups; and aryl-C 1 -C 6 -alkyl groups with 5 to 12 carbon atoms in the aryl portion, which may be substituted with one or more C 1 -C 6 -alkyl groups and/or halogen atoms.
[0042] More preferred ionic liquids for preparing supported ionic liquid phase catalysts of the invention include 1-butyl-3-methylimidazolium triflate, 1-ethyl-3-methylpyridinium ethylsulfate, 1-butyl-1-methylpyrrolidinium triflate, 1-butyl-2,3-dimethylimidazolium triflate, 1-butyl-3-methylimidazolium tricyanomethane, 1-butyl-3-methylimidazolium methylsulfate, 1-butyl-3-methylimidazolium octylsulfate, 1-butyl-3-methylimidazolium tetrafluoroborate, 1-ethyl-3-methylimidazolium ethylsulfate, 1-ethyl-3-methylimidazolium methylphosphonate, 1-ethyl-3-methylimidazolium triflate, 1-butyl-1-methylpyrrolidinium bis(trifluoromethylsulfonyl)imide, 1-butyl-1-methylpyrrolidinium tetracyanoborate, 1-butyl-1-methylpyrrolidinium tris(pentafluoroethyl)trifluorophosphate, 1-butyl-3-methylimidazolium bis(trifluoromethylsulfonyl)imide, 1-butyl-3-methylimidazolium tricyanomethane, 1-ethyl-3-methylpyridinium bis(trifluoromethylsulfonyl)imide, 1-ethyl-3-methylimidazolium tetracyanoborate, 1-ethyl-3-methylimidazolium tris(pentafluoroethyl)trifluorophosphate, 1-ethyl-3-methylpyridinium bis(trifluoromethylsulfonyl)imide, 1-methyl-3-octylimidazolium triflate, ethyldimethyl-(2-methoxyethyl)ammonium tris(pentafluoroethyl)trifluorophosphate, tributylmethylammonium dicyanamide, tricyclohexyltetradecylphosphonium tris(pentafluoroethyl)trifluorophosphate, 1-ethyl-3-methylimidazolium bis(trifluoromethylsulfonyl)imide, and mixtures thereof.
[0043] More preferred ionic liquids further include those of the formula (I), wherein [A] n + is selected from the group consisting of 1-butyl-1-methylpyrrolidinium, 1-butyl-2,3-dimethylimidazolium, 1-butyl-3-methylimidazolium, 1-ethyl-3-methylimidazolium, 1-ethyl-3-methylpyridinium, 1-methyl-3-octylimidazolium, ethyldimethyl-(2-methoxyethyl)ammonium, tributylmethylammonium, tricyclohexyltetradecylphosphonium, and mixtures thereof, and wherein [Y] n − is selected from the group consisting of bis(trifluoromethylsulfonyl)imide, dicyanamide, ethylsulfate, methylphosphonate, methylsulfate, octylsulfate, tetracyanoborate, tetrafluoroborate, tricyanomethane, triflate, tris(pentafluoroethyl)trifluorophosphate, and mixtures thereof.
[0044] For the production of catalyst compositions of the invention, the ionic liquid or mixtures of several ionic liquids are dissolved or suspended in a solution agent suitable for the purpose, such as for example water, alcohols, acetone etc., or in a solution agent mixture, and applied continuously onto the already pre-formed catalyst inside a reaction chamber with the aid of a nozzle. For this the solution agent is continuously removed from the reaction chamber during the process. In order to achieve an even coating of the substrate, the substrate material is continuously fluidized through a process gas in a process known as fluidized bed coating. Further suitable coating processes are dip coating or spray application with a spray pistol or a spray drying pistol.
[0045] Apart from the application of ionic liquid by means of coating technologies, the same can also be applied by impregnating with a solution or suspension. For this the ionic liquid or mixtures of several ionic liquids are dissolved or suspended in a suitable solution agent (mixture) and subsequently brought into contact with the pre-formed catalyst. The solution agent is then removed under vacuum or at an increased temperature (or both), by resting in air, or by means of a gas stream. The quantity of solution agent used can be equal to or smaller or greater than the pore volume of the catalyst used.
[0046] The quantity of ionic liquid used is equal to or smaller than the pore volume of the catalyst used. After the application of the ionic liquid, one is left with an externally dry solid body coated with the desired quantity of ionic liquid. The pore volume of the resulting catalyst composition is reduced by the volume of the ionic liquid. Related to the total weight of the catalyst 0.1-5 wt. %, preferably 0.2-3 wt. %, and particularly preferably 0.3-1.5 wt. % of ionic liquid is used. The distribution of ionic liquid on the macroscopic substrate form body, granulate or powder is freely adjustable by selecting the coating conditions. Depending on the selection of the conditions, a formation of a so-called eggshell, egg-white, egg-yolk, or a uniform distribution of the ionic liquid may result on the substrate. In addition, any concentration gradient of ionic liquid can be created on the substrate. The ionic liquid is preferably applied to the substrate surface as a thin shell. The shell thickness of the ionic liquid on the substrate surface of this invention usually lies within a range of 10 to 2000 μm, preferably within a range of 20 to 1000 μm, and particularly preferably within a range of 50 to 250 μm.
[0047] The resulting catalyst can be used without restricting the target reaction. The reduction of metal particles required for activating the catalyst can either take place prior to a coating with the ionic liquid or following the same.
[0048] The catalyst can for example be reduced prior to coating with an ionic liquid. The methods to be used for the same are known to the expert, and can for example include wet chemical methods through reduction such as for example NaBH 4 , LiAlH 4 , hydrazine (hydrate), hypophosphite, formic acid, or salts of the same (formates). In addition a reduction can be brought about in the gaseous phase with hydrogen (in all mixtures with an inert gas; preferably 5% in N 2 ) within a temperature range of 50-200° C., preferably at 80-120° C.
[0049] The reduced metal particles obtained in this way usually have a diameter within a range of 1 to 30 nm, preferably within a range of 1 to 10 nm, and particularly preferably within a range of 2 to 8 nm.
EXAMPLES
Example 1
[0050] Sample A contains 0.017 wt % Pd on 1-2 mm alumina spheres with a BET surface area of 4.0 m 2 /g. In order to make Sample A, 1100 g Alpha Alumina was added to 1075 mL PdCl 2 solution (0.178 mg Pd/mL) heated at 70° C. After the carrier was soaked in the solution for 1 hour, the solution was drained and then the catalyst was washed 10 times using 5 minute soak times with room temperature deionized water. After final wash, the catalyst was calcined in a muffle oven in air at 565° C. for 4 hours.
[0051] Sample A1 was made by adding 0.5 wt % of EMIM[EtSO 4 ] (1-ethyl-3-methylimidazolium ethylsulfate) on Sample A. In order to make Sample A1, Sample A (516.0 mg) was impregnated with an aqueous solution of 1-ethyl-3-methylimidazolium ethylsulfate (232 μL, 11.11 mg/mL) by incipient wetness. The catalyst was dried at 80° C. for 16 hours and reduced at 100° C. in 5% H 2 /N 2 for 1 hour.
[0052] Sample A2 was made by adding 0.5 wt % of BMIM[OTf] (1-butyl-3-methylimidazolium triflate) on Sample A. In order to make Sample A2, Sample A (476.3 mg) was impregnated with an aqueous solution of 1-butyl-3-methylimidazolium triflate (214 μL, 11.11 mg/mL) by incipient wetness. The catalyst was dried at 80° C. for 16 hours and reduced at 100° C. in 5% H 2 /N 2 for 1 hour.
[0053] Sample A3 was made by adding 0.5 wt % of BMPr[OTf] (1-butyl-1-methylpyrrolidinium triflate) on Sample A. In order to make Sample A3, Sample A (499.7 mg) was impregnated with an aqueous solution of 1-butyl-1-methylpyrrolidinium triflate (225 μL, 11.11 mg/mL) by incipient wetness. The catalyst was dried at 80° C. for 16 hours and reduced at 100° C. in 5% H 2 /N 2 for 1 hour.
[0054] Sample A4 was made by adding 0.5 wt % of BMMIM[OTf] (1-Butyl-2,3-dimethylimidazolium triflate) on Sample A. In order to make Sample A4, Sample A (528.8 mg) was impregnated with an aqueous solution of 1-Butyl-2,3-dimethylimidazolium triflate (238 μL, 11.11 mg/mL) by incipient wetness. The catalyst was dried at 80° C. for 16 hours and reduced at 100° C. in 5% H 2 /N 2 for 1 hour.
[0055] Sample A5 was made by adding 0.5 wt % of BMIM[BF 4 ] (1-butyl-3-methylimidazolium tetrafluoroborate) on Sample A. In order to make Sample A5, Sample A (508.2 mg) was impregnated with an aqueous solution of 1-butyl-3-methylimidazolium tetrafluoroborate (229 μL, 11.11 mg/mL) by incipient wetness. The catalyst was dried at 80° C. for 16 hours and reduced at 100° C. in 5% H 2 /N 2 for 1 hour.
[0056] Sample A6 was made by adding 0.5 wt % of BMIM[MeSO 4 ] (1-butyl-3-methylimidazolium methylsulfate) on Sample A. In order to make Sample A6, Sample A (511.8 mg) was impregnated with an aqueous solution of 1-butyl-3-methylimidazolium methylsulfate (230 μL, 11.11 mg/mL) by incipient wetness. The catalyst was dried at 80° C. for 16 hours and reduced at 100° C. in 5% H 2 /N 2 for 1 hour.
[0057] Sample A7 was made by adding 0.5 wt % of BMIM[C 8 H 17 SO 4 ] (1-butyl-3-methylimidazolium octylsulfate) on Sample A. In order to make Sample A7, Sample A (485.7 mg) was impregnated with an aqueous solution of 1-butyl-3-methylimidazolium octylsulfate (218 μL, 11.11 mg/mL) by incipient wetness. The catalyst was dried at 80° C. for 16 hours and reduced at 100° C. in 5% H 2 /N 2 for 1 hour.
[0058] Sample A8 was made by adding 0.5 wt % of EMIM[OTf] (1-ethyl-3-methylimidazolium triflate) on Sample A. In order to make Sample A8, Sample A (509.9 mg) was impregnated with an aqueous solution of 1-ethyl-3-methylimidazolium triflate (229 μL, 11.11 mg/mL) by incipient wetness. The catalyst was dried at 80° C. for 16 hours and reduced at 100° C. in 5% H 2 /N 2 for 1 hour.
[0059] Sample A9 was made by adding 0.5 wt % of EMPy[EtSO 4 ] (1-ethyl-3-methylpyridinium ethylsulfate) on Sample A. In order to make Sample A9, Sample A (504.0 mg) was impregnated with an aqueous solution of 1-ethyl-3-methylpyridinium ethylsulfate (227 μL, 11.11 mg/mL) by incipient wetness. The catalyst was dried at 80° C. for 16 hours and reduced at 100° C. in 5% H 2 /N 2 for 1 hour.
[0060] Sample A10 was made by adding 0.5 wt % of EMIM[MePO 3 ] (1-ethyl-3-methylimidazolium methylphosphonate) on Sample A. In order to make Sample A10, Sample A (517.1 mg) was impregnated with an aqueous solution of 1-ethyl-3-methylimidazolium methylphosphonate (233 μL, 11.11 mg/mL) by incipient wetness. The catalyst was dried at 80° C. for 16 hours and reduced at 100° C. in 5% H 2 /N 2 for 1 hour.
[0061] Sample A11 was made by adding 0.5 wt % of BMIM[C(CN) 3 ] (1-butyl-3-methylimidazolium tricyanomethane) on Sample A. In order to make Sample A11, Sample A (504.0 mg) was impregnated with a solution of 1-butyl-3-methylimidazolium bis(trifluoromethylsulfonyl)imide in 2-butanone (227 μL, 11.11 mg/mL) by incipient wetness. The catalyst was dried at 60° C. for 4 hours and reduced at 100° C. in 5% H 2 /N 2 for 1 hour.
[0062] Sample A12 was made by adding 0.5 wt % of BMIM[NTf 2 ] (1-butyl-3-methylimidazolium bis(trifluoromethylsulfonyl)imide) on Sample A. In order to make Sample A12, Sample A (513.4 mg) was impregnated with a solution of 1-butyl-3-methylimidazolium bis(trifluoromethylsulfonyl)imide in 2-butanone (231 μL, 11.11 mg/mL) by incipient wetness. The catalyst was dried at 60° C. for 4 hours and reduced at 100° C. in 5% H 2 /N 2 for 1 hour.
[0063] Sample A13 was made by adding 0.5 wt % of MOIM[OTf] (1-methyl-3-octylimidazolium triflate) on Sample A. In order to make Sample A13, Sample A (502.1 mg) was impregnated with a solution of 1-methyl-3-octylimidazolium triflate in 2-butanone (226 μL, 11.11 mg/mL) by incipient wetness. The catalyst was dried at 60° C. for 4 hours and reduced at 100° C. in 5% H 2 /N 2 for 1 hour.
[0064] Sample A14 was made by adding 0.5 wt % of EMIM[NTf 2 ] (1-ethyl-3-methylimidazolium bis(trifluoromethylsulfonyl)imide) on Sample A. In order to make Sample A14, Sample A (490.3 mg) was impregnated with a solution of 1-ethyl-3-methylimidazolium bis(trifluoromethylsulfonyl)imide in 2-butanone (220 μL, 11.11 mg/mL) by incipient wetness. The catalyst was dried at 60° C. for 4 hours and reduced at 100° C. in 5% H 2 /N 2 for 1 hour.
[0065] Sample A15 was made by adding 0.5 wt % of EMIM[B(CN) 4 ] (1-ethyl-3-methylimidazolium tetracyanoborate) on Sample A. In order to make Sample A15, Sample A (504.8 mg) was impregnated with a solution of 1-ethyl-3-methylimidazolium tetracyanoborate in 2-butanone (227 μL, 11.11 mg/mL) by incipient wetness. The catalyst was dried at 60° C. for 4 hours and reduced at 100° C. in 5% H 2 /N 2 for 1 hour.
[0066] Sample A16 was made by adding 0.5 wt % of EMIM[PF 3 (C 2 F 5 ) 3 ] (1-ethyl-3-methylimidazolium tris(pentafluoroethyl)trifluorophosphate) on Sample A. In order to make Sample A16, Sample A (514.4 mg) was impregnated with a solution of 1-ethyl-3-methylimidazolium tris(pentafluoroethyl)trifluorophosphate in 2-butanone (231 μL, 11.11 mg/mL) by incipient wetness. The catalyst was dried at 60° C. for 4 hours and reduced at 100° C. in 5% H 2 /N 2 for 1 hour.
[0067] Sample A17 was made by adding 0.5 wt % of EMPy[NTf 2 ] (1-ethyl-3-methylpyridinium bis(trifluoromethylsulfonyl)imide) on Sample A. In order to make Sample A17, Sample A (531.6 mg) was impregnated with a solution of 1-ethyl-3-methylpyridinium bis(trifluoromethylsulfonyl)imide in 2-butanone (239 μL, 11.11 mg/mL) by incipient wetness. The catalyst was dried at 60° C. for 4 hours and reduced at 100° C. in 5% H 2 /N 2 for 1 hour.
[0068] Sample A18 was made by adding 0.5 wt % of BMPr[NTf 2 ] (1-butyl-1-methylpyrrolidinium bis(trifluoromethylsulfonyl)imide) on Sample A. In order to make Sample A18, Sample A (512.5 mg) was impregnated with a solution of 1-butyl-1-methylpyrrolidinium bis(trifluoromethylsulfonyl)imide in 2-butanone (230 μL, 11.11 mg/mL) by incipient wetness. The catalyst was dried at 60° C. for 4 hours and reduced at 100° C. in 5% H 2 /N 2 for 1 hour.
[0069] Sample A19 was made by adding 0.5 wt % of BMPr[PF 3 (C 2 F 5 ) 3 ] (1-butyl-1-methylpyrrolidinium tris(pentafluoroethyl)trifluorophosphate) on Sample A. In order to make Sample A19, Sample A (510.3 mg) was impregnated with a solution of 1-butyl-1-methylpyrrolidinium tris(pentafluoroethyl)trifluorophosphate in 2-butanone (229 μL, 11.11 mg/mL) by incipient wetness. The catalyst was dried at 60° C. for 4 hours and reduced at 100° C. in 5% H 2 /N 2 for 1 hour.
[0070] Sample A20 was made by adding 0.5 wt % of BMPr[B(CN) 4 ] (1-butyl-1-methylpyrrolidinium tetracyanoborate) on Sample A. In order to make Sample A20, Sample A (516.0 mg) was impregnated with a solution of 1-butyl-1-methylpyrrolidinium tetracyanoborate in 2-butanone (232 μL, 11.11 mg/mL) by incipient wetness. The catalyst was dried at 60° C. for 4 hours and reduced at 100° C. in 5% H 2 /N 2 for 1 hour.
[0071] Sample A21 was made by adding 0.5 wt % of TBMA[N(CN) 2 ] (tributylmethylammonium dicyanamide) on Sample A. In order to make Sample A21, Sample A (474.2 mg) was impregnated with a solution of tributylmethylammonium dicyanamide in 2-butanone (213 μL, 11.11 mg/mL) by incipient wetness. The catalyst was dried at 60° C. for 4 hours and reduced at 100° C. in 5% H 2 /N 2 for 1 hour.
[0072] Sample A22 was made by adding 0.5 wt % of {EtMe 2 (MeOEt)}N[PF 3 (C 2 F 5 ) 3 ] (ethyldimethyl-(2-methoxyethyl)ammonium tris(pentafluoroethyl)trifluorophosphate) on Sample A. In order to make Sample A22, Sample A (477.6 mg) was impregnated with a solution of ethyldimethyl-(2-methoxyethyl)ammonium tris(pentafluoroethyl)trifluorophosphate in 2-butanone (215 μL, 11.11 mg/mL) by incipient wetness. The catalyst was dried at 60° C. for 4 hours and reduced at 100° C. in 5% H 2 /N 2 for 1 hour.
Example 2
[0073] Sample B1 was made by adding 0.001 wt % of EMIM[EtSO 4 ] (1-ethyl-3-methylimidazolium ethylsulfate) on Sample A. In order to make Sample B1, Sample A (485.8 mg) was impregnated with an aqueous solution of 1-ethyl-3-methylimidazolium ethylsulfate (219 μL, 0.022 mg/mL) by incipient wetness. The catalyst was dried at 80° C. for 16 hours and reduced at 100° C. in 5% H 2 /N 2 for 1 hour.
[0074] Sample B2 was made by adding 0.007 wt % of EMIM[EtSO 4 ] (1-ethyl-3-methylimidazolium ethylsulfate) on Sample A. In order to make Sample B2, Sample A (505.1 mg) was impregnated with an aqueous solution of 1-ethyl-3-methylimidazolium ethylsulfate (227 μL, 0.16 mg/mL) by incipient wetness. The catalyst was dried at 80° C. for 16 hours and reduced at 100° C. in 5% H 2 /N 2 for 1 hour.
[0075] Sample B3 was made by adding 0.025 wt % of EMIM[EtSO 4 ] (1-ethyl-3-methylimidazolium ethylsulfate) on Sample A. In order to make Sample B3, Sample A (512.8 mg) was impregnated with an aqueous solution of 1-ethyl-3-methylimidazolium ethylsulfate (231 μL, 0.56 mg/mL) by incipient wetness. The catalyst was dried at 80° C. for 16 hours and reduced at 100° C. in 5% H 2 /N 2 for 1 hour.
[0076] Sample B4 was made by adding 0.05 wt % of EMIM[EtSO 4 ] (1-ethyl-3-methylimidazolium ethylsulfate) on Sample A. In order to make Sample B4, Sample A (468.0 mg) was impregnated with an aqueous solution of 1-ethyl-3-methylimidazolium ethylsulfate (210 μL, 1.11 mg/mL) by incipient wetness. The catalyst was dried at 80° C. for 16 hours and reduced at 100° C. in 5% H 2 /N 2 for 1 hour.
[0077] Sample B5 was made by adding 0.1 wt % of EMIM[EtSO 4 ] (1-ethyl-3-methylimidazolium ethylsulfate) on Sample E. In order to make Sample B5, Sample A (497.3 mg) was impregnated with an aqueous solution of 1-ethyl-3-methylimidazolium ethylsulfate (224 μL, 2.22 mg/mL) by incipient wetness. The catalyst was dried at 80° C. for 16 hours and reduced at 100° C. in 5% H 2 /N 2 for 1 hour.
[0078] Sample B6 was made by adding 0.25 wt % of EMIM[EtSO4] (1-ethyl-3-methylimidazolium ethylsulfate) on Sample A. In order to make Sample B6, Sample A (480.9 mg) was impregnated with an aqueous solution of 1-ethyl-3-methylimidazolium ethylsulfate (216 μL, 5.56 mg/mL) by incipient wetness. The catalyst was dried at 80° C. for 16 hours and reduced at 100° C. in 5% H 2 /N 2 for 1 hour.
Comparative Example 3
[0079] Comparative Sample C contains 0.019 wt % Pd on 1-2 mm alumina spheres with a BET surface area of 50 m 2 /g. In order to make Comparative Sample C, 10 g alumina was added to 11.4 mL PdCl 2 solution (0.1667 mg Pd/mL) heated at 70° C. After the carrier was soaked in the solution for 1 hour, the solution was withdrawn and then the catalyst was washed 10 times using 5 minute soak times with room temperature deionized water. After the final washing step, the catalyst was calcined in muffle oven in air at 565° C. for 4 hours.
[0080] Comparative Sample C1 was made by adding 0.5 wt % of EMIM[EtSO 4 ] (1-ethyl-3-methylimidazolium ethylsulfate) on Comparative Sample C. In order to make Comparative Sample C1, Comparative Sample C (502.1 mg) was impregnated with an aqueous solution of 1-ethyl-3-methylimidazolium ethylsulfate (316 μL, 7.94 mg/mL) by incipient wetness. The catalyst was dried at 80° C. for 16 hours and reduced at 100° C. in 5% H 2 /N 2 for 1 hour.
[0081] Comparative Sample C2 was made by adding 0.5 wt % of BMIM[OTf] (1-butyl-3-methylimidazolium triflate) on Comparative Sample C. In order to make Comparative Sample C2, Comparative Sample C (484.4 mg) was impregnated with an aqueous solution of 1-butyl-3-methylimidazolium triflate (305 μL, 7.94 mg/mL) by incipient wetness. The catalyst was dried at 80° C. for 16 hours and reduced at 100° C. in 5% H 2 /N 2 for 1 hour.
Example 4
[0082] Sample A, Samples A1-A22, Samples B1-B6, and Comparative Samples C, C1 and C2 were tested as prepared in a microreactor test unit at typical front-end hydrogenation conditions. In the test, a simulated de-propanizer feed containing 0.35 mol % acetylene, 15 mol % hydrogen, 0.02 mol % CO, 47 mol % ethylene, and balance nitrogen was passed over a 260 μl catalyst bed at 478 psig (34 bar) in total pressure and 7000 h −1 in Gas Hourly Space Velocity (GHSV), while the bed temperature was gradually increased from about 45° C. The acetylene concentration at the reactor outlet was monitored with an on-line gas chromatograph (GC). The acetylene concentration at reactor outlet continued decreasing with increasing temperature until reaching <25 ppm. The temperature at this point was defined as the “clean up temperature” (T1). Catalyst bed temperature was further increased until 125° C. (the maximum temperature the test unit could reach) or a certain temperature (T2), at which the outlet ethane concentration was >2% due to the increased non-selective reaction of hydrogen with ethylene. The temperature range between T1 and T2 is called the “operation window”. Test results of Sample A, Samples A1 to A22, Samples B1-B6, as well as of Comparative Sample C, C1-C2 are listed in the table below. For catalysts that did not run away at the maximum temperature the test unit could reach, T2 was calculated by fitting the data at temperatures above complete acetylene conversion with a first order kinetic model.
[0000] Test Results of Samples A, A1 to A22, B1 to B6, and Comparative Samples C and C1 to C2 Operation Selectivity Ethane T1 T2 Window at Make at [° C.] [° C.] [° C.] T1 [%] [125° C.] Sample A 63 84 21 92.8 10.439 Sample A1 68 176 108 96.1 0.429 Sample A2 68 137 69 96.9 0.714 Sample A3 61 113 52 89.0 3.316 Sample A4 62 113 51 85.6 3.228 Sample A5 69 164 95 94.5 0.462 Sample A6 68 167 99 97.6 0.390 Sample A7 68 157 89 95.5 0.594 Sample A8 65 141 76 96.2 1.139 Sample A9 65 100 35 95.8 9.45 Sample A10 82 188 106 90.1 0.194 Sample A11 68 157 89 90.0 0.637 Sample A12 61 100 39 89.5 4.668 Sample A13 67 115 48 66.1 3.005 Sample A14 60 110 50 99.8 3.477 Sample A15 71 149 78 90.6 0.821 Sample A16 67 145 78 90.1 1.199 Sample A17 62 86 24 93.0 10.23 Sample A18 64 101 37 88.9 4.836 Sample A19 62 120 58 74.8 2.382 Sample A20 69 150 81 98.9 0.906 Sample A21 65 153 88 85.2 0.982 Sample A22 66 122 56 93.2 2.315 Sample B1 62 82 20 47.3 10.444 Sample B2 63 101 38 69.0 8.691 Sample B3 60 113 53 96.3 9.122 Sample B4 61 119 58 95.5 5.378 Sample B5 65 121 56 98.4 3.838 Sample B6 67 123 56 100 2.428 Comparative 56 76 20 91.1 10.506 Sample C Comparative 68 99 31 81.3 5.725 Sample C1 Comparative 65 98 33 96.1 6.878 Sample C2
The operation window as well as the selectivity markedly increase with decrease in BET surface area (Samples A1 and A2 compared to Comparative Samples C1 and C2).
Example 5
[0083] Sample D is a commercial selective hydrogenation catalyst that is supplied by Süd-Chemie AG under trade name OleMax® 251. It contains 0.019 wt % Pd and 0.05 wt % Ag on 4×4 mm alumina tablets with a BET surface area of about 4.0 m 2 /g.
[0084] Sample D1 was made by adding 0.5 wt % of BMMIM[OTf] (1-Butyl-2,3-dimethylimidazolium triflate) on Sample D. In order to make Sample D1, 0.6 g of the ionic liquid BMMIM[OTf] were dissolved in 150 ml deionized water. At the same time 120 g of the dry Sample D is fluidized in a reaction chamber with synthetic air as the process gas. The solution of BMMIM[OTf] in water was introduced into the reaction chamber at a flow rate of 5 ml/min via a feed pump and sprayed onto the solid catalyst via a spray nozzle at a temperature of 80° C. Once the entire solution has been applied and the substrate is dry, the catalyst formulation is further dried at 80° C. for 2 hours.
[0085] Sample D2 was made by adding 1.0 wt % of BMMIM[OTf] (1-Butyl-2,3-dimethylimidazolium triflate) on Sample D. In order to make Sample D2, 1.2 g of the ionic liquid BMMIM[OTf] were dissolved in 150 ml deionized water. At the same time 120 g of the dry Sample D is fluidized in a reaction chamber with synthetic air as the process gas. The solution of BMMIM[OTf] in water was introduced into the reaction chamber at a flow rate of 5 ml/min via a feed pump and sprayed onto the solid catalyst via a spray nozzle at a temperature of 80° C. Once the entire solution has been applied and the substrate is dry, the catalyst formulation is further dried at 80° C. for 2 hours.
[0086] Sample D3 was made by adding 2.0 wt % of BMMIM[OTf] (1-Butyl-2,3-dimethylimidazolium triflate) on Sample D. In order to make Sample D3, 2.4 g of the ionic liquid BMMIM[OTf] were dissolved in 150 ml deionized water. At the same time 120 g of the dry Sample D is fluidized in a reaction chamber with synthetic air as the process gas. The solution of BMMIM[OTf] in water was introduced into the reaction chamber at a flow rate of 5 ml/min via a feed pump and sprayed onto the solid catalyst via a spray nozzle at a temperature of 80° C. Once the entire solution has been applied and the substrate is dry, the catalyst formulation is further dried at 80° C. for 2 hours.
[0087] Sample D4 was made by adding 3.0 wt % of BMMIM[OTf] (1-Butyl-2,3-dimethylimidazolium triflate) on Sample D. In order to make Sample D4, 3.6 g of the ionic liquid BMMIM[OTf] were dissolved in 150 ml deionized water. At the same time 120 g of the dry Sample D is fluidized in a reaction chamber with synthetic air as the process gas. The solution of BMMIM[OTf] in water was introduced into the reaction chamber at a flow rate of 5 ml/min via a feed pump and sprayed onto the solid catalyst via a spray nozzle at a temperature of 80° C. Once the entire solution has been applied and the substrate is dry, the catalyst formulation is further dried at 80° C. for 2 hours.
[0088] Sample D1′ was made by impregnation of Sample D with a BMMIM[OTf] (1-Butyl-2,3-dimethylimidazolium triflate) solution containing 0.5 g of BMMIM[OTf] in 38 ml deionized water. The clear solution is added to 120 g of dry Sample D. The mixture is then mixed at room temperature for approx. 60 minutes. The catalyst formulation is then dried at 80° C. for 16 h to finally obtain Sample D1′.
Example 6
[0089] Samples prepared in Example 5 were tested as prepared in a bench scale test unit at typical front-end hydrogenation conditions. In the test, a simulated de-ethanizer feed containing 0.35 mol % acetylene, 20 mol % hydrogen, 0.02 mol % CO, 45 mol % ethylene, and balance methane was passed over a 25 ml catalyst bed at 500 psig (35.5 bar) in total pressure and 7000 h −1 in Gas Hourly Space Velocity (GHSV), while the bed temperature was gradually increased from about 35° C. The acetylene concentration at the reactor outlet was monitored with an on-line gas chromatograph (GC). The acetylene concentration at reactor outlet continued decreasing with increasing temperature until reaching <25 ppm. The temperature at this point was defined as the “clean up temperature” (T1). Catalyst bed temperature was further increased until 105° C. (the maximum temperature the water bath could reach) or a certain temperature (T2), at which the outlet ethane concentration was >2% due to the increased non-selective reaction of hydrogen with ethylene. The temperature range between T1 and T2 is called the “operation window”. Test results of Sample D and Samples D1 to D4 and D1′ are listed in the table below.
[0000]
Front End Deethanizer Feed Test Results
Operation
Selectivity
T1
T2
Window
at T1
[° C.]
[° C.]
[° C.]
[%]
Sample D
52
57
5
−1
Sample D1
61
97
36
52
Sample D2
61
105
44
61
Sample D3
69
>105
>36
48
Sample D4
73
>105
>32
56
Sample D1′
67
99
32
38
[0090] The operation window as well as the selectivity markedly increase with increasing BMMIM[OTf] content. The optimum BMMIM[OTf] loading seems to be 0.5-1%. At higher loading, the runaway temperature continued to increase at the expense of a higher T1 temperature. Adding BMMIM[OTf] onto Sample D can be realized by coating or wet impregnation; and both methods can generate a new catalyst with significantly improved operation window.
Example 7
[0091] Sample E is a commercial front end selective hydrogenation catalyst that is supplied by Süd-Chemie AG under the trade name OleMax® 250. It contains 0.018 wt % Pd on 4×4 mm alumina tablets with a BET surface area of about 4.0 m 2 /g.
[0092] Sample E1 was made by adding 1.0 wt % of BMMIM[OTf] (1-Butyl-2,3-dimethylimidazolium triflate) on Sample E. In order to make Sample E1, 1.2 g of the ionic liquid BMMIM[OTf] were dissolved in 150 ml deionized water. At the same time 120 g of the dry Sample E is fluidized in a reaction chamber with synthetic air as the process gas. The solution of BMMIM[OTf] in water was introduced into the reaction chamber at a flow rate of 5 ml/min via a feed pump and sprayed onto the solid catalyst via a spray nozzle at a temperature of 80° C. Once the entire solution has been applied and the substrate is dry, the catalyst formulation is further dried at 80° C. for 2 hours.
[0093] Sample E2 was made by adding 2.0 wt % of BMMIM[OTf] (1-Butyl-2,3-dimethylimidazolium triflate) on Sample E. In order to make Sample E2, 2.4 g of the ionic liquid BMMIM[OTf] were dissolved in 150 ml deionized water. At the same time 120 g of the dry Sample E is fluidized in a reaction chamber with synthetic air as the process gas. The solution of BMMIM[OTf] in water was introduced into the reaction chamber at a flow rate of 5 ml/min via a feed pump and sprayed onto the solid catalyst via a spray nozzle at a temperature of 80° C. Once the entire solution has been applied and the substrate is dry, the catalyst formulation is further dried at 80° C. for 2 hours.
[0094] Sample E3 was made by adding 3.0 wt % of BMMIM[OTf] (1-Butyl-2,3-dimethylimidazolium triflate) on Sample E. In order to make Sample E3, 3.6 g of the ionic liquid BMMIM[OTf] were dissolved in 150 ml deionized water. At the same time 120 g of the dry Sample E is fluidized in a reaction chamber with synthetic air as the process gas. The solution of BMMIM[OTf] in water was introduced into the reaction chamber at a flow rate of 5 ml/min via a feed pump and sprayed onto the solid catalyst via a spray nozzle at a temperature of 80° C. Once the entire solution has been applied and the substrate is dry, the catalyst formulation is further dried at 80° C. for 2 hours.
Example 8
[0095] Sample E, Sample E1, Sample E2 and Sample E3 were tested after in-situ reduction at 94° C. for 1 hour in a bench scale test unit at typical front-end hydrogenation conditions. In the test, a simulated de-ethanizer feed containing 0.35 mol % acetylene, 20 mol % hydrogen, 0.02 mol % CO, 45 mol % ethylene, and balance methane was passed over a 25 ml catalyst bed at 500 psig (35.5 bar) in total pressure and 7000 h −1 in Gas Hourly Space Velocity (GHSV), while the bed temperature was gradually increased from about 35° C. The acetylene concentration at the reactor outlet was monitored with an on-line gas chromatograph (GC). The acetylene concentration at reactor outlet continued decreasing with increasing temperature until reaching <25 ppm. The temperature at this point was defined as the “clean up temperature” (T1). Catalyst bed temperature was further increased until 105° C. (the maximum temperature the water bath could reach) or a certain temperature (T2), at which the outlet ethane concentration was >2% due to the increased non-selective reaction of hydrogen with ethylene. The temperature range between T1 and T2 is called the “operation window”. Test results of Sample E and Samples E1 to E3 are listed in the table below.
[0000]
Test Results of Sample E and Samples El to E3
Operation
Selectivity
T1
T2
Window
at T1
[° C.]
[° C.]
[° C.]
[%]
Sample E
53
62
9
58
Sample E1
53
69
16
65
Sample E2
52
81
29
74
Sample E3
62
92
30
78
[0096] Upon addition of BMMIM[OTf] onto the Pd/alumina catalyst, the operation window increases linearly up to a loading of 2% and then stays constant at 30° C. At higher loading, both T1 and operation window increased.
Example 9
[0097] Comparative Sample F is a commercial selective hydrogenation catalyst that is supplied by Süd-Chemie AG under trade name OleMax® 201. It contains 0.03 wt % Pd and 0.18 wt % Ag on 2-4 mm alumina spheres with a BET surface area of about 35 m 2 /g.
[0098] Comparative Sample F1′ was made by adding 0.5 wt % of EMIM[EtSO 4 ] (1-ethyl-3-methylimidazolium ethylsulfate) onto Sample F by incipient wetness impregnation method. The EMIM[EtSO 4 ] solution contains 0.5 g of EMIM[EtSO 4 ] in 60 ml deionized water. The clear solution was added to 100 g of Comparative Sample F and mixed for about 5 min. The catalyst formulation is then dried at 80° C. for 16 hr to obtain the final product.
[0099] Comparative Sample F2′ was made by adding 1.0 wt % of EMIM[EtSO 4 ] (1-ethyl-3-methylimidazolium ethylsulfate) onto Sample F by incipient wetness impregnation method. The EMIM[EtSO 4 ] solution contains 1 g of EMIM[EtSO 4 ] in 60 ml deionized water. The clear solution was added to 100 g of Comparative Sample F and mixed for about 5 min. The catalyst formulation is then dried at 80° C. for 16 hr to obtain final product.
[0100] Sample D2′ was made by adding 0.5 wt % EMIM[EtSO 4 ] (1-ethyl-3-methylimidazolium ethylsulfate) on Sample D by incipient wetness impregnation. The EMIM[EtSO 4 ] solution contains 0.5 g of EMIM[EtSO 4 ] in 24 ml deionized water. The clear solution was added to 100 g of Sample D and mixed for about 5 min. The catalyst formulation is then dried at 80° C. for 16 hr to obtain final product.
[0101] Sample D3′ was made by adding 1 wt % EMIM[EtSO 4 ] (1-ethyl-3-methylimidazolium ethylsulfate) on Sample D by incipient wetness impregnation. The EMIM[EtSO 4 ] solution contains 1 g of EMIM[EtSO 4 ] in 24 ml deionized water. The clear solution was added to 100 g of Sample D and mixed for about 5 min. The catalyst formulation is then dried at 80° C. for 16 hr to obtain final product.
Example 10
[0102] Samples and Comparative Samples prepared in Example 9 were tested as prepared in a bench scale test unit at typical front-end hydrogenation conditions. In the test, a simulated de-ethanizer feed containing 0.35 mol % acetylene, 20 mol % hydrogen, 0.02 mol % CO, 45 mol % ethylene, and balance methane was passed over a 25 ml catalyst bed at 500 psig (35.5 bar) in total pressure and 7000 h −1 in Gas Hourly Space Velocity (GHSV), while the bed temperature was gradually increased from about 35° C. The acetylene concentration at the reactor outlet was monitored with an on-line gas chromatograph (GC). The acetylene concentration at reactor outlet continued decreasing with increasing temperature until reaching <25 ppm. The temperature at this point was defined as the “clean up temperature” (T1). Catalyst bed temperature was further increased until 105° C. (the maximum temperature the water bath could reach) or a certain temperature (T2), at which the outlet ethane concentration was >2% due to the increased non-selective reaction of hydrogen with ethylene. The temperature range between T1 and T2 is called the “operation window”. Test results of Sample F2′ and F3′ did not run away at the maximum temperature the test unit could reach: the ethane make was 0.35% at 102° C. for both catalysts. Their T2's for 2% ethane make were calculated by fitting the data at temperatures above complete acetylene conversion with a first order kinetic model.
[0000] Front End Deethanizer Feed Test Results Selectivity Ethane T1 T2 T2-T1 at T1 Make at [° C.] [° C.] [° C.] [%] 102° C. [%] Sample F 51 53 2 −5 Not operable Sample F1′ 54 75 21 76 Not operable Sample F2′ 59 80 21 86 Not operable Sample D 52 57 5 −1 Not operable Sample D2′ 65 148 83 91 0.35 Sample D3′ 66 149 83 94 0.35
It appears that EMIM[EtSO 4 ] has much lower impact on Sample F than on Sample D.
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This invention relates to heterogeneous catalysts useful for selective hydrogenation of unsaturated hydrocarbons, comprising palladium and optionally a promoter, supported on a substrate, having an uncoated BET surface area of ≦9 m 2 /g, the surface being coated with an ionic liquid. Also described are methods of making the catalysts and methods of selective hydrogenation of acetylene and/or dienes in front-end mixed olefin feed streams.
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TECHNICAL FIELD
[0001] This invention relates generally to large-scale synthesis of non-ionic X-ray contrast agents. It further relates to an alternative acetylation process for the synthesis of 5-acetamido-N,N′-bis(2,3-dihydroxypropyl)-2,4,6-triiodoisophthalamide (“Compound A”), an intermediate in the industrial preparation of non-ionic X-ray contrast agents. The process can be performed on an industrial scale to produce Compound A with improved purity and improved yields compared to the established processes.
BACKGROUND OF THE INVENTION
[0002] Non-ionic X-ray contrast agents constitute a very important class of pharmaceutical compounds produced in large quantities. 5-[N-(2,3-dihydroxypropyl)-acetamido]-N,N′-bis(2,3-dihydroxypropyl)-2,4,6-triiodo-isophthalamide (“iohexol”), 5-[N-(2-hydroxy-3-methoxypropyl)acetamido]-N,N′-bis(2,3-dihydroxypropyl)-2,4,6-triiodo-isophthalamide (“iopentol”) and 1,3-bis(acetamido)-N,N′-bis[3,5-bis(2,3-dihydroxypropyl-aminocarbonyl)-2,4,6-triiodophenyl]-2-hydroxypropane (“iodixanol”) are important examples of such compounds. They generally contain one or two triiodinated benzene rings.
[0003] For example, iodixanol, marketed under the trade name Visipaque®, is one of the most used agents in diagnostic X-ray procedures. It is produced in large quantities by GE Healthcare in Lindesnes, Norway. The industrial production of iodixanol involves a multistep chemical synthesis as shown in Scheme 1 below. See also U.S. Pat. No. 6,974,882. To reduce the cost of the final product, it is critical to optimize each synthetic step. Even a small improvement in reaction design can lead to significant savings in a large scale production.
[0000]
[0004] 5-acetamido-N,N′-bis(2,3-dihydroxypropyl)-2,4,6-triiodoisophthalamide (“Compound A”) is a key intermediate in both the industrial scale synthesis of such non-ionic X-ray contrast agents. Compound A is prepared by the acetylation of 5-amino-N,N′-bis(2,3-dihydroxypropyl)-2,4,6-triiodoisophthalamide (Compound B). The acetylation is achieved by using a mixture of acetic anhydride and acetic acid as the acetylating reagent. However, upon acetylation, not only is Compound A produced but several by-products are formed as well.
[0005] Thus there exists a need in the art for an acetylation process that can produce Compound A with a lower level of by-products; thus increasing both purity and yield of Compound A. Such an acetylation process must not only be able to be performed on a laboratory scale but also on an industrial scale. The instant invention, as described below, answers such a need.
SUMMARY OF THE INVENTION
[0006] According to the present invention, it has now been found that by significantly reducing the reaction temperature during the Compound B acetylation reaction, a reduction in the level of by-products produced can be achieved; hence higher yields and higher purity of Compound A can be produced. It has also now been found how to achieve such lower reaction temperature during the Compound B acetylation step on an industrial scale. Specifically, it has now been found that by adding a catalytic amount of an acid catalyst as described herein (e.g. para-toluene sulfonic acid (PTSA)) carefully into the Compound B acetylation reaction mixture over a period of several hours, lower acetylation temperatures can be achieved. In turn, the level of by-products formed in the acetylation is reduced which in turn results in improved purity of Compound A and consequently increased yield of Compound A in the subsequent purification steps. The present invention provides an alternative acetylation process for producing Compound A that can be performed on both a laboratory and/or industrial scale. In a preferred embodiment of the invention, the process is performed as a batch process. The present invention provides an alternative acetylation process for producing Compound A that can be performed as either a batch process or a continuous process. In a preferred embodiment of the invention, the process is performed as a batch process.
[0007] The present invention provides process comprising the steps of:
[0008] (i) reacting 5-amino-N,N′-bis(2,3-dihydroxypropyl)-2,4,6-triiodoisophthalamide (“Compound B”) with a mixture of acetic anhydride/acetic acid to form a slurry;
[0009] (ii) heating said slurry to about 60° C.; and
[0010] (iii) adding an acid catalyst (preferably, para-toluene sulfonic acid (PTSA)) to said slurry at a rate such that the reaction temperature is maintained at a temperature range of about 65-85° C.
[0011] The present invention also provides an industrial scale process comprising the steps of:
[0012] (i) reacting 5-amino-N,N′-bis(2,3-dihydroxypropyl)-2,4,6-triiodoisophthalamide (“Compound B”) with a mixture of acetic anhydride/acetic acid to form a slurry;
[0013] (ii) heating said slurry to about 60° C.;
[0014] (iii) adding an acid catalyst (preferably, para-toluene sulfonic acid (PTSA)) to said slurry at a rate such that the reaction temperature is maintained at a temperature range of about 65-85° C. to form overacetylated Compound A; and
[0015] (iv) deacetylating said overacetylated Compound A to form Compound A.
[0016] The present invention also provides an industrial scale process comprising the steps of:
[0017] (i) reacting 5-amino-N,N′-bis(2,3-dihydroxypropyl)-2,4,6-triiodoisophthalamide (“Compound B”) with a mixture of acetic anhydride/acetic acid to form a slurry;
[0018] (ii) heating said slurry to about 60° C.; and
[0019] (iii) adding an acid catalyst (preferably, para-toluene sulfonic acid (PTSA)) to said slurry at a rate such that the reaction temperature is maintained at a temperature range of about 65-85° C. to form overacetylated Compound A;
[0020] (iv) deacetylating overacetylated Compound A to form Compound A; and
[0021] (v) isolating Compound A.
DETAILED DESCRIPTION OF THE INVENTION
[0022] In the established industrial scale process, Compound B is added to a mixture of acetic anhydride and acetic acid. The resulting slurry is then heated to approximately 60° C. When the temperature is achieved, an acid catalyst (e.g., para-toluene sulfonic acid (PTSA)(s)) is added in one portion and in catalytic amounts. Despite maximum cooling in the reactor jacket, the temperature of the reaction mixture increases rapidly to about 120-125° C. due to the exothermic acetylation reaction. The main part of the acetylation reaction will accordingly occur at 120-125° C. Because of the high reaction temperature, considerable levels of the following by-products I, II, and III in addition to Compound A are formed:
[0000]
[0023] According to the present invention, an alternative acetylation process is provided. According to the present invention, Compound B is added to a mixture of acetic anhydride and acetic acid. The resulting slurry is then heated to approximately 60° C. At this temperature, a catalytic amount of an acid catalyst is added. Examples of a suitable acid catalyst include, for example, a sulfonic acid such as methanesulfonic acid, para-toluenesulfonic acid (PTSA) and sulphuric acid. Of these, para-toluenesulfonic acid (PTSA) is preferred. According to the invention, the acid catalyst can be added as a solid or as a solution. Examples of suitable solvents to form such a solution include acetic acid, acetic anhydride or a mixture of acetic acid and acetic anhydride. The addition is performed carefully while the temperature is controlled. In one embodiment, the PTSA is added as a solid in several portions. In one embodiment, the PTSA is added as a solution where PTSA is dissolved in a small volume of acetic acid. In one embodiment, the PTSA is added as a solution where PTSA is dissolved in a small volume of acetic anhydride. In one embodiment, the PTSA is added as a solution where PTSA is dissolved in a small volume of a mixture of acetic acid and acetic anhydride. The rate/speed of the addition of the acid catalyst, preferably PTSA, is such that the maximum reaction temperature is maintained at about 65-85° C. In general, the addition time will be over several hours in order to control the exothermic reaction.
[0024] In a preferred embodiment, the rate/speed of the addition of the acid catalyst, preferably PTSA, is such that the maximum reaction temperature is maintained at about 70-80° C.
[0025] According to the present invention, addition of the acid catalyst, preferably PTSA, produces a reaction mixture comprising overacetylated Compound A with lower levels of by-products compared to the established acetylation process. The reaction mixture comprising overacetylated Compound A can then be deacetylated using a deacetylating agent. There is no particular restriction upon the nature of the deacetylating agent used, and any deacetylating agent commonly used in conventional reactions may equally be used here. Examples of suitable deacylating agents include aqueous inorganic bases including alkali metal carbonates, such as sodium carbonate, potassium carbonate or lithium carbonate; and alkali metal hydroxides, such as sodium hydroxide, potassium hydroxide or lithium hydroxide. Of these, the alkali metal hydroxides, particularly sodium hydroxide or potassium hydroxide, and most preferably sodium hydroxide are preferred. For example, the reaction mixture comprising overacetylated Compound A can be deacetylated by the addition of base, such as sodium hydroxide, to form Compound A which in turn can then be purified (e.g., crystallization) and isolated by techniques known in the art.
[0026] The invention is illustrated further by the following examples that are not to be construed as limiting the invention in scope to the specific procedures described in them.
EXAMPLES
Examples 1 and 2
Established Acetylation
[0027] Acetylation: For both Examples 1 and 2, Compound B (200 g) was added to a mixture of acetic anhydride (191.8 mL) and acetic acid (103.3 mL). The slurry was heated to approximately 60° C., before PTSA powder (1.0 g) was added in one portion. Because of the exothermic reaction, the temperature rapidly increased to approximately 120-125° C.
[0028] In Example 1, the temperature were held at about 120° C. for approximately 2 hours to form over-acetylated Compound A, before moving on to the next deacetylation process step to form Compound A.
[0029] In Example 2, the solution was cooled in a reactor jacket to 70° C. immediately after reaching the maximum temperature of approximately 120-125° C. The cooling rate was about 1° C./minute, and the solution was held at 70° C. overnight to form over-acetylated Compound A before moving on to the next deacetylation process step to form Compound A.
[0030] Deacetylation: After acetylation, the reaction solution containing over-acetylated Compound A was concentrated under reduced pressure, before methanol and water was added prior to the deacetylation step. Sodium hydroxide was then added to methanol-water reaction mixture to carry out the deacetylation. The resulting reaction mixture was then further diluted with water before crystallization.
[0031] Crystallization: To achieve crystallization, hydrochloric acid was first added until the reaction mixture until it was slightly turbid, and then the reaction mixture was seeded with Compound A. The resulting slurry was stirred for 45 minutes before additional hydrochloric acid was added until about pH 7. The slurry was then cooled to 15° C. over night. Next day the slurry was filtered, and the filter cake was washed with methanol and then dried in a vacuum oven.
[0032] The reaction mixture was analysed by HPLC prior to the crystallization step, and the total level of by-products formed during the acetylation synthesis was 1.38% in Example 1, and 1.34% in Example 2. The majority of the by-products being formed during the acetylation step.
[0033] Both experiments resulted in a total concentration of Compound A and by-products in the mother liquor separated in the filtration step after the crystallization of 1.1 g/100 mL.
Comparative Examples 3 and 4
Alternative Acetylation
[0034] Acetylation: For each of Examples 3 and 4, Compound B (200 g) was added to a mixture of acetic anhydride (150.4 mL) and acetic acid (141.6 mL) to form a slurry. PTSA (1.6 g) was separately dissolved in a small amount of acetic anhydride (3.0 mL). The slurry was heated to approximately 60° C., before the PTSA solution was added over a period of approximately 2 hours to form over-acetylated Compound A, before moving on to the next deacetylation process step to form Compound A.
[0035] In Example 3, the temperature was held at 80-85° C. while PTSA solution was added, and kept at 80° C. overnight.
[0036] In Example 4, the temperature was held at 65-70° C. while PTSA was added, and kept at 65° C. overnight.
[0037] Deacetylation: After acetylation, the reaction mixture containing overacetylated Compound A was concentrated under reduced pressure, before methanol and water was added prior to the deacetylation step. Sodium hydroxide was then added to methanol-water reaction mixture to carry out the deacetylation. The resulting reaction mixture was then further diluted with water before crystallization.
[0038] Crystallization: To achieve crystallization, hydrochloric acid was first added until the reaction mixture until it was slightly turbid, and then the reaction mixture was seeded with Compound A. The resulting slurry was stirred for 45 minutes before additional hydrochloric acid was added until about pH 7. The slurry was then cooled to 15° C. over night. Next day the slurry was filtered, and the filter cake was washed with methanol and then dried in a vacuum oven.
[0039] The reaction mixture was analysed by HPLC prior to the crystallization step, and the total level of by-products formed during the acetylation synthesis was 0.11% in Example 3, and 0.10% in Example 4.
[0040] Both experiments resulted in a total concentration of Compound A and by-products in the mother liquor separated in the filtration step of 0.6 g/100 mL. The alternative acetylation gave an increased total purity of A by approximately 0.2% points after crystallization, compared to the established process, analysed by HPLC.
[0041] All patents, journal articles, publications and other documents discussed and/or cited above are hereby incorporated by reference.
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An alternative acetylation process for the synthesis of 5-acetamido-N,N′-bis(2,3-dihydroxypropyl)-2,4,6-triiodoisophthalamide (“Compound A”), an intermediate in the industrial preparation of non-ionic X-ray contrast agents, is described. The process can be performed on an industrial scale to produce Compound A with improved purity and improved yields compared to the established processes.
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BACKGROUND OF THE INVENTION
The present application is a continuation-in-part of applicants' prior application Ser. No. 370,874 filed on June 18, 1973 now abandoned.
The present invention relates to a novel fabric, particularly a fabric having high elasticity and power stretch.
This new fabric is the positive result of thorough tests and trials carried out with the main purpose of achieving at a commercial scale a fabric which, due to its construction, good appearance and moderate cost, will stand out advantageously in comparison with certain conventional type elastic fabrics available at present in the market.
It is a known fact that the quality of a fabric represents the sum total of a series of factors, conditions and elements which properly interrelated allow the proposed performance to be achieved. Thus, this novel fabric we have created offers as an outstanding feature that which the textile industry calls "hand", that is, that the fabric possesses a very soft feel, which under the requirements of today's fashion is an interesting and much sought contribution.
As stated before, there are various elastic fabrics in the market, their elasticity normally depending on two factors; the one, given by the stitch produced by the knitting machine; the other by the yarn itself, that is, that if we take as an example the case of a fabric of the so-called "stretch" type, one may assign a value of 1 to the degree of elasticity obtained with the knitting machine, and a value of 2 to the proper degree of elasticity provided by the yarn, the latter being a yarn texturized in a "stretch" system providing it with a high elasticity.
The sum of the yarn value 2 plus the machine value 1 totals a value of 3 which can be obtained purely and exclusively with texturized type yarns.
Obviously, if rigid or inelastic type yarns such as cotton, wool, acetate or any equivalent one based on natural or synthetic fibers are to be used, the degree of elasticity of the yarn descends to a very low value which, taking into account the relative values we are using an an example, would finally reach an extremely low value; this means that in the case of said rigid yarns the degree of elasticity of the fabric will be given exclusively by the stitch of the knitted fabric. Consequently, a fabric knitted with a cotton yarn may be assigned the same value 1 assigned to the previous one, but as on its part the low elasticity of the fabric results in a practically zero value, the degree of elasticity of the fabric would only be of a value 1.
SUMMARY OF THE INVENTION
It is therefore an object of this invention to provide a novel type of elastic fabric having high elasticity and power stretch indexes, using unconventional yarns having a lower cost than yarns currently used for elastic fabrics at present in the market.
It is a more specific object of this invention to provide a novel type of elastic fabric having high elasticity and power stretch indexes, knitted in a circular machine of interlock basis, and comprising rigid synthetic yarns not previously texturized or warped, which define rigid yarns knitted in pique interlacing on the basis of an interchange of courses of interlock and jersey, the rigid yarn forming the jersey stitch courses constituting a carrier or "companion" for a polyurethane originated elastomeric fiber tensioned under control, forming together with the rigid yarn said jersey stitch courses.
One of the basic features of the novel fabric we have developed is precisely the inclusion therein as the main component, in a proportion ranging from 87 to 89 percent, of a yarn known in the art as a producer or prim twist, i.e., a yarn directly issued from spinning and not subsequently submitted to any texturizing process, thus being a rigid yarn.
If this yarn were knitted in a circular machine, it would have a practically zero degree of elasticity, as the elasticity of the resulting fabric would be provided only by the machine.
The novel fabric of the present invention, precisely due to its construction and components -one of the, fundamental by being an elastomeric yarn of spandex origin- makes it possible to obtain therewith a degree of elasticity and power stretch that normally would have to be provided by a type of fabric made with a texturized yarn. This means that by starting from a yarn which would enable one to obtain conventionally a fabric having an elasticity of 1, it is possible to obtain a fabric attaining an elasticity value of 21/2 and a higher power stretch.
According to this invention, the possibility of obtaining precisely an excellent elasticity with a type of yarn which shall hereinafter be referred to as a producer twist or rigid yarn is essential. Since a producer twist or rigid yarn instead of a so-called texturized yarn is used, several fundamental conditions can be obtained. In the first place, an extremely soft hand, as a normal feature for a non-texturized yarn; secondly, the actual possibility of a fabric having a clean, smooth appearance, i.e. a smooth surface which is the basic contribution of a producer yarn, in contrast with any fabric made with texturized yarn, which presents a spongy surface somewhat similar to crepe, while the new developed fabric offers, apart from a very smooth hand and an excellent "wet-hand", a full, fleshy and absolutely non gummy or spongy hand.
Another negative detail in the texturized yarn as compared with the yarn used in this invention lies in that having been submitted to a "swelling" process it exhibits an air retention within the fiber mass, which causes a voluminous thickness; while in the fabric of the invention, since such a possibility of "swelling" does not exist, one can obtain a much "flatter" fabric.
Also worth mentioning is the fact that in using a producer twist or rigid yarn in the new fabric, a remarkable luster is achieved, so that the fabric has both an excellent luster and a good satin look. These features are neither normal or achieved in a fabric made with texturized yarn, even in the case of high quality and high cost fabrics.
One should also point out in respect of the fabric of the invention that non-texturized yarn, i.e. the producer twist or rigid yarn, has a far lower cost than texturized yarn. Indeed, a texturized yarn is initially a producer twist or rigid yarn subsequently submitted to a series of processing operations and passing several commercial stages, all of which, of course, cause a considerable increase in the cost of said texturized yarn.
Regarding the brightness of the fabric, mentioned above, it is worthwhile to note that apart from the producer twist or rigid yarn, which is a semi-dull yarn having luster on account of its not being texturized, we have contemplated increasing or emphasizing said brightness in the fabric by incorporating thereinto a further producer twist or rigid yarn, but in this case of a trilobal fiber, this yarn precisely being the one added or associated with the aforementioned elastomeric yarn of spandex origin. The main feature of said trilobal fiber is that while all producer twists or rigid yarns, either semi-dull or bright, present a circular cross-section, said fiber shows a cross-section forming three lobes or rounded projections (a configuration resembling a clover leaf), giving rise to formation of different light reflecting faces causing a very bright yarn.
In addition to the logical balance that should exist between yarn number and machine features, the amount of filaments forming the yarn is extremely important, for the simple reason that the higher the number of filaments so much the more will the smoothness of the fabric be, while with a lower amount of filaments the fabric will be coarser. These significant details show that if instead of using, for instance, a 90/28 yarn a 90/10 or 90/14 yarn is employed, the features themselves of the fabric would be far more rough than if the first named yarn were used; on the other hand, if a 90/36 yarn is used instead of a 90/28 yarn, an increase in the fabric's softness will automatically be obtained, so that it shall readily be understood that there is the possibiity of a substantial number of variations as far as yarn numbers are concerned.
If the process whereby the novel fabric of the invention is produced in a circular interlock type machine of, for instance, 28 needles per inch, the variations in deniers to manufacture the novel fabric may fluctuate between 80 and 90 deniers, approximately, because if they were perceptibly to exceed such limits a good coverage would not be obtained, i.e., openings in the fabric might be noted. In short, there must be a necessary and pre-established equilibrium between yarn deniers and machine fineness, which is the same as saying yarn number and machine gauge, since gauge means in the art number of needles per inch.
The novel fabric and the process for producing it have been developed taking into account that conventional fabrics including elastomeric fiber exist, which are made in a warp knitting machine. But in this case there is a very important negative factor, which complicates and substantially increases the cost of said production in a warp knitting machine: the elastomeric fiber must be used already warped, that is, wound on warp beams wherein the required number of elastomeric fiber yarns are provided already warped.
This means that, considering the source of said raw material (polyurethane elastomeric fiber) whoever may want to undertake the above manufacture will forcibly have to buy the warped beams of elastomeric fiber, with all the resulting evident difficulties of a practical and economic order, because a raw material having in itself a high cost suffers a severe increase therein by having to undergo said prior warping operation.
On the other hand, in the novel fabric of the invention and in the process for producing it, the elastomeric yarn is used simply from the cone, that is to say, just as it comes wound on the cone when placed in the creel for warping, so that, as with the producer twist or rigid yarn, it can be purchased directly from the spinning mill. Normally the same supplier of elastomeric yarn not only sells it in tubes, but also beamed, a case similar to texturized yarns; however, by this additional process the yarn substantially increases its cost, much more notable due to the already high cost of elastomeric fiber itself.
It is also worth mentioning that in elastic fabrics processed in warp knitting machines it is quite difficult to limit the elastomeric fiber percentages, which generally are as high as 25 %, that is to say, that in each kilogram of fabric there are 250 grams of elastomeric fiber included. Taking into account the extra charge the prior operation implies, it is easy to see the reason for the extremely high cost of such conventional fabrics.
Instead, in the novel fabric and the method for making it, the percentage of elastomeric fiber incorporated therein is in the range of 5 to 7 percent, so that there is practically a 20 percent saving of elastomeric fiber for fabrics having very similar features. It should be born in mind that we are not speaking of equal fabrics, but of equal features of same, for example as to elasticity, recovery power, a certain similitude in hand or feel, but in no way as to thickness, because a fabric made in a warp knitting machine is always far thinner and of a much lesser weight per area unit than the fabric of the invention. The latter, in a line oriented, for instance, towards the manufacture of swim suits and other garments, offers optimum conditions of thickness, elasticity, compactness, etc., in comparison with other conventional fabrics in which, as in the case of those made in warp knitting machines, an interesting degree of elasticity is obtained, but in spite of their high percentages of elastomeric fiber have a relatively lower recovery power.
In order to provide a clear and ready understanding of the present invention three illustrative drawings are accompanied diagramming the fabric and the manufacturing process according to a preferred embodiment, with a purely exemplary and in no way limitative purpose.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagram showing unfolded according to the current textile standards a knitting cycle of the novel fabric of the invention;
FIG. 2 is a schematic illustration showing the arrangement of courses forming the fabric and their location relative to the respective needles, and
FIG. 3 is a schematic illustration showing how the elastomeric yarn and the corresponding rigid yarn acting as carrier thereof are directly fed to the needles,
In the several Figures, the same reference characters indicate equal or corresponding parts.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
As shown in the accompanying drawings, the novel fabric of the invention comprises in its essential arrangement rigid synthetic yarns with no previous texturing or warping, which as producer twists or rigid yarns are pique knitted on the basis of interchanging courses of interlock and jersey; and annexed to the rigid yarn forming the courses of jersey stitches there is an elastomeric fiber of polyurethane origin under controlled tension.
The above basic arrangement corresponds to a fabric produced in an interlock type large diameter circular knitting machine according to knitting or construction cycles as the one shown in FIG. 1 of the drawings, wherein numerals I to VI indicate the several courses forming said construction and to which the respective feeders correspond.
According to that order and following a procedure used to produce the fabric of the invention, course I evolves with a rigid yarn 1, consisting, for example, in a polyamide yarn having a 90 denier number, the feeder of which works in interlock with long needles identified by reference numeral 2; course II is made with rigid yarn 3, based on polyamide fiber of a 90 denier number, the feeder working in interlock with short needles shown at 4; course III is conducted with rigid yarn 5 of a 40 denier number polyamide fiber, its feeder knitting jersey with long needles indicated at 6; course IV consists of rigid yarn 7 of a 90 denier number polyamide fiber, the feeder working in interlock with short needles 8; course V is formed with rigid yarn 9 of a 90 denier number polyamide fiber, the feeder working in interlock with long needles shown at 10, while course VI is made with rigid yarn 11 of a 40 denier number polyamide fiber, its feeder working jersey with short needles 12.
According to the process and on the pique basis outlined above, the polyurethane originated elastomeric fiber is incorporated. To such effect, in jersey courses III and VI preferably consisting of a trilobal rigid yarn having a 40 denier number, the above mentioned elastomeric fiber is directly introduced in the needle so as to be accompanied by said rigid yarn identified at 5 and 11, the elastomeric fiber being indicated in both courses by reference numeral 13, it may have, for instance, a 70 denier number. It is interesting to note that both the yarns as the yarn numbers mentioned above are simply demonstrative and not limitative examples.
One of the advantages of this process of rigid yarn knitted with elastomeric or spandex yarn in a circular machine for producing the fabric of the invention lies in the fact that this fabric can be perfectly dyed with a wide line of dyestuffs allowing at the same time any variation in shades.
Normally a fabric including elastomeric or spandex yarn has problems during the dyeing process due to various circumstances, one of them residing in that elastomeric yarn has to be well under control so as to avoid the play of tensions, which normally may cause differences in the width, or differences in tension, with the consequence being that part of the fabric wrinkles while the other does not. Furthermore, in the case of elastic fabrics processed in a warp knitting machine the problem arises that the elastomeric yarn, or at least part of it, is exposed and this forces the dyer to undertake a careful selection of dyestuffs in order to obtain a good leveling of shades, because if there are defects in said levelling two-color effects are caused which devaluate the fabric and are even a motive for rejection by the customer.
In the process for producing the fabric of the invention, the elastomeric yarn is completely "hidden" or is invisible in the face of the fabric, so that it is possible to treat it as a common polyamide fabric; however, it is always sought to give the elastomeric yarn a good covering; this, however, should not be taken as limitative. Moreover, save in the case of black, any color can be achieved without need of working with selected dyestuffs because even if the elastomeric yarn does not take dye and remains white, it is in no way directly visible in the face of the fabric, so that in fact there is no problem.
The three basic components used in manufacturing the fabric of the invention are constituted by 90/28 rigid yarn which may be a polyamide yarn, or even a polyester yarn, incorporated into the fabric in a 87 to 88 percent proportion; a second, 40/10 yarn, also polyamide and having a trilobal cross section, included in a proportion of 5 to 7 percent on the total weight of the fabric, and finally a polyurethane originated elastomeric yarn is an amount representing from 5 to 7 percent of the total weight of the fabric.
The types and proportions of the above yarns are considered a mere example devised to achieve a perfect balance with the knitting machine, a circular knitting machine (with two sets of needles), 28 needles per inch. It will be easy to see that on the basis mentioned above there is a wide range of variations demanding as the only requirement a proper balance between the yarns and the machine gauge, that is, the number of needles per inch.
As already mentioned, the present process is carried out with the help of a large diameter circular knitting machine, interlock type, provided with Rossen type furnishers, which ensure perfect feeding regularity plus an absolute uniformity in the resulting fabric, with no possibility or barre problems. The machine is equipped with, for example, 36 feeders to produce six cycles, one of which has already been discussed in detail hereinbefore. One of the basic points in the process for producing the fabric of the invention is not only the possibility of introducing an elastomeric yarn in the machine, but also of retaining or maintaining such a yarn in the machine according to a required position.
This has been achieved by attaching to the trilobal hard yarn part of the fabric the role of carrier or "companion", with the addition of an action which even if appearing rather unorthodox is one of the main aspects of the process for making the fabric of the invention, to wit, to feed two threads to one and the same needle, and this is shown in FIG. 3 of the drawings. In this figure, a indicates the corresponding section of the machine and b the needles thereof, the rigid yarn being shown in dash lines 14 and running through yarn-guide 15, while reference numeral 16 indicates the elastomeric yarn trained around a small pulley 17. Both yarns 14 and 16 are directed, as indicated by the drawing, so as to be positioned in such a manner that upon arrival at needles b they may be jointly caught by the needles as the jersey courses III and VI of FIG. 1 are developed.
Complementary to the diagram of FIG. 1 -which is the normal way of illustration in the textile art- and with the purposes of providing a more clear interpretation of the invention, the knitting courses are shown schematically in FIG. 2 as separated, instead of overlapped as in practice, so that to follow them or distinguish them in the fabric is quite difficult if not impossible. Thus, in the flat arrangement shown, the course numbers I to VI and the reference numbers 1 to 13 are the same as those used in FIG. 1, and further the courses are shown by distinctive means (white, dot-shaded, line-shaded and blacked), location of the needles being indicated by small blacked circles for the short cylinder needles, small white circles for the long cylinder needles; while white squares indicate long dial needles and and black squares identify the short dial needles.
The schematic drawing of FIG. 2 clearly shows how the rigid yarn 5 or 11 and the polyurethane fiber yarn 13 are taken up together by needles 6 or 12.
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An elastic fabric containing producers twist continuous filament yarns, which in spite of their features make it possible to obtain a fabric having high elasticity and power stretch indexes; said synthetic yarns are knit just as issued from spinning, without previously being submitted to any texturing or warping operation, in a large diameter interlock type circular machine, with two sets of needles, on a pique basis and with interlacing interlock and jersey courses. In the interlock courses a first synthetic yarn is incorporated, while in the jersey courses a polyurethane originated elastomeric yarn tensioned under control, having as a companion or carrier yarn a second synthetic yarn, is incorporated.
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[0001] The present invention relates to a method for the manufacture of sulphate pulp from disintegrated wood material.
STATE OF THE ART
[0002] EP 1115943 (=U.S. Pat. No. 6,468,390) discloses a method for cooking wherein early cooking liquor with a high content of dissolved hemicellulose, mainly in the to form of Xylan, is withdrawn from the cooking process, most suitably directly after the end of the impregnation step, and is then reintroduced in the end of the cooking process where the hemicellulose is allowed to precipitate on the softened wood chips by giving it an extended retention time. With this method it is possible to increase the yield by at least 1% and also improve the beatability of the pulp. EP 1115943 discloses in detail the process for selective precipitation of hemicellulose/Xylan and prior art at the date of filing.
[0003] U.S. Pat. No. 3,354,029 discloses a process whereby cooking liquor is added to the last 15 minutes of the cooking process and alkalinity is reduced by adding an acid to reduce pH to 11.5-13, so that a precipitation of lignin, so called lignin condensation, and to some extent hemicellulose occurs. The process in EP 1115943 is different from this process in that the object is to precipitate Xylan, and not obtain a lignin condensation at all, since high alkalinity must be maintained in the process.
[0004] U.S. Pat. No. 3,937,647 discloses another process where it is only desired to precipitate organic material, i.e. also lignin, where this precipitation process is activated by lowering pH to a value under 11, specifically a pH in the range of 5.5-10.
[0005] U.S. Pat. No. 3,802,956 discloses another such process with precipitation in the end of the cooking process with a short retention time allowed for the dissolved organic material together with the softened wood chips.
OBJECTIVE OF THE INVENTION
[0006] Upon application of the method according to EP 1115943 it was found that the amount of dissolved hemicellulose during the cooking process varies with time, and that the characteristics of the hemicellulose that has just been dissolved also vary with time. The hemicellulose that has dissolved early in the cooking process begins to degrade, i.e. the hemicellulose in the form of in the Xylan chains is broken down, whereby the yield increasing effect of the Xylan precipitation from the early dissolved Xylan is completely or partly lost. During the cooking process Xylan dissolves easier from the surface of the partly softened wood chips, which is why the likewise early dissolved hemicellulose on average contains longer chains than the hemicellulose which is dissolved later from the interior of the softened wood chips. Among others, Herbert Sixta's “ Handbook of Pulp ”, Vol. 1, discloses the rate of dissolution for different kinds of hemicellulose. Xylan is dissolved relatively quickly and after 100 minutes in an alkali cooking process, with a maintained temperature of 170° C., 25% of Xylan has been dissolved after 100 minutes, while 25% of Glucomannan has been dissolved after 200 minutes. Hexenuronic acids are dissolved even more quickly. Already after less than 100 minutes more than 75% has been dissolved from the wood. It is often desirable to remove hexenuronic acids from the pulp because pulp with a high content of Hexenuronic acids is hard to bleach. It is often necessary to use very aggressive bleaching steps with either a high temperature or highly effective bleaching chemicals.
[0000] The late dissolved hemicellulose has also been subjected to the high cooking temperature for a longer period of time, a factor that also affects this late dissolved hemicellulose.
[0007] To be able to fully optimize a so called Xylan cooking process according to EP 1115943 it has been found suitable to withdraw cooking liquor with the different fractions of early and late dissolved hemicellulose, before these cooking liquors are reintroduced in the end of the cooking process where a selective precipitation of hemicellulose occurs on the softened wood chips, i.e. without any significant lignin precipitation.
[0008] These withdrawals of cooking liquor are most suitably performed in combination with the addition of replacement fluid, so that the amount of hemicellulose in the cooking liquor may be diluted and facilitate the dissolving the hemicellulose still bound in the wood chips.
[0009] According to the present invention, a first withdrawal is initiated during the cooking process at a position between the later half of the impregnation step and the first quarter of the cooking zone (measured in time), and a second withdrawal is performed later in the cooking zone, where the liquids that have been withdrawn with their contents of dissolved hemicellulose are reintroduced to the last phase of the cooking zone to there be able to precipitate on the wood chips softened in the cooking process. This way it is possible to quickly withdraw the early dissolved hemicellulose, which has a long chain length, and continue to dissolve more hemicellulose in a later phase, whereupon these liquids with the “freshly” dissolved hemicellulose are reintroduced to the last phase of the digester for precipitation on wood chips, when the cleavage of carboxylic acid groups in the Xylan start to reduce the solubility of the Xylan. By withdrawing the primary dissolved hemicellulose early it is possible to prevent that the degradation of Xylan reaches a point where the yield increasing effect is lost.
[0010] The invention may be applied on both steam phase digesters and hydraulic digesters, in both single-vessel and two-vessel cooking systems.
FIGURE
[0011] FIG. 1 shows the invention in its simplest embodiment with 5 different treatment zones.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0012] FIG. 1 shows an example of a continuous digester 10 used for the manufacture of sulphate pulp from disintegrated wood material in the form of wood chips. Wood chips C IN are continuously fed into the top of the digester and cooked wood chips C OUT in the form of softened cellulose pulp are fed out continuously from the bottom of the digester. The digester may either be a steam phase digester or a hydraulically filled digester. The invention may be applied in the same way for both these types of digesters.
[0013] The wood chips are fed into the top of the digester with a suitable feeding system 1 , in the form of a wood chips-liquid mixture, and any, for the cooking process superfluous transport liquid, may be drawn off with a strainer in the top and then be reintroduced into a flow 2 to the feeding system. The feeding system may either be a conventional tap or a sluice feeding valve or pumps, or in some cases a prior filled impregnation vessel which pressurizes the wood chips mixture before being transferred to the top of the digester.
[0014] In the figure, the flows of cooking liquors in concurrent treatment zones of the digester are indicated with DF (Down Flow) and counter current treatment zones with UF (Up Flow), and the flow of wood chips is indicated with CF (Chip Flow).
[0015] In the upper part of the digester a first impregnation zone may be provided down to the strainer 11 B, and optionally a cooking circulation 11 A- 18 A may be provided prior to this, in which circulation the cooking liquor is drawn off through the strainer 11 A and reintroduced to the center of the digester via a conventional central tube with pipe 18 A.
[0000] In the upper impregnation zone the wood chips are impregnated with an impregnation liquid at a temperature that is above 80° C. but at the same time below the cooking temperature by at least 20° C. The Impregnation should occur at a lower temperature to allow the wood chips to be thoroughly impregnated with cooking liquor and alkali. If the impregnation occurs at a temperature which is too high, the alkali will be spent before it completely reaches the core of the wood chips, which may lead to only partially cooked wood chips and high reject levels (bundles of uncooked wood chip aggregates). The impregnation may in some cases take place completely in a prior impregnation vessel, in a so called two-vessel cooking system. The shown embodiment includes only a single-vessel cooking system.
After impregnation, the cooking process is initiated by subjecting the wood chips and cooking liquor to a higher cooking temperature at which initial delignification and bulk delignification occurs.
Heating to a cooking temperature may for example be accomplished by a heating circulation, where the cooking liquor is drawn off from the strainer 11 B, and via pipe 12 B, heater HE and reintroduction pipe 13 , is reintroduced to the center of the digester through a conventional central pipe. Under the strainer 11 B a cooking zone is established at a cooking temperature in the range of 120-170° C., with a predetermined total retention time for the wood material in this cooking zone.
A first withdrawal XYL 1 , with a first withdrawn cooking liquor, comprising a first amount of hemicellulose dissolved from the wood material, is performed from the cooking process between the later half of the impregnation zone and the first quarter of the cooking zone after the wood material has had a first retention time in these zones, and where this first withdrawn cooking liquor is reintroduced to the last phase of the cooking process at cooking temperature. In the figure this first withdrawal XYL 1 is reintroduced into the circulation 11 E, 12 E to be introduced into the center of the digester, and allowed to be present in the last cooking zone of the digester, which occurs in an up stream flow up to strainer 11 D.
A last wash zone may be established in the bottom of the digester, where diluting or wash liquor is added to the bottom of the digester via a plurality of nozzles 6 b , 6 C and via outlets (not shown) in the bottom scraper 5 of the digester.
In the case a cooking zone is established in the digester it extends from the strainer 11 B to the strainer 11 E.
The invention is characterized in that a second withdrawal of a second withdrawn cooking liquor XYL 2 comprising a second amount of hemicellulose dissolved from the wood material, is done from the cooking zone after the wood material has been allowed a second retention time in the cooking zone, where this second retention time is longer than the first retention time at which the first withdrawal was performed. The second retention time is shorter than the total retention time in the cooking zone. In the figure this first withdrawal XYL 2 is also reintroduced to the circulation 11 E, 12 E to be reintroduced to the center of the digester, and to be allowed to be present in the last cooking zone of the digester provided in a upstream flow up to strainer 11 D. The final withdrawal of spent black liquor is drawn from the strainer 11 D and is sent to recovery REC, or may alternatively be used as a first impregnation liquor. In the case where the black liquor is sent directly to recovery, the residual alkali content is in the range of 5-10 g/l, typically around 8 g/l, but in the case where the black liquor is used for black liquor impregnation, the residual alkali content is typically 4-6 g/l higher. In both cases, the black liquor will no longer be used in the digester, or in the cooking zone. Some single-vessel digesters comprise a first upper impregnation zone with black liquor in the top of the digester, but this requires an additional withdrawal to recovery directly after this impregnation zone to draw off completely spent black liquor followed by addition of fresh cooking liquor and white liquor.
[0016] According to the invention the first retention time for the wood chips between the start of the cooking process (i.e. both the impregnation and cooking zone) and the withdrawal of the first withdrawal XYL 1 is shorter than the retention time of the wood chips in the cooking process between the start of the cooking process and the second withdrawal. In the figure XYL 1 is drawn off directly at the start of the cooking zone and XYL 2 is drawn off partly into the cooking zone.
[0017] A suitable first retention time is at least 30 minutes in the cooking process, and for cooking liquor withdrawn in a subsequent withdrawal, these cooking liquors have had increasing retention times between the beginning of the cooking process and the subsequent withdrawal.
[0018] The amount of cooking liquor withdrawn is at least 0,5-1,5 cubic meters comprising dissolved hemicellulose from each withdrawal position and reintroduced to the last phase of the cooking process.
[0019] Due to the fact that the first dissolved hemicellulose has a longer chain length and has been in the cooking process the shortest time, the first withdrawn cooking liquor XYL 1 with a first content of dissolved hemicellulose may be allowed a longer retention time in the last phase of the cooking process than the cooking liquors which have been withdrawn in subsequent withdrawals and which have also been reintroduced to the last phase of the cooking process.
[0020] The withdrawn cooking liquor XYL 1 of the first withdrawal with a first content of dissolved hemicellulose may also be allowed a longer retention time externally of the digester than the cooking liquors which have been withdrawn in a subsequent withdrawal, prior to the reintroduction of these cooking liquors to the last phase of the cooking process. In this way, the characteristics of the early dissolved hemicellulose will be similar to the characteristics of the later dissolved hemicellulose, so that these, upon addition to the same position in the cooking process behave similarly upon precipitation on the fibers in the digester.
[0021] The first withdrawn cooking liquor in the first withdrawal is most suitably withdrawn in a position in the cooking process where the proportion of from the wood material dissolved hemicellulose per unit of time begins to decrease. Initial dissolution of hemicellulose happens relatively quickly, whereupon continued dissolution of hemicellulose from the interior of the wood chips is a longer process.
[0022] The withdrawals of cooking liquor with the dissolved content of hemicellulose may occur in more than two positions. In an additional third withdrawal of cooking liquor with a third content of dissolved hemicellulose (not shown), cooking liquor is drawn off from the digester after a third retention time of wood chips in the cooking process, the third retention time being longer than the first and second retention time, whereupon the third cooking liquor is also reintroduced to the last phase of the cooking process.
[0023] The withdrawn cooking liquors with their dissolved content of hemicellulose may also first be decompressed to increase the dry content of the cooking liquors, whereupon these cooking liquors are reintroduced to the last phase of the cooking process via pumping/pressurization. In this way water and other volatile liquids and gases may be separated from the cooking liquor, while the proportion of hemicellulose increases in the pressure released cooking liquor. This cooking liquor with its dissolved content of hemicellulose may also be subjected to a separation of its part of hemicellulose, whereupon this separated part of the cooking liquor which is enriched in hemicellulose is reintroduced to the last phase of the cooking process via pumping/pressurization. The separation may be performed by filtration or some other suitable processes. As indicated in FIG. 1 , such a separation apparatus 30 may be provided for the withdrawn liquid, which preferably separates at least parts of the dissolved lignin. The separated lignin may then be transferred directly to recovery (REC, not shown). The separation apparatus is shown herein in one of the flows, XYL 1 , but may also be provided for flow XYL 2 , or in the combined flow XYL 1 +XYL 2 .
[0024] The invention may also be modified in a number of ways within the context of the enclosed claims.
[0025] The whole digester, or the zone or zones to which the hemicellulose-rich cooking liquor is added, may also be arranged concurrently instead of, as is shown in the figure, as a countercurrent cooking zone where the cooking liquor flows countercurrent to the sinking motion of the wood chips down through the digester.
[0026] The cooking process may also be provided in a two-vessel system, where the first impregnation is carried out in a first vessel, and the first withdrawal occurs in the end of this impregnation vessel or during the transfer to the second digestion vessel.
[0027] The technique may also be implemented in batch wise cooking, where the cooking liquors rich in hemicellulose are withdrawn at different time points during impregnation or cooking in this digestion vessel, and reintroduced to the later phase of the cooking process, in the same digestion vessel or in a digestion vessel set up in parallel with this and provided later in the cooking process.
[0028] Application of the technique does not depend on if the continuous digester is operated as a hydraulic digester (completely filled with cooking liquor) or as a steam phase digester (with a gas phase in the top of the digester).
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The method increases the yield and improves the beatability of kraft pulp. During the progression of the cooking process, more than one cooking liquor with a dissolved content of hemicellulose is drawn off and then reintroduced to the last phases of the cooking process, to re-precipitate the hemicellulose on the fibers. The hemicellulose rich cooking liquors are adjusted so that they, upon being added to the last phase of the cooking process are optimized. Early dissolved hemicellulose has a longer chain length than the hemicellulose that dissolves in the cooking liquor in the later phases of the cooking process, and they also have different tendencies to precipitate on the wood chips softened in the cooking process.
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[0001] This invention is a continuation-in-part patent application to 09/255,442 filed Feb. 22, 1999 which is a continuation of patent application Ser. No. 09/022/314 filed Feb. 11, 1998 which is a continuation of patent application Ser. No. 08/471372, now issued as U.S. Pat. No. 5,762,639.
FIELD OF THE INVENTION
[0002] The present invention provides for a simple method and device for infusing or injecting medication; it is applicable to medical or dental and the like procedures. More particularly, the invention is directed to catheterized delivery of anesthesia and other medication. More particularly still, it is directed to catheterized delivery of dental anaesthetic to a targeted nerve and to an apparatus for such delivery.
BACKGROUND OF THE INVENTION
[0003] There are a variety of methods currently in use for providing local anaesthetic in dentistry. These methods and apparatuses however all have disadvantages, either being difficult for practitioners to perform or painful and unpleasant to the patient.
[0004] An example of a method used currently in dentistry is the infiltration method, whereby a local anaesthetic solution is injected into the soft tissue of gingiva. In doing so, the solution eventually passes through the cortical plate affecting the nerve bundle entering the tooth. Disadvantages of this method include the delay of onset of anaesthesia after the injection and, in most cases, ballooning of the injected tissue. As well, there is an extended period of time for recovery of the tissue until return to normal condition.
[0005] Another method which is currently used is the regional block method whereby an anaesthetic solution is injected locally in proximity to the nerve trunk as it enters the bone. Disadvantages of this procedure are that it is extremely difficult to locate the nerve trunk, there is discomfort to the patient and a delay for the anaesthetic to take effect. As in the case of the infiltration method, this method necessitates a long recovery period for tissue to return to normal.
[0006] At present, two types of apparatus have been used to perform intra-osseous anaesthesia. These are surgical burs used to perforate the cortical plate and the villet injectors.
[0007] The use of a surgical bur has disadvantages in that burs are expensive and they have to be sterilized between uses or a new bur used each time. In addition, the method is slow, requiring the attached gingiva and periosteum to be anaesthetized before the cortical plate is perforated. The villet injector is an apparatus that serves both as a perforator and injector. It uses specially designed needles rotated by a conventional dental motor. A disadvantage of this device is that the needle often becomes clogged with pulverized bone which obstructs the passage in the needle and prevents injection of the anaesthetic solution. It is generally difficult to remove the clogging material from the needle and often the use of a second needle is necessary. Other disadvantages of this method include the initial capital cost of the instrument purchase, and the cost of the needles which are somewhat expensive. In addition, the design of the instrument makes access to various parts of the mouth difficult and sometimes impossible.
[0008] Intra-osseous and targeted root-canal nerve anaesthesia have not become popular for the reason that there has not been a practical technique of making the injections successfully. For example, there has been a general belief that this method is radical and to be restored to only if nerve block and infiltration anaesthetic do not accomplish the desired result. However, intra-osseous and targeted injections produce positive, more profound anaesthesia and could be made with less pain than either of the other types according to the present invention.
[0009] Targeted anaesthesia has several advantages over prior art nerve block or infiltration methods. There is no feeling of numbness in the tongue, cheek, or lips during or after the injection and there is no after-pain. The anaesthetic is profound and acts immediately alleviating the necessity of waiting for the anaesthetic to take effect as with the nerve block and infiltration methods. Furthermore, as only a few drops of anaesthetic are injected, there is no feeling of faintness or increasing of the pulse rate.
[0010] To achieve targeted anaesthesia one must gain access, if intra-osseous, to the cancellous bone by going through the cortical layer; or to the bottom of the tooth, if root-canal targeted anaesthesia is desired. Because of instant anaesthesia and profound pulpal anaesthesia, there is a much greater control over the region one wishes to anaesthetize, resulting in a much smaller dose of anaesthetic; as well as, of course, other medication, where applicable.
[0011] U.S. Pat. No. 5,173,050 (Dillon) discloses a dental apparatus for perforating the cortical plate of human maxillary and mandibular bones. The apparatus of Dillon comprises a metal needle moulded into a plastic shank. The shank is being formed with means for cooperation with a dental hand piece for transmitting the rotational movement to the needle. The needle used for drilling is solid and has a sharp bevelled free end. The apparatus described by Dillon is disposable.
[0012] However, the device disclosed in Dillon's patent cannot be used as a catheter for injecting anaesthetic by inserting a hypodermic needle through the drilling needle. As well, the device disclosed by Dillon is not provided with means for blocking entry of bone debris into the needle passageway. In addition, the direct connection between the hand piece and the perforator does not provide for a safe and reliable barrier against bacteria passing from the needle to the hand piece.
[0013] U.S. Pat. No. 3,534,476 (Winters) discloses a drilling and filling root canal apparatus. The drilling is performed by a drill having a central bore. The depth of the root canal is determined in advance and a stop is placed on the drill to limit the depth of drilling. The device is provided with a flexible rod which is pushed into the root canal so that the drill is directed along this road to follow the contour of the canal so that resulting bore will have an uniform diameter which is free of shoulders or ledges. The apparatus disclosed by Winters is concerned with enlarging the root canal after the nerve has been extracted. This apparatus is not used for injecting medication in close proximity to a targeted area for treatment or anaesthetic.
[0014] U.S. Pat. No. 4,944,677 (Alexandre) discloses a smooth hollow needle with a bevelled point for drilling a hole into the jawbone near the apex of the tooth to be anaesthetized. Thereafter, the drilling device 13 removed from the jaw, and a hypodermic needle of substantially the same gauge is inserted into the hole and anaesthesia is injected. Thus, there is no cathetized delivery of medication, with the attendant disadvantage that the pre-drilled hole may be difficult to locate when inserting the hypodermic needle.
[0015] One significantly older United States patent that is discussed by Alexandre (above) is U.S. Pat. No. 2,317,648 (Siqveland) granted in 1943. In addition to the disadvantage mentioned by Alexandre, the fact that Siqveland teaches use of threaded sleeve which penetrates the bone during drilling and is left (screwed) in the bone to serve as a guide for insertion of the actual injection needle. Due to the cost of such a device, it cannot be made disposable; but more importantly, for the threaded sleeve to be securely fastened in the bone it would have to rotate at a much slower speed than the drill (as in Siqveland) or the drilling catheter (as in the present invention).
[0016] Several other U.S. patents such as U.S. Pat. No. 5,332,398 in the name of Miller, and U.S. Pat. No. 4,969,870 in the name of Kramer have followed the teaching of Siqveland wherein the catheter is at least somewhere along its outer periphery threaded, or designed to implant itself fixedly within the bone it is being disposed in; Furthermore, designs of this type require slowly turning the drilling shaft (or catheter sleeve) into the bone until resistance is encountered at which point the catheter is determined to be in place.
[0017] Over the past 50 year or so, and at least since the invention of Siqveland, patented in 1943, devices and processes for intraosseous anesthesia have been developed and refined. However, heretofore, no other inventors have provides a useful, workable convenient and inexpensive solution that affords all of the benefits provided by this invention. For example, non of the prior art devices allow a motorized handpiece to drive a small intraosseous catheter/drill having a rod/drill therein wherein the device can be placed by drilling at high or slower speeds and removed by simple withdrawal by pulling out the catheter. Most of the effort in this field had been directed toward longer term delivery of medication wherein the catheters have had some means of latching into the bone for more permanent placement. Furthermore, the instant invention does not suffer from may of the drawbacks of inserting the needle/drill into the bore being cut by the end tip of the drill, since the outside walls of the needle/drill are of a uniform diameter and non-varying. With the long-felt want of this device, in the past decade in view of the many publications in this field, no such optimal device has been suggested.
[0018] In contrast to the prior art, the instant invention provides a dual purpose perforator which includes a needle/sleeve that serves as a relatively high-speed drill bit and which serves as a catheter that is removable by withdrawing it by pulling it out, and not by unscrewing it. The perforator has a substantially uniform outer diameter and has a smooth non-threaded outer surface; preferably, the catheter is a larger gauge needle than the removable rod contained within which may also be in the form of a beveled needle for preventing bone, skin and debris from entering the catheter during entry into the bone. A hypodermic needle of same gauge as the rod is later placed in the catheter after the rod is removed.
[0019] Advantageously, the beveled end of the rod assists the cutting of the opening into the bone along with the perforator as they are both rotated by the dental hand piece they are coupled therewith.
[0020] To our knowledge, there are no prior art patents, which teach the use of a perforator having a hypodermic needle-like cutting tool wherein the outer diameter is uniform allowing both precise cutting of a small hole, and allowing easy removal by simply pulling the device out without unthreading, wherein the perforator has an upper end adapted to be connected to a motorized dental hand piece; and, wherein the perforator has a rod therein which turns with the perforator needle-like cutting tool assisting in preventing debris from entering the perforator; and wherein the rod is itself a needle-like cutting tool assisting in the cutting of the opening.
[0021] To our knowledge, aside from the parent patent application, now issued as U.S. Pat. No. 5,332,398, there are no prior art patents, which teach the use of a perforator having a hypodermic needle-like cutting tool wherein the outer diameter is uniform allowing both precise cutting of a small hole, and allowing easy removal by simply pulling the device out without unthreading, wherein the perforator has an upper end adapted to be connected to a motorized dental hand piece; and, wherein the perforator has a rod therein which turns with the perforator needle-like cutting tool assisting in preventing debris from entering the perforator; and wherein the perforator serves as a catheter for accommodating a hypodermic needle having a same outer diameter as the rod, after the catheter is inserted into the bone.
[0022] It is the belief of the inventor, that this novel method and combination of elements will eventually change the way in which many dentists infuse medication and local anesthesia.
[0023] Unlike the prior art catheters the catheter drill of the instant invention will not bind or increase its resistance against the drilling hand piece as it is drilling into the bone. The uniform outer diameter allows the drill/needle to cut without binding and acting as a self-tapping hollow screw.
SUMMARY OF THE INVENTION
[0024] The present invention endeavours to mitigate the problems and disadvantages of delivering dental anaesthetic encountered with the prior art methods and devices.
[0025] The present invention provides a perforator having a central passage, which perforator then remains in place as a catheter for allowing a hypodermic needle to be inserted through the passage to deliver the desired medication. The preferred apparatus is provided with means for obstructing the entry of debris in the perforator's passage.
[0026] In accordance with the invention, there is provided a device for perforating the periodontal ligaments, cortical plate or small bones, and the like and for injecting substances at a predetermined site, comprising:
[0027] perforator for drilling a hole into the ligament, bone or tissue, wherein said perforator is provided with an inner passage to form a catheter adapted to remain in the hole for directing a hypodermic needle to the predetermined site; and
[0028] an adapter for coupling to an end of the perforator and for latching a latching-type powered dental handpiece thereto and for transmitting rotational movement from the powered dental handpeice to said perforator, the perforator having a drilling needle extending from an end thereof, the drilling needle having a uniform outer diameter and a smooth non-varying outer surface allowing removal once inserted into the periodontal ligaments, cortical plate or small bones and the like by withdrawing the needle by pulling backwards along a line defined by a longitudinal axis of the inserted drilling needle; the adapter for coupling with the perforator in a locking engagement such that rotational motion imparted to the adapter, rotates the perforator when the adapter is coupled with the perforator, the adapter having an upper end having a driving shank extending along a rotational axis for removably engaging the powered dental hand tool, the adapter having a rod sized to be accommodated within the perforator and sized to fit into a passage in said drilling needle at a lower end thereof.
[0029] In a further aspect, the rotary drive shaft comprises an axial rod adapted to be inserted into the hollow drilling catheter when engaging it.
[0030] According to another aspect of the present invention, there is provided a device for perforating the periodontal ligaments, cortical plate of small bones, and the like, for injecting substances at a predetermined site, comprising:
[0031] a perforator for drilling a hole into the ligament, bone or tissue, wherein said perforator is provided with an inner passage to form a catheter adapted to remain in the hole perforated for directing a hypodermic needle to said predetermined site, and an adaptor for latching in a latching-type powered dental handpiece for transmitting rotational movement to said perforator, the adapter having a rod at an end thereof sized to be disposed within the perforator inner passage.
[0032] The catheterized intra-osseous delivery system of the present invention comprises a perforator with a bevelled drilling needle that is used as a drill and a catheter. The needle is attached at one end to a plastic or metal body. For drilling, the body is attached to a matching adaptor provided with a driving shank which is rotated by a conventional contra angle or straight dental hand piece. Then, the perforator is used as a catheter, whereby a hypodermic needle is inserted through the drilling needle without losing access to the already perforated bone.
[0033] In the preferred form of the invention the apparatus is disposable. Before disposal, the perforator receives a cap over the needle for protection against accidental contamination of environment.
[0034] The present invention also provides a method of medical treatment, comprising the steps of: inserting a catheter, at a point in the gingival sulcus between outer tooth surface and marginal gingiva, or through gingiva and cortical plate, to a predetermined depth; and injecting medication or anaesthesia through said catheter.
[0035] Advantageously, the system of the present invention provide users with a more secure and less painful method and device for direct access for injecting medication to a target area into the cortical plate of the bone.
[0036] In addition, the system facilitates and adds a level of security previously unavailable for the anaesthetic in that it has a sure and immediate effect.
[0037] Another advantage of this system is that it provides benefits to the dentists by facilitating the use of a low cost, disposable device.
[0038] Still another advantage of this invention is that the risk of contamination is lower than with the current devices. This is because the device is disposable and because the risk of the dental equipment used with the device of the invention becoming contaminated is low.
BRIEF DESCRIPTION OF THE DRAWINGS
[0039] These and other features of the invention will become more apparent from the following description of the preferred embodiments, in which reference is made to the appended drawings, wherein:
[0040] [0040]FIG. 1 illustrates an exploded view of the device showing the component parts and their inter-relationship;
[0041] [0041]FIG. 2A illustrates the device assembled for drilling;
[0042] [0042]FIG. 2B Illustrated a longitudinal cross-section through the device illustrated in FIG. 2A, taken along line A-A of FIG. 2A;
[0043] [0043]FIG. 3 shows a detailed view of the area marked on FIG. 2B;
[0044] [0044]FIG. 3B shows a detailed view of the rod-needle inserted in the perforator cutting/drilling-needle inserted in a different orientation than in FIG. 3;
[0045] [0045]FIG. 4 is a cross-sectional view of the body of the perforator taken along lines B-B of FIG. 2;
[0046] [0046]FIG. 5 is a cross-sectional view of the adaptor body;
[0047] [0047]FIG. 6 is a cross-sectional view of the cap;
[0048] FIGS. 7 A- 7 C illustrate the method according to the invention, FIG. 7A shows the device drilling, in the bone tissue; FIG. 7B shows the perforator inserted into the bone tissue and the adaptor de-coupled; and FIG. 7C shows the perforator inserted into the bone tissue as a catheter and a hypodermic needle set for delivering an injection;
[0049] [0049]FIG. 8 illustrates another embodiment of the invention;
[0050] [0050]FIG. 9 illustrates an alternative method of delivery medication to treat a root-canal nerve;
[0051] [0051]FIG. 10 illustrates from a plan view the point of catheter insertion for the alternative method shown in FIG. 9;
[0052] [0052]FIG. 11 is a perspective, exploded view of the parts of an alternative embodiment of the invention wherein the catheter and adapter can be temporarily locked while drilling occurs;
[0053] [0053]FIG. 12 is a sectional elevation of the same catheter assembly; and,
[0054] [0054]FIG. 13 is a plane view of an additional, optional component of the assembly.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0055] [0055]FIG. 1 illustrates an exploded view of the device showing the component parts and their inter-relationship. The device comprises a perforator 1 , an adaptor 3 and a cap 5 .
[0056] The perforator 1 has a bevelled drilling needle 7 which is used both as a drill and a catheter. Needle 7 is bevelled at both ends, as better shown on FIG. 2B. The first end 9 is formed as a drilling tip in that it has cutting teeth along the edge, as shown in FIG. 3. The second end 11 is bevelled for receiving and directing the needle of a hypodermic syringe and for easy coupling with the adaptor 3 , as will be seen later.
[0057] A flange 13 is fixed on the needle about the second end 11 , so that the needle passes along the geometrical axis of the flange 13 . The flange 13 is manufactured or moulded of a plastic or other material, and it has a generally cylindrical outer shape. This shape is preferred as the flange 13 rotates together with the needle 7 for drilling. Variations of the shape illustrated in the attached drawings may also be contemplated.
[0058] The flange 13 is adapted for receiving cap 5 at one end and for coupling with the adaptor 3 at the other end. As an example, a collar 15 may be provided on the flange 13 so that the cap 5 holds over the collar 15 when pressed. The cap 5 is needed to protect and cover the tip 9 of the needle 7 before use and when the device is disposed of.
[0059] For ease of manipulation the internal diameter of the cap 5 and the external diameter of the collar 15 should be as large as is reasonable and preferably between 10 to 20 times greater than the diameter of the needle 7 . Another advantage of the collar 15 is that it provides a stop to limit the depths of penetration of the needle 7 (the depth of penetration of the needle 7 is, therefore, termed the drilling length, as opposed to the remaining length of the needle 7 , which is termed the attachment length). The flange 13 is shaped to form an inner axial shaft 17 projecting from the centre of the collar 15 , and a female connector 19 for coupling with a corresponding male connector provided in the adaptor 3 .
[0060] The coupling between the perforator and the adaptor is illustrated on FIGS. 2B, 4 and 5 . FIG. 2B shows a longitudinal section of a female connector 19 provided in the flange 13 and a male connector 21 provided in the adaptor 3 . FIG. 4 illustrates a cross-section of an exemplary female connector 19 , while FIG. 5 shows a cross-section of the corresponding male connector 21 . The male connector is provided with radial ribs 23 , extending towards the centre but not meeting to leave room for the central shaft 17 , while corresponding grooves 25 are provided in the female connector, alternating with islands 20 . The female connector is also formed with a clearance ring 22 for accommodating the thickness of the body 29 of the adaptor.
[0061] The tubular shaft 17 forms a reinforced passage for drilling needle 7 . The shaft also provides enough contact surface between the drilling needle and the body to ensure that these two parts rotate together during drilling. As could be seen on FIG. 2B, end 11 of the needle is bevelled and extends a little over the shaft 17 , but there is a clearance between the tip of end 11 and the male connector when the device is assembled for drilling.
[0062] When rotated, the drilling needle 7 penetrates in the bone tissue through gingiva or ligament and drills a hole with the cutting tip 9 . The perforator 1 may remain in place as a catheter, with the drilling needle inserted into the bone. Then, a hypodermic needle may be introduced through the passage of drilling needle 7 to inject a medicament directly into the bone. Therefore, the drilling needle 7 is selected to have a wide enough passage for allowing a hypodermic needle with a smaller gauge to be inserted through needle 7 .
[0063] The adaptor 3 has several important functions. Firstly, the adaptor conveys the rotational movement from a dental hand piece or the like to the perforator. As well, the adaptor is provided with means for blocking bone debris for entering into the syringe passage and also aligns and reinforces the needle 7 during drilling. In the preferred embodiment of this invention is it important that the adapter be coupled with the dental hand tool which dives the adapter about its longitudinal axis. It is also important that the adapter conveys its rotational movement from the dental hand piece to the perforator 3. By providing this novel arrangement, after the perforator is inserted into the bone, where it is to remain, all that is required is that the adapter with the dental handpiece be removed from the perforator. Hence the order of dental hand piece driving the adapter including the rod 27 which in turn drives the perforator and its drilling needle is important in the preferred embodiment.
[0064] The adaptor includes a rod 27 , a body 29 and a shank 31 .
[0065] Body 29 includes male connector 21 which is formed, as indicated above, with longitudinal ribs 23 which couple with grooves 25 of the female connector 19 for driving needle 7 . The shank 31 extends along the axis of the adaptor and is formed with a joint 33 for attachment with a contra-angle or straight hand piece. The shank 31 has a groove 35 and a cut-out 37 to fix the shank in place in the known manner. Generally, the shank transmits to the needle 7 the rotational movement from the hand piece.
[0066] The shank 31 also acts as a barrier for contamination, at it is generally thought that bacteria is reluctant to change direction, and there are a plurality of 90° angles between the tip 9 of drilling needle 7 and the joint 33 .
[0067] The rod 27 has the diameter and length selected in accordance with the size of needle 7 . The rod 27 is fixed in the geometrical centre of body 29 so as to readily penetrate into the hollow passage of the needle, when the device is assembled for drilling. When the rod 27 is inserted within the needle passage, it advances through the length of the needle up to the bevelled end, as shown on FIGS. 2A and 3 and 3 B in dotted lines. In this way, the debris from drilling cannot penetrate to block the needle passage. In addition, the rod gives additional rigidity, strength and alignment to needle 7 during drilling. The rod also Advances through the a portion of the shank as is illustrated in FIG. 2B in dotted lines. Furthermore, the rod which can itself be in the form of a needle similar to the hypodermic needle for delivery of medication, wherein the rod end is sharp and pointed, to assist in the drilling process. By using standard hypodermic needle tubing for the rod, the cost of the device can be minimized while gaining the benefit of the cutting tip. In manufacture, the cutting tip of the drilling needle 7 and the rod can be cut at the same time to a desired length.
[0068] [0068]FIG. 8 illustrates an alternative embodiment of the present invention. In this variant, body 13 is provided with an internal thread while body 29 is provided with a matching external thread. By threading one to the other and using the central rod 27 to align the two bodies together, the perforator could be driven by the hand piece in a similar manner as in the variant disclosed above. Of course, the thread is going in an opposite direction to the direction of rotation of the device for avoiding disconnection of the two bodies.
[0069] An alternative method of targeted delivery is shown in FIGS. 9 and 10. The perforator 7 is inserted at a point 30 between teeth, parallel to the tooth 31 in treatment, and penetrates through gingival sulcus 32 and ligament 33 to a depth near the entry of the nerve, artery and vein bundle 34 through the bone 35 and into the tooth-root canal 36 . This method of targeted delivery, say, of anaesthesia is suitable, where perforating vertical to the tooth through gingiva and cortical bone is not convenient or possible; as in the case of rear molars.
[0070] There are a variety of ways that this invention can be devised but the end result is to perform catheterized intra-osseous delivery system.
[0071] The device of this invention operates as follows:
[0072] First, a site for the injection is selected by the practitioner. The gingiva over the injection side is disinfected and topically anaesthetized. A small amount of anaesthetic solution is injected until blanching of the tissue, and this will anaesthetize the gingiva and the periosteum. The following operations are illustrated in FIGS. 7A, 7B and 7 C, and FIGS. 9 and 10.
[0073] As can be seen in FIG. 7A, the bevelled end 9 of the needle 7 is placed against the gingiva and shank 31 is attached with joint 33 to a contra angle or to a straight dental hand piece. The adaptor and perforator are coupled for drilling.
[0074] The perforator should be held perpendicular to the cortical plate, or if not possible or convenient, it should be held vertical and parallel to the long axis of the tooth as shown in FIG. 9, having been inserted between teeth as shown in FIG. 10. The perforator is then operated in small bursts of rotation from the hand piece until resistance is no longer felt, as is well known to dentists.
[0075] Next, the adaptor 3 is removed from the engagement with perforator 1 by applying pressure to the body 13 with the fingers thus keeping the needle 7 in the perforated cortical plate. This is shown in FIG. 7B.
[0076] The presence of the needle 7 in the cortical plate, or down the side of the tooth as in FIG. 9, allows an injection to be made without complicated manoeuvres to find the perforation in the case of floating gingiva or the free or marginal gingiva. FIG. 7C illustrates the next step, namely how the injection needle is inserted through the perforator 1 for delivering the anaesthetic solution required.
[0077] The last step is to remove the perforator 1 from the cortical plate and reinstall the cover cap 5 over the needle 7 , then insert the adaptor to the perforator making the unit complete and disposable. The cap 5 provides a means whereby the apparatus may be removed from the dental hand piece without any risk of the user being in contact with body fluids which will be present on the needle after use. This is extremely important particularly since there may be a risk of contacting Aids or Hepatitis should the user accidentally prick a finger with the needle. It is therefore desirable that the cap should be of a hard or rigid rubber or plastic material not easily penetrated by the needle. Referring to FIG. 11 and 12 , the catheter assembly comprises a disposable contamination protective cap or housing 10 which, in the assembled state, surrounds a hollow drilling needle or catheter 11 , preferably of stainless steel, having a drilling tip 12 and a non-drilling end with an outwardly flaring end portion 13 . The end portion is fixed, and preferably molded, within a cylindrical driven flange 14 which is made of plastic material and is disposable along with the needle.
[0078] The flange is adapted bo be driven by the drive means including a drive flange 16 which has a periphery matching radius of the flange 14 , and which is integrally formed with a shaft 17 suitably dimensioned to fit into the handpiece of a standard dental drill; the diameter of this shaft being preferably between 2.27 and 2.45 mm. Parts 16 and 17 may either be metal or plastic, and will also normally be considered disposable. The flange 16 and shaft 17 have an axial bore into which is secured a rod 20 having a cutting tip (not shown) which projects from the flange 17 by an amount equivalent to the main drilling length of the needle 11 , and which prevents the needle from becoming blocked with debris during operation.
[0079] The driven flange 14 and the drive flange 16 each have a longitudinal groove, indicated respectively at 14 a, 16 a. When all the parts are assembled, these grooves are occupied by a longitudinal internal rib 21 in the cylindrical wall of the a locking sleeve 22 . This is a thin-walled, disposable cap-type part, the cylindrical wall of which is capable of substantially enclosing the two flanges 14 and 16 , and having an upper end flange 22 a which, when the sleeve is fully engaged with the two flanges 14 and 16 , rests against the upper surface of the flange 16 . The sleeve 22 serves to hold the flanges together, as well as transmitting rotary motion from the drive to the driven flange. The sleeve is a push fit within the housing 10 .
[0080] The parts are sold in the assembled condition as shown in FIG. 12. For use the housing 10 is removed, the shaft 17 is fitted into a drilling machine, and a drilling proceeds in the normal way. After drilling, the shaft 17 with flange 16 , and rod 20 and sleeve 22 , are removed from the flange 14 , and anaesthetic is then introduced through the needle 11 which then acts as a catheter.
[0081] All parts of the assembly are disposable after use.
[0082] [0082]FIG. 13 shows a further feature of this embodiment, namely a holder 30 which comprises a rod 30 a fixed at one end to part circular clip portion 30 b which is formed to encircle a circumferentially grooved central area 14 b of the flange 14 . This holder may be placed in position to hold the flange 14 after drilling has taken place, with its rod 30 a lying along side of the patients mouth and preventing undesirable movement of the flange 14 during the injection step.
[0083] In summary, this invention provides particular advantages not suggested in prior art devices. The provision of an adapter piece having a rod at a lower end, a shaft at an upper end for coupling with a motorized dental handpeice, and an intermediate hub disposed between the rod and the shaft wherein the hub has means for locking with a catheter having a drilling needle provides numerous advantages. The drilling needle has a uniform outer diameter and can be withdrawn by simply pulling it out. The adapter is designed to prevent the drilling needle from becoming blocked during drilling and is designed to turn the drilling needle when powered by the handpeice. More importantly, when the catheter has drilled the hole in the bone, the adapter can be removed with the handtool leaving the catheter in place.
[0084] Numerous other embodiments can be envisaged without departing from the spirit and scope of the invention. For example, the end of the rod can be provided with a cutting tip assisting the cutting needle in drilling the hole. Furthermore, the rod itself can be a square rod for engaging a complementary recess in the catheter opening. This embodiment would allow the device to function even if the rod was partially extracted during the drilling of the hole as any portion of the square rod could be used to drive the cutting needle.
[0085] Another embodiment this invention provides an automatic delivery of fluid or medication to the catheter. Here, a medication injection device comprises a housing for grasping by an operator, wherein the housing has a distal end; a rotatable hollow drill bit mounted to the distal end of the housing, wherein the drill bit includes a bore therethrough, and wherein the drill bit is suitable for intraosseous drilling; means disposed in the housing for rotating the drill bit; and fluid dispensing means including a fluid reservoir stationarily mounted in the housing and means for supplying a controlled dose of medication fluid for intraossaous injection through the bore of the drill bit. Yet still further, a removable rod is inserted into the drill bit for preventing material from blocking the catheter. In order to prevent debris from entering the drilling needle, a solid or hollow rod is disposed within the drill bit which is spring loaded in the head of the housing opposite the drill bit. The rod under spring tension is removed by removing a cap on the head of the handpiece.
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Apparatus and method for catheterized delivery or infusion of medication and anaesthesia are disclosed. The perforating catheter is first used to perforate the periodontal ligament and/or the cortical plate of bone tissue, and is then left in place and used as a catheter for insertion of a hypodermic needle of smaller gauge to deliver medication or anaesthesia to a target area. The perforator is a bevelled needle for drilling into the ligament or bone tissue. For drilling, the device comprises an adaptor which transmits the rotational movement from a dental hand piece or the like to the bevelled needle. A cap is also included for protecting the bevelled needle during storage of the device. The adaptor may have a rod which extends axially into the bevelled needle when the device is assembled for drilling. The rod is used to prevent the debris resulting from drilling from blocking the passage in the bevelled needle. As well, the rod reinforces the needle and maintains the alignment between the perforator and the adaptor for improved drilling efficiency.
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BACKGROUND OF THE INVENTION
1. Technical Field
The present invention relates in general to telecommunications, and in particular to cellular phones. Still more particularly, the present invention relates to performing proximity based routing of a cellular phone call.
2. Description of the Related Art
Cellular (cell) phones have become a ubiquitous aid in allowing a person to be constantly accessible. However, there are times when a person may not desire, or may be unable, to take an incoming call.
SUMMARY OF THE INVENTION
A method, system, and computer program for routing an incoming voice call in real time is presented. A call is received from a caller to an intended receiving wireless telecommunication device. In response to the call failing to connect to the intended receiving wireless telecommunication device, a short range wireless query signal is transmitted to determine if another wireless communication device is within a predefined proximity to the intended receiving wireless telecommunication device. If the intended receiving wireless telecommunication device receives a response from the other wireless telecommunication device indicating that the other wireless telecommunication device is within the predefined proximity to the intended receiving wireless telecommunication device, then the call is rerouted to the other wireless telecommunication device.
The above as well as additional objectives, features, and advantages of the present invention will become apparent in the following detailed written description.
BRIEF DESCRIPTION OF THE DRAWINGS
The novel features believed characteristic of the invention are set forth in the appended claims. The invention itself, however, as well as a preferred mode of use, further objects and advantages thereof, will best be understood by reference to the following detailed descriptions of an illustrative embodiment when read in conjunction with the accompanying drawings, wherein:
FIG. 1 is a block diagram of a data processing system in which the present invention may be implemented;
FIG. 2 . is a block diagram of an exemplary system for routing a phone call; and
FIG. 3 . is a high-level logical flowchart of an exemplary set of steps performed to re-route a phone call.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
With reference now to FIG. 1 , there is depicted a block diagram of an exemplary computer 102 in which the present invention may be implemented. Computer 102 includes one or more processors 104 that are coupled to a system bus 106 . A video adapter 108 , which drives/supports a display 110 , is also coupled to system bus 106 . System bus 106 is coupled via a bus bridge 112 to an Input/Output (I/O) bus 114 . An I/O interface 116 is coupled to I/O bus 114 . I/O interface 116 affords communication with various I/O devices, including a keyboard 118 , a mouse 120 , a Compact Disk-Read Only Memory (CD-ROM) drive 122 , a floppy disk drive 124 , and a flash drive memory 126 . The format of the ports connected to I/O interface 116 may be any known to those skilled in the art of computer architecture, including but not limited to Universal Serial Bus (USB) ports.
Computer 102 is able to communicate with a software deploying server 150 via a network 128 using a network interface 130 , which is coupled to system bus 106 . Network 128 may be an external network such as the Internet, or an internal network such as an Ethernet or a Virtual Private Network (VPN). Note the software deploying server 150 may utilize a same or substantially similar architecture as computer 102 .
A hard drive interface 132 is also coupled to system bus 106 . Hard drive interface 132 interfaces with a hard drive 134 . In a preferred embodiment, hard drive 134 populates a system memory 136 , which is also coupled to system bus 106 . System memory is defined as a lowest level of volatile memory in computer 102 . This volatile memory includes additional higher levels of volatile memory (not shown), including, but not limited to, cache memory, registers and buffers. Data that populates system memory 136 includes computer 102 's operating system (OS) 138 and application programs 144 .
OS 138 includes a shell 140 , for providing transparent user access to resources such as application programs 144 . Generally, shell 140 is a program that provides an interpreter and an interface between the user and the operating system. More specifically, shell 140 executes commands that are entered into a command line user interface or from a file. Thus, shell 140 (also called a command processor) is generally the highest level of the operating system software hierarchy and serves as a command interpreter. The shell provides a system prompt, interprets commands entered by keyboard, mouse, or other user input media, and sends the interpreted command(s) to the appropriate lower levels of the operating system (e.g., a kernel 142 ) for processing. Note that while shell 140 is a text-based, line-oriented user interface, the present invention will equally well support other user interface modes, such as graphical, voice, gestural, etc.
As depicted, OS 138 also includes kernel 142 , which includes lower levels of functionality for OS 138 , including providing essential services required by other parts of OS 138 and application programs 144 , including memory management, process and task management, disk management, and mouse and keyboard management.
Application programs 144 include a browser 146 . Browser 146 includes program modules and instructions enabling a World Wide Web (WWW) client (e.g., computer 102 ) to send and receive network messages to the Internet using HyperText Transfer Protocol (HTTP) messaging, thus enabling communication with software deploying server 150 .
Application programs 144 in computer 102 's system memory (as well as software deploying server 150 's system memory) also include a Call Routing Logic (CRL) 148 . CRL 148 includes code for implementing the processes described in FIGS. 2-3 . In one embodiment, computer 102 is able to download CRL 148 from software deploying server 150 , including in an “on demand” basis, as described in greater detail below in FIGS. 2-3 .
The hardware elements depicted in computer 102 are not intended to be exhaustive, but rather are representative to highlight essential components required by the present invention. For instance, computer 102 may include alternate memory storage devices such as magnetic cassettes, Digital Versatile Disks (DVDs), Bernoulli cartridges, and the like. These and other variations are intended to be within the spirit and scope of the present invention.
Note further that, in a preferred embodiment of the present invention, software deploying server 150 performs all of the functions associated with the present invention (including execution of CRL 148 ), thus freeing computer 102 from having to use its own internal computing resources to execute CRL 148 .
Note also the architecture shown in FIG. 1 for computer 102 may be substantially implemented in Caller Telecommunication Device (CTD) 202 , Host Carrier 204 , Intended Recipient Wireless Telecommunication Device (IRWTD) 206 , Proximate Telecommunication Devices (PTDs) 208 a - n , and computer 210 shown below in FIG. 2 . That is, although CTD 202 , IRWTD 206 and PTDs 208 a - n are described as cellular phones, by including a wireless transceiver 152 in the architecture of computer 102 , the appropriate elements illustrated as components of computer 102 can operate as a “smart” phone that communicates with a host carrier (e.g., host carrier 204 shown below in FIG. 2 ).
With reference now to FIG. 2 , a block diagram of the routing system used in an exemplary embodiment of the present invention is presented. A Caller Telecommunication Device (CTD) 202 (e.g., a cell phone, a Plain Old Telephone System (POTS) land line, a cell-capable Personal Assistant Device (PDA), etc.) connected to Host Carrier 204 initiates a voice call to an Intended Recipient Wireless Telecommunication Device (IRWTD) 206 . Host Carrier 204 is a remote service host such as a cellular service provider that is remotely connected to both CTD 202 and IRWTD 206 . If IRWTD's 206 ringer is “on”, and thus the called user is available, the voice call will be connected. As described below, however, in the present invention, several options are available for routing the voice call if IRWTD's 206 ringer is “off” or if the user of the IRWTD 206 is otherwise unavailable.
When the user of IRWTD 206 is unavailable or IRWTD's 206 ringer is “off,” a first routing option is for the caller who is using CTD 202 to leave a voicemail message, which will be retrievable when IRWTD 206 is either turned back on or the user becomes available. Using preferences established on software (e.g., CRL 148 depicted in FIG. 1 ) of CTD 202 and/or IRWTD 206 , when IRWTD 206 is unavailable to receive an incoming call from CTD 202 , additional options are available to reroute the voice call to a selected one of the Proximate Telecommunication Devices (PTDs) 208 a - n (where “n” is an integer), or to send a text notification to a Computer 210 .
When it is desired (according to predetermined preferences set by the user of IRWTD 206 ) that rerouting of an incoming voice call is preferred to a text notification, CTD 202 routes the incoming voice call to a phone selected from PTDs 208 a - n according to a contact list 207 located within IRWTD 206 . This is accomplished using software internal to IRWTD 206 (e.g., CRL 148 ) that autonomously utilizes a hardware based wireless technology internal to IRWTD 206 , such as a short-range radio or infrared signal, to determine if any PTDs 208 a - n within a contact list 207 (stored within IRWTD 206 ) are within a physically proximate short range of IRWTD 206 , and are available to receive the incoming voice call. Optionally an unlicensed secure wireless personal area network (PAN), may be implemented for wireless transmission. The short range of the device is the maximum range of communication available between IRWTD 207 and one or more of the PTDs 208 a - n without the use of a network carrier service (e.g., a cell phone carrier service), and is further determined by the internal wireless technology common to IRWTD 206 and PTD 208 . If one of the PTDs 208 a - n is in close proximity to IRWTD 206 , and is available to receive a call, the voice call is routed directly to one of the PTDs 208 a - n in proximate range. If more than one of the PTDs 208 a - n is in range, software internal to IRWTD 206 (e.g., CRL 148 ) allows a user to select the desired recipient (from PTDs 208 a - n ) of the voice call, or to automatically route the voice call based on information preferences internal to IRWTD 206 and the target PTDs 208 a - n , in addition to usage information, such as battery strength or signal strength. That is, self-monitoring processes controlled by CRL 148 within IRWTD 206 and/or PTDs 208 a - n determine which of the PTDs 208 a - n is a best candidate for receiving the re-routed phone call, based on which user is associated with a particular PTD 208 , what the current battery strength of a particular PTD 208 is in present time, etc.
If the re-routing of the voice call from IRWTD 206 to one of the PTDs 208 a - n should fail, software (e.g., CRL 148 ) internal to CTD 202 and IRWTD 206 determines if another routing attempt should be made. Preferences in CTD 202 and IRWTD 206 software can be utilized to limit call routing attempts to a specific number. For example, if routing of the call from the IRWTD 206 to one of the PTDs 208 a - n fails after trying to re-route the call to three different PTDs from PTDs 208 a - n , then a voicemail may be left for IRWTD 206 (i.e., a voicemail may be stored with the host carrier 204 ).
Software (e.g., CRL 148 ) internal to CTD 202 , IRWTD 206 , PTDs 208 a - n allows a user to establish additional preferences related to the call routing. These preferences can be stored on CTD 202 , IRWTD 206 , PTDs 208 , and/or on Host Carrier 204 . Some examples of such preferences include routing lists as well as preferences regarding battery strength or signal strength. Routing lists may be organized based on the priority of the contacts as determined by the end user. Routing lists may contain contacts that calls should always or never be routed to, or lists that enable the device to automatically accept or decline incoming routing attempts from specific contacts or groups of contacts known or unknown to the device. For example, a routing preference (which in one embodiment is set by the user of IRWTD 206 ) may state that if a call comes from “Caller A” (as identified by a caller identification associated with the incoming call), then that call should be sent to PTD 208 a or 208 b , but never to PTD 208 n . Preferences within CTD 202 , IRWTD 206 , PTDs 208 a - n also allow a user to automatically re-route calls when battery life in IRWTD 206 and/or an initial one of the PTDs 208 a - n is low, or when a weak signal is detected. For example, one of the preferences may state that if IRWTD 206 detects that PTD 208 a has a low battery and/or a weak signal, then other PTDs 208 b - n are polled until one of sufficient battery and signal strength (as well as authorization) is located. The call will then be automatically re-routed to the PTD 208 that meets the requisite conditions (e.g., strong battery, strong signal strength with the IRWTD 206 , authorized to take the call from “Caller A,” etc.)
Additionally, software (e.g., CRL 148 ) internal to PTDs 208 a - n may enable the PTDs 208 a - n to differentiate a re-routed voice call from a normal voice call by utilizing unique aural, visual, or tactile signals to the user. PTDs 208 a - n may audibly signal the user of an incoming re-routed voice call by using methods such as playing a unique sound effect or a specific ring tone. PTDs 208 a - n may visually signal the user of an incoming re-routed voice call by using methods such as flashing a specific service light color or pattern of colors, or by displaying caller identifying information of CTD 202 and IRWTD 206 on the screen. PTD 208 a - n may also use a vibration function or a specific vibration pulse pattern to signal the user of an incoming re-routed voice call. Thus, these unique aural and/or visual cues alert a user of one of the PTDs 208 a - n that the incoming call was intended for the user of IRWTD 206 , but has been re-routed to the user of that PTD 208 . Therefore, when the user of that PTD 208 answers the call, he will be forewarned that the caller is likely to be expecting the user of IRWTD 206 to have answered the call.
When user input or preferences internal to CTD 202 or IRWTD 206 specify that call routing is not desired, a text notification message with critical information concerning the incoming call can be transmitted to computer 210 . This text based message may or may not be used in conjunction with a voice mail message that is left and stored on the host carrier 204 as described above. The text notification message contains information such as a phone number and contact information for CTD 202 and IRWTD 206 , as well as date and time stamp information of the voice call. Additionally, utilizing voice-to-text software common to CTD 202 , IRWTD 206 , and/or computer 210 , the user may choose to leave a text notification message containing a voice-to-text translation of a voice message left by the user (and stored with host carrier 204 ). Computer 210 is a telecommunication device, a personal computer, or a combination of any number of telecommunication devices or personal computers. The text notification message can be presented in such means as an e-mail, an instant message, a short message service (SMS) message, or as posted text on an internet portal.
With reference now to FIG. 3 , a high-level logical flowchart of an exemplary set of steps performed to route a phone call is presented. After initiator block 300 , a voice call is initiated from a Caller Telecommunication Device (CTD) to an Intended Recipient Wireless Telecommunication Device (IRWTD) (block 302 ). It is then determined by the Host Carrier if the IRWTD is available (block 304 ). If IRWTD is available, the call is picked up and the process ends at terminator block 330 . When IRWTD is not available, a user input or software common to the CTD and the IRWTD identifies a user's preference for the type of routing desired, if a text notification message is to be generated, assuming that rerouting and/or processing of the voice call is desired and appropriate (block 306 ).
As shown at query block 306 , if a text notification message for the incoming call is desired, based on user input and preferences internal to the CTD and the IRWTD, the IRWTD determines if any preferred Proximate Telecommunication Devices (PTDs) are within am predefined proximity of the IRWTD (block 308 ). The term “predefined proximity” is defined as the distance between the IRWTD and a PTD in which local wireless communication is possible without the use of an intervening network or carrier. That is, the term “predefined proximity” is defined as a distance within which the IRWTD and PTD can directly communicate using local electromagnetic signals (including radio, infrared, secure PAN, etc.) to directly communicate between one another.
A text notification message contains a date stamp, a time stamp, caller information, intended recipient contact information, and/or a voice-to-text message. This text notification message is sent to any preferred PTDs in proximate range of IRWTD and/or one or more remote computers as determined by software internal to IRWTD (block 310 ). The process terminates at block 330 .
Returning to query block 306 , if voice call rerouting is desired (instead of or in addition to creating the text message describe above), based on user input and preferences internal to the CTD and the IRWTD, the IRWTD determines if any preferred Proximate Telecommunication Devices (PTDs) are within the predefined proximity (as defined above) to the IRWTD (query block 312 ). If no preferred PTD(s) are within the predefined proximity to IRWTD, a voicemail is left with the host carrier for the IRWTD (block 314 ). The process terminates at block 332 .
Returning to query block 312 , if a preferred PTD(s) is within physical proximity to the IRWTD, the IRWTD next determines if a first PTD is available (block 316 ). PTD priority is determined by preferences internal to the CTD, the IRWTD, and the PTD, and can also be determined by factors such as signal strength and battery strength within one or more of these devices. If the first PTD is available the voice call is routed to that first PTD (block 318 ), and the process terminates at block 332 . However, if the first preferred PTD is unavailable, then software internal to the IRWTD and the CTD determines if the maximum call routing attempts have been made (block 320 ). If another call route attempt is desired based upon user input, and the number of routing attempts performed is still less than the maximum allowed, then the process loops back to query block 312 in an iterative manner to determine if there are other PTD devices in proximity to the IRWTD (block 312 ). If another call route attempt is not to be performed (i.e., the number of authorized attempts has been reached), then a voicemail is left with the IRWTD (block 322 ), and the process terminates at block 332 .
Although aspects of the present invention have been described with respect to a computer processor and program application/logic, it should be understood that at least some aspects of the present invention may alternatively be implemented as a program product for use with a data storage system or computer system. Programs defining functions of the present invention can be delivered to a data storage system or computer system via a variety of data storage media, which include, without limitation, non-writable storage media (e.g. CD-ROM), and writable storage media (e.g. network attached storages, hard disk drive, read/write CD-ROM, optical media). It should be understood, therefore, that such data storage media, when storing computer readable instructions that direct method functions of the present invention, represent alternative embodiments of the present invention. Further, it is understood that the present invention may be implemented by a system having means in the form of hardware, software, or a combination of software and hardware as described herein or their equivalent.
Having thus described the invention of the present application 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.
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A method, system, and computer program for routing an incoming voice call in real time is presented. A call is received from a caller to an intended receiving wireless telecommunication device. In response to the call failing to connect to the intended receiving wireless telecommunication device, a short range wireless query signal is transmitted to determine if an other wireless communication device is within a predefined proximity to the intended receiving wireless telecommunication device. If the intended receiving wireless telecommunication device receives a response from the other wireless telecommunication device indicating that the other wireless telecommunication device is within the predefined proximity to the intended receiving wireless telecommunication device, then the call is rerouted to the other wireless telecommunication device.
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FIELD OF THE INVENTION
This invention relates to a fluid flow control device. It may be used to control the flow of liquids or gases and may, for example, be used to provide velocity control of high pressure flowing fluids. Devices of this general type are sometimes known as variable fluid restrictor control values, and are exemplified by Self U.S. Pat. Nos. 3,451,404 and 3,514,074 which have frictional passageways, and by Self U.S. Pat. No. 3,513,864 which has multiple abrupt, angular turn passageways.
BACKGROUND OF THE INVENTION
In the handling of flowing high pressure fluids, it has been customary to utilise orifice means having a high velocity short throat section to attain energy losses or high pressure drops. If the fluid is in a liquid state and liable to flash, that is, vaporise or turn to a gaseous condition on the downstream side of the orifice or valve opening, it may condense implosively and induce damaging shock waves, cause erosion, and the like. Also, as the velocity of the fluid in the valve exceeds the velocity of the fluid in the line, several disturbing reactions occur. A most serious problem is rapid erosion of the valve surfaces by direct impingement of the liquid and any foreign particle suspended therein. Additional erosion results from cavitation. Cavitation may be defined as the high speed implosion of vapour against those internal parts of the valve controlling flow (the valve trim) and the valve body.
In addition to the severe problems resulting from erosion, the increased velocity also causes the flow characteristics of the valve to become unpredictable and erratic.
Other problems created by the high fluid velocity in the valve are severe noise generation, trim fatigue and possible degradation of flowing fluid materials such, for example, as polymers.
Fluid-borne noise downstream of control valves is often very high. If not treated or contained with the pipe, this noise can result in sound pressure levels of 110 to 170 dB three feet from the valve exit. Sound sources of this magnitude are hazardous to personnel and frequently result in complaints from local residents.
Mufflers and silencers can typically only attenuate fluid-borne noise 20 to 30 dB. Therefore, only partial success has been achieved with them in obtaining desired sound pressure levels.
Furthermore, a typical path treatment system ie, the muffler, lagging support structure etc is very cumbersome and expensive, often, the total cost of path treatment for noise can exceed the valve cost many times over.
In order to overcome or ameliorate the above problems, there have been introduced devices which effect energy losses in high pressure fluids without increasing velocity and shock wave reaction by sub-dividing the flow into a plurality of small, long passageways with abrupt turns creating friction and pressure drop in the fluid, thus avoiding damage and erosion in the equipment. Such a device is disclosed, for example, in U.S. Pat. No. Re. 32,197. There, the passageways are provided in an annular stack of separate members having abutting faces enclosing a plurality of individual passageway grooves which are angular between the inlet and outlet of the stack to turn the fluid and to provide a substantially longer flow length than between the inlet and outlet ends of the stack. The stack is mounted in the fluid passage of a valve housing and a valve plug movable within the annular structure controls the number of passageways in the stack through which the fluid can flow.
A modified device of this type is disclosed in GB-A-2,273,579 in which at least one passageway in the stack of members of discs includes a void between the inlet and outlet region of the disc, the void expanding the cross-sectional area of the energy loss passageway.
Valves incorporating a flow control device including a stack of discs having energy-loss passageways have become very successful commercially and it is an object of the present invention to provide an improvement in devices of this type.
SUMMARY OF THE INVENTION
According to the invention a fluid flow control device comprises a plurality of pairs of annular discs forming a rigid structure which incorporates a series of substantially radial passageways for fluid flow,
each disc of said pair having passageways therein which extend only partially through said disc in a radial direction,
the pair of discs being aligned with one another such that the passageways in one disc interconnect with the passageways in the other disc of the pair so as to provide for fluid flow through the pair of discs.
The invention further provides a fluid flow control device comprising a plurality of discs forming a rigid structure which incorporates a series of passageways for fluid flow, the discs having abutting surfaces and passageways therebetween for fluid flow, inlet means formed in said discs to define a predetermined inlet area for conducting fluid to the series of passageways formed by said rigid structure, outlet means associated with said inlet means to provide a series of openings for exhausting fluid from the passageways, and wherein at least one of the passageways is of smaller cross-section in a mid-region of its respective discs and increases in cross-section from said mid-region towards the inlet and towards the outlet region of said discs.
The invention also provides a pair of discs for incorporation in a structure as defined in the immediately preceding paragraph, each disc containing a radially-extending series of holes through its thickness, and the series of holes being different in the two discs, so that the discs may be superimposed with their holes overlapping, the overlapped holes providing radial flow passageways through the superimposed pair of discs, wherein the passageways are of smaller cross-section in a mid-region of the discs and increasing in cross section from said mid-region towards the centre and towards the outer peripheries of the discs.
The discs may be annular and the passageways increase in cross-section from the mid-region of the annuli towards their inner and outer peripheries.
The discs of the superimposed pair may be identical so that each disc comprises at least two different radially-extending series of holes and the discs are rotated relative to each other so that a first series of holes of one disc is superimposed on a second series of holes of the other disc and vice versa.
Each adjacent pair of discs in a stack of discs may be provided with a flow passageway having the smaller cross-section in the mid-region or, if desired, the invention may be applied to a proportion only of the discs in the structure.
The discs are preferably annular so that the rigid structure or stack formed from the discs contains a central passageway in which a reciprocating valve plug may move to increase or decrease, as desired, the number of flow passages open through the stack. The inlets to the passageways may be at the inner circumference of the discs with the outlets at the outer circumference or, alternatively, the outlets may be at the inner circumference and the inlets at the outer circumference.
The invention in this aspect provides a bidirectional flow path through the device. It is particularly useful, therefore, for the regulation of fluid flow both in and out of, for example, a storage system, e.g. an underground gas storage system. A valve incorporating a flow device according to this aspect of the invention may, therefore, advantageously replace two valves conventionally used, i.e. one for injection and one for withdrawal of the fluid, e.g. natural gas into and from an underground storage.
In another aspect the invention provides a fluid flow control device comprising a plurality of discs forming a rigid structure which incorporates a series of passageways for fluid flow, the discs having abutting surfaces and passageways therebetween for fluid flow,
and wherein each disc has at least one first passageway formed through the entire thickness of the disc and extending from the outer edge of the disc to end in a mid-region of the disc and at least one second passageway formed through the entire thickness of the disc and extending from the inner edge of the disc to end in a mid-region of the disc, adjacent pairs of discs being orientated so that each first passageway of one disc communicates with a second passageway of the other disc and each second passageway of said one disc communicates with a first passageway of said other disc.
The invention also provides a disc suitable for incorporation in a structure according to the immediately preceding paragraph, the disc having at least one first passageway formed through the entire thickness of the disc and extending from the outer edge of the disc to end in a mid-region of the disc and at least one second passageway formed through the entire thickness of the disc and extending from the inner edge of the disc to end in a mid-region of the disc.
By appropriate orientation of each pair of discs in the stack, each pair of discs may provide one or more passageways isolated from the passageways provided by other pairs of discs in the stack.
The passageways so defined may be designed to have abrupt turns to create drag and pressure drop in a fluid. They may be of smaller cross-section in the mid-region of the disc--as defined in the first aspect of the present invention. Alternatively or additionally, they may increase in section so as to provide an expanding volume from inlet to outlet so as to provide a desired reduction in energy of fluid flowing through the passageways. In another embodiment the passageways may define a void between the inlet and outlet to expand the cross-sectional area of the passageway as disclosed in GB-A-2,273,579.
The discs defined by the second aspect of the invention are particularly advantageous in that the passageways are easier to machine. Thus they may be wire EDM-or water jet-machined through the thickness of the disc and discs of carbide or ceramic material may be machined without the need for special tooling.
BRIEF DESCRIPTION OF THE DRAWINGS
Embodiments of the invention will now be described by way of example only with reference to the accompanying drawings in which:
FIG. 1 is a longitudinal cross-section of a valve utilising a flow control device of the present invention;
FIG. 2a) is a plan view of a portion of one form of disc according to one aspect of the invention for use, for example, in the flow control device of FIG. 1;
FIG. 2b) is a plan view of a portion of a pair of discs of the type shown in FIG. 2a) superimposed one upon the other;
FIGS. 2c) and 2d) are identical sections along line A--A of FIG. 2b) with the addition of separator plates but showing flow in opposite directions;
FIG. 3a) is a plan view of a disc according to a second aspect of the invention;
FIG. 3b) is a similar view of another disc as shown in FIG. 3a) but rotated through 45°;
FIG. 3c) shows the two discs of FIGS. 3a) and 3b) superimposed one upon the other;
FIG. 3d) shows four discs of the type shown in FIGS. 3a) and 3b) superimposed on each other;
FIG. 4a) is a plan view of another disc according to the second aspect of the invention;
FIG. 4b) is a similar view of another disc as shown in FIG. 4a) but rotated through 221/2°;
FIG. 4c) shows the two discs of FIGS. 4a) and 4b) superimposed one upon the other; and
FIG. 4d) is a plan view of a separator plate to be used as described below in conjunction with the two stacked discs of FIG. 4c).
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 discloses a fluid exhaust valve assembly 10 for exhausting, e.g. a predetermined amount of steam, to the atmosphere 12 through an inlet 16. The fluid flows into a chamber 18 from which a predetermined amount of the fluid is allowed to exhaust through the stack assembly 14 by a movable valve plug 20. The valve plug 20 is movable between a first position completely blocking the fluid from entering the stack assembly 14 by completely blocking all the inlets 22 of the stack assembly 14 and a second position opening all the inlets 22 by moving up into a space 24 formed by a top casing 26 of the valve assembly 10. The plug 20 is moved by a connecting rod 28 connected to an actuator (not shown) which is responsive to system control signals in a well-known manner. To minimise the force that the actuator has to exert to move the plug 20 between positions, fluid pressure is balanced across the plug 20 by providing a pair of passageways 30 extending longitudinally across the plug 20 for fluid communication between the chamber and the space 24.
The disc stack assembly 14 includes a series of individual discs 32 which are aligned with respect to the plug 20 and are clamped together by tension rods 34 between a bottom mounting plate 36 to encompass the stack assembly 14 and safely direct the fluid exiting from outlets 42 of the stack assembly up into the atmosphere. The disc stack assembly provides a labyrinth for the fluid as it travels from the inlets 22 to the outlets 42 by means of variously configured discs 32 as it will be described below.
In FIG. 2a) an annular disc 32A has two repeating series of radially-extending, generally rectangular holes through it. Series 33 comprises a slot 33A at the outer periphery 34, an intermediate hole 33B of smaller transverse dimensions than slot 33A and a slot 33C at the inner periphery 35 of the disc. Slot 33C is of similar dimensions to slot 33A. The second series of holes is positioned radially at 45° to the first series. The second series comprises two holes 36A and 36B, again of generally rectangular form. Holes 36A and 36B are intermediate in transverse dimensions between slots 33A and 33C on the one hand and hole 33B on the other hand. They are also radially centred to lie between the radial centres of the holes of the first series. The two series (only one of each being shown) alternate at 45° intervals around the disc.
FIG. 2b) shows two discs according to FIG. 2a), one of which has been rotated at 45° with respect to the other and the two discs are superimposed so that a hole 36A of the top disc partially overlies a slot 33A and a hole 33B of the bottom disc to form passageways 37A and 37B and a hole 36B of the top disc partially overlies hole 33B and a slot 33C of the bottom disc to form passageways 37C and 37D.
A similar overlap takes place at each 45° interval but with alternate series of passageways being formed with the holes 36A and 36B being in the lower disc.
It will be seen the passageway 37A towards the periphery of the discs is of greater cross-section than passageways 37B and 37C in the mid-region of the discs and that passageway 37D towards the inner periphery of the discs is again of greater cross-section than passageways 37B and 37C.
FIGS. 2c) and 2d) both show in section a stack of two discs 32A superimposed as shown in FIG. 2b) and with separator discs 38 and 39 to close off and define the top and bottom respectively of the passageways. As shown by arrows the flow may be from the inner periphery to the outer periphery--FIG. 2c) or from the outer periphery to the inner periphery--FIG. 2d).
In FIG. 3a), disc 32B is shown having four equi-spaced passageways 62, each cut through the entire thickness of the disc and extending from the outer edge 64 of the disc to end in a central region 66 of the disc. The disc also has four equi-spaced passageways 68, each also cut through the entire thickness of the disc and extending from the inner edge 70 to the mid-region 66 of the disc. Each passageway 62 is positioned midway between an adjacent pair of passageways 68 and vice versa.
In FIG. 3b) a similar disc 32B' is shown rotated through 45° with respect to disc 32B. Disc 32B' has the same arrangement of passageways 62' and 68' as has disc 32B and like parts are indicated by the same but prime numbers.
A pair of discs 32B and 32B' are abutted face to face with one of the discs rotated through 45° with respect to the other and this is shown in FIG. 3c). The mid-region end of each passageway 62 on disc 32B overlaps with the mid-region end of a passageway 68' on the other disc 32B' and similarly with passageways 62' and 68 thereby creating eight flow passageways between the outer edges 64, 64' and inner edges 70, 70' of the pair of discs.
As shown, each passageway 62, 68' or 62', 68 is provided with a number of right angle turns 69 to provide friction and energy loss for a fluid passing through the passageway.
In FIG. 3d) is shown in plan a stack 71 of two pairs of discs, the discs of each pair being superimposed on each other in the manner shown in FIG. 3c) but each pair being rotated at 221/2° with respect to the other pair. By this means passageways 72 and 72' in the upper pair are defined in between passageways 62 and 62' of the lower pair. It will be appreciated that each passageway from the outer to inner edges of the discs is isolated from adjacent passageways of that pair by the intervening areas of the discs and each passageway in one pair of discs is isolated from each passageway in an adjacent pair of discs by the abutting faces of adjacent discs.
In FIG. 4a) a disc 32C has eight equi-spaced passageways 82, each cut through the entire thickness of the disc and extending from the outer edge 84 of the disc to end in a mid-region 86. The disc also has eight equi-spaced passageways 88 cut through the entire thickness of the disc and extending from the inner edge 90 to the mid-region 86 of the disc. Each passageway 82 is positioned midway between an adjacent pair of passageways 88 and vice versa.
In FIG. 4b) a similar disc 32C' is shown rotated through 221/2° with respect to the disc 32C. Disc 32C' has the same arrangement of passageways 82' and 88' as has disc 32C and like parts are indicated by the same but prime numbers.
A pair of discs 32C and 32C' are abutted face to face with one of the discs rotated through 221/2° with respect to the other and this is shown in FIG. 4c). The mid-region end of each passageway 82 on disc 32C overlaps with the mid-region end of a passageway 88' on the other disc and similarly with passageways 82' and 88 thereby creating sixteen flow passageways between the outer edges 84, 84' and 90, 90' of the pair of discs.
As shown each passageway 82, 88' or 82', 88 is provided with a number of right angle turns 89 as before.
FIG. 4d) shows a plan view of an annular separator disc 100. One disc 100 can be located between each pair of superimposed discs 32C and 32C' in a stack of such pairs in order to maintain the flow passageways within their respective pairs of discs.
It will be appreciated that the invention is not limited to the embodiments shown. For example, in the FIGS. 3 and 4 embodiments, there may be more or less passageways as desired. The passageways may contain voids as described above.
The valve arrangement of FIG. 1 may be changed so that the fluid travels in the reverse direction, i.e. fluid inlets at 42 and outlets at 22 and 16.
The device may be utilised in a valve arrangement to control flow into and out of a fluid storage system.
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A fluid flow control device for use in a variable fluid restrictor control valve or severe service control valve. These valves employ a moveable plug and are used to control high pressure fluids e.g. superheated steam. The control device of the invention includes annular discs with fluid passageways through them. Pairs of discs together form a radial passageway for fluid between the interior of a stack of discs and its radially outer circumference. The passageways may have a smaller cross-section at a mid-region of the disc than at the radially inner or outer side of the disc.
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The present invention relates to sealing off a problematic zone during drilling of a well to permit forward drilling below the problematic zone. More particularly this invention relates to a method using specific components and materials for placing a cement lining in a selected portion of a wellbore that traverses a severely unconsolidated or problematic formation.
BACKGROUND OF THE INVENTION
The recovery of fluids, such as gas and/or oil from underground formations, has been found to be troublesome in subterranean zones where the formation is composed of one or more unconsolidated or abnormally pressured layers. Conventionally, aqueous-based drilling fluids containing water, clay and various additives are circulated through the wellbore during the drilling operation to carry drill cuttings from the wellbore to the surface. These clay containing drilling fluids form a mud cake on the wellbore wall which reduces the sloughing of the unconsolidated formation as long as the fluid pressure in the wellbore due to the standing column of drilling fluid, exceeds the pressure of any connate fluid in the unconsolidated formation. Accordingly drilling through certain unconsolidated formations is not a particularly serious problem. It is commonplace, however, to encounter a lost circulation zone in drilling a well, either in a severely unconsolidated formation itself or in an underlying stratum, so as to lose the column of drilling fluid into the earth. This loss of drilling fluid results in a considerable loss of time and a considerable increase in expense.
It is also known in the art that formation stabilization, i.e., prevention of drilling fluid loss, wellbore cave-ins or influx can be effected by installing a solid barrier, such as a casing or liner between the formation to be stabilized and the open end hole. This is conventionally accomplished by setting a long casing string from the surface extending through the formation to be stabilized, or by setting an intermediate size casing in the desired location and then filling a space between the formation wall and the intermediate casing with a hydraulic cement slurry. After the cement hardens, drilling operations can resume. These methods of stabilization, however, require the time and expense of setting the longer casing from the surface or setting the intermediate casing. Further, if a permanent intermediate size casing section is set, reduced hole size results, which is often a disadvantage.
As drilling depth increases, which is common when drilling wells in offshore sub-salt plays, still further problems commonly arise in that adjacent zones of significantly different pressure, and faulted zones are often encountered below the salt layer. In these deep zones, casing shoes, which typically provide integrity for forward drilling from a specific depth, are not effective for their intended purpose, and reinforcement of the "below shoe" well is also required for this reason.
If sub-salt play in the oil industry is to continue to grow, cost reductions are necessary in drilling and completing subsalt wells. Accordingly, an urgent need exists for new and improved methods and materials that reduce the time required for sub-salt well completion.
Accordingly, it is an object of this invention to reduce the time required for drilling and completing subsalt wells.
A more specific object is to seal off a potentially troublesome zone encountered at a location deep in a wellbore so as to provide for forward drilling from a specific depth below the troublesome zone.
Another more specific object is to place a high strength wellbore lining material at a specific location deep in a wellbore to remedy troubles caused by unstable formations.
Another still more specific object of this invention is to place a high strength wellbore lining material across an abnormally pressured zone at a specific location deep in a wellbore.
Yet another object is to eliminate the need for setting a permanent intermediate length casing section in a wellbore to isolate a severely unconsolidated problem zone.
Another more specific object is to provide a drillable metal liner that is useful in a wellbore for problem zone mitigation.
SUMMARY OF THE INVENTION
According to the present invention, the foregoing and other objects and advantages are attained by applying several different techniques and materials to isolate a problem zone that is encountered at a location deep in a wellbore, so that forward drilling progress below the problem zone can be restored. The problem zone, which is typically an unconsolidated and/or abnormally pressured formation, is identified and then conventionally drilled to the desired diameter of the wellbore. Next, according to the invention the problem zone and a slight section both above and below the problem zone is under-reamed, and a drillable metal liner, which is of a much smaller diameter than the wellbore and includes features for centralizing the liner, is positioned to overlap each end the under-reamed section of the wellbore. The drillable liner is centrally positioned in the wellbore using fiberglass bowspring centralizers. A highly resilient fiber reinforced and nitrified cement, which is impermeable to gas and water, is then pumped into the annular cavity between the drillable liner and the wall of the wellbore to seal the wellbore wall by forming a thick walled sheath of impermeable cement around the drillable liner. Using the drillable liner as a guide, a piloted milling assembly is then employed to mill out the drillable liner along with a portion of the surrounding cement sheath to restore the preliner dimensions to the wellbore, while leaving a thick-walled cement sheath to stabilize the problem zone.
The thus provided cement sheath bridging the problem zone is of sufficient thickness to seal off the problem zone from the wellbore. The method and apparatus of this invention, which includes a drillable metal liner centralized in an under-reamed problem zone mostly filled with cement, speeds up a piloted milling operation for restoring the cement filled under-reamed section of the wellbore to preliner dimensions. A metal liner of carbon steel is preferred for use in this invention because of advantages in millibility, hole cleaning, cement bonding and availability in standard well sizes. However, any drillable material, such as fiberglass or aluminum, can be employed depending upon availability and job specifics. The drillable liner is thus used to guide the piloted milling assembly through the problem zone, and further to facilitate providing uniform dimensions for the cement sheath remaining in the wellbore after milling out the drillable liner and a portion of the surrounding cement in the under-reamed section of the wellbore.
Still other objects and advantages of the present invention will become readily apparent to those skilled in this art from the following detailed description, wherein there is shown and described only the preferred embodiment of the invention, simply by way of illustration of the best mode contemplated for carrying out the invention. As will be realized, the invention can be accomplished by other and different embodiments, and its several details can be modified in various obvious respects, all without departing from the present invention. Accordingly, the drawings and description are to be regarded as illustrative in nature, and not as restrictive.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic illustration of a conventional casing scheme with an open-hole wellbore extension having an under-reamed section traversing a problem zone.
FIG. 2 is a schematic illustration of a drillable liner surrounded by cement with the liner bridging a severe problem zone according to the present invention.
FIG. 3 is a schematic illustration of a borehole lining that has been applied to seal off a trouble zone according to this invention.
FIG. 4 is a schematic illustrating centralizers applied to the drillable liner according to this invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The inventive method preferably utilizes a fiber reinforced foamed cement composition which when set is nonpermeable to oil, gas, other formation fluids, and formation particulates, and which has sufficient tensile strength to resist wear and fragmentation when sideways contacted with a rotating drill string. Nonpermeable foamed cement compositions, which are formed by introducing nitrogen, air or some other gas into a cement slurry, have been used heretofore in oil and gas wells for performing various primary cementing operations. Compared to non-foamed cement compositions, foamed cement compositions typically have low densities, low fluid loss properties and good resilient properties.
Fiber containing cement has also been used heretofore in oil and gas wells as a high strength material that could be used to line a borehole. Being made of an inert material the synthetic fibers do not influence the chemically adjusted properties of a cement slurry, e.g., pumping time, fluid loss etc. The fibers are added to the slurry at the last stage, after it has been mixed to its final chemical composition, and are added in such an amount that they take up about 1.5% of the volume of the fiber containing slurry. Fiber containing cement, which can be mixed and pumped with standard oilfield cementing equipment, has a better tensile strength, ductility and wear resistance than cement without fibers. A suitable fiber reinforced foamed cement is available for example from Halliburton Co. in Dunkin, Okla.
In performing cementing operations with a fiber reinforced foamed cement composition, the cement composition is pumped down a casing disposed in a wellbore such that, when the cement slurry reaches the bottom of the casing, the cement slurry flows upwardly and into the annulus existing between the exterior of the well casing and the earthen wall of the wellbore. Upon setting, the cement bonds to the casing and to the wellbore. Due to its low density, foamed cement compositions can be advantageously used in operations where it is necessary to minimize hydrostatic pressure effects on weak formations.
The inventive method begins with under-reaming a section of the wellbore, where the under-reamed section includes all of the unconsolidated section and extends slightly into competent sections both above and below the unconsolidated section. Preferably the diameter of the under-reamed section is in a range of from about 1.5 to about 1.2 times the diameter of the wellbore.
The invention also uses any suitable metallic material for a drillable liner that is millable by ordinary milling tools, and as previously mentioned includes features directed to centralizing the liner within the under-reamed section of the wellbore. The drillable liner, which is preferably made of carbon steel, is positioned to overlap the under-reamed section of the wellbore and is cemented by conventional methods using fiber reinforced foamed cement. One preferred liner material is N-80 grade steel or equivalent. Another preferred liner material is aluminum, which may be advantageous in terms of material cost, and availability in standard sizes. Yet another preferred drillable liner is a combination steel/aluminum liner, which includes alternate sections of steel and aluminum.
After the cement is set, the liner and a portion of the surrounding cement is milled out to restore preliner diameter to the wellbore. Whatever the material used for the liner, collection of the debris generated in the milling operation is an important consideration, since this debris must be circulated out of the well.
In a particularly successful test of the milling operation according to this invention, it has been found that polymer drilling fluid mud such as FLOZEN™ circulated at an annular velocity of about 30-ft./sec. satisfactorily collected both steel and aluminum cuttings from a 7-inch diameter liner weighing 29-lb./ft. and also from a 95/8-inch diameter liner weighing 40-lb./ft., as well as debris generated in partially milling up the cement ring surrounding the liner. This was accomplished while drilling a 121/2-inch hole at a drilling rate in a range of about 20-ft./hr. to about 40-ft./hr. using conventional piloted mill tools, for example, a Smith "Parahna" mill and a Baker Oil Tool "Metal Muncher". The condition of the remaining cement sheath was determined by logs, sidewall cores, changes in wellbore hydrostatic and video logs. Generally, the cement sheath produced competent sidewall cores.
A preferred embodiment of the method of this invention is illustrated in FIGS. 1 through 4. As shown in these figures, where like reference numerals are used to refer the same elements in each of the figures, a wellbore 10 extends from the surface of the earth 12 through three subterranean formations 14, 16 and 18 and into a fourth subterranean formation 20 located deep in the wellbore 10. As shown formations 14, 16 and 20 are reasonably competent and do not require consolidation. Typically, formation 16 is a durable salt formation. Formation 18, however, is severely unconsolidated and prone to sloughing into the wellbore 10. Below formation 18 is a fluid bearing reservoir 20 such as a reservoir containing oil or gas or other mineral deposit of interest. The objective of the wellbore is to penetrate into formation 20 to tap the fluid contained therein, however, as drilling depth increases so does the complexity of isolating zones of incompetent formations.
Referring specifically now to FIG. 1, there is illustrated the condition of the wellbore 10 after the wellbore has been drilled from the surface into the formation 20, and the problem zone 18 has been under-reamed. The wellbore 10 is drilled and the zone 18 is under-reamed in a conventional manner using a rotating drill string, a bit, circulating drilling fluid, etc., (none of which is illustrated). By way of example, the wellbore 10, as shown in FIG. 1 can include a conventional 135/8-inch casing section 15 extending from the surface through the formation 14, a 121/2-inch hole extending through zone 16, an under-reamed section of 16-inch diameter through the incompetent zone 18, with the 121/2-inch hole extending, if possible, about 100-ft. into the production zone 20. The under-reamed zone through section 18 begins slightly above (e.g., 60-ft.) the unconsolidated zone 18, and extends slightly below (e.g., 30-feet) the unconsolidated zone 18, thus providing about a 70-ft. rathole of reduced diameter for setting the drillable liner in the formation 20 below the unconsolidated zone 18.
FIG. 2 illustrates the condition of the wellbore 10 after the drillable liner 24 has been run and cemented in the wellbore 10 using fiber reinforced cement illustrated at 26. Setting and cement 24 of the drillable liner 24 are accomplished using ordinary off-the-shelf tools including shoe joint, float collar joint, landing collar joint, and liner running/releasing tool joints, which are not illustrated but which are familiar to those skilled in the art.
Referring now to FIG. 3, there is illustrated the condition of the wellbore 10 after the liner 24 and a portion of its surrounding cement 26 have been milled out. In the aforementioned test of drilling operations, after the cement 26 was set, the drillable metal liner 24 and a portion of the fiber cement layer 26 were successfully milled out with a 121/2-inch pilot mill, using the drillable liner as a guide. With the various diameters of wellbore 10 referenced in the discussion of FIG. 1, the remaining cement sheath 26 in FIG. 3 is about two inches thick and generally cylindrical in shape. However, thicker cement sheaths can be provided if desired.
Referring now to FIG. 4, there is illustrated the same condition of wellbore 10 as shown in FIG. 2, where the wellbore is drilled through consolidated layers 14, and 16, then through unconsolidated layer 18 and into the producing layer 20, with the drillable liner 24 surrounded with cement 26. FIG. 4, however, shows greater detail and illustrates features not shown in FIG. 2. In particular the drillable liner 24 can consist of a 7-inch diameter or a 95/8-inch diameter specialized drillable pipe preferably constructed of alternate sections of steel and aluminum, and fitted with customized bow spring centralizers 28. The fiberglass centralizers allow for good centralization, which is critical to placement of the cement sheath. These centralizers, which are well known to those skilled in the art, also provide good milling characteristics and minimize the transfer of destructive shock loads to the cement sheath when milling the liner as would otherwise be witnessed with standard metal solid-body centralizers. Centralizers made of glass fiber reinforced epoxy are preferred for use in this invention. Also shown in FIG. 4 is a pilot hole 30 in which the lower end of the drillable liner 24 is centered by metal centralizers 32, and in addition a casing shoe 36 is illustrated at the terminal end of the casing 15 extending to the surface.
Accordingly, the present invention is well adapted to achieve the objects and attain advantages for rapidly bridging a problem zone in a sub-salt zone in a wellbore. While presently preferred embodiments have been described for purposes of illustration, numerous changes and modifications will be apparent to those skilled in the art. Such changes and modifications are encompassed within the spirit of this invention as defined by the appended claims.
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A fiber reinforced cement lining for an unconsolidated or otherwise problematic zone in a wellbore is built up by first under-reaming the section of the wellbore to be stabilized by the cement lining. Next a drillable metallic liner is centralized in the under-reamed section and the annulus formed between the metal liner and the wellbore wall is filled with the fiber cement. After the cement has hardened, the drillable liner and a portion of its surrounding cement are milled out using the drillable liner as a guide for a piloted mill tool, thus leaving a relatively uniform thick-walled cement sheath bridging the zone to be stabilized in the wellbore while restoring the original diameter of the wellbore through the unconsolidated zone.
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FIELD OF THE INVENTION
The present invention relates to processes for preparing block copolymers in a family of polysulfones, i.e. polymers containing sulfone linkages, particularly Polysulfones (PSU), Polyether Sulfones (PES) and Polyphenylene Sulfones (PPSU), and to block copolymers prepared therefrom. Furthermore, the present invention relates to di- and tri-blocks, as well as random multi-block copolymers and processes of their preparation. These homoblocks may have varying molecular weights or may have similar molecular weights as compared to their original molecular weights, when present in block copolymers. These block copolymers show essentially a single glass transition temperature (Tg), good transparency and can be readily processed using traditional plastics processing techniques. They can be used directly for molding, extrusion and also used as compatibilizers for their high molecular weight homologues.
BACKGROUND OF THE INVENTION
The family of polysulfone polymers is well known in the art and three types of polysulfone have been available commercially viz. Polysulfone (PSU), Polyether Sulfone (PES) and Polyphenylene Sulfone (PPSU).
The commercially available Polysulfones (PSU, PPSU, PES) have good high temperature resistance and generally do not degrade or discolor at their processing temperatures of 350° C. to 400° C. Additionally, they are transparent, light amber colored amorphous plastics with excellent mechanical and electrical properties, and good chemical and flame resistance. These Polysulfones are readily processible using common plastics processing techniques such as injection molding, compression molding, blow molding and extrusion. This makes them very versatile and useful plastics, having a myriad of applications in electronics, the electrical industry, medicine, general engineering, food processing and other industries.
The Polysulfone PSU was discovered in early 1960 at Union Carbide (U.S. Pat. No. 4,108,837, 1978). Since then, activity in improving the quality of PSU has remained strong and improvements in color, thermal stability, molecular weights and reduction in residual monomer and solvent are continuously sought.
While, there are many similarities among PSU, PES, and PPSU as regards color, electrical properties, chemical resistance, flame resistance etc., there are also important differences. The foremost difference among these is the Glass Transition Temperature (Tg). PSU has a Tg of 189° C., PES has a Tg of 225° C., while PPSU has a Tg of 222° C. Thus, PSU has a lower overall thermal resistance in terms of its dimensional stability compared to PPSU and especially PES, which has the highest thermal resistance. Besides this, PES also has a higher tensile strength (>90 MPa) compared to PSU and PPSU (both 70-75 MPa). On the other hand, PPSU, like Polycarbonate (PC), has an outstanding impact resistance, and its Izod notched impact strength is 670-700 J/m. Both PES and PSU have lower Izod notched impact strengths of only 50-55 J/m. Similarly, it is known in the art that articles made from PPSU can withstand >1000 sterilization cycles without crazing, while PSU based articles withstand about 80 cycles and PES based articles withstand only about 100 cycles. PSU, on the other hand, has the lightest color and can be more readily processed, while PPSU is darker and more difficult to process than either PSU or PES.
Thus, a combination of PSU properties such as easy processibility and light color properties with PPSU properties such as high temperature and impact resistance would be desirable. Incorporating a proportion of PSU into PPSU may also bring down the overall cost. Although the physical blending of PPSU and PSU is one way of accomplishing this, it destroys one of the most important properties of both the homopolymers, namely their transparency. Similarly, a physical blend of PES and PSU is not only opaque, but also cannot be processed to give blends with desirable properties since they are very incompatible polymers.
Other polysulfone combinations, as discussed later, are also desirable as they give higher Tg's than that of PES, further boosting the high temperature resistance of these polymers by incorporating these units and making them more readily processible by incorporating PES, PSU or PPSU into their chain structures.
The unit chain structures of the part of family of polysulfones are given below:
PPSU:
—C 6 H 4 —SO 2 —C 6 H 4 —O—C 6 H 4 —C 6 H 4 —O—
PSU:
—C 6 H 4 —SO 2 —C 6 H 4 —O—C 6 H 4 —C(CH 3 ) 2 —O—
PES:
—C 6 H 4 —SO 2 —C 6 H 4 —O—C6H4—SO2—C6H4—O—
PSS:
—C6H4—C6H4—O—C6H4—SO2—C6H4—C6H4—SO2—C6H4—O—
The representative polysulfones shown above are prepared using one or more aromatic Dihalo compound such as Dichlorodiphenyl sulfone (DCDPS) or Dichlorodiphenyl disulfonylbiphenyl (CSB) and one or more of aromatic di-hydroxy monomer such as Bisphenol A, Dihydroxy diphenylsulfone (DHDPS), Biphenol, Dihydroxy diphenyl ether, Dihydroxy diphenyl methane, or their respective mono, di or tetra substituted Methyl derivatives, etc.
For PPSU, the di-hydroxy compound used is Biphenol (HO—C 6 H 4 —C 6 H 4 —OH), for PES, it is DHDPS (—HO—C6H4—SO2—C6H4—OH) and for PSU, it is Bisphenol A (HO—C 6 H 4 —C(CH 3 ) 2 —C 6 H 4 —OH), while DCDPS (Cl—C6H4—SO2—C6H4—Cl) is used as the aromatic dihalo compound for all three of these commercially available polysulfones.
The use of more than one dihydroxy monomers is also known. For example, “PAS”, polyaryl sulfone, manufactured by Amoco is known to include a small quantity of hydroquinone in addition to DCDPS and DHDPS. The third monomer is added at the start of the manufacturing process and so gets polymerized in a random sequence in the polymer chain.
Other random copolymers in the prior art have shown that a third monomer may be added in much larger quantities. Thus, GB Patent 4,331,798 (1982) and U.S. Pat. No. 5,326,834 (1994) teach the preparation of terpolymers using 80-40 mole % of DHDPS and correspondingly 20-60 mole % of Biphenol with equivalent mole % of DCDPS. Since both patents teach that polymerization is to be started with the monomers themselves, it can be seen that the distribution of DHDPS and Biphenol in the final copolymer will be at random. Thus, one gets a random sequence such as: -ABAABBBAABAAABBABABBAAABB-, where A and B are present in a random sequence and in variable amounts depending upon the initial concentrations of A and B or DHDPS and Biphenol. The DCDPS moiety will be present in between A-A, A-B & B-B groups, although not shown here. Similarly, European Patent No. 0,331,492 teaches the synthesis of random terpolymers of DCDPS and DHDPS/Biphenol or Bisphenol A/Biphenol. The synthesis starts with three monomers and gives random terpolymers (and not block copolymers) in which the sequence of A & B in the chains cannot be predicted.
The prior art shows that block copolymers have been prepared where only one of the blocks is polysulfone. Hedtmann-Rein and Heinz (U.S. Pat. No. 5,036,146-1991) teach the preparation of a block copolymer of PSU with a polyimide (PI). In this case, a homoblock of an amine terminated polysulfone was prepared first. This was preformed using DCDPS, Bisphenol A and p-aminophenol to give a homoblock having a molecular weight in the range of 1500 to 20000. The homoblock produced was subsequently reacted with a tetracarboxylic acid, such as benzophenonetetracarboxylic dianhydride, and another diamine, such as 4,4′-diaminodiphenylmethane, to make a block copolymer of PSU-PI. The copolymers were prepared in the melt phase at 350° C.
McGrath and coworkers (Polymer preprints, 25, 14, 1984) have prepared PSU-Polyterphthalate copolymers. This was done using DCDPS (0.141 mole) and a mixture of hydroquinone and biphenol (0.075 mole each) to give a homoblock in solution, and then reacting the homoblock with a terephthaloyl chloride and biphenol, using solution or interfacial techniques, to give a block copolymer.
McGrath et al (Polymer Preprints, 26, 275, 1985) have further described preparations using acetyl end capped PSU with p-acetoxy benzoic acid or biphenol diacetate/terephthalic acid to obtain block copolymers of PSU/Polyethers, the latter part being highly crystalline or even liquid crystalline polymers. The synthesis of the block copolymer was carried out as a melt or in the presence of diphenyl sulfone at 200-300° C. Block copolymer preparation was indicated by the fact that the product was not soluble in common organic solvents.
McGrath and coworkers (Polymer Preprints, 26, 277, 1985) have also developed block copolymers of PSU and PEEK using a hydroxy terminated oligomeric PSU homoblock and difluoro benzophenone alone or optionally adding hydroquinone and/or biphenol. The first method, rather than giving a block copolymer, gives PSU blocks joined by difluorobenzophenone. However, the second method has the possibility of producing both random and block structures in the copolymers of PSU and PEEK.
While the above investigations have prepared PSU block copolymers, it can be seen that most have opted for the combination of hydroxy terminated PSU with other monomers, which on polymerization give block copolymers. In this process, it is quite likely that the polymerizing monomers would give block sizes so varied that some of the PSU blocks may be joined by nothing more than a single monomer unit having a molecular weight of only 300 or less, and certainly <1000. Thus, the molecular weight of the second block will not be that of a PSU oligomer, which should ideally be >1000 to be called a block. Thus, depending on the concentration, it is likely that the second homoblock will be no more than a single or double monomer unit. (sentence deleted)
Noshay and coworkers (J. Polymer Sci. A-1, 3147, 1971) have prepared block copolymers of amine terminated dimethyl Siloxanes and hydroxy terminated PSU. The hydroxy terminated PSU was prepared using a slight excess of Bisphenol A (0.495 mole) over DCDPS (0.450 mole). The —ONa groups were then converted to —OH groups using oxalic acid and the product was precipitated. The dried PSU powder was reacted with a separately prepared amine terminated polysiloxane in ether at 60° C. It may be noted that while PSU is plastic, Polysiloxane is elastomeric and hence the combination gives a block copolymer with thermoplastic elastomer like properties.
Surprisingly however, there has been no described method, nor synthesis carried out, whereby two Sulfone homoblocks have been used to form a block copolymer with thermoplastic properties.
The usual method of preparation of these polysulfones consists of the following process:
An aprotic organic solvent selected usually from Sulfolane, N-methyl pyrrolidone (NMP), Dimethyl Acetamide (DMAc), Diphenyl sulfone, Dimethyl sulfone or Dimethyl sulfoxide (DMSO), usually distilled over an alkali, is placed in the reactor. DCDPS or a similar dihalo monomer and the second dihydroxy monomer (Bisphenol A or Biphenol, etc.), generally in a molar proportion of 1.00:1.00, are added to this reactor along with sodium or potassium carbonate. Toluene or monochlorobenzene (MCB) is added to facilitate dehydration. The temperature of the mixture is then slowly increased from RT to 140° C. to 200° C. depending on the solvent utilized, whereupon the alkaline carbonate reacts with the phenol to give a salt and liberate water. The water gets distilled off, which is facilitated by toluene or MCB, if present.
The reaction mixture after water removal is then heated to a temperature in the range of 170° C. to 230° C., depending on the solvent, alkali and the dihydroxy monomer used, until the desired viscosity or molecular weight is attained. Thereafter, the growing chains are end-capped with MeCl and the reaction mass is filtered to remove salt. The polymer chains are then precipitated in water or MeOH, further treated to remove the residual solvent, and dried. Alternately, the solvent may be removed by flash evaporation and the reaction mass passed through a devolatizing extruder directly to remove residual solvent and for polymer granulation.
Adding more than one hydroxy monomer to the above leads to ter-polymers with three, instead of two, monomer units incorporated randomly in the chains.
It is desirable that a method of block copolymer formation is evolved whereby two plastics, both of which are sulfone-based oligomers, are connected to form a single chain as a block copolymer. As noted earlier, block copolymers comprising two or more different polysulfones are not known in the art.
In general, as is known in art, three requirements need to be met for the successful formation of block copolymers from homoblocks:
i) The two homoblocks should have end groups that react with each other, i.e. —OH & —CNO. ii) Each homoblock should have identical end groups i.e. —OH or —CNO. iii) The two homoblocks should be mixed in exact stoichiometric proportions in order to obtain high molecular weights.
The present invention discloses a process of preparing block copolymers using two or more different polysulfones homoblocks and avoids the strict requirement that the individual homoblocks must have the same end groups. Similarly, it is not necessary for the two or more homoblocks used to be in equivalent stoichiometric proportions for high molecular weight block copolymer formation.
SUMMARY OF THE INVENTION
The present invention relates to a process for preparing block copolymers comprising at least two types of homoblock, all belonging to the polysulfone family, wherein each of the said homoblocks has an identical or different molecular weight of at least 1000 and comprising at least 5% of the overall weight of the block copolymer, and wherein the block copolymer has a molecular weight of at least 2000 and the process comprising the steps of:
(a) preparing each of the aforesaid homoblocks by heating at least one aromatic diol with at least one aromatic dihalo compound, one of which contains at least one sulfone group, in the presence of at least one alkali, optionally in at least one solvent and further optionally in the presence of an azeotropic agent, (b) reacting the aforesaid homoblocks together optionally in at least one solvent, optionally followed by end-capping said block copolymer, and (c) recovering the block copolymer.
The present invention also relates to the block copolymers prepared using the aforesaid process.
The present invention describes the preparation of block copolymers of various types of polysulfones. These novel block copolymers are prepared using a technique whereby lower molecular weight homoblocks are first separately prepared and then mixed in different proportions and reacted further to give high molecular weight block copolymers. It becomes possible, using this technique, to ensure the formation of the block structures, as well as their sequences and the block molecular weights. Besides segmented multi-blocks copolymers, even high molecular weight di-blocks or tri-blocks as well as multi-blocks with known block molecular weights are feasible using this method. Block copolymers thus prepared find usage as novel polysulfone plastics, and also as compatibilizers.
DESCRIPTION OF THE INVENTION
In general, two possible chain end structures exist on a polymeric chain of a homoblock of a polysulfone. These end groups are —Cl, emanating from a dihalo, (i.e. DCDPS) moiety and —OH emanating from the Phenolic (i.e. Biphenol) monomer. A mixture of the both end groups is also possible for a given polymeric chain.
For block copolymers, one expects, based on prior art, that the one homoblock should have two —Cl end groups per chain and the second homoblock should have two —OH end groups per chain. Mixing and reacting them in a 1:1 ratio would then yield a high molecular weight block copolymer. However, since it is possible to have —Cl or —OH mixed end groups on both the homoblocks, the present invention shows that it is possible to do away with the stringent requirement stated earlier that each homoblock should have identical end groups and the two homoblocks must be mixed in a 1:1 ratio.
Polysulfones usually have some —Cl and some —OH end groups. The concentration of each is decided by two important factors: firstly the initial molar ratio of DCDPS to Phenolic monomer and secondly the molecular weight of the polymer, if the molar ratio is not strictly 1:1, that is allowed to build up. The ratio of the two monomers is a very important factor because, in order to build a very high molecular weight, the ratio must be kept closer to 1:1 on a molar basis. Usually, no monomer should be present in a concentration of more than approximately 1-2 mole % higher than the other monomer. Thus, the mole ratio generally remains within the range 1.02:1.00 to 1.00:1.02 to get high molecular weights. An increase in the concentration of any one monomer to a value outside of this range generally results in a disturbance in stoichiometry to such a substantial extent that the molecular weight of the copolymer does not get built up enough and most polymeric properties suffer, as they do not reach optimum values. However, for the preparation for oligomeric homoblocks, such a stringent stoichiometry is not necessary since high molecular weight build up is not required. Thus, for homoblock preparation, a monomer ratio as high as 1.15:1.00 has been employed successfully in the present invention. The monomer ratio range, as homoblocks, has thus been increased from 1.02:1.00 to 1.15:1.00, without sacrificing the molecular weights of the ultimate block copolymer.
The present invention relates to novel polysulfone block copolymer structures and the novel process by which their preparation takes place. In particular, this invention relates to the preparation of new types of block copolymers made using PSU, PES and PPSU and similar polysulfones and the novel methods of their preparation. The block copolymers may be made using at least two different types of polysulfones and may be made using more than two types of polysulfones.
The process of the present invention involves the preparation of novel block copolymers of the polysulfone family using solution polymerization techniques. These block copolymers are prepared using lower molecular weight, oligomeric homoblocks of, for example, Polyphenylene Sulfone (PPSU) and Polysulfone (PSU). The invention consists not only of novel block copolymers using the above mentioned homoblocks, but also of the process used for preparation of these novel block copolymers.
A major novel and unexpected aspect of the process of the present invention is that it can do away with the stringent requirements that the given homoblock should have only one type of end group and that the stoichiometry between the homoblocks used must be 1:1. Thus, the process of the present invention makes it possible to prepare high molecular weight block copolymers without having identical end groups on each homoblock and without the stoichiometry being closely controlled. The present invention therefore greatly simplifies the formation of block copolymers. Also, a broader range of block copolymer structures can be readily made using the same homoblocks compared to the earlier methods of segmented block copolymer preparation. Of course, using homoblocks with identical end groups in exact stoichiometric proportions does not harm the process in any way, but these are no longer preconditions for the build up of high molecular weight block copolymers.
This process means that, by controlling the end groups of the homoblocks, block copolymers in which the two homoblocks have a variety of molecular weights can be prepared. The block copolymer can also have a large range of molecular weights and ratios of one homoblock to the other, which was not easy or even not possible in other type of block copolymers discussed earlier.
The novel block copolymers are made by first using initially separately prepared lower molecular weight homoblocks with reactive chain end groups. By the term “homoblock”, it is meant that each block has either a PSU, PPSU or PES or some such polysulfone structure and different homoblocks have structures differing from each other. The two homoblocks are separately prepared and are arranged to have two end groups which in turn are either the same or different. It is important to realize as taught by this invention that there should be, nevertheless, a near stoichiometric balance of the two differing end groups, in this case say —Cl and —OH. What is important is that both end groups are allowed to be present on both the homoblocks.
The different ways of preparing homoblocks are as follows:
The first set of homoblocks are prepared with predominantly halogen end groups, such as —F, —Cl, —Br and —I. The second set of homoblocks are prepared with predominantly the second type of end group such as —OH (which may be present as the salts —OK, —ONa, or —OLi), which is capable of reacting with a halogen end group. This is done by taking large molar excess of dihalo monomer as compared to the dihydroxy monomer in the first case and reversing this ratio in the second. In general, when the lower molecular weight homoblock having predominantly one type of end group is reacted with another homoblock having predominantly the second type of end group, block copolymers having high molecular weights are obtained. Thus, for example, reacting low molecular weight PPSU homoblock having predominantly —OH end groups with low molecular weight PSU homoblock having predominantly —Cl end groups gives novel block copolymers with [PPSU-PSU]z in the block copolymer sequence. When one homoblock has predominantly all the same end groups (—Cl for example) and is reacted with a second homoblock having predominantly all of a second type of end groups (—OH for example), the block copolymer obtained has blocks of similar molecular weights to the homoblocks. The present invention makes it possible for the molecular weights of the homoblocks inside the block copolymer to be nearly same as the molecular weights of the homoblocks used to prepare it.
It is also possible to prepare, according to this invention, block copolymers where the homoblock of PPSU has halogen end groups and the PSU homoblock has phenolic —OH end groups, as well as the reverse case, where PPSU has the hydroxy end groups and PSU has the halogen end groups. As shown by this invention, the end groups may be interchangeable for a given homoblock. Where each homoblocks has identical end groups (—Cl and —OH for example), it is important to have them in stoichiometric proportions. In case of making one or both high molecular weight homoblocks, it is important to keep end groups of both different to the extent possible, as in the case of di-blocks and tri-blocks preparations.
It is, however, possible according to this invention for both homoblocks to have both end groups and still being used for making high molecular weight block copolymers. This can be done by taking both monomers in near equal molar ratio. In such cases, the end groups will be halogen and hydroxy, irrespective of molecular weights. Thus, using the above example, it is possible to make PPSU and PSU homoblocks both having —Cl and —OH end groups and to react them together to form block copolymers of a desired molecular weight. In such cases, the block copolymers formed may have blocks having in-chain molecular weight that is similar or higher than the molecular weights of the parent homoblocks.
This invention also teaches that besides random homoblock sequence in the block copolymer thus prepared, one can also make di- and tri-block copolymers by adjusting the molecular weights of the homoblocks and the stoichiometry of the two homoblocks reacted to form the block copolymers.
The invention therefore teaches the preparation of di-block, tri-block as well as segmented block copolymers where the homoblocks may alternate or be present in a random sequence.
If the molecular weights of the homoblocks are kept low enough and end groups are carefully controlled, this invention makes it possible to build high molecular weight copolymers having essentially alternate homoblock structures in the chains. In such block copolymers all the blocks will have similar molecular weights to those of the two initial homoblocks. If the molecular weights of the homoblocks are kept high, then one can build di- and tri-block copolymers of relatively high molecular weights.
It is also another important part of this invention as given above that z, degree of block copolymerization, can be varied from as low as 1 (for a di-block) to as high as 100 or higher for an alternate or random multi block copolymer.
It is also another important part of this invention that special tri-block copolymers can also be prepared by using judicious control of the molecular weight, stoichiometry and end groups of the homoblocks.
The novel aspect of this invention is the recognition that by varying the stoichiometry of the basic monomers that are used for the preparation of homoblocks, particularly when they are of lower molecular weights, one can make these homoblocks with predominantly known end groups. Thus using one monomer, say, DCDPS in an excess of, say, 3 mole % over Biphenol i.e. a molar stoichiometry of >1.03:1.00, one obtains PPSU with essentially only —Cl as end groups. This is due to the fact that higher concentrations of DCDPS lead to essentially complete reaction of all of the —OH groups present on Biphenol, thereby limiting the molecular weight build up but providing essentially only —Cl end groups for the homoblock PPSU. Similarly, when Bisphenol A is used at higher concentration in PSU production, one gets essentially all end groups as —OH, as its Na or K salt. PSU, having essentially these phenolic groups, will not react with itself to give higher molecular weights PSU. Similarly, PPSU with —Cl end groups also cannot react with itself to give higher molecular weight PPSU. Under such conditions, the molecular weight does not increase further, indicating that the chains with the other end groups have all reacted.
However, when a homoblock of PPSU with essentially all —Cl end groups is mixed with a homoblock of PSU with essentially all —OK end groups, further polymerization occurs and a PSU-PPSU block is generated. Allowing this reaction to proceed further results in random block copolymer formation with a structure of the type [PSU-PPSU-]z, where z is greater than or equal to 1, and is dependant on the molecular weights of homoblocks, and the stoichiometry and the molecular weight that is allowed to be built up.
One important aspect of this invention is deliberate use of higher ratios of the two monomers for the preparation of homoblocks to give essentially one type of end groups. The ratio may be 1.03-1.15:1.00 that is having 3 to 15 mole % higher quantity of one monomer over the second monomer.
Another important aspect of this invention is that the homoblocks can also be conveniently prepared using near equal stoichiometry of the two base monomers, keeping the molecular weights of the homoblocks as desired and, by mixing, preparing high molecular weight block copolymers of the desired composition.
The important aspect of this invention is therefore the preparation of lower molecular weight homoblocks with known end groups and their mixing in the right proportions to yield essentially alternating or random block sequence in block copolymers of higher molecular weights.
A further novel and important aspect of this invention is the preparation of di- and tri-block copolymers. These di- and tri-block copolymers are also materials of a novel composition. For this preparation, it is again recognized that homoblocks can be prepared with different molecular weights with essentially known end groups. In general, by recognizing that controlling the molecular weights of the homoblocks and the block copolymers can give good control of the number of homoblocks present in the block copolymer, one can stop the reaction at di or tri block stage. Polysulfones of sufficiently high molecular weight or inherent viscosity, (Inh. V.) are required to give optimum mechanical and other polymer properties, one can build that range of molecular weight homoblocks. Thus, PPSU of a number average molecular weight (Mn) of say 50000 with —Cl end groups and PSU of say similar molecular weight with —OK end groups, when mixed and reacted in a proportion of 1:1 on a molar basis will give almost double the molecular weight, giving a di-block. The molecular weight can be controlled on-line using gel permeation chromatography (GPC).
If di-blocks are allowed to react further to give still higher molecular weight, we get a tri- and tetra-block and so on. Thus, di-blocks of the structure -[-PSU-PPSU-]- will further react to give tri-blocks of the structure -[-PSU-PPSU-PSU-]- and -[PPSU-PSU-PPSU-]- and which, on further reaction, will yield tetra-blocks and higher multi-blocks.
Thus, by controlling molecular weight, stoichiometry and end groups, this invention makes it possible to prepare di-block and tri-block and multi-block copolymers of PSU and PPSU.
This invention further makes it possible to prepare a tri-block using three different types of homoblocks as follows. First a di-block is prepared using two homoblocks, where the two end groups present on one homoblock are the same and similarly the second homoblock has two identical end groups on its chains, but different to those on the first homoblock. This di-block is reacted with a third homoblock having two end groups similar to either the first or the second homoblock to give a tri-block.
The block polymers thus produced may be checked for GPC molecular weight, Inh. V., DSC, Tg, MFI, etc. for quality control. The block copolymers may be used as powder for compounding and subsequently for granulation or may be added as a compatibilizer to the already separately manufactured high molecular weight homologue polysulfones.
The present invention seeks to achieve the following:
to provide novel block copolymers of two or more different polysulfone homoblocks, with controlled structures of di-blocks, tri-blocks and multi-blocks. to use these homoblocks of polysulfones having low molecular weight and controlled chain end groups to prepare high molecular weight block copolymers. to prepare high molecular weight di-block and tri-block copolymers using the homoblocks of lower molecular weight and reactive chain ends. to prepare two types of homoblocks each essentially having either only halogen or hydroxy end groups and thus giving a multi-block copolymer on reaction between the two, the blocks present in block copolymer with molecular weight being similar to the initial homoblock molecular weight. to prepare block copolymers of two polysulfones, where the ratio of the two homoblocks is in the range 95:5 to 5:95. to prepare block copolymers of two or more homoblocks of polysulfones, which are transparent and which show a single intermediate Tg. to prepare block copolymers that are thermally stable and processible in the temperature range of 350° C. to 400° C., using traditional injection molding, extrusion or other acceptable plastics processing methods. to provide a process by which the homoblocks of polysulfones of known molecular weights and controlled end groups are prepared. to provide a process for the preparation of low molecular weight controlled chain end homoblocks and another process for the preparation of high molecular weight block copolymers having di/tri/multi-block in-chain structures.
According to this invention there is provided a process that allows one to prepare low molecular weight, controlled chain-end homoblocks and utilize these homoblocks to prepare di-, tri-, and multi-block copolymers of high molecular weight.
The invention preferably uses Sulfolane, NMP, DMAc, DMSO, DMSO2, Diphenyl sulfone or any other aprotic organic solvent for the preparation of low molecular weight homoblocks and the high molecular weight block copolymers thereof.
Preferably MCB or Toluene or any other non-reacting solvent is used as a diluent and dehydrating agent for the salt formation, dehydration and polymerization steps.
Preferably the process uses the above mentioned solvent in the temperature range of 120° C. to 250° C. and with alkali such as NaOH, KOH, NaHCO 3 , KHCO 3 , Na 2 CO 3 or K 2 CO 3 either by themselves or in a combination of these or any other such suitable alkaline substances.
According to this invention there is provided a process of producing novel homoblocks and multi-block copolymers, using an aprotic organic solvent or solvents in the temperature range of 120° C.-250° C. and then end capping with MeCl or any suitable end capping agent. The process includes the preferred steps of filtration of the salt and precipitation of the block copolymer from the reaction mixture in a non-solvent like H 2 O or MeOH or a mixture of the two, and then giving further water/or MeOH treatments to reduce the residual solvent content of the powder and subsequently drying the polymeric powder.
The present invention will now be described with reference to the following examples. The specific examples illustrating the invention should not be construed to limit the scope thereof.
EXAMPLES
Example 1
A Block-Copolymer of 50:50 PPSU:PSU (B-0)
The following three part procedure was used to prepare this PPSU-PSU block copolymer.
Part 1: The Preparation of the PPSU Homoblock
A 4-necked, 3-litre glass flask was equipped with an overhead stirrer attached to a stainless steel paddle through its center neck. Through one of its side necks, a Cloisonné adapter was attached. The other neck of the Cloisonné adapter was attached to a Dean-Stark trap and a water-cooled condenser. A thermocouple thermometer was inserted through another of the side necks. A nitrogen gas inlet was inserted through the other side neck. The flask was placed in an oil bath, which was connected to a temperature controller.
Dimethyl acetamide (DMAc) (873 gms, 950 ml/mole) and toluene (344 gms, 400 ml/mole) were placed in the flask and heated to 45° C. Biphenol (186 gms) and 4,4′-dichlorodiphenyl sulfone (DCDPS) (307 gms) were added to the flask, the DCDPS and biphenol being in a molar ratio of 1.07:1.00, and the reactants were stirred for 30 minutes. Anhydrous potassium carbonate (152 gms) and sodium carbonate (21 gms) were added to the flask. A nitrogen atmosphere was maintained in the flask by purging. The temperature of the reactants was slowly increased to 165° C. over 9 hours and the stirring speed set to 400 rpm. The water formed due to the reaction of K 2 CO 3 with biphenol was distilled over as an azeotrope with toluene and collected in the Dean-Stark trap. The toluene was then returned to the reaction mixture once it had been separated from the water. Once the water had been completely removed, toluene addition back to reaction vessel was stopped. The toluene was then removed completely from the reaction mixture as the temperature of the reactants increased. The desired temperature was reached after 9 hours. The reaction temperature was then maintained at 165° C. and when the viscosity started to increase the stirring speed was raised to 500 rpm. Once the viscosity increase slowed, a sample was taken out to check the molecular weight. The GPC Mn achieved was about 32,000, with a Mw of 43,000 and a MWD of 1.34. The reaction mixture was allowed to cool in preparation for its reaction with the product of part 2. The relatively high molar ratio of DCDPS to Biphenol gave PPSU of a relatively low molecular weight and with predominantly end groups of —Ph—Cl.
Part 2: The Preparation of the PSU Homoblock
DMAc (873 gms, 950 ml/mole) and toluene (400 ml/mole) were placed in the flask, through which nitrogen gas was bubbled continuously, and heated to 45° C. Bisphenol A (244 gms) and 4,4′-dichlorodiphenyl sulfone (DCDPS) (287 gms) were added to the flask, the Bisphenol A and DCDPS being in a molar ratio of 1.07:1.00, and the reaction mixture was stirred for 30 minutes. Anhydrous potassium carbonate (170 gms) was added. The toluene acts as an azeotropic solvent. The temperature of the reactants was slowly increased to 165° C. over 9 hours and the stirring speed was set to 400 rpm. The water formed due to the reaction was distilled over as an azeotrope with toluene and collected in the Dean-Stark trap. The toluene was then returned to the reaction mixture once it had been separated from the water. Once the water had been completely removed, toluene addition back to the reaction vessel was stopped. The toluene was then removed completely from the reaction mixture as the temperature of the reactants increased. The desired temperature was reached after 9 hours. The reaction temperature was then maintained at 165° C. and when the viscosity started to increase the stirring speed was raised to 500 rpm. At the required Mn of 17,000, MW of about 26,000 and MWD 1.5 the viscosity of the reaction mixture remained almost constant, indicating the end of the polymerization reaction.
Part 3: The Preparation of the Block Copolymer
The reaction mixtures of Part 1 and Part 2 were mixed in equal proportions by weight and the block polymerization was conducted at 165° C. After the required MW was achieved, as shown by GPC, the reaction mixture was quenched with DMAc (376 gms, 400 ml/mole) and its temperature reduced to 160° C. Methyl Chloride gas was then bubbled through the reaction mixture for 5 hrs to ensure complete end capping. The reaction mixture was then diluted with DMAc (600 ml/mole) for a second time. The polymer solution was filtered through a 15 micron filter in a pressure filter funnel using 2 kg/cm 2 of nitrogen to remove any salts. The block copolymer was finally recovered by slowly adding the salt-free polymer solution to de-ionized water (13 ml/gm of polymer) under high-speed agitation. The precipitated polymer was then recovered by filtration. The precipitated polymer was ground and refluxed three times with de-ionized water at 90° C. to completely remove all salts and DMAc. The precipitated polymer was then filtered and dried in an oven at 140° C. until the moisture content as determined by Karl Fischer titration was <0.5%.
GPC analysis of the block copolymer showed an Mn of 94,000, an Mw of 135,000 and an MWD of 1.44 based on the polystyrene standards. Thus, the copolymer produced had a significantly higher molecular weight than the two homoblocks used as monomer units, indicating the preparation of a block copolymer. The block copolymer powder was then mixed with 0.3% heat stabilizer and 0.2% Ca stearate and granulated using a twin screw extruder. The Tg and the specific gravity of PSU are 189° C. and 1.235 respectively, whilst those of PPSU are 222° C. and 1.290. The transparent granules of block copolymer showed a DSC Tg of 206° C. and a specific gravity of 1.260. The transparency of the granules, the single GPC peak, the intermediate Tg and the specific gravity of the product clearly indicate that a block-copolymer of PSU and PPSU had indeed been formed and that the product was not simply a blend of the two homopolymers, PSU and PPSU. The remaining properties and also those of the blends are given in Table 1.
Example 2
A Block-Copolymer of 75:25 PPSU:PSU (B-1)
An experimental set up similar to that described in Example 1 was used.
Part 1: The Preparation of the PPSU Homoblock
DMAc (2679 gms, 950 ml/mole) and toluene (1032 gms, 400 ml/mole) were placed in the flask, through which nitrogen gas was bubbled continuously, and heated to 45° C. Biphenol (558 gms) and 4,4′-dichlorodiphenyl sulfone (DCDPS) (921 gms) were added to the flask, the DCDPS and biphenol being in a molar ratio of 1.07:1.00, and the reactants were stirred for 30 minutes. Anhydrous potassium carbonate (455 gms) and sodium carbonate (64 gms) were added to the flask. The toluene acts as an azeotropic solvent.
The rest of the procedure is the same as that described in Part 1 of Example 1. The homoblock obtained had a GPC molecular weight of Mn 16,000, an Mw of 25,000 and an MWD of 1.52.
Part 2: The Preparation of the PSU Homoblock
Dimethyl Acetamide (DMAc) (893 gms, 950 ml/mole) and Toluene (344 gms, 400 ml/mole) were placed in the flask, through which nitrogen gas was bubbled continuously, and heated to 45° C. Bisphenol A (244 Gms) and 4,4′-dichlorodiphenyl sulfone (DCDPS) (287 gms) were added to the flask, the Bisphenol A and DCDPS being in a molar ratio of 1.07:1.00, and the reaction mixture was stirred for 30 minutes. Anhydrous potassium carbonate (170 gms) was added to the flask. The toluene acts as an azeotropic solvent.
The rest of the procedure is the same as that described in Part 2 of Example 1. The homoblock obtained had a GPC molecular weight of Mn 14,000, an Mw of 21,000 and an MWD of 1.49.
Part 3: The Preparation of the Block Copolymer
The reaction mixtures of Part 1 (3 parts) and Part 2 (1 Part) were mixed together and the block polymerization was conducted at 165° C. After the required GPC MW was achieved, the reaction mixture was quenched with DMAc (344 gms, 400 ml/mole) and its temperature reduced to 160° C. Methyl Chloride gas was then bubbled through the reaction mixture for 5 hrs to ensure complete end capping. The reaction mixture was then diluted with DMAc (600 ml/mole) for a second time. The polymer solution was passed through a 15 micron filter in a pressure filter funnel using 2 kg/cm 2 nitrogen to remove any salts. The block copolymer was finally recovered by slowly adding the salt-free polymer solution to de-ionized water (13 ml/gm of polymer) under high-speed agitation. The precipitated polymer was then recovered by filtration. The precipitated polymer was treated three times with refluxing de-ionized water at 90° C. The precipitated polymer was then filtered and dried in oven at 140° C. until the moisture content as determined by Karl Fisher titration was <0.5%.
GPC analysis of the block copolymer showed an Mn of 83,000, an Mw of 119,000 and an MWD of 1.44 based on the polystyrene standards. The block copolymer was then granulated as in Example 1 and its properties were measured. These were a Tg of 210° C. and a specific gravity of 1.27. This data, and the product being obtained as clear transparent granules, indicated that PPSU and PSU were present as a block copolymer and not simply as a blend of the two homopolymers. The remaining properties and also those of the blend of similar proportions are given in Table 1.
Example 3
A Block Copolymer of 25:75 PPSU:PSU (B 2)
An experimental set up similar to that described in Example 1 was used.
Part 1: The Preparation of the PPSU Homoblock
DMAc (893 gms, 950 ml/mole) and toluene (344 gms, 400 ml/mole) were placed in the flask, through which nitrogen gas was bubbled continuously, and heated to 45° C. Biphenol (199 gms) and DCDPS (287 gms) were added to the flask, the DCDPS and biphenol being in a molar ratio of 1.00:1.07, and the reactants were stirred for 30 minutes. Anhydrous potassium carbonate (162 gms, 1.10 mole/mole) and sodium carbonate (23 gms) were then added to the flask.
The rest of the procedure is same as that described in Part 1 of Example 1. The homoblock obtained had a GPC molecular weight of Mn 17,000, an Mw of 30,000 and an MWD of 1.70 based on the polystyrene standards.
Part 2: The Preparation of the PSU Homoblock
DMAc (2679 gms, 950 ml/mole) and toluene (1032 gms 400 ml/mole) were placed in the flask, through which nitrogen gas was bubbled continuously, and heated to 45° C. Bisphenol A (226 ms) and DCDPS (921 gms) were added to the flask, the Bisphenol A and DCDPS being in a molar ratio of 1.00:1.07, and the reaction mixture was stirred for 30 minutes. Anhydrous potassium carbonate (486 gms) was then added to the flask.
The rest of the procedure is same as that described in Part 2 of Example 1. The homoblock obtained had a GPC molecular weight of Mn 14,000, an Mw of 21,000 and an MWD of 1.49 based on the polystyrene standards.
Part 3: The Preparation of the Block Copolymer
The reaction mixtures of Part 1 (1 part) and Part 2 (3 parts) were mixed together and the block polymerization was conducted at 165° C. After the required GPC MW was achieved, the reaction mixture was quenched and the copolymer worked up as in Example 1.
GPC analysis of the copolymer showed an Mn of 79,000, an Mw of 114,000 and an MWD of 1.44. The block copolymer powder was then extruded and granulated as per the procedure given in Example 1. The DSC Tg of the copolymer was 195° C. and the specific gravity was 1.24. This data, and the product being obtained as light amber colored transparent granules, indicated that the polymer obtained was indeed a block copolymer and not simply a blend of PPSU and PSU. The remaining properties and also those of the blends are given in Table 1.
Example 4
A Copolymer of 90:10 PPSU:PSU (B 3)
An experimental set up similar to that described in Example 1 was used.
Part 1: The Preparation of the PPSU Homoblock
DMAc (3215 gms, 950 ml/mole) and toluene (1238 gms, 400 ml/mole) were placed in the flask, through which nitrogen gas was bubbled continuously, and heated to 45° C. Biphenol (670 gms) and 4,4′-dichlorodiphenyl sulfone (DCDPS) (1075 gms), were added to the flask, the DCDPS and biphenol being in a molar ratio of 1.04:1.00, and the reactants were stirred for 30 minutes. Anhydrous potassium carbonate (546 gms) and sodium carbonate (76 gms) were added to the flask. The toluene acts as an azeotropic solvent.
The rest of the procedure is the same as that described in Part 1 of Example 1. The homoblock obtained had a GPC molecular weight of Mn 22,000, an Mw of 26,000 and an MWD of 1.16.
Part 2: The Preparation of the PSU Homoblock
DMAc (357 gms, 950 ml/mole) and Toluene (138 gms 400 ml/mole) were placed in the flask, through which nitrogen gas was bubbled continuously, and heated to 45° C. Bisphenol A (96 gms) and DCDPS (115 gms) were added to the flask, the Bisphenol A and DCDPS being in a molar ratio of 1.05:1.00, and the reaction mixture was stirred for 30 minutes. Anhydrous potassium carbonate (64 gms) was added to the flask. The toluene acts as an azeotropic solvent. The reaction vessel was evacuated using a vacuum pump and filled with nitrogen.
The rest of the procedure is the same as that described in Part 2 of Example 1. The homoblock obtained had a GPC molecular weight of Mn 18,000, an Mw of 29,000 and an MWD of 1.62
Part 3: The Preparation of the Block Copolymer
The reaction mixtures of Part 1 (9 parts) and Part 2 (1 Part) were mixed together and the block polymerization conducted at 165° C. After the required GPC MW was achieved, the reaction mixture was quenched with DMAc (376 gms, 400 ml/mole) and its temperature reduced to 160° C. Methyl Chloride gas was then bubbled through the reaction mixture for 5 hrs to ensure complete end capping. The reaction mixture was then diluted with DMAc (564 gms, 600 ml/mole) for a second time. The polymer solution was passed through a 15 micron filter in a pressure filter funnel using 2 kg/cm 2 nitrogen to remove any salts. The block copolymer was finally recovered by slowly adding the salt-free polymer solution to de-ionized water (13 ml/gm of polymer) under high-speed agitation. The precipitated polymer was recovered by filtration. The precipitated polymer was treated three times with refluxing de-ionized water at 90° C. The precipitated polymer was then filtered and dried in an oven at 140° C. until the moisture content as determined by Karl Fisher titration was <0.5%.
GPC analysis of the copolymer showed an Mn of 80,000, an Mw of 110,000 and an MWD of 1.36 based on polystyrene standards. The block copolymer was then granulated as in Example 1 and its properties were measured. These were a Tg of 215° C. and a specific gravity of 1.28. This data, and the product being obtained as clear transparent granules, indicated that PPSU and PSU were indeed present as a block copolymer and not just as a blend of the two homopolymers. The remaining properties and also those of the blends are given in Table 1.
Example 5
Physical Blends of PPSU and PSU
In order to study the properties of the physical blending of PPSU and PSU dry blending of the powders was carried out in the following proportions, followed by extrusion on ZE25 twin screw extruder and evaluation (Table 1).
C1:
PPSU powder (50%) + PSU powder (50%)
C2:
PPSU powder (75%) + PSU Powder (25%)
C3:
PPSU powder (25%) + PSU powder (75%)
The PPSU used was the commercially available GAFONE-P 4300 grade and the PSU used was the commercially available GAFONE-S PSU 1300, both from Gharda Chemicals Ltd. India.
Example 6
Copolymer of 90:10 of PPSU-PSU (B 4)
An experimental set up similar to that described in Example 1 was used.
Part 1: The Preparation of the PPSU Homoblock
DMAc (8037 gms, 950 ml/mole) and toluene (3096 gms, 400 ml/mole) were placed in the flask, through which nitrogen gas was bubbled continuously, and heated to 45° C. Biphenol (1674 gms) and 4,4′-dichlorodiphenyl sulfone (DCDPS) (2635 gms), were added to the flask, the DCDPS and biphenol being in a molar ratio of 1.02:1.00, and the reactants were stirred for 30 minutes. Anhydrous potassium carbonate (1366 gms) and anhydrous sodium carbonate (191 gms) were added to the flask. The toluene acts as an azeotropic solvent.
The rest of the procedure is the same as that described in Part 1 of Example 1. The homoblock obtained had a GPC molecular weight of Mn 17,000, an Mw of 26,000 and an MWD of 1.54.
Part 2: The Preparation of the PSU Homoblock
DMAc (893 gms, 950 ml/mole) and toluene (344 gms 400 ml/mole) were placed in the flask, through which nitrogen gas was bubbled continuously, and heated to 45° C. Bisphenol A (239 gms) and 4,4′-dichlorodiphenyl sulfone (DCDPS) (287 gms) were added to the flask, the Bisphenol A and DCDPS being in a molar ratio of 1.05:1.00, and the reaction mixture was stirred for 30 minutes. Anhydrous potassium carbonate (167 gms) was added to the flask. The toluene acts as an azeotropic solvent.
The rest of the procedure is the same as that described in Part 2 of Example 1. The homoblock obtained had a GPC molecular weight of Mn 10,000, an Mw of 15,000 and an MWD of 1.50/
Part 3: The Preparation of the Block Copolymer
The reaction mixtures of Part 1 (9 parts) and Part 2 (1 Part) were mixed together and the block polymerization was conducted at 165° C. After the required GPC MW was achieved, the reaction mixture was quenched with DMAc (376 gms, 400 ml/mole) and its temperature reduced to 160° C. Methyl Chloride gas was then bubbled through the reaction mixture for 5 hrs to ensure complete end capping. The reaction mixture was then diluted with DMAc (564 gms, 600 ml/mole) for the second time. The polymer solution was passed through a 15 micron filter in a pressure filter funnel using 2 kg/cm 2 nitrogen to remove any salts. The block copolymer was finally recovered by slowly adding the salt-free polymer solution to de-ionized water (13 ml/gm of polymer) under high-speed agitation. The precipitated polymer was recovered by filtration. The precipitated polymer was treated three times with refluxing de-ionized water at 90° C. The precipitated polymer was then filtered and dried in an oven at 140° C., until the moisture content as determined by Karl Fisher titration was <0.5%.
GPC analysis of the block copolymer showed an Mn of 80,000, an Mw of 115,000 and an MWD of 1.44 based on polystyrene standards. The block copolymer was then granulated as in Example 1 and its properties were measured. These were a Tg of 216° C. and a specific gravity of 1.28. This data, and the product being obtained as clear transparent granules, indicated that PPSU and PSU were indeed present as a block copolymer and not simply as a blend of the two homopolymers. The remaining properties and also those of the blends are given in Table 2.
Example 7
A Block Copolymer of 90:10 PPSU:PSU (B 5)
An experimental set up similar to that described in Example 1 was used.
Part 1: The Preparation of the PPSU Homoblock
DMAc (8037 gms, 950 ml/mole) and toluene (3096 gms, 400 ml/mole) were placed in the flask, through which nitrogen gas was bubbled continuously, and heated to 45° C. Biphenol (1674 gms) and 4,4′-dichlorodiphenyl sulfone (DCDPS) (2816 gms) were added to the flask, the DCDPS and biphenol being in a molar ratio of 1.09:1.00, and the reactants were stirred for 30 minutes. Anhydrous potassium carbonate (1366 gms) and anhydrous sodium carbonate (191 gms) were added to the flask. The toluene acts as an azeotropic solvent.
The rest of the procedure is the same as that described in Part 1 of Example 1. The homoblock obtained had GPC molecular weights of Mn 42,000, an Mw of 55,000 and an MWD of 1.31.
Part 2: Preparation of the PSU Homoblock
DMAc (893 gms, 950 ml/mole) and toluene (344 gms 400 ml/mole) were placed in the flask, through which nitrogen gas was bubbled continuously, and heated to 45° C. Bisphenol A (244 gms) and 4,4′-dichlorodiphenyl sulfone (DCDPS) (287 gms), were added to the flask, the Bisphenol A and DCDPS being in a molar ratio of 1.07:1.00, and the reaction mixture was stirred for 30 minutes. Anhydrous potassium carbonate (170 gms) was added to the flask. The toluene acts as an azeotropic solvent.
The rest of the procedure is the same as that described in Part 2 of Example 1. The homoblock obtained had GPC molecular weights of Mn 18,000, an Mw of 24,000 and an MWD of 1.34.
Part 3: The Preparation of the Block Copolymer
The reaction mixtures of Part 1 (9 parts) and Part 2 (1 Part) were mixed together and the block polymerization was conducted at 165° C. An insufficient viscosity rise took place during the polymerization. The GPC analysis showed an Mn of 48,000, an Mw of 67,000 and an MWD of 1.39, so an extra 0.04 mole/mole of biphenol was added and the polymerization was continued. After the required GPC MW was achieved, the reaction mixture was quenched with DMAc (376 gms, 400 ml/mole) and its temperature reduced to 160° C. Methyl Chloride gas was then bubbled through the reaction mixture for 5 hrs to ensure complete end capping. The reaction mixture was then diluted with DMAc (564 gms, 600 ml/mole) for a second time. The polymer solution was passed through a 15 micron filter in a pressure filter funnel using 2 kg/cm 2 nitrogen to remove any salts. The block copolymer was finally recovered by slowly adding the salt-free polymer solution to de-ionized water (13 ml/gm of polymer) under high-speed agitation. The precipitated polymer was then recovered by filtration. The precipitated polymer was treated three times with refluxing de-ionized water at 90° C. The precipitated polymer was then filtered and dried in an oven at 140° C. until the moisture content as determined by Karl Fisher titration was <0.5%.
GPC analysis of the copolymer showed an Mn of 93,000, an Mw of 132,000 and an MWD of 1.41 based on polystyrene standards. The block copolymer was then granulated as in Example 1 and its properties were measured. These were a Tg of 219° C. and a specific gravity of 1.28. This data, and the product being obtained as clear transparent granules, indicated that PPSU and PSU were indeed present as a block copolymer and not simply as a blend of the two homopolymers. The remaining properties and also those of the blends are given in Table 2.
Example 8
A Block Copolymer of 80:20 PPSU:PSU (B 6)
An experimental set up similar to that described in Example 1 was used.
Part 1: The Preparation of the PPSU Homoblock
DMAc (7144 gms, 950 ml/mole) and toluene (2752 gms, 400 ml/mole) were placed in the flask, through which nitrogen gas was bubbled continuously, and heated to 45° C. Biphenol (1488 gms) and 4,4′-dichlorodiphenyl sulfone (DCDPS) (2503 gms) were added to the flask, the DCDPS and biphenol being in a molar ratio of 1.09:1.00, and the reactants were stirred for 30 minutes. Anhydrous potassium carbonate (1215 gms) and anhydrous sodium carbonate (170 gms) were added to the flask. The toluene acts as an azeotropic solvent.
The rest of the procedure is the same as that described in Part 1 of Example 1. The homoblock obtained had GPC molecular weights of Mn 42,000, an Mw of 53,000 and an MWD of 1.25.
Part 2: The Preparation of the PSU Homoblock
DMAc (1786 gms, 950 ml/mole) and toluene (688 gms 400 ml/mole) were placed in the flask, through which nitrogen gas was bubbled continuously, and heated to 45° C. Bisphenol A (524 gms) and 4,4′-dichlorodiphenyl sulfone (DCDPS) (574 gms), were added to the flask, the Bisphenol A and DCDPS being in a molar ratio of 1.15:1.00, and the reaction mixture was stirred for 30 minutes. Anhydrous potassium carbonate (365 gms) was added to the flask. The toluene acts as an azeotropic solvent.
The rest of the procedure is the same as that described in Part 2 of Example 1. The homoblock obtained had GPC molecular weights of Mn 17,000, an Mw of 23,000 and an MWD of 1.33
Part 3: The Preparation of the Block Copolymer
The reaction mixtures of Part 1 (8 parts) and Part 2 (2 Part) were mixed together and the polymerization was conducted at 165° C. When the GPC molecular weight showed an Mw of 94,000. The reaction mass was quenched with DMAc (376 gms, 400 ml/mole) and its temperature reduced to 160° C. Methyl Chloride gas was then bubbled through the reaction mixture for 5 hrs to ensure complete end capping. The reaction mixture was then diluted with DMAc (564 gms, 600 ml/mole) for a second time. The polymer solution was passed through a 15 micron filter in a pressure filter funnel using 2 kg/cm 2 nitrogen to remove any salts. The block copolymer was finally recovered by slowly adding the salt-free polymer solution to de-ionized water (13 ml/gm of polymer) under high-speed agitation. The precipitated polymer was then recovered by filtration. The precipitated polymer was treated three times with refluxing de-ionized water at 90° C. The precipitated polymer was then filtered and dried in an oven at 140° C. until the moisture content as determined by Karl Fisher titration was <0.5%.
GPC analysis of the copolymer showed an Mn of 68,000, an Mw of 96,000 and an MWD of 1.40 based on Polystyrene standards. The block copolymer was then granulated as in Example 1 and its properties were measured. These were a Tg of 210° C. and a specific gravity of 1.27. This data, and the product being obtained as clear transparent granules, indicated that PPSU and PSU were indeed present as a block copolymer and not simply as a blend of the two homopolymers. The remaining properties and also those of the blends are given in Table 2.
Example 9
The Solubility of a Block Copolymer of 90:10 PPSU:PSU
Polyphenylene sulfone (PPSU) is insoluble in tetrahydrofuran (THF) at 65° C., whereas polyether sulfone (PSU) is soluble. The 90:10 PPSU:PSU block copolymer was only 0.64% soluble in ThF, clearly indicating its block structure.
The other block copolymers of PPSU-PSU (B-0, B-1 and B-2) were also soluble in THF.
Example 10
The Hydrolytic Stability of a Block Copolymer
Samples of the PPSU-PSU block copolymer from Example No. 6 were kept in boiling water at 100° C. for 7 days. The tensile properties of the samples were measured before and after their boiling in water and the results are shown below:
Tensile properties
before boiling in water
after boiling in water
Tensile Strength(Mpa)
73
70
Tensile Modulus(Mpa)
1915
1900
Elongation at break(%)
69
70
This data indicates that there is no drop in the tensile strength of the block copolymer after being stored in boiling water for 7 days and hence it can find applications where hydrolytic stability is important.
In the following Tables 1 and 2 the abbreviations used have the following meanings:—
TABLE 1 PROPERTIES COMPARISION OF PPSU-PSU COPOLYMERS WITH NEAT PPSU & NEAT PSU & THEIR BLENDS: C-1 C-2 C-3 B-0 B-1 B-2 B-3 PPSU = 75% PPSU = 50% PPSU = 25% PPSU = 50% PPSU = 75% PPSU = 25% PPSU = 90% PROPERTY PPSU PSU PSU = 25% PSU = 50% PSU = 75% PSU = 50% PSU = 25% PSU = 75% PSU = 10% Mn 80 90 85 94 97 94 83 79 80 Mw 111 129 122 131 135 135 119 114 110 MWD 1.39 1.44 1.43 1.39 1.39 1.44 1.40 1.44 1.36 SPECIFIC 1.290 1.235 1.277 1.259 1.248 1.26 1.27 1.248 1.28 GRAVITY TENSILE 74 76 75 78 76 74 75 76 76 STRENGTH (Mpa) TENSILE 2500 2300 2195 2400 2304 2175 2252 2501 2281 MODULUS (Mpa) ELONGATION @ >80 >80 68 ? 60 36 48 44 59 BRECK % IMPACT 650 45 117 76 61 97 94 61 160 STRENGTH (J/M) FLEXURAL 100 114 104 108 105 110 111 113 99 STRENGTH (Mpa) FLEXURAL 2200 2455 2323 2439 2228 2478 2402 2518 2293 MODULUS (Mpa) YIELD STRESS (%) 8 7 8 8 8 7.3 8.0 7.4 8.4 Tg1 & Tg2 (° C.) 223 189 192&221 191&220 191&221 206 210 194 215 HDT (° C.) 198 166 192 183 188 MVR at 400° C./2.16 kg/ 13 12.8 23 28 38 6′
The higher impact properties, one intermediate Tg and transparency of granules indicate that B0, B1, B2 & B3 are block copolymers and not just physical mixtures like C1, C2 & C3.
TABLE 2 B-4 B-5 B-6 PPSU = 90% PPSU = 90% PPSU = 80% PROPERTY PPSU PSU PSU = 10% PSU = 10% PSU = 20% Mn 80 90 80 93 68 Mw 111 129 115 132 96 MWD 1.39 1.44 1.44 1.41 4.41 SPECIFIC GRAVITY 1.290 1.235 1.28 1.28 1.27 TENSILE 74 76 70 76 78 STRENGTH (Mpa) TENSILE 2500 2300 2149 2165 2120 MODULUS (Mpa) ELONGATION @ >80 >80 72 69 50 BRECK % IMPACT 650 45 586 723 113 STRENGTH (J/M) FLEXURAL 100 114 99 115 122 STRENGTH (Mpa) FLEXURAL MODULUS 2200 2455 2291 2514 2637 (Mpa) YIELD STRESS (%) 8 7 8 9 8.6 Tg. 223 189 216 219 210 HDT (° C.) 198 166 193.6 16.3 MVR at 400° C./2.16 kg/6′ 13 5 20.6 7.7 58.8 CC/10 min.
The higher impact properties, one intermediate Tg and transparency of granules indicate that B4, B5, B6 are block copolymers
Example 11
A Block-Copolymer of 75:25 PSU:PES (BC-07)
The following three part procedure was used to prepare this PSU-PES block copolymer.
Part 1: The Preparation of the PSU Homoblock
DMAc (873 gms, 950 ml/mole) and toluene (400 ml/mole) were placed in the flask, through which nitrogen gas was bubbled continuously, and heated to 45° C. Bisphenol A (684 gms) and 4,4′-dichlorodiphenyl sulfone (DCDPS) (886.8 gms) were added to the flask, the DCDPS and Bis Phenol A being in a molar ratio of 1.03:1.00, and the reaction mixture was stirred for 30 minutes. Anhydrous potassium carbonate (476 gms) was added. The toluene acts as an azeotropic solvent. The temperature of the reactants was slowly increased to 165° C. over 9 hours and the stirring speed was set to 400 rpm. The water formed due to the reaction was distilled over as an azeotrope with toluene and collected in the Dean-Stark trap. The toluene was then returned to the reaction mixture once it had been separated from the water. Once the water had been completely removed, toluene addition back to the reaction vessel was stopped. The toluene was then removed completely from the reaction mixture as the temperature of the reactants increased. The desired temperature was reached after 9 hours. The reaction temperature was then maintained at 165° C. and when the viscosity started to increase the stirring speed was raised to 500 rpm. At the required Mn of 13,000, MW of about 17,000 and MWD 1.36 the viscosity of the reaction mixture remained almost constant, indicating the end of the polymerization reaction.
Part 2: The Preparation of the PES Homoblock
A 4-necked, 3-litre glass flask was equipped with an overhead stirrer attached to a stainless steel paddle through its center neck. Through one of its side necks, a Cloisonné adapter was attached. The other neck of the Cloisonné adapter was attached to a Dean-Stark trap and a water-cooled condenser. A thermocouple thermometer was inserted through another of the side necks. A nitrogen gas inlet was inserted through the other side neck. The flask was placed in an oil bath, which was connected to a temperature controller.
Dimethyl acetamide (DMAc) (873 gms, 950 ml/mole) and toluene (344 gms, 400 ml/mole) were placed in the flask and heated to 45° C. DHDPS (257.5 gms) and 4,4′-dichlorodiphenyl sulfone (DCDPS) (287 gms) were added to the flask, the DHDPS and DCDPS being in a molar ratio of 1.03:1.00, and the reactants were stirred for 30 minutes. Anhydrous potassium carbonate (158.7 gms) was added to the flask. A nitrogen atmosphere was maintained in the flask by purging. The temperature of the reactants was slowly increased to 165° C. over 9 hours and the stirring speed set to 400 rpm. The water formed due to the reaction of K 2 CO 3 with DHDPS was distilled over as an azeotrope with toluene and collected in the Dean-Stark trap. The toluene was then returned to the reaction mixture once it had been separated from the water. Once the water had been completely removed, toluene addition back to reaction vessel was stopped. The toluene was then removed completely from the reaction mixture as the temperature of the reactants increased. The desired temperature was reached after 9 hours. The reaction temperature was then maintained at 165° C. and when the viscosity started to increase the stirring speed was raised to 500 rpm. Once the viscosity increase slowed, a sample was taken out to check the molecular weight. The GPC Mn achieved was about 22,000, with a Mw of 25,000 and a MWD of 1.15. The reaction mixture was allowed to cool in preparation for its reaction with the product of part 2. The relatively high molar ratio of DCDPS to DHDPS gave PES of a relatively low molecular weight and with predominantly end groups of —Ph—Cl.
Part 3: The Preparation of the Block Copolymer
The reaction mixtures of Part 1 (3 parts) and Part 2 (1 part) were mixed by weight proportion and the block polymerization was conducted at 165° C. After the required MW was achieved, as shown by GPC, the reaction mixture was quenched with DMAc (376 gms, 400 ml/mole) and its temperature reduced to 140° C. Methyl Chloride gas was then bubbled through the reaction mixture for 5 hrs to ensure complete end capping. The reaction mixture was then diluted with DMAc (600 ml/mole) for a second time. The polymer solution was filtered through a 15 micron filter in a pressure filter funnel using 2 kg/cm 2 of nitrogen to remove any salts. The block copolymer was finally recovered by slowly adding the salt-free polymer solution to de-ionized water (13 ml/gm of polymer) under high-speed agitation. The precipitated polymer was then recovered by filtration. The precipitated polymer was ground and refluxed three times with de-ionized water at 90° C. to completely remove all salts and DMAc. The precipitated polymer was then filtered and dried in an oven at 140° C. until the moisture content as determined by Karl Fischer titration was <0.5%.
GPC analysis of the block copolymer showed an Mn of 77,000, an Mw of 108,000 and an MWD of 1.39 based on the polystyrene standards. Thus, the copolymer produced had a significantly higher molecular weight than the two homoblocks used as monomer units, indicating the preparation of a block copolymer. The block copolymer powder was then mixed with 0.3% heat stabilizer and granulated using a twin screw extruder. The Tg and the specific gravity of PSU are 190° C. and 1.24 respectively, whilst those of PES are 224° C. and 1.37. The transparent granules of block copolymer showed a DSC Tg of 198° C. and a specific gravity of 1.27. The transparency of the granules, the single GPC peak, the intermediate Tg and the specific gravity of the product clearly indicate that a block-copolymer of PSU and PES had indeed been formed and that the product was not simply a blend of the two homopolymers, PSU and PES. The remaining properties and also those of the blends are given in Table 1.
Example 12
A Block-Copolymer of 50:50 PSU:PES (B-8)
An experimental set up similar to that described in Example 1 was used.
Part 1: The Preparation of the PSU Homoblock
Dimethyl Acetamide (DMAc) (1786 gms, 950 ml/mole) and Toluene (688 gms, 400 ml/mole) were placed in the flask, through which nitrogen gas was bubbled continuously, and heated to 45° C. Bisphenol A (461 Gms) and 4,4′-dichlorodiphenyl sulfone (DCDPS) (574 gms) were added to the flask, the Bisphenol A and DCDPS being in a molar ratio of 1.01:1.00, and the reaction mixture was stirred for 30 minutes. Anhydrous potassium carbonate (318 gms) was added to the flask. The toluene acts as an azeotropic solvent.
The rest of the procedure is the same as that described in Part 1 of Example 1. The homoblock obtained had a GPC molecular weight of Mn 8,000, an Mw of 11,000 and an MWD of 1.43.
Part 2: The Preparation of the PES Homoblock
DMAc (1786 gms, 950 ml/mole) and toluene (688 gms, 400 ml/mole) were placed in the flask, through which nitrogen gas was bubbled continuously, and heated to 45° C. DHDPS (500 gms) and 4,4′-dichlorodiphenyl sulfone (DCDPS) (586 gms) were added to the flask, the DCDPS and DHDPS being in a molar ratio of 1.02:1.00, and the reactants were stirred for 30 minutes. Anhydrous potassium carbonate (318 gms) was added to the flask. The toluene acts as an azeotropic solvent.
The rest of the procedure is the same as that described in Part 2 of Example 1. The homoblock obtained had a GPC molecular weight of Mn 28,000, an Mw of 34,000 and an MWD of 1.21.
Part 3: The Preparation of the Block Copolymer
The reaction mixtures of Part 1 and Part 2 were mixed together and the block polymerization was conducted at 165° C. After the required GPC MW was achieved, the reaction mixture was quenched with DMAc (344 gms, 400 ml/mole) and its temperature reduced to 140° C. Methyl Chloride gas was then bubbled through the reaction mixture for 5 hrs to ensure complete end capping. The reaction mixture was then diluted with DMAc (600 ml/mole) for a second time. The polymer solution was passed through a 15 micron filter in a pressure filter funnel using 2 kg/cm 2 nitrogen to remove any salts. The block copolymer was finally recovered by slowly adding the salt-free polymer solution to de-ionized water (13 ml/gm of polymer) under high-speed agitation. The precipitated polymer was then recovered by filtration. The precipitated polymer was treated three times with refluxing de-ionized water at 90° C. The precipitated polymer was then filtered and dried in oven at 140° C. until the moisture content as determined by Karl Fisher titration was <0.5%.
GPC analysis of the block copolymer showed an Mn of 67,000, an Mw of 92,000 and an MWD of 1.37 based on the polystyrene standards. The block copolymer was then granulated as in Example 1 and its properties were measured. These were a Tg of 208° C. and a specific gravity of 1.3. This data, and the product being obtained as clear transparent granules, indicated that PES and PSU were present as a block copolymer and not simply as a blend of the two homopolymers. The remaining properties and also those of the blend of similar proportions are given in Table 1.
Example 13
A Block Copolymer of 25:75 PSU:PES (BC 09)
An experimental set up similar to that described in Example 1 was used.
Part 1: The Preparation of the PSU Homoblock
DMAc (893 gms, 950 ml/mole) and toluene (344 gms 400 ml/mole) were placed in the flask, through which nitrogen gas was bubbled continuously, and heated to 45° C. Bisphenol A (232 gms) and DCDPS (287 gms) were added to the flask, the Bisphenol A and DCDPS being in a molar ratio of 1.00:1.02, and the reaction mixture was stirred for 30 minutes. Anhydrous potassium carbonate (162 gms) was then added to the flask.
The rest of the procedure is same as that described in Part 1 of Example 1. The homoblock obtained had a GPC molecular weight of Mn 17,000, an Mw of 22,000 and an MWD of 1.29 based on the polystyrene standards.
Part 2: The Preparation of the PES Homoblock
DMAc (2679 gms, 950 ml/mole) and toluene (1032 gms, 400 ml/mole) were placed in the flask, through which nitrogen gas was bubbled continuously, and heated to 45° C. DHDPS (750 gms) and DCDPS (878 gms) were added to the flask, the DCDPS and DHDPS being in a molar ratio of 1.02:1.00, and the reactants were stirred for 30 minutes. Anhydrous potassium carbonate (476 gms, 1.15 mole/mole) added to the flask.
The rest of the procedure is same as that described in Part 2 of Example 1. The homoblock obtained had a GPC molecular weight of Mn 15,000, an Mw of 20,000 and an MWD of 1.33 based on the polystyrene standards.
Part 3: The Preparation of the Block Copolymer
The reaction mixtures of Part 1 (1 part) and Part 2 (3 parts) were mixed together and the block polymerization was conducted at 165° C. After the required GPC MW was achieved, the reaction mixture was quenched and the copolymer worked up as in Example 1.
GPC analysis of the copolymer showed an Mn of 68,000, an Mw of 104,000 and an MWD of 1.53. The block copolymer powder was then extruded and granulated as per the procedure given in Example 1. The DSC Tg of the copolymer was 218° C. and the specific gravity was 1.33. This data, and the product being obtained as light amber colored transparent granules, indicated that the polymer obtained was indeed a block copolymer and not simply a blend of PSU and PES. The remaining properties and also those of the blends are given in Table 3.
Example 14
A Block Copolymer of 10:90 PSU:PES (BC 10)
An experimental set up similar to that described in Example 1 was used.
Part 1: The Preparation of the PSU Homoblock
DMAc (357 gms, 950 ml/mole) and toluene (138 gms 400 ml/mole) were placed in the flask, through which nitrogen gas was bubbled continuously, and heated to 45° C. Bisphenol A (93 gms) and DCDPS (115 gms) were added to the flask, the Bisphenol A and DCDPS being in a molar ratio of 1.02:1.00, and the reaction mixture was stirred for 30 minutes. Anhydrous potassium carbonate (65 gms) was then added to the flask.
The rest of the procedure is same as that described in Part 1 of Example 1. The homoblock obtained had a GPC molecular weight of Mn 49,000, an Mw of 63,000 and an MWD of 1.29 based on the polystyrene standards.
Part 2: The Preparation of the PES Homoblock
DMAc (3215 gms, 950 ml/mole) and toluene (1238 gms, 400 ml/mole) were placed in the flask, through which nitrogen gas was bubbled continuously, and heated to 45° C. DHDPS (900 gms) and DCDPS (1044 gms) were added to the flask, the DCDPS and DHDPS being in a molar ratio of 1.01:1.00, and the reactants were stirred for 30 minutes. Anhydrous potassium carbonate (571 gms, 1.15 mole/mole) added to the flask.
The rest of the procedure is same as that described in Part 2 of Example 1. The homoblock obtained had a GPC molecular weight of Mn 35,000, an Mw of 51,000 and an MWD of 1.46 based on the polystyrene standards.
Part 3: The Preparation of the Block Copolymer
The reaction mixtures of Part 1 (1 part) and Part 2 (9 parts) were mixed together and the block polymerization was conducted at 165° C. After the required GPC MW was achieved, the reaction mixture was quenched and the copolymer worked up as in Example 1.
GPC analysis of the copolymer showed an Mn of 87,000, an Mw of 113,000 and an MWD of 1.29. The block copolymer powder was then extruded and granulated as per the procedure given in Example 1. The DSC Tg of the copolymer was 222° C. and the specific gravity was 1.357. This data, and the product being obtained as light amber colored transparent granules, indicated that the polymer obtained was indeed a block copolymer and not simply a blend of PSU and PES. The remaining properties and also those of the blends are given in Table 3.
Example 15
Physical Blends of PSU and PES:
In order to study the properties of the physical blending of PPSU and PSU dry blending of the powders was carried out in the following proportions, followed by extrusion on ZE 25 twin screw extruder and evaluation (Table 3).
C1:
PSU powder (75%) + PES powder (25%)
C2:
PSU powder (50%) + PES Powder (50%)
C3:
PSU powder (25%) + PES powder (75%)
C4:
PSU powder (10%) + PES powder (90%)
The PES used was the commercially available GAFONE-3300 grade and the PSU used was the commercially available GAFONE-S PSU 1300, both from Gharda Chemicals Ltd. India.
TABLE 3 PROPERTIES COMPARISION OF PPSU-PSU COPOLYMERS WITH NEAT PSU & NEAT PES & THEIR BLENDS C-1 C-2 C-3 C-4 BC-7 BC-8 BC-9 BC-10 PSU = 75% PSU = 50% PSU = 25% PSU = 90% PSU = 75% PSU = 50% PSU = 25% PSU = 10% PROPERTY PES PSU PES = 25% PES = 50% PES = 75% PES = 10% PES = 25% PES = 50% PES = 75% PES = 90% Mn 86 90 In all cases Extrusion was not FAILED due to 77 67 68 87 immiscibility of PES & PSU. Mw 120 129 108 92 104 113 MWD 1.39 1.44 1.39 1.37 1.53 1.29 SPECIFIC 1.37 1.235 1.27 1.3 1.33 1.357 GRAVITY TENSILE 76 82 72 88 STRENGTH (Mpa) TENSILE 2300 1993 2457 2110 MODULUS (Mpa) ELONGA- □ 80 53 25 17 TION @ BRECK % IMPACT 45 4.8 4.9 5.1 5.2 STRENGTH (J/M) YIELD 7 7.5 7.3 7.7 STRESS (%) Tg1 & 189 198 208 218 223 Tg2 (° C.) HDT (° C.) 166 MVR at 40.25 28 60.9 380° C./ 2.16 kg/6′
The g and transparency of granules indicate that BC7, BC8, BC9 & BC10 are block copolymers and not just physical mixtures like C1, C2, C3 & C4, are not miscible.
Example 16
A Block-Copolymer of 90:10 PES: PPSU (D-2)
The following three part procedure was used to prepare this PES-PPSU block copolymer.
Part 1: The Preparation of the PES Homoblock
DMAc (2876 gms, 850 ml/mole) and toluene (400 ml/mole) were placed in the flask, through which nitrogen gas was bubbled continuously, and heated to 65° C. 4,4′-dihydroxydiphenyl sulfone (DHDPS) (900 gms) and 4,4′-dichlorodiphenyl sulfone (DCDPS) (1044 gms) were added to the flask, the DCDPS and DHDPS being in a molar ratio of 1.01:1.00, and the reaction mixture was stirred for 30 minutes. Anhydrous potassium carbonate (572 gms) was added. The toluene acts as an azeotropic solvent. The temperature of the reactants was slowly increased to 165° C. over 9 hours and the stirring speed was set to 400 rpm. The water formed due to the reaction was distilled over as an azeotrope with toluene and collected in the Dean-Stark trap. The toluene was then returned to the reaction mixture once it had been separated from the water. Once the water had been completely removed, toluene addition back to the reaction vessel was stopped. The toluene was then removed completely from the reaction mixture as the temperature of the reactants increased. The desired temperature was reached after 9 hours. The reaction temperature was then maintained at 165° C. and when the viscosity started to increase the stirring speed was raised to 500 rpm. At the required Mn of 11,000, MW of about 14,000 and MWD 1.20 the viscosity of the reaction mixture remained almost constant, indicating the end of the polymerization reaction.
Part 2: The Preparation of the PPSU Homoblock
A 4-necked, 3-litre glass flask was equipped with an overhead stirrer attached to a stainless steel paddle through its center neck. Through one of its side necks, a Cloisonné adapter was attached. The other neck of the Cloisonné adapter was attached to a Dean-Stark trap and a water-cooled condenser. A thermocouple thermometer was inserted through another of the side necks. A nitrogen gas inlet was inserted through the other side neck. The flask was placed in an oil bath, which was connected to a temperature controller.
Dimethyl acetamide (DMAc) (357 gms, 950 ml/mole) and toluene (400 ml/mole) were placed in the flask and heated to 45° C. Biphenol (75.9) and 4,4′-dichlorodiphenyl sulfone (DCDPS) (114.8 gms) were added to the flask, the Biphenol and DCDPS being in a molar ratio of 1.02:1.00, and the reactants were stirred for 30 minutes. Anhydrous potassium carbonate (61 gms) Anhydrous Sodium carbonate (8.5 gms) ware added to the flask. A nitrogen atmosphere was maintained in the flask by purging. The temperature of the reactants was slowly increased to 165° C. over 9 hours and the stirring speed set to 400 rpm. The water formed due to the reaction of K 2 CO 3 & Na 2 CO 3 with Biphenol was distilled over as an azeotrope with toluene and collected in the Dean-Stark trap. The toluene was then returned to the reaction mixture once it had been separated from the water. Once the water had been completely removed, toluene addition back to reaction vessel was stopped. The toluene was then removed completely from the reaction mixture as the temperature of the reactants increased. The desired temperature was reached after 9 hours. The reaction temperature was then maintained at 165° C. and when the viscosity started to increase the stirring speed was raised to 500 rpm. Once the viscosity increase slowed, a sample was taken out to check the molecular weight. The GPC Mn achieved was about 17,000, with a Mw of 22,000 and a MWD of 1.33. The reaction mixture was allowed to cool in preparation for its reaction with the product of part 2. The relatively high molar ratio of DCDPS to Biphenol gave PPSU of a relatively low molecular weight and with predominantly end groups of —Ph—Cl.
Part 3: The Preparation of the Block Copolymer
The reaction mixtures of Part 1 (9 part) and Part 2 (1 part) were mixed by weight proportion and the block polymerization was conducted at 165° C. After the required MW was achieved, as shown by GPC, the reaction mixture was quenched with DMAc (376 gms, 400 ml/mole) and its temperature reduced to 140° C. Methyl Chloride gas was then bubbled through the reaction mixture for 5 hrs to ensure complete end capping. The reaction mixture was then diluted with DMAc (600 ml/mole) for a second time. The polymer solution was filtered through a 15 micron filter in a pressure filter funnel using 2 kg/cm 2 of nitrogen to remove any salts. The block copolymer was finally recovered by slowly adding the salt-free polymer solution to de-ionized water (13 ml/gm of polymer) under high-speed agitation. The precipitated polymer was then recovered by filtration. The precipitated polymer was ground and refluxed three times with de-ionized water at 90° C. to completely remove all salts and DMAc. The precipitated polymer was then filtered and dried in an oven at 140° C. until the moisture content as determined by Karl Fischer titration was <0.5%.
GPC analysis of the block copolymer showed an Mn of 78,000, an Mw of 112,000 and an MWD of 1.43 based on the polystyrene standards. Thus, the copolymer produced had a significantly higher molecular weight than the two homoblocks used as monomer units, indicating the preparation of a block copolymer. The block copolymer powder was then mixed with 0.3% heat stabilizer and granulated using a twin screw extruder. The Tg and the specific gravity of PES are 224° C. and 1.37 respectively, whilst those of PPSU are 223° C. and 1.29. The transparent granules of block copolymer showed a DSC Tg of 224° C. and a specific gravity of 1.36. The transparency of the granules, the single GPC peak, the intermediate Tg and the specific gravity of the product clearly indicate that a block-copolymer of PES and PPSU had indeed been formed and that the product was not simply a blend of the two homopolymers, PES and PPSU.
Various homoblocks can be prepared using one or more dichloro compounds and one or more dihydroxy compounds, some of which are listed below:
Aromatic Dihalo Compounds
Dichloro diphenyl sulfone (DCDPS), 4,4′ Bis(4-chlorophenyl sulfonyl)biphenyl (CSB), Dichloro Benzophenone, Dichloro diphenyl ether, Dichloro biphenyl, Dichloro diphenyl methylene, Di Methyl dichloro diphenyl sulfone, tetra methyl dichloro diphenyl sulfone.
Aromatic Dihydroxy Compounds
Dihydroxy diphenyl Sulfone (DHDPS), Bisphenol A, Biphenol, Hydroquinone, Dimethyl Dihydroxy diphenyl sulfone, Tetramethyl dihydroxy diphenyl sulfone, Tetramethyl Bisphenol A, Tetramethyl Biphenol.
Example 17
A Block-Copolymer of 75:25 PES:PPSU (MPES # S-01)
The following three part procedure was used to prepare this PES-PPSU block copolymer.
Part 1: The Preparation of the PES Homoblock
A 4-necked, 3-litre glass flask was equipped with an overhead stirrer attached to a stainless steel paddle through its center neck. The other neck of the flask attached with steel head and vertical cooled condenser. A thermocouple thermometer was inserted through another of the side necks. A nitrogen gas inlet was inserted through the other side neck. The flask was placed in an oil bath, which was connected to a temperature controller.
Sulfolane (945 gms, 750 ml/mole) were placed in the flask and heated to 45° C. and 4,4′-dichlorodiphenyl sulfone (DCDPS) (222 gms) and 4,4′Dihydroxy Diphenyl sulfone (DHDPS) (187.5 gms) were added to the flask, the DCDPS and DHDPS being in a molar ratio of 1.03:1.00, and the reactants were stirred for 30 minutes. Anhydrous sodium carbonate (94 gms) were added to the flask. A nitrogen atmosphere was maintained in the flask by purging. The temperature of the reactants was slowly increased to 225° C. over 6 hours and the stirring speed set to 400 rpm. The water formed due to the reaction of Na 2 CO 3 with DHDPS was distilled through condenser. The reaction temperature was then maintained at 220° C. and when the viscosity started to increase the stirring speed was raised to 500 rpm. Once the viscosity increase slowed, a sample was taken out to check the molecular weight. The GPC Mn achieved was about 24,000, with a Mw of 34,000 and a MWD of 1.37. The reaction mixture was allowed to cool in preparation for its reaction with the product of part 2. The relatively high molar ratio of DCDPS to DHDPS gave PES of a relatively low molecular weight and with predominantly end groups of —Ph—Cl.
Part 2: The Preparation of the PPSU Homoblock
Sulfolane (315 gms, 250 ml/mole) and toluene (400 ml/mole) were placed in the flask, through which nitrogen gas was bubbled continuously, and heated to 45° C. 4,4′-dichlorodiphenyl sulfone (DCDPS) (71.75 gms) and Biphenol (48 gm) were added to the flask, and Biphenol:DCDPS being in a molar ratio of 1.03:1.00, and the reaction mixture was stirred for 30 minutes. Anhydrous potassium carbonate (39.7 gms) was added. The toluene acts as an azeotropic solvent. The temperature of the reactants was slowly increased to 190° C. over 4 hours and the stirring speed was set to 400 rpm. The water formed due to the reaction was distilled over as an azeotrope with toluene and collected in the Dean-Stark trap. The toluene was then returned to the reaction mixture once it had been separated from the water. Once the water had been completely removed, toluene addition back to the reaction vessel was stopped. The toluene was then removed completely from the reaction mixture as the temperature of the reactants increased. The desired temperature was reached after 4 hours. The reaction temperature was then maintained at 190° C. and when the viscosity started to increase the stirring speed was raised to 500 rpm. At the required Mn of 18,000, MW of about 22,000 and MWD 1.14 The relatively high molar ratio of Biphenol to DCDPS gave PPSU of a relatively low molecular weight and with predominantly end groups of —Ph—OH
Part 3: The Preparation of the Block Copolymer
The reaction mixtures of Part 1 and Part 2 were mixed in equal proportions by weight and the block polymerization was conducted at 220° C. After the required MW was achieved, as shown by GPC, the reaction mixture was quenched with Sulfolane (252 gms, 200 ml/mole) and its temperature reduced to 210° C. Methyl Chloride gas was then bubbled through the reaction mixture for 3 hrs to ensure complete end capping. The reaction mixture was then diluted with Sulfolane (400 ml/mole) for a second time. The polymer solution was filtered through a 15 micron filter in a pressure filter funnel using 2 kg/cm 2 of nitrogen to remove any salts. The block copolymer was finally recovered by slowly adding the salt-free polymer solution to de-ionized water (13 ml/gm of polymer) under high-speed agitation. The precipitated polymer was then recovered by filtration. The precipitated polymer was ground and refluxed three times with de-ionized water at 90° C. to completely remove all salts and Sulfolane. The precipitated polymer was then filtered and dried in an oven at 140° C. until the moisture content as determined by Karl Fischer titration was <0.5%.
GPC analysis of the block copolymer showed an Mn of 85,000, an Mw of 119,000 and an MWD of 1.39 based on the polystyrene standards. Thus, the copolymer produced had a significantly higher molecular weight than the two homoblocks used as monomer units, indicating the preparation of a block copolymer. The block copolymer powder was then mixed with 0.25% heat stabilizer and granulated using a twin screw extruder. The Tg and the specific gravity of PES are 225° C. and 1.37 respectively, whilst those of PPSU are 222° C. and 1.290. The transparent granules of block copolymer showed a DSC Tg of 224° C. and a specific gravity of 1.34. The transparency of the granules, the single GPC peak, the intermediate Tg and the specific gravity of the product clearly indicate that a block-copolymer of PES and PPSU had indeed been formed and that the product was not simply a blend of the two homopolymers, PES and PPSU.
Example 18
A Block-Copolymer of 50:50 PSSD:PSSB (MPSS #2)
The following three part procedure was used to prepare this PSSD-PSSB block copolymer.
PSSD: PSS made by using DHDPS and CSB as monomer
Part 1: The Preparation of the PSSD Homoblock
A 4-necked, 10-liter glass flask was equipped with an overhead stirrer attached to a stainless steel paddle through its center neck. The other neck of the flask attached with steel head and vertical cooled condenser. A thermocouple thermometer was inserted through another of the side necks. A nitrogen gas inlet was inserted through the other side neck. The flask was placed in an oil bath, which was connected to a temperature controller.
Sulfolane (4410 gms, 3500 ml/mole) and toluene (1000 ml/mole) were placed in the flask, through which nitrogen gas was bubbled continuously, and heated to 45° C. 4,4′ Bis [(4-Chlorophenyl) Sulfonyl] Biphenyl (CSB) (523 gms) and 4,4′ Dihydroxy diphenyl sulfone (DHDPS) (250 gms) were added to the flask and CSB:DHDPS being in a molar ratio of 1.04:1.00 and the reaction mixture was stirred for 30 minutes. Anhydrous sodium carbonate (123 gms) was added. A nitrogen atmosphere was maintained in the flask by purging. The toluene acts as an azeotropic solvent. The temperature of the reactants was slowly increased to 220° C. over 5 hours and the stirring speed was set to 400 rpm. The water formed due to the reaction of Na2CO3 with DHDPS was distilled over as an azeotrope with toluene and collected in the Dean-Stark trap. The toluene was then returned to the reaction mixture once it had been separated from the water. Once the water had been completely removed, toluene addition back to the reaction vessel was stopped. The toluene was then removed completely from the reaction mixture as the temperature of the reactants increased. The desired temperature was reached after 5 hours. The reaction temperature was then maintained at 220° C. and when the viscosity started to increase the stirring speed was raised to 500 rpm. At the required Mn of 17,000, MW of about 20,000 and MWD 1.19 The relatively high molar ratio of CSB to DHDPS gave PSSD of a relatively low molecular weight and with predominantly end groups of —Ph—Cl
Part 2: The Preparation of the PSSB Homoblock
PSSB:PSS made by using Biphenol and CSB as monomer
Sulfolane (4410 gms, 3500 ml/mole) and toluene (1000 ml/mole) were placed in the flask, through which nitrogen gas was bubbled continuously, and heated to 45° C.
4,4′ Bis [(4-Chlorophenyl) Sulfonyl] Biphenyl (CSB) (503 gms) and Biphenol (188 gms) were added to the flask and Biphenol:CSB being in a molar ratio of 1.01:1.00, and the reaction mixture was stirred for 30 minutes. Anhydrous sodium carbonate (123 gms) was added. The toluene acts as an azeotropic solvent. The temperature of the reactants was slowly increased to 220° C. over 5 hours and the stirring speed was set to 400 rpm. The water formed due to the reaction was distilled over as an azeotrope with toluene and collected in the Dean-Stark trap. The toluene was then returned to the reaction mixture once it had been separated from the water. Once the water had been completely removed, toluene addition back to the reaction vessel was stopped. The toluene was then removed completely from the reaction mixture as the temperature of the reactants increased. The desired temperature was reached after 4 hours. The reaction temperature was then maintained at 220° C. and when the viscosity started to increase the stirring speed was raised to 500 rpm. At the required Mn of 29,000, MW of about 38,000 and MWD 1.31 The relatively high molar ratio of Biphenol to CSB gave PSSB of a relatively low molecular weight and with predominantly end groups of —Ph—OH
Part 3: The Preparation of the Block Copolymer
The reaction mixtures of Part 1 and Part 2 were mixed in equal proportions by weight and the block polymerization was conducted at 220° C. After the required MW was achieved, as shown by GPC, the reaction mixture was quenched with Sulfolane (504 gms, 400 ml/mole) and its temperature reduced to 210° C. Methyl Chloride gas was then bubbled through the reaction mixture for 3 hrs to ensure complete end capping. The reaction mixture was then diluted with Sulfolane (400 ml/mole) for a second time. The polymer solution was filtered through a 15 micron filter in a pressure filter funnel using 2 kg/cm 2 of nitrogen to remove any salts. The block copolymer was finally recovered by slowly adding the salt-free polymer solution to de-ionized water (13 ml/gm of polymer) under high-speed agitation. The precipitated polymer was then recovered by filtration. The precipitated polymer was ground and refluxed three times with de-ionized water at 90° C. to completely remove all salts and Sulfolane. The precipitated polymer was then filtered and dried in an oven at 140° C. until the moisture content as determined by Karl Fischer titration was <0.5%.
GPC analysis of the block copolymer showed an Mn of 88,000, an Mw of 121,000 and an MWD of 1.37 based on the polystyrene standards. Thus, the copolymer produced had a significantly higher molecular weight than the two homoblocks used as monomer units, indicating the preparation of a block copolymer. The block copolymer powder was then mixed with 0.25% heat stabilizer and granulated using a twin screw extruder. The Tg and the specific gravity of PSSD are 259° C. and 1.29 respectively, while those of PSSB are 270° C. and 1.320. The transparent granules of block copolymer showed a DSC Tg of 266° C. and a specific gravity of 1.31. The transparency of the granules, the single GPC peak, the intermediate Tg and the specific gravity of the product clearly indicate that a block-copolymer of PSSD and PSSB had indeed been formed and that the product was not simply a blend of the two homo polymers, PSSD and PPSB.
The present subject matter being thus described, it will be apparent that the same may be modified or varied in many ways. Such modifications and variations are not to be regarded as a departure from the spirit and scope of the present subject matter, and all such modifications and variations are intended to be included within the scope of the following claims.
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Processes for preparing block copolymers and the block copolymers prepared therefrom comprising at least two types of homoblock, all belonging to the polysulfone family, wherein each of the said homoblocks has an identical or different molecular weight of at least 1000 and comprises at least 5% of the overall weight of the block copolymer, and wherein the block copolymer has a molecular weight of at least 2000, the process steps comprising preparing each of the aforesaid homoblocks by reacting at least one aromatic diol with at least one aromatic dihalo compound, one of which contains at least one sulfone group, in at least one aprotic solvent in the presence of at least one alkali, optionally in the presence of an azeotropic agent and then reacting the aforesaid homoblocks together in at least an aprotic solvent, optionally followed by end-capping said block copolymer. The invention also relates to the block copolymers themselves, which are useful for molding, extrusion and can also be used as compatibilizers for their high molecular weight homologues.
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FIELD OF THE INVENTION
The present invention relates generally to enhanced training capabilities which enable a live training aid to simulate one unconstrained by range and geographical limitations. More particularly, embodiments of the present invention relate to a system and method for integration of a virtual training aid acting in cooperation and association with the live training aid to offer a realistic training scenario unlimited by the physical and behavior constraints of the live training aid.
BACKGROUND OF THE INVENTION
Traditional training may be accomplished using a live training aid limited by live geographical and performance based constraints. For example, a live training aid aircraft may be used to simulate a hostile threat and perform tactics associated with those of a hostile threat. A trainee may receive information concerning the scenario problem and assess the scenario and tactics thereof. The trainee then makes execution decisions based on the received information. For example, at a distance out of on-board sensor range, a live training aid simulating a hostile threat aircraft may not be a factor to friendly assets associated with the trainee aircraft. At this range, the trainee may only receive information concerning the live training aid via offboard sensors (e.g. datalink).
These live training aids, however, are constrained by physical boundaries making limited the training available to a trainee. For example, live training typically is performed with multiple platforms on a training range. A “range” as used herein may include a fixed, charted geographical section of airspace with 1) a horizontal boundary and 2) a lower vertical boundary and 3) an upper vertical boundary. For example, range airspace may have a an east west limit of 50 Nautical Miles (NM) and a north south limit of 60 NM while encompassing a trapezoidal shape normally associated with a radial/Distance Measuring Equipment (DME) from a Navigational Aid (navaid). This range airspace may exemplarily possess a lower vertical boundary or “floor” of 7000 ft. MSL and an upper vertical boundary “ceiling” of 50,000 ft. MSL.
For example, two aircraft filling a “Blue Air” role practicing friendly tactics while two aircraft filling a “Red Air” role are practicing hostile tactics would oppose each other within such a range. The Red forces presenting a problem against which the Blue Air forces may learn to solve through training. The Red forces are enlisted to provide scenario presentations as training aids for the Blue forces. These scenario presentations require separation between the forces for accuracy and consistency. Occasionally, atmospheric conditions (e.g., strong winds, cloud layers) preclude the Red forces from an accurate or valuable training scenario presentation.
Many high performance aircraft and operational capabilities of weapons systems may exceed the capabilities of a live training aid. For example, modern aircraft require large blocks of airspace both horizontally and vertically due to aircraft speed and altitude capabilities and ranges of ordinance and distances involved. Such large blocks of reserved space are difficult to arrange and finite in geography and suffer from additional limitations including stationary in location, impacted by weather, available at Air Traffic Control discretion, and shared with civilian aircraft. Live training aids may be constrained by service ceiling, maintenance issues and speed limitations limiting an accurate presentation of a high performance threat.
Virtual training aids may solve some of these limitations and provide a limited level of training. Virtual training aids may solve the issue of range but lack the capability for close in visual or local sensor based training. For example, the Blue forces may be presented a scenario in which the Red forces were beyond visual range (BVR) or beyond local sensor range. A BVR scenario may be virtually created and valuable training may occur during prosecution of the virtual training aids. The trainee may make valid operational decisions based on this BVR hostile threat aircraft data received.
However, once the virtual training aid reaches a point where the trainee sensors (radar, targeting pod, pilot's eyeballs) are realistically designed to image the training aid, negative training may result if the trainee's sensors do not successfully image the training aid. For example, at a specific range threshold, an aircraft radar is designed to successfully image a live target aircraft and display the imaged data to the trainee/pilot. Should the radar not image and display the target, the trainee may not receive the desired level of training. Similarly, at closer range, a trainee may expect to visually acquire the training aid and make further decisions based on the visual presentation. A virtual training aid is incapable of producing this actual visual image
Therefore, a need remains for training methods and systems which offer a virtual training aid unlimited by physical, geographic and behavior constraints of a live training aid while maintaining a realistic sensor-based problem for the trainee to solve to complete the scenario.
SUMMARY OF THE INVENTION
Accordingly, an embodiment of the present invention is directed to a method for blending an instance of a virtual entity with an actual presentation of a live entity within a trainee presentation, comprising: receiving a training scenario, generating the instance of the virtual entity in compliance with the training scenario, generating the trainee presentation, the trainee presentation including the instance of the virtual entity, the trainee presentation further including an occlusion of the actual presentation of the live entity, communicating the trainee presentation to a trainee, presenting emulation information to an operator of the live entity in compliance with the training scenario, correlating a characteristic of the live entity with a characteristic of the virtual entity, blending, within the trainee presentation, the instance of the virtual entity with the actual presentation of the live entity based on the correlating, removing the virtual entity from the trainee presentation after the blending, removing the occlusion of the actual presentation of the live entity from the trainee presentation after the blending.
An additional embodiment of the present invention includes receiving data associated with presentation of the virtual entity and generating a plurality of virtual entities in compliance with the training scenario.
An additional embodiment of the present invention includes a trainee presentation configured for at least one of: a graphic display, a pictorial display, and a communication of information perceptible by a human, and a trainee presentation configured for presentation on an avionics display onboard a trainee aircraft.
An additional embodiment of the present invention includes presenting information to the live entity to mimic a behavior of the virtual entity and correlating at least one of: a position, an altitude, an airspeed, and a heading of the virtual entity with the live entity.
An additional embodiment of the present invention includes receiving at least one characteristic associated with the live entity and determining if the live entity is within a correlating tolerance and removing the occlusion of the actual presentation of the live entity and discontinuing a presentation of the instance of the virtual entity. Once the live entity is within the correlating tolerance, the method enables an onboard sensor based display of information.
An additional embodiment of the present invention includes a non-transitory computer readable medium having non-transitory computer readable program code embodied therein for blending an instance of a virtual entity with an actual presentation of a live entity within a trainee presentation, the computer readable program code comprising instructions which, when executed by a computer device or processor, perform and direct the steps of: receiving a training scenario, generating the instance of the virtual entity in compliance with the training scenario, generating the trainee presentation, the trainee presentation including the instance of the virtual entity, the trainee presentation further including an occlusion of the actual presentation of the live entity, communicating the trainee presentation to a trainee, presenting emulation information to an operator of the live entity in compliance with the training scenario, correlating a characteristic of the live entity with a characteristic of the virtual entity, blending, within the trainee presentation, the instance of the virtual entity with the actual presentation of the live entity based on the correlating, removing the virtual entity from the trainee presentation after the blending, removing the occlusion of the actual presentation of the live entity from the trainee presentation after the blending.
It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not necessarily restrictive of the invention as claimed. The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate embodiments of the invention and together with the general description, serve to explain the principles of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
The numerous advantages of the present invention may be better understood by those skilled in the art by reference to the accompanying figures in which:
FIG. 1 is a block diagram of a system for blending an instance of a virtual entity with an actual presentation of a live entity within a trainee presentation illustrative of an embodiment of the present invention;
FIG. 2 is a diagram of an exemplary orientation of a trainee aircraft and a training aid illustrative of an embodiment of the present invention;
FIGS. 3A and 3B are diagrams of an exemplary progression of a method for blending an instance of a virtual entity with an actual presentation of a live entity within a trainee presentation illustrative of an embodiment of the present invention;
FIGS. 4A and 4B are diagrams of an exemplary progression of a method for blending an instance of a virtual entity with an actual presentation of a live entity within a trainee presentation illustrative of an embodiment of the present invention;
FIGS. 5A and 5B are diagrams of an exemplary progression of a method for blending an instance of a virtual entity with an actual presentation of a live entity within a trainee presentation illustrative of an embodiment of the present invention;
FIGS. 6A and 6B are diagrams of an exemplary progression of a method for blending an instance of a virtual entity with an actual presentation of a live entity within a trainee presentation illustrative of an embodiment of the present invention;
FIG. 7 is a timeline of an exemplary merge progression in a training scenario in accordance with an embodiment of the present invention; and
FIG. 8 is a flow diagram for a method for blending an instance of a virtual entity with an actual presentation of a live entity within a trainee presentation.
DETAILED DESCRIPTION OF THE INVENTION
Reference will now be made in detail to the presently preferred embodiments of the invention, examples of which are illustrated in the accompanying drawings.
The following description presents certain specific embodiments of the present invention. However, the present invention may be embodied in a multitude of different ways as defined and covered by the claims. In this description, reference is made to the drawings wherein like parts are designated with like numerals throughout.
Embodiments of the present invention are directed to a system and related method for blending an instance of a virtual entity with an actual presentation of a live entity within a trainee presentation. Beyond local trainee sensor range, a trainee is oblivious as to which presentation is before him; the virtual entity or the live entity. As the virtual entity is presented to the trainee, the live entity is occluded from the trainee presentation to simulate characteristics not capable by the live entity and capable by the virtual entity. As the criticality of the training scenario increases, the live entity is offered emulation information to closely emulate characteristics of the virtual entity. Once a desired characteristic of the live entity is within a correlation threshold of the corresponding characteristic of the virtual entity, the virtual entity is no longer presented to the trainee and the live entity is no longer occluded from the trainee presentation. A seamless transition of the trainee presentation from the virtual to the live entity guarantees an accurate training scenario. The live entity continues with the scenario for a realistic training presentation.
It is contemplated herein; embodiments of the present invention may be applicable to a plurality of training scenarios and training methods. One exemplary embodiment of the virtual/live hybrid behavior to mitigate range and behavior constraints may include pilot training in a fighter aircraft. Additional embodiments may include training of an emergency room physician, training of a police officer and training of a ground based operator of a mobile weapons system. The underlying concept remains consistent regardless of the training type or trainee.
A timeline/flow of embodiments disclosed herein may exemplarily include:
1. a live entity is present, but occluded from a trainee presentation/perception; 2. trainee interacts with a virtual entity to solve a problem; 3. trainee perceives the virtual entity decreasing in range/problem threat increases/problem criticality increases; 4. live entity is given characteristic data to emulate virtual entity; 5. if the live entity meets a correlation threshold with the virtual entity, the system blends the entities eliminating the presentation of the virtual entity and removing the occlusion of the live entity from the trainee presentation; 6. trainee interacts with the live entity as a continuation of the problem.
In this manner, a seamless scenario may be presented to the trainee via the trainee presentation. The trainee may make operational decisions based at first on trainee interpretation of characteristics the virtual entity. Secondly, after correlation and blending of the virtual entity with the live entity, the trainee may make decisions based on trainee's interpretation of live entity characteristics received via actual sensors (e.g., visual, tactile, radar, sensor pod, aural, etc.). The scenario may further include the live entity retreating to beyond local sensor capability where the trainee presentation returns to the virtual entity.
Referring to FIG. 1 , a block diagram of a system for blending an instance of a virtual entity with an actual presentation of a live entity within a trainee presentation illustrative of an embodiment of the present invention is shown. Trainee presentation 120 resides on board trainee aircraft 110 to communicate with trainee via a visual communications medium. Within trainee presentation 120 an object 122 is presented to the trainee. The origin of object 122 is dependent upon a training scenario within training function 140 .
Object 122 may be generated as a virtual entity originating from training function 140 or object 122 may be an actual object originating from one of the aircraft sensors such as data link 132 , radar 134 and sensor pod 136 as interpreted by mission computer 130 . The origin of object 122 is unknown to the trainee as one goal of a training scenario may include a seamless transition from virtual to live and a possible return to virtual entities effectively presenting a problem for trainee to solve.
Trainee may have access to a variety of sensors. Sensors may include those extensions of human senses onboard the aircraft such as datalink 132 , air-to-air radar 134 and sensor pod 136 . Mission computer 130 may receive data from the various sensors and process the data for appropriate presentation upon trainee presentation 120 . Sensors may further include those human sensors such as vision, tactile and auditory. System 100 may present object 122 in virtual form perceptible to one of the human senses. For example, in FIG. 1 object 122 is presented in visual form configured for a pilot of trainee aircraft 110 .
System 100 may present object in virtual form in additional form perceptible by and configured for a human senses. System 100 may present object 122 with characteristics such as a tactile characteristic (e.g., heat, texture, consistency). For example, in a medical training scenario, system 100 may present trainee with a virtual entity associated with a virtual patient. A trainee in this scenario would be required to assess the characteristics of virtual entity 122 and make decisions based on the observed and sensed characteristics.
It is contemplated herein; system 100 may generate additional virtual entities 122 which possess characteristics sensible by a human trainee. For example, system 100 coupled with and controlling a simulator may generate olfactory and gustatory characteristics configured for human perception and thus a potential additional training tool.
One preferable method for system 100 to accurately present trainee presentation 120 is to effectively manage which objects are available to trainee presentation 120 . In some scenarios, system 100 may send a virtual entity to trainee presentation 120 and maintain an occlusion 142 of actual objects. In some scenarios, system may send a virtual entity to trainee presentation 122 and allow a partial occlusion of actual objects to most accurately comply with the training scenario. In other instances, system 100 may remove occlusion 142 from the system allowing all actual data to be presented on trainee presentation 120 . In this case, system 100 may add virtual entities to trainee presentation 120 to further enhance and complicate the training scenario available to trainee.
Training scenario may reside within training function 140 available to system 100 . For example, a trainee pilot may load data to training function 140 via a permission cartridge loader. A well-known Data Transfer Unit (DTU) may provide the data transfer function mobility available from a ground based system to training function 140 .
Referring to FIG. 2 , a diagram of an exemplary orientation of a trainee aircraft and a training aid illustrative of an embodiment of the present invention is shown. Trainee aircraft 110 is within the horizontal confines of range 210 along with live training aid 230 . Each aircraft is limited to the horizontal confines of the range 210 since additional traffic 250 may be present nearby.
One goal of the present invention may include offering to trainee a trainee presentation 120 unavailable to a training scenario using only live training aids 230 . For example, live training aid may be limited to a service ceiling of 25,000 ft. Mean Sea Level (MSL) due to operational or weather issues within range 210 . However, the training scenario designed for trainee on board trainee aircraft 110 calls for a presentation of an aircraft at 50,000 ft. MSL and Mach 1.8 at a range of 100 NM from trainee aircraft 110 . Live training aid 230 is unable to support this training scenario. System 100 may present trainee with virtual entity 220 to fulfill the portion of the scenario operationally unattainable by live training aid 230 .
Referring to FIGS. 3A and 3B , diagrams of an exemplary progression of a method for blending an instance of a virtual entity with an actual presentation of a live entity within a trainee presentation illustrative of an embodiment of the present invention are shown. FIG. 3A illustrates an overhead view of a range 210 in which aircraft may operate while FIG. 3B illustrates trainee presentation 120 according to training scenario. System 100 may present to the trainee the trainee presentation 120 comprising virtual entities 220 and live training aids 230 . In compliance with the training scenario, system 100 may display only virtual entities 220 , a combination of virtual entities 220 and live training aids 230 and only live training aids 230 .
As shown in FIG. 3A , actual aircraft present in the range 210 are trainee aircraft 110 and training aid 230 . As shown in FIG. 3B , virtual entity 220 is virtual, and displayed on trainee presentation 120 as a contact 222 . Live training aid 230 is 70 NM from trainee aircraft 110 but occluded from trainee presentation 120 in compliance with training scenario. Occlusion 142 functions as a block to the raw data information of training aid 230 from reaching trainee display 130 . Should a sensor onboard trainee aircraft be able to image live training aid 230 , occlusion 142 would block the image data from entering trainee presentation 120 . At this point in the training scenario, trainee is aware of only a single contact, 222 , at 110 NM from trainee aircraft and trainee assesses the situation and reacts with appropriate blue force tactics.
Referring to FIGS. 4A and 4B , diagrams of an exemplary progression of a method for blending an instance of a virtual entity with an actual presentation of a live entity within a trainee presentation illustrative of an embodiment of the present invention are shown. In accordance with training scenario, virtual entity 220 may change a characteristic behavior. For example, system 100 may command virtual entity 220 to maneuver while remaining outside of range 210 boundaries. This maneuver may change a characteristic of virtual entity 220 to more closely align with operational abilities of live training aid 230 . For example, virtual entity 220 may turn right 90 degrees, decelerate and descend from 50,000 ft. MSL to 30,000 ft. MSL. As before, trainee presentation 120 may display only virtual entity 220 via contact 222 and trainee remains oblivious to live training aid 230 . However, as the scenario progresses, virtual entity 220 may be unable to fulfill the end state role of the training scenario for the trainee.
Should virtual entity 220 be unable to fulfill a portion of the training scenario requirement, system 100 may present emulation information to an operator of the live entity 230 in compliance with the training scenario. For example, one training scenario may begin with a 120 NM presentation and result in a radar rendezvous followed by a visual merge. In this situation, live training aid 230 must emulate virtual entity 220 and must maintain similar characteristics in order for presentation of an accurate training scenario to trainee. System 100 presents emulation information to an operator of live training aid 230 so the operator may manipulate/maneuver live training aid 230 to emulate virtual entity 220 .
For example, system 100 may present a pilot of training aid 230 rendezvous information to “join” with virtual entity. In reality, system 100 is providing steering/rendezvous information for operator of live training aid 230 to fly to a point in space. This rendezvous information may be in well-known form of a steering queue, an altitude, heading and airspeed assignment. Preferably, system 100 may offer a visual “fly to” queue to the pilot of training aid 230 to effectively match performance characteristics of virtual entity 220 .
Referring to FIGS. 5A and 5B , diagrams of an exemplary progression of a method for blending an instance of a virtual entity with an actual presentation of a live entity within a trainee presentation illustrative of an embodiment of the present invention are shown. Once live training aid 230 has matched characteristics with virtual entity 220 , system 100 blends the instance of the virtual entity with an actual presentation of the live training aid 230 within the trainee presentation 120 .
The result will preferably be a seamless transition from virtual entity 220 to live training aid 230 within trainee presentation 120 . System 100 may first ensure the characteristics of live training aid 130 are within a correlation tolerance with those of the virtual entity 220 . For example, one correlation tolerance may include an altitude of +/−500 ft., airspeed of +/−20 knots, heading of +/−5 degrees, and a lateral position within 1000 ft. Should operator of live training aid 230 fail to match these characteristic within tolerances, system 100 may command a termination or “knock-it-off” of the training scenario and a reset of all assets. Alternatively, should operator of live training aid 230 fail to match these characteristic within tolerances, system 100 may command virtual entity 220 to maneuver and create a second opportunity for live training aid to maneuver to come within the required correlation tolerances.
These correlation tolerances may be rigid or more flexible depending on the required scenario and desired presentation. For example, should live training aid fly to an exact position matching the position characteristic of virtual entity, but arrive 30 knots slow in airspeed, system 100 may allow the successful blending of entities and continue with the training scenario.
As system 100 carries out the blending of the entities, the virtual entity 220 is eliminated from the trainee presentation 120 and the live training aid 230 is presented via a removal of occlusion 142 .
System 100 may begin the blending of the entities (live to virtual-virtual to live) as a result of one or more of a plurality of triggers. One such trigger may include a desired range at which a trainee may be presented a problem. For example, a specific air-to-air setup may include a training scenario for blue forces operating against a small Radar Cross Section (RCS) target where trainee ownship sensors may be able to actually sense the target at an exemplary 25 NM. In this training scenario, range from trainee ownship to target may operate as the trigger for system 100 to begin the blending.
In another exemplary embodiment, actions of virtual entity 220 may be the trigger system 100 may use to begin the blend from virtual to live and vice versa. For example, should virtual entity 220 begin a presentation as an unknown, and then take action allowing blue forces to label virtual entity 220 a hostile, the actions of virtual entity 220 may trigger system 100 to begin the blend.
In yet another exemplary embodiment, anticipated visual range may be the trigger for system 100 to begin the blending from virtual entity 220 to live training aid 230 . For example, a small fighter sized target may be visible at 15 NM, one possible trigger for system 100 to begin the blending. Additional larger targets or high altitude targets emitting contrails may be visible at a greater range allowing for system 100 to trigger a blend at such range.
In an additional exemplary embodiment, system 100 may receive a training scenario in which blue forces are operating against red forces. Each blue force member (e.g., Blue 1 , Blue 2 , Blue 3 , etc.) may have radar responsibility for coverage of a specific section of airspace. For example, with a cursor coordination range of 20 NM, Blue 1 may be responsible for an altitude coverage of 20,000 ft. and above while Blue 2 may be responsible for 25,000 ft. and below. At a specific pre-briefed point in the scenario, each blue member may discontinue this radar coverage and concentrate on a high threat problem. At this pre-briefed point, the high threat target may be one previously blended. In such a scenario, Blue 1 may have awareness on and be presented a virtual entity 220 blended with a live training aid 230 while Blue 2 may be presented only the live training aid 230 at the pre-briefed point.
In this situation, for Blue 2 , both datalink and radar are being occluded 142 offering Blue 2 the desired presentation. At a specific point in the desired scenario, occlusion 142 may be removed for Blue 2 allowing Blue 2 local sensors to present information to Blue 2 . Also, fused contacts may be defined as those contacts which more than one sensor (e.g., radar 134 , data link 132 , sensor pod 136 ) is sensing and are fused by mission computer 130 into a single contact displayed on trainee presentation 120 . A fused contact may be occluded 142 in its entirety. For example, if the target from mission computer 130 is fused from multiple sources, such as being simultaneously communicated on datalink 132 and as a return from a live radar 134 , occlusion 142 will occlude all the fused data associated with the target as a set.
Referring to FIGS. 6A and 6B , diagrams of an exemplary progression of a method for blending an instance of a virtual entity with an actual presentation of a live entity within a trainee presentation illustrative of an embodiment of the present invention are shown. In FIGS. 6A and 6B , system 100 has removed both the virtual entity 220 and occlusion 142 allowing local sensors onboard trainee aircraft 110 to image live training aid display live contact 232 on trainee display 130 .
Referring to FIG. 7 , a timeline of an exemplary merge progression in a training scenario in accordance with an embodiment of the present invention is shown. At 120 NM from trainee aircraft 110 , the training scenario may begin with a display 710 of virtual entity 220 . A maneuver at 60 NM continues the scenario with virtual entity 220 maneuvering in altitude and airspeed. At approximately 45 NM, system 100 blends 720 the presentation of the virtual entity with the presentation of the live training aid 230 . Within 45 NM, the trainee presentation 120 is limited to the display 730 of live training aid 230 . At 30 NM the aircraft are nose to nose with zero aspect and a visual merge may begin at 10 NM.
Referring to FIG. 8 , a flow diagram for a method for blending an instance of a virtual entity with an actual presentation of a live entity within a trainee presentation is shown. Method 800 begins at step 802 with receiving a training scenario, and, at step 804 , generating the instance of the virtual entity in compliance with the training scenario, and, at step 806 , generating the trainee presentation, the trainee presentation including the instance of the virtual entity, the trainee presentation further including an occlusion of the actual presentation of the live entity, and, at step 808 communicating the trainee presentation to a trainee. Method 800 continues at step 810 with presenting emulation information to an operator of the live entity in compliance with the training scenario, and, at step 812 correlating a characteristic of the live entity with a characteristic of the virtual entity, and, at step 814 blending, within the trainee presentation, the instance of the virtual entity with the actual presentation of the live entity based on the correlating, and, at step 816 removing the virtual entity from the trainee presentation after the blending, and, at step 818 removing the occlusion of the actual presentation of the live entity from the trainee presentation after the blending.
CONCLUSION
Specific blocks, sections, devices, functions, processes and modules may have been set forth. However, a skilled technologist will realize that there are many ways to partition the system, and that there are many parts, components, processes, modules or functions that may be substituted for those listed above.
While the above detailed description has shown, described and pointed out the fundamental novel features of the invention as applied to various embodiments, it will be understood that various omissions and substitutions and changes in the form and details of the system illustrated may be made by those skilled in the art, without departing from the intent of the invention. The foregoing description details certain embodiments of the invention. It will be appreciated, however, that no matter how detailed the foregoing appears, the invention may be embodied in other specific forms without departing from its spirit or essential characteristics. The described embodiment is to be considered in all respects only as illustrative and not restrictive and the scope of the invention is, therefore, indicated by the appended claims rather than by the foregoing description. All changes which come within the meaning and range of equivalency of the claims are to be embraced within their scope.
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A system and method are disclosed for offering a trainee presentation blending live and virtual entities to create a training scenario unconstrained by live entity operational performance and geographical limitations. The system blends an instance of a virtual entity with an actual presentation of a live entity within a trainee presentation. Outside of trainee local sensor range, the system presents a virtual entity to the trainee while occluding local sensor presentation of the live entity. As the scenario progresses to a lessor range or higher criticality, the system offers the live entity emulation information concerning characteristics of the virtual entity so the live entity may anticipate and begin to emulate the virtual. At a crossover point, the system determines if the live entity has successfully emulated the virtual and if so, discontinues presentation of the virtual while removing the occlusion allowing presentation of the live entity.
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This application relates to U.S. Ser. No. 12/817,414, filed Jun. 17, 2010, which is incorporated by reference in its entirety.
FIELD OF THE INVENTION
The present invention relates to a method and/or architecture for image processing generally and, more particularly, to a high performance warp correction in two-dimensional images.
BACKGROUND OF THE INVENTION
Camera image processing uses a warp correction system to correct for warping in an input image. Warp correction is a mapping of a pixel in an output image to a pixel in the input image. The mapping is defined by a two-dimensional (2D) warp field that depends on the optical characteristics of the lens and a zoom factor. Conventionally, the warp field is computed for a camera design and stored in 2D tables of an actual camera. Since the table entry spacing covers more than a single pixel, 2D bilinear interpolation is used to calculate the warp field at the missing pixels. The warp field spans hundreds of lines across the input image and so a large buffer space is used to hold sufficient input image data. Management of the buffer is based on a minimum warp field calculated across a next pixel line. Conventional approaches hold the warp field in either a 5-ported memory or 5 memory banks to achieve a single pixel per clock performance.
It would be desirable to achieve the single pixel per clock performance with a single-ported memory.
SUMMARY OF THE INVENTION
The present invention concerns an apparatus generally having a first memory, a second memory and a circuit. The first memory may be configured to store a warp table. The warp table is generally accessed through a single data port of the first memory. The second memory may be configured to buffer an input image. The input image may have a plurality of input pixels arranged in two dimensions. The circuit may be configured to generate an output image by a warp correction of an input image. The warp correction may be defined by the warp table. The output image may include a plurality of output pixels. At least one of the output pixels may be generated during each clock cycle of the circuit.
The objects, features and advantages of the present invention include providing a high performance warp correction in 2-dimensional images that may (i) achieve a single output pixel per clock performance, (ii) store a warp field in a single-port memory, (iii) read fewer warp table entries than conventional techniques for interpolation calculations, (iv) compute interpolation parameters in advance of warping an input image, (v) utilize pipelining and chaining of the interpolation parameters, (vi) compute warp fields at every pixel using the adders instead of multipliers and/or (vii) achieve a small hardware cost while maintaining high performance compared with conventional designs.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other objects, features and advantages of the present invention will be apparent from the following detailed description and the appended claims and drawings in which:
FIG. 1 is a block diagram of an example method for warp correction in two-dimensional images;
FIG. 2 is a diagram of an example two-dimensional image;
FIG. 3 is a diagram of a rectangular grid superimposed on an output image;
FIG. 4 is a block diagram of an apparatus in accordance with a preferred embodiment of the present invention;
FIG. 5 is a flow diagram of an example method for calculating a minimum warp field;
FIG. 6 is a flow diagram of an example method for calculating interpolation parameters;
FIG. 7 is a diagram of the interpolation parameters and a chaining operation when crossing a grid boundary;
FIG. 8 is a flow diagram of an example method for calculating a motion vector and fetching an input tile; and
FIG. 9 is a flow diagram of an example method for calculating the output pixels.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Some embodiments of the present invention may concern an apparatus having a single-ported memory, multiple (e.g., 4) stages of a process pipeline, an arbitration logic, an input tile buffer and an output tile buffer. The single-ported memory generally holds a two-dimensional (2D) warp field. The input tile buffer may be configured to hold multiple input tiles. An on-chip memory or an off-chip memory may store a partial image. An initial stage of a circuit may be configured to compute a minimum warp field across a pixel line. The next stage of the circuit may be configured to compute a warp field at specific points. Another stage of the circuit is generally configured to fetch the input tiles from the image buffer. A subsequent stage of the circuit may be configured to calculate a warp field at every output pixel point and compute output pixels from the fetched input tile. All stages of the circuit generally work in a pipelined fashion to achieve a high performance circuit. Access to the warp table may be arbitrated between the two front-end stages by the arbitration logic. A later of the front-end stages generally reads several (e.g., 4) warp table entries where an initial output tile is being generated. The later stage may read a few (e.g., 2) warp table entries where other output tiles are being generated. Since grid spacing in the warp field usually covers many pixels, the initial stage may utilize several clock cycles to access the appropriate warp table entries.
Referring to FIG. 1 , a block diagram of an example method 100 for warp correction in 2D images is shown. The method (or process) 100 generally comprises a step (or block) 102 , a step (or block) 104 , a step (or block) 106 , a step (or block) 108 . The steps 102 to 108 may be implemented in hardware, software, firmware or any combination thereof in an apparatus.
In the step 102 , one or more portions of an input image within a signal (e.g., IN) may be buffered in an image buffer. From the image buffer, a warp correction along a horizontal direction may be performed on an input image portion in the step 104 . Operations of the step 104 may generate an intermediate image portion. The step 104 may be implemented in a unit (or circuit) of the apparatus referred to as a horizontal warp correction unit. In the step 106 , the intermediate image portion may be buffered in another image buffer. In some embodiments, both image buffers may reside within a common memory device in different addressable regions. In other embodiments, each image buffer may reside in a separate memory. The step 108 generally performs another warp correction in a vertical direction on the intermediate image portion to generate a corresponding portion of an output image in a signal (e.g., OUT). The step 108 may be implemented by a unit (or circuit) of the apparatus referred to as a vertical warp correction unit. In some embodiments, the horizontal warp correction unit and the vertical warp correction unit may be the same unit within the apparatus. The horizontal warp correction unit generally works on horizontal components of a warp field and thus achieves warp correction in the horizontal direction. The vertical warp correction unit may work on vertical components of the warp field and thus achieve warp correction in the vertical direction.
Referring to FIG. 2 , a diagram of an example 2D image 120 is shown. The image (or region) 120 may have a height (e.g., H) and a width (e.g., W). The image 120 may represent an input image or an output image. The height H may be a distance between (i) an upper-left corner (e.g., (X,Y)=(0,0)) and a lower-left corner (e.g., (X,Y)=(0,H) of the image 120 and/or (ii) an upper-right corner (e.g., (X,Y)=(W,0)) and a lower-right corner (e.g., (X,Y)=(W,H) of the image 120 . The width W may be a distance between the upper-left corner and the upper-right corner of the image 120 and/or the lower-left corner and the lower-right corner of the image 120 .
The image 120 is generally divisible into multiple tiles (or subregion) 122 a - 122 n . Each tile 122 a - 122 n may be a rectangle. Tiles 122 a - 122 n in an input image may be referred to as input tiles. The tiles 122 a - 122 n in the intermediate image may be referred to as intermediate tiles. Tiles 122 a - 122 n in an output image may be referred to as output tiles.
The tiles 122 a - 122 n may be arranged in one or more tile rows 124 a - 124 k (only rows 124 c and 124 f are shown for clarity). Each input tile 122 a - 122 n may comprise a 2D array of input pixels. Each intermediate tile 122 a - 122 n may comprise a 2D array of intermediate pixels. Each output tile 122 a - 122 n may comprise a 2D array of output pixels. By way of example, a particular tile (e.g., 122 g ) may be defined by four corners (e.g., A 1 , B 1 , C 1 and D 1 ).
The warp correction units generally fetch fixed-size tiles from the corresponding image buffers (e.g., image buffer 102 , image buffer 106 ). The warp correction units may generate fixed-size intermediate tiles and fixed-size output tiles. For example, the vertical warp correction unit may (i) fetch intermediate tiles having a size of 64 rows by 8 columns and (ii) generate output tiles having a size of 16 rows by 8 columns. Furthermore, the horizontal warp correction unit generally (i) fetches input tiles having a size of 1 row by 6 columns and (ii) generate intermediate tiles having a size of 1 row by 1 column (e.g., a single intermediate pixel).
Referring to FIG. 3 , a diagram of a rectangular grid 126 superimposed on an output image (e.g., 120 ) is shown. The row 124 f of output tiles is also shown. The output tiles may be generated in a raster scan order.
A grid field is generally specified at the crossing points of the grid 126 and stored in a single-port memory. The single-port memory may have only a single x-bit wide data port. An address to the single-port memory is generally a number formed by a concatenating a grid row value (e.g., GRIDROW) and a grid column value (e.g., GRIDCOL) such that the address accesses data at {GRIDROW, GRIDCOL}.
The value GRIDROW value may be stored in an n-bit register. A value of 2^n is generally designed to be greater than or equal to a maximum number of grid rows in the grid 126 . The value GRIDCOL may be stored in an m-bit register. A value 2^m is generally designed to be greater than or equal to a maximum number of grid columns in the grid 126 . A grid spacing value (e.g., GHS) of the grid 126 may refer to a grid spacing in the horizontal direction. A grid spacing value (e.g., GVS) of the grid 126 generally refers to a grid spacing in the vertical direction. The value GHS may be an integer fraction of the width of the output tiles. The value GVS may be another integer fraction of the height of the output tiles.
Referring to FIG. 4 , a block diagram of an apparatus 130 is shown in accordance with a preferred embodiment of the present invention. The apparatus (or device) 130 generally comprises a circuit (or module) 132 , a circuit (or module) 134 and a circuit (or module) 136 . The signal IN may be received by the circuit 136 . The signal OUT may be generated and presented by the circuit 136 . A clock signal (e.g., CLK) may be received by the circuit 132 . The circuits 132 - 136 may be implemented in hardware, software, firmware or any combination thereof in an apparatus. In some embodiments, the apparatus 130 may be a digital video camera, a digital still camera or a hybrid digital video/still camera.
The circuit 132 may implement a pipelined processor circuit. The circuit 132 is generally operational to generate an output image by a warp correction of an input image. Warp correction may be defined by multiple values stored in a warp table. The warp correction may include a directional warp correction along an initial direction (e.g., horizontal direction) of the input image to create an intermediate image. The warp correction may also include another directional warp correction along a different direction (e.g., vertical direction) of the intermediate image to create the output image.
The circuit 134 may implement a single-port memory circuit. The circuit 134 may be operational to store the warp table 140 used by the circuit 132 . The circuit 134 generally has a single x-bit wide data port, a single y-bit wide address port and corresponding command and control interfaces. In some embodiments, the circuit 134 may implement a nonvolatile memory. In other embodiments, the circuit 134 may implement a volatile memory with the warp table 140 being loaded at power up and/or reset. In still other embodiments, the circuit 134 may implement a multi-port memory with a single port being utilized in a design of the circuit 130 . The circuit 134 may be fabricated either on (in) a same die as the circuit 132 or on (in) a separate die from the circuit 132 .
The circuit 136 may implement one or more memory circuits. The circuit 136 may be operational to establish an input tile buffer 142 and an output tile buffer 144 in different addressable areas. In some embodiments, the circuit 136 may comprise two or more memories with the buffer 142 residing in one memory circuit and the buffer 144 residing in another memory circuit. The circuit 136 may be fabricated either on (in) a same die as the circuit 132 or on (in) a separate die from the circuit 132 . The circuit 136 may also be fabricated either on (in) a same die as the circuit 134 or on (in) a separate die from the circuit 134 .
The circuit 132 generally comprises a circuit (or module) 146 , a circuit (or module) 148 , a circuit (or module) 150 , a circuit (or module) 152 and a circuit (or module) 154 . The circuits 146 and 148 may bidirectionally communicate with the circuit 154 . The circuit 154 may bidirectionally communicate with the circuit 134 to access the warp table 140 . The circuit 150 may bidirectionally communicate with the circuit 136 to access the buffer 142 . The circuit 152 may bidirectionally communicate with the circuit 136 to access the buffer 142 and the buffer 144 . The circuits 146 - 154 are generally arranged in a pipeline fashion such that each circuit 146 - 152 is in bidirectional communication with a neighboring circuit 146 - 152 . In some embodiments, additional pipelined circuits may be included in the circuit 132 at the output-end of the circuit 152 .
The circuit 146 may implement a stage of the pipeline. The circuit 146 is generally operational to fetch a portion of the warp table 140 from the circuit 134 corresponding to a current tile row being analyzed. The circuit 146 may also generate a minimum warp field across the current tile row in the output image utilizing the warp table 140 . Generally, the circuit 146 may calculate warp fields at the top-left point of the tile row using one-dimensional interpolation. The one-dimensional interpolation may be repeated at incremental points along the top line at every vertical grid crossing. The above approach may result in reading at most two table entries from the warp table 140 per grid spacing. The minimum warp field may be passed to the circuit 148 .
The circuit 148 may implement another stage of the pipeline. The circuit 148 is generally operational to fetch a portion of the warp table 140 from the circuit 134 corresponding to the current tile row. The circuit 148 may also generate multiple interpolation parameters of the tile row based on the warp table 140 . The interpolation parameters and the minimum warp field may be passed to the circuit 150 .
The circuit 150 may implement another stage of the pipeline. The circuit 150 is generally operational to fetch an input tile of an input image into the buffer 142 . The fetching may be based on the interpolation parameters generated by the circuit 148 and the minimum warp field generated by the circuit 146 . The circuit 150 is also operational to generate multiple phasing parameters corresponding to the input tile. The interpolation parameters, minimum warp field and phasing parameters may be transferred to the circuit 152 .
The circuit 152 may implement another stage of the pipeline. The circuit 152 is generally operational to fetch several neighboring input pixels from the buffer 142 . The circuit 152 may generate output tiles in the tile row of the output image based on the interpolation parameters, the phasing parameters and the input tile. The output tiles may be written to the buffer 144 for subsequent use in other parts of the apparatus 130 .
The circuit 154 may implement an arbitrator circuit. The circuit 154 is generally operational to perform arbitration between the circuits 146 and 148 for access to the circuit 134 and the warp table 140 therein. In some embodiments, the circuit 154 may be formed external to the circuit 132 .
When information generated by a particular circuit 146 - 152 is ready, the particular circuit 146 - 152 may assert a signal (e.g., VALID) to the next neighboring circuit 148 - 152 in the pipeline. A signal (e.g., NEXT) may be generated by the next neighboring circuit 148 - 152 when ready for more information, the signal NEXT may be transferred back to the previous neighboring circuit 146 - 152 . The information may be transferred from a one circuit (e.g., circuit 148 ) to another circuit (e.g., circuit 150 ) when both the signal VALID and the signal NEXT between the neighboring circuits are asserted in the same clock cycle of the signal CLK. Once the information has been transferred, the information may be latched locally in the receiving circuit 148 - 152 and used in the next computations of the stage.
The circuits 146 and 148 may arbitrate for access to warp table 140 . The circuit 154 may perform the arbitration. In some embodiments, the arbitration scheme may be a priority arbitration with a highest priority to the circuit 148 . If the circuit 148 is trying to access the circuit 134 , the circuit 148 is generally granted access in the same cycle. If the circuit 148 is not requesting access and the circuit 146 is requesting access, access may be granted to the circuit 146 . Accesses to the warp table 140 from the circuit 146 and the circuit 148 may be time multiplexed with circuit 148 having higher priority. Other arbitration schemes may be implemented to meet the criteria of a particular application.
The following definitions are generally used in the descriptions below:
OUT_TILE_HEIGHT: Height of the output tile in units of pixels; OUT_TILE_WIDTH: Width of the output tile in units of pixels; GHS: Horizontal grid spacing in units of pixels; GVS: Vertical grid spacing in units of pixels; GVS_: GVS/OUT_TILE_HEIGHT; FILTERTAPS: Number of taps of a Finite Impulse Response (FIR) filter used for generating the output pixels.
Referring to FIG. 5 , a flow diagram of an example method 160 for calculating the minimum warp field is shown. The method (or process) 160 may be implemented by the circuit 146 . The method 160 generally comprises a step (or block) 162 , a step (or block) 164 , a step (or block) 166 , a step (or block) 168 , a step (or block) 170 , a step (or block) 172 , a step (or block) 174 , a step (or block) 176 , a step (or block) 178 and a step (or block) 180 . The steps 162 to 180 may be implemented in hardware, software, firmware or any combination thereof in an apparatus.
The circuit 146 generally comprises multiple internal registers. A register (e.g., OUT_TILE_ROW) may point to a current row of a current output tile. Another register (e.g., GRIDCOL) may point to a current grid column. Another register (e.g., GA) may store a warp value read from the warp table 140 . A register (e.g., GC) may store another warp value read from the warp table 140 . A register (e.g., MINIMUM_WARP) may store the minimum warp field value. The circuit 146 may calculate the minimum warp field value across a next output tile row and transfer the minimum warp field value to the circuit 148 . The computation generally occurs once for each output tile row.
On power up and/or reset, (i) the value GRIDCOL may be initialized (e.g., GRIDCOL=0), (ii) the value OUT_TILE_ROW may be initialized (e.g., OUT_TILE_ROW=0) and (iii) the circuit 146 may wait for a start of frame in the step 162 . The register GRIDCOL and the register OUT_TILE_ROW may be used as local counters. The start of frame is generally a software mechanism used to start hardware processing. In the step 164 , the circuit 146 may (i) compute GRIDROW=integer(OUT_TILE_ROW/GVS_) and (ii) clear the value MINIMUM_WARP (e.g., MINIMUM_WARP=0).
In the step 166 , the circuit 146 may (i) form an address by concatenating the value GRIDROW and the value GRIDCOL (e.g., ADDRESS={GRIDROW, GRIDCOL}), (ii) read the warp table 140 at the address and (iii) latch the read data into the register GA. The step 166 may include (i) generating another address by concatenating the values GRIDROW+1 and GRIDCOL (e.g., ADDRESS={GRIDROW+1,GRIDCOL}), (ii) reading the warp table 140 at the address and (iii) latching the read data into the register GC. In the step 168 , the circuit 146 generally computes a temporary value (e.g., TEMP) as TEMP=GA+(GC−GA)*FRACTION, where FRACTION=(OUT_TILE_ROW % GVS)/GVS_. The function x % y may be a modulus function that returns the remainder of x divided by y. The circuit 146 may compute MINIMUM_WARP=min(MINIMUM_WARP, TEMP) in the step 170 , where min(a,b)=if(a<b)?a:b. The function x?y:z generally means that if x is true, return the value y, else return the value z.
A check may be performed in the step 172 to determine if the value GRIDCOL is that of the rightmost column of the output image. If true (e.g., the YES branch of step 172 ), (i) the signal VALID may be asserted in the step 174 , (ii) the value MINIMUM_WARP may be presented to the circuit 148 and (iii) the circuit 146 waits for the signal NEXT to be activated by the circuit 148 . If false (e.g., the NO branch of step 172 ), the GRIDCOL counter may be incremented in the step 176 and the method 160 returns to the step 166 .
Once the signal NEXT has been asserted by the circuit 148 , a check may be performed in the step 178 to determine if the value OUT_TILE_ROW is that of the last row of the output image. If the check is true (e.g., the YES branch of step 178 ), the method 160 may return to the step 162 and wait for the next start of frame. If false (e.g., the NO branch of step 178 ), the value GRIDCOL may be cleared (e.g., GRIDCOL=0) and the value OUT_TILE_ROW may be incremented in the step 180 . The method 160 generally returns from the step 180 to the step 164 .
Referring to FIG. 6 , a flow diagram of an example method 190 for calculating the interpolation parameters is shown. The method (or process) 190 may be implemented by the circuit 148 . The method 190 generally comprises a step (or block) 192 , a step (or block) 194 , a step (or block) 196 , a step (or block) 198 , a step (or block) 200 , a step (or block) 202 , a step (or block) 204 , a step (or block) 206 , a step (or block) 208 , a step (or block) 210 , a step (or block) 212 and a step (or block) 214 . The steps 192 to 214 may be implemented in hardware, software, firmware or any combination thereof in an apparatus.
The circuit 148 generally comprises multiple internal registers similar to the internal registers of the circuit 146 . The register OUT_TILE_ROW may point to a current row of a current output tile. The register GRIDCOL may point to a current grid column. The register GA may store a warp value read from the warp table 140 . The register GC may store another warp value read from the warp table 140 . The register MINIMUM_WARP may store the minimum warp field value. The circuit 148 may calculate value for multiple interpolation parameters and transfer the values to the circuit 150 .
Referring to FIG. 7 , a diagram 218 of the interpolation parameters and the chaining operation when crossing a grid boundary (e.g., going from grid X to grid (X+1)) is shown. The circuit 148 is generally operational to compute the interpolation parameters. When a grid boundary is crossed, the circuit 148 may chain the interpolation parameters. The circuit 148 may (i) transfer a N_START_POINT parameter (e.g., warp field at top right corner) into a START_POINT parameter (e.g., warp field at top left corner), (ii) transfer a N_END_POINT parameter (e.g., warp field at bottom right corner) into an END_POINT parameter (e.g., warp field at bottom left corner) and (iii) compute the N_START_POINT parameter and the N_END_POINT parameter for the next grid. The interpolation parameters may include, but are not limited to (i) the START_POINT parameter, (ii) the END_POINT parameter, (iii) the N_START_POINT parameter, (iv) the N_END_POINT parameter, (v) a HORZ_S_INC parameter (e.g., increment along top pixel line) and (vi) a HORZ_E_INC parameter (e.g., increment along bottom pixel line) as illustrated.
Returning to FIG. 6 , on power up and/or reset, the circuit 148 may (i) initialize the value GRIDCOL (e.g., GRIDCOL=0) and (ii) initialize the OUT_TILE_ROW (e.g., OUT_TILE_ROW=0) in the step 192 . The register GRIDCOL and the register OUT_TILE_ROW may be used as local counters. Upon receiving the start of frame, the circuit 148 may compute the value GRIDROW as GRIDROW=integer(OUT_TILE_ROW/GVS_) and wait for the signal VALID to be asserted by the circuit 146 in the step 194 .
When the signal VALID is asserted by the circuit 146 , the circuit 148 may (i) latch the value MINIMUM_WARP in a local register in the step 196 , (ii) generate an address by concatenation of GRIDROW and GRIDCOL (e.g., ADDRESS={GRIDROW,GRIDCOL}), (iii) read the warp table 140 from the address and (iv) latch the read data into the register GA. In the step 196 may also include (i) forming another address by concatenation of the values GRIDROW+1 and GRIDCOL (e.g., ADDRESS={GRIDROW+1,GRIDCOL}), (ii) read data from the warp table 140 from the address and (iii) latch the read data into register GC.
In the step 198 , the circuit 148 may compute (i) START_POINT=GA+(GC-GA)*FRACTION, where FRACTION=(OUT_TILE_ROW % GVS_)/GVS_, (ii) ENDPOINT=START_POINT+(GC−GA)*FRACTION where FRACTION=1/GVS_ and (iii) increment the value GRIDCOL (e.g., GRIDCOL=+1). The circuit 148 may use the step 200 to (i) form an address by concatenating the values GRIDROW and GRIDCOL (e.g., ADDRESS={GRIDROW,GRIDCOL}), (ii) read the warp table 140 from the address and (iii) latch the read the read data into register GA. The step 200 may also include (i) forming another address by concatenating the values GRIDROW+1 and GRIDCOL (e.g., ADDRESS={GRIDROW+1,GRIDCOL}), (ii) read the warp table 140 from address and (iii) latch the read data into register GC.
In the step 202 , the circuit 148 may compute (i) N_START_POINT=GA+(GC−GA)*FRACTION, where FRACTION=(OUT_TILE_ROW % GVS_)/GVS_ and (ii) N_END_POINT=N_START_POINT+(GC−GA)*FRACTION, where FRACTION=1/GVS_. The circuit 148 may compute (i) an increment along the top horizontal line (e.g., HORZ_S_INC=(N_START_POINT-START_POINT)/GHS, where the value GHS is horizontal grid spacing in units of pixels) in the step 204 and (ii) an increment along the bottom horizontal line (e.g., HORZ_E_INC=(N_END_POINT-END_POINT)/GHS.
In the step 206 , the signal VALID may be asserted to the circuit 150 and the circuit 148 may wait for the signal NEXT to be asserted by the circuit 150 . Once the signal. NEXT has been asserted by the circuit 150 , the circuit 148 may check to determine if the value GRIDCOL is that of the rightmost column of the image in the step 208 . If true (e.g., the YES branch of step 208 ), the circuit 148 may check in the step 210 to determine if the value OUT_TILE_ROW is that of the last row. If the check in the step 208 is false (e.g., the NO branch of step 208 ), the circuit 148 may (i) move the value N_START_POINT into the value START_POINT, (ii) move the value N_END_POINT into the value END_POINT, (iii) increment the value GRIDCOL in the step 212 and proceed to the step 200 .
If the value OUT_TILE_ROW is that of the last row of the image (e.g., the YES branch of step 210 ), the process may return to step 192 and wait for the next start of frame. If the check is false (e.g., the NO branch of step 210 ), the circuit 148 may (i) increment the value OUT_TILE_ROW by one, (ii) clear the value GRIDCOL (e.g., GRIDCOL=0) and return to the step 194 .
Referring to FIG. 8 , a flow diagram of an example method 220 for calculating a motion vector and fetching an input tile is shown. The method (or process) 220 may be implemented by the circuit 150 . The method 220 generally comprises a step (or block) 222 , a step (or block) 224 , a step (or block) 226 , a step (or block) 227 , a step (or block) 228 , a step (or block) 230 , a step (or block) 232 , a step (or block) 234 , a step (or block) 236 , a step (or block) 238 , a step (or block) 240 and a step (or block) 242 . The steps 222 to 242 may be implemented in hardware, software, firmware or any combination thereof in an apparatus.
The circuit 150 may be operational to fetch input tiles into the buffer 142 . Once a complete input tile is in the buffers local to the circuit 150 , the signal VALID may be asserted to the circuit 152 . The circuit 150 generally comprises multiple internal registers. A pair of registers (e.g., A and B) may be used to store intermediate calculated values. A register (e.g., CURRENT_PHASE) may store a pointer into the input picture. For an output pixel line N, a value of CURRENT_PHASE may be N*PHASE_INC. A register (e.g., SBASE) may store an address of the initial row stored in the image buffer 102 , image buffer 106 . The address may refer to the input picture. An address=0 may be an initial row of the input picture. The register MINIMUM_WARP may store the value of the minimum warp field. A register (e.g., ZERO_POINT) may store an address of an initial row of an input tile in the buffer 142 . A register (e.g., MV) may store an offset address into the image buffer 102 , image buffer 106 . MV=(row=0, column=0) generally means an initial row and an initial column in the image buffer 102 , image buffer 106 . A register (e.g., OUT_TILE_WIDTH) may store the width of the output tiles. The circuit 150 may calculate values for multiple phasing parameters and transfer the phasing parameter values, the interpolation values and the value MINIMUM_WARP to the circuit 152 . The phasing parameters may include, but are not limited to, the value CURRENT_PHASE and the value ZERO_POINT. The values in the registers CURRENT_PHASE and SBASE may be used to compute the value in the register MV, which is an address into the image buffer 102 , image buffer 106 . The values in the registers CURRENT_PHASE and ZERO_POINT are generally used to compute the address into the buffer 142 .
On power up and/or reset, the circuit 150 may (i) clear the register SBASE (e.g., SBASE=0), the register CURRENT_PHASE (e.g., CURRENT_PHASE=0), the register MINY (e.g., MINY=0) and the register OUT_TILE_COL (e.g., OUT_TILE_COL=0) in the step 222 . Upon receipt of the start of frame, the circuit 150 may wait for the circuit 148 to assert the signal VALID in the step 224 .
Once the signal VALID has been asserted by the circuit 148 , the circuit 150 may latch the values START_POINT, END_POINT, HORZ_S_INC, HORZ_E_INC and MINIMUM_WARP in the step 226 as received from the circuit 148 . In step 227 , the circuit 150 may compute a motion vector (e.g., MV) as:
B=A +(OUT_TILE_WIDTH−1)*HORZ_ S _INC 1.
ZERO_POINT=CURRENT_PHASE+min( A,B )+1−FILTERTAPS/2 2.
MV =ZERO_POINT− S BASE 3.
A check may be performed in the step 228 to determine if space is available in the buffer 142 to hold a complete new input tile. If space is available (e.g., the YES branch of step 218 ), the circuit may fetch the new input tile into the buffer 142 in the step 230 from an ADDRESS (X,Y)=(OUT_TILE_COL,MV) of the image buffer 102 , image buffer 106 . If insufficient space is available (e.g., the NO branch of step 228 ), the circuit 150 may wait in the step 232 for space to become available, then fetch the new input tile in the step 230 .
A check may be performed in the step 234 to determine if a grid boundary crossing is in progress. If the condition is true (e.g., the YES branch of step 234 ), another check may be made in the step 236 . If the condition is false (e.g., the NO branch of step 234 ), the circuit 150 may calculate A=+OUT_TILE_WIDTH*HORZ_S_INC in the step 238 and return to the step 227 .
The step 236 may determine if the right edge of the image has been reached. If false (e.g., the NO branch of step 236 ), the method 220 may proceed to the step 242 . If true (e.g., the YES branch of step 236 ), the circuit 150 may calculate CURRENT_PHASE=+PHASE_INC*OUT_TILE_HEIGHT in the step 240 , where PHASE_INC may be programmable from (0,1]. When the value PHASE_INC is programmed less than 1, an up-sampling may be achieved as well as warping. If the value PHASE_INC is programmed with 1, a warping may be achieved without up-sampling. The step 240 may also set SBASE=integer(CURRENT_PHASE+MINIMUM_WARP−FILTERTAPS/2+1). Thereafter, the method 220 may proceed to the step 242 .
A check may be made in the step 242 to determine if an end of frame has been reached. If the end of frame has been reached (e.g., the YES branch of step 242 ), the method 220 may return to step 222 and wait for a next start of frame. If no end of frame has been reached (e.g., the No branch of step 242 ), the method 220 may return to the step 224 and wait for the circuit 148 to assert the signal VALID.
Referring to FIG. 9 , a flow diagram of an example method 250 for calculating the output pixels is shown. The method (or process) 250 may be implemented by the circuit 152 . The method 250 generally comprises a step (or block) 252 , a step (or block) 254 , a step (or block) 256 , a step (or block) 258 , a step (or block) 260 , a step (or block) 262 , a step (or block) 264 , a step (or block) 266 and a step (or block) 268 . The steps 252 to 268 may be implemented in hardware, software, firmware or any combination thereof in an apparatus.
The circuit 152 may be operational to fetch pixels from the buffer 142 , generate the output pixels and store the output pixels in the buffer 144 . Generation of the output tiles may be performed in inverse raster scan order. Once a complete output tile is written to the buffer 144 , the output tile may be sent to either a next camera block in the pipeline of the circuit 132 and/or stored to an external memory for display/modification later.
On power up and/or reset, the circuit 152 may clear the local registers in the step 252 and wait for the signal VALID to be asserted by the circuit 150 . Once the signal VALID is asserted, the circuit 152 may (i) latch into the local registers the values CURRENT_PHASE, ZERO_POINT, END_POINT, START_POINT, HORZ_S_INC and HORZ_E_INC as received from the circuit 150 and (ii) initialize a column counter (e.g., COLUMN=0) in the step 254 .
In the step 256 , the circuit 152 may (i) compute a vertical increment (e.g., VERTICAL_INCREMENT) as VERTICAL_INCREMENT=END_POINT-START_POINT, (ii) compute PHASE=CURRENT_PHASE (e.g., the CURRENT_PHASE received from the circuit 150 ) and (iii) initialize a row counter (e.g., ROW=0). In the step 258 , the circuit 152 may fetch input pixels from the buffer 142 starting from an ADDRESS=integer(PHASE−FILTERTAPS/2−1)−ZERO_POINT. The number of pixels fetched generally depends upon the filter values (e.g., FILTERTAPS) of the FIR filter. The step 258 may include (i) applying the FIR filtering on the fetched input pixels to generate an output pixel at a point (ROW,COLUMN) in the output tile and (ii) computing PHASE=+(PHASE_INC+VERTICAL_INCREMENT).
A check may be performed by the circuit 152 in the step 260 to determine if the counter ROW is less than the value OUT_TILE_HEIGHT. If counter ROW is less (e.g., the NO branch of step 260 ), the counter ROW may be incremented in the step 262 and the method 250 returns to the step 258 to calculate the next output pixel. Once the counter ROW reaches the value OUT_TILE_HEIGHT (e.g., the NO branch of step 260 ), the counter COLUMN may be incremented in the step 264 .
A check may be performed in the step 266 to determine if the counter COLUMN is less than the value OUT_TILE_WIDTH. If the counter COLUMN is less (e.g., the YES branch of step 266 ), the circuit 152 may (i) compute START_POINT=START_POINT+HORZ_S_INC and (ii) END_POINT=END_POINT+HORZ_E_INC in the step 268 . Thereafter, the method 250 may return to the step 256 to work on the next output column. Once the counter COLUMN reaches the value OUT_TILE_WIDTH (e.g., the NO branch of step 266 ), the method 250 may return to the step 252 and wait for the signal VALID to be come active again
The functions performed by the diagrams of FIGS. 1, 4, 6, 8 and 9 may be implemented using one or more of a conventional general purpose processor, digital computer, microprocessor, microcontroller, RISC (reduced instruction set computer) processor, CISC (complex instruction set computer) processor, SIMD (single instruction multiple data) processor, signal processor, central processing unit (CPU), arithmetic logic unit (ALU), video digital signal processor (VDSP) and/or similar computational machines, programmed according to the teachings of the present specification, as will be apparent to those skilled in the relevant art(s). Appropriate software, firmware, coding, routines, instructions, opcodes, microcode, and/or program modules may readily be prepared by skilled programmers based on the teachings of the present disclosure, as will also be apparent to those skilled in the relevant art(s). The software is generally executed from a medium or several media by one or more of the processors of the machine implementation.
The present invention may also be implemented by the preparation of ASICs (application specific integrated circuits), Platform ASICs, FPGAs (field programmable gate arrays), PLDs (programmable logic devices), CPLDs (complex programmable logic device), sea-of-gates, RFICs (radio frequency integrated circuits), ASSPs (application specific standard products) or by interconnecting an appropriate network of conventional component circuits, as is described herein, modifications of which will be readily apparent to those skilled in the art(s).
The present invention thus may also include a computer product which may be a storage medium or media and/or a transmission medium or media including instructions which may be used to program a machine to perform one or more processes or methods in accordance with the present invention. Execution of instructions contained in the computer product by the machine, along with operations of surrounding circuitry, may transform input data into one or more files on the storage medium and/or one or more output signals representative of a physical object or substance, such as an audio and/or visual depiction. The storage medium may include, but is not limited to, any type of disk including floppy disk, hard drive, magnetic disk, optical disk, CD-ROM, DVD and magneto-optical disks and circuits such as ROMs (read-only memories), RAMS (random access memories), EPROMs (electronically programmable ROMs), EEPROMs (electronically erasable ROMs), UVPROM (ultra-violet erasable ROMs), Flash memory, magnetic cards, optical cards, and/or any type of media suitable for storing electronic instructions.
The elements of the invention may form part or all of one or more devices, units, components, systems, machines and/or apparatuses. The devices may include, but are not limited to, servers, workstations, storage array controllers, storage systems, personal computers, laptop computers, notebook computers, palm computers, personal digital assistants, portable electronic devices, battery powered devices, set-top boxes, encoders, decoders, transcoders, compressors, decompressors, pre-processors, post-processors, transmitters, receivers, transceivers, cipher circuits, cellular telephones, digital cameras, positioning and/or navigation systems, medical equipment, heads-up displays, wireless devices, audio recording, storage and/or playback devices, video recording, storage and/or playback devices, game platforms, peripherals and/or multi-chip modules. Those skilled in the relevant art(s) would understand that the elements of the invention may be implemented in other types of devices to meet the criteria of a particular application.
While the invention has been particularly shown and described with reference to the preferred embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made without departing from the spirit and scope of the invention.
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An apparatus generally having a first memory, a second memory and a circuit is disclosed. The first memory may be configured to store a warp table. The warp table is generally accessed through a single data port of the first memory. The second memory may be configured to buffer an input image. The input image may have a plurality of input pixels arranged in two dimensions. The circuit may be configured to generate an output image by a warp correction of an input image. The warp correction may be defined by the warp table. The output image may include a plurality of output pixels. At least one of the output pixels may be generated during each clock cycle of the circuit.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to provisional application Ser. No. 61/481,480 filed on May 2, 2011 titled Universal Outdoor Modular Kitchen System, the entire disclosure of which is hereby incorporated by reference.
TECHNICAL FIELD
[0002] The present disclosure provides an outdoor kitchen system with modular units that are configured to universally fit a wide range of kitchen accessories. Related methods are also provided.
BACKGROUND
[0003] Outdoor cooking has increased in sophistication from simply including a charcoal grill to full kitchen systems that include multiple components (e.g., gas grills, refrigerators, countertops, bars, storage cabinets, and trash cabinets). The arrangement, size, and shapes of these components vary. To accommodate these variables, the cabinet structures that support these components are often either constructed on site or pre-constructed based on customer specification and shipped fully assembled for installation. There is a need in the art to provide outdoor kitchen systems that are more easily and efficiently constructible.
SUMMARY
[0004] The present disclosure provides an outdoor kitchen system that includes universal cabinet structures that are modular. The cabinets provided are configured to accommodate a wide range of kitchen components and are also configured to be arranged to form kitchens having various layouts. The system allows for quick and efficient construction of outdoor kitchen systems.
BRIEF DESCRIPTION OF THE FIGURES
[0005] FIG. 1 is a perspective view of a kitchen system according to the principles of the present disclosure;
[0006] FIG. 2 is a perspective view of a grill cabinet frame assembly of the kitchen system of FIG. 1 ;
[0007] FIG. 3 is an assembly view of the cabinet frame assembly of FIG. 2 ;
[0008] FIG. 4 is an enlarged assembly view of portion A of FIG. 3 ;
[0009] FIG. 5 is an enlarged assembly view of portion B of FIG. 3 ;
[0010] FIG. 6 is a portion of the top plane of the cabinet frame assembly of FIG. 2 ;
[0011] FIG. 7 is a portion of the top plane of the cabinet frame assembly of FIG. 2 ;
[0012] FIG. 8 is a portion of the front plane of the cabinet frame assembly of FIG. 2 ;
[0013] FIG. 9 is a portion of the bottom plane of the cabinet frame assembly of FIG. 2 ;
[0014] FIG. 10 is a portion of the back plane of the cabinet frame assembly of FIG. 2 ;
[0015] FIG. 11 is a perspective view of a side burner cabinet frame assembly according of the kitchen system of FIG. 1 ;
[0016] FIG. 12 is an assembly view of the cabinet frame assembly of FIG. 11 ;
[0017] FIG. 13 is a perspective view of a one hundred thirty-five degrees filler cabinet frame assembly of the kitchen system of FIG. 1 ;
[0018] FIG. 14 is an assembly view of the cabinet frame assembly of FIG. 13 ; and
[0019] FIGS. 15-29 depict other variations of the kitchen system that are also in accordance with the principles of the present disclosure.
DETAILED DESCRIPTION
[0020] Referring to FIG. 1 an embodiment of an outdoor kitchen system according to the principles of the present disclosure is shown. The outdoor kitchen system includes modular units that are configured to universally fit a wide range of kitchen accessories. In the depicted embodiment the kitchen system 10 includes a number of different modular cabinets including a side burner cabinet 12 , a grill cabinet 14 , a filler cabinet 16 , a trash cabinet 18 , a dishwasher cabinet 20 , and a refrigerator cabinet 22 .
[0021] Referring generally to FIGS. 2-10 , the grill cabinet 14 is described in further detail. In the depicted embodiment the grill cabinet includes a modular frame assembly that is configured to support a kitchen accessory (i.e., a grill unit). It should be appreciated that other types of cabinets have frames that are configured to support other types of kitchen accessories (e.g., trash units, refrigerators, dishwashing machines, sinks, side burners, etc.) In the depicted embodiment, the frame assembly 24 is configured to support a first sheet of backing material attached to the front, top and back planes. The sheet of backing material can be of the type that is designed to withstand prolonged exposure to moisture, for example, cement based boards such as National Gypsum's PermaBase or HardiBacker Cement Board. The sheet of backing material can be pre-attached to at least some components of the frame via fasteners (e.g., screws, rivets, etc.) and/or attached to the frame at the job site. In the depicted embodiment an outdoor veneer (stone veneer, tile, etc.) can be attached (e.g., glued, cemented) over the backing material.
[0022] Referring more particularly to FIGS. 3 , 4 , 9 , and 10 , the primary components of the frame assembly 24 are described in further detail. In the depicted embodiment, the frame assembly 24 is constructed of a plurality of preassembled, generally planar sub-structures (top sub-structure 26 , back sub-structure 28 , front sub-structure 30 , and bottom sub-structure 32 ), which are configured to be assembled at job sites by aligning mating structures 34 thereon. In the depicted embodiment the mating structures 34 on the bottom sub-structure 32 include first tabs 40 adjacent to posts 42 . The posts 42 are received in post receiving apertures 44 on the front sub-structure 30 and the back sub-structure 28 . When the posts 42 are received in the post receiving apertures, the first tabs 40 are configured to abut second tabs 46 , which are fixed to the front sub-structure 30 and the back sub-structure 28 . Each of the first and second tabs 40 , 46 include apertures that are configured to align with each other and receive a fastener 48 therethrough. When the kitchen layout includes multiple cabinet frame assemblies arranged adjacent each other, the fasteners 48 can be extended through the first and second tabs of adjacent frame assemblies, thereby securing the modular units together. Since in the depicted embodiment many of the cabinets have generally the same height and depth, the cabinets are modular in nature in that they can be arranged and connected to form kitchen systems having multiple layouts.
[0023] It should be appreciated that the above-described sub-structures can be nested one on top of another to form a compact package for shipping. In the depicted embodiment the assembled frame assembly 24 is 36 inches high, 26 inches deep, and 60 inches wide. Each of the four primary components are 3 inches high including the height of the posts. Therefore, even if the posts are not nested, the package dimensions would be 12 inches high, 26 inches deep, and 60 inches wide. This would result in a shipping size that is ⅓60 of the assembled size. In some applications the posts can be nested or removable, which would thereby further decrease the package. For example, if the posts are nested or removable, the shipping size could be 4 inches high, 26 inches deep, and 60 inches wide.
[0024] Referring more particularly to FIGS. 2 , 5 - 8 , the universality of the frame assembly 24 is described in greater detail. In the depicted embodiment, the frame assembly 24 defines two openings: a grill receiving opening 36 and a grill storage compartment opening 38 . Both of these openings are adjustable in shape and size so that they can accommodate many different styles and brands of grills and grill storage compartments. The adjustability of the openings of the frame assembly 24 makes the cabinet universal in that it does not need to be manufactured specifically to fit a particular grill or grill storage compartment. In the depicted embodiment the grill receiving opening 36 is in part defined by the top sub-structure 26 and in part defined by the front sub-structure 30 . Four structural members define the borders of the opening 36 : a first adjustable length member 48 , a first member with slide rails 50 , a first L-shaped member 52 , and a second L-shaped member 54 . The first adjustable length member 48 includes an external face 56 that is in the top plane of the frame assembly 24 . The first member with slide rails 50 includes an external face 58 that is in the front plane of the frame assembly 24 . Both the first adjustable length member 48 and the first member with slide rails 50 extend in widthwise direction of the frame assembly 24 . The first L-shaped member 52 and the second L-shaped member 54 include external faces 60 , 62 that are both in the top plane and front plane of the frame assembly 24 . The first and second L-shaped members 52 , 54 are parallel to each other and perpendicular to the first adjustable length member 48 and the member with slide rails 50 .
[0025] In the depicted embodiment the first adjustable length member 48 can be adjusted forward and rearward to accommodate grill units of different depths, and the first and second L-shaped members 52 , 54 can be adjusted in the widthwise direction to accommodate grill units of different widths.
[0026] In the depicted embodiment the grill storage compartment opening 38 is defined by the front sub-structure 30 . Four structural members define the borders of the opening 38 : a second adjustable length member 64 , a third adjustable length member 66 , a first vertical member 68 , and a second vertical member 70 . In the depicted embodiment, each of the four structural members include external faces 72 , 74 , 76 , 78 in the front plane of the frame assembly 24 . In the depicted embodiment the widthwise distance between the vertical members can be adjusted to accommodate grill storage units that have different widths.
[0027] Still referring to FIGS. 2 , 5 - 8 , the example mechanisms for adjusting the size of the openings 36 , 38 are further described. In the depicted embodiment the first, second, and third adjustable length members 48 , 64 , 66 include a telescoping construction including two tubular members each having different cross-sectional dimensions such that one of the tubular members fits within the other. The adjustable length members 48 , 64 , 66 are attached between members that include tabbed ends 80 that ride in channels 82 in the slide rails 50 (see FIG. 5 ). In the depicted embodiment the tabbed ends 80 include a set screw assembly that can be used to secure the connection between the tabbed end 80 and the channel 82 once the desired adjustments have been made.
[0028] Referring particularly to FIGS. 2 and 7 , an interlock sub-assembly 84 that is configured to engage adjacent frame assemblies for auxiliary support is described in further detail. In the depicted embodiment, the interlock sub-assembly includes auxiliary support rods 86 configured to provide auxiliary support to cantilevered members 88 of the top sub-structure 26 . The support rods 86 are attached to the cantilevered members 88 at a first end and include second ends that slide into engagement with the frame assemblies of an adjacent cabinet. In the depicted embodiment adjacent cabinets have holes configured to receive the support rods 86 . In addition to providing auxiliary support to the cantilevered members 88 , the support rods 86 further connect the modular cabinets into a single structure, thereby increasing the stability and structural integrity of the of overall system.
[0029] Referring to FIGS. 11 and 12 , the frame assembly 90 of the side burner cabinet 12 is shown. Referring to FIGS. 13 and 14 , the frame assembly 92 of the filler cabinet 16 is shown. Both the frame assembly 90 of the side burner cabinet and the frame assembly 92 of the filler cabinet share features of the frame assembly 24 of the grill cabinet and therefore will not be described herein in detail. It should be appreciated that many other alternative frame assembly configurations, which are in accordance with the principles of the present disclosure, are possible.
[0030] The above specification, examples and data provide a complete description of the manufacture and use of the composition of the invention. Since many embodiments of the invention can be made without departing from the spirit and scope of the invention, the invention resides in the claims hereinafter appended.
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The present disclosure provides an outdoor kitchen system that includes universal cabinet structures that are modular. The cabinets provided are configured to accommodate a wide range of kitchen components and are also configured to be arranged to form kitchens having various layouts. The system allows for quick and efficient construction of outdoor kitchen systems.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention is directed to a self-supporting cantilevered arm attached to a vertical mast to provide a cantilever structure especially adapted to support lighted signals along a railroad, such as traffic signals at a grade crossing.
2. Description of Related Art
Some type of warning system is usually installed at grade crossings where railroad tracks cross a road or highway. Increasingly, governments require overhead warning lights and signals. State Departments of Transportation now typically require a set of signal lights in each lane of the roadway.
In addition, each light in such a warning display must be equipped with a restrictive filter that concentrates the light to be seen in the lane directly in front of the light. To meet this requirement, lens filters for overhead lights must direct the light into a cone having a total horizontal field of twenty degrees (20°), i.e. ten degrees (10°) to the left of the light's center line and ten degrees (10°) to the right of the light's center line, and a total vertical field of thirty-two degrees (32°) down, i.e. zero degrees (0°) up from the light's center line and thirty-two degrees (32°) down from the light's center line. To ensure that the resulting cone of light will be seen by a car in the lane in front of the light, the structure upon which the light is mounted must be fixed and not subject to excessive deflection.
The American Association of State and Highway Transportation Officials (AASHTO) also sets deflection and other performance criteria for such cantilevers. In a wind of 130 miles per hour (209 kph), that is, a Beaufort number greater than 17, a cantilever boom of any length is allowed to have a maximum vertically downward deflection of six inches (6") (15.24 cm) from the unstressed equilibrium position, and a maximum horizontal angular deflection of three degrees fifteen minutes (3° 15') in front of or behind the equilibrium position. These are the maximum deflections that will allow the cone of light from each warning lamp to be seen by a driver in the lane beneath it. Such structures also should withstand snow and ice loading of three pounds per square foot and a live load of 500 pounds (186.5 kg) at the end of the cantilevered boom without exceeding these same deflection standards.
One approach to meeting such requirements is to build an elevated truss spanning the entire roadway and supported at both ends. This solution has generally not been commercially undertaken because it is too costly, since the truss need not cross the entire roadway but only the lanes of traffic that travel in one direction.
One prior art approach to the problem of providing overhead warning signals at grade crossings is a cantilever having a vertically disposed mast fixed to a supporting pad, such as a poured concrete pad embedded in the ground, and having a cantilever arm attached to the mast. The cantilever arm includes three main members, two of which form a triangular base disposed in a horizontal plane, and the third member is spaced above these two bottom members. Reinforcing members maintain the orientation of the three main members. Such structures, however, are not self-supporting. Instead, much of the support for the cantilevered arm comes from a pair of tensioned cables strung between the top of the mast and cable-retaining fixtures near the convergent end of the bottom members of the arm.
Such structures typically will not hold a 500 pound (186.5 kg) live load and are only good for a two-lane road at best. They will not support a walkway or a worker. Instead, whenever the warning lamps or signals require any maintenance or inspection, a hand crank is turned, swinging the cantilevered arm into a position parallel with the road and a supplied ladder is placed against the cantilevered arm at the spot where work is needed. Naturally, a worker must climb down the ladder and move it in order to work on more than one lamp or signal fixture.
Furthermore, the cables that hold the cantilevered arm must be tightened annually because they stretch. Eventually, the cables will stretch beyond their limit and must be replaced. If this maintenance is neglected, the result could be the collapse of the cantilevered arm.
Another proposed solution to the problem of providing overhead warning systems at grade crossings is a cantilevered arm consisting of a rectangular frame with some reinforcing members between the two long sides of the rectangle. The frame is oriented in a vertical plane and cantilevered from a mast. Such a cantilevered arm may include a walkway, allowing the maintenance worker to walk along inside the length of the arm to work on the lighting and warning fixtures. The space for walking inside the arm is small and restrictive. Moreover, the cost of this type of structure is high.
Accordingly, there is a significant need for an overhead cantilevered boom warning signal carrier for railroad grade crossings that can be extended to a length of forty feet (40') (12.19 km) while maintaining the necessary strength; that can carry a 500 pound (186.5 kg) live load at the end of the arm without deflecting more than six inches (6") (15.24 cm) downward; that will withstand a 130 miles per hour (209 kph) wind with a maximum vertical deflection of six inches (6") (15.24 cm) downward and a maximum horizontal angular deflection of plus or minus three degrees fifteen minutes (3° 15') from equilibrium at the end of a forty foot (40') (12.19 m) long cantilever boom; that includes a catwalk for allowing easy access to the lighting fixtures; that allows the worker ready access to the lighting and warning fixtures without any superstructure members to crawl around or under; that remains in place over the roadway during maintenance on the warning fixtures, obviating the need to rotate the cantilevered boom; that weighs less than cantilevered booms of the prior art; and that is less expensive to manufacture, transport and erect than cantilevered booms in present use.
OBJECTS OF THE INVENTION
Accordingly, it is an object of the invention to provide a triangular truss walkout cantilever having a cantilevered arm that can be extended to a length of forty feet (40') (12.19 m) while maintaining the desired strength.
It is a further object of the invention to provide a triangular truss walkout cantilever that can carry a 500 pound (186.5 kg) live load at the end of the truss arm without deflecting downward more than six inches (6") (15.24 cm).
It is a further object of the invention to provide a triangular truss walkout cantilever that will withstand a 130 miles per hour (209 kph) wind with a maximum vertical deflection of six inches (6") (15.24 cm) downward and a maximum horizontal angular deflection of plus or minus thirty degrees fifteen minutes (30° 15') from equilibrium at the end of a cantilever arm 12' (3.7 m) to and including forty feet (40') (12.19 m) long.
It is another object of the invention to provide a triangular truss walkout cantilever that includes a catwalk for allowing easy access to the lighting and warning fixtures.
It is a further object of the invention to provide a triangular truss walkout cantilever that allows a worker ready access to the lighting and warning fixtures without any superstructure members to crawl around or under.
It is another object of the invention to provide a triangular truss walkout cantilever that can remain in place over the roadway during maintenance on the lighting and warning fixtures, obviating the need to rotate the cantilevered arm.
It is a further object of the invention to provide a triangular truss walkout cantilever that weighs less than cantilevered booms of prior designs.
It is a further object of the present invention to provide a triangular truss walkout cantilever that is less expensive to manufacture, transport and erect than cantilevered booms in present use.
The triangular truss walkout cantilever achieves these and other objects of the present invention by providing a vertical mast having a cantilever arm attached to the top of it. The cantilever arm includes three primary members, or longitudinal truss members, that are mutually parallel and form a uniformly triangular cross section throughout their length. In a preferred embodiment, the triangular cross section is an isosceles cross section. The triangular truss walkout cantilever is provided with means for interlocking the three longitudinal truss members, which comprise a variety of internal braces and supports. Also included is a horizontally disposed catwalk joined to the bottom truss members by a plurality of supporting ribs, and including a handrail supported by vertical handrail supports.
A cantilever arm less than twenty-five feet (25') (7.6 m) long may be supported by a single ten and three-quarter inch outside diameter (103/4" O.D.) (27 cm), tubular aluminum mast. When the cantilever arm is twenty-five to thirty feet (25' to 30') (6 m to 9.2 m) long, a double mast consisting of two eight and five-eighths inch outside diameter (85/8" O.D.) (22 cm), tubular aluminum masts is used. Alternatively, galvanized steel masts can be employed. In either case, the bottom of the truss arm is intended to be seventeen and one-half feet (171/2') (5.33 m) from the road beneath it, with a minimum clearance of seventeen feet (17') (5.2 m)
In a preferred embodiment, all structural members of the triangular truss walkout cantilever are aluminum.
More particularly, the triangular truss walkout cantilever comprises a base adapted to overlie a supporting pad; at least one vertically disposed mast having a bottom end and a top end, said bottom fixed to said base; a horizontally disposed truss arm having a mounting end and a free end, with said mounting end attached to said mast proximate said top end of said mast, said truss arm including three longitudinal truss members disposed parallel to one another, said truss members including a first bottom truss member, a second bottom truss member and a top truss member, said longitudinal truss members forming a cross sectional triangular pattern having a horizontal base and an upwardly projecting apex; means for interlocking said longitudinal truss members; a plurality of cross members disposed in the plane of said first and second bottom truss members, between said first and second bottom truss members, and perpendicular to said first and second bottom truss members, said cross members being attached to said first and second bottom truss members, thereby forming a series of bottom rectangles; at least one bottom brace within each said rectangle disposed along a diagonal of said rectangle; a plurality of side braces attached to and extending from said first bottom truss member to said top truss member and joined thereto; a plurality of side braces attached to and extending from said second bottom truss member to said top truss member and joined thereto; a plurality of vertical braces attached to and extending from said cross members to said top truss member and joined thereto; and a plurality of center diagonals attached to and extending from said cross members to said top truss member.
Through a computer simulation stress analysis and subsequent field tests of the triangular truss walkout cantilever of the present invention, it has been found that the primary truss members can be made from smaller diameter aluminum tubing than was previously customary, due to the strength and stiffness of the mast and cantilevered arm. In particular, primary truss members of three inches (3") (7.62 cm) may be used with cantilever arms of twelve feet to twenty-eight feet (12' to 28') (3.7 m to 8.6 m); and primary truss members of four inches (4") (10.2 cm) may be used with cantilever arm of twenty-nine feet to forty feet (29' to 40') (8.9 m to 12.2 m). This results in less wind resistance in the finished installed cantilever, and in significant weight reductions, which save money in manufacturing, shipping and installing such cantilevers. The primary members comprise the first bottom truss member, the second bottom truss member, the top truss member, and the vertical braces. A triangular truss walkout cantilever made in accordance with the teachings of the present invention and having a cantilever arm forty feet (40') (12.19 cm) long can exhibit a downward deflection of only three inches (3") (8.62 cm) when subjected to a 1,000 pound (454 kg) live load at the free end of the cantilever arm. In addition, such a cantilever arm weighs only about 720 pounds (326.9 kg). Eight warning lights add about another 160-300 pounds (72.6-145.2 kg) to the total dead load, providing a lightweight cantilever arm for a structure of this size.
Other objects and advantages of the invention will become apparent from the following description taken in connection with the accompanying drawings, wherein is set forth by way of illustration and example, an embodiment of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the triangular truss walkout cantilever primarily featuring the cantilever arm.
FIG. 2 is a front elevation of the triangular truss walkout cantilever featuring a double mast model.
FIG. 3 is a cross section taken along lines 3--3 of FIG. 2.
FIG. 4 is a fragmentary perspective view of the triangular truss walkout cantilever viewed from the mast end.
FIG. 5 is a plan view of the triangular truss walkout cantilever featuring a single mast model, simplified for clarity.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 2, there is shown a triangular truss walkout cantilever 10 having a first mast 12, a second mast 14, which are both vertical and are fixed to a supporting pad (not shown). The supporting pad may be, for example, poured concrete embedded in the ground and having a plurality of spaced bolts embedded therein and protruding from the top of the supporting pad. A base plate 16 or other base is fixed to the bottom ends of masts 12, 14 by means of welding or the like and the connection is reinforced by a plurality of triangular struts 18 that are welded to base plate 16 and masts 12, 14. Three triangular struts 18 are equally spaced about the circumference of each mast 12, 14. Four reinforcing spacer members 20 are horizontally disposed between first mast 12 and second mast 14, and welded thereto at each end, to maintain the parallel relationship between the masts 12, 14. In a preferred embodiment, masts 12, 14 are made from approximately ten inch (10") (25.4 cm) diameter tubular aluminum. If the cantilever arm is less than twenty-five feet (7.6 m) long, only one such aluminum mast is required. Base plate 16 includes a plurality of apertures which align with the bolts protruding from the supporting pad, allowing the triangular truss walkout cantilever 10 to be fixed to the supporting pad by nuts.
A ladder 15 is fixed to mast 12 by ladder brackets 17 for allowing workers to climb to catwalk 44 easily. A locked anti-climbing device (not shown) may be included at the lower end of ladder 15 to discourage unauthorized use of ladder 15.
Truss arm 22 includes three longitudinal truss members disposed parallel to one another, forming a triangular cross section throughout their length (see FIG. 3), and numerous reinforcement members. First bottom truss member 24 and second bottom truss member 26 are parallel and define a horizontal plane. Top truss member 28 is disposed above truss members 24, 26 to form an isosceles triangular cross section, that is, top truss member 28 is disposed parallel to the center line between first bottom truss member 24 and second bottom truss member 26, and is vertically disposed above that center line. Thus, all side braces 30 are of equal length.
Cross members 32 are disposed between first bottom truss member 24 and second bottom truss member 26, and are perpendicular to both bottom truss members and lie in the plane defined by the bottom truss members 21, 26. A plurality of spaced parallel cross members 32 is employed, with six cross members being used in the model shown in FIG. 2.
A bottom brace 34 lies in the plane defined by first bottom truss member 24 and second bottom truss member 26 and forms a diagonal brace across each rectangular frame formed by bottom truss members 24, 26 and two adjacent cross members 32. Bottom braces 34 are arranged so that each pair of adjoining rectangles 36 includes a common cross member 32, (or 33, see below) joined at one of its ends to bottom member 24 or 26 at the proximal ends of adjacent braces 34, thereby forming a zigzag pattern of bottom braces 34 in the plane of first bottom truss member 24 and second bottom truss member 26.
Referring to FIG. 4, the triangular truss walkout cantilever 10 further includes a plurality of center diagonals 38. A center diagonal 38 is attached to the middle of the length of cross member 32 and runs to the bottom of top truss member 28 at an angle of between about thirty to seventy-five degrees (30°-75°) and is fastened to top truss member 28. In the preferred embodiment disclosed herein, two center diagonals 38 are attached to a single cross member 32, with one center diagonal 38 leaning toward the mast end or mounting end 23 of truss arm 22 and the other center diagonal 38 leaning toward the free end 21 of truss arm 22. Center diagonals 38 may be fixed to each cross member 32, or to every other cross member 32, as shown in the figures.
A plurality of spaced parallel vertical braces 40 are fixed to the mid-point of cross members 33 and to the bottom of top truss member 28. Cross members 33 are the same part as cross members 32. Cross members 32, however, have attached to them side braces 30, which appear vertical in elevation, that is, they lean inward from the outer corner of the isosceles triangle cross section of truss arm 22 to the apex of that triangle (as shown most clearly in FIG. 3). Alternatively, side braces 30 may be configured to display in front elevation an angle relative to the vertical of from about twenty degrees (20°) to about fifty degrees (50°). Cross members 32 are also provided with the center diagonals 38. Every other cross member is a cross member 32 having these other members associated with it.
In contrast, cross member 33 has attached at its mid-point vertical brace 40 whose opposite end is attached to the bottom portion of top truss member 28. Thus, in the embodiment shown in FIG. 2, every other cross member includes a vertical brace 40. Lighting and signal warnings 42 are attached to each vertical brace 40. The construction recited herein allows ready access to lighting and warning signals 42 because there are no superstructure or support members between catwalk 44 and vertical braces 40, each of which supports a corresponding warning signal unit 42. Specifically, no side braces 30 interfere with the workman's access to warning signals 42.
A plurality of spaced horizontal ribs 46 is attached to first bottom truss member 24 and extend outwardly from the triangular cross section formed by truss members 24, 26, 28. Horizontal ribs 46 are welded to first bottom truss member 24. Catwalk 44, consisting of a pair of parallel longitudinal channel walkway members 45, is equipped with handrail 48 supported by handrail supports 50. Reinforcing rail 49 runs parallel to handrail 48 approximately midway between channel walkway members 45 and handrail 48.
Triangular truss walkout cantilever 10 is designed for two-piece assembly in the field through means for joining a completed truss arm 22 to masts 12, 14 or in the case of a single mast cantilever (FIG. 5 only), mast 13. This end is accomplished by having matching plate brackets on the mounting end of truss arm 22 and mounting means attached to the masts. In particular, stub arm 52 penetrates apertures 54 through first mast 12 and second mast 14 and is welded thereto. Stub arm 52 terminates in upper bracket 58, which comprises a square metal plate bracket welded to tubular stub arm 52 and comprising an integral part thereof. Upper truss arm bracket 59 is a matching flat metal bracket welded to the mounting end of top truss member 28. Brackets 58, 59 include four apertures 60 adapted to receive nuts and bolts 62 for fastening these pieces together.
Caliper bracket 66 embraces some portions of the circumference of first mast 12 and second mast 14 and is welded thereto. Caliper bracket 66 terminates in mounting bracket 67, which is a rectangular metal plate bracket welded to caliper bracket and vertically oriented, and includes a plurality of apertures 60. Lower truss arm bracket 64 is a matching rectangular metal plate bracket welded to first bottom truss member 24 and second bottom truss member 28 and adapted for matching engagement with mounting bracket 67 and including a plurality of apertures 60 which align with the apertures in mounting bracket 67, allowing for connection of the mast and cantilever arm 22 by nuts and bolts 62.
Cantilever arm 22 includes a repeating pattern in which every other cross member 32 is associated with two center diagonals 38 and two side braces 30 while every other cross member 33 is associated with vertical braces 40. All cross members 32, 33 are associated with a bottom brace 34 which is in the plane defined by first bottom truss member 24 and second bottom truss member 26. This repeating pattern, however, does not begin precisely at the mounting end 23 of truss arm 22. The cross member 32 closest to mounting end 23 includes two side braces 30, a center diagonal 38, which is at a steeper angle (approximately forty-five degrees (45°) to the horizontal) than other center diagonals 38, and an associated bottom brace 34. These two particular side braces 30 join top truss member 28 adjacent to upper truss arm bracket 59.
It is to be understood that while certain forms of this invention have been illustrated and described, it is not limited thereto, except insofar as such limitations are included in the following claims.
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A triangular truss walkout cantilever for displaying railroad warning signals above the individual lanes of a road or highway at a railroad grade crossing is disclosed. The cantilever includes a cantilever arm attached to a vertical roadside mast. The cantilever arm has three parallel truss members that form a triangular cross section. These members are reinforced by a system of struts and braces. A catwalk allows a worker access to the warning signals for maintenance and no braces interfere with such access.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention pertains to the art of dishwashers and, more particularly, to a system for limiting pressure in a filter chamber in a dishwasher.
[0003] 2. Discussion of the Prior Art
[0004] A typical dishwasher includes a closed system where washing fluid is pumped from a sump into upper and lower wash arms such that kitchenware retained on vertically spaced racks within a tub of the dishwasher will be sprayed with the washing fluid for cleaning purposes. The washing fluid is heated, filtered and recirculated. Prior to recirculating the washing fluid, the fluid is directed through one or more filters to remove soil from the fluid, with the soil being collected in a chamber. Periodically, the system is purged in order to drain the collection chamber of the soil.
[0005] In general, washing fluid is circulated in the system at a relatively high pressure in order to ensure an adequate fluid supply to the upper and lower wash arms. At some point in the system, washing fluid is passed or diverted into a filter chamber, often at the same, relatively high pressure that is supplied to the wash arms. Unfortunately, supplying the filter at high pressure will often reduce the overall efficiency of the filtering process. When operating at high pressure, the filter becomes clogged quickly, causing food soils to be released back into the wash system to circulate with the washing fluid. Without proper filtration, the level of food soils circulating in the washing fluid will rise, resulting in a decrease in the overall efficiency of the washing operation.
[0006] Based on the above, there exists a need for a system to limit pressure in a filter chamber of a dishwasher. More specifically, there exists a need for a system that minimizes the pressure of washing fluid entering the filter chamber while, at the same time, ensuring proper operation of the wash arms.
SUMMARY OF THE INVENTION
[0007] The present invention is directed to a dishwasher including a tub having top, bottom, rear and opposing side walls that collectively define a wash chamber. In a manner known in the art, the dishwasher is provided with a wash pump for establishing a flow of washing fluid in the wash chamber and a drain pump for selectively withdrawing washing fluid from the wash chamber during portions of a washing operation. In addition, the dishwasher includes a washing fluid manifold having an inlet portion for receiving the flow of washing fluid, an outlet portion that directs the flow of washing fluid upward into the wash chamber and a passage interconnecting the inlet and the outlet portions. A filter chamber is fluidly connected to the washing fluid manifold for removing fool soil and other debris from the washing fluid. The filter chamber includes an inlet for receiving washing fluid flowing through the manifold and an outlet that leads back into the wash chamber.
[0008] In accordance with the invention, a venturi is arranged in the passage interconnecting the inlet and outlet portions of the washing fluid manifold. With this arrangement, the flow of washing fluid passing through the venturi increases in velocity, while at the same time decreasing in pressure. In this manner, the venturi establishes a low pressure zone in the passage. In accordance with a preferred embodiment of the invention, a sampling port is provided in the low pressure zone portion of the passage. The sampling port enables a portion of the washing fluid, flowing through the passage, to be diverted into the filter chamber.
[0009] In accordance with the most preferred embodiment of the invention, in addition to the venturi, a bleed port is located proximate to the inlet of the filter chamber. The location and size of the bleed port serves to further reduce the pressure of the washing fluid entering the filter chamber. With this arrangement, the pressure of the washing fluid entering the filter chamber can remain low for efficient filter operation while, at the same time, the velocity of the washing fluid that is supplied to the wash arms is held high for efficient cleaning purposes.
[0010] Additional objects, features and advantages of the present invention will become more readily apparent from the following detailed description of preferred embodiments when taken in conjunction with the drawings wherein like reference numerals refer to corresponding parts in the several views.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is an upper right perspective view of a drawer-type dishwasher incorporating a pump and filter system employing the pressure limiting system of the present invention;
[0012] FIG. 2 is an upper perspective view of a washing tub of the dishwasher of FIG. 1 ;
[0013] FIG. 3 is a lower perspective view of the washing tub of FIG. 2 , illustrating portions of the pump and filter system of FIG. 1 ;
[0014] FIG. 4 is a partial, cross-sectional view taken along a bottom wall portion of the washing tub of the present invention;
[0015] FIG. 5 is an enlarged view of a portion of FIG. 4 ;
[0016] FIG. 6 is a partial, cross-sectional view of a bottom wall portion of the washing tub illustrating a valve sealing a fine particle collection chamber portion employed in connection with the overall invention;
[0017] FIG. 7 is a partial, cross-sectional view of a bottom wall portion of the washing tub of FIG. 6 illustrating the valve open position wherein fine soil particles are guided to a drain pump;
[0018] FIG. 8 is a partial perspective view of a flow plate portion of the pump and filter system constructed in accordance with a first embodiment of the present invention; and
[0019] FIG. 9 is a partial, perspective view of a flow plate portion of the pump and filter system constructed in accordance with a second embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0020] With initial reference to FIGS. 1 and 2 , a dishwasher constructed in accordance with the present invention is generally indicated at 2 . As shown, dishwasher 2 includes a support frame 4 arranged below a kitchen countertop 6 . Also below kitchen countertop 6 is shown cabinetry 8 including a plurality of drawers 9 - 12 , as well as cabinet doors 13 and 14 . Although the actual dishwasher into which the present invention may be incorporated can vary, the invention is shown in connection with dishwasher 2 depicted as a dual cavity dishwasher having an upper drawer 16 and a lower drawer 18 . As best illustrated in FIG. 1 , upper drawer 16 takes the form of a slide-out drawer unit having a small or medium capacity so as to be used for cleaning glassware and the like, while lower drawer 18 is illustrated as a larger capacity drawer for washing items such as dinnerware, cookware and other large sized objects. Of course, upper and lower drawers 16 and 18 could also be similar in size.
[0021] Upper drawer 16 is shown to include a front wall 20 , a rear wall 21 , a bottom wall 22 as well as opposing side walls 23 and 24 that collectively define an upper washing tub 28 . Upper washing tub 28 is provided with a dish rack 30 for supporting various objects, such as glassware, utensils and the like, to be exposed to a washing operation. Upper washing tub 16 is slidingly supported within support frame 4 through a pair of extendible drawer support guides, one of which is indicated at 31 . In the embodiment shown, bottom wall 22 actually forms part of a sump 33 that, as will be discussed more fully below, manages a flow of washing fluid within drawer 16 .
[0022] As best shown in FIGS. 2-4 , bottom wall 22 is provided with a recessed portion 34 having a generally U-shaped cross section defining an intake ring 35 . A coarse particle strainer 36 extends about recessed portion 34 to trap/prevent large articles, such as utensils, bones and the like, from entering sump 33 . Toward that end, coarse particle strainer 36 is includes a plurality of openings, one of which is indicated at 37 , provided with a coarse filter screen (not shown) formed from, for example, a polyester mesh, plastic or stainless steel. Coarse particle strainer 36 traps larger objects that are collected in a coarse particle collection chamber 38 , while allowing other particles to enter into sump 33 .
[0023] Referring to FIG. 3 , sump 33 includes a plurality of fluid conduits 67 - 69 formed along bottom wall 22 of washing tub 28 . Alternatively, conduits 67 - 69 could be detachably secured to bottom wall 22 . In any event, fluid conduit 67 constitutes a wash fluid supply conduit, fluid conduit 68 constitutes a wash fluid recirculation conduit and fluid conduit 69 constitutes a wash fluid drain conduit. Each of fluid conduits 67 - 69 provides wash fluid flow management during a washing operation. Preferably, fluid conduits 67 - 69 are spaced from, and arranged substantially parallel to, one another on bottom wall 22 , with conduits 67 and 69 extending from a central portion 71 of intake ring 35 to an outer edge portion 74 of washing tub 28 . More specifically, supply conduit 67 includes a first end 78 which is in fluid communication with an interior portion of washing tub 28 and leads to a second end 79 . Second end 79 is provided with an attachment flange 80 . Likewise, recirculation conduit 68 extends from a first end 81 , which extends beyond intake ring 35 toward a front portion of drawer 16 to a second end 82 . In a manner corresponding to supply conduit 67 , recirculation conduit 68 is provided with a corresponding attachment flange 83 . Finally, drain conduit 69 extends from a first end 85 to a second end 86 which is also provided with an attachment flange 88 .
[0024] In addition to managing the flow of washing fluid in dishwasher 2 , sump 33 serves as a mounting platform for a plurality of wash system components. As best shown in FIG. 3 , a wash pump 110 and a drain pump 111 are mounted to washing tub 28 along outer edge portion 74 . Preferably, wash pump 110 includes a wash motor housing 115 and a wash pump housing 116 . More preferably, wash pump housing 116 includes a supply outlet 119 and a recirculation inlet 120 that conducts wash fluid back from washing tub 28 to pump housing 116 . Toward that end, wash pump housing 116 is generally F-shaped, with supply outlet 119 and recirculation outlet 120 projecting into attachment flanges 80 and 83 of supply and recirculation conduits 67 and 68 respectively. In the embodiment shown, a heater element 122 is positioned within recirculation conduit 68 to heat the washing fluid that is circulating into and out of washing tub 28 . With this arrangement, a substantially closed loop recirculation system is formed within washing tub 28 . Likewise, drain pump 111 includes a drain motor housing 123 and a drain pump housing 124 . Drain pump housing 124 includes an inlet port (not shown) and an outlet port 126 adapted to be interconnected to a drain hose (not shown). The inlet port is preferably provided with a chopping mechanism 130 , as best represented in FIGS. 6 and 7 , for macerating food particles before being expelled with the washing fluid from washing tub 28 during periodic drain or purging operations.
[0025] Referring to FIGS. 2 and 4 - 7 , dishwasher 2 includes a filter assembly 140 arranged centrally within coarse particle strainer 36 . In accordance with the preferred form of the invention, filter assembly 140 is actually divided into a filter chamber 143 and a washing fluid manifold 145 . Washing fluid manifold 145 is configured to receive a flow of washing fluid from wash pump 110 through an inlet portion 148 and thereafter direct or guide the washing fluid through a passage 149 to an upward into washing tub 28 . As will be discussed more fully below, washing fluid manifold 145 is provided with a sampling port 153 that diverts a portion of the washing fluid flowing through passage 149 into filter chamber 143 .
[0026] Filter assembly 140 includes a cover member 155 having a plurality of large openings, one of which is indicated at 158 . Preferably, cover member 155 is secured in place through a plurality of fasteners (not shown) that extend through a plurality of mounting bosses 159 . In the embodiment shown, openings 158 are provided with a fine mesh filtering screen, which is partially shown at 160 , for entrapping soil from the washing fluid in filter chamber 143 , while permitting cleansed washing fluid to be directed back upward into washing tub 28 . Therefore, openings 158 are provided solely over filter chamber 143 of filter assembly 140 . In addition, cover member 155 is provided with a central opening 162 including an annular lip 163 ( FIG. 5 ) that defines a recessed flange 164 . As will be detailed more fully below, central opening 162 provides a passage for a stationary hub member 170 ( FIGS. 6 and 7 ) that extends upward beyond cover member 155 into washing tub 28 .
[0027] As best shown in FIG. 5 , stationary hub member 170 is adapted to rotatably support a wash arm 172 that directs jets of water onto kitchenware and the like arranged upon dish rack 30 . In the embodiment shown, wash arm 172 includes a plurality of upwardly projecting openings 173 , each of which includes a corresponding upstanding annular flange 174 . Flange 174 is adapted to snap-fittingly receive an adjustable jet cap (not shown) that can be oriented, either at the factory or by a consumer, to obtain an optimal water spray in washing tub 28 . In addition to upwardly projecting openings 173 , wash arm 172 is provided with a plurality of downwardly projecting openings 175 that are directed onto mesh screen 160 . In any event, stationary hub member 170 includes an outer surface 178 that defines a central passage or conduit 180 that guides washing fluid from washing fluid manifold 145 up into wash arm 172 . In addition, extending about outer surface 178 is a sealing surface 184 that abuts cover member 155 to provide a seal about stationary hub 170 . Actually, sealing surface 184 is forced against recessed flange 164 of central opening 159 in the presence of a flow of washing fluid to establish the seal. This particular configuration limits pressure losses to increase washing efficiency. Stationary hub member 170 includes a central shaft 187 that, when in position, abuts against a bottom portion (not separately labeled) of washing fluid manifold 145 . Shaft 187 causes an upper portion 188 of stationary hub 170 to project above cover member 155 . In this manner, stationary hub 170 is properly positioned to facilitate the assembly of wash arm 172 . In the embodiment shown, upper portion 188 is provided with an outlet 189 that opens into wash arm 172 . Arranged centrally on upper portion 188 is an attachment lug 191 provided to rotatably support wash arm 172 above stationary hub 170 .
[0028] As outlined above, a portion of the washing fluid that is directed into wash arm 172 is diverted into filter chamber 143 through sampling port 153 . Soil particles too large to pass through filtering screen 160 are trapped within filter chamber 143 and, ultimately, collect into a fine particle collection chamber 215 ( FIGS. 6 and 7 ). Fine particle collection chamber 215 is provided with an opening 218 that leads into drain passage 69 . Opening 218 is provided with a valve 225 that, during select portions of a washing operation, opens to allow the soil particles collected within fine particle collection chamber 215 to pass into drain passage 69 . Preferably, valve 225 is constituted by an electrically activated solenoid-type valve that, upon activation, causes a plunger 227 to be drawn into a valve body 228 , thus allowing passage through opening 218 . Actually, in accordance with the most preferred form of the present invention, drain passage 69 constitutes a bifurcated drain passage having a coarse particle portion 236 and a fine particle portion 237 . Thus, as best shown in FIGS. 6 and 7 , large soil particles flowing into intake ring 35 travel with the washing fluid and ultimately collect within coarse particle collection chamber 38 . The coarse particles are withdrawn from dishwasher 2 during various drain/purge operations performed by drain pump 111 . In addition, fine soil particles collecting within fine soil particle collection chamber 215 are withdrawn from filter chamber 143 during the various drain/purge operations concurrently with coarse soil particles from coarse soil particle collection chamber 38 . Alternatively, in the event that filter screen 160 becomes clogged, valve 225 can open, as shown in FIG. 7 , allowing the passage of soil into fine particle conduit 237 in order to prevent an excessive pressure build-up within fine soil filter chamber 143 . With this particular arrangement, a multi-size particle collection system can be incorporated into dishwasher 2 without allowing fine soil particles and coarse soil particles to intermix prior to draining.
[0029] With particular reference to FIG. 4 , filter assembly 140 includes a flow plate 246 over which passes fluid leading from washing tub 28 and filter chamber 143 back into intake ring 35 to be recirculated with the washing fluid. Flow plate 246 includes an annular plateau 247 that leads to a downwardly projecting lip 248 which extends into intake ring 35 . In addition, interposed between coarse particle strainer 36 and flow plate 246 is an annular filter ring 249 that prevents large objects from entering into, and possibly clogging, intake ring 35 . Annular filter ring 249 rests within a notch 250 defined by an inner perimeter of coarse particle strainer 36 . Annular filter ring 249 extends through an angled portion 251 that includes a plurality of openings 252 and abuts annular plateau 247 . In still further accordance with the present invention, filter assembly 140 includes a bleed valve 260 ( FIGS. 6 and 7 ) that enables air trapped within lower portions of sump 33 during an initial fill portion of the washing operation to pass up into washing tub 28 . More specifically, as washing fluid enters washing tub 28 , sump 33 and fluid conduits 67 - 69 , air may become trapped within various regions of filter assembly 140 and sump 33 . Thus, during an initial operation of wash pump 110 to recirculate washing fluid in washing tub 28 , air may be ingested into wash pump 110 causing cavitation or hesitation of wash pump 110 . In order to prevent this particular problem, as washing fluid is being introduced into washing tub 28 , air being displaced by the washing fluid is allowed to pass upward through bleed valve 260 and escape into washing tub 28 so as to purge any trapped air from within filter assembly 140 and sump 33 . In this manner, the overall performance of dishwasher 2 can be enhanced with particular focus being upon noise reduction and increasing pump life.
[0030] In any event, the particular construction and arrangement of filter assembly 140 contributes to forming a washing tub 28 with minimal vertical height, without sacrificing washing operation performance. In other words, sump 33 and filter assembly 140 of the present invention enables the construction of drawer-type dishwasher 2 that includes many of the advantageous features of larger dishwashers, such as multi-stage filtering, wash fluid flow management, food choppers and the like without increasing an overall vertical height of dishwasher 2 . In addition, the construction of sump 33 simplifies the overall assembling process for dishwasher 2 . Furthermore, washing tub 28 can be provided with a turbidity sensor 300 ( FIG. 3 ) to control advantageous washing operations, particularly unscheduled drain or purging operations. In general, the structure described above is provided for the sake of completeness and the present invention is particularly directed to a system for reducing pressure in filter chamber 143 .
[0031] In accordance with a preferred embodiment of the invention as shown in FIG. 8 , washing fluid manifold 145 includes a flow restrictor 300 arranged within passage 149 . Flow restrictor 300 functions to create a low pressure zone or region in washing fluid manifold 145 . More specifically, the flow of washing fluid entering inlet portion 148 initially enters passage 149 at a first pressure and at a first velocity. Flow restricter 300 is preferably constituted by a venturi, as generally indicated at 303 . As shown, venturi 303 includes a first tapered portion 305 exposed to inlet portion 148 of washing fluid manifold 145 . First tapered portion 305 leads to a second tapered portion 310 through a narrow, throat section 315 . With this construction, the pressure of the washing fluid entering throat section 315 is reduced while, at the same time, the washing fluid flow experiences an increase in velocity. The increase in velocity of the washing fluid enables proper operation of, for example, wash arm 172 , while the low pressure ensures efficient operation of filter assembly 140 . In the most preferred form of the invention, sampling port 153 is located in the low pressure region of washing fluid manifold 145 and, most preferably, within flow restrictor 300 . That is, in order to ensure that filter chamber 143 is supplied with washing fluid at a low pressure, sampling port 153 is preferably located within throat section 315 .
[0032] In still further accordance with the invention, in order to supplement the pressure reduction accomplished by passing the washing fluid through venturi 303 , filter chamber 143 is provided with a bleed port 340 . As shown, bleed port 340 is located in a bottom wall (not separately labeled) of filter chamber 143 . In order to prevent soil from being released into washing tub 28 , bleed port 340 is preferably positioned directly adjacent to an inlet 345 to filter chamber 143 from sampling port 153 . In accordance with the invention, bleed port 340 is defined by a first cross-sectional area, inlet 345 is defined by a second cross-sectional area, and sampling port 153 is defined by a third cross-sectional area. In the most preferred form of the present embodiment, the cross-sectional area of sampling port 153 is sized so as to be less than the combined cross-sectional areas of bleed port 340 and inlet 345 . In this manner, washing fluid entering filter chamber 143 can be maintained at a low pressure to further ensure efficient filtration and removal of soil particles from the washing fluid prior to re-entering washing tub 28 .
[0033] FIG. 9 is presented to reference certain modifications which can be made in accordance with the invention. More particularly, the embodiment of FIG. 8 sets forth the combination of sampling port 153 located in throat section 315 , venturi 303 and bleed port 340 . However, it should be initially noted that sampling port 153 can be repositioned in accordance with the invention. FIG. 9 illustrates an embodiment wherein sampling port 153 is located closely adjacent to inlet portion 148 , rather than in throat section 315 . FIG. 9 also illustrates a potential modification wherein venturi 303 is not employed. That is, the flow for filtering and spraying purposes could be established through only the use of sampling port 153 and bleed port 340 . In addition, it should be noted that the combination of sampling port 153 and venturi 303 could be utilized without the inclusion of bleed port 340 . Regardless, the most preferred embodiment of the invention incorporates each of sampling port 153 , venturi 303 and bleed port 340 . However, although described with reference to preferred embodiments of the invention, it should be readily apparent to one of ordinary skill in the art that various changes and/or modifications can be made to the invention without departing from the spirit thereof. In general, the invention is only intended to be limited to by the scope of the following claims.
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A dishwasher includes wash chamber, a wash system for supplying washing fluid to wash arms to clean articles arranged in the wash chamber, and a washing fluid manifold having an inlet portion, an outlet portion and a passage interconnecting the inlet and outlet portions. A filter chamber is fluidly connected to the washing fluid manifold for removing food soil from the washing fluid. A venturi is provided in the passage for establishing a low pressure region. A sampling port for feeding the filter chamber is located in the low pressure region. In addition, a bleed port is provide near an inlet of the filter chamber. In this manner, washing fluid enters the filter chamber at low pressure to increase the efficiency of a filtering process, while washing fluid enters the wash arms at a high velocity to efficiently perform a washing operation.
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FIELD OF THE INVENTION
The present invention relates to optical switching devices. More particularly, the invention concerns reconfigurable optical switching devices for forming a switching system.
BACKGROUND OF THE INVENTION
One of the main components needed for optical interconnections is a dynamic switch. In order to make such a switch compatible with a planar interconnection system, it must be as compact as possible. It is preferable that the switch be an integral part of the planar optical system; that is, the switching should be effected within the planar substrate. Furthermore, the process of fabricating the dynamic switch must be simple enough so as to ensure that the entire system is suitable for mass production.
DISCLOSURE OF THE INVENTION
It is a broad object of the present invention to provide an optical switching device based on polarization-selective holographic elements.
A further object of the present invention is to provide an architecture for an optically dynamic switching system.
A still further object of the invention is to provide a method for producing an holographic plate having a plurality of holographic elements.
In accordance with the present invention, there is therefore provided an optical switching device, comprising a substrate having at least one polarization-selective multiplexing grating; at least one polarization-selective demultiplexing grating, and a polarization rotation element acting as a dynamic ½ λ plate, optically interposed between the optical path of said multiplexing grating and said demultiplexing grating.
The invention further provides a method for producing an holographic plate having a plurality of holographic elements, said method comprising the steps of (a) defining a first intermediate holographic element; (b) defining a second intermediate holographic element located at the plane parallel to the plane of said first holographic element; (c) determining, for each holographic element, a pair of parent holograms to be formed on said intermediate elements in such a way that combining said pair of parent holograms with a pre-defined readout wave will yield two coherent light waves wherein the interference of said two light waves in said holographic plate produces the desired final holographic effect; (d) determining the signs of the x components of the projections from the paraxial rays of said pairs of parent holograms for all of the holographic elements on said holographic plate; (e) dividing said holographic elements into two groups according to the signs of said x components; (f) producing, for each of said two groups, a different holographic plate comprising the parent holograms of the relevant holographic elements; (g) attaching the plates produced in step (f) to an optical prism in such a way that while illuminating said plates through the prism with said pre-determined readout wave, the first diffracted order from the intermediate hologram produces the desired holographic effect on the holographic plates, the zero order is coupled out of the prism by total internal reflections, and the other orders are evanescent waves; and (h) repeating the recording process for each group of holographic elements as defined in steps (d) and (e).
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be described in connection with certain preferred embodiments with reference to the following illustrative figures, so that it may be more fully understood.
With specific reference now to the figures in detail, it is stressed that the particulars shown are by way of example and for purposes of illustrative discussion of the preferred embodiments of the present invention only, and are presented in the cause of providing what is believed to be the most useful and readily understood description of the principles and conceptual aspects of the invention. In this regard, no attempt is made to show structural details of the invention in more detail than is necessary for a fundamental understanding of the invention, the description taken with the drawings making apparent to those skilled in the art how the several forms of the invention may be embodied in practice.
In the drawings:
FIG. 1 is a schematic illustration of a thick phase transmission hologram;
FIG. 2 is a graph showing the diffraction efficiencies of the s and p polarizations of a transmission thick phase hologram;
FIG. 3 is a schematic illustration showing top and side views of a first embodiment of a building block of a dynamic switching device according to the present invention;
FIG. 4 schematically illustrates a first embodiment of the geometry of an entire optical switching device according to the present invention;
FIG. 5 schematically illustrates a cross-sectional view of a further embodiment of the geometry of an entire optical switching device;
FIG. 6 is a schematic side view of the geometry of a still further embodiment of an entire optical switching device;
FIGS. 7 and 8 are plan views of the bottom and top surfaces, respectively, of the embodiment of FIG. 6 ;
FIGS. 9 and 10 , respectively, are schematic illustrations of 4×4 and 8×8 optical switching systems according to the present invention;
FIG. 11 is an isometric view of a planar optical switching system according to the present invention;
FIG. 12 illustrates a recording scheme of the final holographic element, in the presence of a wavelength shift between recording and readout;
FIG. 13 is a schematic representation of a recording architecture of the final holographic element with an intermediate holographic plate;
FIG. 14 illustrates a PMMA coupling element consisting of an aspherical mirror and a reflection surface relief grating, and
FIG. 15 is an MTF graph showing the calculated spot size of the optical system illustrated in FIG. 14 .
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
The diffraction efficiency of a thick phase transmission hologram ( FIG. 1 ) is given by the expression:
η = sin 2 φ 2 + ψ 2 1 + ψ 2 φ 2 ( 1 )
in which the Bragg deviation coefficient ψ is defined as
ψ ≡ ( α r - α r B ) K → D sin ( α G - α r B ) 2 cos α s - ( λ - λ B ) K → 2 D 8 π v cos α s , ( 2 )
wherein:
{overscore (K)} is the three-dimensional grating function of the hologram; D is the thickness of the emulsion, α r , α s , and α G , are the off-axis angles of the readout wave, signal wave, and the grating function, respectively; λ and λ B are the actual and the designed readout wavelengths, and α r B is the off-axis angle of the designed readout wave.
The grating coupling coefficient is defined as
φ s = π v 1 D λ cos α s cos α r ( 3 )
for s-polarization, and as
φ p =−φ s ( {overscore (r)}·{overscore (s)} ) (4)
for p-polarization, wherein:
v 1 is the maximum phase modulation of the refraction index of the emulsion, and {overscore (r)} and {overscore (s)} are the unit vectors of the readout and the signal rays respectively.
Fulfilling Bragg conditions (namely, ψ=0) yields
η s,p =sin 2 (φ s,p ). (5)
It is clear from Equation (4) that, for an off-axis hologram, the coupling coefficient for the p polarization is smaller than that for the s polarization. Consequently, it can be deduced from Equation (5) that the diffraction efficiencies of the s and p polarizations will be different, as a function of the obliquity of the hologram.
FIG. 2 illustrates the diffraction efficiencies of the s and p polarizations of a hologram having the following parameters:
D=15 μm; α r =0; α s =45°; λ=850 nm; v=151 (6)
where v is the refractive index. It is important to emphasize that the angle α s is inside the emulsion; consequently, the signal wave is trapped inside the substrate due to total internal reflection.
Fabrication of an holographic element which is very efficient for one polarization and, at the same time, is actually transparent to the other, is possible with a variety of methods. Such an element is necessary for polarization multiplexing or demultiplexing. There are two distinct approaches that exploit the special behavior of a Bragg hologram when the signal wave is normal to the readout wave within the emulsion:
1. The “Normal-Waves” Approach
Suppose that the holographic element is recorded in such a geometry that the signal wave is normal to the readout wave during the readout process. In this case, the unit vector of these two waves fulfill the condition:
{overscore (r)}·{overscore (s)}= 0. (7)
Inserting Equation (7) inside Equation (4) yields
φ p =0 η p =0. (8)
This result, that the diffraction efficiency of the p polarization is zero, does not depend on parameters which are difficult to precisely control, such as index modulation or emulsion thickness, but depends only on the readout geometry which is much easier to achieve with good accuracy.
FIG. 3 illustrates the building block of the “three-dimensional” version. As shown, the readout wave bounces inside the substrate with an off-axis angle α to the normal of the substrate plane. The holographic element diffracts the incoming wave in such a way that the bouncing angle remains α, but there is an angle β between the projections of the readout and the signal waves in the substrate plane.
In order to achieve the necessary condition of {overscore (r)}·{overscore (s)}=0, the following equation:
cos β=cot 2 α (9)
must be satisfied. Clearly, Equation (9) imposes the following constraint upon the bouncing angle inside the substrate:
α min =45°. (10)
A direct result of Equation (10) is that, even for substrate materials with low indices of refraction, such as BK-7 and other crown materials, the optical waves are trapped inside the substrate by total internal refraction and there is no need for a reflective coating on the substrate surfaces. Unfortunately, in order to couple the waves into the substrate with an off-axis angle higher than 45°, a holographic element with very high special frequency would be required (more than 1200 line-pairs/mm for λ=850 nm). This would indicate that the only practical way to realize the hologram is by interferometric recording, and that it will be very difficult to fabricate it by direct writing or lithographic methods.
A possible way of recording the desired hologram is to use an off-axis angle of α=60°. For example, inserting this value into Equation (10) yields
β=70.5°. (11)
As shown in FIG. 4 , two light waves s and p, of orthogonal polarization, are coupled into the substrate 2 by coupling means such as the holograms H 1 and H 2 , respectively. The hologram H 3 diffracts the s in a direction so as to join it onto p. H 4 is the multiplexing hologram, which is shown and described with reference to FIG. 3 . H 4 is very efficient to s polarization and is actually transparent top polarization. Here, it does not effect p, but rather, it diffracts s into the same direction of p. As a result, p and s are multiplexed together into a single optical wave which illuminates the dynamic switch. Instead of the holograms, other coupling means, such as reflective surfaces or prisms, can be utilized.
After passing through the switch S, which either rotates the polarizations by 90° (operation mode) or has no influence upon the waves (non-operation mode), the waves meet the demultiplexing hologram H 5 , which is identical to H 4 but to the opposite effect; that is, it separates p and s into different directions. H 6 , which is an optional hologram, rotates s so that it becomes parallel to p in the substrate. The final holograms, H 7 and H 8 , couple the light waves back out of the substrate onto the detectors. In order to minimize the cross-talk between the channels, special coating facets 4 may be added onto the surface of the substrate, to filter out the s-polarization from the p channel and vice-versa.
There are clear advantages to the switch shown in FIG. 4 . Its dimensions can be very compact, it can be easily integrated into the planar optical interconnection scheme, it is appropriate for multi-stage devices, and finally, it has the potential to provide very high efficiency and negligible cross-talk between the channels. The device does, however, have some drawbacks: as described above, the switch can be realized only with interferometrically recorded Bragg holograms. Also, the recording process of holograms H 5 and H 6 is very complicated, and in addition, since the waves pass through the switch while bouncing inside the substrate at an oblique, off-axis angle, a special SLM, or similar device, must be fabricated in order to perform the desired polarization rotation in the correct fashion.
FIG. 5 illustrates the building block of a “two-tier” version. As with the two-dimensional embodiment of FIG. 4 , the holograms H 1 and H 2 couple the input waves into the substrate 2 , but here the off-axis angle of wave propagation inside the substrate is set at 45°. The waves are multiplexed together by the hologram H 3 . Since the angle of the direction of propagation between the two waves is 90°, the hologram will be very efficient with respect to wave A and practically transparent with respect to wave B. The next hologram, H 4 , couples the waves out of the first substrate 2 . The waves then illuminate an SLM 6 , which acts as a dynamic ½ λ plate, normal to its surface. After passing through SLM 6 , the waves are coupled into a second substrate 8 by the hologram H 5 . The next hologram, H 6 , is the demultiplexing grating that diffracts the s polarization by 90°. The final holograms H 7 and H 8 couple the light back out of the substrate onto detectors (not shown). Clearly, the two substrates 2 and 8 , and the SLM, can be easily integrated into one piece, to minimize the overall size of the device.
The embodiment of the optical switch shown in FIG. 5 can also be very compact, is appropriate for multi-stage devices, and has the potential to provide very high efficiency and negligible cross-talk between the channels. In addition, it has some additional advantages over the embodiment of FIG. 4 : with slight modification of the geometry, not only Bragg holograms, but also surface-relief gratings, can be used as the multiplexing/demultiplexing devices. This is a fairly simple process of recording the holograms, and furthermore, since the waves illuminate the SLM in a direction normal to its surface, a commercially available SLM 6 can be used as the dynamic ½ λ plate.
There are still some drawbacks to the embodiment of FIG. 5 . First, the fan-in and fan-out gratings are each combined from a different pair of holograms (H 3 -H 4 and H 5 -H 6 , respectively). The holograms in each pair must be recorded separately on two different emulsion layers. This can be done either by recording the first layer, then adding a second emulsion layer and then making the next recording step, or alternatively, by recording two separate substrates and then combining them together. In both cases, the procedure is long, cumbersome and not very suitable for mass production.
The second area of concern is the geometry of the proposed switch. As can be seen in FIG. 5 , the projection of the output waves, after they are separated by the fan-out gratings, is identical to the projection of the incoming waves. This constraint imposes a limit upon the feasibility of using the switch in a multi-stage architecture. Moreover, there are two differently-polarized waves inside the substrate having s and p polarizations. It is desirable, for the sake of achieving minimal cross-talk to filter undesired polarizations from the signals. This can be done with a simple coating for a single substrate, but is impossible to perform for two orthogonal polarizations.
2. The “Different Coupling Coefficients” Approach
As can be seen in FIG. 2 , one method to achieve polarization separation is by choosing parameters whereby the efficiency of one polarization is 0 and that of the second is close to 100%. For example, a holographic element with the parameters described in Equation (6), and wherein the index modulation is vν 1 =0.041, has diffraction efficiencies of 0 for the p polarization and 95% for the s polarization. It is comparatively easy to record this hologram for achieving the necessary polarization separation. In the following, how to calculate the exact conditions required for optimal polarization separation is shown.
For a diffraction angle smaller than 90°, there are two cases in which the hologram can perform a highly polarization-selective property:
η s =100% and η p =0 φ s =( n+ 0.5)π and φ p =nπ (12)
or
η s =0% and η p =100% φ s =nπ and φ p =( n− 0.5)π (13)
wherein:
n is a natural number.
In our particular case, we have the readout condition
α r =0° cos α r =1. (14)
Therefore, the coupling coefficients φ become
φ s = π v 1 D λ cos α s , ( 15 ) φ p = π v 1 D λ cos α s . ( 16 )
Substituting the values of φ s in Equation (15) and φ p in Equation (16) into Equation (12) yields
π v 1 D λ cos α s = n + 0.5 ; π v 1 D λ cos α s = n . ( 17 )
Solving Equation (17) yields
α s = arccos n n + 0.5 ; v 1 D λ = n ( n + 0.5 ) . ( 18 )
To illustrate the calculations, for the values of n=1, λ=830 nm, and D=17 mm, the desired phase modulation of the refractive index of the substrate is v 1 =0.06, which can easily be achieved using recording materials such as DCG or photopolymer. The off-axis angle inside the substrate is α s =48.2°.
Using similar algebraic manipulations for Equation (13) yields another solution:
α s = arccos n - 0.5 n ; v 1 D λ = n ( n - 0.5 ) . ( 19 )
For the same parameters given above, the desired values now are v 1 =0.034 and α s =60.0°.
FIGS. 6 to 8 illustrate a possible embodiment for the building block of a 2×2 optical switch. Two light waves, A and B, having orthogonal polarizations s and p, are coupled into the substrate 10 by the holograms H 1 and H 2 , respectively. The angle between the projection of the two waves on the substrate plane is 90° and the off-axis angle inside the substrate is set according to the solutions of Equations (18) or (19). Both light waves have an s polarization with respect to the plane of the holographic plate. The waves are multiplexed and coupled out of the plate by the hologram H 3 , which is a: combination of two orthogonal holograms, H 3A and H 3B . Since the angle between the two waves is 90°, their polarizations are mutually orthogonal. Hence, the hologram H 3A can be highly efficient in blocking wave A and practically transparent to wave B. Similarly, the hologram H 3B will be highly efficient in blocking wave B and transparent with respect to wave A. The waves then illuminate an SLM 6 , which acts as a dynamic ½ λ plate, normal to its surface. After passing through the SLM 6 , which either rotates the polarizations by 90° (operation mode), or has no influence on the waves (non-operation mode), the waves impinge upon the demultiplexing hologram H 4 in substrate 12 , which is identical to H 3 but has the opposite effect, i.e., separating A and B into two orthogonal directions. Holograms H 7 and H 8 couple the waves out of the substrate 12 . It should be noted that the axis system of the upper substrate 12 in FIG. 6 is rotated by 90° about the z axis in contrast to the axis system of the lower plate. Clearly, the two substrates 10 and 12 and the SLM 6 can easily be integrated into one piece so as to minimize the overall size of the device.
There are clear advantages to the configuration of this embodiment. The optical switch can be made very compact, and has the potential of very high efficiency and negligible cross-talk between channels. Not only Bragg holograms, but also surface-relief gratings, can be used for the polarization-sensitive element. Since the polarization of both waves is the s-polarization, a simple coating can filter out the undesired p-polarization in order to eliminate cross-talk. As shown below, a fairly simple fabrication process can be used to record the holograms. Building blocks of such configuration are very suitable for producing multi-stage devices.
It is important to note that the embodiment described with reference to FIG. 6 is merely an example of a method for coupling the input waves into a substrate. Input waves could also be coupled into a substrate by other optical means, including, but not limited to, integrated reflecting surfaces, folding prims, bundles of fiber optics, diffraction gratings, and the like. Also, in the example of FIG. 6 , the input waves and the image waves are located on opposite sides of the substrate. Other configurations are envisioned in which the input and image waves can both be located on the same side of the substrate. There may even be applications in which the input waves can be coupled into the substrate through one of its edges.
FIGS. 9 and 10 illustrate possible arrangements for 4×4 and 8×8 optical switches, respectively. Seen in FIG. 9 are the relative dispositions of the light sources A, B, C and D; the optical switches I, II, III, IB, and the detectors E, F, G and I. FIG. 10 illustrates the architecture of an 8×8 configuration without reference numbers, for clarity.
The accuracy of the recording and developing processes of the Bragg holograms is very crucial for achieving optical switches with high efficiencies and minimal cross-talk. In addition, considering the mass production of the device, an appropriate recording procedure should be developed in which a large number of holographic facets can be recorded simultaneously onto the same substrate.
FIG. 11 illustrates the geometry of a switching device according to the present invention. The system consists of an opto-electronic circuit 14 and two holographic substrates 10 and 12 carrying holographic emulsion layers 16 and 18 , separated by a two-dimensional array of SLM devices 6 . The entire system can be very compact and compatible to utilizing VLSI architectures. Three-dimensional arrays of switching devices can likewise be arranged.
One of the more advantageous ways of achieving mass production of the device is the use of surface relief gratings that are very easy to replicate. Even with the use of Bragg holograms, a large number of holographic facets can be recorded simultaneously onto the same substrate. Hence, also with Bragg holograms, the mass production process is expected to be rather simple. It is possible to record the holographic elements one by one; however, this procedure is very long and cumbersome, and it certainly is not advantageous for mass production. Instead, a recording method is described herein which may exploit both binary optics and volume holographic elements, for relatively easy, large scale fabrication of the holographic switching devices.
The recording architecture of the final HOE, in the presence of a wavelength shift between recording and readout, is shown in FIG. 12 . As described above, each HOE on the final holographic plate can be recorded using a pair of “parent” gratings, pre-prepared on an intermediate plate. As can be seen in FIG. 12 , for each final HOE in the holographic substrate 10 , the sign of the x component of the projection from the paraxial rays of the intermediate HOEs is identical for both HOEs. Hence, the n final HOEs can be divided into two groups, according to the sign of this x component. Since there is a large number of HOEs in the holographic plate, it is apparent that each group contains about n/2 elements.
FIG. 13 shows the recording procedure for one of these groups. (The recording geometry of the second group is similar, with opposite x components.) Seen is an intermediate holographic plate 20 , carrying the final holographic substrate 10 . The readout wave for all the parent gratings is a plane wave which is entered into substrate 10 through a glass prism 22 with an off-axis angle. Several other schemes, likewise employing wedge devices, are also possible.
Due to the high obliquity of the intermediate holographic plate 20 , the only diffracted order is the first order. The zero order is coupled out of the prism by total internal reflections and the other orders are evanescent waves. Hence, the only order that illuminates the final holographic substrate 10 during the recording procedure is the desired first order; there is no undesired illumination from the other orders. Since the intermediate gratings 24 can be put very close to the final holographic substrate, possible overlapping between different parent gratings can also be eliminated.
The intermediate holographic plates 20 can be constructed by either one of the following methods. They can be recorded holographically, or can be fabricated directly as surface relief holograms. In both cases, the constructing procedure should be done only once for each of the intermediate holographic plates. The efficiency of the parent gratings is not a crucial point, i.e., the efficiency of these gratings need not be close to 100%; a much lower efficiency is sufficient for the procedure of recording the final plate. Hence, it is chosen to fabricate the intermediate plate as a surface relief holographic plate; only one level is necessary for these binary gratings, and their fabrication procedure is relatively simple. As for the final HOEs, it is clear that the two-step recording procedure of the final holographic plate is quite simple and can be performed with relative ease.
As mentioned above, an alternative method for fabrication of polarization-selective holograms is as surface relief gratings. High polarization-selectivity can be achieved with this approach when the angle between the readout and the image waves is 90°. For different off-axis angles, the situation is much more complicated.
FIG. 14 illustrates a preliminary design of a building block for an optical switching system 26 based on a surface relief grating. The light source 30 is located next to a transparent plate 32 , fabricated, e.g., of PMMA polymeric material. The light wave diverging inside the plate is reflected back to the front surface by an aspherical mirror (not shown) that collimates the input beam and is reflected back again by a reflection grating that couples the light inside the substrate.
FIG. 15 illustrates the optical performance of the above-described element. The element has a diffraction-limited performance. With minor changes, it can be used also as the building block for the polarization-selective element. Hence, the entire holographic plate can be fabricated into one monolith plate by injection molding, embossing, or other methods which are appropriate for mass production. Moreover, such an holographic plate is not only easy to duplicate, but it can also be easily integrated with the opto-electronic plate shown in FIG. 14 .
As described above, there are only two gratings for each optical switch. For a system having N=2 n sources, the number of optical switches for each channel is Log 2 N=n. Hence, the diffraction efficiency for each interconnection is
η=[φ( 1−ρ)] 2n , (20)
wherein:
φ is the efficiency for the s polarization, and ρ is the efficiency for the p polarization.
For φ=95%, ρ=5% and n=7 (128×128 switch), the total efficiency of each channel is
η=24% . (21)
The overall area of the system can now be calculated. As shown in FIG. 10 , for a system having 2 n sources, the total number of switches in each step is 2 n−1 . For each switch there are two holographic elements, and there are n steps in each channel. In addition, there are 2 n elements which couple the light waves from the sources into the optical substrate and the same number to couple the light out from the plate onto the detectors. Hence, the total number of holographic elements on a single plate is:
M= 2·2 n +2· n· 2 n−1 =( n+ 2)2 n . (22)
For n=7 (128×128 switch) the number of the holographic elements is M=1152. Assuming that for each holographic element the necessary area on the holographic plate is a square of 200 μm, and that there are two separated plates, the total area of the system is in the order of 1 cm 2 .
It will be evident to those skilled in the art that the invention is not limited to the details of the foregoing illustrated embodiments and that the present invention may be embodied in other specific forms without departing from the spirit or essential attributes thereof. The present embodiments are therefore to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims rather than by the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein.
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The invention provides an optical switcing device, including a substrate having at least one polarization-selective multiplexing grating; at least one polarization-selective demultiplexing grating, and a polarization rotation element acting as a dynamic ½ λ plate, optically interposed between the optical path of said multiplexing grating and said demultiplexing grating. The invention also provides a method for producing an holographic plate having a plurality of holographic elements.
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RELATED APPLICATION
[0001] This application is a continuation of PCT/EP07/002968, filed Apr. 3, 2007, the entire disclosure of which is expressly incorporated herein by reference.
TECHNICAL FIELD
[0002] The present disclosure relates to the field of optical analysis of small sample volumes such as those which for example occur when diagnosing blood samples.
BACKGROUND
[0003] The determination of the concentration of various analytes in physiological samples is of growing importance in our society. Such samples are analysed in various fields of application for example in clinical laboratories or in “home monitoring”. In particular this also includes glucose measurement in diabetes management and the measurement of cholesterol for cardiac and vascular diseases. Medical blood diagnostics always requires that a blood sample is collected from the individual to be examined.
[0004] The analytics carried out after the lancing process are often carried out in a small portable measuring instrument a so-called “hand-held device” in which test elements wetted with blood are analysed. Measurement in these instruments is primarily carried out electrochemically or optically. In the case of the optically based measurements, the sample is illuminated with light and the reflected light is detected in order to determine the analyte concentration. Test elements such as test strips are primarily used for this purpose which are wetted with the sample such as blood or interstitial fluid. Subsequently the sample reacts with the reagents which are applied to this test element. This can lead to a change in colour which can be subsequently detected.
[0005] When conventional methods are used to analyse test elements, it is of major importance that the detection area of the test element is uniformly wetted with the test liquid. Non-uniform or inadequate wetting of the detection area can result in erroneous results. Especially when a small amount of test liquid is used, the distribution on the test element may not be uniform and only a part of the detection area is wetted with sample material. In the conventional optically-based methods of measurement the reflected light is often measured from the entire detection area which results in a high degree of inaccuracy of the measured glucose because different proportions of unwetted area enter into the determination depending on the applied amount of sample. Thus, if the detection area is inadequately wetted it may fall short of the size of measured section required for an error-free measurement. This may necessitate either a repetition of the measurement for the patient or false measured values may be generated.
[0006] Attempts to overcome inadequate or non-uniform wetting of the test element have previously not led to a satisfactory solution. In the simplest case the patient is forced to visually verify the wetting of the test element. This is not easy especially in the case of diabetics who often already have a reduced vision.
[0007] The object resulting from the disadvantages of the prior art is to develop a system which ensures simpler and more accurate analytics.
SUMMARY OF THE DISCLOSURE
[0008] According to the disclosure a system for determining the concentration of an analyte in a liquid is described said system comprising an illumination or detection unit for detecting light intensities which are radiated from subareas of a detection area of a test element. Furthermore, an evaluation unit is described which determines a frequency distribution for the detected light intensities, wherein the frequency distribution has at least one first maximum caused by unwetted subareas or at least one reference area and a second maximum caused by wetted subareas and at least one light intensity is selected on the basis of the frequency distribution and the concentration of the analyte is determined with small sample volumes from the at least one selected light intensity.
[0009] By taking into account frequencies of intensities it is possible to identify and analyse homogeneously wetted areas which are less effected by secondary effects such as inhomogeneous reagent and/or sample distribution, varying viscosity properties of the applied liquid or impurities in the sample and/or in the test element. In this manner results can be achieved in which measuring errors which are due to properties of the test element or the liquid are reduced.
[0010] Liquids (which are also referred to as sample or sample liquid) are to be understood especially as physiological liquids such as blood (venous or capillary), blood components, interstitial fluid, plasma, serum, urine or saliva but are not limited thereto. In the following text blood is referred to in particular as the sample. This is to be understood as an example for the term liquid without being limited thereto.
[0011] Blood samples are required especially for self tests of a patient who has to regularly examine a blood parameter such as for example in the case of diabetics. In order to make the lancing as painless as possible, the lancing depth is chosen to be as low as possible. Only a small amount of blood is collected in this process. For this reason the analytical methods must be able to precisely measure increasingly smaller volumes of blood. The system according to the present disclosure is therefore even suitable for analysing sample volumes below 100 nl. A preferred volume range is between 1 and 500 nl, and a particularly preferred volume range is between 10 and 100 nl. Larger volumes can, however, also be measured. Especially in the case of instruments which include an automated sampling after the puncture, the amount of sample to be analysed may even be below 1 nl . For this reason a system is described which enables very small sample volumes to be analysed irrespective of their applied form. This occurs with the aid of frequency determinations of light intensities of the reacted areas on the detection area in the form of a histogram.
[0012] A histogram can be used to illustrate the principle of evaluating frequencies. The light intensities (e.g., in the form of grey values) are determined and ranked into intensity intervals. The frequency of the respective light intensity in an intensity interval is plotted against the grey value. A detection unit or an illumination unit is required for this which detects or irradiates the detection area in a spatially-resolved manner. A plurality of subareas on the detection area is examined wherein the spatial information does not have to be used for the further analysis. These subareas are not real sub-divisions of the detection area but are rather the result of the optical spatially-resolved measurement of the detection area. The number of these subareas thus depends on the number of irradiated or detected areas. The more subareas are examined, the more accurately can the differentiation of the intensity differences of various regions be determined. The intensities of the wetted subareas correlate with the concentration of the analyte in the sample. In one embodiment, 256 intensities are distinguished. This number of intensity steps is sufficient to achieve an adequate precision/resolution to determine the concentration of the analyte. This also allows the amount of data to be kept to such a small size that it can be processed by small data carriers which are either in an evaluation unit in the detector or in an evaluation unit separate from the detector. In contrast to systems of the prior art which subsequently process all intensity values to analyse the spatially-resolved measurements, in the system according to the present disclosure preferably only certain frequencies and their associated intensities are used to calculate the concentration of the analyte. Especially in the case of time-resolved measurements in which a high cycle rate of image taking is necessary, the analysis according to the present disclosure without storing the complete image data considerably reduces the current consumption and memory requirements. This allows an instrument which has a low memory requirement to be produced with cheap components. Consequently the device can be manufactured and operated more cost-effectively than conventional devices.
[0013] The frequency distribution of the intensities on the detection area can be determined before a test element is wetted. The subareas of the detection area have very similar intensities or grey values determined therefrom. Alternatively intensities of subareas before or after application of the sample can be determined which are detected from a reference area. This reference area can be part of the detection area or it can be located outside the detection area. No reaction takes place in or on this reference area irrespective of whether the reference area is wetted by the sample or not.
[0014] The unwetted subareas or the reference area can be identified in the histogram by a first maximum which has a narrow distribution of intensities or grey shades around the maximum. A maximum of frequencies is characterized in that the curve which represents the frequencies has a slope of zero at the point of the maximum. An unwetted test element ideally has intensities in a small intensity range on its detection area. If this is the case it can be assumed that there are only a few or no interfering sites on the detection area. This is a prerequisite for an error-free measurement of a sample. If there is a significant number of intensities outside this small “normal” intensity interval, then it may be assumed that it is not possible to carry out an error-free measurement with this test element. This can be used as a quality control in order to exclude defective test elements from the measurement.
[0015] When for example a drop of the sample is applied to the detection area, a change in the frequency distribution of the intensities takes place. This is independent of the wavelength with which the detection area is irradiated. Thus, light in the infrared range, in the visible as well as in the UV range can be used. A fluorescent measurement is also possible with this method. A representative method is described in which the test element is irradiated or detected at a wavelength of 660 nm. In this case a reagent is located in or on the detection area which is distributed as homogenously as possible and undergoes a reaction with the analyte during which a dye is released which absorbs light at 660 nm. If the analyte is present in the sample liquid, the wetted sites of the detection area of the test element become darker in the detected wavelength range. This results in a reduction of the intensity in the wetted subareas. If the reagent is homogeneously distributed on the detection area, this results in a corresponding number of test fields which have a similar intensity. A redistribution of frequencies of intensities due to the colouration of the detection area is seen in the histogram. An accumulation of grey values at a lower intensity occurs. A second maximum is visible in the histogram which is caused by the wetted subareas. If the detection area is completely wetted, all grey values of the first maximum are shifted to a different grey value. The more homogeneous the reagent or sample is distributed, the narrower is the distribution around the mean intensity value of the shifted intensity values of the wetted areas.
[0016] This distribution of intensity frequencies before and after the sample is applied to the detection area can be used to determine the analyte. In one embodiment the intensity differences of the maximum values in the frequency distribution before and after wetting the detection area are used to determine the concentration of the analyte. Another embodiment is an analysis on the basis of the rate of change of frequencies of the irradiated light intensities after wetting the detection area. A multivariate analysis may be carried out especially for the time-related observation of the change of frequencies as well as for the other methods of analysis.
[0017] Another embodiment for determining the analyte concentration is the determination of the slope of the intensity curve between the lowest intensity and the most frequent intensity of the wetted area. In this case the intensity which has the highest frequency of an intensity interval or grey value can be used to determine the analyte.
[0018] Another embodiment for determining the concentration of the analyte can be carried out on the basis of intensities which exceed a frequency threshold value. This frequency threshold value ensures that the area used for the analysis has the most homogeneous colouration of the wetted area.
[0019] In addition the system has a quality control capability based on the frequency distribution. As already mentioned the distribution of intensities is narrow when the reagent is ideally spread on the test element. This intensity distribution becomes broader as the reaction becomes more inhomogeneous. The inhomogeneity of the reaction depends on the distribution of the reagent in or on the detection area as well as on the spreading of the drop on the detection area. This drop can have an edge area of different sizes on the detection area depending on the viscosity and component distribution of the blood. The reaction of the blood in this edge area with the reagents in or on the detection area can have a different behaviour to that in the centre of the sample drop.
[0020] According to the present disclosure a method for determining the concentration of an analyte in a liquid is also described. For this an intensity frequency of the unwetted detection area of the test element is determined. This can be carried out before applying a sample drop or afterwards, depending on whether the detection area is completely wetted or not. Furthermore, the method comprises the detection of light intensities of the light radiated from the at least one subarea of the detection area. These light intensities are analysed on the basis of their frequencies as described above.
[0021] The analysis of light intensities with the aid of a histogram can be used in various systems in which light intensities change due to the presence of an analyte. An example of such a system is the determination of glucose in a biological sample such as for example blood, plasma, serum or interstitial fluid. Sample volumes between 1 and 500 nl can be measured with the aid of this method of analysis. A preferred range is between 10 and 100 nl and a particularly preferred range is between 10 and 50 nl.
[0022] Furthermore, an instrument is described which comprises a detection unit for detecting light intensities which are radiated from subareas of a detection area of a test element and an evaluation unit which determines the concentration of the analyte on the basis of frequencies of light intensities of the light radiated from the subareas wherein the detection unit can contain a CMOS detector the pixels of which are connected to at least one A/D converter. In addition the evaluation unit can be connected to a display unit or the display unit can be integrated into the evaluation unit. In one embodiment the detection unit and evaluation unit are integrated on a chip, a configuration that may reduce space requirements. Since the memory requirement is very small due to the reduced amount of data for the analysis, the current consumption of such an integrated element is considerably lower than with conventional instruments.
[0023] Test elements such as those known from the documents EP-A 0 885 591, EP-B 0 535 480 and EP-B 0 477 322 can be used in conventional devices for determining a blood parameter. The test element contains a detection area. This detection area preferably contains all reagents and optionally auxiliary substances required for the detection reaction of the target analyte in the sample. The detection element can also contain only some of or even none of the reagents or auxiliary substances. Such reagents and auxiliary agents such as those described in the documents EP-A 0 885 591, EP-B 0 535 480 and EP-B 0 477 322 are well-known to a person familiar with the technology of analytical test elements or diagnostic test carriers. In the case of analytes which are to be detected enzymatically, enzymes, enzyme substrates, indicators, buffer salts, inert fillers and suchlike can be present in the detection element. The detection element can be composed of one or more layers and optionally contain an inert carrier preferably on the side of the test element which is not brought into contact with the sample. In the case that the detection reaction results in an observable change in colour (which can also be outside the visible range) which in this connection is to be understood either as a change in colour, formation of a colour or disappearance of colour, it must be ensured through suitable measures that the carrier allows a visual or optical observation of the detection reaction. For this purpose the carrier material of the detection element may itself be transparent and for example have a transparent plastic foil such as for example a polycarbonate foil or a transparent cutout on the detection side. In the case of the preferred reflection measurement, test elements such as those described in the patent application WO 99/29429 can be used. These test elements contain a pigment layer (preferably TiO 2 ) in the detection layer. This diffusely scattering TiO 2 layer increases the reflection of light which leads to a greater interaction of the incident radiated light with the reagents. This can amplify the measured effect such as the absorption of light. In a particularly preferred embodiment the dye which is formed preferably absorbs light at a wavelength of 660 nm.
[0024] In another embodiment a test element is used which serves to analyse very small sample volumes. This test element can be present in a system where the sample application is carried out by the system. For this purpose the sample is preferably transported by the system to the test element and the application is transferred onto the test element from a sample collecting site. In this transfer the sample drop on the test element adopts a certain shape provided there is an adequate amount of sample. This sample drop can be analysed independently of its shape with the aid of the histogram analysis.
[0025] The detection area can be illuminated by one or more light sources. In this connection the detection area can be homogeneously illuminated or only in subareas. If only one light source is used, a homogeneous illumination of the detection area can be improved by using a milk glass or other scattering units.
[0026] An alternative to illuminating the detection area with at least one light source is to utilize ambient light (sunlight or artificial illumination) to illuminate the detection area. Since ambient light is multispectral, a filter can be used between the test element and detector in order to detect only one particular wavelength range.
[0027] Alternatively the system can be provided with various illumination units for the sequential illumination of the test element. A simple laser diode combined with a reflector which can be adjusted by a micromechanism can for example be used as a light source. The light beam can scan the test element without gaps with the aid of the reflector. Alternatively a laser array can be used, preferably a VCSEL array (Vertical Cavity Surface Emitting Laser). Each laser in the array can be individually addressed. The advantage of the VCSEL is that the light is emitted with a low beam divergence. These laser structures have a beam divergence of about 5-8°. This not only allows a small area to be irradiated but in addition the amount of light on this area is very high. Another possibility is a laser diode array. In this case the light can either be coupled into an image guide which guides the excitation light to the test element or the light is focussed on the various areas of the test element by means of a microlens array which is arranged between the LED array and the test element. An OLED chessboard (Organic Light Emitting Diodes) could also serve as a further illumination unit. In this case an illumination LED and a detector can be arranged directly adjacent to one another. A large area can be illuminated in a planar or sequential manner and the reflection can be detected by means of an arrangement of several such illumination/detector units. Since the illumination as well as the detection are arranged at a similar angle to the test element, this arrangement may be preferred for fluorescence measurements because the excitation light and the light emitted from the detection area can be readily separated from one another by means of filters.
[0028] The illumination unit can consist of a monochromic or multispectral, coherent or incoherent radiation source. The radiation from the illumination unit serves to penetrate the detection area which is also referred to as the sample site in order to measure the analyte directly or to measure the colour reaction of a reagent with the analyte. The illumination unit preferably consists of one or more LEDs the light of which causes a specially selected spatial intensity distribution or a homogeneous illumination at the sample site. In order to obtain depth information, the illumination can have a focussed design. The focus is then shifted in the direction of the depth dimension. The excitation can optionally be by means of a multispectral LED array. A coherent excitation with laser diodes for example in the blue/ultraviolet spectral range is conceivable especially in fluorimetry. In a preferred embodiment light at a wavelength of ca. 660 nm is used. This can be implemented by the selection of the light source or by incorporating imaging units such as filters which are only light permeable for a defined wavelength range.
[0029] An imaging unit can be incorporated between the illumination unit and the detection area. This imaging unit consists of imaging optical elements such as lenses, mirrors, diaphragms, prisms, light-guiding or holographic elements. This ensures an illumination of the detection area. Another imaging unit serves to project the irradiated sample body onto the detection unit. This imaging unit also consists of imaging optical elements such as lenses, mirrors, prisms, diaphragms, light-guiding or holographic elements. A microoptical lens array can be optionally used in which each individual element images defined spatial areas of the test element onto individual elements of the detection unit. When using a multispectral light source it is appropriate to place a filter in front of the detector or in front of the test element.
[0030] Detection units for use in the system of the present disclosure can consist of a planar or linear element which enables a spatially-resolved as well as time-resolved measurement of the scattered radiation which is imaged from the detection area. This element is preferably a two-dimensional CMOS array, a CCD array or linear diode array in which the spatially-resolved imaging of the detection area is carried out by a scan process. Often a simple photodiode without spatial resolution may also be sufficient. This can for example be used in combination with a spatially-resolved radiation of the detection area.
[0031] The detection unit converts the amount of light incident on an optically sensitive area of the detector into an electrical signal. This electrical signal can be directly passed onto the evaluation unit and can be processed further there. In the case of a spatially-resolved detector, the optically sensitive area is subdivided into subareas which are also referred to as pixels. The larger the number of pixels, the smaller are the subareas of the detected object that can be distinguished. In one embodiment a CMOS detector is used which can have more than 1 million pixels. A preferred range is between 100 and 100,000 pixels and a particularly preferred range is between 1000 and 10,000 pixels. These pixels are preferably arranged in a quadratic or rectangular shape and form a two-dimensional array. The array consists of at least one line and at least one column. The number of lines and the number of columns can differ from one another. Depending on the geometry of the object to be detected, the array can also adopt a round or oval shape. One arrangement of pixels is an array of 256×256 pixels.
[0032] In another embodiment an A/D converter can be additionally attached to each pixel. In a preferred embodiment each line or each column of the array is connected to A/D converters. In this manner it is possible to read out the signals in columns or lines. Furthermore, the CMOS detector can be integrated on a chip together with at least one A/D converter. This chip can be a silicon chip known from the prior art as described in “CMOS Bildsensoren” by D. Scheffler and J. Seijnaeve in Laser+Photonik; May 2005; p. 32-35.
[0033] The A/D converter converts the analogue electrical signal into a digital value. This is adequately described in the prior art. In one embodiment an 8 bit A/D converter known in the prior art is used. This A/D converter converts the electrical signals into 256 different intensity levels. The intensity levels are each of equal size. In this manner the detected measured values can be processed further with considerably less memory capacity. In addition or alternatively it is possible to integrate an amplifier on each pixel. This additionally results in an amplification of the signals and thus the possibility of also detecting smaller signal changes. This data conversion and/or amplification can considerably reduce the amount of data that is passed onto the evaluation unit. This results in the following advantages:
1. A rapid reading of the data is possible. 2. Certain areas can be read in a targeted manner. 3. After a coarse scanning of the detection area it is possible to determine and read particularly interesting areas, so-called “ROI” (regions of interest).
[0037] The signals received by the detection unit are passed on to an evaluation unit. This evaluation unit can be integrated into the detection unit or can be present separately. The evaluation unit can in turn be connected to a display unit or the display unit can be integrated into the evaluation unit. The electrical signals from each pixel of the detection unit are counted in the evaluation unit. If the signals have not already been converted into digital values in the detection unit, this can take place in the evaluation unit. Furthermore, the signals can be additionally amplified. The level of the individual signals corresponds to an intensity of light that has been detected by individual pixels.
[0038] In one embodiment the maximum signal which can be received by the detector, is made to equal a grey value of 255. If the detector receives no light, then the signal corresponds to the grey value 0 . All intensities which lie between the maximum grey value 255 and the minimum grey value 0 are subdivided into 254 grey values. According to the present disclosure a histogram analysis is described which can determine the concentration of an analyte on the basis of frequencies of light intensities converted into grey values of the light radiated from the subareas. When measuring a sample it is possible to firstly measure the detection area of the test element without sample. In doing so a frequency distribution of grey values is determined. If the unwetted test element has few to no interfering sites, there is a narrow distribution of frequencies around the most frequent grey value in the histogram.
[0039] When the sample is applied to the detection area, at least part of the detection area is wetted with sample liquid. A reaction between the analyte in the sample and the reagent on the detection area can take place in this at least one subarea. This can lead to a change in an optical property (such as for example a colour change) of the reagent. In one embodiment a darkening of the wetted subarea occurs. This darkening is due to the release of a dye in the reaction of the analyte with the detection reagent. The released dye absorbs the light irradiated onto the detection area as a result of which less light is reflected from the detection area and thus less light is detected. This darkening leads to a change in the grey values of these subareas. This can be observed in the histogram as a shift in the grey values of at least some of the frequencies. If the reagents and the sample are very homogeneously distributed in the detection area, almost all subareas of the wetted detection area will have a similar grey value which is seen in the histogram as a second maximum of frequencies at this grey value in addition to the first maximum of unwetted areas.
[0040] The concentration of the analyte can be determined on the basis of the change in the frequency distributions before and after wetting at least a part of the detection area. For this purpose a referencing of the grey value shift is carried out. The at least one grey value for calculating the analyte concentration can be chosen freely. One grey value is sufficient to determine the concentration of the analyte, but it is also possible to select several grey values. The relationship between the grey value or the selected grey values and the analyte concentration to be analysed should, however, be known. This relationship is referred to as referencing. The referencing can either be based on a grey value shift of at least one selected grey value with reference to an unwetted subarea or with reference to a reference area. In this referencing the grey value shift i.e. the difference between the selected grey value of the sample to be analysed and the grey value of the unwetted subarea or of the reference area is determined. This grey value shift or difference is compared with grey value shifts for different known glucose concentrations. From this comparison it is possible to immediately deduce the glucose concentration in the sample. In order to ensure a reproducible relationship between the selected grey value of the sample to be determined and the grey value of the referencing system, care should be taken that this selected grey value is representative for the glucose concentration. An example of a representative grey value of the wetted subareas is the grey value which has the maximum frequency.
[0041] One method of determining this grey value shift from the measured values is to determine the distance between the maximum values of frequencies before and after wetting. Alternatively one of the at least one grey values can be taken which has a certain percentage, for example 50, 60, 70 or 80 %, of the frequency of the maximum frequency. It is also possible to use the means of several grey values having a certain frequency.
[0042] In one embodiment the analysis of the detection area should take place after the reaction has run to completion. For this purpose an end point of the reaction should be determined. This can be carried out by observing the rates of change of the frequencies during the reaction process. In doing so it can be determined that the reaction is completed when it falls below a rate threshold value for the rate of change. At this time point it can be assumed that the reaction is for example more than 95 % completed.
[0043] Another method of using the frequency distribution to determine the concentration of the analyte is to determine the grey value at which the slope of the intensity curve between the lowest intensity and the most frequent intensity is largest. For this purpose it is also possible to use frequencies which reach a certain percentage (e.g. 50 %) of the maximum slope.
[0044] Alternatively the concentration of the analyte can be determined on the basis of grey values which exceed a frequency threshold value. The selection of grey values having a sufficient frequency avoids analysing areas which have an inadequate homogeneity of sample and/or reagent. An example of an area with an inhomogeneous sample distribution is the edge area of the wetted areas of the detection area. In order to eliminate a falsification of the measured results by this inhomogeneous area, the frequency threshold value can be selected such that the edge area is not used for the analysis. In this connection only grey values should be used which are representative for the wetted area. Since this frequency threshold value can also be exceeded in the unwetted area, a grey value threshold value for the grey value may also be used to delimit the grey values of the wetted detection area. In one embodiment only frequencies of grey values are used for the analyte determination which are below the grey value threshold value. In a further embodiment the average frequency is determined from the frequencies of the wetted areas that are above the frequency threshold value and used to evaluate the concentration.
[0045] Another embodiment is an analysis based on the rates of change of the frequencies of the emitted light intensities after wetting the detection area. For this it is necessary to observe the change of frequency distribution over time after wetting the detection area. In this method the intensity of the subareas is determined at preset time intervals before and/or after wetting the detection area and the frequency distribution of the grey value is calculated from the intensities. In one embodiment in which a dye is formed during the reaction of the analyte with a reagent on the detection area, the change in the frequency distribution of the grey values takes place the more rapidly, the more analyte is present in the sample. These differences in the rate of colour formation depending on the analyte concentration can be used to carry out a concentration determination on the basis of the rate of darkening of the detection area. The rate of darkening is reflected in the rate of the frequency shift.
[0046] A further embodiment for determining the concentration of an analyte can be carried out on the basis of at least some of the frequencies which have a lower intensity than the maximum value of the second maximum caused by the wetted subareas.
[0047] This at least one grey value selected to determine the concentration can be compared with an appropriate reference system and the concentration of the analyte can be deduced from this.
[0048] The frequency distribution can additionally be used to determine whether an adequate wetting of the detection area has taken place. For this purpose it is determined whether an adequate number of pixels had a shift in their grey value. If a certain number of all shifted intensities is exceeded, it can be determined that the detection area is adequately wetted.
[0049] Furthermore, the reaction end point can be determined by determining the change in frequency distribution over time after applying the sample. If the frequency distribution only changes within a certain range over a certain period, it can be assumed that the reaction is completed. This time interval may be in the range of minutes, but in one embodiment it is within 1-10 seconds. In this case the interval in which the frequency distribution may still change is a few percent and should not exceed 5 percent.
[0050] An alternative method for determining the analyte concentration is to track the time course of the frequency distribution of intensities or grey values after wetting the detection area. Multivariate analytical methods can be used for this such as those that are known in the prior art. For example an analysis of the histograms at various times during the reaction can be carried out with the aid of the “partial least square” (PLS) method or the “principle component regression” (PCR) method as described in the publication by H. Martens and T. Naes, “multivariate calibration”, ISBN 0471 90979 3. Other statistical methods can also be used for this purpose.
[0051] The frequency distribution of the intensities can additionally be used for quality control. Depending on the size of the blood quantity and distribution of the analyte on the detection area, edge effects in the form of an edge area may play a decisive role and impair the measurement result. One can speak about an edge area especially when the detection area is not completely wetted. The edge area is seen in the histogram between the intensity accumulations around the frequency maximum of the unwetted and of the wetted portion of the detection area. Since the edge area is characterized by an inhomogeneous distribution of the sample on the detection area, it can comprise an interval of grey values of different widths depending on the analyte concentration in the sample. An altered sample distribution is found in the edge areas despite a substantially homogeneous distribution of the sample in the middle of the spot. Analyte exchange between the blood drop and reagent layer can be changed in these edge areas. Since this is usually an interference of the analyte exchange, reduced conversion of the analyte takes place. In one embodiment the reduced conversion of analyte means a higher detected intensity in the edge area. This change depends on many factors including the viscosity and the concentration distribution of various blood parameters such as glucose and haematocrit in the sample. Another cause of inhomogeneities is the consistency of the test element in the detection area. These inhomogeneities can also result in altered exchange of analyte with the reagents. Especially when analysing small volumes in which the edge/area ratio greatly increases in favour of the edges, a simple averaging over the sample spot leads to highly falsified measured results. An averaging over all inhomogeneously and homogeneously wetted subareas could, in the case of very small sample quantities, lead to an inadequate accuracy of the measurement results. In the case of very small sample volumes the extent of the edge area of the drop can be of a similar size to the homogeneous core area of the drop. The result may be that no grey value of the wetted subareas exceeds a lower frequency threshold value. If this is the case, an additional algorithm can be used that takes into account the frequencies of the edge area.
[0052] Depending on whether the detection area is measured from the side on which the blood is applied or from the opposite side, the reflection behaviour may be different. Thus it was found that the described inhomogeneous distribution of the sample leads to different accumulations of various components in various areas of the detection area especially in the edge areas. In one embodiment test elements are for example used which have a detection area which contains several layers. One of these layers is designed such that large components of the sample such as for example red blood corpuscles in a blood sample are prevented from penetrating further. Light is reflected differently from the edge area of this layer than from the opposite side of the detection area. In a preferred embodiment the detection area is measured from the side opposite to that of blood application. In contrast the blood application side is detected in the case of transmission measurement.
[0053] In order to optimally analyse a detection area of a test element, it is possible to carry out a quality control before using the test element. For this purpose the test element is measured in a spatially-resolved manner with the aid of a detection unit before wetting. Based on the frequency distribution of the measured intensities of the various subareas it can be examined whether the test element has an adequate homogeneity and whether the test element is suitable for use. Various quality criteria can be used for this purpose. One quality criterion is the number of intensities within a specified intensity interval. The proportion of intensity frequencies which are within the specified interval must exceed an interval threshold value in order that the test element can be released for use. If for example less than 90% of the measured intensities are found in this interval, then the test element can be excluded from use because it must be feared that irregularities in the detection area may interfere with the measurement results. In this case the breadth of the intensity interval depends on the properties of the detection area. The unsuitability of the test element can be indicated to the patient by the system through a warning signal such as e.g. an acoustic or optical signal.
[0054] Another method of checking the quality of the detection area is to alternatively or in addition compare the intensity or the grey value associated with the mean or maximum frequency with a quality threshold value. If the grey value which corresponds to the mean or maximum frequency is below the quality threshold value, then it can be assumed that the test element is contaminated in the detection area and should for this reason not be used.
[0055] Another method of quality control is to compare the maximum frequency with a reference threshold value. If this reference threshold value is not exceeded, it can be assumed that too many pixels have a modified grey value due to contamination and could falsify the measurement after wetting.
BRIEF DESCRIPTION OF THE FIGURES:
[0056] FIG. 1 a is a schematic representation of a system for illuminating a test element including a detection unit to detect the reflected radiation and an evaluation unit.
[0057] FIG. 1 b is a schematic representation of a system for illuminating a test element including a detection unit to detect the transmitted radiation and an evaluation unit.
[0058] FIG. 1 c is a schematic representation of a system for the spatially-resolved illumination of a test element including a detection unit to detect reflected radiation and an evaluation unit.
[0059] FIG. 2 a is a graphical depiction of a grey value distribution of an unwetted test strip.
[0060] FIG. 2 b is a graphical depiction of a grey value distribution after wetting part of the detection area.
[0061] FIG. 3 is a diagram of a reference curve for determining analyte concentrations in unknown samples.
[0062] FIG. 4 a is a diagram of a drop on a detection area.
[0063] FIG. 4 b is a diagram of the intensity distribution (converted into grey values) of the drop from 4 a in a histogram.
[0064] FIG. 4 c is a diagram of the darkest points on the detection area in a histogram.
[0065] FIG. 4 d is a diagram of the grey values that occur most frequently in the wetted area in a histogram.
[0066] FIG. 4 e is a diagram of the edge area of the applied drop in a histogram.
[0067] FIG. 4 f is a diagram of the unwetted area on the detection area in a histogram.
[0068] FIG. 5 is a diagram of a time course of the grey distribution when part of the detection area is wetted.
DETAILED DESCRIPTION OF EMBODIMENTS
[0069] FIG. 1 a shows a system which contains a test element ( 1 ) with a detection area ( 2 ) which is irradiated by a light source ( 3 ). Imaging units such as for example lenses and/or diaphragms can be mounted between the light source ( 3 ) and the test element ( 1 ). In this example a diaphragm ( 4 ) and also a lens ( 5 ) are arranged between the light source and detection area ( 2 ) of the test element ( 1 ) in order to illuminate the detection area ( 2 ) as homogeneously as possible. The light radiated from the detection area ( 2 ) is captured by a detector ( 6 ). This detector ( 6 ) should comprise at least 10 pixels ( 17 ) in order to be able to detect the detection area ( 2 ) in a spatially-resolved manner. The signals of the detector ( 6 ) are analysed in an evaluation unit ( 7 ) which is connected to the detector ( 6 ). A preferred embodiment of the detector is a CMOS detector which comprises at least one A/D converter in order to convert the analogue electrical signals into digital signals. These digital signals can be transmitted to the evaluation unit ( 7 ) where they can be subjected to various analyses. The calculated measured values can be shown on a display unit ( 7 b ) which is connected to the evaluation unit or integrated into this unit. In one embodiment a detector ( 6 ) is used which has a converter in a range of 8 to 12 bit. The detector ( 6 ) is used to subdivide the measuring range into 256 grey values between its zero value and its maximum value. The evaluation unit ( 7 ) is designed to count the frequencies of the 256 grey values. These frequencies can be plotted in a histogram ( 10 ) versus the intensity intervals which are also referred to as grey values ( 11 ). In this connection each intensity interval is assigned a grey value.
[0070] A system for transmission measurement is shown in FIG. 1 b. In this case the test element ( 1 ) with its detection area ( 2 ) is located between the light source ( 3 ) and the detector ( 6 ). Also in this case imaging units can be used between the test element ( 1 ) and the light source ( 3 ) as well as between the test element ( 1 ) and the detector ( 6 ). In this example a diaphragm ( 4 ) as well as a lens ( 5 ) are located between the light source ( 3 ) and the test element ( 1 ), and a lens ( 5 a ) is located between the test element ( 1 ) and detector ( 6 ). The detector ( 6 ) is also able to carry out a spatially-resolved measurement which is why it has a plurality of pixels ( 17 ). The detector ( 6 ) is in turn connected to an evaluation unit ( 7 ). A display unit ( 7 b ) is in turn connected to the evaluation unit ( 7 ) or is integrated into the evaluation unit. This transmission arrangement can be used for fluorescence measurements. In such an arrangement a filter ( 8 ) which blocks the excitation light is provided between the test element ( 1 ) and detector ( 6 ).
[0071] FIG. 1 c shows a system for the spatially-resolved illumination of the detection area ( 2 ). In this arrangement a light source ( 3 ) is used which illuminates only a subarea of the detection area ( 2 ). If only one light source ( 3 ) is used, the light is focussed by a reflector (not shown here) onto various subareas of the detection area ( 2 ). In the system shown here various light sources ( 3 ) which, as shown here, are arranged in an array ( 3 a ), are directed onto the detection area ( 2 ). In this manner it is possible to sequentially or simultaneously illuminate at least one subarea of the detection area ( 2 ). If the detection area ( 2 ) is sequentially illuminated, which is also referred to as scanning, it is possible to use an individual photodiode as the detector ( 6 ). If, however, the detection area ( 2 ) is simultaneously illuminated by more than one light source ( 3 ) of the array ( 1 a ), a spatially-resolving detector ( 6 ) is then required for a spatially-resolved measurement. Also in this case the detector ( 6 ) is connected to an evaluation unit ( 7 ) which receives the measurement signals of the detector ( 6 ) for further analysis. A display unit ( 7 b ) is connected to the evaluation unit ( 7 ) or is integrated into the evaluation unit.
[0072] All other measurements which are shown in FIGS. 2-5 are measured with an apparatus as described in FIG. 1 c.
[0073] FIG. 2 a shows the grey value distribution ( 9 ) of an unwetted test element ( 1 ). It is shown in the form of a histogram ( 10 ) in which the grey values ( 11 ) ( 256 in the example shown) are plotted on the X axis ( 11 a ) whereas the number of detected grey values ( 12 ) are depicted on the Y axis ( 12 a ). The homogeneity of the detection area ( 2 ) of the test element ( 1 ) can be deduced on the basis of the distribution of grey values ( 11 ). In this example the grey values ( 11 ) are between 0 and 200 and the most frequent grey value of the unwetted detection area is at 173. This is evident from the maximum ( 13 ) of the grey value histogram ( 10 ) in FIG. 2 a. The higher the grey value ( 11 ), the brighter is the corresponding object. If the detection area ( 2 ) is now partially wetted, then a part of the detection area ( 2 ) becomes darker as do some pixels in its image on the detector ( 6 ).
[0074] FIG. 2 b shows a darkening of the detection area ( 2 ) after applying a drop of sample. Since the detection area ( 2 ) has only been partially wetted, in this case somewhat more than half the subareas were wetted, the histogram ( 10 ) has two maxima ( 13 ) and ( 13 a ) of grey values ( 11 ). As a result of this darkening the intensity of the light which is radiated from the wetted subareas decreases and the pixels of the detector which measure these subareas detect a lower signal. This results in lower grey values in the histogram ( 10 ). The smaller proportion of pixels which represents the unwetted area still exhibits a grey value ( 11 ) of about 173 whereas the larger proportion of pixels now has an average grey value ( 11 ) of 115. The difference between the mean grey value ( 11 ) of the unwetted area of the detection area ( 2 ) and the grey value ( 11 ) of the darker area after wetting depends on the colouration of the detection area ( 2 ) and thus on the glucose concentration. Thus it is possible to directly deduce the glucose concentration from the change in the grey values ( 11 ).
[0075] FIG. 3 shows a typical reference curve ( 15 ) such as that which is required to calculate the concentration of the analyte (in this case glucose) in a sample by means of the described histogram analysis. Liquid samples containing known concentrations are examined with the aid of one of the methods described above in order to determine this reference curve ( 15 ). In this process a glucose concentration is allocated to a frequency shift of the grey values (referred to as Δ GW) ( 16 ) of the maxima ( 13 ) and ( 13 a ). This is only a schematic representation of such a reference curve ( 15 ) because the absolute values can vary depending on the grey values ( 11 ) that are used from the histogram ( 10 ). This reference curve ( 15 ) can be used to illustrate how the shift in the frequencies of the grey values ( 16 ) can be converted into a concentration. Thus a large shift of frequencies ( 16 ) corresponds to a high analyte concentration and vice versa.
[0076] In order to calculate an unknown sample, the Δ GW value is determined in the evaluation unit ( 7 ) with the aid of the intensities of the wetted detection area ( 2 ) measured by the detector ( 6 ). This is carried out using the same method as that used to determine the reference curve ( 15 ). Since the reference curve ( 15 ) is stored in the evaluation unit ( 7 ), the analyte concentration can be read immediately.
[0077] The relationship between the grey value distribution in the histogram ( 10 ) and the associated wetted areas is shown in FIGS. 4 a to 4 e. FIG. 4 a shows a black and white diagram of a drop ( 14 ) which has been applied to the detection area ( 2 ). In this example, the detection area has a dimension of about 650 * 650 μm. FIG. 4 b shows the associated histogram ( 10 ) which shows the grey values ( 11 )of the entire detection area ( 2 ). It can be seen that most of the detection area ( 2 ) is still unwetted which is why the larger maximum ( 13 ) of grey values ( 11 ) is still at about 173 . There is a further maximum ( 13 a ) at a grey value ( 11 ) of about 65. If, as shown in FIG. 4 d, one observes the grey values ( 11 ) which lie around this maximum ( 13 a ) i.e. above the frequency threshold value in this grey value range, then it is evident in the drop diagram ( 14 ) in FIG. 4 d that these pixels belong to the inner area of the drop. These pixels are very homogeneously distributed over the core of the drop. There are a few pixels adjacent to this homogeneous area in the histogram ( 10 ) which have a very low grey value as shown in FIG. 4 a in the drop diagram ( 14 ). These points are also located in the centre of the sample drop. The edge area of the drop is shown in the drop diagram ( 14 ) of FIG. 4 e. The grey values ( 11 ) of this edge area are between the grey values ( 11 ) of the unwetted and of the homogeneously wetted area. The pixels of the unwetted portion of the detection area ( 2 ) are shown in FIG. 4 f. Since in this example only a portion of the detection area ( 2 ) is wetted, the frequency of the grey values ( 11 ) around the maximum value is very large.
[0078] FIG. 5 shows a time course of the grey value distribution during the wetting process. In this diagram the time is plotted on the X axis ( 11 a ) versus the grey values ( 11 ) on the Y axis ( 12 a ). At the start of the measurement until the time point of 4 seconds, the detection area ( 2 ) is unwetted and has a grey value ( 11 ) of approximately 173 . During the wetting process at about 4 seconds the grey value ( 11 ) briefly decreases due to the darkening of the detector ( 6 ) and subsequently proceeds further in two different directions from the grey value ( 11 ) at about 173 . The unwetted portion ( 14 a ) of the section shown in the image ( 14 ) of a partially wetted detection area ( 2 ) continues to remain at a grey value ( 11 ) of 173 . The most frequently measured grey values of the unwetted portion are shown in the curve ( 14 a’ ). All grey values ( 11 ) of the unwetted area ( 14 a ) are between the curves ( 14 a″ ) and ( 14 a″’ ). A similar distribution of grey values ( 11 ) can be seen around the maximum frequency of the grey values ( 11 ) of the wetted area ( 14 b ). The majority of the wetted subareas of the detection area ( 2 ) are on the curve ( 14 b ). In the wetted subarea ( 14 b ) there are also pixels which have a lower grey value ( 11 ) or a higher grey value ( 11 ) than the pixels of the curve ( 14 b’ ). This grey value range is delimited by the curves ( 14 b″ ) towards smaller grey values and by the curve ( 14 b″’ ) towards larger grey values. This curve shows that the reaction on the detection area is completed at a time of about 15 seconds. The course of the curve ( 14 b’ ) can be used to determine the analyte if the curve courses for various concentrations of the analyte are known. In addition the rate of frequency change can be used to determine the completion of the reaction. A rate threshold value can be determined as a lower limit of the rate of frequency change. If it falls below the rate threshold value, then this time point can be used to start the analysis of the analyte if this is necessary.
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A system for determining the concentration of an analyte in a liquid sample comprising a detection unit for detecting light intensities which are radiated from subareas of a detection area of a test element as well as an evaluation unit which determines a frequency distribution for the detected light intensities wherein the frequency distribution has at least one first maximum caused by unwetted subareas or at least one reference area and a second maximum caused by wetted subareas and selects at least one light intensity on the basis of the frequency distribution and determines the concentration of the analyte from the at least one selected light intensity.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an organic light emitting device (OLED) in which a charge transport material is used as the host material and/or as the charge transport layer.
2. Description of the Related Art
Significant efforts have been expended in developing suitable materials for use in organic light emitting devices (OLEDs). Such devices are commercially attractive because they offer the promise of low-cost fabrication of high-density pixeled displays exhibiting bright electroluminescence with long life times, high efficiency and wide color range.
A typical OLED is fabricated by sandwiching an emissive layer between an anode and a cathode. Improved performance can be obtained by the provision of additional layers around the emissive layers so as to provide charge transport capabilities, such as an electron transport layer or a hole transport layer.
The stability and lifetime of an OLED may change with the various combinations of emissive material and charge transport material. As most luminescent materials have limited charge injection and transporting ability, and/or unbalanced charge injection ability in the device, the doping of emissive material (with a volume content less than 20%) into a host material can lead to much better performance because the host material can either enhance electron transport or enhance hole transport. Since electron injection of organic luminescent material has been less efficient than hole injection of organic luminescent material, host materials that have an electron enhancement function, have been widely used for high performance OLEDs. For example, U.S. Pat. No. 5,935,720 shows an OLED utilizing tris(8-hyroxyquinoline) aluminum Alq3 as host material because of its electron enhancement function. Due to its high electron affinity, Alq3 has also been widely explored as electron transport material for OLEDs.
However, recent scientific evidence showed that an OLED with Alq3 as the emissive layer and/or host material has intrinsic instability due to the poor hole injection ability of Alq3. In addition, current findings show that Alq3 has little electrochemical reversibility even under normal electrochemical reduction process.
Accordingly, because of consumer expectations of good efficiency, long lifetime and pure color for OLEDs, a need still exists for development of suitable materials used for OLEDs.
SUMMARY OF THE INVENTION
It is an object of the invention to provide an improved OLED in which pyrylium salt or its derivatives are used as the charge transport material in a pure charge transport layer or in a host material to enhance charge transport property.
Thus, in one aspect, the invention is an OLED in which an emissive layer is sandwiched between at least a cathode and an anode, and in which the OLED includes a pyrylium salt or its derivatives such as thiapyrylium, selenapyrylium, and telluropyrylium as a charge transport material. Suitable pyrylium salts and their derivatives are expressed according to the following general formula (I):
wherein R 1 , R 2 and R 3 represent an alkyl, aryl, or heteroaryl having up to 50 carbon atoms; Z represents an anionic function-including ion, such as Cl − , Br − , F − , tetrafluoroborate, perchlorate, methanesulfonate, or phosphohexafluoride; and X is oxygen, sulfur, or selenium. The compound expressed according to formula (I) can be used directly as transport layer, can be used as a dopant in a charge transport layer, or can be incorporated into an emissive layer as a host to enhance the emissive layer's charge transport property.
Fabrication of a suitable charge transport layer using a pyrylium salt or its derivatives according to the above formula (I) can be accomplished through use of thermal deposition in a vacuum, or by spin coating of a solution thereof. In addition, high-density pixeled displays can be fabricated through use of suitable masking procedures, or by use of thermal or piezoelectric ink jet printing techniques.
The compound expressed according to formula (I) can be used directly as the charge transport layer, or can be incorporated into a polymer as a unit or as a pendent side group. In addition, the compound of the expressed formula can be doped into a matrix medium when the charge transport layer comprises a charge transport functional material plus a dopant. Further, the compound can be used as a host to enhance charge injection and transport property wherein a dopant emitter may be doped for controlling emission color.
The compound expressed according to formula (I) exhibits characteristics of high electron affinity and excellent reversibility. Representative charge transport mechanisms are shown below in accordance with Schemes 1 and 2, which show examples of the charge injection process for 2,4,6-triphenylpyrylium salt and 4,4′-bipyryllium salt, respectively.
This brief summary has been provided so that the nature of the invention may be understood quickly. A more complete understanding of the invention can be obtained by reference to the following detailed description of the preferred embodiment thereof in connection with the attached drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic cross-sectional view of a two layer organic light emitting device.
FIG. 2 is a schematic cross-sectional view of a three layer organic light emitting device.
FIG. 3 is a schematic cross-sectional view of a single layer organic light emitting device.
FIG. 4 illustrates the cyclic voltametric analysis curve for Alq3.
FIG. 5 illustrates the cyclic voltametric analysis curve for TPPBF 4 .
DETAILED DESCRIPTION OF THE INVENTION
The pyrylium salt and its derivatives used in the present invention have the following general structure:
In the above formula (I), R 1 , R 2 and R 3 represent an alkyl, aryl, or heteroaryl having up to 50 carbon atoms; Z represents an anionic function-including ion, such as Cl − , Br − , F − , tetrafluoroborate, perchlorate, methanesulfonate, or phosphohexafluoride; and X is oxygen, sulfur, or selenium.
The compound expressed according to formula (I) exhibits characteristics of high electron affinity and excellent reversibility. Representative charge transport mechanisms are shown below in accordance with schemes 1 and 2, which show examples of the charge injection process for 2,4,6-triphenylpyrylium salt and 4,4′-bipyryllium salt, respectively.
Some preferred pyrylium salts or pyrylium derivatives represented by formula (I) include the following compounds:
In the above preferred pyrylium salts or pyrylium derivatives, X is either O or S; and Z is an anionic function-including ion, such as Cl − , Br − , F − , tetrafluoroborate, perchlorate, methanesulfonate, or phosphohexafluoride.
The compound expressed according to formula (I) can be used directly as the charge transport layer, or can be incorporated into a polymer as a unit or as a pendant side group. In addition, such a pyrylium salt or pyrylium derivative can be doped into a matrix medium when the charge transport layer comprises a charge transport functional material plus a dopant. Further, the pyrylium salt or pyrylium derivative can be used as a host to enhance charge injection and transport property wherein a dopant emitter may be doped for controlling emission color.
In one typical application, the compound expressed according to the above formula (I) can be used directly as the transport layer in multi-layer devices, such as a two layer device, shown in FIG. 1 , or a three layer device, shown in FIG. 2 , as described more fully below.
In FIG. 1 , a two layer device comprises an emissive layer 103 and an electron transport layer 105 sandwiched between a cathode 106 and an anode 101 .
In FIG. 2 , a three layer device comprises an emissive layer 203 sanwiched between an electron transport layer 205 and a hole transport layer 202 . Additionally, the emissive layer 203 , electron transport layer 205 and hole transport layer 202 are sandwiched between a cathode 206 and an anode 201 .
General procedures for an fabrication of an OLED are as follows: To contruct a three layer device, as in FIG. 2 , a clean substrate coated with a patterned layer of indium tin oxide (ITO) is first obtained. Next, the substrate is treated with O 2 plasma for 1-5 minutes. Afterwards, the substrate is placed in a thermal evaporator and the pressure is lowered. Then, organic and metallic layers are evaporated onto the substrate at a rate approximately between 1-3 Å/s. These organic and metallic layers may vary depending upon the desired OLED. A hole transport layer is usually evaporated with a thickness of ˜200 Å. Next, an emissive layer is evaporated with a host and dopant. Normally, 100-400 Å of the emissive layer is deposited. Then, an electron transport material is evaporated to form a layer that is usually 200-400 Å thick. After the evaporation of the preferred organic and metallic layers, a mask is placed adjacent to the layer to define where metal areas corresponding to cathodes are to be evaporated. Then, about 120 Å of a Li—Al alloy is evaporated to improve electron injection into the device. Finally, after about 1500 Å of Al is deposited, the evaporator is allowed to cool.
Fabrication of a suitable charge transport layer using a pyrylium salt or its derivatives according to the above formula (I) can be accomplished through use of thermal deposition in a vacuum, or by spin coating of a solution thereof. In addition, high-density pixeled displays can be fabricated through use of suitable masking procedures, or by use of thermal or piezoelectric ink jet printing techniques.
In another typical application, the compound expressed according to the above formula (I) can be incorporated into an emissive layer as a host to enhance charge transport property in a single layer device, as shown in FIG. 3 , in which the pyrylium salt or pyrylium derivative is doped into the emissive layer.
In FIG. 3 , a single layer device comprises a combined layer 303 , comprising an emissive layer and an electron transport layer, sandwiched between a cathode 306 and an anode 301 .
COMPARATIVE EXAMPLE 1
Cyclic voltametric (CV) analysis of known electron transport material, tris(8-hyroxyquinoline) aluminum (Alq3), was carried out using tetrabutylammonium tetrafluoroborate (TBABF 4 , 0.1 M in acetonitrile) as an electrolyte, Pt as a work electrode and Ag/Ag + (0.1 M) as a reference electrode at a scan speed of 100 mV/s. FIG. 4 shows the CV curve, indicating an onset reduction, or surge of reduction at the electrode surface, of −1.68 V. The lowest unoccupied molecular orbital (LUMO) was estimated according to a general formula that gives LUMO (in eV) as the difference between −4.8 and the Ered (onset reduction potential in volts) of −1.68. According to this formula, the LUMO was approximately −3.12 eV.
EXAMPLE 1
A similar CV measurement for a pyrylium salt, 2,4,6-triphenyl pyrylium tetrafluoroborate (TPPFB 4 ), was performed according to the same conditions as above, in the measurement of Alq3. FIG. 5 shows the CV curve of the pyrylium salt, which indicates a lower onset reduction of −0.44 V and −1.53 V, demonstrating that reduction (or electron injection) is easier for pyrylium salt than Alq3. The LUMO for the pyrylium salt was −3.27 eV (using the second reduction onset for the estimation), being lower than Alq3. A CV comparison also indicates that pyrylium salt not only has lower LUMO level (easier electron injection), but also has more reversible charge injection character (more stable electrochemical property) than Alq3, as revealed by the features of both CV curves.
EXAMPLE 2
An OLED device was fabricated with the device structure of ITO/α-NPD 30 nm/Alq3+DCM2 (2%) 20 nm/TPPFB 4 30 nm/Al 100 nm, in which ITO refers to indium tin oxide coated glass substrate, α-NPD refers to a hole transport layer with N,N′-Di(naphthalen-1-yl)-N,N′diphenyl-benzidine, DCM2 refers to a red dopant emitter, 4-(Dicyanomethylene)-2-methyl-6-(p-dimethylaminostyryl)-4H-pyran, and TPPFB 4 refers to 2,4,6-triphenyl pyrylium tetrafluoroborate as the electron transport layer. The device was fabricated according to procedures known in the art. The device emitted red light with a brightness of 315 cd/m 2 when a forward bias voltage of 5.2 V was applied. The brightness changed to 250 cd/m 2 at 5.2 V (retained 80% original brightness) after continuously working for 6 hours at 5.2 V.
COMPARATIVE EXAMPLE 2
An OLED device was fabricated in a similar manner as described in Example 2, with the exception of using Alq3 as the electron transport layer. The OLED had a device structure of ITO/α-NPD 30 nm/Alq3+DCM2 (2%) 20 nm/Alq3 30 nm/Al 100 nm. The device emitted red light with a brightness of 315 cd/m 2 when a forward bias voltage of 5.8 V was applied. The brightness changed to 180 cd/m 2 at 5.8 V (retained 58% original brightness) after continuously working for 6 hours at 5.8 V.
EXAMPLE 3
An OLED device was fabricated in a similar manner as described in Example 2, with the exception of using TPPBF 4 as a host material. The OLED had a device structure of ITO/α-NPD 30 nm/TPPBF 4 +DCM2 (2%) 20 nm/TPPBF 4 30 nm/Al 100 nm. The device emitted red light with a brightness of 315 cd/m 2 when a forward bias voltage of 4.8 V was applied. The brightness changed to 300 cd/m 2 at 4.8 V (retained 95% original brightness) after continuously working for 6 hours.
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An organic light-emitting device (OLED) in which pyrylium salt or its derivative, such as thiapyrylium, selenapyrylium, or telluropyrylium, is used as a charge transport material and/or at least a dopant or principal component in a charge transport layers.
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BACKGROUND OF THE INVENTION
The present invention generally pertains to battery testers, and more particularly, relates to on-label thermochromic battery testers.
Batteries are often stored before being used. Batteries are typically stored by retailers before being sold. After purchase by a consumer, such batteries are again typically stored for some period of time prior to use. If the period of storage is significant, batteries may self-discharge. Therefore, it is desirable to utilize a battery tester to determine if a battery has sufficient charge to operate a desired device.
It is also desirable, on frequent occasions, to determine the remaining life of batteries which are in use. Many "good" batteries are discarded simply because the user cannot recall how long they have been used in a particular device, i.e., a camera, tape deck, etc. For similar reasons, batteries often reach a useless or near useless state of discharge when no replacements are readily available. Separate or stand-alone battery testers are known which indicate remaining battery power. However, such testers are easily misplaced and cumbersome to use.
Battery testers have been described that are included in a label secured to a battery. One type of on-label battery tester is known as a "thermochromic battery tester." Thermochromic battery testers typically include a conductive element that is selectively connected between opposite terminals of the battery. The conductive element includes a switch pad at one or both ends that is pressed by the user to connect the conductive element across the terminals of the battery. When the conductive element is connected between the battery terminals, it generates heat as a function of its resistivity and the current flowing from the battery. The level of current produced by the battery is one indicator of remaining battery capacity. Thermochromic testers further include a thermochromic layer, which changes its color or visual appearance as a function of the heat generated by the conductive element. By changing the visual appearance of the thermochromic layer, a thermochromic on-label battery tester may provide an indication of the discharge level of the battery. For example, a thermochromic material that changes between opaque and transparent states may be utilized to expose indicia underlying the thermochromic layer indicating that the battery is still "good" when a sufficient level of current is output from the battery.
To produce such thermochromic battery testers in the simplest manner and at the lowest cost, the conductive heating element is printed at a single printing station using a single conductive ink material. A suitable material that may be readily printed on a substrate and that exhibits suitable heat-generating properties in response to the current from the battery, is silver ink. The silver ink is typically printed so that the resistivity of the ink film is the same in all portions of the circuit. Although the thermal flux can be focused by making the circuit narrower and the resistance higher where a high flux is required, the entire circuit acts as a heater. As a result, a low resistance circuit which draws high current is required to produce sufficient thermal flux in the display section. Because silver ink is relatively expensive, the conductive heating element thus constitutes a significant portion of the total cost of providing a battery tester on a battery label.
Another problem associated with conventional thermochromic on-label battery testers is that the contact switches that a user is required to press to activate the tester may become relatively hot due to the high current levels flowing through the conductive element. Although the heat generated at the switch contacts is not hot enough to burn the user's fingers, this heat nevertheless may create an unpleasant sensation for the user.
SUMMARY OF THE INVENTION
Accordingly, one aspect of the present invention is to solve the above problems by providing an on-label thermochromic battery tester that is lower in cost and that has reduced levels of heat generated at the switch contacts. To achieve these and other aspects and advantages, the battery tester of the present invention comprises a heating element having a display portion and first and second connecting portions on either side of the display portion that have a lower resistivity than the display portion. The lower resistivity of the connecting portions may be achieved by using a different material than that used for the display portion or using the same material for both the display and the connecting portions but changing a property in the layers that results in a lower resistivity for the connecting portions. For example, the thickness of the display portion layer may be reduced relative to the connecting portions or a binder fraction may be higher for the display portion than for the connecting portion.
The features and advantages of the invention may be realized and obtained by means of the instrumentalities and combinations particularly pointed out in the written description and claims hereof, as well as the appended drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings:
FIG. 1 is an illustration of a battery having a battery tester label in accordance with this invention disposed about the outer periphery of the battery;
FIG. 2 is a cross section of the battery tester label taken along plane II--II of FIG. 1;
FIG. 3 is an exploded view of a subcomponent of the battery tester label, referred to herein as the tester device;
FIG. 4 is a top plan view of the inserted tester device;
FIG. 5 is a bottom plan view of the inserted tester device, the cross-hatching indicating a layer of adhesive;
FIG. 6 is an exploded view of another subcomponent of the battery tester label, referred to herein as the base layer;
FIG. 7 is a cross section of a battery and the battery tester label;
FIG. 8 is an exploded view of the battery tester label;
FIG. 9 is an exploded view of a plurality of battery tester labels disposed on a common releasable liner;
FIG. 10 is a top view of a conductive circuit constructed in accordance with a second embodiment of the present invention; and
FIG. 11 is a partial cross section of a variation of the conductive circuit of the present invention taken along plane XI--XI of FIG. 10.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
FIG. 1 illustrates a battery and label assembly 1 comprising a battery can 2, a negative terminal 4, and a positive terminal 6. Can 2 may be in electrical contact with positive terminal 6. Battery 1 may include one or more electrochemical cells, which may be primary or secondary cells. Extending around and attached to the periphery of can 2 is a label 10 including a battery tester device 15, which is the subject of this invention. As shown, tester device 15 comprises switches 64 and 65 which activate tester 15 to indicate the state of charge of the battery by exposing indicia 23 or producing some other visual indication.
As illustrated in FIGS. 2-5, tester device 15 generally comprises a laminate or layered assembly having a substrate layer 20, an elongated electrically conductive circuit 18 disposed on a first face of substrate 20, and a pressure-sensitive adhesive 16 disposed on portions of both conductive circuit 18 and the first face of substrate 20. Adhesive 16, indicated by cross-hatching in FIG. 5, is preferably applied over conductive layer 18 in the pattern illustrated. Adhesive 16 is omitted from those areas which will overlie printed insulation 44 and switch pads 42 (FIGS. 6 and 8) when tester 15 is affixed to a base laminate 30. This adhesive pattern retards moisture from migrating to switch segments 60 and 61 of conductive circuit 18 while not interfering with the function of either the switches or the insulation discussed below.
Tester device 15 further comprises one or more graphic layers 22, preferably of decorative ink, and indicia 23 that are disposed on a second face of substrate 20 opposite the face containing conductive circuit 18. Tester device 15 also comprises a layer of a temperature-sensitive (i.e., thermochromic) indicating material 24 that is deposited upon the second face of substrate 20, preferably upon graphic layers 22 and indicia 23. A layer of a clear protective coating (not shown) is preferably deposited over indicator layer 24 and optionally upon graphic layers 22 and other exposed regions of the second face of substrate 20.
Conductive circuit 18 preferably has a central display portion 62 provided between two lower resistivity portions 82 and 84. The low resistivity portions 82 and 84 include switch segments 60 and 61. By forming switch segments 60 and 61 in a portion of conductive circuit 18 having a lower resistivity, the amount of heat generated at the contact switches 64 and 65 is substantially reduced. Conductive circuit 18 may be made of a single material such as a highly-conductive silver ink layer. To obtain different resistivities in portions 62, 82, and 84, the thickness of the layer forming portion 62 may be relatively thinner than that of connecting portions 82 and 84 or the binder fraction in the ink may be increased for portion 62.
An alternative method for obtaining different resistivities in the portions of conductive circuit 18 is to utilize different materials for these portions. For example, if connecting portions 82 and 84 are formed using a silver ink, central display portion 62 may be formed using materials of higher resistance such as carbon, nickel, silver-plated copper, or combinations of these materials.
The ratio of resistivities of display portion 62 to connecting portions 82 and 84 is preferably about 10:1, with the resistivity of display portion 62 being within the range of 100 mΩ/cm 2 to 10Ω/cm 2 and the resistivity of connecting portions 82 and 84 being within the range of 10 to 200 mΩ/cm 2 . It will be appreciated, however, that the present invention may be practiced using resistivities outside these preferred ranges and at ratios different from the preferred ratio identified above. Moreover, the preferred values listed above are those for a 1.5 V cell. Different values may be desirable for different cell constructions and types.
FIG. 10 shows a conductive circuit 118 having a pattern according to a second embodiment of the invention. As shown, connecting portions 182 and 184 include narrower sections 183 and 185 that connect between display portion 162 and switch segments 160 and 161, respectively. Like the first embodiment, the resistivity of connecting portions 182 and 184 is lower than that of display portion 162. This difference in resistivity may be accomplished by making the connecting portions thinner than the display portion (as shown in FIG. 11) or by making these portions of different materials.
By using less-expensive materials, such as copper, in place of the silver ink that is commonly used, and/or by narrowing the width of silver connecting portions 82 and 84 (182 and 184), the cost of conductive circuit 18 may be significantly reduced particularly when the tester circuit is configured to extend the entire length of the battery.
The tester device 15, as shown in FIGS. 2-5 and 8, is preferably prepared as follows. A plastic film is provided for substrate 20. Although FIG. 3 illustrates substrate 20 as being transparent, substrate 20 could be formed from a wide variety of other materials including opaque and translucent materials. Conductive circuit 18 is deposited on one face of substrate 20. Conductive circuit 18 is preferably deposited in the form of a pattern comprising two distal regions for forming switches, referred to and illustrated herein as switch segments 60 and 61, and a medially disposed area 62 which undergoes an increase in temperature upon passage of electrical current. The pressure-sensitive adhesive material 16 is deposited on at least portions of either or both conductive circuit 18 and a face of substrate 20. As previously noted, particular regions of conductive circuit 18 are left exposed and not covered with pressure-sensitive adhesive 16; namely, the switch segments 60 and 61 and area of controlled resistivity 62. A silicone-coated release liner, such as a silicone-coated paper or plastic film (not shown), is applied onto the previously deposited pressure-sensitive adhesive 16 to facilitate handling and/or storage of tester device 15.
Graphics and/or other labeling colors 22 in the form of a layer or layers of decorative ink and indicia 23 are printed onto the opposite side of substrate 20 from that on which the conductive circuit 18 is positioned. It is preferred that indicia 23 be disposed directly above the area of controlled resistivity 62 of conductive circuit 18 located on the other side of substrate 20. Additional graphics are also preferably printed to designate switch regions 64 and 65. If necessary, one or more curing operations may be performed to cure or partially cure the graphic or coloring layers.
On the same side of the substrate as the graphics and/or labeling colors, a thermochromic ink or other indicator material 24 is deposited onto substrate 20 such that it is situated directly above the area of controlled resistivity 62 of conductive circuit 18 and preferably over indicia 23. A clear protective coatings such as a varnish film, is then applied over and onto the indicator material, and optionally over the remaining regions of this side of substrate 20 to protect such regions from damage by subsequent manufacturing or storage operations. Each of the previously described layers or elements preferably have a thickness of from about 0.00005 inch to about 0.005 inch. The tester device, if necessary, can be cut to an appropriate size.
The second subcomponent of the preferred embodiment label 10 is a base laminate 30. As illustrated in FIGS. 2 and 6, base laminate 30 is a laminate or layered structure comprising a substrate 34, with one face having a layer of pressure-sensitive adhesive 32 for subsequent contact with a battery, and another face having one or more layers as follows: a metallization layer 36; a primer and/or decorative layer 38; an electrical insulation layer 40; and a thermal insulation layer 44. Also residing proximate to the thermal insulation layer are one or more switch throw pads 42 described in greater detail below.
Base laminate 30 is preferably prepared as follows. A plastic film is provided for the base layer substrate 34. The pressure-sensitive adhesive material 32 is deposited upon the face of the base layer substrate 34 that will subsequently face and contact the battery can 2. A silicone release liner is applied on the pressure-sensitive adhesive to facilitate handling and other processing operations. On the opposite face of base layer substrate 34, one or more graphic or labeling color layers are deposited, for instance, by printing. Preferably, metallization layer 36 is utilized to provide a decorative reflective layer. If a metallization layer is deposited, it will in most instances be necessary to deposit a receptive coating or primer layer 38 onto those regions of metallization layer 36 upon which other decorative layers are to be deposited. Primer layer 38 may in itself be a decorative layer. It is also desirable to deposit a layer of electrical insulation 40 upon metallization layer 36 and/or primer layer 38 to prevent electrical contact, i.e., shorting, between layer 36 and the conductive circuit 18 of tester device 15 during assembly of label 10.
Thermal insulation 44 is positioned in an area of base layer substrate 34 that will be disposed beneath the indicator material 24 and the maximum resistance area 62 of conductive circuit 18 of the previously described tester device 15. This thermal insulation reduces heat transfer from the area of controlled resistivity 62 of conductive circuit 18 to the battery. If such heat transfer is not controlled and the battery is permitted to act as a heat sink, the change in temperature at indicator material 24 may be insufficient to provide an accurate indication of the battery state of charge.
Thermal insulation 44, as shown, preferably comprises a plurality of apertures 46a which, when assembled into the laminate structure of the preferred label 10, provide air pockets which further thermally insulate the conductive circuit 18 from the battery. Optionally, a larger region of air space or void may be formed to serve as insulation by depositing a suitable spacer material onto the base laminate 30. The preferred insulative pattern is a series of islands printed onto layer 30 in the manner shown in FIG. 1A of U.S. Pat. No. 5,389,458.
A switch throw pad 42 is also formed surrounding a switch aperture 46b. This raised pad provides spacing between switch segment 61 of the conductive circuit 18 and battery can 2, and significantly minimizes the occurrence of accidental switch closure. Raised switch throw pad 42 is preferably formed by depositing or printing a dielectric ink or other suitable material. A second switch pad 42 may be formed proximate a switch aperture 47 as shown in FIGS. 6 and 8. This pad has not been found necessary for proper functioning of the tester.
In all of the foregoing operations, one or more cure steps may be utilized when depositing or printing any of the previously described layers, particularly the decorative inks. Each of the previously described layers or elements preferably has a thickness from about 0.00005 inch to about 0.005 inch.
Switch apertures 46b and 47 are preferably formed in base laminate 30 after printing thermal insulation 44 and switch throw pad 42. Such apertures are preferably formed by suitable punching operations. Registry problems are minimized by printing what is to become switch pad 42 as a solid disk and thereafter punching aperture 46b centrally through this disk. Switch apertures are formed in the base laminate 30 so that when the previously described inserted tester device 15 is combined with base laminate 30, switch apertures 46b and 47 are located directly beneath the distal switch segments 60 and 61 of conductive circuit 18. The preferred geometry for such switch apertures is a notch 47 for the negative switch segment 64 and a circle 46b for the positive switch segment 65.
The switches utilized in the battery tester label are preferably membrane switches such that a switch segment 60 or 61 of conductive circuit 18 overlies apertures 46b and 47 in base laminate 30. Apertures 46b and 47 in base laminate 30 enable contact between conductive circuit 18 and either a battery terminal or can 2 on the other side of base laminate 30. Upon application of a force to a switch segment, such as by applying finger or thumb pressure at switch segments 64 or 65, a portion of the switch segment is pressed or deformed through the opening in base laminate 30 to contact the battery terminal or can 2. Upon release of the pressure, the portion of the switch segment resiliently "springs" away from and, thus, out of electrical contact with the battery terminal or can 2. This configuration is referred to herein as "switchably connected."
A significant advantage provided by the present invention battery tester label is the absence of electrically conductive layers or members to electrically connect and disconnect the tester, i.e., conductive circuit 18, to and from the battery. This is remarkable and of significant benefit particularly when manufacturing a battery tester label in large volumes and at a high rate. This advantage of eliminating otherwise necessary electrically conductive switching components is achieved in part by providing a first switch 64 which is disposed very near a battery terminal, such as negative terminal 4. Such close proximity eliminates the need for additional conductive elements to electrically connect an end of circuit 18 to the negative battery terminal. It is most preferred to fold or shrink the peripheral edge of label 10 over the battery end at which the negative terminal is disposed, as illustrated in FIG. 1.
The tester device 15 is combined with base laminate 30 as follows and as best shown in FIG. 8. The tester device is positioned onto or adjacent base laminate 30 so that switch segments 60 and 61 of conductive circuit 18 overlie switch apertures 46b and 47, respectively. Tester device 15 is oriented such that the layer of pressure-sensitive adhesive 16 (the release liner having been removed if previously applied) is facing base laminate 30. Upon application of sufficient pressure to tester device 15 and base laminate 30, the two assemblies are securely attached to each other via adhesive 16, and form the preferred battery tester label 10 of the present invention. Optionally, a clear laminating adhesive 52 is deposited upon the outward facing surface of the resulting tester label as illustrated in FIG. 2, and a clear film 54, such as polyvinyl chloride or polyester, is applied over the coating and the resulting assembly cured. A coating of adhesive 52 and film 54, when applied onto the tester label, provide protection for the tester device and components thereof. It is most preferred that the transparent protective layer resulting from adhesive coating 52 and film 54 is deposited upon the battery tester label prior to application of the tester label to a battery.
The resulting battery tester label 10 is appropriately die cut to the size of the battery desired. Upon removal of excess trimmed label, a plurality of individual tester labels are left remaining on the release liner previously applied to substrate 34 of base laminate 30. The liner and label array may then be cut into strips and wound into a roll and stored for subsequent application to batteries.
The substrate layer utilized for either or both the base layer substrate 34 and the tester device substrate 20 can be made of any desired dielectric polymer material. It is preferable to use a dielectric polymer material that will shrink when assembled on a battery. Generally, polyvinyl resins, polyolefin resins, polyester resins and the like would be suitable. Specific examples include polyvinyl chloride, polyethylene and polypropylene. It is contemplated that substrate 20 could also be formed from other dielectric materials besides plastics such as paper or other cellulose-based materials. The thickness of the substrate layers is not particularly limited, but is preferably in the range of from about 0.0005 to about 0.005 inch, and most preferably from about 0.001 to about 0.003 inch.
The previously described indicator layer 24 in the inserted tester device 15 comprises a thermally sensitive material for indicating the capacity of the battery. The preferred thermally sensitive materials change color in response to a temperature change, which change is readily viewable by a consumer. Thus, the consumer, based on the color change, can determine whether the battery is good or needs to be replaced. Examples of such thermally sensitive materials include liquid crystal materials and thermochromic inks. Examples of suitable liquid crystal materials are of the cholesteric type, such as cholesteryl oleate, cholesteryl chloride, cholesteryl caprylate and the like. The indicator material could change from colored to colorless, colorless to colored, or from one color to a second color. A tri-color material could also be used. The preferred battery tester 10 shown in FIGS. 1-8 utilizes an indicating material which changes from colored to colorless upon activation to reveal indicia 23 underneath the indicator material 24.
Indicating materials, such as thermochromic inks, can be used singly or in combination. For example, in one embodiment different layers of the indicating material are employed. The layers are activated at different temperatures or states and can be designed to change different colors at different temperatures. For example, the layer of indicating material activated at the highest temperature will preferably be the bottom layer, i.e., closest to the battery, and the outer layers are arranged in decreasing temperatures of activation with lowest temperature material in the outermost layer, and so, readily viewable at the exterior of the battery.
Either one or both switch segments 60 and 61 of conductive circuit 18 can be out of contact with the respective terminals of the battery so that the tester circuit is open. In one embodiment of the invention, one of the switch segment ends is permanently in electrical connection with one terminal of the battery, while the other switch segment end is positioned out of contact with the other battery terminal. By forcing the switch segment end into contact with the other battery terminal, the switch is closed and the tester circuit is completed to test the battery. The most preferred embodiment is to utilize a dual switch tester as shown in the accompanying drawings.
The labels useful in this invention can also comprise additional electrical and thermal insulative layers, printing layers, protective layers and the like. Suitable materials for use as the different layers are those typically used in battery labels and include plasticized or unplasticized polyvinyl chloride (UPVC), polyesters, metallic films, paper and the like. The tester label can be in the form of a shrinkable tube label in which a battery is encased.
The battery tester label of the present invention is preferably applied to a battery as follows. A previously assembled tester device 15, having its underside containing pressure-sensitive adhesive 16 exposed, is aligned with a previously formed base laminate 30 (disposed upon a releasable liner) such that the electrically conductive circuit 18 of the inserted tester device is positioned to contact the thermal insulation 44 of base laminate 30. Upon application of sufficient pressure, the respective layers are secured and joined to one another via pressure-sensitive adhesive 16 disposed on the mating surface of tester device 15. The resulting battery tester label 10 is then attached to the outer periphery of a battery can 2 by removing the liner of base laminate 30 to expose adhesive 32 on the underside of label 10 and contacting the underside of base laminate 30 to the battery can 2. FIG. 7 (not to scale) illustrates a typical cross section of the battery and label assembly 1. It is also possible to produce the tester label of the present invention and apply such to a battery without using preassembled tester device and/or base laminate subcomponents. In another embodiment, the battery and tester label assembly is formed by combining the tester device 15 and base laminate 30 as previously described. The resulting label is then itself stored, such as on a releasable liner in a wound roll, until needed.
The present invention also enables the production of multiple tester label assemblies. That is, a plurality of tester devices 15 can be aligned and mated with a plurality of base layer components, i.e., regions of thermal insulation, switch throw pads, and switch apertures, disposed upon and defined within a common base layer to form a plurality of battery tester labels 10. The resulting set of multiple label assemblies can then be stored for subsequent use, or separated into smaller groups of multiple label assemblies or into individual battery tester labels.
In the most preferred embodiment, a series of battery tester labels 10, as illustrated in FIG. 9, are formed on a common releasable liner 70 for subsequent application to batteries. In this most preferred process, an array of tester devices 15 is provided, each tester device formed as previously described and disposed upon a common releasable liner (not shown). A base laminate 30 is provided comprising a dielectric substrate 34, a liner 70 that is releasably secured to the underside of the substrate such as by previously noted pressure-sensitive adhesives, and a plurality of regions of thermal insulation 44 disposed on substrate 34. A plurality of apertures 46b and 47 are formed in the base layer through preprinted switch pad 42, in the case of aperture 46b. The arrays of base layers and tester devices are then slit into serial rolls. Upon removal of the releasable liner from the serial roll of tester devices, thereby exposing adhesive 16 on the underside of substrate 20, the tester devices 15 are oriented with base laminate 30 such that each conductive circuit (not shown) of the tester device roll faces a corresponding region of thermal insulation 44 of the base laminate 30, and so that the switch segments of each conductive circuit directly overlie a corresponding pair of apertures 46b and 47 formed in the base layer. The roll of tester devices is then affixed or otherwise secured to the base laminate, for instance by adhesive 16, to form a roll of battery tester labels 10 disposed on the common releasable liner 70 residing underneath the base laminate.
It is preferable to apply a layer of a transparent adhesive and clear film, such as 52 and 54 illustrated in FIG. 2, upon the exposed face of the array of tester devices 15. Upon sufficient curing, if necessary, the resulting coated assembly is die cut so that each individual battery tester label disposed on releasable liner 70 is correctly sized for the battery to receive the tester label. Die cutting is performed so that releasable liner 70 is not cut, so that the tester labels 10 remain on a common sheet to facilitate handling and storage. The excess trimmed label, referred to as the matrix, is then removed.
Although the tester circuit of the present invention has been described as being implemented in a battery label, it will be appreciated by those skilled in the art that the tester circuit may be provided on the battery packaging, on a separate tester strip, on the housing of a battery pack, or on a device that utilizes batteries.
The above description is considered that of the preferred embodiments only. Modifications of the invention will occur to those skilled in the art and to those who make or use the invention. Therefore, it is understood that the embodiments shown in the drawings and described above are merely for illustrative purposes and are not intended to limit the scope of the invention, which is defined by the following claims as interpreted according to the principles of patent law, including the Doctrine of Equivalents.
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The battery tester of the present invention includes a heating element for generating heat in response to current supplied from a battery, and an indicator provided in proximity to the heating element for providing a visual indication of the remaining capacity of the battery in response to the heat generated by the heating element. The heating element has a display portion and first and second connecting portions on either side of the display portion that are selectively coupled to opposite terminals of the battery. The connecting portions of the heating elements have a lower resistivity than the display portion thereby reducing the heat generated at the switch contacts that are pressed by the user to activate the tester.
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This is a continuation of application Ser. No. 08/055,822, filed Apr. 30, 1993 now abandoned.
BACKGROUND
The present invention relates to a viscoelastic material for use in medical procedures, particularly for placement into the eye during ophthalmic surgical procedures to maintain the shape of the eye and to protect delicate tissue lining the inner walls of the eye.
Cataracts in human eyes, a clouding of the lens which severely effects vision and can render an individual blind, have been removed by surgical procedures for centuries. One of the earliest techniques, known as couching, utilized a long thorn to pry lose the clouded lens. However, safe and effective cataract removal followed by the implantation of an artificial lens has been practiced only since the early 1970's. Prior to then the patient was usually fitted with thick glasses in an attempt to provide at least some acceptable level of vision after removal of the clouded lens. Cataract removal and artificial lens implantation is now performed in the United States on over one million patients per year.
One of the hazards of the cataract removal and lens implantation procedure is the fact that the inside cell layer of the cornea (corneal endothelium) as well as other internal tissues is very sensitive to abrasion or inadvertent contact. In particular, damage to, or removal of, the cells on the cornea may compromise corneal physiology and lead to corneal edema, opacification and eventually complete loss of the cornea.
As a result, a great deal of effort has been devoted to protecting the corneal endothelium, during cataract surgery. In particular, various different materials have been injected into the anterior portion of the eye including balanced salt solution, an air bolus (both of limited utility as they are easily dispersed from the eye) and viscoelastic materials. Viscoelastic materials prepared from various naturally occurring substances or synthesized in the laboratory induce sodium hyaluronate, chondroitin sulfate and combinations thereof, cellulosic materials, and polymers based on acrylamide. While viscoelastic materials remain in the eye and offer better protection to the ocular tissue, each of the prior used viscoelastics have disadvantages which included allergic reactions, neurotoxic impurities, inadequate viscosity or viscoelasticity, unacceptable levels of particulate materials, gels or bulky polymer chains which enter and plug the trabecular mesh work causing excessive intraocular pressure in the eye, variation in properties from batch to batch due to variability of naturally occurring raw materials, and excessive cost. These materials, because they result in increased ocular pressure also generally require that they be irrigated from the eye. Further, hyaluronic acid based materials also require refrigerated storage and may have a limited shelf life.
The use of prior art hydroxypropylmethylcellulose solutions in animal toxicity studies has shown that these materials are generally non-toxic both locally and systemically when ingested or injected into various animal systems. Also, various prior art HPMC formulations in intraocular use have been shown to be non-toxic to endothelial cells and to result in only minimal and transient intraocular pressure rise and to clear the eye rapidly.
Dow Chemical Company has studied the toxicology and metabolic fate of HPMC polymers extensively to support the use of their Methocel trademark HPMC. These studies have shown that the polymer is non-pyrogenic, non-immunogenic, non-cytotoxic, non-toxic in extended animal metabolic studies, is not metabolized and is rapidly eliminated after ingestion. The majority of these reports deal with the tolerance of animal systems to HPMC via feeding studies. However, a review of the data on toxicology reveals that intradermal and vascular injections of HPMC polymers in mice and rats do not provide any evidence of toxicity, teratogenicity, or other negative metabolic effects. It is concluded from these reports that HPMC polymers do not interfere with normal animal metabolism, are not themselves metabolized, and are filtered from the bloodstream into the kidneys and excreted without negative effects to the animal systems studied. In confirmation of these studies, the Dow Chemical Company Methocel brand of HPMC has been issued Drug Master File No. 76 by the Food and Drug Administration.
Robert et al have provided evidence of the lack of systemic toxicity of intraocular injections of 2% HPMC solutions into rabbit eyes. (Robert, Y., Gloor, B., Wachsmuth, E. D., Herbst, M., “Die Uberprufung der Vertraglichkeit von Intraokular injizerter Hydroxypropylmethylcellulose im Tierversuch,” Klin Montasbl Augenheilkd, 192:337-339, 1988.) These researchers injected aliquots of a 2% HPMC solution into rabbit anterior chambers, and into rabbit posterior chamber vitreous, and followed the course of intraocular and systemic changes for 12 days. They found no intraocular changes, and also no systemic changes. These results clearly demonstrate that the HPMC polymer is non-toxic to the animal eyes and is systemically non-toxic in rabbits.
The available evidence in the literature demonstrates that HPMC is not metabolized by mammalian systems, is non-toxic on oral, intradermal, intraocular and vascular introduction, and is safely cleared from the systems via excretion in the urine. Thus it may be inferred from these reports that HPMC solutions are safe for human intraocular and systemic use.
HPMC solutions have been used as intraocular visco-elastic surgical fluids for several years in Europe, the USA, and elsewhere. The literature reports on the clinical use of HPMC solutions reflect a general consensus that these polymers are safe and effective for use as ophthalmic viscoelastic surgical fluids, easy to use and do not result in inflammatory reactions or excessive intraocular pressure postoperatively, but are only marginally equivalent to hyaluronic acid products in ability to maintain the chamber and protect the endothelium during cataract surgery.
However, the use of HPMC solutions for intraocular surgery has been criticized by Rosen. (Rosen. E. S., Gregory, R. P. F., Barnett, F., “Is 2% hydroxypropyl methylcellulose a safe solution for intraoperative clinical applications?” J. Cataract and Refractive Surgery, 12:679 (1986); Rosen. E. S., “The use of hydroxypropyl methylcellulose in extracapsular cataract extraction with intraocular lens implantation,” Am J. Ophthalmology, 103:727 (1987)). Rosen bases his criticism on the microscopic examination of HPMC preparations produced by hospital pharmacies in Europe. Rosen reports that significant amounts of debris and particulates are found in these and other commercial preparations, which could lead to problems during surgical use. Further, Rosen states that current attempts to filter HPMC have been ineffective and “it seems to be impossible to prepare HPMC solutions for clinical use without a degree of particulate vegetable matter content.” However, Momose et al report that counts of the particulate levels by automated laser particle counters reveal that 2% methylcellulose preparations prepared in his institute actually had fewer large particles than commercially available hyaluronic acid preparations. (Momose, A., Baba, T., Kasahara, A., “Particles in Viscosurgical Materials,” Journal of the Eye, 5:314 (1988)).
Fernandez-Vigo et al. reported in 1989 that the half life of clearance of various concentrations and viscosities of HPMC solutions from rabbit eyes was in the range of 3 to 4 ½ hr. (Fernandez-Vigo, J. F., Refojo, M. F., Jumblatt, M., “Elimination of hydroxypropylmethylcellulose from the anterior chamber of the rabbit,” J. Cataract Refractive Surgery. 15:191 (1989)). Their experiments involved introduction of large doses of relatively low molecular weight HPMC solutions (86,000 or 120,000 Daltons) into rabbit eyes, and assays of the HPMC remaining after various periods of time. They found that after 24 hr., there were no detectable amounts of HPMC remaining in the samples of aqueous removed from the rabbit eyes. They concluded that HPMC clearance was complete within 24 hrs. The authors also concluded that the removal of the HPMC from the eye was by the normal trabecular meshwork outflow system, with no metabolic degradation within the eye. Their report further found no damage to endothelial cells, only a transient increase in intraocular pressure after the injection of the HPMC solutions within the eye, and no long term inflammatory reactions.
Jacobi et al reported that their studies of the intraocular (anterior chamber and intravitreal) injections of HPMC solutions into the rabbit resulted in no inflammatory reactions, only transient rise in intraocular pressure, and rapid clearance from the eye. (Jacobi, K. W., Schott, K., Gloor, B., “Kongress der Deutschen Gesellschaft fur Intraokularlinsen Implantation,” Berlin, Springer-Verlag, 1987 pp 86-89.) They concluded that the HPMC was cleared from the eye by the normal outflow mechanism, and was diluted into the bloodstream.
These published evaluations of the rapid clearance of HPMC polymer from the eye demonstrate that this polymer does not interfere biochemically with the normal aqueous clearance through the trabecular meshwork, and only raises intraocular pressure transiently due solely to its high molecular weight and viscosity.
However, these solutions still contain unnecessarily high levels of particulate contamination. Additionally, the prior art solutions are composed of low molecular weight HPMC materials and thus, to obtain the desired viscosity higher concentrations of HPMC must be used, thus increasing the possibility of introducing a higher percentage of contaminants. Further, because the polymers have a lower molecular weight, the solutions may not have a suitable viscoelasticity. The prior art ophthalmic HPMC solutions, because they were prepared from lower molecular weight materials had viscosities of about 4,000 to 5,000 cps at 25° C. As a result, these materials also were not very viscoelastic. Additionally, they had high levels of particulate material. As a result, they could not be filtered through a 0.5 μm filter as the filter pores became immediately plugged as the material passed through the filter. A further problem with prior art HPMC solutions was the tendency to dehydrate when autoclaved at temperatures above 100° C. resulting in large amorphous aggregates. Most of these aggregates would rehydrate upon cooling but a significant portion remained permanently insoluble. Prior art autoclaving and cooling procedures following autoclaving also resulted in the release and suspension of gas bubbles in the resultant gels and the compositions did not have a uniform viscosity distribution, the more viscous, higher molecular weight materials tending to settle to the lowest point in the container.
Thus there is a need for a low cost, stable, high viscosity material for use in ocular surgical procedures which is nontoxic and allergy free and is free of particulate material or gels which can cause an increase in intraocular pressure. In particular, there is a need for a high viscosity, low HPMC concentration solution prepared from high molecular weight material which is substantially free of harmful particulate material.
SUMMARY
These needs are met by the present invention which comprises a viscoelastic material composed of hydroxypropyl-methylcellulose in an aqueous physiological solution and a process for preparing the solution. The solution also contains salts of sodium, potassium, calcium and magnesium whose concentrations are chosen so that the formulation has an osmolality slightly greater than human aqueous, a calcium concentration almost identical to that of human aqueous, and a pH approaching physiological. Additionally, the composition is purified to remove inflammatory materials and processed to tailor the weight average molecular weight to greater than 375,000 but less than 420,000 and a static viscosity of 25,000 to 40,000 centipoise at 25° C. as measured by a capillary viscometer.
These and other features, aspects and advantages of the present invention will become better understood with reference to the following description and appended claims.
DESCRIPTION
The present invention consists of a viscous, aqueous solution of a hydroxypropylmethylcellulose (HPMC) for use in ocular applications and the method for preparation of these unique solutions. Other components of the solutions embodying features of the invention can be NaCl, KCl, CaCl 2 , MgCl and Na based buffers such as NaC 2 H 3 O 2 or Na 3 C 6 HO 7 . The concentrations of the components of the HPMC solutions were derived to have an osmolality and pH based on the aqueous solution in the human eye. The osmolality of human aqueous is about 305 mOsm/kg (±25 mOsm/kg). Accordingly, the NaCl concentration in the viscous solution was adjusted to be about 325 mOsm/kg (±25 mOsm/kg) to minimize swelling of the corneal endothelial cells during use in the eye. The pH of human aqueous is about 7.4; the pH of the HPMC solution was adjusted to a final pH of about 7.2±0.2. The concentration of the other salts and the buffering agents were chosen to be similar to that of commercially available intraocular irrigating solutions and viscoelastic surgical fluids.
In formulating the solutions of the invention, one of the concerns was the formation of precipitates during use as was reported for a commercially available chondroitin sulfate/sodium hyaluronate solution. (Ullman, S., Lichtenstein, S. B., Heerlein. K., “Corneal Opacities Secondary to Viscoat,” J. Cataract and Refractive Surgery, 12:489 (1986)). This was accomplished by keeping the calcium concentration to approximately the same level as in human aqueous and avoiding the use of phosphates in the buffering components. This eliminates the possibility of the formation of Ca 3 (PO 4 ) 2 . Tests in rabbit eyes have confirmed the absence of precipitates.
Of particular concern in the preparation of solutions embodying features of the invention was the possibility of inflammatory responses caused by trace impurities in the materials or the presence of particulate contaminates, particularly in the HPMC, which is critical to the invention. Accordingly, extensive steps have been taken to eliminate the undesirable trace contaminates. Additionally, multiple filtration and separation procedures have been utilized to generate HPMC materials having a narrow preferred molecular weight and to eliminate changes in this preferred molecular weight which can result from high temperature sterilization of the solution.
Prior HPMC solutions had viscosities from 4,000 to 5,000 cps at 25° C. In contrast thereto, viscosities in the range of 15,000 to 40,000 cps can be obtained by using a blend of a high and a low molecular weight HPMC material. The higher molecular weight material results in the much improved viscoelasticity. A preferred blend consists of a 2:1 ratio of a 85,000 average molecular weight material with a 220,000 average molecular weight material, the initial composition having about 3% HPMC. Processing as described below significantly reduces the concentration of the low molecular weight materials so that the average molecular weight of the remaining material ranges from 250,000 to about 420,000. However, the preferred range of the average molecular weight of the HPMC remaining in the solution is from about 375,000 to no greater than about 420,000 Daltons and the preferred solution viscosity is from about 25,000 to about 40,000 centipoise.
A preferred starting material for preparing the high viscosity, toxicity and particulate free solutions of the invention are HPMC polymers available from Dow Chemical Company under the tradename Methocel ®. In contrast to the prior art HPMC solutions, a particular preferred starting materials is a blend of a low molecular weight HPMC (Methocel E10M) and a high molecular weight HPMC material (Methocel K100M) the two materials being initially blended in the ratio of 2:1. The two materials are reported to have the following viscosities:
Methocel E10M: 2% viscosity=14,000 cps
Methocel K100M: 2% viscosity=100,900 cps
While the initial combined concentration of the HPMC materials is about 3.0%, after the filtration procedures are completed the concentration of the HPMC materials in the solution is reduced to about 2.0 to 2.5%.
Processing steps which result in the unique properties of the solutions embodying features of the invention are as follows:
Removal of Particulate Contamination—The previous technique used to filter HPMC solutions was to force the solution through a 0.5 μm filter at a high pressure. However, since a significant portion of the material to be removed was gelatinous in nature the pressure merely reshaped the gels and forced them through the pores of the filter. In addition, at very high pressure, the filter would plug up and only salt solution would be forced through the filter. It was discovered that greatly improved filtration could be obtained by raising the temperature of the solution to about 40°-45° C. resulting in a significant reduction in viscosity, thus requiring less pressure. Secondly, the solution was passed through a series of successively smaller filters so that the larger gels and particles could be removed before they reached the smallest filters. A suitable filtration procedure included passing the solution at least twice through a cascade consisting of a 50 μm, 25 μm, 10 μm, 5 μm, 1 μm and a 0.5 μm filters. This procedure eliminates the need for excessive pressure during filtration and virtual eliminates all material above 0.5 μm in size.
Processing described below significantly reduces the concentration of the low molecular weight materials.
Purification—In order to remove all undesirable low molecular weight material the dry HPMC blend is suspended with constant stirring in a salt solution at 60° C., which is lower than the literature recommended temperature of 100° C. for forming solutions. This allows the polymer granule pore structure of the HPMC to expand and the lower molecular weight materials to solvate. When the HPMC is solvated at the higher temperature the low molecular weight material becomes trapped in the resultant gel and can't be readily separated. Once the low molecular weight material has been solvated the composition can be raised slowly with constant stirring to around 100° C. Stirring is then terminated and the high molecular weight material is allowed to settle to the bottom of the mixing chamber. Once the settling has ceased the supernatant liquid containing the undesirable low molecular weight material is carefully removed and discarded. The process is repeated several times, four times appearing to be optimal. This procedure removes the low molecular weight contaminates and pyrogens which, in turn, results in a higher viscosity final solution.
Removal of Aggregates Caused by Autoclaving—An intermediate (midprocess) autoclaving and filtering step is performed to eliminate aggregates which don't readily rehydrate. The procedure consisting of heating the composition to 115° C., in an autoclave cooling with rapid stirring to 95° C. to break up aggregates and assure homogeneous rehydration, further cooling to 40° C., and filtering through a 1.0 μm filter to remove un-dissolved HPMC aggregates. This eliminates the possibility of aggregates forming during the final autoclaving step. This step also eliminates any bioburden so that solution storage problems caused by bacterial contamination don't arise.
Elimination of Non-homogeneous Viscosity Regions—If the product is cooled too rapidly after final autoclaving in the syringe, the more viscous material tends to settle to the bottom of the delivery syringe resulting in a layering of the composition. In contrast, if the solution filled syringe is allowed to cool slowly from 90° C. to room temperature at a rate of less than about 6° C. per hour a very uniform gel is formed.
Elimination of Bubble Formation—Dissolved gases released during processing become entrapped in the viscous solution. If they are not removed prior to the final product packaging stage the final product will include gas bubbles which can obscure the physicians visualization of the surgical site during the ophthalmic procedure.
EXAMPLE 1
The following example embodies features of the present invention.
a) 30 liters of a salt solution was prepared by adding 174 grams of NaCl, 22.5 grams of KCl, 14.4 grams of CaCl 2 .2H 2 O, 9.0 grams of MgCl.6H 2 O, 117.0 grams of NaC 2 H 3 O 2 .3H 2 O and 51.0 grams of Na 3 C 6 HO 7 .2H 2 O to distilled water and the pH was adjusted to 8.70 using NaOH. b) Five (5) liters of the salt solution were then heated to 60° C. and a mixture of 300 gr of Methocel E10M and 150 gr of Methocel K100M were stirred into the salt solution and held at temperature for 20 minutes. The composition was then heated with stirring to 95° C. and held at temperature for 20 minutes. Stirring was then discontinued and the solution allowed to settle for about 15 minutes at which point the supernatant liquid was aspirated off. c) The polymer remaining after removal of the supernatant was then resuspended in 4.0 liters of the salt solution at 100° C. and stirred for ten minutes. The solution was then allowed to settle for 15 minutes followed by aspiration of the supernatant. The procedure was then repeated two more times using 3.0 liters of salt solution for resuspension. d) After removing the supernatant following the third resuspension the remaining polymer was again resuspended in 15 liters of the salt solution at 100° C. and stirred for 5 hours while cooling slowly to 40° C. The solution was then held without stirring for 5 hours, allowing a thick gel to form. e) While maintaining 40° C., the gel was filtered through a series of filters having a porosity of 50 μm, 25 μm, 10 μm, 5 μm, 1 μm and 0.5 μm. At least two of each filter size were used. f) The material that passed through the final filter was heated to 115° C. in a pressure autoclave (12 psi.) for 25 minutes, cooled slowly for about 30 minutes to 99° C., removed from the autoclave and cooled over a five hour period to 40° C. and then held for 5 hours at 40° C. while being maintained under sterile conditions. g) While maintaining sterility, the solution was passed through a 1.0 μm filter, collected in a 10 liter vessel and, while being maintained at 40° C., subjected to a vacuum for 10 hours to outgas any dissolved nitrogen. The degassed, sterile solution was then dispensed aseptically into storage containers which were stored at 0° to 4° C. h) The process was completed by aseptically dispensing the stored solution into syringes which were autoclaved at 121° C. for 20 minutes, cooled to room temperature at 6° C. per hour, and then pressurized for 24 hours at 20 psi.
The resultant product was a clear, viscous solution having a zero shear viscosity of 40,000 cps, an average molecular weight of 409,800, an HPMC concentration of 2.32% and a refractive index of 1.333.
The solution prepared in Example 1 was tested both biologically and in animals. A single maximum dose evaluation was conducted in the rabbit eye model, with evaluation of intraocular pressure, endothelial cell status, and general inflammatory response. The rabbit eye model is commonly used for evaluation of endothelia cell, intraocular pressure, and inflammatory response to viscoelastics as well as acute endothelial cell toxicity studies. Other tests were performed to evaluate systemic antigenicity, cytotoxicity, and irritability in animal models, and mutagenicity and hemolytic activity in in vitro models. The results are summarized below:
Test Result Cytotoxicity, Agarose Overlay Non-cytotoxic Cytotoxicity, MEM Elution Non-cytotoxic Intraocular Irritation in the Rabbit with tonometry and Non-irritant and specular photography non-toxic Mutagenicity, Ames Soluble Chemical Non-mutagenic Sensitization (Maximization Method), in Guinea Pig Non-sensitizing Hemolysis, In vitro Direct Contact Non-hemolytic Systemic Antigenicity in Guinea Pig Non-antigenic Primary Skin Irritation Rabbit Non-irritant Acute Oral Toxicity Non-toxic Acute Intraperitoneal Toxicity in Mouse Non-toxic
It was concluded from these studies that the HPMC solution is non-toxic, non-mutagenic, non-antigenic, non-hemolytic, non-irritating, non-inflammatory to ocular tissues, and did not cause a dangerous intraocular pressure rise. Further, the material had no effect on the ability of the cells to undergo normal mitotic division and, subsequently, normal cellular growth. Intraocular pressure increases in the rabbit from a maximum dose were transient and, in all cases, were within the normal range within a 24 hour period. Endothelial cells were not affected
Although the present invention has been described in considerable detail with reference to a certain preferred versions and uses thereof, other versions and uses are possible. For example, while the viscoelastic solution is designed for ophthalmic applications, it may be used for other physiological applications such as lubricating bone joints (knees, hips, etc.), preventing tissue adhesion following surgical procedures, or as a carrier for nutritional products or cosmetics. Also, the viscosity of the solutions can be varied by selecting different molecular weight starting materials or blending the materials in different proportions or using higher concentrations of the starting materials. While a particular blend of HPMC materials is disclosed the combination selected and concentrations can depend on the desired properties of the end product. Therefore, various different HPMC may be used. Further, it is not necessary that two different materials be used. One HPMC material may be processed as described above or a blend of more than two materials may be used. Additionally, different salts and buffers can be used for different applications and other materials can be added to the solutions for special purposes. Further, one skilled in the art will recognize that a different combination of filters may be used to remove debris and, depending on the dimensions and nature of debris in the composition, one or more of each size of filter can be used. Also, the order in which various processing steps are performed may be interchanged. Therefore, the spirit and scope of the appended claims should not be limited to the description of the preferred versions contained herein.
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A viscoelastic composition for injection into a human eye comprised of about 2.0 to 2.5 percent of hydroxypropyl methylcellulose dissolved in a physiological salt solution, the composition, the composition having a viscosity from about 15,000 to about 40,000 centipoise and the hydroxypropyl methylcellulose having a molecular weight from about 220,000 to less than about 420,000 Daltons, the composition being free of debris or gels greater than 0.5 μm. Also described is a process for preparing the clean, high molecular weight hydroxy propylmethyl cellulose composition.
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BACKGROUND OF THE INVENTION
[0001] This invention relates to a washing machine agitator having a helical rib and a method for using same.
[0002] U.S. Pat. Nos. 5,829,277 and 6,220,063 both disclose a washing machine having a spherical basket for containing the fabrics to be washed. In the spherical basket are a pair of circular concave agitators nested against the opposite side walls of the spherical agitator basket.
[0003] In order to achieve satisfactory cleaning of the fabrics being washed, it is desirable to achieve “turn over” of the fabrics being washed. The two agitators accomplish this by lifting the fabrics and causing them to be dropped downwardly towards the center of the washing basket. It is therefore desirable to provide agitators having the capability of lifting the fabrics during their rotation so that the fabrics are lifted up and dropped down the center to achieve the turn over necessary for satisfactory cleaning.
[0004] Therefore a primary object of the present invention is the provision of an improved washing machine agitator having a helical rib.
[0005] A further object of the present invention is the provision of a washing machine agitator having a helical rib which commences at an inner central point adjacent the rotational axis of the agitator and progresses helically and radially outwardly therefrom to an outer edge.
[0006] A further object of the present invention is the provision of a spiral rib or baffle which smoothly engages the fabrics near the center of rotation of the pan and as the pan rotates the engagement point increases in radius.
[0007] A further object of the present invention is the provision of a washing machine agitator having a helical rib or baffle that gives the fabrics being washed a smooth application of force to turn the load over with a minimum of tangling.
[0008] A further object of the present invention is the provision of a washing machine agitator having a helical rib with two tapered surfaces which are joined along a helical ridge, one of the surfaces having a sharper angle of inclination than the other of the surfaces.
[0009] A further object of the present invention is the provision of an improved washing machine agitator that is economical to manufacture, durable in use, and efficient in operation.
BRIEF SUMMARY OF THE INVENTION
[0010] The foregoing objects may be achieved by a washing machine comprising a washing machine cabinet. A wash basket is mounted within the washing machine cabinet for rotation about a wash basket axis. The wash basket includes an opening for placing materials to be washed within the wash basket.
[0011] A first agitator is mounted in the basket for rotation about a first agitator axis that extends in a direction different from the wash basket axis. The first agitator includes a first helical rib thereon for engaging and agitating the materials to be washed within the washing basket when the first agitator is rotating about the first agitator axis.
[0012] According to another feature of the invention, a second agitator is mounted within the basket for rotation about a second agitator axis extending in a direction different from the wash basket axis and the first agitator axis. The second agitator includes a second helical rib thereon for engaging and agitating the materials to be washed within the wash basket when the second agitator is rotating about the second agitator axis.
[0013] According to another feature of the invention the first and second agitators each include a concave surface and the first and second helical ribs protrude from the concave surfaces of the first and second agitators respectively.
[0014] According to another feature of the invention an agitator drive mechanism is connected to the first and second agitators for driving first and second agitators in opposite rotational directions.
[0015] According to another feature of the present invention, the first and second helical ribs extend in first and second helical directions that are opposite to one another.
[0016] According to another feature of the present invention each of the first and second helical ribs commence adjacent the first and second agitator axes respectively and extend in an outward radial helical direction therefrom.
[0017] According to another feature of the present invention, the basket includes a concave interior surface and each of the first and second agitators include a convex surface opposite from the concave surface thereof. The convex surfaces of the first and second agitators face toward the concave interior surface of the basket.
[0018] According to the method of the present invention, the fabrics being washed are lifted with the first and second helical ribs on the first and second agitators during rotation of the first and second agitators about the first and second agitator axes respectively. The helical ribs then drop the fabrics after they lift the fabrics whereby the fabrics will turn over and fall into the center portion of the basket.
[0019] According to another feature of the method of the present invention, the first and second agitators are rotated in first and second opposite rotational directions.
[0020] According to another feature of the method of the present invention, the rotational directions of the first and second agitators are reversed.
[0021] According to another feature of the present invention, each of the first and second helical ribs include first and second side walls which angle toward one another and are joined together at an elongated helical rib. The first side wall has a first angle of inclination and the second side wall has a second angle of inclination that is steeper than the first angle of inclination. The method further comprises rotating the first and second helical ribs about the first and second agitator axes respectively in a rotational direction that causes the first side wall of the first and second helical ribs to engage and lift the fabrics.
[0022] According to another feature of the present invention the rotational directions of the first and second helical ribs are reversed so that the second side walls of the first and second helical ribs engage and lift the fabrics.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] [0023]FIG. 1 is a perspective view of the washing machine of the present invention.
[0024] [0024]FIG. 2 is a vertical sectional view of the washing machine shown in FIG. 1.
[0025] [0025]FIG. 3 is a perspective detail showing one of the agitators and the gear mechanism for rotating the agitator.
[0026] [0026]FIG. 4 is a perspective view of one of the agitators of the present invention.
[0027] [0027]FIG. 5 is a perspective view of the second of the agitators of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0028] Referring to the drawings the numeral 10 generally designates the washing machine of the present invention. Washing machine 10 includes a cabinet 12 , a control panel 14 , an access opening 15 (FIG. 2), and a door 16 which is hinged to move from an open to a closed position over the access opening 15 .
[0029] Mounted within the lower end of cabinet 12 on a web 23 is a reversible motor 18 of conventional construction. Motor 18 has an output shaft 20 which extends upwardly through a bearing 22 in the web 23 . Motor 18 is attached to the web 23 by brackets 24 . Shaft 20 extends upwardly through a clutch 26 shown schematically in FIG. 2. Clutch 26 is adapted to respond to rotation of the shaft 20 in a first direction to drive a hub 34 which is connected to a spherically shaped basket 40 . Rotation of the shaft 20 in the opposite direction disengages the clutch and permits the shaft 20 to rotate independently of hub 34 .
[0030] A tub 28 includes at its lower end a basin 30 for holding washing fluid. Extending upwardly from basin 30 is a spherically shaped lower tub portion 31 . The tub 28 extends upwardly to the top of basket 40 and terminates at an upper edge 32 . A tub cover 33 is attached to the upper edge 32 and extends inwardly over a portion of the top opening 41 of basket 40 . The tub cover 33 is cooperable with access opening 15 for providing an access into basket 40 .
[0031] Hub 34 includes a central bore 36 which receives output shaft 20 . Output shaft 20 is attached at its upper end to a drive gear 38 .
[0032] Hub 34 extends through the basin 30 by way of rotary seal arrangement shown schematically at 43 in FIG. 2, and is attached to the basket 40 which includes a spherical portion 42 and a gear box portion 44 at its lower end. Extending over the top of the gear box portion 44 is a curved wall 46 which forms an extension of the spherically shaped walls of spherical portion 42 . Curved wall 46 includes a first gear hole 48 and a second gear hole 50 therein. The space below the curved wall 46 comprises a gear box chamber 52 for housing the gear drive to be described hereafter.
[0033] Basket 40 includes a plurality of perforations or apertures 54 in its spherically shaped walls 42 for permitting fluid communication between the interior of basket 40 and the tub 28 . Thus as fluid is introduced into the basket 40 , the fluid flows through the apertures 54 and enters the tub 28 also. As further depicted in FIG. 2 the web 23 , drive motor 18 and the washing assembly are shown suspended from the inside of cabinet 12 by a conventional hung strut suspension system 25 which is of known construction and does not comprise part of the instant invention.
[0034] Agitators or lifters 56 , 58 each include a circular peripheral rim 60 and a circular gear 62 which extends circumferencially around the back side of the rim 60 . Agitators or lifters 56 , 58 are each rotatably mounted to the basket 40 by an agitator mount assembly 64 . The agitator mount assembly 64 is shown and described in U.S. Pat. No. 6,220,063, and is adapted to permit the agitators 56 , 58 to rotate about the axes identified by the numerals 116 , 118 respectively.
[0035] The individual structure of agitator 56 is shown in FIG. 4 and of agitator 58 is shown in FIG. 5. Each agitator 56 , 58 includes a concave surface 66 (FIG. 2) which is presented inwardly toward the interior of the tub 40 (FIG. 2). At the center of the concave surface 66 is a central bulge 68 , and commencing from this central bulge is a helical rib or baffle 70 . Each helical rib 70 includes a central starting point 72 which commences adjacent the rotational axes 116 , 118 (FIG. 2) respectively of agitators 56 , 58 . The helical rib or baffle 70 progresses in an outward radial direction and also in a helical direction to an outer peripheral end 74 which is located adjacent the rim 60 of the agitators 56 , 58 . Each helical rib 70 includes a first wall 76 and a second wall 78 which are tapered toward one another and which join together at a helical ridge 80 . As can be seen in FIG. 2 the first wall 76 is inclined at a less steep angle of inclination than the second wall 78 . As can be seen in FIGS. 2, 4 and 5 the ridge 80 commences in the center bottom of agitators 56 , 58 , and progresses upwardly to the approximate level of rim 60 of agitators 56 , 58 . Ridge 80 also progresses in a spiral or helix from the center to the outer rim 60 of agitators 56 , 58 .
[0036] A pair of spaced apart wedges 81 are positioned on the outer edge of each agitator 56 , 58 as best seen in FIGS. 4 and 5. Each wedge has a steep surface 83 and a less steep surface 85 . The steep surfaces 83 of wedges 81 are facing toward the more steep wall 78 of helical rib 70 . These wedges 81 facilitate tumbling of small loads of fabric. Each of the agitators 56 , 58 is provided with a plurality of holes 87 that permit flow through of washing fluid.
[0037] Each of the agitators 56 , 58 includes a convex back surface 82 which is opposite from the concave surface 66 . The convex surface 82 nests against the concave surface 84 of spherical basket 40 . The helical direction of the first agitator 56 commences at the center and progresses outward in a clockwise helical direction as viewed in FIG. 4. The helical shape of the rib 70 in the agitator 58 is in the opposite direction, commencing at the center and progressing in a counterclockwise direction toward the outer radial rim 60 .
[0038] The spinner rotational position is random. The agitators 56 , 58 preferably rotate in a cooperative rotational direction to cause the clothes load to tumble in one direction as indicated by arrows 86 , 88 in FIGS. 4 and 5 respectively. When rotating in this direction the less steep walls 76 of the two helical ribs engage the fabrics 134 being washed and lift them upwardly as shown in FIG. 2. At the top of the rotational cycle, the fabrics 134 are dropped downwardly in a central direction, and as they are dropped they turn over in the direction indicated by arrows 120 , 122 . This creates the turnover necessary in order to adequately clean the fabrics. It is possible however, to reverse the direction of the rotational movement of the agitators 56 , 58 so that the steeper wall 78 engages the fabrics and lifts them. This imparts a more aggressive cleaning action. If desired, the agitators 56 , 58 can initially be operated in one rotational direction and then reversed.
[0039] Also, the relative positions of the helical ribs 70 in agitators 56 , 58 are preferably set so that agitator 58 points at 12 o'clock and the agitator 56 points at 6 o'clock. This places the two helical ribs 70 , 180° out of phase with one another and results in further agitation of the fabrics for improved cleaning.
[0040] Referring to FIGS. 2 and 3, a gear assembly 92 is housed within the gear box chamber 52 and includes a first driven gear 94 which directly engages the annular teeth of the drive gear 38 . First driven gear 94 is connected to a first agitator gear 96 . An idler gear 100 in turn engages gear 104 which has a second agitator gear 106 on its upper surface.
[0041] In operation shaft 20 drives gear 38 in a clockwise direction indicated by arrow 108 (FIG. 3). This rotates gears 94 , 100 in the directions shown by arrows 110 , 114 respectively. Rotation of gear 94 causes similar rotation of the first agitator gear 96 in the direction indicated by arrow 112 . The first agitator gear 96 engages the teeth of circumferencial gear 62 on the back of peripheral rim 60 of agitator 56 . This causes rotation of the agitator 56 about its axis formed by the agitator mount assembly 64 in the direction shown by arrow 86 .
[0042] Agitator gears 96 , 106 rotate in opposite directions, thereby causing the agitators 56 , 58 also to rotate in opposite directions. Alternatively, gearing can be provided to cause the agitators 56 , 58 to rotate in the same direction if desired or to reverse the rotational direction of agitators 56 , 58 .
[0043] As can be seen in FIG. 2 the water or washing fluid level 126 is at approximately the level of the agitator mounts 64 . The rotation of the two agitators 56 , 58 creates a tumbling action of the fabrics being washed within the washing basket 40 . This tumbling action is facilitated by the helical ribs or baffles 70 .
[0044] The. helical ribs 70 of the present invention provide an improved washing capability. The tumbling action provided by the helical ribs 70 during rotation of the agitators 56 , 58 is a gentle action that minimizes damage and wear to delicate fabrics.-Furthermore, the helical ribs 70 cause a lifting of the washing fluid and improve the cleaning of the fabrics within the basket.
[0045] After the washing cycle has been completed, motor 18 is reversed and the reverse rotation of shaft 20 causes the clutch 26 to engage with the hub 34 , thereby causing the basket 40 to rotate for its spin cycle. During the spin cycle the washing fluid passes outwardly through apertures 54 due to centrifugal force. The fluid within tub 28 is drained away.
[0046] In the drawings and specification there has been set forth a preferred embodiment of the invention, and although specific terms are employed, these are used in a generic and descriptive sense only and not for purposes of limitation. Changes in the form and the proportion of parts as well as in the substitution of equivalents are contemplated as circumstances may suggest or render expedient without departing from the spirit or scope of the invention as further defined in the following claims.
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A washing machine includes a washing machine cabinet. A wash basket is mounted within the washing machine cabinet. A first agitator is mounted in the basket for rotation about a first agitator axis that extends in a direction different from the rotational axis of the wash basket. First agitator includes a first helical rib thereon for engaging and agitating the materials to be washed within the wash basket. A second agitator with a second helical rib may also be contained within the wash basket.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a method for producing (+)-estrone derivatives useful for oral contraceptives by using dicyclopentadiene derivatives as starting materials, and to intermediates which is used for the production of (+)-estrone derivatives.
2. Description of the Prior Art
(+)-Estrone is a compound useful for oral contraceptives, and it has been known from a long time to obtain the compound by methods in which natural materials are used (U.S. Pat. Nos. 1,967,350 (1934) and 135,992 (1962). However, the efficiency and yields of the methods are too inferior to those of synthetic methods to compare with.
Synthetic methods of (+)-estrone whose configuration is a natural type have been developed. Posner et al. (J. Am. Chem. Soc., 108,1239(1986) disclosed that a compound having an AB ring skeleton and a compound having a D ring skeleton which is asymmetrically derived are reacted by an asymmetric Michael addition reaction, and a C ring skeleton is formed by an intramolecular Diels-Alder reaction to construct an estron skeleton having a diastereo selectivity of 91-94%. However, the total yield is low, 6.3%, and the process has inefficiently nine steps.
Moreover, Taber et al. (J. Org. Chem.,52 28(1987)) constructed a β-ketoester having a D ring skeleton by using a camphor derivative as a chiral source, combined the compound with a benzocyclobutene derivative, and constructed a BC ring skeleton by internal cyclization reaction in one step to synthesize (+)-estrone having an optical purity of 91% ee. However, the process has many reaction steps. To construct the β-ketoester, it needs five steps. To synthesize the benzocyclobutene derivative, it needs three steps. To combine the both compounds and to obtain the objective skeleton, it needs three steps. The yield of the ring formation is low, 41%, and the total yield from the β-ketoester precursor is 9.8%. The stereoselectivity of the (+)-estrone is comparatively good, but the efficciency of the process is no good.
Before the present invention, (+)-estrone was much in demand, but it was not provided well.
SUMMARY OF THE INVENTION
As described above, the inventors of the present invention has earnestly studied to attain an object for efficiently obtaining the (+)-estrone derivatives having high optical purities, and they have found that the (+)-estrone is efficiently obtained by using dicyclopentadiene derivative as a starting material.
The present invention is a method for producing (+)-estrone derivatives, characterized in that it comprises starting from (-)-tricyclo [5.2.1.0 2 .6 ] deca-4,8-diene-3-one (1) represented by the formula: ##STR2## reacting the compound (1) with 4-vinyl-7-alkoxy-1,2-dihydronaphthalene (2) represented by the formula: ##STR3## wherein R is alkyl of 1-20 carbon atoms, by employing an asymmetric Diels-Alder reaction, obtaining a compound (3) represented by the formula: ##STR4## wherein R is the same as described above, and obtaining a (+)-estrone derivative represented by the formula: ##STR5## wherein R is the same as described above.
Preferably, in the steps to obtain (+)-estrone derivatives, (4) via compound (3), intermediates are represented by the formulas: ##STR6## wherein R is alkyl of 1-20 carbon atoms.
The reaction steps of the production method of the present invention are as follows: ##STR7##
The starting material of the present invention, (-)-tricyclo [5.2.1.0 2 .6 ] deca-4,8-diene-3-one (1) is obtained by oxidizing dicyclopentadiene with selenium(IV) oxide, reacting the obtained racemic-tricyclo [5.2.1.0 2 .6 ] deca-3-hydroxy-4,6-diene with an acylating agent in the presence of lipase by a transesterification reaction (Japanese Patent Unexamined Publication No. 3-98597(1991)), or acetylating the racemic-tricyclo [5.2.1.0 26 ] deca-3-hydroxy-4,6 diene and hydrolyzing the obtained compounds in the presence of lipase by hydrolyzing reaction (J, Chem. Soc, Chem, Commun.) 1989, 271), and obtaining the optically active alcohols.
The obtained (-)-tricyclo [5.2.1.0 2 .6 ] deca-4,8-diene-3-one (1) and 4-vinyl-7-alkoxy-1,2-dihydronaphthalene (2) which is obtained by a method of Schmidt et al. (Liebigs Ann. Chem., 536, 196 (1938); ibid 537, 246 (1939)) are reacted in the presence of a Lewis acid by an asymmetric Diels-Alder reaction, and the compound (3) can be obtained. As the Lewis acid used here, diethyl aluminum chloride is preferred, but a compound such as titanium tetrachloride or aluminum chloride, which can catalize the reaction controling the configuration, can be used. The reaction temperature is between -78° C. to -10° C., preferably -30° C.
Hydrocarbons or halogenated solvents can be used as the reaction solvents, especially preferably n-hexane and dichloromethane.
Although the reaction time shall be altered by the treating amounts, usually it is 12-96 hours, preferably 24-36 hours.
The obtained compound (3) can be converted to the compound (5) by methylation with methyl iodide in the presence of a base. As the base, potassium t-butoxide is preferred. However, any kind of base by which the methylation proceeds can be used. Further, methyl bromide or methyl chloride can be used as a methylation agent.
The compound (8) which is an O-methyl compound obtained as a byproduct in this step is separated off by column chromatography or the like, and the separated compound (8) is treated with hydrochloric acid at 0° C. to easily return to the compound (3), and can be used as a reaction intermediate of (+)-estrone.
The compound (6) is obtained by treating the compound (5) with trifluoroacetic acid and triethyl silane.
Further, by heating the compound (6), the compound (7) is obtained by a retro-Diels-Alder reaction.
At the final step, the compound (7) is reduced at an unsaturated bond by catalytic hydrogenation, and the objective (+)-estrone derivatives (4) can be obtained. A catalyst such as Raney nickel or the like, preferably paradium carbon, can be used.
As described above, (+)-estrone derivatives having high total yield can be obtained by reduced reaction steps from the starting materials of dicyclopentadiene derivatives (1). Considering the recovery of the compound (8), the yield of the (+)-estrone derivatives becomes better.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The following examples illustrate the present invention more specifically. However, the present invention is not limited by these examples. EXAMPLE 1
To 25 ml of dichloromethane, 1.72 g (11.8 mmol) of (-)-tricyclo [5. 2. 1. 0 2 .6 ] deca-4,8-diene-3-one (1) and 2.63 g (14.1 mmol) of 4-vinyl-7-methoxy-1,2-dihydronaphthalene (2) are dissolved, and the mixture was cooled to -30° C. To the solution, 15 ml (14.1 mmol) of diethyl aluminium chloride (0.94M, n-hexane solution) was dropwisely added. After being stirred for 32 hours at -30° C., 5% hydrochloric acid was added, and the mixture was extracted with dichloromethane. Then, the dichloromenthane layer was succesively, washed saturated sodium bicarbonate solution and saturated sodium chloride solution, and dried over magnesium sulfate. After dichloromethane was distilled off, the residue was subjected to silica gel column chromatography, and 3.1 g (yield 81.5%) of the compound (3) was obtained.
The physical properties of the compound are as follows:
[α] D 31 -168.3° (c 1.01, CHCl 3 ).
IR (film) ν max 1730, 1605 cm -1 .
1 H-HMR (500 MHz, CDCl 3 ) J, 1.35 (1H, d, J=8.5 Hz), 1.51 (1H, d, J=7.9 Hz), 1.84 (1H, ddd, J=17.1, 12.2, 4.9 Hz), 1.95-2.02 (1H, m), 2.16-2.27 (2H, m), 2.36-2.51 (3H, m), 2.58-2.62 (1H, m), 2.72-2.91 (4H, m), 3.09-3.12 (1H, m), 3.80 (3H, s), 6.15-6.22 (3H, m), 6.66 (1H, d, J=8.6 Hz), 7.47 (1H, d, J=8.6 Hz).
MS m/z 332 (M + ), 266 (100%).
Elemental analysis:
Calculated for C 23 H 24 O 2 : C 83.10, H 7.28.
Found: C 83.16, H 7.34.
Example 2
To a solution of 560 mg (1.96 mmol) of the compound (3) in 8 ml of dimethoxyethane, 37.8 mg (3.37 mmol) of potassium t-butoxide was dropwisely added at room temperature, and the mixture was stirred for 12 minutes. 1.1 ml (17 mmol) of methyl iodide was added under cooling with ice, followed by stirring for 12 minutes, adding saturated sodium bicarbonate solution, and extractubg the mixture with ether. The organic layer was washed with saturated sodium chloride solution and dried over magnesium sulfate, the solvent was distilled off, and the residue was subjected to silica gel column chromatography using an eluent of ether/n-hexane (1/1). 334 mg (yield 57%) of the compound (5) and 123 mg (yield 21%) of the compound (8) were obtained from corresponding fractions. The compound (5) was recrystalized from methanol to obtain colorless needle crystals.
The physical properties of the compound are as follows:
[α] D 31 +130° (c 0.665, CHCl 3 ).
IR (film) ν max 1735, 1606 cm -1 .
1 H-HMR (90 MHz, CDCl 3 ) J, 1.09 (3H, s,), 1.48-2.65 (9H, m), 2.80-3.21 (5H, m), 3.78 (3H, s), 5.81-6.06 (2H, m), 6.10-6.28 (1H, m), 6.57-6.79 (2H, m), 7.39 (1H, d, J=8.3 Hz).
MS m/z 246 (M + 100%).
Elemental analysis: Calculated for C 24 H 26 O 2 : C 83.20, H 7.56. Found: C 83.21, H 7.88.
EXAMPLE 3
To a solution of 304 mg (0.878 mmol) of the compound (5) in 6 ml of dichloromethane, 0.68 ml (8.83 mmol) of trifluoroacetic acid and 0.70 ml (4.38 mmol) of triethyl silane were dropwisely added, and the mixture was stirred for 20 hours at room temperature, followed by adding saturated sodium carbonate under cooling with ice, and extracting the mixture with dichloromethane. The extract was washed with saturated sodium chloride and dried over magnesium sulfate. The solvent was distilled off under reduced pressure, the residue was subjected to silica gel column chromatography using an eluent of ether/n-hexane (1/15), and 2.65 mg (yield 87%) of the compound (6) was obtained from the fraction. The product was recrystalized from methanol to obtain colorless needle crystals.
The physical properties are as follows.
Melting point: 173°-174° C.
[α] D 31 +126° (c 0.96, CHCl 3 ).
IR (nujol) ν max 1728 cm -1 .
1 H-HMR (500 MHz, CDCl 3 ) J, 1.07 (3H, s,), 1.35-1.48 (3H, m), 1.52-1.74 (5H, m), 2.07-2.18 (2H, m), 2.25-2.32 (1H, m), 2.77 (1H, tb, J=10.4, 4.3 Hz), 2.87-2.98 (3H, m), 3.08 (1H, br, s), 3.24 (1H, dd, J=10.3, 4.2 Hz), 3.77 (3H, s), 6.02 (1H, dd, J=5.5, 3.0 Hz), 6.22 (1H, dd, J=5.5, 3.0 Hz), 6.64 (1H, d, J=3.0 Hz), 6.70 (1H, dd, J=11.0, 2.5 Hz), 7.16 (1H, d, J=9.1 Hz).
MS m/z 348 (M + ), 282 (100%).
Elemental analysis: Calculated for C 24 H 28 O 2 : C 82.72, H 8.10 Found: C 82.55, H 8.10.
EXAMPLE 4
13 mg (0.037 mmol) of the compound (6) and 1 ml of diphenyl ether were heated and refluxed for 1.5 hours. The reaction solution was subjected to silica gel column chromatography, and 8 mg (yield 76%) of the enone compound (7) was obtained. 4 mg of 10% paradium carbon was added to ethanol solution of 39 mg (0.14 mmol) of the enone compound, and the mixture was stirred for 50 minutes in a stream of hydrogen. After filtering with cerite, the filtrate was concentrated under reduced pressure. The residue was subjected to silica gel column chromatography using an eluent of ether/n-hexane (1/6), and 33 mg (yield 84%) of estrone methyl ether (4) was obtained from the fraction.
The physical properties of the compound are as follows.
Melting point: 174°-175.5° C.
α] D 33 +159° (c 0.72, CHCl 3 ).
IR (nujol) ν max 1735 cm -1 .
1 H-HMR (90 MHz, CDCl 3 ) J, 0.88 (3H, s), 1.20-2.51 (13H, m), 2.72-2.98 (2H, m), 3.77 (3H, s), 6.54-6.67 (2H, m), 6.55-6.76 (1H, m), 7.20 (1H, d, J=8.3 Hz).
MS m/z 248 (M + 100%).
EXAMPLE 5
To 5 ml of a mixture solvent of 10% HCl-THF (1:3) having a temperature of 0° C., 123 mg of the compound (8) (melting point 103°-105° C., [α] D 33 +215° (c 1.0.1., CHCl 3 ) was dissolved. Upon slowly warming from 0° C. to room temperature, the mixture was stirred for 1.5 hours. Saturated sodium bicarbonate was added to the mixture under cooling with ice, the neutralized mixture was extracted with dichloromethane, and the extract layer was washed with sodium chloride and dried over magnesium sulfate. After dichloromethane was distilled off, the residue was subjected to silica gel column chromatography, and 100 mg of the compound (3) was quantitatively obtained.
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The present invention provides a method for producing (+)-estrone derivatives, characterized in that it comprises starting from a certain cyclopentadiene derivative, reacting the derivative with a certain diene compound by an asymmetric Diels-Alder reaction, and via intermediates obtaining a (+)-estron derivative represented by the following formula: ##STR1## wherein R is alkyl of 1-20 carbon atoms. According to the present invention, (+)-estron derivatives can be obtained by limited steps from the starting materials of dicyclopentadiene derivatives.
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CROSS-REFERENCE TO RELATED APPLICATIONS
The present application claims the benefit of U.S. Provisional Patent Application Ser. No. 60/793,912 filed on Apr. 21, 2006.
BACKGROUND OF THE INVENTION
Commercial food preparation is, in effect, a manufacturing operation in which a team of skilled workers operates together to produce meals from component ingredients. Such preparation involves several major activity areas centered on appliances such as a stove, an oven, a refrigerator, a sink, and one or more preparation tables where food ingredients may be chopped or peeled or mixed or set for cooling or staging.
Unlike conventional manufacturing operations, much of the work in kitchens is performed manually using equipment and methods that differ only in slight degrees from those used hundreds of years ago. The work preparing food can be difficult, especially in commercial quantities, which may involve moving of large and bulky food containers that may be hot, in an environment where spills and moisture are inevitable. Mixing and cutting large quantities of food can involve repetitive manual activities that may promote repetitive motion injuries.
The variety and range of tasks undertaken in a commercial kitchen nevertheless require great flexibility in the equipment. Space is normally at a premium and specialized equipment that may be appropriate in a manufacturing environment may be commercially impractical in a commercial kitchen operating in a highly competitive environment.
BRIEF SUMMARY OF THE INVENTION
The present invention provides a novel new appliance for use in commercial and other kitchens providing a mobile stove unit including a food transfer platform. Motorized columns allow change in height of the food transfer platform and stove-top, allowing the mobile stove unit to be used for transferring heavy or bulky items in the kitchen environment. The stove unit also allows the appliance to be used as a conventional stove, eliminating the need for space that would be required for two separate devices. In addition to height adjustment, the invention allows conventional mixing or food preparation activities to take place at an appropriate height for a range of individuals so as to reduce repetitive motion injuries.
Specifically, then, the present invention comprises a kitchen appliance having a base with a plurality of downwardly extending wheels, to engage the floor and allow the base to move across a floor and providing a food transfer platform, sized to allow food preparation. The food transfer platform holds least one heating element for cooking, supported by the top of the food transfer platform. The appliance further has an extendible column that has a motor to adjust the height. The column is extendible by using a control panel providing electrical switches to control the motor. The appliance is powered by a power cord having an electrical plug to engage an electrical outlet and provide energy to at least one heating element.
It is thus one aspect of one embodiment of the invention that it provides a stove unit that can be used for preparation and transfer of food items in a kitchen.
In one embodiment of the invention, the column is extendible by more than 12 inches. This allows the cooking and food transfer platform to extend between about 27 inches and about 42 inches.
It is one aspect of one embodiment of the invention to cover the proper working height for up to 90 percent of the population for a variety of cooking tasks. This aspect of the invention allows the food transfer platform to move up and down to accommodate different areas of the kitchen. For example, a user may move the stove over to the refrigerator, adjust the height of the food transfer platform to equal the height of the refrigerator shelf and slide a heavy pot from the refrigerator to the food transfer platform, eliminating the need for picking up the pot and carrying it. The user could then move the appliance to a different area and adjust the food transfer platform to a height suitable for that particular user's needs.
In one embodiment, the heating element is an electrical resistance heater. This allows an electrical heating element to evenly distribute heat for cooking, sautéing, or keeping food warm.
It is one aspect of one embodiment of the invention to provide a simple and familiar stove unit.
In one embodiment, the heating element is alternatively an induction heater. An induction heater only warms the pot or pan on the heater, but when an induction heater is turned off, the heating element is immediately cool to the touch.
It is one aspect of one embodiment of the invention to allow the appliance to easily transfer from cooking use to food preparation use.
The invention may further include a set of upwardly extending glide rails affixed to the top of the food transfer platform.
It is one aspect of one embodiment of the invention to facilitate the transfer of heavy pots and the like to allow easy motion in a parallel direction to the rails, but difficulty to slide objects in a perpendicular direction to the rails. The guide rails may corral pots and pans when the user is moving the height-adjustable appliance from one area to another.
The appliance may further include at least one sensor that perceives an adjacent surface and communicates with the control panel and motor to adjust the height of the food transfer platform to a height of an adjacent surface.
Thus it is another aspect of at least one embodiment of the invention to automatically adjust to the height of an adjacent surface. Such a feature allows a user to be able to slide a heavy stockpot from a standard counter to the invention's food transfer platform, without needing to pick up the pot and risk injury.
More particularly, the appliance may include a sensor that may read particular encoded signals from infrared transmitters on adjacent work surfaces to automatically change the height to be compatible with those work surfaces.
The appliance may further include, on the periphery of the food transfer platform, along its vertical surface, pressure-sensitive switches and/or sensors, such as infrared or ultrasonic sensors that may sense the proximity or contact of the edge of the food transfer platform and other surfaces.
It is thus another aspect of one embodiment of the invention to reduce the possibility of finger pinching when the food transfer platform is raised or lowered.
The invention may further include at least one brake affixed to the wheels.
It is an aspect of one embodiment to allow a user to secure the height-adjustable appliance in place during cooking or food preparation.
The brake may be electromechanical and may communicate with the control panel, such that the brake locks in place if the heating element is in use.
It is therefore another aspect of at least one embodiment of the invention to prevent moving the appliance while it is being used to cook food.
The electromechanical brake may communicate with the power cord such that the brake locks in place when the power cord is engaged with an electrical outlet.
It is thus another aspect of an embodiment of the invention to prevent a user from inadvertently attempting to move the height-adjustable appliance when it is still plugged into an electrical outlet.
The appliance may include a battery, wherein the battery powers the motor that elevates the food transfer platform. One aspect of one embodiment allows a user to use the height-adjustable appliance as a food transfer platform alone. The user can move the food transfer platform vertically, using only battery power. Therefore, such a user need not be near an electrical outlet when using the height-adjustable appliance for food preparation only or adjusting to surfaces after moving.
The battery may be capable of recharging when the power cord is engaged with an electrical outlet. One aspect of one embodiment allows the food transfer platform to be moved vertically even when the appliance's power cord is not plugged into an electrical outlet. This allows the appliance to be used as an extra food preparation area, with the ability to provide proper height for up to 90 percent of the population.
A waste receptacle may be affixed to the food transfer platform. In one embodiment, there is an opening in the food transfer platform surface, with a waste receptacle underneath. Another embodiment may include an inset bin that may slide in underneath an aperture in the food transfer platform, for receiving waste during food preparation. One aspect of at least one embodiment allows the user to immediately discard excess or inedible parts of food during food preparation and cooking.
The appliance may also include a pull-out storage in the form of drawers in the food transfer platform. One aspect of one embodiment allows pots, pans, or utensils to be stored conveniently with the appliance. More particularly, plastic food preparation items, such as bowls or utensils, could be stored with the appliance, unlike with conventional electric ranges.
The appliance may have an adjustment mechanism between the column and the food transfer platform to allow the food transfer platform to be leveled or tilted.
The appliance may include a charger for charging the battery when the unit is stationary or not in use through the use of a separate low amperage charging cord. The motor controller may further provide a power converter to provide a necessary conversion of voltage between the battery, for example, a sealed lead acid battery, and the motor units.
The base may further include an upper cowling at each end and an upper cover that are upwardly convex to prevent items from being rested or stacked on the upper cowling or cover or balanced thereon.
The invention may further include a frame that supports and surrounds a downwardly extending tray which provides a bottom that is substantially below the frame allowing the extendible columns to descend to a point allowing the food transfer platform and heating element height to be as low as 27 inches and to extend as high as 42 inches. The bottom of the tray, as well as a battery and other circuitry provide the base.
One aspect of at least one embodiment of the invention is that the height-adjustable appliance has an extremely low center of gravity and an extremely low mounting point for the extendable columns.
It is specifically intended that the present invention not be limited to the embodiments and illustrations contained herein, but that modified forms of those embodiments including portions of the embodiments and combinations of elements of different embodiments also be included as coming within the scope of the following claims.
Various other features, objects and advantages of the invention will be made apparent from the following description taken together with the drawings. These particular features and advantages may apply to only some embodiments falling within the claims and thus do not define the scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a height-adjustable appliance such as may incorporate the present invention;
FIG. 2 is a fragmentary partial cross-section of the height-adjustable appliance; and
FIG. 3 is a schematic block diagram of the electrical connections of the height-adjustable appliance.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to FIG. 1 , a height-adjustable appliance 10 of the present invention may include a generally horizontal and planar food transfer platform 12 , such as may be used for food preparation or as a cooking surface.
Preferably, the food transfer platform 12 is formed of a stainless steel sheet, for example a 16 gauge stainless steel sheet, and may have an upper area as much as thirty inches by sixty inches. The edges of food transfer platform 14 may be raised to provide a drip edge containing spilled liquids and upwardly extending glide rails 16 may be embossed in the food transfer platform 12 , providing upward ridges whose crests support the bottoms of pans or the like (not shown) to limit contact between the food transfer platform 12 and the pans reducing sliding friction, heat transfer, and contact with spilled liquids.
A heating element 18 , for example an induction heating unit, may be installed in the food transfer platform 12 , allowing for cooking of foods. The induction heating unit reduces the incidental heating of the food transfer platform and eliminates flame such as may ignite oils or the like. Alternatively element 18 may be a standard resistance type heating element.
Opposed ends of the food transfer platform 12 are supported by two corresponding extendible columns 20 whose upper ends attach to an underside of the food transfer platform 12 and whose lower ends are supported on a base 22 .
The base 22 provides a rectangular platform roughly the size of the food transfer platform 12 and may include wheels 24 in each corner to allow the base 22 to roll over a smooth floor 34 or the like. The base 22 includes an upper cowling 28 covering the upper surfaces of the base 22 which is upwardly convex to prevent items from being rested or stacked on the base 22 or balanced thereon.
Referring now also to FIG. 2 , the base 22 may have a frame 32 being in a preferred embodiment a rectangular frame of square tube steel elevated sufficiently above the floor to receive on its underside the wheels 24 , which may be of food grade quality and which may provide foot actuated or electrically activated brakes 66 , and offset swivels as is understood in the art allowing the wheels 24 to rotate to align with the direction in which the base 22 is pushed.
The frame 32 supports and surrounds a downwardly extending tray 36 which provides a bottom supporting the bottom of the columns 20 that is substantially below the frame allowing the food transfer platform 12 and heating element 18 height to be as low as about 27 inches and to extend as high as about 42 inches. The bottom of the tray 36 also supports the batteries 40 and other circuitry as will be described providing the base 22 and thus the height-adjustable appliance with an extremely low center of gravity.
Referring to FIGS. 1 and 3 , the heating element 18 may receive power from a retractable power cord 46 such as may be optionally provided with a spring-loaded retractor 47 . The cord 46 may extend from the base 22 to be plugged into a stationary outlet 48 when the height-adjustable appliance is positioned for cooking. Conductors of the cord 46 may pass through an elastomerically extensible tube 50 , such as a molded bellow, joining the base 22 and the food transfer platform 12 to restrain and guide the conductors. Alternatively or in addition, the conductors (not shown) extending between the base 22 and the food transfer platform 12 , may be coiled as with a telephone cable to reduce the chance of the conductors kinking or breaking throughout a range of extensions corresponding to different heights of the food transfer platform 12 .
At the food transfer platform 12 , power from the cord 46 may also be routed to two ground fault circuit interrupter (GFCI) outlets 26 that may be positioned on edges of the food transfer platform 12 .
The power from the cord 46 may also be routed to a controller 60 that may monitor the power, for example, to operate the electromagnetic brake or to provide a warning signal.
The periphery of the food transfer platform 12 along its vertical surface may include pressure-sensitive switches 54 and/or sensors 56 , such as infrared or ultrasonic sensors that may sense the proximity or contact of the edge of the food transfer platform 12 and other surfaces 68 to reduce the possibility of finger pinching when the food transfer platform 12 is raised or lowered. These switches 54 and sensors 56 may also communicate with controller 60 . Further, the sensors 56 may allow for automatic height adjustment when the food transfer platform 12 is moved between surfaces of different heights, for example, in the transfer of materials from one surface to another, aligning the top of the food transfer platform 12 with the adjacent surface to aid in the loading and unloading of materials. The sensors 56 may read particular encoded signals from infrared transmitters on adjacent work surfaces to signal the controller 60 to automatically change the height to be compatible with those work surfaces.
A control panel 58 may also be placed conveniently on an edge of the food transfer platform 12 to allow for control of the elevation through simple button presses communicated to the controller 60 . The control panel 58 may employ membrane switches 54 that may be easily cleaned. Similar standard controls 55 may be used for the induction or resistance heating elements 18 .
Referring still to FIG. 3 , the motor controller 60 receives power from the battery 40 at a low voltage, for example, twelve volts, to provide power to motor units 38 controlling the extension or telescoping of the columns 20 . The motor units 38 may include height feedback signals through encoders or limit switches allowing the motor controller 60 to provide infinitely variable height adjustment from 27 inches to 42 inches as well as up to four pre-programmed height settings that may be accessed through preset buttons on the control panel 58 .
A charger 62 may be provided for charging the battery 40 when the unit is stationary through the use of a separate low amperage charging cord 64 . Alternatively, and, in addition, the charger 62 may connect to the cord 46 to provide charging when the cord 46 is plugged in.
An inset bin 70 may slide in underneath an aperture in the food transfer platform 12 , for example, for receiving waste during food preparation. Pull-out storage may be provided in the form of drawers in the food transfer platform (not shown). Adjustments may be provided between the columns 20 and the food transfer platform 12 to allow the food transfer platform 12 to be leveled or tilted.
An electromechanical brake 66 may be adjacent to the wheels 24 . The brake 66 may connect to the controller 60 to provide energy to engage the brake 66 when the power cord 46 is connected to an electrical outlet 48 . The controller 60 may also connect to the control 55 so that the brake 66 is engaged when the heating element 18 is energized.
Various alternatives and embodiments are contemplated as being within the scope of the following claims particularly pointing out and distinctly claiming the subject matter regarded as the invention.
The present invention has been described in terms of the preferred embodiment, and it is recognized that equivalents, alternatives, and modifications, aside from those expressly stated, are possible and within the scope of the appending claims.
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A food transfer platform incorporating a stove unit elevates to different heights, by an extendible column, and can move along a floor.
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CROSS REFERENCE TO RELATED APPLICATIONS
The present application claims priority to U.S. Provisional Application 60/625,425 filed on Nov. 5, 2004.
FIELD OF THE INVENTION
The present invention relates to an interactive moving toy, such as a plush figure or animal, that has an area or enclosure that the figure automatically returns to and enters.
BACKGROUND OF THE INVENTION
Interactive toys are well known in the prior art. A toy created by one of the current inventors included a toy vehicle that returned to and entered a “garage.” However, various improvements in returning a toy to an area or enclosure are desired. For example, toys are often placed on tracks or rails to direct and guide a toy into an enclosure. And a toy's ability to enter into a designated area or enclosure and turn around such that it is facing out is often limited to having tracks or rails in the designated area. It is thus an improvement over the prior art to provide a toy that can be freely directed without tracks or rails into a designated area and have the toy automatically turn around. In addition, it is desired to have a toy that if placed around the side of the area could use sensing devices to move itself and maneuver into a proper position and automatically guide itself into the area.
SUMMARY OF THE INVENTION
In accordance with the present invention an interactive toy includes a body, a head extending from a front portion of the body and a plurality of feet extending downwardly from the body. A sensor is positioned on the left and right sides of the toy, and the sensors activate upon receiving a signal. A microprocessor, which is in communication with the pair of sensors, controls a mechanical means to move the toy upon activation of the sensors. In one embodiment the means to move the toy includes a pair of motors separately driving a gear spur meshed to a wheel. Each wheel extends from underneath the toy to drive the toy on a surface.
The toy may also include a pair of feet positioned on either side of the toy. Each foot includes a bottom portion secured to a cam that is driven by a gear train meshed to the gear spur. And each foot includes a slot in a top portion sized to receive a pin secured to the body of the toy. Thus when the gear spur rotates, each foot moves up and down while the bottom portion reciprocates.
The toy may also include a lead switch positioned in the front end of the toy and in communication with the microprocessor that will play preprogrammed responses upon activation of the lead switch. The lead switch has a portion extending outwardly from the front end of the toy that when pulled activates the lead switch.
In another aspect of the invention, the toy is used in connection with a designated area therefor. The designated area has an entrance, and a transmitter positioned within the designated area for sending a signal out of the entrance. The microprocessor will guide and move the toy through the entrance of the designated area when the toy's sensors receive the signal from the transmitter.
In another aspect of the invention, the toy includes a reference pointer sensor positioned underneath the toy and in communication with the microprocessor that plays preprogrammed responses upon activation of the reference pointer sensor. The reference pointer sensor is used in connection with pointers on the floor of the designated area. The microprocessor controls and moves the toy within the designated area as the toy moves over the pointers on the floor such that the toy is able to turn itself around and face out the entrance of the designated area.
In another aspect of the invention the toy includes pairs of transmitter/sensors, and has a microprocessor that moves the toy in response to the sensors receiving signals reflected off of an obstacle on the surface. The toy is thus able to automatically maneuver around such obstacles and orient itself to a proper position for entering the designated area.
Numerous other advantages and features of the invention will become readily apparent from the following detailed description of the invention and the embodiments thereof, from the claims, and from the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
A fuller understanding of the foregoing may be had by reference to the accompanying drawings, wherein:
FIG. 1 is a perspective view of a toy and enclosure therefor in accordance with the present invention;
FIG. 2 is a perspective view of the toy without its outer covering;
FIG. 3 is a sectional view of the internal components of the toy;
FIG. 4 is a bottom perspective view of the toy;
FIG. 5 is a perspective view of the motor and drive train used to rotate the wheels and reciprocate the legs of the toy;
FIG. 6 is a back perspective view of the enclosure and a transmitter;
FIG. 7 is a top view of a toy positioned at three different angles towards the entrance of the enclosure;
FIG. 8 is a top view of the toy and enclosure illustrating the magnetic strips and rails used to guide and orient the toy within the enclosure;
FIG. 9 is a sectional view of the internal components of another embodiment of the toy having a pair receiver/transmitters;
FIG. 10 a is a sectional view of the internal components of another embodiment of the toy having a pair receivers on either side of the toy and a pair of receiver/transmitters on either side of the toy to help maneuver the toy around objects;
FIG. 10 b illustrates the toy from FIG. 10 a being able to move around a designated area and which is capable of orienting itself into position to move into the designated area; and
FIG. 11 is a sectional view of the internal components of another embodiment of the toy having a pair receiver/transmitters on either side of the toy and a single receiver in the front of the toy.
DETAILED DESCRIPTION OF THE EMBODIMENTS
While the invention is susceptible to embodiments in many different forms, there are shown in the drawings and will be described herein, in detail, the preferred embodiments of the present invention. It should be understood, however, that the present disclosure is to be considered an exemplification of the principles of the invention and is not intended to limit the spirit or scope of the invention and/or claims of the embodiments illustrated.
Referring now to FIG. 1 , in accordance with the present invention, an interactive moving toy 100 is shown along with a designated area 300 or in this instance an enclosure. The toy is illustrated as a animal, however, the toy's shape or appearance can change without effecting the scope of the invention. In addition, the appearance or shape of the designated area 300 may relate to the toy's appearance. For example, if the toy is a car the designated area may be a car port or garage, alternatively, if the toy is a dog, the designated area may be dog house or have the appearance of a fenced yard. It is important to note that the designated area may or may not include walls, roofs or related items.
The toy 100 , shown without its outer covering 102 in FIGS. 2-5 , includes a body 104 . In the present exemplary embodiment, the toy 100 includes various appendages extending from the body 104 . The appendages include legs 106 and a head 108 . The toy 100 also includes switches positioned about the body that when activated sets off specific pre-programmed responses that are stored on a microprocessor 110 . For example, the toy 100 includes a head switch 120 that when a user actives by rubbing or pressing the user's hand across the top of the head 108 , activates a set of pre-programmed responses. The pre-programmed responses may include movement and/or sound responses. The movement of the toy 100 is explained in detail below. The sound responses are emitted through a speaker 122 . Various pre-recorded sounds may be stored on the microprocessor 110 .
The toy 100 may also include a sound activated switch or microphone 124 , which when activated by a loud sound sets off specific pre-programmed responses that are stored on the microprocessor 110 . Similarly, the responses may include movement and/or sound responses.
The toy 100 may also include a mouth switch or sensor 126 positioned in the front of the head 108 . If a mouth switch is used (such as a mechanical switch) the switch will activate when a user presses a object (such as a dog toy 128 ) into the mouth switch. The mouth switch preferably is configured to also frictionally grab and hold onto the object. As such, as long as the bone 128 is pressed and held against the mouth switch, the activation of the switch will cause the microprocessor to run a set of pre-programmed responses. If a mouth sensor 126 is used, a magnet 127 positioned in the mouth sensor engages and holds onto a magnet 129 positioned in the bone 128 . The mouth switch or sensor would be sewn into the outer covering 102 .
The toy 100 may further include a lead switch 130 positioned about or below the neck or collar portion 114 . When the lead switch 130 is pulled it is activated, causing the microprocessor to run a set of pre-programmed responses. The pre-programmed responses could move the toy backwards such as in a tug of war or could move the toy forwards such as if the toy was following the user. A leash 132 can be removably attached to the lead switch 130 by providing a clip (not shown) that the user secured around a ring 134 operatively secured to the lead switch 130 . When the user pulls the leash 132 , the ring 134 pulls and activates the lead switch 132 . The lead switch 130 may automatically return to the off position once the leash is released. However, once the lead switch 130 is activated, the microprocessor may run the pre-programmed responses in their entirety or randomly, and will keep playing the pre-programmed responses as long as the lead switch is subsequently activated.
The toy 100 moves along a surface through a pair of wheels 140 that partially protrude from a bottom plate 116 in the body 104 of the toy 100 . As further explained below, when the wheels 140 are rotating, the legs 106 of the toy 100 move up and down and back and forth providing the appearance that the legs 106 are moving the toy.
To drive the wheels 140 and reciprocate the legs 106 , the toy 100 includes a pair of motors 150 . Depending upon the type of movement desired the number of motors may change and dedicated motors may be used to reciprocate the legs. As shown in FIG. 5 , the pair of motors separately operate one side of the toy 100 , with each side including identical gear trains. Each motor 150 drives a first gear train 152 that is meshed to a drive spur 154 attached to a wheel 140 .
Branching from the drive spur 154 are a pair of foot gear trains 156 , one branching to the front and one branching to the rear. Meshed to the end of each foot gear train 156 is a cam 158 with a knob 160 extending outwardly therefrom. Each leg 106 has an opening 164 (see FIG. 2 ) to accommodate the knob 160 and has a slot 166 that accommodates a pin 168 secured to the body 104 of the toy. As the cam 158 rotates the knob 160 reciprocates the leg 106 back and forth. In addition, the slot 166 allows the leg 106 to slide up and down during upward and downward movement of the cam, giving the overall appearance that the leg is moving in an up and down, back and forth movement.
The motors 150 are controlled through the microprocessor 110 and switch 124 such that movement may be made forwards, backwards, left turns, right turns and spins. In a forward direction both motors are moving the wheels 140 forwards. In a backwards direction both motors are moving the wheels 140 in a reverse direction. In a left or right turn, only one motor is operating, causing the toy to turn in the direction of the stalled motor or non-rotating wheel. To spin the toy, the motors rotate the wheels in reverse directions to each other.
The toy 100 also includes a caster wheel 170 positioned towards the front of the toy and a pair of skids 172 positioned in the rear of the toy. The caster wheel and skids provides extra stability when the toy is moving. In addition, the toy 100 may include an on/off switch 178 and an enclosure sensor 176 . The enclosure sensor 176 is used to orient the toy 100 when it is inside the designated area, explained in greater detail below.
Referring now to FIG. 6 , the designated area 300 has an exterior back portion 302 with an indented section 304 , which matches an object or bone 310 . Within the indented section 304 is an aperture 306 to the interior of the designated area that will permit a transmitter 308 in the bone 310 to emit a signal through the designated area 300 , when the bone 310 is positioned in the indented section 304 . The designated area 300 also includes an entrance opening with walls on either side connecting the entrance to a back wall. The bone 310 may also be removed from the designated area 300 and used separately apart therefrom. The user may angle the bone 310 towards the toy 100 such that the transmitter 308 emits a signal that is received by the toy 100 . The toy 100 can then follow the user or bone 310 around.
Referring now to FIGS. 3 and 7 , the toy 100 includes a pair of receivers 180 , positioned in the collar section 114 . The receivers 180 are slightly recessed to help keep the receivers 180 separated and the reception of signals clearer. The toy 100 may enter a programming mode or phase that directs the toy to “go home.” This phase may be initiated upon the activation of a switch or sensor. In this mode, the toy 100 begins to look for a signal emitting from the entrance 310 of the designated area 300 . When the toy 100 is positioned at an angle to the entrance of the designated area, such as in positioned A or B, only one of the receivers 180 is sensing the transmitted signal. The microprocessor will continually cause the toy to move or turn the toy until both sensors 180 are receiving the signal. In addition, if the toy 100 is 180° from the entrance 310 and neither sensor 180 is receiving a signal, the motors 150 may spin the toy until a sensor 180 begins to receive the signal.
Referring now to FIG. 8 , once the toy 100 begins entering the designated area 300 , both the toy 100 and the designated area 300 employ a means to help properly guide the toy into the designated area 300 . The designated area 300 includes a rail 315 and the toy 100 includes a railing guard 190 that extends outwardly from the bottom plate 116 in the body 104 of the toy 100 . If the guard 190 comes into contact with the rail 315 , the toy is pushed towards the correct position in the designated area. The rail 315 does not extend into the designated area 300 and is used only to help position the toy 100 . The rail 315 is not used to turn the toy 100 around once inside the designated area.
Continuing to refer to FIG. 8 , in addition, the designated area and the toy further include a means to orient the toy such that the toy is turned around in the designated area to face the toy towards the outside. The orientation means used is preferably a pair of position reference pointers, such as magnetic pointer or optical pointers 340 , 342 positioned on the floor 320 of the designated area 300 . A first position reference pointer 340 is positioned in a first corner 322 of the back portion 324 of the designated area 300 , and a second position reference pointer 342 is positioned in a second corner 326 that is diagonal from the first corner (or in the front portion 328 of the designated area 300 . As mentioned above the toy 100 includes a position reference sensor 176 . While the toy 100 is in the designated area, the position reference sensor 176 is activated by moving over the first position reference pointer 340 , the microprocessor spins the toy 100 until the position reference sensor 176 is activated by the other position reference pointer 342 . At this point the toy 100 has turned around inside the designated area and is facing outwardly. Once in the designated area, a noise or sound may activate the toy's sound sensor 124 causing the microprocessor to move the toy forwards and out of the designated area. Additional position reference pointers may be positioned in the designated area to turn or orient the toy in different directions. In other embodiments, the position reference pointers 342 may cause the toy to stop at a predetermined position, for example, if the enclosure included a window, the toy may stop to look out the window and then after a predetermined time or after hearing a noise may continue to orient itself such that it is facing out of the designated area. Moreover, the predetermined position may itself be such that the toy is facing out of the designated area.
In another embodiment of the present invention, the toy 400 , illustrated in FIG. 9 , may include a pair of receiver/transmitters 410 positioned on either side of the toy. The receiver/transmitters work in concert to move and orient the toy inside the designated area, especially within an enclosure. As the transmitter is bounced off of the interior of the enclosure, the receiver can identify the bounced signal which in turn causes the microprocessor to move the toy until the toy is facing out of the enclosure.
Referring now to FIG. 10 a , in another embodiment, the toy 450 includes a pair of receivers 460 to receive and recognize a signal emanating from within the designated area or from a bone, as mentioned above, will cause the toy to move and orient itself such that the toy can enter the designated area. The toy 450 also includes a pair of receiver/transmitters 470 oriented on either side of the toy 450 . This receiver/transmitters 470 permits the toy to move itself around objects or the outside perimeter or walls of the designated area until it is oriented towards the entrance and until the toy 450 picks up the transmitted signal from inside of the designated area and then the toy 450 would go inside the designated area, See FIG. 10 b.
Referring now to FIG. 11 , in another embodiment, the toy 480 includes a pair of receiver/transmitters 470 oriented on either side of the toy 480 , permitting the toy to move itself around objects or the outside perimeter or walls of the designated area. The toy 480 also includes a single receiver 490 positioned directly in front of the toy 480 . The single receiver 490 works with a single coming out of the designated area to orient the toy 480 in a position to move into the designated area.
From the foregoing and as mentioned above, it will be observed that numerous variations and modifications may be effected without departing from the spirit and scope of the novel concept of the invention. It is to be understood that no limitation with respect to the specific methods and apparatus illustrated herein is intended or should be inferred. It is, of course, intended to cover by the appended claims all such modifications as fall within the scope of the claims.
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In accordance with the present invention an interactive toy includes a body, a head extending from a front portion of the body and a plurality of feet extending downwardly from the body. A pair of sensors are separately positioned on the left and right sides of the toy, and the sensors activate upon receiving a signal. A microprocessor is in communication with the pair of sensors controls a mechanical movements of the toy upon activation of the sensors. In one embodiment the mechanical movements of the toy include a pair of motors separately driving a gear spur meshed to a wheel. Each wheel extends from underneath the toy to drive the toy on a surface.
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BACKGROUND OF THE INVENTION
The present invention relates to network communication systems. It finds particular application in conjunction with controlling admission of voice calls to a packet-based network, and efficiently selecting paths for admitted calls so as to balance the traffic load within the network. However, it is to be appreciated that the present invention is also amenable to other like applications such as video or real-time data, provided that they manifest in the form of “calls”, where a need exists to improve the quality of service of data transfer over a packet network.
The internet, intranets, and other internet protocol (IP) networks are handling ever increasing volumes of data. Beyond the worldwide web and e-mail capabilities of such networks, applications and protocols are being developed to further add to the volume of traffic. Among these are voice related applications such as telephony or voice over IP, and video applications, such as video telephony, video conferencing, and the like. Unfortunately, even at current usage levels packet loss due to congestion is becoming problematic degrading the performance of data transfer.
Streams of packets typically enter the network from packet switching edge devices or gateways which serve as portals to the interconnected web of routers comprising the network. Typically these gateways are indiscriminant in their treatment of packet streams in that they merely port the packet streams onto the network without regard for congestion levels or likelihood of the packets reaching their final destination. Moreover, the networks typically are unaware of any, coherence or association among packet streams, and merely forward individual packets from router to router on a first-come-first-served basis, without regard to their relative priorities. These two limitations severely constrain the ability to provide quality-of-service guarantees for real-time services such as voice in IP-based networks.
Some attempts have been made to address portions of this problem. For example, packet prioritization schemes such as differentiated services or Diffserv distinguish packet streams among several classes. Protocols are also evolving which route higher priority packets more reliably, for example, by allocating certain bandwidth on links between routers for each class. Another partial solution that has been articulated is that of establishing explicit routing paths through the network between frequently traveled points. Multi-protocol label switching (MPLS) is a protocol which enables a label to be assigned to a packet stream which specifies a predetermined path through the network. This allows better monitoring and control of congestion over the paths taken by voice streams, for example. However, the problem introduced by the edge-devices not being aware of congestion levels within the interior of the network still remains. One strategy being pursued to tackle this limitation is to dedicate a certain amount of bandwidth for each MPLS path, on each network link that it traverses. This effectively creates a voice trunk between every pair of nodes, much akin to the telephone trunk routes currently employed between major call centers, and hence abandons the inherent flexibility afforded by the IP network. In particular, this strategy does not lead to a scalable solution. The number of trunks grows as the square of the number of nodes, and the consequent bandwidth fragmentation among hundreds or thousands of MPLS paths can exhaust the link capacities rather quickly. Furthermore, the servicing and provisioning of the multitude of voice trunks across the network are both cumbersome and slow to accommodate new nodes within the network.
The present invention contemplates a new and improved method and apparatus for voice-over-IP call management which overcomes the above-referenced problems and others associated with the existing approaches.
BRIEF SUMMARY OF THE INVENTION
The above problems are alleviated and an advance is made over the prior art in accordance with the teachings of applicants' invention wherein, a method of regulating admission of a packet stream to a network includes identifying a source and a destination gateway in response to receipt of a connection admission request. An optimal path between the gateways is then selected, and cost data associated with the path is compared to a threshold value. Based on the comparison the packet stream is selectively blocked.
In accordance with another aspect of the present invention, the method further includes at selected times, updating cost data associated with the network links, mapping the link costs to costs associated with the various paths, and storing the updated cost data.
In accordance with another aspect of the present invention, the updating cost step includes for each packet stream either admitted to or released from the path, adjusting the cost data associated with the links in the path to reflect the cost of the particular packet stream.
In accordance with another aspect of the present invention, each path includes a plurality of links interconnecting routers within the network. The updating cost data step includes measuring link usage at these routers.
In accordance with another aspect of the present invention, the path includes links adapted to discriminate between different classes of packet streams. The cost data step includes aggregating link use data based on a particular class associated with packet stream.
In accordance with another aspect of the present invention, the updating cost data step further includes tracking class-based link use data at an admission control point, for example, a gatekeeper (the entity that controls a group of voice gateways).
In accordance with another aspect of the present invention, the selectively blocking step includes blocking the packet stream based on a variable probability calculated as a function of cost data associated with the set of paths available between the source and destination gateways (by suitable mapping from the constituent links in the paths).
In accordance with another aspect of the present invention, a plurality of paths exists between the source and the destination gateways. The selectively blocking step includes blocking the packet stream when cost data associated with every one of the paths exceeds a threshold value.
In accordance with another embodiment of the present invention, a system for controlling admission of a packet stream to a network includes a database which stores information including cost data associated with various links and paths through the network. The system further provides a processor in communication with the database, where the processor coordinates cost data updates from a data source, such as routers or gatekeepers, to the database.
In accordance with another aspect of the present invention, the data source includes an admission control point (for example a gatekeeper) which controls packet stream entry to the network. The system further includes connections enabling communication between the admission control points and the processor.
In accordance with another aspect of the present invention, the data source includes a sampling probe associated with a router within the network. The system further includes connections enabling communication between the sampling probe and the processor.
In accordance with another aspect of the present invention, the processor calculates an admission decision for a path through the network. The system includes a second database accessible to an admission control point, where the processor forwards the calculated admission decision to the second database.
In accordance with another embodiment of the present invention, a method is provided which includes updating cost data for a path through a network at selected times. An admission decision for the path through the network is computed based on the cost data, and the admission decision is applied responsive to a packet stream (call) admission request.
In accordance with another aspect of the present invention, the computing step includes determining the minimum cost path between a source and a destination. The cost of the minimum cost path is compared to a threshold and based on the comparison a variable is set which indicates the result of the comparison.
In accordance with another aspect of the present invention, the computing step includes determining a cost factor for each path between a source and a destination in terms of the current costs associated with the constituent links. The method further includes determining a probability that a particular path will be selected, where the probability is based on the cost factor and individual cost data for each path. A variable is then set indicative of the determined probability.
In accordance with another aspect of the present invention, the updating cost data step includes adjusting cost data for the network links comprising the path upon each call admission and release.
In accordance with another aspect of the present invention, the computing step includes at a central location, computing an admission decision for at least one path through the network. The computed admission decision is then forwarded to a satellite location which enables decentralized admission control decisions.
In accordance with another aspect of the present invention, the network links include a plurality of links interconnecting routers within the network. The updating cost data step includes measuring link usage at the routers.
In accordance with another aspect of the present invention, the path includes links adapted to discriminate between classes of packet streams. The updating cost data step includes determining cost data by class.
In accordance with another aspect of the present invention, the updating cost data step further includes tracking path use data at an admission control point.
One advantage of the present invention resides in a scalable efficient method to enable improved quality of service for voice and other applications across a network.
Another advantage of the present invention resides in better bandwidth sharing compared against reserving bandwidth distinctly for each path. This results in efficient network utilization.
Still another advantage of the present invention resides in load balancing of packets across the network and providing overload protection capabilities without requiring modifications to existing standards.
Still further advantages and benefits of the present invention will become apparent to those of ordinary skill in the art upon reading and understanding the following detailed description of the preferred embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention may take form in various components and arrangements of components, and in various steps and arrangements of steps. The drawings are only for purposes of illustrating the preferred embodiments, and are not to be construed as limiting the invention.
FIG. 1 is a simplified illustration of a voice-over-IP network suitably adapted to practice the present invention;
FIG. 2 is an illustration of a generic set of data tables within the database of FIG. 1 ;
FIG. 3 is a flowchart describing one major function of an embodiment of the present invention based on an exact strategy;
FIG. 4 is a flowchart describing another major function of the embodiment based on the exact strategy;
FIG. 5 is an illustration of another embodiment of a network suitably adapted to practice the present invention;
FIG. 6 is an illustration of one embodiment of the data tables within the satellite databases of FIG. 5 ;
FIG. 7 is a generic flowchart for another embodiment of the present invention, based on an inexact strategy;
FIG. 8 is a flowchart detailing one embodiment of FIG. 7 ;
FIG. 9 is a flowchart detailing another embodiment of FIG. 7 ;
FIG. 10 is a graphical depiction of one embodiment to update the database according to the inexact variant of the present invention shown in FIG. 7 ;
FIG. 11 is a graphical depiction of another embodiment to update the database according to the inexact variant of the present invention shown in FIG. 7 ;
FIG. 12 shows a specialized embodiment of the set of data tables shown in FIG. 1 , for adapting the current invention to work in conjunction with a widely used form of network routing;
FIG. 13 shows a specialized embodiment of the set of data tables within the satellite database of FIG. 5 , for adapting the current invention to work in conjunction with a widely used form of network routing;
FIG. 14 is a specialized embodiment of the flowchart in FIG. 3 , for adapting the current invention to work in conjunction with a widely used form of network routing; and,
FIG. 15 is a specialized embodiment of the flowchart given in FIG. 9 , for adapting the current invention to work in conjunction with a widely used form of network routing.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The discussion that follows will address the general case, where a set of alternate spatially diverse MPLS explicit paths is assumed to be set up between each pair of source and destination edge nodes. The plurality of paths between a given pair of edge nodes allows the load balancing capability embodied in the present invention. However, unlike the MPLS trunking approach mentioned earlier, there is no per-path bandwidth reservation in our model. As will be explained later, voice bandwidth reservation on each network link is done here on an aggregate basis for all the MPLS paths carrying voice on the link. A mechanism such as Diffserv is used for this purpose, independently of MPLS. Thus our solution is not affected by the scaling concerns that pertain to the trunking approach as observed earlier. Note that the admission control feature of the proposed scheme can also be implemented in conjunction with the special case based on the conventional OSPF routing instead of MPLS. However, the load balancing feature is not available with this case since there is no flexibility to set up multiple explicit paths among a given pair of edge nodes. The modifications in the overall scheme to effectuate this latter variant will be highlighted below where appropriate.
We shall use an H.323-based Voice-over-IP 2-stage call model as a vehicle to describe the invention. The principles of the invention are however not to be construed as being tied to this protocol or the sequence of steps described below. It can be implemented with equal ease in conjunction with any of the competing protocol standards available to support Voice-over-IP call management. With reference to FIG. 1 , a voice-over-IP (VOIP) call is initiated by a calling party 10 wanting to establish a call to the called party 12 . Once the calling party 10 has dialed the local number for the originating media gateway 24 (MG), the LEC end office 22 (originating EO) selects the particular DSO channel to the originating media gateway 24 (MG) to place -the call on and forwards the information to a Signaling System 7 (SS 7 ) network 26 . The SS 7 network 26 , in urn, sends an ISUP IAM message to the signaling gateway 28 (SG), identifying the local number being called and the DSO channel to be used.
SG 28 selects the media gateway controller 30 (MGC) to handle the call and sends a “setup” message to MGC 30 . MGC 30 sends a “connect” message to MG 24 indicating the call parameters, and MG 24 responds and provides its own IP address. MG 24 then prompts the calling party 10 to enter the destination number, which is sent to MGC 30 . MGC 30 sends an “admission request” to a local gatekeeper 32 (GK), indicating the IP address of the calling MG 24 and destination phone number.
GK 32 queries a LNP database (not shown) to identify the destination LEC 22 ′ and hence the domain gatekeeper 32 ′ that handles the dialed number, and sends a setup message to GK 32 ′. First, GK 32 ′ queries a local routing database (not shown) to locate an available media gateway 24 ′ that can terminate the called number; it also obtains the IP address of this gateway. The remaining steps of the H.323 call flow described below are specialized to support the present invention. Nevertheless, it is again emphasized that analogous entities and procedures may be readily identified for the invention to operate in conjunction with any of the competing protocol alternatives, rather than H.323.
GK 32 ′ next sends a path query message to a Call Admission Control and Load Balancing agent 36 , identifying both the source and destination media gateways 24 , 24 ′ and the amount of bandwidth required (except if all calls consume a fixed, known bandwidth). Those skilled in the art will appreciate that the gateway identification can be made, for example, by using IP addresses, or more efficiently, some VoIP-specific codes. In the illustrated embodiment, the agent comprises a database 36 a and a processor 36 b , collectively referred to as the Call Control Database (CCDB).
The CCDB 36 determines a most favored path (an MPLS path) from the set of alternatives R 1 , R 2 , . . . R p available in the forward direction and the one in the reverse direction through a network 40 . The procedures for path selection will be explained in greater detail below. Once the CCDB 36 establishes (as per one of the procedures to be described) that sufficient bandwidth exists on both the forward and return paths to carry the new call, the corresponding MPLS path identifiers are returned to GK 32 ′. If, on the other hand, it is determined that the available bandwidth is insufficient on at least one of the selected forward and reverse paths, a “call reject” message is communicated to GK 32 ′.
If GK 32 ′ receives a “call reject” message it is relayed to GK 32 , which in turn initiates procedures to block and clear the call at the caller's end. Otherwise, GK 32 ′ sends a “connect” message to the destination media gateway controller 30 ′ including the IP addresses of the caller MG 24 and the called MG 24 ′, the MPLS path identifiers in the forward and reverse directions, and the called number.
MGC 30 ′ in turn sends a “connect” message to MG 24 ′ including the identity of the reverse MPLS path and the IP address of the caller MG 24 . Next, MGC 30 ′ sends a request including the destination telephone number to SG 28 ′ to set up a circuit switched path segment across the terminating LEC EO 22 ′, between MG 24 ′ and the called number 12 . MGC 30 ′ also sends an “alerting” message to the caller MGC 30 , which includes the IP address of the terminating gateway MG 24 ′ as well as the forward MPLS path identifier provided bv GK 32 ′. MGC 30 passes the IP address and MPLS path identifier to MG 24 and also instructs MG 24 to generate ringing.
Once SG 28 ′ receives confirmation for the path setup across the destination LEC EO 22 ′, it sends a “connect” message to MGC 30 ′, which is relayed to MGC 30 . MGC 30 then requests MG 24 to provide call progress tone to the caller. The connection is now established and both the forward and reverse voice paths are available end-to-end.
When a call terminates, the gatekeeper GK 32 ′ alerts the CCDB 36 of this change and appropriate database updates are performed indicating the release of bandwidth and hence the extra capacity available on the paths. Further details on the setup and termination processes not directly germane to this discussion can be found for example in ITU-T Recommendation H.323—“Packet-based multimedia communication systems”.
As discussed above, the CCDB 36 tracks network usage and provides a mechanism for voice gatekeepers to determine the status of the network 40 . There are many database designs that capture the necessary information of the CCDB. We illustrate in FIG. 2 one such design. that captures the generic structure of the database portion 36 a of the CCDB. It is generic in that it incorporates a superset of the data structures needed by the different variants of the call admission control and load balancing algorithm to be presented. As will become apparent to those skilled in the art, certain data items or fields are irrelevant in specific embodiments and hence may be eliminated or not populated.
We will first describe the generic case using MPLS explicit routes (with path diversity among pairs of edge nodes); the special case involving OSPF routing will be addressed subsequently. The database portion of the CCDB 36 a is comprised of four tables with a linked list arrangement as shown in FIG. 2 . To understand this structure, consider a network comprised of N edge routers 42 (ER) and L IP links 44 . Note that multiple voice gateways would typically connect to each edge router. However, the voice MPLS paths are set up among pairs of edge-routers rather than among pairs of gateways so as to improve scalability. To simplify the discussion, all calls from a given source edge router 42 to a given destination edge router 42 are treated in an identical manner, without regard to the specific gateways at which they originate or terminate. Resolution of the voice packet streams among the specific voice gateways that home on to the same edge router can be done in a number of ways, as will be apparent to those skilled in the art. One strategy is to use the (unique) IP addresses of the gateways to effectuate proper packet forwarding between the edge routers and gateways, while routing across the network is via MPLS, using the forward and reverse paths identified by the admission control algorithm presented here for the pair of edge routers in question.
Typically, the forward and reverse paths of a voice connection in an IP network 40 are independent, with each potentially traversing entirely different physical segments. As is clear, the network 40 has a total of U=N(N−1) potential source-destination edge router pairs. To establish a voice call between any given pair, two circuits should be setup, one in each direction.
For each source-destination pair i (iε1, . . . , U), a total of R i independent explicit MPLS paths are set up from the source edge router s(i) to the destination edge router d(i). Thus, there are a total of P=Σ i=1 U R i distinguishable MPLS paths within the network domain 40 altogether. These physical paths are established a-priori by a network management system with maximal spatial diversity, so as to promote better reliability and load balancing. However, as mentioned earlier, no bandwidth is dedicated to any particular path; bandwidth reservation is done on each link on an aggregate basis to be shared by all MPLS paths carrying voice.
Each MPLS path within the network 40 is assigned a unique path index number (PIN) (e.g. PINε1, . . . ,P). To the extent that the PIN's are used to exchange the identities of specific MPLS paths, a common understanding among system components (i.e. the CCDB 36 , the gatekeepers 32 and the voice gateways 24 ) is used to uniquely identify these paths. In particular, the CCDB 36 may convey the identity of a selected path in terms of its PIN, and the source edge router 42 /gateway 24 can translate this PIN into the appropriate outgoing MPLS tag. In an analogous manner, each edge-router 42 that connects to one or more voice gateways 24 is assigned a unique node index number (NIN), again, with a common understanding among the gatekeepers 32 and CCDB 36 . Use of VoIP-specific index numbers (e.g. PIN and NIN) for the MPLS paths and edge routers (instead of their IP addresses). as described above allows direct array indexing operations in the algorithms to be presented. This reduces the need for character string matching, and thus facilitates fast and simple implementation.
As seen in FIG. 2 , the four tables in CCDB 36 are referred to as INDEX table 50 , PATH GROUP table 52 , PATHS table 54 and LINKS table 56 . The INDEX table 50 is a two-dimensional array that can be directly addressed by the indices (NIN's) of a given source node and destination node. Each entry in this table provides the array index of a specific entry (row) in the PATH GROUP table 52 (which has a total of U entries). The second field 52 b of each entry i in the PATH GROUP table 52 indicates R i , or the number of alternative MPLS paths available from source node s(i) to destination node d(i). Fields 3 through R i +2 ( 52 c - 52 x ) store the PIN's of these specific MPLS paths, which are also identical to the array indices of the corresponding entries in the PATHS table 54 . The first field 52 a of row i in the PATH GROUP table 52 , referred to as “Opt-path”, indicates the PIN of the optimal MPLS path (from among the R i alternatives) that should be used to carry the voice packet stream from s(i) to d(i), if the next call arrival between these two nodes is to be admitted.
In selected embodiments to be more fully developed below, a negative number stored in the “Opt-path” field 52 a is understood to signify that all of the R i paths from s(i) to d(i) are currently blocked. Note that this field is used only by certain versions of the call admission control and load balancing algorithm to be presented below; it is ignored (or eliminated) in other embodiments.
The PATHS table 54 has a total of P=Σ i=1 U R i entries (rows), one corresponding to each MPLS path within the network domain, and indexed by the PIN's. The second field 54 b of each entry j in the PATHS table 54 provides the number of hops H j in the MPLS path with PIN j. Fields 3 , . . . , H j +2 ( 54 c - 54 x ) provide the indices of the entries (rows) in the LINKS table 56 which store information pertaining to the links in the path with PIN j. The first field 54 a of entry j in the PATHS table stores a number between 0 and 1.0. This number indicates the probability of assigning the path with PIN j to carry the voice packet stream from the corresponding source node to the destination node, should the next call arrival between these nodes be admitted. For a given source and destination, the sum of the selection probabilities for the corresponding R i MPLS paths can be less than 1.0 in which case the residual amount signifies the probability that none of these paths is selected hence blocking the call in one direction. As above, the probability field is used only by certain embodiments described below; it is ignored (or eliminated) in others.
Each of the L entries in the LINKS table 56 has two fields, the first one 56 a indicates the capacity reserved for voice on the link in question, and the second one 56 b stores a current status metric (e.g., percent utilization or unused bandwidth) used in call admission control and load balancing decisions.
The INDEX, PATH GROUP and PATHS tables 50 , 52 , 54 together provide a record of the exact sequence of links traversed by each of the alternate paths set up across the IP network between every pair of edge nodes. The LINKS table 56 provides (i) the capacity 56 a allocated for voice on each network link and (ii) a metric 56 b reflecting the current voice occupancy status of that link. The data stored in the four tables comprise the information needed to make call admission control and load balancing decisions.
The INDEX table 50 , the PATH GROUP table 52 except for the “Opt-path” column 52 a , the PATHS table 54 except for the “Sel-prob” column 54 a , and the “Capacity” column 56 b of the LINKS table 56 , are populated in advance. This may be done either by human operator, or the CCDB 36 may have the capability to program these tables in response to messages containing routing and bandwidth reservation information sent by higher level control functions that actually set up the MPLS paths and assign priority weighting at the nodes 42 . In fact, these configurations may be re-programmed periodically to “tune” to major shifts in the traffic pattern, albeit on a time scale much slower than that of the real-time call admission control and load balancing functions. On the other hand, the “Opt-path” column 52 a of the PATH GROUP table 52 and the “Sel-prob” column 54 a of the PATHS table 54 , and the “Metric” column 56 a of the LINKS table 56 , are dynamically updated to reflect real-time link and path status. This is accomplished either by update messages from the Gatekeepers 32 , in one embodiment known as the accounting-based approach, or by traffic measurement reports sent by the IP routers 42 , in another embodiment known as the measurement-based approach.
With reference now to FIGS. 3 and 4 , a specific algorithm for centralized VOIP call admission control and load balancing is shown based on the framework described above. It operates on per-call updates and decision making performed at the CCDB 36 (FIG. 1 ). Henceforth referred to as the exact algorithm, this is an accounting-based approach and all the control capabilities are fully centralized within the CCDB 36 . It offers the advantage of being precise in the sense that it can match the level of QoS assurance and bandwidth efficiency attainable in TDM networks.
Accounting-based call management is preferably implemented assuming two general principles:
There is a distinct voice sub-network by virtue of a prioritization scheme such as Diffserv or the like. The gatekeepers 32 are collectively cognizant of the state of this sub-network, or can access data relating thereto by aggregating information at a central location such as the CCDB 36 .
Note that the “Opt-path” column 52 a of the PATH GROUP table 52 and the “Sel-prob” column 54 a of the PATHS table 54 ( FIG. 2 ) are not used by the exact algorithm, and may be eliminated. The description of the exact algorithm below will envisage link occupancy metering in terms of link utilization, but those skilled in the art can appreciate that the algorithm could easily be converted to measure link occupancy in terms of other suitable criteria such as the unused bandwidth. Accordingly, the Metric field 56 b of entry 1 in the LINKS table 56 in CCDB 36 ( FIG. 2 ) provides the most recent estimate of the percentage utilization of the capacity available for voice on link 1 . The exact minmax algorithm has two components, one corresponding to call arrival ( FIG. 3 ) and the other corresponding to call departure (FIG. 4 ). These are described below.
The admission control and load balancing function shown in FIG. 3 begins with a gatekeeper 32 requesting to admit a call of bandwidth B between a pair of edge nodes i, and j as shown in step 60 . The CCDB 36 then determines availability of a forward path through the network 40 by setting the source edge node 42 as i and the destination edge node 42 as j, in step 62 . For each path r from among the R sd choices available for the source-destination pair (s, d), as indicated by the INDEX table 50 and the PATH GROUP table 52 , the CCDB 36 determines util (r)=Max{[Metric (l)+B/Capacity(l)]; lεset of links in path r as indicated by the PATHS table 54 and LINKS table 56 }. In other words, in step 64 , the CCDB 36 assigns a cost to each path between the source and destination equivalent to the maximum of the costs associated with the set of links that it is comprised of. By adding B/Capacity(l) to Metric(l), the path cost computation step accounts for the effect the new call would have on the link utilizations, should it be admitted on the path. The path cost thus equals the link cost of the bottleneck link, with the impact of the new call accounted for. It is to be understood that “cost” as used here is a measure of the degree to which a link 44 or path is loaded. As an example, we employ percentage utilizations of network link capacities to specify their associated costs. This notion of cost is readily distinguishable to those skilled in the art, from the more common use of the term “cost” in reference to financial considerations. After computing the path costs the processor 36 b selects the minimum cost path k such that util (k)≦util (r) for every path r from the source node s to the destination node d, as illustrated in step 66 . This completes the “load balancing” portion of the decision in the forward direction.
After identifying the smallest cost path, the CCDB 36 determines if the minimum path cost exceeds a utilization threshold in step 70 , where the threshold indicates the point at which new calls should not be accepted on any link. If the minimum path cost is too high, the CCDB generates and forwards a BLOCK signal to the requesting gatekeeper 32 , as seen in step 72 . On the other hand, if the threshold is not exceeded, the CCDB sets the minimum cost path selected as the forward path, step 74 . This completes the “admission control” portion of the decision in the forward direction.
In IP networks, availability and optimality of a bandwidth guaranteed forward path does not in general imply the availability or optimality of one in the reverse direction. In particular, as noted earlier, the forward and reverse paths could even traverse different sets of nodes and links. Continued reference to FIG. 3 illustrates the determination of the reverse path by first reversing the source node and destination node, indicated by step 82 . Steps 84 , 86 and 90 illustrate selection of a minimum cost path and a threshold comparison substantially similar to the above described steps 64 , 66 and 70 . If a suitable reverse path could not be identified, the gatekeeper 32 is notified with a BLOCK signal as in the case of the earlier decision in the forward direction. In the event that neither the forward path nor the reverse path exceed the threshold, the decrease in bandwidth available on the links 44 comprising these two paths due to the call about to be admitted is reflected in the stored cost metrics 56 b as shown in step 96 . We presently employ the percentage utilization of the voice capacity on each link as its cost metric. Accordingly B/Capacity(l) is added to Metric(l) ( FIG. 2 , 56 b ), for each link 1 on the forward path as well as on the reverse path, as indicated by the PATHS and LINKS tables 54 , 56 . At this point in the algorithm, the paths have been selected and metrics for the links to be used have been adjusted. The PIN's of the forward and reverse voice paths are conveyed to the requesting gatekeeper 32 , to be used to set up the call, as illustrated in step 98 .
FIG. 4 illustrates the procedures to reclaim the allocated bandwidth upon termination of a call. A gatekeeper 32 submits a request to release a call of bandwidth B that had occupied an MPLS path in the forward direction, and an MPLS path in the reverse direction as seen in step 100 . CCDB 36 then subtracts B/Capacity(l) from Metric(l) for each link 1 of the forward path and the reverse path, as indicated by the PATHS and LINKS tables 54 , 56 and depicted in step 102 .
Per-call updates and decision making, as used in the above algorithm, can potentially impose relatively high processor as well as communication overhead; for example, the gatekeepers 32 will need to communicate with CCDB 36 and the latter will need to execute the procedures described, on a per-call basis. Hence, several alternate, less exact, algorithms are also provided. The first inexact alternative that we will present also has an accounting-based flavor. However, database updates as well as decision making are now performed on a periodic rather than on a per-call basis. This leads to significant reductions in call processor and signaling overhead, but runs the risk of occasional QoS violations and bandwidth inefficiency. The former drawback can be overcome at the cost of maintaining adequate guard bands (safety margins) on network links; this will translate into added bandwidth overhead. Apart from the accounting-based inexact algorithm, we shall also present a measurement-based inexact algorithm which is similar, with the exception that database updates are based on real-time traffic measurement reports sent by the IP routers 42 rather than on call counts sent by the gatekeepers 32 .
FIG. 5 illustrates a system employing a modified gatekeeper 132 used to reduce interactions between CCDB 36 and the gatekeepers 32 . Accordingly, each modified gatekeeper 132 is retrofitted with certain data structures, referred to as satellite control databases 136 . A generic structure of the satellite database 136 that applies to all the different variants of the inexact algorithms to be described below is depicted in FIG. 6 . Again, certain components of these data structures may not apply to certain variants and may be eliminated or left unpopulated as appropriate.
Referring now to FIG. 6 , the basic structure of the satellite database 136 is similar in many respects to that of the CCDB 36 (FIG. 2 ). The main differences are (a) the LINKS table 56 ( FIG. 2 ) is absent in the satellite database 136 , and (b) the PATHS table 154 has only two columns, a path selection probability column 154 a (similar to the Sel-prob column 54 a in FIG. 2 ), and a “local” bandwidth usage column 154 b for each MPLS path. The number of entries within the satellite database 136 is considerably smaller than in the CCDB 36 . In particular, if there are K gatekeepers 132 within the network administration domain, each gatekeeper database 136 tracks, on the average, only N(N−1)/K source-destination node pairs. In the interest of minimizing the processing load, the same array indexing structure (in terms of PIN's and NIN's) as used in CCDB 36 is employed in the satellite databases 136 as well. As noted earlier, direct array manipulations avoid the need for string matching operations, and thereby lead to faster and simpler implementation.
FIG. 7 shows a generic inexact algorithm, as opposed to the exact algorithm discussed above (FIGS. 3 and 4 ). It is centered on the notion of a sequence of steps executed repeatedly after a pre-determined interval referred to as the update interval. During each such cycle, the processor 36 a first updates the Metric field column 56 b of the LINKS table 56 in the CCDB 36 , seen in step 200 . As more fully developed below, this is alternately accomplished either by messages initiated by gatekeepers 132 (i.e., accounting based) or by traffic measurement reports from the IP routers 42 (i.e., measurement-based). The processor 36 a then computes the admission control and load balancing decisions exhaustively for all source-destination node pairs within the administrative domain, to be used by the gatekeepers 132 until the next update epoch, seen in step 202 . As will be more fully developed below, there can be a deterministic and a probabilistic variant of the control decisions. The processor 36 a disseminates the computed control decisions to the gatekeepers 132 , for storage in the satellite databases 136 , as seen in step 204 . For each new call arrival to a gatekeeper 132 , the locally stored control decisions are executed until the next update is received. The process cycles periodically according to the determined update interval, as seen in step 206 .
Focusing on steps 202 , 204 , since they do not depend on the specific form of link metric update (i.e., whether accounting-based or measurement-based), there are two variants of the control decisions that may be used, namely, a deterministic variant and a probabilistic variant. These are described below.
A. Deterministic Form of Control:
Referring to FIG. 8 , with deterministic control each gatekeeper 132 either assigns a fixed path for all call originations between each source-destination pair that it handles, or blocks all calls between them, for the duration of the current update cycle. The deterministic variant uses the Opt-path column 52 a of the PATH GROUP table 52 ( FIG. 2 ) within the CCDB 36 and the Opt-path columns 152 a of the PATH GROUP tables 152 ( FIG. 6 ) in the satellite databases 136 . However, the Sel-prob column 54 a of the PATHS table 54 ( FIG. 2 ) in the CCDB 36 and the Sel-prob columns 154 a of the PATHS tables 154 ( FIG. 6 ) in the satellite databases 136 are not used; hence these may be eliminated. Following the LINKS table 56 update during each update cycle, step 200 , the CCDB 36 computes the “optimal” paths to be used by all the source-destination pairs in the administrative domain, based on the current link status information. These optimal paths are then stored in the “Opt-path” fields 52 a in the PATH GROUP table 52 (FIG. 2 ). Also, if all paths are blocked between a given pair of source and destination edge routers 42 , a negative number is stored in the respective “Opt-path” field 52 a . These steps are taken in the following manner, which is a simplified version of the algorithm described earlier for the exact scheme.
Select a source-destination pair, (s, d), s, dε1, . . . , N; s≠d, as seen in step 220 . For each path r from among the R sd choices available for the source-destination pair (s, d), as indicated by the INDEX 50 and PATH GROUP 52 tables, determine util(r)=Max{Metric(l); lεset of links in path r as indicated by the PATHS 54 and LINKS 56 tables}. In other words, for each path between the source-destination pair, set a path utilization metric equal to the link metric of its bottleneck link. However, unlike with the exact approach, the bandwidth of an individual incoming call is not factored into the metric computation. Next, the minimum cost path k is selected such that util (k)≦util(r) for every path r from source node s to destination node d, as seen in step 222 . Next, a comparison is made as to whether the minimum path cost util (k)≧U max , the maximum threshold on allowable utilization. If so Opt-path(INDEX(s, d)) is set to −1, as seen in step 226 , otherwise Opt-path(INDEX(s, d)) is set to k, as seen in step 228 . In the case of the inexact algorithm, the threshold U max attains added significance as the guardband that needs to be maintained on the link capacities to protect against potential Qos violations introduced by the inexactness of the approach. Depending on the duration of the update interval, this may have to be set sufficiently large; in contrast, the value of U max can be very small in the case of the exact scheme, since the control database is updated on a call-by-call basis. The above steps are repeated until the optimum paths (or blocked status) are computed for all valid source-destination node pairs.
Finally, as seen in step 204 ( FIG. 7 ) above, CCDB 36 sends the decision variables in a set of messages to the gatekeepers 132 . The decision update message sent to each gatekeeper 132 includes {(i, j, Opt-path), (j, i, Opt-path)}, where i=1, . . . , N; jεthe set of edge routers 42 each of which interfaces with one or more voice gateways 24 that are managed by the gatekeeper 132 in question. Upon receipt of the decision update message, each gatekeeper 132 copies each received data item (i, j, Opt-path) into the corresponding local Opt-path variable 152 a in its satellite database 152 by following the link provided by INDEX(i,j) in table 150 . Until the next decision update message is received from CCDB 36 , the gatekeeper 132 locally looks up the Opt-path field 152 a upon each new call arrival between a given source-destination pair. If a negative value is indicated, all paths are understood to be blocked and the call is not admitted, else the path with PIN equal to the alue stored in Opt-path 152 a is assigned.
B. Probabilistic Form of Control:
In this embodiment, each gatekeeper 132 stores a probability with which it is expected to select each of the available MPLS paths between a given pair of source and destination edge routers 42 , for the duration of the current update cycle. In other words, for each source-destination pair (s, d) which has RSd available MPLS paths, the applicable gatekeepers 132 are provided with a set of fractions p 1 , . . . , p Rsd . While processing each new call arrival, a gatekeeper 132 would select path i with probability p i , and block the call with probability 1−Σp j . Note that this model requires each gatekeeper 132 to have the capability to select a path (or to reject the call) with a specified probability, based on suitable generalized round-robin algorithms. This strategy offers the potential to allow a more graceful and even distribution of the load, particularly when the update intervals are not small enough.
The probabilistic approach uses the “Sel-prob” column 54 a of the PATHS table 54 within CCDB 36 and the “Sel-prob” columns 154 a of the PATHS tables 154 within the satellite databases 136 . However, the “Opt-path” columns 52 a , 152 a of the PATH GROUP tables are not used, and may be eliminated. Following the LINKS table 56 update during each update interval, the CCDB 36 computes the admission decisions 202 (FIG. 7 ), in this case a selection probability associated with every path within the administrative domain. As above, this decision is based on the current link status information, the origin of which will be more thoroughly discussed below.
Reference to FIG. 9 depicts a relatively simple, exemplary embodiment, for the sake of illustrating the computation of the admission decisions. The processor 36 b selects a source and destination pair of end nodes 42 , as seen in step 250 . For each path r from among the R sd available choices between source s and destination d (where s, dε1, . . . , N; s≠d, and N is the number of edge nodes 42 ), the processor 36 b determines a path utilization metric U r =Max{Metric(l); lεset of links in path r as indicated by the PATHS and LINKS tables 54 , 56 }. In other words, the processor 36 b sets each path utilization equal to the utilization associated with its bottleneck link as in the previous embodiments; this is indicated in step 252 . Processor 36 b next computes two sets of parameters: (a) the probability of blocking the call as a function of the average utilization of the R sd available paths between source s and destination d, and (b) the conditional probability of selecting each path r, should a decision be made to admit an incoming call. For computing the blocking probability, the processor 36 b first calculates U avg , the average utilization of the R sd available paths between source s and destination d, given by
1 R sd ∑ j = 1 R sd U j .
Next, a specified function Block(U avg ) is applied to U avg to compute the blocking probability. Specifically, if U avg is the average path utilization, then the call is blocked with a certain probability Block(U avg ). The function Block(.) is determined in advance and statically programmed into the processor 36 b logic, and could for example have a form such as:
Block ( U avg ) = 0.0 , 0 ≤ U avg < 0.8 ; 0.25 , 0.8 ≤ U avg < 0.9 , 0.5 , 0.9 ≤ U avg < U max ; 1.0 , U avg ≥ U max
In other words, if the average path is between zero and 80% capacity, the call blocking probability function returns a zero value indicating the admissibility of all calls. If the average path is between 80% and 90% capacity, the call blocking probability function returns a 0.25 value signifying that 25%. of the incoming calls should be blocked. If the path is between 90% capacity and the threshold capacity U max , the call blocking probability function returns a 0.50 value indicating that only half of the incoming calls should be admitted. And to complete the example, if the path is over the threshold capacity U max , the call blocking probability function returns a value of 1.0 signifying that all calls should be blocked. Note that the objective of such a statistical blocking function (rather than admitting all calls indiscriminately till all paths are saturated) is to allow graceful traffic throttling and prevent potential oscillatory behavior, especially when the update interval is not small enough. Computation of the average path utilization and its mapping into the call blocking probability as described above is implemented by step 254 in FIG. 9 . To obtain the conditional selection probabilities, the processor 36 B first calculates the residual utilization of each path r available from source s to destination d, given by max{ 0 , U max −U r } where U max denotes the allowable peak utilization of any link (or path). The maximization operation is to ensure that the computed residual utilization is never negative; if a path occupancy is greater than or equal to the allowable threshold U max , then its residual capacity is identically zero. Next, the conditional selection probability {circumflex over (p)} r for each path r is selected proportional to its residual utilization according to the following rule:
If
∑ j = 1 R sd max { 0 , U max - U j } = 0 , set p ^ r = 0 , r = 1 , … , R sd
Else, set
p ^ r = max { 0 , U max - U i } ∑ j = 1 R sd max { 0 , U max - U j } , r = 1 , … , R sd .
In other words, if the sum of residual utilizations over all paths is zero, then it indicates that every available path is at, or exceeds, the utilization threshold U max . Accordingly, the conditional probability of selecting any path is set to zero or {circumflex over (p)} r =0 for all the R sd path choices because the source-destination pair is blocked. If this is not the case, the processor 36 b calculates the conditional probability {circumflex over (p)} r for each path r between the source and destination in question by dividing its residual utilization by the sum of residual utilizations over all available paths. This strategy is adopted to encourage utilization of under-utilized paths over those that are over-utilized. Calculation of the conditional path selection probabilities {{circumflex over (p)} r } as described above is carried out in step 256 of FIG. 9 .
Finally, the unconditional path selection probability of each path r, denoted by p r , is calculated by multiplying the corresponding conditional probability {circumflex over (p)} r computed in step 256 and the probability of call admission given by subtracting the probability of blocking Block(U avg ) computed in step 254 from 1. In equation form this computation is given by p r ={circumflex over (p)} r ×(1-Block(U avg )), and is implemented by step 257 in FIG. 9 . The interpretation of the set of parameters {p r } thus computed for a given source node s and destination node d is that an incoming call from s to d should be blocked with probability 1−Σ r=1 R sd p r , and admitted on path r with probability p r .
The selection probabilities are stored in the “Sel-prob” fields 54 a in the PATHS table 54 (FIG. 2 ), and the algorithm loops back as seen in step 260 , until the selection probabilities for all source-destination pairs in the domain are calculated.
The CCDB 36 sends the decision variables {p r } in a set of decision update messages to the gatekeepers as seen in step 262 . The decision update message sent to each gatekeeper is of the form, {(PIN, Sel-prob)}, with one data item corresponding to each path that either originates or terminates at an edge router 42 that interfaces with one or more voice gateways 24 managed by the gatekeeper 132 in question. Upon receipt of the decision update message, each gatekeeper 132 copies each received data item (PIN, Sel-prob) into the corresponding local “Sel-prob” variable in its satellite database 136 by using the array index PIN.Until the next decision update message is received from CCDB 36 , the gatekeeper 132 locally looks up the relevant “Sel-prob” fields, upon each new call arrival between a given source-destination pair. As is clear from the above discussion, an arriving call is blocked with probability 1−Σp r , and admitted on path r with probability p r .
Referring back to FIG. 7 , the embodiments above have not specifically addressed updating the LINK cost metric fields in the CCDB as seen in step 200 . Two embodiments are presented below to more fully describe a gatekeeper 132 initiated (i.e., accounting-based) system and a system initiated at the IP router 42 level (i.e., measurement-based).
The flow of information in the gatekeeper-initiated update approach is illustrated in FIG. 10 . With this update system, each gatekeeper 132 tracks the bandwidth usage of the various MPLS paths due to calls that it admits. This is tracked in the Bw-usage fields 154 b of the PATHS table 154 ( FIG. 6 ) within the satellite database 136 . In particular, whenever a gatekeeper 132 admits a call of bandwidth requirement B, this is added to the Bw-usage fields 154 b corresponding to the PIN's of the forward and reverse paths assigned to the call. Similarly, whenever a call terminates, the gatekeeper 132 subtracts the bandwidth it had occupied from the Bw-usage fields 154 b corresponding to the PIN's of the forward and reverse paths that had carried the call. In this sense, the satellite database 136 updates occur on a per-call basis; however, no complex computations or manipulations are needed, as in the case of the exact algorithm discussed earlier.
During each update interval of duration T, each gatekeeper 132 sends a status update message to the CCDB 36 . This message is of the form {[PIN, Bw-usage]}, which is essentially a copy of the Bw-usage column 154 b of the PATHS table 154 ( FIG. 6 ) in its satellite database 136 . The CCDB 36 writes the status update message received from each gatekeeper 132 into a buffer assigned to that gatekeeper. The buffer allows graceful degradation in the event of the loss of a status update message, in the sense that the update message from the previous update cycle, albeit a little outdated, could still be used to perform the update calculations. At the end of the update interval, the CCDB 36 first resets all the LINKS table 56 Metric field entries 56 B to zero. It then processes each data item in the most recent status update message received from each gatekeeper 132 in sequence. For each data item of the form [PIN, Bw-usage], the CCDB identifies each affected link 1 by looking up the PATHS and LINKS tables 54 , 56 (recall that the former can be directly indexed by the PIN) and adds [Bw-usage/Capacity l] to Metric l 56 b.
Once all the data items from all the gatekeepers 132 have been processed, the Metric field 56 b corresponding to each link should provide the most recent estimate of its utilization. The CCDB processor 36 b can now proceed with steps 202 and 204 ( FIG. 7 ) of the inexact algorithm described above for the current update cycle.
The flow of information in the measurement-based usage status update model is illustrated in FIG. 11 . With the measurement-based system, the gatekeepers 132 are not involved in the link status updates at the CCDB 36 . Thus the Bw-usage column 154 b in the PATHS table of the satellite databases can be eliminated. Status update is accomplished instead by traffic measurement reports sent by each IP router 42 , 42 ′, once every T seconds. The report from a specific router 42 , 42 ′ will include a data item in the form [flinkid, voice-count], corresponding to each link emanating from it. Linkid provides the identity of the link in a form that the CCDB 36 can interpret, and voice-count provides a bit count corresponding to the Diffserv priority class assigned to voice on the link in question. Upon receipt of a status update message, CCDB 36 looks up the LINKS table 56 ( FIG. 6 ) for an entry indexed by each linkid in the received message, and writes [voice-count/(T×Capacity(linkid))] into the corresponding Metric field 56 b , where T as may be recalled is the duration of the update cycle. Again, a buffering strategy is applied to the update messages from each router, as in the case of the accounting-based update system, to allow graceful degradation in the event of the loss of update messages. Once all the LINKS table entries are updated, the CCDB processor 36 b can proceed with steps 202 and 204 ( FIG. 7 ) of the inexact algorithm described above for the current update cycle.
The simplicity of the measurement-based approach compared to the gatekeeper-initiated approach may readily be appreciated. There is no need to perform per-call updates within the satellite databases, or to perform the aggregation operations within the CCDB mentioned above for every update cycle.
One advantage with the measurement-based usage status update is that it can facilitate greater distribution of implementation. In particular, all the CAC and LB calculations can be fully distributed among the gatekeepers 132 , with a few modifications. With the latter strategy, the CCDB 36 merely functions as a management module that collects the link status updates from the IP routers 42 every T seconds, and simply forwards them to the gatekeepers 132 . Each gatekeeper (or an adjunct module) replicates the full-fledged CCDB database 36 b structure shown in FIG. 2 within its satellite database, instead of the limited version shown in FIG. 6 for the centralized inexact schemes presented above. Upon receipt of the link updates forwarded by the CCDB 36 during an update cycle, each gatekeeper 36 writes them into the local copy of the LINKS table within its satellite database. It then proceeds with the execution of step 202 ( FIG. 7 ) of the inexact algorithm to generate the decision variables as described earlier. This is carried out either based on the deterministic variant or on the probabilistic variant; the resulting decision variables are stored either in the “Opt-path” column or in the “Sel-prob” column of the enhanced satellite database, to be used to make admission control and load balancing decisions during call arrivals over the current update cycle. Note that step 204 in the flowchart shown in FIG. 7 is absent in the distributed model since there is no need to disseminate the admission control decisions computed locally at each gatekeeper. The advantage with the distributed approach is that the computational burden on each gatekeeper 132 is less than on the CCDB 36 in the centralized mode, by a factor of K, where K is the number of gatekeepers in the administrative domain. This is due to the fact that each gatekeeper 132 deals with N(N−1)/K source-destination pairs on the average. A second advantage is the superior robustness, since the failure of the control functions at one gatekeeper 132 affects only those voice gateways that it manages, whereas the failure of CCDB 36 in the centralized mode can affect the whole network domain.
Those skilled in the art can appreciate that ptions exist to adapt the connection admission control capability of the embodiments presented to the special case where network routing is based on the widely available Open Shortest Path First (OSPF) routing standard (rather than being limited to MPLS). However, OSPF does not allow setting up explicit paths; hence the flexibility to set up multiple explicit routes with spatial diversity between pairs of nodes does not exist. Therefore the load balancing (LB) capability cannot be extended to networks that employ OSPF-based routing.
Absence of the load balancing option in the OSPF context implies that a PATH GROUP table 52 ( FIG. 2 ) would become unnecessary in the CCDB 36 ( FIGS. 1 , 5 ). In that case, each entry in the INDEX table 50 could provide the PIN of the corresponding unique routing path as selected by the OSPF algorithm. The PIN would refer to an entry in the PATHS table 254 ( FIG. 12 ) which should now have only P=U=N(N−1) entries altogether. As before, each PATHS table entry provides references to a set of entries in the LINKS table, which correspond to the network links chosen by the OSPF algorithm to route the path in question. The reduced structure of the CCDB applicable to the OSPF context is shown in FIG. 12 . Along similar lines, the generic version of the satellite database shown in FIG. 6 can be modified to the reduced version shown in FIG. 13 , to be used in conjunction with OSPF routing.
Without load balancing, the algorithms shown in FIGS. 3 , 8 and 9 would be simplified when adapted to an OSPF-based network. The version of the exact algorithm applicable to OSPF is shown in FIG. 14 . The key difference from the generic version in FIG. 3 is the absence of steps analogous to steps 66 and 86 (FIG. 3 ), since there is no path selection in the OSPF scenario; all that is needed is to determine if the unique path has enough residual bandwidth to admit the new call. With the load balancing capability removed, the distinction between the deterministic form of the inexact scheme shown in FIG. 8 and the probabilistic version shown in FIG. 9 also blur.
In FIG. 15 we show a modified version of the probabilistic inexact algorithm applicable to the OSPF context. As may be noted, steps analogous to steps 256 and 257 ( FIG. 9 ) from the generic version are absent in the OSPF-specific version. In the latter case, a path utilization metric U is computed for the unique path between a source and destination pair, and mapped into an admission probability. For the latter, a suitably chosen blocking function Block(U) is subtracted from 1 and stored in the Adm_prob field 354 a of the CCOB ( FIG. 12 ) and disseminated to the gatekeepers where they are stored in the respective reduced satellite databases. Upon each call arrival during the current update cycle, the call is admitted on the unique path with probability Adm_prob and blocked with probability 1−Adm_prob. Note that in the absence of load balancing, the deterministic variant of the inexact algorithm degenerates to the special case of the probabilistic variant corresponding to the blocking function: Block(U)=0.0, U<U max ; 1.0, U≧U max .
The only remaining step to implement the CAC capability in conjunction with OSPF is providing the means to infer the routes autonomously selected by OSPF. Those skilled in the art will appreciate that unlike in the case of MPLS one cannot externally influence the routing decisions made by OSPF.
Several embodiments exist to extract the routing information in an OSPF domain. One is to collect the routing table entries at the transit routers 42 ′, which correspond to the (limited number of) destination edge routers 42 terminating voice. A second option would be to program the traffic monitors at the routers 42 ′ ( FIGS. 1 , 5 ) to randomly sample the transiting voice packets (distinguishable, for example, by the Diffserv-Code-Point (DSCP) field) on each link, and record the distinct source-destination address pairs that it encounters. The information generated by either mechanism can be sent to a central location that can interpret the data, e.g., the CCDB 36 . The collection and reporting of the data for inferring routes can be done at a much slower time scale (e.g., once in 15 minutes), compared to the real-time CAC and LB control actions discussed here.
With the first strategy above, one may map each pair of source and destination NIN's to the corresponding IP addresses, and the respective chain of routing table segments collected may be traced to identify all the links in the path. These may then be programmed into the PATHS table 354 (FIG. 12 ). With the second approach, each data item reported by a router 42 ( FIGS. 1 , 5 )will indicate a source node IP address, a destination node IP address, and the identity of a network link. The two IP addresses may be used first to look up a “reverse map” and identify the corresponding source and destination NIN's. These indices can be used to locate the particular entry in the PATHS table 354 corresponding to the specified source-destination pair, and the network link indicated by the data item can be added if not already present, by creating a new logical linkage to the respective entry in the LINKS table 356 . Also, to be able to track changes in the routing pattern, each link pointer in a PATHS table 354 entry is subject to aging. In other words, unless a fresh data item is received within a specified aging interval to confirm the inclusion of a particular network link in the path (unique, in the OSPF case) for a given source-destination pair, that link is removed from the path. Note that the “reverse map” search indicated above is not particularly burdensome since this will be done relatively infrequently (e.g., once every 15 minutes), and furthermore, since the number of edge routers 42 that terminate voice within a domain would be relatively small (e.g., 100). Finally, a third option to infer routes in the OSPF scenario would be to initiate trace-route messages periodically from every source edge node to every destination edge node, and use the feedback received to update the CCDB entries.
The invention has been described with reference to the preferred embodiments. Modifications and alterations will occur to others upon a reading and-understanding of the preceding detailed description. It is intended that the invention be construed as including all such modifications and alterations insofar as they come within the scope of the appended claims or the equivalents thereof.
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An admission control and load balancing system controls admission of packet streams or calls to a network and balances the packet traffic across the network, improving quality of service. The system includes a central database which stores information including cost data associated with individual paths and links across the network. A processor, in communication with the database, coordinates the admission control and load balancing decisions, and updates of the database cost data to reflect the dynamic network conditions, based on input from appropriate data sources. In one embodiment, referred to as the exact algorithm, the database is consulted by the admission control points or gatekeepers prior to admitting each arriving packet stream, and the database contents are updated call-by-call to reflect the allocation of resources to each admitted stream. In another embodiment, referred to as the inexact algorithm, control decision as well as database updates occur on a periodic rather than on a call-by-call basis to promote better scalability. In this embodiment, the processor periodically calculates admission decisions based on cost data in the central database. These admission decisions are then periodically forwarded to a satellite database associated with each gatekeeper, for storage and use in admission decisions until the next update epoch.
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RELATED APPLICATIONS
[0001] This application is a continuation in part of Ser. No. 09/354,243, filed on Jul. 16, 1999, which in turn is a continuation in part of Ser. No. 09/178,973, filed Oct. 26, 1998. Both of these applications are incorporated by reference in its entirety.
FIELD OF THE INVENTION
[0002] This invention relates to newly isolated nucleic acid molecules and their uses. The nucleic acid molecules are shown to be upregulated by the cytokine interleukin-9 (“IL-9”). Also disclosed are the proteins encoded thereby. They are described as T Cell Derived Inducible Factors (“TIFs”). These nucleic acid molecules encode proteins which induce STAT activation in cells. They can be used, for example, in the stimulation of regeneration of targeted tissues. Further, their inhibitors or antagonists can be used to retard, prevent or inhibit differentiation of other tissues.
BACKGROUND AND PRIOR ART
[0003] The last decade has seen knowledge of the immune system and its regulation expand tremendously. One area of particular interest has been that of research on the proteins and glycoproteins which regulate the immune system. One of the best known families of these molecules are the cytokines. These are molecules which are involved in the “communication” of cells with each other. The individual members of the cytokine family have been found to be involved in a wide variety of pathological conditions, such as cancer and allergies. Whereas sometimes the cytokines are involved in the pathology of the condition, they are also known as being therapeutically useful.
[0004] Interleukins are one type of cytokine. The literature on interleukins is vast. An exemplary, but by no means exhaustive listing of the patents in this area includes U.S. Pat. No. 4,778,879 to Mertelsmann et al.; U.S. Pat. No. 4,490,289 to Stern; U.S. Pat. No. 4,518,584 to Mark et al.; and U.S. Pat. No. 4,851,512 to Miyaji et al., all of which involve interleukin-2 or “IL-2.” Additional patents have issued which relate to interleukin-1 (“IL-1”), such as U.S. Pat. No. 4,808,611 to Cosman. The disclosure of all of these patents are incorporated by reference herein. More recent patents on different interleukins include U.S. Pat. Nos. 5,694,234 (IL-13); 5,650,492 (IL-12); 5,700,664, 5,371,193 and 5,215,895 (IL-11); 5,728,377, 5,710,251, 5,328,989 (IL-10); 5,580,753, 5,587,302, 5,157,112, 5,208,218 (IL-9); 5,194,375, 4,965,195 (IL-7); 5,723,120, 5,178,856 (IL-6), and 5,017,691 (IL-4). Even a cursory review of this patent literature shows the diversity of the properties of the members of the interleukin family. One can assume that the larger cytokine family shows even more diversity. See, e.g., Aggarwal et al., ed., Human Cytokines: Handbook For Basic And Clinical Research (Blackwell Scientific Publications, 1992), Paul, ed., Fundamental Immunology (Raven Press, 1993), pg 763-836, “T-Cell Derived Cytokines And Their Receptors”, and “Proinflammatory Cytokines and Immunity.” All cited references are incorporated by reference.
[0005] The relationships between various cytokines are complex. As will be seen from the references cited herein, as the level of a particular cytokine increases or decreases, this can affect the levels of other molecules produced by a subject, either directly or indirectly. Among the affected molecules are other cytokines.
[0006] The lymphokine IL-9, previously referred to as “P40,” is a T-cell derived molecule which was originally identified as a factor which sustained permanent antigen independent growth of T4 cell lines. See, e.g., Uyttenhove et al., Proc. Natl. Acad. Sci. 85: 6934 (1988), and Van Snick et al., J. Exp. Med. 169: 363 (1989), the disclosures of which are incorporated by reference, as is that of Simpson et al., Eur. J. Biochem. 183: 715 (1989).
[0007] The activity of IL-9 was at first observed on restricted T4 cell lines, failing to show activity on CTLs or freshly isolated T cells. See, e.g., Uyttenhove et al., supra, and Schmitt et al., Eur. J. Immunol. 19: 2167 (1989). This range of activity was expanded when experiments showed that IL-9 and the molecule referred to as T cell growth Factor III (“TCGF III”) are identical to MEA (Mast Cell Growth Enhancing Activity), a factor which potentiates the proliferative response of bone marrow derived mast cells to IL-3, as is described by Hültner et al., Eur. J. Immunol. and in U.S. patent application Ser. No. 498,182 filed Mar. 23, 1990, the disclosures of both being incorporated by reference herein. It was also found that the human form of IL-9 stimulates proliferation of megakaryoblastic leukemia. See Yang et al., Blood 74: 1880 (1989). Recent work on IL-9 has shown that it also supports erythroid colony formation (Donahue et al., Blood 75(12): 2271-2275 (Jun. 15, 1990)); promotes the proliferation of myeloid erythroid burst formation (Williams et al., Blood 76: 306-311 (Sep. 1, 1990); and supports clonal maturation of BFU-E's of adult and fetal origin (Holbrook et al., Blood 77(10): 2129-2134 (Aug. 15, 1991)). Expression of IL-9 has also been implicated in Hodgkins's disease and large cell anaplastic lymphoma (Merz et al., Blood 78(8): 1311-1317 (Sep. 1, 1990). Genetic analyses of mice that were susceptible or resistant to the development of bronchial hyperresponsiveness have unraveled a linkage with the IL-9 gene as well as a correlation between IL-9 production and susceptibility in this model (Nicolaides et al., Proc. Natl. Acad. Sci. USA, 94, 13175-13180, 1997). Human genetic studies also point to the IL-9 and IL-9R genes as candidates for asthma (Doull et al., Am. J. Respir. Crit. Care Med., 153, 1280-1284, 1996; Holroyd et al., Genomics 52, 233-235, 1998). Secondly, IL-9 transgenic mice allowed for the demonstration that increased IL-9 expression result in lung mastocytosis, hypereosinophilia, bronchial hyperresponsiveness and high levels of IgE (Temann et al., J. Exp. Med. 188, 1307-1320, 1998; Godfraind et al., J. Immunol. 160, 3989-3996, 1998; McLane et al., Am. J. Resp. Cell. Mol. 19:713-720 (1999). Taken together, these observations strongly suggest that IL-9 plays a major role in this disease Additional work has implicated IL-9 and muteins of this cytokine in asthma and allergies. See, e.g. PCT Application US96/12757 (Levitt, et al), and PCT US97/21992 (Levitt, et al), both of which are incorporated by reference..
[0008] IL-9 is known to affect the levels of other molecules in subjects. See Louahed et al., J. Immunol. 154: 5061-5070 (1995; Demoulin et al., Mol. Cell. Biol. 16: 4710-4716 (1996), both incorporated by reference. It will be recognized that the molecules affected have their own functions in biological systems. For example, Demoulin et al. show that many of the known activities of IL-9 are mediated by activation of STAT transcription factors. As such, there is continued interest in trying to identify molecules whose presence and/or level is affected by other molecules, such as cytokines.
[0009] The disclosure which follows describes such molecules. It was found that nucleic acid molecules encoding the proteins of the invention were expressed in the presence of IL-9, but not in its absence. Hence, these molecules are, inter alia, “markers” for the expression or effect of IL-9 in a subject. The molecules are referred to as T Cell Derived Inducible Factors or “TIFs” hereafter. These and other features of the invention will be seen in the disclosure which follows.
BRIEF DESCRIPTION OF THE FIGURE
[0010] [0010]FIG. 1 compares deduced amino acid sequences of murine and human TIF (SEQ ID NOS: 27 and 28, respectively).
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
EXAMPLE 1
[0011] The murine lymphoma cell line BW5147 is well known as a cell line which can be grown in vitro, without the need to add any cytokines to its culture medium. In order to identify genes induced by IL-9, samples of BW5147 were cultured either with (200 U/ml), or without IL-9, for 24 hours. Then, total RNA was isolated, using guanidium isothiocyanate lysis, and CsCl gradient centrifugation. These techniques are well known in the art. Following this, polyadenylated RNA was purified from the total RNA, by using an oligo(dT) cellulose column. The isolated, polyA RNA was then used to generate double stranded cDNA. A commercially available oligo(dT) primer was used. Anywhere from 3-5 ug of polyA RNA were heated to 70° C. for 10 minutes with 1 μg of oligo dT, and then incubated with 5× first strand buffer (250 mM HCl (pH 8.3), 375 mM KCl, 15 mM MgCl 2 ), 10 mM dithiothreitol, 500 uM of deoxynucledtide triphosphates, and 800 U of reverse transcriptase. Total volume of the reaction mixture was 20 ul, and the reaction was allowed to proceed at 37° C. for one hour. This resulted in synthesis of the first stand of cDNA. Second strand synthesis was accomplished by adding 30 ul of 5 second strand buffer (100 mM Tris-HCl (pH 6.9)), 450 mM KCl, 23 mM MgCl 2 , 0.75 mM β-NAD + , 50 mM (NH 4 ) 2 SO 4 , together with 60U of E. coli derived DNA polymerase I, 2U of E. coli RNase H, 10 U of E. coli DNA ligase, and 250 uM of deoxynucleotide triphosphates, and brought to a final volume of 150 ul. The mixture was incubated for two hours, at 16° C.
[0012] The product was extracted using phenol-chloroform, and was precipitated with ethanol. The final cDNA product was then resuspended in 200 μl of TE.
[0013] These steps were carried out for both the stimulated BW5147 cells (“tester” hereafter), and for parallel, unstimulated BW5147 cells (“driver” hereafter).
EXAMPLE 2
[0014] The cDNA prepared in Example 1 was then subjected to subtraction cloning in accordance with well known methods. To do this, six oligonucleotides were prepared:
[0015] 5′-AGCACTCTCC AGCCTCTCAC CGCA-3 (SEQ ID NO: 1);
[0016] 5′-GATCTGCGGT GA-3′ (SEQ ID NO: 2);
[0017] 5′-ACCGACGTCG ACTATCCATG AACA-3′ (SEQ ID NO: 3);
[0018] 5′-GATCTGTTCA TG-3′ (SEQ ID NO: 4);
[0019] 5′-AGGCAACTGT GCTATCCGAG GGAA-3′ (SEQ ID NO: 5); and
[0020] 5′-GATCTTCCCT CG-3′ (SEQ ID NO: 6).
[0021] These were used as explained herein. Double stranded cDNA (2 ug), was digested with restriction endonuclease DpnII, extracted with phenol-chloroform, precipitated with ethanol, and resuspended in 20 ul of TE (10 mM Tris-HCl (pH 7.5); 1 mM EDTA). Twelve ul (1.2 ug), of cut cDNA was ligated to double stranded SEQ ID NOS: 1 and 2, in a mixture which included 4 ul of desalted SEQ ID NO: 1 (2 mg/ml), 4 ul desalted SEQ ID NO: 2 (1 mg/ml), 10 μl of 5X adapter buffer (330 mM Tris-HCl, pH 7.6, 50 mM MgCl 2 , 5 mM ATP), 7 μl DTT (100 mM), and 28 μl of H 2 O). The oligonucleotides were annealed to each other and to the sample DNA by heating the mixture to 50° C. and then cooling it to 10° C. over one hour, followed by adding 5 ul of T4 DNA ligase, and incubation for 12-14 hours, at 12-16° C. The mixtures were diluted by adding 140 ul of TE. PCR was then carried out on 200 ul samples, as described infra.
EXAMPLE 3
[0022] To carry out PCR, 200 ul samples containing 2 ul of the ligation product in a buffer of 66 mM Tris-HCl, pH 8.8, 4 mM MgCl 2 , 16 mM (NH 4 ) 2 SO 4 , 33 ug/ml BSA, 0.3 mM of each dNTP (concentration: 500 μM), and 2 ug of SEQ ID NO: 2 were first heated at 72° C. for three minutes to remove any of SEQ ID NO: 1 which was hybridized to the product of Example 2. The 3′ ends were then filled in by using 5U of Taq polymerase (5 minutes, 72° C.). Twenty cycles of amplification were carried out (1 cycle: 1 minute at 95° C., and three minutes at 72° C.), after which products were combined, phenol extracted, ethanol precipitated, and resuspended in TE buffer, at a concentration of 0.5 ug/ul. Hereinafter, this is referred to as the representation.
EXAMPLE 4
[0023] The representation was then prepared for subtractive hybridization by removing SEQ ID NO: 1 therefrom by digestion with Dpn II. The resulting digest was phenol extracted and ethanol precipitated. In the case of the unstimulated sample, this resulted in the driver, while the stimulated sample resulted in the tester. Portions of tester (20 ug) were gel purified on a 1.2% agarose gel and isolated. Samples (2 ug), were ligated to SEQ ID NOS: 3 and 4, in the same way that SEQ ID NOS: 1 and 2 were ligated, as described, supra.
[0024] In a first cycle of subtractive hybridization, 0.4 ug samples of tester with SEQ ID NOS: 3 and 4 ligated thereto were mixed with 40 ug of driver cDNA. The mixture was phenol extracted, ethanol precipitated, dissolved in 2 ul of 3XEE buffer (30 mM EPPS pH 8.0), 3 mM EDTA; pH 8.0, 3 mM EDTA. This was overlaid with 30 ul of mineral oil, and denatured for five minutes at 98° C. A 5M NaCl solution (0.5 ul) was added, and DNA was hybridized for 20 hours, at 67° C. The reaction mixture was diluted to 200 ul with TE, and tRNA carrier. The samples were incubated for three minutes at 72° C. to melt away SEQ ID NO: 4, and then four PCR reactions (200 ul) were prepared. These included 20 ul of diluted hybridization mix without primer, to fill in the ends of the reannealed tester, followed by 10 cycles of amplification after adding samples of SEQ ID NO: 3 (1 cycle: 1 minute at 95° C., three minutes at 70° C.) after which products were combined, phenol extracted, ethanol precipitated, and resuspended in 40 μL of 0.2XTE buffer. Single stranded DNA was degraded by a 30 minute treatment of 20 μl of this material with 20 U of mung bean nuclease, at a total volume of 40 ul. Samples was diluted (1:5), in 50 mM Tris-HCl, at pH 8.9, followed by five minutes of heating at 98° C. to inactivate the enzyme. A second PCR was carried out, using 20 ul of the product described supra, 2 ul of SEQ ID NO: 3 (1 mg/ml), and 1 ul (5 U) of Taq DNA polymerase. A total of 18 cycles (1 cycle:1 minute at 95° C., three minutes at 70° C.) were carried out. Products were combined, phenol extracted, ethanol precipitated, and resuspended at 0.5-1 ug/μl. The product is referred to hereafter as “DP1”, or the first difference product.
EXAMPLE 5
[0025] DPI was then digested with endonuclease DpnII, as described above, and was ligated to SEQ ID NOS: 5 and 6, following the same processes described for SEQ ID NOS: 1, 2, 3 and 4. Subtractive hybridization and selective amplification, as described in example 4, was repeated, and second difference product, or “DP2”, was generated. In these experiments, 50 ng of DP 1 was the tester. The driver (40 ug), was as described supra. The process was repeated to generate a third difference product, using SEQ ID NOS: 3 and 4 as adapters. To generate the third product, 100 pg of tester were mixed with 40 μg of driver. All steps of the protocols supra were repeated, except the final amplification was carried out for 22 cycles, where one cycle was one minute at 95° C., and three minutes at 70° C. This yielded the final difference product.
EXAMPLE 6
[0026] The final difference products were digested with DpnII, and then cloned into the BamHI site of a commercially available vector, i.e., ptZ19R. Double stranded DNA plasmids were prepared, and then sequenced, using standard methods. The sequences were compared to known sequences in the GenBank and EMBL data bases, using a BLAST search program.
[0027] At the end of this subtraction procedure, a short cDNA fragment was identified, i.e., a fragment about 200 base pairs long. This fragment was used to screen a cDNA library from BW 5147 cells. The largest clone was sequenced. It is discussed infra. It does not correspond to any known sequence.
[0028] The nucelotide sequence (SEQ ID NO: 7), is 1121 bases long, including a 537 base pair open reading frame, which encodes a protein 179 amino acids long. The predicted molecular weight of the protein is 20,093. There are two additional ATG codons which, if they acted as start codons, would produce proteins 172 and 167 amino acids in length, with molecular weights of 19,335 and 18,770 daltons, respectively. Each form of the protein is characterized by a sequence of hydrophobic amino acids which would be cleaved off of the molecule via the endoplasmic reticulum to provide a mature protein.
[0029] Analysis of the sequence shows three AT rich motifs (TTATTTAT). These motifs are often found in 5′-untranslated regions of cytokines and oncogenes. Kruys, et al., Science 245: 852 (1989), have shown that these repeats modulate stability of mRNA for TIF.
EXAMPLE 7
[0030] The cDNA isolated and analyzed in example 6, supra, was then used as a probe to identify genomic DNA for TIFα.
[0031] A genomic library prepared from mouse strain 129 was screened with SEQ ID NO: 7, following standard methods. An EcoRI fragment from a positive clone was subcloned into plasmid pZERO and partially sequenced. The partial sequence is presented as SEQ ID NO: 8.
EXAMPLE 8
[0032] A second EcoRI fragment from the positive clone described in Example 7, supra, was also subcloned. There was a great deal of homology, but the sequences were not identical. To be specific, intron 1 of this sequence was 98% identical to SEQ ID NO: 8, intron 2 was 100% identical and intron 3 was 92% identical.
[0033] What is striking about the sequences is that the promoters are not at all homologous, suggesting independent regulation. The 5′ untranslated regions are 92% identical. The first exon for TIFα is split into exon 1 α and exon 1 β. The first coding exon (which is exon 1for TIFα and exon 1 for TIFβ) are 99.5% identical, while the second exons are 100% identical, the third exons 97% identical, the fourth exons 98.5% identical, and 96% for the fifth exon. In the untranslated 3′-region, homology is 96%.
EXAMPLE 9
[0034] Using the information described in example 8, supra, a cDNA sequence for the second clone, designated TIFβ was deduced, and is set forth as SEQ ID NO: 9. The genomic DNA sequence was also ascertained, in the same manner as is described, supra, and is set forth as SEQ ID NO: 29.
[0035] As compared to the coding region for TIFα, that of TIFβ has six silent changes. There are two changes which result in an inconsequential amino acid change (at both of positions 36 and 113, Val in TIFα becomes Ile in TIFβ). There is also a more significant change, at position 112, where Gln becomes Arg.
EXAMPLE 10
[0036] Experiments were undertaken to study expression of the TIFs. BW 5147 cells were stimulated with recombinant murine IL-9 (200 U/ml), for varying periods of time (0.2, 0.5, 1, 2 & 24 hours). Total RNA was then isolated, using standard methods and reagents. Reverse transcription was then carried out, using 5 μg total RNA and an oligo (dT) primer. Samples of cDNA corresponding to 20 ng of total RNA were then amplified for 25 cycles using different primers. (One cycle was 4 minutes at 94° C., 1 minute at 57° C., and 2 minutes at 72° C.). The TIF primers were:
[0037] -5′-CTGCCTGCTT CTCATTGCCC T-3′ (SEQ ID NO: 10) and
[0038] 5-CAAGTCTACC TCTGGTCTCA T-3′ (SEQ ID NO: 11) (sense and antisense, respectively).
[0039] These correspond to nucleotides 106-126, and 764-784 of SEQ ID NO: 7, respectively. As a control, β-actin was amplified as well, for 18 cycles (first cycle: 4 minutes at 94° C., 1 minute at 60° C., 2 minutes at 72° C. Succeeding cycles were 1 minute at 94° C., 1 minute at 60° C., 2 minutes at 72° C.).
[0040] Following amplification, post PCR products were analyzed on a 1% agarose gel, and specific amplification was confirmed, following blotting, using internal radioactive probes. The probe for TIF was:
[0041] 5′-GACGCAAGCA TTTCTCAGAG-3′ (SEQ ID NO: 12)
[0042] the conditions and probes set forth were not specific for one or the other of the forms of TIF; however, the amplification product of TIFα contains a KpnI restriction site, while the restriction site for TIFβ does not. Digestion of the amplification products with KpnI indicated that most, if not all, of the TIF mRNA induced by IL-9 was TIFα, suggesting that the TIFα expression was induced rapidly via the IL-9. The mRNA for TIFα was detectable after 30 minutes of stimulation, and reached a plateau over a 1-24 hour time period.
EXAMPLE 11
[0043] Experiments were then carried out which showed that the induction of TIF mRNA by IL-9, described supra, does not require protein synthesis. In these experiments, total RNA was extracted from cells stimulated for 24 hours, as described in example 10, but with or without 10 μg/ml of a protein synthesis inhibitor, cycloheximide, for 4.5 hours. In a parallel set of experiments, cells were not stimulated. The total RNA was extracted, and RT-PCR amplification was carried out as described in example 10. Post-PCR products were analyzed on an ethidium bromide-stained, 1% agarose gel. What was seen was that the induction by IL-9 still occurred when protein synthesis was blocked. Hence, the effect of IL-9 is a direct effect, not requiring the synthesis of a protein mediator.
EXAMPLE 12
[0044] In these experiments, the role of STAT proteins in induction of TIF mRNA was studied on derivatives of the cell line BW5147. The first line, BWh9R, expresses wild type human IL-9 receptors. The line BW-Phe116 is a transfectant with a single mutation (at position 116), which renders the receptor unable to activate STAT transcription factors. Still another cell line, BW-mut6, has a mutation which renders the receptor unable to activate STAT5, while retaining the ability to activate STAT1 and STAT3. Finally, cell line BW-mut7 has a single mutation which renders the IL-9 receptor unable to activate STAT1 and STAT3, but which retains the ability to activate STAT5.
[0045] Cell stimulation, isolation of total RNA, reverse transcription and amplification of cDNA were all carried out as described in example 10 (Cells were stimulated for 24 hours. Both human and murine recombinant IL-9 were used). The PCR products were analyzed on an ethidium bromide stained, 1% agarose gel, as describe supra.
[0046] The analysis revealed that human IL-9 did not induce expression in BW-Phe116, suggesting that STAT transcription factors are implicated. It was found that IL-9 induced TIF expression in the BW-mut6 mutant, but not the mut7 variant, suggesting that STAT1 or STAT3 are involved, but not STAT5.
EXAMPLE 13
[0047] The expression of TIF mRNA in normal mouse spleen cells was then studied.
[0048] Spleen cells from 10-12 week old Balb/c mice were cultured for 24 hours in control medium or the control medium supplemented with 20 μg/ml of LPS (which activates B lymphocytes and macrophages), or ConA (which activates T cells), or ConA plus 1% of a blocking antiserum against murine IL-9, with β actin being used as a control. Purification of RNA, RT-PCR analysis were carried out as described supra.
[0049] The data indicated that TIF is, at best, very weakly expressed in resting spleen cells, not induced by LPS, but strongly induced by ConA. Anti IL-9 antiserum did not affect induction by ConA, suggesting that its effect is not mediated by IL-9, or is mediated by other cytokines.
[0050] When the ConA activated spleen cells were analyzed using sequences of RT-PCR products, it was found that these cells were expressing TIFα predominantly, or exclusively.
EXAMPLE 14
[0051] Further experiments showed that TIF mRNA was expressed even in the absence of IL-9 induction.
[0052] Spleen cells from 5 week old FVB mice were enriched for T cells, using a nylon wool column. Then, the cells were stimulated for 24 hours in medium supplemented with ConA (a T cell activator), or PMA (which activates PKC in most cells), either with or without IL-9.
[0053] Total RNA was isolated using standard techniques, and then ten microgram samples were fractionated via electrophoresis on a 1.3% agarose gel containing 2.2M formaldehyde. The fractions were then transferred to a nitrocellulose membrane, labeled, and assayed in a hybridization assay following Van Snick, et al, J. Exp. Med. 169: 363 (1989), incorporated by reference.
[0054] The results indicated that the induction of TIF by ConA was not modified, and that IL-9 did not induce TIF RNA in PMA activated spleen cells.
EXAMPLE 15
[0055] The expression of TIF mRNA in various cell lines was tested. In these experiments, murine cell lines were stimulated for at least one day, with a particular cytokine. Specifically, 9T7 is a T cell lymphoma, which responds to IL-2, IL-4 or IL-9. Cell lines TS3 and TS6 are derived from T helper cell clones, and proliferate in the presence of either IL-2 or IL-9. MC9 and LI38 are mast cell lines, which proliferate in the presence of either IL-3 or IL-9.
[0056] Following stimulation, total RNA was prepared using standard guanidium isothiocyanate lyses, and CsCl gradient centrifugation.
[0057] The 9T7 line was then analyzed by Northern blotting, as described in example 14, while the other lines were assayed using RT-PCR analysis, as described supra.
[0058] It was found that IL-9 upregulated TIF expression in T helper cells and mast cells, while IL-2 and IL-3 did not. The 9T7 cell line, however, showed roughly the same level of expression, regardless of the cytokine, indicating that IL-9 is not mandatory for TIF expression.
EXAMPLE 16
[0059] The expression of TIF mRNA in B cell lines was then studied. The cell lines A20, 70Z/3, and BCL-1 are B cell leukemia cell lines which grow, in vitro, without cytokines. These cells were stimulated for 24 hours with IL-4 and IL-9 and total RNA was isolated, using standard methods. Expression was analyzed by RT-PCR which was carried out for 35 cycles, followed by blotting and hybridization, as described supra.
[0060] The results indicated that TIF expression is detectable in B cells, but is weakly upregulated at best in the presence of IL-9 and IL-4.
EXAMPLE 17
[0061] Experiments were then carried out to study expression of the inventive molecules in T helper cell lines. TS2 and TS1 are known T helper cell lines, derived from T helper cell clones, which proliferate in the presence of either IL-9 or IL-2 (TS2), and either IL-9 or IL-4 (TS1). Specifically, TS1 or TS2 cells were grown in the presence of the listed cytokines for at least 10 days, after which RNA was extracted using known methods. Expression of the molecules was studied via RT-PCR (35 cycles), using the protocols described supra. In TS1 cells both IL-4 and IL-9 induce TIF expression, but IL-2 does not do so in TS2 cells.
EXAMPLE 18
[0062] Expression of TIF mRNA in various mouse organs were studied. Total RNA was prepared from liver, kidney, heart, brain, intestine, spleen, thymus, lung, muscle and bone marrow, using standard guanidium isothiocyanate methodologies and CsCl gradient centrifugation. Forty cycles of RT-PCR were carried out, using the protocols described supra. Strongest expression was found in thymus tissue, while less intense signals were found in brain tissue, and weaker expression in the remaining tissues.
EXAMPLE 19
[0063] The following experiments describe production of TIFα in 293-EBNA cells.
[0064] Complementary DNA for TIFα was described supra. It was subcloned into a commercially available expression vector pCEP-4, in operable linkage with a CMV promoter. The resulting plasmids were transfected into 293-EBNA cells, using standard lipofectamine methods. Following transfection, the cells were incubated in a methionine free medium, supplemented with 35 S labeled methionine, for 24 hours. Supernatant was harvested, and run on an acrylamide gel, followed by electrophoresis. The gel was then dried and exposed to autoradiography for 1 day. A control was then run by transfecting cells with the same plasmid, in which the cDNA was cloned in the antisense direction.
[0065] A heterogenous band of about 25-30 kilodaltons was found from the cells transfected with TIF in the sense direction. Any discrepancies between the predicted molecular weight, the actual molecular weight in the system, and the heterogeneity, can be attributed to glycosylation. In a series of parallel experiments, cDNA encoding human TIF was expressed in the same way as the murine cDNA was expressed. With the exception of the change of the cDNA, all experimental parameters were the same.
EXAMPLE 20
[0066] Further experiments were carried out to study production of TIFα in COS cells. Specifically, TIFα cDNA was subcloned into the plasmid pEF-BOS.puro described by Demoulin et al., supra, in operable linkage with the EF-1α promoter. The plasmid cDNA was transfected into COS cells, using the same lipofectamine method described supra. The cells were incubated in methionine free medium, supplemented with 35 S methionine for 24 hours, after which supernatant was treated as described in example 20, supra. Again, a heterogenous band of 25-30 kilodaltons was observed, as well as an 18 kilodalton band, which probably represents a non-glycosylated form of the molecule.
EXAMPLE 21
[0067] In these experiments, it was discovered that TIF induces STAT activation in mesangial, neuronal melanoma, and hepatoma cells. It is known that when cytokines activate STAT factors, the factors dimerize, move from cytoplasm to the nucleus, and bind to target sequences in promoters. The details of the experiments follow.
[0068] Transfected 293-EBNA cells as described supra were used following incubation in normal medium for 48 hours, as were supernatant from the controls, also described supra. Samples of a mouse kidney mesangial cell line, (“MES13” hereafter), a rat pheochromocytoma cell line, (“PC12” hereafter), four different human melanomas (SK23, AUMA, NA-8mel and MULL), human heptaoma (HepG3) and rat hepatoma (H-4-II-K) were used. Cell samples (0.5×10 6 ) were stimulated for 5-10 minutes in the presence of 1% of supernatant. Nuclear extracts were then prepared, in accordance with Demoulin et al., Mol. Cell. Biol. 16: 4710 (1996), incorporated by reference. In brief, cells were washed with PBS and then resuspended in 1 ml of ice cold hypotonic buffer for 15 minutes. (Buffer was 10 mM HEPES buffer, pH 7.5, with 10 mM KCl, 1 mM MgCl 2 , 5% glycerol, 0.5 mM EDTA, 0.1 mM EGTA, 0.5 mM dithiothreitol, and 1 mM Pefabloc, 1 mM Na 3 V 4 , and 5 mM NaF). Cells were then lysed by adding 65 μl of NP-40, followed by vortexing. Nuclei were pelleted, by vortexing for 30 seconds at 14,000 rpm, followed by extraction in buffer supplemented with HEPES (20 mM), glycerol (20%), and NaCl (420 mM). Nuclear debris was removed by centrifuging for 2 minutes. DNA binding activity was determined in accordance with Demoulin et al., supra, using a 32 P labeled double stranded oligonucleotide called “GRR,” which contains the STAT binding site of the FcγRI gene promoter, i.e.:
[0069] 5′ATGTATTTCC CAGAAA-3′ (SEQ ID NO: 13) and
[0070] 5′-CCTTTTCTGG GAAATAC-3′ (SEQ ID NO: 14)
[0071] corresponding to the upper and lower strands of the binding sites in the GRR probe. Briefly, 5 μl volume of nuclear extracts were incubated in binding buffer (12 mM HEPES, pH 7.6, 10 mM KCl, 0.5 mM EDTA, 2.5% glycerol, 0.1 mg of poly(dI-dC) per ml) for 5 minutes. Radiolabeled GRR probe (10 5 cpm; approximately 0.5 ng) was added, and incubation was continued for 25 minutes before loading onto a non-denaturing polyacrylamide gel.
[0072] It was also noted that the complexes observed in MES13 cells, described supra, were partially overshifted by both anti-STAT5 and anti-STAT3 antibodies, showing that (i) the cells under examination were targets for TIF, and (ii) that STAT3 and STAT5 are major components of the complex activated by TIF. The difference in STAT profile, as compared to the profile in Example 12, supra, is attributable to the difference in cell source (human versus mouse). It was also observed that human TIF works on murine cells, and vice versa.
EXAMPLE 22
[0073] This example details the isolation and cloning of a nucleic acid molecule which encodes human TIF. First, human peripheral blood mononuclear cells were prepared via standard density gradient centrifugation. Following this preparation, samples were cultured for 24 hours, at 3×10 6 cells/ml, either with or without anti-CD3 monoclonal antibody (The antibody was the commercially available OKT3 mAb, used in the form of ascites fluid at {fraction (1/500)} dilution). This antibody was used because T cell derived cytokines are generally expressed only upon activation by e.g., CD3 specific antibodies.
[0074] Total RNA was isolated from these cells, using standard guanidine-isothiocyanate/CsCl ultra-centrifugation techniques. Following isolation, 10 μg samples of the RNA were reverse transcribed using an oligo (dT)15 primer.
[0075] Following preparation of cDNA, as outlined supra, samples which corresponded to 100 ng of total RNA were amplified, via PCR, using the following primers:
[0076] 5′-AGCTGCTCAA CTTCACCCTG GA-3′ (SEQ ID NO: 15)
[0077] 5′-CCACTCTCTC CAAGCTTTTT CA-3′ (SEQ ID NO: 16)
[0078] which are based upon a murine cDNA sequence, (i.e., SEQ ID NO: 7). The PCR conditions involved 30 cycles of amplification, with one cycle defined as 1 minute at 94° C., followed by 1 minute at 42° C., and then 2 minutes at 72° C. Amplification product was separated on an agarose gel, using standard methods, and then sequenced. The result indicated that fragments of the cDNA had been amplified. Hence, a second reaction was carried but, using the same materials except SEQ ID NO: 16 was replaced by SEQ ID NO: 17, i.e.:
[0079] 5′-CAAGTCTACC TCTGGTCTCA T-3′
[0080] This second PCR reaction was carried out for 25 cycles, with one cycle being defined as 1 minute at 94° C., followed by 1 minute at 45° C., and then 2 minutes at 72° C. The amplification product was subjected to the same steps as the first one. Again, fragments of cDNA were amplified.
EXAMPLE 23
[0081] Following preparation of amplification product, the 5′ end of cDNA was isolated by using standard, 5′-RACE techniques. In brief, first strand cDNA was prepared by using SEQ ID NO: 18 as a primer, i.e.:
[0082] 5′-TGGCCAGGAA GGGCACCACC T-3′
[0083] This primer was based upon the sequence information obtained in accordance with example 22. In brief, the 5′-RACE method was carried out by combining 1 μg of total RNA, prepared as described supra, 2.5 pmoles of SEQ ID NO: 18, reverse transcriptase, reverse transcriptase buffer, 2.5 μl of dNTP mix (10 mM), 2.5 μl of MgCl 2 (25 mM), and 2.5 μl of dithiothreitol (0.1 M). The reaction was carried out and, after completion, original RNA was removed via adding RnaseH, and Rnase TI. Any unincorporated dNTPs, as well as primer and proteins, were removed. The cDNA was tailed using terminal transferase, or “TdT.” This enzyme creates a 3′-binding site for the abridged anchor primer, as described infra. Tailing was carried out by combining the purified, first strand cDNA, TdT, buffer (10 mM Tris-HCl, 25 mM KCl, 1.5 mM MgCl 2 ), and 200 μM of dCTP.
[0084] Following the tailing reaction, PCR was carried out using
[0085] 5′-TGGCCAGGAA GGGCACCACC T-3′ (SEQ ID NO: 19), and 5′-RACE abridged anchor primer:
[0086] 5′-GGCCACGCGT CGACTAGTAC GGGIIGGGIIGGGIIG-3′ (SEQ ID NO: 20).
[0087] The amplification involved 35 cycles (1 cycle defined as 1 minute at 94° C., 1 minute at 56° C., and 2 minutes at 72° C.). Following this, nested amplification was performed on 5 μl of a {fraction (1/100)} dilution of the amplification product, using SEQ ID NO: 19 and the abridged universal amplification primer:
[0088] 5′-GGCCACGCGT CGACTAGTAC-3′ (SEQ ID NO: 21).
[0089] Amplification involved 30 cycles (1 cycle being defined as 1 minute at 94° C., 1 minute at 56° C., and 2 minutes at 72° C.). The resulting PCR product was cloned, following standard procedures, and sequenced.
[0090] These three protocols, i.e., the two experiments described supra which generated fragments, and the 5′-RACE PCR, also described supra, permitted alignment of the sequenced amplification product, to generate the complete sequence.
[0091] Following the alignment, oligonucleotides were generated which flanked the deduced open reading frame, i.e.:
[0092] 5′-CCTTCCCCAG TCACCAGTTG-3′ (SEQ ID NO: 22) and
[0093] 5′-TAATTGTTAT TCTTAGCAGG-3′ (SEQ ID NO: 23).
[0094] These primers were used to amplify the entire open reading frame, using mRNA from CD3 specific mAb stimulated cells, as described supra. For amplification, 25 cycles (1 cycle being defined as 1 minute at 94° C., 1 minute at 56° C., and 2 minutes at 72° C.).
[0095] The complete sequence of the human cDNA is set forth at SEQ ID NO: 24.
[0096] As with the murine sequence, there are potential start codons at positions of SEQ ID NO: 24 which correspond to amino acids 1 and 13, as well as codons corresponding to methionine at amino acid positions 58, 85, and 92. The possible initiator codons correspond to proteins with calculated molecular weight of 19,998 daltons, and 18,735 daltons respectively (for 176 or 167 amino acids, respectively). As with the murine form of the protein, hydrophobic leader sequences are seen, indicating an N-terminal signal sequence of from about 20 to about 40 amino acids.
EXAMPLE 24
[0097] These experiments detail work on the isolation of human genomic DNA corresponding to the cDNA discussed supra.
[0098] Based upon the cDNA sequences, primers were developed which correspond to nucleotides 51-70 and the complement of nucleotides 631-650 of SEQ ID NO: 24. PCR was carried out, using standard methodologies. Specifically, 100 ng of genomic DNA was used as a template, and 33 cycles of amplification were carried out (one cycle of amplification being defined as 94° C. for 30 seconds, 50° C. for 30 seconds, and 72° C. for 5 minutes). Once a sequence was isolated, it was sequenced, and this is set forth as SEQ ID NO: 25. The sequence is about 4.8 kilobases in length, and is believed to contain the entire genomic sequence encoding the TIF molecule, lacking only the 5′ flanking region, the promoter, and the 3′ end.
EXAMPLE 25
[0099] It was of interest to identify where the genomic DNA discussed supra was located in the human genome. In order to do this, two different approaches were taken. In the first, the sequence discussed supra, i.e., SEQ ID NO: 25, was labeled with a flourescent label, and then was used to probe the human genome via fluorescent, in situ hybridization (“FISH”) using standard methods.
[0100] In a second approach, a panel of radioactive hybrid clones were screened using the probe consisting of nucleotides 51-70 of SEQ ID NO: 24, and 5′-ATCAGATGGA TTACTGAATG-3′ (SEQ ID NO:26). PCR was carried out using 25 ng of genomic DNA as a template, for 35 cycles, where one cycle is defined as 94° C. for in minute, 55° C. for 1 minute and 72° C. for 2 minutes.
[0101] Both methodologies indicated that the gene is located at chromosome 12q15. Some work links diseases associated with asthma at this site. See, e.g. Nat. Genet. 15:389-392 (1997); Ober, et al, Hum. Mol Genet. 7(9):1393-1398(1998); Nickel, et al, Genomic 46(1):159-162(1997); Takahashi, et al, Genomics 44(1):150-2(1997); Barnes, et al, Genomics 37(1):41-50(1996), all incorporated by reference.
EXAMPLE 26
[0102] These experiments describe the manufacture of antibodies which bind to the TIF protein. To make these, a peptide consisting of amino acids 40-61 encoded by SEQ ID NO: 7 was coupled to KLH carrier protein, using standard methods and a ratio of 1 mg peptide to 1 mg carrier protein. Subject animals (rabbits), were immunized 3 times, at 2 week intervals, with 150 μg of the complex. The immunogen was emulsified in Complete Freund's Adjuvant for the first injection, and then Incomplete Freund's Adjuvant for the next two.
[0103] A first bleed was performed one month after the last injection, and serum was prepared, following known methods.
[0104] The serum was then tested in a standard Western Blot. In brief, 10 μl of supernatant from cells transfected with either SEQ ID NO: 7 or SEQ ID NO:24 were separated via SDS-PAGE electrophoresis, and then blotted onto PVDF membranes. Antiserum was diluted to 1:500, and used in a standard Western Blot protocol, together with anti-rabbit antibody as the secondary antibody, and a commercially available detection kit.
[0105] It was found that the serum did, in fact, recognize the TIF protein.
[0106] In FIG. 1, the deduced amino acid sequences of murine and human TIF are set out. The high degree of homology is seen in the boxed regions.
[0107] The foregoing examples describe the invention, one aspect of which are isolated nucleic acid molecules, which encode TIF proteins such as those with the amino acid sequence of the protein encoded by the nucleotide sequence of SEQ ID NO: 7, 24 or 25. It will be appreciated by one of ordinary skill that the degeneracy of the genetic code facilitates the preparation of nucleic acid molecules which may not be identical to the nucleotide sequence of SEQ ID NO: 7, 24 or 25, but which encode the same protein. Of course, SEQ ID NOS: 7, 24 and 25 are preferred embodiments of this invention, but other embodiments are also a part of the invention. Genomic DNA, complementary DNA, and RNA, such as messenger RNA, are all to be included therein. Isolated nucleic acid molecules from other animal species, including other mammals, are also a part of the invention. A preferred aspect of the invention are isolated nucleic acid molecules whose complements hybridize to SEQ ID NO: 7, SEQ ID NO: 8, SEQ ID NO: 9, or SEQ ID NO: 24 under stringent conditions. “Stringent conditions,” as used herein, refer, for example, to hybridization at 65° C. in buffer (3.5xSSC), 0.02% Ficoll, 0.02% polyvinylpyrrolidone, 0.02% bovine serum albumin, 25 mM NaH 2 PO 4 (pH 7), 0.1% SDS, 2 mM EDTA, followed by a final wash at 2xSSC, room temperature and then 0.1xSSC/0.2xSDS at temperatures as high as, e.g., about 65° C. More stringent conditions, such as 0.1xSSC, can also be used. These nucleic acid molecules encode proteins of about 17-22 kD as determined by SDS-PAGE, which activates STAT proteins, such as STAT 1, STAT3 and/or STAT5. In glycosylated form, these proteins can range from about 17 to about 30 kilodaltons, as determined by SDS-PAGE.
[0108] Also a part of the invention are expression vectors which include the nucleic acid molecules of the invention, operably linked to a promoter, so as to facilitate expression of the DNA. It is well within the skill of the artisan to prepare such vectors.
[0109] The vectors, as well as the nucleic acid molecules per se, can be used to prepare recombinant cells, be these eukaryotic or prokaryotic, wherein either an expression vector or the nucleic acid molecule itself is incorporated therein. E. coli cells, COS cells, CHO cells, etc., are all examples of types of cells which may be used in accordance with this aspect of the invention.
[0110] Proteins encoded by the above referenced nucleic acid molecules, preferably in isolated form, are another feature of this invention. By “protein” is meant both the immediate product of expression of the nucleic acid molecules, glycosylated forms of it, as well as multimeric forms, such as dimers, trimers, and so forth. Also a part of the invention are multimers, such as dimers, which contain at least one protein molecule of the invention, and at least one, different protein molecule. Preferably, this different protein molecule is a cytokine, such as IL-10. Also included as a feature of the inventions are constructs, such as fusion proteins, where all or a part of the proteins described supra are linked in some fashion, such as in a fusion protein, to at least one additional protein or peptide, or amino acid sequence. The “fusion partner” may be, for example, a molecule which provides a recognizable signal, either directly or indirectly, such as a FLAG peptide, β-galactosidase, luciferase, and so forth. These fusion partners are preferably joined to the molecule which is described supra at the N- and/or C-terminus of the protein; however, it is to be understood that there are many techniques known for joining molecules to amino acids, and any and all of these methodologies can produce constructs which are a part of the invention.
[0111] The individual protein molecules of the invention, as noted supra, will preferably have a molecular weight of from about 17. to about 30 kilodaltons, as determined by SDS-PAGE. In multimeric forms, the molecular weight of the complex will, of course, vary, but the TIF molecules contained therein will each have a molecular weight of about 17 to 30 kilodaltons, as determined by SDS-PAGE.
[0112] The proteins preferably consist of at least about 120 and no more than about 200 amino acids. Preferably, the amino acids sequences consists of or comprises all or part of the amino acid sequences encoded by SEQ ID NOS: 7, 8, 9, 24 or 25. More preferably, the amino acid sequence contains all but about the first 40 amino acids encoded by said SEQ ID's. Even more preferably, it contains all but about the first 20 amino acids encoded by these sequences. Most preferably, the protein comprises amino acids set forth at SEQ ID NO: 27 or 28.
[0113] It will be appreciated by the skilled artisan that the proteins encoded by the above recited nucleic acid molecules are a feature of the invention, and may be used to produce antibodies, in accordance with standard protocols. Such antibodies, in monoclonal and polyclonal form, constitute a further feature of the invention as do fragments of said antibodies, chimeric forms, humanized forms, recombinant forms, and so forth. Also a feature of the invention are immunogens, comprising all or a part of the amino acid sequence protein molecules of the invention, preferably combined with an adjuvant, such as Complete or Incomplete Freund's Adjuvant. Portions of the protein sequences may be linked to other molecules, such as keyhole limpet hemocyanin, to render them more immunogenic. These antibodies can be used, e.g., to determine if the proteins of the invention are present. This is a further feature of the invention, as is now explained. It has been shown, in the examples, that the nucleic acid molecules of the invention were expressed in the presence of the IL-9. Hence, a further feature of the invention is a method to determine if IL-9 is or has been present, wherein one detects either the proteins of the invention, using antibodies for example, or mRNA using the nucleic acid molecules of the invention, as probes. The mRNA can be determined directly, or in the form of cDNA. Such probes may or may not be labeled, as a matter of choice for the user. Hence, one can determine, for example, if, following administration of IL-9, the cytokine is still efficacious, by determining if the nucleic acid molecule of the invention is present. This type of assay can be adapted, for quantitative studies, wherein one determines, for example, either if a cell is sensitive to IL-9, and if so, how sensitive it is. One can also use the proteins of the invention to phosphorylate STAT proteins such as STAT1 , STAT3 and/or STAT 5. This in turn results in dimerization of the STAT protein, followed by migration to the nucleus to provoke the effect that these STAT proteins have on cells.
[0114] One could also use these molecules to test the efficacy of IL-9 agonists or antagonists when administered to a subject, such as a subject suffering from lymphoma, an immune system disorder such as an allergy, acquired immune deficiency syndrome, autoimmune diabetes, thyroiditis, or any of the other conditions described in, e.g, U.S. Pat. No. 5,830,454; 5,824,551, and pending application Ser. No. 08/925,348, filed on Sep. 8, 1997 now allowed, all of which are incorporated by reference. The molecules can also be used to mediate the role of IL-9 in these and other conditions. To elaborate, since IL-9 induces TIFs, the TIFs are useful as IL-9 activity mediators. Thus, a further aspect of the invention is a method to determine activity of endogenous IL-9, such as in situations where excess IL-9 activity is implicated, such as asthmas, allergies, and lymphomas. One can also block or inhibit IL-9 activity by blocking or inhibiting TIF or TIF activity, using, e.g., antisense molecules, antibodies which bind to TIF, or other antagonists of these molecules. For example, m uteins of TIF, which bind to the TIF receptor but do not activate it, therby inhibiting IL-9 induced activity, are a feature of the invention. Examples of conditions which can be treated by the use of such TIF muteins are allergies, asthma, and so forth. Muteins in accordance with the invention can be made in accordance with, e.g., Weigel, et al, Eur. J. Biochem 180 (2):295-300 (1989) and Epps, et al, Cytokine 9(3):149-156 (1997), both of which are incorporated by reference. Such muteins can be used in the treatment of asthma, allergies, or both. Further, it will be clear to the skilled artisan that the models set forth, supra, can also be used to screen for appropriate muteins/ The ability to regulate IL-9 activity is important in conditions such as those listed supra, as well as conditions such as apoptosis, including cortisol induced apoptosis, conditions involving the nuclear expression of BCL-3, since IL-9 is known to induce such expression, and so forth. “Antibodies,” as used herein, refers to any portion of an antibody which binds to TIF, including chimeric and humanized antibodies.
[0115] Another feature of the invention relates to the ability of the TIF type molecules of the invention to either promote regeneration or inhibit differentiation of tissue types on which the molecules are active. As was shown, supra, the TIF molecules target various cancer and normal cell lines (i.e., mesangial and neuronal cells, as well as melanoma and hepatoma cells). Hence, one can stimulate regeneration of tissue via, e.g., adding an amount of a TIF type molecule to a sample in need of regeneration of a tissue acted on by the TIF molecule. This approach can be used both in vitro, and in vivo. Similarly, antagonists of TIF may be added when the situation is one where the aim is to inhibit differentiation of a particular type of tissue, such as melanoma or hepatoma.
[0116] The genes which encode TIF, as noted in Example 25, supra, are located on chromosome 12. This chromosome is associated with asthma, as is known in the art. Hence, a further embodiment of the invention is a method for determining susceptibility to conditions such as, or related to asthma, by determining if aberrations, such as polymorphisms, deletions, additions, etc., are present at the site of the TIF gene. Such aberrations may be an indicia of susceptibility to, or of the presence of, asthma, an allergic condition, or one or more related conditions. The ability to detect aberrations in a DNA sequence is well known in the art, and such methods need not be set forth herein. Preferably, the aberration or aberrations is detected via standard techniques, such as PCR, using the methodologies and primers referred to supra.
[0117] Other features of the invention will be clear to the artisan and need not be discussed further.
[0118] The terms and expressions which have been employed are used as terms of description and not of limitation, and there is no intention in the use of such terms and expressions of excluding any equivalents of the features shown and described or portions thereof, it being recognized that various modifications are possible within the scope of the invention.
1
29
1
24
DNA
Mus musculus
1
agcactctcc agcctctcac cgca 24
2
12
DNA
Mus musculus
2
gatctgcggt ga 12
3
24
DNA
Mus musculus
3
accgacgtcg actatccatg aaca 24
4
12
DNA
Mus musculus
4
gatctgttca tg 12
5
24
DNA
Mus musculus
5
aggcaactgt gctatccgag ggaa 24
6
12
DNA
Mus musculus
6
gatcttccct cg 12
7
1119
DNA
Mus musculus
7
taaacaggct ctcctctcac ttatcaactg ttgacacttg tgcgatctct gatggctgtc 60
ctgcagaaat ctatgagttt ttcccttatg gggactttgg ccgccagctg cctgcttctc 120
attgccctgt gggcccagga ggcaaatgcg ctgcccgtca acacccggtg caagcttgag 180
gtgtccaact tccagcagcc gtacatcgtc aaccgcacct ttatgctggc caaggaggcc 240
agccttgcag ataacaacac agacgtccgg ctcatcgggg agaaactgtt ccgaggagtc 300
agtgctaaag atcagtgcta cctgatgaag caggtgctca acttcaccct ggaagacgtt 360
ctgctccccc agtcagacag gttccagccc tacatgcagg aggtggtacc tttcctgacc 420
aaactcagca atcagctcag ctcctgtcac atcagcggtg acgaccagaa catccagaag 480
aatgtcagaa ggctgaagga gacagtgaaa aagcttggag agagtggaga gatcaaggcg 540
attggggaac tggacctgct gtttatgtct ctgagaaatg cttgcgtctg agcgagaaga 600
agctagaaaa cgaagaactg ctccttcctg ccttctaaaa agaacaataa gatccctgaa 660
tggacttttt tactaaagga aagtgagaag ctaacgtcca tcatcattag aagatttcac 720
atgaaacctg gctcagttga aaaagaaaat agtgtcaagt tgtccatgag accagaggta 780
gacttgataa ccacaaagat tcattgacaa tattttattg tcactgatga tacaacagaa 840
aaataatgta ctttaaaaaa ttgtttgaaa ggaggttacc tctcattcct ttagaaaaaa 900
agcttatgta acttcatttc catatccaat attttatata tgtaagttta tttattataa 960
gtatacattt tatttatgtc agtttattaa tatggattta tttatagaaa cattatctgc 1020
tattgatatt tagtataagg caaataatat ttatgacaat aactatggaa acaagatatc 1080
ttaggcttta ataaacacat ggatatcata aaaaaaaaa 1119
8
7445
DNA
Mus musculus
8
gtctatcacc tgcttaagat tcttctaatt tataaaaaaa actatttctt aaaatgaaaa 60
gcaaccagag cacgtattta tagcatggtg ttctgaccat gcaggtacag agtggaatgg 120
taagaggcgc tattatcagc attaaccaac atgttaatgt tttcttctgg caagcaaact 180
tgaaatctat gtcttaaaca atcttcaagc ctctaatata gtgctaacga ctggagtccg 240
ctgctgtcca acagagctct tgagcacgct ctcctctgtt tgcaatttta tgttctttga 300
tcgactcccc aacctctcac cttcggctcc tgatggccac ctttcaactt tctgcattta 360
tgaactccat gttttaatct ttttattaaa atattcacac aatcagtgtt tgtgcaagtc 420
tgtttcaccc acatgtatgt ctgtgcacca agtgctgcct ggtgcttgtg ggggcaagga 480
gcaggagagg gtgccctggc accggagtca cggatggttg tgagccacca tgaggatgct 540
gggagttaga cccaggtcct ccagaagtgc agcaaatgct cttaaccaca cgcaggcatt 600
tctctctcca gccccaacat gagtgctttt agattccacc tagaatagag atctgatggc 660
ttcactcact gccacctccc ctttgcatct ttctgccaag gaacaccaaa aagcaagaat 720
ccccacactg ctttcgctcc tcaagtctgc acctctcaac aggtcaagat tctccagtgt 780
ccctctaaca ctttccccag tgtccctcta acactttctc cagtgtccct ctaacacttt 840
ctccagtgtc cctctaacac ttttgatctc aattagctga ggggagaaag atctcacaca 900
gtgattttca tgacttcgcg ttctagtcta gatgtaggca tttgcgtgtc agtctagggt 960
aggcgtctgc tcccgctgct taggaaagac tttcctagtc tagttgtcag gtgctatctg 1020
ggattcagtg tacatacaat gcaaaaaatc ccagtatttt gtaaattctc ttcttcaact 1080
atccatctat atagtatgtt attgtaggct catttaaaaa taatattttg agacttatgc 1140
ttgcacaagt aaaatgtcag agaattagca aatgtatagt attattttat tttaaaaaaa 1200
tctatgctta aaatgtctat tagattgttc actaccgata tttccaaact taacttgacc 1260
ttggctatga tttcaacctt tgtatttgca tctaccataa cagtctctga accagaacat 1320
tctgtggcaa tgggagctgt gaagaaagcc aacattctta ttaaaaaaaa aaaacagcta 1380
gttatagttt aggattccat atactaaaaa aaatagagat ataattattt taaaaattga 1440
aataatctcc aagttttcat tatggcttat ttcaaagcac agaatatagg acacgggtct 1500
tttatttctg gtcacttcta aagagataag aatctatgaa gttggtggga aaatgagtcc 1560
gtgaccaaaa cgctgactca atagctacgg gagatcaaag gctgctctac tcaatcagaa 1620
tctactacgg caaagccatg gctttctttg aaaaccgtgt ttagaagatt tctgggattt 1680
gtgtgcaaaa gcaccttgtt ggccctcacc gtgacgtttt agggaagact tcccatctct 1740
caaggtggga aggcttggag gtggtgtctt gtggcctcct atggtggtta ggtacttctc 1800
agaagacagg actggaaatt agataatgtc tgatgtcata tcattcacaa taccaaaaaa 1860
accctggtgt cccgatggct ataaaagcag caacttctgc ctctcccatc acaagcagag 1920
acacctaaac aggtaagcac tcagacctct acagacaatc atctgcttgg taccatgcta 1980
cccgacgaac atgctcccct gatgtttttg ccttttgctc tctcactaac aggctctcct 2040
ctcacttatc aactgttgac acttgtgcga tctctgatgg ctgtcctgca gaaatctatg 2100
agtttttccc ttatggggac tttggccgcc agctgcctgc ttctcattgc cctgtgggcc 2160
caggaggcaa atgcgctgcc cgtcaacacc cggtgcaagc ttgaggtgtc caacttccag 2220
cagccgtaca tcgtcaaccg cacctttatg ctggccaagg aggtacagct gcatctcttt 2280
ctctccatac cgccttgcca ttttctctga agcacttgca aactctttag gggcgcttta 2340
tctccgcagg tctcactacc tatgttttct gtctctttag agactcttta aggactgggt 2400
ctttttctat ttctatttca aggtctcagg accatttcct atcttggcct tcaggacaca 2460
tatactgaat tttatctaca gaggcgcatt tagaaagcca cccacgactg caatactttc 2520
catttctctg tgctctcttc tgaactcata ctctcttggc tactcctgag acccactgcg 2580
gacatacatc tctacttaca ggcttttctt ccatctcctt gtcacccagg cacttagggt 2640
tttctctctt tcaggccagc cttgcagata acaacacaga cgtccggctc atcggggaga 2700
aactgttccg aggagtcagt gtaagtcctc actgtgatga gcagggctag ctgcgggagc 2760
tggtggaccc tctgggatag tctgacgtat gacccctgct gcttcttgtc tacctgcagg 2820
ctaaagatca gtgctacctg atgaagcagg tgctcaactt caccctggaa gacgttctgc 2880
tcccccagtc agacaggttc cagccctaca tgcaggaggt ggtacctttc ctgaccaaac 2940
tcagcaatca gctcagctcc tgtgtaagtc tgactctggc tacctatgct cctctctctt 3000
cctcttctat tccagtaaga acccgaggtc ctgccctctc tctcttcaca agagtgagga 3060
gggcctcagc accaccacca tcataggcca cttgaaatag gtcacaaagg ctttggcttc 3120
aattgagtaa tactttgagt ttgtatgagt gaagctttat ttgttttatc catggaaaga 3180
aatcaactca aattctgtag gatgagaaag atgttgggaa cgaaaaaagg cctagataga 3240
gaaacagatc tgctgagtat agtacttatg gggggagcag ggggcgatat ccactgagta 3300
caagtacttg tggggagaga aatccactga gtacaagtac ttgttggcat ggagatccac 3360
tgagtacaag tacttgtggg gggagggaat ggcacagagc aaaagttgaa gggaaggaag 3420
atggagaggc ctcatggttg ggggtgtgaa aggtcactcc ttttccatgt gatggagagt 3480
taagaaaaac cagtgtgtga gtttgatgtc ttcagacacc cccaactatg aaacatatcc 3540
acgaggagcg ggcagactgt gggagacctg gcatttaggg aaggcgcggc ttttcacacg 3600
agaaacttta tgctcatctc ttgtgctaca ctcccacctt tgatgaggtt cagctcaggt 3660
ttcgtttcta ccgttcttgc tactggtgga aacttcagta ggattcccca aagacgagga 3720
cagctcttct gtaagggagg gacctggatt tcagtgtcct agagaacgaa atagctcaga 3780
gaatctaggt caacgtgaaa tctaggtcac agcgggcaaa aatgactgaa cgcctctatt 3840
ccaggtgaac ggtcacgtgc ctcagatata ctgaggtatt gggctcccac cggataagat 3900
tctgttagtg agtctgcttt tattttgcag cacatcagcg gtgacgacca gaacatccag 3960
aagaatgtca gaaggctgaa ggagacagtg aaaaaggtac tattggcaag ccacaatact 4020
aagccattca gtaggagacg tggggatttc tttctctgct tcccagtccc ttctactttg 4080
taacatttta tttgacttgt ctactatctg gtccattact cgcttagctg cacctgtatc 4140
tagctgggtc tatagatctt tcaatctgtg tctaaatttg taagtcacaa ttctggagct 4200
agcagaaagc ttagctcagc cagtctcatg agcacttgct cggaggatgg cttgtgacag 4260
agtcaatgct agaagacagc atccctgatt cccagctctg cacttgccta gtggccatgt 4320
gtaattactt tggcttgatt aagtatttgg gaaagccagt tcccacggac ctacataatc 4380
tgaagaacca tgcattgaaa actagaaagc tgggcacaaa cttactagag atgatttttg 4440
agctcattaa acggatgctc tgaaatgtgg caaaatcaac ccagaataac aacaaaagag 4500
ctggatttgc aaataggaca agtatttaga atcactggta ttaatagcta tcatcttaat 4560
taaaatatag ggcctatata tatatttaag attaaacaca agagtggata gcctcccaat 4620
ttacttggcc tggtttcaaa agagtaaaaa tatcagtcat ggattaatta tagtgtcatg 4680
aaagtatgag atggaaaccc tttccttact ttttaccttc atttcttagt tttttttttc 4740
ttcacaccct gatcaagcca ctagtaagca cctatctgct gtgagctatt atatgacttt 4800
acagcaaaca acattgctgt gtggcctctt tggggaaggg aacaggatag caggaggctc 4860
aggctagcaa gtctgacttg ccctaaagcc agaggcatgg ttgatagcag agaaagtgag 4920
gctcttcgca agtgggtgtg cttaagtaat cagaaacagg aaggctccgg ttgatggaat 4980
tatcagtaag atatctaccc ttatctcctt ctatcgaacc taaatcgtct ctttttcttg 5040
tgtgtaggct gataaacaca cttgttttct tttgagtgtt catggctttg tagattttta 5100
gtgctctgcc agttcttgtt agagggtttg ttaccttgac acctgggctt ggatgttagc 5160
atgccaaagg cacacacttc tgaatgcctg tgtaaaaggt tattattcat ttactttgtc 5220
tttggaaagg tgaagcgtgt gtgagaaaga actcacagga gatgtgttct ctgtaggaaa 5280
actttttttt tccccttaaa tgcctataat ccactttcag tcaactttga cttttatacc 5340
atgctgtcac atgaaagagt gtttaggccc gctctcatgg ctctgggaaa agcaccaata 5400
ggggaaggaa tgttatgctg agaaatctga ccggcaggga aactggtcag agctcccccg 5460
aagaccacca caggtgttaa gtaggaacag tccagggtgg gctcatgtaa tagaatggaa 5520
cagagcgagg gaagataagc tacaaagttt catagggtcc ggagtcttaa agatacaaaa 5580
tagctgcttg ggcttcataa caaaggaagt ctgggaaggc agcaagtgag agggaaatgg 5640
aaagggaaaa aacagaatgt agaggacttg aacagctaca aatcctctac cagacgattt 5700
ttcttggaac aatctagaag gtagtggatt aggtgattgc agggggactt gctttgccat 5760
ttgaatctgg gtttttgtct ctccattgag gttgaaagcg tcaccctttt taccctcgaa 5820
tggaggagga aagaaggggt gttatgactc ctacctggag ttttactagt ttacgcaatg 5880
gaacagacac tcgggacctc ctcttgacaa aaaaaatgga aacctgttgt ttgtcttgtt 5940
tgttcttttg ttaagaaagc acaggcaaag cccgaccaca tgggttgaat gtgggtcttt 6000
gagtcaaggc ttttgagttg agcactcatc aatagttgat catggtcagg tggagggcta 6060
cctgtcaggc cgagccctgc tggcttcgca cttaacatct ccaggtctca gtatcacttc 6120
ctgctactta gcacagttag gagttgagca aacctttttt tccaaccccc actaaaattt 6180
aattgacaaa agactgtgta atttgtggga tacagtgtga taattgatct atgtgtgcat 6240
tgtgcaaggt tcaataagat agattaatag gcccatcaac agctttatgg gtgtgaaatg 6300
caagtaatat aggtagatgc ctgtggtgtc cttaggtcag aaaggcatga ttttaaggtc 6360
ttgggcaaat catattatac tcatgctaaa aatacattat gttgattatt aatcttttag 6420
agaaggctga tacttggttt tggtgctcag caagcaaatg tcaccagctc tttctaactg 6480
gtaccacttt agaaaatgct acctgtgctc aaattggttt gtattcttat tttcatagct 6540
tggagagagt ggagagatca aggcgattgg ggaactggac ctgctgttta tgtctctgag 6600
aaatgcttgc gtctgagcga gaagaagcta gaaaacgaag aactgctcct tcctgccttc 6660
taaaaagaac aataagatcc ctgaatggac ttttttacta aaggaaagtg agaagctaac 6720
gtccatcatc attagaagat ttcacatgaa acctggctca gttgaaaaag aaaatagtgt 6780
caagttgtcc atgagaccag aggtagactt gataaccaca aagattcatt gacaatattt 6840
tattgtcact gatgatacaa cagaaaaata atgtacttta aaaaattgtt tgaaaggagg 6900
ttacctctca ttcctttaga aaaaaagctt atgtaacttc atttccatat ccaatatttt 6960
atatatgtaa gtttatttat tataagtata cattttattt atgtcagttt attaatatgg 7020
atttatttat agaaacatta tctgctattg atatttagta taaggcaaat aatatttatg 7080
acaataacta tggaaacaag atatcttagg ctttaataaa cacatggata tcataaatct 7140
tctgtcttgt aatttttctc cctttaatat caacaatacc atcatcatca tcattaccca 7200
atcattctca tgatttcatg cttgacccat attatactgt taaagttggt tcctggaggc 7260
ctgtggtttt gtgtgtgttg tgtgtgtgtg tggggttatg catgtgaaag ccagagatgg 7320
atattaggtg ttcttctcta tcagtctttg ccttattatt tgagacaggg tctgtcactg 7380
aacctgtagc taggctggcc aacaagctct attaattttt tttaagatta attaattatg 7440
tgtat 7445
9
1111
DNA
Mus musculus
9
10
21
DNA
Mus musculus
10
ctgcctgctt ctcattgccc t 21
11
21
DNA
Mus musculus
11
caagtctacc tctggtctca t 21
12
20
DNA
Mus musculus
12
gacgcaagca tttctcagag 20
13
16
DNA
Homo sapiens
13
atgtatttcc cagaaa 16
14
17
DNA
Homo sapiens
14
ccttttctgg gaaatac 17
15
22
DNA
Homo sapiens
15
agctgctcaa cttcaccctg ga 22
16
22
DNA
Homo sapiens
16
ccactctctc caagcttttt ca 22
17
21
DNA
Homo sapiens
17
caagtctacc tctggtctca t 21
18
21
DNA
Homo sapiens
18
tggccaggaa gggcaccacc t 21
19
21
DNA
Homo sapiens
19
tggccaggaa gggcaccacc t 21
20
36
DNA
Homo sapiens
24,25,29, 30,34,35
n is inosine
20
ggccacgcgt cgactagtac gggnngggnn gggnng 36
21
20
DNA
Homo sapiens
21
ggccacgcgt cgactagtac 20
22
20
DNA
Homo sapiens
22
ccttccccag tcaccagttg 20
23
20
DNA
Homo sapiens
23
taattgttat tcttagcagg 20
24
690
DNA
Homo sapiens
24
25
4797
DNA
Homo sapiens
25
26
20
DNA
Homo sapiens
26
atcagatgga ttactgaatg 20
27
179
PRT
Mus musculus
27
Met Ala Val Leu Gln Lys Ser Met Ser Phe Ser Leu Met Gly Thr Leu
1 5 10 15
Ala Ala Ser Cys Leu Leu Leu Ile Ala Leu Trp Ala Gln Glu Ala Asn
20 25 30
Ala Leu Pro Val Asn Thr Arg Cys Lys Leu Glu Val Ser Asn Phe Gln
35 40 45
Gln Pro Tyr Ile Val Asn Arg Thr Phe Met Leu Ala Lys Glu Ala Ser
50 55 60
Leu Ala Asp Asn Asn Thr Asp Val Arg Leu Ile Gly Glu Lys Leu Phe
65 70 75 80
Arg Gly Val Ser Ala Lys Asp Gln Cys Tyr Leu Met Lys Gln Val Leu
85 90 95
Asn Phe Thr Leu Glu Asp Val Leu Leu Pro Gln Ser Asp Arg Phe Gln
100 105 110
Pro Tyr Met Gln Glu Val Val Pro Phe Leu Thr Lys Leu Ser Asn Gln
115 120 125
Leu Ser Ser Cys His Ile Ser Gly Asp Asp Gln Asn Ile Gln Lys Asn
130 135 140
Val Arg Arg Leu Lys Glu Thr Val Lys Lys Leu Gly Glu Ser Gly Glu
145 150 155 160
Ile Lys Ala Ile Gly Glu Leu Asp Leu Leu Phe Met Ser Leu Arg Asn
165 170 175
Ala Cys Val
28
179
PRT
Homo sapiens
28
Met Ala Ala Leu Gln Lys Ser Val Ser Ser Phe Leu Met Gly Thr Leu
1 5 10 15
Ala Thr Ser Cys Leu Leu Leu Leu Ala Leu Leu Val Gln Glu Gly Ala
20 25 30
Ala Ala Pro Ile Ser Ser His Cys Arg Leu Asp Lys Ser Asn Phe Gln
35 40 45
Gln Pro Tyr Ile Thr Asn Arg Thr Phe Met Leu Ala Lys Glu Ala Ser
50 55 60
Leu Ala Asp Asn Asn Thr Asp Val Arg Leu Ile Gly Glu Lys Leu Phe
65 70 75 80
His Gly Val Ser Met Ser Glu Arg Cys Tyr Leu Met Lys Gln Val Leu
85 90 95
Asn Phe Thr Leu Glu Glu Ile Leu Phe Pro Gln Ser Asp Arg Phe Arg
100 105 110
Pro Tyr Met Gln Glu Val Val Pro Phe Leu Ala Arg Leu Ser Asn Arg
115 120 125
Leu Ser Thr Cys His Ile Glu Gly Asp Asp Leu His Ile Gln Arg Asn
130 135 140
Val Gln Lys Leu Lys Cys Thr Val Lys Lys Leu Gly Glu Ser Gly Glu
145 150 155 160
Ile Lys Ala Ile Gly Glu Leu Asp Leu Leu Phe Met Ser Leu Arg Asn
165 170 175
Ala Cys Ile
29
5935
DNA
Homo sapiens
29
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The invention involves isolation of nucleic acid molecules, the expression of which are upregulated by interleukin-9. The amino acid sequences of the proteins which correspond to the nucleic acid molecules show some structural features of cytokines. In addition to the nucleic acid molecules and the proteins, various uses of the molecules are disclosed. The molecules are referred to as T cell inducible factors.
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BACKGROUND OF INVENTION
1. Field of the Invention
The present invention relates to a device for locking the cover of a container intended to be emptied by tilting more than 90°, such as a garbage can or dumpster for waste collection.
2. Description of the Related Art
As is known, dumpsters for waste collection tend to remain periodically on the public right-of-way, to be emptied by tilting into a collecting vehicle. The dumpsters are then left unattended, and it may happen that they will be picked over. This may be dangerous, depending on the kind of waste contained in them.
Moreover, free access to the interior of the dumpsters may enable third parties to fill them with unsuitable waste, thereby possibly denaturing the contents in the case of selective collection, or adding to the user's expense if the collection is charged for.
Locking devices for locking the cover of the dumpster when it is upright and waiting to be emptied, and unlocking it when it is being emptied, have already been proposed to solve these problems. For example, French Patent No. 2 721 912 to the assignee describes a locking device comprising a pivoting part pivotably mounted on the dumpster body inside a protective casing. When the container is upright, this pivoting part assumes a locked position in which it keeps the cover in closed position. When the container is tilted for emptying, the pivoting part, by force of gravity, moves from its locked position to an unlocked position.
Also, German Utility Model No. 295 11 098 U discloses a device for locking the cover of a container, comprising a pivoting part directly engaging the plastic of the upper rim of the container, which may cause wear. In addition, this prior art device comprises unlocking means attached to the cover, so that it is exposed to major impacts when the cover is opened or closed. Furthermore, the pivoting part comprises an upper arm and a lower arm, and the unlocking means comprises a key mechanism either pulling on the upper arm or resting on the lower arm near the geometrical axis of rotation of the pivoting part. In either case, the force exerted on the pivoting part is rather great, making the key mechanism rather difficult to operate.
SUMMARY OF THE INVENTION
The object of the present invention is to further improve the means of locking the cover of a container, of the type comprising a pivoting part pivotably mounted on the cover between a locked position, in which the cover is kept in closed position when the container is erect, and an unlocked position, in which the cover is released, the pivoting part moving from its locked position to its unlocked position by the force of gravity when the container is tilted.
This object is accomplished because the pivoting part comprises a lower arm capable of engaging a catch member, such as a lug, for example, when the cover is closed and when the pivoting part is in a position to lock the cover. According to the invention, because the pivoting part is mounted on the cover of the container, the pivoting part is less exposed to the waste while the dumpster is being filled. Thus, it is not necessary to house it in a protective casing, as was done with the device described in French Patent 2 721 912, supra. The result is an increase of space in the dumpster container and a lower cost of producing the locking device.
Furthermore, according to the invention, the pivoting part does not come into direct contact with the plastic of the container body, but contacts the catch member so that it does not cause wear. The catch member may be operated by a key mechanism and retracted by actuating the key mechanism to disengage from a hole in the pivoting part. Thus, the pivoting part may be unlocked without exerting much force on the catch member, and the key mechanism can be operated with relative ease. As a variant, the locking means comprises a mechanism consisting of a member pushing back the lower arm of the pivoting part when the user actuates a key.
In a preferred embodiment of the invention, the pivoting part is pivotably mounted about a geometrical axis of rotation parallel to the geometrical axis of tilt on which the container is emptied. This arrangement uses the movement of the container as a whole when it is being emptied, which helps the pivoting part to reach its position unlocking the cover.
As a comparison, in the device described in French Patent 2 721 912, the pivoting part is pivotably mounted about a geometrical axis of rotation perpendicular to the geometrical axis of tilt. In order to ensure dependable operation when emptying, a weight with some play is provided, for example, in a cavity of the pivoting part, to create a boost when the container is tilted and help it reach the unlocked position.
Continuing with a preferred embodiment of the invention, the pivoting part is connected to the cover substantially in the middle of the side of the cover opposing the articulating hinges.
In another preferred embodiment of the invention, the pivoting part comprises, in addition to the lower arm, an upper arm that extends into the interior volume of the cover.
The locking device according to the invention can readily be installed on an existing container.
Preferably, the device further comprises, on the interior side of the container, a protective wall or frame generally U-shaped in cross-section, whose arms are fixed to the inside wall of the container on either side of the catch member, the protective frame defining a housing open to the top and to the bottom. Because of this protective frame, the waste does not interfere with the unlocking of the lower arm.
The invention further relates to a dumpster for collecting waste, comprising locking means as aforesaid.
BRIEF DESCRIPTION OF THE DRAWINGS
Other features and advantages of the invention will appear from reading the detailed description which follows and the two non-limiting embodiments of the invention, and from examining the accompanying drawings, in which:
FIG. 1 is a schematic side view of a dumpster equipped with a locking device according to the invention;
FIG. 2 is a schematic cross-section showing a locking means according to a first embodiment of the invention;
FIGS. 3 and 4 illustrate the operation of the device shown in FIG. 1, when the container is emptied; and
FIG. 5 is a view similar to that of FIG. 2, showing a locking means according to a second embodiment of the invention.
FIG. 6 is a view similar to FIG. 5 showing a keying activated locking mechanism according to another embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION
The rolling container 1 shown in FIG. 1 comprises a body 3 of plastic material and a cover 2 , also of plastic, joined to the body 3 by means of hinges 5 in a known manner. The cover 2 may be equipped with an opening for selective collection of glass or paper, for example.
In the non-limiting example shown, the container 1 comprises at the bottom, on the same side of the body 3 as the hinges 5 , a pair of wheels 4 that rotates about a geometrical axis parallel to the geometrical axis of articulation (hinging) of the cover 2 . It will be understood that other types of rolling containers, in particular containers of large capacity comprising, for example, four wheels, are not beyond the scope of the present invention. The wall of the container body 3 , located opposite from the hinges 5 and wheels 4 , will henceforth bear the reference 9 .
The body 3 comprises in its upper portion an outer rim 6 , on the side opposite from the hinges 5 , defining a channel open downward for engagement by suitable hoisting means of a collection vehicle. These hoisting means, known in the art, are arranged to lift the container and empty it after tilting it to the right in FIG. 1, on a substantially horizontal axis of tilt parallel to the geometrical axis of articulation of the cover 2 . The cover 2 comprises a slightly convex top wall 23 , extended below at its periphery by a sealing skirt 8 borne by its lower edge resting on the rim 6 of the body 3 when the dumpster is closed.
A locking means 7 , according to a first embodiment of the invention and shown in FIG. 2, is mounted inside of the container 1 . This locking means 7 comprises a pivoting part 10 connected to an angle foot 11 which serves as a pedestal, fixed by its base substantially in the middle of the side of the skirt 8 located opposite from the hinges 5 . The foot 11 is so oriented in relation to the skirt 8 of the cover 2 that the geometrical axis of articulation of the pivoting part 10 is parallel to the geometrical axis of articulation of the cover 2 .
The pivoting part 10 comprises an upper arm 12 and a lower arm 13 joined to make a right angle about a hub 14 . The upper arm 12 is rectilinear and extends under the wall 23 into the interior volume of the cover 2 .
The lower arm 13 is made up of four consecutive rectilinear segments 12 a , 12 b , 12 c and 12 d . Segment 12 a , nearest to the upper arm 12 , is perpendicular to the latter. Continuing down the lower arm 13 , the next three segments 12 b , 12 c , and 12 d describe substantially half of a hexagon whose concavity faces the interior of the body 3 . The second segment from the bottom, 12 c , is traversed by a hole 15 in which a catch member may be inserted when the cover 2 is closed. As described in this embodiment, this catch member consists of a lug 16 fixed to the inner surface of the wall 9 , substantially at the same height as the rim 6 .
As will be noted upon examining FIG. 2, this lug 16 is lightly inclined towards the bottom of the body 3 , the better to retain the lower arm 13 . In the example shown in the figures, the lug 16 is cylindrical. In a modification not shown, the lug 16 is flat and made by cutting and folding an electrogalvanized sheet.
The upper arm 12 is integral with a block 17 , which may be made in one piece with the rest of the pivoting part 10 in the form of a bend, for example, or, as a variant, be formed as a compound part. The angular swing of the upper arm 12 under the cover 2 , approaching the wall 23 , is enough to permit the pivoting part 10 to rotate as required to disengage the hole 15 in the lower arm 13 from the lug 16 .
The letter G is used to mark the location of the center of gravity of the pivoting part 10 , and the resultant force exerted upon it by gravity is indicated by an arrow. It will be understood that this force, when the container rests upright on its base with the cover 2 closed, creates a torque tending to hold the pivoting part 10 in locked position in cover 2 , that is, with the lug 16 engaged in the hole 15 . The lower segment 12 d of the lower arm 13 extends obliquely towards the interior of the body, so as to slide on the end of the lug 16 when the cover is swung back on the body, to permit engagement of the lug 16 in the hole 15 .
In FIG. 3, the locking means 7 is represented, after the container is tilted and after the vertical line passing through the center of gravity G of the pivoting part 10 has passed the vertical plane containing the geometrical axis of articulation of the pivoting part 10 on the cover 2 . This tilting generates a torque tending to drive the pivoting part 10 rotationally towards the unlocked position of cover 2 . In this figure, the lower arm 13 is shown already disengaged from the lug 16 , and the upper arm 12 is shown resting against the inner face of the wall 23 of the cover 2 . Thus unlocked, the cover 2 is free to open under the force of gravity as shown in FIG. 4 .
FIG. 5 shows a second embodiment of the device according to the invention. This embodiment differs from the preceding one in that a means is provided to enable the user to unlock the cover 2 when the body 3 rests erect on its base. In this example, the cover 2 is not provided with any opening for selective collection.
The aforesaid unlocking means consists, for example, of a mechanism 20 comprising a member 21 thrusting back the lower arm 13 near its free end when the user actuates a key 22 introduced into the mechanism 20 . In dashed lines, FIG. 5 shows the position taken by the member 21 and by the lower arm 13 when the cover is unlocked.
Of course, without departing from the scope of the present invention, other means might be provided to enable the user to unlock the cover 2 . Thus, through the wall 9 of the body 3 , one could make a hole having a particular outline, enabling the user to introduce a member of matching cross-section to push the lower arm 13 enough to release the cover 2 . Also, the lug 16 may be 40 actuated by a key mechanism 42 and retracted when key 22 is activated, as shown in FIG. 6, to disengage the lower arm 13 from the hole 15 and release it.
In addition, a protective wall or frame 30 , of generally U-shaped cross-section, might be placed on the inside wall of the body, the arms of the frame fixed to the wall of the body on either side of the lug 16 .
The protective frame 30 is dimensioned and positioned on the body so as to be wide open to the top and to the bottom, which keeps bits of waste from being caught inside of it. The frame 30 prevents waste from blocking the lower arm while in locked position.
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A locking mechanism ( 7 ) for the cover ( 2 ) of a container ( 1 ), especially a garbage can or dumpster, that is emptied by tilting. The mechanism ( 7 ) includes a pivoting part ( 10 ) pivotably mounted on the cover ( 2 ) of the container ( 1 ). When the container ( 1 ) is tilted, the pivoting part ( 10 ) moves from a locked position to an unlocked position by force of gravity. The pivoting part ( 10 ) includes a lower arm ( 13 ) capable of engaging a catch member such as a lug ( 16 ) when the cover ( 2 ) is closed and when the pivoting part is in a position to lock the cover. The invention further relates to a container ( 1 ) equipped with such a locking mechanism ( 7 ).
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a Continuation-In-Part of Application No. PCT/US2015/015413, filed Feb. 11, 2015, which claims priority to U.S. Provisional Patent Application No. 61/938,452 filed Feb. 11, 2014. The disclosures of the above applications are incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to liftgate systems for automobiles. More specifically, to a composite liftgate and method of manufacture.
BACKGROUND OF THE INVENTION
[0003] One of the current trends in the automobile industry is to lower vehicle weight to help achieve better fuel economy, thus helping to meet fuel economy standards and to offset the higher fuel prices. Another trend is that there is a broader range of vehicle models, which in turn reduces the volume of vehicles produced on a per model basis. Sport utility and crossover vehicles remain popular and typically include fairly heavy rear liftgates making this part of the vehicle a target area for weight reduction. Liftgates are traditionally made from stamped steel panels that are heavy and have a high tooling cost. Traditional steel liftgates are expensive investments, heavy, take up a lot of OEM floor space in areas from stamping plant, body shop, paint shop, and trim line. Further, steel liftgates have limited styling flexibility, take a lot of time to tool, and have corrosion concerns. Sheet Molding Compound (SMC) is an alternative to steel for the inner and outer panels of the liftgate. Using SMC has several manufacturing concerns related to the material and process. Steel and SMC liftgates have a mass penalty over thermoplastics. There are also styling restrictions with traditional sheet metal components. Thermoplastic composite type materials used for liftgate applications also have difficulty meeting customer performance specifications.
[0004] Another concern with the manufacture of liftgates is that typical liftgates are manufactured as a relatively flat or smoothly contoured panel, with structural reinforcements such as ribs added onto the panel. This will also add weight and increase manufacturing complexity as well and when thermoplastics are used there are read through areas where the ribs are placed which must be dealt with by design modifications or expensive processes such as gas assist injection molding. Ribs are also weaker and do not carry the load through the liftgate panel. Recently magnesium inner reinforcement panels have been used with an outer polymer skin in order to reduce weight. While such panels are an improvement in weight, this is an expensive solution. Another concern with typical liftgates is that the structural reinforcements are steel or larger steel structures adding weight and increased manufacturing complexity. Another concern is typically reinforcement material is used for reinforcement in the structural areas and attachment structures are fixed using bolts. However, the use of bolts does not provide a continuous attachment structure and improved strength since there is distance between the bolts. Yet another concern with the manufacture of liftgates is that typical liftgates are manufactured as relatively solid with no access features such as access doors added into the panel to allow for easy access for general maintenance and repair of built in components.
[0005] A known 2008 Nissan Murano composite liftgate system helped to satisfy the weight savings and the tooling cost concerns, but utilized a typical bolt in small steel reinforcement at the latch which secures one end of the liftgate to the vehicle. This does not meet the higher load requirements desired in some applications, such as the latch pull test. A known Nissan Rogue composite liftgate system utilizes a steel one-piece outer panel and steel brackets. This does not improve density, painting efficiency, hold tighter tolerances, is more expensive and complex to manufacture, and adds weight to the liftgate/vehicle.
[0006] Accordingly, there exists a need for a composite liftgate which is both lightweight, as well as structurally sound enough to meet various load requirements, while being more mass and cost effective.
SUMMARY OF THE INVENTION
[0007] In accordance with the present invention, there is provided a composite liftgate system with inner panel construction including at least one strengthening channel structure and at least one reinforcement connected to the inner panel. The reinforcement is structural composite preform reinforcement bonded to the inner panel. The structural composite reinforcements are woven glass reinforcement. Tapping plates are minimized in size to minimize the use of steel. The present inventive provides extra strength when compared to steel or conventional composite liftgates while reducing overall weight by several pounds.
[0008] Further areas of applicability of the present invention will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while indicating the preferred embodiment of the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] The present invention will become more fully understood from the detailed description and the accompanying drawings, wherein:
[0010] FIG. 1 is a front perspective view of a composite liftgate assembly with D-pillars removed to depict the inner structure including struts, in accordance with the present invention;
[0011] FIG. 2 is a front elevation view of an inner panel sub-assembly for the liftgate system, in accordance with the present invention;
[0012] FIG. 3 is a front elevation view of the inner panel with a strut reinforcement bracket connected to a strut preform reinforcement, hinge reinforcement bracket, connected to a hinge preform reinforcement, and structural channel reinforcements in accordance with the present invention;
[0013] FIG. 4 is a front elevation view of an upper outer panel connected to the inner panel, in accordance with the present invention;
[0014] FIG. 5 is a front elevation view of the upper outer panel and a lower outer panel connected to the inner panel, in accordance with the present invention;
[0015] FIG. 6 is a rear perspective view depicting the inner panel sub-assembly for the liftgate system, in accordance with the present invention;
[0016] FIG. 7 is a front perspective view of the composite liftgate assembly of FIG. 1 ;
[0017] FIG. 8 is a rear perspective view of a lower trim panel connected to the inner panel for the composite liftgate assembly, in accordance with the present invention;
[0018] FIG. 9 is an exploded elevation view of the composite liftgate system, in accordance with the present invention;
[0019] FIG. 10 is a sectional view taken alone section A-A of FIG. 1 ; and
[0020] FIG. 11 is a sectional view taken alone section B-B of FIG. 1 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0021] The following description of the preferred embodiment(s) is merely exemplary in nature and is in no way intended to limit the invention, its application, or uses.
[0022] Referring to the figures generally, there is provided a composite liftgate assembly with bonded composite preform reinforcements. Structural channels molded into an inner panel of the liftgate add structure where needed and manage the main loading paths as the liftgate is utilized in the various load cases. Also composite preforms structurally bonded in place (or Insert molded) to add structure where needed are used, allowing for the need for no steel reinforcements and/or minimization of the size of steel tapping plates. Bonding through the use of adhesive provides a more continuous attachment structure and improved strength over bolting alone. A two-piece outer panel allows for styling, molding, painting, tolerance, weight, and assembly advantages. The features and process of the present invention help to achieve desired weight targets, while keeping costs at target levels. In addition, the composite liftgate has several business case advantages for supplying a module, and reducing assembly plant complexity and improving throughput. Additionally, the present invention improves styling options and flexability when compared to sheet metal and one-piece panels. Corrosion and durability are also improved.
[0023] An embodiment of a composite liftgate system is shown in the Figures generally at 10 . The liftgate 10 includes an outer panel 12 formed of an upper outer panel, shown generally at 14 , and a lower outer panel, shown generally at 16 . A spoiler 18 is incorporated into the upper outer panel 14 . A glass window 20 or rear window liftgate of the tailgate 10 is adhered to the upper and lower outer panels 14 , 16 and to an inner panel. The upper outer panel 14 and separate lower panel 16 thereby form a two-piece outer panel. This has significant benefits and superior results over having a one-piece panel (especially over one that is also steel or not bonded in place), including, but not limited to, improved density, more efficient painting, tighter tolerances, less manufacturing issues, and more cost effectiveness. Alternatively, the outer panel 12 may be formed as a single piece.
[0024] The spoiler 18 incorporated with the upper outer panel 14 has significant benefits and superior results over having a separate spoiler, including, but not limited to, optimized structure and strength and efficient processing.
[0025] The inner panel 22 is formed with a channel pattern arrangement including a plurality of structural channels molded into the inner panel 22 to manage the loading paths as the liftgate is utilized in various load cases. The channel pattern of the present invention provides more structural shape where needed and allows for carrying the full thickness and load through the part, whereas ribbing is weaker and will not carry the load. The channels have significant benefits and superior results over ribbing. The channels will now be explained in greater detail.
[0026] Molded into the inner panel 22 are at least one first pair of channels 24 that run horizontally, substantially parallel to and below a horizontal plane of the viewing opening 25 formed in the inner panel 22 . The channels of the first pair 24 are substantially centrally located in the portion of the inner panel 22 below the opening 25 and an upper first pair channel 26 is longer than a lower first pair channel 28 . The first pair of channels 24 are raised, as in substantially extending outward generally toward the rear of the vehicle (See FIGS. 2 and 6 ).
[0027] The first pair of channels 24 terminate at a second pair of channels 30 that run in a diagonal pattern at a predetermined angle, substantially in diagonal directions away from each other with the largest distance apart being toward the opening 25 . The second pair of channels 30 are depressed, as in substantially extending inward generally toward the interior of the vehicle (See FIGS. 2 and 6 ).
[0028] A third pair of channels 32 extend substantially along each side of the second pair of channels 30 on the side away from the center of the inner panel 22 . The third pair of channels 32 are raised, as in substantially extending outward generally toward the rear of the vehicle (See FIGS. 2 and 6 ). Preferably, the second pair of channels 30 and fourth pair of channels 32 have one side wall longer than the other side wall, sharing the common of the longer wall.
[0029] Each of the channels in the second pair of channels 30 is substantially a mirror image of the other channel of the pair 30 . Each of the channels in the third pair of channels 32 is substantially a mirror image of the other channel of the pair 32 .
[0030] A fourth pair of channels 33 run substantially vertically from the lower first pair channel 28 to the upper first pair channel 26 of the first pair of channels 24 . The fourth pair of channels 33 are depressed, as in substantially extending inward generally toward the interior of the vehicle (See FIGS. 2 and 6 ).
[0031] Each of the pairs of channels 24 and 30 - 33 have predetermined lengths, widths, depths, and material thickness suitable to provide structural support and strength for the inner panel 22 , including under predetermined load conditions. Optionally, additional channels can be formed as part of the inner panel 22 .
[0032] Formed as part of the inner panel 22 is an upper trim ring portion, generally shown at 34 , incorporated into a D-pillar area (‘D’ FIG. 8 ) rather than providing the upper trim ring as a separate panel. The upper trim ring 34 incorporated into the inner panel 22 in the D-pillar area has significant benefits and superior results over having a separate panel, including, but not limited to, optimized structure and strength. The upper trim ring portion 34 has a predetermined size that is small suitable for access, e.g., for a lower trim panel installation and retention.
[0033] The liftgate 10 is additionally reinforced in areas where extra structure is needed. There is provided a plurality of composite preforms or composite reinforcements to add structure where needed to reinforce areas such as the D-pillar, top corners of the inner panel 22 at the hinge nuts, side nuts, backlight, and/or latch areas, as will be described further below. Composite preforms have significant benefits and superior results over steel reinforcements, which steel, among other things, adds weight.
[0034] All of the composite reinforcements are bonded directly to the inner panel 22 such that the composite reinforcements are structurally bonded in place (or, alternatively, insert molded to connect the reinforcements to the inner panel 22 ) to add structure where needed. This allows for the elimination of steel reinforcements and to minimize the size of a plurality of tapping plates made of metal. The bonding of the present invention uses predetermined adhesive(s) applied to select the areas of the inner panel 22 . Most preferably, the adhesive is a structural two-part urethane adhesive. The bonding with the use of adhesives has significant benefits and superior results over steel reinforcements connected to the inner panel by bolts. Tapping plates that are formed of steel are minimized in size and are not only bolted in place—but additionally bonded with adhesive for added strength and structure, as will be described further below. This has significant benefits and superior results over the conventional need for larger steel tapping plates that are merely bolted.
[0035] One of the composite preforms connected to the inner panel 22 is a pair of strut reinforcements 36 or strut preforms. The pair of strut reinforcements 36 are bonded to the inner panel 22 using adhesive. These are located generally in the area adjacent to the lower corner of the opening 25 .
[0036] A pair of strut reinforcement brackets 44 or tapping plates, preferably formed of steel, are bonded to the pair of strut reinforcements 36 using adhesive. A first plurality of fasteners 46 , e.g., push nuts, are added to further hold the strut reinforcements 36 and strut reinforcement brackets 44 in position.
[0037] Another one of the composite preforms connected to the inner panel 22 is a pair of hinge reinforcements 38 or hinge preforms. These are located generally in the area adjacent to the upper corner of the opening 25 . The pair of hinge reinforcements 38 are bonded to the inner panel 22 using adhesive. A second plurality of fasteners 50 , e.g., push nuts, are added to further hold the hinge reinforcements 38 in position. The lower end portion 40 of each hinge reinforcement 38 overlaps an upper end portion 42 ( FIG. 9 ) of each strut reinforcement 36 . Preferably, this upper end portion 42 has a lower profile for connecting to the inner panel 22 below the lower end portion 40 of hinge reinforcement 38 and provide a butting engagement with the hinge reinforcement 38 . Most preferably, the lower end portion 40 is bonded to the upper end portion 42 with adhesive.
[0038] A pair of hinge reinforcement brackets 48 or tapping plates, preferably formed of steel, are bonded to the pair of hinge reinforcements 38 using adhesive. A third plurality of fasteners 52 , e.g., screws, are added to further hold the hinge reinforcements 38 and hinge reinforcement brackets 48 in position.
[0039] Each hinge reinforcement bracket 48 also has a hinge assembly 54 coupled thereto. Each hinge reinforcement 38 and strut reinforcement 36 also has at least one compression limiter 56 coupled thereto. At least one compression limiter 56 is coupled near the bottom rear edge of the inner panel 22 .
[0040] A latch reinforcement bracket 58 or tapping plate, preferably formed of steel, is bonded to the inner panel 22 using adhesive in the area where a latch handle 60 is connected to the lower outer panel 16 . Optionally, a fourth plurality of fasteners, e.g., screws, are added to further hold the latch reinforcement bracket 58 in position. The latch handle 60 actuates a latch manual and/or power liftgate device 62 coupled to the inner panel 22 generally adjacent to the latch reinforcement bracket 58 when engaged by an operator of the liftgate 10 .
[0041] Formed as part of the inner panel 22 are additional structural reinforcements such as ribs and fins. A set of sloped fin-like shaped 64 ridges are each connected to a top surface of both channels of the fourth pair of channels 33 and within the upper first pair channel 26 ( FIG. 6 ). At least one pair of first ribs 66 are connected to a bottom surface of the fourth pair of channels 33 . A plurality of second ribs 68 , e.g., at least three ribs, are connected within each of the second pair of channels 30 . A plurality of third ribs 70 , e.g., two pairs of two ribs, are connected to a top surface of the upper first pair channel 26 and run generally vertically to a predetermined distance below the opening 25 . A plurality of fourth rips 72 , e.g., at least three ribs, run substantially diagonal across the lower inside corner areas of the inner panel 22 . Each fin or rib in the respective sets and pairs are substantially parallel with one another.
[0042] Each fin or rib in the respective sets and pairs have predetermined lengths, widths, depths, and material thickness suitable to provide structural support and strength for the inner panel 22 and improve the rigidity of the liftgate 10 system, including under predetermined load conditions. Optionally, additional fins and/or ribs can be formed as part of the inner panel 22 .
[0043] There is provided a main wiring harness 74 and a washer device 76 with a motor and wider coupled to the inner panel 22 . The outer panel 12 is bonded to the inner panel 22 by using adhesive 78 (“ 78 ” indicates adhesive for various components, e.g., FIGS. 4 and 9 ) applied in a predetermined pattern and locations on the inner panel 22 . Also provided is a center high-mount stop light (CHMSL) device 80 connected to the upper outer panel 14 . A tail light assembly 82 is operably connected to the lower outer panel 16 . Preferably, the tail light assembly 82 is bonded to the lower outer panel 16 with adhesive and additionally a plurality of fasteners.
[0044] As further illustrated in FIG. 10 , the inner panel 22 is bonded to the glass panel 20 and reinforcement brackets, e.g., each strut reinforcement bracket 44 , through the use of adhesive 78 such that packaging for wiring, e.g., the main wiring harness 74 , and an adjacent gas strut is provided. The reinforcement has a predetermined thickness and is bonded, rather than merely bolting in a few locations, with structural adhesive to bond in place with continuous attachment of the structure. The inner panel connected to the brackets and outer panel forms predetermined operable cross sections.
[0045] Also connected to the inner panel 22 is a lower trim panel, shown generally at 84 , substantially facing toward the vehicle interior and running generally from the D-pillar to near the bottom edge of the inner panel 22 . The lower trim panel has class A surfaces and at least one access panel 86 or door. A pair of handle pockets 88 is also provided in the lower trim panel 84 for an operator to selectively grasp when operating the liftgate 22 , in particular to cycle to the liftgate 10 from an open to a closed position.
[0046] The access door 86 is removable and/or rotatable for gaining access to at least the latch mechanism assembly 62 for maintenance and/or repair. The access panel 86 is a significant benefit over conventional liftgates requiring disassembly and maintenance/repair complexity. Preferably, there are at least five access panels 86 suitably situated where maintenance and repair of various components not otherwise easily accessible is desired. Most preferably, at least one access panel 86 is located in each of the following areas: the latch mechanism assembly 62 , tail light assembly 82 (e.g., for changing both burnt out tail lights), CHMSL 80 , and wiper device 76 (e.g., to access a wiper motor) areas.
[0047] A pair of gas struts 90 is operably connected to the inner panel 22 and/or a hinge system. The gas strut and hinge system are connected to the vehicle.
[0048] By non-limiting example, the inner panel 22 is bonded to the outer panel 12 to using urethane bonding. The inner panel 22 provides structural support for the composite liftgate of the present invention not only through the shape of the inner panel as described above, but the material used to make the inner panel provides structural support as well. The inner panel 22 is made of a structural thermoplastic, such as a polypropylene, a thermoset or thermoplastic such as a reinforced polypropylene (RPP), and is preferably a 40% glass-filled polypropylene. The inner panel 22 is preferably thermoplastic 0.5 inch long glass filament filled polypropylene. By way of non-limiting example, the outer panel 12 is made of a suitable thermoplastic used as a show surface, such as a thermoplastic polyolefin (TPO). The structural composite reinforcements preferably comprise woven glass reinforcement.
[0049] The inner panel 22 is preferably thermoplastic injection molded with mold-in color, and grain in areas of class A surface(s). Thereafter, the inner panel 22 is painted and bonded with the structural composite reinforcements. Alternatively, the structural composite reinforcements are insert molded to connect the reinforcements to the inner panel 22 . At least the hitch reinforcement brackets are additionally affixed with fasteners. The reinforcement brackets are bonded in place and further held in position with fasteners. Bonding is substantially beneficial over conventional liftgates. The outer panel 12 is painted prior to connecting to the inner panel 22 . The outer panel 12 is bonded to the inner panel 22 and the glass pane 20 is bonded to the inner panel 22 and outer panel 12 (fasteners are additionally contemplated in addition to the adhesive). The lower trim panel 84 is operably connected to the inner panel 22 by at least adhesive.
[0050] The description of the invention is merely exemplary in nature and, thus, variations that do not depart from the gist of the invention are intended to be within the scope of the invention. Such variations are not to be regarded as a departure from the spirit and scope of the invention.
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A composite liftgate system with an inner panel construction having a strengthening channel structure. Structural composite reinforcements are bonded to the inner panel where additional strength is needed to meet predetermined performance requirements. Where the extra structure is needed, no steel or a minimum amounts of steel is used and the structural reinforcements are bonded in place using adhesive prior to application of additional fasteners.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a divisional of U.S. application Ser. No. 11/936,334 filed Nov. 7, 2007, which claims priority to U.S. Provisional Application Ser. No. 60/864,731 filed on Nov. 7, 2006, the contents of which are incorporated herein by reference in their entireties for all purposes.
FIELD OF THE INVENTION
[0002] The present invention generally relates to devices and methods for treating degenerative conditions of the spine or for alleviating pain or discomfort associated with the spinal column. More specifically, the present invention is directed to laminoplasty fixation devices.
BACKGROUND OF THE INVENTION
[0003] In certain circumstances, the spinal canal extending through a patient's vertebrae is or becomes too narrow and constricts the spinal cord extending therethrough. Narrowing can be attributable to causes such as age, injury or removal of a spinal disk.
[0004] For instance, cervical spondylosis is a common degenerative condition of the cervical spine that most likely is caused by age-related changes in the intervertebral disks. As disk degeneration occurs, mechanical stresses result in osteophytic spurs, which may form along the interior aspect of the spinal canal and can compress the spinal cord. The constriction of the spinal cord in the cervical spine, for example, often produces pain, weakness, or loss of feeling in extremities. Other causes for narrowing of the spinal canal include disc shrinkage, which causes the disc space to narrow and the annulus to bulge and mushroom out, resulting in pressure on the spinal cord. Degenerative arthritis of facet joints can cause joints to enlarge, or the vertebra to slip with respect to each other, also compressing the spinal cord. Instability between vertebrae, such as caused by stretched and thickened ligaments can also produce pressure on the spinal cord and nerve roots.
[0005] Myelopathy, or affliction or injury of the spinal cord, occurs due to its compression. The rubbing of the spine against the cord can also contribute to this condition, and the spinal cord compression can ultimately compromise the blood vessels feeding the spinal core, further aggravating the myelopathy.
[0006] Traditional procedures for decompressing the spinal cord include a laminectomy, in which the lamina and spinal processes are removed to expose the dura covering the spinal cord. Another known procedure is a laminoplasty, in which the lamina is lifted off the dura, but not completely removed. According to one laminoplasty procedure sometimes referred to as an “open door” procedure, an osteotomy is performed in which a complete cut is made through one side of the vertebra, approximately between the lamina and lateral mass, while a partial-depth cut is made on the opposite lateral side. The lamina is then hinged open about the partial cut to increase the cross-sectional size of the spinal canal to decompress the spinal cord therein. In certain procedures, a laminoplasty plate is then fixed between the facet and the hinged open lamina. According to some known methods, the plate of an appropriate size is selected and bent to the desired shape and generally has a plurality of screw holes. In other known techniques, a strut of bone may be placed in the open portion within the lamina and the facet to help hold the open position of the lamina. In general, prior to the operation, the surgeon needs to measure the vertebra to determine the size of the plate necessary for implantation. At that point, a plate can be selected with the appropriate dimensions, and implanted at the site.
[0007] Improved laminoplasty fixation devices are needed. For example, a laminoplasty fixation device that may be varied in size prior to implantation is desirable so that a plate does not have to be custom selected and intensively shaped and formed prior to each surgery.
SUMMARY OF THE INVENTION
[0008] The present invention generally relates to laminoplasty fixation devices and methods of use. One embodiment of a vertebral implant constructed according to the invention comprises a first bone engaging portion configured for securing to a first cut portion of a vertebra and a second bone engaging portion configured for securing to a second cut portion of the vertebra. A body portion is provided for associating the first and second bone engaging portions at a preselected spacing from each other, wherein the implant is adjustable to select said spacing.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] The invention will be more readily understood with reference to the embodiments thereof illustrated in the attached figures, in which:
[0010] FIG. 1 is a top view of one embodiment of a laminoplasty fixation device according to the invention;
[0011] FIG. 2 is a side view of the embodiment of FIG. 1 shown in an implanted position on a portion of a vertebral body;
[0012] FIG. 3 is a side view of another embodiment of a laminoplasty fixation device shown in an implanted position on a portion of a vertebral body;
[0013] FIG. 4 is a side view of another embodiment of a laminoplasty fixation device according to the invention;
[0014] FIG. 5 is a side view of another embodiment of a laminoplasty fixation device shown in an implanted position on a portion of a vertebral body;
[0015] FIG. 5A is a perspective view of another embodiment of a laminoplasty fixation device according to the invention;
[0016] FIG. 6 is a perspective view of another embodiment of a laminoplasty fixation device according to the invention;
[0017] FIG. 7 is a side view of another embodiment of a laminoplasty fixation device according to the invention;
[0018] FIG. 8 is a perspective view of another embodiment of a laminoplasty fixation device according to the invention;
[0019] FIG. 9 is a side view of another embodiment of a laminoplasty fixation device according to the invention;
[0020] FIG. 9A is a partial top view of the embodiment of FIG. 9 ;
[0021] FIG. 9B is a side view of another embodiment of a laminoplasty fixation device shown in an implanted position on a portion of a vertebral body;
[0022] FIG. 10 is a side view of another embodiment of a laminoplasty fixation device shown in an implanted position on a portion of a vertebral body;
[0023] FIG. 11 is a side view of another embodiment of a laminoplasty fixation device;
[0024] FIG. 12 is a side view of another embodiment of a laminoplasty fixation device shown in an implanted position on a portion of a vertebral body;
[0025] FIG. 13 is a side view of another embodiment of a laminoplasty fixation device shown in an implanted position on a portion of a vertebral body;
[0026] FIG. 13A is an exploded side view of the embodiment depicted in FIG. 13 ;
[0027] FIG. 14 is an exploded side and top view of an alternative to the embodiment depicted in FIG. 13 ;
[0028] FIG. 15 is an exploded side and top view of another embodiment of a laminoplasty fixation device;
[0029] FIG. 16 is a perspective view of the embodiment depicted in FIG. 15 ;
[0030] FIG. 17 is a side view of another embodiment of a laminoplasty fixation device shown in an implanted position on a portion of a vertebral body;
[0031] FIG. 18 is a perspective view of another embodiment of a laminoplasty fixation device according to the invention;
[0032] FIG. 18A is a cross-sectional view of the embodiment of FIG. 18 ;
[0033] FIG. 18B is a top and side view of another embodiment of a laminoplasty fixation device according to the invention;
[0034] FIG. 19 is a perspective view of another embodiment of a laminoplasty fixation device according to the invention;
[0035] FIG. 20 is a cross-sectional view of the embodiment of FIG. 19 ;
[0036] FIG. 21 is a perspective view of another embodiment of a laminoplasty fixation device according to the invention;
[0037] FIG. 22 is a perspective view of another embodiment of a laminoplasty fixation device according to the invention;
[0038] FIG. 23 is a perspective view of another embodiment of a laminoplasty fixation device according to the invention;
[0039] FIG. 24 is a side view of another embodiment of a laminoplasty fixation device shown in an implanted position on a portion of a vertebral body;
[0040] FIGS. 25-29 are a side views installation steps for implanting the laminoplasty fixation device of FIG. 24 ;
[0041] FIG. 30 is a perspective view of another embodiment of a laminoplasty fixation device according to the invention; and
[0042] FIG. 31 is a side view of the embodiment of FIG. 30 shown in an implanted position on a portion of a vertebral body.
DETAILED DESCRIPTION OF THE INVENTION
[0043] Embodiments of the invention will now be described. The following detailed description of the invention is not intended to be illustrative of all embodiments. In describing embodiments of the present invention, specific terminology is employed for the sake of clarity. However, the invention is not intended to be limited to the specific terminology so selected. The features of one embodiment may be employed with other embodiments as the skilled artisan would recognize, even if not explicitly stated herein. It is to be understood that each specific element includes all technical equivalents that operate in a similar manner to accomplish a similar purpose.
[0044] Referring to FIGS. 1-29 , embodiments of devices or implants for use in a unilateral or “open door” laminoplasty procedure are shown. Generally, in an “open door” laminoplasty procedure, an osteotomy is performed in which a complete cut is made through one side of the vertebra, approximately between the lamina and lateral mass, while a partial-depth cut is made on the opposite lateral side. The lamina is then hinged open about the partial cut to enlarge the spinal canal.
[0045] Referring to FIGS. 1 and 2 one exemplary embodiment of a laminoplasty fixation device 10 according to the invention is shown. In general, fixation device 10 comprises a unitary plate body 12 with a first portion 14 and a second portion 16 separated by a bendable section 18 . Bendable section 18 generally comprises a thinner less rigid portion of plate body 12 configured allow second portion 16 to bend or rotate relative to first portion 14 . Plate body 12 generally comprises a plurality of openings or holes 20 for receiving a bone fastener, such as a bone screw. The holes 20 may be disposed for accessing and inserting the fasteners from the outside of the bone to facilitate implantation. According to one embodiment, fixation device 10 is configured for use in an “open door” laminoplasty procedure with the first portion 14 generally configured for securing to a portion of a lamina 22 that has been cut and hinged away from the lateral mass 24 . Second portion 16 of plate body 12 generally comprises a serrated or spiked free end 26 . The spikes or serrations 28 at end 26 are configured to engage the lateral mass to prop the lamina open when the second portion 16 is rotated with respect to first portion 14 . In one embodiment, plate 12 is made from a titanium material; however, in alternate embodiments any suitable implant material known to those skilled in the art may be used. In one embodiment a bone strut 29 may be attached to the inner surface of plate 12 to facilitate bone fusion or regeneration between the lateral mass and lamina. In alternate embodiments, plate 12 may comprise separate plate portions interconnected by a hinge member.
[0046] Referring to FIG. 3 , another embodiment of a laminoplasty implant 30 is shown. Implant 30 generally comprises a swing plate body 32 with a first portion 34 rotatably connected to a second portion 36 . Implant 30 is generally similar to plate 10 described above, except the integrated spikes 28 are replaced with a separate lateral mass anchor portion 38 . In operation, first portion 34 and anchor portion 38 can be attached or fixed to the lamina prior to cutting through the lamina thereby facilitating an easier implantation procedure than attaching the first and anchor portions 34 , 38 after cutting through the lamina. In one variation, plate body 32 comprises a slotted hole 39 to provide adjustability. Once the lamina is cut, the second portion of the plate may be swung into place and may be attached or fixed to anchor portion 38 with a fixation device, such as a screw. In alternate embodiments, a latch mechanism may be used to fixably connect second portion 36 to anchor portion 38 .
[0047] Referring to FIG. 4 , another embodiment of a laminoplasty fixation device or implant 40 is shown. Implant 40 generally comprises an elongate body 42 with a first end portion 44 having one or more openings or holes 46 configured to receive fasteners and an opposite second end 47 comprising a bifurcated, yoked, or claw-like portion 48 . Bifurcated portion 48 comprises bone engaging or locking features such as serrations, knurls, or teeth 49 positioned along the inner portion thereof. Claw 48 is configured to be deformable to compress teeth 49 against bone to fix plate body 42 to bone. According to one application of plate 42 for a laminoplasty, first end 44 may be attached to the lateral mass and second end 47 may be crimped to the lamina once it is cut and rotated or opened during the laminoplasty procedure. According to one embodiment, implant 40 may be made from titanium; however, in alternate embodiments any suitable biocompatible material may be used.
[0048] Referring to FIG. 5 another embodiment of a laminoplasty device or implant 50 constructed according to the invention is shown. Implant 50 generally comprises a flexible mesh body 52 that may be screwed or otherwise secured adjacent the lateral mass at one end and adjacent the lamina or spinous process at the opposite end. A rigid strut 54 may be attached to mesh body 52 for positioning between the lamina 56 and lateral mass 58 . In one embodiment, mesh body 52 may be attached to bone at any location along its length by, for example, fasteners or screws 59 . According to one embodiment, implant 50 may be made from a Dacron® or Gore-Tex® material. Referring to FIG. 5A , another embodiment of an implant 60 constructed according to the invention is shown. Implant 60 , is similar to implant 50 except strut 64 is fixably slidably positionable along flexible strap 66 . In one variation, strut 64 may comprise strap receiving members or slots 68 adjacent an upper sidewall 69 to slidingly accommodate strap 66 therethrough. In the embodiment of FIG. 5A , rigid strut 64 may be made from a PEEK material and may have a through-hole to permit bone growth and/or packing with bone or DBM material. The lateral ends of strut 64 may be indented or comprise a birdmouth-like profile to capture cut portions of the lateral mass and lamina and generally prevent movement of strut 64 in the posterior-anterior direction, i.e. into the spinal canal. Also, strap 66 generally prevents strut 64 from migrating. One advantageous feature of such a flexible mesh or strap body is that the implant may readily conform to the anatomy and it generally provides variability in placement of fasteners to secure the implant in place.
[0049] Referring to FIG. 6 another embodiment of a laminoplasty device or implant 70 constructed according to the invention is shown. Implant 70 generally comprises a unitary plate body 72 with a first portion 73 and a second portion 74 separated by an intermediate portion 75 . Body 72 has a general “S” shape when viewed from the side, as shown in FIG. 6 . When implant 70 is used in an “open door” laminoplasty procedure, the first portion 73 is generally configured for securing to a portion of a cut lamina and the second portion 74 is generally configured for securing to a portion of the lateral mass. In one embodiment, first portion 73 comprises a bifurcated or yoked end with spaced tines 71 configured and dimensioned to receive a portion of the lamina therebetween. According to one embodiment, intermediate portion 75 may have a hollow central region 76 . The hollow region 76 may be packed with osteogenic material to facilitate fusion of the implant 70 with the patients cut bone portions. In addition, hollow region 76 allows access to cut bone portions after implantation and facilitates packing of osteogenic material therein. Also, a base wall may 79 be provided along the anterior side of hollow region 76 to prevent osteogenic material and bone growth from migrating into the spinal canal. In one variation, base wall 79 may be between about 1 mm and 2 mm thick. Plate body 72 generally comprises a plurality of openings or holes 77 for receiving a bone fastener, such as a bone screw. The holes 77 may be disposed for accessing and inserting the fasteners from the outside of the bone to facilitate implantation. In one embodiment, a countersink or scalloped region 78 may be provided adjacent openings or holes 77 to accommodate, among other things, a variable-angle screw to allow angulation of implant 70 with a fastener inserted therethrough.
[0050] Instead of a unitary or single plate body, laminoplasty fixation devices may comprise multiple components. For example, as shown in FIGS. 7-29 , fixation devices generally comprise more than one component.
[0051] Referring to FIG. 7 another embodiment of a laminoplasty implant 80 according to the invention is shown. Implant 80 is similar to implant 70 shown in FIG. 6 and described above, except the implant body 82 comprises two separate components slidably connected together. According to one embodiment, first body portion 84 is slidably received within a receiving portion 85 of second body portion 86 with a dovetail fit. Such a sliding dovetail configuration facilitates distractability between the bone engaging end portions. As one skilled in the art may appreciate, such a feature is desirable for accommodating a variety of spacing between a lateral mass and lamina. According to one embodiment, the first and second body portions may be fixed relative to one another by a set screw or other know fixation device.
[0052] Referring to FIG. 8 , another embodiment of a laminoplasty implant 90 according to the invention is shown. Implant 90 is similar to implant 80 described above with respect to FIG. 7 except the first and second body portions 92 , 94 are adjustably connected by a ratchet mechanism. In one embodiment, first body portion has an upper surface comprising a plurality of ratchet features or teeth 96 that matingly interface with corresponding ratchet teeth (not shown) on the under surface of second body portion 94 . In one embodiment, teeth 96 are unidirectional and first body portion 92 may be fixed with respect to second body portion 96 with a unidirectional or distraction movement. Such a ratchet interconnection promotes adjustability, since it is easy for a practitioner to increase the distraction or spacing of the device. For example, the first and second body portions may be immediately locked in position or fixed with respect to one another, thus eliminating the need for a set screw or other additional fixation device. In this regard, such an arrangement permits one step distraction and generally eliminates the need to use a trial insert to find a proper fit. As a result, a set of implants for use in surgery may have fewer parts. In addition, the distraction or relative movement between the first and second body portions is unidirectional which prevents recoil, retraction, bounce back, or backward movement during insertion.
[0053] Referring to FIG. 9 , another embodiment of a laminoplasty implant 100 according to the invention is shown. Implant 100 is similar to implants 80 and 90 , described above, except that the first and second body portions 102 , 104 are fixably adjustable with an elongate slot and screw connection. As best seen in FIG. 9A , an elongate slot 105 is configured to receive a fastener such as a screw therethrough. In one variation, one or more indentations or scalloped portions 106 are positioned about the perimeter of slot 105 to locate or position the fastener along the length of slot 105 . According to one embodiment, first body portion 102 may be able to articulate with respect to bone engaging end portion 107 . In this regard, bone engaging portion 107 may be attached to a lamina portion prior to bending or hinging of the lamina during the laminoplasty procedure. In one embodiment, a pivot pin 108 extends through first body portion 102 and bone engaging portion 107 to facilitate articulation. In an alternate embodiment, illustrated in FIG. 9B , first and second body portions 102 , 104 may comprise unitary arched plate bodies with a slot 105 provided in one body portion for receiving a fastener 109 therethrough to facilitate fixable relative adjustment of the first and second body portions 102 , 104 .
[0054] Referring to FIG. 10 , another embodiment of a laminoplasty implant 110 according to the invention is shown. Implant 110 is similar to implants 80 , 90 and 100 described above, except the intermediate body portion comprises an elongate rod 112 fixably adjustable between first and second bone engaging portions 114 , 116 . First and second bone engaging portions 114 , 116 are configured to receive one or more fasteners to secure portions 114 , 116 to bone. In one variation, shown in FIG. 10 , first portion 114 comprises a yoke or forked end 118 with a top tine 120 and a bottom tine 122 and the tines 120 , 122 are spacedly configured to engage opposite sides of a portion of bone, such as the lamina 124 . According to one embodiment, rod 112 may be able to slide or move with respect to bone engaging portions 114 , 116 . Such a sliding configuration facilitates distractability between the bone engaging end portions. As one skilled in the art may appreciate, such a feature is desirable for accommodating a variety of spacing between a lateral mass and lamina. In addition, such a slidable rod configuration advantageously provides minimal canal encroachment while still allowing adjustable distraction. In another embodiment, one or both bone engaging portions 114 , 116 may comprise a multi-axial screw and may allow screw angulation, such as adjacent the lateral mass 126 .
[0055] Referring to FIG. 11 , another embodiment of a laminoplasty implant 130 according to the invention is shown. Implant 130 is similar to implant 110 described above with respect to FIG. 10 , except that the intermediate body portion or rod 132 is spherically connected to first bone engaging portion 134 and slidably connected to second bone engaging portion 136 . In this regard, such a spherical connection facilitates distractability between the bone engaging end portions while also allowing the first bone engaging portion 134 to articulate or move with distraction.
[0056] Referring to FIG. 12 , another embodiment of a laminoplasty implant 140 according to the invention is shown. Implant 140 is similar to implant 130 described above, except that the first body portion 142 comprises an elongate body with an integrated first bone engaging portion 144 . First bone engaging portion 144 comprises a yoke or forked end 146 with a top tine 147 and a bottom tine 148 and the tines 147 , 148 are spacedly configured to engage opposite sides of a portion of bone, such as the lamina 149 . According to one embodiment, first body portion 142 may be able to slide or move with respect to second bone engaging portion 145 . Such a sliding configuration facilitates distractability between the bone engaging end portions. As one skilled in the art may appreciate, such a feature is desirable for accommodating a variety of spacing between a lateral mass and lamina.
[0057] Referring to FIGS. 13-14 , another embodiment of a laminoplasty implant 150 according to the invention is shown. Implant 150 is similar to implant 110 , described above with respect to FIG. 10 except that a first body portion comprises an elongate body 152 with an integrated first bone engaging portion 154 at distal end 156 . First bone engaging portion 154 comprises a bottom hook portion 158 configured to engage opposite sides of a portion of bone, such as the lateral mass 159 , as illustrated in FIG. 13 . According to one embodiment, elongate body 152 may be able to slide or move with respect to second bone engaging portion 160 . In one variation, elongate body 152 has a cylindrical cross-section and generally resembles a rod. In alternate embodiments, elongate member 152 may have a rectangular cross-section and generally resemble a bar. Second bone engaging portion 160 comprises a bottom hook portion 162 integrated with an upper receiving portion 164 . Hook portion 162 is generally configured to engage opposite sides of a portion of bone, such as the lamina 165 , as illustrated in FIG. 13 . Receiving portion 164 is configured and dimensioned to fixably slidably receive a portion of elongate body 152 . According to one embodiment, elongate body 152 may be fixed with respect to receiving portion 164 with a set screw 166 . Such a fixable sliding configuration facilitates distractability between the bone engaging end portions. As one skilled in the art may appreciate, such a feature is desirable for accommodating a variety of spacing between a lateral mass and lamina.
[0058] Referring to FIGS. 15-16 , another embodiment of a laminoplasty implant 170 according to the invention is shown. Implant 170 is similar to implant 150 , described above with respect to FIGS. 13-14 except that a first body portion 172 comprises an elongate bar 174 with an upper ratchet portion comprising a plurality of ratchet features or teeth 176 . According to one embodiment, bar 174 is integrated with a first bone engaging portion 178 at distal end 176 thereof. Bar 174 may be able to slide or move with respect to second bone engaging portion 180 . Similar to the embodiment of FIGS. 13-14 , first and second bone engaging portions 174 , 180 generally comprise bottom hook portions 178 , 182 configured to engage opposite sides of a portion of bone, such as the lateral mass and lamina, when implant 170 is installed. Second bone engaging portion 180 comprises an upper portion with a bar receiving portion 184 configured to slidably receive a portion of bar 172 . According to this embodiment, receiving portion 184 generally comprises unidirectional teeth complimentary to ratchet teeth 176 of bar 172 and bar 172 may be fixed with respect to receiving portion 184 with a unidirectional ratchet mechanism. Such a ratchet interconnection facilitates easy adjustability. For example, the first and second bone engaging portions may be immediately locked in position or fixed with respect to one another, thus eliminating the need for a set screw or other additional fixation device. In this regard, such an arrangement permits one step distraction between the bone engaging portions 174 , 180 . In addition, the distraction or relative movement between the first and second bone engaging portions 174 , 180 is unidirectional which prevents recoil, bounce back, or backward movement during insertion.
[0059] Referring to FIG. 17 another embodiment of a laminoplasty implant 190 according to the invention is shown. Implant 190 is similar to implant 100 shown in FIG. 9B described above, except the first and second body portions 192 , 194 are linkable together by a ball-and-socket connection. According to one embodiment, first body portion 192 comprises a ball shaped end 196 configured and dimensioned to be received within a correspondingly shaped female or socket end 198 of second body portion 194 . Such a ball-and-socket configuration facilitates angulation or hinging between the bone engaging end portions 193 , 195 . As one skilled in the art may appreciate, such a feature is desirable for accommodating a variety of spacing between a lateral mass and lamina. In alternative embodiments, different types of linkages may be utilized. For example, in one variation a puzzle piece type connection may be used. In another embodiment a dovetail type linkage connection may be utilized. According to these various embodiments, one skilled in the art may appreciate that such removably linkable connections may facilitate insertion of first and second body portions individually.
[0060] Referring to FIGS. 18 and 18A , another embodiment of a laminoplasty implant 200 according to the invention is shown. Implant 200 is similar to implant 80 shown in FIG. 7 described above; except the implant body 202 comprises a strut 204 fixably slidable with respect to body portion 202 . According to one embodiment, strut 204 may be slidably received within body portion 202 with a slotted fit, as best seen in FIG. 18A . Such a sliding configuration facilitates distraction along the length of body portion 202 . According to one embodiment, the strut 204 may be fixed relative to body portion 202 by a set screw or other know fixation device. Referring to FIG. 18B an alternate embodiment of an implant with an adjustable strut member is shown.
[0061] Referring to FIGS. 19-20 another embodiment of a laminoplasty implant according to the invention is shown. Implant 210 comprises two separate components slidably connected together. According to one embodiment, first body portion 212 is slidably received within second body portion 214 with an offset finger fit. First body portion 212 generally comprises first and second finger portions 216 , 218 extending longitudinally from opposite corner sections of a first bone engaging end 220 . Second body portion 214 generally comprises third and fourth finger portions 222 , 224 extend longitudinally from opposite corner sections of a second bone engaging end 226 . As seen in FIG. 19 , first and second finger portions 216 , 218 of first body portion 212 are configured and dimensioned to meshingly longitudinally engage and fixably slide with respect to third and fourth finger portions 222 , 224 of second body portion 214 . As shown in FIG. 20 , first and second finger portions 216 , 218 are configured may be angularly offset with respect to third and fourth finger portions 222 , 224 to facilitate uni-axial sliding of first body portion 212 with respect to second body portion 214 and prevent torsion or twisting. Such a sliding configuration facilitates distractability between the bone engaging end portions. As one skilled in the art may appreciate, such a feature is desirable for accommodating a variety of spacing between a lateral mass and lamina. According to one embodiment, the first and second body portions may be fixed relative to one another by a set screw or other know fixation device. Referring to FIG. 19 , in one embodiment first and second body portions 212 , 214 may have a hollow central region 228 . The hollow region 228 may be packed with osteogenic material to facilitate fusion of the implant 210 with cut bone segments.
[0062] Referring to FIG. 21 , another embodiment of a laminoplasty implant 230 according to the invention is shown. Implant 230 comprises two bone engaging strut members 232 , 234 disposed along a track plate 236 . Struts 232 , 234 generally comprise bone engaging portions configured to engage opposite sides of a portion of bone, such as the lamina and lateral mass in a laminoplasty procedure. According to one embodiment, track 236 is slidably received within hollow central portion 238 of strut members 232 , 234 and strut members may generally be positioned anywhere along the length of track 236 as desired by a practitioner. In this regard, one ore more holes 237 or slots 239 may be provided along the length of track 236 for receiving a fastener therethrough to fix struts 232 , 234 in place along the length of track 236 . Such a fixable sliding configuration facilitates distractability between the struts 232 , 234 . As one skilled in the art may appreciate, such a feature is desirable for accommodating a variety of spacing between a lateral mass and lamina. Referring to FIG. 22 , in an alternate embodiment, strut members 232 , 234 may be fixably slidably disposed along a lateral side of a track plate 236 . In another embodiment, shown in FIG. 23 , strut members 232 , 234 may be positioned adjacent a scissor bar expansion mechanism 235 to facilitate fixable variable spacing of strut members 232 , 234 .
[0063] Referring to FIGS. 24-29 , another embodiment of a laminoplasty implant 250 and installation method is shown. In this embodiment end plates 252 are inserted between cut bone segments with a distractor tool 254 to facilitate distraction, as best seen in FIG. 24 . Plates 252 generally comprise an “L” shaped body 256 with a bone cover arm portion 258 extending distally from an elongate upper surface 260 . According to one embodiment, plates 252 are configured and dimensioned to be attached to a distractor tool 254 , as illustrated in FIGS. 24-25 , to facilitate insertion between bone segments. Once the plate tips 252 are inserted between bone segments and sufficient distraction is achieved, plates 252 may be detached from distractor 254 and left in place against opposing portions 262 , 264 of the spaced bone segments. Referring to FIG. 27 , in one embodiment, a spacer insert 266 may then be inserted between end plates 252 to maintain the spacing between the bone segments and facilitate bony fusion. In one variation, spacer 266 may slide into place between arm portions 258 by a mating fit, such as a dovetail fit, to prevent movement of spacer 266 in a lateral or torsional direction. Spacer 266 may be various sizes and shapes as desired by a practitioner depending on the indication. As shown in FIG. 29 , once installed between end plates 252 , spacer 266 may fixed in place with respect to the bone segments and endplates with a fastener 268 , such as a screw. According to one variation, endplates 252 and spacer 266 may be made from titanium.
[0064] Referring to FIGS. 30-31 , an embodiment of an implant for use in a bilateral or “french door” laminoplasty procedure is shown. In a “french door” laminoplasty procedure, the spinous process of a targeted vertebra is bisected along the saggital plane and the segments are separated to enlarge the spinal canal.
[0065] FIGS. 30 and 31 are perspective and side views of another embodiment of an implant 300 according to the invention. Implant 300 comprises a general trapezoidal peripheral shape when viewed from the side with bone engaging end walls 302 , 304 extending angularly inward from posterior wall 306 toward anterior wall 308 . In one variation anterior wall 308 is shorter in length than posterior wall 306 , thus forming a general wedge-like profile. A bird-mouth, shelf, or lip 310 may be provided along end walls 302 , 304 . In one embodiment, lip 310 is positioned closer to anterior wall 308 than posterior wall 306 , such that end walls 302 , 304 widen laterally outward from the lip toward anterior wall 308 . In this regard, such a bird-mouth or lip 310 facilitates secure engagement with an anterior portion of the bisected spinous process and generally prevents movement of implant 300 in the posterior direction when the implant is installed. In one variation, end walls 302 , 304 of implant 300 may comprises serrations or ridges 312 to facilitate engagement or purchase with bone. In one embodiment, implant 300 may comprise a hollow central portion 314 to accommodate packing of osteogenic material therein, promote bone growth therethrough, and facilitate bone fusion. One or more through holes 316 may be provided to facilitate attachment via suture and/or bone fastener. In one embodiment, implant 300 may be made from a made of a polyether-ether-ketone (PEEK) plastic material; however any known biocompatible material may be used. Several known advantages of PEEK plastic material include that it is radiolucent and may be more easily sterilized than other plastics in addition to providing proven bio-compatibility with a modulus of elasticity approximating that of bone.
[0066] While the invention herein disclosed has been described by means of specific embodiments and applications thereof, numerous modifications and variations can be made thereto by those skilled in the art without departing from the scope of the invention.
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Devices and methods for treating degenerative conditions of the spine or for alleviating pain or discomfort associated with the spinal column are disclosed. In particular, laminoplasty fixation devices and methods are disclosed. Also disclosed, is a vertebral implant comprising a first bone engaging portion configured for securing to a first cut portion of a vertebra and a second bone engaging portion configured for securing to a second cut portion of the vertebra. A body portion is provided for associating the first and second bone engaging portions at a preselected spacing from each other, wherein the implant is adjustable to select said spacing.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to an exposure system and an exposure method for forming a semiconductor device, and more particularly to a method and a system for controlling an exposure value in an exposure system and an exposure method to reduce variation of a resist pattern size.
[0003] 2. Description of the Related Art
[0004] A lithography process is used for forming a semiconductor device. A resist film is applied by an applicator onto a semiconductor wafer surface, and the resist film is then baked, before an exposure and a subsequent development are carried out. After the applied resist film is previously baked, it is actually needed to take a waiting time for starting the subsequent exposure process. In this application, the word “Waiting time” is defined to be a time duration after a pre-baking process for the applied resist film and until an exposure process is started, For this waiting time, the wafer is stoked between the applicator and the exposure system. This waiting time is variable for individual carrier units for matching the timings among the sequential processes.
[0005] It has been know that variation in waiting time of the wafer causes variation in size or dimension of the resist pattern after the exposure and development processes. FIG. 1 is a diagram illustrative of various sizes of a photo-resist pattern versus waiting time. The size of the photo-resist pattern is variable. As the waiting time increases, an averaged size of the photo-resist pattern tends to increase. As the waiting time increases up to a time T 1 from zero, the rate of increase in the averaged size of the photo-resist pattern is rapid. As the waiting time further increases from the time T 1 and approaches a longer time T 5 , the rate of increase in the averaged A size of the photo-resist pattern becomes gentle. As the waiting time becomes much longer, the variation in size of the photo-resist pattern becomes small.
[0006] As may be seen from FIG. 1, the variation in waiting time of the wafer causes variation in size or dimension of the resist pattern after the exposure and development processes. The waiting time may be different between different carrier units of the wafers. Thus, the size or dimension of the resist pattern may be different between different carrier units of the wafers.
[0007] An excessive increase of the waiting time is effective in order to reduce the variation in size or dimension of the resist pattern, but also reduces the throughput of the wafer. For this reason, the excessive increase of the waiting time is undesirable practically.
[0008] It has also been known that the variation in size of the resist pattern may depend on not only variation of the waiting time but also variation in the atmospheric pressure. If the atmospheric pressure is reduced, then the thickness of the resist is increased, The variation in the atmospheric pressure causes variation in the atmospheric density, which further varies the refractive index of an optical lens to an air, resulting in variation in the focusing point.
[0009] [0009]FIG. 2 is a schematic block diagram of a conventional semiconductor manufacturing system for photo-lithography processes and subsequent anisotropic etching process. A system 201 includes a host 210 , a photo-resist applicator 202 , an exposure and development apparatus 203 , a first size-measuring device 205 , an etching apparatus 204 , and a second size-measuring device 206 . The first size-measuring device 205 measures the size of the photo-resist pattern immediately after the development process. The second size-measuring device 206 measures the size of the etched region of the wafer immediately after the etching process.
[0010] The size-measured results by the first and second size-measuring devices 205 and 206 are transmitted to the host 210 . The host 210 changes, if any, resist application conditions for applying the resist film by the applicator 202 and also exposure conditions by the exposure and development apparatus 203 , and further etching conditions by the etching apparatus 204 .
[0011] The above conventional technique depends upon the past-measured pattern sizes manufactured in the past process, in order to set the conditions for the future wafers, namely, not responsible in real time to the variations in the waiting time and the atmospheric pressure. It is, therefore, difficult for the conventional technique to suppress the size variation of the wafer based on the variations in the waiting time and the atmospheric pressure.
[0012] Japanese laid-open patent publication No. 8-172046 discloses that various data about a pre-baking termination time, wafer not numbers, and the kinds of the wafer resist are transmitted from a storage device through a data transmitter to an exposure controller, so that the exposure controller calculates the waiting time of the wafers based on the transmitted data in order to set an appropriate exposure value based on the calculated waiting time. This conventional technique avoids that the size of the resist patterns varies depending on the waiting time.
[0013] The above conventional technique of the above Japanese publication also depends upon the past-measured pattern sizes manufactured in the past process, in order to set the conditions for the future wafers, namely, not responsible in real time to the variations in the waiting time and the atmospheric pressure. It is, therefore, difficult for the conventional technique to suppress the size variation of the wafer based on the variations in the waiting time and the atmospheric pressure.
[0014] Consequently, the above two conventional techniques determine the exposure value for the resist film based on the past waiting time of the past-processed wafers in the past processes, without considering the current waiting time of the current wafer to be processed from now.
[0015] In the above circumstances, the development of a novel exposure system and exposure method free from the above problems is desirable.
SUMMARY OF THE INVENTION
[0016] Accordingly, it is an object of the present invention to provide a novel exposure system free from the above problems.
[0017] It is a further object of the present invention to provide a novel method of determining an exposure value free from the above problems.
[0018] The present invention provides a method of determining an exposure value for exposing a resist film, comprising the steps of: estimating a size variation of a resist pattern from a predetermined target size based on a waiting time of a currently processing resist film to be patterned in subsequent sequential exposure and development processes; and compensating a reference exposure value based on said size variation to obtain a compensated exposure value.
[0019] The above and other objects, features and advantages of the present invention will be apparent from the following descriptions.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] Preferred embodiments according to the present invention will be described in detail with reference to the accompanying drawings.
[0021] [0021]FIG. 1 is a diagram illustrative of various sizes of a photo-resist pattern versus waiting time.
[0022] [0022]FIG. 2 is a schematic block diagram of a conventional semiconductor manufacturing system for photo-lithography processes and subsequent anisotropic etching process.
[0023] [0023]FIG. 3 is a block diagram of a system for manufacturing a semiconductor device in a first embodiment in accordance with the present invention.
[0024] [0024]FIG. 4 is a view of individual processes in individual apparatuses included in the system of FIG. 3.
[0025] [0025]FIG. 5 is a flow chart of individual steps involved in the exposure process of FIG. 4.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0026] A first embodiment according to the present invention will be described in detail with reference to FIG. 3. A system 101 may include first, second and third resist-applicators 102 A, 102 B and 102 C, each of which applies a resist film on a semiconductor wafer and then pre-bakes the applied resist film, The system 101 may also include first, second, and third exposure and development apparatuses 103 A, 103 B and 103 C, each of which carries out an exposure and subsequent development processes for patterning said resist film. The exposure process may be carried out by using optionally selected one of beams of various types such as ultraviolet ray, X-ray and electron beam.
[0027] The system 101 may also include first, second, and third etching apparatuses 104 A, 104 B and 104 C for anisotropically etching said wafer with said resist pattern. The system 101 may also include first, second, and third resist-pattern-size measuring apparatuses 105 A, 105 B and 105 C for measuring a size of the resist pattern over said wafer. The first, second, and third resist-pattern-size measuring apparatuses 105 A, 105 B and 105 C may have follower positions to the first, second, and third exposure and development apparatuses 103 A, 103 B and 103 C. The system 101 may also include first, second, and third wafer-pattern-size measuring apparatus 106 A, 106 B and 106 C for measuring a size of the wafer pattern defined by the etching process using the resist pattern. The first, second, and third wafer-pattern-size measuring apparatus 106 A, 106 B and 106 C may have follower positions to the first, second, and third etching apparatuses 104 A, 104 B and 104 C.
[0028] A plurality of wafers may be carried by a single carrier for batch-processing plural wafers concurrently in a lot unit in the order of the resist-applicators 102 A, 102 B and 102 C, the exposure and development apparatuses 103 A, 103 B and 103 C, the resist-pattern-size measuring apparatuses 105 A, 105 B and 105 C, the etching apparatuses 104 A, 104 B and 104 C, the wafer-pattern-size measuring apparatus 106 A, 106 B and 106 C.
[0029] The system 101 may also include a bus line 110 which is connected in parallel to the resist-applicators 102 A, 102 B and 102 C, the exposure and development apparatuses 103 A, 103 B and 103 C, the resist-pattern-size measuring apparatuses 105 A, 105 B and 105 C, the etching apparatuses 104 A, 104 B and 104 C, the wafer-pattern-size measuring apparatus 106 A, 106 B and 106 C. The bus line 110 may transfer data. The bus line 110 may receive work history data from each of the resist-applicators 102 A, 102 B and 102 C, the exposure and development apparatuses 103 A, 103 B and 103 C, and the etching apparatuses 104 A, 104 B and 104 C after the individual process has been made. The bus line 110 may receive measured data from each of the resist-pattern-size measuring apparatuses 105 A, 105 B and 105 C, and the wafer-pattern-size measuring apparatuses 106 A, 106 B and 106 C. Each of the exposure and development apparatuses 103 A, 103 B and 103 C may receive the compensated exposure value, so that the exposure process is carried out based on the compensated exposure value.
[0030] The system 101 may also include a controller 111 , a data base 112 , a monitor 113 and an atmospheric pressure measuring apparatus 114 , which are connected in parallel to the bus line 110 . The data base 112 stores work history data, size-measured data and read exposure values. The work history data are transferred through the bus line 110 from each of the resist-applicators 102 A, 102 B and 102 C, the exposure and development apparatuses 103 A, 103 B and 103 C, and the etching apparatuses 104 A, 104 B and 104 C. The resist pattern size measured data may be transferred through the bus line 110 from each of the resist-pattern-size measuring apparatuses 105 A, 105 B and 105 C. The wafer pattern size measured data may be transferred through the bus line 110 from each of the wafer-pattern-size measuring apparatuses 106 A, 106 B and 106 C.
[0031] The controller 111 may fetch the work history data, the resist pattern size measured data and the wafer pattern size measured data through the bus line 110 from the data base 112 , so that the controller 111 calculates a compensated exposure value based on the fetched data. The data of calculated compensated exposure values are transferred through the bus line 110 to the data base 112 for storing the data into the data base 112 . The process for calculating the compensated exposure value will be described below.
[0032] The monitor 113 may monitor data about the compensated exposure values stored in the data base 112 for analysis for those data in below-mentioned processes, in order to verify whether the compensated exposure value is within a predetermined acceptable range. If the compensated exposure value is within the predetermined acceptable range, then the monitor 113 renders the compensated exposure value effective. If the compensated exposure value is not within the predetermined acceptable range, then the monitor 113 renders the compensated exposure value ineffective.
[0033] The atmospheric pressure measuring apparatus 114 may measure an atmospheric pressure at a position of the exposure and development apparatuses 103 A, 103 B and 103 C for transmitting data about the measured atmospheric pressures through the bus line 110 to the data base 112 for storing the data in the data base 112 . The atmospheric pressure measuring apparatus 114 continuously measures the pressure and renews the atmospheric pressure data for every constant time periods. The atmospheric pressure measuring apparatus 114 may optionally measure other positions of the other apparatus such as the applicators, the measuring apparatuses and the etching apparatus.
[0034] The wafers are parallel-processed by the above first, second and third manufacturing apparatuses. The manufacturing processes by the above described system 101 will be described with reference to FIG. 4. Each of the first, second and third resist applicators 102 A, 102 B and 102 C picks up a single wafer from the wafer carrier which contains plural wafers, and applies a resist film on the wafer surface, before pre-bakes the resist film. The wafer with the pre-baked resist film is then contained in the wafer carrier. After all of the wafers in the wafer carrier have been processed by the first, second and third resist applicators 102 A, 102 B and 102 C, then the wafer carrier is carried toward the first, second and third exposure and development apparatuses 103 A, 103 B and 103 C. At the same time, the work history data may also be transferred through the bus line 110 to the data base 112 for storing the same, wherein the work history data may include a carrier data for indicating a carrier for carrying the wafers, a resist data for indicating the kind of the resist film, a process data for indicating the kind of processes, and an output time data for the output time when the carrier is outputted from the applicators 102 A, 102 B and 102 C.
[0035] The wafer is carried to the first, second and third exposure and development apparatuses 103 A, 103 B and 103 C. The first, second and third exposure and development apparatuses 103 A, 103 B and 103 C may fetch various wafer-related data based on the carrier ID data from the data base 112 through the bus line 110 , prior to the exposure process, so that the first, second and third exposure and development apparatuses 103 A, 103 B and 103 C may receive selected ones or all of the available informations about the wafers to be processed before the exposure process.
[0036] Each of the first, second and third exposure and development apparatuses 103 A, 103 B and 103 C picks up a single wafer from the wafer carrier and carries out the compensated exposure value. Usually, the exposure and development apparatus has been set to have a predetermined constant intensity of exposure beam, for which reason the exposure value may be controlled by controlling an exposure time period. Namely, each of the first, second and third exposure and development apparatuses 103 A, 103 B and 103 C may set the exposure time period based on the compensated exposure value for carrying out the exposure process with the controlled exposure time period.
[0037] Subsequently, each of the first, second and third exposure and development apparatuses 103 A, 103 B and 103 C may carry out the development process to form a resist pattern over the wafer. This processed wafer is then contained in the carrier. After all of the wafers in the carrier have been processed, then the carrier is carried toward the resist-pattern-size measuring apparatuses 105 A, 105 B and 105 C. At the same time, the first, second and third exposure and development apparatuses 103 A, 103 B and 103 C output the work history data which include the carrier ID data for indicating the carrier of the processed wafers, an exposure and development apparatus indicating data for indicating operated one of the first, second and third exposure and development apparatuses 103 A, 103 B and 103 C, an exposure value data for the exposure value, an exposure time data for indicating when the exposure process is carried out. The work history data are transferred through the bus line 110 to the data base 112 .
[0038] The wafer carrier is then carried to the first, second and third resist-pattern-size measuring apparatuses 105 A, 105 B and 105 C Each of the first, second and third resist-pattern-size measuring apparatuses 105 A, 105 B and 105 C picks up a single wafer for measuring a resist pattern size of the wafer. The measured size data of the wafers are then transferred through the bus line 110 to the data base 112 .
[0039] The wafer carrier is further carried to the first, second and third etching apparatuses 104 A, 104 B and 104 C. Each of the first, second and third etching apparatuses 104 A, 104 B and 104 C picks up a single wafer for etching the wafer by use of the resist pattern as a mask.
[0040] After all of the wafers in the carrier are etched, then the carrier is carried toward the first, second, and third wafer-pattern-size measuring apparatus 106 A, 106 B and 106 C. Each of the first, second, and third wafer-pattern-size measuring apparatus 106 A, 106 B and 106 C picks up a single wafer for measuring a size of the wafer pattern defined by the etching process using the resist pattern.
[0041] The above exposure process by the first, second and third exposure and development apparatuses 103 A, 103 B and 103 C will be described in detail with reference to FIG. 5.
[0042] In a step S 101 , the carriers are carried to the first, second and third exposure and development apparatuses 103 A, 103 B and 103 C.
[0043] In a step S 102 , the controller 111 fetches the work history data stored in the data base 112 , wherein the work history data had already been given to the data base 112 from the first, second and third exposure and development apparatuses 103 A, 103 B and 103 C in the past exposure processes The controller 111 recognizes carrier ID data from the fetched data and also inquires a line system with the carrier ID to recognize process items of the carrier.
[0044] In a step S 103 , the controller 111 may retrieve, from the data base 112 , work history data when the currently processing carrier has been outputted from the resist applicator 102 and process data about the same and similar past items, so that the controller 111 may read data which indicate the kind of the resist film, data which indicates the type of process, and the carrying time, based on the retrieved data.
[0045] In a step S 104 , the controller 111 may calculate a compensated exposure value for processing the wafers in the currently processing wafer carrier based on those just obtained data and the data previously stored in the data base 112 .
[0046] Operations of calculating the compensated exposure value will be described in detail.
[0047] In a step S 104 a , the controller 111 calculates a compensating value for compensation to the reference exposure value. The reference exposure value is defined to be an averaged value of past real exposure values which have been compensated based on the measured size of the resist pattern or the processed wafer pattern for making the resist pattern size correspond to the designed size. The compensating value is a compensating time for adjusting the exposure time.
[0048] The compensating value may be calculated by the following equations.
[0049] Compensating value =[{(size average value)−(center standard value)}×(exposure coefficient)×(adjustment coefficient)]−{(waiting time size variation)×(exposure coefficient)}
[0050] (a) size average value is an averaged value of the wafer pattern sizes of the past semiconductor wafers;
[0051] (b) center standard value is a target wafer pattern size of the semiconductor wafer;
[0052] (c) exposure coefficient is the exposure value when the resist pattern size is varied by 1 micrometers.
[0053] (d) adjustment coefficient is the value designed based on a pattern size variation tendency which has been obtained experimentally from the kind of resist film, the kind of the exposure apparatus, and the characteristics of the exposure apparatus.
[0054] (e) waiting time size variation is a time-dependent variation in size of the resist pattern, which depends on the waiting time.
[0055] The size average value, the center standard value, the exposure coefficient, the adjustment coefficient and the waiting time size variation may be obtained from the past processes for the semiconductor wafers, and also have been stored in the data base 112 .
[0056] The controller 111 read out, from the data base, the size average value, the center standard value, the exposure coefficient, the adjustment coefficient and the waiting time size variation. Further, the controller 111 calculates the waiting time from the work history data from the resist applicator 102 and the carrying time data for the time when the carrier is carried to the exposure and development apparatus. The waiting time size variation is obtained based on the waiting time. The exposure coefficient and the adjustment coefficient are respectively obtained based on the work history data and the exposure process data. The the size average value, the center standard value, the exposure coefficient, the adjustment coefficient and the waiting time size variation are incorporated into the above equation to obtain the compensating value.
[0057] In a step S 104 b , the compensated exposure value is obtained by subtracting the compensating value from the reference exposure value.
[0058] compensated exposure value =[(reference exposure value)−(compensating value)]
[0059] The reference exposure value is an averaged value of the real exposure values for past-processing the same and/or similar items.
[0060] In a step S 105 , the compensated exposure value is transferred through the bus line 110 to the data base 112 .
[0061] In a step S 106 , the exposure and development apparatus 103 carries out the exposure process at a controlled exposure time period which depending on the compensated exposure value.
[0062] This compensated exposure value was based on the data obtained immediately after the operations by the controller 111 . Namely, the compensated exposure value was based on the resist pattern size data of the prior semiconductor wafers measured by the resist-pattern-size measuring apparatuses 105 and also based on the wafer pattern size data of the prior semiconductor wafers measured by the wafer-pattern-size measuring apparatuses 106 . The compensation to the exposure value may be realized by real time base.
[0063] The above sequential steps S 105 and S 106 are repeated for processing all of the wafer carriers.
[0064] All of the data outputted from the resist applicators 102 , the exposure and development apparatuses 103 , the etching apparatuses 104 , the resist-pattern-size measuring apparatuses 105 and the wafer-pattern-size measuring apparatuses 106 are stored in the data base 112 . The controller 111 may calculate the compensated exposure value based on the updated data in the data base 112 in order to realize a real-time response to the size variation due to the variable waiting time. This allows a highly accurate pattern size of the semiconductor wafer. Particularly, if the exposure process is carried out immediately after the resist film is applied on the wafer surface, then the exposure process at the compensated exposure value may avoid the resist pattern size variation. It is unnecessary for reducing the resist pattern size variation to take a long waiting time for subsequent exposure process for the pre-baked wafer. This means it possible to increase the throughput.
[0065] Optionally, it is possible that the compensated exposure value may be calculated in further consideration of an atmospheric pressure data measured by the atmospheric pressure measuring apparatus 114 . The measured atmospheric pressure is transferred through the bus line 110 to the data base 112 , and the atmospheric pressure data is stored therein. The controller 111 may read out the current pressure data from the data base 112 for compensating the current pressure data to a reference pressure data to obtain a pressure difference between them. The compensating value may be calculated in further reference to the pressure difference. The drop of the pressure increases the thickness of the resist film.
[0066] Variation in pressure causes variation in refractive index of the optical system of the exposure apparatus, whereby a focusing position is varied. Those factors vary the resist pattern size. The possible pattern size variation is estimated based on the variation of the atmospheric pressure and the compensating value to the reference exposure value is calculated based on not only the above variable factors but also the atmospheric pressure variation.
[0067] The monitor 113 continuously monitors the individual data stored in the data base 112 for analysis to the data. The monitor 113 refers the past compensated exposure values for the same or similar items and processes to obtain an averaged compensated exposure value. The monitor 113 verifies whether the currently calculated compensated exposure value is within a predetermined acceptable range, which has a center value corresponding to the averaged compensated exposure value. The predetermined acceptable range may, for example, be −10% to +10%.
[0068] If the currently calculated compensated exposure value is not within the predetermined acceptable range, then the monitor 113 renders the currently calculated compensated exposure value ineffective for inhibiting the controller 111 to use the currently calculated compensated exposure value, and in place instructs the controller 111 to select the past-calculated compensated exposure value. The exposure and development apparatus 103 carries out the exposure process at the past-calculated compensated exposure value.
[0069] If the currently calculated compensated exposure value is not within the predetermined acceptable range, then the monitor 113 renders the currently calculated compensated exposure value effective for enabling the controller 111 to use the currently calculated compensated exposure value, whereby the exposure and development apparatus 103 carries out the exposure process at the currently calculated compensated exposure value.
[0070] In the above-described embodiment, the wafer carrier is an unit for the individual processes for batch-processing the plural wafers. It is, however, possible to apply the present invention to a single wafer process system, wherein the wafers are separately processed. In this case, the compensating value for compensating the reference exposure value is obtained based on the last-updated data stored in the data base. This allows the resist pattern to have a highly accurate size.
[0071] In the in-line system for flow processes, if a part of the in-line system has a fault and the sequential processes are temporally discontinued, the waiting time is unexpectedly long. In this case, the present invention is effective to avoid the pattern size variation.
[0072] In the above-described embodiment, the system includes the unitary formed exposure and development apparatus which carry out both sequential exposure and development processes. It is, of course, possible to apply the present invention to another system which includes an exposure apparatus and a development apparatus separately.
[0073] Although the invention has been described above in connection with several preferred embodiments therefor, it will be appreciated that those embodiments have been provided solely for illustrating the invention, and not in a limiting sense. Numerous modifications and substitutions of equivalent materials and techniques will be readily apparent to those skilled in the art after reading the present application, and all such modifications and substitutions are expressly understood to fall within the true scope and spirit of the appended claims.
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A method of determining an exposure value for exposing a resist film, comprises the steps of: estimating a size variation of a resist pattern from a predetermined target size based on a waiting time of a currently processing resist film to be patterned in subsequent sequential exposure and development processes; and compensating a reference exposure value based on said size variation to obtain a compensated exposure value.
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BACKGROUND OF INVENTION
The present invention relates to a trim assembly for framing windows, doors, or the like in a wall fenestration. Modern building constructions, particularly of homes and residents, ordinarily provide wall fenestrations in the building wall which receive windows or the like. A variety of window constructions may be inserted in these fenestrations, including simple window panes framed by sashes or casement windows or doors. In these installations, it has been common to provide a trim system to provide a finished look to the window by providing a frame about the window or door positioned in the opening. These trim assemblies function not only to provide an attractive finish, but also serve the dual function of providing means for interengaging siding or other covering materials which ordinarily are used to cover or finish the building walls.
It is also an object of the present invention to provide an improved trim kit or system for use in finishing a window or door casing in a manner that is attractive, easily installed, and adaptable to a wide range of sizes, shapes, and uses, including the adaptability of the unit for various color combinations.
It is therefore an object of the present invention to provide an inexpensive trim assembly kit which may be adapted for a wide range of building constructions for purposes of finishing fenestrations and window casings in a manner that is inexpensive, easy to install, attractive in appearance, and adapted for a wide range of designs, appearances and uses.
SUMMARY OF INVENTION
In the present invention, there is provided a system which includes a minimum number of trim members which may be readily formed of metal, wood, plastic components or other building material in a variety of shapes by extrusions or simple bending processes and cut to size or assembled on site. The trim assembly comprises an arrangement of a casing face, a casing molding that is continuous with the casing face, and a J-channel, with the J-channel, in turn, securing and supporting in fixed relation the various siding or other finishing materials used on the outside of the building construction. These three components, namely the casing face, casing molding and J-channel, may be selectively formed as two or three interchangeable components to permit use of different color trim elements for visual contrasts as well as for selective use of molding designs to enhance shadow effects of outdoor light on the assembled unit.
Each of these components, the casing face, the casing molding and the J-channel, may be extruded or otherwise formed of suitable material such as metal, vinyl, plastic or other material normally used in building constructions. The components may also be formed in length of sheets appropriately folded and bent to conform to the cross-sectional dimensions desired for the element. The various components may be made in various shapes to interlock one with the other and to simultaneously provide a selection of various finishes and appearances. If desired, one or more of the components may be painted or otherwise color formed to provide a contrasting color component to one or more of the elements forming this trim.
BRIEF DESCRIPTION OF DRAWINGS
These and other objects and advantages of the present invention will be more clearly understood when considered in conjunction with the accompanying drawings in which:
FIG. 1 is a plan elevational view of a window assembly embodying the present invention;
FIG. 2 is a fragmentary, cross-sectional detail taken along the lines 2 - 2 of FIG. 1 ;
FIG. 3 is a cross-sectional detail of a modification of the preferred embodiment, also taken essentially along the line 2 - 2 of FIG. 1 ;
FIG. 4 is a cross-sectional detail of a modification of the preferred embodiment, also taken substantially along the line 2 - 2 of FIG. 2 ;
FIG. 5 is a fragmentary, perspective view of a segment of a window and trim assembly embodying the present invention;
FIG. 6 a is a cross-sectional detail of a sill cover;
FIG. 6 b is a top-plan view of the sill cover of FIG. 6 a;
FIG. 7 b is an end view of the cap of FIG. 7 a ; and
FIG. 7 c is a plan view of the right end of the cap for the end of the sill cover shown in FIG. 6 a.
FIG. 8 is a fragmentary, cross-sectional view showing a modified form of a casing face installed in a window frame using a blind nailing technique;
FIG. 9 is a plan view of the casing face shown in FIG. 8 ;
FIG. 10 is a cross-sectional view of a modification of the casing face shown in FIG. 8 ;
FIG. 11 is a cross-sectional view of a casing molding;
FIG. 12 is a top plan view of the casing molding of FIG. 12 ;
FIG. 13 is a cross-sectional view of a casing face and casing molding combination used for what is characterized in the trade as “brick molding”;
FIG. 14 is a cross-sectional detail of a J-channel used with the casing molding of FIGS. 11 and 13 ; and
FIG. 15 is a plan view of the J-channel shown in FIG. 14 .
FIG. 16 is a further cross-sectional view of a further modification of the casing molding.
DETAILED DESCRIPTION OF INVENTION
As noted, the present invention is directed primarily to a window, doors and other fenestrations treatment for residential and commercial buildings, but has other applications. In the specific embodiments illustrated, there is shown a window trim assembly designed primarily for a residential building in which the building wall may be conventionally formed with a window opening or fenestration in which a window 10 is positioned. The window 10 may be a wide range of designs including simple designs in which the window pane is framed by a sash 12 or by other casement type windows. The window is secured to the building construction which may comprise standard construction. For example, a wooden wall 14 supported by studs and framing (not shown) to form the shell of the building. The window opening is framed by a casing 15 which preferably extends about the sides and top of the opening and is finished by a sill suitably covered by a sill cover shown and further described in connection with FIGS. 6 a through 7 c . The window trim system comprises primarily a casing face 16 , a casing molding 20 and a J-channel 30 interlocked and secured to the casing 15 as hereafter described. Finish siding material 50 ( FIG. 5 ) positioned over the casing 15 is secured and fits into the J-shaped channel 30 .
The casing face 16 , as illustrated in FIGS. 2 and 3 , may be formed by an elongated, metal plastic or other sheet or extrusions providing a facing web 16 a that lies against the outer surface of the casing 15 . An inwardly extending flange 16 b terminating in a lip 16 c closely conforming to and covering the end or border of the casing 15 . Material for the casing face 16 may be formed initially of extruded lengths of plastic material or bent metal in varying lengths, as for example 20 feet long, which are then cut to size on site to the length of the sides and the upper end of the casing. The casing face 16 is suitably secured to the casing by suitable means such as nails 19 which extend through spaced holes in the web 16 a of the casing face 16 . (See also FIG. 8 )
The window sill at the bottom of the window opening is similarly covered as illustrated in FIGS. 5-7 c . In this arrangement, the sill cover 17 fits closely around a sill 17 a ( FIG. 6 a ). The sill cover includes an upper web 17 b which extends close to the angled sill and terminates in a downwardly extending flange 17 c which in turn is integral with the inwardly extending flange 17 d , with the inwardly extending flange 17 d terminating in a lip 17 e that is secured to the wall 14 below the opening. The sill cover 17 may be secured to the sill by means of nails secured to the sill through openings 17 e . The ends of the sill cover 17 may be closed by end caps 17 f and 17 g shown in FIGS. 7 a and 7 c.
In the embodiment of FIG. 1 , the casing face 16 is interengaged with a casing molding generally shown at 20 in FIG. 1 . The fold 16 d formed along the length of the outer periphery of the casing face 16 is interengaged with the casing molding 20 . The casing molding 20 includes a web 21 that terminates along one edge in the inwardly extending flange 22 that interlocks with the fold 16 d formed along the outer edge of the casing face 16 . The casing molding 20 includes a web 23 that extends outwardly of the casing face 16 from the fold 16 d . A loop 24 extends lengthwise of the molding along its outer edge. The web 23 extends away from the casing face 16 at its interengaged end. A spacing 26 between the outer end of the loop 24 ( FIG. 4 ) and the outer surface of the wall 14 is formed to receive siding material 50 .
The casing web 23 may vary in shape, depending upon the decorative selection as illustrated in the embodiments of FIGS. 2 , 3 and 13 . In this arrangement, the web is formed with essentially two channels 23 a and 23 b ( FIG. 3 ). These channels may vary in width and depth and number. Their specific design is calculated to provide an attractive surface for light impinging on the web and for enhancement of shadows created by sunlight.
The spacing between the loop 24 and the wall 14 provides a space in which the J-shaped channel 30 is positioned. The J-shaped channel 30 has a leg 31 that lies flush against the inner surface of the casing molding with the leg 31 inserted in and frictionally interengaged with the loop 24 .
As illustrated in FIG. 3 , the loop 24 may be closed to form an essentially re-entrant slot 24 b that frictionally engages and secures the leg 31 of the J-shaped channel. An outwardly extending leg 34 of the J-shaped channel lies in facing relation to the casing 15 or wall sheathing 14 .
The assembly of FIGS. 2 and 3 may be secured by nails 19 which effectively provide a blind nail arrangement.
As illustrated in FIG. 5 , the J-shaped channel 30 forms a recess at its inner end to receive shingling or siding material 50 . The siding material may, as illustrated in FIG. 5 , comprise shingles or sheets of vinyl or other plastics or composite construction material shaped to simulate a shingle effect. These sheets are secured by conventional means to the outer wall of the building construction 53 .
As noted above, the casing face may be varied in size and styling as exemplified by FIGS. 8 & 9 . In this arrangement, the casing face 16 is formed with a web 16 a , inwardly extending flange 16 b (into the window opening), and a lip 16 c . In this arrangement, however, the web 16 a has a folded end 16 H forming a flange engaging member to engage an inwardly extending flange formed near the edge of the casing molding. In place of the folded end 16 h , an extruded flange 16 d ( FIG. 2 ) may be used. Suitable nail holes 16 h may be provided along the length of the facing web 16 a to secure it to the casing.
In the embodiment of FIG. 10 , the casing face 16 is similar in overall construction to the previously described casing face as provided with an extruded or otherwise similarly formed slot 16 m to engage an outwardly directed flange of the casing molding in a manner previously described.
FIGS. 11 & 12 show a somewhat enlarged view of the casing molding illustrated in FIGS. 2 & 3 . In this configuration, the loop 24 a may be bulbous as shown at 26 in FIG. 2 to provide an interengagement with a corresponding end of the J-channel.
FIG. 13 illustrates a combined or integrated casing face and molding design specifically for what is characterized in the trade as “brick molding” or similar trim configurations on the outside of the building. In this configuration, the portion of the unit forming the casing molding 55 is integrally formed with casing face 57 , which trim is shaped to fit over the side of the brick or other substitute wall covering and is secured thereto by nails or the like. The casing facing then is terminated at its other end in a loop 53 which may have a constricted opening to receive and group the edge of the J-channel more securely.
FIGS. 14 & 15 show further modifications of the J-channel in which a flange 61 of the J-channel 60 terminates at its free end in a curved loop 63 which may be interlocked with the loop 53 shown in FIG. 13 or similar loops. Similar to the other embodiments siding extends into the J-channel as described in the other embodiments.
FIG. 16 illustrates a still further embodiment of a modified shape for the casing molding in which the outwardly extending flange 70 terminates in an S-shaped segment having legs 71 , 72 , 73 , and 74 in which the base of the J-shaped channel may be secured.
The casing face 16 , casing molding 20 and J-channel 30 may each be made for a trim kit package adapted for on-site fabrication. In this arrangement, these components may be formed as extruded plastic or bent metal components having lengths, such as 20′ that will exceed the dimensions of the fenestration. On site they are cut to fit the particular installation using well-known techniques for installing window components.
As used in this specification the terms inward or inwardly, unless otherwise expressly stated, means in a direction parallel, or essentially parallel, to the major surface of the casing and construction wall toward the fenestration, and outwardly refers to the opposite direction.
While aspects of the invention have been described with reference to various illustrative embodiments, such aspects are not limited to the embodiments described. Thus, it is evident that many alternatives, modifications, and variations of the embodiments described will be apparent to those skilled in the art. Accordingly, embodiments as set forth herein are intended to be illustrative, not limiting. Various changes may be made without departing from the spirit of aspects of the invention.
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A window frame assembly for a window opening in which the assembly comprises a casing facing that covers the casing with a J-channel secured to the casing facing and defining an outwardly facing channel to receive bordering edges of siding material, and a casing molding having one longitudinal edge continuous with the casing facing and a second longitudinal edge outwardly and non-planar with the one longitudinal edge and engaging the J-channel. The casing molding of a color contrasting with either or both of the J-channel and casing facing.
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RELATED APPLICATION
This application is a divisional of application Ser. No. 10/334,752 filed Dec. 31, 2002 by these inventors, and claims benefit of that filing date.
BACKGROUND OF THE INVENTION
1. Technical Field of the Invention
This invention relates generally to electromagnetic transducers such as audio speakers, and more specifically to an electromagnetic transducer having a diaphragm or cone which is asymmetric, meaning that the ID of the cone is not at the geometric center of the OD of the cone. The ID or inner diameter refers to the location, typically but not always a hole, where the bobbin attaches to the diaphragm. The OD or outer diameter refers to the outer perimeter where typically the surround attaches to the diaphragm.
2. Background Art
FIG. 1 illustrates a conventional audio speaker 10 such as is known in the prior art. The speaker includes a motor assembly 12 coupled to a diaphragm assembly 14 by a frame 16 . The motor assembly includes a magnetic air gap 18 over which magnetic flux flows. The diaphragm assembly includes an electrically conductive voice coil 20 which is rigidly attached to a bobbin or voice coil former 22 . The voice coil is suspended within the magnetic air gap to provide mechanical force to an acoustical radiating member 24 , often termed a diaphragm or cone, which is coupled to the bobbin. When an alternating electric current is passed through the voice coil, the voice coil moves axially in the air gap, causing the diaphragm to generate sound waves. The diaphragm assembly further includes two suspension components which serve to keep the bobbin and diaphragm centered and aligned with respect to the motor assembly, while allowing axial movement. A damper or spider 26 is coupled to the bobbin and the frame, and a surround 28 is coupled to the diaphragm and the frame. A dust cap 30 seals the assembly and protects against infiltration of dust particles and other stray materials which might contaminate the magnetic air gap and thereby interfere with the operation or quality of the speaker.
The motor assembly has an axis A m typically understood to be at the axial center of the magnetic air gap in which the voice coil rides. The diaphragm has an OD or outer perimeter which has a geometric center or axis A od . It is the same distance OD 1 from the axis A od to a first point on the OD and to a second point on the OD, which two points are radially opposite each other. The diaphragm may be axisymmetric, in the case of e.g. a round 6″ speaker. Alternatively, the diaphragm may be bilaterally symmetric, in the case of e.g. an elliptical 6×9 speaker. Other diaphragm OD shapes are known in the art, as well. The diaphragm also has an ID or inner perimeter which has a geometric center or axis A id . It is the same distance ID 1 from the axis A id to a first point on the ID and to a second point on the ID, which two points are radially opposite each other. In nearly all cases, speakers use a cylindrical bobbin and a circular ID, but a few exceptions are known. The spider has a center or axis of suspension A sp , and the surround has an center or axis of suspension A su .
As shown in FIG. 1 , virtually all known speakers are constructed such that the motor axis A m , the axis A od of the OD, the axis A id of the ID, the axis of suspension A sp of the spider, and the axis of suspension A su of the surround, are all coaxial with one another.
Ordinarily, in most engineering applications it is desirable to achieve symmetry. However, in audio applications, symmetry has some disadvantages. For example, a symmetric cone exhibits the same breakup modes in all radial segments, as each radial segment has the same shape, size, mass, etc. as the others. As another example, a symmetric speaker exhibits equal diffraction characteristics and cone/edge junction modes at all radial segments.
FIGS. 2 and 3 are copied from U.S. Pat. No. 5,022,488 “Transducer Enclosure” issued Jun. 11, 1991 to William House and assigned to Harman International. The House patent teaches a speaker 31 having an asymmetric diaphragm 33 . That inventor was addressing a completely unrelated problem, that of fitting two speakers 35 , 37 into a single cabinet 39 with separate pressure venting for each. He appears to have moved the woofer's motor structure 41 away from the center of the woofer's diaphragm 33 merely for the purpose of providing physical space for the tweeter 37 to fit in front of a portion of the woofer's diaphragm, and not to have recognized any other benefits from the asymmetry. Indeed, the patent states that “it is not necessary for diaphragm [of the woofer] to be asymmetric, nor for diaphragm [of the tweeter] to be symmetric, nor for either transducer to be a diaphragm type at all.” (col. 3 lines 57–60, reference numbers omitted, bracketed text added). It is noteworthy that the woofer diaphragm is an inverted cone, rather than a conventionally oriented cone with its bell facing outward. This was clearly done to make still more room for the tweeter within the design constraint of gaining “the benefits of shallow loudspeaker mounting” (col. 1 line 11).
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be understood more fully from the detailed description given below and from the accompanying drawings of embodiments of the invention which, however, should not be taken to limit the invention to the specific embodiments described, but are for explanation and understanding only.
FIG. 1 shows, in cross-section, a conventional speaker geometry according to the prior art.
FIGS. 2 and 3 show a prior art two-speaker arrangement according to U.S. Pat. No. 5,022,488, in which one of the speakers has an asymmetric diaphragm.
FIG. 4 shows a front view of a circular OD diaphragm having an off-center ID.
FIG. 5 shows a front view of an elliptical OD diaphragm having an ID which is located on one line of symmetry but off the other line of symmetry of the ellipse.
FIG. 6 shows a front view of an elliptical OD diaphragm having an ID which is located off both lines of symmetry of the ellipse.
FIG. 7 shows, in cross-section, a speaker having an asymmetric diaphragm and an on-motor-axis symmetric spider.
FIG. 8 shows, in cross-section, a speaker having an asymmetric diaphragm and an asymmetric spider.
FIG. 9 shows, in cross-section, a speaker having an asymmetric diaphragm and an asymmetric spider.
FIG. 10 shows, in cross-section, a speaker having an asymmetric diaphragm and an off-motor-axis symmetric spider.
FIG. 11 shows, in cross-section, a speaker having an asymmetric diaphragm and an on-motor-axis symmetric spider, frame, and surround.
FIG. 12 shows, in cross-section, a speaker having an asymmetric diaphragm and an on-motor-axis symmetric spider, frame, and surround.
FIG. 13 shows, in partial cutaway top view, a speaker having an asymmetric diaphragm.
FIG. 14 shows, in cross-section, a portion of an asymmetric diaphragm assembly with mass balancing of the diaphragm by making the shorter side thicker than the longer side.
FIG. 15 shows, in cross-section, a portion of an asymmetric diaphragm assembly with mass balancing of the diaphragm by tapering the diaphragm thickness and weighting each side toward the outer edge of the short side.
FIG. 16 shows, in cross-section, a portion of an asymmetric diaphragm assembly with mass balancing after differential foaming of the diaphragm material to increase the stiffness of the long side.
FIG. 17 shows, in cross-section, a portion of an asymmetric diaphragm assembly with mass balancing assisted by suitably making the inactive attachment portion of the surround longer, and thus heavier, at the short side of the diaphragm.
FIG. 18 shows, in cross-section, a portion of an asymmetric diaphragm assembly with mass balancing assisted by making the inactive attachment portion of the surround thicker, and thus heavier, at the short side of the diaphragm. For convenience, a rear-attach surround is used.
DETAILED DESCRIPTION
The invention may be utilized in a variety of magnetic transducer applications, including but not limited to audio speakers, microphones, and the like. For the sake of convenience, the invention will be described with reference to audio speaker embodiments, but this should be considered illustrative and not limiting. For ease of illustration only, the invention will be illustrated with reference to an external magnet geometry speaker, but is not so limited.
FIG. 4 illustrates a front view of an axisymmetric-OD (round) diaphragm 24 A in which the ID is not concentric with the OD. The axis A id is not coaxial with the axis A od .
FIG. 5 illustrates a front view of an elliptical diaphragm 24 B in which the ID center is not at the center of the OD. The elliptical diaphragm is bilaterally symmetric about a vertical line and a horizontal line. The ID is located on one of these lines but not on the other. The axis A id is not coaxial with the axis A od .
FIG. 6 illustrates a front view of an elliptical diaphragm 24 C in which the ID center is not at the center of the OD. The elliptical diaphragm is bilaterally symmetric about a vertical line and a horizontal line. The ID center is not located on either of these lines. The figure further suggests that it is not necessarily the case that an asymmetric cone have its ID completely on or off a particular bilateral symmetry line; in other words, zero, one, or both of those lines may pass through the ID, so long as they are not both coincident with the center of the ID. The axis A id is not coaxial with the axis A od .
The reader will readily appreciate that, while round and elliptical asymmetric diaphragms have been shown, the invention is not thus limited. The reader will further appreciate that the asymmetric diaphragm may be practiced with conventional, concave cones, or with inverted cones, or with flat diaphragms, or with other diaphragm configurations.
FIG. 7 illustrates one embodiment of a speaker 40 in which the axis A od of the OD of the diaphragm is not coaxial with the axis A id of the ID of the diaphragm. In this example, the A id is coaxial with the axis A m of the motor assembly. With the ID off-center from the OD, the diaphragm 24 includes a short side 24 S and a long side 24 L on opposite sides of the ID. The frame includes a first portion 16 A adapted to hold the short side 24 S and a second portion 16 B adapted to hold the long side 24 L. A symmetric spider 26 is coupled to and centered about the bobbin 22 , which is coaxial with the axis A m of the motor assembly.
The axis of suspension A su of the symmetric surround 28 is generally coaxial with the A od , but the axis of suspension A sp of the symmetric spider 26 is generally coaxial with the A id , and the A od and A id are not coaxial. This may tend to cause rocking of the diaphragm assembly during operation of the speaker.
The short side 24 S and long side 24 L of the diaphragm have respected projected chords SS and LS.
The high frequency dispersion pattern of the speaker will be asymmetrically controlled by the resultant angle, from the primary motor axis, of the long side with respect to that of the short side. By employing an asymmetric diaphragm, the speaker designer can control the dispersion by modifying the ratio of the long side to short side, which in turn affects the respective angles of the diaphragm at those locations.
FIG. 8 illustrates a speaker 42 , demonstrating one possibility for making the A sp more coaxial with the A su . The spider 26 is formed so as to not be axisymmetric about the bobbin 22 . The asymmetric spider includes a short side 26 A and a long side 26 C. The frame includes a first portion 16 A adapted to hold the short side 24 S of the diaphragm and the short side 26 A of the spider, and a second portion 16 C adapted to hold the long side 24 L of the diaphragm and the long side 26 C of the spider. Typically, the frame and spider may each be constructed with a continuously varying shape to provide a smooth transition from its first portion to its second portion. The geometric center of the spider has been moved from the axis A m of the motor assembly toward the geometric center of the diaphragm A od , but at the cost of having larger, more compliant rolls of material in the longer side of the spider.
This embodiment has the disadvantage that the softer portion of the spider suspension (with larger, more compliant rolls) is supporting the heavier portion of the diaphragm on the diaphragm's longer side. The long side of the diaphragm may have a greater moment of rotational inertia about the A id than does the short side, which may cause rocking in response to acceleration of the diaphragm assembly. This may be exacerbated by the spider being softer on the long side of the diaphragm. In other words, while the A sp has been moved off of the A m , it has moved toward the A su rather than away from it, and both suspension components have their axis of suspension on the same side of A m .
FIG. 9 illustrates one embodiment of a speaker 44 in which the axes of suspension have been adjusted to reduce rocking. The frame includes a first portion 16 A adapted to hold the short side 24 S of the diaphragm, and a second portion 16 D adapted to hold the long side 24 L of the diaphragm. A first portion 26 A of the spider is adapted to secure the bobbin to the first portion 16 A of the frame, and a second portion 26 D of the spider is adapted to secure the bobbin to the second portion 16 D of the frame. The A sp of the asymmetric spider has been moved from the A m of the motor assembly farther away from the A od of the diaphragm, with the result of having smaller, and therefore stiffer, rolls of material in the shorter side of the spider which is suspending the bobbin on the long side of the diaphragm. Thus, the stiffer portion of the spider is suspending the longer, heavier side of the diaphragm, in order to balance the diaphragm displacement of both sides of the speaker, at resonance, which will in turn minimize the tendency for rocking to occur. In addition, the A sp is moved to the opposite side of A m from the A su and thus the average of A sp and A su more closely coincides with A m with the result that, if rocking occurs, the rotational center of the rocking will more closely coincide with the center of the voice coil, minimizing the chances of the voice coil striking or rubbing the motor structure.
In either of these embodiments, one could reduce the rocking tendency by altering the shape or compliance of the surround instead the spider. Or, one could alter both the spider and the surround. The skilled designer will need to take into account the relative stiffnesses of the surround and the spider, and the relative mass and balance of the diaphragm, as well as the relative mass and balance of the rest of the moving components including the spider and the surround, in determining where to place the axes of suspension of the surround and spider in order to achieve a balanced, non-rocking speaker.
FIG. 10 illustrates another embodiment of a speaker 46 which uses a symmetric spider 27 , but which moves the axis A sp of the spider's suspension to be substantially coaxial with the axis A su of the surround's suspension. The frame includes a first portion 16 A adapted to hold the short side 24 S of the diaphragm, and a second portion 16 E adapted to hold the long side 24 L of the diaphragm. A rigid, eccentric spacer 48 is coupled between the bobbin and the spider. The spacer includes a short side 48 S located with the short side of the diaphragm, and a long side 48 L located with the long side of the diaphragm. The geometric center of the spacer, as measured by distance R os from points along its outer perimeter where it mates with the spider, is substantially coaxial with the A od of the diaphragm and, thus, coaxial with the A su of the surround. With the spacer rigidly coupled to the bobbin, the bobbin is effectively suspended by the spider about the axis A od of the diaphragm, although the voice coils and bobbin themselves remain centered about the axis A m of the motor assembly. The A sp and A su are substantially coaxial with A od , to reduce rocking.
FIG. 11 illustrates another embodiment of a speaker 50 which uses a similar arrangement, except that an eccentric diaphragm spacer 52 is coupled between the bobbin and the diaphragm, rather than between the bobbin and the spider. This speaker has the further advantage that, except for its asymmetric cone and the eccentric spacer, the rest of its components can be conventional, symmetric parts, including the frame 16 , spider 26 , and surround 28 . With a symmetric frame, the A od is coaxial with the A m , the A su is coaxial with the A sp , and, in fact, all four of those may be coaxial, with only the A id being at a different location, which makes balancing the diaphragm assembly relatively simple.
FIG. 12 illustrates another embodiment of a speaker 54 , in which the eccentric diaphragm spacer 56 has an OD which is coupled to the bobbin ID, meaning that the spacer is disposed within the bobbin with a short side 56 S of the spacer adjacent the short side 24 S of the diaphragm, and a long side 56 L of the spacer adjacent the long side 24 L of the diaphragm. The off-center cone ID is coupled to the ID of the eccentric spacer.
FIG. 13 illustrates the speaker 40 of FIG. 7 , in partial cutaway top view with some of the components removed for better visibility of underlying components. The speaker includes a motor assembly having a magnet 60 and a top plate 62 surrounding a pole piece 64 . The diaphragm assembly includes a voice coil 20 coupled to a bobbin 22 within the magnetic air gap 18 between the pole piece and the top plate. An asymmetric diaphragm 24 is coupled to the bobbin and includes a short side 24 S, a long side 24 L opposite the short side, and an intermediate portion 24 M providing a size transition between the short side and the long side. The A id is not coincident with the A od .
FIG. 14 illustrates a partial diaphragm assembly in which the diaphragm has been balanced by adding mass to the short side 24 S by making it thicker, and/or by removing mass from the long side 24 S by making it thinner. Typically, but not necessarily, the thickness transition may be continuous around the diaphragm thickness from the thick side to the thin side.
FIG. 15 illustrates a partial diaphragm assembly in which the balancing has further been accomplished by tapering the diaphragm to bias one or both sides 24 S, 24 L of the diaphragm toward the outer edge of the short side 24 S. The short side is thicker at its OD edge (at the surround 28 ) than it is at its ID edge (at the bobbin 22 ), and the long side is thicker at its ID edge than it is at its OD edge. Typically, but not necessarily, the taper transition may be continuous around the diaphragm from one side to the other.
FIGS. 15 and 16 together also illustrate one particularly advantageous method of forming the diaphragm. The diaphragm is formed from a plastic such as polypropylene, or any other suitable material, in a mould having a taper as shown in FIG. 15 . Then, at the correct time during the moulding and curing process, the mould halves for the top and bottom surfaces of the diaphragm are hinged partially open, with the hinge at or near the OD edge of the short side 24 S of the diaphragm, such that the mould opens more at the OD edge of the long side 24 L of the diaphragm than it does in the middle near the bobbin, and more in the middle than at the hinge. When the mould is hinged open, the material (typically in the presence of an activating agent) will foam to fill the newly enlarged space. Thus, the OD edge of the long side 24 L will foam to a more increased thickness than will the other portions of the diaphragm. The mass in each locality will stay the same as before the differential foaming, but the density will change in relationship to the locality's distance and angle from the hinge. The longer side will be less dense than the shorter side. In general, the more the foaming increases the thickness, the stiffer that locality will be. By appropriately selecting the diaphragm material, shaping the mould halves, locating the hinge, and hinging the mould halves open to induce foaming, the designer can achieve a diaphragm having any desired stiffness, thickness, and mass profile. In particular, it may be desirable to create a diaphragm which demonstrates equal stiffness along each chord, in every angle, to minimize cone breakup modes and other undesirable effects which may distort the sound produced by the speaker, and at the same time, achieve mass balancing in order to reduce rocking modes.
Alternatively, rather than shifting the mass of the diaphragm material, balancing may be accomplished by simply affixing a weight to the diaphragm in a suitable location.
FIG. 17 illustrates a different balancing mechanism, in which the mass of the surround 28 is used to balance the diaphragm 24 . On the short side, the portion 70 of the surround which is affixed to the diaphragm (and therefore is simply moving mass, and not an active part of the suspension) is cut or formed so as to be longer than that portion 72 which is affixed to the long side of the diaphragm.
FIG. 18 illustrates a similar balancing mechanism, in which the portion 74 of a rear-attached surround which is affixed to the short side of the diaphragm is made thicker than the portion 76 which is affixed to the long side of the diaphragm.
With reference now to any of the figures describing the invention, in order to achieve desired acoustic results, the dimensional ratio between the short side and the long side may be adjusted by moving the ID relative to the OD. Below are given example formulas which can be used in selecting ratios for round speakers.
Table 1 gives the formula for Phi, the value upon which the Fibonacci sequence and other natural phenomena are built.
TABLE 1
Phi
Phi
=
1
+
1
+
1
+
…
Table 2 gives a simpler formula for approximating Phi, which may also be termed the golden ratio GR. Having an LS:SS ratio of approximately Phi or Phi 2 may, in many applications, produce good results. In some applications, having a ratio of the LS or the SS versus the intermediately sized portions of Phi or Phi 2 may be advantageous.
TABLE 2
Golden Ratio aka Phi
GR
=
0.5
+
5
2
=
1.618034
Table 3 gives a formula for calculating the functional diameter FOD of the diaphragm, which is the overall diameter minus the distance which is occupied by the voice coil.
TABLE 3
Functional OD
FOD = OD − ID
Table 4 gives a formula for calculating the length of the projected chord LS on the longer side of the diaphragm, measured from the bobbin to the surround. Bdepth is the depth of the cone or diaphragm, or, in other words, the distance between the diaphragm's OD plane and the diaphragm's ID plane.
TABLE 4
Length of Projected Long Chord
LS
=
⌊
GR
2
·
FOD
-
(
-
Bdepth
2
+
2
·
GR
2
·
Bdepth
2
+
GR
2
·
FOD
2
-
GR
4
·
BDepth
2
)
⌋
GR
2
-
1
Table 5 gives a formula for calculating the distance which the geometric center A od of the diaphragm is offset from the axis A m of the motor assembly.
TABLE 5
Offset from A m to A od
Offset
=
LS
-
FOD
2
Table 6 gives a formula for calculating the length of the projected chord on the shorter side of the diaphragm, measured from the bobbin to the surround.
TABLE 6
Length of Projected Short Chord
SS = FOD − LS
Table 7 gives a formula for calculating the centeredness ratio of the speaker, which is the ratio of the lengths of the short and long projected chords.
TABLE 7
Centeredness Ratio
CenterRatio
=
SS
LS
Table 8 gives the value of rho, the density of air.
TABLE 8
Density of Air
ρ = 1.18
Table 9 gives a formula for calculating the air load mass on the diaphragm, ignoring the air load mass that will be on the dust cap, or, more precisely, the portion of the dust cap which overlies the bobbin.
TABLE 9
Air Load Mass, Excluding Voice Coil Area
M
al
=
ρ
·
FOD
3
3,000,000
In order to prevent rocking of the diaphragm, which may distort the sound or, if it becomes exaggerated enough, may even cause the bobbin to impact the pole piece or plate, it is desirable to balance the diaphragm. The diaphragm may be balanced, to a first order of approximation, by forming the diaphragm such that any two opposing chord cross-sections are of equal area; in other words, opposite strips of diaphragm will have equal mass.
Table 10 gives a formula for calculating how much the mass of the short chord side of the diaphragm should be adjusted upward, and the mass of the long chord side of the diaphragm should be adjusted downward from this equal mass configuration, in order to balance the diaphragm over the axis of the bobbin to a next order of approximation, which includes the air load mass difference.
TABLE 10
Diaphragm Mass Adjustment
Delta
=
M
al
·
CenterRatio
2
·
ConeMass
CONCLUSION
In order to achieve desired acoustic results, the dimensional ratio between the short side and the long side may be adjusted by moving the ID relative to the OD. In some applications, the speaker designer may elect to design a speaker in which the ratio is determined as between one of the long side and short side versus a midpoint side (e.g. 24 M in FIG. 13 ).
In order to prevent rocking of the diaphragm, which may distort the sound or, if it becomes exaggerated enough, may even cause the bobbin to impact the pole piece or plate, it is desirable to balance the diaphragm. The diaphragm may be balanced, to a first order of approximation, by forming the diaphragm such that any two opposing chord cross-sections are of equal area; in other words, opposite strips of diaphragm will have equal mass.
Further improvements may be made by making further adjustments for the relative moments of rotational inertia of the respective chords, to further reduce the tendency of the diaphragm assembly to rock as it accelerates in and out of the motor assembly.
The invention may be practiced with diaphragms of any suitable shape, such as but not limited to circular, elliptical, oval, egg-shaped, rectangular, or any polygon. In some implementations, a conical diaphragm may be used. A conical diaphragm may be said to have an apex at its “deepest” point; this is typically where the bobbin is mounted.
Mass may be added to portions of the diaphragm, to balance it, either by adding actual diaphragm material, or by adding some other material or fixture. Suspension stiffness may be adjusted asymmetrically in order to compensate for mass imbalances or differences in rotational moments.
Reference in the specification to “an embodiment,” “one embodiment,” “some embodiments,” or “other embodiments” means that a particular feature, structure, or characteristic described in connection with the embodiments is included in at least some embodiments, but not necessarily all embodiments, of the invention. The various appearances “an embodiment,” “one embodiment,” or “some embodiments” are not necessarily all referring to the same embodiments.
If the specification states a component, feature, structure, or characteristic “may”, “might”, or “could” be included, that particular component, feature, structure, or characteristic is not required to be included. If the specification or claim refers to “a” or “an” element, that does not mean there is only one of the element. If the specification or claims refer to “an additional” element, that does not preclude there being more than one of the additional element.
When one component is said to be “adjacent” another component, it should not be interpreted to mean that there is absolutely nothing between the two components, only that they are in the order indicated.
The several features illustrated in the various figures may be combined in many ways, and should not be interpreted as though limited to the specific embodiments in which they were explained and shown.
Those skilled in the art having the benefit of this disclosure will appreciate that many other variations from the foregoing description and drawings may be made within the scope of the present invention. Indeed, the invention is not limited to the details described above. Rather, it is the following claims including any amendments thereto that define the scope of the invention.
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An electromagnetic transducer such as an audio speaker which includes an asymmetric diaphragm to deliver smooth frequency response with reduced distortion by reduction of common modes in the diaphragm. Other benefits such as asymmetric directivity patterns can be realized. The asymmetric cone has a perimeter OD at which a surround may be coupled, and an ID at which a bobbin or spacer may be coupled. The center of the ID is not coincident with the center of the OD. The transducer further includes a stabilization mechanism for reducing rocking of the diaphragm assembly. The stabilization mechanism may include mass balancing of the diaphragm and/or adjustments to the location or symmetry of the suspension components.
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This is a nonprovisional application based on provisional application Ser. No. 60/353,585, filed on Feb. 1, 2002.
INTRODUCTION
The invention relates to novel, water-soluble porphyrin platinum compounds with high tumor selectivity and their use for the treatment of benign and malignant tumor diseases. In particular, the inventive compounds are suitable for photodynamic anti-tumor therapy in man and mammals.
PRIOR ART
Platinum(II) complexes with porphyrin ligands and their application as potent cytostatic and phototoxic antitumor agents have already been described in the following publications.
W. M. Sharman, C. M. Allen and J. E. van Lier, DDT 4, (11) 507–517 (1999). Photodynamic therapeutics: basic principles and clinical applications
T. Okunaka and H. Kato, Rev. Contemp. Pharmacother., 10, 59–68 (1999). Potential Applications of Photodynamic Therapy.
H. Brunner, H. Obermeier and R.-M. Szeimies, Chem. Ber., 1995, 128, 173–181. Platinum(II) complexes with porphyrin ligands: synthesis and synergism during photodynamic therapy.
H. Brunner, K.-H. Schellerer and B. Treittinger, Inorg. Chim. Acta 1997, 264, 67–69. Synthesis and in vitro testing of hematoporphyrin type ligands in platinum(II) complexes as potent cytostatic and phototoxic antitumor agents.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 2 shows comparative data of the cytotoxic effect of additional compounds on human bladder tumor cells in the dark and under irradiation with light at a wavelength of 600–730 nm.
DESCRIPTION OF THE INVENTION
In the invention, novel porphyrin platinum derivatives are described, which have cytotoxic properties. Surprisingly, the compounds have good water solubility and a high selectivity. The compounds can be used for the treatment of cancer and, in particular, for the photodynamic treatment of tumors.
The general formulas of the claimed compounds of the tetraarylporphyrin platinum derivatives type are:
The general formulas of the claimed compounds of the hematoporphyrin platinum derivatives type are:
If the inventive compounds have at least one center of asymmetry, they can be in the form of their racemates, their pure enantiomers and/or their diastereoisomers or in the form of mixtures of these enantiomers or diastereoisomers.
The inventive compounds exhibit cytotoxic activity in selected tumor cell lines. The antitumor activity is intensified by irradiating with electromagnetic radiation having a wavelength of 600 to 730 nm. The invention accordingly relates to the chemical combination of the cytotoxic principle of the platinum compounds of the cis platinum type with a photodynamically active molecule of the porphyrin derivative type, in such a manner, that compounds of good water solubility and high selectivity are obtained.
The inventive compounds can be administered intraaterially, intracerebrally, intramuscularly, intraperitoneally, intrathecally, intravenously, orally, parenterally, intranasally, rectally, subcutaneously and/or topically in the form of tablets, film-coated tablets, capsules, coated tablets, powders, granulates, drops, syrups, ointments, powders for inhalation, infusion solutions, drinking solutions or in some other suitable form.
The medicaments comprise one or more compounds in addition to customary physiologically tolerable carriers and/or diluents or auxiliaries.
The process for the production of the medicament is characerized in that one or more compounds are processed to give pharmaceutical preparations or brought into a therapeutically administrable form using customary pharmaceutical carriers and/or diluents or other auxiliaries.
The synthesis of the inventive compounds is described.
Tetraarylporphyrin Platinum Derivatives
Synthesis of the substituted benzaldehydes. For the reaction with 4-hydroxy-benzaldehyde the respective oligo- and polyethyleneglycol monomethylethers had to be activated at their alcohol terminus with tosyl chloride according to a literature procedure. The etherification was performed by refluxing the tosylated alcohols and 4-hydroxybenzaldehyde together with K 2 CO 3 in DMF. The substituted benzaldehydes were separated by filtration and purified by column chromatography.
For platinum coordination to the tetraarylporphyrins to be synthesized it is necessary to introduce two adjacent carboxylic acid groups in one of the substituted benzaldehydes. Therefore, 4-hydroxybenzaldehyde was etherified with diethyl bromomalonate under alkaline conditions. The diethyl 2-(4-formylphenoxy)malonate was used together with the substituted benzaldehydes for the synthesis of asymmetric tetraarylporphyrins.
Synthesis of the porphyrin ligands. The synthesis of the asymmetric tetraarylporphyrins was performed using the Lindsey method. Pyrrol and the respective benzaldehydes were reacted under Lewis acid catalysis to porphyrinogens, which were oxidized with p-chloranil to the corresponding porphyrins. The tetraarylporphyrin esters were purified by several column chromatographies. The carboxylic acids, which were required for coordination to the platinum(II) fragments, were prepared by hydrolysis of the esters with a mixture of CHCl 3 and 20% methanolic KOH solution or pure 20% methanolic KOH solution only.
Synthesis of the platinum fragments. 1,2-Diaminoethane, 1,3-diaminopropane, trans-1,2-diaminocyclohexane and 2,2′-bipyridine were commercially available and used as ligands to prepare the corresponding dichloroplatinum(II) complexes according to literature procedures. Ethyl DL-2,3-diaminopropionate dihydrochloride, ethyl L-2,4-diaminobutanoate dihydrochloride and diethyl meso-4,5-diaminosuberate dihydrochloride were synthesized according to literature procedures and used as ligands for the preparation of the corresponding diiodoplatinum(II) complexes.
Synthesis of the platinum complexes. For the reaction with the porphyrincarboxylic acids cisplatin had to be activated by conversion into diammine(diaqua)platinum(II) hydroxide. It was reacted with an equimolar amount of the porphyrin ligand in a mixture of CHCl 3 , ethanol and water or, in the case of the water-soluble ligand, in pure water. The resulting diammine(malonato)platinum(II) complexes precipitated. To the reaction mixture of the water-soluble complex CH 2 Cl 2 was added to remove neutral impurities. The aqueous hphase was evaporated to obtain the product.
The diamine(dichloro)platinum(II) fragments were activated by conversion into diamine(dihydroxy)platinum(II) species, which were reacted with an equimolar amount of the respective porphyrin malonic acid in a mixture of CH 2 Cl 2 , ethanol and water or, in the case of the water-soluble ligand, in pure water. The complexes precipitated. To the water-soluble complex CH 2 Cl 2 was added to remove neutral impurities, before the aqueous phase was evaporated to obtain the product.
For the reaction with the porphyrinmalonic acids it was necessary to activate the diamine(diiodo)platinum(II) complexes by conversion into diamine(dinitrato) platinum(II) species, which are water-soluble. In this form they were reacted with an equimolar amount of the porphyrin ligands, in a mixture of CH 2 Cl 2 , ethanol and water. The water-insoluble complexes precipitated after concentrating the solutions.
Hematoporphyrin Platinum Derivatives Type
Synthesis of the porphyrin ligands and the platinum precursors. Hemin was transferred to protoporphyrin dimethylester, from which all the subsequent reactions started. First, protoporphyrin dimethylester was treated with 30% hydrobromic acid in acetic acid to give the labile Markownikoff adduct of HBr to the two vinyl double bonds, which was reacted with different types of alcohols to replace bromide by the corresponding alkoxides. As alcohols we chose hydrophilic oligo- and polyethyleneglycol monomethylethers. During the etherification the HBr formed catalyzed the transesterification of the methylesters into the esters of the corresponding alcohols. The etherified hematoporphyrin esters were purified by column chromatography. The carboxylic acids, which were required for coordination to the platinum(II) moieties, were prepared by hydrolysis of the esters with 20% methanolic KOH solution.
1,2-Diaminoethane, 1,3-diaminopropane, trans-1–2-diaminocyclohexane and 2,2′-bi-pyridine were commercially available and used as ligands to prepare the corresponding dichloroplatinum(II) complexes according to literature procedures. Ethyl DL-2,3-diaminopropionate dihydrochloride, ethyl L-2,4-diaminobutanoate dihydrochloride and diethyl meso-4,5-diaminosuberate dihydrochloride were synthesized according to literature procedures and used as ligands for the preparation of the corresponding diiodoplatinum(II) complexes.
Synthesis of the platinum complexes. Reaction of the porphyrin carboxylic acids with cisplatin did not result in the desired complexes. Therefore, cisplatin had to be activated by conversion into diammine(diaqua)platinum(II) hydroxide, which was reacted with an equimolar amount of the porphyrin ligand in a mixture of ethanol and water or, in the case of the water-soluble ligands, in pure water. The resulting diammine(dicarboxylato)platinum(II) complexes precipitated. To the reaction mixtures of the water-soluble complexes CH 2 Cl 2 was added to remove neutral impurities before the aqueous phase was evaporated to obtain the products.
The diamine(dichloro)platinum(II) precursors were activated by conversion into diamine(dihydroxy)platinum(II) species, which were reacted with an equimolar amount of the respective porphyrin carboxylic acid in a mixture of ethanol and water or, in the case of the water-soluble ligands, in pure water. The complexes precipitated. To the water-soluble complex CH 2 Cl 2 was added to remove neutral impurities and the aqueous phase was evaporated to obtain the product.
For the reaction with the porphyrincarboxylic acids it is necessary to activate the diamine(diiodo)platinum(II) complexes by conversion into diamine(dinitrato) platinum(II) species, which are water-soluble. In this form they were reacted with an equimolar amount of the porphyrin ligand in a mixture of ethanol and water or, in the case of the water-soluble ligand, in pure water. The water-insoluble complexes precipitated after concentrating the solution. The water-soluble complexes were isolated by chromatography on silica.
Exemplary Embodiments
The following examples are intended to explain the invention in more detail. The inventive compounds are tetraarylporphyrin platinum derivatives, covered by way of example by examples 1 and 2, and hematoporphyrin platinum derivatives, covered by way of example by examples 3, 4 and 5.
EXAMPLES
Example 1
Diammine[2-(4-{10,15,20-tris[4-(1,4,7-trioxaoctyl)phenyl]porphyrin-5-yl}phenoxy)malonato]platinum(II) (No. 21 in FIG. 1 )
The compound 2-(4-{10,15,20-Tris[4-(1,4,7-trioxaoctyl)phenyl]porphyrin-5-yl}phenoxy)malonic acid (109 mg, 0.100 mmol) was dissolved in 10 ml of CHCl 3 and 20 ml of EtOH, combined with 0.100 mmol of the aqueous diammine(diaqua)platinum(II) hydroxide solution and stirred for 20 h. Yield: 81.0 mg (54.2 μmol, 54%) purple powder, mp 213–214° C.
Anal. (C 62 H 66 N 6 O 14 Pt.10H 2 O, 1494,5) C: calcd. 49,83; found. 49,19. H, N: calcd. 5,62; found 6.09.
Example 2
(+)-trans-1,2-Diaminocyclohexane[2-(4-{10,15,20-tris[4-(1,4,7,10-tetraoxaundecyl)phenyl]porphyrin-5-yl}phenoxy)malonato]platinum(II) (No. 29 in FIG. 1 ).
122 mg (0.100 mmol) Of the compound 2-(4-{10,15,20-Tris[4-(1,4,7,10-tetraoxaundecyl)phenyl]porphyrin-5-yl}phenoxy)malonic acid in 10 ml of CH 2 Cl 2 and 20 ml of EtOH were reacted with 0.100 mmol of activated (+)-trans-1,2-diaminocyclohexane(dichloro)platinum(II). Yield: 113 mg (73.9 μmol, 74%) purple solid, mp 208° C. Anal. (C 74 H 86 N 6 O 17 Pt, 1526.6) C, H, N.
Example 3
Diammine{7,12-bis[1-(1,4,7-trioxaoctyl)ethyl]-3,8,13,17-tetramethylporphyrin-2,18-dipropionato}platinum(II) (No. 21 in FIG. 2 ).
The compound 7,12-Bis[1-(1,4,7-trioxaoctyl)ethyl]-3,8,13,17-tetramethylporphyrin-2,18-dipropionic acid (80.3 mg, 0.100 mmol) was dissolved in 6 ml EtOH, combined with 0.100 mmol of the aqueous diammine(diaqua)platinum(II) hydroxide solution and stirred for 20 h. Yield: 23.0 mg (22.3 μmol, 22%) dark brown powder, mp>250° C. Anal. (C 44 H 62 N 6 O 10 Pt, 1030.1). C: calcd. 51.30; found. 50.75. H: calcd. 6.07; found. 5.49. N
Example 4
(+)-trans-1,2-Diaminocyclohexane{7,12-bis[1-(1,4,7,10,13,16-hexaoxaheptadecyl)ethyl]-3,8,13,17-tetramethylporphyrin-2,18-dipropionato}platinum(II) (No. 38 in FIG. 2 ).
The compound 7,12-Bis[1,4,7,10,13,16-hexaoxaheptadecyl)ethyl]-3,8,13,17-tetramethylporphyrin-2,18-dipropionic acid (107 mg, 0.100 mmol) in 10 ml of EtOH were reated with 0.100 mmol of activated (+)-trans-1,2-Diaminocyclohexane(dichloro)platinum(II).
Yield: 25.5 mg (17.2 μmol, 17%) reddish brown powder; mp 245° C. Anal. (C62H94N6O16Pt.6 H2O, 1482,6). C: calcd. 50.23; found. 49.02. H: calcd. 7.21; found. 6.33. N: calcd. 5,67; found. 6.41.
Example 5
2,2′-Bipyridyl{7,12-bis[1-(1,4,7-trioxaoctyl)ethyl]-3,8,13,17-tetramethylporphyrin-2,18-dipropionato}platinum(II) (No. 40a in FIG. 2 ).
42.2 mg (0.100 mmol) of the compound 2,2′-Bipyridyl(dichloro)platinum(II) were suspended in 15 ml of H 2 O. After 10 min ultrasonic treatment 34.0 mg (0.200 mmol) of AgNO 3 were added and the mixture was stirred for 4 h in the dark at room temperature. The precipitated AgCl was filtered off and washed with water. The filtrate containing the activated platinum(II) complex was evaporated. The residue was dissolved in 5 ml of H 2 O and combined with a solution of 80.3 mg (0.100 mmol) 7,12-Bis[1-(1,4,7-trioxaoctyl)ethyl]-3,8,13,17-tetramethylporphyrin-2,18-dipropionic acid in 10 ml of EtOH. After stirring for 20 h at 50° C. and cooling to room temperature the precipitated solid was filtered, washed with water and EtOH and dried in vacuo.
Yield: 64.0 mg (55.5 μmol, 55%) dark purple powder, mp>250° C. Anal. (C 54 H 64 N 6 O 10 Pt, 1152.2) C, H, N.
Biological Data.
Data of the cytotoxic effect was obtained, for instance, on the human tumor cell lines TCC-SUP and J82. The effect of the compounds was investigated in the dark and under irradiation with light at a wavelength of 600–730 nm. Selected compounds are clearly more activ cytotoxically under irradiation. There is a synergism between the cytotoxic effect of the platinum component and the photodynamic principle.
Cell Lines and General Procedures.
To determine the antiproliferative activity of the new porphyrin ligands and the corresponding platinum complexes with different amine non-leaving groups two bladder cancer cell lines TCC-SUP and J82 were selected as in vitro models.
To discriminate between the cytotoxic and phototoxic effects all experiments were carried out in duplicate. The cells were seeded into microplates and the test compounds were added after 48 h. One batch of the microplates was kept in the dark until the end of the experiment, whereas the other microplates were irradiated 48 h after addition of the substances for 10 min with a light dose of 24 J·cm −2 , before the plates were reincubated in the dark.
End-Point Chemosensitivity Assay.
Hematoporphyrin Platinum Derivatives Type.
At a dosage of 1 μM, both the dark- and phototoxicity of the porphyrin-platinum conjugates are influenced by the type of the non-leaving group. The platinum complexes with 2,2′-bipyridyl (40, 41), ethyl DL-2,3-diaminopropionate (42–46), ethyl DL-2,3-diaminobutanoate (47–51), diethyl meso-4,5-diaminosuberate (52–55) ligands were inactive at a concentration of 1 μM, both in the dark and after irradiation. The compounds bearing 1,2-diaminoethane (27–30) and 1,2-diaminopropane (31–34) non-leaving groups were also inactive against TCC-SUP cells. The most interesting porphyrin-platinum conjugates were those with the diammine (21–26) and the (+)-trans-1,2-diaminocyclohexane (35–39) ligands. Within these series of compounds the water-soluble complexes 26 and 39 were most active with T/C corr. of around 30% and 15%, respectively. At 1 μM concentration the reference cisplatin had a T/C corr. value of approximately 2%. At this dosage there was no statistically significant enhancement of the cytotoxicity by irradiation of the bladder cancer cells.
An increase in the concentration of complexes 40–55 to 5 μM resulted in no or only marginal augmentation of the dark toxicity ( FIG. 2 ). For most of these complexes the phototoxicity is not much higher than the cytotoxicity observed without irradiation. However, for 42, 45, 47, 49, 50 and 53 there is a distinct effect and for 40 and 44 a very strong effect on the proliferativation of the TCC-SUP cells upon irradiation is observed ( FIG. 2 ). The highest synergism was found for compound 52 resulting in the lysis of the tumor cells.
Apart from cisplatin, the highest antitumor activities were measured within the series of porphyrin-platinum conjugates bearing diammine (21–26) and (+)-trans-1,2-diaminocyclohexane (35–39) non-leaving groups. The differences between dark and light-induced toxicities were best for the water-soluble porphyrin-platinum complexes 26 and 39 with a side chain length of n≅17 in position 7 and 12 of the porphyrin leaving group. All the ethylenediamine and propylenediamine complexes 27–34 showed a remarkable light-induced toxicity ( FIG. 2 ).
Tetraarylporphyrin Platinum Derivatives Type.
At a dosage of 1 μM and 5 μM, both the dark- and phototoxicity of the tetraarylporphyrin-platinum conjugates 21–38 were highly influenced by the type of the non-leaving group the results agreeing with those of the hematoporphyrin-platinum complexes discussed above. 23, 29 and 30 were the most active tetraarylporphyrin-platinum conjugates with T/C corr. values of around 37%, 57% and 63%, respectively, at 1 μM concentration. This is analogous to the hematoporphyrin-platinum complexes, the most active of which were those with the diammine or the (+)-trans-1,2-diaminocyclohexane non-leaving groups. At 1 μM concentration there was only a slight enhancement of the cytotoxicity of the tetraarylporphyrin-platinum conjugates with the side chain length n=2 and n=3 upon irradiation. On the average the light-induced T/C corr. values were by approximately 20% lower than the dark-only cytotoxicities (data not shown). An increase in the concentration of the complexes to 5 μM enhanced the dark effects and the phototoxicities as shown in FIG. 1 . Apart from cisplatin, the highest antitumor activities were measured for the tetraarylporphyrin-platinum conjugates bearing diammine (21–23) and (+)-trans-1,2-diaminocyclohexane (28–30) non-leaving groups. The differences between dark and light-induced toxicities were best for the tetraarylporphyrin-platinum complexes 24, 27, 32–34, 36 and 38 with a side chain length of n=2 or n=3 ( FIG. 1 ).
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The invention relates to novel, water-soluble porphyrin platinum compounds of the tetraarylporphyrin platinum derivatives type or of the hematoporphyrin platinum derivatives type with high tumor selectivity and their use for the treatment of benign and malignant tumor diseases. In particular, the compounds are suitable for photodynamic anti-tumor therapy.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to material handling, and in particular, to equipment and methods for facilitating removal of finished rolls after rewinding.
2. Description of Related Art
Sheet material made of paper, plastic or other materials is manufactured in a web that is wound into a relatively large roll. In many instances, this roll is too large for use in other manufacturing processes. For that reason, the web is often unwound and rewound into smaller rolls. In some cases, the web is slit into a plurality of webs that are then simultaneously wound into a number of axially shorter rolls.
A difficulty with such rewinding is the labor involved with removing finished, rewound rolls. These rolls may be relatively heavy and require special handling equipment. Also, the finished rolls may be distributed on a number of separate mandrels and special techniques are needed to remove these rolls in an orderly fashion.
In U.S. Pat. No. 4,611,769 a slitter feeds strips to one of the shafts on a turnstile. After a group of rolls is wound, the turnstile moves the shaft to an unloading position where the shaft is retracted to allow the rolls to fall onto an unloading plate. The retracted shaft is later moved with the turnstile to a loading position and redeployed to penetrate the centers of a fresh batch of empty cores. This arrangement is only satisfactory for relatively lightweight rolls that can be swung by a turnstile and later allowed to fall as a winding shaft retracts.
U.S. Pat. No. 3,845,915 shows a cantilevered shaft that is axially movable for either positioning or ejecting a roll. An ejected roll can fall “onto a hoisting device which then transports the roll out of the machine.” Column 3, lines 33-34. This reference has little disclosure on the unloading of the rolls.
In U.S. Pat. No. 5,217,177 strips are wound on spindles that are mounted on a revolver. A loaded spindle can be taken off the revolver by a turret to a station where a comb can pull the rolls off the spindle while new cores are loaded from the opposite end. The spindle does not axially retract.
In U.S. Pat. No. 5,620,151 a slitter feeds a rewinder. When a complete roll is wound, a lifter rises to support the roll. After contact with the roll is detected, chucks disengage the roll, which is then lowered to a carriage that carries the roll from the machine. This reference does not disclose techniques for axially shifting the rolls.
In U.S. Pat. No. 4,346,852 a table moves between a core loading station and a station for winding and discharging rolls. When a roll is wound, holding devices are released and the rolls are lowered by receivers. Again, this reference does not disclose techniques for axially shifting the rolls.
For devices that lower a roll on swing arms, see U.S. Pat. Nos. 4,508,283; 4,749,140; 5,356,087; and 5,445,341. For a device that lowers a roll on hoisting hooks, see U.S. Pat. No. 5,121,885.
See also U.S. Pat. Nos. 4,458,853; and 5,782,425.
SUMMARY OF THE INVENTION
In accordance with the illustrative embodiments demonstrating features and advantages of the present invention, there is provided a rewinder for rewinding a web into one or more rolls on separate cores. The rewinder includes at least one rewinding mandrel having a distal end. The rewinder also has a supply means for supplying the web to the rewinding mandrel, as well as a drive means. The drive means can (a) rotate the rewinding mandrel in order to wind at least a portion of the web onto the rewinding mandrel, and (b) axially retract the mandrel to unload the portion of the web wound on the mandrel. Also included is a holder for holding the one or more rolls. The rewinder also has a lift means for (a) raising the holder to support the portion of the web wound on the mandrel, and (b) lowering the holder.
According to another aspect of the invention, a method is provided employing a holder and at least one rewinding mandrel for rewinding a web into one or more rolls on separate cores. The method includes the step of rotating the rewinding mandrel in order to wind at least a portion of the web onto the rewinding mandrel. Another step in the method is raising the holder to support the portion of the web wound on the mandrel. The method also includes the step of axially retracting the mandrel to unload the portion of the web wound on the mandrel, and lowering the holder.
By employing apparatus and techniques of the foregoing type, an improved unloading technique is achieved. In a preferred embodiment, a web is pulled from a large roll, in some cases being divided into several strips by a web slitter. This preferred embodiment has a pair of mandrels, although a different number of mandrels may be employed instead. These mandrels may grip the cores on which the web is rewound firmly without slipping, or loosely with slipping permitted. The cores can be gripped preferably with a tab that is deployed by an inflatable bladder inside the mandrel. When slipping is permitted, the cores may be kept in a desired axial position by a number of locating tabs that are deployed by another inflatable bladder inside the mandrel. The web, if slit, may be wound into a plurality of separate rolls on the mandrels. Each roll will preferably be rewound with the incoming web passing over a touch roll that touches the growing roll in order to avoid air entrapment and to stabilize the rewinding process. A retractable center support can be articulated into a central position on the mandrel to prevent sagging for embodiments with relatively long mandrels.
When a roll has been rewound on a mandrel, the preferred control system will automatically stop rotation of the mandrels and allow the operator to cut the web. The resulting loose tail of the incoming web can be caught on a preferred tail support bar that rises into position to catch this loose tail and prevent it from becoming entangled with the rolls or roll holder during an unloading sequence.
The mandrels may be rotatably mounted on a journal that rides on axially extending tracks. The journal can be moved axially by a driving belt that connects to the journal. In one embodiment, the mandrel is rotated in the journal by a series of pulleys that are driven by an engagement wheel with a number of apertures. Spring-loaded pins on a motor-driven drive wheel can engage these apertures when the journal moves into a working position.
In a preferred embodiment, an urging means can axially shift finished rolls that are rewound onto cores on the mandrels. For the lower mandrel a pressure plate is mounted on a pressing bar that axially extends to shift the finished rolls to the distal end of the mandrel. For the upper mandrel a similar pressure plate and pressing bar can be deployed but by a lesser amount. In this latter case, the mandrel can be retracted to retract the finished rolls and stack them against the upper pressure plate. An excessively high bending moment could be applied to the upper mandrel if it were retracted unsupported, with a full load of finished rolls. For this reason, a hook-like grappling means is connected to the distal end of the upper mandrel to follow and support this distal end during retraction.
A preferred holder, in the form of a platform, is supported by end rollers that act as followers that ride between vertical guides. This platform is designed to rise and support finished rolls that are rewound onto cores on the mandrels. Preferably, load sensors on the platform can detect when the platform has reached and is supporting the finished rolls.
As an example, the platform can rise to support rolls on the lower mandrel, which can then fully retract as its journal is pulled back by the above mentioned drive belt. If the above mentioned pressure plate was just operated, all of these finished rolls will be positioned for delivery to one end of the platform. Under these circumstances, the platform can then rise to the upper mandrel. Assuming the upper mandrel has retracted to bring the finished rolls against the deployed pressure plate, these finished rolls will be delivered to the opposite end of the platform as the upper mandrel fully retracts.
Once loaded, the platform can descend along the guides. The lower end of one of the vertical guides preferably diverges at a lower spur to allow a follower to retreat, so that the platform tilts. This tilting causes the finished rolls to roll off the platform. While the foregoing describes unloading both mandrels in one session, in other modes, the mandrels can be separately unloaded in two separate sessions. In still other modes a single roll can be rewound on a single mandrel (log wind).
In another embodiment, the holder platform could be detachable from the lifting mechanism and have casters that would permit transportation either manually or under power to another location for unloading.
In the preferred embodiment, the system can then go into a configuration that facilitates the loading of fresh cores. For example, with the platform in the down position, the mandrels can extend 90% to provide some clearance for loading fresh cores. In the preferred embodiment, the bearings that normally support the distal ends of the mandrels can also retract vertically to provide additional clearance for loading fresh cores.
BRIEF DESCRIPTION OF THE DRAWINGS
The above brief description as well as other objects, features and advantages of the present invention will be more fully appreciated by reference to the following detailed description of presently preferred but nonetheless illustrative embodiments in accordance with the present invention when taken in conjunction with the accompanying drawings, wherein:
FIG. 1 is a schematic diagram of the web path from an unwinding roll to rewinding rolls in a rewinder according to principles of the present invention;
FIG. 2 is an axonometric view of the rewinder of FIG. 1;
FIG. 3 is a detailed axonometric view of a portion of the rewinder of FIG. 2 near the distal end of the mandrels;
FIG. 4 is a detailed schematic diagram of a portion of the web path of FIG. 1 near the mandrels;
FIG. 5 is a detailed axonometric view of the upper, retractable end support of FIG. 2 and its relationship to its mandrel and the grappling means;
FIG. 6 is an axonometric viewing of a portion of one of the retractable center supports of FIG. 3 about to engage its mandrel;
FIG. 7 is an exploded, axonometric view of the mechanism supporting the carriage that carries the touch roll of FIG. 3;
FIG. 8 is a cross-sectional view of the touch roll and supporting beam of FIGS. 3 and 7;
FIG. 9 is an axonometric view of axially extending tracks carrying a journal for one of the mandrels of FIG. 2, which is driven by a drive means;
FIG. 10 is a side view, partially in section, of a portion of the drive means of FIG. 9;
FIG. 11 is an end view of the rewinder of FIG. 2 with its side frame shown in phantom;
FIG. 12 is a schematic diagram of a control means connecting to various pieces of equipment associated with the rewinder of FIG. 2;
FIG. 13 is a front view of the manually operable input device of FIG. 12, showing a touch screen and a number of other manual controls;
FIGS. 14A through 14F show a sequence of operations being performed by the rewinder of FIG. 2 in an automatic shared mode;
FIGS. 15A and 15B show a sequence of operations being performed by the rewinder of FIG. 2 in an automatic discrete mode; and
FIGS. 16A through 16D are flow charts illustrating operations associated with the control means of FIG. 14 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1, a rewinder is shown rewinding rolls 10 and 12 on the cores 16 , which are mounted on a first (lower) rewinding mandrel 18 and a second (upper) rewinding mandrel 20 . The rolls 10 and 12 are fed by a supply roll 22 , which is wound with a web 24 . Supply roll 22 is mounted on a mandrel 26 (or by chucks located at both ends) that can be motor driven and/or braked so that web 24 is supplied at a predetermined tension. This tension can be controlled by a conventional feedback loop (not shown).
Web 24 is supplied over an idler roller 28 and a load cell idler 30 to a another driven roller 32 that is part of a supply means. Driven roller 32 cooperates with a nip roller 34 to deliver web 24 over idler rollers 36 , 38 and 40 . The web 24 need not follow the illustrated path but may be routed to different sides of the idler rollers, as suggested by the alternate course of broken line 24 A.
In this embodiment, web 24 is shown routed through a slitter comprising a driven anvil (female knife) 42 cooperating with blade wheel 44 to deliver a number of slitted webs around idler roller 45 . In a known manner, web 24 can be slit into a plurality of narrower webs, some routed along course 46 and others routed along course 48 . Webs routed through course 46 pass around driven roller 50 , which cooperates with nip bar 52 . After passing around driven roller 50 , the webs on course 46 pass over touch roll 54 before being wound into rolls 12 . Webs routed along course 48 pass around driven roller 56 , which cooperates with nip bar 58 . After passing around driven roller 56 , the webs on course 48 pass over touch roll 60 before being wound into rolls 10 . Bars 52 and 58 are round bars that do not rotate. They nip against rollers 50 and 56 to clamp web tails during the subsequently described unload sequence. This helps maintain tension on webs leading back to the knives.
Referring to FIGS. 1-4, the previously mentioned rolls 10 are shown as five separate rolls 10 A through 10 E mounted on mandrel 18 . Previously mentioned rolls 12 are shown as four separate rolls 12 A through 12 D mounted on mandrel 20 . Mandrels 18 and 20 are shown with gripping means in the form of gripping tabs 84 and 86 , respectively. Gripping tabs 84 and 86 are axially repositionable in a longitudinal track in the mandrels over an internal strip (not shown) that can be outwardly driven by an inflatable bladder (not shown) inside the mandrels. Axially repositionable locating tabs 88 and 90 are shown mounted on mandrels 18 and 20 , respectively, at angular positions that are different than that of tabs 84 and 86 . Locating tabs 88 and 90 are axially repositionable in a longitudinal track in the mandrels over an internal strip (not shown) that can be outwardly driven by an inflatable bladder (not shown) inside the mandrels. The inflatable bladders that drive tabs 84 and 88 are located at angularly spaced positions inside mandrel 18 . Likewise, the inflatable bladders that drive tabs 86 and 90 are located at angularly spaced positions inside mandrel 20 .
A retractable center support is shown as an arm 62 mounted on shaft 64 . Arm 62 has a hooked distal end 66 for centrally supporting the underside of second mandrel 20 . Arm 62 can be rotated through a pneumatically actuated lever arm 65 , schematically illustrated in FIG. 4. A rotatably mounted retractable center support 68 is shown with a hooked end 70 centrally supporting first mandrel 18 (FIG. 3 ). Support 68 is rotatably supported on a shaft, illustrated schematically in FIG. 4 as shaft 72 . Shaft 72 is rotated by lever arm 73 , which is schematically shown linked to the drive arm 67 on shaft 64 . Thus linked, rotation of pneumatically operated arm 65 simultaneously rotates linked arms 67 and 73 to likewise rotate support arms 62 and 68 . In the preferred embodiment, once the center supports are in place a hydraulic ram (not shown) is advanced to mechanically latch the center supports in place.
The distal end 21 of mandrel 20 is shown in FIG. 3 supported by a swinging hook 74 , referred to herein as a grappling means. As described further hereinafter, swinging hook 74 can support and follow the distal end 21 of mandrel 20 as it retracts with a load of rolls, such as rolls 12 A- 12 D. The distal end 19 of mandrel 18 does not have such a grappling means in this embodiment, although both mandrels could be supplied with grappling means in alternate embodiments. Swinging hook 74 is shown mounted on a carrier 76 (FIG. 2 ). In this embodiment, hook 74 has on its upper end a linear bearing (not shown) that rides on a track on carrier 76 . Carrier 76 is rotatably mounted between side frame 78 and frame assembly 80 . Carrier 76 can be rotated pneumatically using the lever arm 82 illustrated schematically in FIG. 4 .
Frame assembly 80 supports among other things, mandrels 18 and 20 and is adjacent to a cabinet 265 housing equipment for rotating and retracting/extending the mandrels, etc.
A pair of horizontal bars 106 and 108 , herein referred to as tail supports, are mounted between two pairs of support brackets 110 and 112 , respectively. The brackets 110 and 112 are mounted on opposite ends of carrying rods 114 . Two identical carrying rods 114 are mounted near frame 78 and frame assembly 80 . Each of the carrying rods 114 can be lifted by an air cylinder (not shown) to lift the support rods 106 and 108 .
Referring to FIGS. 2, 3 , 4 , and 11 , a holder, shown as platform 92 , is supported at either end by upright struts 94 . Struts 94 are located off-center and support a pair of followers 96 in the form of a pair of wheels that ride between the vertical guides 98 . The inner one of the guides 98 has a lower spur 100 that diverges outwardly to increase the spacing between the guides. Accordingly, platform 92 is kept relatively level when the followers 96 are riding between the upper portions of guides 98 . However, the lower one of the followers 96 will occasionally reach the lower spur 100 and swing backwardly to allow tilting of platform 92 . Platform 92 is lifted by a chain 102 , which is part of a lift means. Chain 102 rides over a pulley 104 and may terminate in a counter weight (not shown). Chain 102 can be driven by a pneumatic cylinder attached to the end of the chain. Alternatively, pulley 104 can be rotated by an electric motor (not shown).
In one embodiment the holder platform can employ a platform that is elevated by a scissor-like structure having a pair of pivotally connected members. In another embodiment, the holder platform could be detachable from the lifting mechanism and have casters (not shown) that would permit transportation either manually or under power to another location for unloading.
Referring to FIGS. 2 and 5, previously mentioned side frame 78 is shown supporting a slide plate 116 . Previously mentioned grappling means 74 is shown in a working position adjacent to side plate 116 . Grappling means 74 can also retract by swinging backwardly as illustrated by the phantom position. In the working position, hooked lower end 75 can engage the distal end 21 of mandrel 20 . (For clarity, mandrel 20 is shown retracted from the hooked end 75 of grappling means 74 , although normally mandrel 20 will be deployed inside the hooked end 75 whenever it descends to the illustrated working position.)
A collar-like journal 118 (also referred to as a chuck) is shown centrally mounted on a lower portion of the plate 116 for rotatably supporting the reduced diameter portion 21 A of distal end 21 of mandrel 20 . As described in further detail hereinafter, mandrel 20 can alternately extend into, and retract from, journal 118 . Also, after retraction of the mandrel, plate 116 can be pneumatically lifted upwardly into the notch 120 in side frame 78 . Accordingly, plate 116 and journal 118 can act as a retractable end support. In FIG. 2 a similar slide plate 116 ′ is shown acting as a retractable end support for mandrel 18 . As before, a notch 120 ′ in side frame 78 allows clearance when slide plate retracts upwardly.
Referring to FIG. 6, previously mentioned support arm 62 is shown about to swing into position under mandrel 20 . It will be appreciated that the description of this figure will likewise apply to previously mentioned support arm 68 (FIG. 3 ). A pair of side plates 122 and 124 are attached to opposite sides of the distal end of support arm 62 . Rotatably mounted between plates 122 and 124 are a pair a rotatably supported wheels 126 and 128 . Wheels 126 and 128 project slightly above the upper edges of plates 122 and 124 . A circumferentially grooved collar 130 is releasably clamped to mandrel 20 , so that wheels 126 and 128 can ride in the groove of collar 130 .
Referring to FIGS. 7 and 8, a rack 132 is shown attached to the inside face of side frame 78 . It will be appreciated that the structure shown in this figure will be replicated on the opposing inside face of frame assembly 80 (FIG. 2 ). A pinion 134 is shown driven by a motor 136 by means of drive shaft 138 . Motor 136 is supported by shaft 138 , but is prevented from rotating by a follower wheel 140 attached to the motor and riding in slot 142 . Shaft 138 is journaled in bracket 144 , which is attached between hollow beam 146 and linear bearing 148 . The bearing 148 rides on track 150 mounted on the inside face of side frame 78 . The bracket 152 attached to the underside of beam 146 supports a photo-detector 154 , which controls retraction of the beam 146 , in response to growth of the previously mentioned rewinding roll, in a manner to be described hereinafter.
A linear bearing 156 attached to the forward face of beam 146 supports a laterally adjustable bracket 158 , which can be locked in place by turning handle 162 to tighten the threaded shaft 160 . A standard 164 attached to bracket 158 pivotally supports a pair of levers 166 , which rotatably support touch roll 54 (or in another location touch roll 60 ). The upper end of bracket 158 supports a pneumatic cylinder 168 that can be operated to swing the levers 166 . A pair of pressure channels 170 are mounted atop beam 146 . Channels 170 have a number of fittings 172 that can be used to provide pneumatic pressure to cylinder 168 at the various positions where it may be located along the beam 146 .
Referring to FIGS. 9 and 10, mandrel 18 is shown connected to a drive means including a journal 174 , which is a relatively long bearing supported on a platform 176 . Platform 176 includes a linear bearing (hereinafter shown) that rides on the axially extending tracks 178 mounted along the longitudinal opening in C-shaped beam 180 . A motor-driven belt 182 connects to platform 176 to move journal 174 along tracks 178 . A bearing block 184 mounted in one corner of platform 176 rotatably supports pulleys 186 and 188 . An engagement means is shown as a wheel 190 with four equiangularly spaced apertures 196 . Wheel 190 is mounted on a common shaft 191 with pulley 188 to drive that pulley. Pulley 188 drives a belt 192 that circulates over idler pulley 186 and a driven pulley 194 , which is coaxially connected to mandrel 18 in order to drive it.
An axially stationary drive pulley 198 (also referred to as a rotor) is mounted on a common shaft 200 , rotatably supported on bearing housing 202 , to be rotated by a motor-driven belt 204 . Pulley 198 has a pair of axial bores fitted with spring loaded pins 206 and 208 located at diametrically opposite positions. Pins 206 and 208 have inside flanges that keep the pins trapped inside the bores in pulley 198 . These bores contain springs 210 and 212 , which are trapped between backer plate 214 and pins 206 and 208 , respectively. Arranged in this fashion, wheel 190 can move against pins 206 and 208 , which can retract. As rotor 198 turns, eventually pins 206 and 208 reach the apertures 196 and snap into these apertures so that pulley 198 can drive the wheel 190 .
In other embodiments the motor for driving the mandrel can move axially with the mandrel, in which case the foregoing engagement means is unnecessary.
Referring to FIG. 12, a control means is shown herein as a programmable logic controller 216 (also referred to as a digital processor means). Controller 216 is a digital computer having a memory 218 and an input/output section 220 . Input/output section 220 has drive circuits connecting to blocks 222 - 243 in order to operate relays and other equipment needed to control the foregoing rewinder. Block 222 has an output for controlling the supply roll 22 (FIG. 1 ). The unwinding supply roll 22 can have a drive motor and/or brake to regulate the web delivery. This subsystem can also have a sensor (not shown) for measuring web tension to produce a feedback signal to control the above mentioned motor and/or brake.
Block 224 has two outputs for controlling the drive to the motors that rotate the upper and lower mandrels 18 and 20 (see FIG. 9 ). Block 226 has outputs for controlling inflation of the bladders inside mandrels 18 and 20 . Specifically, this block can control the gripping tabs 84 and 86 , as well as the locating tabs 88 and 90 (FIG. 3 ). Block 228 can control the extension and retraction of mandrels 18 and 20 by operating the motor-driven belt 182 (FIG. 9 ). Block 230 can control the articulation of hook 74 by operating the pneumatic cylinder that controls lever arm 82 (FIG. 4 ). Block 232 can articulate the arms 62 and 68 by operating the pneumatic cylinder that rotates lever 65 (FIG. 4 ).
Block 234 can operate platform 92 by circulating chain 102 (FIG. 4 ). Block 234 can also receive input signals that sense the weight of rolls being supported on the platform 92 . In the preferred embodiment, two pressure sensitive mats are placed at opposite ends of the platform to act as load sensors for detecting weight on either the left or right end of the platform, in order to produce a corresponding weight signal.
Block 236 controls pushers that will be described presently. Block 238 can control both of the retractable end supports, such as the one shown in FIG. 5 . Block 240 can control the touch rolls 54 and 60 . Specifically, block 240 can control the pressure applied to cylinder 168 (FIG. 8) and the position of beam 146 carrying the touch rolls by operating motor 136 (FIG. 7 ). As described further hereinafter, motor 136 can be controlled by the positioning signals received from photo-detector 154 . Block 242 can operate the motors of the supply means that supplies the web. Block 243 can operate the web tail puller 106 and 108 (FIG. 3 ).
FIGS. 12 and 13 show a manually operable input device 244 having a touch screen 246 . Screen 246 is an LCD display that can produce an image of a virtual pushbutton. Screen 246 is touch-sensitive so that the displayed buttons can actually be “pressed” in the sense that the computer 216 attached to device 244 can sense tactile pressure on the screen at a determinable position. Buttons 248 - 258 are conventional pushbuttons that are labeled to indicate the following functions: Run, Jog, Emergency Stop Reset, Machine Stop, Unload Sequence Stop, and Emergency Stop. The nature of these functions will be described further hereinafter.
Knob 260 is designed for adjusting the web speed. The angular position of knob 260 can be detected by the previously mentioned computer 216 and can be taken as an operator command to establish web speed at a desired magnitude. Knob 262 is designed for adjusting the unwind tension from the supply roll 22 (FIG. 1 ). The angular position of knob 262 can be detected by the previously mentioned computer and can be taken as an operator command to establish web tension at the supply roll 22 . Device 244 is shown in FIG. 2 as a case mounted on support rod 276 .
Referring to FIGS. 14A through 14F, previously mentioned mandrel 18 is shown rotatably mounted in journal 174 , which is supported on the platform 176 that rides on the linear bearings 177 on track 178 of beam 180 . In a similar fashion, mandrel 20 is shown rotatably mounted in journal 174 ′, which is supported on the platform 176 ′ that rides on the linear bearings 177 ′ on track 178 ′ of beam 180 ′. Mandrels 18 and 20 are shown with their distal ends 19 and 21 supported in chucks 118 ′ and 118 (also referred to as retractable end supports).
A first urging means is shown as pusher plate 268 mounted on one end of threaded rod 266 . Rod 266 is threadably supported in the motor-driven, threaded collar 264 to act as a lead screw. Accordingly, rotation of collar 264 will cause pusher plate 268 to extend and retract. A second urging means is shown with a pusher plate 274 mounted on one end of guide rod 272 . Rod 272 is axially movably mounted in collar 270 . Pneumatic actuation will cause pusher plate 274 to extend and retract.
To facilitate an understanding of the principles associated with the foregoing apparatus, its operation will be briefly described. Referring to the flow chart of FIG. 16A, an operator may set various parameters at step 276 using touch screen 246 (FIG. 13 ). In addition, the operator can save all of these parameters to memory 218 of control means 216 (FIG. 12) for later recall.
In this manner, the operator may enter the thickness and density of the web, as well as the desired tension in the web as it unwinds from the supply roll 22 (FIG. 1 ). The operator may also enter the number and the width of the rolls that are to be rewound on the mandrels 18 and 20 . The operator may also enter the diameter of the cores 16 , as well as the desired outside diameter of the finished rolls 10 and 12 on the mandrels 18 and 20 . As an alternate target for ending the rewinding process, the operator can also enter the desired length of web to be rewound. The operator may also enter a web length adjustment factor for initial calibration of the length measurement means.
Since the desired tension in the web preferably varies during the process, the operator can enter the desired web tension for the beginning and end of the rewinding process. The operator may also enter the desired pressure to be applied by the touch rolls 54 and 60 (FIGS. 3 and 4 ). In some embodiments, the touch rolls can be pressured by different size pneumatic cylinders. For this reason, the operator can enter the size of the installed pneumatic cylinders to allow accurate adjustment of the pressure of the touch rolls 54 and 60 . Also, in some cases the pressure applied by the touch rolls 54 and 60 ought to vary dynamically. For this reason, the operator may enter a compensation value that will increase the pressure of the touch rolls as speed increases. It has also been found that the pressure of the touch rolls may need to be increased as the rewinding package increases in diameter. Accordingly, the operator can enter a compensation value that provides the desired amount of increase.
In some cases it is desirable to allow the mandrels 18 and 20 to slip inside cores 16 by running the mandrels at a speed in excess of that needed to produce the desired web speed. The operator can specify this overspeed or slip speed by entering (1) a desired slip speed in rpm, or (2) a percentage overspeed value based on the speed needed to produce the desired web speed.
While the torque applied to the mandrels 18 and 20 might normally determine the tension of the web being rewound onto the mandrels, various mechanical losses may affect this value. For this reason, the operator may enter a friction compensation value that allows more precise control of tension.
The operator may also enter the time permitted for accelerating and decelerating mandrels 18 and 20 . Additionally, the operator can enter the speed at which the machine will advance when the operator depresses the jog control button 250 .
In step 278 (FIG. 16A) the operator can indicate through touch screen 246 how rolls will be removed from mandrels 18 and 20 . In this example, the operator will select manual unloading of both mandrels together, which is also referred to herein as the manual shared mode. In the manual mode, the operator is prompted to initiate each subsequent action in the unloading process. In addition, a fully automatic mode exists which steps through the entire cycle while only prompting operator actions that are manually performed within the overall sequence such as cut-off and core loading operations. Automatic removal will only be allowed if the diameter of the rewound rolls exceeds 12 inches (30.5 cm). In other cases, the two mandrels can be unloaded in separate stages, if desired. In still other cases, only one mandrel will be rewinding and will contain a single roll (log roll mode).
In step 280 the operator can press a virtual “start” button displayed on touch screen 246 to begin the unloading sequence, assuming the rolls have been fully rewound to the target dimension. In succeeding step 282 , computer 216 will send a signal through block 240 (FIG. 12) to the actuators for the touch rolls 54 and 60 (FIG. 4 ). Specifically, pneumatic cylinders 168 (FIG. 8) will be activated to withdraw the touch rolls, while electric motor 136 (FIG. 7) will be activated to withdraw the beam 146 carrying the touch rolls. The system will also verify execution of the desired action by monitoring changes in the signals in any feedback loop associated with the touch rolls.
Next in step 284 , computer 216 will send a signal through block 226 to retract the tabs 84 , 86 , 88 , and 90 . In the following step 286 , block 224 will cause mandrels 18 and 20 to rotate at 5 rpm to bring the gripping tabs 84 and 86 to a 6 o'clock (down) position, as sensed by position sensors (not shown), in order to maximize the clearance between the cores 16 and the mandrels. Again, the system will also verify execution of the desired action by monitoring these position sensors. Once the mandrels 18 and 20 have been properly positioned, the drive to the mandrels is disabled in step 288 .
In step 290 (FIG. 16B) computer 216 will display on screen 246 the message “Operator to Cut Tails.” In response, the operator must now cut the web near the rolls on mandrels 18 and 20 , thereby producing relatively short tails from these rolls. Once these tails are cut, the operator can signal completion of this cutting operation by depressing a virtual, flashing pushbutton displayed on touch screen 246 and labeled “Operator Procedure Completed.” Thereafter in step 292 , the operator will be presented with a flashing, virtual pushbutton labeled “Center Supports Lower.” Upon pressing this virtual pushbutton, computer 216 , operating through block 232 , will operate the associated pneumatic cylinder to rotate lever 65 and retract arms 62 and 68 (FIG. 4 ). Thereafter in step 294 the operator will be presented with a flashing, virtual pushbutton labeled “Raise Rewind Web Tail Puller.” Upon pressing this virtual pushbutton (in the automatic mode the process proceeds without requesting or awaiting a manual signal from an operator), computer 216 , operating through block 243 , will operate the associated pneumatic cylinder to lift web tail puller bars 106 and 108 (FIG. 3 ). Bars 106 and 108 will hold the ends of the incoming web so they do not fall into the path of the rolls during unloading and become tangled.
Next in step 296 a flashing, virtual pushbutton labeled “Roll Pushers Extend” can be pressed. When this pushbutton is pressed (in the automatic mode the process proceeds without requesting or awaiting a manual signal from an operator), computer 216 , operating through block 236 will operate the lead screw mechanism 264 and pneumatic actuator 270 , which in other embodiments could be a lead screw mechanism. Pusher plate 268 will extend to move the rolls 10 A- 10 E from the position shown in FIG. 14A to the right position shown in FIG. 14 B. Pusher plate 268 will extend to a calculated position. The actual position of pusher plate 268 is continually measured and fed back to computer 216 by a position sensor (not shown) associated with pusher plate 268 . Note that pusher plate 274 will also be extended at this time, but without further effect. Computer 216 will now display a virtual, flashing pushbutton labeled “Upper Hooker Engage.” When this pushbutton is pressed (in the automatic mode the process proceeds without requesting or awaiting a manual signal from an operator), computer 216 , operating through block 230 , will rotate pneumatically operated lever 82 (FIG. 4) to swing hook 74 onto the distal end 21 of mandrel 20 .
Computer 216 will now display a virtual pushbutton on touch screen 246 labeled “Upper Mandrel Retract.” When this pushbutton is pressed (in the automatic mode the process proceeds without requesting or awaiting a manual signal from an operator), computer 216 , operating through block 228 , will retract journal 174 ′ as shown in FIG. 14 C. Journal 174 ′ will ride on linear bearings 177 ′ under the control of a driving belt, similar to driving belt 182 shown in FIG. 9 . The positions of the mandrels are monitored continuously by computer 216 by a position feedback device (not shown) on the mandrels. As mandrel 20 retracts, hook 74 stays connected to distal end 21 . Hook 74 is mounted through a linear bearing to shaft 76 (FIG. 2 ). Hook 74 is biased by an air cylinder (not shown) to move to the left (as viewed in FIG. 2 ). Accordingly, rolls 12 A- 12 D will be drawn to the left against pusher plate 274 into a position that avoids later interference with rolls 10 A- 10 E.
The system will verify the execution of a proper response by monitoring the signals associated with hook 74 , mandrel 20 , lead screw mechanism 264 , and pneumatic actuator 270 .
In step 298 a flashing, virtual pushbutton will be displayed on touch screen 246 labeled “Raise Cart to Lower Mandrel.” When this pushbutton is pressed (in the automatic mode the process proceeds without requesting or awaiting a manual signal from an operator), computer 216 , operating automatically through block 234 , will pull chain 102 and lift platform 92 (FIG. 4 ). Platform 92 will rise until reaching the position shown in FIG. 14 C. At this time, a pressure sensitive mat (load sensor) on platform 92 will relay a weight signal through block 234 to computer 216 as indicated by step 300 . In response, computer 216 will stop platform 92 , as indicated by step 302 .
If instead, the system is in the “fully manual” mode, then platform 92 will only move when the operator is pressing the virtual pushbutton. In this latter case, the operator will observe the motion of the platform 92 in order to pilot it into a position for supporting the rolls 10 A- 10 E.
In step 304 a flashing, virtual pushbutton will be displayed on screen 246 with the label “Lower Mandrel Retract.” If this pushbutton is pressed (in the automatic mode the process proceeds without requesting or awaiting a manual signal from an operator), computer 216 , operating through block 228 , will circulate belt 182 (FIG. 9) to retract journal 174 and mandrel 18 to the position shown in FIG. 14 C. Accordingly, rolls 10 A- 10 E will be totally supported on the right end of platform 92 . Also, by providing a virtual, flashing pushbutton labeled “Lower Mandrel Retract” the operator can signal a command through computer 216 and block 236 to operate lead screw mechanism 264 and retract pusher plate 268 to the position shown in FIG. 14D (in the automatic mode the process proceeds without requesting or awaiting a manual signal from an operator).
In step 306 (FIG. 16C) computer 216 displays on touch screen 246 a flashing, virtual pushbutton labeled “Raise Cart to Upper Mandrel.” If this pushbutton is pressed by the operator (in the automatic mode the process proceeds without requesting or awaiting a manual signal from an operator), computer 216 , operating through block 234 , will pull chain 102 (FIG. 4) to lift platform 92 . Platform 92 will rise with rolls 10 A- 10 E until reaching the position shown in FIG. 14 D. At this time, a pressure sensitive mat (load sensor) on the left of platform 92 will relay a weight signal through block 234 to computer 216 as indicated by step 308 . In response, computer 216 will stop platform 92 as indicated by step 310 .
If instead, the system is in the “fully manual” mode then platform 92 will only move when the operator is pressing the virtual pushbutton. In this latter case, the operator will observe the motion of the platform 92 in order to pilot it into a position for supporting the rolls 12 A- 12 D.
Next in step 312 , computer 216 retracts hook 74 from the distal end 21 of mandrel 20 . Also, computer 216 retracts journal 174 ′ and mandrel 20 to the position shown in FIG. 14 D. Consequently, all rolls now rest on platform 92 .
Next, computer 216 operates a pneumatic cylinder (not shown) to retract pusher plate 274 to the position shown in FIG. 14 E. The signals associated with the foregoing operation of hook 74 and upper mandrel 20 are monitored to verify proper operation.
In step 314 computer 216 displays on touch screen 246 a virtual, flashing pushbutton labeled “Cart Down to Unload Rolls.” While this pushbutton is pressed (in the automatic mode the process proceeds without requesting or awaiting a manual signal from an operator), computer 216 , operating through block 234 , lowers platform 92 to the floor as shown in FIG. 14 E. When platform 92 reaches the ground, lower follower wheel 96 (FIG. 11) swings back along spur 100 allowing platform 92 to tilt, so that rolls 10 A- 10 E and 12 A- 12 D will roll off the platform 92 .
In step 316 , the air cylinder associated with hook 74 will slide the hook along shaft 76 to the home position next to frame 78 . At this time, computer 216 , operating through block 238 , will pneumatically lift plates 116 and 116 ′ to raise the chucks 118 and 118 ′ into notches 120 and 120 ′ (FIGS. 2 and 5) to reach the positions shown in FIG. 14 E.
While the foregoing described a manual shared mode (and indicated the differences from an automatic shared mode), in a manual or automatic discrete mode, the platform can remove rolls from one mandrel and deliver the rolls to the production floor before the platform returns to unload rolls from the other mandrel. As shown in FIG. 15A, platform 92 can support rolls 10 A- 10 E after mandrel 18 is withdrawn. In this case however, rolls 10 A- 10 E are not pushed together but remain separated as shown. Eventually, platform 92 descends to allow rolls 10 A- 10 E to roll onto the production floor.
In this discrete mode, the platform 92 now rises to support rolls 12 A- 12 D as shown in FIG. 15 B. Thereafter, mandrel 20 can be withdrawn so that rolls 12 A- 12 D are fully supported on platform 92 . Finally, platform 92 descends to allow rolls 12 A- 12 D to roll onto the production floor.
Regardless of the mode (shared or discrete), in step 318 (FIG. 16C) computer 216 will now display on touch screen 246 a virtual, flashing pushbutton labeled “Extend Both Mandrels 90%.” While this pushbutton is pressed, computer 216 , operating through block 228 , will move journals 174 and 174 ′ and mandrels 18 and 20 until reaching a position constituting a 90% extension of the mandrels, as shown in FIG. 14F, at which point the mandrels automatically stop. This 90% extension allows cores 16 to be inserted through the spaces vacated by sliding plates 116 and 116 ′ and onto mandrels 18 and 20 , as shown in FIG. 14 F.
In step 320 computer 216 will pause and display on touch screen 246 the message “Operator to Load Cores on Both Upper and Lower Mandrels.” Computer 216 will also display on touch screen 246 a virtual, flashing pushbutton labeled “Operator Procedure Completed.” If this pushbutton is pressed, computer 216 will display in succeeding step 322 (FIG. 16D) a flashing, virtual pushbutton on touch screen 246 labeled “Extend Both Mandrels 100%.” While this pushbutton is pressed (in the automatic mode the process proceeds without requesting or awaiting a manual signal from an operator), computer 216 , operating through block 238 , will lower the supporting plates 116 and 116 ′ to place the chucks 118 and 118 ′ (FIGS. 2 and 5) in alignment with mandrels 18 and 20 . Next, so long as the above virtual pushbutton is pressed, computer 216 , operating through block 228 , will fully extend mandrels 18 and 20 until their distal ends 19 and 21 engage chucks 118 and 118 ′. At this time the mandrels will automatically stop at 100% extension.
In succeeding step 324 , computer 216 will display a flashing, virtual pushbutton on touch screen 246 labeled “Retract Web Tail Puller.” If this pushbutton is pressed (in the automatic mode the process proceeds without requesting or awaiting a manual signal from an operator), computer 216 , operating through block 243 , will lower bars 106 and 108 (FIGS. 3 and 4 ). In succeeding step 326 , computer 216 will display a flashing, virtual pushbutton on touch screen 246 labeled “Center Supports Raise.” If this pushbutton is pressed (in the automatic mode the process proceeds without requesting or awaiting a manual signal from an operator), computer 216 , operating through block 232 , will pneumatically rotate lever 65 (FIG. 4) to rotate arms 62 and 68 into position to support the centers of mandrels 20 and 18 .
It will be understood that any of the foregoing unloading procedures can be interrupted by depressing the unload sequence stop button 256 (FIG. 13 ).
The system will now prepare for a new rewinding phase by resetting various parameters in step 328 . For example, the system will reset the counters associated with registering the amount of web rewound onto the mandrels. Also, the operator can review and alter the various parameters entered into computer memory 218 as described above in connection with step 276 .
The operator may now use jog button 250 (FIG. 13) to slowly advance the web and allow the operator to the tape the incoming web to the cores 16 . The operator can then confirm completion of this procedure by pressing a virtual pushbutton displayed on touch screen 246 as indicated in step 330 . The operator can also set the touch rolls 54 and 68 to operate in an automatic mode and direct them to move against the rolls 10 and 12 as indicated in step 332 .
Computer 216 will also allow the operator to control various elements through virtual pushbuttons presented on screen 246 . For example, the operator can operate the main brake, position the web guide, and place the web guide in a manual or automatic mode. The web guide is a motor-driven system for axially repositioning the supply roll 22 . The operator will also be given control over the equipment associated with supply roll 22 . Specifically, the operator can operate the chucks supporting the supply roll 22 , as well as adjust the elevation of supply roll 22 . The operator will also be able to select brake pucks that are used with the supply roll 22 .
The operator will also be able to specify whether the rewinding proceeds with the cores 16 either slipping or locked into position on the mandrels 18 and by gripping tabs 84 and 86 . The operator can also select the direction of rotation of the mandrels so that the web can approach from above or below. Also, the slitter may produce some trimming waste that can be removed by a vacuum system, which is under the control of the operator. In addition, certain nip rolls can be made active or inactive based on selections by the operator.
Once these settings are accomplished and machine interlocks are completely satisfied, the operator can begin the rewinding process of step 334 by pressing “run” pushbutton 248 on panel 244 . Supply roll 22 will then be paid out and web 24 pulled by driven rollers 32 and 36 (FIG. 4 ). Web 24 can then be slit into a number of narrower webs by means of the slitter combination 42 , 44 . Driven rollers 50 and 56 pull the slitted webs and deliver them over touch rolls 54 and 60 to the rolls 10 and 12 .
The operator can also adjust the target speed that should be reached after initial acceleration, by adjusting knob 260 (FIG. 13 ). The operator can also manually adjust the tension of the web as delivered by supply roll 22 , by adjusting knob 262 .
Beams 146 (FIG. 7) can be retracted so that the touch rolls 54 and 60 do not produce excessive pressure as the rewinding rolls 10 and 12 grow. By operating motor 136 to rotate pinion 134 , bracket 144 and beam 146 retract with the growth of the rewinding rolls 10 and 12 . Motor 136 is operated intermittently in response to the photo sensor 154 signaling that more room is needed for growth.
The pressure asserted by air cylinder 168 (FIG. 8) causes touch rolls 54 and 60 to apply an appropriate pressure to rewinding rolls 10 and 12 . As discussed previously, this touch pressure can vary during the course of the rewinding. In addition to winding with touch rolls 54 and 60 kept in contact with rewinding rolls 10 and 12 , there is an additional mode that maintains a small constant gap between the touch rolls and rewinding rolls (gap mode). Diameter feedback from rolls 10 and 12 is compared to positional feedback for beams 146 , and motor 136 operates to position rolls 54 and 60 accordingly (under these circumstances rolls 54 and 60 are referred to as flanking rolls). There are separate independent systems for operating each beam 146 . In other embodiments, there could be a single central system working in conjunction with beams 146 that are linked to operate together.
If an emergency occurs, the operator can stop the rewinding process by depressing button 258 (FIG. 13 ). This will bring the machine to a sudden stop. Thereafter, the operator can depress the “Emergency Stop Reset” button 252 to restore various registers in computer 216 to the pre-stop condition, provided all other safety conditions are met. In less urgent situations, the machine can be stop by pressing “Machine Stop” button 254 . This will cause the machine to decelerate to a controlled stop.
As the rewinding rolls 10 and 12 grow, counters inside a computer 216 keep track of the amount of rewinding, awaiting the delivery of a full load onto cores 16 . When the rolls 10 and 12 grow to the desired diameter or web length, computer 216 can automatically decelerate mandrels 18 and 20 . Thereafter, an unloading procedure can be performed as described previously.
It is appreciated that various modifications may be implemented with respect to the above described, preferred embodiments. While two mandrels are disclosed, in other embodiments a different number of mandrels may be employed. Also the length of the mandrels as well as the number of cores supported by the mandrels can be different in different embodiments. Additionally, while inflation-operated gripping tabs and locating tabs are shown, in other embodiments the gripping and locating can be performed by other mechanical means. Furthermore, the steps of the flow chart can be performed in an order different than that described above. Moreover, in other embodiments steps can be added or deleted. While various supports are shown for the center and end of the mandrels, in other embodiments a greater or lesser number of supports may be employed. Also, while swinging hooks or arms are shown, other embodiments may employ supports that are moved into a working position linearly. Furthermore, some embodiments may eliminate the sliding plates supporting the chucks for the distal ends of the mandrels in which case, the mandrels may be extended an amount different than 90% when loading the cores. Also, the dimensions, materials, shapes, and locations of the various components described herein may be varied depending upon the desired strength, capacity, clearance, rigidity, etc.
Obviously, 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 specifically described.
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A rewinder for rewinding a web into one or more rolls on separate cores, includes at least one rewinding mandrel having a distal end. The rewinder also has a supply device for supplying the web to the rewinding mandrel, and a drive device. The drive device can (a) rotate the rewinding mandrel in order to wind at least a portion of the web onto the rewinding mandrel, and (b) axially retract the mandrel to unload the portion of the web wound on the mandrel. Also included is a holder for holding the one or more rolls. The rewinder also has a lifter for (a) raising the holder to support the portion of the web wound on the mandrel, and (b) lowering the holder. This rewinding mandrel is rotated in order to wind at least a portion of the web onto the rewinding mandrel. The holder is then raised to support the portion of the web wound on the mandrel. Next, the mandrel is axially retracted to unload the portion of the web wound on the mandrel, before lowering the holder.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of U.S. Provisional Application No. 60/109,368, filed Nov. 21, 1998.
FIELD OF THE INVENTION
The present invention relates to a method and device for linked gaming. More specifically, the present invention is a method and device for issuing progressive bonuses at linked gaming machines.
BACKGROUND OF THE INVENTION
Players gamble to win and to be entertained. Thus, it is well known in the gambling industry that one of the best ways to attract and retain players is to make the player believe that he has a better chance of winning or that, if successful, he could win more. It is also known that players will tend to play the more exciting and entertaining games. Two methods which utilize this knowledge are progressive jackpots and bonuses.
In a progressive jackpot system, several interconnected gaming machines each contribute a portion of the wagers received by the gaming machine to a progressive jackpot. Because several gaming machines contribute to the progressive jackpot, the jackpot can grow large. Players place wagers and play a primary game at the interconnected gaming machines in a conventional fashion, such as by spinning the reels of a slot machine or by playing hands of video poker. The progressive jackpot is awarded when a player at one of the interconnected gaming machines obtains a predetermined jackpot outcome in the primary game. For example, in Celona (U.S. Pat. No. 5,564,700), a number of gaming machines are linked to a central controller. The central controller computes the amount of the progressive jackpot by adding a predetermined percentage of each wager made at each gaming machine to the progressive jackpot. The jackpot is paid when a player at one of the gaming machines obtains a jackpot-winning outcome. The jackpot is shared among all eligible players regardless of whether the player obtained a jackpot-winning outcome or not, although the player who obtains the jackpot-winning outcome will receive a larger portion of the progressive jackpot.
The drawback of progressive jackpots, however, is that a player at one of the interconnected gaming machines must obtain a jackpot outcome to trigger the progressive jackpot payoff. Consequently, progressive jackpot payoffs are usually rare occurrences and, thus, only marginally contribute to the entertainment value of the game.
By contrast, bonus systems typically pay players without requiring that any player obtain a particular primary game outcome. For example, in Acres et al. (U.S. Pat. No. 5,752,882) several gaming machines are linked to a floor controller. The floor controller selects less than all the linked gaming machines to receive bonus treatment. The floor controller compares wager information from the gaming machines to a fixed bonus minimum and monitors any other bonus criteria specified by the operator such as the time of day, the level of play, the time since the most recent bonus, or the like. When all the criteria are met, the bonus, corresponding to an altered pay table or a designated bonus outcome, is awarded.
The drawback of this system is that the selection of gaming machines to receive bonus treatment is completely random and unrelated to game play. Consequently, the bonus system does not contribute to the entertainment value of the game. Moreover, the criteria for turning on the bonus is a fixed bonus minimum. Thus, the frequency with which the bonus will be turned on will change dramatically depending on the number of players playing at the interconnected machines and the amount each player is wagering. Finally, the bonus minimum criteria is fixed; that is, the bonuses and the bonus pool are not exactly computed. Thus, it is possible that the bonuses will not be inadequately funded.
Thus, there is a need in the art for a progressive bonus system which awards a bonus related to the primary game, but without requiring an immediately preceding primary game outcome, when a dynamic bonus threshold is met.
SUMMARY OF THE INVENTION
The present invention is a method and device for distributing a progressive bonus to one or more players playing linked gaming machines. In the method of the present invention, a primary game is provided at a plurality of linked gaming machines. The player makes a wager and plays the primary game in a conventional fashion to obtain an outcome. In addition to the conventional outcomes, a bonus outcome is provided in the primary game. If the player obtains a bonus outcome, a bonus symbol is randomly selected from a plurality of bonus symbols. The gaming machine stores the selected bonus symbol until another bonus outcome is obtained or the gaming machine becomes inactive for a predetermined amount of time. The selected bonus symbol may be displayed at the gaming machine.
A portion of each wager wagered at the linked gaming machines is accrued in an accrual pool. A bonus award between a minimum bonus award and a maximum bonus award is randomly selected and the number of eligible gaming machines in play is determined. A gaming machine is determined to be in play by measuring the time since the most recent wager, or alternatively, measuring the time between wagers. A gaming machine is eligible when the player meets predetermined criteria such as wagering the maximum amount per game. A dynamic bonus threshold is calculated by multiplying the bonus award by the number of eligible gaming machines in play. In other words, the bonus threshold is the total amount that would be paid if every gaming machine in play issued the bonus award. The bonus threshold is compared to the accrual pool. If the accrual pool is less than the bonus threshold, a new bonus award is randomly selected and the bonus threshold is recalculated.
In one embodiment of the present method, when the accrual pool is equal to, or greater than, the bonus threshold, a bonus indicator is randomly selected from a plurality of bonus indicators which correspond to the bonus symbols. The bonus indicator is compared to the bonus symbols at each gaming machine. If at least one gaming machine has selected a bonus symbol corresponding to the selected bonus indicator, the bonus award is issued at all gaming machines displaying a bonus symbol corresponding to the selected bonus indicator. If no gaming machine has selected a bonus symbol corresponding to the selected bonus indicator, the selection process is repeated.
In an alternate embodiment of the present method, when the accrual pool is greater than, or equal to, the bonus threshold, the bonus symbols which have been selected by the gaming machines are detected. A bonus indicator is randomly selected from only those bonus indicators which correspond to selected bonus symbols. This insures that the selected bonus indicator will correspond to at least one selected bonus symbol. The bonus award is issued at all gaming machines which have selected a bonus symbol which corresponds to the bonus indicator.
In the device of the present invention, each of a plurality of gaming machines is electronically linked to a system server. At each gaming machine, a player deposits a wager as a token, coin, or bill. The machine accepts the wager in a manner known in the art. The gaming machine and the system server each includes a computer processor. The gaming machine processor communicates data representing the amount of the wager to the system server which adds a percentage of the wager to the accrual pool. The player plays the primary game in a conventional fashion with winning outcomes being paid and losing outcomes resulting in a loss to the player. If, however, the player obtains certain bonus outcomes in the primary game, the gaming machine processor randomly selects a bonus symbol from a plurality of bonus symbols stored in a first data structure. The gaming machine may include a plasma display which displays the selected bonus symbol. The gaming machine processor stores the selected bonus symbol in a second data structure until the player obtains another bonus outcome or the gaming machine becomes inactive for a pre-determined period of time. The gaming machine processor communicates data representing the outcome of the primary game, and any bonus symbol selected, to the system server.
The system server processor begins the selection process by randomly selecting a bonus award between a maximum and a minimum award. The system server processor also determines the number of eligible gaming machines in play. To determine how many machines are in play, the system server tracks the amount of time elapsed since each gaming machine received a wager, or alternatively, the amount of time elapsed between wagers. To determine eligibility of players, the system server examines the wagering data received from the gaming machines to detect whether the player is wagering the maximum amount per game. The product of the bonus award and the number of eligible gaming machines in play is the dynamic bonus threshold.
The system server processor compares the accrual pool to the bonus threshold. If the accrual pool is less than the bonus threshold, the system server processor randomly re-selects the bonus award and recalculates the bonus threshold. This process repeats until the accrual pool is equal to, or greater than, the bonus threshold.
According to one embodiment of the present device, when the accrual pool meets or exceeds the bonus threshold, the system server processor randomly selects a bonus indicator from a plurality of bonus indicators stored in a third data structure. The bonus indicators correspond to the bonus symbols stored in each gaming machine. The system server detects the bonus symbols, if any, selected by each gaming machine in play. If the bonus indicator selected by the system server matches the bonus symbol selected by at least one gaming machine, the system server communicates an instruction to all gaming machines having a bonus symbol corresponding to the bonus indicator to issue the bonus award. If no gaming machine displays a bonus symbol corresponding to the bonus indicator, the system server begins the selection process anew by randomly selecting a bonus award.
In an alternate embodiment of the present device, when the accrual pool meets or exceeds the bonus threshold, the system server processor detects which bonus symbols have been selected by gaming machines. The system server then selects a bonus indicator from only those bonus indicators which correspond to selected bonus symbols. In other words, the system server selects from a data structure which stores the possible bonus indicators depleted by the bonus indicators which have not had their corresponding bonus symbol selected by a gaming machine. Consequently, the system server processor will always select a bonus indicator corresponding to a bonus symbol selected by at least one gaming machine. The system server sends a signal to issue the bonus award at all gaming machines which have selected the corresponding bonus symbol.
An object of the present invention is to provide a method and device which may reward more than a single player. Another object of the present invention is to reward players based on a continuously active bonus indicia rather than the immediate outcome of the primary game. Yet another object of the invention is to provide a method and device which calculates a dynamic bonus threshold and compares the bonus threshold to the available pool before paying the bonuses to insure that the bonuses are adequately funded.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a schematic diagram of the device of the present invention;
FIG. 2 shows a logic diagram of the method of the present invention;
FIG. 3 shows a logic diagram according to another embodiment of the method of the present invention;
FIG. 4 shows a logic diagram according to another embodiment of the method of the present invention;
FIG. 5 shows a logic diagram according to another embodiment of the method of the present invention;
FIG. 6 shows a more detailed logic diagram of the step of calculating the bonus award according to the embodiment of FIG. 5 .
DESCRIPTION
Reference is now made to the figures wherein like parts are referred to by like numerals throughout. Pictured in FIG. 1 is a gaming device according to the present invention adapted to practice the method disclosed herein. A plurality of gaming machines 10 are electronically linked to a system server 12 to enable the gaming machines 10 to communicate data to the system server 12 and the system server 12 to issue commands to the gaming machines 10 .
Referring now to FIG. 2, a player places a wager 20 , as either a bill, token, or coin, at a gaming machine 10 in a manner known in the art. The gaming machine 10 accepts and verifies the wager 20 , then signals to the gaming machine processor that the wager 20 has been accepted as well as the amount of the wager. The player then plays the game 22 in a conventional fashion. For example, if the game 22 is a slot machine, the player spins the reels; if the game 22 is video poker, the player signals the gaming machine processor to deal representations of five playing cards. The player obtains outcomes from the game 22 in a conventional fashion; that is, a winning outcome results in the player being rewarded and a losing outcome results in the players wager 20 being retained by the gaming machine 10 . The outcomes are displayed at a gaming machine display 14 . In addition to the conventional outcomes, there is also supplied at least one bonus outcome 24 . When a player obtains a bonus outcome 24 , the gaming machine processor selects at 26 a bonus symbol from a first data structure storing a plurality of bonus symbols 28 . The data structure could be any suitable data structure such as random access memory, read-only memory, or computer readable media such as a hard disc, floppy disc, digital video disc (DVD) or CD. The bonus symbols 28 could be any plurality of symbols, words, or pictures or streaming video images. In a preferred embodiment, the bonus symbols 28 have a common theme related to the theme of the gaming machine game 22 . For example, the bonus symbols 28 could each be depictions of well-known landmarks of cities of the world such as Paris, Rome, or Chicago and the theme of the game 22 could be global shopping.
The gaming machine processor stores the selected bonus symbol 26 in a second data structure and displays at a second display or at a location of the game display 14 . The gaming machine 10 then continues with its normal operation by accepting a wager 20 for the next game 22 . The selected bonus symbol 26 (e.g., a landmark of Chicago) is retained and displayed for all subsequent games until (1) another bonus outcome 24 is obtained and the gaming machine processor selects at 26 another bonus symbol (e.g., a landmark of Rome) or (2) the gaming machine 10 is inactive for a predetermined period of time implying that the player has left the machine or that the machine no longer qualifies for bonusing. In the example, if the bonus symbol Chicago were selected at 26 by the gaming machine processor, it would act as the bonus symbol 26 for that gaming machine 10 until another bonus symbol 26 is chosen or the gaming machine 10 is idle for a period of time set by the operator or is otherwise de-selected from the set of machines 10 entitled to participate in the bonus. Thus, to receive bonus treatment, it is not required that the player obtain the bonus outcome 24 immediately preceding the bonus award because the selected bonus symbol 26 will be retained for any subsequent bonus award periods. Thus, a player could obtain a bonus outcome at 24 , and have the gaming machine processor select a bonus symbol at 26 , many games 22 in advance of the awarding of the bonus award and still receive bonus treatment if the player is eligible as hereinafter described.
In a preferred embodiment, the gaming machines 10 each include a plasma display 16 for displaying at 30 the selected bonus symbol 26 or a representation of the selected bonus symbol 26 . For example, if Chicago were selected, the plasma display 16 may show the word “Chicago” or it may show photographs or animations of sights in and around Chicago. Similarly, the plasma display 16 may be used to display at 30 photographs, pictures, or animations at specified points during the course of a game 22 or a bonus session. Other bonus symbols and presentations could be used such as movie stars, animals, storefronts or the like.
The gaming machines 10 are connected to a system server 12 . As each wager 20 is made, the system server 12 adds a specified portion of the wager 20 to an accrual pool 40 stored in a third data structure.
As the gaming machines 10 operate, the system server 12 operates concurrently to determine whether a bonus award should be issued. The system server 12 includes a system server processor receiving input from each of the linked gaming machines 10 . At 42 , the system server processor randomly selects a game threshold, T g , which is an integer between a fixed maximum game threshold, T gmax , and a fixed minimum game threshold, T gmin , inclusive. The possible game thresholds are evenly weighted so there is an equal probability that any integer value between T gmax and T gmin inclusive will be selected as T g . The purpose of T g is to calculate the amount of money that would be required to pay the bonuses. In one embodiment, the bonus threshold, T g , is equal to the bonus award. In this embodiment, the use of T g in the calculations would yield the exact amount of money required to pay the bonus awards.
In an alternate embodiment, an extra step of selecting a bonus award is used. The bonus award is selected by the system server processor from a weighted pay table stored in a suitable data structure. In this embodiment, the use of T g yields an estimate of the amount of money required to pay the bonus awards. To yield an accurate estimate, the operator specifies T gmin and T gmax so that the mean of T gmin and T gmax is equal to the average bonus award. For example, if, according to the weighted pay table, the average bonus award is fifty coins per machine per session, the operator could set T gmin at thirty coins and T gmax at seventy coins. Thus, the mean would be fifty coins. This would insure that, on average, the bonus award is adequately funded.
At step 44 , the system server 12 determines the number of eligible gaming machines 10 in play, Ng. To determine whether a gaming machine 10 is in play, the system server processor detects the time since the most recent wager 20 , or alternatively, the time between wagers 20 and, if desired, the amount of the wager to encourage the player to wager a maximum amount. If a gaming machine 10 has been idle for a specified period of time, it is assumed that the player has left the gaming machine 10 and, thus, the gaming machine 10 will not receive bonus treatment.
The gaming machine operator may set any eligibility criteria. However, in a preferred embodiment, a player must wager 20 the maximum amount per game 22 for the player's gaming machine 10 within a predetermined time interval from the last maximum wager to commence and continue eligibility. In a preferred embodiment, the gaming machine processor will communicate data to a display to display the gaming machine's eligibility status.
At step 43 , the dynamic bonus threshold is calculated. The dynamic bonus threshold is the product of the game threshold and the number of eligible gaming machines 10 in play. Thus, the following formula is used:
Dynamic Bonus Threshold= T g N g .
The dynamic bonus threshold may be continuously updated or, alternatively, the operator may specify some other criteria to determine the frequency of the updates. For example, the operator may specify that the dynamic bonus threshold be updated according to a set period. Thus, an operator could instruct the system processor to update the dynamic bonus threshold every two minutes. Likewise, the operator may specify that the dynamic bonus threshold update every time there is a specified change in the number of eligible gaming machines 10 . For example, the operator may specify that the dynamic bonus threshold update every time the number of eligible gaming machines changes by two or more.
The dynamic bonus threshold is compared to the accrual pool 40 at step 45 . If the accrual pool 40 is less than the dynamic bonus threshold, the system server processor randomly re-selects a game threshold and recalculates the bonus threshold as shown at 50 . If the accrual pool 40 is greater than, or equal to, the dynamic bonus threshold, the system server processor selects a bonus indicator 46 as shown at 52 .
In one embodiment of the method and device of the present invention, the system server processor selects a bonus indicator 46 from a plurality of bonus indicators 48 stored in a fourth data structure. Each of the bonus indicators 48 corresponds to a bonus symbol 28 stored at the gaming machines 10 . For example, the player could be rewarded when the selected bonus indicator 46 matches the selected bonus symbol 26 at the gaming machine 10 ; that is, the player wins the bonus award when the bonus symbol “Chicago” matches the bonus indicator “Chicago.” The system server processor detects which of the bonus symbols 28 have been selected by the gaming machines 10 within the set of eligible machines and compares the selected bonus indicator 46 to the selected bonus symbols 26 at step 56 . If the selected bonus indicator 46 corresponds to at least one of the bonus symbols 26 selected at the gaming machines 10 , the system server processor communicates a command to issue the bonus award 64 at all the eligible gaming machines 10 in play which have selected at 26 the bonus symbol corresponding to the bonus indicator 46 . In other words, if the bonus indicator is the city “Chicago,” the system server processor would communicate a command 64 to issue the bonus award at all eligible gaming machines 10 in play which have selected and displayed “Chicago” as a bonus symbol. If the selected bonus indicator 46 does not correspond to at least one bonus symbol selected at 26 by a gaming machine 10 in the set of eligible machines, the bonus indicator selection process is restarted by the system server processor selecting a new T g as shown at 54 .
In an alternate embodiment, the system server processor detects which bonus symbols 28 have been selected by the gaming machines 10 . The system server processor compares the selected bonus symbols 26 to the possible bonus indicators 48 stored in a fourth data structure. At 60 , the system server processor depletes the possible bonus indicators 48 by removing those bonus indicators which do not correspond to selected bonus symbols 26 and storing the remaining bonus indicators in a fifth data structure. At step 62 , the system server processor then selects a bonus indicator from the bonus indicators stored in the fifth data structure. Thus, the system server processor will not select a bonus indicator 62 which will not correspond to a selected bonus symbol 26 . For example, if the possible bonus indicators 48 are Paris, Rome, and Chicago, and no linked gaming machine 10 has selected Paris, at step 62 the system server processor will select from Rome or Chicago only. The system server processor then communicates a command 64 to the gaming machines 10 to issue the bonus award at all eligible gaming machines 10 in play which have selected at 26 a bonus symbol corresponding to the selected bonus indicator 62 .
Referring now to FIG. 4, in another embodiment of the method and device of the present invention, rather than selecting a bonus indicator when the accrual pool 40 is equal to, or greater than, bonus threshold, the system server processor monitors the outcomes of the games 22 at the gaming machines 10 at step 68 . When a bonus outcome 24 is obtained at any of the gaming machines 10 , the system server processor communicates a command to the gaming machines 10 to issue the bonus award at all eligible gaming machines 10 . Eligibility, as heretofore described, is preferably determined by detecting whether the player had wagered the maximum amount per game 22 .
In yet another embodiment, rather than awarding the bonus award, the system server processor communicates a command to the gaming machines 10 having a selected bonus symbol 26 corresponding to the bonus indicator to initiate a bonus session 66 wherein the player is given the opportunity to win the bonus award through a bonus session of chance or outcomes or a sport such as “free kicks” in soccer. For example, the bonus session 66 could have a sports theme where the amount of the bonus award awarded is proportional to the number of “free soccer kicks” the player makes during a timed period.
In a further embodiment of the present invention shown in FIG. 5, the bonus threshold is fixed but the size of the bonus award is controlled to insure that the bonuses are adequately funded. The operator inputs a base payout, a bonus threshold, and a minimum bonus change at step 70 . The system server processor initializes the bonus award at the base payout amount. A portion of each wager 20 made at any of the linked gaming machines 10 is added by the system server processor to the accrual pool 40 . The amount of the bonus award is calculated at step 69 .
FIG. 6 shows a detailed flowchart of step 69 . At step 72 , when the accrual pool 40 reaches the bonus threshold, the system server processor updates the bonus award to the bonus threshold amount. Thus, if the base payout were ten and the bonus threshold were fifty, the bonus award would be initialized at ten and remain ten until the accrual pool 40 is equal to, or greater than, fifty, at which point the bonus award would be updated to fifty. As the accrual pool 40 increases beyond the bonus threshold, the bonus award is updated in increments equal to the minimum bonus change. Thus, if the minimum bonus change were twenty, the bonus award would be increased in multiples of twenty each time the accrual pool 40 increased by twenty or more as shown in steps 74 and 76 . In the above example, the bonus award would be fifty until the accrual pool 40 met or exceeded seventy, at which time the bonus award would be updated to seventy, and so on.
When a player obtains a bonus outcome 24 in the game 22 , the system server processor signals the amount of the bonus award to the gaming machine 10 at which the bonus outcome 24 was obtained. The gaming machine 10 then issues the bonus award or initiates a bonus session in which the player is given the opportunity to win the bonus award through the bonus game. In a preferred embodiment, the bonus game is a maze though which the gaming machine processor maneuvers a marker to reach a goal. If the goal is reached, the bonus award is issued; if the goal is not reached, the bonus award is retained.
When the bonus award is issued, the gaming machine processor may communicate data to the plasma display 16 to display a message, picture, or animation indicating to the player that a bonus award has been issued.
An advantage of the present invention is that the bonus method and device rewards more than a single player because all players with a selected bonus symbol 26 corresponding to the selected bonus indicia 46 are rewarded. Moreover, players are rewarded based on a continuously active bonus indicia rather than the immediate outcome of the primary game because the selected bonus symbol 26 is used for all subsequent bonus awards until the machine becomes inactive or another bonus outcome 24 is obtained. Finally, the present method and device calculates a dynamic bonus threshold and compares the bonus threshold to the accrual pool before paying the bonus awards to insure that the bonus awards are adequately funded.
While I have shown and described certain embodiments of the present invention it is to be understood that it is subject to many modifications and changes without departing from the spirit and scope of the appended claims.
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A system and method are set for providing a progressive bonus to eligible devices in a set of linked gaming machines. A server is linked to the machines and from wagers accumulates a bonus pool. Each machine has a designated bonus outcome which, if obtained, causes the system to select from a set of displays, a bonus display for the machine. The bonus display remains until another bonus outcome is obtained and another bonus display is selected or the machine falls from the set of eligible machines based upon lack of play or the like. The system periodically selects a bonus prize and compares it to the bonus pool to make sure the pool is sufficient to award the prize. If the pool is greater than or equal to the selected prize, the system selects a winning bonus corresponding to a bonus display of the set and awards the prize to any eligible machine displaying the selected bonus display.
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BACKGROUND AND/OR ENVIRONMENT OF THE INVENTION
1. Field of the Invention
The present invention pertains to rope ladders, and more particularly to rope ladders wherein a damaged platform or rung thereof can be replaced without disengaging other than the damaged platform or rung from the rope or the like suspending the platforms or rungs.
2. Description of the Contemporary and/or Prior Art
Collapsible ladders, and more particularly ladders which have the platforms or rungs thereof suspended by flexible stiles, such as ropes or the like, have been put to various uses including shipboard applications. In such applications, the ladders usually are subjected not only to heavy use but also to a rather hostile environment. Therefore, it is essential that these ladders not only be sturdy and durable but they also must be serviceable in the event of wear or damage.
Various flexible ladders have been proposed which provide different means for affixing a rope, cable, or the like to a ladder platform, sometimes called a rung, wherein the rope passes through a hole disposed in the platform. Ladders configured in this manner are shown, for example, in U.S. Pat. Nos. 800,934, 898,286, 899,552, 1,611,768, 3,077,241, 4,177,878, and 4,241,809, and in British Pat. Nos. 217,766, 496,194, and 935,645. A common disadvantage of these ladders is that in the event one of the platforms thereof, disposed between other platforms, becomes damaged, other platforms in addition to the damaged platform must be disassembled from the rope in order to replace the damaged platform. In the case of some designs, numerous platforms have to be disengaged so that the entire ladder can be restrung. At best, this is a time consuming chore and where the ropes are affixed using lashing such as that shown in British Pat. Nos. 217,766, 496,194 and 935,645, a major reworking of the ladder is required.
One design avoiding the problem of having to remove several platforms of a ladder to replace a damaged platform is shown in U.S. Pat. No. 641,741 and British Pat. No. 599,349. In these ladder configurations a pair of ropes clamped together at spaced apart locations are employed. The platform ends are disposed between the clamped ropes. Although this will permit replacement of a single platform, a great sacrifice is made in terms of platform stability.
To enhance stability and to still provide the feature of being able to replace a single ladder platform, various ladder configurations have been proposed which provide a notch or slot into which a rope or cable can be clamped. While such ladder configurations do permit the desired platform removability, the means heretofore proposed for clamping the ropes or cables within the notches are less than optimum by a virtue of placing undue strain upon the ropes or cables employed, by permitting slippage of the platforms along the longitudinal axes of the ropes or cables, or by providing platforms which are not particularly stable.
U.S. Pat. Nos. 2,638,260 and 3,415,341 teach ladders which have rope type stiles that are retained within a recess in the edge of a rung. The ropes are straight when the ladder is in use and the rungs are affixed thereto through crimping engagement of elements which are disposed around the ropes and are engaged by the rungs. A crimping connection with a straight rope as taught in these two patents inherently suffers from loosening since most forces on the rungs will tend to open the crimps therefore causing rung slippage along the ropes. If the crimps are tightened to try to preclude slippage, it is likely that the rope will be damaged from abrasion.
British Pat. No. 798,371 teaches the retention of a rope in the notched end of a ladder rung by a compression type clamp. Such a configuration suffers from the same problems of slippage and/or rope damage as noted in regard to the previously mentioned patents which employ crimping engagement. In an apparent attempt to minimize the slippage problem, this patent teaches the crossing of the ropes between rungs.
An alternate approach is shown in U.S. Pat. No. 1,349,125 wherein a rung which is divided in half is provided. The halves of the rung are clamped around the ropes employed and protrusions are provided adjacent to the ropes so that the rungs will be somewhat limited in slippage. Unfortunately, uneven weight distribution will cause stress upon the fasteners used to join the rungs together and rung slippage or shearing of the fastener is possible.
Other rope ladder configurations are shown in U.S. Pat. Nos. 2,079,034 and 2,373,346 as well as French Pat. No. 471,433 and Dutch Pat. No. 43,380.
The present invention overcomes the problems associated with the prior art by providing a rope clamp for ladder platforms which firmly precludes slippage and which is divided into two halves that engage adjacent ropes disposed in rope notches located in a platform, the halves of the clamp being secured together in a fashion to cause the ropes to be securely sandwiched between the clamp halves and the rope notches.
SUMMARY OF THE INVENTION
Therefore, a primary object of the present invention is to provide a ladder which is collapsible.
A further object of the present invention is to provide a collapsible ladder which is sturdy and durable even in hostile marine environments.
A still further object of the present invention is to provide a collapsible ladder wherein the individual platforms or rungs thereof can be serviced without the necessity of disengaging other platforms or rungs from the flexible supporting stiles of the ladder.
Still another object of the present invention is to provide a collapsible ladder wherein the rungs or platforms thereof are firmly precluded from slipping along the provided supporting rope or cable.
Still another further object of the present invention is to provide a collapsible ladder which is simple in design, relatively inexpensive to manufacture, rugged in construction, easy to use, and efficient in operation.
These objects, as well as further objects and advantages of the present invention will become readily apparent after reading the ensuing description of a nonlimiting illustrative embodiment and viewing the accompanying drawing.
A collapsible ladder, according to the principles of the present invention, comprises a plurality of elongated platforms each having a pair of spaced apart longitudinal side edges and a pair of spaced apart transverse end edges, a first pair of adjacent notches being disposed in each of the platforms adjacent to one of the end edges thereof, the first notch of the first pair of notches opening through one of the side edges of the associated platform, the second notch of the first pair of notches opening through the other of the side edges of the associated platform, a second pair of adjacent notches being disposed in each of the platform adjacent to the other of the end edges, the first notch of the second pair of notches opening through one of the side edges of the associated platform, the second notch of the second pair of notches opening through the other of the side edges of the associated platform; a plurality of rope segments extending between the elongated platforms for supporting the platforms in a spaced apart use position, selected portions of selected rope segments being disposed in the first and second pairs of notches; and a plurality of clamp means, some of the clamp means for clamping selected portions of the selected rope segments in the first pairs of notches, the balance of the clamp means for clamping selected rope segments in the second pairs of notches, each of the clamp means being divided into two halves, a rope engaging portion of each half of each of the clamp means being dimensioned to reside within a corresponding notch, each of the clamp means including means for securing the halves thereof together to wedge the selected portions of the rope segments between the rope engaging portions of the clamp means halves and the elongated platforms.
BRIEF DESCRIPTION OF THE DRAWINGS
In order that the present invention may be more fully understood, it will now be described, by way of example, with reference to the accompanying drawing in which:
FIG. 1 is a pictorial representation of a ladder incorporating the principles of the present invention;
FIG. 2 is an enlarged perspective view of one half of the clamps of the present invention;
FIG. 3 is a rear view in elevation of the clamp of FIG. 2; and
FIG. 4 is a fragmentary partially broken away perspective view of a pair of clamps of the present invention in a disassembled and assembled condition relative to one of the platforms of the present invention.
FIG. 5 is an enlarged fragmentary cross sectional view of the present invention taken substantially along the lines 5--5 of FIG. 4.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the figures, and more particularly to FIG. 1 thereof, there is illustrated therein a collapsible ladder 10 constructed in accordance with the principles of the present invention. The ladder 10 is suspended from a rail R of a ship S by a plurality of rope segments 12, 14, 16, and 18. The rope segments 12, 14, 16, and 18 are fixed at their upper ends to the rail R in a suitable manner. The rope segments 12, 14, 16, and 18 can be part of the same rope, a pair of ropes, or can be individual ropes as desired and preferably are formed of a braided nylon material although hemp, steel cable or the like can be employed.
The rope segments 12 through 18 serve to suspend a plurality of elongated platforms 20 in a spaced apart substantially parallel relationship for use as a ladder. The elongated platforms 20 are preferably constructed of aluminum although suitable materials such as wood or plastic can be employed. To enhance the safety of the collapsible ladder 10 the upper face of each of the elongated platforms 20 is provided with a friction inducing surface 22.
In addition to the elongated platforms 20 provided, a spreader 24 having a friction including surface 26 is also suspended from the rope segments 12, 14, 16, and 18. The spreader platform is mounted substantially in the same manner as the elongated platforms 20, as will hereinafter be described, but it is longer in length. The spreader platform 24 also may be sized so that it is wider in width so that its rear edge can abut against the ship S to keep the narrower elongated platforms 20 away from the ship S and is so sized in length to preclude the twisting of the ladder 10 about its rope segments.
The rope segments 12, 14, 16, and 18 are clamped to the elongated platforms 20 and the spreader platform 24 by a plurality of clamps 28. The clamps 28 are each divided into clamp halves 30 and 32, as further illustrated in FIG. 4.
With reference to FIGS. 2 and 3, the nature of the clamp halves 30 and 32 of the clamps 28 can be clearly ascertained. Illustrated in FIGS. 2 and 3 is a clamp half 30 with the complementary clamp half 32, not shown, being substantially identical thereto, the ensuing description of clamp half 30 therefore also applying to clamp half 32. Clamp half 30 is substantially U-shaped and includes a bight portion 34 and a pair of leg portions 36 and 38. The bight portion 34 of the clamp half 30 is dimensioned for insertion into notches, hereinafter described, disposed in the platforms 20 and 24. The legs 36 and 38 include, respectively, rope receiving recesses 40 and 42 which open, respectively, through the ends 44 and 46 of the leg portions 36 and 38. The rope receiving recesses 40 and 42, in conjunction with the inner surface 48 of the bight portion 34 of the clamp 30, form the rope engaging portion of the clamp 30.
Formed with the inner surface 48 of the bight portion 34 of the clamp 30 is a ridge 50 designed to engage a portion of a spiral recess in the rope which the clamp engages, the spiral recess being formed by the braiding of the rope components. Similarly, alternate ridges or protusions can be employed to enhance engagement of the clamp 30 with the adjacent portion of the rope disposed therein when the collapsible ladder 10 is assembled. However, since the rope is precluded from lateral movement by the shape of the clamp 30, and the ridge 50 is disposed at an angle relative to the longitudinal axis of the rope when in position, very effective gripping of the rope is effected.
The leg portions 36 and 38 of the clamp 30 are wider than the bight portion 34 so that when the bight portion 34 is inserted into a notch disposed in the platforms 20 and 24 the leg portions 36 and 38 can engage the upper and lower faces of the platforms to retain the clamp 30 locked in position, the bight portion 34 being disposed within the notch.
Disposed through the bight portion 34 of the clamp 30 is an aperture 52 through which an elongated fastener can be placed, as shown in FIG. 4. The aperture 52 preferably has a countersunk end diameter to accommodate the head of the fastener. The clamp halves 30 and 32 are preferably constructed of cast aluminum or the like although other suitable materials can be selected.
With reference to FIGS. 4 and 5, the manner in which the clamps 28 are fastened to an elongated platform 20, representative of all the platforms 20, can be observed. The clamps 28 are fastened to the spreader platform 24 in the same manner as to the elongated platforms 20 and therefore the following description in relation to the elongated platform 20 illustrated also applies to the spreader platform 24. Each elongated platform 20 includes a pair of spaced apart longitudinal side edges 54 and 56 and a pair of spaced apart transverse end edges 58 and 60. A first pair of adjacent notches 62 and 64 are disposed in the platform 20 adjacent to the end edge 58 and open, respectively, through longitudinal side edges 54 and 56 as well as through the faces of the platform 20. A second pair of adjacent notches 66 and 68 are disposed in the platform 20 adjacent to the end edge 60 thereof, the notches 66 and 68 opening, respectively, through longitudinal side edges 54 and 56 as well as through the faces of the platform 20.
The notches 62 through 68 are slightly larger in width than the diameter of the rope segments 12, 14, 16, and 18 and are rounded at the innermost portions thereof to have a curvature substantially similar to the outer curvature of the rope segments. The rope receiving recesses 40 and 42 of the clamp half 30 also have a width sized to accommodate the width of the rope segments. The rope receiving recesses 70 and 72 of the clamp half 32 are similarly sized.
An elongated passage 74 is disposed within the platform 20 between the innermost portions of each of the first pair of notches 62 and 64 and an elongated passage 76 is disposed in the platform 20 between the innermost portions of each of the second pair of notches 66 and 68. The passages 74 and 76 are located in the platform 20 such that they align with the aperture 52 in the clamp half 30 and an aperture 78 disposed in the clamp half 32 when the clamp halves 30 and 32 are positioned on the platform 20 with the bight portion 34 of the clamp half 30 disposed within the notch 64 and the bight portion 80 of the clamp half 32 disposed in the notch 62. This permits placement of a bolt 82 through the aperture 52, the elongated passage 74, and the aperture 78, in regard to the clamp 28 disposed in the first pair of notches 62 and 64, and permits the placement of another bolt 82 through the aperture 52, the elongated passage 76, and the aperture 78, in regard to the clamp 28 disposed in the notches 66 and 68. The bolts 82 are threaded and are each secured in position by complementary threaded nuts 84, the tightening of the nuts 84 drawing the clamp halves 30 and 32 together, as illustrated in FIGS. 4 and 5 by the clamp 28 disposed in the second pair of notches 66 and 68. The bolts 82 pass through the braids of the rope segments in a nondamaging fashion, this relationship tending to preclude slippage of the platforms 20 in relation to the rope segments.
When the halves of the clamps 28 are secured together by the bolts 82 and the nuts 84, the rope segments which pass through the platforms 20 are bent into a configuration wherein they extend partially around the faces of the platform 20 adjacent to the innermost surfaces of the associated notch. Therefore, each pair of rope segments which are clamped together by the clamps 28 tightly sandwich therebetween the portion of the platform 20 between the associated notches, further precluding slippage of the platform 20 relative to the rope segments without causing undue strain on the rope segments or a force which might tend to cut or weaken the rope segments.
Although the bolts 82 are illustrated as fastening together the clamp halves 30 and 32 in a particular manner it is to be understood that other than a longitudinal fastener can be employed so long as the clamp halves 30 and 32 are firmly drawn toward each other and are caused to reside within the associated notches. The exact number of rope segments employed and the positioning of the notches in the elongated platforms 20 and the spreader platform 24 as well as the number of spreader platforms 24 included in any particular collapsible ladder can be selected as desired by the user with the scope of the invention.
It will be understood that various changes in the details, materials, arrangements of parts and operational conditions which have been herein described and illustrated in order to explain the nature of the invention may be made by those skilled in the art within the principles and scope of the invention.
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A collapsible ladder which includes a plurality of platforms suspended from several rope segments. The rope segments are placed in open-ended notches disposed in the platforms and are clamped thereto by a plurality of clamp means, the clamp means being divided in half, each half engaging one notch and the rope therein and being clamped by an elongated fastener to the other half of the clamp means which engages another notch and the rope therein. As a result of this configuration, the elongated platforms, if damaged, can be changed individually without necessity of removal of other than the damaged platform.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. application Ser. No. 13/226,769, filed Sep. 7, 2011 in the U.S. Patent and Trademark Office, which is a continuation of U.S. application Ser. No. 12/166,527, filed Jul. 2, 2008 in the U.S. Patent and Trademark Office, now patented as U.S. Pat. No. 8,030,887, issued Oct. 4, 2011, which claims the benefit of Korean Application No. 10-2008-0015114, filed Feb. 20, 2008, in the Korean Intellectual Property Office. All disclosures of the document(s) named above are incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a power charging system, and more particularly, to a non-contact power charging system and a control method thereof, in which power transmission can be interrupted when foreign materials are deposited on a charge plate of the non-contact power charging system, a charging operation can be continuously maintained at a stable voltage even if a non-contact power receiving apparatus moves by touching or displacement on the charge plate of the non-contact power charging system in the charging operation, and thus charging efficiency can be improved.
[0004] 2. Description of the Related Art
[0005] Portable electronic devices, such as cellular phones, personal digital assistants (PDAs), portable media players (PMPs), digital multimedia broadcasting terminal (DMB terminals), MPEG audio layer 3 (MP3) players or notebook computers, cannot be plugged into a regular power source at home or office since they are generally used while the users are moving. Accordingly, the portable electronic devices are equipped with batteries or rechargeable batteries.
[0006] A charging system has been used to charge electric power, supplied from the regular power source, to the batteries or a battery pack of the portable devices via power supply lines or power supply connectors. However, when the charger and the batteries are connected or disconnected to replenish the electric power of the batteries with this connector supply system, an instant discharge may happen because of the potential differences between the charger connector and the battery connector. Hence the foreign substances will be gradually gathered on both connectors and finally there may be a fire disaster. Further, the collected humidity thereon will cause the discharge of the battery and other problems will be involved like the declining battery life, the low battery quality, and so on.
[0007] To solve the above-mentioned problems of the connector supply system, non-contacting charging systems have been developed. In this non-contacting charging system in accordance with the prior art, the device having the battery to be charged is placed over the primary coil of the non-contacting charging system and the battery will be charged by a secondary coil of the battery. The battery is charged with the induced electricity from the induced electromotive force of the secondary coil by the generated magnetic field from the primary coil.
[0008] The existing non-contacting charging systems with the prior art can only be used to supply the electricity to the portable devices. There are limited practical uses because they cannot be used in various alternatives.
[0009] Besides, if a metal is placed inside the effective radius of the generated magnetic field of the primary coil, there would be a lot loss of the electricity in the primary coil due to the changes of the magnetic field, so that non-contacting charging system may be damaged.
SUMMARY OF THE INVENTION
[0010] The present invention has been made to solve the foregoing problems with the prior art, and therefore the present invention is directed to prevent a non-contact power receiving apparatus and a non-contact power transmission apparatus by stopping power transmission when a foreign material is deposited on a charge plate.
[0011] The present invention is also directed to improve charging efficiency by ensuring that a charging operation be performed at a stable voltage even if the non-contact power receiving apparatus moves by touching or displacement on the charge plate of the non-contact power transmission apparatus while being powered.
[0012] Further, the present invention is also directed to protect a battery cell from a magnetic field created by primary and secondary charge cores such that the battery cell can be stably charged.
[0013] According to an aspect of the present invention, there is provided a non-contact power charging system, including a non-contact power transmission apparatus generating a power signal at a primary charge core thereof; and a non-contact power receiving apparatus receiving the power signal from the non-contact power transmission apparatus so as to be charged with power by the control of the non-contact power charging system. The non-contact power receiving apparatus includes a secondary charge core generating induced current in response to the primary charge core of the non-contact power transmission apparatus; a rectifier block connected to the secondary charge core to rectify the induced current; a charge IC block causing to charge a battery cell with the power from the rectifier block; a received power monitor module monitoring the power received through the secondary charge core; and a power receiver control unit constructed to control the rectifier block, the charge integrated circuit (IC) block and the received power monitor module, and to control identifier (ID) generation and a charge status signal. The received power monitor module includes a low voltage monitor module comparing and discerning whether or not the received power is detected to have a low voltage and a high voltage monitor module comparing and discerning whether or not the received power is detected to have a high voltage.
[0014] According to another aspect of the present invention, there is provided a control method of a non-contact power charging system, which includes a non-contact power transmission apparatus generating a power signal at a primary charge core thereof and a non-contact power receiving apparatus receiving the power signal from the non-contact power transmission apparatus so as to be charged with power. The control method includes procedures:
[0015] transmitting, at the primary core of the non-contact power transmission apparatus, an object detection signal including a call signal that call a unique ID value from the non-contact power receiving apparatus, and standing by for a response signal;
[0016] discerning whether or not a normal unique ID signal is received from the non-contact power receiving apparatus by discerning a signal detected according to load modulation by the primary charge core;
[0017] if it is discerned that a normal unique ID signal is received from the non-contact power receiving apparatus, generating, at the primary charge core through a gate driver module of the non-contact power transmission apparatus, a full power transmission signal;
[0018] requesting charge status information from the non-contact power receiving apparatus and adjusting charge level based on the charge status information received from the non-contact power receiving apparatus; and
[0019] if fully-charged state information is received from the non-contact power receiving apparatus, terminating a charging operation and displaying fully-charged state on a liquid crystal display panel or a charge status indicator light emitting module.
[0020] Here, the procedure of discerning whether or not a normal unique ID signal is received from the non-contact power receiving apparatus by discerning a signal detected according to load modulation by the primary charge core, includes: if the signal detected according to load modulation by the primary charge core is not a normal signal that has normal ID data transmitted from the non-contact power receiving apparatus, converting into a foreign material detection mode; and if a detected foreign material is metal or an electronic device, displaying a foreign material error on the liquid crystal display panel or the charge status indicator light emitting module and terminating a charging operation of a corresponding charging block.
[0021] Further, the procedure of adjusting charge level based on the charge status information received from the non-contact power receiving apparatus, includes: requesting data information on charge status information from the non-contact power receiving apparatus; receiving the charge status information transmitted from the non-contact power receiving apparatus, the charge status information including charged amount information and voltage data of received power; analyzing and discerning data on the charge status information on the power signal, received from the non-contact power receiving apparatus; and calculating a frequency of the power signal in order to compensate for transmission power based on the voltage data, received from the non-contact power receiving apparatus, and transmitting a power signal at a compensated frequency.
[0022] According to a further aspect of the present invention, there is provided a control method of a non-contact power charging system, which includes a non-contact power transmission apparatus generating a power signal from a primary charge core thereof, and a non-contact power receiving apparatus receiving the power signal from the non-contact power transmission apparatus so as to be charged with power. The control method includes procedures of:
[0023] detecting, at the non-contact power receiving apparatus in a standby mode for receiving the power signal, detecting a call signal transmitted together with an object detection signal from the primary charge core of the non-contact power transmission apparatus to call a unique ID value from the non-contact power receiving apparatus, and transmitting a signal related with the call ID value of the non-contact power receiving apparatus to the non-contact power transmission apparatus;
[0024] converting into a charge standby mode after the unique ID value is transmitted, rectifying the power signal transmitted from the non-contact power transmission apparatus and charging a battery cell with the rectified power signal;
[0025] discerning whether or not the power signal transmitted from the non-contact power transmission apparatus has a reference voltage, and transmitting a voltage adjustment signal to request voltage step-up if the discerned power signal is below the reference voltage or to request voltage step-down if the discerned power signal is above the reference voltage;
[0026] after the voltage adjustment signal is transmitted, if a received voltage is the reference voltage, generating a signal indicative of normal reception; and
[0027] discerning whether or not the battery cell is in fully charged status, and if the battery cell is in fully charged status, terminating a charging operation.
[0028] As set forth above, the present invention can prevent the non-contact power receiving apparatus and the non-contact power transmission apparatus from being damaged by stopping power transmission when a foreign material is deposited on the charge plate.
[0029] Further, the present invention can also improve charging efficiency by ensuring that a charging operation be performed at a stable voltage even if the non-contact power receiving apparatus moves by touching or displacement on the charge plate of the non-contact power transmission apparatus while being powered.
[0030] Moreover, the present invention can also protect the battery cell from a magnetic field created by the primary and secondary charge cores such that the battery cell can be stably charged.
[0031] Additional aspects and/or advantages of the invention will be set forth in part in the description which follows and, in part, will be obvious from the description, or may be learned by practice of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0032] The above and other objects, features and other advantages of the present invention will be more clearly understood from the following detailed description taken in conjunction with the accompanying drawings, in which:
[0033] FIG. 1 is a schematic configuration view illustrating a non-contact power transmission apparatus of a non-contact power charging system in accordance with the present invention;
[0034] FIG. 2 is a schematic configuration view illustrating a non-contact power receiving apparatus of the non-contact power charging system in accordance with the present invention;
[0035] FIG. 3 is a flowchart illustrating a non-contact power transmission process of the non-contact power charging system in accordance with the present invention;
[0036] FIG. 4 is a flowchart illustrating a non-contact power receiving process of the non-contact power charging system in accordance with the present invention;
[0037] FIG. 5 is a control flow diagram illustrating a non-contact power transmission process of the non-contact power charging system in accordance with the present invention;
[0038] FIG. 6 is a control flow diagram illustrating a non-contact power receiving process of the non-contact power charging system in accordance with the present invention;
[0039] FIGS. 7 and 8 are circuit diagrams illustrating the non-contact power receiving apparatus of the non-contact power charging system in accordance with the present invention;
[0040] FIG. 9 is an exploded perspective view illustrating the construction of the non-contact power receiving apparatus of the non-contact power charging system in accordance with the present invention;
[0041] FIG. 10 is a side cross-sectional view of FIG. 9 ;
[0042] FIGS. 11 and 12 are graphs illustrating power control efficiencies of the prior art;
[0043] FIGS. 13 through 16 are graphs illustrating power control efficiencies of the non-contact power charging system in accordance with the present invention;
[0044] FIG. 17 is a graph illustrating efficiencies of repeated charge/discharge test on the non-contact power receiving apparatus of the non-contact power charging system in accordance with the present invention; and
[0045] FIGS. 18 and 19 illustrate operations of the non-contact power charging system in accordance with the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0046] Hereinafter, the present invention will be described more fully with reference to the accompanying drawings, in which exemplary embodiments thereof are shown.
[0047] FIG. 1 is a schematic configuration view illustrating a non-contact power transmission apparatus of a non-contact power charging system in accordance with the present invention;
[0048] FIG. 2 is a schematic configuration view illustrating a non-contact power receiving apparatus of the non-contact power charging system in accordance with the present invention; FIG. 3 is a flowchart illustrating a non-contact power transmission process of the non-contact power charging system in accordance with the present invention; FIG. 4 is a flowchart illustrating a non-contact power receiving process of the non-contact power charging system in accordance with the present invention; FIG. 5 is a control flow diagram illustrating a non-contact power transmission process of the non-contact power charging system in accordance with the present invention; FIG. 6 is a control flow diagram illustrating a non-contact power receiving process of the non-contact power charging system in accordance with the present invention; FIGS. 7 and 8 are circuit diagrams illustrating the non-contact power receiving apparatus of the non-contact power charging system in accordance with the present invention; FIG. 9 is an exploded perspective view illustrating the construction of the non-contact power receiving apparatus of the non-contact power charging system in accordance with the present invention; FIG. 10 is a side cross-sectional view of FIG. 9 ; FIGS. 11 to 16 are graphs illustrating power control efficiencies of the non-contact power charging system in accordance with the present invention; FIG. 17 is a graph illustrating efficiencies of repeated charge/discharge test on the non-contact power receiving apparatus of the non-contact power charging system in accordance with the present invention; and FIGS. 18 and 19 illustrate operations of the non-contact power charging system in accordance with the present invention.
[0049] Referring to FIGS. 1 to 19 , a non-contact charging system A of the present invention includes a non-contact power transmission apparatus 10 that is constructed to transmit a power signal to a non-contact power receiving apparatus 30 without actual contacts.
[0050] As shown in FIG. 1 , the non-contact power transmission apparatus 10 includes a central control unit and a full bridge resonant converter 22 , which act to transmit a power signal to the non-contact power receiving apparatus 30 without actual contacts.
[0051] The non-contact power transmission apparatus 10 also includes a gate driver module 23 , which causes the full bridge resonant converter 22 to transmit a converted power signal, and a received signal processing module 24 , which processes a signal transmitted from the non-contact power receiving apparatus and sends the processed signal to the central control unit 21 .
[0052] The non-contact power transmission apparatus 10 also includes a power transmission apparatus case (not shown). The power transmission apparatus case includes, on the front side thereof, a power on/off switch, an input panel for signal input, a liquid crystal display (LCD) panel 153 and a charge status indicator light emitting diode (LED) module 154 . The LCD panel 153 and the LED module 154 serve to display the status and the charge status of a non-contact charge plate (not shown) and the non-contact power receiving apparatus 30 . Inside the power transmission apparatus case, a power supply unit 25 is installed.
[0053] As such, as shown in FIG. 1 , the non-contact power receiving apparatus 30 implemented as a battery of a mobile device, such as a mobile phone, a personal digital assistant (PDA), a portable multimedia player (PMP), a digital multimedia broadcasting terminal (DMB terminal), a moving picture experts group (MPEG) audio layer 3 player (MP3 player) or a notebook computer, is mounted on the charge plate of the non-contact power transmission apparatus. When the non-contact power receiving apparatus is placed on the charge plate, the non-contact power transmission apparatus 10 starts a charging operation by detecting the placement of the non-contact power receiving apparatus 30 .
[0054] Below a description will be given of the construction of the central control unit 21 controlling the charging operation of the non-contact power transmission apparatus 10 . As shown in FIG. 1 , the central control unit 21 includes a power supply block 211 connected to the power supply unit 25 to supply power to the non-contact power transmission apparatus 10 ; a signal output block 212 outputting an indicator signal to the LCD panel 153 and the charge status LED module 154 ; a gate output signal processing block 213 connected to the gate driver module 23 to transmit a control signal in response to an output power signal from a primary charge core 13 ; a received signal processing block 214 connected to the primary charge core 13 to process a signal transmitted from the received signal processing module 24 , which processes a signal transmitted from the non-contact power receiving apparatus 30 ; and a main controller 210 controlling parts of the non-contact power transmission apparatus 10 including the power supply block 211 , the signal output block 212 , the gate output signal processing-block 213 , the received signal processing block 214 and so on.
[0055] The power supplied to the power supply unit 25 may be provided from a universal serial bus (USB) port of a computer, an alternating current (AC) adaptor, a cigar jack and so on.
[0056] The central control unit 21 also includes a temperature detector 26 , which detects the temperature of the non-contact power transmission apparatus 10 during the charging operation. The central control unit 21 can be constructed to interrupt the charging operation when a temperature detected by the temperature detector 26 indicates overheating, or to suspend the operation of the whole system when the detected temperature indicates overheating of the whole part of the non-contact power transmission apparatus 10 .
[0057] A current sensing member may also be provided in each of the power supply unit 25 , the gate driver module 23 , the full bridge resonant converter 22 and the received signal processing module 24 in order to detect a flow of electric current. The non-contact power transmission apparatus 10 , particularly, the central control unit 21 can be constructed to interrupt the charging operation or the operation of the system, and generates a corresponding signal when the current sensing member detects an over-current or over-voltage state from a corresponding part.
[0058] The non-contact power receiving apparatus 30 is an apparatus that receives a power signal from the non-contact power transmission apparatus 10 . As shown in FIG. 2 , the non-contact power receiving apparatus 30 generally includes a secondary charge core 32 having a construction corresponding to that of the primary charge core 13 of the non-contact power transmission apparatus 10 so as to generate induced current; a rectifier block 33 connected to the secondary charge core 32 to rectify induced current; a smoothing filter block 34 connected to the rectifier block to filter current and power; a charger integrated circuit (IC) block 36 connected to the rectifier block 33 to charge a battery cell 35 with power; a protection circuit module (PCM) block 37 disposed between the charger IC block 36 and the battery cell 35 to detect current charged to the battery cell 35 and transmit the charge status information of the battery 35 to a power receiver control unit 39 so as to detect the status of the battery, such over-voltage, under-voltage, over-current and short-circuit; and a static voltage regulator block 38 supplying power to the PCM block 37 . The power receiver control unit is also provided in the non-contact power receiving apparatus 30 , and is constructed to control the rectifier block 33 , the smoothing filter block 34 , the charger IC block 36 , the PCM block 37 and the static voltage regulator block 38 and to monitor an occurrence of an identifier (ID) and a charge status.
[0059] The non-contact power receiving apparatus 30 also includes a received power monitor module 31 , which monitors power received through the secondary charge coil 32 , in order to detect whether or not power is stably received. A reference voltage of a power source, which is received as above, can be variously selected according to the detailed specification of the non-contact power charging system A and the non-contact power receiving apparatus 30 . For example, the reference voltage can be set, generally, in the range from 2 to 20V, and when applied to a typical mobile phone device, on the order of 4V.
[0060] The received power monitor block 31 includes, as subsidiary components thereof, a low voltage monitor module 311 discerning whether or not received power has a low voltage and a high voltage monitor module 312 discerning whether or not received power has a high voltage.
[0061] In the low voltage monitor module 311 as above, the voltage level acting as a reference of a low voltage can be selectively set according to the detailed specification of the non-contact power charging system A and the non-contact power receiving apparatus 30 . The voltage level may be set −1V or −0.5V when the reference voltage is set 5V as in the foregoing illustration.
[0062] Likewise, the voltage level acting as a reference of a low voltage in the high voltage monitor module 312 can also be selectively set according to the detailed specification of the non-contact power charging system A and the non-contact power receiving apparatus 30 . The voltage level may be set +1V or +0.5V when the reference voltage is set 5V as in the foregoing illustration.
[0063] The power receiver control unit 39 includes a power signal processing block 393 connected to the smoothing filter block 34 to process a transmission signal about data information on a power signal transmitted from the non-contact power transmission apparatus 10 ; a charge signal processing block 394 connected to the charge IC block 36 and the PCM block 37 to process a transmission signal about data information on the charge capacity and charge status of the battery cell 35 ; a signal processing block 392 processing charge capacity information and data information on a unique ID, which are transmitted to the non-contact power transmission apparatus 10 by the control of a device controller 390 ; and a device memory 391 . The device memory 391 stores data information on a unique ID, temporarily stores charge capacity information and charge status data, which are transmitted from the PCM block 37 and the charge IC block 36 , and storing data transmitted from the non-contact power transmission apparatus 10 . The device controller 390 is also included in the power receiver control unit 39 .
[0064] Referring to an exemplary construction shown in FIG. 7 , a part for monitoring the voltage of power transmitted from the non-contact power transmission apparatus 10 is implemented as the received power monitor module 31 separate from the power receiver control unit 39 .
[0065] As such, the monitoring part can be constructed as a separate module from the power receiver control unit 39 . Further, as shown in FIG. 8 , a single control module can be constructed by integrating the power receiver control unit 39 with a received power monitor block 31 ′. In the case where the power receiver control unit 39 including the received power monitor module 31 (a low voltage monitor block 311 ′ and high voltage monitor block 312 ′) is constructed as a single module, the advantage is that the construction of the non-contact power receiving apparatus 30 can be simplified, thereby reducing the entire size thereof. Another advantage is that lines for monitoring received power can be simplified so as to simplify the entire circuit construction.
[0066] While the foregoing embodiment has been illustrated with respect to a voltage-monitoring construction which monitors a received power signal with reference to the upper or lower limit of a voltage, a current-monitoring construction can also be provided alone or in combination with the voltage-monitoring construction. Of course, it CaO be constructed to monitor both the voltage and the current in order to ensure circuit stability. According to installation conditions, only one of a voltage-monitoring circuit and a current-monitoring circuit can be provided. While following embodiments will be illustrated with respect to the upper or lower limit of a voltage, this is not intended to limit the present invention. Rather, the circuit can also be constructed to monitor received power using the upper and lower limits of current such that power can be stably received.
[0067] The non-contact power charging system A as described above has an advantage in that a power signal transmitted from the non-contact power transmission apparatus 10 is stably received in the non-contact power receiving apparatus 30 such that charging power can be transmitted in optimized conditions.
[0068] Below, a description will be given of the charging operation of the non-contact power charging system A in accordance with the present invention constructed as above.
[0069] In the non-contact power transmission apparatus 10 of the non-contact power charging system A, a power signal is periodically transmitted to the gate output signal processing block 213 , the gate driver module 23 , the full bridge resonant converter block 22 and the primary charge core 13 through gate signal lines 234 by the control of the central control unit 21 (standby mode S 01 ). In the standby mode S 01 , the power signal periodically transmitted through the primary charge core 13 includes a call signal that request a unique ID from the non-contact power receiving apparatus 30 , and the process stands by for a response signal to the call signal.
[0070] In the procedure of standing by for a response signal after the transmission of the unique ID call signal in the standby mode S 01 , an object is detected using a received detection signal in response to load modulation by the primary charge core 13 . The object, which can be placed on the charge plate, may include not only a mobile non-contact power receiving apparatus 30 , such as a mobile phone, a PDA, a PMP, a DMB device, an MP3 player or a notebook computer, but also a metallic object, a non-metallic object and an electronic device incapable of non-contact charging. Accordingly, the non-contact power transmission apparatus 10 discerns whether or not any one of the above-described objects is placed on the charge plate by receiving the detection signal in response to load modulation produced by the object.
[0071] In the case of load modulation caused by the presence of the non-metallic object or the movement of the object, the operation may convert to the standby mode S 01 unless there is a specific problem. However, in the case of the metallic object or electronic device incapable of non-contact charging rather than the non-contact power receiving apparatus 30 , the charging operation may bring in heating or malfunction.
[0072] To this end, a foreign material is monitored by parasitic metal detection (PMD). That is, when the detection signal in response to load modulation caused by an object is detected by the primary charge core 13 and the received signal processing module 24 , this procedure is carried out to discern whether or not the detection signal is a normal signal. Particularly, the procedure discerns whether or not the detection signal is an abnormal signal incapable of signal discerning by comparing the detection signal with a signal generated by the control of the central control unit 21 . If the object is detected as a foreign material, the process converts into a foreign material detection status, causes the LCD panel 153 or the charge status indicator LED module 154 to display a foreign material error (a PMD error) if the foreign material is a metallic object or an electronic device. Further, the charging operation is interrupted.
[0073] If the received detection signal is discerned as data information on the unique ID of the non-contact power receiving apparatus 30 that can be charged without contacts, the received detection signal in response to load modulation is analyzed and discerned (unique ID discerning S 02 ). In the standby mode S 01 , a search signal for the non-contact power receiving apparatus 30 is transmitted and a call signal requesting data information on the unique ID of the non-contact power receiving apparatus is also transmitted. Correspondingly, in the non-contact power receiving apparatus 30 , induced current from the secondary charge core 32 is rectified by the rectifier block 33 and is then filtered by the smoothing filter block 34 . During this procedure, the call signal requesting the unique ID data information is transmitted to the device controller 390 of the power receiver control unit, and correspondingly, unique ID data of the non-contact power receiving apparatus 30 stored in the device memory 391 is transmitted to the non-contact power transmission apparatus 10 through the signal processing block 392 . Then, the main control unit 210 discerns whether or not the corresponding non-contact power receiving apparatus is a normal apparatus that can be charged without contacts. That is, the main control unit 210 discerns whether or not the received data is a unique ID data type of a normal non-contact power receiving apparatus, and then discerns whether or not the received data is unique ID data transmitted from a normal non-contact power receiving apparatus.
[0074] If the received data is discerned as unique ID data transmitted from a normal non-contact power receiving apparatus, the primary charge core 13 is caused to generate a full power transmission signal through the gate driver module 23 (full power transmission S 03 ).
[0075] Describing the full power transmission S 03 in the non-contact power transmission apparatus 10 , the main controller 210 of the central control unit 21 determines that a normal non-contact power receiving apparatus is placed on the charge plate (not shown), thereby generating a control signal to transmit a power signal through the gate output signal processing block 213 and the gate signal lines 234 .
[0076] The control signal generated as above is transmitted to the gate driver module 23 and is transmitted through the full bridge resonant converter 22 to the primary charge core 13 , which then generates an induced magnetic field, such that the power signal is transmitted to the non-contact power receiving apparatus.
[0077] The gate signal lines 234 and the gate driver module 23 , associated with the above-described process, can have a construction as rendered in a following embodiment.
[0078] The control signal of the main controller 210 is transmitted through the gate signal lines 234 to the gate driver module 23 . The gate driver module 23 can be constructed to include a gate signal converter 232 performing gate signal processing on the control signal, an output driver 233 transmitting the processed signal to the full bridge resonant converter 22 , a gate controller 231 and so on.
[0079] The gate controller 231 can be constructed to control the signal transmitting/receiving and processing operations in the gate driver module 23 . Thereby, the control signal from the main controller 210 is transmitted to corresponding parts, and a resultant power signal is transmitted and an induced magnetic field is stably generated.
[0080] Next, in the charging operation, a signal requesting charge statue information is transmitted to the non-contact power receiving apparatus 30 , and the charge level of the non-contact power receiving apparatus 30 is adjusted based on the charge status information (adjustment of charging S 04 ).
[0081] Then, after the full power transmission S 03 , the non-contact power receiving apparatus 30 charges the power, supplied through the rectifier block 33 and the smoothing filter block 34 , in the battery cell 35 through the charge IC block 36 and the PCM block 37 by the control of the device controller 390 .
[0082] In response to this charging operation, the device controller 390 is inputted with information on the charge status through the charge IC block 36 and the PCM block 37 , and temporarily stores the charge status information in the device memory 391 . When the battery cell 35 is fully charged, the device controller 390 controls the charge IC block 36 to terminate the charging operation and controls to generate fully-charged status information from the secondary charge core 32 through the signal processing block 392 . Further, if the voltage of the charged battery cell 35 is lower than a predetermined reference voltage, the charging operation can be resumed. If it is discerned fully-charged status, the charging operation is terminated (No operation).
[0083] Accordingly, in the adjustment of charging S 04 , the main controller 210 of the non-contact power transmission apparatus 10 requests status information on stepwise charge level from the non-contact power receiving apparatus 30 . As a response, the device controller 390 of the non-contact power receiving apparatus 30 transmits the charged status information to the non-contact power transmission apparatus 10 by load modulation.
[0084] The charged status information from the non-contact power receiving apparatus is transmitted through the received signal processing module 24 to the main controller 210 connected to the received signal processing block 214 . The signal processing module 24 includes a received signal input 243 receiving a signal detected by load modulation, a received signal processor 242 converting the signal detected by load modulation and a received signal controller 241 controlling the operation of the received signal processing module 24 .
[0085] According to this construction, the transmission information of the non-contact power receiving apparatus 30 received through load modulation is signal-converted in the received signal processing module 24 and is then transmitted to the main controller 210 through the received signal processing block 214 . The received signal processing module 24 may generally include a plurality of amplifiers, a low pass filter (LPF), an OR circuit and so on.
[0086] When signals in response to load modulation are transmitted, a plurality of the received signal processors 242 , constructed in accordance with an embodiment, processes respective signals and transmits the processed signals to the main controller 210 through received signal lines 244 .
[0087] Accordingly, the non-contact power transmission apparatus 10 requests the data information on the charge level of the non-contact power receiving apparatus 30 , particularly, via the gate driver module 23 and the primary charge core 13 . As a response, the non-contact power receiving apparatus 30 transmits the data information on the charge level of the battery cell 35 , received via the charge IC block 36 and the PCM block 37 , to the non-contact power transmission apparatus 10 . The data information is then transmitted to the main controller 210 through the primary charge core 13 and the received signal processing module 24 .
[0088] As an alternative construction, when the voltage of the power signal received from non-contact power receiving apparatus 30 is determined to be lower or higher than a reference voltage, a corresponding signal can be transmitted to the non-contact power receiving apparatus 10 so as to adjust the voltage of the power signal. For example, as shown in FIG. 18 , when the non-contact power receiving apparatus 30 moves to an outer area while being properly charged in the central area of the charge plate, the voltage of a received power signal is relatively lowered. To compensate for the lowered value, a voltage step-up request signal is transmitted to the non-contact power transmission apparatus 10 . Conversely, as shown in FIG. 19 , when the non-contact power receiving apparatus 30 moves to the central area from the outer area of the charge plate, a relatively better power signal is received, in which the voltage of the power signal is relatively raised. Then, a voltage step-down request signal is transmitted to the non-contact power transmission apparatus 10 in order to stably receive power.
[0089] Describing the adjustment of charging S 04 during the charging operation in accordance with an embodiment of the present invention, the non-contact power transmission apparatus 10 requests data on the charged status information (charge capacity information) from the non-contact power receiving apparatus 30 . As a response, the non-contact power receiving apparatus 30 transmits a signal including charge information data, such as the charge capacity data and the charged status information on the voltage of received power, and the non-contact power transmission apparatus receives the signal including the charge information data (step of receiving charge information data S 042 ).
[0090] Data analysis and discerning is performed on the charged status information of the power signal transmitted from the non-contact power receiving apparatus (step of discerning power data S 043 ). A compensation frequency with respect to the voltage data on the power signal transmitted from the non-contact power receiving apparatus 30 is calculated and a compensated power signal having the compensation frequency is transmitted (step of transmitting compensated power signal S 044 ).
[0091] In the above-mentioned example, the voltage of the received power signal acting as a reference in the non-contact power receiving apparatus 30 was 5V. In this case, it is assumed that the voltage 5V be stably received when the non-contact power receiving apparatus 30 does not move. However, when the voltage of the received power signal drops or rises in response to the movement of the non-contact power receiving apparatus 30 , the non-contact power transmission apparatus 10 modifies the frequency of the transmission power signal in order to compensate for a variation in the voltage of the received power signal, such that the non-contact power receiving apparatus 30 can receive the power signal at a stable voltage.
[0092] Accordingly, a compensation frequency variation .DELTA.f of the transmitting power signal can be suitably determined based on the setting of the non-contact charging system A, the non-contact power transmission apparatus 10 and the non-contact power receiving apparatus 30 . For example, the compensation frequency variation .DELTA.f can be variously set with 10 Hz, 50 Hz, 100 Hz, 500 Hz, 1 KHz, 2 KHz, 5 KHz and so on.
[0093] Based on data indicating the charge level of the non-contact power receiving apparatus 30 , the main controller 210 of the central control unit 21 displays the charge level or the state information using letters or a diagram on the LCD panel 153 through the signal output block 212 and also controls the charge status indicator LED module 154 to indicate the charging operation. Further, the charge status indicator LED module 154 is lighted in various fashions to indicate different statuses. For example, the charge status indicator LED module 154 may be turned off to indicate the termination of the charging operation, or flicker to indicate the charging operation. In addition, a green lamp of the charge status indicator LED module 154 may be turned on to indicate the fully-charged status, and a red lamp of the charge status indicator LED module 154 may be turned on to indicate an error caused by a foreign material, a unique ID error, and etc.
[0094] When the non-contact power receiving apparatus 30 moves on or from the charge plate during the charging operation, the power signal transmitted from the non-contact power transmission apparatus 10 can be varied so as to optimize the charging efficiency of the non-contact power receiving apparatus 30 .
[0095] Then, information on the fully-charged status is received from the non-contact power receiving apparatus 30 , the fully-charged status is displayed using the LCD panel 153 or the charge status indicator LED module 154 , corresponding to a charging block 14 , and the charging operation in the charging block 14 is terminated (fully-charged stage S 06 ).
[0096] Preferably, the user can remove the fully-charged non-contact power receiving apparatus 30 from the stopped charging block 14 , and leave the charging block 14 in the standby mode until a starting signal is inputted.
[0097] In the case of foreign material error (a PMD error) or ID error status, an error status is displayed and the operation is interrupted in order to ensure stability for the non-contact power transmission apparatus 10 , the non-contact power receiving apparatus 30 , a metallic object, or another electronic device. Accordingly, when the operation is interrupted due to an error, the process can preferably remain in the standby mode until a restarting signal is inputted from the user.
[0098] Of course, in the case of the error status or the fully-charged status, a pulse signal can be periodically transmitted, the non-contact power receiving apparatus 30 can be detached or the foreign material can be removed so as to remove the error based on a signal caused by resultant load modulation. Then, the process can be converted into a normal standby mode.
[0099] Furthermore, when the power signal is received in response to the request signal from the non-contact power transmission apparatus 10 , the device controller 390 of the non-contact power receiving apparatus 30 can control the data value of the voltage of the power signal to be transmitted to the non-contact power transmission apparatus 10 .
[0100] A description will be given of charge-related procedures in the non-contact power receiving apparatus 30 . In the standby mode of the non-contact power receiving apparatus 30 for receiving a power signal, a call signal, transmitted together with an object detection signal from the primary charge core 13 of the non-contact power transmission apparatus 10 , is detected. Here, the call signal calls the unique ID value of the non-contact power receiving apparatus 30 . Then, a signal on the unique ID value of the non-contact power receiving apparatus 30 is transmitted to the non-contact power transmission apparatus (unique ID value transmitting step S 21 ).
[0101] After the unique ID value transmitting step S 21 , the process is converted into a charge standby mode and a power signal received from the non-contact power transmission apparatus 10 is rectified and is then charged in the battery cell 35 (charging step S 22 ).
[0102] Accordingly, a monitor module can be constructed to monitor the voltage of a power signal received from the non-contact power transmission apparatus 10 in response to a request or by the control of the device controller 390 . It is discerned whether or not the voltage of the received power signal is a reference voltage, if the voltage of the received power signal is below the reference voltage, a voltage adjustment signal is transmitted to request voltage step-up. Conversely, if the voltage of the received power signal is above the reference voltage, the voltage adjustment signal requests voltage step-down (voltage adjustment requesting step S 23 ).
[0103] When a voltage received after the voltage adjustment requesting step S 23 is a reference voltage, a signal indicative of normal reception is transmitted (normal voltage signal transmitting step S 24 ). It is discerned whether or not the battery cell 35 is fully charged, and in the case of the fully-charged status, the charging operation is terminated (charging operation terminating step S 25 ).
[0104] In the voltage adjustment requesting step S 23 , the level of the voltage of the received power signal can be discerned, and the charge level of the battery cell 35 can also be discerned.
[0105] In the case of discerning the voltage of the received power signal, as shown in FIG. 18 where the non-contact power receiving apparatus 30 is moved to the outer area from the central area of the non-contact power transmission apparatus 10 , received power is temporarily weakened since the non-contact power receiving apparatus 30 is located relatively in an outer position with respect to the primary charge core 13 . When a normally-received voltage is 5V, the low voltage monitor module 311 of the received power monitor module 31 detects a voltage 4.5V indicative of a voltage drop −0.5V. Accordingly, a signal requesting the stepping-up of transmission power (a power-up request signal) is transmitted to the non-contact power transmission apparatus 10 .
[0106] Further, as shown in FIG. 19 , the non-contact power receiving apparatus 30 is moved to the central area from the outer area of the non-contact power transmission apparatus 10 , where a stable voltage of about 5V is received. Here, received power is temporarily intensified since the non-contact power receiving apparatus 30 is located relatively in a central position with respect to the primary charge core 13 . Then, the low voltage monitor module 311 of the received power monitor module 31 detects a voltage 5.5V indicative of a voltage rise 0.5V. Accordingly, a signal requesting the stepping-down of transmission power (a power-down request signal) is transmitted to the non-contact power transmission apparatus 10 .
[0107] As a result, the non-contact power transmission apparatus 10 can modify the frequency of the transmission power signal, such that the power signal can be received and charged at a more stable voltage. The stable reception of the voltage can be observed from graphs of FIGS. 13 to 16 .
[0108] Below, a detailed description will be given of the power control process in accordance with the adjusting of charging.
[0109] As shown in FIGS. 7 and 13 to 16 , a power signal transmitted from the primary charge core 13 of the non-contact power transmission apparatus 10 is received through the secondary charge core 32 of the non-contact power receiving apparatus 30 . Here, information on the intensity of the input voltage of the power signal is sent to the device controller 390 .
[0110] If the voltage of the received power signal is detected as being transmitted at a stable voltage (e.g., 5V), the voltage can preferably be maintained to be uniform. Conversely, if the voltage of the received power signal is too low or high, information on voltage adjustment is transmitted by load modulation to the non-contact power transmission apparatus 10 , such that a uniform value of voltage can be received. When the voltage is adjusted to be uniform, the operation of the charge IC of the charge IC block 36 of the non-contact power receiving apparatus 30 is activated by the control of the device controller 390 , such that the power can be charged in the battery cell 35 .
[0111] While the power transmitted from the non-contact power transmission apparatus 10 is charged in the battery cell 35 of the non-contact power receiving apparatus 30 , the PCM block 37 discerns whether or not the battery cell 35 is stabilized in order to ensure a stable charging operation.
[0112] In the charging operation of the non-contact power charging system A including the non-contact power transmission apparatus 10 and the non-contact power receiving apparatus 30 , as shown in FIGS. 18 and 19 , when the non-contact power receiving apparatus 30 moves on the charging plate of the non-contact power transmission apparatus 10 , the primary charge core 13 and the secondary charge core 32 are relocated, thereby dropping the receptibility of the power signal in the non-contact power receiving apparatus 30 . The location of the primary charge core 13 and the secondary charge core 32 becomes less efficient with the distance between the centers of the cores, such that induced electromotive force is rarely generated from the primary charge core 13 and the secondary charge core 32 .
[0113] Accordingly, in the non-contact power charging system A of the present invention, when the voltage of the power signal received in the non-contact power receiving apparatus 30 placed on the charging block drops below or rises above the reference voltage, a compensation request signal is transmitted to the non-contact power transmission apparatus 10 , requesting the non-contact power transmission apparatus 10 to transmit a compensated power signal.
[0114] For example, it is assumed that the reference voltage of the received power signal be 5V and a reference variation of the received voltage be +/−0.5V. As shown in FIG. 18 , when the non-contact power receiving apparatus 30 is moved from the central portion to the outer portion, a voltage lower than 4.5V is received. Then, the control of the device controller 390 of the non-contact power receiving apparatus control unit 39 controls to transmit a voltage step-up request signal, such that the voltage is stepped up about 0.5V. Here, the secondary charge core 32 is controlled through the signal processing block 392 to transmit the voltage step-up request signal.
[0115] Further, as shown in FIG. 19 , when the non-contact power receiving apparatus 30 is moved from the outer portion to the central portion, a voltage higher than 5.5V is received. Then, the control of the device controller 390 of the non-contact power receiving apparatus control unit 39 controls to transmit a voltage step-down request signal, such that the voltage is stepped down about 0.5V. Here, the secondary charge core 32 is controlled through the signal processing block 392 to transmit the voltage step-down request signal.
[0116] In response to the voltage step-up request signal or the voltage step-down request signal, the non-contact power transmission apparatus 10 transmits a compensated power signal, which is compensated for 0.5V. As an example of increasing the power signal transmitted from the non-contact power transmission apparatus 10 , it can be controlled to modify the oscillation frequency.
[0117] As such, the power signal transmitted from the non-contact power transmission apparatus 10 is adjusted according to the location of the non-contact power receiving apparatus 30 . The charging efficiencies according to the replacement are illustrated in the graphs of FIGS. 13 to 16 .
[0118] In the test reported in FIGS. 13 to 16 , the reference power in the secondary side of the non-contact power receiving apparatus 30 was on the order of 2.5 W. While the non-contact power receiving apparatus 30 was being moved horizontally and vertically moved on the charging plate of the non-contact power transmission apparatus 10 to a distance ranging from −7 mm to 7 mm, primary side power W at the non-contact power transmission apparatus 10 , secondary side power W at the non-contact power receiving apparatus 30 and the resultant efficiency (%) were measured and calculated. The efficiency (%) is produced by dividing the output power in the secondary side of the non-contact power receiving apparatus 30 with the input power in the primary side of the non-contact power transmission apparatus 10 as expressed in the formula:
[0000] efficiency (%)=(secondary side power)/(primary side power)*100.
[0119] In the meantime, FIGS. 11 to 14 illustrate graphs related with power compensation tests, in which transmission power compensation was 0.5 W, and the secondary side power in the non-contact power receiving apparatus was in the range from 2 to 2.5 W. Here, the charging efficiency in the non-contact power transmission apparatus was obtained by changing the horizontal and vertical distance between the non-contact power transmission apparatus and the non-contact power receiving apparatus. Particularly. FIGS. 11 and 12 illustrate cases in which power compensation according to frequency modification was not applied. Here, when the non-contact power receiving apparatus was moving horizontally or vertically with respect to the non-contact power transmission apparatus, the secondary side power of the non-contact power receiving apparatus decreased with the distance from the center, thereby lowering the charging efficiency.
[0120] Comparatively, FIG. 13 shows a graph resulting from horizontal movement and FIG. 14 shows a graph resulting from vertical movement in the non-contact charging system A of the present invention. Information on the voltage variation of the received power in the non-contact power receiving apparatus was transmitted when the non-contact power receiving apparatus 30 was moving horizontally or vertically on the top surface of the charging block 14 of the non-contact battery pack as an example of the non-contact power transmission apparatus 10 . In response to this information, the non-contact power transmission apparatus 10 controlled (compensates for) power through frequency modification. Referring to the efficiencies in the graphs, power transmission was stable and thus power transmission efficiency was also good.
[0121] FIG. 15 is an efficiency graph related with the horizontal movement, and FIG. 16 is an efficiency graph related with the vertical movement. Referring to FIGS. 15 and 16 , the charging efficiencies of compensated power transmission according to frequency modification (square-dotted profiles in the upper part, Power Control) were better than those without compensated power transmission according to frequency modification (circle-dotted profiles in the lower part, Fixed Power).
[0122] Accordingly, the non-contact power charging system A including the non-contact power transmission apparatus 10 and the non-contact power receiving apparatus can stably transmit power without contacts. The non-contact power transmission apparatus 10 and the non-contact power receiving apparatus 30 of the non-contact power charging system A can be used as a stable system.
[0123] When the user touches the non-contact power receiving apparatus 30 or the non-contact power transmission apparatus 10 shakes during the charging operation, the relative location of the primary charge core of the non-contact power transmission apparatus 10 and the secondary charge core of the non-contact power receiving apparatus 30 may be changed. However, the charging power compensation as described above makes it possible to charge the non-contact power receiving apparatus 30 with a stable voltage, such that the non-contact power receiving apparatus 30 can be charged in succession before being fully charged.
[0124] As shown in FIGS. 9 , 10 and 17 , the non-contact power receiving apparatus 30 of the present invention also includes a shield member, which protects the non-contact power receiving apparatus 30 and the battery cell 35 from a magnetic field generated by the primary charge core 13 of the non-contact power transmission apparatus 10 and the secondary charge core 32 of the non-contact power receiving apparatus 30 .
[0125] Firstly, FIG. 9 is an exploded perspective view illustrating the construction of the non-contact power receiving apparatus 30 having a wireless power receiver module. The non-contact power receiving apparatus 30 is made of a coil, fine metal, a thin sheet of aluminum (e.g., an aluminum foil), and lithium ion or lithium polymer includes Aluminum in order to shield a magnetic field 100%, so that the cell can be free from the influence of the magnetic field. As a result, the cell can be charged and discharged for a predetermined cycle of 500 times or more. Here, the secondary charge core can have any core shapes. That is, the shape of the secondary charge core can include a quadrangle, a circle and an ellipse, and can be implemented as various types of cores such as a wound core and a spiral core. Accordingly, the non-contact power receiving apparatus 30 having a wireless power receiver module includes a wireless power receiver circuit 40 on one lateral side of the rechargeable battery cell 35 and a shied member 41 surrounding the wireless power receiver circuit 40 . The wireless power receiver circuit 40 is constructed including some parts of the non-contact power receiving apparatus 30 , such as the power receiver control unit 39 and the charge IC block 36 .
[0126] Further, shielding plates 42 , 43 , 44 , 45 and 46 are provided on the bottom and four side surfaces of the battery cell 35 , respectively, to shield a magnetic field from the primary charge core and the secondary charge core 32 so as to protect the battery cell 35 from the magnetic field.
[0127] A total of five (5) shielding plates 42 to 46 is provided in total five directions including the four lateral directions and the downward direction of the battery cell 35 to completely shield the magnetic field from the primary charge core and the secondary charge core 32 so as to protect the battery cell 35 from being damaged by the magnetic field. Alternatively, a shielding plate can also be provided on the top surface of the rechargeable battery cell 35 if temperature rise due to the completely-enclosed structure of the battery cell 35 does not cause a trouble.
[0128] The shielding plates 42 to 46 and the shielding member 41 can be formed as a thin sheet of metal such as Al, Cu or Ni alloy.
[0129] Further, magnetic plates 48 are provided between the shielding plate 46 , which is placed under the battery cell 35 , and a charge receiver module 321 having the secondary charge core 32 . The magnetic plates 48 help the magnetic field be better induced to the secondary charge core 32 . The magnetic plates 48 may be constructed of amorphous ferrite, Mn—Zn (50 parts by weight: 50 parts by weight), Ni—Fe (80 parts by weight: 20 parts by weight), or fine metal (Fe—Si—Cu—Nb).
[0130] The magnetic plates 48 include an upper magnetic plate 481 , placed between the shielding plate 46 and the charge receiver module 321 , and a lower magnetic plate, placed under the charge receiver module 321 . The lower magnetic plate 482 is formed with a lower plate through-hole 483 , which extends vertically through the lower magnetic plate 482 , particularly, the central portion of the lower magnetic plate 482 . The shape of the lower plate through-hole 483 may preferably conform to that of the secondary charge core 32 . Accordingly,
[0131] FIG. 16 illustrates an example in which the lower plate through-hole 483 of the lower magnetic plate 482 was circular-shaped in order to conform to the circular shape of the secondary charge core 32 . Of course, when the core is quadrangular- or polygonal-shaped, the lower plate through-hole 483 may preferably be shaped in the same shape. The lower plate through-hole 483 configured as above helps induced electromotive force be better formed in the second charge core 32 in an induced magnetic field and signals be better transmitted.
[0132] An insulating plate 47 is further provided between the battery cell 35 and the shielding plate 46 below the battery cell 35 to insulate the battery cell 35 . The insulating plate 47 is implemented with a mesh member or a thin film of Ni—Cu so as to prevent the heat of the shielding plate 46 from being conducted to the battery cell 35 .
[0133] FIG. 10 shows another form of the magnetic field shielding member, which includes a battery cell case 35 ′ of aluminum encasing the battery cell 35 , a magnetic plate 48 of first Hanrim Postech electro-magnetic shield (HPES), which is placed between the battery cell case 35 ′ and the secondary charge core 32 , and a shielding mesh member 49 of second HPES, which is sandwiched between the magnetic plate 48 of first HPES and the battery cell case 35 ′. The magnetic plate 48 of first HPES and the shielding mesh member 49 of second HPES can have a composition the same as that of the above-described shielding member.
[0134] The magnetic plate 48 of first HPES shields a majority of magnetic field, such that magnetic lines of force are bent by the magnetic plate 48 acting as a shielding plate, and thereby do not influence on the battery cell (see FIG. 17 ). The magnetic lines of force generate heat in the top portion, and the heat is dissipated to the outside by the magnetic plate 48 made of metal. Further, the shielding mesh member 49 of second HPES is constructed with a mesh metal sheet coated with a coating agent composed of amorphous ferrite, Mn—Zn (50 parts by weight: 50 parts by weight), Ni—Fe (80 parts by weight: 20 parts by weight), or fine metal (Fe—Si—Cu—Nb). As such, the shielding mesh member 49 of second HPES serves to shield a remaining portion of the magnetic lines of force, which are not shielded by the magnetic plate 48 of first HPES. The mesh metal sheet of the shielding mesh member 49 of second HPES generate eddy current, which in turn protects the battery pack from the magnetic field generated by the primary charge core and the secondary charge core. According to tests, the magnetic plate 48 of first HPES shields about 90% and the shielding mesh member 49 shields about 10% of the magnetic field.
[0135] 500 times (500 cycles) of charging/discharging tests were performed on the non-contact power receiving apparatus 30 to which the magnetic plate 48 of first HPES and the shielding mesh member 49 of second HPES are applied. In FIG. 17 , the reference was that the battery and the charging system were not charged and discharged without contacts but were charged and discharged via wires. When 500 times of charging and discharging were stably repeated, an efficiency curve of about 80% was set as reference efficiency segment (D). In FIG. 17 , the graph shows the test results compared to the reference efficiency segment (D) of about 80%. Here, “N” indicates a resultant profile of a test using electrical contacts connected by wires without exposure to a magnetic field. The profile “N” of this test is positioned above the reference efficiency segment, thereby showing stable efficiency.
[0136] Comparably, in FIG. 17 indicates a profile of a test using the non-contact power receiving apparatus 30 of the invention, to which the magnetic plate 48 of first HPES, the shielding mesh member 49 and the like were applied. In this test profile, stable efficiency of 83.9% was observed at 500 times of charging and discharging.
[0137] However, when second HPES was not applied (i.e., in a profile indicated with “B” in FIG. 17 ), efficiency of 75.3% was observed at 460 times of charging and discharging. When neither first HPES nor second HPES was applied (i.e., in a profile indicated with “C” in FIG. 17 ), poor efficiency of 74.5% was observed at 340 times of charging and discharging, which fall short of the reference 500 times. It can be understood that the test of the invention has much better efficiency.
[0138] While the present invention has been described with reference to the particular illustrative embodiments and the accompanying drawings, it is not to be limited thereto. Accordingly, the foregoing embodiments can be suitably modified and altered, and such applications fall within the scope and spirit of the present invention that shall be defined by the appended claims.
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A non-contact power charging, in which power transmission can be interrupted when foreign materials are deposited on a charge plate of the non-contact power charging system. A charging operation can be continuously maintained at a stable voltage even if a non-contact power receiving apparatus moves by touching or displacement on the charge plate of the non-contact power charging system in the charging operation. Charging efficiency is improved.
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CROSS REFERENCE TO RELATED APPLICATION
[0001] This application is based upon and claims priority on U.S. Provisional Application No. 60/450,394, filed on Feb. 27, 2003, the contents of which are fully incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] This invention is directed to a frame and a seal and more specifically to a window assembly incorporating a window frame and seal and to a method for forming such frame and seal and assembly.
[0003] A window, such as an aircraft type of window, as for example shown in FIG. 1 a, is mounted on a frame 8 which may be an integral of the windshield or separate part of the structure of the vehicle, such as an aircraft. As shown in FIGS. 1A and 1B, an exemplary aircraft window 10 is a laminate structure and includes a main ply 12 which is typically made out of a polycarbonate, acrylic or glass. An interlayer 14 typically made of polyurethane or polyvinyl is bonded on an outer face of the main ply. A face ply 16 is bonded on top of the interlayer. The face ply is typically made of glass. A heater layer or coating 15 may be applied to the inner surface of the face ply allowing for the heating of the face ply for purposes of defrosting, and the prevention of ice build-up on the face ply.
[0004] The face ply does not extend to the ends of the main ply. As such, an end portion 18 of the main ply is not covered by the face ply and interlayer. This end portion is mated to the frame 8 . Typically, the end portion of the main ply is fastened to the window frame using fasteners 20 , or may simply clamp an end portion of a windshield.
[0005] The face ply is typically coated with Tin Oxide. The Tin Oxide coating is typically grounded to the frame 8 using a wire braid 21 .
[0006] When the main ply is mounted to the frame, a gap 22 is left between an end of the frame and the ends of the face ply and interlayer. This gap allows for expansion and contraction of the window, i.e., the main play, the face ply and interlayer. The gap is sealed with a sealant, typically a polysulfide sealant, which fills in the gap and extends over the face ply forming a hump seal 24 for preventing moisture from entering through the gap. Such moisture can cause delamination the window 10 . Typically, the hump seal extends a distance 26 about half an inch over the face ply.
[0007] By extending over the outer surface of the face ply, the hump seal is exposed to the outer environment, and is consequently susceptible to erosion, cracking and lifting which results in the intrusion of moisture into the laminate structure of the window 10 . As a result, the hump seal has to be frequently inspected and repaired to prevent window delamination and/or heater layer failure.
[0008] Another problem with a hump seal is that it is costly to manufacture in that it requires a specific amount of sealant of a specific thickness to extend a specific amount over the face ply. As a result, the process of forming and controlling a hump seal is very labor intensive. The hump seal can also fail due to the delamination of the edge of the face ply abutting the hump seal and/or the delamination of the hump seal from the face ply.
[0009] A further problem with conventional aircraft window assemblies is that with time the face ply separates, i.e., delaminates, from at its edge from the interlayer 14 , and/or the interlayer 14 and face ply delaminate from the main ply. This delamination also results in failure of the seal and is a frequent cause of aircraft window failures.
[0010] As such, a frame and seal system incorporated in a window assembly is desired that is more resistant to erosion, cracking and lifting and provides more resistance to face ply edge delamination and which is easier to manufacture.
SUMMARY OF THE INVENTION
[0011] A window assembly incorporating a window a frame and a seal and a method of forming the same are provided. In a first exemplary embodiment, a window assembly is provided. The assembly includes a window frame, a window transparency first ply coupled to the frame and extending beyond the frame, and a window transparency second ply coupled to the first ply. The second ply extends beyond the frame and is spaced apart from the frame defining a gap between the frame and the second ply. A portion of the frame extends over the second ply. A seal is placed, fitted or formed within the gap and between the second ply and the portion of the frame extending over the second ply. In another exemplary embodiment, a spacer is sandwiched between the frame and the first ply. In yet another exemplary embodiment, the frame portion extending over the second ply also extends over the gap and the thickness of the frame portion extending over the second ply and gap is less than the thickness of the frame not extending over the second ply and gap. In another exemplary embodiment, the portion of the frame extending over the second ply has a sufficient stiffness for preventing a portion of the second ply, over which extends the portion of the frame, from delaminating from the first ply. In another exemplary embodiment, the portion of the frame extending over the second ply provides a clamping force on the second ply.
[0012] In a further exemplary embodiment, a window assembly is provided having a window frame, a spacer coupled to the frame, a window transparency first ply coupled to the frame and extending beyond the frame, such that the spacer is sandwiched between the frame and first ply, and a window transparency second ply coupled to the first ply and extending beyond the spacer and being spaced apart from the spacer defining a gap between the spacer and the second ply, such that a portion of the frame extends over the second ply. A seal is placed, fitted or formed within the gap and between the second ply and the portion of the frame extending over the second ply. In yet another exemplary embodiment, the frame portion extending over the second ply also extends over the gap and the thickness of the frame portion extending over the second ply and gap is less than the thickness of the frame not extending over the second ply and gap.
[0013] In another exemplary embodiment a window assembly is provided having a window frame, a window transparency first ply coupled to the frame and extending beyond the frame, and a window transparency second ply coupled to the first ply and extending beyond the frame. The second ply is spaced apart from the frame defining a gap between the frame and the second ply. A supporting member is coupled to the frame and has a portion extending over the second ply, such that a portion of the frame is sandwiched between the supporting member and the first ply. A seal is placed, fitted or formed within the gap and between the second ply and the portion of the supporting member extending over the second ply. In yet another exemplary embodiment, the portion of the supporting member extending over the second ply extends over the gap and has a thickness that is less than a thickness of a portion of the supporting member not extending over the second ply and the gap.
[0014] In yet a further exemplary embodiment, a window assembly is provided having a window first structure, a window transparency first ply coupled to the first structure, a window transparency second ply coupled to the first ply and spaced apart from the first structure wherein a gap is defined between the second ply and the first structure. The assembly also includes a window second structure coupled to the first structure, such that a portion of the second structure extends beyond the first structure and over the second ply. A seal is located, fitted or formed within the gap and between the second ply and the portion of the second structure extending over the second ply. In another exemplary embodiment, the portion of the second structure extending over the second ply has a sufficient stiffness for preventing a portion of the second ply, over which extends the portion of the second structure, from delaminating from the first ply. In another exemplary embodiment, the portion of the second structure extending over the second ply provides a clamping force on the second ply.
[0015] In another exemplary embodiment a method of forming a window assembly is provided. The method includes providing a window frame, coupling a window transparency first ply to the frame such that a portion of the first ply extends beyond the frame, and coupling a window transparency second ply to the first ply at a location spaced apart from the frame, wherein a gap is defined between the second ply and the frame, and wherein a portion of the frame extends over the second ply. The method further requires providing a seal within the gap and between the second ply and the portion of the frame extending over the second ply.
[0016] In another exemplary embodiment the method further includes compressing the seal between the frame, the first ply and the second ply, and removing a portion of the seal extending beyond the frame. In a further exemplary embodiment, the providing a seal includes applying a sealing material to the gap and between the frame and the second ply and removing a portion of the sealing material extending beyond the frame. The sealing material may be selected from group of sealing materials consisting of silicones, polyurethanes, polysulfides, or other elastomeric materials.
[0017] In a further exemplary embodiment, the method includes selecting the thickness of the frame portion extending over the second ply to be sufficient for preventing a portion of the second ply over which extends the portion of the frame from delaminating from the first ply. In another exemplary embodiment the method includes providing a clamping force on the second ply with the portion of the frame extending over the second ply. In an exemplary embodiment, the clamping force provided is in reaction to an outward pressurization deflection of the first ply.
[0018] In yet a further exemplary embodiment, a method for forming a window assembly is provided including providing a window first structure, coupling a window transparency first ply to the first structure, coupling a window transparency second ply to the first ply at a location spaced apart from the first structure wherein a gap is defined between the second ply and the first structure, and providing a window second structure, wherein a portion of the second structure ply extends beyond the first structure and over the second ply. The method further includes providing a seal within the gap and between the second ply and the portion of the second structure extending over the second ply. In another exemplary embodiment, the method further requires removing excess seal extending beyond the second structure portion extending over the second ply. In a further exemplary embodiment, the method includes selecting the thickness of the second structure portion extending over the second ply to be sufficient for preventing a portion of the second ply over which extends the portion of the second structure from delaminating from the first ply. In another exemplary embodiment the method includes providing a clamping force on the second ply with the portion of the second structure extending over the second ply. In an exemplary embodiment, the clamping force provided is in reaction to an outward pressurization deflection of the first ply.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] [0019]FIG. 1A is a top view of a conventional aircraft window assembly.
[0020] [0020]FIG. 1B is a cross-sectional view of a conventional window assembly taken along arrows 1 B- 1 B shown in FIG. 1A.
[0021] [0021]FIG. 2 is a cross-sectional view of an exemplary embodiment window assembly of the present invention.
[0022] [0022]FIG. 3A is a cross-sectional view of another exemplary embodiment window assembly of the present invention.
[0023] [0023]FIG. 3B is a cross-sectional view of a further exemplary embodiment window assembly of the present invention.
[0024] [0024]FIG. 4 is a cross-sectional view of yet another exemplary embodiment window assembly of the present invention.
[0025] [0025]FIG. 5 is a cross-sectional view of another exemplary embodiment window assembly of the present invention.
[0026] [0026]FIG. 6 is a cross-sectional view of a further exemplary embodiment window assembly of the present invention.
[0027] [0027]FIG. 7 is a cross-sectional view of another exemplary embodiment window assembly of the present invention.
DETAILED DESCRIPTION
[0028] An exemplary embodiment window assembly of the present invention includes a frame having an overhang portion 30 that overhangs beyond the frame and over the face ply 16 at a distance 32 such that it extends a distance 26 from the edge of the face ply equal to the distance that the seal is required to extend over the face ply. In an exemplary embodiment the distance 26 is about half an inch.
[0029] For convenience, the same reference numerals are used to identify the same elements in the exemplary embodiments of the present invention as in the prior art. Moreover, the terms “over” and “under” are used herein as relative terms for descriptive purposes and not for denoting the exact location of the object they refer to.
[0030] In an exemplary embodiment shown in FIG. 2, the overhang portion 30 of the frame is formed by removing an end portion of the frame facing the main ply. This may be accomplished by many well known methods including machining. The overhang portion extends beyond a first end 36 of the frame 8 . A frame second end 38 is defined at the end overhang portion.
[0031] With this exemplary embodiment, a spacer 40 is used over the end portion 49 of the main ply 12 extending beyond the frame first end 36 . The spacer in an exemplary embodiment is made of plastic or a nylon laminate and has a thickness 41 between the main ply and the frame of about 0.15 inch. The main ply is mounted on the frame sandwiching the spacer against the frame. In the exemplary embodiment, the frame is fastened to the main ply with fasteners 20 that penetrates the frame, the spacer and the main ply.
[0032] When the main ply and spacer are mounted on the frame, the first end 36 of the frame is aligned with an end 42 of the spacer closer to the face ply. A gap 44 is defined between the end 42 of the spacer closer to the face ply and the face ply. In an exemplary embodiment, the gap has a width of about ¼ inch.
[0033] With this exemplary embodiment, a seal or a sealing material such as silicone, polyurethane, polysulfide or other elastomeric material or a dry seal of any such material is fitted into the gap and extends over the face ply for forming the seal 45 . When the main ply is mounted to the frame, such that the spacer is sandwiched between the main ply and the frame, the seal is fitted within the gap 44 and between the frame overhang portion 30 and the face ply 16 . If the seal is in a fluid form or in an elastomeric form, excess seal material may extend beyond the frame overhang portion as the frame overhang portion compresses the seal against the face ply. Since the frame overhang portion extends to the location 38 over the face ply to which the seal is required extend for proper sealing, the excess sealing material or seal extending beyond the overhang may be removed ensuring that the proper length of seal extends over the face ply. In this regard, the length and thickness of the seal extending over the face ply are easily obtained without having to measure or machine. In an exemplary embodiment, the thickness 47 of the seal hump portion 48 , i.e., the seal portion extending over the face ply between the face ply and the frame overhang is in the range 0.05 to 0.10 inch.
[0034] In a further exemplary embodiment, the spacer 40 may be of sufficient thickness spacing the frame from the main ply such that the frame can extend over the face ply 16 without the end of the frame having to be machined to define an overhang portion. With this embodiment, the seal will be fitted within the gap 44 and between the face ply and the frame portion extending over the face ply.
[0035] In another exemplary embodiment, if the face ply is coated with Tin Oxide, the seal 45 may be made from or include a conductive material for grounding the Tin Oxide coating of the frame. In an alternate exemplary embodiment, conductive material such as conductive silicone may be placed in appropriate locations for grounding the Tin Oxide coating. In this regard a wire braid is not required for grounding the Tin Oxide coating.
[0036] In a further alternate embodiment, instead of using a spacer, a thicker frame may be used. The frame 43 may just have a thicker portion 48 A or 48 B for interfacing with the main ply end portion 49 extending beyond the first end 36 of the frame as shown in FIGS. 3A and 3B, respectively, or the entire frame 50 may be thicker as for example shown in FIG. 4. As can be seen from FIGS. 3A and 3B, the thicker portion 48 A or 48 B of the frame may be formed by stepping outward the outer surface 53 of the frame as for example shown in FIG. 3B, or by stepping inward the inner surface 51 of the frame as shown for example in FIG. 3A.
[0037] In yet a further alternate embodiment, instead of a spacer, the main ply end portion 49 extending beyond the first end 36 of the frame may be made thicker by including an additional portion 52 , as for example shown in FIG. 5. With this embodiment, the frame may be formed by machining out a portion of the thicker frame defining a well 55 for accommodating the face ply 16 .
[0038] In another exemplary embodiment, the thickness of the spacer, if used, and the thickness of the frame overhang portion and main ply may be varied as necessary for obtaining a proper space between the overhang portion and the face ply for accommodating the seal. For example, the spacer may be made thinner thus requiring that the frame be thicker.
[0039] In an alternate exemplary embodiment, including any of the aforementioned exemplary embodiments, the seal with overhang portion or hump portion 48 is preformed and fitted into the gap such the hump portion extends over the face ply. The main ply is then mounted on the frame, sandwiching the spacer, if used, between the main ply and the frame, and the seal itself is compressed between the frame overhang portion and the face ply. Again with these embodiments, excess seal material extending beyond the face ply due to the compression, may be easily removed ensuring that the seal hump is at a desired length. Consequently, with either of these embodiments, the cost of manufacturing or forming the seal is reduced since one does not have to pre-form the seal hump to an exact length and/or thickness.
[0040] In yet a further exemplary embodiment, the frame may be formed without an overhang portion. With this embodiment, a separate supporting member 59 having a main body portion 60 and an overhang portion 62 may be coupled or otherwise attached to the frame. The overhang portion 62 may have a thinner thickness than an immediate adjacent portion 64 of the supporting member to accommodate the hump portion 48 of the seal as for example shown in FIG. 7. In alternate exemplary embodiments, the frame may be made thicker and/or a spacer may be incorporated between the frame and the main ply such that the thickness of the supporting member overhang portion 62 does not have to be less than its adjacent portion 64 for providing sufficient space between the face ply and the supporting member overhang portion for accommodating the seal hump portion. In the exemplary embodiment shown in FIG. 7, the supporting member is fastened to the frame with fasteners 20 . The supporting member may be a plate or other structure that spans the entire frame or portions of the frame.
[0041] With any of the aforementioned exemplary embodiments, the frame or supporting member overhang portion provides a force such as a clamping force for preventing the prying action of the face ply when the main ply is deflected outward toward the face ply due to aircraft pressurization and thus, preventing the delamination of the end of face ply from the interlayer and/or the delamination of the end of the face ply and interlayer from the main ply. Moreover, the frame or supporting member overhang portion prevents the seal from lifting. With any such exemplary embodiment, the thickness of the overhang portion should be chosen so that the overhang portion stiffness is sufficient for preventing the deflection and thus the delamination of the face ply from the interlayer or the delamination of the face ply and interlayer from the main ply.
[0042] With all of these embodiments, the frame overhang portion 30 or the supporting member overhang portion 62 protects the seal from exposure to the outer environment. Only an edge 54 of the seal is exposed to the outer environment. In this regard, seal erosion and cracking is minimized.
[0043] In yet another exemplary embodiment, the frame overhang portion 30 or the supporting member overhang portion includes a lip portion 58 extending from the end of the frame overhang portion and in a direction toward the face ply as for example shown in relation to the frame in FIG. 6. In this regard, a smaller portion of the edge 54 of the seal 45 is exposed to the outer environment, thus further protecting the seal from the consequences of such exposure.
[0044] With any of the aforementioned exemplary embodiments, the frame or supporting member overhang portion may not have to span the entire perimeter of a window. Rather, the overhang portion may be selectively used in areas that are most prone to face ply prying action and delamination, and/or most susceptible to seal erosion.
[0045] Although specific exemplary embodiments are disclosed herein, it is expected that persons skilled in the art can and will design or derive alternative window assemblies and/or methods of forming window assemblies that are within the scope of the following claims either literally or under the doctrine of equivalents.
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A window assembly incorporating a window frame and seal and a method of forming the same are provided. The window assembly includes a window transparency first ply coupled to a first window structure. A window transparency second ply is coupled to the first ply and is spaced apart from the first structure defining a gap there between. A portion of the first structure, or a second window structure coupled to the first structure, extends over the second ply. A seal is placed, fitted or formed within the gap and between the second ply and the portion of the first structure or the second structure extending over the second ply.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This patent application claims under 35 U.S.C. §119(a) the benefit of Korean Patent Application No. 10-2007-0130438 filed Dec. 13, 2007, the entire contents of which are incorporated herein by reference.
BACKGROUND
[0002] (a) Technical Field
[0003] The present invention relates to a non-woven web useful for the manufacture of suede-like fabric for a car seat cover and a preparation method thereof.
[0004] (b) Background Art
[0005] With the recent trends in well-being, in-vehicle comfort becomes more important. It is because people spend more time in a car than before, and they want to protect themselves from various environmental pollutions. For the reasons, public interest on sheet materials for car seats is increasing.
[0006] Natural leather, artificial leather and fabric are used as sheet materials for car seats. In mid- to low-price cars, sheets made of fabric are used more frequently than natural leather.
[0007] Conventional fabrics for car seats are mostly prepared from fibers based on polyethylene terephthalate (PET). With good crystallinity, PET is advantageous in fiber strength, but it is unfavorable in touch and dyeability. In order to solve this problem, there have been attempts to modify the fiber configuration, for example, by changing the yarn thickness. But, the result is unsatisfactory.
[0008] Recently, use of suede-like materials mimicking natural leather is increasing in car seats. Suede-like fabric is prepared from the process of spinning, preparing single fibers, forming web through interlocking of the single fibers, and polyurethane impregnation, raising and dyeing.
[0009] Conventionally, artificial fiber for such suede-like material has been prepared from polyethylene terephthalate polymer or a blend thereof with other polymers. But, because of differences in physical properties along the length and width directions, uneven shrinkage and deformation may occur under harsh conditions such as long riding. Accordingly, there has been a need for the development of an artificial fiber for suede-like materials having isotropic physical properties.
[0010] The above information disclosed in this Background section is only for enhancement of understanding of the background of the invention and therefore it may contain information that does not form the prior art that is already known in this country to a person of ordinary skill in the art.
SUMMARY OF THE DISCLOSURE
[0011] The inventors of the present invention have made various efforts to solve the aforesaid problems. As a result, they have found that a non-woven web prepared using a copolymer of PET and polytrimethylene terephthalate (PTT) as base resin has improved isotropic physical properties, touch and dyeability, since the anisotropic crystallinity and stiffness of the polyethylene terephthalate are compensated for by the elasticity provided by the PTT.
[0012] Accordingly, an object of the present invention is to provide a non-woven web having improved isotropic physical properties, touch and dyeability.
[0013] Another object of the present invention is to provide a preparation method of the non-woven web.
[0014] To attain the aforesaid objects, in one aspect, the present invention provides a non-woven web prepared by dispersing in water single fibers prepared from a copolymer of PET and PTT and crosslinking the same using flowing water.
[0015] In a preferred embodiment of the present invention, the copolymer comprises 30 to 45 weight % of PTT based on the total weight of the copolymer.
[0016] In another aspect, the present invention provides a preparation method of a non-woven web comprising the steps of: condensation polymerizing terephthalic acid, ethylene glycol and 1,3-propanediol to obtain a copolymer; spinning the copolymer to form monofilaments and cutting the same to obtain single fibers; adding the single fibers along with a surfactant in a bath filled with water and dispersing the same in water by stirring; discharging water from the resultant dispersion and adding a polyurethane binder; and subjecting the resultant mixture of single fibers and polyurethane binder to flowing water to crosslink the single fibers.
[0017] In a preferred embodiment of the present invention, the thickness of the monofilaments is from 0.1 to 1.0 denier.
[0018] In another preferred embodiment of the present invention, the length of the single fibers is from 1 to 15 mm.
[0019] In yet another preferred embodiment of the present invention, the surfactant is at least one selected from the group consisting of C 14 -C 20 higher alcohol polyoxyethylene ether, C 13 -C 18 alkylphenol polyoxyethylene ether, C 15 -C 20 fatty acid amine ethoxylate and C 13 -C 17 ethoxylated alkanoamide.
[0020] In still yet another preferred embodiment of the present invention, the dispersion comprises 0.1 to 1.0 g of single fibers per liter (L) of water.
[0021] In a further preferred embodiment of the present invention, the polyurethane binder is added in an amount of 20 to 50 weight % based on the total weight of the mixture.
[0022] In a still further preferred embodiment of the present invention, the polyurethane binder is a condensation copolymer of methylene isocyanate and propyldiethanolamine.
[0023] The non-woven web according to the present invention has superior mechanical properties including touch, dyeability, wear resistance, etc. suitable to be used as car seat cover material.
[0024] It is understood that the term “vehicle” or “vehicular” or other similar term as used herein is inclusive of motor vehicles in general such as passenger automobiles including sports utility vehicles (SUV), buses, trucks, various commercial vehicles, watercraft including a variety of boats and ships, aircraft, and the like.
[0025] The above and other features and advantages of the present invention will be apparent from or are set forth in more detail in the accompanying drawings, which are incorporated in and form a part of this specification, and the following Detailed Description, which together serve to explain by way of example of the principles of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] The above and other features of the present invention will now be described in detail with reference to certain exemplary embodiments thereof illustrated by the accompanying drawings which are given hereinbelow by way of illustration only, and thus are not limitative of the present invention, and wherein:
[0027] FIG. 1 shows the molecular structures of PET and PTT;
[0028] FIG. 2 illustrates the process of copolymerization of PET and PTT; and
[0029] FIG. 3 schematically illustrates a water flow providing apparatus that can be used in the present invention, wherein (a) and (c) are water jet spraying means and (b) represents interlocked single fibers.
DETAILED DESCRIPTION
[0030] Reference will now be made in detail to the preferred embodiments of the present invention, examples of which are illustrated in the drawings attached hereinafter.
[0031] The present invention provides a non-woven web prepared by dispersing in water single fibers prepared from a copolymer of PET and PTT and crosslinking the single fibers using flowing water.
[0032] PTT has a molecular structure similar to that of PET, but exhibits different properties because of difference in the number of methylene groups, and compensates for the drawbacks of PET. PET has dense crystalline structure provided by repeated methylene units in the molecule, which, while providing good strength, shows poor touch and dyeability and exhibits anisotropic tensile characteristics. That is, it has different tensile characteristics in the transverse and longitudinal directions. For this reason, products made of PET tend to shrink and fold anisotropically upon long-term use (see FIG. 1 ).
[0033] To solve this problem associated with the use of PET homopolymer, the present invention proposes the use of a copolymer of PET and PTT.
[0034] PTT is prepared by condensation polymerization of terephthalic acid (PTA) and 1,3-propanediol (1,3-PDO). The three repeating methylene units of 1,3-PDO reduce the crystallinity of the product. These methylene units result in a helical crystalline structure. Accordingly, PTT is highly elastic, and provides improved touch when raising is performed after the manufacture of fabrics.
[0035] Consequently, in the copolymer, the anisotropic physical properties of PET are compensated for by PTT.
[0036] In the copolymer according to the present invention, PTT is preferably comprised in an amount that can provide the compensation effect while maintaining other properties of PET. That is, PTT is preferably comprised in the copolymer in an amount from 30 to 45 weight %. When the content is below 30 weight %, the isotropic properties of the resultant non-woven web fabric may be deteriorated because of strong crystalline characteristics of PET. On the other hand, when the content exceeds 45 weight %, strength, wear resistance, etc., may be deteriorated.
[0037] In another aspect, the present invention further provides a preparation method of a non-woven web. The method comprises: condensation polymerizing terephthalic acid, ethylene glycol and 1,3-propanediol to obtain a copolymer; spinning the copolymer to form monofilaments and cutting the same to obtain single fibers; adding the single fibers along with a surfactant in a bath filled with water and dispersing the same in water by stirring; discharging water from the resultant dispersion and adding a polyurethane binder; and subjecting the resultant mixture of single fibers and polyurethane binder to flowing water to crosslink the single fibers.
[0038] In the condensation polymerization of terephthalic acid, ethylene glycol and 1,3-propanediol, terephthalic acid and ethylene glycol are condensed to give PET, and terephthalic acid and 1,3-propanediol are condensed to give PTT (see FIG. 2 ). The proportions of the reactants terephthalic acid, ethylene glycol and 1,3-propanediol are determined so that the PTT content of the resultant copolymer is from 30 to 45 weight %. Preferably, for example, 20 to 40 weight % of terephthalic acid, 30 to 50 weight % of ethylene glycol and 20 to 40 weight % of 1,3-propanediol may be used.
[0039] Further, the condensation polymerization may be performed under any known condition in the related art, but the present invention is not limited thereto.
[0040] Subsequently, the thus prepared copolymer of PET and PTT is spun to form monofilaments, which are cut to obtain single fibers.
[0041] The spinning of the copolymer to form monofilaments may be performed by any known method in the related art. Preferably, for example, melt spinning may be used.
[0042] Preferably, the monofilaments prepared by the spinning have a thickness from 0.1 to 1.0 denier, more preferably from 0.25 to 0.5 denier. When the thickness is smaller than 0.1 denier, mechanical properties may be deteriorated upon formation of the non-woven web. Meanwhile, when the thickness is greater than 1.0 denier, isotropic properties of the resultant non-woven web may be deteriorated.
[0043] Also, preferably, the single fibers obtained by cutting the monofilaments have a length from 1 to 15 mm, more preferably from 5 to 10 mm. When the single fibers are shorter than 1 mm, it is not easy to crosslink the single fibers by flowing water, thereby resulting in decreased productivity. By contrast, when they are longer than 15 mm, the single fibers may form clusters during crosslinking, thereby resulting in non-uniform dispersion and leading to anisotropic mechanical properties of the resultant non-woven web.
[0044] Subsequently, the prepared single fibers are added along with a surfactant in a bath filled with water and stirred to disperse the single fibers in water.
[0045] The surfactant is added to promote the dispersion of the single fibers in water. Preferably, a non-ionic surfactant is used. A non-ionic surfactant is dissolved in aqueous solution without being ionized. It has several polar groups in the molecule. Typically, it consists of a polar head comprising oxyethylene (—CH 2 CH 2 O—) or oxypropylene (—CH 2 CH(CH 3 )O—) repeating units and a non-polar tail. Preferred examples of the non-ionic surfactant include C 14 -C 20 higher alcohol polyoxyethylene ether, C 13 -C 18 alkylphenol polyoxyethylene ether, C 15 -C 20 fatty acid amine ethoxylate and C 13 -C 17 ethoxylated alkanoamide. In the present invention, at least one selected from the above-listed surfactants may be used. For example, C 13 -C 18 alkylphenol polyoxyethylene ether, alone or in combination with the other surfactant or surfactants may be used.
[0046] The amount of the single fibers to be added is preferably from 0.1 g/L to 1.0 g/L, more preferably from 0.2 g/L to 0.7 g/L, based on the volume of water. When the amount is less than 0.1 g/L, the industrial productivity will be deteriorated because of wasted water. In contrast, when the amount exceeds 1.0 g/L, the single fibers may not be dispersed uniformly, thus resulting in cluster formation and leading to anisotropic mechanical properties of the resultant non-woven web. Preferably, the stirring is performed sufficiently, so that the single fibers can be sufficiently dispersed in water. The present invention is not limited to specific conditions, including stirring speed or the like.
[0047] Subsequently, water is discharged from the resultant dispersion and a polyurethane binder is added. The polyurethane binder is added to prevent the single fibers from being blown away by the water flow during the crosslinking. Any known polyurethane binder in the related art may be used. Preferably, for example, a polyurethane obtained from the reaction of methylene isocyanate and propyldiethanolamine may be used.
[0048] Preferably, the polyurethane binder is added in an amount from 20 to 50 weight %, more preferably from 30 to 40 weight %, based on the total weight of the mixture. When single fibers are added less than 20 weight %, single fibers may be blown away by the strong water flow during the crosslinking. In contrast, when the single fibers are added more than 50 weight %, isotropic properties of the resultant web may be deteriorated.
[0049] Subsequently, the resultant mixture of single fibers and polyurethane binder is subjected to strong water flow to crosslink the single fibers. The crosslinking may be performed by providing strong water flow to the interlocked single fibers using a water flow providing apparatus. For example, the water flow providing apparatus may be a water jet, but the present invention is not limited thereto (see FIG. 3 ).
[0050] Thus prepared non-woven web provides improved isotropic tensile strength, touch, dyeability, and so forth over conventional PET homopolymer or a blend of PET with other polymer(s).
EXAMPLES
[0051] The following examples illustrate the present invention but they should not be construed as limiting the scope of the present invention.
Examples 1 and 2
[0052] Copolymers of PET and PTT were prepared (see Table 1) and melt spun using an extruder maintained at 260° C. to obtain monofilaments of about 0.4 denier. The monofilaments were cut to a size of 5 to 10 mm to obtain single fibers, which were dispersed in water by adding the single fibers in water at a proportion of about 0.5 g/L, using polyoxyethylene nonylphenol ether (KONION NP-2, Greensoft Chem, Korea) as surfactant, and sufficiently stirring. After discharging water, a polyurethane binder prepared from the reaction of methylene isocyanate and propyldiethanolamine was added in an amount of 35 weight % based on the total weight of the mixture. The resultant mixture of single fibers and polyurethane binder was subjected to physical crosslinking using water flow. Strong water flow was provided downwardly and upwardly to the interlocked single fibers using a water jet. Isotropic tensile properties, touch, dyeability, color fastness and wear resistance of the thus prepared non-woven webs were evaluated as described below. The evaluation result is given in Table 2.
Comparative Examples 1 and 2
[0053] Non-woven webs were prepared in the same manner as in Examples 1 and 2, except for using a PET homopolymer (Comparative Example 1) or a PTT homopolymer (Comparative Example 2). Evaluation of the non-woven webs was performed in the same manner as in Examples 1 and 2.
Comparative Examples 3 and 4
[0054] Non-woven webs were prepared in the same manner as in Examples 1 and 2, except for preparing the non-woven webs by needle punching. Evaluation was performed in the same manner as in Examples 1 and 2. Needle punching is one of the methods used to make a non-woven web. Through repeated punching using various needles, single fibers are entangled mechanically to give a non-woven fabric with constant thickness and fiber density.
Comparative Examples 5 and 6
[0055] Non-woven webs were prepared in the same manner as in Examples 1 and 2, except for using a blending composition of PET and PTT. Evaluation was performed in the same manner as in Examples 1 and 2.
[0000]
TABLE 1
Comp.
Comp.
Comp.
Comp.
Comp.
Comp. Ex.
Ex. 1
Ex. 2
Ex. 1
Ex. 2
Ex. 3
Ex. 4
Ex. 5
6
PET (wt %)
60
55
100
0
60
55
60
55
PTT (wt %)
40
45
0
100
40
45
40
45
Crosslinking
♯
♯
♯
♯
♯
♯
♯
♯
using water
flow
Needle
X
X
X
X
♯
♯
X
X
punching
Surfactant
♯
♯
♯
♯
X
X
♯
♯
Evaluation
[0056] (1) Tensile Strength
[0057] In order to identify isotropy of the tensile properties of the non-woven web, tensile strength was measured according to ASTM D368 while varying the direction at 0°, 30°, 60°, 90°, 120° and 150°. When the tensile strength varies a lot at different directions, the non-woven web has poor isotropy.
[0058] (2) Touch
[0059] Touch of the fabric prepared by processing the non-woven web, including elongation and dyeing, was evaluated by five experts. The experts touched the fabric with hands and evaluated as good or bad. Evaluation standards are as follows: superior=evaluated as good by 4 or more experts; moderate=evaluated as good by 3 experts; poor=evaluated as good by 2 or less experts.
[0060] (3) Dyeability (Color Fastness)
[0061] Color fastness measurement was made according to the following Korean Industrial Standards (KS).
[0062] Fastness to washing: KS K 0430-A2
[0063] Fastness to abrasion: KS K 0650
[0064] Fastness to light: KS K 0218
[0065] (4) Wear Resistance
[0066] Sample was taken from the prepared non-woven web and rubbed against abrasion wheel CS-10 1,000 revolutions at a load of 500 g. A higher point means that abrasion occurred less.
[0000]
TABLE 2
Comp.
Comp.
Comp.
Comp.
Comp.
Comp.
Category
Ex. 1
Ex. 2
Ex. 1
Ex. 2
Ex. 3
Ex. 4
Ex. 5
Ex. 6
Tensile
0.2 ± 0.05
0.2 ± 0.05
0.2 ± 0.1
0.2 ± 0.15
0.2 ± 0.1
0.2 ± 0.15
0.2 ± 0.2
0.2 ± 0.2
strength
(N/m 2 )
Touch 1)
♯
♯
Δ
Δ
Δ
Δ
X
X
Fastness to
4
4
4
3.5
4
3.5
3.5
3.5
washing
(Level)
Fastness to
4
4
4
4
4
4
3.5
3.5
abrasion
(Level)
Fastness to
4
4
3.5
3.5
3.5
3.5
3.5
3.5
light (Level)
Wear
5
5
5
5
5
5
5
2
resistance
(Level)
1) ♯: superior; Δ: moderate; X: poor
[0067] As shown in Table 2, the non-woven webs prepared according to the present invention (Examples 1 and 2) exhibited superior touch and dyeability and, particularly, significantly less variation of tensile strength at different directions, as compared with those of Comparative Examples 1 to 6.
[0068] A blending composition of PET and PTT is a physical mixture, in which the crystalline structures of PET and PTT are maintained. Accordingly, a non-woven web prepared from the blending composition exhibits anisotropic mechanical properties and is industrially less desirable. In contrast, a copolymer of polyethylene terephthalate and polytrimethylene terephthalate has polyethylene terephthalate and polytrimethylene terephthalate moieties in the same polymer. Accordingly, the properties thereof are compensated for and the resultant non-woven web has isotropic mechanical properties.
[0069] The invention has been described in detail with reference to preferred embodiments thereof. However, it will be appreciated by those skilled in the art that changes may be made in these embodiments without departing from the principles and spirit of the invention, the scope of which is defined in the appended claims and their equivalents.
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The present invention relates to a non-woven web useful for the manufacture of suede-like fabric for a car seat cover and a preparation method thereof. The non-woven web according to the present invention is prepared from a copolymer of polyethylene terephthalate and polytrimethylene terephthalate by dispersion in water using a surfactant and crosslinking using flowing water, and has superior mechanical properties including touch, dyeability, wear resistance, etc. Particularly, with superior isotropic mechanical properties over existing materials, it is suitable to be used as car seat cover material.
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BACKGROUND OF THE INVENTION
[0001] This invention relates to systems and methods for removing unwanted elements from a gas stream. The new system and method treats a biogas stream that may be produced at facilities such as a municipal wastewater treatment plants that have methane gas as well as other gases such as hydrogen sulfide H 2 S, carbon dioxide CO 2 and other trace gases like siloxanes.
[0002] Use of gas produced in wastewater treatment facilities has long been a challenge because of the mixture of gases in the biogas produced during treatment. Of particular interest have been natural gases such as methane that can be recycled or used in cogeneration equipment or as a vehicle fuel as a cost efficiency and for reduction in greenhouse gas generation. The burning or combustion of methane that may be contaminated with other gases such as carbon dioxide and hydrogen sulfide has been increasingly regulated by air quality control regulations. In some areas even the hydrogen sulfide must be removed from biogas produced during water treatment before the gas can be flared or burned.
[0003] Current water treatment processes and methods may normally react biogas with iron in iron sponge scrubbers to clean the gas. There are various commercially available methods of iron scrubbing processes; however, they rely on adsorption and reaction of the sulfide into an iron matrix. The matrix is regenerated by oxidation of the iron to ferric oxide and oxidation of the sulfide to elemental sulfur or sulfates. Discharge of effluents is back to the head of the treatment plant.
[0004] A more efficient method is required for biogas produced in wastewater treatment in order to realize the benefit of use of combustible gas for cogeneration use in treatment facilities. The beneficial use of biogas generated in wastewater treatment depends on the cost to separate a gas such as methane from the other gases present in order to obtain a high energy gas stream similar to commercial gas.
SUMMARY OF THE INVENTION
[0005] The present invention is directed to systems and methods for removing unwanted elements from a gas stream. A biogas stream may be combined with a water stream influent in a venturi device to produce a gas-water mixture effluent. The gas-water mixture effluent is processed in a degas separator to separate and produce a relatively low solubility gas effluent and a relatively high solubility gas-water mixture effluent. The relatively high solubility gas-water mixture effluent is processed through a discharge pressure control valve based on a selected pressure to be maintained in said degas separator and then discharged or reused.
[0006] These and other features, aspects and advantages of the present invention will become better understood with reference to the following drawings, description and claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] FIG. 1 illustrates a functional diagram of a gas scrubbing process according to an embodiment of the invention;
[0008] FIG. 2 illustrates a functional diagram of a gas scrubbing process with a gas-water recycle process according to an embodiment of the invention.
DETAILED DESCRIPTION
[0009] The following detailed description represents the best currently contemplated modes for carrying out the invention. The description is not to be taken in a limiting sense, but is made merely for the purpose of illustrating the general principles of the invention.
[0010] Referring to FIG. 1 , a gas scrubbing process 10 receives a biogas 20 from a wastewater treatment system 50 . The wastewater treatment system 50 may also serve as the source of a steady supply of water influent 22 that may be under high pressure from the treatment wash water or plant water system. This availability of water at water treatment plants is an asset that can be used to produce combustible gas such as methane gas using an efficient method as compared to existing processes.
[0011] The gas scrubbing process 10 may mix the biogas 20 in the water influent 22 in a venturi device 30 . The gas-water mixture 24 produced may be communicated to a degas separator 32 to separate low solubility gas 26 such as methane gas from the gas-water mixture 24 . The degas separator 32 may produce low solubility gas 26 that is controlled at a gas-water separation device 34 such as a gas pressure release valve, and may discharge a high solubility gas-water mixture 28 to be communicated to a drain 38 through a discharge pressure control valve 36 .
[0012] Referring to FIG. 2 , the gas scrubbing process 10 may also include a gas-water return recycle process. The discharged high solubility gas-water mixture 28 may be communicated to a water return vessel 40 . Purge overflow gas-water may be discharged to the drain 38 and the recycle high solubility gas-water mixture 46 may be returned through a pump 42 to the venturi device 30 . In this gas scrubbing process 10 , makeup water 44 may be introduced into the water return vessel 40 rather than supply water influent 22 being an influent directly into the venturi device 30 .
[0013] The operation of the gas scrubbing system 10 separates methane gas from other gases present in gas produced from anaerobic decomposition of organic matter. The biogas 20 is introduced with pressurized water 22 in the venturi device 30 and the mixed gas-water flow is maintained in the system 10 by a pressure control valve 36 at approximately 1 to 250 psi. The biogas 20 may be urged into the venturi device 30 by the vacuum caused by the water 22 pressurized flow through the venturi device 30 or by biogas pressure flow of approximately −2 to +50 psi into the throat or constriction of the venturi device 30 . The water may be pressurized to feed the venturi device 30 at pressures of approximately 10 to 500 psi. The merging of the biogas and water flow causes the relatively high soluble gases, for example, carbon dioxide, hydrogen sulfide and siloxanes, to be dissolved in the water while the methane and other relatively lower soluble gases may be maintained in gas or undissolved form. In experiments it was found the water pressure should be at least 20 psi and the system 10 operated effectively at 30 to 40 psi of water pressure. A water pressure above 250 to 500 psi caused increasing loss of methane gas to the gas-water mixture. The discharge pressure control valve 36 should be operated at as low a discharge pressure as is effective to scrub methane gas. The valve 36 sets the operating pressure of the system 10 .
[0014] The gas-water mixture 24 is communicated to a degassing separator vessel 32 for separation of the biogas lower solubility gas, for example, methane, from the gas-water mixture 24 to be conveyed to a gas-water separation device 34 that may be a pressure release valve that allows scrubbed gas to exit the system 10 . The high solubility gas-water mixture 28 is conveyed to a discharge pressure control valve 36 or backpressure regulator that allows pressure release of the high solubility gas-water mixture 28 to a drain 38 or a water return vessel 40 for recycling.
[0015] The water return vessel 40 may have an overflow drain 38 . A portion of the high solubility gas-water mixture 28 may be returned. The high solubility gas-water mixture 28 return rates may be between 1 and 100 percent of the water needed for operation of the venturi device 30 . The water influent 22 may be between 1 and 100 percent of the water needed for venturi device 30 operation. A percentage of the two water sources may be merged to produce the total water influent for system 10 operation. There may also be make-up water 44 influent to the water return vessel 40 to maintain proper water flow and pressure conditions in the system 10 .
Example
[0016] The following experimental example illustrates the use of the method and system when practicing the invention. A pilot plant size, one inch, venturi injector was connected to a degas separator and the gas effluent was controlled by a discharge pressure control valve. The high solubility gas-water mixed effluent was controlled by a discharge backpressure regulator and drained to a wastewater aeration basin. The pilot system was installed at operating wastewater treatment facilities as an alternative to flaring the acid phase gas. The following Table 1 illustrates the industry standard valves for biogas and the range and composition of the biogas tested.
[0000]
TABLE 1
Component
Typical
Observed
Methane (by deduction)
55-65%
30 1 ; 50-65%
Carbon Dioxide
35-45%
68 1 ; 32-39%
Hydrogen Sulfide
1,500 ppm
7,000 1 ; 150-8,000 ppm
Water
Saturated at 95° F.
Saturated at 95° F.
Pressure
2-12 in W.C. 2
3-7 in W.C. 2
Note:
1 Acid phase gas sample:
2 Units inches of water column
[0017] The Table 1 illustrates the differences in observed gas quality between published textbook values and the actual gas composition that was measured.
[0018] The pilot system demonstration was based on the differential solubility of the hydrogen sulfide and carbon dioxide to methane. Table 2 below illustrates the solubility differences for the three gases in water.
[0000]
TABLE 2
Compound
Solubility 1
Difference
Methane
4.11
N/A
Carbon Dioxide
300.27
730%
Hydrogen Sulfide
256.01
640%
Note:
1 Units are ft 3 gas/1,000 Gallons of water.
[0019] The pressurized water source was the wastewater treatment plant wash water/plant water system as the influent to the venturi device injector inlet and the biogas was that produced at the treatment plant in an anaerobic process with the biogas influent connected to the vacuum or suction port of the venturi device. The gas-water mixture effluent of the venturi device was then processed through the degas separator for the cleaned gas, primarily methane, to be collected at the top of the degas separator at a pressure release valve, and for the high solubility gas-water mixture, primarily carbon dioxide and hydrogen sulfide in water, to be drained through a discharge pressure control valve to a drain to aeration basins of the waste treatment plant. In the experiments the pressure of the high solubility gas-water mixture 28 after the discharge pressure control valve 36 was less than 5 psi. The degas separator used was a centrifugal vortex structure that separates entrained gases from a liquid based on density differences between the gases and the liquid. Table 3 below illustrates results obtained from the pilot system testing.
[0000]
TABLE 3
Component
Inlet
Outlet
Methane (by deduction)
30 1 ; 50-65%
95-98%
Carbon Dioxide
68 1 ; 32-39%
<2%
Hydrogen Sulfide
7,000 1 ; 150-8,000
<3 ppm
Water
Saturated at 95° F.
Saturated at 65° F. 2
Pressure
3-7 in. W.C.
1.5 psig
Note:
1 Acid phase gas sample:
2 Water cools gas removing moisture.
[0020] Methane has limited solubility in water; therefore, a mass balance was determined to identify the amount of methane that might be lost to the water in this process. Based on the solubility of methane presented in Table 2, less than 1.8 percent of the methane in the biogas treated by the system should be lost to the water. This should make the system 98.2 percent efficient in methane recovery. A full size gas scrubbing system for a typical wastewater treatment plant that may be capable of treating 50 scfm of acid phase biogas may require a four inch venturi injector and 350 gpm of water.
[0021] While the invention has been particularly shown and described with respect to the illustrated embodiments thereof, it will be understood by those skilled in the art that the foregoing and other changes in form and details may be made therein without departing from the spirit and scope of the invention.
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A system and method for removing unwanted elements from a gas stream. A biogas stream may be combined with a water stream influent in a venturi device to produce a gas-water mixture effluent. The gas-water mixture effluent is processed in a degas separator to separate and produce a relatively low solubility gas effluent and a relatively high solubility gas-water mixture effluent. The relatively high solubility gas-water mixture effluent is processed through a discharge pressure control valve based on a selected pressure to be maintained in said degas separator and then discharged or reused.
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RELATED APPLICATIONS
[0001] This application is a Divisional of Application of: Choong-Chin Liew, Filed: Mar. 12, 2004, Ser. No.: Not Yet Assigned, Entitled: A Method for the Detection of Coronary Artery Disease Related Gene Transcripts in Blood, Our Reference No.: 4231/2055B, which a continuation in part of application Ser. No. 10/601,518, filed on Jun. 20, 2003, which is a continuation-in-part of application Ser. No. 10/085,783, filed on Feb. 28, 2002, which claims the benefit of U.S. Provisional Application No. 60/271,955, filed on Feb. 28, 2001, U.S. Provisional Application No. 60/275,017 filed Mar. 12, 2001, and U.S. Provisional Application No. 60/305,340; filed Jul. 13 2001, and is also a continuation-in-part of application Ser. No. 10/268,730 filed on Oct. 9, 2002, which is a continuation of U.S. application Ser. No. 09/477,148 filed Jan. 4, 2000, now abandoned, which claims the benefit of U.S. Provisional Application No. 60/115,125 filed on Jan. 6, 1999. Each of these applications is incorporated herein by reference in their entirety, including figures and drawings.
TABLES
[0002] This application includes a compact disc in duplicate (2 compact discs: Tables—Copy 1 and Tables—Copy 2), which are hereby incorporated by reference in their entirety. Each compact disc is identical and contains the following files (corresponding to Tables 2-4):
TABLE DESCRIPTION SIZE CREATED Text File Name 1 2 multi-gene comparison 371,563 Mar. 25, 2004 TABLE2.TXT 2 3A GLF 8 - hypertension 138,940 Mar. 28, 2004 TABLE3A.TXT 3 3AA GLF 29 - asthma 36,121 Mar. 27, 2004 TABLE3AA.TXT 4 3AB multi OA 29,898 Mar. 27, 2004 TABLE3AB.TXT 5 3AC GL MDS vs. schizo 114,078 Mar. 27, 2004 TABLE3AC.TXT 6 3AD steroid differential 64,646 Mar. 27, 2004 TABLE3AD.TXT 7 3B GLF 9 - obesity 147,421 Mar. 25, 2004 TABLE3B.TXT 8 3C GLF 10 - allergies 95,700 Mar. 25, 2004 TABLE3C.TXT 9 3D GLF 11 - steroids 93,808 Mar. 25, 2004 TABLE3D.TXT 10 3E GLF 12 - hypertension 314,854 Mar. 25, 2004 TABLE3E.TXT 11 3F GLF 13 - obesity 181,310 Mar. 25, 2004 TABLE3F.TXT 12 3G GLF 14 - diabetes 146,212 Mar. 26, 2004 TABLE3G.TXT 13 3H GLF 15 - hyperlipidemia 165,909 Mar. 26, 2004 TABLE3H.TXT 14 3I GLF 16 - lung 92,936 Mar. 25, 2004 TABLE3I.TXT 15 3J GLF 17 - bladder 1,143,423 Mar. 26, 2004 TABLE3J.TXT 16 3K GLF 18 - bladder 953,119 Mar. 26, 2004 TABLE3K.TXT 17 3L GLF 19 - Coronary Art Dis. 246,178 Mar. 26, 2004 TABLE3L.TXT 18 3M GLF 20 - rheumarth 329,672 Mar. 26, 2004 TABLE3M.TXT 19 3N GLF 21 - depression 153,108 Mar. 26, 2004 TABLE3N.TXT 20 3O GLF 22 - rheumarth 49,043 Mar. 26, 2004 TABLE3O.TXT 21 3P GLF hypertension 577 only 84,945 Mar. 26, 2004 TABLE3P.TXT 22 3Q GLF OA hypertension shared 33,081 Mar. 26, 2004 TABLE3Q.TXT 23 3R GL obesity 519 79,544 Mar. 26, 2004 TABLE3R.TXT 24 3S GL obesity shared 152 24,583 Mar. 26, 2004 TABLE3S.TXT 25 3T GL allergy specific 39,547 Mar. 25, 2004 TABLE3T.TXT 26 3U GL allergy OA shared 241 35,603 Mar. 25, 2004 TABLE3U.TXT 27 3V GL steroid 362 54,954 Mar. 26, 2004 TABLE3V.TXT 28 3W GL OA steroid shared 31,459 Mar. 27, 2004 TABLE3W.TXT 29 3X GLF 26 - liver cancer 435,093 Mar. 27, 2004 TABLE3X.TXT 30 3Y GLF 27 - schizophrenia 578,949 Mar. 26, 2004 TABLE3Y.TXT 31 3Z GLF 28 - chagas 202,477 Mar. 28, 2004 TABLE3Z.TXT 32 4 sequence listing 114,765 Mar. 11, 2004 TABLE4.TXT
BACKGROUND
[0003] The blood is a vital part of the human circulatory system for the human body. Numerous cell types make up the blood tissue including monocytes, leukocytes, lymphocytes and erythrocytes. Although many blood cell types have been described, there are likely many as yet undiscovered cell types in the human blood. Some of these undiscovered cells may exist transiently, such as those derived from tissues and organs that are constantly interacting with the circulating blood in health and disease. Thus, the blood can provide an immediate picture of what is happening in the human body at any given time.
[0004] The turnover of cells in the hematopoietic system is enormous. It was reported that over one trillion cells, including 200 billion erythrocytes and 70 billion neutrophilic leukocytes, turn over each day in the human body (Ogawa 1993). As a consequence of continuous interactions between the blood and the body, genetic changes that occur within the cells or tissues of the body will trigger specific changes in gene expression within blood. It is the goal of the present invention that these genetic alterations be harnessed for diagnostic and prognostic purposes, which may lead to the development of therapeutics for ameliorating disease.
[0005] For example, isoformic myosin heavy chain genes are known to be generally expressed in cardiac muscle tissue. In the rodent, the βMyHC gene is only highly expressed in the fetus and in diseased states such as overt cardiac hypertrophy, heart failure and diabetes; the αMyHC gene is highly expressed shortly after birth and continues to be expressed in the adult heart. In the human, however, βMyHC is highly expressed in the ventricles from the fetal stage through adulthood. This highly expressed βMyHC, which harbours several mutations, has been demonstrated to be involved in familial hypertrophic cardiomyopathy (Geisterfer-Lowrance et al. 1990). It was reported that mutations of βMyHC can be detected by PCR using blood lymphocyte DNA (Ferrie et al., 1992). Most recently, it was also demonstrated that mutations of the myosin-binding protein C in familial hypertrophic cardiomyopathy can be detected in the DNA extracted from lymphocytes (Niimura et al., 1998).
[0006] Similarly, APP and APC, which are known to be tissue specific and predominantly expressed in the brain and intestinal tract, are also detectable in the transcripts of blood. These cell- or tissue-specific transcripts are not detectable by Northern blot analysis. However, the low number of transcript copies can be detected by RT-PCR analysis. These findings strongly demonstrate that genes preferentially expressed in specific tissues can be detected by a highly sensitive RT-PCR assay. In recent years, evidence has been obtained to indicate that expression of cell or tissue-restricted genes can be detected in the certain peripheral nucleated blood cells of patients with metastatic transitional cell carcinoma (Yuasa et al. 1998) and patients with prostate cancer (Gala et al. 1998).
[0007] In the prior art, there is a need for large samples and/or costly and time-consuming separation of cell types within the blood (Kimoto (1998) and Chelly et al. (1989; 1988)). The prior art, however, is deficient in non-invasive methods of screening for tissue-specific diseases. The present invention fulfills this long-standing need and desire in the art.
SUMMARY OF THE INVENTION
[0008] The present invention relates generally to the molecular biology of human diseases. More specifically, the present invention relates to a process using the genetic information contained in human peripheral whole blood for the diagnosis, prognosis and monitoring of genetic and infectious disease in the human body.
[0009] This present invention discloses a process of using the genetic information contained in human peripheral whole blood in the diagnosis, prognosis and monitoring of genetic and infectious disease in the human body. The process described herein requires a simple blood sample and is, therefore, non-invasive compared to conventional practices used to detect tissue specific disease, such as biopsies.
[0010] The invention is based on the discovery that gene expression in the blood is reflective of body state and, as such, the resultant disruption of homeostasis under conditions of disease can be detected through analysis of transcripts differentially expressed in the blood alone. Thus, the identification of several key transcripts or genetic markers in blood will provide information about the genetic state of the cells, tissues, organ systems of the human body in health and disease.
[0011] The present invention demonstrates that a simple drop of blood may be used to determine the quantitative expression of various mRNAs that reflect the health/disease state of the subject through the use of RT-PCR analysis. This entire process takes about three hours or less. The single drop of blood may also be used for multiple RT-PCR analyses. It is believed that the present finding can potentially revolutionize the way that diseases are detected, diagnosed and monitored because it provides a non-invasive, simple, highly sensitive and quick screening for tissue-specific transcripts. The transcripts detected in whole blood have potential as prognostic or diagnostic markers of disease, as they reflect disturbances in homeostasis in the human body. Delineation of the sequences and/or quantitation of the expression levels of these marker genes by RT-PCR will allow for an immediate and accurate diagnostic/prognostic test for disease or to assess the efficacy and monitor a particular therapeutic.
[0012] One object of the present invention is to provide a non-invasive method for the diagnosis, prognosis and monitoring of genetic and infectious disease in humans and animals.
[0013] In one embodiment of the present invention, there is provided a method for detecting expression of a gene in blood from a subject, comprising the steps of: a) quantifying RNA from a subject blood sample; and b) detecting expression of the gene in the quantified RNA, wherein the expression of the gene in quantified RNA indicates the expression of the gene in the subject blood. An example of the quantifying method is by mass spectrometry.
[0014] In another embodiment of the present invention, there is provided a method for detecting expression of one or more genes in blood from a subject, comprising the steps of: a) obtaining a subject blood sample; b) extracting RNA from the blood sample; c) amplifying the RNA; d) generating expressed sequence tags (ESTs) from the amplified RNA product; and e) detecting expression of the genes in the ESTs, wherein the expression of the genes in the ESTs indicates the expression of the genes in the subject blood. Preferably, the subject is a fetus, an embryo, a child, an adult or a non-human animal. The genes are non-cancer-associated and tissue-specific genes. Still preferably, the amplification is performed by RT-PCR using random sequence primers or gene-specific primers.
[0015] In still another embodiment of the present invention, there is provided a method for detecting expression of one or more genes in blood from a subject, comprising the steps of: a) obtaining a subject blood sample; b) extracting DNA fragments from the blood sample; c) amplifying the DNA fragments; and d) detecting expression of the genes in the amplified DNA product, wherein the expression of the genes in the amplified DNA product indicates the expression of the genes in the subject blood.
[0016] In yet another embodiment of the present invention, there is provided a method for monitoring a course of a therapeutic treatment in an individual, comprising the steps of: a) obtaining a blood sample from the individual; b) extracting RNA from the blood sample; c) amplifying the RNA; d) generating expressed sequence tags (ESTs) from the amplified RNA product; e) detecting expression of genes in the ESTs, wherein the expression of the genes is associated with the effect of the therapeutic treatment; and f) repeating steps a)-e), wherein the course of the therapeutic treatment is monitored by detecting the change of expression of the genes in the ESTs. Such a method may also be used for monitoring the onset of overt symptoms of a disease, wherein the expression of the genes is associated with the onset of the symptoms. Preferably, the amplification is performed by RT-PCR, and the change of the expression of the genes in the ESTs is monitored by sequencing the ESTs and comparing the resulting sequences at various time points; or by performing single nucleotide polymorphism analysis and detecting the variation of a single nucleotide in the ESTs at various time points.
[0017] In still yet another embodiment of the present invention, there is provided a method for diagnosing a disease in a test subject, comprising the steps of: a) generating a cDNA library for the disease from a whole blood sample from a normal subject; b) generating expressed sequence tag (EST) profile from the normal subject cDNA library; c) generating a cDNA library for the disease from a whole blood sample from a test subject; d) generating EST profile from the test subject cDNA library; and e) comparing the test subject EST profile to the normal subject EST profile, wherein if the test subject EST profile differs from the normal subject EST profile, the test subject might be diagnosed with the disease.
[0018] In still yet another embodiment of the present invention, there is provided a kit for diagnosing, prognosing or predicting a disease, comprising: a) gene-specific primers; wherein the primers are designed in such a way that their sequences contain the opposing ends of two adjacent exons for the specific gene with the intron sequence excluded; and b) a carrier, wherein the carrier immobilizes the primer(s). Preferably, the gene-specific primers are selected from the group consisting of insulin-specific primers, atrial natriuretic factor-specific primers, zinc finger protein gene-specific primers, beta-myosin heavy chain gene-specific primers, amyloid precursor protein gene-specific primers, and adenomatous polyposis-coli protein gene-specific primers. Further preferably, the gene-specific primers are selected from the group consisting of SEQ ID Nos. 1 and 2; and SEQ ID Nos. 5 and 6. Such a kit may be applied to a test subject whole blood sample to diagnose, prognose or predict a disease by detecting the quantitative expression levels of specific genes associated with the disease in the test subject and then comparing to the levels of same genes expressed in a normal subject. Such a kit may also be used for monitoring a course of therapeutic treatment or monitoring the onset of overt symptoms of a disease.
[0019] In yet another embodiment of the present invention, there is provided a kit for diagnosing, prognosing or predicting a disease, comprising: a) probes derived from a whole blood sample for a specific disease; and b) a carrier, wherein the carrier immobilizes the probes. Such a kit may be applied to a test subject whole blood sample to diagnose, prognose or predict a disease by detecting the quantitative expression levels of specific genes associated with the disease in the test subject and then comparing to the levels of same genes expressed in a normal subject. Such a kit may also be used for monitoring a course of therapeutic treatment or monitoring the onset of overt symptoms of a disease.
[0020] Furthermore, the present invention provides a cDNA library specific for a disease, wherein the cDNA library is generated from whole blood samples.
[0021] In one embodiment of the present invention, there is a method of identifying one or more genetic markers for a disease, wherein each of said one or more genetic markers corresponds to a gene transcript, comprising the steps of: a) determining the level of one or more gene transcripts expressed in blood obtained from one or more individuals having a disease, wherein each of said one or more transcripts is expressed by a gene that is a candidate marker for disease; and b) comparing the level of each of said one or more gene transcripts from said step a) with the level of each of said one or more genes transcripts in blood obtained from one or more individuals not having a disease, wherein those compared transcripts which display differing levels in the comparison of step b) are identified as being genetic markers for a disease.
[0022] In another embodiment of the present invention, there is a method of identifying one or more genetic markers for a disease, wherein each of said one or more genetic markers corresponds to a gene transcript, comprising the steps of: a) determining the level of one or more gene transcripts expressed in blood obtained from one or more individuals having a disease, wherein each of said one or more transcripts is expressed by a gene that is a candidate marker for a disease; and b)comparing the level of each of said one or more gene transcripts from said step a) with the level of each of said one or more genes transcripts in blood obtained from one or more individuals having a disease, wherein those compared transcripts which display the same levels in the comparison of step b) are identified as being genetic markers for a disease.
[0023] In another embodiment of the present invention, there is a method of identifying one or more genetic markers of a stage of a disease progression or regression, wherein each of said one or more genetic markers corresponds to a gene transcript, comprising the steps of: a) determining the level of one or more gene transcripts expressed in blood obtained from one or more individuals having a stage of a disease, wherein said one or more individuals are at the same progressive or regressive stage of a disease, and wherein each of said one or more transcripts is expressed by a gene that is a candidate marker for determining the stage of progression or regression of a disease, and; b) comparing the level of each of said one or more gene transcripts from said step a) with the level of each of said one or more genes transcripts in blood obtained from one or more individuals who are at a progressive or regressive stage of a disease distinct from that of said one or more individuals of step a), wherein those compared transcripts which display differing levels in the comparison of step b) are identified as being genetic markers for the stage of progression or regression of a disease.
[0024] In another embodiment of the present invention, there is a method of identifying one or more genetic markers of a stage of a disease progression or regression, wherein each of said one or more genetic markers corresponds to a gene transcript, comprising the steps of: a) determining the level of one or more gene transcripts expressed in blood obtained from one or more individuals having a stage of a disease, wherein said one or more individuals are at the same progressive or regressive stage of a disease, and wherein each of said one or more transcripts is expressed by a gene that is a candidate marker for determining the stage of progression or regression of a disease, and b) comparing the level of each of said one or more gene transcripts from said step a) with the level of each of said one or more genes transcripts in blood obtained from one or more individuals who are at a progressive or regressive stage of a disease identical to that of said one or more individuals of step a), wherein those compared transcripts which display the same levels in the comparison of step b) are identified as being genetic markers for the stage of progression or regression of a disease.
[0025] Further embodiments of the methods described in the previous four paragraphs include the embodiments wherein each of said one or more markers identifies one or more transcripts of one or more non immune response genes, wherein each of said one or more markers identifies a transcript of a gene expressed by non-blood tissue, wherein each of said one or more markers identifies a transcript of a gene expressed by non-lymphoid tissue, wherein said one or more markers identifies a sequence selected from the sequences listed in any one of Table 3A-Z and Tables 3AA, 3AB, 3AC and 3AD, wherein said one or more markers identifies the sequence of one or more of the sequences selected from the group consisting of ANF, ZFP and βMyHC, wherein said blood comprises a blood sample obtained from said one or more individuals, wherein said blood sample consists of whole blood, wherein said blood sample consists of a drop of blood, and wherein said blood sample consists of blood that has been lysed.
[0026] In another embodiment of the present invention, there is a method of diagnosing or prognosing a disease in an individual, comprising the steps of: a) determining the level of one or more gene transcripts in blood obtained from said individual suspected of having a disease, and b) comparing the level of each of said one or more gene transcripts in said blood according to step a) with the level of each of said one or more gene transcripts in blood from one or more individuals not having a disease, wherein detecting a difference in the levels of each of said one or more gene transcripts in the comparison of step b) is indicative of a disease in the individual of step a).
[0027] In another embodiment of the present invention, there is a method of diagnosing or prognosing a disease in an individual, comprising the steps of: a) determining the level of one or more gene transcripts in blood obtained from said individual suspected of having a disease, and b) comparing the level of each of said one or more gene transcripts in said blood according to step a) with the level of each of said one or more gene transcripts in blood from one or more individuals having a disease, wherein detecting the same levels of each of said one or more gene transcripts in the comparison of step b) is indicative of a disease in the individual of step a).
[0028] In another embodiment of the present invention, there is a method of determining a stage of disease progression or regression in an individual having a disease, comprising the steps of: a) determining the level of one or more gene transcripts in blood obtained from said individual having a disease, and b) comparing the level of each if said one or more gene transcripts in said blood according to step a) with the level of each of said one or more gene transcripts in blood obtained from one or more individuals who each have been diagnosed as being at the same progressive or regressive stage of a disease, wherein the comparison from step b) allows the determination of the stage of a disease progression or regression in an individual.
[0029] In another embodiment of the present invention, there is a method of diagnosing or prognosing osteoarthritis in an individual, comprising the steps of: a) determining the level of one or more gene transcripts expressed in blood obtained from said individual, wherein said one or more gene transcripts correspond to said one or more markers of claim 1 and claim 2 , and b) comparing the level of each of said one or more gene transcripts in said blood according to step a) with the level of each of said one or more gene transcripts in blood from one or more individuals having osteoarthritis, c) comparing the level of each of said one or more gene transcripts in said blood according to step a) with the level of each of said one or more gene transcripts in blood from one or more individuals not having osteoarthritis, d) determining whether the level of said one or more gene transcripts of step a) classify with the levels of said transcripts in step b) as compared with the levels of said transcripts in step c) wherein said determination is indicative of said individual of step a) having osteoarthritis.
[0030] In another embodiment of the present invention, there is a method of determining a stage of disease progression or regression in an individual having osteoarthritis, comprising the steps of: a) determining the level of one or more gene transcripts expressed in blood obtained from said individual having said stage of osteoarthritis, wherein said one or more gene transcripts correspond to the markers of claim 3 and claim 4 , and b) comparing the level of each of said one or more gene transcripts in said blood according to step a) with the level of each of said one or more gene transcripts in blood from one or more individuals having said stage of osteoarthritis, c) comparing the level of each of said one or more gene transcripts in said blood according to step a) with the level of each of said one or more gene transcripts in blood from one or more individuals not having said stage of osteoarthritis, d) determining whether the level of said one or more gene transcripts of step a) classify with the levels of said transcripts in step b) as compared with levels of said transcripts in step c), wherein said determination is indicative of said individual of step a) having said stage of osteoarthritis.
[0031] Further embodiments of the methods described in the previous ten paragraphs include embodiments comprising a further step of isolating RNA from said blood samples, and embodiments comprising determining the level of each of said one or more gene transcripts comprising quantitative RT-PCR (QRT-PCR), wherein said one or more transcripts are from step a) and/or step b) of said methods. Further embodiments of these methods include embodiments wherein said QRT-PCR comprises primers which hybridize to one or more transcripts or the complement thereof, wherein said one or more transcripts are from step a) and/or step b) of said methods, embodiments wherein said primers are 15-25 nucleotides in length, and embodiments wherein said primers hybridize to one or more of the sequences of any one of Table 3A-Z and Tables 3AA, 3AB, 3AC and 3AD, or the complement thereof. Further embodiments of the methods described in the previous eight paragraphs include embodiments wherein the step of determining the level of each of said one or more gene transcripts comprises hybridizing a first plurality of isolated nucleic acid molecules that correspond to said one or more transcripts to an array comprising a second plurality of isolated nucleic acid molecules, wherein in one embodiment said first plurality of isolated nucleic acid molecules comprises RNA, DNA, cDNA, PCR products or ESTs, wherein in one embodiment said array comprises a plurality of isolated nucleic acid molecules comprising RNA, DNA, cDNA, PCR products or ESTs, wherein in one embodiment said array comprises two or more of the genetic markers of said methods, wherein in one embodiment said array comprises a plurality of nucleic acid molecules that correspond to genes of the human genome.
[0032] In another embodiment of the present invention, there is a plurality of nucleic acid molecules that correspond to two or more sequences from each of any one of Table 3A-Z and Tables 3AA, 3AB, 3AC and 3AD.
[0033] In another embodiment of the present invention, there is an array which comprises a plurality of nucleic acid molecules that correspond to two or more sequences from each of any one of Table 3A-Z and Tables 3AA, 3AB, 3AC and 3AD.
[0034] In another embodiment of the present invention, there is a kit for diagnosing or prognosing a disease comprising: a) two gene-specific priming means designed to produce double stranded DNA complementary to a gene selected from the group consisting of Table 3L; wherein said first priming means contains a sequence which can hybridize to RNA, cDNA or an EST complementary to said gene to create an extension product and said second priming means capable of hybridizing to said extension product; b) an enzyme with reverse transcriptase activity c) an enzyme with thermostable DNA polymerase activity and d) a labeling means; wherein said primers are used to detect the quantitative expression levels of said gene in a test subject In another embodiment of the present invention, there is a kit for monitoring a course of therapeutic treatment of a disease, comprising a) two gene-specific priming means designed to produce double stranded DNA complementary to a gene selected group consisting of any one of Table 3A-Z and Tables 3AA, 3AB, 3AC and 3AD; wherein said first priming means contains a sequence which can hybridize to RNA, cDNA or an EST complementary to said gene to create an extension product and said second priming means capable of hybridizing to said extension product; b) an enzyme with reverse transcriptase activity c) an enzyme with thermostable DNA polymerase activity and d) a labeling means; wherein said primers are used to detect the quantitative expression levels of said gene in a test subject.
[0035] In another embodiment of the present invention, there is a kit for monitoring progression or regression of a disease, comprising: a) two gene-specific priming means designed to produce double stranded DNA complementary to a gene selected group consisting of any one of Table 3A-Z and Tables 3AA, 3AB, 3AC and 3AD; wherein said first priming means contains a sequence which can hybridize to RNA, cDNA or an EST complementary to said gene to create an extension product and said second priming means capable of hybridizing to said extension product; b) an enzyme with reverse transcriptase activity c) an enzyme with thermostable DNA polymerase activity and d) a labeling means; wherein said primers are used to detect the quantitative expression levels of said gene in a test subject.
[0036] In another embodiment of the present invention, there is a plurality of nucleic acid molecules that identify or correspond to two or more sequences from any one of Table 3A-Z and Tables 3AA, 3AB, 3AC and 3AD.
[0037] Other and further aspects, features, and advantages of the present invention will be apparent from the following description of the presently preferred embodiments of the invention. These embodiments are given for the purpose of disclosure.
BRIEF DESCRIPTION OF THE DRAWINGS
[0038] The above-recited features, advantages and objects of the invention, as well as others which will become clear, are attained and can be understood in detail, more particular descriptions of the invention briefly summarized above may be had by reference to certain embodiments thereof which are illustrated in the appended drawings. These drawings form a part of the specification. It is to be noted, however, that the appended drawings illustrate preferred embodiments of the invention and therefore are not to be considered limiting in their scope.
[0039] [0039]FIG. 1 shows the following RNA samples prepared from human blood; FIG. 1A: Lane 1, Molecular weight marker; Lane 2, RT-PCR on APP gene; Lane 3, PCR on APP gene; Lane 4, RT-PCR on APC gene; Lane 5, PCR on APC gene; FIG. 1B: Lanes 1 and 2, RT-PCR and PCR of βMyHC, respectively; Lanes 3 and 4, RT-PCR of βMyHC from RNA prepared from human fetal and human adult heart, respectively; Lane 5, Molecular weight marker.
[0040] [0040]FIG. 2 shows quantitative RT-PCR analysis performed on RNA samples extracted from a drop of blood. Forward primer (5′-GCCCTCTGGGGACCTGAC-3′, SEQ ID No. 1) of exon 1 and reverse primer (5′-CCCACCTGCAGGTCCTCT-3″, SEQ ID No. 2) of exons 1 and 2 of insulin gene. Blood samples of 4 normal subjects were assayed. Lanes 1, 3, 5 and 7 represent overnight “fasting” blood sample and lanes 2, 4, 6 and 8 represent “non-fasting” samples.
[0041] [0041]FIG. 3 shows quantitative RT-PCR analysis performed on RNA samples extracted from a drop of blood. Lanes 1 and 2 represent normal healthy person and lane 3 represents late-onset diabetes (Type II) and lane 4 represents asymptomatic diabetes.
[0042] [0042]FIG. 4 shows multiple RT-PCR assay in a drop of blood. Primers were derived from insulin gene (INS), zinc-finger protein gene (ZFP) and house-keeping gene (GADH). Lane 1 represents normal person. Lane 2 represents late-onset diabetes and lane 3 represents asymptomatic diabetes.
[0043] [0043]FIG. 5 shows standardized levels of insulin gene (FIG. 5A) and ZFP gene (FIG. 5B) expressed in a drop of blood. The first three subjects were normal, second two subjects showed normal glucose tolerance, and the last subject had late onset diabetes type II. FIG. 5C shows standardized levels of insulin gene expressed in each fractionated cell from whole blood.
[0044] [0044]FIG. 6 shows the differential screening of human blood cell cDNA library with different cDNA probes of heart and brain tissue. FIG. 6A shows blood cell cDNA probes vs. adult heart cDNA probes. FIG. 6B shows blood cell cDNA probes vs. human brain cDNA probes.
[0045] [0045]FIG. 7 graphically shows the 1,800 unique genes in human blood and in the human fetal heart grouped into seven cellular functions.
[0046] [0046]FIG. 8 shows a diagrammatic representation of gene expression profiles of blood samples from individuals having both osteoarthritis and hypertension as compared with gene expression profiles from normal individuals.
[0047] [0047]FIG. 9 shows a diagrammatic representation of gene expression profiles of blood samples from individuals who were identified as having both osteoarthritis and who were obese as described herein as compared with gene expression profiles from normal individuals
[0048] [0048]FIG. 10 shows a diagrammatic representation of gene expression profiles of blood samples from individuals who were identified as having both osteoarthritis and allergies as described herein as compared with gene expression profiles from normal individuals.
[0049] [0049]FIG. 11 shows a diagrammatic representation of gene expression profiles of blood samples from individuals having osteoarthritis and who were subject to systemic steroids as described herein as compared with gene expression profiles from normal individuals.
[0050] [0050]FIG. 12 shows a diagrammatic representation of gene expression profiles of blood samples from individuals having hypertension as compared with gene expression profiles from samples of both non-hypertensive and normal individuals.
[0051] [0051]FIG. 13 shows a diagrammatic representation of gene expression profiles of blood samples from individuals who were identified as obese as described herein as compared with gene expression profiles from normal and non-obese individuals.
[0052] [0052]FIG. 14 shows a diagrammatic representation of gene expression profiles of blood samples from individuals who were identified as having type 2 diabetes as described herein as compared with gene expression profiles from normal and non-type 2 diabetes individuals.
[0053] [0053]FIG. 15 shows a diagrammatic representation of gene expression profiles of blood samples from individuals who were identified as having hyperlipidemia as described herein as compared with gene expression profiles from normal and non-hyperlipidemia patients.
[0054] [0054]FIG. 16 shows a diagrammatic representation of gene expression profiles of blood samples from individuals who were identified as having lung disease as described herein as compared with gene expression profiles from normal and non lung disease individuals.
[0055] [0055]FIG. 17 shows a diagrammatic representation of gene expression profiles of blood samples from individuals who were identified as having bladder cancer as described herein as compared with gene expression profiles from non bladder cancer individuals.
[0056] [0056]FIG. 18 shows a diagrammatic representation of gene expression profiles of blood samples from individuals who were identified as having advanced stage bladder cancer or early stage bladder cancer as described herein as compared with gene expression profiles from non bladder cancer individuals.
[0057] [0057]FIG. 19 shows a diagrammatic representation of gene expression profiles of blood samples from individuals who were identified as having coronary artery disease (CAD) as described herein as compared with gene expression profiles from non-coronary artery disease individuals.
[0058] [0058]FIG. 20 shows a diagrammatic representation of gene expression profiles of blood samples from individuals who were identified as having rheumatoid arthritis as described herein as compared with gene expression profiles from non-rheumatoid arthritis individuals.
[0059] [0059]FIG. 21 shows a diagrammatic representation of gene expression profiles of blood samples from individuals who were identified as having depression as described herein as compared with gene expression profiles from non-depression individuals.
[0060] [0060]FIG. 22 shows a diagrammatic representation of gene expression profiles of blood samples from individuals who were identified as having various stages of osteoarthritis as described herein as compared with gene expression profiles from normal individuals.
[0061] [0061]FIG. 23 shows RT-PCR of overexpressed genes in CAD peripheral blood cells identified using microarray experiments, including PBP, PF4 and F13A.
[0062] [0062]FIG. 24 shows the “Blood Chip”, a cDNA microarray slide with 10,368 PCR products derived from peripheral blood cell cDNA libraries. Colors represent hybridization to probes labelled with Cy3 (green) or Cy5 (red). Yellow spots indicate common hybridization between both probes. In slide A, normal blood cell RNA samples were labelled with Cy3 and CAD blood cell RNA samples were labelled with Cy5. In slide B, Cy3 and Cy5 were switched to label the RNA samples. (Cluster analysis revealed distinct gene expression profiles for normal and CAD samples.)
[0063] [0063]FIG. 25 shows a diagrammatic representation of gene expression profiles of blood samples from individuals who were identified as having liver cancer as described herein as compared with gene expression profiles from normal individuals.
[0064] [0064]FIG. 26 shows a diagrammatic representation of gene expression profiles of blood samples from individuals who were identified as having schizophrenia as described herein as compared with gene expression profiles from normal individuals.
[0065] [0065]FIG. 27 shows a diagrammatic representation of gene expression profiles of blood samples from individuals who were identified as having symptomatic or asymptomatic chagas disease as described herein as compared with gene expression profiles from normal individuals.
[0066] [0066]FIG. 28 shows a diagrammatic representation of gene expression profiles of blood samples from individuals who were identified as having asthma and OA as compared with individuals having just OA.
[0067] [0067]FIG. 29 shows a venn diagram illustrating a summary of the analysis comparing hypertension and OA patients vs. normal (Table 3A) hypertension and OA patients vs. OA patients (Table 3P) and the intersection between the two populations of genes (Table 3Q).
[0068] [0068]FIG. 30 shows a venn diagram illustrating a summary of the analysis comparing obesity and OA patients vs. normal (Table 3B) obesity and OA patients vs. OA patients (Table 3R) and the intersection between the two populations of genes (Table 3S).
[0069] [0069]FIG. 31 shows a venn diagram illustrating a summary of the analysis comparing allergy and OA patients vs. normal (Table 3C) allergy and OA patients vs. OA patients (Table 3T) and the intersection between the two populations of genes (Table 3U).
[0070] [0070]FIG. 32 shows a venn diagram illustrating a summary of the analysis comparing systemic steroids and OA patients vs. normal (Table 3D) systemic steroids and OA patients vs. OA patients (Table 3V) and the intersection between the two populations of genes (Table 3W).
[0071] [0071]FIG. 33 shows a diagrammatic representation of gene expression profiles of blood samples from individuals who were identified as having Manic Depression as compared with those individuals who have Schizophrenia.
[0072] [0072]FIG. 34 shows a diagrammatic representation of gene expression profiles of blood samples from individuals who were identified as having OA and being one form of systemic steroids.
DETAILED DESCRIPTION
[0073] In accordance with the present invention, there may be employed conventional molecular biology, microbiology, and recombinant DNA techniques within the skill of the art. Such techniques are explained fully in the literature. See, e.g., Sambrook, Fritsch & Maniatis, “Molecular Cloning: A Laboratory Manual (1982); “DNA Cloning: A Practical Approach,” Volumes I and II (D. N. Glover ed. 1985); “Oligonucleotide Synthesis” (M. J. Gait ed. 1984); “Nucleic Acid Hybridization” [B. D. Hames & S. J. Higgins eds. (1985)]; “Transcription and Translation” [B. D. Hames & S. J. Higgins eds. (1984)]; “Animal Cell Culture” [R. I. Freshney, ed. (1986)]; “Immobilized Cells And Enzymes” [IRL Press, (1986)]; B. Perbal, “A Practical Guide To Molecular Cloning” (1984). Therefore, if appearing herein, the following terms shall have the definitions set out below.
[0074] A “cDNA” is defined as copy-DNA or complementary-DNA, and is a product of a reverse transcription reaction from an mRNA transcript. “RT-PCR” refers to reverse transcription polymerase chain reaction and results in production of cDNAs that are complementary to the mRNA template(s).
[0075] In addition to RT-PCR, other methods of amplifying may also be used for the purpose of measuring/quantitating tissue-specific transcripts in human blood. For example, mass spectrometry may be used to quantify the transcripts (Koster et al., 1996; Fu et al., 1998). The application of presently disclosed method for detecting tissue-specific transcripts in blood does not restrict to subjects undergoing course of therapy or treatment, it may also be used for monitoring a patient for the onset of overt symptoms of a disease. Furthermore, the present method may be used for detecting any gene transcripts in blood. A kit for diagnosing, prognosing or even predicting a disease may be designed using gene-specific primers or probes derived from a whole blood sample for a specific disease and applied directly to a drop of blood. A cDNA library specific for a disease may be generated from whole blood samples and used for diagnosis, prognosis or even predicting a disease.
[0076] The term “oligonucleotide” is defined as a molecule comprised of two or more deoxyribonucleotides and/or ribonucleotides, preferably more than three. Its exact size will depend upon many factors which, in turn, depend upon the ultimate function and use of the oligonucleotide. The upper limit may be 15, 20, 25, 30, 40 or 50 nucleotides in length. The term “primer” as used herein refers to an oligonucleotide, whether occurring naturally as in a purified restriction digest or produced synthetically, which is capable of acting as a point of initiation of synthesis when placed under conditions in which synthesis of a primer extension product, which is complementary to a nucleic acid strand, is induced, i.e., in the presence of nucleotides and an inducing agent such as a DNA polymerase and at a suitable temperature and pH. The primer may be either single-stranded or double-stranded and must be sufficiently long to prime the synthesis of the desired extension product in the presence of the inducing agent. The exact length of the primer will depend upon many factors, including temperature, source of primer and the method used. For example, for diagnostic applications, depending on the complexity of the target sequence, the oligonucleotide primer typically contains 15-25 or more nucleotides, although it may contain fewer nucleotides. The factors involved in determining the appropriate length of primer are readily known to one of ordinary skill in the art.
[0077] As used herein, random sequence primers refer to a composition of primers of random sequence, i.e. not directed towards a specific sequence. These sequences possess sufficient complementary to hybridize with a polynucleotide and the primer sequence need not reflect the exact sequence of the template.
[0078] “Restriction fragment length polymorphism” refers to variations in DNA sequence detected by variations in the length of DNA fragments generated by restriction endonuclease digestion.
[0079] A standard Northern blot assay can be used to ascertain the relative amounts of mRNA in a cell or tissue obtained from plant or other tissue, in accordance with conventional Northern hybridization techniques known to those persons of ordinary skill in the art. The Northern blot uses a hybridization probe, e.g. radiolabelled cDNA, either containing the full-length, single stranded DNA or a fragment of that DNA sequence at least 20 (preferably at least 30, more preferably at least 50, and most preferably at least 100 consecutive nucleotides in length). The DNA hybridization probe can be labelled by any of the many different methods known to those skilled in this art. The labels most commonly employed for these studies are radioactive elements, enzymes, chemicals which fluoresce when exposed to ultraviolet light, and others. A number of fluorescent materials are known and can be utilized as labels. These include, for example, fluorescein, rhodamine, auramine, Texas Red, AMCA blue and Lucifer Yellow. A particular detecting material is anti-rabbit antibody prepared in goats and conjugated with fluorescein through an isothiocyanate. Proteins can also be labelled with a radioactive element or with an enzyme. The radioactive label can be detected by any of the currently available counting procedures. The preferred isotope may be selected from 3 H, 14 C, 32 P, 35 S, 36 C, 51 Cr, 57 Co, 58 Co, 59 Fe, 90 Y, 125 I, 131 I, and 86 Re. Enzyme labels are likewise useful, and can be detected by any of the presently utilized colorimetric, spectrophotometric, fluorospectrophotometric, amperometric or gasometric techniques. The enzyme is conjugated to the selected particle by reaction with bridging molecules such as carbodiimides, diisocyanates, glutaraldehyde and the like. Many enzymes which can be used in these procedures are known and can be utilized. The preferred are peroxidase, β-glucuronidase, β-D-glucosidase, β-D-galactosidase, urease, glucose oxidase plus peroxidase and alkaline phosphatase. U.S. Pat. Nos. 3,654,090, 3,850,752, and 4,016,043 are referred to by way of example for their disclosure of alternate labeling material and methods.
[0080] As used herein, “individual” refers to human subjects as well as non-human subjects. The examples herein are not meant to limit the methodology of the present invention to human subjects only, as the instant methodology is useful in the fields of veterinary medicine, animal sciences and such. The term “individual” refers to human subjects and non-human subjects who are disease or condition free and also includes human and non-human subjects diagnosed with one or more diseases or conditions, as defined herein. “Co-morbid individuals” or “comorbidity” or “individuals considered as co-morbid” are individuals who have more than one disease or condition as defined herein. For example a patient diagnosed with both osteoarthritis and hypertension is considered to present with comorbidities.
[0081] As used herein, “detecting” refers to determining the presence of a gene expression product, for example cDNA, RNA or EST, by any method known to those of skill in the art or taught in numerous texts and laboratory manuals (see for example, Ausubel et al. Short Protocols in Molecular Biology (1995) 3rd Ed. John Wiley & Sons, Inc.). For example, methods of detection include but are not limited to, RNA fingerprinting, Northern blotting, polymerase chain reaction, ligase chain reaction, Qbeta replicase, isothermal amplification method, strand displacement amplification, transcription based amplification systems, nuclease protection (SI nuclease or RNAse protection assays) as well as methods disclosed in WO 88/10315, WO89/06700, PCT/US87/00880, PCT/ US89/01025.
[0082] As used herein, a disease of the invention includes, but is not limited to, blood disorder, blood lipid disease, autoimmune disease, arthritis (including osteoarthritis, rheumatoid arthritis, lupus, allergies, juvenile rheumatoid arthritis and the like), bone or joint disorder, a cardiovascular disorder (including heart failure, congenital heart disease; rheumatic fever, valvular heart disease; corpulmonale, cardiomyopathy, myocarditis, pericardial disease; vascular diseases such as atherosclerosis, acute myocardial infarction, ischemic heart disease and the like), obesity, respiratory disease (including asthma, pneumonitis, pneumonia, pulmonary infections, lung disease, bronchiectasis, tuberculosis, cystic fibrosis, interstitial lung disease, chronic bronchitis emphysema, pulmonary hypertension, pulmonary thromboembolism, acute respiratory distress syndrome and the like), hyperlipidemias, endocrine disorder, immune disorder, infectious disease, muscle wasting and whole body wasting disorder, neurological disorders (including migraines, seizures, epilepsy, cerebrovascular diseases, alzheimers, dementia, Parkinson's, ataxic disorders, motor neuron diseases, cranial nerve disorders, spinal cord disorders, meningitis and the like) including neurodegenerative and/or neuropsychiatric diseases and mood disorders (including schizophrenia, anxiety, bipolar disorder; manic depression and the like, skin disorder, kidney disease, scleroderma, stroke, hereditary hemorrhage telangiectasia, diabetes, disorders associated with diabetes (e.g., PVD), hypertension, Gaucher's disease, cystic fibrosis, sickle cell anemia, liver disease, pancreatic disease, eye, ear, nose and/or throat disease, diseases affecting the reproductive organs, gastrointestinal diseases (including diseases of the colon, diseases of the spleen, appendix, gall bladder, and others) and the like. For further discussion of human diseases, see Mendelian Inheritance in Man: A Catalog of Human Genes and Genetic Disorders by Victor A. McKusick (12th Edition (3 volume set) June 1998, Johns Hopkins University Press, ISBN: 0801857422) and Harrison's Principles of Internal Medicine by Braunwald, Fauci, Kasper, Hauser, Longo, & Jameson (15th Edition, 2001), the entirety of which is incorporated herein.
[0083] In another embodiment of the invention, a disease refers to an immune disorder, such as those associated with overexpression of a gene or expression of a mutant gene (e.g., autoimmune diseases, such as diabetes mellitus, arthritis (including rheumatoid arthritis, juvenile rheumatoid arthritis, osteoarthritis, psoriatic arthritis), multiple sclerosis, encephalomyelitis, myasthenia gravis, systemic lupus erythematosis, automimmune thyroiditis, dermatitis (including atopic dermatitis and eczematous dermatitis), psoriasis, Sjogren's Syndrome, Crohn's disease, aphthous ulcer, iritis, conjunctivitis, keratoconjunctivitis, ulcerative colitis, asthma, allergic asthma, cutaneous lupus erythematosus, scleroderma, vaginitis, proctitis, drug eruptions, leprosy reversal reactions, erythema nodosum leprosum, autoimmune uveitis, allergic encephalomyelitis, acute necrotizing hemorrhagic encephalopathy, idiopathic bilateral progressive sensorineural hearing, loss, aplastic anemia, pure red cell anemia, idiopathic thrombocytopenia, polychondritis, Wegener's granulomatosis, chronic active hepatitis, Stevens-Johnson syndrome, idiopathic sprue, lichen planus, Graves' disease, sarcoidosis, primary biliary cirrhosis, uveitis posterior, and interstitial lung fibrosis), graft-versus-host disease, cases of transplantation, and allergy.
[0084] In another embodiment, a disease of the invention is a cellular proliferative and/or differentiative disorder that includes, but is not limited to, cancer e.g., carcinoma, sarcoma or other metastatic disorders and the like. As used herein, the term “cancer” refers to cells having the capacity for autonomous growth, i.e., an abnormal state of condition characterized by rapidly proliferating cell growth. “Cancer” is meant to include all types of cancerous growths or oncogenic processes, metastatic tissues or malignantly transformed cells, tissues, or organs, irrespective of histopathologic type or stage of invasiveness. Examples of cancers include but are nor limited to solid tumors and leukemias, including: apudoma, choristoma, branchioma, malignant carcinoid syndrome, carcinoid heart disease, carcinoma (e.g., Walker, basal cell, basosquamous, Brown-Pearce, ductal, Ehrlich tumour, in situ, Krebs 2, Merkel cell, mucinous, non-small cell lung, oat cell, papillary, scirrhous, bronchiolar, bronchogenic, squamous cell, and transitional cell), histiocytic disorders, leukaemia (e.g., B cell, mixed cell, null cell, T cell, T-cell chronic, HTLV-II-associated, lymphocytic acute, lymphocytic chronic, mast cell, and myeloid), histiocytosis malignant, Hodgkin disease, immunoproliferative small, non-Hodgkin lymphoma, plasmacytoma, reticuloendotheliosis, melanoma, chondroblastoma, chondroma, chondrosarcoma, fibroma, fibrosarcoma, giant cell tumors, histiocytoma, lipoma, liposarcoma, mesothelioma, myxoma, myxosarcoma, osteoma, osteosarcoma, Ewing sarcoma, synovioma, adenofibroma, adenolymphoma, carcinosarcoma, chordoma, craniopharyngioma, dysgerminoma, hamartoma, mesenchymoma, mesonephroma, myosarcoma, ameloblastoma, cementoma, odontoma, teratoma, thymoma, trophoblastic tumour, adeno-carcinoma, adenoma, cholangioma, cholesteatoma, cylindroma, cystadenocarcinoma, cystadenoma, granulosa cell tumour, gynandroblastoma, hepatoma, hidradenoma, islet cell tumour, Leydig cell tumour, papilloma, Sertoli cell tumour, theca cell tumour, leiomyoma, leiomyosarcoma, myoblastoma, mymoma, myosarcoma, rhabdomyoma, rhabdomyosarcoma, ependymoma, ganglioneuroma, glioma, medulloblastoma, meningioma, neurilemmoma, neuroblastoma, neuroepithelioma, neurofibroma, neuroma, paraganglioma, paraganglioma nonchromaffin, angiokeratoma, angiolymphoid hyperplasia with eosinophilia, angioma sclerosing, angiomatosis, glomangioma, hemangioendothelioma, hemangioma, hemangiopericytoma, hemangiosarcoma, lymphangioma, lymphangiomyoma, lymphangiosarcoma, pinealoma, carcinosarcoma, chondrosarcoma, cystosarcoma, phyllodes, fibrosarcoma, hemangiosarcoma, leimyosarcoma, leukosarcoma, liposarcoma, lymphangiosarcoma, myosarcoma, myxosarcoma, ovarian carcinoma, rhabdomyosarcoma, sarcoma (e.g., Ewing, experimental, Kaposi, and mast cell), neoplasms (e.g., bone, breast, digestive system, colorectal, liver, pancreatic, pituitary, testicular, orbital, head and neck, central nervous system, acoustic, pelvic respiratory tract, and urogenital), neurofibromatosis, and cervical dysplasia, and other conditions in which cells have become immortalized or transformed.
[0085] In another embodiment, a disease of the invention includes but is not limited to a condition wherein said condition is reflective of the state of a particular individual, whether said state is a physical, emotional or psychological state, said state resulting from the progression of time, treatment, environmental factors or genetic factors.
[0086] As used herein, a gene of the invention is a gene that is expressed in blood and is either upregulated, or downregulated and can be used, either solely or in conjunction with other genes, as a marker for disease as defined herein. By a gene that is expressed in blood or in a blood sample is meant a gene that is expressed in the cells which typically make up blood including monocytes, leukocytes, lymphocytes and erythrocytes, all other cells derived directly from haemopoietic or mesenchymal stem cells, or derived directly from a cell which typically makes up the blood.
[0087] The term “gene” includes a region that can be transcribed into RNA, as the invention contemplates detection of RNA or equivalents thereof, i.e., cDNA or EST. A gene of the invention includes but is not limited to genes specific for or involved in a particular biological process, such as apoptosis, differentiation, stress response, aging, proliferation, etc.; cellular mechanism genes, e.g. cell-cycle, signal transduction, metabolism of toxic compounds, and the like; disease associated genes, e.g. genes involved in cancer, schizophrenia, diabetes, high blood pressure, atherosclerosis, viral-host interaction and infection and the like.
[0088] For example, the gene of the invention can be an oncogene (Hanahan, D. and R. A. Weinberg, Cell (2000) 100:57; and Yokota, J., Carcinogenesis (2000) 21(3):497-503) whose expression within a cell induces that cell to become converted from a normal cell into a tumor cell. Further examples of genes of the invention include, but are not limited to, cytokine genes (Rubinstein, M., et al., Cytokine Growth Factor Rev. (1998) 9(2):175-81); idiotype (Id) protein genes (Benezra, R., et al., Oncogene (2001) 20(58):8334-41; Norton, J. D., J. Cell Sci. (2000) 113(22):3897-905); prion genes (Prusiner, S. B., et al., Cell (1998) 93(3):337-48; Safar, J., and S. B. Prusiner, Prog., Brain Res., (1998) 117:421-34); genes that express molecules that induce angiogenesis (Gould, V. E. and B. M. Wagner, Hum. Pathol. (2002) 33(11):1061-3); genes encoding adhesion molecules (Chothia, C. and E. Y. Jones, Annu. Rev. Biochem. (1997) 66:823-62; Parise, L. V., et al., Semin. Cancer Biol. (2000) 10(6):407-14); genes encoding cell surface receptors (Deller, M. C., and Y. E. Jones, Curr. Opin. Struct. Biol. (2000) 10(2):213-9); genes of proteins that are involved in metastasizing and/or invasive processes (Boyd, D., Cancer Metastasis Rev. (1996) 15(1):77-89; Yokota, J., Carcinogenesis (2000) 21(3):497-503); genes of proteases as well as of molecules that regulate apoptosis and the cell cycle (Matrisian, L. M., Curr. Biol. (1999) 9(20):R776-8; Krepela, E., Neoplasma (2001) 48(5):332-49; Basbaum and Werb, Curr. Opin. Cell Biol. (1996) 8:731-738; Birkedal-Hansen, et al., Crit. Rev. Oral Biol. Med. (1993) 4:197-250; Mignatti and Rifkin, Physiol. Rev. (1993) 73:161-195; Stetler-Stevenson, et al., Annu., Rev. Cell Biol., (1993) 9:541-573; Brinkerhoff, E., and L. M. Matrisan, Nature Reviews (2002) 3:207-214; Strasser, A., et al., Annu., Rev. Biochem., (2000), 69:217-45; Chao, D. T. and S. J. Korsmeyer, Annu. Rev. Immunol. (1998) 16:395-419; Mullauer, L., et al., Mutat. Res. (2001) 488(3):211-31; Fotedar, R., et al., Prog., Cell Cycle Res., (1996), 2:147-63; Reed, J. C., Am. J. Pathol., (2000) 157(5):1415-30; D'Ari, R., Bioassays (2001) 23(7):563-5); or multi-drug resistance genes, such as MDR1 gene (Childs, S., and V. Ling, Imp., Adv. Oncol., (1994) 21-36). In another embodiment, a gene of the invention contains a sequence found in Tables 2 or 3 or FIGS. 22-34. In another embodiment, a gene of the invention can be an immune response gene or a non-immune response gene. By an immune response gene is meant a primary defense response gene located outside the major histocompatibility region (MHC) that is initially triggered in response to a foreign antigen to regulate immune responsiveness. All other genes expressed in blood are considered to be non-immune response gene. For example, an immune response gene would be understood by a person skilled in the art to include: cytokines including interleukins and interferons such as TNF-alpha, IL-10, IL-12, IL-2, IL-4, IL-10, IL-12, IL-13, TGF-Beta, IFN-gamma; immunoglobulins, complement and the like (see for example Bellardelli, F. Role of interferons and other cytokines in the regulation of the immune response APMIS., 1995, March; 103(3): 161-79; ).
[0089] Construction of a Microarray
[0090] A nucleic acid microarray (RNA, DNA, cDNA, PCR products or ESTs) according to the invention was constructed as follows:
[0091] Nucleic acids (RNA, DNA, cDNA, PCR products or ESTs) (˜40 μl) are precipitated with 4μl ({fraction (1/10)} volume) of 3M sodium acetate (pH 5.2) and 100 μl (2.5 volumes) of ethanol and stored overnight at −20° C. They are then centrifuged at 3,300 rpm at 4° C. for 1 hour. The obtained pellets were washed with 50 μl ice-cold 70% ethanol and centrifuged again for 30 minutes. The pellets are then air-dried and resuspended well in 50% dimethylsulfoxide (DMSO) or 20 μl 3×SSC overnight. The samples are then deposited either singly or in duplicate onto Gamma Amino Propyl Silane (Corning CMT-GAPS or CMT-GAP2, Catalog No. 40003, 40004) or polylysine-coated slides (Sigma Cat. No. P0425) using a robotic GMS 417 or 427 arrayer (Affymetrix, Calif.). The boundaries of the DNA spots on the microarray are marked with a diamond scriber. The invention provides for arrays where 10-20,000 different DNAs are spotted onto a solid support to prepare an array, and also may include duplicate or triplicate DNAs.
[0092] The arrays are rehydrated by suspending the slides over a dish of warm particle free ddH20 for approximately one minute (the spots will swell slightly but not run into each other) and snap-dried on a 70-80° C. inverted heating block for 3 seconds. DNA is then UV crosslinked to the slide (Stratagene, Stratalinker, 65 mJ—set display to “650” which is 650×100 μJ, or baked at 80° C. for two to four hours. The arrays are placed in a slide rack. An empty slide chamber is prepared and filled with the following solution: 3.0 grams of succinic anhydride (Aldrich) is dissolved in 189 ml of 1-methyl-2-pyrrolidinone (rapid addition of reagent is crucial); immediately after the last flake of succinic anhydride dissolved, 21.0 ml of 0.2 M sodium borate is mixed in and the solution is poured into the slide chamber. The slide rack is plunged rapidly and evenly in the slide chamber and vigorously shaken up and down for a few seconds, making sure the slides never leave the solution, and then mixed on an orbital shaker for 15-20 minutes. The slide rack is then gently plunged in 95° C. ddH 2 0 for 2 minutes, followed by plunging five times in 95% ethanol. The slides are then air dried by allowing excess ethanol to drip onto paper towels. The arrays are then stored in the slide box at room temperature until use.
[0093] Nucleic acid Microarrays
[0094] Any combination of the nucleic acid sequences generated from nucleotides complimentary to regions of DNA expressed in blood are used for the construction of a microarray. In one embodiment, the microarray is chondrocyte-specific and encompasses genes which are important in the osteoarthritis disease process. A microarray according to the invention preferably comprises between 10, 100, 500, 1000, 5000, 10,000 and 15,000 nucleic acid members, and more preferably comprises at least 5000 nucleic acid members. The nucleic acid members are known or novel nucleic acid sequences described herein, or any combination thereof. A microarray according to the invention is used to assay for differential gene expression profiles of genes in blood samples from healthy patients as compared to patients with a disease.
[0095] Microarray Used According to the Invention
[0096] The Human Genome U133 (HG-U133) Set, consisting of two GeneChip® arrays, contains almost 45,000 probe sets representing more than 39,000 transcripts derived from approximately 33,000 well-substantiated human genes. This set design uses sequences selected from GenBank®, dbEST, and RefSeq.
[0097] The sequence clusters were created from the UniGene database (Build 133, Apr. 20, 2001). They were then refined by analysis and comparison with a number of other publicly available databases including the Washington University EST trace repository and the University of California, Santa Cruz Golden Path human genome database (April 2001 release).
[0098] The HG-U133A Array includes representation of the RefSeq database sequences and probe sets related to sequences previously represented on the Human Genome U95Av2 Array. The HG-U133B Array contains primarily probe sets representing EST clusters.
[0099] 15 K ChondroChip™—The ChondroChip™ is chondrocyte-specific microarray chip comprising 15,000 novel and known EST sequences of the chondrocyte from human chondrocyte-specific cDNA libraries.
[0100] Controls on the ChondroChip™—There are two types of controls used on microarrays. First, positive controls are genes whose expression level is invariant between different stages of investigation and are used to monitor:
[0101] a) target DNA binding to the slide,
[0102] b) quality of the spotting and binding processes of the target DNA onto the slide,
[0103] c) quality of the RNA samples, and
[0104] d) efficiency of the reverse transcription and fluorescent labelling of the probes.
[0105] Second, negative controls are external controls derived from an organism unrelated to and therefore unlikely to cross-hybridize with the sample of interest. These are used to monitor for:
[0106] a) variation in background fluorescence on the slide, and
[0107] b) non-specific hybridization.
[0108] There are currently 63 control spots on the ChondroChip™ consisting of:
Type No. Positive Controls: 2 Alien DNA 12 A. thaliana DNA 10 Spotting Buffer 41
[0109] BloodChip™—The “BloodChip™” is a cDNA microarray slide with 10,368 PCR products derived from peripheral blood cell cDNA libraries as shown in FIG. 24.
[0110] Target Nucleic Acid Preparation and Hybridization
[0111] Preparation of Fluorescent DNA Probe from mRNA
[0112] Fluorescently labelled target nucleic acid samples are prepared for analysis with an array of the invention.
[0113] 2 μg Oligo-dT primers are annealed to 2 μg of mRNA isolated from a blood sample of a patient in a total volume of 15 μg, by heating to 70° C. for 10 min, and cooled on ice. The mRNA is reverse transcribed by incubating the sample at 42° C. for 1.5-2 hours in a 100 μg volume containing a final concentration of 50 mM Tris-HCl (pH 8.3), 75 mM KCl, 3 mM MgCl 2 , 25 mM DTT, 25 mM unlabelled dNTPs, 400 units of Superscript II (200 U/μL, Gibco BRL), and 15 mM of Cy3 or Cy5 (Amersham). RNA is then degraded by addition of 15μl of 0.1N NaOH, and incubation at 70° C. for 10 min. The reaction mixture is neutralized by addition of 15 μl of 0.1N HCl, and the volume is brought to 500 μl with TE (10 mM Tris, 1 mM EDTA), and 20 μg of Cot1 human DNA (Gibco-BRL) is added.
[0114] The labelled target nucleic acid sample is purified by centrifugation in a Centricon-30 micro-concentrator (Amicon). If two different target nucleic acid samples (e.g., two samples derived from a healthy patient vs. patient with a disease) are being analyzed and compared by hybridization to the same array, each target nucleic acid sample is labelled with a different fluorescent label (e.g., Cy3 and Cy5) and separately concentrated. The separately concentrated target nucleic acid samples (Cy3 and Cy5 labelled) are combined into a fresh centricon, washed with 500 μl TE, and concentrated again to a volume of less than 7 μl. 1 μl of 10 μg/μL polyA RNA (Sigma, #P9403) and 1 μl of 10 μg/μl tRNA (Gibco-BRL, #15401-011) is added and the volume is adjusted to 9.5 μl with distilled water. For final target nucleic acid preparation 2.1 μl 20×SSC (1.5M NaCl, 150 mM NaCitrate (pH8.0)) and 0.35 μl 10% SDS is added.
[0115] Hybridization
[0116] Labelled nucleic acid is denatured by heating for 2 min at 100° C., and incubated at 37° C. for 20-30 min before being placed on a nucleic acid array under a 22 mm×22 mm glass cover slip. Hybridization is carried out at 65° C. for 14 to 18 hours in a custom slide chamber with humidity maintained by a small reservoir of 3×SSC. The array is washed by submersion and agitation for 2-5 m in n2×SSC with 0.1% SDS, followed by 1×SSC, and 1×SSC. Finally, the array is dried by centrifugation for 2 min in a slide rack in a Beckman GS-6 tabletop centrifuge in Microplus carriers at 650 RPM for 2 min.
[0117] Signal Detection and Data Generation
[0118] Following hybridization of an array with one or more labelled target nucleic acid samples, arrays are scanned immediately using a GMS Scanner 418 and Scanalyzer software (Michael Eisen, Stanford University), followed by GeneSpring™ software (Silicon Genetics, Calif.) analysis. Alternatively, a GMS Scanner 428 and Jaguar software may be used followed by GeneSpring™ software analysis.
[0119] If one target nucleic acid sample is analyzed, the sample is labelled with one fluorescent dye (e.g., Cy3 or Cy5).
[0120] After hybridization to a microarray as described herein, fluorescence intensities at the associated nucleic acid members on the microarray are determined from images taken with a custom confocal microscope equipped with laser excitation sources and interference filters appropriate for the Cy3 or Cy5 fluorescence.
[0121] The presence of Cy3 or Cy5 fluorescent dye on the microarray indicates hybridization of a target nucleic acid and a specific nucleic acid member on the microarray. The intensity of Cy3 or Cy5 fluorescence represents the amount of target nucleic acid which is hybridized to the nucleic acid member on the microarray, and is indicative of the expression level of the specific nucleic acid member sequence in the target sample.
[0122] After hybridization, fluorescence intensities at the associated nucleic acid members on the microarray are determined from images taken with a custom confocal microscope equipped with laser excitation sources and interference filters appropriate for the Cy3 and Cy5 fluors. Separate scans are taken for each fluor at a resolution of 225 μm 2 per pixel and 65,536 gray levels. Normalization between the images is used to adjust for the different efficiencies in labeling and detection with the two different fluors. This is achieved by manual matching of the detection sensitivities to bring a set of internal control genes to nearly equal intensity followed by computational calculation of the residual scalar required for optimal intensity matching for this set of genes.
[0123] The presence of Cy3 or Cy5 fluorescent dye on the microarray indicates hybridization of a target nucleic acid and a specific nucleic acid member on the microarray. The intensities of Cy3 or Cy5 fluorescence represent the amount of target nucleic acid which is hybridized to the nucleic acid member on the microarray, and is indicative of the expression level of the specific nucleic acid member sequence in the target sample. If a nucleic acid member on the array shows no color, it indicates that the gene in that element is not expressed in either sample. If a nucleic acid member on the array shows a single color, it indicates that a labelled gene is expressed only in that cell sample. The appearance of both colors indicates that the gene is expressed in both tissue samples. The ratios of Cy3 and Cy5 fluorescence intensities, after normalization, are indicative of differences of expression levels of the associated nucleic acid member sequence in the two samples for comparison. A ratio of expression not equal to is used as an indication of differential gene expression.
[0124] The array is scanned in the Cy 3 and Cy5 channels and stored as separate 16-bit TIFF images. The images are incorporated and analyzed using Scanalyzer software which includes a gridding process to capture the hybridization intensity data from each spot on the array. The fluorescence intensity and background-subtracted hybridization intensity of each spot is collected and a ratio of measured mean intensities of Cy5 to Cy3 is calculated. A liner regression approach is used for normalization and assumes that a scatter plot of the measured Cy5 versus Cy3 intensities should have a scope of one. The average of the ratios is calculated and used to rescale the data and adjust the slope to one. A post-normalization cutoff of a ratio not equal to 1.0 is used to identify differentially expressed genes.
[0125] When comparing two or more samples for differences, results are reported as statistically significant when there is only a small probability that similar results would have been observed if the tested hypothesis (i.e., the genes are not expressed at different levels) were true. A small probability can be defined as the accepted threshold level at which the results being compared are considered significantly different. The accepted lower threshold is set at, but not limited to, 0.05 (i.e., there is a 5% likelihood that the results would be observed between two or more identical populations) such that any values determined by statistical means at or below this threshold are considered significant.
[0126] When comparing two or more samples for similarities, results are reported as statistically significant when there is only a small probability that similar results would have been observed if the tested hypothesis (i.e., the genes are not expressed at different levels) were true. A small probability can be defined as the accepted threshold level at which the results being compared are considered significantly different. The accepted lower threshold is set at, but not limited to, 0.05 (i.e., there is a 5% likelihood that the results would be observed between two or more identical populations) such that any values determined by statistical means above this threshold are not considered significantly different and thus similar.
[0127] Identification of genes differentially expressed in blood samples from patients with disease as compared to healthy patients or as compared to patients without said disease is determined by statistical analysis of the gene expression profiles from healthy patients or patients without disease compared to patients with disease using the Wilcox Mann Whitney rank sum test. Other statistical tests can also be used, see for example (Sokal and Rohlf (1987) Introduction to Biostatistics 2 nd edition, W H Freeman, New York), which is incorporated herein in their entirety.
[0128] In order to facilitate ready access, e.g. for comparison, review, recovery and/or modification, the expression profiles of patients with disease and/or patients without disease or healthy patients can be recorded in a database, whether in a relational database accessible by a computational device or other format, or a manually accessible indexed file of profiles as photographs, analogue or digital imaging, readouts spreadsheets etc. Typically the database is compiled and maintained at a central facility, with access being available locally and/or remotely.
[0129] As would be understood by a person skilled in the art, comparison as between the expression profile of a test patient with expression profiles of patients with a disease, expression profiles of patients with a certain stage or degree of progression of said disease, without said disease, or a healthy patient so as to diagnose or prognose said test patient can occur via expression profiles generated concurrently or non concurrently. It would be understood that expression profiles can be stored in a database to allow said comparison.
[0130] As additional test samples from test patients are obtained, through clinical trials, further investigation, or the like, additional data can be determined in accordance with the methods disclosed herein and can likewise be added to a database to provide better reference data for comparison of healthy and/or non-disease patients and/or certain stage or degree of progression of a disease as compared with the test patient sample.
[0131] Use of Expression Profiles for Diagnostic Purposes
[0132] As would be understood to a person skilled in the art, one can utilize sets of genes which have been identified as statistically significant as described above in order to characterize an unknown sample as having said disease or not having said disease. This is commonly termed “class prediction”.
[0133] Methods that can be used for class prediction analysis have been well described and generally involve a training phase using samples with known classification and a testing phase from which the algorithm generalizes from the training data so as to predict classification of unknown samples (see for Example Slonim, D. (2002), Nature Genetics Supp., Vol. 32 502-8, Raychaudhuri et al., (2001) Trends Biotechnol., 19: 189-193; Khan et al. (2001) Nature Med., 7 673-9; Golub et al. (1999) Science 286: 531-7. Hastie et al., (2000) Genome Biol., 1(2) Research 0003.1-0003.21, all of which are incorporated herein by reference in their entirety).
[0134] As additional samples are obtained, for example during clinical trials, their expression profiles can be determined and correlated with the relevant subject data in the database and likewise be recorded in said database. Algorithms as described above can be used to query additional samples against the existing database to further refine the diagnostic and/or prognostic determination by allowing an even greater association between the disease and gene expression signature.
[0135] The diagnosing or prognosing may thus be performed by detecting the expression level of two or more genes, three or more genes, four or more genes, five or more genes, six or more genes, seven or more genes, eight or more genes, nine or more genes, ten or more genes, fifteen or more genes, twenty or more genes thirty or more genes, fifty or more genes, one hundred or more genes, two hundred or more genes, three hundred or more genes, five hundred or more genes or all of the genes disclosed for the specific disease in question.
[0136] Data Acquisition and Analysis of Differentially Expressed EST Sequences
[0137] The differentially expressed EST sequences are then searched against available databases, including the “nt”, “nr”, “est”, “gss” and “htg” databases available through NCBI to determine putative identities for ESTs matching to known genes or other ESTs. Functional characterisation of ESTs with known gene matches are made according to any known method. Preferably, differentially expressed EST sequences are compared to the non-redundant Genbank/EMBL/DDBJ and dbEST databases using the BLAST algorithm (Altschul SF, Gish W, Miller W, Myers E W, Lipman D J., Basic local alignment search tool., J Mol Biol., 1990; 215:403-10). A minimum value of P=10 −10 and nucleotide sequence identity >95%, where the sequence identity is non-contiguous or scattered, are required for assignments of putative identities for ESTs matching to known genes or to other ESTs. Construction of a non-redundant list of genes represented in the EST set is done with the help of Unigene, Entrez and PubMed at the National Center for Biotechnology Information (NCBI) web site at www.ncbi.nlm.nih.gov.
[0138] Genes are identified from ESTs according to known methods. To identify novel genes from an EST sequence, the EST should preferably be at least 100 nucleotides in length, and more preferably 150 nucleotides in length, for annotation. Preferably, the EST exhibits open reading frame characteristics (i.e., can encode a putative polypeptide).
[0139] Because of the completion of the Human Genome Project, a specific EST which matches with a genomic sequence can be mapped onto a specific chromosome based on the chromosomal location of the genomic sequence. However, no function may be known for the protein encoded by the sequence and the EST would then be considered “novel” in a functional sense. In one aspect, the invention is used to identify a novel differentially expressed EST, which is part of a larger known sequence for which no function is known, is used to determine the function of a gene comprising the EST. Alternatively, or additionally, the EST can be used to identify an mRNA or polypeptide encoded by the larger sequence as a diagnostic or prognostic marker of a disease.
[0140] Having identified an EST corresponding to a larger sequence, other portions of the larger sequence which comprises the EST can be used in assays to elucidate gene function, e.g., to isolate polypeptides encoded by the gene, to generate antibodies specifically reactive with these polypeptides, to identify binding partners of the polypeptides (receptors, ligands, agonists, antagonists and the like) and/or to detect the expression of the gene (or lack thereof) in healthy or diseased individuals.
[0141] In another aspect, the invention provides for nucleic acid sequences that do not demonstrate a “significant match” to any of the publicly known sequences in sequence databases at the time a query is done. Longer genomic segments comprising these types of novel EST sequences can be identified by probing genomic libraries, while longer expressed sequences can be identified in cDNA libraries and/or by performing polymerase extension reactions (e.g., RACE) using EST sequences to derive primer sequences as is known in the art. Longer fragments can be mapped to particular chromosomes by FISH and other techniques and their sequences compared to known sequences in genomic and/or expressed sequence databases.
[0142] The amino acid sequences encoded by the ESTs can also be used to search databases, such as GenBank, SWISS-PROT, EMBL database, PIR protein database, Vecbase, or GenPept for the amino acid sequences of the corresponding full-length genes according to procedures well known in the art.
[0143] Identified genes can be catalogued according to their putative function. Functional characterization of ESTs with known gene matches is preferably made according to the categories described by Hwang et al Compendium of Cardiovascular Genes. Circulation 1997;96:4146-203. The distribution of genes in each of the subcellular categories will provide important insights into the disease process.
[0144] Alternative methods for analysing ESTs are also available. For example, the ESTs may be assembled into contigs with sequence alignment, editing, and assembly programs such as PHRED and PHRAP (Ewing, et al., 1998, Genome Res., 3:175, incorporated herein; and the web site at bozeman.genome.washington.edu). Contig redundancy is reduced by clustering nonoverlapping sequence contigs using the EST clone identification number, which is common for the nonoverlapping 5 and 3 sequence reads for a single EST cDNA clone. In one aspect, the consensus sequence from each cluster is compared to the non-redundant Genbank/EMBL/DDBJ and dbEST databases using the BLAST algorithm with the help of unigene, Entrez and PubMed at the NCBI site.
[0145] Known Nucleic acid Sequences or ESTs and Novel Nucleic Acid Sequences or ESTs
[0146] An EST that exhibits a significant match (>65%, and preferably 90% or greater, identity) to at least one existing sequence in an existing nucleic acid sequence database is characterised as a “known” sequence according to the invention. Within this category, some known ESTs match to existing sequences which encode polypeptides with known function(s) and are referred to as a “known sequence with a function”. Other “known” ESTs exhibit a significant match to existing sequences which encode polypeptides of unknown function(s) and are referred to as a “known sequence with no known function”.
[0147] EST sequences which have no significant match (less than 65% identity) to any existing sequence in the above cited available databases are categorised as novel ESTs. To identify a novel gene from an EST sequence, the EST is preferably at least 150 nucleotides in length. More preferably, the EST encodes at least part of an open reading frame, that is, a nucleic acid sequence between a translation initiation codon and a termination codon, which is potentially translated into a polypeptide sequence.
[0148] The following references were cited herein:
[0149] Claudio J O et al. (1998). Genomics 50:44-52.
[0150] Chelly J et al. (1989). Proc. Nat. Acad. Sci. USA. 86:2617-2621.
[0151] Chelly J et al. (1988). Nature 333:858-860.
[0152] Drews J & Ryser S (1997). Nature Biotech. 15:1318-9.
[0153] Ferrie R M et al. (1992). Am. J Hum. Genet. 51:251-62.
[0154] Fu D-J et al. (1998). Nat. Biotech 16: 381-4.
[0155] Gala J L et al. (1998). Clin. Chem. 44(3):472-81.
[0156] Geisterfer-Lowrance A A T et al. (1990). Cell 62:999-1006.
[0157] Groden J et al. (1991). Cell 66:589-600.
[0158] Hwang D M et al. (1997). Circulation 96:4146-4203.
[0159] Jandreski M A & Liew C C (1987). Hum. Genet. 76:47-53.
[0160] Jin O et al. (1990). Circulation 82:8-16
[0161] Kimoto Y (1998). Mol. Gen. Genet 258:233-239.
[0162] Koster M et al. (1996). Nat. Biotech 14: 1123-8.
[0163] Liew & Jandreski (1986). Proc. Nat. Acad. Sci. USA. 83:3175-3179
[0164] Liew C C et al. (1990). Nucleic Acids Res. 18:3647-3651.
[0165] Liew C C (1993). J Mol. Cell. Cardiol. 25:891-894
[0166] Liew C C et al. (1994). Proc. Natl. Acad. Sci. USA. 91:10645-10649.
[0167] Liew et al. (1997). Mol. and Cell. Biochem. 172:81-87.
[0168] Niimura H et al. (1998). New Eng. J Med. 338:1248-1257.
[0169] Ogawa M (1993). Blood 81:2844-2853.
[0170] Santoro I M & Groden J (1997). Cancer Res. 57:488-494.
[0171] Yuasa T et al. (1998). Japanese J Cancer Res. 89:879-882.
[0172] Description of Tables:
[0173] Table 1: Overlap of Genes Expressed in Blood
[0174] (Estimated from about 5,100 unique known genes from the over 25,000 ESTs obtained from human blood cDNA libraries).
[0175] Table 2: Comparison of Approximately 5,140 Unique Genes Identified in the Blood Cell cDNA Library to Genes Previously Identified in Specific Tissues
[0176] Column 1: List of unique genes derived from 25,000 known ESTs from blood cells.
[0177] Column 2: Number of genes found in randomly sequenced ESTs from blood cells.
[0178] Column 3: Accession number.
[0179] Column 4: “+” indicates the presence of the unique gene in publicly available cDNA libraries of blood (Bl), brain (Br), heart (H), kidney (K), liver (Li) and lung (Lu).
[0180] **Comparison to previously identified tissue-specific genes was determined using the GenBank of the National Centre of Biotechnology Information (NCBI) Database.
[0181] Table 3 shows genes that are differentially expressed in blood samples from patients with different diseases as compared to blood samples from healthy patients.
[0182] Table 3A shows the identity of those genes that are differentially expressed in blood samples from patients with osteoarthritis and hypertension as compared with normal patients as depicted in FIG. 8
[0183] Table 3B shows the identity of those genes that are differentially expressed in blood samples from patients with osteoarthritis and obesity as compared with normal patients as depicted in FIG. 9.
[0184] Table 3C shows the identity of those genes that are differentially expressed in blood samples from patients with osteoarthritis and allergies as compared with normal patients as depicted in FIG. 10.
[0185] Table 3D shows the identity of those genes that are differentially expressed in blood samples from patients with osteoarthritis and subject to systemic steroids as compared with normal patients as depicted in FIG. 11.
[0186] Table 3E shows the identity of those genes that are differentially expressed in blood samples from patients with hypertension as depicted in FIG. 12.
[0187] Table 3F shows the identity of those genes that are differentially expressed in blood samples from patients obesity as depicted in FIG. 13.
[0188] Table 3G shows the identity of those genes that are differentially expressed in blood samples from patients with type II diabetes as depicted in FIG. 14.
[0189] Table 3H shows the identity of those genes that are differentially expressed in blood samples from patients with hyperlipidemia as depicted in FIG. 15.
[0190] Table 3I shows the identity of those genes that are differentially expressed in blood samples from patients with lung disease as depicted in FIG. 16.
[0191] Table 3J shows the identity of those genes that are differentially expressed in blood samples from patients with bladder cancer as depicted in FIG. 17.
[0192] Table 3K shows the identity of those genes that are differentially expressed in blood samples from patients with bladder cancer as depicted in FIG. 18.
[0193] Table 3L shows the identity of those genes that are differentially expressed in blood samples from patients with coronary artery disease (CAD) as depicted in FIG. 19.
[0194] Table 3M shows the identity of those genes that are differentially expressed in blood samples from patients with rheumatoid arthritis as depicted in FIG. 20.
[0195] Table 3N shows the identity of those genes that are differentially expressed in blood samples from patients with depression as depicted in FIG. 21.
[0196] Table 3O shows the identity of those genes that are differentially expressed in blood samples from patients with various stages of osteoarthritis as depicted in FIG. 22.
[0197] Table 3P shows the identity of those genes that are differentially expressed in blood samples from patients with hypertension and OA when compared with patients who have OA only wherein genes identified in Table 3A have been removed so as to identify genes which are unique to hypertension.
[0198] Table 3Q shows the identity of those genes which were identified in Table 3A which are shared with those genes differentially expressed in blood samples from patients with hypertension and OA when compared with patients who have OA only.
[0199] Table 3R shows the identity of those genes that are differentially expressed in blood samples from patients who are obese and have OA when compared with patients who have OA only and wherein genes identified in Table 3B have been removed so as to identify genes which are unique to obesity.
[0200] Table 3S shows the identify of those genes identified in Table 3B which are shared with those genes differentially expressed in blood samples from patients who are obese and have OA when compared with patients who have OA.
[0201] Table 3T shows the identity of those genes that are differentially expressed in blood samples from patients with allergies and OA when compared with patients who have OA only wherein genes identified in Table 3C have been removed so as to identify genes which are unique to allergies.
[0202] Table 3U shows the identify of those genes identified in Table 3C which are shared with those genes differentially expressed in blood samples from patients with allergies and OA when compared with patients who have OA only.
[0203] Table 3V shows the identity of those genes that are differentially expressed in blood samples from patients who are on systemic steroids and have OA when compared with patients who have OA only wherein genes identified in Table 3D have been removed so as to identify genes which are unique to patients on systemic steroids.
[0204] Table 3W shows the identify of those genes identified in Table 3D which are shared with those genes differentially expressed in blood samples from patients who are on systemic steroids and have OA when compared with patients who have OA only.
[0205] Table 3X shows the identity of those genes that are differentially expressed in blood samples from patients with liver cancer as depicted in FIG. 25.
[0206] Table 3Y shows the identity of those genes that are differentially expressed in blood samples from patients with schizophrenia as depicted in FIG. 26.
[0207] Table 3Z shows the identity of those genes that are differentially expressed in blood samples from patients with Chagas disease as depicted in FIG. 27.
[0208] Table 3AA shows the identity of those genes that are differentially expressed in blood samples from patients with asthma as depicted in FIG. 28.
[0209] Table 3AB shows the identity of those genes that are differentially expressed in blood from patients with either mild or severe OA, but for which genes relevant to asthma, obesity, hypertension, systemic steroids and allergies have been removed.
[0210] Table 3AC shows the identity of those genes that are differentially expressed in blood from patients with schizophrenia as compared with manic depression syndrome (MDS).
[0211] Table 3AD shows the identity of those genes that are differentially expressed in blood from patients taking either birth control, prednisone or hormone replacement therapy and presenting with OA as depicted in FIG. 34.
[0212] Table 4 shows 102 EST sequences of Tables 3A-3AD with “no-significant match” to known gene sequences.
[0213] Table 5 shows a list of genes showing greater than two fold differential expression in CAD peripheral blood cells vs. normal blood cells.
[0214] The following examples are given for the purpose of illustrating various embodiments of the invention and are not meant to limit the present invention in any fashion.
EXAMPLE 1
[0215] Construction of a cDNA Library
[0216] RNA extracted from human tissues (including fetal heart, adult heart, liver, brain, prostate gland and whole blood) were used to construct unidirectional cDNA libraries. The first mammalian heart cDNA library was constructed as early as 1982. Since then, the methodology has been revised and optimal conditions have been developed for construction of human heart and hematopoietic progenitor cDNA libraries (Liew et al., 1984; Liew 1993, Claudio et al., 1998). Most of the novel genes which were identified by sequence annotation can now be obtained as full length transcripts.
EXAMPLE 2
[0217] Catalogue of EST Database
[0218] Random partial sequencing of expressed sequence tags (ESTs) of cDNA clones from the blood cell library was carried out to establish an EST database of blood. The known genes as derived from the ESTs were categorized into seven major cellular functions (Hwang, Dempsey et al., 1997). The preparation of the chondrocyte-specific EST database is reported in WO 02/070737, which is hereby incorporated by reference in its entirety.
EXAMPLE 3
[0219] Differential Screening of cDNA Library
[0220] cDNA probes generated from transcripts of each tissue were used to hybridize the blood cell cDNA clones or chondrocyte cDNA clones (Liew et al., 1997; WO 02/070737). The “positive” signals which were hybridized with P-labelled cDNA probes were defined as genes which shared identity with blood and respective tissues. The “negative” spots which were not exposed to P-labelled cDNA probes were considered to be blood-cell-enriched or low frequency transcripts.
EXAMPLE 4
[0221] Reverse Transcriptase-Polymerase Chain Reaction (RT-PCR) Assay
[0222] RNA extracted from samples of human tissue was used for RT-PCR analysis (Jin et al. 1990). Three pairs of forward and reverse primers were designed for human cardiac beta-myosin heavy chain gene (MyHC), amyloid precursor protein (APP) gene and adenomatous polyposis-coli protein (APC) gene. The PCR products were also subjected to automated DNA sequencing to verify the sequences as derived from the specific transcripts of blood.
EXAMPLE 5
[0223] Detection of Tissue Specific Gene Expression in Human Blood Using RT-PCR
[0224] The beta-myosin heavy chain gene (βMyHC) transcript (mRNA) is known to be highly expressed in ventricles of the human heart. This sarcomeric protein is important for heart muscle contraction and its presence would not be expected in other non-muscle tissues and blood. In 1990, the gene for human cardiac βMyHC was completely sequenced (Liew et al. 1990) and was comprised of 41 exons and 42 introns.
[0225] The method of reverse transcription polymerase chain reaction (RT-PCR) was used to determine whether this cardiac specific mRNA is also present in human blood. A pair of primers was designed; the forward primer (SEQ ID No. 3) was on the boundary of exons 21 and 22, and the reverse primer (SEQ ID No. 4) was on the boundary of exons 24 and 25. This region of mRNA is only present in βMyHC and is not found in the alpha-myosin heavy chain gene (αMyHC).
[0226] A blood sample was first treated with lysing buffer and then undergone centrifuge. The resulting pellets were further processed with RT-PCR. RT-PCR was performed using the total blood cell RNA as a template. A nested PCR product was generated and used for sequencing. The sequencing results were subjected to BLAST and the identity of exons 21 to 25 was confirmed to be from βMyHC (FIG. 1A).
[0227] Using the same method just described, two other tissue specific genes—amyloid precursor protein (APP, forward primer, SEQ ID No. 7; reverse primer, SEQ ID No. 8) found in the brain and associated with Alzheimer's disease, and adenomatous polyposis coli protein (APC) found in the colon and rectum and associated with colorectal cancer (Groden et al. 1991; Santoro and Groden 1997)—were also detected in the RNA extracted from human blood (FIG. 1B).
EXAMPLE 6
[0228] Multiple RT-PCR Analysis on a Drop of Blood from a Normal/Diseased Individual
[0229] A drop of blood was extracted to obtain RNA to carry out quantitative RT-PCR analysis. Specific primers for the insulin gene were designed: forward primer (5′-GCCCTCTGGGGACCTGAC-3′, SEQ ID NO 1) of exon 1 and reverse primer (5′-CCCACCTGCAGGTCCTCT-3”, SEQ ID NO 2) of exons 1 and 2 of insulin gene. Such reverse primer was obtained by deleting the intron between the exons 1 and 2. Blood samples of 4 normal subjects were assayed. It was found that the insulin gene is expressed in the blood and the quantitative expression of the insulin gene in a drop of blood is influenced by fasting and non-fasting states of normal healthy subjects (FIG. 2). This very low level of expression of the insulin gene reflects the phenotypic status of a person and strongly suggests that there is a physiological and pathological role for its expression, contrary to the basal or illegitimate theory of transcription suggested by Chelly et al. (1989) and Kimoto (1998).
[0230] Same quantitative RT-PCR analysis was performed using insulin specific primers on RNA samples extracted from a drop of blood from a normal healthy person, a person having late-onset diabetes (Type II) and a person having asymptomatic diabetes. It was found that the insulin gene is expressed differentially amongst subjects that are healthy, diagnosed as type II diabetic, and also in an asymptomatic preclinical patient (FIG. 3).
[0231] Similarly, specific primers for the atrial natriuretic factor (ANF) gene were designed (forward primer, SEQ ID No. 5; reverse primer, SEQ ID No. 6) and RT-PCR analysis was performed on a drop of blood. ANF is known to be highly expressed in heart tissue biopsies and in the plasma of heart failure patients. However, atrial natriuretic factor was observed to be expressed in the blood and the expression of the atrial natriuretic factor gene is significantly higher in the blood of patients with heart failure as compared to the blood of a normal control patient.
[0232] Specific primers for the zinc finger protein gene (ZFP, forward primer, SEQ ID No. 9; reverse primer, SEQ ID No. 10) were also designed and RT-PCR analysis was performed on a drop of blood. ZFP is known to be high in heart tissue biopsies of cardiac hypertrophy and heart failure patients. In the present study, the expression of ZFP was observed in the blood as well as differential expression levels of ZFP amongst the normal, diabetic and asymptomatic preclinical subjects (FIG. 4); although neither of the non-normal subjects has been specifically diagnosed as suffering from cardiac hypertrophy and/or heart failure, the higher expression levels of the ZFP gene in their blood may indicate that these subjects are headed in that general direction.
[0233] It was hypothesized that a housekeeping gene such as glyceraldehyde dehydrogenase (GADH) which is required and highly expressed in all cells would not be differentially expressed in the blood of normal vs. disease subjects. This hypothesis was confirmed by RT-PCR using GADH specific primers (FIG. 4). Thus, GADH is useful as an internal control.
[0234] Standardized levels of insulin gene or ZFP gene expressed in a drop of blood were estimated using a housekeeping gene as an internal control relative to insulin or ZFP expressed (FIGS. 5A & 5B). The levels of insulin gene expressed in each fractionated cell from whole blood were also standardized and shown in FIG. 5C.
EXAMPLE 7
[0235] Human Blood Cell cDNA Library
[0236] In order to further substantiate the present invention, differential screening of the human blood cell cDNA library was conducted. cDNA probes derived from human blood, adult heart or brain were respectively hybridized to the human blood cDNA library clones. As shown in FIG. 7, more than 95% of the “positively” identified clones are identical between the blood and other tissue samples.
[0237] DNA sequencing of randomly selected clones from the human whole blood cell cDNA library was also performed. This allowed information regarding the cellular function of blood to be obtained concurrently with gene identification. More than 20,000 expressed sequence tags (ESTs) have been generated and characterized to date, 17.6% of which did not result in a statistically significant match to entries in the GenBank databases and thus were designated as “Novel” ESTs. These results are summarized in FIG. 7 together with the seven cellular functions related to percent distribution of known genes in blood and in the fetal heart.
[0238] From 20,000 ESTs, 1,800 have been identified as known genes which may not all appear in the hemapoietic system. For example, the insulin gene and the atrial natriuretic factor gene have not been detected in these 20,000 ESTs but their transcripts were detected in a drop of blood, strongly suggesting that all transcripts of the human genome can be detected by performing RT-PCR analysis on a drop of blood.
[0239] In addition, approximately 400 novel genes have been identified from the 20,000 ESTs characterized to date, and these will be subjected to full length sequencing and open reading frame alignment to reduce the actual number of novel ESTs prior to screening for disease markers.
[0240] Analysis of the approximately 6,283 ESTs which have known matches in the GenBank databases revealed that this dataset represents over 1,800 unique genes. These genes have been catalogued into seven cellular functions. Comparisons of this set of unique genes with ESTs derived from human brain, heart, lung and kidney demonstrated a greater than 50% overlap in expression (Table 1).
TABLE 1 Overlap of Genes Expressed in Blood Tissue UniGene* Overlap Brain 19,158 70% Heart 17,021 67% Kidney 19,414 69% Liver 22,836 71% Lung 22,209 75%
[0241] There are about 5,100 unique known genes from the over 25,000 ESTs obtained from human blood cDNA libraries. These genes were searched against human UniGene, Build #160 (with a total of 111,064 clusters).
EXAMPLE 8
[0242] Blood Cell ESTs
[0243] The results from the differential screening clearly indicate that the transcripts expressed in the whole blood are reflective of genes expressed in all cells and tissues of the body. More than 95% of detectable spots were identical from two different tissues. The remaining 5% of spots may represent cell- or tissue-specific transcripts; however, results obtained from partial sequencing to generate ESTs of these clones revealed most of them not to be cell- or tissue-specific transcripts. Therefore, the negative spots are postulated to be reflective of low abundance transcripts in the tissue from which the cDNA probes were derived.
[0244] An alternative approach that was employed to identify transcripts expressed at low levels is the large-scale generation of expressed sequence tags (ESTs). There is substantial evidence regarding the efficiency of this technology to detect previously characterized (known) and uncharacterized (unknown or novel) genes expressed in the cardiovascular system (Hwang & Dempsey et al. 1997). In the present invention, 20,000 ESTs have been produced from a human blood cell cDNA library and resulted in the identification of approximately 1,800 unique known genes (Table 2)
[0245] In the most recent GenBank release, analysis of more than 300,000 ESTs in the database (dbESTs) generated more than 48,000 gene clusters which are thought to represent approximately 50% of the genes in the human genome. Only 4,800 of the dbESTs are blood-derived. In the present invention, 20,000 ESTs have been obtained to date from a human blood cDNA library, which provides the world's most informative database with respect to blood cell transcripts. From the limited amount of information generated so far (i.e. 1,800 unique genes), it has already been determined that more than 50% of the transcripts are found in other cells or tissues of the human body (Table 2). Thus, it is expected that by increasing the number of ESTs generated, more genes will be identified that have an overlap in expression between the blood and other tissues. Furthermore, the transcripts for several genes which are known to have tissue-restricted patterns of expression (i.e. βMyHC, APP, APC, ANF, ZFP) have also been demonstrated to be present in blood.
[0246] Most recently, a cDNA library of human hematopoietic progenitor stem cells has also been constructed. From the limited set of 1,000 ESTs, there are at least 200 known genes that are shared with other tissue related genes (Claudio et al. 1998).
[0247] Table 2 demonstrates the expression of known genes of specific tissues in blood cells. Previously, only the presence of “housekeeping” genes would have been expected. Additionally, the presence of at least 25 of the currently known 500 genes corresponding to molecular drug targets was detected. These molecular drug targets are used in the treatment of a variety of diseases which involve inflammation, renal and cardiovascular function, neoplastic disease, immunomodulation and viral infection (Drews & Ryser, 1997). It is expected that additional novel ESTs will represent future molecular drug targets.
EXAMPLE 9
[0248] Blood cDNA chip Microarray Data Analysis of gene expression profiles of blood samples from individuals having coronary artery disease as compared with gene expression profiles from normal individuals.
[0249] A microarray was constructed using cDNA clones from a human peripheral blood cell cDNA library, as described herein. A total of 10,368 polymerase chain reaction (PCR) products of the clones from the human peripheral blood cell cDNA library described herein were arrayed using GNS 417 arrayer (Affymetrix). RNA for microarray analysis was isolated from whole blood samples obtained from three male and one female patients with coronary heart disease (80-90% stenosis) receiving vascular extension drugs and awaiting bypass surgery, and three healthy male controls.
[0250] A method of high-fidelity mRNA amplification from 1 pg of total RNA sample was used. Cy5- or Cy3-dUTP was incorporated into cDNA probes by reverse transcription of anti-sense RNA, primed by oligo-dT. Labelled probes were purified and concentrated to the desired volume. Pre-hybridization and hybridization were performed following Hegde's protocol (Hegde P et al., A concise guide to cDNA microarray analysis. Biotechniques, 2000; 29: 548-56). After overnight hybridization and washing, hybridization signals were detected with a GMS 418 scanner at 635-nm (Cy5) and 532-nm (Cy3) wave lengths (see FIG. 24). Two RNA pools were labelled alternatively with Cy5- and Cy3-dUTP, and each experiment was repeated twice. Cluster analysis using GeneSpring™ 4.1.5 (Silicon Genetics) revealed two distinct groups consisting of four CAD and three normal control samples. Two images scanned at different wavelengths were super-imposed. Individual spots were identified on a customized grid. Of 10,368 spots, 10,012 (96.6%) were selected after the removal of spots with irregular shapes. Data quality was assessed with values of Ch1GTB2 and Ch2GTB2 provided by ScanAlyze. Only spots with Ch1GTB2 and Ch2GTB2 over 0.50 were selected. After evaluation of signal intensities, 8750 (84.4%) spots were left. Signal intensities were normalized using a scatter-plot of the signal intensities of the two channels. After normalization, the expression ratios of β-actin were 1.00+0 21, 1.11+0.22, 1.14+0.20 and 1.30+0.18 (24 samples of β-actin were spotted on this slide as the positive control) in the four images. Gene differential expression was assessed as the ratio of two wave-length signal intensities. Spots showing a differential expression more than twofold in all four experiments were identified as peripheral blood cell, differentially expressed candidate genes in CAD. 108 genes are differentially expressed in CAD peripheral blood cells. 43 genes are downregulated in CAD blood cells and 65 are upregulated (see Table 5). Functional characterization of these genes shows that differential expression takes place in every gene functional category, indicating that profound changes occur in CAD blood cells.
[0251] The differential expression of three genes, pro-platelet basic protein (PBP), platelet factor 4 (PF4) and coagulation factor XIII A1 (F13A), initially identified in the microarray data analysis, was further examined by reverse transcriptase-PCR (RT-PCR) using the Titan One-tube RT-PCR kit (Boehringer Mannheim). Reaction solution contains 0.2 mM each dNTP, 5 mM DTT, 1.5 mM MgCl 0.1 pg of total RNA from each sample and 20 pmol each of left and right primers of PBP (5′- GGTGCTGCTGCTTCTGTCAT-3′ and 5′-GGCAGATTTT CCTCCCATCC-3′), F13A (5′-AGTCCACCGTGCTAACCATC-3′ and 5′-AGGGAGTCACTGCTCATGCT-3′) and PF4 (5′ GTTGCTGCTCCTGCCACTT 3′ and 5′ GTGGCTATCAGTTGGGCAGT-3′). RT-PCR steps are as follows: 1. reverse-transcription: 30 min at 60° C.; 2. PCR: 2 min at 94° C., followed by 30-35 cycles (as optimized for each gene) for 30 s at 94° C., 30 s at optimized annealing temperature and 2 min at 68° C.; 3. final extension: 7 min at 68° C. PCR products were electrophoresed on 1.5% agarose gels. Human (β-actin primers (5′-GCGAGAAGATGACCCAGATCAT-3′ and 5′-GCTCAGGAGGAGCAATGATCTT-3′) were used as the internal control. The RT-PCR analysis confirmed that the expression of the three secreted proteins: PBP, PF4 and F13A were all upregulated in CAD blood cells (see FIG. 23).
TABLE 5 Protein Accession Fold Functional Accession number (average) category Number Upregulated gene in CAD REV3-like, catalytic AF035537 2.3 Cell cycle NP_002903 subunit of DNA polymerase zeta TGFB1-induced anti- D86970 2.2 Cell cycle NP_510880 apoptotic factor 1 A disintegrin and AA044656 2.7 Cell signaling NP_001101 metalloproteinase domain 10 Centaurin, delta 2 AA351412 2 Cell signaling NP_631920 Chloride intracellular AA411940 2.2 Cell signaling NP_039234 channel 4 Endothelin receptor typeA D90348 2.1 Cell signaling NP_001948 Glutamate receptor, N33821 2.4 Cell signaling NP_777567 ionotropic Mitogen-activated protein L38486 3.7 Cell signaling NP_002395 kinase 7 Mitogen-activated protein AB009356 4.5 Cell signaling NP_663306 kinase kinase kinase 7 Myristoylated alanine-rich D10522 2.5 Cell signaling NP_002347 protein kinase C substrate NIMA-related kinase 7 AA093324 3.5 Cell signaling NP_598001 PAK2 AA262968 3.5 Cell signaling Q13177 Phospholipid scramblase 1 AA054476 3.3 Cell signaling NP_066928 Serum deprivation Z30112 4.5 Cell signaling NP_004648 response Adducin 3 AA029158 2.9 Cell structure NP_063968 Desmin AF167579 4.4 Cell structure NP_001918 Fibromodulin W23613 2.9 Cell structure NP_002014 Laminin, beta 2 S77512 2.2 Cell structure NP_002283 Laminin, beta 3 L25541 2.4 Cell structure NP_000219 Osteonectin Y00755 3.1 Cell structure NP_003109 CD59 antigen p18-20 W01111 2.4 Cell/organism NP_000602 defense Clusterin M64722 3.5 Cell/organism NP_001822 defense F13A M14539 2.1 Cell/organism NP_000120 defense Defensin, alpha 1 M26602 4.2 Cell/organism NP_004075 defense PF4 M25897 2.1 Cell/organism NP_002610 defense PBP M54995 5.5 Cell/organism NP_002695 defense E2F transcription factor 3 D38550 2.1 Gene NP_001940 expression Early growth response 1 M62829 2.7 Gene NP_001955 expression Eukaryotic translation N86030 2.3 Gene NP_001393 elongation factor 1 alpha 1 expression Eukaryotic translation M15353 2.1 Gene NP_001959 initiation factor 4E expression F-box and WD-40 domain AB014596 2.7 Gene NP_387449 protein 1B expression Makorin, ring finger AA331966 2.1 Gene NP_054879 protein, 2 expression Non-canonical ubiquitin- N92776 2.5 Gene NP_057420 conjugating enzyme 1 expression Nuclear receptor subfamily Z30425 4.7 Gene NP_005113 1, group I, member 3 expression Ring finger protein 11 T08927 3 Gene NP_055187 expression Transducin-like enhancer M99435 3.3 Gene NP_005068 of split 1 expression Alkaline phosphatase, AB011406 2.2 Metabolism NP_000469 liver/bone/kidney Annexin A3 M63310 3.4 Metabolism NP_005130 Branched chain AA336265 4.8 Metabolism NP_005495.1 aminotransferase 1, cytosolic Cytochrome b AF042500 2.5 Metabolism Glutaminase D30931 2.6 Metabolism NP_055720 Lysophospholipase I AF035293 2.8 Metabolism NP_006321 NADH dehydrogenase 1, AA056111 2.5 Metabolism NP_002485 subcomplex unknown 1, 6 kDa Phosphofructokinase M26066 2.2 Metabolism NP_000280 Ubiquinol-cytochrome c M22348 2.5 Metabolism NP_006285 reductase binding protein CGI-110 protein AA341061 2.4 Unclassified NP_057131 Dactylidin H95397 2.7 Unclassified NP_112225 Deleted in split-hand/split- T24503 2.4 Unclassified NP_006295 foot 1 region Follistatin-like 1 R14219 2.7 Unclassified NP_009016 FUS-interacting protein 1 W37945 2.8 Unclassified NP_473357 Hypothetical protein W47233 7 Unclassified NP_112201 FLJ12619 Hypothetical protein from N68247 2.7 Unclassified EUROIMAGE 588495 Hypothetical protein AA251423 2.2 Unclassified NP_057702 LOC51315 KIAA1705 protein T80569 2.7 Unclassified NP_009121.1 Mesoderm induction early AI650409 2.2 Unclassified NP_065999 response 1 Phosphodiesterase 4D- AA740661 2.5 Unclassified NP_055459 interacting protein Preimplantation protein 3 D59087 2.5 Unclassified NP_056202 Putative nuclear protein W33098 2.8 Unclassified NP_115788 ORF1-FL49 Similar to rat nuclear H09434 2.2 Unclassified Q9H1E3 ubiquitous casein kinase 2 Similar to RIKEN AA297412 2.5 Unclassified T02670 Spectrin, beta AI334431 2.5 Unclassified Q01082 Stromal cell-derived factor H71558 4.1 Unclassified NP_816929 receptor 1 Thioredoxin-related AA421549 2.8 Unclassified NP_110437 protein Transmembrane 4 D29808 2.4 Unclassified NP_004606 superfamily member 2 Tumor endothelial marker 8 D79964 2.5 Unclassified NP_444262 Downregulated gene in CAD CASP8 and FADD-like AF015450 0.45 Cell cycle NP_003870 apoptosis regulator CD81 antigen M33680 0.41 Cell cycle NP_004347 Cell division cycle 25B M81934 0.4 Cell cycle NP_068660 DEAD/H (Asp-Glu-Ala- AA985699 0.42 Cell cycle NP_694705 Asp/His) box polypeptide 27 F-box and leucine-rich R98291 0.27 Cell cycle NP_036440 repeat protein 11 Minichromosome H10286 0.43 Cell cycle NP_003897 maintenance deficient 3 associated protein Protein phosphatase 2, J02902 0.48 Cell cycle NP_055040 regulatory subunit A, alpha isoform Thyroid autoantigen 70 kDa J04607 0.25 Cell cycle NP_001460 A disintegrin and R32760 0.37 Cell signaling metalloproteinase domain 17 A kinase anchor protein 13 M90360 0.31 Cell signaling NP_658913 Calpastatin AF037194 0.39 Cell signaling NP_006471 Diacylglycerol kinase, AF064770 0.44 Cell signaling NP_001336 alpha 80 kDa gamma-aminobutyric acid AJ012187 0.42 Cell signaling NP_068705 B receptor, 1 Inositol polyphosphate-5- U84400 0.41 Cell signaling NP_005532 phosphatase, 145 kDa Lymphocyte-specific X05027 0.45 Cell signaling NP_005347 protein tyrosine kinase RAP1B, member of RAS P09526 0.4 Cell signaling P09526 oncogene family Ras association AF061836 0.43 Cell signaling NP_733835 (RalGDS/AF-6) domain family 1 CDC42-effector protein 3 AF104857 0.28 Cell signaling NP_006440 Leupaxin AF062075 0.31 Cell signaling NP_004802 Annexin A6 D00510 0.45 Cell structure NP_004024 RAN-binding protein 9 AB008515 0.41 Cell structure NP_005484 Thymosin, beta 10 M20259 0.26 Cell structure NP_066926 GranzymeA M18737 0.17 Cell/organism NP_006135 defense ThromboxaneA synthase 1 M80646 0.44 Cell/organism NP_112246 defense Coatomer protein AA357332 0.39 Gene NP_057535 complex, subunit beta expression Cold-inducible RNA- H39820 0.27 Gene NP_001271 binding protein expression Leucine-rich repeat U69609 0.44 Gene NP_004726 interacting protein 1 expression Proteasome subunit, alpha D00762 0.31 Gene NP_687033 type, 3 expression Proteasome subunit, alpha AF022815 0.35 Gene NP_689468 type, 7 expression Protein phosphatase 1G, AI417405 0.5 Gene NP_817092 gamma isoform expression Ribonuclease/angiogenin M36717 0.44 Gene NP_002930 inhibitor expression RNA-binding protein- AF021819 0.3 Gene NP_009193 regulatory subunit expression Signal transducer and U16031 0.45 Gene NP_003144 activator of transcription 6 expression Transcription factor A, M62810 0.41 Gene NP_036383 mitochondrial expression Ubiquitin-specific protease 4 AF017306 0.31 Gene NP_003354 expression Dehydrogenase/reductase AA100046 0.46 Metabolism NP_612461 SDR family member 1 Solute carrier family 25, J03592 0.3 Metabolism NP_001627 member 6 Amplified in osteosarcoma U41635 0.45 Unclassified NP_006803 Expressed in activated C00577 0.45 Unclassified NP_009198 T/LAK lymphocytes Integral inner nuclear W00460 0.4 Unclassified NP_055134 membrane protein Phosphodiesterase 4D- T95969 0.45 Unclassified NP_055459 interacting protein Tumor endothelial marker N93789 0.45 Unclassified NP_065138 7 precursor Wiskott-Aldrich syndrome AF031588 0.22 Unclassified NP_003378 protein interacting protein
EXAMPLE 10
[0252] ChondroChip™ Microarray Data Analysis of gene expression profiles of blood samples from co-morbid individuals having osteoarthritis and hypertension as compared with gene expression profiles from normal individuals.
[0253] This example demonstrates the use of the claimed invention to detect differential gene expression in blood samples taken from patients with osteoarthritis and hypertension as compared to blood samples taken from healthy patients.
[0254] As used herein, the term “hypertension” is defined as high blood pressure or elevated arterial pressure. Patients identified with hypertension herein include persons who have an increased risk of developing a morbid cardiovascular event and/or persons who benefit from medical therapy designed to treat hypertension. Patients identified with hypertension also can include persons having systolic blood pressure of >130 mm Hg or a diastolic blood pressure of >90 mm Hg or a person takes antihypertensive medication.
[0255] Osteoarthritis (OA), as used herein also known as “degenerative joint disease”, represents failure of a diarthrodial (movable, synovial-lined) joint. It is a condition, which affects joint cartilage, and or subsequently underlying bone and supporting tissues leading to pain, stiffness, movement problems and activity limitations. It most often affects the hip, knee, foot, and hand, but can affect other joints as well.
[0256] OA severity can be graded according to the system described by Marshall (Marshall K W. J. Rheumatol, 1996:23(4) 582-85). Briefly, each of the six knee articular surfaces was assigned a cartilage grade with points based on the worst lesion seen on each particular surface. Grade 0 is normal (0 points), Grade I cartilage is soft or swollen but the articular surface is intact (1 point). In Grade II lesions, the cartilage surface is not intact but the lesion does not extend down to subchondral bone (2 points). Grade III damage extends to subchondral bone but the bone is neither eroded nor eburnated (3 points). In Grade IV lesions, there is eburnation of or erosion into bone (4 points). A global OA score is calculated by summing the points from all six cartilage surfaces. If there is any associated pathology, such as meniscus tear, an extra point will be added to the global score. Based on the total score, each patient is then categorized into one of four OA groups: mild (1-6), moderate (7-12), marked (13-18), and severe (>18). As used herein, patients identified with OA may be categorized in any of the four OA groupings as described above.
[0257] Blood samples were taken from patients who were diagnosed with osteoarthritis and hypertension as defined herein. Gene expression profiles were then analysed and compared to profiles from patients unaffected by any disease. In each case, the diagnosis of osteoarthritis and hypertension was corroborated by a skilled Board certified physician.
[0258] Total mRNA from a drop of peripheral whole blood taken from each patient was isolated using TRIzol® reagent (GIBCO) and fluorescently labelled probes for each blood sample were generated as described above. Each probe was denatured and hybridized to a 15K Chondrogene Microarray Chip (ChondroChip™) as described herein. Identification of genes differentially expressed in blood samples from patients with disease as compared to healthy patients was determined by statistical analysis using the Wilcox Mann Whitney rank sum test (Glantz S A., Primer of Biostatistics., 5th ed., New York, USA: McGraw-Hill Medical Publishing Division, 2002).
[0259] [0259]FIG. 8 shows a diagrammatic representation of gene expression profiles of blood samples from individuals having hypertension and osteoarthritis as compared with gene expression profiles from normal individuals. Expression profiles were generated using GeneSpring™ software analysis as described herein. Each column represents the hybridization pattern resulting from a single individual. In this example, hypertensive patients also presented with OA, as described herein. Normal individuals have no known medical conditions and were not taking any known medication. Hybridizations to create said gene expression profiles were done using the ChondroChip™. A dendogram analysis is shown above. Samples are clustered and marked as representing patients who are hypertensive or normal. The “*” indicates those patients who abnormally clustered as either hypertensive, or normal despite presenting with the reverse. The number of hybridizations profiles determined for either hypertensive patients or normal individuals are shown. 861 differentially expressed genes were identified as being differentially expressed with a p value of <0.05 as between the hypertensive patients and normal individuals. The identity of the differentially expressed genes is shown in Table 3A.
[0260] Classification or class prediction of a test sample as either having hypertension and OA or being normal can be done using the differentially expressed genes as shown in Table 3A in combination with well known statistical algorithms for class prediction as would be understood by a person skilled in the art and described herein. Commercially available programs such as those provided by Silicon Genetics (e.g. GeneSpring™) for Class Predication are also available.
EXAMPLE 10A
[0261] ChondroChip™ Microarray Data Analysis of gene expression profiles of blood samples from individuals having osteoarthritis and hypertension as compared with gene expression profiles from patients having osteoarthritis only.
[0262] This example demonstrates the use of the claimed invention to detect differential gene expression in blood samples taken from co-morbid patients with osteoarthritis and hypertension as compared to blood samples taken from OA patients only.
[0263] Blood samples were taken from patients who were diagnosed with osteoarthritis and hypertension as defined herein. Gene expression profiles were then analysed and compared to profiles from patients having OA only. In each case, the diagnosis of osteoarthritis and/or hypertension was corroborated by a skilled Board certified physician.
[0264] Total mRNA from a drop of peripheral whole blood taken from each patient was isolated using TRIzol® reagent (GIBCO) and fluorescently labelled probes for each blood sample were generated as described above. Each probe was denatured and hybridized to a 15K Chondrogene Microarray Chip (ChondroChip™) as described herein. Identification of genes differentially expressed in blood samples from patients with disease as compared to OA patients only was determined by statistical analysis using the Wilcox Mann Whitney rank sum test (Glantz S A., Primer of Biostatistics., 5th ed., New York, USA: McGraw-Hill Medical Publishing Division, 2002).
[0265] Expression profiles were generated using GeneSpring™ software analysis as described herein (data not shown). The gene list generated from this analysis was identified and those genes previously identified in Table 3A removed so as to identify those genes which are unique to hypertension. 790 differentially expressed genes were identified as being differentially expressed with a p value of <0.05 as between the OA and hypertensive patients when compared with OA individuals. 577 genes were identified as unique to hypertension. The identity of these differentially expressed genes are shown in Table 3P. A gene list is also provided of the 213 genes which were found in common as between those genes identified in Table 3A and genes differentially expressed in blood samples taken from patients with osteoarthritis and hypertension as compared to blood samples taken from OA patients only. The identity of these intersecting differentially expressed genes is shown in Table 3Q and a venn diagram showing the relationship between the various groups of gene lists is found in FIG. 29.
[0266] Classification or class prediction of a test sample as having hypertension or not having hypertension can be done using the differentially expressed genes as shown in Table 3P as the predictor genes in combination with well known statistical algorithms as would be understood by a person skilled in the art and described herein. Commercially available programs such as those provided by Silicon Genetics (e.g. GeneSpring™) for Class Predication are also available. Classification of individuals as having both OA and hypertension using the genes in Table 3Q can also be performed.
EXAMPLE 11
[0267] ChondroChip™ Microarray Data Analysis of gene expression profiles of blood samples from co-morbid individuals having osteoarthritis and obesity as compared with gene expression profiles from normal individuals.
[0268] This example demonstrates the use of the claimed invention to detect differential gene expression in blood samples taken from patients with obesity and OA as compared to blood samples taken from healthy patients.
[0269] As used herein, “obesity” is defined as an excess of adipose tissue that imparts a health risk. Obesity is assessed in terms of height and weight in the relevance of age. Patients who are considered obese include, but are not limited to, patients having a body mass index or BMI ((defined as body weight in kg divided by (height in meters) 2 ) greater than or equal to 30.0.
[0270] Blood samples were taken from patients who were diagnosed with osteoarthritis and obesity as defined herein. Gene expression profiles were then analysed and compared to profiles from patients unaffected by any disease. In each case, the diagnosis of the disease was corroborated by a skilled Board certified physician. Total mRNA from a drop of peripheral whole blood taken from each patient was isolated using TRIzol® reagent (GIBCO) and fluorescently labelled probes for each blood sample were generated as described above. Each probe was denatured and hybridized to a 15K Chondrogene Microarray Chip (ChondroChip™) as described herein. Identification of genes differentially expressed in blood samples from patients with disease as compared to healthy patients was determined by statistical analysis using the Wilcox Mann Whitney rank sum test (Glantz S A., Primer of Biostatistics., 5th ed., New York, USA: McGraw-Hill Medical Publishing Division, 2002).
[0271] [0271]FIG. 9 shows a diagrammatic representation of gene expression profiles of blood samples from individuals who were identified as obese as described herein as compared with gene expression profiles from normal individuals. Expression profiles were generated using GeneSpring™ software analysis as described herein. Each column represents the hybridization pattern resulting from a single individual. In this example, obese patients also presented with OA, as described herein. Normal individuals have no known medical conditions and were not taking any known medication. Hybridizations to create said gene expression profiles were done using the ChondroChip™. A dendogram analysis is shown above. Samples are clustered and marked as representing patients who are obese or normal. The “*” indicates those patients who abnormally clustered as either obese or normal despite presenting with the reverse. The number of hybridization profiles determined for obese patients with OA and normal individuals are shown. 913 genes were identified as being differentially expressed with a p value of <0.05 as between the obese patients with OA and normal individuals is noted. The identity of the differentially expressed genes is shown in Table 3B.
[0272] Classification or class prediction of a test sample as either having obesity and OA or being normal can be done using the differentially expressed genes as shown in Table 3B in combination with well known statistical algorithms as would be understood by a person skilled in the art and described herein. Commercially available programs such as those provided by Silicon Genetics (e.g. GeneSpring™) for Class Predication are also available.
EXAMPLE 11A
[0273] ChondroChip™ Microarray Data Analysis of gene expression profiles of blood samples from co-morbid individuals having osteoarthritis and obesity as compared with gene expression profiles from patients having osteoarthritis only.
[0274] This example demonstrates the use of the claimed invention to detect differential gene expression in blood samples taken from patients with obesity and OA as compared to blood samples taken from patients with OA only.
[0275] Blood samples were taken from patients who were diagnosed with osteoarthritis and obesity as defined herein. Gene expression profiles were then analysed and compared to profiles from patients affected by OA only.
[0276] In each case, the diagnosis of the disease was corroborated by a skilled Board certified physician. Total mRNA from a drop of peripheral whole blood taken from each patient was isolated using TRIzol® reagent (GIBCO) and fluorescently labelled probes for each blood sample were generated as described above. Each probe was denatured and hybridized to a 15K Chondrogene Microarray Chip (ChondroChip™) as described herein. Identification of genes differentially expressed in blood samples from patients with obesity and OA as compared to OA patients only was determined by statistical analysis using the Wilcox Mann Whitney rank sum test (Glantz S A., Primer of Biostatistics., 5th ed. New York, USA: McGraw-Hill Medical Publishing Division, 2002).
[0277] Expression profiles were generated using GeneSpring™ software analysis as described herein (data not shown). 671 genes were identified as being differentially expressed with a p value of <0.05 as between the obese patients with OA and those patients with only OA. Those genes previously identified in Table 3B were removed so as to identify those genes which are unique to obesity. The identity of these 519 genes unique to obesity are shown in Table 3R. A gene list is also provided of those genes which were found in common as between those genes identified in Table 3B and genes differentially expressed in blood samples taken from patients with osteoarthritis and obesity as compared to blood samples taken from OA patients only. 152 genes are shown in Table 3S. A venn diagram showing the relationship between the various groups of gene lists is found in FIG. 30.
[0278] Classification or class prediction of a test sample as having obesity or not having obesity can be done using the differentially expressed genes as shown in Table 3R as the predictor genes in combination with well known statistical algorithms as would be understood by a person skilled in the art and described herein. Commercially available programs such as those provided by Silicon Genetics (e.g. GeneSpring™) for Class Predication are also available. Classification of individuals as having both OA and obesity using the genes in Table 3S can also be performed.
EXAMPLE 12
[0279] ChondroChip™ Microarray Data Analysis of gene expression profiles of blood samples from co-morbid individuals having osteoarthritis and allergies as compared with gene expression profiles from normal individuals.
[0280] This example demonstrates the use of the claimed invention to detect differential gene expression in blood samples taken from patients with allergies as compared to blood samples taken from healthy patients.
[0281] As used herein, “allergies” encompasses diseases and conditions wherein a patient demonstrates a hypersensitive or allergic reaction to one or more substances or stimuli such as drugs, food stuffs, plants, animals etc. and as a result has an increased immune response. Such immune responses can include anaphylaxis, allergic rhinitis, asthma, skin sensitivity such as urticaria, eczema, and allergic contact dermatitis and ocular allergies such as allergic conjunctivitis and contact allergy. Patients identified as having allergies includes patients having one or more of the above noted conditions.
[0282] Blood samples were taken from patients who were diagnosed with osteoarthritis and allergies as defined herein. These patients are classified as presenting with co-morbidity, or multiple disease states. Gene expression profiles were then analysed and compared to profiles from patients unaffected by any disease. In each case, the diagnosis of osteoarthritis and allergies was corroborated by a skilled Board certified physician.
[0283] Total mRNA from a drop of peripheral whole blood taken from each patient was isolated using TRIzol® reagent (GIBCO) and fluorescently labelled probes for each blood sample were generated as described above. Each probe was denatured and hybridized to a 15K Chondrogene Microarray Chip (ChondroChip™) as described herein. Identification of genes differentially expressed in blood samples from patients with osteoarthritis and allergies as compared to healthy patients was determined by statistical analysis using the Wilcox Mann Whitney rank sum test (Glantz S A., Primer of Biostatistics., 5th ed., New York, USA: McGraw-Hill Medical Publishing Division, 2002).
[0284] [0284]FIG. 10 shows a diagrammatic representation of gene expression profiles of blood samples from individuals who were identified as having allergies as described herein as compared with gene expression profiles from normal individuals. Expression profiles were generated using GeneSpring™ software analysis as described herein. Each column represents the hybridization pattern resulting from a single individual. In this example, patients with allergies also presented with OA, as described herein. Normal individuals had no known medical conditions and were not taking any known medication. Hybridizations to create said gene expression profiles were done using the ChondroChip™. A dendogram analysis is shown above. Samples are clustered and marked as representing patients who are obese or normal. The “*” indicates those patients who abnormally clustered as either having allergies or being normal despite presenting with the reverse. The number of hybridizations profiles determined for patients with allergies and normal individuals are shown. 633 genes were identified as being differentially expressed with a p value of <0.05 as between patients with allergies and normal individuals is noted. The identity of the differentially expressed genes is shown in Table 3C.
[0285] Classification or class prediction of a test sample as either having allergies and OA or being normal can be done using the differentially expressed genes as shown in Table 3C in combination with well known statistical algorithms as would be understood by a person skilled in the art and described herein. Commercially available programs such as those provided by Silicon Genetics (e.g. GeneSpring™) for Class Predication are also available.
EXAMPLE 12A
[0286] ChondroChip™ Microarray Data Analysis of gene expression profiles of blood samples from individuals having osteoarthritis (OA) and allergies as compared with gene expression profiles from individuals with OA only.
[0287] This example demonstrates the use of the claimed invention to detect differential gene expression in blood samples taken from patients with allergies and OA as compared to blood samples taken from OA patients.
[0288] Blood samples were taken from patients who were diagnosed with osteoarthritis and allergies as defined herein. Gene expression profiles were then analysed and compared to profiles from patients affected by OA only. In each case, the diagnosis of osteoarthritis and allergies was corroborated by a skilled Board certified physician.
[0289] Total mRNA from a drop of peripheral whole blood taken from each patient was isolated using TRIzol® reagent (GIBCO) and fluorescently labelled probes for each blood sample were generated as described above. Each probe was denatured and hybridized to a 15K Chondrogene Microarray Chip (ChondroChip™) as described herein. Identification of genes differentially expressed in blood samples from patients with osteoarthritis and allergies as compared to OA patients only was determined by statistical analysis using the Wilcox Mann Whitney rank sum test (Glantz S A., Primer of Biostatistics., 5th ed., New York, USA: McGraw-Hill Medical Publishing Division, 2002).
[0290] Expression profiles were generated using GeneSpring™ software analysis as described herein (data not shown). 498 genes were identified as being differentially expressed with a p value of <0.05 as between patients with allergies and OA as compared with patients with OA only. Of the 498 genes identified, those genes previously identified in Table 3C were removed so as to identify those genes which are unique to allergies. 257 differentially expressed genes were identified as being as unique to allergies. The identity of these differentially expressed genes is shown in Table 3T. A gene list is also provided of the 241 genes which were found in common as between those genes identified in Table 3C and genes differentially expressed in blood samples taken from patients with osteoarthritis and allergies as compared to blood samples taken from OA patients only. The identity of these intersecting differentially expressed genes is shown in Table 3U and a venn diagram showing the relationship between the various groups of gene lists is found in FIG. 31.
[0291] Classification or class prediction of a test sample as having allergies or not having allergies can be done using the differentially expressed genes as shown in Table 3T as the predictor genes in combination with well known statistical algorithms as would be understood by a person skilled in the art and described herein. Commercially available programs such as those provided by Silicon Genetics (e.g. GeneSpring™) for Class Predication are also available. Classification of individuals as having both OA and allergies using the genes in Table 3U can also be performed.
EXAMPLE 13
[0292] ChondroChip™ Microarray Data Analysis of gene expression profiles of blood samples from co-morbid individuals having osteoarthritis and subject to systemic steroids as compared with gene expression profiles from normal individuals
[0293] This example demonstrates the use of the claimed invention to detect differential gene expression in blood samples taken from patients subject to systemic steroids as compared to blood samples taken from healthy patients.
[0294] As used herein, “systemic steroids” indicates a person subjected to artificial levels of steroids as a result of medical intervention. Such systemic steroids include birth control pills, prednisone, and hormones as a result of hormone replacement treatment. A person identified as having systemic steroids is one who is on one or more of the following of the above treatment regimes.
[0295] Blood samples were taken from patients who were diagnosed with osteoarthritis and subject to systemic steroids as defined herein. Gene expression profiles were then analysed and compared to profiles from patients unaffected by any disease. In each case, the diagnosis of osteoarthritis and systemic steroids was corroborated by a skilled Board certified physician.
[0296] Total mRNA from a drop of peripheral whole blood taken from each patient was isolated using TRIzol® reagent (GIBCO) and fluorescently labelled probes for each blood sample were generated as described above. Each probe was denatured and hybridized to the 15K Chondrogene Microarray Chip (ChondroChip™) as described herein. Identification of genes differentially expressed in blood samples from patients with osteoarthritis and subject to systemic steroids as compared to healthy patients was determined by statistical analysis using the Wilcox Mann Whitney rank sum test (Glantz S A., Primer of Biostatistics., 5th ed., New York, USA: McGraw-Hill Medical Publishing Division, 2002).
[0297] [0297]FIG. 11 shows a diagrammatic representation of gene expression profiles of blood samples from individuals who were subject to systemic steroids as described herein as compared with gene expression profiles from normal individuals. Expression profiles were generated using GeneSpring™ software analysis as described herein. Each column represents the hybridization pattern resulting from a single individual. In this example, patients taking systemic steroids also presented with OA, as described herein. Normal individuals have no known medical conditions and were not taking any known medication. Hybridizations to create said gene expression profiles were done using the ChondroChip™. (A dendogram analysis is shown above. Samples are clustered and marked as representing patients who are taking systemic steroids or normal. The “*” indicates those patients who abnormally clustered as either systemic steroids or normal despite presenting with the reverse. The number of hybridizations profiles determined for patients with systemic steroids and normal individuals are shown. 605 genes were identified as being differentially expressed with a p value of <0.05 as between patients with systemic steroids and normal individuals is noted. The identity of the differentially expressed genes is shown in Table 3D.
[0298] Classification or class prediction of a test sample from a patient as indicating said patient takes systemic steroids and has OA or as being normal can be done using the differentially expressed genes as shown in Table 3A in combination with well known statistical algorithms for class prediction as would be understood by a person skilled in the art and is described herein. Commercially available programs such as those provided by Silicon Genetics (e.g. GeneSpring™) for Class Predication are also available.
EXAMPLE 13A
[0299] ChondroChip™ Microarray Data Analysis of gene expression profiles of blood samples from co-morbid individuals having osteoarthritis and subject to systemic steroids as compared with gene expression profiles from with osteoarthritis only.
[0300] This example demonstrates the use of the claimed invention to detect differential gene expression in blood samples taken from patients subject to systemic steroids and having OA as compared to blood samples taken from OA patients only.
[0301] Blood samples were taken from patients who were diagnosed with osteoarthritis and subject to systemic steroids as defined herein. Gene expression profiles were then analysed and compared to profiles from patients having OA only. In each case, the diagnosis of osteoarthritis and systemic steroids was corroborated by a skilled Board certified physician.
[0302] Total mRNA from a drop of peripheral whole blood taken from each patient was isolated using TRIzol® reagent (GIBCO) and fluorescently labelled probes for each blood sample were generated as described above. Each probe was denatured and hybridized to the 15K Chondrogene Microarray Chip (ChondroChip™) as described herein. Identification of genes differentially expressed in blood samples from patients with osteoarthritis and subject to systemic steroids as compared patients with OA only was determined by statistical analysis using the Wilcox Mann Whitney rank sum test (Glantz S A., Primer of Biostatistics., 5th ed., New York, USA: McGraw-Hill Medical Publishing Division, 2002).
[0303] Expression profiles were generated using GeneSpring™ software analysis as described herein (data not shown). 553 genes were identified as being differentially expressed with a p value of <0.05 as between patients taking systemic steroids and OA as compared with patients with OA only. Of the 553 genes identified, those genes previously identified in Table 3D were removed so as to identify those genes which are unique to systemic steroids. 362 differentially expressed genes were identified as being as unique to systemic steroids. The identity of these differentially expressed genes are shown in Table 3V. A gene list is also provided of the 191 genes which were found in common as between those genes identified in Table 3D and genes differentially expressed in blood samples taken from patients with osteoarthritis and systemic steroids as compared to blood samples taken from OA patients only. The identity of these intersecting differentially expressed genes is shown in Table 3W and a venn diagram showing the relationship between the various groups of gene lists is found in FIG. 32.
[0304] Classification or class prediction of a test sample of an individual as either taking systemic steroids or not taking systemic steroids can be done using the differentially expressed genes as shown in Table 3V as the predictor genes in combination with well known statistical algorithms as would be understood by a person skilled in the art and described herein. Commercially available programs such as those provided by Silicon Genetics (e.g. GeneSpring™) for Class Predication are also available. Classification of individuals as having both OA and taking systemic steroids using the genes in Table 3W can also be performed.
EXAMPLE 13B
[0305] ChondroChip™ Microarray Data Analysis of gene expression profiles of blood samples from co-morbid individuals having osteoarthritis and subject to systemic steroids as compared with gene expression profiles from normal individuals.
[0306] This example demonstrates the use of the claimed invention to detect differential gene expression in blood samples taken from patients subject to various specific systemic steroids as compared to blood samples taken from healthy patients, and the ability to categorize and differentiate as between the systemic steroid being taken.
[0307] As used herein, “systemic steroids” indicates a person subjected to artificial levels of steroids as a result of medical intervention. Such systemic steroids include birth control pills, prednisone, and hormones as a result of hormone replacement treatment. A person identified as having systemic steroids is one who is on one or more of the following of the above treatment regimes.
[0308] Blood samples were taken from patients who were diagnosed with osteoarthritis and subject to systemic steroids as defined herein. Gene expression profiles were then analysed and compared as between the systemic steroids as compared to profiles from patients unaffected by any disease. In each case, the diagnosis of osteoarthritis and systemic steroids was corroborated by a skilled Board certified physician.
[0309] Total mRNA from a drop of peripheral whole blood taken from each patient was isolated using TRIzol® reagent (GIBCO) and fluorescently labelled probes for each blood sample were generated as described above. Each probe was denatured and hybridized to the 15K Chondrogene Microarray Chip (ChondroChip™) as described herein. Identification of genes differentially expressed in blood samples from patients with osteoarthritis and subject to systemic steroids as compared to healthy patients was determined by statistical analysis using the Wilcox Mann Whitney rank sum test (Glantz S A., Primer of Biostatistics., 5th ed., New York, USA: McGraw-Hill Medical Publishing Division, 2002).
[0310] [0310]FIG. 34 shows a diagrammatic representation of gene expression profiles of blood samples from individuals who were subject to either birth control, prednisone, or hormone replacement therapy as described herein as compared with gene expression profiles from normal individuals. Expression profiles were generated using GeneSpring™ software analysis as described herein. Each column represents the hybridization pattern resulting from a single individual. In this example, patients taking with each of the systemic steroids also presented with OA, as described herein. Normal individuals have no known medical conditions and were not taking any known medication. Hybridizations to create said gene expression profiles were done using the ChondroChip™. A dendogram analysis is shown above. Samples are clustered and marked as representing patients who are taking birth control, prednisone, hormone replacement therapy or normal. The “*” indicates those patients who abnormally clustered. The number of hybridizations profiles determined for patients with birth control, prednisone, hormone replacement therapy or normal individuals are shown. 396 genes were identified as being differentially expressed with a p value of <0.05 as between patients with systemic steroids and normal individuals is noted. The identity of the differentially expressed genes is shown in Table 3AD.
[0311] Classification or class prediction of a test sample from a patient as indicating said patient takes systemic steroids and has OA or as being normal can be done using the differentially expressed genes as shown in Table 3AD in combination with well known statistical algorithms for class prediction as would be understood by a person skilled in the art and is described herein. Commercially available programs such as those provided by Silicon Genetics (e.g. GeneSpring™) for Class Predication are also available.
EXAMPLE 14
[0312] ChondroChip™ Microarray Data Analysis of gene expression profiles of blood samples from individuals having hypertension as compared with gene expression profiles from normal individuals.
[0313] This example demonstrates the use of the claimed invention to detect differential gene expression in blood samples taken from patients with hypertension but without osteoarthritis as compared to blood samples taken from healthy patients.
[0314] As used herein, the term “hypertension” is defined as high blood pressure or elevated arterial pressure. Patients identified with hypertension herein include persons who have an increased risk of developing a morbid cardiovascular event and/or persons who benefit from medical therapy designed to treat hypertension. Patients identified with hypertension also can include persons having systolic blood pressure of >130 mm Hg or a diastolic blood pressure of >90 mm Hg or a person takes antihypertensive medication.
[0315] Blood samples were taken from patients who were diagnosed with hypertension as defined herein. Gene expression profiles were then analysed and compared to profiles from patients unaffected by any disease. In each case, the diagnosis of hypertension was corroborated by a skilled Board certified physician.
[0316] Total mRNA from a drop of peripheral whole blood taken from each patient was isolated using TRIzol® reagent (GIBCO) and fluorescently labelled probes for each blood sample were generated as described above. Each probe was denatured and hybridized to a 15K Chondrogene Microarray Chip (ChondroChip™) as described herein. Identification of genes differentially expressed in blood samples from patients with hypertension as compared to healthy patients was determined by statistical analysis using the Wilcox Mann Whitney rank sum test (Glantz S A., Primer of Biostatistics., 5th ed., New York, USA: McGraw-Hill Medical Publishing Division, 2002).
[0317] [0317]FIG. 12 shows a diagrammatic representation of gene expression profiles of blood samples from individuals having hypertension as compared with gene expression profiles from samples of both non-hypertensive and normal individuals. Expression profiles were generated using GeneSpring™ software analysis as described herein. Each column represents the hybridization pattern resulting from a single individual. Non-hypertensive individuals presented without hypertension, but may have presented with other medical conditions and may be under various treatment regimes. Normal individuals have no known medical conditions and were not taking any known medication. Hybridizations to create said gene expression profiles were done using the ChondroChip™. A dendogram analysis is shown above. Samples are clustered and marked as representing patients who are hypertensive, normal or non-hypertensive. The “*” indicates those patients who abnormally clustered as either hypertensive, non-hypertensive or normal despite actual presentation. The number of hybridizations profiles determined for hypertensive patients, non-hypertensive patients and normal individuals are shown. 1,993 genes identified as being differentially expressed with a p value of <0.05 as between the hypertensive patients and the combined normal and non-hypertensive individuals is noted. The identity of the differentially expressed genes are shown in Table 3E.
[0318] Classification or class prediction of a test sample of an individual so as to determine whether said individual has or does not have hypertension can be done using the differentially expressed genes as shown in Table 3E as the predictor genes in combination with well known statistical algorithms as would be understood by a person skilled in the art and described herein. Commercially available programs such as those provided by Silicon Genetics (e.g. GeneSpring™) for Class Predication are also available.
EXAMPLE 15
[0319] ChondroChip™ Microarray Data Analysis of gene expression profiles of blood samples from individuals having obesity as compared with gene expression profiles from normal individuals.
[0320] This example demonstrates the use of the claimed invention to detect differential gene expression in blood samples taken from patients with obesity but without osteoarthritis as compared to blood samples taken from healthy patients.
[0321] As used herein, “obesity” is defined as an excess of adipose tissue that imparts a health risk. Obesity is assessed in terms of height and weight in the relevance of age. Patients who are considered obese include, but are not limited to, patients having a body mass index or BMI ((defined as body weight in kg divided by (height in meters) 2 ) greater than or equal to 30.0.
[0322] Blood samples were taken from patients who were diagnosed with hypertension as defined herein. Gene expression profiles were then analysed and compared to profiles from patients unaffected by any disease. In each case, the diagnosis of obesity was corroborated by a skilled Board certified physician.
[0323] Total mRNA from a drop of peripheral whole blood taken from each patient was isolated using TRIzol® reagent (GIBCO) and fluorescently labelled probes for each blood sample were generated as described above. Each probe was denatured and hybridized to a (ChondroChip™) as described herein. Identification of genes differentially expressed in blood samples from patients with obesity as compared to healthy patients was determined by statistical analysis using the Wilcox Mann Whitney rank sum test (Glantz S A., Primer of Biostatistics, 5th ed., New York, USA: McGraw-Hill Medical Publishing Division, 2002).
[0324] [0324]FIG. 13 shows a diagrammatic representation of gene expression profiles of blood samples from individuals who were identified as obese as described herein as compared with gene expression profiles from normal and non-obese individuals. Expression profiles were generated using GeneSpring™ software analysis as described herein. Each column represents the hybridization pattern resulting from a single individual. Normal individuals have no known medical conditions and were not taking any known medication. Non-obese individuals presented without obesity, but may have presented with other medical conditions and may be under various treatment regimes. Hybridizations to create said gene expression profiles were done using the ChondroChip™. A dendogram analysis is shown above. Samples are clustered and marked as representing patients who are obese, normal or non-obese. The “*” indicates those patients who abnormally clustered as either obese, normal or non-obese despite actual presentation. The number of hybridizations profiles determined for obese patients, non-obese patients and normal individuals are shown. 1,147 genes were identified as being differentially expressed with a p value of <0.05 as between the obese patients and the combination of normal and non-obese individuals is noted. The identity of the differentially expressed genes is shown in Table 3F.
[0325] Classification or class prediction of a test sample as being obese or not being obese can be done using the differentially expressed genes as shown in Table 3F as the predictor genes in combination with well known statistical algorithms as would be understood by a person skilled in the art and described herein. Commercially available programs such as those provided by Silicon Genetics (e.g. GeneSpring™) for Class Predication are also available.
EXAMPLE 16
[0326] ChondroChip™ Microarray Data Analysis of gene expression profiles of blood samples from individuals having type 2 diabetes as compared with gene expression profiles from normal individuals.
[0327] This example demonstrates the use of the claimed invention to detect differential gene expression in blood samples taken from patients with type 2 diabetes but without osteoarthritis as compared to blood samples taken from healthy patients.
[0328] As used herein, “diabetes”, or “diabetes mellitus” includes both “type 1 diabetes” (insulin-dependent diabetes (IDDM)) and “type 2 diabetes” (insulin-independent diabetes (NIDDM). Both type 1 and type 2 diabetes characterized in accordance with Harrison's Principles of Internal Medicine 14th edition, as a person having a venous plasma glucose concentration ≧140mg/dL on at least two separate occasions after overnight fasting and venous plasma glucose concentration ≧200mg/dL at 2 h and on at least one other occasion during the 2-h test following ingestion of 75 g of glucose. Patients identified as having type 2 diabetes as described herein are those demonstrating insulin-independent diabetes as determined by the methods described above.
[0329] Blood samples were taken from patients who were diagnosed with type II diabetes as defined herein. Gene expression profiles were then analysed and compared to profiles from patients unaffected by any disease. In each case, the diagnosis of type II diabetes was corroborated by a skilled Board certified physician.
[0330] Total mRNA from a drop of peripheral whole blood taken from each patient was isolated using TRIzol® reagent (GIBCO) and fluorescently labelled probes for each blood sample were generated as described above. Each probe was denatured and hybridized to a 15K Chondrogene Microarray Chip (ChondroChip™) as described herein. Identification of genes differentially expressed in blood samples from patients with type 2 diabetes as compared to healthy patients was determined by statistical analysis using the Wilcox Mann Whitney rank sum test (Glantz S A., Primer of Biostatistics., 5th ed., New York, USA: McGraw-Hill Medical Publishing Division, 2002).
[0331] [0331]FIG. 14 shows a diagrammatic representation of gene expression profiles of blood samples from individuals who were identified as having type 2 diabetes as described herein as compared with gene expression profiles from normal and non-type 2 diabetes individuals. Expression profiles were generated using GeneSpring™ software analysis as described herein. Each column represents the hybridization pattern resulting from a single individual. Normal individuals have no known medical conditions and were not taking any known medication. Non-type 2 diabetes individuals presented without type 2 diabetes, but may have presented with other medical conditions and may be under various treatment regimes. Hybridizations to create said gene expression profiles were done using the ChondroChip™. A dendogram analysis is shown above. Samples are clustered and marked as representing patients who have type 2 diabetes, are normal or do not have type 2 diabetes. The “*” indicates those patients who abnormally clustered despite actual presentation. The number of hybridizations profiles determined for type 2 diabetes, non-type 2 diabetes and normal individuals are shown. 915 were identified as being differentially expressed with a p value of <0.05 as between the type 2 diabetes patients and the combination of normal and non type 2 diabetes individuals is noted. The identity of the differentially expressed genes is shown in Table 3G.
[0332] Classification or class prediction of a test sample of an individual so as to determine whether said individual has type 2 diabetes or does not have type 2 diabetes can be done using the differentially expressed genes as shown in Table 3G as the predictor genes in combination with well known statistical algorithms as would be understood by a person skilled in the art and described herein. Commercially available programs such as those provided by Silicon Genetics (e.g. GeneSpring™) for Class Predication are also available.
EXAMPLE 17
[0333] ChondroChip™ Microarray Data Analysis of gene expression profiles of blood samples from individuals having hyperlipidemia as compared with gene expression profiles from normal individuals.
[0334] This example demonstrates the use of the claimed invention to detect differential gene expression in blood samples taken from patients with hyperlipidemia but without osteoarthritis as compared to blood samples taken from healthy patients.
[0335] As used herein, “hyperlipidemia” is defined as an elevation of lipid protein profiles and includes the elevation of chylomicrons, very low-density lipoproteins (VLDL), intermediate-density lipoproteins (IDL), low-density lipoproteins (LDL), and/or high-density lipoproteins (HDL) as compared with the general population. Hyperlipidemia includes hypercholesterolemia and/or hypertriglyceridemia. By hypercholesterolemia, it is meant elevated fasting plasma total cholesterol level of>200mg/dL, and/or LDL-cholesterol levels of >130mg/dL. A desirable level of HDL-cholesterol is>60mg/dL. By hypertriglyceridemia it is meant plasma triglyceride (TG) concentrations of greater than the 90 th or 95 th percentile for age and sex and can include, for example, TG>160mg/dL as determined after an overnight fast.
[0336] Blood samples were taken from patients who were diagnosed with hyperlipidemia as defined herein. Gene expression profiles were then analysed and compared to profiles from patients unaffected by any disease. In each case, the diagnosis of hyperlipidemia was corroborated by a skilled Board certified physician.
[0337] Total mRNA from a drop of peripheral whole blood taken from each patient was isolated using TRIzol® reagent (GIBCO) and fluorescently labelled probes for each blood sample were generated as described above. Each probe was denatured and hybridized to a 15K Chondrogene Microarray Chip (ChondroChip™) as described herein. Identification of genes differentially expressed in blood samples from patients with hyperlipidemia as compared to healthy patients was determined by statistical analysis using the Wilcox Mann Whitney rank sum test (Glantz S A., Primer of Biostatistics, 5th ed., New York, USA: McGraw-Hill Medical Publishing Division, 2002).
[0338] [0338]FIG. 15 shows a diagrammatic representation of gene expression profiles of blood samples from individuals who were identified as having hyperlipidemia as described herein as compared with gene expression profiles from normal and non-hyperlipidemia patients. Expression profiles were generated using GeneSpring™ software analysis as described herein. Each column represents the hybridization pattern resulting from a single individual. Normal individuals have no known medical conditions and were not taking any known medication. Non hyperlipidemia individuals presented without elevated cholesterol or elevated triglycerides but may have presented with other medical conditions and may be under various treatment regimes. Hybridizations to create said gene expression profiles were done using the ChondroChip™. A dendogram analysis is shown above. Samples are clustered and marked as representing patients who have elevated lipids and/or cholesterol, are normal or do not have elevated lipids or cholesterol. The “*” indicates those patients who abnormally clustered as having either hyperlipidemia, normal or non-hyperlipidemia despite actual presentation. The number of hybridizations profiles determined for hyperlipidemia patients, non-hyperlipidemia patients and normal individuals are shown. 1,022 genes were identified as being differentially expressed with a p value of <0.05 as between the patients with hyperlipidemia and the combination of normal and non hyperlipidemia individuals. The identity of the differentially expressed genes is shown in Table 3H.
[0339] Classification or class prediction of a test sample of an individual as having hyperlipidemia or not having hyperlipidemia can be done using the differentially expressed genes as shown in Table 3H as the predictor genes in combination with well known statistical algorithms as would be understood by a person skilled in the art and described herein. Commercially available programs such as those provided by Silicon Genetics for Class Predication (e.g. GeneSpring™) are also available.
EXAMPLE 18
[0340] ChondroChip™ Microarray Data Analysis of gene expression profiles of blood samples from individuals having lung disease as compared with gene expression profiles from normal individuals.
[0341] This example demonstrates the use of the claimed invention to detect differential gene expression in blood samples taken from patients with lung disease but without osteoarthritis as compared to blood samples taken from healthy patients.
[0342] As used herein, “lung disease” encompasses any disease that affects the respiratory system and includes bronchitis, chronic obstructive lung disease, emphysema, asthma, and lung cancer. Patients identified as having lung disease includes patients having one or more of the above noted conditions.
[0343] Blood samples were taken from patients who were diagnosed with lung disease as defined herein. Gene expression profiles were then analysed and compared to profiles from patients unaffected by any disease. In each case, the diagnosis of lung disease was corroborated by a skilled Board certified physician.
[0344] Total mRNA from a drop of peripheral whole blood taken from each patient was isolated using TRIzol® reagent (GIBCO) and fluorescently labelled probes for each blood sample were generated as described above. Each probe was denatured and hybridized to a 15K Chondrogene Microarray Chip (ChondroChip™) as described herein. Identification of genes differentially expressed in blood samples from patients with lung disease as compared to healthy patients was determined by statistical analysis using the Wilcox Mann Whitney rank sum test (Glantz S A., Primer of Biostatistics., 5th ed., New York, USA: McGraw-Hill Medical Publishing Division, 2002).
[0345] [0345]FIG. 16 shows a diagrammatic representation of gene expression profiles of blood samples from individuals who were identified as having lung disease as described herein as compared with gene expression profiles from normal and non lung disease individuals. Expression profiles were generated using GeneSpring™ software analysis as described herein. Each column represents the hybridization pattern resulting from a single individual. Normal individuals have no known medical conditions and were not taking any known medication. Non-lung disease individuals presented without lung disease, but may have presented with other medical conditions and may be under various treatment regimes. Hybridizations to create said gene expression profiles were done using the ChondroChip™. A dendogram analysis is shown above. Samples are clustered and marked as representing patients who have lung disease, are normal or do not have lung disease. The “*” indicates those patients who abnormally clustered despite actual presentation. The number of hybridizations profiles determined for either the lung disease patients, non-lung disease patients and normal individuals are show. 596 genes were identified as being differentially expressed with a p value of <0.05 as between the lung disease patients and the combination of normal and non lung disease individuals is noted. The identity of the differentially expressed genes is shown in Table 3I.
[0346] Classification or class prediction of a test sample of an individual to determine whether said individual has lung disease or does not having lung disease can be done using the differentially expressed genes as shown in Table 3I as the predictor genes in combination with well known statistical algorithms as would be understood by a person skilled in the art and described herein. Commercially available programs such as those provided by Silicon Genetics (e.g. GeneSpring™) for Class Predication are also available.
EXAMPLE 19
[0347] Affymetrix U133A Chip Microarray Data Analysis of gene expression profiles of blood samples from individuals having bladder cancer as compared with gene expression profiles from normal individuals.
[0348] This example demonstrates the use of the claimed invention to detect differential gene expression in blood samples taken from patients with bladder cancer but without osteoarthritis as compared to blood samples taken from healthy patients.
[0349] As used herein, the term “cancer” or “carcinoma” is defined as a disease in which cells behave abnormally and includes; (i) cancers which originate from a single cell proliferating to form a clone of malignant cells, (ii) cancers wherein the growth of the cell is not regulated by normal biological and physical influences of the environment, (iii) anaplasic cancer, wherein the cells lack normal coordinated cell differentiation and (iv) metastasis cancer, wherein the cells have the capacity for discontinuous growth and dissemination to other parts of the body. The diagnosis of cancer can include careful clinical assessment and/or diagnostic investigations including endoscopy, imaging, histopathology, cytology and laboratory studies.
[0350] As used herein, “bladder cancer” includes carcinomas that occur in the transitional epithelium lining the urinary tract, starting at the renal pelvis and extending through the ureter, the urinary bladder, and the proximal two-thirds of the urethra. As used herein, patients diagnosed with bladder cancer include patients diagnosed utilizing any of the following methods or a combination thereof: urinary cytologic evaluation, endoscopic evaluation for the presence of malignant cells, CT (computed tomography), MRI (magnetic resonance imaging) for metastasis status.
[0351] Blood samples were taken from patients who were diagnosed with bladder cancer as defined herein. Gene expression profiles were then analysed and compared to profiles from patients unaffected by any disease. In each case, the diagnosis of bladder cancer was corroborated by a skilled Board certified physician.
[0352] Total mRNA from a drop of peripheral whole blood taken from each patient was isolated using TRIzol® reagent (GIBCO) and fluorescently labelled probes for each blood sample were generated as described above. Each probe was denatured and hybridized to an Affymetrix U133A Chip as described herein. Identification of genes differentially expressed in blood samples from patients with bladder cancer as compared to healthy patients was determined by statistical analysis using the Wilcox Mann Whitney rank sum test (Glantz S A., Primer of Biostatistics., 5th ed., New York, USA: McGraw-Hill Medical Publishing Division, 2002).
[0353] [0353]FIG. 17 shows a diagrammatic representation of gene expression profiles of blood samples from individuals who were identified as having bladder cancer as described herein as compared with gene expression profiles from non bladder cancer individuals. Expression profiles were generated using GeneSpring™ software analysis as described herein. Each column represents the hybridization pattern resulting from a single individual. Non bladder cancer individuals presented without bladder cancer, but may have presented with other medical conditions and may be under various treatment regimes. Hybridizations to create said gene expression profiles were done using the Affymetrix U133A chip. A dendogram analysis is shown above. Samples are clustered and marked as representing patients who have bladder cancer, or do not have bladder cancer. The “*” indicates those patients who abnormally clustered as either bladder cancer, or non bladder cancer despite actual presentation. The number of hybridizations profiles determined for patients with bladder cancer and without bladder cancer are shown. 4,228 genes were identified as being differentially expressed with a p value of <0.05 as between the bladder cancer patients and the non bladder cancer individuals is noted. The identity of the differentially expressed genes is shown in Table 3J.
[0354] Classification or class prediction of a test sample of an individual to determine whether said individual has bladder cancer or does not having bladder cancer can be done using the differentially expressed genes as shown in Table 3J as the predictor genes in combination with well known statistical algorithms as would be understood by a person skilled in the art and described herein. Commercially available programs such as those provided by Silicon Genetics (e.g. GeneSpring™) for Class Predication are also available.
EXAMPLE 20
[0355] Affymetrix U133A Chip Microarray Data Analysis of gene expression profiles of blood samples from individuals having early or advanced bladder cancer as compared with gene expression profiles from normal individuals.
[0356] This example demonstrates the use of the claimed invention to detect differential gene expression in blood samples taken from patients with early or advanced late stage bladder cancer but without osteoarthritis as compared to blood samples taken from healthy patients.
[0357] As used herein, “early stage bladder cancer” includes bladder cancer wherein the detection of the anatomic extent of the tumour, both in its primary location and in metastatic sites, as defined by the TNM staging system in accordance with Harrison's Principles of Internal Medicine 14th edition can be considered early stage. More specifically, early stage bladder cancer can include those instances wherein the carcinoma is mainly superficial.
[0358] As used herein, “advanced stage bladder cancer” is defined as bladder cancer wherein the detection of the anatomic extent of the tumour, both in its primary location and in metastatic sites, as defined by the TNM staging system in accordance with Harrison's Principles of Internal Medicine 14th edition, can be considered as advanced stage. More specifically, advanced stage carcinomas can involve instances wherein the cancer has infiltrated the muscle and wherein metastasis has occurred.
[0359] Blood samples were taken from patients who were diagnosed with early or advanced late stage bladder cancer as defined herein. Gene expression profiles were then analysed and compared to profiles from patients unaffected by any disease. In each case, the diagnosis of early or advanced late stage bladder cancer was corroborated by a skilled Board certified physician.
[0360] Total mRNA from a drop of peripheral whole blood taken from each patient was isolated using TRIzol® reagent (GIBCO) and fluorescently labelled probes for each blood sample were generated as described above. Each probe was denatured and hybridized to an Affymetrix U133A Chip as described herein. Identification of genes differentially expressed in blood samples from patients with early or advanced late stage bladder cancer as compared to healthy patients was determined by statistical analysis using the Wilcox Mann Whitney rank sum test (Glantz S A., Primer of Biostatistics., 5th ed., New York, USA: McGraw-Hill Medical Publishing Division, 2002).
[0361] [0361]FIG. 18 shows a diagrammatic representation of gene expression profiles of blood samples from individuals who were identified as having advanced stage bladder cancer or early stage bladder cancer as described herein as compared with gene expression profiles from non bladder cancer individuals. Expression profiles were generated using GeneSpring™ software analysis as described herein. Each column represents the hybridization pattern resulting from a single individual. Non bladder cancer individuals presented without bladder cancer, but may have presented with other medical conditions and may be under various treatment regimes. Hybridizations to create said gene expression profiles were done using the Affymetrix U1338 chip. A dendogram analysis is shown above. Samples are clustered and marked as representing patients who have early stage bladder cancer, advanced stage bladder cancer, or do not have bladder cancer. The “*” indicates those patients who abnormally clustered despite actual presentation. The number of hybridizations profiles determined for either early stage bladder cancer, advanced bladder cancer or non-bladder cancer are shown. 3,518 genes were identified as being differentially expressed with a p value of <0.05 as between the bladder cancer patients and the non bladder cancer individuals is noted. The identity of the differentially expressed genes is shown in Table 3K.
[0362] Classification or class prediction of a test sample of an individual to determine whether said individual has advanced bladder cancer, early stage bladder cancer or does not have bladder cancer can be done using the differentially expressed genes as shown in Table 3K as the predictor genes in combination with well known statistical algorithms as would be understood by a person skilled in the art and described herein. Commercially available programs such as those provided by Silicon Genetics (e.g. GeneSpring™) for Class Predication are also available.
EXAMPLE 21
[0363] Affymetrix U133A Chip Microarray Data Analysis of gene expression profiles of blood samples from individuals having coronary artery disease as compared with gene expression profiles from normal individuals.
[0364] This example demonstrates the use of the claimed invention to detect differential gene expression in blood samples taken from patients with coronary artery disease but without osteoarthritis as compared to blood samples taken from healthy patients
[0365] As used herein, “Coronary artery disease” (CAD) is defined as a condition wherein at least one coronary artery has >50% luminal diameter stenosis, as diagnosed by coronary angiography and includes conditions in which there is atheromatous narrowing and subsequent occlusion of the vessel. CAD includes those conditions which manifest as angina, silent ischaemia, unstable angina, myocardial infarction, arrhythmias, heart failure, and sudden death. Patients identified as having CAD herein Coronary artery disease is defined
[0366] Blood samples were taken from patients who were diagnosed with Coronary artery disease as defined herein. Gene expression profiles were then analysed and compared to profiles from patients unaffected by any disease. In each case, the diagnosis of Coronary artery disease was corroborated by a skilled Board certified physician.
[0367] Total mRNA from a drop of peripheral whole blood taken from each patient was isolated using TRIzol® reagent (GIBCO) and fluorescently labelled probes for each blood sample were generated as described above. Each probe was denatured and hybridized to an Affymetrix U133A Chip as described herein. Identification of genes differentially expressed in blood samples from patients with Coronary artery disease as compared to healthy patients was determined by statistical analysis using the Wilcox Mann Whitney rank sum test (Glantz S A., Primer of Biostatistics, 5th ed., New York, USA, McGraw-Hill Medical Publishing Division, 2002).
[0368] [0368]FIG. 19 shows a diagrammatic representation of gene expression profiles of blood samples from individuals who were identified as having coronary artery disease (CAD) as described herein as compared with gene expression profiles from non-coronary artery disease individuals. Expression profiles were generated using GeneSpring™ software analysis as described herein. Each column represents the hybridization pattern resulting from a single individual. Non coronary artery disease individuals presented without coronary artery disease, but may have presented with other medical conditions and may be under various treatment regimes. Hybridizations to create said gene expression profiles were done using the Affymetrix™ U133A chip. A dendogram analysis is shown above. Samples are clustered and marked as representing patients who have coronary artery disease or do not have coronary artery disease. The “*” indicates those patients who abnormally clustered despite actual presentation. The number of hybridizations profiles determined for patients with CAD or without CAD are shown. 967 genes were identified as being differentially expressed with a p value of <0.05 as between the coronary artery disease patients and those individuals without coronary artery disease is noted. The identity of the differentially expressed genes is shown in Table 3L.
[0369] Classification or class prediction of a test sample of an individual to determine whether said individual has CAD or does not have CAD can be done using the differentially expressed genes as shown in Table 3L as the predictor genes in combination with well known statistical algorithms as would be understood by a person skilled in the art and described herein. Commercially available programs such as those provided by Silicon Genetics for Class Predication (e.g. GeneSpring™) are also available.
EXAMPLE 22
[0370] Affymetrix U133A Chip Microarray Data Analysis of gene expression profiles of blood samples from individuals having Rheumatoid arthritis as compared with gene expression profiles from normal individuals.
[0371] This example demonstrates the use of the claimed invention to detect differential gene expression in blood samples taken from patients with Rheumatoid arthritis but without osteoarthritis as compared to blood samples taken from healthy patients.
[0372] Rheumatoid arthritis (RA) is defined as a chronic, multisystem disease of unknown etiology with the characteristic feature of persistent inflammatory synovitis. Said inflammatory synovitis usually involves peripheral joints in a systemic distribution. Patients having RA as defined herein were identified as having one or more of the following; (i) cartilage destruction, (ii) bone erosions, and/or (iii) joint deformities.
[0373] Blood samples were taken from patients who were diagnosed Rheumatoid arthritis as defined herein. Gene expression profiles were then analysed and compared to profiles from patients unaffected by any disease. In each case, the diagnosis of Rheumatoid arthritis was corroborated by a skilled Board certified physician.
[0374] Total mRNA from a drop of peripheral whole blood taken from each patient was isolated using TRIzol® reagent (GIBCO) and fluorescently labelled probes for each blood sample were generated as described above. Each probe was denatured and hybridized to an Affymetrix U133A Chip as described herein. Identification of genes differentially expressed in blood samples from patients with Rheumatoid arthritis as compared to healthy patients was determined by statistical analysis using the Wilcox Mann Whitney rank sum test (Glantz S A., Primer of Biostatistics., 5th ed., New York, USA: McGraw-Hill Medical Publishing Division, 2002).
[0375] [0375]FIG. 20 shows a diagrammatic representation of gene expression profiles of blood samples from individuals who were identified as having rheumatoid arthritis as described herein as compared with gene expression profiles from non-rheumatoid arthritis individuals. Expression profiles were generated using GeneSpring™ software analysis as described herein. Each column represents the hybridization pattern resulting from a single individual. Normal individuals have no known medical conditions and were not taking any known medication. Non rheumatoid arthritis individuals presented without rheumatoid arthritis, but may have presented with other medical conditions and may be under various treatment regimes. Hybridizations to create said gene expression profiles were done using ChondroChip™. A dendogram analysis is shown above. Samples are clustered and marked as representing patients who have rheumatoid arthritis or do not have rheumatoid arthritis. The “*” indicates those patients who abnormally clustered despite actual presentation. The number of hybridizations profiles determined for patients with rheumatoid arthritis and without rheumatoid arthritis are shown. 2,068 genes were identified as being differentially expressed with a p value of <0.05 as between the rheumatoid arthritis patients and a combination of those individuals without rheumatoid arthritis and normal is noted. The identity of the differentially expressed genes is shown in Table 3M.
[0376] Classification or class prediction of a test sample of an individual as having rheumatoid arthritis or not having rheumatoid arthritis can be done using the differentially expressed genes as shown in Table 3M as the predictor genes in combination with well known statistical algorithms as would be understood by a person skilled in the art and described herein. Commercially available programs such as those provided by Silicon Genetics for Class Predication (e.g. GeneSpring™) are also available.
EXAMPLE 23
[0377] Affymetrix U133A Chip Microarray Data Analysis of gene expression profiles of blood samples from individuals having depression as compared with gene expression profiles from normal individuals.
[0378] This example demonstrates the use of the claimed invention to detect differential gene expression in blood samples taken from patients with depression but without osteoarthritis as compared to blood samples taken from healthy patients
[0379] As used herein “mood disorders” are conditions characterized by a disturbance in the regulation of mood, behavior, and affect. “Mood disorders” can include depression, anxiety, schizophrenia, bipolar disorder, manic depression and the like.
[0380] As used herein “depression” includes depressive disorders or depression in association with medical illness or substance abuse in addition to depression as a result of sociological situations. Patients defined as having depression were diagnosed mainly on the basis of clinical symptoms including a depressed mood episode wherein a person displays a depressed mood on a daily basis for a period of greater than 2 weeks. A depressed mood episode may be characterized by sadness, indifference, apathy, or irritability and is usually associated with changes in a number of neurovegetative functions, including sleep patterns, appetite and weight, fatigue, impairment in concentration and decision making.
[0381] Blood samples were taken from patients who were diagnosed with depression as defined herein. Gene expression profiles were then analysed and compared to profiles from patients unaffected by any disease. In each case, the diagnosis of depression was corroborated by a skilled Board certified physician.
[0382] Total mRNA from a drop of peripheral whole blood taken from each patient was isolated using TRIzol® reagent (GIBCO) and fluorescently labelled probes for each blood sample were generated as described above. Each probe was denatured and hybridized to an Affymetrix U133A Chip as described herein. Identification of genes differentially expressed in blood samples from patients with depression as compared to healthy patients was determined by statistical analysis using the Wilcox Mann Whitney rank sum test (Glantz S A., Primer of Biostatistics, 5th ed., New York, USA: McGraw-Hill Medical Publishing Division, 2002).
[0383] [0383]FIG. 21 shows a diagrammatic representation of gene expression profiles of blood samples from individuals who were identified as having depression as described herein as compared with gene expression profiles from non-depression individuals. Expression profiles were generated using GeneSpring™ software analysis as described herein. Each column represents the hybridization pattern resulting from a single individual. Normal individuals have no known medical conditions and were not taking any known medication. Non depression individuals presented without depression, but may have presented with other medical conditions and may be under various treatment regimes. Hybridizations to create said gene expression profiles were done using ChondroChip™. A dendogram analysis is shown above. Samples are clustered and marked as representing patients who have depression, having non-depression or normal. The “*” indicates those patients who abnormally clustered despite actual presentation. The number of hybridizations profiles determined for patients with depression, non-depression and normal are shown. 941 genes were identified as being differentially expressed with a p value of <0.05 as between the patients with depression and a combination of those individuals without depression and normal is noted. The identity of the differentially expressed genes is shown in Table 3N.
[0384] Classification or class prediction of a test sample of an individual to determine whether said individuals has depression or does not having depression can be done using the differentially expressed genes as shown in Table 3N as the predictor genes in combination with well known statistical algorithms as would be understood by a person skilled in the art and described herein. Commercially available programs such as those provided by Silicon Genetics (e.g. GeneSpring™) for Class Predication are also available.
EXAMPLE 24
[0385] ChondroChip™ Microarray Data Analysis of gene expression profiles of blood samples from individuals having osteoarthritis as compared with gene expression profiles from normal individuals.
[0386] This example demonstrates the use of the claimed invention to detect differential gene expression in blood samples taken from patients who were identified as having various stages of osteoarthritis as compared to blood samples taken from healthy patients.
[0387] Osteoarthritis (OA), as used herein also known as “degenerative joint disease”, represents failure of a diarthrodial (movable, synovial-lined) joint. It is a condition, which affects joint cartilage, and or subsequently underlying bone and supporting tissues leading to pain, stiffness, movement problems and activity limitations. It most often affects the hip, knee, foot, and hand, but can affect other joints as well.
[0388] OA severity can be graded according to the system described by Marshall (Marshall, K. W., J. Rheumatol., 1996, 23(4):582-85). Briefly, each of the six knee articular surfaces was assigned a cartilage grade with points based on the worst lesion seen on each particular surface. Grade 0 is normal (0 points), Grade I cartilage is soft or swollen but the articular surface is intact (1 point). In Grade II lesions, the cartilage surface is not intact but the lesion does not extend down to subchondral bone (2 points). Grade III damage extends to subchondral bone but the bone is neither eroded nor ebumated (3 points). In Grade IV lesions, there is eburnation of or erosion into bone (4 points). A global OA score is calculated by summing the points from all six cartilage surfaces. If there is any associated pathology, such as meniscus tear, an extra point will be added to the global score. Based on the total score, each patient is then categorized into one of four OA groups: mild (1-6), moderate (7-12), marked (13-18), and severe (>18). As used herein, patients identified with OA may be categorized in any of the four OA groupings as described above.
[0389] Blood samples were taken from patients who were diagnosed with osteoarthritis and a specific stage of osteoarthritis as defined herein. Gene expression profiles were then analysed and compared to profiles from patients unaffected by any disease. In each case, the diagnosis of osteoarthritis and the stage of osteoarthritis was corroborated by a skilled Board certified physician.
[0390] Total mRNA from a drop of peripheral whole blood taken from each patient was isolated using TRIzol® reagent (GIBCO) and fluorescently labelled probes for each blood sample were generated as described above. Each probe was denatured and hybridized to a 15K Chondrogene Microarray Chip (ChondroChip™) as described herein. Identification of genes differentially expressed in blood samples from patients with disease as compared to healthy patients was determined by statistical analysis using the Wilcox Mann Whitney rank sum test (Glantz S A., Primer of Biostatistics, 5th ed., New York, USA: McGraw-Hill Medical Publishing Division, 2002).
[0391] [0391]FIG. 22 shows a diagrammatic representation of gene expression profiles of blood samples from individuals having osteoarthritis as compared with gene expression profiles from normal individuals. Expression profiles were generated using GeneSpring™ software analysis as described herein. Each column represents the hybridization pattern resulting from a single individual. Normal individuals have no known medical conditions and were not taking any known medication. Hybridizations to create said gene expression profiles were done using the ChondroChip™. A dendogram analysis is shown above. Samples are clustered and marked as representing patients who presented with different stages of osteoarthritis or normal. The “*” indicates those patients who abnormally clustered despite actual presentation. The number of hybridizations profiles determined for either osteoarthritis patients or normal individuals are shown. 300 differentially expressed genes were identified as being differentially expressed with a p value of <0.05 as between the osteoarthritis patients and normal individuals. The identity of the differentially expressed genes is shown in Table 3O.
[0392] Classification or class prediction of a test sample of an individual as having OA, having mild OA, having marked OA, having moderate OA, having severe OA or not having OA can be done using the differentially expressed genes as shown in Table 3O as the predictor genes in combination with well known statistical algorithms as would be understood by a person skilled in the art and described herein. Commercially available programs such as those provided by Silicon Genetics (e.g. GeneSpring™) for Class Predication are also available.
EXAMPLE 25
[0393] Microarray Data Analysis of gene expression profiles of blood samples from individuals having a condition as compared with gene expression profiles from individuals not having said condition, and wherein said individual is undergoing therapeutic treatment in light of said condition.
[0394] This example demonstrates the use of the claimed invention to detect differential gene expression in blood samples taken from individuals undergoing therapeutic treatment of a condition as compared with gene expression profiles from individuals not undergoing treatment.
[0395] Blood samples are taken from patients who are undergoing therapeutic treatment. Gene expression profiles are then analysed and compared to profiles from patients not undergoing treatment.
[0396] Total mRNA from a drop of peripheral whole blood taken from each patient is isolated using TRIzol® reagent (GIBCO) and fluorescently labelled probes for each blood sample are generated as described above. Each probe is denatured and hybridized to a microarray for example the 15K Chondrogene Microarray Chip (ChondroChip™), Affymetrix Genechip or Blood chip as described herein. Identification of genes differentially expressed in blood samples from patients undergoing therapeutic treatment as compared to patients not undergoing treatment is determined by statistical analysis using the Wilcox Mann Whitney rank sum test (Glantz S A., Primer of Biostatistics. 5th ed., New York, USA: McGraw-Hill Medical Publishing Division, 2002). Expression profiles are generated using GeneSpring™ software analysis as described herein. The number of differentially expressed genes are then identified as being differentially expressed with a p value of <0.05.
EXAMPLE 26
[0397] Affymetrix U133A Chip Microarray Data Analysis of gene expression profiles of blood samples from individuals having liver cancer as compared with gene expression profiles from normal individuals.
[0398] This example demonstrates the use of the claimed invention to detect differential gene expression in blood samples taken from patients with liver cancer as compared to blood samples taken from healthy patients.
[0399] As used herein, “liver cancer” means primary liver cancer wherein the cancer initiates in the liver. Primary liver cancer includes both hepatomas or hepatocellular carcinomas (HCC) which start in the liver and chonalgiomas where cancers develop in the bile ducts of the liver.
[0400] Blood samples were taken from patients who were diagnosed with liver cancer as defined herein. Gene expression profiles were then analysed and compared to profiles from patients unaffected by any disease. In each case, the diagnosis of liver cancer was corroborated by a skilled Board certified physician.
[0401] Total mRNA from a drop of peripheral whole blood taken from each patient was isolated using TRIzol® reagent (GIBCO) and fluorescently labelled probes for each blood sample were generated as described above. Each probe was denatured and hybridized to an Affymetrix U133A Chip as described herein. Identification of genes differentially expressed in blood samples from patients with liver cancer as compared to healthy patients was determined by statistical analysis using the Weltch t-Test.
[0402] [0402]FIG. 25 shows a diagrammatic representation of gene expression profiles of blood samples from individuals who were identified as having liver cancer as described herein as compared with gene expression profiles from non-liver cancer disease individuals. Expression profiles were generated using GeneSpring™ software analysis as described herein. Each column represents the hybridization pattern resulting from a single individual. Control samples presented without liver cancer but may have presented with other medical conditions and may be under various treatment regimes.
[0403] Hybridizations to create said gene expression profiles were done using the Affymetrix™ U133A chip. A dendogram analysis is shown above. Samples are clustered and marked as representing patients who have liver cancer or control. The number of hybridizations profiles determined for patients with liver cancer or who are controls are shown. 1,475 genes were identified as being differentially expressed with a p value of <0.05 as between the liver cancer patients and those control individuals. The identity of the differentially expressed genes is shown in Table 3X.
[0404] Classification or class prediction of a test sample of an individual to determine whether said individual has liver cancer or does not have liver cancer can be done using the differentially expressed genes as shown in Table 3X as the predictor genes in combination with well known statistical algorithms as would be understood by a person skilled in the art and described herein. Commercially available programs such as those provided by Silicon Genetics (e.g. GeneSpring™) for Class Predication are also available.
EXAMPLE 27
[0405] Affymetrix U133A Chip Microarray Data Analysis of gene expression profiles of blood samples from individuals having schizophrenia as compared with gene expression profiles from normal individuals.
[0406] This example demonstrates the use of the claimed invention to detect differential gene expression in blood samples taken from patients with schizophrenia as compared to blood samples taken from healthy patients.
[0407] As used herein, “schizophrenia” is defined as a psychotic disorders characterized by distortions of reality and disturbances of thought and language and withdrawal from social contact. Patients diagnosed with “schizophrenia” can include patients having any of the following diagnosis: an acute schizophrenic episode, borderline schizophrenia, catatonia, catatonic schizophrenia, catatonic type schizophrenia, disorganized schizophrenia, disorganized type schizophrenia, hebephrenia, hebephrenic schizophrenia, latent schizophrenia, paranoic type schizophrenia, paranoid schizophrenia, paraphrenia, paraphrenic schizophrenia, psychosis, reactive schizophrenia or the like.
[0408] Blood samples were taken from patients who were diagnosed with schizophrenia as defined herein. Gene expression profiles were then analysed and compared to profiles from patients unaffected by any disease. In each case, the diagnosis of schizophrenia was corroborated by a skilled Board certified physician.
[0409] Total mRNA from a drop of peripheral whole blood taken from each patient was isolated using TRIzol® reagent (GIBCO) and fluorescently labelled probes for each blood sample were generated as described above. Each probe was denatured and hybridized to an Affymetrix U133A Chip as described herein. Identification of genes differentially expressed in blood samples from patients with schizophrenia as compared to healthy patients was determined by statistical analysis using the Wilcox Mann Whitney rank sum test (Glantz S A., Primer of Biostatistics, 5th ed., New York, USA: McGraw-Hill Medical Publishing Division).
[0410] [0410]FIG. 26 shows a diagrammatic representation of gene expression profiles of blood samples from individuals who were identified as having schizophrenia as described herein as compared with gene expression profiles from non schizophrenic individuals. Expression profiles were generated using GeneSpring™ software analysis as described herein. Each column represents the hybridization pattern resulting from a single individual. Control samples presented without schizophrenia but may have presented with other medical conditions and may be under various treatment regimes. Hybridizations to create said gene expression profiles were done using the Affymetrix™ U133A chip. A dendogram analysis is shown above. Samples are clustered and marked as representing patients who have schizophrenia or control individuals. The number of hybridizations profiles determined for patients with liver cancer or who are controls are shown. 1,952 genes were identified as being differentially expressed with a p value of <0.05 as between the schizophrenic patients and those control individuals. The identity of the differentially expressed genes is shown in Table 3Y.
[0411] Classification or class prediction of a test sample of an individual to determine whether said individual has schizophrenia or does not having schizophrenia can be done using the differentially expressed genes as shown in Table 3Y as the predictor genes in combination with well known statistical algorithms as would be understood by a person skilled in the art and described herein. Commercially available programs such as those provided by Silicon Genetics (e.g. GeneSpring™) for Class Predication are also available.
EXAMPLE 28
[0412] Affymetrix U133A Chip Microarray Data Analysis of gene expression profiles of blood samples from individuals having Chagas disease as compared with gene expression profiles from normal individuals.
[0413] This example demonstrates the use of the claimed invention to detect differential gene expression in blood samples taken from patients with symptomatic Chagas disease, asymptomatic Chagas disease or control individuals wherein said control individuals were confirmed as not having Chagas disease.
[0414] As used herein, “Chagas disease” is defined as a condition wherein an individual is infected with the protozoan parasite Trypanosoma cruzi and includes both acute and chronic infection. Acute infection with T. cruzi can be diagnosed by detection of parasites by either microscopic examination of fresh anticoagulated blood or the buffy coat, giemsa-stained thin and thick blood smears and/or mouse inoculation and culturing of the blood of a potentially infected individual. Even in the absence of a positive result from the above, an accurate determination of infection can be made by xenodiagnosis wherein reduviid bugs are allowed to feed on the patient's blood and subsequently the bugs are examined for infection. Chronic infection can be determined by detection of antibodies specific to the T. cruzi antigens and/or immunoprecipitation and electrophoresis of the T. cruzi antigens.
[0415] As used herein “Symptomatic Chagas disease” includes symptomatic acute chagas and symptomatic chronic chagas disease. Acute symptomatic chagas disease can be characterized by one or more of the following: area of erythema and swelling (a chagoma); local lymphadenopathy; generalized lymphadenopathy; mild hepatosplenomegaly; unilateral painless edema of the palpebrae and periocular tissues; malaise; fever; anorexia and/or edema of the face and lower extremities. Symptomatic chronic Chagas' disease includes one or more of the following symptoms: heart rhythm disturbances, cardiomyopathy, thromboembolism, electrocardiographic abnormalities including right bundle-branch blockage; atrioventricular block; premature ventricular contractions and tachy- and bradyarrhythmias; dysphagia; odynophagia, chest pain; regurgitation; weight loss, cachexia and pulmonary infections.
[0416] As used herein “Asymptomatic Chagas disease” is meant to refer to individuals who are infected with T. cruzi but who do not show either acute or chronic symptoms of the disease.
[0417] Blood samples were taken from patients who were diagnosed symptomatic or asymptomatic Chagas disease as defined herein. Gene expression profiles were then analysed and compared to profiles from patients unaffected by any disease. In each case, the diagnosis of Chagas disease was corroborated by a qualified physician.
[0418] Total mRNA from a drop of peripheral whole blood taken from each patient was isolated using TRIzol® reagent (GIBCO) and fluorescently labelled probes for each blood sample were generated as described above. Each probe was denatured and hybridized to an Affymetrix U133A Chip as described herein. Identification of genes differentially expressed in blood samples from patients with Chagas disease as compared to healthy patients was determined by statistical analysis using the Weltch ANOVA test (Michelson and Schofield, 1996).
[0419] [0419]FIG. 27 shows a diagrammatic representation of gene expression profiles of blood samples from individuals who were identified as having symptomatic Chagas disease; asymptomatic Chagas disease or who were control individuals as described herein as compared with gene expression profiles from non-schizophrenic individuals. Expression profiles were generated using GeneSpring™ software analysis as described herein. Each column represents the hybridization pattern resulting from a single individual. Control samples presented without Chagas disease but may have presented with other medical conditions and may be under various treatment regimes.
[0420] Hybridizations to create said gene expression profiles were done using the Affymetrix™ U133A chip. A dendogram analysis is shown above. Samples are clustered and marked as representing patients who have symptomatic chagas disease; asymptomatic chagas disease or control. The number of hybridizations profiles determined for patients with chagas disease; asymptomatic chagas disease or who are controls are shown. 668 genes were identified as being differentially expressed with a p value of <0.05 as between the symptomatic, asymptomatic Chagas patients and those control individuals. The identity of the differentially expressed genes is shown in Table 3Y.
[0421] Classification or class prediction of a test sample of an individual to determine whether said individual has symptomatic Chagas disease, asymptomatic Chagas disease or does not have Chagas disease can be done using the differentially expressed genes as shown in Table 3Y as the predictor genes in combination with well known statistical algorithms as would be understood by a person skilled in the art and described herein. Commercially available programs such as those provided by Silicon Genetics (e.g. GeneSpring™) for Class Predication are also available.
EXAMPLE 29
[0422] Identification of Genes Specific for OA Only by Removing Genes Relevant to Co-Morbidities and Other Disease States.
[0423] This example demonstrates the use of the claimed invention to detect differential gene expression in blood unique to Osteoarthritis as compared with other disease states.
[0424] Blood samples were taken from patients who were diagnosed with mild OA or severe OA and compared with individuals who were identified as normal individuals as defined herein. Gene expression profiles were then analysed to identify genes which are differentially expressed in OA as compared with normal. In each case, the diagnosis of OA was corroborated by a qualified physician.
[0425] Total mRNA from a drop of peripheral whole blood taken from each patient was isolated using TRIzol® reagent (GIBCO) and fluorescently labelled probes for each blood sample were generated as described above. Each probe was denatured and hybridized to a ChondroChip™ as described herein. Identification of genes differentially expressed in blood samples from patients with mild or severe OA as compared to healthy patients was determined by statistical analysis using the Weltch ANOVA test (Michelson and Schofield, 1996). (Dendogram analysis not shown).
[0426] In order to identify genes differentially expressed in blood unique to OA but not differentially expressed as a result of possible co-morbidities including hypertension, obesity, asthma, taking systemic steroids, or allergies, genes identified as differentially expressed in both OA and any of the genes identified as differentially expressed as a result of co-morbidity, e.g., Table 3A (co-morbidity of OA and hypertension v. normal), Table 3B (co-morbidity of OA and obesity v. normal), Table 3C (co-morbidity of OA and allergy v. normal), Table 3D (co-morbidity of OA and taking systemic steroids v. normal), and genes in common with people identified as having asthma and OA (Table 3AA) were removed. Similarly any genes and unique to obesity (Table 3R), hypertension (Table 3P), allergies (Table 3T), systemic steroids (Table 3V) were also removed. As a result of these comparisons, a list of genes unique to individuals with OA was identified. The identity of the differentially expressed genes is shown in Table 3AB.
[0427] It would be clear to a person skilled in the art that rather than simply remove those genes which are relevant to other disease states, one could use a more refined analysis and remove those genes which show the same trend in gene expression, e.g. remove those genes which show up regulation in a co-morbid state and also show up-regulation in the single disease state, but retain those genes which show a different trend in gene expression e.g. retain those genes which show up regulation in a co-morbid state as compared to down regulation in a single disease state.
[0428] Classification or class prediction of a test sample of an individual to determine whether said individual has OA or does not have OA can be done using the differentially expressed genes as shown in Table 3AB, irrespective of whether the individual presents with co-morbidity using well known statistical algorithms as would be understood by a person skilled in the art and described herein. Commercially available programs such as those provided by Silicon Genetics (e.g. GeneSpring™) for Class Predication are also available.
EXAMPLE 30
[0429] Analysis of gene expression profiles of blood samples from individuals having brain cancer as compared with gene expression profiles from normal individuals.
[0430] This example demonstrates the use of the claimed invention to detect differential gene expression in blood samples taken from patients diagnosed with brain cancer as compared to blood samples taken from healthy patients.
[0431] As used herein “brain cancer” refers to all forms of primary brain tumours, both intracranial and extracranial and includes one or more of the following: Glioblastoma, Ependymoma, Gliomas, Astrocytoma, Medulloblastoma, Neuroglioma, Oligodendroglioma, Meningioma, Retinoblastoma, and Craniopharyngioma.
[0432] Blood samples are taken from patients diagnosed with brain cancer as defined herein. Gene expression profiles are then analysed and compared to profiles from patients unaffected by any disease. Preferably healthy patients are chosen who are age and sex matched to said patients diagnosed with disease. In each case, the diagnosis of brain cancer is corroborated by a skilled Board certified physician.
[0433] Total mRNA from a drop of peripheral whole blood is taken from each patient and isolated using TRIzol® reagent (GIBCO) and fluorescently labelled probes for each blood sample are generated as described above. Each probe is denatured and hybridized to an Affymetrix U133A Chip and/or ChondroChip™ as described herein. Identification of genes differentially expressed in blood samples from patients with brain cancer as compared to healthy patients is determined by statistical analysis using the Wilcox Mann Whitney rank sum test (Glantz S A., Primer of Biostatistics, 5th ed., New York, USA: McGraw-Hill Medical Publishing Division, 2002).
[0434] Classification or class prediction of a test sample of an individual to determine whether said individuals has brain cancer or does not having brain cancer can be done using the differentially expressed genes identified as described above as the predictor genes in combination with well known statistical algorithms as would be understood by a person skilled in the art and described herein. Commercially available programs such as those provided by Silicon Genetics (e.g. GeneSpring™) for Class Predication are also available.
EXAMPLE 31
[0435] Analysis of gene expression profiles of blood samples from individuals having ankylosing spondylitis as compared with gene expression profiles from normal individuals.
[0436] This example demonstrates the use of the claimed invention to detect differential gene expression in blood samples taken from patients diagnosed with ankylosing spondylitis as compared to blood samples taken from healthy patients.
[0437] As used herein “ankylosing spondylitis” refers to a chronic inflammatory disease that affects the joints between the vertebrae of the spine, and/or the joints between the spine and the pelvis and can eventually cause the affected vertebrae to fuse or grow together.
[0438] Blood samples are taken from patients diagnosed with ankylosing spondylitis as defined herein. Gene expression profiles are then analysed and compared to profiles from patients unaffected by any disease. Preferably healthy patients are chosen who are age and sex matched to said patients diagnosed with disease. In each case, the diagnosis of ankylosing spondylitis is corroborated by a skilled Board certified physician.
[0439] Total mRNA from a drop of peripheral whole blood is taken from each patient and isolated using TRIzol® reagent (GIBCO) and fluorescently labelled probes for each blood sample is generated as described above. Each probe is denatured and hybridized to an Affymetrix U133A Chip and/or a ChondroChip™ as described herein. Identification of genes differentially expressed in blood samples from patients with ankylosing spondylitis as compared to healthy patients is determined by statistical analysis using the Wilcox Mann Whitney rank sum test (Glantz S A, Primer of Biostatistics, 5th ed., New York, USA: McGraw-Hill Medical Publishing Division, 2002).
[0440] Classification or class prediction of a test sample of an individual to determine whether said individuals has ankylosing spondylitis or does not having ankylosing spondylitis can be done using the differentially expressed genes identified as described above as the predictor genes in combination with well known statistical algorithms as would be understood by a person skilled in the art and described herein. Commercially available programs such as those provided by Silicon Genetics (e.g. GeneSpring™) for Class Predication are also available.
EXAMPLE 32
[0441] Analysis of gene expression profiles of blood samples from individuals having prostate cancer as compared with gene expression profiles from normal individuals.
[0442] This example demonstrates the use of the claimed invention to detect differential gene expression in blood samples taken from patients diagnosed with prostate cancer as compared to blood samples taken from healthy patients
[0443] As used herein “prostate cancer” refers to a malignant cancer originating within the prostate gland. Patients identified as having prostate cancer can have any stage of prostate cancer, as determined clinically (by digital rectal exam or PSA testing) and or pathologically. Staging of prostate cancer can done in accordance with TNM or the Staging System of the American Joint Committee on Cancer (AJCC). In addition to the TNM system, other systems may be used to stage prostate cancer, for example, the Whitmore-Jewett system.
[0444] Blood samples are taken from patients diagnosed with prostate cancer as defined herein. Gene expression profiles are then analysed and compared to profiles from patients unaffected by any disease to identify genes which differentiate as between the two groups. Similarly gene expression profiles can be analysed so as to differentiate as between the severity of the prostate cancer. Preferably healthy patients are chosen who are age and sex matched to said patients diagnosed with disease or with a specific stage of said disease. In each case, the diagnosis of prostate cancer is corroborated by a skilled Board certified physician.
[0445] Total mRNA from a drop of peripheral whole blood is taken from each patient and isolated using TRIzol® reagent (GIBCO) and fluorescently labelled probes for each blood sample is generated as described above. Each probe is denatured and hybridized to an Affymetrix U133A Chip and/or a ChondroChip™ as described herein. Identification of genes differentially expressed in blood samples from patients with prostate cancer as compared to healthy patients is determined by statistical analysis using the Wilcox Mann Whitney rank sum test (Glantz S A., Primer of Biostatistics, 5th ed., New York, USA: McGraw-Hill Medical Publishing Division, 2002).
[0446] Classification or class prediction of a test sample of an individual to determine whether said individuals has prostate cancer, has a specific stage of prostate cancer, or does not having prostate cancer can be done using the differentially expressed genes identified as described above as the predictor genes in combination with well known statistical algorithms as would be understood by a person skilled in the art and described herein. Commercially available programs such as those provided by Silicon Genetics (e.g. GeneSpring™) for Class Predication are also available.
EXAMPLE 33
[0447] Analysis of gene expression profiles of blood samples from individuals having ovarian cancer as compared with gene expression profiles from normal individuals.
[0448] This example demonstrates the use of the claimed invention to detect differential gene expression in blood samples taken from patients diagnosed with ovarian cancer as compared to blood samples taken from healthy patients.
[0449] As used herein “ovarian cancer” refers to a malignant cancerous growth originating within the ovaries. Patients identified as having ovarian cancer can have any stage of ovarian cancer. Staging is done by combining information from imaging tests with the results of a surgical examination done during a laprotomy. Numbered stages I to IV are used to describe the extent of the cancer and whether it has spread (metastasized) to more distant organs.
[0450] Blood samples are taken from patients diagnosed with ovarian cancer, or with a specific stage of ovarian cancer as defined herein. Gene expression profiles are then analysed and compared to profiles from patients unaffected by any disease. Preferably healthy patients are chosen who are age and sex matched to said patients diagnosed with disease or with a specific stage of said disease. In each case, the diagnosis of ovarian cancer is corroborated by a skilled Board certified physician.
[0451] Total mRNA from a drop of peripheral whole blood is taken from each patient and isolated using TRIzol® reagent (GIBCO) and fluorescently labelled probes for each blood sample is generated as described above. Each probe is denatured and hybridized to an Affymetrix U133A Chip and/or a ChondroChip™ as described herein. Identification of genes differentially expressed in blood samples from patients with ovarian cancer and or a specific stage of ovarian cancer as compared to healthy patients is determined by statistical analysis using the Wilcox Mann Whitney rank sum test (Glantz S A., Primer of Biostatistics, 5th ed., New York, USA: McGraw-Hill Medical Publishing Division, 2002).
[0452] Classification or class prediction of a test sample of an individual to determine whether said individuals has ovarian cancer, has a specific stage of ovarian cancer or does not having ovarian cancer can be done using the differentially expressed genes identified as described above as the predictor genes in combination with well known statistical algorithms as would be understood by a person skilled in the art and described herein. Commercially available programs such as those provided by Silicon Genetics (e.g. GeneSpring™) for Class Predication are also available.
EXAMPLE 34
[0453] Analysis of gene expression profiles of blood samples from individuals having kidney cancer as compared with gene expression profiles from normal individuals.
[0454] This example demonstrates the use of the claimed invention to detect differential gene expression in blood samples taken from patients diagnosed with kidney cancer as compared to blood samples taken from healthy patients.
[0455] As used herein “kidney cancer” refers to a malignant cancerous growth originating within the kidneys. Kidney cancer includes renal cell carcinoma, transitional cell carcinoma, and Wilms' tumor. Patients identified as having renal cell carcinoma can also be categorized by stage of said cancer as determined by the System of the American Joint Committee on Cancer (AJCC). Numbered stages I to IV are used to describe the extent of the carcinoma and whether it has spread (metastased) to more distant organs.
[0456] Blood samples are taken from patients diagnosed with kidney cancer, or with a specific stage of renal cell carcinoma as defined herein. Gene expression profiles are then analysed and compared to profiles from patients unaffected by any disease. Preferably healthy patients are chosen who are age and sex matched to said patients diagnosed with disease or with a specific stage of said disease. In each case, the diagnosis of kidney cancer is corroborated by a skilled Board certified physician.
[0457] Total mRNA from a drop of peripheral whole blood is taken from each patient and isolated using TRIzol® reagent (GIBCO) and fluorescently labelled probes for each blood sample is generated as described above. Each probe is denatured and hybridized to an Affymetrix U133A Chip and/or a ChondroChip™ as described herein. Identification of genes differentially expressed in blood samples from patients with kidney cancer and or a specific stage of kidney cancer as compared to healthy patients is determined by statistical analysis using the Wilcox Mann Whitney rank sum test (Glantz S A, Primer of Biostatistics, 5th ed., New York, USA: McGraw-Hill Medical Publishing Division, 2002).
[0458] Classification or class prediction of a test sample of an individual to determine whether said individuals has kidney cancer, has a specific stage of kidney cancer or does not having kidney cancer can be done using the differentially expressed genes identified as described above as the predictor genes in combination with well known statistical algorithms as would be understood by a person skilled in the art and described herein. Commercially available programs such as those provided by Silicon Genetics (e.g. GeneSpring™) for Class Predication are also available.
EXAMPLE 35
[0459] Analysis of gene expression profiles of blood samples from individuals having gastric cancer as compared with gene expression profiles from normal individuals.
[0460] This example demonstrates the use of the claimed invention to detect differential gene expression in blood samples taken from patients diagnosed with gastric cancer as compared to blood samples taken from healthy patients.
[0461] As used herein “gastric or stomach cancer” refers to a cancerous growth originating within the stomach and includes gastric adenocarcinoma, primary gastric lymphoma and gastric nonlymphoid sarcoma. Patients identified as having stomac can also be categorized by stage of said cancer as determined by the System of the American Joint Committee on Cancer (AJCC).
[0462] Blood samples are taken from patients diagnosed with stomach cancer, or with a specific stage of stomach cancer as defined herein. Gene expression profiles are then analysed and compared to profiles from patients unaffected by any disease. Preferably healthy patients are chosen who are age and sex matched to said patients diagnosed with disease or with a specific stage of said disease. In each case, the diagnosis of stomach cancer is corroborated by a skilled Board certified physician.
[0463] Total mRNA from a drop of peripheral whole blood is taken from each patient and isolated using TRIzol® reagent (GIBCO) and fluorescently labelled probes for each blood sample is generated as described above. Each probe is denatured and hybridized to an Affymetrix U133A Chip and/or a ChondroChip™ as described herein. Identification of genes differentially expressed in blood samples from patients with stomach cancer and or a specific stage of stomach cancer as compared to healthy patients is determined by statistical analysis using the Wilcox Mann Whitney rank sum test (Glantz S A, Primer of Biostatistics, 5th ed., New York, USA: McGraw-Hill Medical Publishing Division, 2002).
[0464] Classification or class prediction of a test sample of an individual to determine whether said individuals has stomach cancer, has a specific stage of stomach cancer or does not having stomach cancer can be done using the differentially expressed genes identified as described above as the predictor genes in combination with well known statistical algorithms as would be understood by a person skilled in the art and described herein. Commercially available programs such as those provided by Silicon Genetics (e.g. GeneSpring™) for Class Predication are also available.
EXAMPLE 36
[0465] Analysis of gene expression profiles of blood samples from individuals having lung cancer as compared with gene expression profiles from normal individuals.
[0466] This example demonstrates the use of the claimed invention to detect differential gene expression in blood samples taken from patients diagnosed with lung cancer as compared to blood samples taken from healthy patients.
[0467] As used herein “lung cancer” refers to a cancerous growth originating within the lung and includes adenocarcinoma, alveolar cell carcinoma, squamous cell carcinoma, large cell and small cell carcinomas. Patients identified as having lung cancer can also be categorized by stage of said cancer as determined by the System of the American Joint Committee on Cancer (AJCC).
[0468] Blood samples are taken from patients diagnosed with lung cancer, or with a specific stage of lung cancer as defined herein. Gene expression profiles are then analysed and compared to profiles from patients unaffected by any disease. Preferably healthy patients are chosen who are age and sex matched to said patients diagnosed with disease or with a specific stage of said disease. In each case, the diagnosis of lung cancer is corroborated by a skilled Board certified physician.
[0469] Total mRNA from a drop of peripheral whole blood is taken from each patient and isolated using TRIzol® reagent (GIBCO) and fluorescently labelled probes for each blood sample is generated as described above. Each probe is denatured and hybridized to an Affymetrix U 133A Chip and/or a ChondroChip™ as described herein. Identification of genes differentially expressed in blood samples from patients with lung cancer and or a specific stage of lung cancer as compared to healthy patients is determined by statistical analysis using the Wilcox Mann Whitney rank sum test (Glantz S A, Primer of Biostatistics, 5th ed., New York, USA: McGraw-Hill Medical Publishing Division, 2002).
[0470] Classification or class prediction of a test sample of an individual to determine whether said individuals has lung cancer, has a specific stage of lung cancer or does not having lung cancer can be done using the differentially expressed genes identified as described above as the predictor genes in combination with well known statistical algorithms as would be understood by a person skilled in the art and described herein. Commercially available programs such as those provided by Silicon Genetics (e.g. GeneSpring™) for Class Predication are also available.
EXAMPLE 37
[0471] Analysis of gene expression profiles of blood samples from individuals having breast cancer as compared with gene expression profiles from normal individuals.
[0472] This example demonstrates the use of the claimed invention to detect differential gene expression in blood samples taken from patients diagnosed with breast cancer as compared to blood samples taken from healthy patients.
[0473] As used herein “breast cancer” refers to a cancerous growth originating within the breast and includes invasive and non invasive breast cancer such as ductal carcinoma in situ (DCIS), lobular carcinoma in situ (LCIS), infiltrating ductal carcinoma, and infiltrating lobular carcinoma. Patients identified as having breast cancer can also be categorized by stage of said cancer as determined by the System of the American Joint Committee on Cancer (AJCC) or TNM classification.
[0474] Blood samples are taken from patients diagnosed with breast cancer, or with a specific stage of breast cancer as defined herein. Gene expression profiles are then analysed and compared to profiles from patients unaffected by any disease. Preferably healthy patients are chosen who are age and sex matched to said patients diagnosed with disease or with a specific stage of said disease. In each case, the diagnosis of breast cancer is corroborated by a skilled Board certified physician.
[0475] Total mRNA from a drop of peripheral whole blood is taken from each patient and isolated using TRIzol® reagent (GIBCO) and fluorescently labelled probes for each blood sample is generated as described above. Each probe is denatured and hybridized to an Affymetrix U133A Chip and/or a ChondroChip™ as described herein. Identification of genes differentially expressed in blood samples from patients with breast cancer and or a specific stage of breast cancer as compared to healthy patients is determined by statistical analysis using the Wilcox Mann Whitney rank sum test (Glantz S A, Primer of Biostatistics, 5th ed., New York, USA: McGraw-Hill Medical Publishing Division, 2002).
[0476] Classification or class prediction of a test sample of an individual to determine whether said individuals has breast cancer, has a specific stage of breast cancer or does not have breast cancer can be done using the differentially expressed genes identified as described above as the predictor genes in combination with well known statistical algorithms as would be understood by a person skilled in the art and described herein. Commercially available programs such as those provided by Silicon Genetics (e.g. GeneSpring™) for Class Predication are also available.
EXAMPLE 38
[0477] Analysis of gene expression profiles of blood samples from individuals having nasopharyngeal cancer as compared with gene expression profiles from normal individuals.
[0478] This example demonstrates the use of the claimed invention to detect differential gene expression in blood samples taken from patients diagnosed with nasopharyngeal cancer as compared to blood samples taken from healthy patients.
[0479] As used herein “nasopharyngeal cancer” refers to a cancerous growth arising from the epithelial cells that cover the surface and line the nasopharynx. Patients identified as having nasopharyngeal cancer can also be categorized by stage of said cancer as determined by the System of the American Joint Committee on Cancer (AJCC) or TNM classification.
[0480] Blood samples are taken from patients diagnosed with nasopharyngeal cancer, or with a specific stage of nasopharyngeal cancer as defined herein. Gene expression profiles are then analysed and compared to profiles from patients unaffected by any disease. Preferably healthy patients are chosen who are age and sex matched to said patients diagnosed with disease or with a specific stage of said disease. In each case, the diagnosis of nasopharyngeal cancer is corroborated by a skilled Board certified physician.
[0481] Total mRNA from a drop of peripheral whole blood is taken from each patient and isolated using TRIzol® reagent (GIBCO) and fluorescently labelled probes for each blood sample is generated as described above. Each probe is denatured and hybridized to a Affymetrix U133A Chip and/or a ChondroChip™ as described herein. Identification of genes differentially expressed in blood samples from patients with nasopharyngeal cancer and or a specific stage of breast cancer as compared to healthy patients is determined by statistical analysis using the Wilcox Mann Whitney rank sum test (Glantz S A, Primer of Biostatistics, 5th ed., New York, USA: McGraw-Hill Medical Publishing Division, 2002).
[0482] Classification or class prediction of a test sample of an individual to determine whether said individuals has nasopharyngeal cancer, has a specific stage of nasopharyngeal cancer or does not have nasopharyngeal cancer can be done using the differentially expressed genes identified as described above as the predictor genes in combination with well known statistical algorithms as would be understood by a person skilled in the art and described herein. Commercially available programs such as those provided by Silicon Genetics (e.g. GeneSpring™) for Class Predication are also available.
EXAMPLE 39
[0483] Analysis of gene expression profiles of blood samples from individuals having Guillain Barre syndrome as compared with gene expression profiles from normal individuals.
[0484] This example demonstrates the use of the claimed invention to detect differential gene expression in blood samples taken from patients diagnosed with Guillain Barre syndrome as compared to blood samples taken from healthy patients.
[0485] As used herein “Guillain Barre syndrome” refers to an acute, usually rapidly progressive form of inflammatory polyneuropathy characterized by muscular weakness and mild distal sensory loss.
[0486] Blood samples are taken from patients diagnosed with Guillain Barre syndrome as defined herein. Gene expression profiles are then analysed and compared to profiles from patients unaffected by any disease. Preferably healthy patients are chosen who are age and sex matched to said patients diagnosed with disease. In each case, the diagnosis of Guillain Barre syndrome is corroborated by a skilled Board certified physician.
[0487] Total mRNA from a drop of peripheral whole blood is taken from each patient and isolated using TRIzol® reagent (GIBCO) and fluorescently labelled probes for each blood sample is generated as described above. Each probe is denatured and hybridized to an Affymetrix U133A Chip and/or a ChondroChip™ as described herein. Identification of genes differentially expressed in blood samples from patients with Guillain Barre syndrome as compared to healthy patients is determined by statistical analysis using the Wilcox Mann Whitney rank sum test (Glantz S A, Primer of Biostatistics, 5th ed., New York, USA: McGraw-Hill Medical Publishing Division, 2002).
[0488] Classification or class prediction of a test sample of an individual to determine whether said individuals has Guillain Barre syndrome, or does not have Guillain Barre syndrome can be done using the differentially expressed genes identified as described above as the predictor genes in combination with well known statistical algorithms as would be understood by a person skilled in the art and described herein. Commercially available programs such as those provided by Silicon Genetics (e.g. GeneSpring™) for Class Predication are also available.
EXAMPLE 40
[0489] Analysis of gene expression profiles of blood samples from individuals having Fibromyalgia as compared with gene expression profiles from normal individuals.
[0490] This example demonstrates the use of the claimed invention to detect differential gene expression in blood samples taken from patients diagnosed with Fibromyalgia as compared to blood samples taken from healthy patients.
[0491] As used herein “Fibromyalgia” refers to widespread chronic musculoskeletal pain and fatigue. The pain comes from the connective tissues, such as the muscles, tendons, and ligaments and does not involve the joints. Blood samples are taken from patients diagnosed with Fibromyalgia as defined herein. Gene expression profiles are then analysed and compared to profiles from patients unaffected by any disease. Preferably healthy patients are chosen who are age and sex matched to said patients diagnosed with disease. In each case, the diagnosis of Fibromyalgia is corroborated by a skilled Board certified physician.
[0492] Total mRNA from a drop of peripheral whole blood is taken from each patient and isolated using TRIzol® reagent (GIBCO) and fluorescently labelled probes for each blood sample is generated as described above. Each probe is denatured and hybridized to an Affymetrix U133A Chip and/or a ChondroChip™ as described herein. Identification of genes differentially expressed in blood samples from patients with Fibromyalgia as compared to healthy patients is determined by statistical analysis using the Wilcox Mann Whitney rank sum test (Glantz S A., Primer of Biostatistics, 5th ed., New York, USA: McGraw-Hill Medical Publishing Division, 2002).
[0493] Classification or class prediction of a test sample of an individual to determine whether said individuals has Fibromyalgia, or does not have Fibromyalgia can be done using the differentially expressed genes identified as described above as the predictor genes in combination with well known statistical algorithms as would be understood by a person skilled in the art and described herein. Commercially available programs such as those provided by Silicon Genetics (e.g. GeneSpring™) for Class Predication are also available.
EXAMPLE 41
[0494] Analysis of gene expression profiles of blood samples from individuals having Multiple Sclerosis as compared with gene expression profiles from normal individuals.
[0495] This example demonstrates the use of the claimed invention to detect differential gene expression in blood samples taken from patients diagnosed with Multiple Sclerosis as compared to blood samples taken from healthy patients.
[0496] As used herein “Multiple Sclerosis” refers to chronic progressive nervous disorder involving the loss of myelin sheath surrounding certain nerve fibres. Blood samples are taken from patients diagnosed with Multiple Sclerosis as defined herein. Gene expression profiles are then analysed and compared to profiles from patients unaffected by any disease. Preferably healthy patients are chosen who are age and sex matched to said patients diagnosed with disease. In each case, the diagnosis of Multiple Sclerosis is corroborated by a skilled Board certified physician.
[0497] Total mRNA from a drop of peripheral whole blood is taken from each patient and isolated using TRIzol® reagent (GIBCO) and fluorescently labelled probes for each blood sample is generated as described above. Each probe is denatured and hybridized to an Affymetrix U133A Chip and/or a ChondroChip™ as described herein. Identification of genes differentially expressed in blood samples from patients with Multiple Sclerosis as compared to healthy patients is determined by statistical analysis using the Wilcox Mann Whitney rank sum test (Glantz S A, Primer of Biostatistics, 5th ed., New York, USA: McGraw-Hill Medical Publishing Division, 2002).
[0498] Classification or class prediction of a test sample of an individual to determine whether said individuals has Multiple Sclerosis, or does not have Multiple Sclerosis can be done using the differentially expressed genes identified as described above as the predictor genes in combination with well known statistical algorithms as would be understood by a person skilled in the art and described herein. Commercially available programs such as those provided by Silicon Genetics (e.g. GeneSpring™) for Class Predication are also available.
EXAMPLE 42
[0499] Analysis of gene expression profiles of blood samples from individuals having Muscular Dystrophy as compared with gene expression profiles from normal individuals.
[0500] This example demonstrates the use of the claimed invention to detect differential gene expression in blood samples taken from patients diagnosed with Muscular Dystrophy as compared to blood samples taken from healthy patients.
[0501] As used herein “Muscular Dystrophy” refers to a hereditary disease of the muscular system characterized by weakness and wasting of the skeletal muscles. Muscular Dystrophy includes Duchennes' Muscular Dystrophy, limb-girdle muscular dystrophy, myotonia atrophica, myotonic muscular dystrophy, pseudohypertrophic muscular dystrophy, and Steinhardt's disease.
[0502] Blood samples are taken from patients diagnosed with Muscular Dystrophy as defined herein. Gene expression profiles are then analysed and compared to profiles from patients unaffected by any disease. Preferably healthy patients are chosen who are age and sex matched to said patients diagnosed with disease. In each case, the diagnosis of Muscular Dystrophy is corroborated by a skilled Board certified physician.
[0503] Total mRNA from a drop of peripheral whole blood is taken from each patient and isolated using TRIzol® reagent (GIBCO) and fluorescently labelled probes for each blood sample is generated as described above. Each probe is denatured and hybridized to an Affymetrix U133A Chip and/or a ChondroChip™ as described herein. Identification of genes differentially expressed in blood samples from patients with Muscular Dystrophy as compared to healthy patients is determined by statistical analysis using the Wilcox Mann Whitney rank sum test (Glantz S A, Primer of Biostatistics, 5th ed., New York, USA: McGraw-Hill Medical Publishing Division, 2002).
[0504] Classification or class prediction of a test sample of an individual to determine whether said individuals has Muscular Dystrophy, or does not have Muscular Dystrophy can be done using the differentially expressed genes identified as described above as the predictor genes in combination with well known statistical algorithms as would be understood by a person skilled in the art and described herein. Commercially available programs such as those provided by Silicon Genetics (e.g. GeneSpring™) for Class Predication are also available.
EXAMPLE 43
[0505] Analysis of gene expression profiles of blood samples from individuals having septic joint arthroplasty as compared with gene expression profiles from normal individuals.
[0506] This example demonstrates the use of the claimed invention to detect differential gene expression in blood samples taken from patients diagnosed with septic joint arthroplasty as compared to blood samples taken from healthy patients.
[0507] As used herein “septic joint arthroplasty” refers to an inflammation of the joint caused by a bacterial infection.
[0508] Blood samples are taken from patients diagnosed with septic joint arthroplasty as defined herein. Gene expression profiles are then analysed and compared to profiles from patients unaffected by any disease. Preferably healthy patients are chosen who are age and sex matched to said patients diagnosed with disease. In each case, the diagnosis of septic joint arthroplasty is corroborated by a skilled Board certified physician.
[0509] Total mRNA from a drop of peripheral whole blood is taken from each patient and isolated using TRIzol® reagent (GIBCO) and fluorescently labelled probes for each blood sample is generated as described above. Each probe is denatured and hybridized to an Affymetrix U133A Chip and/or a ChondroChip™ as described herein. Identification of genes differentially expressed in blood samples from patients with septic joint arthroplasty as compared to healthy patients is determined by statistical analysis using the Wilcox Mann Whitney rank sum test (Glantz S A, Primer of Biostatistics, 5th ed., New York, USA: McGraw-Hill Medical Publishing Division, 2002).
[0510] Classification or class prediction of a test sample of an individual to determine whether said individuals has septic joint arthroplasty, or does not have septic joint arthroplasty can be done using the differentially expressed genes identified as described above as the predictor genes in combination with well known statistical algorithms as would be understood by a person skilled in the art and described herein. Commercially available programs such as those provided by Silicon Genetics (e.g. GeneSpring™) for Class Predication are also available.
EXAMPLE 44
[0511] Analysis of gene expression profiles of blood samples from individuals having Alzheimers Disease as compared with gene expression profiles from normal individuals.
[0512] This example demonstrates the use of the claimed invention to detect differential gene expression in blood samples taken from patients diagnosed with Alzheimers as compared to blood samples taken from healthy patients.
[0513] As used herein “Alzheimers” refers to a degenerative disease of the central nervous system characterized especially by premature senile mental deterioration.
[0514] Blood samples are taken from patients diagnosed with Alzheimers as defined herein. Gene expression profiles are then analysed and compared to profiles from patients unaffected by any disease. Preferably healthy patients are chosen who are age and sex matched to said patients diagnosed with disease. In each case, the diagnosis of Alzheimers is corroborated by a skilled Board certified physician.
[0515] Total mRNA from a drop of peripheral whole blood is taken from each patient and isolated using TRIzol® reagent (GIBCO) and fluorescently labelled probes for each blood sample is generated as described above. Each probe is denatured and hybridized to an Affymetrix U133A Chip and/or a ChondroChip™ as described herein. Identification of genes differentially expressed in blood samples from patients with Alzheimers as compared to healthy patients is determined by statistical analysis using the Wilcox Mann Whitney rank sum test (Glantz S A, Primer of Biostatistics, 5th ed., New York, USA: McGraw-Hill Medical Publishing Division, 2002).
[0516] Classification or class prediction of a test sample of an individual to determine whether said individuals has Alzheimers, or does not have Alzheimers can be done using the differentially expressed genes identified as described above as the predictor genes in combination with well known statistical algorithms as would be understood by a person skilled in the art and described herein. Commercially available programs such as those provided by Silicon Genetics (e.g. GeneSpring™) for Class Predication are also available.
EXAMPLE 45
[0517] Analysis of gene expression profiles of blood samples from individuals having hepatitis as compared with gene expression profiles from normal individuals.
[0518] This example demonstrates the use of the claimed invention to detect gene expression in blood samples taken from patients diagnosed with hepatitis as compared to blood samples taken from healthy patients.
[0519] As used herein “hepatitis” refers to an inflammation of the liver caused by a virus or toxin and can include hepatitis A, hepatitis B, hepatitis C, hepatitis D, hepatitis E, and hepatitis F.
[0520] Blood samples are taken from patients diagnosed with hepatitis as defined herein. Gene expression profiles are then analysed and compared to profiles from patients unaffected by any disease. Preferably healthy patients are chosen who are age and sex matched to said patients diagnosed with disease. In each case, the diagnosis of hepatitis is corroborated by a skilled Board certified physician.
[0521] Total mRNA from a drop of peripheral whole blood is taken from each patient and isolated using TRIzol® reagent (GIBCO) and fluorescently labelled probes for each blood sample is generated as described above. Each probe is denatured and hybridized to an Affymetrix U133A Chip and/or a ChondroChip™ as described herein. Identification of genes differentially expressed in blood samples from patients with hepatitis as compared to healthy patients is determined by statistical analysis using the Wilcox Mann Whitney rank sum test (Glantz S A, Primer of Biostatistics, 5th ed., New York, USA: McGraw-Hill Medical Publishing Division, 2002).
[0522] Classification or class prediction of a test sample of an individual to determine whether said individuals has hepatitis, or does not have hepatitis can be done using the differentially expressed genes identified as described above as the predictor genes in combination with well known statistical algorithms as would be understood by a person skilled in the art and described herein. Commercially available programs such as those provided by Silicon Genetics (e.g. GeneSpring™) for Class Predication are also available.
EXAMPLE 46
[0523] Analysis of gene expression profiles of blood samples from individuals having Manic Depression Syndrome (MDS) as compared with gene expression profiles from normal individuals.
[0524] This example demonstrates the use of the claimed invention to detect differential gene expression in blood samples taken from patients diagnosed with MDS as compared to blood samples taken from healthy patients.
[0525] As used herein “Manic Depression Syndrome (MDS)” refers to a mood disorder characterized by alternating mania and depression.
[0526] Blood samples are taken from patients diagnosed with MDS as defined herein. Gene expression profiles are then analysed and compared to profiles from patients unaffected by any disease. Preferably healthy patients are chosen who are age and sex matched to said patients diagnosed with disease. In each case, the diagnosis of MDS is corroborated by a skilled Board certified physician.
[0527] Total mRNA from a drop of peripheral whole blood is taken from each patient and isolated using TRIzol® reagent (GIBCO) and fluorescently labelled probes for each blood sample is generated as described above. Each probe is denatured and hybridized to an Affymetrix U1 33A Chip and/or a ChondroChip™ as described herein. Identification of genes differentially expressed in blood samples from patients with MDS as compared to healthy patients is determined by statistical analysis using the Wilcox Mann Whitney rank sum test (Glantz S A, Primer of Biostatistics, 5th ed., New York, USA: McGraw-Hill Medical Publishing Division, 2002).
[0528] Classification or class prediction of a test sample of an individual to determine whether said individuals has MDS, or does not have MDS can be done using the differentially expressed genes identified as described above as the predictor genes in combination with well known statistical algorithms as would be understood by a person skilled in the art and described herein. Commercially available programs such as those provided by Silicon Genetics (e.g. GeneSpring™) for Class Predication are also available.
EXAMPLE 47
[0529] Analysis of gene expression profiles of blood samples from individuals having Crohn's Disease and/or Colitis as compared with gene expression profiles from normal individuals.
[0530] This example demonstrates the use of the claimed invention to detect differential gene expression in blood samples taken from patients diagnosed with Crohn's Disease and/or Colitis as compared to blood samples taken from healthy patients.
[0531] As used herein “Crohn's Disease” refers to a chronic inflammation of the ileum which is often progressive. As used herein “Colitis” or “Inflammatory Bowel Disease” refers to inflammation of the colon.
[0532] Blood samples are taken from patients diagnosed with Crohn's and or Colitis as defined herein. Gene expression profiles are then analysed and compared to profiles from patients unaffected by any disease. Preferably healthy patients are chosen who are age and sex matched to said patients diagnosed with disease. In each case, the diagnosis of Crohn's and or Colitis is corroborated by a skilled Board certified physician.
[0533] Total mRNA from a drop of peripheral whole blood is taken from each patient and isolated using TRIzol® reagent (GIBCO) and fluorescently labelled probes for each blood sample is generated as described above. Each probe is denatured and hybridized to an Affymetrix U133A Chip and/or a ChondroChip™ as described herein. Identification of genes differentially expressed in blood samples from patients with Crohn's and or Colitis as compared to healthy patients is determined by statistical analysis using the Wilcox Mann Whitney rank sum test (Glantz S A, Primer of Biostatistics, 5th ed., New York, USA: McGraw-Hill Medical Publishing Division, 2002).
[0534] Classification or class prediction of a test sample of an individual to determine whether said individuals has Crohn's and or Colitis, or does not have Crohn's and or Colitis can be done using the differentially expressed genes identified as described above as the predictor genes in combination with well known statistical algorithms as would be understood by a person skilled in the art and described herein. Commercially available programs such as those provided by Silicon Genetics (e.g. GeneSpring™) for Class Predication are also available.
EXAMPLE 48
[0535] Analysis of gene expression profiles of blood samples from individuals having Malignant Hyperthermia Susceptibility as compared with gene expression profiles from normal individuals.
[0536] This example demonstrates the use of the claimed invention to detect differential gene expression in blood samples taken from patients diagnosed with Malignant Hyperthermia Susceptibility as compared to blood samples taken from healthy patients.
[0537] As used herein “Malignant Hyperthermia Susceptibility” refers to a pharmacogenetic disorder of skeletal muscle calcium regulation often developing during or after a general anaesthesia.
[0538] Blood samples are taken from patients diagnosed with Malignant Hyperthermia Susceptibility as defined herein. Gene expression profiles are then analysed and compared to profiles from patients unaffected by any disease. Preferably healthy patients are chosen who are age and sex matched to said patients diagnosed with disease. In each case, the diagnosis of Malignant Hyperthermia Susceptibility is corroborated by a skilled Board certified physician.
[0539] Total mRNA from a drop of peripheral whole blood is taken from each patient and isolated using TRIzol® reagent (GIBCO) and fluorescently labelled probes for each blood sample is generated as described above. Each probe is denatured and hybridized to an Affymetrix U133A Chip and/or a ChondroChip™ as described herein. Identification of genes differentially expressed in blood samples from patients with Malignant Hyperthermia Susceptibility as compared to healthy patients is determined by statistical analysis using the Wilcox Mann Whitney rank sum test (Glantz S A, Primer of Biostatistics, 5th ed., New York, USA: McGraw-Hill Medical Publishing Division, 2002).
[0540] Classification or class prediction of a test sample of an individual to determine whether said individuals has Malignant Hyperthermia Susceptibility, or does not have Malignant Hyperthermia Susceptibility can be done using the differentially expressed genes identified as described above as the predictor genes in combination with well known statistical algorithms as would be understood by a person skilled in the art and described herein. Commercially available programs such as those provided by Silicon Genetics (e.g. GeneSpring™) for Class Predication are also available.
EXAMPLE 49
[0541] Analysis of gene expression profiles of blood samples from horses having osteoarthritis as compared with gene expression profiles from normal or non-osteoarthritic horses.
[0542] This example demonstrates the use of the claimed invention to detect differential gene expression in blood samples taken from horses so as to diagnose equine arthritis as compared to blood samples taken from healthy horses.
[0543] As used herein “arthritis” in reference to horses refers to a degenerative joint disease that affects horses by causing lameness. Although it can appear in any joint, most common areas are the upper knee joint, front fetlocks, hocks, or coffin joints in the front feet. The condition can be caused by trauma, mineral or dietary deficiency, old age, poor conformation, over exertion or infection. The different structures that can be damaged in arthritis are the cartilage inside joints, the bone in the joints, the joint capsule, the synovial membranes, the ligaments around the joints and lastly the fluid that lubricates the insides of ‘synovial joints’. In severe cases all of these structures are affected. In for example osteochondrosis only the cartilage may be affected.
[0544] Regardless of the cause, the disease begins when the synovial fluid that lubricates healthy joints begins to thin. The decrease in lubrication causes the cartilage cushion to break down, and eventually the bones begin to grind painfully against each other. Diagnostic tests used to confirm arthritis include X-rays, joint fluid analysis, and ultrasound.
[0545] Blood samples are taken from horses diagnosed with arthritis as defined herein. Gene expression profiles are then analysed and compared to profiles from horses unaffected by any disease. Preferably healthy horses are chosen who are age and sex matched to said horses diagnosed with disease. In each case, the diagnosis of arthritis is corroborated by a certified veterinarian.
[0546] Total mRNA from a drop of peripheral whole blood is taken from each horse and isolated using TRIzol® reagent (GIBCO) and fluorescently labelled probes for each blood sample is generated as described above. Each probe is denatured and hybridized to an Affymetrix U133A Chip and/or a ChondroChip™ as described herein. An equine specific microarray representing the equine genome can also be used. Identification of genes differentially expressed in blood samples from horses with arthritis as compared to healthy horses is determined by statistical analysis using the Wilcox Mann Whitney rank sum test (Glantz S A, Primer of Biostatistics, 5th ed., New York, USA: McGraw-Hill Medical Publishing Division, 2002).
[0547] Classification or class prediction of a test sample of a horse to determine whether said horse has arthritis or does not have arthritis can be done using the differentially expressed genes identified as described above as the predictor genes in combination with well known statistical algorithms as would be understood by a person skilled in the art and described herein. Commercially available programs such as those provided by Silicon Genetics (e.g. GeneSpring™) for Class Predication are also available.
EXAMPLE 50
[0548] Analysis of gene expression profiles of blood samples from dogs having osteoarthritis as compared with gene expression profiles from normal or non-osteoarthritic dogs.
[0549] This example demonstrates the use of the claimed invention to detect differential gene expression in blood samples taken from dogs so as to diagnose equine arthritis as compared to blood samples taken from healthy horses.
[0550] As used herein “osteoarthritis” in reference to dogs is a form of degenerative joint disease which involves the deterioration of and changes to the cartilage and bone. In response to inflammation in and about the joint, the body responds with bony remodelling around the joint structure. This process can be slow and gradual with minimal outward symptoms, or more rapidly progressive with significant pain and discomfort. Osteoarthritic changes can occur in response to infection and injury of the joint as well.
[0551] Blood samples are taken from dogs diagnosed with osteoarthritis as defined herein. Gene expression profiles are then analysed and compared to profiles from dogs unaffected by any disease. Preferably healthy dogs are chosen who are age, sex and breed matched to said dogs diagnosed with disease. In each case, the diagnosis of osteoarthritis is corroborated by a certified veterinarian.
[0552] Total mRNA from a drop of peripheral whole blood is taken from each dog and isolated using TRIzol® reagent (GIBCO) and fluorescently labelled probes for each blood sample is generated as described above. Each probe is denatured and hybridized to an Affymetrix U133A Chip and/or a ChondroChip™ as described herein. A canine specific microarray representing the canine genome can also be used. Identification of genes differentially expressed in blood samples from dogs with osteoarthritis as compared to healthy horses is determined by statistical analysis using the Wilcox Mann Whitney rank sum test (Glantz S A, Primer of Biostatistics, 5th ed., New York, USA: McGraw-Hill Medical Publishing Division, 2002).
[0553] Classification or class prediction of a test sample of a dog to determine whether said dog has osteoarthritis or does not have osteoarthritis can be done using the differentially expressed genes identified as described above as the predictor genes in combination with well known statistical algorithms as would be understood by a person skilled in the art and described herein. Commercially available programs such as those provided by Silicon Genetics (e.g. GeneSpring™) for Class Predication are also available.
EXAMPLE 51
[0554] Analysis of gene expression profiles of blood samples from individuals having Manic Depression Syndrome (MDS) as compared with gene expression profiles from individuals having Schizophrenia.
[0555] This example demonstrates the use of the claimed invention to detect differential gene expression in blood samples taken from patients diagnosed with MDS as compared to blood samples taken from schizophrenic patients.
[0556] As used herein “Manic Depression Syndrome (MDS)” refers to a mood disorder characterized by alternating mania and depression. As used herein, “schizophrenia” is defined as a psychotic disorders characterized by distortions of reality and disturbances of thought and language and withdrawal from social contact. Patients diagnosed with “schizophrenia” can include patients having any of the following diagnosis: an acute schizophrenic episode, borderline schizophrenia, catatonia, catatonic schizophrenia, catatonic type schizophrenia, disorganized schizophrenia, disorganized type schizophrenia, hebephrenia, hebephrenic schizophrenia, latent schizophrenia, paranoic type schizophrenia, paranoid schizophrenia, paraphrenia, paraphrenic schizophrenia, psychosis, reactive schizophrenia or the like.
[0557] Blood samples are taken from patients diagnosed with MDS or Schizophrenia as defined herein. Gene expression profiles are then analyzed and compared to profiles from patients unaffected by any disease. Preferably healthy patients are chosen who are age and sex matched to said patients diagnosed with disease. In each case, the diagnosis of MDS and Schizophrenia is corroborated by a skilled Board certified physician. Total mRNA from a drop of peripheral whole blood is taken from each patient and isolated using TRIzol® reagent (GIBCO) and fluorescently labelled probes for each blood sample is generated as described above.
[0558] Each probe is denatured and hybridized to an Affymetrix U133A Chip and/or a ChondroChip(tm) as described herein. Identification of genes differentially expressed in blood samples from patients with MDS as compared to Schizophrenic patients as compared to normal individuals is determined by statistical analysis using the Wilcox Mann Whitney rank sum test (Glantz S A, Primer of Biostatistics, 5th ed., New York, USA: McGraw-Hill Medical Publishing Division, 2002) (data not shown). 294 genes were identified as being differentially expressed with a p value of <0.05 as between the schizophrenic patients, the MDS patients and those control individuals. The identity of the differentially expressed genes is shown in Table 3AC.
[0559] Classification or class prediction of a test sample of an individual to determine whether said individuals has MDS, has Schizophrenia or is normal can be done using the differentially expressed genes identified as described above as the predictor genes in combination with well known statistical algorithms as would be understood by a person skilled in the art and described herein. Commercially available programs such as those provided by Silicon Genetics (e.g. GeneSpring (tm) ) for Class Predication are also available.
[0560] One skilled in the art will appreciate readily that the present invention is well adapted to carry out the objects and obtain the ends and advantages mentioned, as well as those objects, ends and advantages inherent herein. The present examples, along with the methods, procedures, treatments, molecules, and specific compounds described herein are presently representative of preferred embodiments, are exemplary, and are not intended as limitations on the scope of the invention. Changes therein and other uses will occur to those skilled in the art which are encompassed within the spirit of the invention as defined by the scope of the claims.
[0561] All patents, patent applications, and published references cited herein are hereby incorporated by reference in their entirety. While this invention has been particularly shown and described with references to preferred embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the scope of the invention encompassed by the appended claims.
1
112
1
110
DNA
Human
1
acacaacgta acaataacat atttagccaa tgtagtagac tgctatataa tacattagag 60
tgtcaattca ttccgtttac agccccattg ggtgtcaaat tttttttgtt 110
2
530
DNA
Human
misc_feature
(16)..(16)
n is a, c, g, or t
2
gcctgttcta tacagnttnt aaatntcatt tcagatcntn tntntgtgat aatgaatgct 60
gttnnntagn natcctatat natgtncgna cacatcctaa agcataggat gaaaaantga 120
nanccttagg atttngagca cantgccttt acctgaatat atacagcaca gttctgnant 180
ncctggcgtg tgnnactgga gatctctann aaaangnata nagtgggngg gcnctntggc 240
gcntgccggt nnnncctaaa ttttccccan gngnnggagg ccngtcacct gnncccatng 300
cgntctngac cngcctgtna acgnntanng gagccttagt cnctnctaaa aacacaaaat 360
tagccnggca tgggggntgg gncccttgta ntctnagctn cttgggaggc tnngccagga 420
antncncttg aanccgggna gngggtggcc tnaagtttgn ggnaaggcca ntgatcaccg 480
ccccttcccc tccangcccn gggngaaggg atttgngact tccgttttgg 530
3
215
DNA
Human
3
cggcacgagg atcaatttgc cttggaagaa caaaaggaaa gtctggaaat gcagaaagta 60
tggatgctga accacataac agcagatggc attgctgtga agtatactgg atggaataca 120
ttcaagcgtt aatatttaat tctttttgtg gaaggtcaca caattaaaat ttaattgggc 180
atggaggctt aggacggggt aaaaaagtct ttaga 215
4
129
DNA
Human
4
gtttcttttt cctaaaacgg ttttatttaa ctcaatgtgt caaagttttt ttttaataat 60
cccaagaggg atgaagccgt gtccacaggg atatatacat cattatggtt cccatctttc 120
atacatgaa 129
5
361
DNA
Human
misc_feature
(13)..(14)
n is a, c, g, or t
5
gggggctttt ttnnancggn nccgnnnncc cttcctggga anttttgggc cnttntntna 60
aangnggnct tncnggnaaa tgggtttttt nagggggctg gncaaaggtt ttttctntaa 120
tgggatnngg ccggcatttt aaaaaaaccc gctttggcct ttttgctana tnggaaaaaa 180
tttttttaaa angcctaaga canggttttc ccttcatatg ccaaactttc cctaacattt 240
ggnntttnng ggngggcagg gggggatttt taaaccggat ttngggtnaa aaaaaatcng 300
gggggaattt ttgggganaa aaccttnggg gggnccccct ttgaaaanaa agggtgggnn 360
g 361
6
839
DNA
Human
misc_feature
(475)..(475)
n is a, c, g, or t
6
ctcgtgccga attcggcacg agcaaagtac ctggacttta tggaatcctt ctatacttca 60
ttgtcaatca tttattggtt ctaaaaagga tcggacaatg tgctatttca gggaagccaa 120
tgttttggag taaaatgcac aaataatttc tcttgccttg caaacacatt tttttttctg 180
tcattgcaat gtgcacaaag ggccacgagg atctacaaga aagcctgcct tattctgacc 240
aggagtgggg agctgacaag aggcttcaca gagcaggtga tgtttagaga ggaatgtctc 300
ccatttccta gtagcctgtg aggctctcaa aaccgggaat caagtttccc ttctgaactc 360
agttctcaat cgtgtaggga tagggttccc aggtgtgcct ctatgtgtag aggctctatt 420
ataccctgga tacacattga tatgcatgtg caatgctgga atcaccagcc cccangtcct 480
cctcccaaat gtgcatgttt tttgacccat gtcacattta attttttttt tcaattgacg 540
ggtttttagg gcaaanttnc caaaacatcc cccactttgc catantcccc tgtcattcca 600
tattgncttg cactgacatg attcactcat tgatattgcc tgtngcgttc ctatggcctt 660
tgagtttgca nactgggttt gggggaaacc cangnaaaaa aacctctttg aaanggggaa 720
cccccccaat ggtgggggaa ananaactgg actttntttg ggagnccnga atttgctctt 780
gaccaggcag ggacctggga ccctgaangc ttttntaatc ttnggggccn gaaaatntg 839
7
118
DNA
Human
7
atgggaaagt gtgtaagatt tagaaaaagc attaactatt agtaaacttt atcttaagct 60
ctaacctttg attaggtccc acaaaaatta ggtgatatgc aatttctaat ttagggcc 118
8
197
DNA
Human
8
gttgcagtga gccgagatca taccactgca ctccagccta ggcaacagag cgagactcgg 60
tcaaaagaaa aaaaaaaagg ggagctgggc gtgggtacta atgccgtaat cccaggcctt 120
tgggaatccc aggcaaggtg gcctttaggg caaggagttc ggaacctccc tgctaacagg 180
taaaccccct ttccctt 197
9
250
DNA
Human
9
gagaccaagg ccgccccgct ctggtctcag accagttgtg ctgctcttgc tctggctcag 60
ctggtgtggg gcgcaggcgg gaaacgagac ctctagcatc tggctgaagg ctctgccaag 120
ctcctcttca gggctgcagt ctgcctgcct gcatataccg acttggccag acactgctgc 180
taaattccag ggactctttc tcccctcctc tgctctccag ccaatccttg aggatttaat 240
aactggaagg 250
10
680
DNA
Human
misc_feature
(433)..(433)
n is a, c, g, or t
10
caccaaagaa gcaagagggc tttcttttgt ttctggggac aataactaac tttaatttgc 60
tcttcaagaa gaaggaagct gggtatatag gggaatggca gaagtgctcg cagatgaacc 120
atgaggagca tggtctttaa gaacatgctg agaaggaagc aacacagact ccatcactgg 180
gggaagcacc tgaatagagc actggtaaag gccagtctgt ggacctgagg ccagaggaga 240
tgccaggggt ccagatttca tggcccacag aaacggaact gatcatattt ggttgctggc 300
cagtgttcca tagaccaaga aggctggtag caagtataga ttcctctaca tagcttgaca 360
ggagaagaga aaggggaatg tagcacacag gatgcagcag gtgaataaga aaacctcctt 420
ttcccaggtt ggngacagtg agtgatctac agtgatactc aaaagattgt gattggtgtg 480
ggaattcctg tctcaatatg caatctgcca agaaaacact gtgatggttt cctgtaaagt 540
aaccctcttt tcttatctct aatttcacaa gactcttaaa tgagaggggg gggagaaagn 600
gttctttctc actcncctaa aactgngggt ctgcctggag aaaanctaca tctgcacaga 660
naatgctggt tagccaggaa 680
11
318
DNA
Human
11
cctgcagagt actccatgga aacaattgcc gagcacgtgc tcgcaatttg ccgagcacgg 60
tccggtttga actcctagac taagactagg taggtgatac ataccttctt cccaccaagt 120
actcacgatc caaactatga attttagatt cggatcaaac gaggattgat ccgagggacc 180
aacgttgtga taaatcttac gtcgtcttat atattaagtt tttgtggagg atcggataag 240
tctatagtgt ttgtcacaga tagtcccgta ccacacccca gaccatagga gtcgctctcc 300
ggaccgcggt ctaatggg 318
12
155
DNA
Human
12
tctcacattg gacatactca aaattcactt ataatcttca caccaccaaa aacttaccca 60
tatcaaatta taaacccacc cacattactt aaaatttttt acatttccca ataaaaaacc 120
caaataaaca aaaacttcca atctccattt aaaat 155
13
125
DNA
Human
13
aataaacaaa catgccctct aatatatgaa ttcatcacac aacacgcaca ctgtccccac 60
aaacaccttt ttggtgtcaa gaagaaaaag actagcttca ctgaacagag aaatgctgga 120
cagtg 125
14
168
DNA
Human
misc_feature
(6)..(6)
n is a, c, g, or t
14
ggcccntggg ggggnagggc cttttcgggg ccggggnngg gcccccnttt ggcccnnggg 60
gggtttcccg gggaacccaa ccctttaagg ggtngggggg aatttccccc caaaaaaagg 120
gaaaaanttt tccggggggc ccacccggga agggntnccg gggaaggg 168
15
438
DNA
Human
15
aaaaaacttc tttatagtcc ttatatattt ttaattgttt atgttagggg aagctataga 60
ggaacaaatt tgggatagaa atataaggct gggattacag gcatgagcca ccaagcccgg 120
cccacatttc catttttaat atatactgtg ctttacaaat attataatat gttttaaaat 180
atgttcacag aagcacctgg tctgtgaatg gcatgccagc attaaaaaaa ataagcattc 240
tttgaatata tatttagttt tttaatgtgg taggaaaatc aaagccagag ggagtagaaa 300
caaaatttgt gattttctaa atacttcttg gctgcaggga agaaaccacg tcccaggcga 360
agtcctacct aatttgatga taaaattaca tggaagggat tcttgttggc atgaggacct 420
accaagatgg tcaacaga 438
16
235
DNA
Human
misc_feature
(5)..(5)
n is a, c, g, or t
16
aaggnctttt ccggnccggc ccggcccccc ttggcccang ggggttnccg gnaaaccacc 60
ctttaaggnt tgggggaatt cccccaaaaa aggaaaaaat tttcccgggg gcccacccgg 120
aaagggggaa ggcccccaaa accggggggg gggnaaaaag gtgggtttcc ccctttttcc 180
aattcccaaa accaatttcc aaaaggnaaa ccaaccnttc ccaaaatggg aaagg 235
17
294
DNA
Human
misc_feature
(18)..(19)
n is a, c, g, or t
17
aaaccaaccc tttaaggnnt ggggggnaat tccccccaaa aaaaggnaaa aattttttcc 60
gggggnccaa accggnaaag gntttgggaa aaccaaattt tttttggncc caaccccccc 120
caaattgggg ggnaaaccaa atttaagggg ggaagggggg gncccccccg ggaaaggccc 180
aaggggggaa aatttttccg ggggtgggtn gggggaacca atttaagggg ggggcccccg 240
ggggggttcc ccttgggccn tttttccttt tgggtnaaaa aaaaaaaccc cttg 294
18
453
DNA
Human
18
gtagaatata gggtgatact ggagatctac tgcgacctag accatgatac ataaccacac 60
aagtttaatc cctgggttct aactaccctt actgtcactt agcttaacct gcctccaatc 120
ctgtacttga actctaaaac tgttggagaa actcagtgct taccccaaca gattcatttc 180
aaatagctgt aaaaggtatg tttactccag aagaccagag ttgcttcttt tgaacttctc 240
attccttggg cctaggaacc ctcatcaccc tcatcccaac gtcaacccag atcttctctt 300
ccataaacag cactccctca ggcccctgcc tgacacaggc atagactgtc atgttggatt 360
cacagacagg ctgtgctaga ggaaacctct ggggctcacc aggggccgtg ggatgggctt 420
ctggggcttc ttggagccca acttcttcat ggc 453
19
242
DNA
Human
misc_feature
(17)..(17)
n is a, c, g, or t
19
gagtcagact gtaaggnacg aaccctcggg gtccccacgn tgttcccccc ggggtaacnt 60
cggcccgggc ccgggnagcc cttcccgggc ttttcccccg ggggggnccc gggggggacc 120
tttaggcggc accccaacaa caccaggccc tactttttcc aaggncgggg aagcccatgg 180
gttctgggna acgggcaatg cgggcttgca acgggnggaa naaaaacagn cccaaaagaa 240
tg 242
20
181
DNA
Human
20
gtttgtttgt ttttgagatg aatctcactc tgtcgcccag gctggaatgc agtggtgtga 60
tctcagctca ctgcaacctc cacctctcag gagaattgct gaacctggga ggcggaggtt 120
gcagggagct gagattgcgc cactgccctc catcctgggc gacagagcaa gaacctgtct 180
c 181
21
100
DNA
Human
misc_feature
(17)..(17)
n is a, c, g, or t
21
gcacaaggaa gggtggncag atnttccngc actggnaaaa ngcngctatg gtngtgaant 60
tnccccnccn nttnanacna aanntngcac tcttggntgc 100
22
100
DNA
Human
misc_feature
(2)..(2)
n is a, c, g, or t
22
cntgcgccat ttactgnagg tggacaagga tactatnaac aaagatgtgg cnnaangaga 60
ataatggaag atagctntga ggatnaacnc tggttnaggg 100
23
100
DNA
Human
misc_feature
(17)..(17)
n is a, c, g, or t
23
acaccttccc acttgcngna aaggggnnng gcccccnnct tgggcnganc attaagcctt 60
tttgnggctg cngcccctgt gcctggtgcc acaacaaatg 100
24
227
DNA
Human
misc_feature
(5)..(5)
n is a, c, g, or t
24
ccggncacca ccnttaaggt tgggggattt ccccaaaaaa ggaaaatttt cggcggccaa 60
cgggaaggcc nttggggaaa aaaccaangg ncaaaccccc ccaaccacnc ggcccccccc 120
aaggggggtg gggaagagcc aaatttcttt gggaaanaac gcccccttgg ggaaaanaag 180
gccaaccacc tttcaacanc ccccaangcg nggaagccat ttcttgg 227
25
306
DNA
Human
25
tccaaaagta gagcagaggg atattttgtt ctactgagcc acgaaaaaca cctgaattgt 60
ttcgaccatg tgccttccca ggttgatgaa gacattgcta cacagtctgc agatcaggaa 120
ggaagaattg tatgtgggag tttttaatgg tctcatttca ttggctataa ctcagttaca 180
aggagaaata taactgcaga ggagctttga aaatttagtt cagctgaggg taaaggaaga 240
agagacaaat tttgtcatca gctagtgatc tgccatacaa ggtgttccct taatatgtgt 300
agaatg 306
26
492
DNA
Human
misc_feature
(299)..(299)
n is a, c, g, or t
26
cggcttcggg ccaagcgttt ccagagtttg ccgaactgct gagcaagttc gctattctcc 60
agatcgccta gccctttgcg ggcgaccacc acgatgtccc agcctgtcag gttgtcctga 120
ttgaggcgaa aggactcgcg gatttgacgc ttgatgcggt tgcgctcgac ggcgagcttg 180
acgctctttt tgccgatcac caaacctagg cggggatgat caagctggtt atcgcgcgct 240
agcagcagga cacttttgcc cgggagcttt accgcttggg gagtcgaaga ctgccttgna 300
ttgccgggga gtcagcagtc gctttttccc ggncgaagcc tcgaactcac cancctgtct 360
ggattaatta gacagcaaga cgcttgcggc ccctttggcg cgaacgaacn ncgaaaagga 420
cttgcgcggc ccgtttcttt ggggggccaa taccggggcn cggggaaaac ccgnggggng 480
gccaaacccc cc 492
27
500
DNA
Human
misc_feature
(348)..(348)
n is a, c, g, or t
27
cgaagcgatg gaagcgcaag cttggtaggg gagcattccc acggcagaga aggtcgggcg 60
acgagccggg ctggagcggt gggaaaagca aatgtaggca taagtaacga caatgcgggc 120
gagaaccccg cacaccgaaa ggctaaggat tcctccgcta tgtcaatcaa cggagggtta 180
gtcgggtact aaggcgttag cgaaggcgaa gcgccgatgt gaagggggtt aatattcctc 240
cacttgccat gcgtgtgaat ccatgacgga gacgaagccg ggggtgcgtc ctgacggaag 300
tgggcgccag caggggcggc cttcgggcca aaccgaacct caggtcanac ttccaagaaa 360
agtgggtgaa acgccagcgc atggcaaccc gtaccgcaaa ccgacacagg tagccggggg 420
anaacatcct aaggngctcg agagtacttt ctagagcggc cgcgggcccc atcgantttt 480
ccacccgggn ggggtaccag 500
28
231
DNA
Human
misc_feature
(18)..(18)
n is a, c, g, or t
28
aagaaattcc gggcacgnag gcacgcccct ggtaattccc caggcgnact tctggggang 60
gctggaaggc ttgnagggca gaaaagggat ccgcctttgg gaggaaccca ggtaaggttt 120
aagaaggaac ccaccctngg ggccaaacaa aaacttaaaa acccccccat ttcntncccc 180
ccaaaaaaaa aatttttaaa aaaaattttt ngcccccggg ggcattgggg g 231
29
109
DNA
Human
misc_feature
(1)..(2)
n is a, c, g, or t
29
nncgaacaat angtctggag ctcgtgcgnc ctgnaggtgc gacactagtg gatccaaaga 60
attcggcacg agggattaca gtcgtgagcc actgcacctg gctgcaatt 109
30
100
DNA
Human
misc_feature
(3)..(6)
n is a, c, g, or t
30
tcnnnntntg gtntnggctn tccgagnggc anngagtgan tgcccgttnn tattgancac 60
cantcantng ttgccntntg atacccnana caaaattgaa 100
31
100
DNA
Human
misc_feature
(12)..(12)
n is a, c, g, or t
31
tcgggcgggg anccctttac ctgtcnttac gatgcgcaag tagatnccng atttngtccn 60
ganggtcgnn aanttaggnt tccagcctgc gncacngcca 100
32
104
DNA
Human
misc_feature
(2)..(2)
n is a, c, g, or t
32
cntgctntta cgatgcgcaa ggtagtnccg tgantttagt ccgtgatgtg tcgaaanatt 60
agnnttncag ccngnnnnan tgccattttn gctctnnnga gaaa 104
33
102
DNA
Human
misc_feature
(5)..(5)
n is a, c, g, or t
33
tgggntggcc cngcttaact tttgcccncg anctcggngt tcgnacaggg gcgaagnaaa 60
ccgccaantt ttttcnaacc cnacttgttt tnggttttag tt 102
34
100
DNA
Human
misc_feature
(3)..(3)
n is a, c, g, or t
34
agnacgcctt tacagcttta ngatgcnnga gagagtancg gatttgnccn tgntggtgga 60
naaattaggg ttncagcntg tgnantgcca ttttcgntaa 100
35
100
DNA
Human
misc_feature
(21)..(22)
n is a, c, g, or t
35
cacgatagca tcagacggcg nncttggngc cnttttgccc gctggtcaca ggacaacgca 60
tttcncnntn tggtgtncgg ctntcacgca tnggcgcgag 100
36
153
DNA
Human
misc_feature
(4)..(4)
n is a, c, g, or t
36
tggngccntt ttgcccgctg gtcacaggna aacgcatttc acnntntggt gttcggntnt 60
cacgcacggc agcgagtgca atgnccgatt cattcttnaa cgacgcacac acccngnngc 120
cctgtgaaac ccataaacag tgggaaatgg tgc 153
37
151
DNA
Human
misc_feature
(7)..(7)
n is a, c, g, or t
37
gcgcgcntgn aggccccgac actagtggat ccaaagtatt ttggcacgag ctnagttcga 60
ngatnnagac cncnnatcac ctaatacanc catnactcan atgactnttt gtgcgccttt 120
tatcanatgc atagcctatc naaaacatca c 151
38
100
DNA
Human
misc_feature
(2)..(2)
n is a, c, g, or t
38
gngcgcttgn aggccgacac taggggatcc aaagaattcg gcacgagctc gtgccgaatt 60
ngncacgagt tnggctgcnt ctttatacaa cttttcttca 100
39
100
DNA
Human
misc_feature
(5)..(5)
n is a, c, g, or t
39
aaagngnntn ctggnnttan gcanttaacc caggcactgg ggcgctgaac agctactcag 60
ctgcttaagt ngtcccactg gtccagacca gcgacccagc 100
40
102
DNA
Human
misc_feature
(80)..(80)
n is a, c, g, or t
40
ttcccccagg atctttctta tatctatcag atctaggtga aaggattact gtcttgtagg 60
tgtcctgaag gacaagccgn ttcgtttgaa nctgtgaaat ac 102
41
325
DNA
Human
41
ttcggcacga ggagaagaga ggagccgtca gaacatatgg gggatgtgtt caagaagcag 60
atttgtggtc ggaagctttg caaagagggg acctgggtct gagtgacatg cgtggccact 120
ggtgctcctg cgtttggact gtgcaggcct ctcctatgct gatgcgtctc cccactcctg 180
agctaatttc tgctctgctc cttctgtgac atgtggcagc gtgggaaata gccactgtcc 240
cctgtccctg ctgttcctgg tgtcacccag caccaggcca ctctgggagc cagggcagat 300
ggtcctccct gtggtcctgg cctct 325
42
103
DNA
Human
misc_feature
(14)..(14)
n is a, c, g, or t
42
gtggcccaag gggnactgaa ggggccctcc ntaagnggag gggttgggga gtaaggcctg 60
ggnaggaccc tgntgactcg gggggcggga gcngggancc agg 103
43
221
DNA
Human
43
catattttga aatacttttc tcccaaactg ggtttattag cgtgtaccct gcttttccac 60
tttaaaaatt tatgccatat gtccagcttc cagtcagtgc ttctggttag catgaggata 120
actagatttt actgtagatg gtagataaaa gtccagtgaa aagcaaagat gtgtaatgtt 180
ttggtagcct cagtgctctt atcccaagta aaagcaaagt t 221
44
100
DNA
Human
misc_feature
(2)..(2)
n is a, c, g, or t
44
anagagatca ntgatttatt gctgggnncc tgtntganng ntctaaggnn tgaagattat 60
nncattnngc aagcgnacnn gcgcngccna gcngaccagg 100
45
106
DNA
Human
misc_feature
(8)..(8)
n is a, c, g, or t
45
atatttcngg agcttgcagc ggcnacacta ggnnactaaa agaattnnag aaagaggnct 60
atnggacnag nanacangaa acctgcanac ttggnngctt ggaagt 106
46
100
DNA
Human
misc_feature
(74)..(74)
n is a, c, g, or t
46
gatgtggaga tgcttgatag gttactgggc ggcaatccag gagttgatga agcgcatatg 60
cgaacatttc acgngcatat tgcggtgcaa gggcttactg 100
47
101
DNA
Human
misc_feature
(7)..(8)
n is a, c, g, or t
47
ccccccnncc cttcttntcc ccnaaagaat aanataagaa tngctannga gnaancgacn 60
anggtnttan nagntatatg tatntnncaa accaantann a 101
48
100
DNA
Human
misc_feature
(5)..(6)
n is a, c, g, or t
48
aaggnnaggc tcgttggggg aaaaaacccg ccntnncggg cncccngnaa acccncacna 60
ggggacccna aaaaccggaa naaaccnccc nagnaancca 100
49
473
DNA
Human
misc_feature
(20)..(20)
n is a, c, g, or t
49
atgagtatga aatgaaaggn tgagatgaaa tgatgatntg agatgagatg aaatgagatg 60
aaaccgagat gaaatgatga aatgatgaga tgagaccgag acgaaatgat gagatgaaat 120
gagatgagat aaaatgagat gaaatgaagt gaaatgaaat gaantcctga aattgacntg 180
agatgaactg agataaaatg ntgagatgaa ntgatgagaa gaaatgagat gaaatgagat 240
gagatgatga gatgaaaaat gctgagatga aacntgatga gatgaaatga tgagatgaat 300
tgaantgaaa tgaaataatg aaataatgac ctgagatgan atgaantgat gaactgatga 360
actaatgaaa tgaaaatgaa atgganntga tgagatgaga agaantgctg agatgagata 420
aaatgagatg aantgatgag atgaantgaa atgctgagat gagatgagat gaa 473
50
453
DNA
Human
misc_feature
(5)..(6)
n is a, c, g, or t
50
ttccnnagct gtnacganac antcttgaat tgaaattgna cacanctngt gtgnagccct 60
gatanggccn gnaagcaatn tanaggatan ccgnangnta tngnaacaca ttncncnagc 120
ntntncanca gctgatgcag gncncctatg atgcgattan ggactacgac tatnnctcan 180
ngtctnaaca gncgcgangg ctgantacta aaagnacaca aanntgtgca ccnncatnac 240
tcncgttgac tgnacantgt agacctgnaa tacctggctn aaaggggtct nactgncatn 300
agagntgnag ntgcccctnc antagngnga gctnnaanng gcctgtnttt gntttacntc 360
ntcgganagg cgatgccatt anagacccna gaacncattg gtgatatacn ctnnaccngg 420
agggnttaca ttgggnaatg atnattatgg ggg 453
51
542
DNA
Human
misc_feature
(19)..(19)
n is a, c, g, or t
51
caactgtgag caaggaatnc cattaaatgc cattgtatat tcattgatca gtgaaatcnc 60
atctgggtca cagtggcatc tatgttnaca gtataaatcc ctgtggctat gaatgaaang 120
cttgtttaga cttgcatctg cacatagaag tagggatttc atgctgttat cagcctaatt 180
ttagcctata gaatttcaag ttngctagag gtttngctct ccatggtata agtttagcaa 240
gaaaagtcat ttgtctgctg ctctagcagg ttanaatgtg gaagtatagt gtgcanagtt 300
ttaatccgna tatgttatta aaacatatac atcattttat atcatacatc tgnaataaat 360
attcaaaatt aaatagtgat ttgggattga ttacatctta ttactagctg taataaatga 420
cctcnnngat ngtttaaaat tgttttcctc ncatataata aaaatacctn angcatanat 480
cgattgtcca aaaattgaat atatatacac acctcttcca ttagaactaa atatgtggaa 540
tg 542
52
733
DNA
Human
misc_feature
(13)..(14)
n is a, c, g, or t
52
atatgacctg cgnncanacn cnctaanang ngactngtta aanacnttcc gtggaatnna 60
ctcagactgc aaantgtnat nctgncnnan nntgnngact gtccngncng atttnnngcn 120
tgnaatacta ttgcctctta tatacacnac caannntgcg aagggcnann nnacctttnc 180
cantnnnctg gggncccacn nnngngaact gagagtggat cttgtgtacc tgacnnacca 240
gntntnnagn agggcgctca ctctgattgg tgcaccatgg ttacacagtg tgtgcaaaga 300
ccngnctatc tcactganga tgattgncag ngccnntggg tggcacnang ggnactgatg 360
ancancactg accctgccga cgccagangc cgcanatccg gagantncat gngacnatat 420
aggttaccnc cttcnaccgg gcancaatct gcttctatgg tgaatgcaga ccatntagaa 480
ntctntcnct ataggcatga ttttnnncag tgcgtcagcc ttganaanga ancnnacttt 540
tgntagatga nnngntgctc ncccttgngg ctnacaaatt ccancaccnt tggtggcngc 600
agccnttaag ancacttntt ttgggttgcg ctnttggatg aattacnaat agnntgtttt 660
gttncaaggc ccttctgcna aatatgaana aaagngcnct tagctttttg ngggaactgn 720
actggaaatt ttg 733
53
100
DNA
Human
misc_feature
(13)..(13)
n is a, c, g, or t
53
gatcagacaa gancntggtc cacagcggga cgagagntct cnannctgcn ggggagnnnc 60
caagtacgcn agcnctgaan ctaaagcaag caagaaaaag 100
54
515
DNA
Human
54
atatggcaag gataacccct atacttctgc ataatgaatt aactaaaata acttgcaagg 60
agagccaagc taaacccccg ataccgacga gtaccagaac aggtaagcac cccgtctatg 120
tagatatggg aagattatag gaggcgacaa ctaccgagcc tggtgatagc tggtgtccaa 180
gaagagtctt agttcattta tttggcccag aaccctctaa tccccttgta atttatgtca 240
agaggaacag ctctttggac actggaaaac cgtgagagag taagatttac acccttaggg 300
gcctaatagc agccaccatt aagaaagcgt tcgctccaca cccactacct aaaaatcgaa 360
tataactgac tcctcacacc caattggcca atcattcccc tataaaagaa ctatgttagt 420
ataagtaacc tgaaaacatt ctcctctgca taagccctgc gttggattat atcctgcact 480
gacaattaac tgccccaata tctacaatcc aaccc 515
55
176
DNA
Human
misc_feature
(5)..(5)
n is a, c, g, or t
55
tgttnaggat caaattataa tattgaaata anaacagctn acatttatat agcatgtttn 60
cntatctcaa ctaatnataa atgggaaaat gggcaactgg gcaggcngaa cccagaggga 120
agcctgccct cattagacca agacagcaag gtttnccctg gtcactagat gaaatt 176
56
317
DNA
Human
misc_feature
(4)..(4)
n is a, c, g, or t
56
cagnagtgat gttgcaatat ctggaactag caaaggatac tgatgagaaa acgtggaatc 60
atgtgggatg tgacctccta ggactcacct tgcacagctg ggtgcagcag ggataggtaa 120
ggatttgggg tttagaggta caattgcctt tttatggtta gagaaaggtc ctggggctgg 180
agggagcctg acgatctgct ctgtgtgcaa ggggagagtt aactctgcac gcaagagcct 240
gcttaaaggg ctgtgtcagt tctattgtaa acaccaactt aaagtggtgg atgctggcag 300
acattgttat tgccatt 317
57
209
DNA
Human
57
ctcatacacc tgtggctact gttttctaca gagtgccaaa actattcgag agaataggct 60
ctggactgga cactgtatac ccacatgcaa gatgaagttg gccccttaca tcctatacgc 120
aggagaattg cgtcatttaa agcctgttga cgcttttctc ccgcagacga atggaaagat 180
taattgggag tgggggctga aacaattcg 209
58
262
DNA
Human
58
aattttgctg ttacatggtg gctcaactga gtcccatact ttgaaggccg ggagttaatc 60
acctggtcac cgagttgcga accagcctcc aatatgtgga accctgtact ctctaaaaat 120
caaatcaccg gcatggagat tgcgcctgtg gtcccaaaat actcgggctg ggacacgatg 180
agttgcttgg cccaaggaag gagggttgta tggctgatca cactggtccg cctgggtgac 240
agagcgagac tccatctcta at 262
59
430
DNA
Human
59
gtcagtttat ttctgactag ggatattttc tttccattta gaaaagaaga aaaaaaaaaa 60
aaacctttat tgtcttacag gggggaacta gcgcggggct gaataaaacc tttggccctt 120
cccgggggag gggtatccgg tttataaacc ccaagggtat tttcttagca aaatacttaa 180
aaccggccgg ggtttttata caaactggga acccactttt gaaaaatttt ggccttttga 240
tctgggatgg gaatatgagt ttttatacat ttcattttct ttttgggcaa aggcccggtt 300
aagtattccc ccccgggggg cctttacaaa aagggcggtt ttaaaagctt ttgggccccc 360
ctagggaatt gttttaacac ctaaaaaccc ctgcttccct taaaggggcg ttctttaatt 420
tgggggcggc 430
60
350
DNA
Human
60
aaacctctct aactatatat cacaataacc tgcgcataag atttacgctc cgatcttttc 60
atcctactag cttggaggat ttgaaccgat tatgaatacg caatactccc ggtcctcatg 120
tatcatgtgt aagcccatct cctgggaggg ctaacatact accatctcca aggagaggca 180
tgattccgaa tcacccacag acagctcgat caccatacgt atcacccaac atatatacct 240
tctaagactt gctagaaaca accaccacat ttgatgctta atcaccactc tgacgcgcat 300
taaagtgagg ggactctcct aatttctgta agttgatttt tgcattctga 350
61
515
DNA
Human
61
cacataaatt ctccataagt taattagtga ttttaacatg atctcaatat aaacatagca 60
cactttcttt gagaattcaa catattgcaa gttaaaattt tcatagacta cacaagaaag 120
aataatcagg caaatcctta agaataaggg caattaagga tgactagccc tacaagattt 180
taaaaaggat tcattagttt aaaaaatgtg atgtagatac atgaataaaa taaaatcttg 240
aagtagatcc aaatatacat ggtcagattg aatacaataa agatggcatc gtagcagtgg 300
agaaaagaag aattatttca taaaccttgt tggaatggct aggcaatcat ctggaaaaaa 360
atgaagttga ataataaaaa tatattctac actagcacaa attataaata aagcagtgat 420
ttaaatgaga aaaattaaat cataatgatt tcaaagataa cataggataa tttctttata 480
gtcttctaaa atatatgact ttatgaattc tgact 515
62
611
DNA
Human
62
caagtacttt accaactaag ccaatcttgt ccccagccag gcatttctat acaaagggcc 60
aagactttgg ttttataaat aaggaggtat atataaatta tatatatttc tgagctgagt 120
aataatccac cagatacaag tttgcatcaa cttctgtgaa atattttttt tcctttttgt 180
tgggcatttt tatggtctaa atatagaatg accaatgcct ctagaacaaa cttgacctgg 240
tcagtgttat caagaagcag actgtttctt actttctttg tatttcctta cttatttaaa 300
tttgttaaaa ttgatatatt gatatataaa acttcttttg ccagtgttgg tggcacacgc 360
ctttaatccc agcacttagg aggcagaggc agggtggatt tctgaatttg agggcaggct 420
agtctacaga gcaagttcca ggtcagccaa ggctatatat agaaactctg gcatgaaaaa 480
ccaaccaaac caaaccaaac caaaccagac cagaccagac cagaccagac caaaccaaac 540
caaaccagac taaaccaaac caaaccagac cagaccagac cagaccagac cagaccagac 600
cagaccaaac t 611
63
291
DNA
Human
63
ccgagagatt ggccactgct taaactcatg cagctcctac tgttcttcaa ttaatgcctt 60
taatgcgaat atacttcctc ttctttttgc atggtcttgc ccagcctctg caatactgat 120
gaacacatgc tgaagatcat ctaactcaat atggcgcata tttctatgtc ttgctgccca 180
ggacatagga caacttcgtc gctcactagt tctaacatat taatgctggc gtaggtggag 240
aactactgca catatactct tactcggagg ctgaggcacg aggatcactt g 291
64
309
DNA
Human
64
gccagatgcc gtgtttcctc gatgaactct ttacatcatt ggctattcag tggagtgttt 60
cattatcacc tctcactctc gcgtgttacc taactctccc tcgcagggga aatcactcca 120
tatatttcaa atgtcttgct aacagtggtt actttgctct atccttagct atacgtctcg 180
aggcacattg ttcctctatg ccccgctacg ctttgcccta gagctcggcg gtatctatat 240
cttaactgcc ctcttgatcc ttacgtgccg gagaaggtgg aggcagaaat tttgtcaaat 300
ctgattaga 309
65
278
DNA
Human
65
tagaatggaa tggagtcgaa tgtgatggaa tggacgcgaa tggaatggaa tggactcgaa 60
tggaataaag tggaatagac tcgaatggaa tggaatgcaa tggaatggac tcgaatggaa 120
agggatggaa tggactcgaa gggaatggaa tggaatggat tcgaatggaa aggaatggaa 180
tggactcaaa aggaatggaa tggaatggac tcaaatggaa tggactcgaa ttgaatgaaa 240
tgtaatggaa tagactcgaa tggaatggaa cgaaattt 278
66
142
DNA
Human
66
agttctcctt aggttaatta atggaatgca atcccaatga aaatgtcacc aaagttgttt 60
tttttttaac tgtaggaggt ttataataat gctcatatgg aaaaataaaa catgtaaaaa 120
atagctagta aactccccct gt 142
67
286
DNA
Human
67
atatctgcca tcctcatcgg ccaatcgtgt tattttgatg acgaatgctt cggagattgg 60
aaagatgatc tcctcatgct tccatgcact gcgagtagaa gacatactga gcatagtgtg 120
attattttcc caacaaattg gcattcatag atagaataag ctgactaaga ctacttagcc 180
ccacattttt ttctacttgc tccaatagca ctaacaaata ggaagctctt gcttgctccc 240
caaagctcca tttccttgaa agcagaagtg taatattact tcttag 286
68
179
DNA
Human
68
atctactttt tattcttttg ataaatgttt atgaaatata aaatactgaa aattagaaag 60
tagaagtcat tattttatta taaaacatgt ggattagata ttttcattta tgtgattaaa 120
ctttctaaac aaagattata tgaattatct taaagattta aaaagtaatt aagttaaat 179
69
390
DNA
Human
misc_feature
(356)..(356)
n is a, c, g, or t
69
cagataagac tattaagaca gataagagcc aaatcatgta gagcctcaga ggtttttgat 60
cttcagtcta agaacgtaaa tccatggaag aattttaagc aggggtgtgc cttgaccaca 120
ttttgaattc taaactgtct ctgggtgggt gtgggtgcca ccaagagcat gtgttcatgt 180
agggagactg gttttttaca gttgtctatg agagagatga cagttgcctg gattatggtg 240
gtgacattgg agataagcag gtagacagat tctcagtgta ttaggagaga aaaatcaata 300
ggaaatttaa aataaataat taactgtggc cataggagga aggagtcttt gggttnggtt 360
ctcaatttct gcatgagaaa aaaggtggac 390
70
481
DNA
Human
misc_feature
(26)..(26)
n is a, c, g, or t
70
atgatgaaat gatgagatga aatgcntgag atgagatgtg atgaaatgat gatatgaaat 60
gatgacataa aatgagatga aatgagatgt aatgatggaa tgagatgaga tgaaatgaga 120
tgaaatgata gatgagataa aatgatgata tgaaatgatg agatgaatga tgagatgatg 180
agatgaatga tgaaatgaaa tgatgagatg agatgatgaa atgaaatggt gagatgaaat 240
gatgagatga aatgaaatag tgaaatgaaa ttgaaataaa atcgaaatga gagatgaaat 300
gatgagatga tgaaattgat gaaatgatga gatgtgatga gatgaaatga tgagatgaga 360
tgagatgaca tgaaataatg aaatgaaatt gaaatgagat aagatacgag ctgagatgca 420
atgagatgaa atgatgagat gaaatgaaat agtgaaatga aattgaaata aaatcgaaat 480
g 481
71
125
DNA
Human
misc_feature
(5)..(5)
n is a, c, g, or t
71
cggtngcaat tgggggccnc atacgcgcng acgagtantg gncangctnc ttgactacac 60
ngacgcgccg tacaggntna attatggnan cttacatggn aaaggggcan ctcaatgtcc 120
cacag 125
72
473
DNA
Human
misc_feature
(151)..(151)
n is a, c, g, or t
72
gaaatgaaat aatgaaatga gatgaaataa cgaaataaaa ttgaaatgag atgagaggaa 60
atgagatgaa atgttgaaaa gaaaggagga aatgatgagg tgagatgaaa tgatgagatg 120
aaatgaatct gagatgaaat gagatgaaaa ntgatacgaa aaatgatata aaaaatatga 180
cctgagatga aatgagatga aaaatgatac gaaaaatgat ataaaaaata tgacatgaaa 240
tgaaatgaga tgatatgaaa tgacataatg aaatgatgaa ttgatgatat tgaaatgaaa 300
ttgaaagatg agatgaaatg atgagatgaa atgaaatgtt gaaatgatga agagatgtga 360
catgaaatga gctgaaatga gatgaaatga aatgagatta aatgatgaga tgaaaaatga 420
tgagatgaaa aatgagatga gatgatgaga tgagatgaga tgaattgaga tga 473
73
500
DNA
Human
misc_feature
(7)..(7)
n is a, c, g, or t
73
aatgagnatg aaaagnatga aatgatgaga tgaaatgaaa tgatgagatg aaatgaggtg 60
aaatgaaatt agatgaaatg taatgagatg aaatgaaatg acctaatgaa atgaaataat 120
gaaatgagat gaaataaaat aatgaaatga tgaaataatg aaatgaaaat gagatggaaa 180
tgatgagatg agaagaaatg atgagatgaa atgatgaaat gatgagatga ganaaaatga 240
gatgaaatga tgagatgaga tgaaatatga tgagttgaaa tgacataatg aatgaaatga 300
tgaaatggaa taatgaaatg gaaatgatga gctgagatgc aatgagttga aatgagatga 360
aatgatgaaa tgatgagatg aaatgatgaa atgaaataat gaaatgagat gaaataaaat 420
aatgaaatga tgaaataatg aaatgaaaat gaaatggaaa tgatgagatg agaagaaatg 480
atgagatgaa atgatgaaat 500
74
299
DNA
Human
misc_feature
(31)..(32)
n is a, c, g, or t
74
ggaaatcctg aagtggaaat gatgagctga nntgcaatga gttgaaatga gatgaancga 60
tgaaatgatg agatgaaatg atgagatgag atgtgatgaa atgatgatat gaaatgatga 120
cataaaatga gatgaaatga gatgtaatga tggaatgaga tgagatgaaa tgagatgaaa 180
tgatagatga gataaaatga tgatatgaaa tgatgagatg aatgatgaga tgatgagatg 240
aatgatgaaa tgaaatgatg agatgagatg atgaaatgaa atggtgagat gaaatgatg 299
75
155
DNA
Human
75
agtgaaatga aattgaaata aaatcgaaat gagatgagat gaaatgatga gatgatgaaa 60
taaaatgatg aaatgatgag gtgatgagat gaaatgatga gatgaaatga tgagatgaga 120
tgagatgaca tgaaataatg aaacgaaatt gaaat 155
76
367
DNA
Human
misc_feature
(11)..(11)
n is a, c, g, or t
76
atagcaaaag ngggtaaaac ccctgagttt gcganannag tantcttgta ggggcnaact 60
ctacttnaga ngaantcctc gcaaaatcct tgaatcaccg cttcagtgca gtgatatcac 120
cgccatgaaa tttctgctcg attagcttac gttgtttgga tagaggccaa acaaggctgt 180
tatcggtacg aggaatggat gttcgatttc gtagaatacg cctgagagac ggcgaatact 240
ctcacgagag gcagcaggcg cgtaaattac ccaattacaa caagtagagg tagcgaagga 300
aaatatgagg ggtggcaagg ttttgcctgt tacattctca aatggaagca aattagatat 360
gtcattg 367
77
257
DNA
Human
misc_feature
(6)..(6)
n is a, c, g, or t
77
actagnacag naattttagc taagtggagt ttgagttaag tggagatgtg agaccatctc 60
atagaaatca ttatttctgt gggatggata attgggccaa attgtaaaat attttaacta 120
tcagtgtttg gggtttattt ttaaaagaat agggtgccac cagatgttct ttagtggagg 180
agaaatgagg ccagagtgac tgcctagaaa attaagttgg taaattaatc acttttttct 240
aggtcctttc ttagtct 257
78
373
DNA
Human
misc_feature
(11)..(11)
n is a, c, g, or t
78
ctttaaaaac ntgttagacn aacnttaaaa nttacccntt ttcctgaact gantcctggg 60
nntaantaaa aagggtgaag aannttactt cncttggtcc taaaaaacnt tttcntcagt 120
tattaccaaa atatttggac cattantaaa gantagggcc aacccnaatt tttcttgaaa 180
tttccgttaa atagccgtta aatgttttta cccatttcat attggatacc ttaaattata 240
ataatggatt ttattgttaa attgtgtgtg tgtggtgtgt atgccctgtc ttttctcctc 300
taccattatt gtcactttat gtttggaacc ccctttaccc ttccttaaag gaaaaaaagg 360
gcccggggtt ttt 373
79
128
DNA
Human
misc_feature
(10)..(10)
n is a, c, g, or t
79
tcctagtaan ctggtttacn ctgaaagann aagangcctc ccctgttcnc tgaaatacca 60
ccttgatgtt caagtattta agaccctatg cnaatatttt ttaccttttc taataaacca 120
tgtttgtt 128
80
213
DNA
Human
misc_feature
(9)..(9)
n is a, c, g, or t
80
cccattggna cagaccccca aaatgggtac attttttagg aaaccaggac ctttccaagg 60
ggccaggcct tccctttaaa aaaaaatnac cgtttttngg gggangnaac ctttaaaagg 120
ggaaaanaaa tcctttttaa anggaantcc aagggaagga ncctgnncaa nacttccccn 180
ccaataaaaa aaaccntttt ggaaangggg aaa 213
81
443
DNA
Human
misc_feature
(22)..(22)
n is a, c, g, or t
81
gaaatgagat gaaaccatga gnatgaaatg aannaatgnc atgcaaatga tgagatgaaa 60
tgatgaaatg agatgagatg agaagaaatg acttgatgag atgagataaa atgatgaaat 120
gaaatgaagt gaaatgaaat tgaaatgaga tgagatgaaa tgagataaaa tgatgagatg 180
aaatgagaag aaatgagatg aaatgatgaa atgatgagat gagatgaaaa atgatgggat 240
gagaaatgag atgaaatgat gggatgaaat gaaatgaaat aatgaaataa tgaaatgaaa 300
tgaattgata atattgaagt gaaattgaaa gatgagattg gatgaaatga tgagatgaaa 360
tgaaatgttg aaatgaaatg aagagatgta acatgaaatg agctgaaatg atgagatgaa 420
atgaaatgaa atgagattaa atg 443
82
442
DNA
Human
misc_feature
(13)..(13)
n is a, c, g, or t
82
tggcccggga acntcnaact gcccatcctg ganttttggg ggggannctt taaaaaacct 60
gacctctgaa tgtattantg anncaagtga tagccaagat attttgaaga aaaatagata 120
ntagggacct gctctataag cccatcataa tttattatga agttataaca agtaaaacag 180
taaggtattt ggcatggaat agagaaccca gaaacagacc caatgcatgg gtacaggata 240
taacacaggg aaatgaggga caatatatgg ttctgggata attatttata tggggaaaat 300
aaagaaattg gatccctacc tcacacatac aaaaaaaatc ataattgaat taaaaacttg 360
catgtgaaag gaaagacttt aaaacattta gaaaaagtat tggaggctat gatcttgggg 420
taggaaagca tttctttttt tt 442
83
135
DNA
Human
misc_feature
(8)..(8)
n is a, c, g, or t
83
gtctaacnta aaaagtaaag aaagtaaagt aaaggnttga aggaaggaag gaaggaagga 60
aggagggaaa agaaagaaag gaaggaagga aggaaaagaa agaaagaaag gaaggaagga 120
aggaaggaag gaagg 135
84
346
DNA
Human
misc_feature
(30)..(30)
n is a, c, g, or t
84
ggaggaggaa gagtgatgag ttctctaatn acttggttgg attagcctta gagttatcgg 60
gagttgcctt ctgtaagtgc ccctactatc aaggtttcat ggaaaatcta ggcaaggcag 120
aacttcctca gaaggacaag agacaaagaa gtgggggagg ccctcctatc catagctgag 180
agggtttatt ctttgtggtt ctgctgtcag agcctttgga tgtctgatct gagatggagc 240
aaccccagct agacagaact ttgtagattt tggggggttt aaaaggcctc aagcaaattc 300
taaaactttc tttgaacccc ctggcatagg ctcagtttcc ctgact 346
85
100
DNA
Human
85
acaaaaagcc cctttaaact tgggcccgct cgaggtcgtt tcgactgggc cgagacttcc 60
gaaaagaaaa tggttttttt tgccgaaatc aaccgggtaa 100
86
201
DNA
Human
86
ttcataacat cgtcattttg ggttatgcga aatacaaatt taaatctttg tgaaatgaaa 60
gaaaagagga agaaacgctt tttaggagtt aaggattaaa gtaaaaatta ttttgacata 120
attacctctt tttgtgacca ctcttaaagg ccaggaacat atttggagaa gcctagttgt 180
atgtaacagt gtggggtttc a 201
87
531
DNA
Human
87
tatagcgggc gttataaaca taccacttcc cggtacaacg gatttcaagg ttaggggtgc 60
aacccagaac gaacgcgtta agtgcgcgtt atcttcctag gatagagtcg gtgacgggaa 120
tcttttaccc cggcactcgg gtccaccctc gcggcaccag aggtattctc cggcgagtcg 180
ttaaccatcg caatcgccga ccgagtttaa ggaccactcc ccacctttct cattagttaa 240
ggagaacgct actttacccc atagacggag aaatcgctac tcaactacca ggcgcgcgcc 300
gtcgagtccc tcttcctctc tttatgcatt tagagcgctt tcgtaagagt tttccctaga 360
ttcttctaag cgtagcgcgt ctactccaat gttttcgtta atccagcccg aactaacgcc 420
gcggaggagt cgatccgtct actcctatcc cgtcggctcg gatttactac aggagctaag 480
aaaacaaaaa gtaccagccc taaaggaaag tcaaaggacg cccgtaaaaa a 531
88
530
DNA
Human
88
aatctcgatc gcaaacatac ggcactctcc ctcttgccgc ggttttcgtc cagcgctttc 60
cattcggtcc agtgcctcgc cctattagcc cttaagccca ccgtttctaa aactcccaga 120
acagccaaac cggtccgccc aaggcctccg tcgttttata atatattccg tttacgtata 180
aggaacgaac cccccttcat taccacggtc ccgcgtccgc ctccttctcc attcgcaaca 240
gttctattcc tttcagcctc ccgtacctgc ttccagaaca tcgcaccgcc atagtcgaaa 300
gatagcaaag attacccagc ttctattcct cgccccagag ccgagtaaat cgaagtttat 360
agaggcggaa tccaaccatt caagagttat aacaagttat cggcactcgg gggatcagaa 420
tataaactta atgtcccctt tattctcccg gacgcccctt ttaaccactt cttcctatct 480
ttcgctaaca agccattgac ggcgctttgc cgcgcgggcc catctcgcgt 530
89
332
DNA
Human
misc_feature
(37)..(37)
n is a, c, g, or t
89
ccatttatgg gccggggata tacccacatg gtacagnaca ttacatnttt atggcaccat 60
ttccaccggc ctggttttgg tttttccata attaattaac cagggggncc anttaaaaaa 120
aattaaggna aggnttaaaa aatttaacca anggggggtt taaagggntt ttttttttta 180
aaaaaaaagg ttaaancccc cccttttttt ttgggttggg gtgggaaaat tttgggaanc 240
cttaaccccc gggtttttgg gtttttttgg ccaaaacccc ccggaaaaaa attaaaaaaa 300
ggaccggttt ccattttaat gggtattggg aa 332
90
185
DNA
Human
90
actgctataa tgcaggggaa catgttctca gggtcatcct gaggggttgt gtcatggggc 60
cggtggtaac tattaaaaca taagtttaat cggtatttaa aattttaaaa tcaaaaaaaa 120
taaaatatat gcaaccctcc attccaagga agtatgatgt tactagatta tctgaaaatt 180
ctcct 185
91
365
DNA
Human
misc_feature
(326)..(326)
n is a, c, g, or t
91
ccagagagcc acaaatgacc aaaatatttt gagatgaaca tgctcgtaga aggtagctga 60
ctagggggta cttgaaaatg ctagaccagg ataactccta agtgtatatc cttggcagac 120
tcgttatgct ttccaatcct gcttgcaata taagacacaa agtcagaata aagctcaaga 180
aaacagaacg tgcaggccat caagcgcaga gcctgctcat tggacaaccg caaagagtag 240
taagtgctgc cgctattcac acttagaaaa ggagaaccac ggggaaaaac caaattaatg 300
gggctgcttt ttgtcactct ggcatnagag aattgtgnng aaantttaac ttttgtaagc 360
ttgta 365
92
113
DNA
Human
misc_feature
(32)..(32)
n is a, c, g, or t
92
acttgacctt atggatgatg ctgcggagtg cntngtaagt gtttcatgat attccttaag 60
aagtcaggat agtagttttc attccttaga tggtacaagt gttgagacaa atg 113
93
210
DNA
Human
93
gttttaggga aatttgccag ttttatgttt taatattttt ggaaggaaaa ctgaaaggta 60
atgaaaatgt tactgttgga ttaaaaaaca aattaagtcc aaatagtgat taggcaagtt 120
ggtgaggtag ggggttgctg caagagcgga agttgaaaga tcttggaaaa attaaagaaa 180
cttcatagaa ccccatctct acaccaaaaa 210
94
506
DNA
Human
misc_feature
(5)..(5)
n is a, c, g, or t
94
ttggnggggg ggcgagatcc tactngagac ccttgatnnt gggnanggac cgaagatcna 60
ttaganaccn atgngatggn cnnncnaaan nnttaaagtg agagtccatc tnngaanaaa 120
atgggnaant ttnnnngggg ggggggaaaa ancccnnggg tnannggggg cccngggntt 180
naaannnggn nctngggggg ggaaantttt ggcccccccc cgggggnttt ncctnaaaaa 240
aaanccnttt naaanacngn nanaattttn ccnnnncggg gaggngngga nntttttttt 300
tnaannagcc ntttttgnna naaaaannnt ggnccccccc ctattccnng gnttttngga 360
ccnttnnanc ntgggnnttt ttagnccttn aaaaaaangc naatnttaag gtaaaaattn 420
ggggggggng ggggggnggn gnnttttttt ttntnnggag gggttttttt ccnncgnggg 480
ngaaagnntg gggcnnnctn cngccn 506
95
400
DNA
Human
misc_feature
(11)..(11)
n is a, c, g, or t
95
catgaaggaa naagcctgta ctanctgccg gtatccatgn taatctgngg ngatgtcagc 60
agacccagct nagcagatan ctncatttct ntctnaagnc ctttggtctg naggnngnca 120
ntnnanctnc ngntnaacat cacagctnct ccnagcatca ccctgctagn tancngnggg 180
ttttctctta tntgnngncn naacatctgc nngctctgnt annaanaatt ncataccgcn 240
canngtctnt gacgntgtga tgcatacgnt tgggcagagn gancaatang tgngcatatg 300
cgtgccttac ncaaggatac ggangngctt gaaattgatg ngaccaanan tttnngtacg 360
gtaagtnacc caaccacttc tgnnttcact ntaagagncn 400
96
800
DNA
Human
misc_feature
(171)..(171)
n is a, c, g, or t
96
gagatgaatg atgaaatgat gagatgagat gatgaaatga aatggtgaga tgaactgatg 60
aaatgaaatg aaataatgaa atgaaattga aataaaattg aaatgagatg agatgaaatg 120
atgagatgat gaaataaaat gatgaaatga gatgtgatga gatgaaatga ngagatgaaa 180
tgatgagatg agatgacatg aaataaatga aataatgaaa tcgaaatgag atgagaagat 240
acgagatgag atgaaatgat gagatgaaat gatgaaatga gataagatga aaagagttga 300
tgagatgatg agatgaaatg agatgaaaag agatgaaatg agatgaaatg aaatgatgag 360
atgaaatgag gtgaaatgaa attagatgaa acgtaatgag atgaaatgac ataatgaaat 420
gaaaaaatga aatgaaataa tgaaatgagg tgaaattaaa tgagatgatg aaattaaatg 480
atgaaatgaa ataatgaaat ggaaatgaaa tggaaatgat gagatgaatg atgagatgaa 540
atgatgagat gagatgtatt gatgagagga aatgatgaga tgtaatgaaa tgagatgaaa 600
tgaatgagat gaaatggaat antggaangg aaattgattg gngatttgag atgaaatgag 660
ntaaatgnga tgaattaatg atgagatgaa atgntgaatg ccggggtgnn tgagatgaat 720
tgagttgaac cctgngatga atgaagattg nntgaatggt ggntgaatgt tgaatggntg 780
gntggnanaa tgcctgtngg 800
97
334
DNA
Human
97
gatgaattga aatgaaatga aataatgaaa taatgaaatg agatgaaatg aaaagaaatg 60
atgaaatgat attgaaatga aattgaaaga tgagatgatg agatgaaatg gtgaaatgtt 120
gaaatgaaat gatgaaatga atagatgtga catgaaatga gctgaaatga tgagatcaaa 180
tgaaatgaaa tgagattaaa tgatgagatg aaaactgatg aaaacttaaa tgatgaaata 240
atgaaatgaa aatgaaatgg aaatgatgag atgagaagaa atgatgagat gagatgagat 300
aaaatgagat gaaatgatga gatgaaatga tgag 334
98
100
DNA
Human
misc_feature
(17)..(17)
n is a, c, g, or t
98
ttcaggccgt ctgcttntac atatactatc gagaatggtg ctgtgcactc ataacaccgt 60
tgcttggtag acgcttttga acccttcagc gctgaaagta 100
99
500
DNA
Human
misc_feature
(8)..(8)
n is a, c, g, or t
99
cccgggantt cggcccttat ggcccgggga aatgatgaga tgaaatgatg aaatgagata 60
agatgaaaag agttgatgag atgatgagat gaaatgagat gaaaagagat gaaatgagat 120
gaaatgaaat gatgagatga aatgaggtga aatgaaatta gatgaaacgt aatgagatga 180
aatgacctaa tgaaatgaaa aaatgaaatg aaataatgaa atgaggtgaa attaaatgag 240
atgatgaaat taaatgatga aatgaaataa tgaaatggaa atgaaatgga aatgatgaga 300
tgaatgatga gatgaaatga tgagatgaga tctaatgatg agaggagatg atgagatgaa 360
ntgagatgaa aagagatgaa atgagatgaa accgaaatga tgagatgaaa tgaggtgaaa 420
tgaaattaga tgaaacgtaa tgagatgaaa tgacataatg aaatgaaaaa atgaaatgaa 480
ataatgaaat gaggtgaaat 500
100
397
DNA
Human
misc_feature
(8)..(8)
n is a, c, g, or t
100
cccgggangt ttaagttagg gggcctgccc ctttaagcnt agtcccaccn tgaaanacac 60
tccccttgaa nntctctaaa ccttaacttt ctggccnttt tgtttcagan atgcctaacc 120
ctcagggggt cttttgttct ctacgcctaa aaacttaatc tgtttggaac aattccnttt 180
cctctctgta gaaattgacc tggccatggc tcctgtgaat gatacggttg ctattatccc 240
tgaacactgt aaaaatgaac tttgaaacag ttgggtagga cccaaacaga aaatgatgta 300
tggcttggaa atagtttagc tgaacattat gctttaatat tttactggcc attgcagcac 360
aggtttagaa atttatgttc ggctttttaa agtttta 397
101
132
DNA
Human
misc_feature
(121)..(121)
n is a, c, g, or t
101
gttacctaat gttttactct cattttcttt ttctttattt ttcatttgta aaataggaac 60
attaattgta ctactttcaa aagaattaat tgaagaaaga gagatacagg gtatctaggc 120
ngaggaagac cc 132
102
246
DNA
Human
102
gggggcttta gttataactg ggctaagcat aattgcgcta ccaattccat attatctcat 60
ggcacttaat tttataattg atatatataa taaaaaattc aatgcagata ttgatataat 120
aaaaatagat aatggtaatc caagcacgat ggtagccatc actctaattg ctttggggtt 180
aacctataac ttattaagta aagtgccaga atggttcttt gacagtatta aaattaaaga 240
aaacag 246
103
18
DNA
Artificial Sequence
forward primer of exon 1 of insulin gene used
for quantitative RT-PCR analysis
103
gccctctggg gacctgac 18
104
18
DNA
Artificial Sequence
reverse primer of exons 1 and 2 of insulin gene
used for quantitative RT-PCR analysis
104
cccacctgca ggtcctct 18
105
24
DNA
Artificial Sequence
forward primer of BMyHC gene used for
quantitative RT-PCR analysis
105
gctggaacgt agagactccc tgct 24
106
24
DNA
Artificial Sequence
reverse primer of aMyHC gene used for
quantitative RT-PCR analysis
106
ggatccttcc agatcatcca cttg 24
107
20
DNA
Artificial Sequence
forward primer of ANF used for quantitative
RT-PCR analysis
107
ggatttcaag aatttgctgg 20
108
20
DNA
Artificial Sequence
reverse primer of ANF used for quantitative
RT-PCR analysis
108
gcagatcgat cagaggagtc 20
109
20
DNA
Artificial Sequence
forward primer of APP used for quantitative
RT-PCR analysis
109
ggatgcttca tgtgaacgtg 20
110
19
DNA
Artificial Sequence
reverse primer of APP used for quantitative
RT-PCR analysis
110
tcattcacac cagcacatg 19
111
21
DNA
Artificial Sequence
forward primer of ZFP used for quantitative
RT-PCR analysis
111
cacargagrc arggtcaacg a 21
112
22
DNA
Artificial Sequence
reverse primer of ZFP used for quantitative
RT-PCR analysis
112
ggattaaaat gaagcaccca ga 22
|
The present invention is directed to detection and measurement of gene transcripts and their equivalent nucleic acid products in blood. Specifically provided is analysis performed on a drop of blood for detecting, diagnosing and monitoring diseases using gene-specific and/or tissue-specific primers. The present invention also describes methods by which delineation of the sequence and/or quantitation of the expression levels of disease-specific genes allows for an immediate and accurate diagnostic/prognostic test for disease or to assess the effect of a particular treatment regimen.
| 2
|
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to microfiche reading equipment specifically for use in motor vehicles. The invention provides quick access to information that recently has become available in microfiche form relating to telephone numbers and addresses for many communities in the United States.
2. Description of the Prior Art
Heretofore, microfiche readers have been developed for various uses in permanent or portable locations. Although some units can be operated in a motor vehicles, no prior art relating to microfiche readers has been developed to provide specific and convenient use in a motor vehicle. U.S. Pat. No. 3,805,429 to Thompson does show a map display device mounted on the steering column of a vehicle but is functionally awkward and optically impractical.
Currently, microfiche readers are available either as large desk top models, medium size brief case enclosed models or hand held models.
While the desk top models such as that disclosed in U.S. Pat. No. 4,094,598 permit easy reading of microfiche information via large screens, the overall size of the unit makes it impractical and inconvenient to use in mobile applications such as motor vehicles. In addition, most units require AC power that is unavailable in a motor vehicle.
The medium size brief case models such as in the Informant II or model Elite II by Anacomp Inc., Atlanta, Ga., permit the user more mobility than the desk units but require an area that is relatively flat and large enough in size to permit opening of the reader and reader housing. Since the viewing screen of the reader is attached to the housing and the screen must be positioned at a minimum distance in order for the operator to be able to clearly see the image, this special requirement may or may not be available within the vehicle. If space is available, the location where the unit may be opened such as a passenger seat, is awkward for a driver to use without changing his seating position. More conveniently, the vehicle driver finds operation of the unit less cumbersome if he moves out of the drivers seat for operation of the viewer.
A hand held microfiche reader is disclosed in U.S. Pat. No. 4,089,593, but the unit requires both hands for operation. In a vehicle, finding an optimum reading position under natural light can be difficult and awkward for the seated driver. If the user attempts to obtain information through the viewer at night or on dark days, he must use batteries that require recharging or replacement at regular intervals. The hand held units can easily be dropped, damaged or lost inside the vehicle. In summary, prior art has not considered a microfiche reader configuration that can be conveniently used by the seated driver of a motor vehicle.
SUMMARY OF THE INVENTION
Accordingly, several objects and advantages that my invention provides over prior art are listed as follows. The reader is intended to provide a convenient means for accessing telephone and other information within a motor vehicle. The reader can be adjusted to an appropriate dash board angle and mounted directly by adhesive onto the dash thereby avoiding the possibility of damage by dropping, an advantage over portable units. Because of its unique pull out, pull down and pull open mechanism, the need for a flat surface to open and operate the reader has been eliminated. An unobvious feature of this particular unit not found in prior art is the location of the viewing screen. This screen is attached directly to the reader with a mirror, providing a means of reflecting the image back onto the reader body. The object of this design configuration is to reduce the distance required from the focusing lens to the viewing screen which provides a size advantage over the "brief case" housed readers. Another object of the unit is to provide the ability of one handed, convenient, operation of the reader while the vehicle is stationary, an advantage over the hand held readers. Since the new reader remains on the dash, power can be conveniently obtained through a cigarette lighter adapter allowing the reader to be operated during dark days or at night without the need for excess power cord necessary in the hand held readers. The reader also includes batteries that are continuously charged thru the cigarette lighter adapter during operation of the vehicle to provide an alternate power source. Another object of this unique design is to enable the reader to be collapsed into a compact box smaller in overall size compared to the medium "brief case" or large sized "desk top" microfiche readers and requiring only a small area on the vehicle dash board for mounting.
BRIEF DESCRIPTION OF THE INVENTION
The microfiche reader is a convenient information access device promoting new use of microfiche telephone and address information within a motor vehicle. The reader and microfiche eliminates the need to transport a full set of yellow and white page telephone books.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 shows an orthographic view of the microfiche reader mounted on a motor vehicle dash board.
FIG. 2 is a full scale plan sectional view of the microfiche reader with a swing out mirror frame in the open position.
FIG. 3 is a full scale end sectional view of the microfiche reader in its closed (storage) position.
FIG. 4 is a sectional view of the holder guide and a full plan view of the sheet holder partially inserted in the guide.
FIG. 5 is a top end view of the holder guide and the sheet holder partially inserted in the guide.
FIG. 6 is a plan view of the microfiche reader, holder guide and sheet holder.
FIG. 7 is a plan view of the microfiche reader and roll film adapter.
FIG. 8 is a plan view of the microfiche reader in operation as viewed by the user.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings, a dash board mounted microfiche reader (1) is shown in FIG. 1 and is mounted on the dash board (2) of a vehicle by a support unit (3). The support unit may be made of metal or plastic.
The support unit (3) includes a dash stand (12) having a base (13) connected to the dash board. The base may be secured by adhesive, or any type of mechanical fasteners, or by suction cups. The base (13) has an upper surface (14) provided with Velcro fastening material (15). Foot portions (13a), (13b) are provided at forward corners of the base.
The Velcro fastening material (15) is used to connect the base with wedge member (16). The wedge member (16) is formed by a lower horizontal member (17), an upstanding back wall (18), and a slanted wall (19). Velcro is also provided on the bottom surface of member (17) and on the top surface of wall (19). The Velcro material On base (13) mates with the Velcro material on the bottom surface of member (17) to detachably support the wedge at any position on base (13).
The dash stand (12) has a tray (20) pivotally connected to base (13) by pins (21) which are received in aperture (22) of the base. The pins (21) project outwardly from side walls (23) of the tray to fit within the apertures (22). The tray (20) has a top surface (24) that includes a bottom surface (25) also covered with Velcro material. The Velcro material on the bottom surface (25) is used to connect the tray to the top surface of wall (19). Accordingly, base (13), wedge (16) and tray (20) are positionable interfitting parts that support the tray at a predetermined number of angles relative to the plane of the dash board and provide the reader with a leveling support.
As illustrated in FIG. 1, the microfiche reader (1), is pivotally mounted to tray (20) by pins (26) which project inwardly from sidewalls (23) of the tray and are received in slots (27) provided in sidewalls of the reader. The pins are mounted for sliding movement within the slots (27) such that the reader is movable to relative horizontal or vertical positions.
The microfiche reader (1) has a housing (30) as pictured in FIG. 1, 2, & 3. In FIG. 2, the housing (30) includes a swing out mirror frame (31) that is pivotally connected to the housing (30) by pin (33a) mounted inside top wall (33) and bottom wall (34)(not shown). In FIG. 3, pin (33a) projects from surface (37) of wall (33) and is received in aperture (37a) of mirror frame (31). Similarly, pin (33b) projects from surface (38) and is received in aperture (37b) of mirror frame (31). In FIG. 2, the frame (31) has a pocket portion (40) formed by back wall (41) and directive wall (42). The top wall (33) and bottom wall (34) integrally form pocket portion (40). A mirror (44) is mounted on inside surface area (45) of directive wall (42). In FIG. 2, a head member (46) is formed on lip (47) of outside surface (48) of directive wall (42).
Reader housing (30) is made of a thermoset or thermoplastic material. The plastic material is used to absorb the normal shocks while a vehicle is traveling on a roadway. Rough streets can create vibrations that are damaging to a delicate optical system and the plastic material used for the housing will help minimize these damaging effects.
Referring now to FIGS. 1-4, the housing (30) has a reader slot (50), for receiving microfiche film, and as shown in FIG. 3, a lower portion (52) and upper portion (53).
In FIG. 3, lower portion (52) has a tubular orifice (55) in lower right corner area (56). A bulb assembly (57) including a bulb (painted with reflectant on the lower side) (57a) is located within the tubular orifice. Also mounted within orifice (55) and forward of bulb (57a) is a lens (59). This lens acts to condense and distribute light energy evenly to the microfiche. The lens (59) also acts as a heat exchanger to prevent damage of the microfiche. Cooling gaps (58) allow circulation of surrounding air to reduce high temperature from the light energy.
In FIG. 3, the upper portion (53), of housing (30) includes a tubular orifice (67) that is aligned with tubular orifice (55). Mounted within orifice (67) is an optic lens assembly (68) having optic lenses (69) and (70). Upper area (71) of orifice (67) is chamfered to provide a more desirable outlet for light passing through the lens assembly. A focus knob (73) is molded integral with to lens assembly (68).
Again, referring to FIG. 3, the upper portion (53) is further provided with interior threads (77) in housing (30). Lens assembly (68) has exterior threads (78) that mate with threads (77). The turning of the focus knob (73) moves the lens assembly (68) within orifice (67) for focusing the microfiche image onto mirror (44).
In FIG. 3, power means (60) is located within compartment (61) of portion (52) and may include batteries (60a and 60b). Additionally located in lower portion (52) is an electrical male plug (63) that is insertable into channel (63b), connected to contact (62) and extends to a cigarette lighter adapter (64). electrical connections (63c), (63d), (63e), are made within the upper and lower portions to operatively connect the power means to the reader. Power from the vehicle battery passes through the connector to power the bulb and recharge the batteries. The batteries are electrically connected to the bulb through bulb connection (65). Batteries (60a), (60b) and head connector (63a) are electrically connected with a switch assembly (66) mounted within a housing (30). Switch assembly (66) is operably connected to bulb (57a), cigarette lighter adapter (64) and power means (60) through electrical connections (63-66). The switch assembly includes a stationary contact plate (81) and spring 72(a) which biases contact plate (82) that is separately wired one to positive and one to ground source electric power means (60) via electrical spring (72). The switch assembly (66) includes an aperture (80) that receives the head (46) of mirror frame (31) which forces plate (84) downwardly and out of contact with plate (81) when the frame (31) is closed. The head (46) is made of nonconductive material and serves to keep the switch (66) open while securing the frame (31) against upper portion (53). If male plug (63) is removed, electrical spring (72) allows electrical connection of (60a) to (66). The reader is now powered entirely by batteries (60a and 60b) through this connection. Although not shown, a cigarette lighter adapter may be used in place of the batteries.
In FIG. 1, upper portion (53) supports a silver colored screen (84) for reviewing an image from lens assembly (68). The screen is secured within the upper portion (53) by conventional means and has an angled position as shown in FIG. 2 to improve image clarity.
In FIG. 4, microfiche indexer (85) includes a sheet holder (86) and a square holder guide (87). In FIGS. 4 and 5, the sheet holder (86) has side support walls (86a, and 86b), bottom support (86c), slot form (86d) and holder pins (86e, 86f, 86g, 86h). A microfiche sheet (88) is inserted in slot form (86d) and is supported by sheet holder walls (86a and 86b) and bottom support (86c). The square holder guide (87) includes horizontal and vertical slots (87a, 87b). Sheet holder pins (86e, 86f, 86g, 86h) of sheet holder (86), can be moved in slots (87a and 87b) of guide (87) to allow positioning of the sheet holder (86) in a horizontal or vertical direction.
In FIGS. 6-8, the indexer (85) is inserted into a fixed position in reader slot (50). The microfiche sheet (88) can now be moved in a supported vertical or horizontal position to enable magnification of a specific portion directly in front of lens (59).
Optionally, and shown in FIG. 7, the reader (1) may receive a roll film adapter (90) for viewing microfiche in roll film format (89). The roll film adapter has roll reels (91) with control knobs (92) and a support plate (93). The support plate has a underside surface (96 and 97) covered with Velcro for connecting with Velcro strips on side surfaces (98, 99) of portions (52 and 53) The roll reels are turned to slide the film in the path of the light for viewing.
In operation, when a user decides to pull the reader from storage, the reader is pulled horizontally away from the dash and pivoted downwardly until the reader is perpendicular to the base. The angle of the tray and vertical plate of the reader is then adjustable by moving the wedge to the desired position. The frame is then opened and the power means illuminates the bulb. The indexer with the microfiche is next slid into the unit for viewing information. The image is adjustable by the focus knob for the sharpest image.
Turning to FIG. 8, light generated from the bulb passes through a lens then through the microfiche sheet held in the form that has been placed in the indexer slot. The light illuminates the information which is magnified through optic lens assembly. The light leaves the lens and reaches the mirror approximately 5 inches away. After being reflected off the mirror, the image is displayed back onto the reader housing at an average distance of 6 inches away onto the angled, small silver colored screen. By incorporating the mirror and creating a reverse direction image, the minimum distance required of the microfiche unit is achieved by allowing the unit to remain compact. After use, the indexer is removed for changing the microfiche and the indexer reinserted into the slot. The reader is then pivoted upwardly and slid back into storage position.
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A dash mounted microfiche reader and support is provided for attaching a portable microfiche reader to the dashboard of a vehicle. The reader includes an adjustable miniature lens assembly and a mirror unit that swings open for operation. A slide out housing for the reader is pivotally mounted on a leveling tray that is detachably mounted to the dashboard of the vehicle. A microfiche index is used to support the fiche during use.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to aircraft flight control instruments, and to the generation and display of commands to allow the flight crew of an aircraft to exit a windshear encounter in an optimal manner. More particularly, it provides a variable speed command derived from the magnitude and duration of the windshear condition, operative between predetermined maximum and minimum safe speed limits.
2. Description of the Prior Art
The phenomenon of windshear can pose a serious threat to the safety of aircraft and in fact has been directly responsible for several serious aircraft accidents. Windshear, either of itself or as a result of attempts by the human pilot to restore the aircraft to its normal flight path, can cause the aircraft to stall or crash. Windshear can be defined as the time rate of change of wind relative to the aircraft, whose effect on the aircraft is to cause large speed or altitude deviations from normal flight. This definition requires that atmospheric turbulence, maneuvering into and out of steady winds, and penetration of a constant wind boundary layer near the ground all be considered windshears since they represent boundary conditions relative to the aircraft. However, usually the magnitude and duration preclude these shears from posing a threat to the aircraft. While the definition requires a rate of change in wind, a constant vertical wind is also considered to be a shear throughout the industry. While not accurately a shear, the effect on the aircraft is identical to a longitudinal wind changing at an equivalent rate.
In the prior art windshear warning systems the detection and guidance provided during a windshear encounter would cause the aircraft to fly at some fixed speed, usually slightly greater than stall speed. The speed commanded was usually a speed known as stick shaker speed, approximately five percent greater than stall speed, and is the speed where artificial means are used to vibrate the control column or stick to warn the human pilot of impending stall. Stick shaker speed is generally considered to be the minimum speed for safe flight, and varies with the angle of attack of the aircraft and flap position. By reducing his forward speed, the pilot is able to gain altitude rate.
As many commercial transport aircraft, general aviation aircraft, and military aircraft are equipped with a Flight Director System whereby pitch command signals may be displayed to the human pilot, the speed command for a windshear encounter is usually presented as a displacement of the pitch command bar. When the human pilot maneuvers the aircraft in such a manner as to reduce the displacement to null, the speed of the aircraft will be at the commanded speed, since the speed is a function of pitch for constant engine thrust.
A shortcoming of the prior art is that the commanded fixed speed may result in the aircraft flying at the minimum "safe" speed when the magnitude and duration of the windshear do not in fact require such a maneuver. Flying at the minimum safe speed results in a degradation of the speed margin of the aircraft and hence reduces the margin of error allowable to the human pilot in controlling the aircraft. Consequently, prior art systems could in fact create a potentially dangerous situation wherein the speed margin of the aircraft was diminished substantially, even though the magnitude and duration of the windshear did not warrant it.
Conversely, prior art systems which utilize a commanded fixed speed significantly greater than stick shaker speed do not command the aircraft to a diminished speed adequate to cope with the windshear condition for windshears whose magnitude and duration warrant the stick shaker speed command.
Prior art systems, in summary, failed to recognize that the important command parameter is not a fixed air speed command but is in fact a variable air speed command derived from the rate of change of air speed due to the windshear encounter. The present invention determines the correct air speed rate command based on both the magnitude and duration of the windshear condition and hence overcomes the shortcomings of the prior art in that its command causes the aircraft to fly at the speed appropriate to the magnitude and duration of the windshear encountered.
SUMMARY OF THE INVENTION
A detected rate of change of longitudinal windshear component is algebraically summed with a detected vertical windshear component, converted into the equivalent of a longitudinal windshear, to derive a signal representative of the magnitude and duration of the windshear, and applied to an aircraft control parameter to produce a variable flight command proportional to airspeed rate. Limits are placed on the computed command such that the minimum speed commanded is stick shaker speed and the maximum is the nominal allowable speed in the absence of the windshear. The resultant signal represents an air speed rate command that yields an optimal flight path for the aircraft to exit the windshear condition.
In a preferred embodiment of the apparatus aspects, the invention comprises an air data computer for providing a signal proportional to airspeed rate, a windshear detection computer for providing a signal proportional to the vector rate of change of the windshear condition, an angle of attack sensor for providing a signal proportional to an angle of attack, assuming junction responsive to the airspeed rate, windshear rate, and angle of attack signals for deriving a command signal representative of a change in the airspeed rate signal and thereupon applying the command signal to provide an output representative of the magnitude thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a graph illustrative of the rate of climb capabilities of an aircraft in the absence of windshear.
FIG. 2 is a graph showing of the effect of longitudinal windshear on the performance capability of an aircraft and illustrates the axis shift between ground and air mass coordinate systems caused by a tail windshear encounter.
FIG. 3 is a graph illustrative of the optimal flight path trajectory for a windshear encounter.
FIG. 4 is a graph illustrative of the effect of vertical windshear on the performance capability of an aircraft and shows the apparent axis shift between ground and air mass coordinate systems caused by the windshear encounter.
FIG. 5 is a block diagram of a preferred embodiment of the present invention showing the generation of an optimal air speed rate command.
FIG. 6 is a graph illustrative of the limiting of an air speed rate command as a function of the difference between a prestored stick shaker value and the actual angle of attack of the aircraft.
FIG. 7 is a graph illustrating the approximate linear relationship between air speed rate and angle of attack rate.
FIG. 8 is a block diagram of a further embodiment of the present invention showing how an optimal angle of attack rate command is generated.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The effect of a constant wind on the aircraft is defined by the well-known equation which relates the wind speed and true air speed of the aircraft to its ground speed:
V.sub.GROUND =V.sub.AIR +V.sub.WIND (1)
where V GROUND is the ground speed of the aircraft measured in feet per second, V AIR is the true air speed of the aircraft measured in feet per second, and V WIND is the wind velocity in feet per second and by convention is positive for a tailwind. True airspeed is the magnitude of the wind relative to the aircraft. In U.S. Pat. No. 3,930,610 true airspeed is defined at column 4, lines 3-17 as a signal which is developed from an airspeed sensor, processed through a true airspeed computer, and then further corrected for position error, and results when the indicated airspeed (IAS-the actual instrument indication for some given flight condition) is corrected for errors of the instrument and errors due to the position or location of the installation to as great an extent as possible to provide the calibrated airspeed (CAS) and for other relevant variables effecting the accuracy of the aircraft airspeed signal, such as compressibility effects and density.
The first derivative of equation (1) with respect to time produces the rate relationship:
V.sub.GROUND =V.sub.AIR +V.sub.WIND (2)
where the dot superscript is understood to be the equivalent of d/dt (i.e.; V is equal to dV/dt) and the units of all variables are in feet per second per second.
Solving equation (2) for the wind rate yields:
V.sub.WIND =V.sub.GROUND -V.sub.AIR (3)
Equation (3) forms the basis for the measurement of the longitudinal wind rate and may be used in the detection of a windshear as in the present assignee's U.S. Pat. No. 4,598,285, filed May 6, 1983 and issued June 3, 1986, Windshear Detection and Warning System With Evasion Command, invented by Harry Miller and Terry L. Zweifel, and Ser. No. 835,446, Vertical Windshear Detection for Aircraft, invented by David A. Johnson and Terry L. Zweifel, and assigned to the assignee of the present invention, which are incorporated herein by reference. The value of ground speed rate may be derived directly from an accelerometer mounted along the longitudinal axes of the aircraft and corrected for pitch and roll, and true air speed rate may be obtained from an air data computer aboard the aircraft.
The performance capability of the aircraft is defined by the equation: ##EQU1## where T=the thrust of the aircraft in pounds
D=the aerodynamic drag of the aircraft in pounds
W=the weight of the aircraft in pounds
V=the speed of the aircraft in feet per second
V=the rate of change of speed in feet per second per second
g=the gravitational constant, 32.17 feet per second per second
h=the altitude rate of the aircraft in feet per second.
Equation (4) is valid for a coordinate system either relative to the ground or relative to the air mass in which the aircraft is flying. FIG. 1 is a graph illustrative of equation (4) for several speeds with a constant thrust and weight of the aircraft in the absence of a windshear. The ordinate axis represents the aircraft's rate of climb capability and the abscissa its longitudinal acceleration capability. Lines 1 through 4 indicate how the capabilities change with varying air speed. Line 1 is representative of the normal air speed while line 4 shows the aircraft's capabilities at stick shaker speed. Lines 2 and 3 represent speeds between these two. Each line is the locus of flight path angles for a constant air speed since flight path angle is defined by the well-known approximate equation for small flight path angles:
γ=h/V (5)
where γ is the flight path angle in radians, h the rate of climb in feet per second of the aircraft and V its true air speed in feet per second.
In the absence of longitudinal windshear, the aircraft's longitudinal acceleration capability relative to a ground coordinate system is identical with its capability relative to the air mass since the wind rate term in equation (2) is null. That is, the coordinate axes relative to the ground and relative to the air mass are coincident.
In the presence of a longitudinal windshear, the wind rate term V WIND in equation (2) is not null and the effect is to cause an apparent displacement of the ordinate axis between the ground and air mass coordinate systems. This displacement for a tailwind shear is illustrated in FIG. 2. Line 5 is the ordinate axis relative to the ground while line 6 is the ordinate axis relative to the air mass. The magnitude of the displacement between the two is the time rate of change of the wind; that is, the value of the longitudinal component of the windshear. The axis displacement is virtually immediate upon encounter with a longitudinal windshear. If the aircraft were not accelerating initially, it would be at the rate of climb and flight path angle of point 7. Relative to the ground coordinate system, there would be no change in longitudinal acceleration; however, relative to the air mass system, the aircraft would lose speed at the rate of the windshear and therefore begin decelerating toward stall speed. If the human pilot were to attempt to arrest the loss of air speed, which at maximum thrust requires a pitch down maneuver, the aircraft would fly to point 8 and thereby be at a significantly lower rate of climb and flight path angle than before the windshear encounter. In addition, the ground speed of the aircraft would increase at the rate of the windshear while the true air speed would be constant. If the human pilot were to try to restore any air speed loss and regain normal speed, an even further reduction in climb rate would result. The aircraft would fly to point 9 and thence have a negative rate of climb and flight path angle, and at the low altitudes typical of the takeoff and landing approach regimes of flight could crash.
FIG. 2 provides the basis for an optimal strategy upon a longitudinal windshear encounter. For an aircraft initially at point 7, if the air speed rate were to be allowed to decrease in an amount equal in magnitude but opposite in sign to the value of the windshear, as the air speed decreased toward stick shaker speed, the altitude rate of climb and flight path angle would decrease until the aircraft arrived at point 12. However, if the duration and magnitude of the windshear were not such as to require the air speed to decrease to stick shaker speed, the aircraft might only achieve either point 10 or 11 until the windshear was exited and the aircraft would be safely accelerated back to its normal flight air speed.
FIG. 3 illustrates the optimal strategy for a tailwind shear encounter of sufficient duration to require flight at stick shaker speed. Line 16 represents the locus of the optimal strategy. Upon initial windshear encounter, the aircraft is flying at point 13. As the air speed is decreased at a rate equal and opposite to the value of the windshear, the aircraft will traverse along the line segment between points 13 and 14, the latter being above stick shaker speed. At point 14, the aircraft must begin to arrest the air speed rate since it is approaching stick shaker speed, the minimum speed for safe flight. To arrest the air speed rate, the aircraft will travel along the line segment between points 14 and 15. When it has achieved point 15, the aircraft will be at stick shaker speed will null air speed rate. It will be clear that during the described process the rate of climb and flight path angle have been maximized, thus also maximizing the gain in altitude which in turn provides the best chance for exiting the shear by flying through and above it.
A strategy which causes the air speed rate to decrease at a rate larger than the magnitude of the windshear will clearly cause the aircraft to fly at stick shaker speed more often than is required; conversely, a strategy which causes the air speed rate to decrease at a rate less than the magnitude of the windshear does not result in maximizing the gain in altitude that may be required to safety exit the windshear.
The effect of vertical windshear on the aircraft is defined by the equation:
h.sub.GROUND =h.sub.AIR +h.sub.WIND (8)
where
h GROUND =the altitude rate of the aircraft relative to the ground in feet per second
h AIR =the altitude rate of the aircraft relative to the air mass in feet per second
h WIND =the velocity of the windshear in feet per second, and by convention is positive downward.
The consequences of a downward vertical windshear are shown on FIG. 4. Line 17 represents the abssissa of the air mass coordinate system and Line 18 represents the abscissa of the ground coordinate system. The magnitude and direction of the displacement of the axis between the two systems is equal to the magnitude and sense of the vertical wind rate.
An examination of equation (4) shows that it is a linear equation relating rate of climb and speed rate for a constant aircraft thrust, speed and weight, of the form:
h=C.sub.1 -C.sub.2 V (9)
where
h=the altitude rate of the aircraft in feet per second
C 1 =the term V(T-D)/W, in feet per second
C 2 =the term V/g in seconds
V=time rate of change of speed in feet per second per second.
The constant C 1 defines the line intercept with the ordinate axis (point 7 on FIG. 2), and C 2 is the slope of the line. Thus, C 2 establishes the relationship between changes in h and V. As was shown, the effect of a vertical windshear is to displace the abscissa between the ground and air mass coordinate systems. This displacement is equivalent to a change in the value of h between the two systems. Hence the change in the value of h may be equated to a longitudinal windshear by the relationship:
Δh=C.sub.2 ΔV (10)
That is, a vertical windshear has the same effect on the aircraft as a longitudinal windshear of the same sign with a magnitude equal to the change in altitude rate divided by C 2 . Hence, the optimal strategy for a vertical windshear is identical with that of the equivalent longitudinal windshear defined by equation (10).
As previously discussed, as the air speed of the aircraft decreases toward the stick shaker value, the air speed rate must be controlled to a null value. In order to accomplish this, the stick shaker speed must be known accurately. Stick shaker speed is a direct function of the aircraft's flap position and weight, the latter usually not known with accuracy. However, the angle of attack corresponding to the stick shaker speed for any weight is a constant for a given flap position. That is, the aircraft's angle of attack for stick shaker speed is independent of weight. As the actual angle of attack can be accurately measured, the difference between the acutal and stick shaker angles of attack can be used as an indication of approaching stick shaker speed and thus establish the point when the air speed rate must be arrested.
The present invention may be implemented by using conventional analog circuitry and computation techniques or by using conventional wholely digital techniques, or by a combination of conventional hybrid digital-analog techniques. For example, summation devices, limiting functions, and amplifiers may be implemented by operational amplifiers appropriately configured, while logic and mathematical functions may be implemented in a digital computer or the hardware equivalent. Since the functional units represented by the various blocks may be any one of the numerous devices for each respective function well-known in the art, it is considered unnecessary to show circuit detail. For clarity and understanding of the invention, it will be explained by using a generally analog format as shown in FIGS. 5 and 8, it being understood that the same analog format may also represent the programming of a programmable digital computer wherein the various analog inputs are converted to digital signals for digital processing and the various digital outputs are converted to analog signals for providing the flight instrument commands.
Referring now to FIG. 5, conventional air data computer 30 supplies a signal proportional to true air speed on lead 31 to conventional rate taker 32 whose action is such as to produce the time rate of change of true air speed on lead 33. Simultaneously, in the manner heretofore described, windshear detection computer 34 supplies windshear component signals derived from the vertical axis rate and longitudinal axis displacement on leads 35 and 43, respectively. The signal on lead 35 is supplied to a conventional divider 36 whose output, appearing on lead 37, is the quotient of vertical axis rate and true air speed. Lead 37 supplies gain 38 which multiplies the signal thereon by the gain factor G 1 whose value is the gravitational constant (32.17 feet per second per second). The factor g/V represents the inverse of the term C 2 in equation (10). The output, which appears on lead 39, converts the rate of vertical axis shift into an equivalent longitudinal axis displacement, and is supplied to conventional integrator 40. Conventional integrator 40 acts in such a manner as to impress the time integral of the signal on lead 39 upon lead 41 whenever a windshear condition has been detected by windshear detection computer 34.
The signal on lead 41 is supplied to a conventional summation device 42 whose function is to supply the algebraic sum of the signals on lead 43 and 41 to lead 44. The signal on lead 44 is supplied to conventional gain 45 which multiplies the value of gain G 2 , for example 1.0, by the signal on lead 44. The signal on lead 44 represents the combination of the vertical and the longitudinal coordinate axis displacements due to windshear. The output of gain 45 appears on lead 51 and is a signal proportional to the rate of change of air speed required for the aircraft to exit the windshear in an optimal manner. Lead 51 supplies limiter 52, whose action will now be described.
A signal proportional to the true angle of attack of the aircraft appears on lead 58 and is supplied by an angle of attack vane 50. Simultaneously, the aircraft's angle of attack computer 89 receives a signal proportional to the flap position of the aircraft from flap position sensor 83 and lead 84. The angle of attack computer 89 outputs a signal proportional to the stick shaker angle of attack for the measured flap position, which has been prestored in a memory, on lead 59 and switch terminal 61, and a prestored normal angle of attack signal on lead 60 and switch terminal 62. The normal angle of attack is that angle of attack which provides a nominal design speed for a given flap position and flight regime. If a windshear condition has been detected by detection computer 34, switch blade 63 will be in the position shown in FIG. 5; otherwise switch blade 63 will be in contact with terminal 62. Switch blade 63 and terminal 64 supply a signal to a conventional summation device 66 which acts in such a manner as to form the algebraic difference between the signal on lead 58, the actual angle of attack signal, and the selected signal on lead 65. The output of summation device 66 appears at junction 68 and represents the difference between the actual and prestored angle of attack values. One output from junction 68 is supplied to conventional multiplier 71 which uses the same signal via lead 69 to form the square thereof, which signal appears on lead 72 and is coupled to conventional gain 73. Gain 73 multiplies the signal on lead 72 by the value of G 4 , as for example, 1.0, and supplies the result on lead 74 which in turn supplies the signal to limiter 52.
Limiter 52 uses the signal on lead 74 to constrain the value of the signal appearing on lead 51 within a computed value appearing on lead 74. By this action, as the actual angle of attack approaches the prestored value of stick shaker angle fo attack, the output of the limiter 52 which appears on lead 53 and represents the optimal commanded airspeed is continuously diminished until it reaches a null value when the actual and stick shaker angles of attack are identical. The operation of limiter 52 is shown graphically in FIG. 6, where the ordinate axis 90 represents the commanded airspeed rate to produce the optimum response in a windshear encounter. The abscissa 91 represents the difference between the prestored stick shaker angle of attack and the actual angle of attack. Lines 92 through 96 represent specific values of the derived wind rate and wound appear on lead 51 of FIG. 5. Line 97 represents the effect on limiting of the commanded air speed as the difference between stick shaker angle of attack and actual angle of attack diminishes. By way of example, assume the derived wind rate is represented by line 92 and that the initial actual angle of attack is significantly less than the prestored stick shaker value. Then the output of limiter 52 of FIG. 5 would be the exact value represented by point 99. As the actual angle of attack increases, i.e. the air speed of the aircraft diminishes, the difference between the actual and stick shaker angles of attack will also diminish until the point corresponding to point 98 is achieved. As the actual angle of attack increases further, the difference in angles of attack diminishes even more and the output of limiter 52 will decrease along the locus of points of line 97 until, finally when the actual and stick shaker angles of attack are identical, the output will be null, regardless of the current value of lead 51.
Referring again to FIG. 5, the output of limiter 52 appears on lead 53 and is supplied to conventional summation device 54. Summation device 54 operates in such a fashion as to output the algebraic difference of the signals on leads 53 and 33 on lead 55. The signal on lead 55 thus represents the difference between the optimal commanded air speed rate and the true air speed rate of the aircraft. Lead 55 supplies switch terminal 77. In the presence of a detected windshear condition, switchblade 76 will be in the position shown in the figure; otherwise, it will be in contact with terminal 75. Hence, in a windshear condition, the signal on the lead 55 will be supplied to gain 80 through switch terminal 77, switch blade 76, which terminal 78, and lead 79. Gain block 80 multiplies the value of lead 79 by the value of gain G 5 , which converts the signal to an appropriate value for use by the flight director instrument 57. The output of gain 80 appears on lead 81 and is the command signal to be displayed to the human pilot. Conventional flight director instrument 57 receives the command signal via lead 81 and moves a pitch command bar 56 in a proportional amount via conventional and well-known mechanisms.
The signal on lead 81 may also be coupled via lead 82, contact 83, switch arm 84, and lead 85 to the autopilot pitch channel 86 of an automatic flight control system to energize an elevator servo 88 coupled via lead 87 to produce a predetermined optimum flight path angle during a windshear encounter.
The operation of the selector switch arms 63 and 76 is controlled as follows:
A logical windshear detected signal is supplied by the windshear detection computer 34 and appears on lead 46. This signal is such that a signal representing a logical 1 appears when a windshear is detected and a logical zero appears in the absence of a windshear. The signal is used to change the state of switch blades 63 and 76 in a manner analogous to a conventional electromechanical relay, solid state switching device, or as a digital computer program variable that decides which of two programs shall be executed. If the signal is a logical 1, the switch blades will be in the positions shown on the Figure; if the signal is a logical zero, switch blade 63 will contact switch terminal 62 and switch blade 76 will contact switch terminal 75. In addition, the signal on lead 46 is supplied to integrator 40 via lead 47. A logical 1 on lead 47 will cause the integrator to work in a normal fashion as described previously. A logical zero will cause the integrator to be reset; that is, the output on lead 41 will be null and the integrator will be inactive.
In the absence of windshear, that is if the logical windshear detected signal is a logical zero, the switch blades will be in the positions described in the preceeding paragraph. Therefore, the prestored normal angle of attack signal will be supplied to summation device 66 via lead 60, switch terminal 62, switch blade 63, switch terminal 64, and lead 65. Summation device 66 will thus provide a signal representative of the algebraic difference of actual angle of attack and the prestored normal angle of attack to terminal 68 and then to the flight director instrument 57 via lead 70, switch terminal 75, switch blade 76, switch terminal 78, lead 79, gain 80, and lead 81. Hence, in the absence of windshear, the command signal to the flight director instrument will be such as to cause the aircraft to fly at the prestored normal angle of attack.
FIG. 8 shows a further embodiment of the invention in which an angle of attack rate command is provided to the flight director indicator. The flight regimes in which the aircraft is most seriously endangered by a windshear encounter are the take off and landing approach regimes. In these regimes, the true air speeds of the aircraft are typically low in relation to the other regimes of flight. For these lower speeds, the angle of attack of the aircraft is an approximate linear function of its air speed. Consequently, angle of attck rate is also approximately linearly proportional to air speed rate. FIG. 7 illustrates this relationship. The ordinate axis 100 represents angle of attack rate in units of degrees per second. The abscissa 101 represents true air speed rate in feet per second, per second. Line 103 represents a typical actual relationship between the two parameters and line 102 is a linear approximation to the actual relationship. This phenomenon can be utilized in a manner similar to FIG. 5 in computing commands to the flight director instrument.
Referring again to FIG. 8, windshear detection computer 142 supplies a signal on lead 157 proportional to the longitudinal axis displacement created by the windshear condition and simultaneously supplies a signal proportional to the rate of change of the vertical axis displacement on lead 144. Conventional air data computer 155 supplies a signal proportional to the aircraft's true air speed on lead 156 and is coupled to conventional divider 145, the latter also receiving the signal on lead 144.
Divider 145 acts in such a fashion as to produce the quotient of the rate of change of vertical axis displacement and true airspeed signals and is coupled to conventional gain 147. Gain 147, whose magnitude is the value of the gravitational constant g, where g=32.17 feet per second per second, multiplies the signal on lead 146 by its gain value G 9 and creates the product on lead 148. Lead 148 supplies conventional integrator 149 which produces an output appearing on lead 150 representative of the time integral of the signal on lead 148 when a windshear condition has been detected. In the absence of a windshear condition, integrator 149 is in a reset condition; that is, its output on lead 150 is null and the integrator is inactive.
Leads 150 and 157 are supplied to conventional summation device 151 whose output on lead 152 represents the algebraic sum of the longitudinal and vertical axis displacements. Lead 152 is supplied to conventional gain G 7 in block 153. Block 153 multiplies the signal on lead 512 by the value of gain G 7 , which is the slope of the linear line 102 of FIG. 7, thus converting the derived air speed rate to angle of attack rate. The output on lead 154 is supplied to limiter 131 whose action has yet to be discussed.
Angle of attack vane 110 supplies a signal proportional to the actual angle of attack of the aircraft on leads 111, lead 112 and to conventional rate taker 113. Conventional rate taker 113 produces an output on lead 114 that is proportional to the true rate of change of the actual angle of attack. Simultaneously, flap position sensor 160 supplies angle of attack computer 115 with a signal proportional to the actual position of the aircraft's flaps via lead 161. Angle of attack computer 115 utilizes this information to output a signal proportional to a prestored stick shaker angle of attack on led 116 and switch terminal 118, and a signal proportional to the normal flight regime angle of attack on lead 117 and switch terminal 120. If a windshear has been detected by windshear detection computer 142, switch blade 119 will be in the position shown on the Figure; otherwise, it will be in contact with switch terminal 120. Switch blade 119 and switch terminal 121 supply conventional summation device 123 via lead 122. Summation device 123 operates in such a fashion as to produce an error signl on lead 124 which is the algebraic difference of the signals on lead 112, actual angle of attack and lead 122, the prestored value of angle of attack. Lead 124 supplies conventional multiplier 127 directly and also with the same signal via lead 126. The output of conventional multiplier 127, which appears on lead 128, is thus the square of the signal appearing on lead 124. Lead 128 supplies conventional gain 129 which multiplies the signal by the value of the gain, for example, 0.8 and outputs the result on lead 130. Lead 130 supplies one input to Limiter 131.
Limiter 131 operates in a similar fashion to limiter 52 of FIG. 5, whose operation has been discussed above. The difference between the two operations is only in the parameter of the ordinate axis of FIG. 6. This raises because the value on led 154 represents the windshear axis shifts converted by gain G 7 into an equivalent angle of attack rate. Hence, the action of limiter 131 may be represented by FIG. 6 with the ordinate axis, 90, changed to angle of attack rate.
The output of limiter 131 appears at switch terminal 133. Switch blade 134 will be in contct with terminal 133 if a windshear has been detected; otherwise, switch blade 134 will be in contact with switch terminal 132. Switch blade 134 supplies conventional summation device 136 via lead 135. Conventional summation device 136 acts in such a manner as to produce the algebraic difference of the signal on lead 114, angle of attack rate, and the signal on lead 134, the angle of attack rate command, on lead 137.
Lead 137 supplies conventional gain 138 which multiplies the signal by the value of G 8 . The value of G 8 is such as to convert the magnitude of the signal to an appropriate value for flight director instrument 140. Conventional flight director instrument 140 receives the signal from the current invention on lead 139 and thereby displaces the Pitch Command Bar 141 by an amount proportional to the value and in a direction corresponding to the sense of the signal on lead 139 for use by the human pilot.
The signal on lead 139 may also be coupled via lead 158, contact 159, switch arm 160, and lead 161 to the autopilot pitch channel 163 of an automatic flight control system to energize an elevator servo 165 coupled via lead 164 to produce a predetermined optimum flight path angle during a windshear encounter.
In operation, a logical windshear detected signal is supplied by the windshear detection computer 152 and appears on lead 143. This signal is such that a signal representing a logical 1 appears when a windshear is detected and a logical zero appears in the absence of a shear. The signal is used to change the state of switch blades 134 and 119 in a manner analogous to a conventional electromechanical relay, solid state switching device, or as a digital computer program variable that decides which of two programs shall be executed. If the signal is a logical 1, the switch blades will be in the positions shown in FIG. 8; if the signal is a logical zero, switch blade 134 will contact switch terminal 132 and switch blade 119 will contact switch terminal 120. In addition, the signal on lead 143 is supplied to integrator 149 via lead 162. A logical 1 on lead 142 will cause the integrator to work in a normal fashion as described previously. A logical zero will cause the integrator to be reset; that is, the output of lead 150 will be null and the integrator will be inactive.
In the absence of windshear, the normal angle of attack for the actual position of the aircraft's flaps will appear at summation device 123 via leads 117, switch terminal 120, switch blade 119, switch terminal 121 and lead 122. Hence, the output an lead 123 will represent the difference between the prestored normal angle of attack and the actual angle of attack. This signal is supplied to summation device 136 via lead 125, switch terminal 132, switch blade 134 and lead 135.
The output of summation device 136 appears on lead 137 and is supplied to flight director instrument 140 via gain 138 and lead 139. Hence the command to the flight director instrument in the absence of windshear is a signal proportional to the difference between the prestored normal angle of attack and the actual angle of attack with angle of attack rate, lead 114, used for providing damping and anticiptation in a conventional manner.
While the invention has been described in its preferred embodiments, it is to be understood that the words which have been used are words of description rather than of limitation and that many changes or alterations may be made without departing from the true scope and spirit of the invention in its broader aspects.
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Method and apparatus for commanding an optimal flight path for an aircraft encountering a windshear condition. An airspeed rate signal equal in magnitude and opposite in sense to the windshear is applied to derive a variable rate of change of airspeed command for application to a flight director indicator. Limits are placed on the derived command such that the minimum allowable speed command is stick shaker speed and the maximum allowable speed command is the nominal speed in the absence of the windshear. The resultant command signal represents a true airspeed rate that yields an optimal flight path for the aircraft to exit the windshear condition.
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PRIORITY STATEMENT UNDER 35 U.S.C. § 119(E) & 37 C.F.R § 1.78
[0001] This nonprovisional application claims priority based upon the prior U.S. provisional applications entitled “INTERLOCKING RETAINING WALL BLOCKS AND SYSTEM”, Application Nos. 60/349,973, filed Jan. 18, 2002, and 60/363,942, filed Mar. 12, 2002, and the prior U.S. provisional applications entitled “SECURABLE RETAINING WALL BLOCK AND SYSTEM”, Application Nos. 60/350,265 filed Jan. 18, 2002 and 60/363,906 filed Mar. 12, 2002, in the name of Larry Shaw.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to retaining walls, and more particularly disposed, but not by way of limitation, to retaining wall systems using interlocking retaining wall blocks that may incorporate stabilizing elements between the retaining wall blocks, and methods of their manufacture.
[0004] 2. History of Related Art
[0005] Retaining walls having been used in general construction, and particularly in landscaping for many years. The design of and the materials used for retaining walls have varied over time. Retaining walls are typically used to support or retain soil or the like in place, but also may be used to enhance the appearance of a surrounding area. Such walls typically stand on a ground region and retain therebehind an earthen section or other fill material, which earthen section would otherwise form a natural slope in place of the retaining wall. Such retaining walls are typically vertical or at a slight angle. A generally vertical retaining wall may begin to deform as the mass of the earth retained behind it presses against it. A wall must resist this tendency. In addition, designers of retaining walls are constantly striving to construct retaining walls providing greater strength for support of a greater weight.
[0006] One of the most popular, and aesthetically pleasing forms of retaining wall construction involves the use of manually positionable individual blocks. The blocks may be stacked one on top of the other to form a pattern on an outside face of the retaining wall. It can be very time consuming and tedious aligning numerous blocks to form the proper pattern in the retaining wall. Moreover, a retaining wall may have one or more curved portions. The very design of many retaining wall blocks to assist in maintaining stability may be counter to the formation of a curved wall portion. In addition, current retaining wall anchors are very cumbersome and laborious to install. These wall anchors include one end which is placed in a void of a retaining wall block. The block is then filled with concrete or a similar substance in order to secure the anchor attachment. The concrete must then dry or settle before the assembly of the retaining wall can continue. A block for retaining walls and a retaining wall system is needed which provides enhanced structural support for both curved and linear wall portions, and is simple to use as well as simple and inexpensive to manufacture.
[0007] Related art references discussing subject matter bearing some relation to matters discussed herein include U.S. Pat. No. 5,941,042 to Dueck (Dueck), U.S. Pat. Re. 37,278 to Forsberg (Forsberg), U.S. Pat. No. 5,704,183 to Woolford (Woolford), U.S. Pat. No. 4,964,761 to Rossi (Rossi), U.S. Pat. No. 5,214,898 to Beretta (Beretta), U.S. Pat. No. 5,294,216 to Sievert (Sievert), U.S. Pat. No. 5,711,130 to Shatley (Shatley), U.S. Pat. No. 5,484,236 to Gravier (Gravier), German Gebrauchsmuster DE 295 00 694 U1 to Ming Su (Ming Su), U.S. Pat. No. 5,865,006 to Dawson (Dawson), U.S. Design Pat. No. 380,560 to Forsberg, U.S. Design Pat. No. 384,168 to Stevenson, U.S. Design Pat. No. 397,451 to Stevenson, U.S. Pat. No. 5,540,525 to Miller (Miller), U.S. Pat. No. 5,800,097 to Martin (Martin), U.S. Pat. No. 5,487,623 to Anderson et al (Anderson), U.S. Pat. No. 5,881,511 to Keller, Jr. (Keller), U.S. Pat. No. 5,524,551 to Scheiwiller (Scheiwiller), U.S. Pat. No. 6,260,320 B1 to Di Lorenzo (Di Lorenzo), U.S. Pat. No. 5,226,275 to Trahan (Trahan), U.S. Pat. No. 4,324,293 to Brown et al. (Brown), U.S. Pat. No. 5,522,682 to Egan (Egan), and U.S. Pat. No. 6,176,059 B1 to Cantarano et al (Cantarano). Dueck discloses a retaining wall block with downward-extending cylindrical knobs. Forsberg discloses pins and pockets for interlocking overlapping blocks. Woolford discloses a masonry block which has a centrally-located and dogbone-shaped, or two centrally-located circular, protrusions aligned with an opposing inset (or insets) extending partially into the block. Rossi discloses dry-mounted construction elements for use in a retaining wall with a series of openings within each block. Beretta discloses retaining wall blocks with a cambered front, tapering side walls and an abutment for engagement with an adjacent lower block. Sievert discloses a solid composite masonry retaining wall block with a flange extending down from the block back surface past the height of the block. Shatley discloses a retaining wall building block with rearward and forward aligning elements extending downward, holes extend through the blocks and pins for interlocking them together. Gravier discloses retaining wall blocks with an upward lateral extending front lip and a laterally extending recess. Ming Su apparently discloses a retaining wall block with upward-extending cylindrical knobs. Dawson discloses a retaining wall block with a flange extending downward from the block's rear surface. The Forsberg design patent discloses a three faceted broken front face retaining wall block with a rear edge protrusion from the bottom surface of the block. The 384,168 Stevenson design patent discloses a retaining wall block with 2 rear protrusions from the bottom surface of the block. The 397,451 Stevenson design patent discloses a portion of a retaining block wall using the retaining wall blocks of the 384,168 design patent. Miller discloses a groove in the side of a block and uses a small slat inserted in the groove. Martin discloses an array of projections on the top face of a block that fits into an array of apertures on a bottom face of a higher block. Anderson discloses vertical rods inserted through holes of the blocks in order to form reinforced columns. Keller discloses block having a dovetail section for fitting together with adjacent blocks. The Scheiwiller discloses blocks having holes for attaching with other blocks by filling the holes with concrete. Di Lorenzo discloses wall flanges held together by rods or cables that are held in each adjacent brick. Trahan discloses a block with a lower lip that fits into the block below it. Brown discloses a wall using a tieback to connect to a lower member. Egan discloses a modular wall block with rearward abscesses for receiving grid connectors. Cantarano discloses a wall form panel with interlocking protrusions around the edges which make the panel reversibly symmetric.
[0008] It would be a distinct advantage to have a block which is simple to make and to use in building retaining walls, and which provides greater support, while maintaining the aesthetic beauty of the segmental block pattern.
SUMMARY OF THE INVENTION
[0009] The present invention relates to retaining walls, and more particularly, one aspect of the present invention involves a retaining wall block system incorporating a mounting surface for receiving a stabilizing element and may further include an interlocking mechanism. The retaining wall blocks may be secured by placing a stabilizing element on the mounting surface of two or more adjacent blocks, thereby providing additional support and sturdiness the a retaining wall block system. An entire row, or large portions thereof, can be provided significant stabilization from one or a series of stabilizing elements. The mounting surface receives a stabilizing element without disturbing the assembly of the blocks into the retaining wall system.
[0010] In another embodiment, the block may include a block body having opposing front and back body portions, and two opposing side body portions which define a void in the interior of the block. The block may also include at least one aligning element located on an upper surface of the block body, on the side body portions, adjacent to the void. The aligning elements may be integral with the respective side body portion from which it extends, and may extend across the width thereof The aligning elements are separated laterally from each other. The aligning elements may also extend rearwardly of a line defined by the rear surface defining the void, thereby forming a generally L-shaped element having a rear section extending across a portion of the width of the rear body portion also adjacent to the void. When assembling the blocks on top of each other, the blocks are staggered, so that each block in an upper row rests upon parts of two blocks in a lower row. The void in the upper block is placed over an aligning element of each of the two lower blocks. Configuration of the aligning elements and void size permits use in both straight and curved retaining wall sections without necessitating removal of any parts of the aligning elements.
BRIEF DESCRIPTION OF DRAWINGS
[0011] A more complete understanding of the method and apparatus of the present will become more apparent by reference to the following drawings, in conjunction with the accompanying Detailed Description.
[0012] FIG. 1A is a top plan view of a first embodiment of an interlocking block constructed in accordance with the principles of a first embodiment of the present invention;
[0013] FIG. 1B is a side elevational view illustrating the block in FIG. 1A ;
[0014] FIG. 2 is a top plan view illustrating two of the interlocking blocks of FIGS. 1A and 1B coupled together by a stabilizing element and secured in place by an anchoring element constructed in accordance with the principles of the present invention;
[0015] FIG. 3 is a side elevational cross sectional view of a portion of a straight retaining wall and depicting the placement of the stabilizing element of FIG. 2 ;
[0016] FIG. 4 is a perspective view illustrating several rows of a straight retaining wall using one embodiment of the interlocking blocks of the present invention, and depicting the stabilizing element, staggered blocks, and a mesh section;
[0017] FIG. 5 is a top plan view of a portion of a curved retaining wall constructed in accordance with the present invention utilizing stabilizing elements therewith;
[0018] FIG. 6 is a perspective view illustrating a retaining wall system constructed in accordance with the principles of the present invention and incorporating one embodiment of the interlocking blocks of FIGS. 1A and 1B ;
[0019] FIG. 7A is a top plan view illustrating a second embodiment of an interlocking block according to the principles of the present invention;
[0020] FIG. 7B is a side elevational view illustrating the block in FIG. 7A ;
[0021] FIG. 8 is a top plan view of a portion of a curved retaining wall incorporating the interlocking blocks of FIGS. 7A and 7B , stabilizing elements, and anchoring elements;
[0022] FIGS. 9A and 9B are top plan views further illustrating the interlocking blocks of FIGS. 7A and 7B ;
[0023] FIG. 10A is a top plan view of an alternate embodiment of a retaining wall block constructed in accordance with the principles of the present invention; and
[0024] FIG. 10B is a side elevational view illustrating the block in FIG. 10A .
DETAILED DESCRIPTION
[0025] The present invention relates to a retaining wall system incorporating interlocking wall blocks, stabilizing elements, and anchoring elements forming that wall, and the method of manufacture of the wall blocks.
[0026] Referring now to FIGS. 1A, 1B and 2 in combination, interlocking retaining wall blocks 1 are used in construction of a retaining wall system 50 , which rests upon the ground comprising a supporting surface therefore. Each of the blocks 1 are formed to support both the weight of the blocks 1 disposed above, and also to resist the force of fill material behind, and supported by, the retaining wall system 50 . Commonly, concrete or brick is used to form a block 1 . A block body 27 of the block 1 comprises a left body portion 20 and an opposing right body portion 21 , which each join a front body portion 18 opposing a rear body portion 19 . The left body portion 20 further includes a left interior surface 11 , a left exterior surface 14 , and upper and lower surfaces 2 , 3 . The upper surface 2 and lower surface 3 may be substantially flat. Similarly, the right body portion 21 has a right interior surface 12 , right exterior surface 15 , and upper and lower surfaces 2 , 3 . The width of the front body portion 18 may vary, depending on the construction of the block, and whether and how it is split during that construction. The front body portion 18 may have a “flat” front (not shown), or may be “faceted.” Each front body portion 18 has a forward interior surface 10 , left and right facets 5 , front facet 4 , and upper and lower surfaces 2 , 3 . Rear body portion 19 has rear interior surface 9 , left and right exterior surfaces 14 , 15 , and upper and lower surfaces 2 , 3 . In this embodiment, the rear body portion 19 and the left and right body portions 20 , 21 are shown as substantially uniform in width, but could vary. The forward interior surface 10 , rear interior surface 9 and left and right interior surfaces 11 , 12 define a void 8 within the block 1 . In one embodiment, the void 8 is substantially centered within the block 1 , and is substantially trapezoidal, with the forward interior surface 10 forming the long side thereof.
[0027] Referring still to FIGS. 1A, 1B and 2 in combination, the block 1 also includes a left aligning element 29 , formed on the left body portion 20 and a right aligning element 30 , formed on the right body portion 21 . The aligning elements 29 , 30 extend upwardly from the block body 27 and are used for aligning one interlocking block 1 with another block 1 for forming the retaining wall system 50 , and for causing the blocks 1 to interlock and strengthen the wall. The aligning elements 29 , 30 , extending upwardly (rather than down from the bottom surface 3 of the block body 27 ), are an advantage because this arrangement permits placing blocks 1 on a flat surface without requiring further actions to accommodate a downwardly extending aligning element. For instance, a concrete footing (not shown), may be used in place of the ground in FIG. 4 . Without special design of the concrete footing, it would not accept a downwardly extending aligning element, unless the installation included the additional step of breaking off the downwardly extending aligning element, which takes some time. In addition, a block with a downwardly extending aligning element, if placed on the ground, might require excavating small holes for the aligning elements, or removing them, as above. This would also consume time. In this embodiment, the left and right sides of the aligning elements 29 , 30 comprise, respectively, left exterior and interior surfaces 14 , 11 and right interior and exterior surfaces 12 , 15 . The left aligning element 29 extends completely across the width of the left body portion 20 ; likewise, the right aligning element 30 extends completely across the width of the right body portion 21 , and both are adjacent to the void 8 . This design creates fewer surfaces and corners, and is thus easier to produce. However, the aligning elements 29 , 30 could also be inset slightly from the left and right interior and exterior surfaces 11 , 12 , 14 and 15 . The aligning elements 29 , 30 also each have a front face 16 and a rear face 17 . The aligning elements 29 , 30 have a substantial depth (from face 16 to 17 ) and extend forward from the rear face 17 a substantial portion of the length of the body portions 20 , 21 . In one embodiment, the aligning elements 29 , 30 extend about one-half of the length of the body portions 20 , 21 , but do not extend as far forward as the forward interior surface 10 . In this embodiment, the rear faces 17 of the aligning elements 29 , 30 extend only to, and are flush with, the rear interior surface 9 , and are forward of the rear exterior surface 7 of the block body 27 . This permits a rear body portion 19 of an upper block 1 to rest upon the rear body portion 19 . The full width of the left aligning element 29 (from the left exterior surface 14 to the left interior surface 11 ) and the right aligning element 30 (from the right exterior surface 15 to the right interior surface 12 ) and substantial depth provides a larger aligning element, and specifically a greater cross-sectional size, to support interlocking with the upper blocks 1 (as described below) without a mechanical failure of the aligning elements 29 , 30 . Either of the front faces 16 and/or rears face 17 may be substantially flat. A flat configuration of the rear faces 17 is an advantage by providing larger bearing surfaces against the force applied to it by upper blocks. A flat configuration of the front faces 16 is an advantage by helping retain mesh 22 as shown in FIG. 3 . The rear faces 17 may be aligned to intersect the line formed by an edge between the rear interior surface 9 of the rear body portion 19 and the upper surface 2 . This alignment of the rear faces 17 ensures that when another block 1 is placed on top, and aligned using the aligning elements 29 , 30 , it does not overhang in front of the lower block (see FIG. 4 , described below). In this embodiment, the aligning elements 29 , 30 do not extend rearwardly of the rear interior surface 9 . The aligning elements 29 , 30 can be integrally formed with the block body 27 . This is advantageous, as the absence of a joint improves strength, and reduces cost and complexity of manufacture.
[0028] Referring specifically now to FIG. 2 , a stabilizing element 51 is shown. In addition to the stabilizing force of the aligning elements 29 , 30 , a groove 49 (also seen in FIGS. 1A and 1B ) may be provided for receipt of stabilizing element 51 inset in the upper surface 2 of the block body 27 . The groove 49 as herein shown, includes a front face 52 , rear face 54 , and bottom face 53 . The groove 49 is preferably formed deep enough to retain the entire stabilizing element 51 , but may also be deeper than the height of the stabilizing element 51 . The stabilizing element 51 , such as a length of rebar, rests in the groove 49 , so that when the blocks 1 are stacked on top of each other, the upper surface 2 of the lower block, and the lower surface 3 of the upper block are flush against each other. The groove 49 may be implemented anywhere along the upper surface 2 of the block 1 , however, for this particular embodiment, the grooves 49 are laterally located between the forward interior surface 10 and the aligning elements 29 , 30 . The stabilizing element 51 may be a length of rebar or other sturdy material placed between two blocks, or, alternatively, the stabilizing element 51 may run the entire length of, or a large portion of the retaining wall system 50 . The stabilizing element 51 may also be used to trap or hold the mesh 22 in place as shown in FIG. 3 .
[0029] A retaining wall system 50 may also need supplementary securement in addition to the aligning elements 29 , 30 , and the stabilizing element 51 . In this case, an anchoring element 55 can be attached at one end to the stabilizing element 51 , and the other end of the anchoring element 55 can be secured in the ground. These anchoring elements 55 can be placed throughout the retaining wall system 50 . The anchoring elements 55 of the present invention are advantageous to previously used anchors due to the fact that the anchoring elements 55 can be immediately secured to the stabilizing element 51 without waiting for drying concrete, which secured the previous anchors.
[0030] Now referring to FIGS. 3 and 4 in combination, FIG. 3 is a side elevation/section view depicting two stacked and interlocking blocks of FIG. 2 described above. As shown, the aligning element 30 of a lower block 1 ′ fits into the void 8 of the upper block 1 . The groove 49 is sufficiently deep so that the upper surface 2 of the lower block 1 ′ fits flush against the lower surface 3 of the upper block 1 wherein stabilizing element 51 runs therethrough. The stabilizing element 51 provides additional support for the retaining wall system 50 shown in partial detail as retaining wall 26 in FIG. 4 . As further shown in FIG. 4 , the stabilizing element 51 is placed in the groove 49 . Another securing element shown in FIG. 3 is provided in mesh 22 which can be used in conjunction with the retaining wall system 50 of the present invention. The stabilizing element 51 may run the entire length of the row of the retaining wall 26 , or may span just a few blocks 1 of the retaining wall 26 . One or several stabilizing elements 51 can be used to enhance the sturdiness of the retaining wall 26 . The stabilizing elements 51 may also hold the mesh 22 in place. One or more anchoring elements 55 as shown in FIG. 2 may also be integrated into the retaining wall 26 to increase sturdiness. Furthermore, mesh 22 may be interposed between upper and lower blocks 1 , 1 ′, and may be placed between each layer, or row, of blocks in the retaining wall 26 . Mesh 22 is commonly used in retaining walls to provide additional support to the retaining wall, by transferring forces to the fill material. As shown in the perspective view of FIG. 4 , the mesh 22 includes longitudinal wires 23 and cross-ties 24 joined at generally right angles and forming a welded wire gridwork panel. The mesh 22 may also comprise some other form of metal mesh (such as one having a mesh size smaller than the size of aligning elements on a block), or a geo-synthetic material, such as geogrid. A reinforcing material such as the mesh 22 aids in forming a mechanical interlock of the fill material in or through the relatively flat surface of mesh 22 , transferring tension in mesh 22 to the fill material. A flat geo-synthetic sheet may also be used, which reinforces the wall in much the same way using friction between the sheet and the fill material. As shown in FIG. 4 , a space among cross-ties 24 and wires 23 is placed over aligning elements 29 , 30 . Cross-ties 24 mechanically interlock with the front faces 16 of the aligning elements 29 , 30 of the blocks 1 of the row, which transfers tension to the mesh 22 and provides better support for the retaining wall 26 . Where the mesh size is too small to permit placing it over the aligning elements 29 , 30 , or where a sheet or geogrid is used, a large enough portion of the mesh 22 is placed over the aligning elements 29 , 30 to permit upper blocks 1 to be placed thereover. The mesh 22 may also be deformed to secure it over the aligning elements 29 , 30 before placing upper blocks 1 , or that step may cause the deformation. For low walls, or in other situations when reinforcement may be unnecessary, mesh 22 may also be omitted from the system. If so, lower surface 3 of upper block 1 will rest directly on upper surface 2 of lower block 1 ′. Aggregate, concrete or other reinforcing material, may also be placed within each void 8 of the blocks, again enhancing the overall strength of the retaining wall 26 .
[0031] Again referring to FIG. 4 , blocks 1 , 1 ′ may be aligned adjacently in a line (as shown in FIG. 2 ), or may be curved or angled (as shown in FIG. 5 ). Fill material, such as dirt or gravel (not shown), is placed behind the first row of blocks 1 ′, preferably up to about upper surface 2 . If mesh 22 is to be used, the mesh 22 is placed on top of the fill material, and secured above to the aligning elements 29 , 30 of the first row of the blocks 1 ′. A second row of blocks 1 is placed on top of the first row, trapping the mesh 22 between the rows. Each block 1 of the upper row can be staggered laterally, aligning void 8 of the blocks of the upper row over right aligning element 30 of a left block 1 ′ below and over left aligning element 29 of a right block 1 ′ below, adjacent to the right block 1 ′, and place rear face 17 of left and right aligning elements 29 , 30 in contact with and flush with rear interior surface 9 of rear body portion 19 (as shown in FIG. 3A ). If the retaining wall system 50 is angled or curved, only an edge of rear face 17 may be in contact with rear interior surface 9 (as shown in FIG. 5 ). These steps are repeated as necessary with further rows of blocks 1 , mesh 22 , and fill. Note, that this forms a vertically-aligned retaining wall system 50 , in which the vertical faces of the rear body portions 19 of the blocks 1 lie substantially in a plane, and each row of blocks 1 is not stepped back with reference to blocks 1 below. Although the retaining wall system 50 as shown includes blocks 1 of the same type throughout the retaining wall system 50 , other types of blocks 1 may be dispersed within the retaining wall system 50 . For example, every third block may include a groove 49 and stabilizing element 51 , whereas the remainder of the blocks 1 may include aligning elements 29 , 30 .
[0032] The top plan view of FIG. 5 depicts a curved or angled portion of such a wall. The curved portion in FIG. 5 differs primarily in that the left exterior surface 14 of the right block 1 ′ is brought closer to the right exterior surface 15 of the left block 1 ′. Although the exterior surfaces 14 , 15 are shown here as touching along their length, they may be left apart to provide a curve in retaining wall with the desired radius of curvature. Conversely, the exterior surfaces 14 , 15 may be placed so that only the rear portions thereof are contacting, to provide a smaller-radius curve. The upper block 1 is set forward so that the rear interior surface 9 of the rear body portion 19 is in contact with the rear faces 17 of the aligning elements 29 , 30 of the lower blocks 1 ′. Only an edge of the rear faces 17 at the corners of the aligning elements 29 , 30 contacts the rear interior surface 9 of the upper block 1 . In a curved portion of a retaining wall system 50 , the grooves 49 come together at an angle. Therefore, for a curved wall, either the stabilizing element 51 can be shaped at a particular curvature in order to fit into the angled grooves 49 , or the stabilizing element 51 may be omitted. Other block retaining wall systems include aligning elements on upper and lower blocks that permit alignment only if the blocks form a straight line. Similarly, such systems may include elements to secure placement of a reinforcing material, such as geogrid. If a curved wall is desired, it is often required to break off the aligning or securing elements, which is time-consuming. Blocks 1 with aligning elements 29 , 30 permit alignment, and provide secure placement of mesh 22 , in a curved wall, while reducing this disadvantage.
[0033] Referring now to FIG. 6 , an alternative embodiment to the retaining wall of FIGS. 4 and 5 is illustrated. In this embodiment, the groove 49 and stabilizing element 51 are not included in the retaining wall system 50 . The construction of the retaining wall system 50 is similar to that shown in FIGS. 4 and 5 , excluding the placement of the stabilizing element 51 in the groove 49 . In the embodiment shown in FIG. 6 , a first row of blocks 1 , 1 ′ are arranged so that the left exterior surface 14 of the first block 1 makes contact with the right exterior surface 15 of the second block 1 thereby forming a curved portion of a retaining wall system 50 . However, the embodiment described in FIG. 6 is equally applicable to a straight retaining wall. A second row of blocks 1 may be stacked on top of the first row of blocks 1 , 1 ′ to form the retaining wall system 50 . The blocks 1 of the second row of the retaining wall system 50 are staggered laterally so that the void 8 of the blocks 1 receives the aligning elements 29 , 30 of the blocks 1 , 1 ′ of the first row. The void 8 of the block 1 of the second row is placed over the left aligning element 29 of the first block 1 and the right aligning element 30 of the second block 1 ′. The void 8 is large enough to accommodate at least one aligning element 29 , 30 from each of the two adjacent blocks 1 , 1 ′ in the first row. The aligning elements 29 , 30 ensure that the blocks of the second row are staggered one half unit laterally with respect to the first row of blocks. Staggering the blocks in adjacent rows provides additional stability when compared with a strictly vertical arrangement, particularly if a stabilizing element 51 , aggregate, or another fill material is placed in the voids 8 . The blocks 1 of the second row are also set forward so that its rear interior surface 9 of the rear body portion 19 is in contact with the rear faces 17 of the aligning elements 29 , 30 of the blocks of the first row. This position allows the aligning elements 29 , 30 to help blocks of the second row resist forces that fill material such as dirt will apply to the rear exterior surface 7 (and to a lesser extent, exterior surfaces 14 , 15 ). The blocks 1 form a vertical retaining wall system 50 without the use of the groove 49 or the stabilizing element 51 . This alternate embodiment is also pertinent to stepped retaining wall systems 50 utilizing the retaining wall blocks described below.
[0034] Now referring to FIGS. 7A and 7B , top plan FIG. 7A and elevation FIG. 7B depict an alternative interlocking block 31 of the present invention. The block 31 is constructed in a similar fashion as the block 1 of the first embodiment, and the same reference numerals are used to refer to items that do not differ. The upward orientation of these aligning elements is advantageous as described above. The block 31 differs in the configuration of the left and right aligning elements 34 , 35 , which are substantially L-shaped. The left aligning element 34 comprises a rear portion 42 and a forward portion 36 . The forward portion 36 of the left aligning element 34 extends upwardly from the left body portion 20 , and the rear portion 42 upwardly from the left side of the rear body portion 19 . Similarly, the right aligning element 35 comprises a rear portion 43 and a forward portion 37 . The forward portion 37 of the right aligning element 35 extends upwardly from the right body portion 21 , and the rear portion 43 upwardly from the right side of the rear body portion 19 . In this embodiment, the left and right sides of the aligning elements 34 , 35 comprise, respectively, left exterior and interior surfaces 14 , 11 and right interior and exterior surfaces 12 , 15 . The forward portion 36 of the left aligning element 34 extends completely across the width of the left body portion 20 ; likewise, the forward portion 37 of the right aligning element 35 extends completely across the width of the right body portion 21 , and both are adjacent to the void 8 . This creates fewer surfaces and corners, and is easier to produce. However, as above, the aligning elements 34 , 35 could also be inset slightly from surfaces 11 , 12 , 14 and 15 . The forward portions 36 , 37 of the aligning elements 34 , 35 are similar to the aligning elements 29 , 30 in FIGS. 1A , B, and may be integrally-formed with the rear portions 42 , 43 . The left rear portion 42 comprises a rear face 44 and a left side face 40 . The right rear portion 43 also comprises a rear face 44 and a right side face 41 . The rear faces 44 , and side faces 40 , 41 , are rearward of a line extending along an edge formed at the void 8 by the rear interior surface 9 of the rear body portion 19 and by the upper surface 2 . The rear faces 44 are forward of the rear exterior surface 7 of the block body 27 . This is an advantage to structural strength of a wall formed of blocks 31 , because a rear body portion 19 of an upper block 31 may rest upon that part of the rear body portion 19 of the lower block 31 rearward of the rear faces 44 . The aligning elements 34 , 35 have a substantial depth from faces 16 to 44 and extend forward from the rear faces 44 , a substantial portion of the length of the body portions 20 , 21 . In one embodiment, the aligning elements 34 , 35 extend somewhat more than one-half of the length of the body portions 20 , 21 , but do not extend as far forward as the forward interior surface 10 . This depth includes the depth of both forward portions 36 , 37 and rear portions 42 , 43 . The full width of the left aligning element 34 (from the left exterior surface 14 to the left interior surface 11 ) and the right aligning element 35 (from right exterior surface 15 to right interior surface 12 ) and substantial depth (from faces 16 to 44 ) provides a larger aligning element, which is advantageous as described above. In particular, the aligning elements 34 , 35 have a substantial depth in the direction resisting the forward force applied by interlocking blocks. Left and right rear portions 42 , 43 extend laterally inwardly from, respectively the left and right exterior surfaces 14 , 15 , to, respectively, the side faces 40 , 41 . Although shown as contacting surfaces 14 , 15 , the rear portions 42 , 43 could also be offset somewhat therefrom. In this embodiment, the rear portions 42 , 43 extend inwardly of, respectively, the left and right interior surfaces 11 , 12 , creating an angled, or an L-shaped structure. This provides additional cross-sectional structure for the aligning elements 34 , 35 . The rear portions 42 , 43 of the aligning elements 34 , 35 do not contact one another, and do not extend over the whole lateral extent of the rear body portion 19 .
[0035] As in the interlocking blocks of FIGS. 1A and 1B , a groove 49 for receiving a stabilizing element 51 is inset in the upper surface 2 of the block body 27 . The groove 49 includes a front face 52 , rear face 54 , and bottom face 53 . The stabilizing element 51 rests in the groove 49 , so that when the blocks 31 are stacked on top of each other, the upper surface 2 of the lower block, and the lower surface 3 of the upper block are flush against each other. As noted with respect to the first embodiment, the groove 49 may be implemented anywhere along the upper surface 2 of the block 31 however, for this particular embodiment, the grooves 49 are laterally located between the forward interior surface 10 and the aligning elements 34 , 35 . The groove 49 should be deep enough to retain the entire stabilizing element 51 , but may also be deeper than the height of the stabilizing element 51 . The stabilizing element 51 may be placed between two blocks, or, alternatively, the stabilizing element 51 may run the entire length of, or a large portion of the retaining wall system 50 .
[0036] Referring now to FIG. 8 , this figure is a top plan view of a portion of a retaining wall 26 using the blocks described above and in FIGS. 7A, 7B . The aligning elements 34 , 35 of the blocks 31 permit forming both straight and curved wall sections. There must be a sufficient gap between a left side face 40 and right side face 41 to permit placing therebetween a right body portion 21 of a left block 31 of an upper row and a left body portion 20 of an adjacent left block 31 of an upper row, even when the lower row of blocks 31 ′ is arranged in a line, or for a negative curvature radius (i.e. a curve whose center lies forward of the blocks) (not shown). The retaining wall 26 is constructed in a similar fashion as described in relation to FIGS. 3, 4 , and 5 . The stabilizing elements 51 , anchoring elements 55 , and mesh 22 may be used as discussed above. As compared to a wall such as that shown in FIG. 4 , a wall 26 formed by the blocks 31 will have successive rows of blocks 31 that will be stepped back, or battered, rather than vertical. This is because the aligning elements 34 , 35 of the blocks 31 extend rearwardly of the rear interior surface 9 , so stacked blocks form a vertical offset. This offset increases the overall stability and strength of a wall.
[0037] Referring again to FIGS. 7A, 7B and 8 , the depth of the aligning elements 34 , 35 between the rear face 44 and front faces 16 must be less than, and may be significantly less than, the distance between the rear and forward interior surfaces 9 , 10 . This permits two aligning elements 34 , 35 of lower blocks 31 to be placed in an angled relationship in the void 8 to form a curved wall section as depicted in FIG. 8 . The rear faces 44 may be substantially flat, which is advantageous as described above.
[0038] Referring now to FIGS. 9A and 9B , in another embodiment, the rear portions 42 , 43 may extend no further laterally inward than, respectively, the left and right interior surfaces 11 , 12 . As shown in FIG. 9A , the left and right side faces 40 , 41 may be aligned, respectively, with the interior surfaces 11 , 12 . Alternatively, as shown in FIG. 9B , the side faces 40 , 41 may extend straight rearwardly. In yet other embodiments, all or part of the rear faces 44 and side faces 40 , 41 may be replaced by a convex curved bearing surface, or the rear faces 44 may be angled with respect to the rear exterior surface 7 , such as by it extending more forward inwardly.
[0039] As shown in FIGS. 10A and 10B , the block 1 may also be a solid retaining wall block 1 with a groove 49 inset on the upper surface 2 . In this embodiment, the groove 49 includes a front face 52 , bottom face 53 , and rear face 54 . The stabilizing element (not shown) rests in the groove 49 without disrupting the level of the upper surface 2 . The stabilizing element can be used to anchor one block 1 , or, alternatively, can be used to anchor several blocks, or an entire row of blocks into place. Although the groove 49 depicted in FIGS. 10A and 1B is positioned roughly equidistant from the front facet 4 and the rear exterior surface 7 , the groove 49 may be located anywhere between the front facet and rear exterior surface 4 , 7 . Additionally, though the groove 49 is shown as extending from the left and right exterior surfaces 14 , 15 , the groove 49 may be disposed at any angle. Furthermore, the groove 49 may extend from the front facet 4 to the rear exterior surface 7 .
[0040] It is thus believed that the operation and construction of the present invention will be apparent from the foregoing description. While the apparatus shown and described has been characterized as being preferred, it will be readily apparent that various changes and modifications could be made therein without departing from the scope of the invention as defined in the following claims.
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Retaining wall blocks, retaining wall system formed thereby, and method for manufacturing the retaining wall blocks. The blocks are adapted for assembly to form a retaining wall system. A block of an upper row is laterally positioned by positioning it on top of two lower blocks. Each block also includes at least one mounting surface for securing a stabilizing element therewith. The mounting surface can be embodied as a groove which is inset into the upper surface of the blocks. Each block may additionally include opposing front and back body portions, and opposing side body portions, defining a void therein. The blocks may include aligning elements extending upwardly from an upper surface of the block body. The aligning elements of the lower blocks fit into the void of the upper block and assist in aligning the upper block on the lower blocks and, optionally, in securing a reinforcing structure placed between the layers. The wall, which may be either straight or curved, includes a plurality of blocks stacked in one or more rows. The aligning elements fit into the void and perform the aligning and reinforcing function in straight rows and when the rows curve to form a curved retaining wall. When the wall is assembled, anchoring elements may be placed throughout the wall by attaching an end of the anchoring element to the stabilizing element, while securing another end of the anchoring element to another stable surface, such as the ground.
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CROSS-REFERENCE TO RELATED APPLICATIONS
The present application claims priority from Danish patent application PA 2009 00652 filed on May 25, 2009. In addition, the present application claims the benefit under 35 U.S.C. §119 (e) of the U.S. Provisional Patent Application Ser. No. 61/184,176 filed on Jun. 4, 2009. The content of all prior applications is incorporated herein by reference.
FIELD OF THE INVENTION
The invention relates to a method of and system for controlling a wind power system.
BACKGROUND OF THE INVENTION
Wind power system monitoring, control and regulation data is often correlated in the time domain. Over recent years the performed monitoring, control and regulation in wind power systems have become increasingly more sophisticated and as a consequence requirements to data processing speed, precision and reliability in data communication and in relation to the temporal correlation of data have increased. Consequently, requirements e.g. to precision in the time domain of a wind power system have increased.
SUMMARY OF THE INVENTION
The invention relates to a method of controlling a wind power system comprising a plurality of system elements, said wind power system including a plurality of data processors distributed in said system elements, the method comprising the steps of:
synchronizing at least a part of said data processors to at least one reference signal distributed to said data processors from a time synchronization arrangement, associating said data processors with local clock generation circuitries wherein said local clock generation circuitries associated with data processors of a first subset of the data processors have a peak-to-peak tracking jitter higher than or equal to a predetermined threshold value, wherein said local clock generation circuitries associated with data processors of a second subset of the data processors have a peak-to-peak tracking jitter less than said predetermined threshold value, controlling at least one of said system elements at least partly by means of a data processor from said first subset of data processors susceptible to the jitter of the local clock generation circuitry associated with the data processor from the first subset of data processors, and controlling at least one of said system elements at least partly by means of a data processor from said second subset of data processors on the basis of said at least one reference signal while being susceptible to the jitter of the local clock generation circuitry associated with the data processor from the second subset of data processors, thereby utilizing said second subset of data processors for high precision control in the wind power system.
Hereby high precision control of individual system elements or parts of system elements of a wind power system is possible. System elements such as a plurality of wind turbines and substations of a wind power plant is controlled based on a plurality of data processors, according to the invention a subset of these data processors are high precision data processors and are synchronized to a precise time reference. This enables very precise control of this subset of data processors and thereby also of parts of the individual wind turbines and substations. Such high precision control could e.g. be control of power output of the individual wind turbines. Because the output of the individual wind turbines and substations in a wind power plant is controlled precise and synchronous, a central park controller can control the total power output from the wind power plant and thereby the wind power plant is able to support the utility grid, if a fault occurs in relation to the utility grid.
In other words according to the invention high precision control of the wind power system can be performed disregarding data processors which are not capable of complying with high precision control instructions.
The system elements comprised in the wind power system may according to the invention e.g. be understood as elements of a wind power plant or elements communicating with a wind power plant. Hence system elements may e.g. be wind turbines, substations, controllers located internal or external in relation to the wind power plant, communication units for communicating internally within the wind power plant or from the wind power plant to external communication units.
Whether the system elements are communicating, controlling or processing data, the system elements may comprise one or more data processors, and the data processors are distributed in the system elements according to the individual tasks and implementations of the system elements.
It should be noted that not all system element comprises data processors, an example could be a metrological station only including a temperature or wind measuring unit.
Throughout this description reference signal may also be referred to as precise time. Reference signal or precise time comprises an absolute or relative representation of time in a time domain with a certain precision. Hence a high precision reference signal is accurate with a minimum of jitter enabling the internal time of a plurality data processors to be synchronous with the time domain.
Jitter can be measured in a number of ways, relative to absolute time, another signal or the output clock itself. The first is commonly referred to as absolute jitter or long-term jitter, the second as tracking jitter or input-to-output jitter, when the other signal is the reference signal. If the reference signal is perfectly periodic such that it has no jitter, absolute jitter and tracking jitter for the output signal are equivalent. The third measurement, relative to the output clock, is often called periodic, or cycle-to-cycle, jitter. Cycle-to-cycle jitter can be measured as the time-varying deviations in the period of single clock cycles, or in the width of several clock cycles (referred to as cycle-to-Nth-cycle jitter).
In the claims jitter is meant to be understood as “tracking jitter” but evidently other definitions of jitter and corresponding ways of measuring such jitter are also within the scope of the invention. Allowed peak-to-peak jitter is understood as the maximum allowed time measured between a first and a second transition e.g. in a clock signal, hence 0.5 microsecond peak-to-peak jitter may also be referred to as ±0.25 microsecond jitter, measured from the ideal time of the transition.
The reference signal may e.g. be distributed by means of a data communication network e.g. the same data communication network also used for communicating control and measuring data or distributed by a separate network or wiring.
The reference signal may be transmitted through air e.g. in a wireless network, or through cables e.g. made of cobber, fibers, etc. Furthermore the reference signal may also be derived from a GPS signal.
According to the invention said data processor communicates with a clock generation circuitry to obtain an internal tick or internal clock based on which the data processor processes data. The clock generation circuitry may be located internally within the data processor or externally to the data processor.
According to the invention, the power output from a wind turbine may be controlled with a precision enabling a control of the total power output from a wind power plant to support the utility grid if needed. The support may be in form of increased delivery of reactive power and is possible because the individual wind turbines are capable of reacting promptly and precisely e.g. on grid faults or coupling in of large electrical motors from consumers of the grid. Thereby, the number of conventional energy power plants to support the grid due to varying output from a wind power plant may be decreased.
Furthermore the establishing of a precise time enables communication on the data communication network to be based on time trigged communication protocols, thereby establish communication protocols with guaranteed latencies, enabling critical real-time control of e.g. power converters via the data communication network.
In an embodiment of the invention said second subset of data processors are utilized for high precision control of power converters of energy storage devices of the wind power system.
Hereby it becomes possible to perform a precise control of accumulation of energy produced e.g. by a wind power plant. Accumulation of energy could e.g. be in form of compressed air, batteries, etc.
Furthermore it becomes possible to shape the power output from an energy storage device, which is advantageous e.g. in situations where the wind turbines are not producing energy e.g. due to low wind speed. In such a situation it is possible for an energy storage to deliver energy to the grid and because of the high precision control of the power converter of the storage device, the power output form the energy storage can be shaped to comply with demands from the grid.
In an embodiment of the invention said second subset of data processors are utilized for high precision control of power converters of wind turbines and substations of the wind power system.
Hereby high precision control of the power converters enables the wind turbine controller or substation controller to shape the power output. Shaping the power output can be in form of changing the frequency, phase angle, voltage, etc in the sinusoidal power output from the wind turbine.
Furthermore it becomes possible to shape the power output of wind turbines and substations synchronous across the entire wind power plant.
Furthermore it is advantageous to control the power converters of system elements, when the power converters are precisely synchronized to the precise time PT, both in terms of power output waveforms and in terms of phase displacement of pulse width modulation outputs controlling the switches of the power converters.
In an embodiment of the invention said high precision control of power converters enables the wind turbine controllers and substation controllers to adjust the phase of their pulse width modulators relatively to the reference signal.
In case the transition of switches of the power converters are controlled by means of pulse width modulation, the pulse width modulators controlling the power converters switches may according to the present invention be controlled synchronously according to the reference signal.
This is advantageous because it enables control of power output from the individual wind turbines and substations and thereby it becomes possible to reduce e.g. white noise and harmonics in power output from the wind power plant. One way of implementing this, could be to control the output from a first wind turbine to compensate noise or harmonics originated from second wind turbine.
Furthermore the synchronous control of power switching internally in a wind turbine is advantageous because the synchronous control may contribute to simpler filtering of power output e.g. from the wind turbine.
The high precision control of the power converters may be performed based on at least one operational value in the utility grid e.g. voltage, phase angle, frequency, etc.
In an embodiment of the invention said second subset of data processors are utilized for high precision control of data acquisition within the wind power system.
Data acquisition may e.g. comprise measurements or sampling of data obtained within the wind power system including the grid. The present invention enables measurements from data processors of the second subset to be made e.g. with a very precise time stamp, at a synchronous time in a plurality of system elements, etc.
Furthermore it is very advantageous to use the high precision data acquisition, e.g. within a wind turbine or substation, in relation to condition monitoring. Then conditioning monitoring measurements made or controlled by different data processors with reference to the precise time may be sampled and/or correlated, facilitating a very sophisticated picture of the condition of measured element.
The utility grid may be an element of the wind power system. The utility grid is connected to the wind power plant in a point of common connection and in or through the point of common connection high precision measurements of utility grid operational values can be made. These operational values may e.g. be characteristics of voltage, frequency, phase angle, etc. and used as basis for high precision control of power converters in the wind power system.
According to the invention it is possible to perform synchronous data acquisition across elements of a wind power plant and across data processors of a wind turbine or substation. Furthermore the present invention enables high precision data acquisition of power grid events, lightning event, condition monitoring, etc.
In an embodiment of the invention said predetermined threshold value being selected in the range of 0.1 microseconds to 10 microseconds, preferably in the range of 0.1 microsecond to 2 microseconds and most preferably in the range of 0.35 microseconds to 0.65 microseconds.
Relating to the ranges of threshold values mentioned above the preferred threshold value in some elements e.g. control or monitor units of the wind power system would be 0.1 microsecond and the preferred threshold value at wind power system level e.g. between wind turbines and substations in a wind power system would be 1 microsecond.
Hereby is obtained that internal time of the data processors of the second subset of data processors is synchronous within the specified range, enabling high precision control, data acquisition, etc. This range is preferred to define allowable jitter in a square wave form signal and the selected threshold value is depending on the frequency of the internal time of the data processors.
In an embodiment of the invention the local clock generation circuitries associated with data processors of the first subset of the data processors have a peak-to-peak cycle-to-cycle jitter higher than or equal to a percentage predetermined threshold value and
wherein the local clock generation circuitries associated with data processors of the second subset of the data processors have a peak-to-peak cycle-to-cycle jitter less than said percentage predetermined threshold value,
Hereby it becomes possible to perform high precision control to a subset of data processors while control of a further subset of data processors is not high precision control. This enables a central controller of the wind power plant to perform differentiated control of the wind turbines and substations in a wind turbine plant and thereby the full potential of wind turbines and substations having high precision data processors is utilized.
In an embodiment of the invention said data processor is part of a wind turbine controller, substation controller or a central controller of a wind power plant.
In an embodiment of the invention a time represented by said reference signal is precise to the nearest microsecond.
The reference signal could e.g. be a square wave signal with a frequency of 1 Mhz. Jitter in the reference signal in form of a square wave signal is preferably insignificant compared to jitter in the local clock generating circuitries.
The reference signal is a precise time signal originated from a time synchronisation arrangement located internal or external to the wind power plant. The precise time signal, also in this description referred to as precise time, represents a precise time domain to which data processors may be synchronized.
The reference signal is a precise time signal and is global in the sense that it is distributed to all or at least a subset of all elements of the wind power system and creating a global precision time within the wind power system. It is therefore possible for all or for a subset of all data processors of the wind power system to refer to the precise time signal; hence the data processors which refer to the reference signal thereby become synchronized.
In an embodiment of the invention a data processor from said first subset of the data processors is synchronized to a derivative of said reference signal.
Hereby is obtained that a derivative of the reference signal may e.g. be derived by frequency division and used for synchronizing data processors of said first subset of data processors that are less demanding or less able regarding precision. Thereby it is possible to use the same reference signal for all data processors regardless of their demands.
In an embodiment of the invention said reference signal being generated by one or more clock generating units comprised by said time synchronization arrangement, and wherein said time synchronization arrangement thereby forms a fault-tolerant network ecosystem.
The fault-tolerant network ecosystem may comprise one or more time synchronization arrangements. Such time synchronization arrangements may comprise clusters of clock generation units or circuitries generating a reference signal in mutual cooperation. Hence if one clock generating unit fails another clock generating unit of the cluster continues to generate the reference signal. In this way a time synchronization arrangement is still capable of producing a reference signal if one clock generating unit fails.
In the same way if the network ecosystem e.g. comprises two or more time synchronization arrangements the network ecosystem becomes fault-tolerant i.e. if one of these time synchronization arrangements fails another time synchronization arrangement continues to produce and distribute the reference signal in the network ecosystem.
It should be mentioned that by introducing redundancy in the network ecosystem the fault-tolerance in the network ecosystem may be increased as described below.
In an embodiment of the invention said predetermined threshold value being selected in the range of 0.1 microsecond to 1 microsecond.
In an embodiment of the invention said percentage predetermined threshold value being selected in the range of 0.1% to 10%, preferably in the range of 0.2% to 3% and most preferably in the range of 0.5% to 1.5% of the period of a clock generated by said local clock generation circuitries.
Hereby is obtained that internal time of the data processors of the second subset of data processors is synchronous within the specified range, enabling high precision control, data acquisition, etc. This range is preferred to define allowable jitter in a square wave form signal and the selected threshold value is depending on the frequency of the internal time of the data processors.
Moreover the invention relates to a system for carrying out the methods described above.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates a modern wind turbine,
FIG. 2 illustrates a wind power plant,
FIGS. 3 a and 3 b illustrate a data communication within a wind power plant according to an embodiment of the invention,
FIGS. 3 c and 3 d illustrate a data communication within a wind power plant according to a further embodiment of the invention and
FIG. 4 illustrates precision in relation to data communication within a wind power system according to various embodiments of the invention.
DETAILED DESCRIPTION OF THE INVENTION
The term “wind power system” is in accordance with an embodiment of the invention understood as a system related to the generation of power by means of the wind. A preferred example of a wind power system is a wind power plant WPP comprising a plurality of wind turbines WT and substations SUB, where control/monitoring units are comprised in a wind turbine WT and/or substation SUB. Hence, according to the invention, a system element of a wind power system could be any unit related to a wind power plant WPP or utility grid GD.
The term “data processor” DP may in accordance with an embodiment of the invention be understood as any arrangement or element that is related to processing of data. A data processor DP may be a controller or part of a controller e.g. in measurement equipment for measuring or monitoring of e.g. transformers, lightning, power, condition monitoring of physical elements of the wind power system, etc.
A data processor DP is understood as a unit using or referring to an external or internal clock in processing of data e.g. initiating measurements, activating actuators, comparing or calculating data. Examples of elements of a wind power system comprising one or more data processors DP may be wind turbine controller WTC, top controller TC, pitch controller PIC, hub controller HC, control unit for transformers, etc.
A data processor DP may physically be embodied in a PLC (PLC: Programmable Logic Controller), a DSP (DSP: Digital Signal Processor), a fuzzy logic computer, a biological computer, a neural logic computer or another hardware processing data. It should be noted that a data processor DP may also be understood as software which is dependent or independent on hardware when processing data.
The term “wind power plant” WPP is a term covering elements needed for a wind power plant WPP to produce energy. Such elements could e.g. be wind turbines WT, substation SUB, control units located internally or externally to the wind power plant WPP.
The term “wind turbine” WT is a term covering every unit internal or external to the wind turbine. Examples of such units could e.g. be measuring units for measuring wind speed, vibrations, output power, etc. or everything which is used in relation to wind turbines WT such as gear, generator, converter, aerodynamic control of blades such as pitch and flap mechanisms, etc.
The term “substation” SUB is a term covering everything included in a wind power plant WWP except for the wind turbines WT; hence, the term substation SUB may cover control units and servers, metrological equipment, phase compensation equipment, energy storage device, transformers, etc.
The term “jitter” is understood as unwanted variation of one or more characteristics of a periodic signals e.g. in electronics. Jitter may be seen in characteristics such as the interval between successive pulses, or the amplitude, frequency or phase of successive cycles. In other words jitter may be interpreted as an expression related to the precision of e.g. time between two clocks e.g. differences in time in data processors of the same time domain. Jitter is a determining factor e.g. for the simultaneity of samplings, measurements or activating actuators by data processors DP of the same time domain and for synchronizing of physical separated nodes in a network.
FIG. 1 illustrates a modern wind turbine WT. The wind turbine WT comprises a tower TO positioned on a foundation. A wind turbine nacelle NA with a yaw mechanism is placed on top of the tower TO.
A low-speed shaft extends out of the nacelle front or back and is connected with a wind turbine rotor through a wind turbine hub HU. The wind turbine rotor comprises at least one rotor blade BL e.g. three rotor blades BL as illustrated.
FIG. 2 illustrates an overview of a typical wind power plant WPP, according to an embodiment of the invention. The illustrated wind power plant WPP comprises a number of wind turbines WT 1 -WTn located within a geographical area onshore or offshore. Furthermore, the wind power plant WPP may include one or more substations SUB e.g. metrological stations, filters, converters, capacitor banks, etc. The wind power plant WPP may be assembled to constitute a total unified power producing unit that can be connected to the utility grid.
A wind power plant WPP typically has a “master” or central controller CC. The central controller CC may, according to an embodiment of the invention, be located as part of or in relation to a SCADA (SCADA; Supervisory Control And Data Acquisition) server. The central controller CC may physically be located external to the wind power plant WPP or in relation to a substation SUB which may comprise a number of computers or processing units including data processors DP.
The central controller CC may typically comprise means for continuously controlling and monitoring the condition of the wind power plant WPP, including e.g. wind turbines WT and substations SUB. Furthermore, the central controller CC may collect data which may be used in statistics or analyses on operation and may at the same time send/receive control related data to and from elements of the wind power plant WPP.
The wind power plant WPP may communicate with external control units ECU e.g. located at a utility grid operator UGO or a support division in another country. The communication between the utility grid operator UGO and the wind power plant WPP e.g. in form of the central controller CC may be through a public data communication network PDCN such as the internet.
Within the wind power plant WPP, the central controller CC may be connected to the internal data communication network DCN connecting control and monitoring units of the wind turbine WT and substations SUB. The data communication network DCN within the wind power plant WPP may e.g. be a parallel or serial network implemented e.g. wireless or by means of optical or copper cables. Preferably, the data communication network DCN is a LAN (LAN: Local Area Network) or WLAN (WLAN: Wireless Local Area Network) and/or e.g. a part of a public data communication network PDCN, such as e.g. the internet or an intranet.
It should be mentioned that the network ecosystem also sometimes referred to as data communication network DCN of the wind power system may be fault-tolerant e.g. by redundancy in the network ecosystem. Such redundancy may be obtained by having double, triple or multiple communication paths within the network ecosystem.
A fault-tolerant network ecosystem may be understood as a data communication network DCN where the synchronisation of data processors DP may still be obtained even though a clock generating unit or a node such as a data processor DP in the data communication network DCN fails.
The redundancy may be implemented in the entire network ecosystem of the wind power system i.e. both at wind power system level e.g. between wind turbines WT, between wind turbines WT and substations SUB, etc. in the network ecosystem within the individual system elements of the wind power system e.g. between units of a wind turbine WT such as control and monitoring units, between units in a substation SUB, etc.
It should be understood that redundancy in the network ecosystem should also be understood as including redundancy between units comprised in a plurality of wind turbines WT and substations SUB.
The control related data may typically be data related to control of a wind turbine WT or substation SUB. The control related data may be instructions to a wind turbine WT or substation SUB e.g. to change the produced power (e.g. frequency or phase angle), activate or deactivate actuators, take measurements, pitch blades, etc.
The control of wind turbines WT and substations SUB is typically executed by control units such as e.g. pitch controller PIC, wind turbine controller WTC, substation controller, top controller TC, power converters PC, etc. all comprising one or more data processors DP. The data processors are typically associated with a clock generating circuitry CGC to obtain an internal clock signal also referred to as internal ticks IT. The data processors are able to process data, communicate, execute instructions, etc. according to the rising or falling edge of the internal clock or internal ticks IT.
The clock generating circuitry CGC also referred to as clock generating unit CU may be part of the data processor DP, a unit located within the data processor or a unit located external to the data processor DP. In the latter case more than one data processor may refer to the same clock generating circuitry CGC, typically this is the case when data processors are part of the same or neighboring data processing units. A data processing unit may according to the invention be a unit for carrying out instructions, measuring, controlling, etc.
With this said, it should be mentioned that in order to apply or increase the fault-tolerance of the internal clock signal within the network ecosystem it may be advantageously to build up a cluster of clock generating circuitries CGC. The effect of having a cluster of clock generating circuitries CGC is that if one of the clock generating circuitries CGC of such cluster fails, there is always a further clock generating circuitry CGC in the cluster to ensure an internal clock signal in the network ecosystem.
The data communication network DCN may also be utilized for transmitting monitoring data e.g. within a wind power plant WPP between substations SUB, wind turbines WT, controller units, etc. Furthermore, the data communication network DCN may be used to transmit monitoring data to and from the central controller CC, if the central controller CC is not located within the wind power plant WPP. Monitoring data may e.g. be a reading of a pressure, temperature, vibrations, wind speed, power output of the individual wind turbines WT or any other measured data within a wind power plant WPP. The measurements may be used later e.g. for statistic-, analytic- or control purposes.
The present invention is preferably utilized within a wind power plant WPP comprising a plurality of wind turbines WT and substations SUB but may be utilized within one single wind turbine WT or substation SUB.
FIG. 3 a illustrates a simplified overview of a wind power plant WPP including a number of wind turbines WT 1 -WTn and a substation SUB which are interconnected via a data communication network DCN. Evidently, other equipment may be present in a wind power plant WPP as described with reference to the description of FIG. 2 . The illustrated wind turbines WT and substation SUB may comprise a plurality of internal data processors DP for processing data related to measure and control of the wind power plant WPP. At least part of the data processors DP are synchronized according to a precise time domain represented by a precise time originating from the time synchronizing arrangement TSA or master time synchronizing arrangement MTSA. The precise time is also referred to as precise time PT or reference signal throughout this document.
The precise time PT is handled or distributed from the time synchronizing arrangement TSA to the data processors DP by a precise time protocol such as IEEE-1588. The precision time protocol used to distribute the precise time PT ensures that the time domain in each of the wind turbines WT and substations SUB is as precise as the precise time PT. In other words data processors DP are able to synchronize their internal clock/internal ticks IT with the precise time PT of the time domain.
Alternatively the time synchronizing arrangement TSA or master time synchronizing arrangement MTSA may comprise a cluster of clock generations circuitries CGC from which the precise time PT originates and from which the precise time PT is distributed to relevant data processors DP via the data communication network DCN. According to this alternative way of creating a precise time PT or in combination with the use of a precise time protocol as described above the relevant data processors DP are able to synchronize their internal clock/internal ticks IT with the precise time PT.
As described above using a cluster of clock generating circuitries CGC introduces or increases the fault-tolerance of the precise time PT in the network ecosystem. In this way the precision of the precise time PT is maintained e.g. in a situation where one clock generating circuitry CGC fails. In such situations the relevant data processors DP may continue to synchronize their internal clock signal/internal ticks IT to the precise time PT.
The result of having a fault-tolerant precise time PT in combination with a fault-tolerant data communication network DCN as describes above is a network ecosystem of a wind power system comprising synchronous data processors even in situations where a clock generating circuitry CGC or a node in the data communication system fails.
It should be noted that the precise time domain does not have to be distributed to all wind turbines WT or substations SUB and that e.g. data processors DP of the wind power system may contribute with jitter so that the time domain e.g. in a wind turbine WT may not be completely identical with the time domain represented by the precise time PT.
Furthermore, it should be noted that a plurality of standards or protocols may be used to communicate a precise time PT to elements of a wind power plant WPP and that it may even be possible to develop a new protocol for this specific purpose. Besides the already mentioned IEEE-1588 it may be advantageous to use other precise time protocols or base development of new time synchronizing protocols on other protocols than IEEE-1588. Such protocols could e.g. include the IEEE-1588 with wireless protocol extensions, NTP (NTP; Network Time Protocol), SNTP (SNTP; Simple Network Time Protocol), etc. depending on the network.
Furthermore, it should be mentioned that many industrial real-time LAN protocols can be supported by a precision time such as e.g. POWERLINK™, EtherCAT™, ProfiNET™, etc. Furthermore, it should be mentioned that fault-tolerant clock generation and distribution can be supported by industrial real-time LAN protocols such as TTEthernet. It should be noted that some of the above-mentioned protocols or standards are proprietary.
A time synchronization arrangement TSA is illustrated in the wind power plant WPP in FIG. 3 a where data processors DP of the wind turbines WT 1 -WTn, substations SUB may be connected to the time synchronization arrangement TSA via a data communication network DCN. The time synchronization arrangement TSA comprises at least one clock C from which the at least one precise time PT origins. The internal clock of at least part of the data processors DP of the wind power plant WPP is synchronized to this precision time PT and thereby at least one global precision time domain within the wind power plant is created.
It should be noted that elements outside the wind power plant WPP may also have access to the precise time and thereby the global precision time domain.
According to the invention, at least two time synchronization arrangements TSA or one time synchronization arrangement TSA and one master time synchronization arrangement MTSA is present in relation to the wind turbine plant WPP. This redundancy is a security measure if a defect should occur in one of the synchronization arrangements.
During operation in a master/slave configuration one clock C in one time synchronization arrangement TSA/MTSA is appointed as “master clock”, hence, all other clocks C and data processors DP refers to the precise time PT originating from this “master clock”. If the “master clock” fails, a clock C of one of the other time synchronization arrangements TSA takes over and produces the precise time PT. Which of the additional time synchronization arrangements TSA is taking over, may be determined in advance depending on the system.
During operation in a multiple master configuration two or more time synchronization arrangements TSA may form a network ecosystem in the data communication network DCN generating the precise time PT in mutual cooperation. Such time synchronization arrangements TSA may comprise clusters of clock generation circuitries CGC. If one time synchronization arrangement TSA fails e.g. if one clock generation circuitry CGC fails, the remaining time synchronization arrangements TSA in the ecosystem continue generating the precise time PT thus ensuring flawless generation of the precise time PT in single or multiple failure scenarios.
The same redundancy principle is preferably found in the distribution of the precise time PT in the data communication network DCN. Because it is important to the data processors DP to receive the precise time PT, a redundancy such as e.g. retransmission of the precise time may be performed to secure the precise time reaches the data processors DP expecting the precise time PT. In case the precise time PT fails to reach certain data processors DP this may affect the entire wind power plant performance.
Redundancy in the data communication network DCN may also be established in form of an additional data communication network, hence in case a fault such as e.g. a broken cable or defect network switch occurs in the data communication network DCN the precise time PT is transmitted to the data processors DP via the additional data communication network. Such additional data communication network could e.g. be a wireless, optical or wired network.
It should be noted that the precise time PT may be received centrally at e.g. a wind turbine WT and then via the internal LAN of the wind turbine WT be distributed to the data processors DP of the wind turbine WT.
The time synchronization arrangement TSA may be software or hardware implemented in the wind power plant e.g. as part of the central controller CC or as a stand-alone unit. The time synchronization arrangement TSA continuously communicates e.g. by distributing/broadcasting a precise time PT to at least part of the data processors DP within the wind power plant WPP. The precise time PT may be distributed via data communication networks DCN and methods as described above.
As described the precise time PT creates a time domain which at least a part of the data processors DP distributed e.g. in substations SUB and wind turbines WT of the wind power plant WPP refers to. The clock signal within these data processors DP is referring to the precise time PT from the time synchronization arrangement TSA. The time domain or clock signal of these data processors thereby becomes synchronous with the precision time signal PT, with a precision reflecting the precision of the precise time PT. Hence, an event occurring at the same time in different wind turbines WT may be registered in the respective wind turbines WT with a precise time stamp reflecting the precision of the precision time signal PT.
It should be noted that more than one synchronous time domain may refer to the same precision time signal PT.
It should furthermore be noted that a first synchronous time domain may refer to a first precise time PT, a second synchronous time domain may refer to a second global precise time PT, a N synchronous time domain may refer to a N global precision time signal PT, etc.
Each wind turbine WT and substation SUB may include several data processors DP as illustrated in FIG. 3 a and a desired part of these data processors DP may be chosen to be synchronized. When the desired number of data processors DP of the wind power plant WPP is synchronized i.e. having a common understanding of the precision in the precise time PT, it is possible to perform a very precise and reliable control and analysis e.g. comparison of specific events or effect of events occurring in the wind power system.
FIG. 3 b illustrates a wind power plant WPP where the time synchronization arrangement TSA is located externally from the wind power plant WPP.
The external located time synchronization arrangement TSA may be communicated to elements of the wind power plant WPP e.g. via a wireless data communication network WDCN, earth satellite system such as a GPS, or preferably through an existing data cable/fiber data communication network.
The synchronization of time between the data processors DP of the elements of the wind power plant WPP illustrated on FIG. 3 b may be established as described in relation to FIG. 3 a . Hence, the precise time PT from the synchronization arrangement TSA may be independent of existing internal time signals of the wind power plant WPP and thereby the precise time PT becomes a reference signal.
It should be noted that it may not be relevant to synchronize all data processors DP of e.g. a wind turbine WT or substation SUB. Furthermore is should be noted that the data processors DP is distributed within elements of the wind power system (also referred to as system elements) so that one system element may comprise a plurality of data processors while another system element comprises only a few data processors or even none at all.
FIGS. 3 c and 3 d illustrate a wind power plant WPP with two groups of wind turbines WT 1 , WT 2 and a precision time synchronization arrangement TSA. The wind power system may include an internal or external master time synchronization arrangement MTSA to which one or more of the time synchronization arrangements TSA refer to.
The time synchronization arrangements TSA may comprise one or more clock generating units CU or be slave to a master clock MC from a master precision time synchronization arrangements MTSA. The master precision time synchronization arrangement MTSA may be located within the wind power plant WPP or as illustrated in FIG. 3 a external to the wind power plant WPP.
In case the time synchronization arrangements TSA comprises more than one clock generating unit CU or clock generating circuitry CGC these clock generating units CU may form one or more clusters of clock generating units CU within the time synchronization arrangements TSA. Hence such time synchronization arrangement TSA becomes fault-tolerant because if one clock generating circuitry CGC fails, another clock generating circuitry CGC of the cluster ensures the functionality of the time synchronization arrangement TSA.
Furthermore when such fault-tolerant time synchronization arrangements TSA is connected in a data communication network DCN such network becomes fault-tolerant i.e. the time synchronization arrangements TSA then forms a fault-tolerant network ecosystem. In such network ecosystem the plurality time synchronization arrangements TSA comprising clusters of clock generating units CU are compensating each other in case of fault in one time synchronization arrangement TSA, thereby ensuring that the time synchronization arrangements TSA always are able to create and distribute a precise time PT.
The data processors DP 1 , DP 2 of the illustrated wind turbines WT 1 , WT 2 and substations SUB 1 , SUB 2 are synchronized according to at least one precise time PT originating from the time synchronization arrangement TSA or the master time synchronization arrangement MTSA.
According to an embodiment of the invention, the precise time PT is global in the sense that all elements of a wind power system such as the illustrated wind power plant WPP have access to the precision time signal PT. Even not illustrated external wind power systems communicating with the illustrated wind power plant WPP may also have access to the precision time signal PT.
The data processors DP 1 , DP 2 are synchronized to the global precision time domain based on performance/characteristics of the data processors DP 1 , DP 2 .
In the wind power plant WPP illustrated on FIG. 3 c , data processors DP 1 of a second category 2 C comply with the precision and e.g. also frequency of the precise time PT. This is contrary to the data processors DP 1 of a first category 1 C which do not comply with the precision of the precise time PT. Therefore, the full potential of the precise time PT cannot be utilized in relation to the data processors DP 1 . It should be noted that the precise time PT may still be used to synchronize data processors DP 1 but the precision of data processors DP 1 cannot be better than the precision of the hardware and/or software of data processor DP 1 . See further explanation of precision in relation to the description of FIG. 4 a - 4 g.
By synchronizing data processors DP 2 of elements of the second category 2 C based on a precise time PT from time synchronization arrangement TSA measurements may be obtained with a precision reflecting the precision of this precise time PT. In relation to measurements it should be noted that measurements may be time stamped with a time and date which may in post-analysis be valuable information.
Such measurements may e.g. be used in statistics or analyses e.g. of performance of a wind turbine or fault distribution in a wind power system, testing of e.g. a wind turbine, as basis for controlling the wind turbine, etc.
The illustrated wind power plant WPP comprises a plurality of data processors DP 1 , DP 2 which may be categorized according to the performance e.g. precision of the data processors. In the embodiment illustrated on FIGS. 3 c and 3 d the data processors DP 1 , DP 2 are divided into a first category 1 C and a second category 2 C.
It should be noted that, according to the invention, it is possible to have a plurality of categories and that not all data processors have to be categorized. The categories first 1 C and second 2 C are used to distinguish between data processors capable of meeting different requirements in relation to precision. Hence, second category 2 C data processors DP 2 may process data more precisely than first category 1 C data processors DP 1 .
Categorizing of data processors DP in wind power plants WPP is advantageous e.g. in relation to wind power plant control. This is because today's wind power plants and wind turbines are dynamical in the sense that new wind turbine models are developed, control units of existing wind turbines are replaced with new control units, existing wind power plants are expanded so that different wind turbine models or even wind turbines from different manufacturers are located within the same wind power plant. Therefore, within the same wind power plant or wind turbine, data processors capable of meeting different precision requirements are used.
Typically, at the time a wind turbine is erected, data processors of such new wind turbine would be fast and precise and therefore according to the example above part of the second category 2 C data processors DP 2 . If such a wind turbine is added to an existing wind power plant with wind turbines having first category 1 C data processors DP 1 , this wind power plant WPP would comprise data processors DP 1 , DP 2 of both categories.
The same is applicable for an existing wind power system comprising a control element where data processors of such a control element would be first category 1 C data processors DP 1 . If such a control element is replaced with a new control element e.g. because of defects, data processors DP 2 in the new control element would typically be of the second category 2 C. Hence, the existing wind turbine would then comprise both first category 1 C data processors DP 1 and second category 2 C data processors DP 2 .
Of course the categorizing of data processors into e.g. a first and second category 1 C and 2 C does not solely depend on whether a data processor is replaced or not. A new wind turbine may comprise data processors of different precision; hence, data processors of a wind power plant comprising all new wind turbines may also be categorized into more than one category.
Preferably it is the manufacturing date of the data processors, version of firmware; performance, etc. which decides to which category the data processor belongs. According to an embodiment of the invention, the categorization into one or more categories of data processors may be done manually by selecting the desired data processors of a wind power system and testing or by look-up tables defining the category of this data processor.
The control of a wind power system as described above having both first and second category 1 C, 2 C data processors DP 1 , DP 2 could be optimized by using differentiated control of the wind power system. Where the data processors of the wind power system may be controlled based on which category the data processors belongs to.
It should be noted that the control of a wind power plant WPP according to the invention having more than one category of synchronized data processors may be controlled completely as a wind power plant WPP without categorization of synchronized data processors. The categorized and synchronized data processors may lead to controlling the wind power plant according hereto and at least in certain situations this may be advantageous. This is e.g. because precise measurements may be obtained synchronous in a plurality of wind turbines e.g. for control or analysis, activating actuators fast and precise e.g. in relation to reduction of mechanical stress, respond and analysis on faults within the wind power plant or from the grid, park wide control of energy production e.g. to be able to support the grid with reactive power in case of voltage drop, noise, etc.
As illustrated on FIG. 3 c the wind power plant WPP is connected to the grid GD. The wind power plant WPP comprises wind turbines WT 1 of the first category 1 C and wind turbines WT 2 of the second category with data processors DP 1 and DP 2 , respectfully. Therefore, it is possible to perform time critical control of and measurements on elements of the second category 2 C more precisely than similar control and measurements on elements of the first category 1 C.
In wind power plants WPP as illustrated on FIG. 3 c faults such as short cut, stroke of lightning, grid fault, etc. may occur.
If a grid disturbance (event or fault), resulting in e.g. a change to the amplitude or frequency of the fundamental voltage on the grid, occurs in the grid GD, some or all power converters in the wind power plant WPP may be able to support the grid GD with highly synchronized control of e.g. increased or decreased active or reactive power. The wind power plant WPP has to react rapidly and precisely upon detection of disturbance in the grid voltage, preferably within one period of the frequency of the fundamental voltage on the utility grid, i.e. faster than 10-15 ms. Preferably disturbances in the grid voltage are measured at the point of common coupling PCC.
In an embodiment of the invention the wind turbines WT 2 of the second category 2 C comprises date processors DP 2 with jitter less than 0.5 microsecond and at the same time these data processors DP 2 may be able to process data faster than 1 microsecond. This should not necessarily be understood literal, the second category 2 C data processors DP 2 may also simply enable activation of one or more control outputs at a precise point in time with reference to the precise time PT. Hence the second category 2 C data processors DP 2 is able to finish processing of e.g. a control output in due time before activation and this does not necessarily entail execution or processing of data faster than one microsecond.
It should be noted that the mentioned jitter in the data processor may be the total jitter occurring from different sources such as clock generating circuitry CGC, thermal heat, latencies in electrical or mechanical structure of the data processor, etc.
Another example of the advantages in having a group of fast and precise data processors which can be controlled individually from other data processors is in case of tracking the origin of a fault in the wind power plant WPP.
If the data processors DP 2 of wind turbines WT 2 of the second category 2 C have a data processing speed which is faster and a precision which is better than the distribution of a fault occurring within a wind power plant WPP, it is possible to log time, data and other parameters when the fault is detected in each wind turbine WT 2 and thereby a better opportunity to analyze and learn from such fault is obtained. Hence, in the first wind turbine the fault is registered at time T 0 , in the neighboring wind turbines at T 1 , and soon.
It should be noted that the term data processing includes both software and hardware processing of data. In situations where e.g. a precise high speed time stamping of data is required, it may be preferred to execute such precise high speed time stamp by hardware.
Another example of the advantages in having a group of fast and precise data processors DP 2 which can be controlled individually from other data processors DP 1 is in situations where a wind turbine WT has to be decoupled from the power producing part of the wind power plant WPP. It is preferred to do so when the sinusoid output from the wind turbine WT is zero to minimize emission of noise due to the decoupling of the wind turbine WT. The decoupling may be controlled by the power converter PC within the individual wind turbine WT and according to the invention with a precision reflection the precise time PT.
Furthermore it should be noted that because of the precise reference signal it may be possible to predict the characteristics of emitted noise, e.g. harmonics on a sinusoidal signal, and thereby use the power converters PC to shape harmonics on a sinusoidal signal which are compensating harmonics occurred in other wind turbines WT in the wind power plant WPP.
Another example of the advantages in having a group of fast and precise data processors which can be controlled individually from other data processors is in control of the sinusoidal power output form a wind turbine WT. The sinusoidal output is shaped by the power converter PC and depending on time of switching of the switches the frequency, phase angle, amplitude, etc. of the output can be controlled.
In the wind power plant WPP illustrated in FIG. 3 d the data processors are divided in a plurality of categories (1, 2, . . . , n) of data processors DP 1 , DP 2 , . . . , DPn and illustrated also is data processors which are not categorized DPno. The different categories comprise data processors with different characteristics e.g. from high precision data processors DP 2 in category 2 2 C to the data processors DPno which is not categorized e.g. based on poor precision.
The elements, such as wind turbines WT and substations SUB of the wind power plant WPP; each comprises data processors from different categories.
It should be noted in relation to FIGS. 3 c and 3 d that more than one reference signals also referred to as precise time PT or clock signal may be distributed within the wind power plant WPP and may be used as basis for control and synchronization of data processors. In the same way non-categorized data processors and data processors from different categories may all use the same reference signal such as the precise time PT or other clock signals.
Furthermore, it should be mentioned that if data processors are categorized based on other parameters than precision, the same data processor might be in more than one category. The same data processor might then be both in one category defining very precise data processors and a further category defining data processors processing data with a very high frequency. In this situation the central controller CC of the wind power plant WPP may, as response to a grid fault, control the wind turbines by using one or more of the categories of data processors.
The categorizing of data processors according to the invention as described above may be done by sending a signal from the central controller CC to the data processor which precision needs to be found and then use information in/from a response from the data processor to categorizing.
Another method of categorizing the data processors in existing wind power systems could be a computer with software developed to test the data processor connected to the data processor and thereby testing and obtaining information of the data processor.
When replacing a unit comprising a data processor, the unit with the new data processor may be tested before installing it in the wind power system.
The above methods may of course be supplements to the manufacturer's information of the performance of the data processor when categorizing the data processors.
It should be noted that the characteristics such as precision of the data processors, for categorizing the data processors, may also be found by other methods than described above.
It should be noted that the synchronous data processors may be used to synchronize aviation light.
FIG. 4 a - 4 g illustrates what is understood as jitter and precision according to the invention, by means of the illustrated signals extending in the time.
In a data communication channel such as a data communication network DCN, propagation delay occurs because of the physical distance between the time synchronization arrangement TSA and the data processors DP. Hence, from the time the precise time PT is transmitted from the time synchronization arrangement TSA to the time it is registered at a data processor DP a delay occurs.
To align such delay and thereby obtain a time domain in the data processors, in phase with the precise time PT from the time synchronization arrangement TSA, a time protocol such as e.g. IEEE-1588 may be used to distribute the precise time PT.
Whether time protocol IEEE-1588, a new developed time protocol or a cluster of clock generating circuitries CGC is used, the time protocol may comprise built-in mechanisms for aligning the phase or time of the internal ticks of each data processor with the precise time signal.
Such mechanisms may depend on the used protocol and may be software as well as hardware supported, where the hardware supported mechanisms typically is the most precise. In one example, software supported mechanisms may ensure a precision better than ±100 μs and hardware supported mechanisms better than ±100 ns.
Based on the signals illustrated in FIG. 4 a - 4 h the understanding of jitter in relation to the present invention is described. Jitter in a data processor is, according to the present invention, understood as a time-varying displacement of the rising or falling edges of the internal clock of the data processor DP compared with the rising or falling edges of the desired ideal clock e.g. the precise time PT signal from the time synchronization arrangement TSA or a clock derived from it. Accordingly, the length of two adjacent clock periods is varying which is why this jitter is sometimes also referred to as cycle-to-cycle jitter.
The Unit Interval is often used for defining the jitter, and does so by defining the jitter of a clock in a data processor in terms of a fraction of the ideal clock to which the data processor clock is synchronized.
FIG. 4 a illustrates one definition of an allowable unit interval in relation to one period of a clock signal e.g. the internal clock or ticks of a data processor DP. Jitter in the illustrated clock signal may occur within the hatched area J, hence, allowable jitter in relation to this clock signal is ⅛ of the period signal.
Of course jitter may also be defined by absolute units such as e.g. micro-, nano- or picoseconds or in terms of degrees or radians.
It should be underlined that the signals illustrated throughout FIGS. 4 a - 4 h are for illustrative purpose only and therefore in relation to other signals a period may e.g. be from transition to transition. Furthermore, the size of the illustrated jitter is very large compared to the illustrated signals and because the FIGS. 4 a - 4 h is for illustrative purposes only.
In FIGS. 4 a - 4 h the jitter J, J 1 , J 2 , JPT, JDP, JS, JF is illustrated schematically as a hatched area which might indicate that the illustrated jitter is deterministic. This may also be the case, but often the jitter occurs randomly in a Gaussian distribution centered around the expected ideal edge of the clock signal.
The signals PT, IT, IT 1 , IT 2 illustrated on FIG. 4 a - 4 d are all in phase, hence, the first edges of the mentioned signals are all at time T 0 , second edge at time T 1 , etc. Again this is for illustrative purposes; the signals IT, IT 1 and IT 2 referring to the precise time signal PT may be divided so that the frequency of these signals are lower than the frequency of the precise signal PT. Also the signals IT, IT 1 and IT 2 may be a multiplication of the precise signal PT resulting in a frequency higher than the precise signal PT.
FIG. 4 b illustrates a precise time PT originating from the time synchronization arrangement TSA; hence, this precise time PT may be interpreted as a global master clock to which the internal clocks/internal ticks of the data processors DP are synchronized. The precision time signal PT is here illustrated as an ideal signal without jitter.
FIG. 4 c illustrates a signal representing the internal clocks or ticks IT of a data processor DP. As described above, the precise time PT from the time synchronization arrangement TSA and the precise time protocol ensures that the precise time PT and the internal ticks IT are synchronized and in phase.
The reference signal is created based on the precise time protocol can be said to control jitter due to its ability to establish a low jitter global precise time PT in a wind power system, but the reference signal cannot remove jitter entirely because the data processors run with separate internal clocks that are not in phase.
Therefore what cannot be controlled by the time protocol is jitter occurring in the data processors e.g. in relation to the rising edge of the internal tick IT which according to the illustrated example is expected simultaneously with the rising edge of the precise time PT from FIG. 4 b . In FIG. 4 c jitter occurs twice; at time T 2 and T 5 . Because of the illustrated jitter, the rising and falling edges at T 2 and T 5 are not synchronous with the edge on the precise time PT illustrated in FIG. 4 b . The hatched areas J between the time where the rising edge was expected T 2 and the time the rising edge actually occurred T 2 J is uncertainty introduced by the data processor and this is defined as jitter occurring in the data processor. Hence, the precision of control or measurement initiated by this data processor cannot be more precise than jitter allowed in the data processor.
FIG. 4 d illustrates the precision of the internal tick IT 2 of data processors of the second category 2 C and FIG. 4 e illustrates the precision of the internal tick IT 1 of data processors of the first category 1 C. Again it should be remembered that the ratio between jitter and period (unit interval) is illustrated as very large compared to unit interval in data processors used in wind turbines.
FIGS. 4 d and 4 e illustrate requirements to be met by data processors of the first category 1 C and the second category 2 C, respectfully. Data processors of the second category 2 C have to be more precise (less jitter) than data processors of the first category 1 C. This is illustrated by the fact that the area J 2 defining allowable jitter of data processors of the second category 2 C is less than the area J 1 defining allowable jitter in data processors of the first category 1 C.
FIG. 4 f illustrates the effect of synchronizing a data processor DP with a poor precision with a precise time PT having a high precision. In this situation the limit for jitter in the output signal reflects the limit for jitter in the data processor DP because jitter in the precise time signal PT is very small compared to the jitter in the data processor DP and can therefore be ignored. Hence, even though a high precision signal is fed to the data processor DP, the data processor DP is not capable of utilizing the full potential of this precise signal when processing data, initiating control or measurements, etc.
This is illustrated in FIG. 4 f . The area JPT representing the allowed jitter in the precise time PT is smaller than the area JDP representing the allowed jitter in the output signal OS from the data processor. If the allowed jitter in the data processor DP is larger than the allowed jitter in the precise time PT, the jitter in the output signal OS is determined by the allowed jitter in the data processor DP.
Accordingly, if the allowed jitter in a data processor was less than the allowed jitter in the precise time PT, the precise time PT was determining for the jitter in the output signal OS.
In the situation where jitter in the precise time signal PT and in the data processor DP cannot be ignored the worst case resulting jitter can be an addition of jitter in the precise time signal PT and jitter in the data processor PD.
According to an embodiment of the invention, the frequency of the precise time signal, internal ticks of the data processors, etc. may remove the focus on jitter. FIG. 4 g illustrates a low-frequency signal LFS with almost no jitter JS and FIG. 4 g illustrates a high-frequency signal HFS with no requirements to jitter JF, both signals may represent internal ticks in a data processor.
Even though the result is that jitter JF allowed in the signal LFS illustrated in FIG. 4 h is larger than jitter JS allowed in the signal HFS illustrated in FIG. 4 g , the data processor having the internal ticks illustrated in FIG. 4 h may process data, initiate control or measurements more precisely than the data processor having the internal ticks illustrated on FIG. 4 g . Simply because there are so many rising edges in the high-frequency signal HFS that even with the large jitter JF more periods occur than in the low frequencies. Thereby it is possible for the data processor using the high-frequency signal HFS to initiate e.g. control or measurements more precisely or closer to the desired point in time of control or measure than the data processor using the low-frequency signal LFS with less periods.
When a control instruction is to be carried out at the same time in a plurality of data processors, it is preferred to have precise internal ticks inside the data processor because the less jitter the more synchronous the control is carried out by the plurality of data processors.
When a measurement is to be registered in a plurality of wind turbines e.g. to locate a fault, it is preferred to have a fast signal even though this signal has a large jitter. This is because the fast non-precise data processor has more edges on which measurements can be registered than the slow precise data processor.
It should be noted that in practical use data processors with low jitter is preferred to process data relating to time critical control and measurement.
In relation to the above, it should be mentioned that a large or a small jitter is referred to in the time; hence, a large jitter would typically be understood as many microseconds relative to the time of one period of the signal.
It should be mentioned that anti-jitter circuits may be designed to reduce the level of jitter in the internal clock of a data processor, to make a data processor DP able to comply with precision demands, which was not otherwise possible. An anti-jitter circuit may operate by re-timing the output pulses so they align more closely to an idealized pulse signal, examples of anti-jitter circuits include phase-locked loops, delay-locked loops, etc. Furthermore, different uses of buffers may be used to reduce the level of jitter.
According to the invention the embodiments described in relation to the figures illustrated in FIGS. 1-4 h can be combined in any combination.
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Method of controlling a wind power system comprising a plurality of system elements, the wind power system including a plurality of data processors distributed in the system elements, the method includes the steps of: synchronizing at least a part of the data processors to at least one reference signal distributed to the data processors from a time synchronization arrangement, associating the data processors with local clock generation circuitries, wherein the local clock generation circuitries associated with data processors of a first subset of the data processors have a peak-to-peak tracking jitter higher than or equal to a predetermined threshold value and wherein a second subset of the data processors have a peak-to-peak tracking jitter less than the predetermined threshold value, controlling at least one of said system elements at least partly by mechanism of a data processor from said first or second subset of data processors.
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BACKGROUND OF THE INVENTION
[0001] 1. FIELD OF THE INVENTION
[0002] The present invention relates to frame detection and generation and, more particularly, to processing multiple independently-clocked data streams.
[0003] 2. DESCRIPTION OF THE RELATED ART
[0004] Digital data transmission systems include facilities for frame detection and frame generation. In general, there are two approaches in the prior art for processing the individual data streams.
[0005] In a first conventional method, the frame detection and frame generation facilities are placed in directly in each data path in order to preserve the timing of the individual data streams. However, this requires replication of facilities and requires multiple, independent clock domains.
[0006] Another conventional approach uses state machine logic to handle multiple data streams by preserving the state of individual data streams in static RAM (random access memory). As used herein “state” or “context” of data streams refers to system register settings of a particular data stream. Each stream is typically processed as follows: (a) the prior state of the state machine is loaded out of RAM; (b) the stream is processed; (c) the current state is saved again; (d) the result is output from the state machine. While this approach is relatively efficient in terms of chip size, it does not preserve the timing of individual data streams.
[0007] There is therefore a need for an improved framer array architecture that preserves the timing of individual data streams and requires relatively less chip space.
SUMMARY OF THE INVENTION
[0008] These and other drawbacks in the prior art are overcome in large part by a system and method for frame detection and generation according to the present invention. Briefly, each incoming clock-data stream is divided into two independent data streams: a clock path which preserves the timing of the individual cock domains and a data path which multiplexes an arbitrary number of data streams onto a parallel path or bus. A framer unit is provided to store and update the context of the data streams and to align the data stream to the bus.
[0009] The system may be implemented with synchronous logic operated with a high speed system clock. In particular, incoming data is synchronized to a common clocking domain, converted into a parallel format and forwarded via an internal bus to the outgoing port with a fixed delay. A framer array searches for the frame begin of each individual data stream and adds this information to the data stream. Finally, the data streams are aligned to the internal bus.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] A better understanding of the invention is obtained when the following detailed description is considered in conjunction with the following drawings in which:
[0011] [0011]FIG. 1 is a block diagram of a system according to an implementation of the invention;
[0012] [0012]FIG. 2 is a diagram illustrating frame alignment according to an implementation of the invention;
[0013] [0013]FIG. 3 is a state machine illustrating frame processing according to an implementation of the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0014] FIGS. 1 - 3 illustrate an improved frame detection and generation system. Signal streams are divided into a clock stream and a data stream. Each stream is processed independently. A framer unit is provided offset the path of the data streams to store and update the context of the data streams and to align the data stream to the bus.
[0015] Turning now to the drawings and, with particular attention to FIG. 1, a block diagram of a framer array according to an embodiment of the present invention is shown therein and identified by the reference numeral 100 .
[0016] Shown are a plurality of incoming clock-data pairs 101 a, 101 b for receiving data streams. While only two such pairs are shown, in practice, multiple clock-data pairs may be utilized. The clock-data pair may transport data according to the International Telecommunications Union (ITU) T1 or E1 Standards.
[0017] Each incoming data path includes a clocking branch 103 a, 103 b and a data branch 104 a, 104 b. The clocking branch includes timing options 102 a, 102 b for each data path. The timing options 102 a, 102 b may be any suitable circuitry, such as application specific integrated circuits (ASICs), for extracting the clocks from the respective paths and may perform various functions on the clock, such as de-jittering.
[0018] Each data branch 104 a, 104 b includes a synchronizer 106 a, 106 b for receiving the incoming data streams. The outputs of the synchronizers 106 a, 106 b are serial data streams synchronous to a system clock (not shown) and are provided to serial-to-parallel converters 108 a, 108 b. The outputs of the serial-to-parallel converters 108 a, 108 b are provided to a multiplexer 110 .
[0019] A stream arbiter 112 controls the output of the multiplexer 110 . As illustrated, each serial-to-parallel converter 108 a, 108 b is connected via a request signal line 109 a, 109 b to the stream arbiter 112 . Thus, once an incoming stream has been converted, the serial-to-parallel converter 108 a, 108 b sends a request along the request line 109 a, 109 b to the stream arbiter 112 . The stream arbiter 112 provides a grant signal 111 a, 111 b to each serial-to-parallel converter 108 a, 108 b according to a predetermined selection algorithm. The stream arbiter 112 may implement any of a variety of known selection algorithms, such as round-robin, and the like. The stream arbiter 112 may be implemented as one or more embedded controllers or processors or ASICs.
[0020] The multiplexer 110 outputs a stream identifier 134 and parallel data on the 9 bit wide internal data bus 136 . As will be described in greater detail below, the multiplexer 110 further receives an align signal 138 from a framer state machine 114 , which is used to align the incoming data to the 9-bit data bus 136 .
[0021] A framer state machine 114 and context RAM 116 are coupled to the stream identifier and stream control signal 134 and the 9-bit data bus 136 . As will be described in greater detail below, the framer state machine 114 operates on the data streams by loading and storing the context of individual streams in the context RAM 116 . “Context” is various information related to the data and streams. The framer state machine 114 identifies the start of frames of passing data streams using, for example, any of a variety of known search algorithms such as identifying a start of frame bit or buts. The framer state machine 114 further aligns the incoming data to the 9-bit data bus 136 , as will be described in greater detail below. The framer state machine 114 may also insert alarms, a framing pattern, or similar information by adding such information via a multiplexer 133 to the 9-bit data bus 136 . The framer state machine further outputs an octet identifier 135 to a demultiplexer 118 .
[0022] The modified outgoing data stream is demultiplexed with the demultiplexer 118 onto parallel-to-serial converters 120 a, 120 b. The demultiplexer 118 uses the stream identifier 134 to identify the correct stream for demultiplexing. The outputs of the demultiplexer 118 are provided to parallel-to-serial converters 120 a, 120 b for conversion back to serial format. The serialized data streams are then re-synchronized to their original clocks in the synchronizers 122 a, 122 b.
[0023] During operation, data is placed on the 9-bit data bus 136 together with a stream identifier and stream control signals 134 . When new data is placed on the internal bus, the framer state machine 114 loads the context of the stream to be processed. After processing of the data is finished, the framer state machine 114 stores the current context of the stream in its context RAM 116 .
[0024] The framer state machine 114 calculates the frame position of the new stream in any of a variety of known manners. If the framer array 114 finds the frame boundary of the data stream and the data stream is not aligned, the framer state machine 114 aligns the time slots of the incoming frames to the 9-bit data bus 136 . This is accomplished using the align signal 138 , which informs the serial-to-parallel converter 108 a, 108 b to provide, for example, nine bits during the next data transfer. Thus, time slots of the frame will be aligned in a maximum of seven data transfers as the time slot can be shifted one bit per transfer.
[0025] This process of frame alignment is illustrated more clearly with reference to FIG. 2. Shown are Time Slot 0 , Time Slot 1 , Time Slot 2 , and Time Slot 3 of an incoming frame.
[0026] During normal operation eight data bits are transported over the 9-bit data bus together with the respective stream identifier. As shown, the data bits transported over the 9-bit data bus 136 during the initial data transfer are misaligned to the incoming frame by one (1) bit. In particular, 210 shows a data transfer where bit 256 of a previous frame and bits 1 through 7 of the actual frame are transported over the 9-bit data bus 136 . After the next transfer 212 the framer state machine 114 finds the frame begin. The state machine 114 detects the misalignment as described above and then requests a nine bit data transfer via the align signal 214 in order to align the data to the 9-bit data bus 136 . 214 shows the following nine bit data transfer which aligns time slot 2 to the internal bus. If the frame and the time slot had been misaligned by more than one (1) bit, the process would repeat until the frame and time slot were aligned, as shown at 216 .
[0027] A state diagram of framer state machine handling of the E1 double frame format is shown in FIG. 3. After startup, the framer state machine is in an initial state 302 . When a data stream is enabled for operation, the framer state machine 114 enters a “Wait for 8” state 304 . This state is implemented to fetch the first byte from the internal bus. Afterwards, the framer state machine enters a “Search for FAS (first frame alignment signal)” state 306 . The framer state machine remains in this state as long as it hasn't found the frame alignment signal in the E1 stream. When found, the framer state machine 114 steps to the ‘Wait until second frame’ state 308 . When the beginning of the second frame is reached, the framer state machine 114 moves on to the ‘Verify Service Word’ state 310 . Here the framer state machine 114 checks the service word. If incorrect, it steps back into the ‘Search for first FAS’ state 306 . Otherwise it steps to the ‘Wait until third Frame’ state 312 . When the beginning of the third frame is reached, the framer state machine 114 steps forward to the ‘Verify second FAS’ state 314 where it checks again for the frame alignment signal. If incorrect, the framer state machine 114 goes back to the ‘Search first FAS’ state. Otherwise it goes forward to the ‘Step Phase’ state 316 . In this state, the framer state machine 114 checks if the octet structure of the E1 frame is aligned to the internal data bus. When aligned, the framer state machine 114 moves forward to the ‘Aligned’ state 318 . If the original stream is not aligned to the internal data bus, the framer state machine 114 remains in the ‘Step Phase’ state 316 until the stream is aligned. To align the stream, the framer requests nine bits of data until the octets (or time slots) of a frame are aligned to the 9-bit data bus. When aligned, the framer state machine 114 steps into the ‘Aligned’ state 318 . The framer state machine 114 remains in this state until it goes out of synchronization (i.e., not aligned any more). In this case, the framer state machine returns to the ‘Search first FAS’ state 306 , or the ‘Init’ state 302 when frame processing is disabled (framer turned off).
[0028] The invention described in the above detailed description is not intended to be limited to the specific form set forth herein, but is intended to cover such alternatives, modifications and equivalents as can reasonably be included within the spirit and scope of the appended claims.
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A system and method for frame detection and generation. Each incoming clock-data stream is divided into two independent data streams: a clock path which preserves the timing of the individual cock domains and a data path which multiplexes an arbitrary number of data streams onto a parallel path. A framer array structure implements a context swap and synchronizes the data streams.
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CROSS REFERENCE TO RELATED CASES
This application is a continuation-in-part of U.S. application Ser. No. 11/116,234, filed Apr. 28, 2005 now U.S. Pat. No. 7,855,074, which claims the benefit of priority of U.S. Provisional Application Ser. No. 60/565,846, filed Apr. 28, 2004 and 60/643,175, filed Jan. 13, 2005. This application also claims the benefit of priority of International Application No. PCT/US2005/014444, filed Apr. 28, 2005. Each of these applications is hereby incorporated by reference in their entirety.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH
This invention was made with government support under contract number NBCHC060058, awarded by the Defense Advanced Research Projects Agency, issued by the U.S. Army Medical Research Acquisition Activity, and administered by the U.S. Department of the Interior-National Business Center. The government has certain rights in the invention.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention is directed to a method for constructing an integrated artificial human tissue construct system and, in particular, construction of an integrated human immune system for in vitro testing of vaccines, adjuvants, immunotherapy candidates, cosmetics, drugs, biologics, and other chemicals. The artificial immune system of the present invention is useful for assessing the interaction of substances with the immune system, and thus can be used to accelerate and improve the accuracy and predictability of, for example, vaccine, drug, biologic, immunotherapy, cosmetic, and chemical development.
2. Background of the Technology
Despite the advent and promise of recent technologies, including combinatorial chemistry, high-throughput screening, genomics, and proteomics, the number of new drugs and vaccines reaching the market has not increased. In fact, the attrition rate within drug discovery programs exceeds 90%.
The introduction of these new (and expensive) technologies has not reduced the lost opportunity costs associated with immunotherapy development; rather, these costs have increased. Indeed, it is now estimated that almost $1 billion is required to bring a new drug to the market.
The development and biological testing of human vaccines has traditionally relied on small animal models (e.g., mouse and rabbit models) and then non-human primate models. However, such small animal models are expensive and non-human primate models are both expensive and precious. Furthermore, there are many issues regarding the value of such animal studies in predicting outcomes in human studies.
A major problem remains the translation from test systems to human immunology. Successful transfer between traditional testing systems and human biology requires an intricate understanding of disease pathogenesis and immunological responses at all levels. Given worldwide health problems caused by known and emerging infectious agents and even potential biological warfare pathogens, it is time for a fresh approach to understanding disease pathogenesis, the development and rapid testing of vaccines, and insights gathered from such work.
The body's distributed immune system can be roughly divided into four distinct compartments: tissues and blood, mucosal tissues, body cavities, and skin. Because of ease of study, most is known about the tissue and blood compartment and its lymphoid tissues, the spleen and lymph nodes.
The mammalian immune system uses two general adaptive mechanisms to protect the body against environmental pathogens. When a pathogen-derived molecule is encountered, the immune response becomes activated to ensure protection against that pathogenic organism.
The first immune system mechanism is the non-specific (or innate) inflammatory response. The innate immune system appears to recognize specific molecules that are present on pathogens but not within the body itself.
The second immune system mechanism is the specific or acquired (or adaptive) immune response. Innate responses are fumdamentally the same for each injury or infection; in contrast, acquired responses are custom-tailored to the pathogen in question. The acquired immune system evolves a specific immunoglobulin (antibody) response to many different molecules, or antigens, derived from the pathogen. In addition, a large repertoire of T cell receptors (TCR) is sampled for their ability to bind processed peptides from the antigens that are bound by major histocompatibility complex (MHC) class I and II proteins on the surface of antigen-presenting cells (APCs), such as dendritic cells (DCs).
Acquired immunity is mediated by specialized immune cells called B and T lymphocytes (or simply B and T cells). Acquired immunity has specific memory for specific antigens; repeated exposure to the same antigen increases the memory response, which increases the level of induced protection against that particular pathogen.
B cells produce and mediate their functions through the actions of antibodies. B cell-dependent immune responses are referred to as “humoral immunity” because antibodies are found in body fluids.
T cell-dependent immune responses are referred to as “cell-mediated immunity,” because effector activities are mediated directly by the local actions of effector T cells. The local actions of effector T cells are amplified through synergistic interactions between T cells and secondary effector cells, such as activated macrophages. The result is that the pathogen is killed and prevented from causing diseases.
The functional element of a mammalian lymph node is the follicle, which develops a germinal center (GC) when stimulated by an antigen. The GC is an active area within a lymph node, where important interactions occur in the development of an effective humoral immune response. Upon antigen stimulation, follicles are replicated and an active human lymph node may have dozens of active follicles, with functioning GCs. Interactions between B cells, T cells, and FDCs take place in GCs.
Various studies of GCs in vivo indicate that the many important events occur there, including immunoglobulin (Ig) class switching, rapid B cell proliferation (GC dark zone), production of B memory cells, accumulation of select populations of antigen-specific T cells and B cells, hypermutation, selection of somatically mutated B cells with high affinity receptors, apoptosis of low affinity B cells, affinity maturation, induction of secondary antibody responses, and regulation of serum immunoglobulin G (IgG) with high affinity antibodies. Similarly, data from in vitro GC models indicate that FDCs are involved in stimulating B cell proliferation with mitogens and it can also be demonstrated with antigen (Ag), promoting production of antibodies including recall antibody responses, producing chemokines that attract B cells and certain populations of T cells, and blocking apoptosis of B cells.
Similar to pathogens, vaccines function by initiating an innate immune response at the vaccination site and activating antigen-specific T and B cells that can give rise to long term memory cells in secondary lymphoid tissues. The precise interactions of the vaccine with cells at the vaccination site and with T and B cells of the lymphoid tissues are important to the ultimate success of the vaccine.
Almost all vaccines to infectious organisms were and continue to be developed through the classical approach of generating an attenuated or inactivated pathogen as the vaccine itself. This approach, however, fails to take advantage of the recent explosion in our mechanistic understanding of immunity. Rather, it remains an empirical approach that consists of making variants of the pathogen and testing them for efficacy in non-human animal models.
Advances in the design, creation and testing of more sophisticated vaccines have been stalled for several reasons. First, only a small number of vaccines can be tested in humans, because, understandably, there is little societal tolerance for harmful side effects in healthy people, especially children, exposed to experimental vaccines. With the exception of cancer vaccine trials, this greatly limits the innovation that can be allowed in the real world of human clinical trials. Second, it remains challenging to predict which immunodominant epitopes are optimal for induction of effective CD4 + and CD8 + T cell responses and neutralizing B cell responses. Third, small animal testing, followed by primate trials, has been the mainstay of vaccine development; such approaches are limited by intrinsic differences between human and non-human species, and ethical and cost considerations that restrict the use of non-human primates. Consequently, there has been a slow translation of basic knowledge to the clinic, but equally important, a slow advance in the understanding of human immunity in vivo.
The artificial immune system (AIS) of the present invention can be used to address this inability to test many novel vaccines in human trials by instead using human tissues and cells in vitro. The AIS enables rapid vaccine assessment in an in vitro model of human immunity. The AIS provides an additional model for testing vaccines in addition to the currently used animal models.
Attempts have been made in modulating the immune system. See, for example, U.S. Pat. No. 6,835,550 B1, U.S. Pat. No. 5,008,116, WO 2004/101773 A1, Suematsu et al., [ Nat Biotechnol, 22, 1539-1545, (2004)] and U.S. Patent Application No. 2003/0109042.
Nevertheless, none of these publications describe or suggest an artificial (ex vivo) human cell-based, immune-responsive system comprising a vaccination site (VS) and a lymphoid tissue equivalent (LTE). The present invention comprises such a system and its use in assessing the interaction of substances with the immune system.
SUMMARY OF THE INVENTION
The present invention is directed to artificial immune systems comprising cell cultures of B cells, T cells and antigen-primed dendritic cells.
The present invention is also directed to methods for detecting an immune response to an antigen using the cell cultures of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 : Shows the detection of tetanus-specific antibody responses by ELISPOT and determination of the percentage of antigen-specific B cells using a 2D T and B cell co-culture.
FIG. 2 : Depicts tetanus toxoid: B cell proliferation and comparison between PBMC and 2D T and B cell co-culture.
FIG. 3 : Shows the flow cytometry data indicating B cell proliferation between PBMC and 2D T and B cell co-culture for the same cell donor shown in FIG. 2 .
FIG. 4 : Depicts tetanus toxoid-specific ELISPOT comparing PBMC to 2D T and B cell co-culture for the same cell donor shown in FIGS. 2 and 3 .
FIG. 5 : Shows an in vitro system representative of the physiological state promotes stronger B cell proliferative and tetanus toxoid-specific antibody responses, using a 2D co-culture of T and B cells and TT-pulsed DCs.
FIG. 6 : Depicts tetanus-specific antibody responses to a DTaP (diphtheria and tetanus and acellular pertussis vaccine, adsorbed) vaccine and a simple tetanus toxoid Antigen, using a 2D co-culture of T and B cells and TT-pulsed DCs.
FIG. 7 : Shows the influence of vaccine versus antigen in a lymphoid tissue equivalent (LTE) for the same cell donor shown in FIG. 6 .
FIG. 8 : Depicts Strong B cell and T cell proliferative responses seen against C. albicans , associated with potent activation (HLA-DR high , CD86 high ) of the dividing B cells using a 2D co-culture of T and B cells and TT-pulsed DCs.
FIG. 9 : Shows specificity of the C. albican -stimulated B cells demonstrated by ELIPSOT for the same donor in FIG. 8 . C. albicans -specific ELISPOT data comparing compares the 2D co-culture of T and B cells with PBMCs.
FIG. 10 : Depicts antibody responses when some of the leukocytes are removed.
FIG. 11 : Shows in vitro antigen-specific antibody response to influenza.
FIG. 12 : Shows T and B cell proliferation induced by H1N1 influenza.
DETAILED DESCRIPTION OF THE INVENTION
The present invention concerns the development of accurate, predictive in vitro models to accelerate vaccine testing, allow collection of more informative data that will aid in redesigning and optimizing vaccine formulations before animal or clinical trials, and raise the probability that a vaccine candidate will be successful in human trials. More specifically, the present invention comprises controlling the nature and state of the cells in the lymphoid tissue equivalent (LTE, artificial lymph node) of the artificial immune system (AIS).
The AIS can be used to test vaccines and other pharmaceuticals for immune reactivity in a manner that is more predictive than animal experiments. Consequently, it can provide valuable pre-clinical data earlier in the research and development process. Antigenic molecules introduced to the AIS are acquired by dendritic cells (DCs) at the vaccination site (VS). The DCs are then transferred to the lymphoid tissue equivalent (LTE), where they present the antigen to T cells, activating their immune function. Activated helper T cells co-stimulate B cells to induce antibody production, while activated cytotoxic T cells lyse antigen-bearing cells. Solubilized antigen(s) can also be introduced into the LTE to directly activate B cells for subsequent antibody production.
While a number of published reports have demonstrated antigen-specific B cell responses (to C. albicans , TT, and other antigens) in vitro, these results are typically achieved by stimulating and restimulating cultures of whole PBMCs with antigen and exogenous factors to boost B cell proliferation and/or activation.
The present invention comprises the detection of antibody responses using defined cultures of B cells, T cells, and DCs and optionally follicular dendritic cells (FDCs), in 2-dimensional construct assay. The presence of secondary cells provides a more physiological environment for B cell activation and differentiation, such that artificial factors in the cultures are not necessary to detect specific antibody responses.
Using embodiments of the present invention, we have generated antigen-specific B cell responses using a 2-dimensional (2D) co-culture system comprising T cells, B cells, and antigen-pulsed DCs. In the examples, responses were generated against tetanus toxoid (TT) and a whole protein extract of Candida albicans ( C. albicans ). The results from these examples show that culturing human T and B cells together in vitro at a ˜1:1 ratio, versus the ratio of T and B cells naturally found in the blood, gave stronger antigen responses, by both analysis of activation and proliferation (flow cytometry) and antibody production (ELISPOT). Although the preferred ratio of T cells:B cells is ˜1:1, the ratio of T cells:B cells can range from ˜1:10 to ˜10:1. In the cultures of the examples, “T cells” included both CD4 + and CD8 + T cells. In peripheral blood, the T (total T cells):B cell ratio is ˜7:1. In the lymph node, the T (total T cells):B cell ratio is ˜1:1.6. In the germinal center, the T cell:B cell ratio is ˜1:8, and there the T cells are primarily CD4 + T cells.
In the results of the experiments shown, engineered serum-free media (X-VIVO) was used, though we have also used serum (e.g., human, bovine) in other experiments (data not shown). Dendritic cells (DCs) were generated from CD14-purified monocytes that were cultured for ˜7 days in X-VIVO 15 media, supplemented with GM-CSF (˜100 ng/ml) and IL-4 (˜25 ng/ml). The cytokine-derived DCs were pulsed with antigen or vaccine and then cocultured with T and B cells. After adding the antigen-prepulsed dendritic cells to the cell culture, further soluble antigen can also be added to the cell culture. For PBMC cultures, either the antigen was added to the assay, or antigen-pulsed DCs were added to the assay. In FIGS. 1 to 9 , antigen-pulsed DCs were added to the co-culture of T and B cells, while soluble antigen was added to the PBMC cultures. FIG. 9 shows a comparison of the co-culture to PBMCs, with antigen-pulsed DCs added to both systems.
EXAMPLES
These experiments provide a direct comparison of PBMCs versus a co-culture of negatively selected T and B cells that were plated at a ˜1:1 ratio in—in these examples—a 96-well, round bottom plate. All assays were harvested on day 7 of in vitro culture. All experiments were analyzed by ELISPOT for antibody production and by flow cytometry for proliferation, as determined by loss of CFSE. In the ELISPOT assays because there were different ratios of T and B cells in the PBMC culture compared with the TB-2D cultures, there were fewer B cells plated into the ELISPOT wells. However, in the experiment in FIG. 4 , the numbers of B cells used in the ELISPOT experiments for both the PBMC and co-culture assays were approximately equal. We determined the approximate number of B cells in the ELISPOT wells by flow cytometry to enable comparisons.
These results show that culturing human T and B cells together in vitro at a ˜1:1 ratio compared to the ratio of T and B cells naturally found in the blood give stronger antigen responses, by both analysis of activation and proliferation (flow cytometry) and antibody production (ELISPOT).
Example 1
B and T cell co-culture with tetanus toxoid, showing the ability to detect tetanus-specific antibody responses ( FIG. 1 ).
Example 2a
PBMC versus co-culture, using a tetanus toxoid antigen. Even though similar B cell proliferation responses were seen in PBMC and 2D T and B cell co-cultures ( FIGS. 2 , 3 ), an improved tetanus toxoid-specific antibody response was observed in a T and B cell co-culture LTE, as compared with PBMC cultures ( FIG. 4 ).
Example 2b
PBMC versus co-culture, using Candida albicans antigens. FIG. 9 shows C. albicans -specific ELISPOT data, comparing TB-2D to PBMCs. In this experiment, DCs were pulsed with TT antigen only, but the ELISPOT was conducted on both TT- and C. albicans -coated plates.
Example 2c
PBMC versus co-culture ( FIG. 10 ). In this example we addressed the question of what happens if we take cells from an apparent “non-responder” and use only the GC cells from the leukocytes. Note the response when some of the leukocytes are removed ( FIG. 10 ); non-responders in vitro now show an antibody response.
Here, we used human CD4 + T and B cells with FDCs and formed GCs in vitro and then examined whether IgG production could be obtained against a recall antigen. Specifically, we used tetanus toxoid (TT) in these experiments and isolated human B cells and CD4 + T cells from peripheral blood.
We observed IgG recall responses using only the T cells, B cells, and FDCs that are typically found in GCs. In contrast, in the presence of PBL cells not normally in found in GCs, no antibody response was detectible in cells from some donors. These results show that removing (not including) other cells, such NK cells, monocytes, and CD8 + T cells, improved the IgG response.
Example 3
In vitro system representative of the physiological state promotes higher B cell proliferative and tetanus toxoid-specific antibody responses following tetanus vaccination ( FIG. 5 ). The post tetanus toxoid experiment was conducted 5 weeks following vaccination. The tetanus antibody titer before vaccination was ˜40 μg/mL; after vaccination it was ˜300 μg/mL. T cells represent both CD4 + and CD8 + T cells. Peripheral blood has a T:B ratio of ˜7:1 (total T cells). The lymph node has a T:B ratio of ˜1:1.6 (total T cells). The germinal center has a T:B ratio of ˜1:8 (primarily CD4 + T cells).
Example 4
Use of a vaccine to elicit in vitro immune responses in a co-culture of T and B cells ( FIGS. 6 and 7 ). DCs were pulsed with the vaccine or the tetanus toxoid antigen and were then added to the co-culture of T and B cells. Tripedia® (diphtheria and tetanus toxoids and acellular pertussis vaccine, adsorbed; DTaP), for intramuscular use, is a sterile preparation of diphtheria and tetanus toxoids adsorbed, with acellular pertussis vaccine in an isotonic sodium chloride solution containing thimerosal (preservative) and sodium phosphate (to control pH). After shaking, the vaccine is a homogeneous white suspension. Tripedia® vaccine is distributed by Aventis Pasteur Inc.
Example 5
To detect antigen-specific antibody responses, we developed an ELISPOT approach to quantify B cell responses (antigen specificity) on a per cell basis. In this example, T cells were cultured with B cells at a ˜1:1 ratio, with cytokine-derived DCs included at a DC:T and B (total) cell ratio of ˜1:60. Soluble TT (˜1 μg/ml) or C. albicans (˜10 μg/ml) was included for the entire 7-day culture, while other wells received pokeweed mitogen (PWM; a strong, non-specific lymphocyte stimulator) for the final 3 days of the culture.
On the seventh day, the lymphocytes were examined for marker expression and CFSE profiles by flow cytometry and the frequency of TT and C. albican -specific B cells was calculated by ELISPOT. Briefly, ˜30×10 3 total lymphocytes were plated in duplicate wells of an ELISPOT plate that had been pre-coated with TT, C. albicans , or anti-immunoglobulin (Ig, to gauge total antibody production).
The cells were then serially diluted five times at a ˜1:3 ratio and PWM was added to all wells to trigger antibody production. The cells were then incubated for ˜5 hr at 37° C. in a 5% CO 2 incubator and washed away. Plate-bound antibody was detected using techniques similar to those required for ELISA.
The results in FIG. 8 demonstrate strong B cell and T cell proliferative responses against C. albicans , associated with potent activation (HLA-DR high , CD86 high ) of the dividing B cells. Furthermore, a subset of the most divided B cells appears to have acquired a memory phenotype, indicated by increased CD27 expression.
The lack of a robust response against TT was consistent with the weak serum TT titer for this donor (˜4 μg/ml). As expected, PWM triggered potent T and B cell proliferative responses, though not as many divisions were seen as with specific antigen stimulation, likely because the cells were only cultured with the mitogen for 3 days.
The specificity of the C. albicans -stimulated B cells was demonstrated by ELIPSOT ( FIG. 9 ). This experiment suggests that a 1× stimulation with C. albicans did give rise to a small population of antibody-producing cells (˜0.2% of total B cells) that was not detected in untreated cultures or those stimulated with TT (left and middle wells). This discrepancy between the frequency of proliferating cells and C. albicans -specific B cells detected by ELISPOT could be the result of several factors. A likely explanation is that we used a crude C. albicans whole antigen extract containing ˜19% carbohydrates (by weight). While C. albicans polysaccharides are strong inducers of B cell responses, only protein antigen-specific responses would be detected in the ELISPOT assay.
Example 6
Tetanus-specific antibodies were detected in another ELISPOT experiment where the cell donor's serum anti-tetanus level was higher (63 μg/ml), and DCs were cultivated in XVIVO-15 medium. All other components, concentrations and ratios were left unchanged, except that of the number of cells deposited per ELISPOT well was increased; the higher number used was ˜1×10 5 cells/well.
In this experiment, both TT- and C. albicans -specific antibodies were observed (up to 48 and 33 spots per well, respectively), although a high level of non-specific response, especially in the presence of CCL21/anti-CD40 additives, did not allow a firm conclusion in favor of antigen-specific versus mitogenic activity.
Example 7
The specificity of the C. albicans -stimulated B cells was demonstrated by ELIPSOT ( FIG. 9 ) for both PBMC and 2D co-culture of T and B cells with C. albicans -pulsed DCs added to both systems. This experiment indicates that even if the PBMC cultures have antigen-pulsed DCs added that the co-culture system shows a stronger antibody response, as determined by ELISPOT.
Example 8
In vitro antigen-specific antibody response to influenza ( FIG. 11 ) and T and B cell proliferation induced by H1N1 influenza ( FIG. 12 ). DCs were treated (or not) with H1N1 (New Caledonia) influenza. 2D cultures of DCs and T and B cells were stimulated (or not) with ‘soluble’ H1N1 influenza. As can be seen, there was antigen-specific proliferation of T and B lymphocytes and generation of antigen-specific antibody secreting B lymphocytes (ELISPOT data). Note the largest (apparently synergistic) response was observed when we pulsed the DCs with antigen and then added soluble antigen to the DC/T and B cell cultures, to activate the B cells, which are antigen-presenting cells (APCs). Again, the T and B cell co-culture is superior to PBMC cultures.
While the foregoing specification teaches the principles of the present invention, with examples provided for the purpose of illustration, it will be appreciated by one skilled in the art from reading this disclosure that various changes in form and detail can be made without departing from the true scope of the invention.
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The present invention relates to methods for preparing an artificial immune system. The artificial immune system comprises a cell culture comprising T cells, B cells and antigen-primed dendritic cells. The artificial immune system of the present invention can be used for in vitro testing of vaccines, adjuvants, immunotherapy candidates, cosmetics, drugs, biologics and other chemicals.
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TECHNICAL FIELD
[0001] The present disclosure relates to a nonwoven fabric, and to an absorbent article comprising the nonwoven fabric as a top sheet.
BACKGROUND ART
[0002] As the basic performance of absorbent articles, such as sanitary napkins and panty liners has continued to improve with technological development over many years, leakage after absorption of excreta, such as menstrual blood has become a less frequent occurrence than in the past, and research is currently ongoing with the aim of achieving even higher performance, including a feel similar to underwear, and smoothness of the top sheet even after absorption of excreta, such as menstrual blood.
[0003] Menstrual blood during menstruation, in particular, can also contain components of the endometrium which are highly viscous, and the top sheet preferably remains smooth and stick-free even after absorption of such highly viscous menstrual blood. Highly viscous menstrual blood usually remains on the top sheet in the form of masses, generally leaving the user with a visually unpleasant image, and therefore from this viewpoint as well it is preferred for no highly viscous menstrual blood to remain on the top sheet.
[0004] Nonwoven fabrics for use in top sheets of absorbent articles in the relevant technical field include the one described in PTL 1, for example. The nonwoven fabric described in PTL 1 is designed to provide a nonwoven fabric that has been modified so as to be permeable to fluids at projections, recesses and the like.
[0005] Absorbent articles are also known in the technical field that are coated with lotion compositions.
[0006] For example, PTL 2 discloses an absorbent article having a polypropylene glycol material-containing lotion composition situated on the inner surface of the top sheet (the clothing side surface), the inner surface of the back sheet (the body side surface), and on the base material between the inner surface of the top sheet and the inner surface of the back sheet.
[0007] Also, PTL 3 discloses an absorbent article wherein a polypropylene glycol material-containing lotion composition is applied on the outer surface of the top sheet (body side surface).
CITATION LIST
Patent Literature
PTL 1 Japanese Unexamined Patent Publication No. 2008-25083
PTL 2 Japanese Unexamined Patent Publication No. 2010-518918
PTL 3 Japanese Unexamined Patent Publication No. 2011-510801
SUMMARY OF INVENTION
Technical Problem
[0008] The nonwoven fabric described in PTL 1 is designed to be permeable to fluids, but some of the fibers composing the projections are oriented in the longwise direction, often causing diffusion of the absorbed menstrual blood in the longwise direction at the projections. Further improvement in the function of fluid permeability has therefore been considered for the nonwoven fabric described in PTL 1.
[0009] It is therefore an object of the present disclosure to provide a nonwoven fabric for an absorbent article top sheet, that has low stickiness and is light after absorption of menstrual blood, and that has low diffusion of absorbed menstrual blood on the nonwoven fabric.
Solution to Problem
[0010] As a result of diligent research directed toward solving the problems described above, the present inventors have discovered a nonwoven fabric for a top sheet of an absorbent article, having a longwise direction and a crosswise direction, the nonwoven fabric having a plurality of ridges and a plurality of furrows extending in the longwise direction and alternately disposed in the crosswise direction, wherein the plurality of ridges and the plurality of furrows each have a plurality of through-holes, the ridges having blood lubricity imparter-containing regions that contain a blood slipping agent with a kinematic viscosity of 0.01 to 80 mm 2 /s at 40° C., a water holding percentage of 0.01 to 4.0 mass % and a weight-average molecular weight of less than 1,000.
Advantageous Effects of Invention
[0011] The nonwoven fabric for an absorbent article top sheet according to this disclosure has low stickiness and is light after absorption of menstrual blood, and also has low diffusion of absorbed menstrual blood on the nonwoven fabric.
BRIEF DESCRIPTION OF DRAWING
[0012] FIG. 1 is a front view of a nonwoven fabric according to an embodiment of the disclosure.
[0013] FIG. 2 is a perspective view of section X of FIG. 1 .
[0014] FIG. 3 is a front view of a nonwoven fabric according to another embodiment of the disclosure.
[0015] FIG. 4 is a front view of a nonwoven fabric according to yet another embodiment of the disclosure.
[0016] FIG. 5 is a front view of an absorbent article 11 comprising a nonwoven fabric, according to the disclosure.
[0017] FIG. 6 is a cross-sectional view of the blood slipping agent-containing region 17 of the absorbent article 11 shown in FIG. 3 , along cross-section Y-Y.
[0018] FIG. 7 is a diagram illustrating an example of a method of forming perforated sections in a nonwoven fabric sheet 102 .
[0019] FIG. 8 is an electron micrograph of the skin contact surface of a top sheet in a sanitary napkin wherein the top sheet comprises tri-C2L oil fatty acid glycerides.
[0020] FIG. 9 is a pair of photomicrographs of menstrual blood containing and not containing a blood slipping agent.
[0021] FIG. 10 is a diagram illustrating a method of measuring surface tension.
DESCRIPTION OF EMBODIMENTS
[0022] The absorbent article of this disclosure will now be explained in detail.
DEFINITIONS
[0023] Some of the terms used throughout the present specification will now be defined.
[0024] “Ridge” and “Furrow”
[0025] Throughout the present specification, “ridge” means a section extending basically in the longwise direction and higher than the other regions and “furrow” means a section extending basically in the longwise direction and lower than the other regions, with “ridges” and “furrows” being disposed alternately in the crosswise direction.
[0026] Throughout the present specification, the “ridges” and “furrows” are distinguished by their basis weights, for convenience.
[0027] The ridges are sections having a higher basis weight than the average basis weight of the nonwoven fabric as a whole, and the furrows are sections having a lower basis weight than the average basis weight of the nonwoven fabric as a whole.
[0028] “Fibers Oriented in the Longwise Direction”
[0029] Throughout the present specification, “fibers oriented in the longwise direction” means fibers oriented in a range of >−45° and <+45° with respect to the longwise direction. The “fibers oriented in the longwise direction” may be referred to herein as “longwisely oriented fibers”.
[0030] “Fibers Oriented in the Crosswise Direction”
[0031] Throughout the present specification, “fibers oriented in the crosswise direction” means fibers oriented in a range of >−45° and <+45° with respect to the crosswise direction, which is perpendicular to the aforementioned longwise direction. The “fibers oriented in the crosswise direction” may be referred to herein as “crosswisely oriented fibers”.
[0032] Fibers oriented at −45° or +45° with respect to the longwise direction (i.e. fibers also oriented at −45° or +45° with respect to the crosswise direction) are not included among either longwisely oriented fibers or crosswisely oriented fibers.
[0033] “Through-Hole”
[0034] As used herein, a “through-hole” in a nonwoven fabric is a hole running from the nonwoven fabric side (for example, the skin contact surface of the top sheet) to the opposite side (for example, the clothing side surface of the top sheet). Body fluid, such as menstrual blood that has reached the nonwoven fabric side (for example, the skin contact surface of the top sheet) can migrate to the opposite side (for example, the clothing side surface of the top sheet) through the through-holes.
[0035] The through-holes can be formed in the ridges and/or the furrows. The through-holes are not particularly limited so long as they have this function, and for example, they may be perforated sections formed by a perforation method, or openings formed by reducing the fibers of the nonwoven fabric in prescribed regions. The perforated sections and openings can be formed in the ridges and/or the furrows.
[0036] “Excretory Opening Contact Region”
[0037] As used herein, “excretory opening contact region” as it relates to the top sheet means the region of the top sheet that contacts with the excretory opening (labia minora, etc.) of the wearer. The excretory opening contact region will have a different location depending on the size of the absorbent article, and for an absorbent article with side flaps, the excretory opening contact region will usually be the inner side of the region defined by embossing disposed in a continuous or discontinuous manner surrounding a lengthwise line running through the widthwise center of the absorbent article, and the intersection with a widthwise line running through the lengthwise centers of both wing sections. Also, in the case of an absorbent article without side flaps, usually the excretory opening contact region is defined by embossing that is disposed continuously or discontinuously surrounding the widthwise center section and the lengthwise center section of the absorbent article.
[0038] The nonwoven fabric for an absorbent article top sheet according to the present disclosure will now be described in detail.
[0039] The term “nonwoven fabric for an absorbent article top sheet” may also be referred to hereunder simply as “nonwoven fabric”.
[0040] FIG. 1 is a front view of a nonwoven fabric according to an embodiment of the disclosure, and FIG. 2 is a perspective view of section X of FIG. 1 . The nonwoven fabric 1 shown in FIG. 1 and FIG. 2 has a longwise direction L and a crosswise direction C. The nonwoven fabric 1 shown in FIG. 1 and FIG. 2 has a plurality of ridges 2 and a plurality of furrows 3 extending in the longwise direction L and alternately disposed in the crosswise direction C, the ridges 2 and furrows 3 each having a plurality of through-holes 4 .
[0041] In the nonwoven fabric 1 shown in FIG. 1 and FIG. 2 , the through-holes 4 of the ridges 2 are a plurality of perforated sections 4 ′ formed by perforationg, and the through-holes 4 of the furrows 3 are openings 4 ″ formed by reducing the amount of fibers at the furrows 3 during production of the nonwoven fabric, before coating the blood slipping agent. The perforation method and the method for producing the nonwoven fabric before coating of the blood slipping agent will be described below. Furthermore, in the nonwoven fabric 1 shown in FIG. 1 and FIG. 2 , the furrows 3 have joints 5 between every two adjacent openings 4 ″, that connect every two adjacent ridges 2 .
[0042] In the nonwoven fabric 1 shown in FIG. 1 and FIG. 2 , the content of fibers oriented in the crosswise direction C is higher than the content of fibers oriented in the longwise direction L, at the joints 5 . The nonwoven fabric 1 shown in FIG. 1 and FIG. 2 has about 0.5 to about 5.0 through-holes 4 per 1 cm 2 area of the nonwoven fabric 1 .
[0043] In the nonwoven fabric 1 shown in FIG. 1 and FIG. 2 , the ridges 2 have blood slipping agent-containing regions containing a blood slipping agent having a kinematic viscosity of about 0.01 to about 80 mm 2 /s at 40° C., a water holding percentage of about 0.01 to about 4.0 mass % and a weight-average molecular weight of less than 1,000. Also in the nonwoven fabric 1 shown in FIG. 1 and FIG. 2 , the ridges 2 contain a blood slipping agent with a basis weight of about 1 to about 30 g/m 2 in the blood slipping agent-containing regions.
[0044] The blood slipping agent will be described below.
[0045] FIG. 3 is a front view of another embodiment of the nonwoven fabric of the disclosure. The nonwoven fabric 1 shown in FIG. 3 has a longwise direction L and a crosswise direction C, and a plurality of ridges 2 and a plurality of furrows 3 extending in the longwise direction L and alternately disposed in the crosswise direction C. In the nonwoven fabric 1 shown in FIG. 3 , the ridges 2 and the furrows 3 each have a plurality of through-holes 4 .
[0046] In the nonwoven fabric 1 shown in FIG. 3 , the through-holes 4 of the ridges 2 are perforated sections 4 ′ formed by perforation, and the perforated sections 4 ′ of the ridges 2 are disposed in a zigzag fashion. The through-holes 4 of the furrows 3 are openings 4 ″ formed during production of the nonwoven fabric before coating of the blood slipping agent. Furthermore, in the nonwoven fabric 1 shown in FIG. 3 , the furrows 3 have joints 5 between every two adjacent openings 4 ″, that connect every two adjacent ridges 2 .
[0047] FIG. 4 is a front view of yet another embodiment of the nonwoven fabric of the disclosure. The nonwoven fabric 1 shown in FIG. 4 has a longwise direction L and a crosswise direction C, and a plurality of ridges 2 and a plurality of furrows 3 extending in the longwise direction L and alternately disposed in the crosswise direction C. In the nonwoven fabric 1 shown in FIG. 4 , the ridges 2 and the furrows 3 each have a plurality of through-holes 4 .
[0048] In the nonwoven fabric 1 shown in FIG. 4 , the through-holes 4 of the ridges 2 are perforated sections 4 ′ formed by perforation. The through-holes 4 of the furrows 3 includes both perforated sections 4 ′ and openings 4 ″ formed during production of the nonwoven fabric before coating of the blood slipping agent. In the nonwoven fabric 1 shown in FIG. 4 , the furrows 3 have joints 5 between every two adjacent openings 4 ″, that connect every two adjacent ridges 2 .
[0049] Throughout the present specification, the contents of longwisely oriented fibers and crosswisely oriented fibers are those measured in the following manner.
[0050] (1) A digital microscope is prepared. The digital microscope may be, for example, a VHX-100 Digital Microscope by Keyence Corp.
[0051] (2) The sample to be measured is set on the observation stage so that the longwise direction and crosswise direction are clearly identifiable.
[0052] (3) Fibers irregularly protruding forward are removed from the sample to be measured, and the lens is focused on the foremost fibers of the sample.
[0053] (4) The photographing depth is set and a 3D image of the sample is displayed on a PC screen.
[0054] (5) The photographed 3D image is converted to a 2D image.
[0055] (6) Within the measuring range, multiple parallel lines are drawn on the screen in the longwise direction and the crosswise direction, dividing it into equal portions.
[0056] (7) In each cell formed by the parallel lines, measurement is made of the number of fibers oriented in the longwise direction, the number of fibers oriented in the crosswise direction, and the number of fibers not oriented in either direction.
[0057] (8) The content of longwisely oriented fibers and the content of crosswisely oriented fibers are calculated from the total number of fibers in the prescribed range.
[0058] In a nonwoven fabric according to the disclosure, the ridges have a basis weight of preferably about 15 to about 250 g/m 2 and more preferably about 20 to about 120 g/m 2 . If the basis weight is less than about 15 g/m 2 , the ridges will tend to be highly collapsable and absorbed menstrual blood will tend to rewet when pressure is applied. If the basis weight is greater than about 250 g/m 2 , menstrual blood will not easily migrate downward (into the absorbent body, for example), and the menstrual blood will pool in the ridges, potentially creating a feeling of discomfort for the wearer.
[0059] In a nonwoven fabric according to the disclosure, the furrows have a basis weight of preferably about 3 to about 150 g/m 2 and more preferably about 5 to 80 g/m 2 . If the basis weight is less than about 3 g/m 2 , the strength of the furrows may be inadequate resulting in damage when it is used as a top sheet. Also, if the basis weight is greater than about 150 g/m 2 , menstrual blood that has reached the furrows will not easily migrate downward (into the absorbent body), and the menstrual blood will pool in the furrows, potentially creating a feeling of discomfort for the wearer.
[0060] In a nonwoven fabric according to the disclosure, the average basis weight is preferably about 10 to 200 g/m 2 and more preferably about 20 to about 100 g/m 2 . If the average basis weight is less than about 10 g/m 2 , the strength of the nonwoven fabric may be inadequate resulting in damage when it is used as a top sheet. Also, if the average basis weight is greater than about 200 g/m 2 , menstrual blood can potentially pool in the nonwoven fabric.
[0061] The basis weights of the ridges and the furrows and the average basis weight of the nonwoven fabric are measured in the following manner.
[0062] (1) A mark is created in the region to be measured (ridge, furrow or nonwoven fabric), and the area: SA α (m 2 ) is measured.
[0063] In order to minimize error, marking is made so that the total area of the sample exceeds 5 cm 2 .
[0064] (2) The marked area is cut with a sharp blade, such as a cutter replacement blade, and the total mass measured as TM(g).
[0065] (3) The basis weight BS α (g/m 2 ) of the area to be measured is determined by the following formula:
[0000] BS α (g/m 2 )=TM(g)/ SA α (m 2 ).
[0066] In the nonwoven fabric of this disclosure, the blood slipping agent-containing regions of the ridges contain the blood slipping agent at a basis weight in the range of preferably about 1 to about 30 g/m 2 , more preferably about 2 to about 20 g/m 2 and even more preferably about 3 to about 10 g/m 2 . The action of the blood slipping agent will be described below, but if the basis weight is lower than about 1 g/m 2 , menstrual blood that has reached the nonwoven fabric will tend to remain there without rapidly migrating into the absorbent body, while if the basis weight is greater than about 30 g/m 2 , a greater degree of stickiness will tend to be felt when the article is worn.
[0067] Also, if the ridges region contain a blood slipping agent, menstrual blood that has reached the ridges will tend to slip down into the absorbent article before diffusing in the longwise direction along the longwisely oriented fibers. This reduces reddening of the top sheet with menstrual blood, minimizes rash caused by menstrual blood adhering to the skin, and reduces repulsive appearance.
[0068] In the nonwoven fabric of the disclosure, the furrows may also have blood slipping agent-containing regions that contain a blood slipping agent. If the furrows have blood slipping agent-containing regions, absorbed menstrual blood will easily slip into the absorbent article before diffusing in the crosswise direction. This will minimize reddening of the top sheet by menstrual blood.
[0069] For the purpose of the present specification, the basis weight of the blood slipping agent in the nonwoven fabric is that measured in the following manner.
[0070] (1) The region of the nonwoven fabric that is to be measured is cut out using a sharp blade, such as a cutter replacement blade, avoiding any alteration in thickness, to obtain a sample.
[0071] (2) The area of the sample: SA β (m 2 ) and the mass: SM 0 (g) are measured.
[0072] (3) The sample is stirred for at least 3 minutes in a solvent that can dissolve the blood slipping agent, such as ethanol or acetone, to dissolve the blood slipping agent in the solvent.
[0073] (4) The sample is filtered on mass-measured filter paper, and the sample is thoroughly rinsed with the solvent on the filter paper. The sample on the filter paper is dried in an oven at 60° C.
[0074] (5) The masses of the filter paper and sample are measured, and the mass of the filter paper is subtracted to calculate the dry sample mass: SM 1 (g).
[0075] (6) The basis weight BS β (g/m 2 ) of the blood slipping agent is calculated by the following formula.
[0000] BS β (g/m 2 )=[ SM 0 (g)− SM 1 (g)]/ SA β (m 2 ).
[0076] In order to minimize error, multiple samples are taken from multiple absorbent articles, without the total area of the sample exceeding 100 cm 2 , conducting several repeated measurements and taking the average value.
[0077] Providing a plurality of through-holes in the ridges (especially a plurality of perforated sections in the ridges) in the nonwoven fabric of the disclosure:
[0078] maintains
[0079] (1) faster migration of menstrual blood reaching the nonwoven fabric (migration from the skin contact surface of the top sheet to the clothing side surface of the top sheet), and
[0080] (2) flexiblity due to the bulk of the ridges, while also
[0081] (3) further improving the absorption performance, and specifically
[0082] (3a) inhibiting residue of menstrual blood in the ridges (since the ridges have through-holes),
[0083] (3b) allowing the through-holes of the ridges to function as temporary retaining spaces for menstrual blood, and
[0084] (3c) allowing menstrual blood that has reached the ridges to be guided to the through-holes along the slopes of the ridges (since formation of through-holes and especially perforated sections in the ridges reduces the thickness of the ridges around the through-holes and creates slopes in the ridges), while also
[0085] (4) inhibiting mustiness (since the contact area between the ridges and the skin is reduced).
[0086] In the nonwoven fabric of the disclosure, the ridges and/or furrows have through-hole diameters of preferably about 0.3 mm to about 6.0 mm and more preferably about 0.6 mm to about 3.0 mm. If the diameters are smaller than about 0.3 mm, the through-holes that serve as fluid channels will be less conductive of highly viscous menstrual blood. If the diameters are larger than about 6.0 mm, menstrual blood that has already migrated into the absorbent body may return through the through-holes.
[0087] In the nonwoven fabric of the disclosure, the number of through-holes in the nonwoven fabric as a whole, and in the ridges and furrows, as well as the placement of the through-holes, may be appropriately selected depending on the size of the absorbent article, but at least for use as an absorbent article, the through-holes are preferably situated in the location where the excretory opening contact region is to be formed.
[0088] Generally speaking, the nonwoven fabric as a whole, and/or the ridges and/or furrows have preferably about 0.5 to about 5.0 and more preferably about 1.0 to about 3.0 through-holes per 1 cm 2 area of the nonwoven fabric. If this number is less than about 0.5, it may be difficult to exhibit the effect of the present disclosure, while if the number is greater than about 5.0, problems such rewetting may occur, in which menstrual blood that has already been absorbed returns back to the top sheet.
[0089] The area of the nonwoven fabric for the number of through-holes, as referred to herein, is the projected area from the thickness direction of the nonwoven fabric, and it differs from the surface area of the nonwoven fabric that includes the ridges and furrows.
[0090] In the nonwoven fabric of the disclosure, the heights of the ridges are preferably about 0.1 to about 15.0 mm higher, more preferably about 0.5 to about 5.0 mm higher and even more preferably about 0.5 to about 2.0 mm higher than the heights of the furrows. The pitch of the ridges is preferably about 1.5 to about 17 mm, more preferably about 2.0 to about 12 mm and even more preferably about 3 to about 8 mm. This is so that menstrual blood will slide down from the projections to the recesses and then rapidly migrate into the absorbent body.
[0091] The heights of the ridges and the furrows are measured by a laser displacement meter. An example of a laser displacement meter is the LJ-G Series high precision two-dimensional laser displacement gauge (Model: LJ-G030) by Keyence Corp.
[0092] In a nonwoven fabric according to one embodiment of the present disclosure, having blood slipping agent-containing regions in the furrows, the ridges and the furrows each contain the same blood slipping agent, or the same combination of blood slipping agents, in the blood slipping agent-containing regions.
[0093] Also, in a nonwoven fabric according to another embodiment of the present disclosure, which has blood slipping agent-containing regions in the furrows, the ridges and optionally the furrows each contain a different blood slipping agent, or a different combination of blood slipping agents, in the blood slipping agent-containing regions.
[Blood Slipping Agent]
[0094] In the nonwoven fabric of the disclosure, the ridges have blood slipping agent-containing regions containing a blood slipping agent having a kinematic viscosity of about 0.01 to about 80 mm 2 /s at 40° C., a water holding percentage of about 0.05 to about 4.0 mass % and a weight-average molecular weight of less than 1,000.
[0095] The blood slipping agent has, at 40° C., a kinematic viscosity of about 0 to about 80 mm 2 /s, preferably a kinematic viscosity of about 1 to about 70 mm 2 /s, more preferably a kinematic viscosity of about 3 to about 60 mm 2 /s, even more preferably a kinematic viscosity of about 5 to about 50 mm 2 /s, and yet more preferably a kinematic viscosity of about 7 to about 45 mm 2 /s.
[0096] The kinematic viscosity tends to be higher with a) a larger molecular weight of the blood slipping agent, b) a higher percentage of polar groups, such as carbonyl bonds (—CO—), ether bonds (—O—), carboxyl groups (—COOH) and hydroxyl groups (—OH), and c) a larger IOB.
[0097] In order to have a kinematic viscosity of about 0 to about 80 mm 2 /s at 40° C., the melting point of the blood slipping agent is preferably 45° C. or less. This is because the kinematic viscosity will tend to be higher if the blood slipping agent contains crystals at 40° C.
[0098] As used herein, the “kinematic viscosity at 40° C.” may be referred to simply as “kinematic viscosity”.
[0099] The significance of the kinematic viscosity of the blood slipping agent will be explained below, but a kinematic viscosity exceeding about 80 mm 2 /s will tend to result in high viscosity of the blood slipping agent, so that the blood slipping agent will tend to be resistant to slipping into the absorbent article together with menstrual blood that has reached the skin contact surface of the top sheet.
[0100] The kinematic viscosity can be measured according to JIS K 2283:2000, “5. Kinematic Viscosity Test Method”, using a Cannon-Fenske reverse-flow viscometer, at a testing temperature of 40° C.
[0101] The blood slipping agent has a water holding percentage of about 0.01 to about 4.0 mass %, preferably it has a water holding percentage of about 0.02 to about 3.5 mass %, more preferably it has a water holding percentage of about 0.03 to about 3.0 mass %, even more preferably it has a water holding percentage of about 0.04 to about 2.5 mass %, and yet more preferably it has a water holding percentage of about 0.05 to about 2.0 mass %.
[0102] As used herein, “water holding percentage” means the percentage (mass) of water that can be held by a substance, and it may be measured in the following manner.
[0103] (1) A 20 mL test tube, a rubber stopper, the substance to be measured and deionized water are allowed to stand for a day and a night in a thermostatic chamber at 40° C.
[0104] (2) Into the test tube in the thermostatic chamber there are charged 5.0 g of the substance to be measured and 5.0 g of deionized water.
[0105] (3) The mouth of the test tube is sealed with the rubber stopper in the thermostatic chamber, and the test tube is rotated once and allowed to stand for 5 minutes.
[0106] (4) A 3.0 g portion of the layer of the substance to be measured (usually the upper layer) is sampled into a glass dish with a diameter of 90 mm and a mass of W 0 (g), in the thermostatic chamber.
[0107] (5) The dish is heated at 105° C. for 3 hours in an oven to evaporate off the moisture, and the mass W 1 (g) of each dish is measured.
[0108] (6) The water holding percentage is calculated by the following formula.
[0000] Water holding percentage (mass %)=100 ×[W 0 (g)− W 1 (g)]/3.0(g)
[0109] The measurement is conducted three times, and the average value is recorded.
[0110] The significance of the water holding percentage of the blood slipping agent will be explained below, but a low water holding percentage will tend to lower the affinity between the blood slipping agent and menstrual blood, thus helping to prevent menstrual blood that has reached the skin contact surface of the top sheet from slipping into the absorbent article.
[0111] If the water holding percentage is high, on the other hand, affinity with menstrual blood will be very high, similar to a surfactant, and absorbed menstrual blood will tend to remain on the skin contact surface of the top sheet, resulting in more red coloration of the skin contact surface of the top sheet.
[0112] The water holding percentage tends to be a larger value with a) a smaller molecular weight of the blood slipping agent, and b) a higher percentage of polar groups, such as carbonyl bonds (—CO—), ether bonds (—O—), carboxyl groups (—COOH) and hydroxyl groups (—OH). This is because the blood slipping agent has greater hydrophilicity. The water holding percentage will tend to have a larger value with a greater IOB, i.e with a higher inorganic value or with a lower organic value. This is because the blood slipping agent will have greater hydrophilicity.
[0113] The significance of the kinematic viscosity and water holding percentage of the blood slipping agent will now be explained.
[0114] FIG. 5 is a front view of an absorbent article, and more specifically a sanitary napkin, containing a nonwoven fabric of the disclosure. FIG. 5 is as observed from the skin contact side of the top sheet 12 . The absorbent article 11 shown in FIG. 5 has a liquid-permeable top sheet 12 , an absorbent body 13 , and a liquid-impermeable back sheet (not shown). The absorbent article 11 shown in FIG. 5 also has a pair of side flaps 14 , a side sheet 15 and embossings 16 .
[0115] In the absorbent article 11 shown in FIG. 5 , the left side is the front.
[0116] In the absorbent article 11 shown in FIG. 5 , the top sheet 12 has a plurality of ridges and a plurality of furrows on the skin contact surface, extending in the lengthwise direction of the absorbent article, and the ridges and furrows may be omitted as appropriate. In the absorbent article 11 shown in FIG. 5 , the ridges and furrows are disposed in an alternating fashion in the widthwise direction of the absorbent article 11 .
[0117] Also, although the absorbent article 11 shown in FIG. 5 has a pair of side flaps 14 , a side sheet 15 and embossings 16 , an absorbent article according to another embodiment of this disclosure does not have a pair of side flaps, a side sheet and/or embossings.
[0118] In the absorbent article 11 shown in FIG. 5 , the excretory opening contact region is the region defined by four embossings 16 ′, and the top sheet 12 has a blood slipping agent-containing region 17 over the entire excretory opening contact region.
[0119] FIG. 6 is a cross-sectional view corresponding to cross-section Y-Y of the blood slipping agent-containing region 17 of the absorbent article 11 shown in FIG. 5 , and it is a diagram schematically illustrating migration of menstrual blood into the absorbent body by the blood slipping agent. The absorbent article 11 shown in FIG. 6 has a liquid-permeable top sheet 12 , a liquid-impermeable back sheet 18 , and an absorbent body 13 between the top sheet 12 and the back sheet 18 .
[0120] In FIG. 6 , the top sheet 12 has a plurality of projections 21 and a plurality of recesses 22 on the skin contact surface 23 , and a blood slipping agent 24 is coated on the skin contact surface 23 of the top sheet 12 . In FIG. 6 , the blood slipping agent 24 is shown as droplets (or particles) on the skin contact surface 23 of the top sheet 12 for convenience, but in a nonwoven fabric of this disclosure, and an absorbent article comprising the nonwoven fabric, the form and distribution of the blood slipping agent is not limited to that shown in the drawing.
[0121] As shown in FIG. 6 , menstrual blood 25 that has reached the projections 21 of the top sheet 12 contacts with the blood slipping agent 24 that is present in the projections 21 . A portion of the blood slipping agent 24 present in the projections 21 slips down into the recesses 22 together with the menstrual blood 25 (menstrual blood 25 ′). The menstrual blood 25 ′ then slips down into the recesses 22 , reaching the absorbent body 13 (menstrual blood 25 ″). Next, the menstrual blood 25 ″ is absorbed into the absorbent body 13 .
[0122] More specifically, the blood slipping agent 24 having a water holding percentage of about 0.01 to about 4.0 mass % has a certain affinity with menstrual blood 25 . For example, the hydrophilic portion of the blood slipping agent 24 (for example, a hydrophilic group, such as a polar group, for example, such as carbonyl, oxy, carboxyl, hydroxyl or the like, or a hydrophilic bond, such as a polar bond, for example, such as a carbonyl bond, ester bond, carbonate bond, ether bond or the like) has high affinity with the hydrophilic components (such as blood plasma) in the menstrual blood 25 , and attracts the components with affinity, whereas the hydrophobic portion (for example, the hydrocarbon moiety) of the blood slipping agent 24 has low affinity with the hydrophilic components (such as blood plasma) in the menstrual blood 25 and repels the hydrophilic components, such that it functions as a “lubricant”, causing the menstrual blood 25 to slip down toward the absorbent body 13 .
[0123] Also, since the blood slipping agent 24 having a kinematic viscosity of about 0.01 to about 80 mm 2 /s at 40° C. has very low viscosity near the body temperature of the wearer, a portion thereof slips down from the projections 21 into the recesses 22 together with the menstrual blood 25 , subsequently passing through the recesses 22 into the absorbent article 11 .
[0124] Furthermore, since the blood slipping agent 24 has a water holding percentage of about 0.01 to about 4.0 mass %, its affinity with the hydrophilic components (such as blood plasma) in menstrual blood 25 is not excessively high, and this causes less of the menstrual blood 25 to remain on the top sheet 12 . This is because the hydrophilic components (such as blood plasma) in the menstrual blood 25 repels the hydrophobic portion of the blood slipping agent 24 .
[0125] Also, FIG. 6 schematically illustrates migration of menstrual blood into an absorbent body by a blood slipping agent, but a blood slipping agent-containing composition functions in the same manner.
[0126] The blood slipping agent has a weight-average molecular weight of less than about 1,000, and preferably a weight-average molecular weight of less than about 900. This is because, if the weight-average molecular weight is about 1,000 or higher, tack may result in the blood slipping agent itself, tending to create a feeling of unpleasantness for the wearer. If the weight-average molecular weight increases, the viscosity of the blood slipping agent will tend to increase, and it will therefore be difficult to lower the viscosity of the blood slipping agent by heating to a viscosity suitable for coating, and as a result, the blood slipping agent may need to be diluted with a solvent.
[0127] The blood slipping agent preferably has a weight-average molecular weight of about 100 or greater, and more preferably it has a weight-average molecular weight of about 200 or greater. This is because if the weight-average molecular weight is low, the vapor pressure of the blood slipping agent may be increased, gasification may occur during storage and the amount may be reduced, often leading to problems, such as odor during wear.
[0128] In addition, as used herein, “weight-average molecular weight” includes the concept of a polydisperse compound (for example, a compound produced by stepwise polymerization, an ester formed from a plurality of fatty acids and a plurality of aliphatic monohydric alcohols), and a simple compound (for example, an ester formed from one fatty acid and one aliphatic monohydric alcohol), and in a system comprising N i molecules with molecular weight M, (i=1, or i=1, 2 . . . ), it refers to M w determined by the following formula.
[0000]
M
w
=ΣN
i
M
i
2
/ΣN
i
M
i
[0129] As used herein, the weight-average molecular weights are the values measured by gel permeation chromatography (GPC), based on polystyrene.
[0130] The GPC measuring conditions may be the following, for example.
[0131] Device: Lachrom Elite high-speed liquid chromatogram by Hitachi High-Technologies Corp.
[0132] Columns: SHODEX KF-801, KF-803 and KF-804, by Showa Denko K.K.
[0133] Eluent: THF
[0134] Flow rate: 1.0 mL/min
[0135] Driving volume: 100 μL
[0136] Detection: RI (differential refractometer)
[0137] The weight-average molecular weights listed in the examples of the present specification were measured under the conditions described below.
[0138] The blood slipping agent can have an IOB of about 0.00 to about 0.60.
[0139] The IOB (Inorganic Organic Balance) is an indicator of the hydrophilic-lipophilic balance, and as used herein, it is the value calculated by the following formula by Oda et al.:
[0000] IOB=inorganic value/organic value.
[0140] The inorganic value and the organic value are based on the organic paradigm described in “Organic compound predictions and organic paradigms” by Fujita A., Kagaku no Ryoiki (Journal of Japanese Chemistry), Vol. 11, No. 10 (1957) p. 719-725.
[0141] The organic values and inorganic values of major groups, according to Fujita, are summarized in Table 1 below.
[0000]
TABLE 1
Inorganic
Organic
Group
value
value
—COOH
150
0
—OH
100
0
—O—CO—O—
80
0
—CO—
65
0
—COOR
60
0
—O—
20
0
Triple bond
3
0
Double bond
2
0
CH 2
0
20
iso-branch
0
−10
tert-branch
0
−20
Light metal (salt)
≧500
0
Heavy metal (salt),
≧400
0
amine, NH 3 salt
[0142] For example, in the case of an ester of tetradecanoic acid which has 14 carbon atoms and dodecyl alcohol which has 12 carbon atoms, the organic value is 520 (CH 2 , 20×26) and the inorganic value is 60 (—COOR, 60×1), and therefore IOB=0.12.
[0143] The IOB of the blood slipping agent is preferably between about 0.00 and 0.60, more preferably between about 0.00 and 0.50, even more preferably between about 0.00 and 0.40 and most preferably between about 0.00 and 0.30. If the IOB is within this range, it will be easier to meet the aforementioned conditions for the water-holding capacity and kinematic viscosity.
[0144] The blood slipping agent preferably has a melting point of no higher than 45° C., and more preferably it has a melting point of no higher than 40° C. If the blood slipping agent has a melting point of no higher than 45° C., the blood slipping agent will more easily exhibit a kinematic viscosity in the aforementioned range.
[0145] As used herein, the term “melting point” refers to the peak top temperature for the endothermic peak during conversion from solid to liquid, upon measurement with a differential scanning calorimetry analyzer at a temperature-elevating rate of 10° C./min. The differential scanning calorimetry analyzer used may be, for example, a DSC-60-type DSC measuring apparatus by Shimadzu Corp.
[0146] If the blood slipping agent has a melting point of about 45° C. or less, it may be either liquid or solid at room temperature (about 25° C.), or in other words, the melting point may be either about 25° C. or higher or below about 25° C., and for example, it may have a melting point of about −5° C. or about −20° C.
[0147] The blood slipping agent does not have a lower limit for the melting point, but the vapor pressure is preferably low. The vapor pressure of the blood slipping agent is preferably about 0-200 Pa, more preferably about 0-100 Pa, even more preferably about 0-10 Pa, even more preferably about 0-1 Pa, and even more preferably about 0.0-0.1 Pa at 25° C. (1 atmosphere).
[0148] Considering that the nonwoven fabric of this disclosure is to be used in contact with the human body, the vapor pressure is preferably about 0-700 Pa, more preferably about 0-100 Pa, even more preferably about 0-10 Pa, even more preferably about 0-1 Pa, and even more preferably 0.0-0.1 Pa, at 40° C. (1 atmosphere). If the vapor pressure is high, gasification may occur during storage and the amount of blood slipping agent may be reduced, and as a consequence problems, such as odor during wear, may be created.
[0149] The melting point of the blood slipping agent may be selected depending on the weather or duration of wear. For example, in regions with a mean atmospheric temperature of about 10° C. or less, using a blood slipping agent with a melting point of about 10° C. or less may help the blood slipping agent function after excretion of menstrual blood, even if it has been cooled by the ambient temperature.
[0150] Also, when the absorbent article is to be used for a prolonged period of time, the melting point of the blood slipping agent is preferably at the high end of the range of about 45° C. or less: This is so that the blood slipping agent will not be easily affected by sweat or friction during wearing, and will not easily become biased even during prolonged wearing.
[0151] In the technical field, the skin contact surfaces of top sheets are coated with surfactants in order to alter the surface tension of menstrual blood and promote rapid absorption of menstrual blood. However, the top sheet coated with the surfactant has very high affinity for the hydrophilic components (blood plasma, etc.) in menstrual blood, and acts to attract them, tending to cause menstrual blood instead to remain on the top sheet. The blood slipping agent, unlike conventionally known surfactants, has low affinity with menstrual blood and therefore does not cause residue of menstrual blood on the top sheet and allows rapid migration into the absorbent body.
[0152] Preferably, the blood slipping agent is selected from the group consisting of following items (i)-(iii), and any combination thereof:
[0153] (i) a hydrocarbon;
[0154] (ii) a compound having (ii-1) a hydrocarbon moiety, and (ii-2) one or more, same or different groups selected from the group consisting of carbonyl group (—CO—) and oxy group (—O—) inserted between a C—C single bond of the hydrocarbon moiety; and
[0155] (iii) a compound having (iii-1) a hydrocarbon moiety, (iii-2) one or more, same or different groups selected from the group consisting of carbonyl group (—CO—) and oxy group (—O—) inserted between a C—C single bond of the hydrocarbon moiety, and (iii-3) one or more, same or different groups selected from the group consisting of carboxyl group (—COOH) and hydroxyl group (—OH) substituting for a hydrogen on the hydrocarbon moiety.
[0156] As used herein, “hydrocarbon” refers to a compound composed of carbon and hydrogen, and it may be a chain hydrocarbon, such as a paraffinic hydrocarbon (containing no double bond or triple bond, also referred to as alkane), an olefin-based hydrocarbon (containing one double bond, also referred to as alkene), an acetylene-based hydrocarbon (containing one triple bond, also referred to as alkyne), or a hydrocarbon comprising two or more bonds selected from the group consisting of double bonds and triple bonds, and cyclic hydrocarbon, such as aromatic hydrocarbons and alicyclic hydrocarbons.
[0157] Preferred as such hydrocarbons are chain hydrocarbons and alicyclic hydrocarbons, with chain hydrocarbons being more preferred, paraffinic hydrocarbons, olefin-based hydrocarbons and hydrocarbons with two or more double bonds (containing no triple bond) being more preferred, and paraffinic hydrocarbons being even more preferred.
[0158] Chain hydrocarbons include linear hydrocarbons and branched hydrocarbons.
[0159] When two or more oxy groups (—O—) are inserted in the compounds of (ii) and (iii) above, the oxy groups (—O—) are not adjacent each other. Thus, compounds (ii) and (iii) do not include compounds with continuous oxy groups (i.e., peroxides).
[0160] In the compounds of (iii), compounds in which at least one hydrogen on the hydrocarbon moiety is substituted with a hydroxyl group (—OH) are preferred over compounds in which at least one hydrogen on the hydrocarbon moiety is substituted with a carboxyl group (—COOH). This is because the carboxyl groups bond with metals and the like in menstrual blood, increasing the water holding percentage of the blood slipping agent, which may sometimes exceed the prescribed range. The same is true from the viewpoint of the IOB as well. As shown in Table 1, the carboxyl groups bond with metals and the like in menstrual blood, drastically increasing the inorganic value from 150 to 400 or greater, and therefore a blood slipping agent with carboxyl groups can increase the IOB value to more than about 0.60 during use.
[0161] More preferably, the blood slipping agent is selected from the group consisting of following items (i′)-(iii′), and any combination thereof:
[0162] (i′) a hydrocarbon;
[0163] (ii′) a compound having (ii′-1) a hydrocarbon moiety, and (ii′-2) one or more, same or different bonds selected from the group consisting of carbonyl bond (—CO—), ester bond (—COO—), carbonate bond (—OCOO—), and ether bond (—O—) inserted between a C—C single bond of the hydrocarbon moiety; and
[0164] (iii′) a compound having (iii′-1) a hydrocarbon moiety, (iii′-2) one or more, same or different bonds selected from the group consisting of carbonyl bond (—CO—), ester bond (—COO—), carbonate bond (—OCOO—), and ether bond (—O—) inserted between a C—C single bond of the hydrocarbon moiety, and (iii′-3) one or more, same or different groups selected from the group consisting of carboxyl group (—COOH) and hydroxyl group (—OH) substituting for a hydrogen on the hydrocarbon moiety.
[0165] When 2 or more same or different bonds are inserted in the compound of (ii′) or (iii′), i.e., when 2 or more same or different bonds selected from the group consisting carbonyl bonds (—CO—), ester bonds (—COO—), carbonate bonds (—OCOO—) and ether bonds (—O—) are inserted, the bonds are not adjacent to each other, and at least one carbon atom lies between each of the bonds.
[0166] The blood slipping agent has more preferably about 1.8 or less carbonyl bonds (—CO—), about 2 or less ester bonds (—COO—), about 1.5 or less carbonate bonds (—OCOO—), about 6 or less ether bonds (—O—), about 0.8 or less carboxyl groups (—COOH) and/or about 1.2 or less hydroxyl groups (—OH), per 10 carbon atoms in the hydrocarbon moiety.
[0167] Even more preferably, the blood slipping agent is selected from the group consisting of following items (A)-(F), and any combination thereof:
[0168] (A) an ester of (A1) a compound having a chain hydrocarbon moiety and 2-4 hydroxyl groups substituting for hydrogens on the chain hydrocarbon moiety, and (A2) a compound having a chain hydrocarbon moiety and 1 carboxyl group substituting for a hydrogen on the chain hydrocarbon moiety;
[0169] (B) an ether of (B1) a compound having a chain hydrocarbon moiety and 2-4 hydroxyl groups substituting for hydrogens on the chain hydrocarbon moiety, and (B2) a compound having a chain hydrocarbon moiety and 1 hydroxyl group substituting for a hydrogen on the chain hydrocarbon moiety;
[0170] (C) an ester of (C1) a carboxylic acid, hydroxy acid, alkoxy acid or oxoacid comprising a chain hydrocarbon moiety and 2-4 carboxyl groups substituting for hydrogens on the chain hydrocarbon moiety, and (C2) a compound having a chain hydrocarbon moiety and 1 hydroxyl group substituting for a hydrogen on the chain hydrocarbon moiety;
[0171] (D) a compound having a chain hydrocarbon moiety and one bond selected from the group consisting of ether bonds (—O—), carbonyl bonds (—CO—), ester bonds (—COO—) and carbonate bonds (—OCOO—) inserted between a C—C single bond of the chain hydrocarbon moiety;
[0172] (E) a polyoxy C 3 -C 6 alkylene glycol, or ester or ether thereof; and
[0173] (F) a chain hydrocarbon.
[0174] The blood slipping agent in accordance with (A) to (F) will now be described in detail.
[0000] [(A) Ester of (A1) a Compound Having a Chain Hydrocarbon Moiety and 2-4 Hydroxyl Groups Substituting for Hydrogens on the Chain Hydrocarbon Moiety, and (A2) a Compound Having a Chain Hydrocarbon Moiety and 1 Carboxyl Group Substituting for a Hydrogen on the Chain Hydrocarbon Moiety]
[0175] In the (A) ester of (A1) a compound having a chain hydrocarbon moiety and 2-4 hydroxyl groups substituting for hydrogens on the chain hydrocarbon moiety, and (A2) a compound having a chain hydrocarbon moiety and 1 carboxyl group substituting for a hydrogen on the chain hydrocarbon moiety (hereunder also referred to as “compound (A)”), it is not necessary for all of the hydroxyl groups to be esterified so long as the kinematic viscosity, water holding percentage and weight-average molecular weight are within the aforementioned ranges.
[0176] Examples of (A1) a compound having a chain hydrocarbon moiety and 2-4 hydroxyl groups substituting for hydrogens on the chain hydrocarbon moiety (hereunder also referred to as “compound (A1)”) include chain hydrocarbon tetraols, such as alkanetetraols, including pentaerythritol, chain hydrocarbon triols, such as alkanetriols, including glycerins, and chain hydrocarbon diols, such as alkanediols, including glycols.
[0177] Examples of (A2) a compound having a chain hydrocarbon moiety and 1 carboxyl group substituting for a hydrogen on the chain hydrocarbon moiety include compounds in which one hydrogen on the hydrocarbon is substituted with one carboxyl group (—COOH), such as fatty acids.
[0178] Examples for compound (A) include (a 1 ) an ester of a chain hydrocarbon tetraol and at least one fatty acid, (a 2 ) an ester of a chain hydrocarbon triol and at least one fatty acid, and (a 3 ) an ester of a chain hydrocarbon diol and at least one fatty acids.
[0000] [(a 1 ) Esters of a Chain Hydrocarbon Tetraol and at Least One Fatty Acid]
[0179] Examples of an ester of a chain hydrocarbon tetraol and at least one fatty acid include tetraesters of pentaerythritol and fatty acids, represented by the following formula (1):
[0000]
[0180] triesters of pentaerythritol and fatty acids, represented by the following formula (2):
[0000]
[0181] diesters of pentaerythritol and fatty acids, represented by the following formula (3):
[0000]
[0182] and monoesters of pentaerythritol and fatty acids, represented by the following formula (4).
[0000]
[0183] In the formulas, R 1 -R 4 each represent a chain hydrocarbon.
[0184] The fatty acids consisting of the esters of pentaerythritol and fatty acids (R 1 COOH, R 2 COOH, R 3 COOH, and R 4 COOH) are not particularly restricted so long as the pentaerythritol and fatty acid esters satisfy the conditions for the kinematic viscosity, water holding percentage and weight-average molecular weight, and for example, there may be mentioned saturated fatty acids, such as a C 2 -C 30 saturated fatty acids, including acetic acid (C 2 ) (C 2 representing the number of carbons, corresponding to the number of carbons of each of R 1 C, R 2 C, R 3 C or R 4 C, same hereunder), propanoic acid (C 3 ), butanoic acid (C 4 ) and isomers thereof, such as 2-methylpropanoic acid (C 4 ), pentanoic acid (C 5 ) and isomers thereof, such as 2-methylbutanoic acid (C 5 ) and 2,2-dimethylpropanoic acid (C 5 ), hexanoic acid (C 6 ), heptanoic acid (C 7 ), octanoic acid (C 8 ) and isomers thereof, such as 2-ethylhexanoic acid (C 8 ), nonanoic acid (C 9 ), decanoic acid (C 10 ), dodecanoic acid (C 12 ), tetradecanoic acid (C 14 ), hexadecanoic acid (C 16 ), heptadecanoic acid (C 17 ), octadecanoic acid (C 18 ), eicosanoic acid (C 20 ), docosanoic acid (C 22 ), tetracosanoic acid (C 24 ), hexacosanoic acid (C 26 ), octacosanoic acid (C 28 ), triacontanoic acid (C 30 ), as well as isomers thereof which are not described above.
[0185] The fatty acid may also be an unsaturated fatty acid. Examples of unsaturated fatty acids include C 3 -C 20 unsaturated fatty acids, such as monounsaturated fatty acids including crotonic acid (C 4 ), myristoleic acid (C 14 ), palmitoleic acid (C 16 ), oleic acid (C 18 ), elaidic acid (C 18 ), vaccenic acid (C 18 ), gadoleic acid (C 20 ) and eicosenoic acid (C 20 ), di-unsaturated fatty acids including linolic acid (C 18 ) and eicosadienoic acid (C 20 ), tri-unsaturated fatty acids including linolenic acids, such as α-linolenic acid (C 18 ) and γ-linolenic acid (C 18 ), pinolenic acid (C 18 ), eleostearic acids, such as α-eleostearic acid (C 18 ) and β-eleostearic acid (C 18 ), Mead acid (C 20 ), dihomo-γ-linolenic acid (C 20 ) and eicosatrienoic acid (C 20 ), tetra-unsaturated fatty acids including stearidonic acid (C 20 ), arachidonic acid (C 20 ) and eicosatetraenoic acid (C 20 ), penta-unsaturated fatty acids including bosseopentaenoic acid (C 18 ) and eicosapentaenoic acid (C 20 ), and partial hydrogen adducts thereof.
[0186] Considering the potential for degradation by oxidation and the like, the ester of pentaerythritol and a fatty acid is preferably an ester of pentaerythritol and a fatty acid, which is derived from a saturated fatty acid, i.e., an ester of pentaerythritol and a saturated fatty acid.
[0187] Also, from the viewpoint of lowering the water holding percentage, the ester of pentaerythritol and a fatty acid is preferably a diester, triester or tetraester, more preferably a triester or tetraester, and even more preferably a tetraester.
[0188] From the viewpoint of the IOB being from about 0.00 to about 0.60, in a tetraester of pentaerythritol and a fatty acid, the total number of carbons of the fatty acid composing the tetraester of the pentaerythritol and fatty acid, i.e. the total number of carbons of the R 1 C, R 2 C, R 3 C and R 4 C portions in formula (1), is preferably about 15 (the IOB is 0.60 when the total number of carbon atoms is 15).
[0189] Examples of tetraesters of pentaerythritol and fatty acids include tetraesters of pentaerythritol with hexanoic acid (C 6 ), heptanoic acid (C 7 ), octanoic acid (C 8 ), such as 2-ethylhexanoic acid (C 8 ), nonanoic acid (C 8 ), decanoic acid (C 10 ) and/or dodecanoic acid (C 12 ).
[0190] From the viewpoint of the IOB being from about 0.00 to about 0.60, in a triester of pentaerythritol and a fatty acid, the total number of carbons of the fatty acid composing the triester of the pentaerythritol and fatty acid, i.e. the total number of carbons of the R 1 C, R 2 C and R 3 C portions in formula (2), is preferably about 19 or greater (the IOB is 0.58 when the number of carbon atoms is 19).
[0191] From the viewpoint of the IOB being from about 0.00 to about 0.60, in a diester of pentaerythritol and a fatty acid, the total number of carbons of the fatty acid composing the diester of the pentaerythritol and fatty acid, i.e. the total number of carbons of the R 1 C and R 2 C portion in formula (3), is preferably about 22 or greater (the IOB is 0.59 when the number of carbon atoms is 22).
[0192] From the viewpoint of the IOB being from about 0.00 to about 0.60, in a monoester of pentaerythritol and a fatty acid, the total number of carbons of the fatty acid composing the monoester of the pentaerythritol and fatty acid, i.e. the number of carbons of the R 1 C portion in formula (4), is preferably about 25 or greater (the IOB is 0.60 when the number of carbon atoms is 25).
[0193] The effects of double bonds, triple bonds, iso-branches and tert-branches are not considered in this calculation of the IOB (same hereunder).
[0194] Commercial products which are esters of pentaerythritol and fatty acids include UNISTAR H-408BRS and H-2408BRS-22 (mixed product) (both products of NOF Corp.).
[0000] [(a 2 ) Ester of a Chain Hydrocarbon Triol and at Least One Fatty Acid]
[0195] Examples of esters of a chain hydrocarbon triol and at least one fatty acid include triesters of glycerin and fatty acids, represented by formula (5):
[0000]
[0196] diesters of glycerin and fatty acids, represented by the following formula (6):
[0000]
[0197] and monoesters of glycerin and fatty acids, represented by the following formula (7):
[0000]
[0198] wherein R 5 -R 7 each represent a chain hydrocarbon.
[0199] The fatty acid consisting of the ester of glycerin and a fatty acid (R 5 COOH, R 6 COOH and R 7 COOH) is not particularly restricted so long as the ester of glycerin and a fatty acid satisfies the conditions for the kinematic viscosity, water holding percentage and weight-average molecular weight, and for example, there may be mentioned the fatty acids mentioned for the “(a 1 ) Ester of a chain hydrocarbon tetraol and at least one fatty acid”, namely saturated fatty acids and unsaturated fatty acids, and in consideration of the potential for degradation by oxidation and the like, the ester is preferably a glycerin and fatty acid ester, which is derived from a saturated fatty acid, i.e., an ester of glycerin and a saturated fatty acid.
[0200] Also, from the viewpoint of lowering the water holding percentage and result in greater hydrophobicity, the ester of glycerin and a fatty acid is preferably a diester or triester, and more preferably a triester.
[0201] A triester of glycerin and a fatty acid is also known as a triglyceride, and examples include triesters of glycerin and octanoic acid (C 8 ), triesters of glycerin and decanoic acid (C 10 ), triesters of glycerin and dodecanoic acid (C 12 ), triesters of glycerin and 2 or 3 different fatty acids, and mixtures threreof.
[0202] Examples of triesters of glycerin and 2 or more fatty acids include triesters of glycerin with octanoic acid (C 8 ) and decanoic acid (C 10 ), triesters of glycerin with octanoic acid (C 8 ), decanoic acid (C 10 ) and dodecanoic acid (C 12 ), and triesters of glycerin with octanoic acid (C 8 ), decanoic acid (C 10 ), dodecanoic acid (C 12 ), tetradecanoic acid (C 14 ), hexadecanoic acid (C 16 ) and octadecanoic acid (C 18 ).
[0203] In order to obtain a melting point of about 45° C. or less, preferred triesters of glycerin and fatty acids are those with about 40 or less as the total number of carbons of the fatty acid consisting of the triester of glycerin and the fatty acid, i.e., the total number of carbons of the R 5 C, R 6 C and R 7 C sections in formula (5).
[0204] From the viewpoint of the IOB being from about 0.00 to about 0.60, in a triester of glycerin and a fatty acid, the total number of carbons of the fatty acid composing the triester of the glycerin and fatty acid, i.e. the total number of carbons of the R 5 C, R 6 C and R 7 C portions in formula (5), is preferably about 12 or greater (the IOB is 0.60 when the total number of carbon atoms is 12).
[0205] Triesters of glycerin and fatty acids, being aliphatic and therefore potential constituent components of the human body, are preferred from the viewpoint of safety.
[0206] Commercial products of triesters of glycerin and fatty acids include tri-coconut fatty acid glycerides, NA36, PANACET 800, PANACET 800B and PANACET 810S, and tri-C2L oil fatty acid glycerides and tri-CL oil fatty acid glycerides (all products of NOF Corp.).
[0207] A diester of glycerin and a fatty acid is also known as a diglyceride, and examples include diesters of glycerin and decanoic acid (C 10 ), diesters of glycerin and dodecanoic acid (C 12 ), diesters of glycerin and hexadecanoic acid (C 16 ), diesters of glycerin and 2 or more different fatty acids, and mixtures thereof.
[0208] From the viewpoint of the IOB being from about 0.00 to about 0.60, in a diester of glycerin and a fatty acid, the total number of carbons of the fatty acid composing the diester of the glycerin and fatty acid, i.e. the total number of carbons of the R 5 C and R 6 C portions in formula (6), is preferably about 16 or greater (the IOB is 0.58 when the total number of carbon atoms is 16).
[0209] Monoesters of glycerin and fatty acids are also known as monoglycerides, and examples include glycerin and octadecanoic acid (C 18 ) monoester, and glycerin and docosanoic acid (C 22 ) monoester.
[0210] From the viewpoint of the IOB being from about 0.00 to about 0.60, in a monoester of glycerin and a fatty acid, the total number of carbons of the fatty acid composing the monoester of the glycerin and fatty acid, i.e. the number of carbons of the R 5 C portion in formula (7), is preferably about 19 or greater (the IOB is 0.59 when the number of carbon atoms is 19).
[0000] [(a 3 ) Ester of a Chain Hydrocarbon Diol and at Least One Fatty Acid]
[0211] Examples of an ester of a chain hydrocarbon diol and at least one fatty acid include monoesters and diesters of fatty acids with C 2 -C 6 chain hydrocarbon diols, such as C 2 -C 6 glycols, including ethylene glycol, propylene glycol, butylene glycol, pentylene glycol and hexylene glycol.
[0212] Specifically, examples of an ester of a chain hydrocarbon diol and at least one fatty acid include diesters of C 2 -C 6 glycols and fatty acids, represented by the following formula (8):
[0000] R 8 COOC k H 2k OCOR 9 (8)
[0213] wherein k represents an integer of 2-6, and R 8 and R 9 each represent a chain hydrocarbon,
[0000] and monoesters of C 2 -C 6 glycols and fatty acids, represented by the following formula (9):
[0000] R 8 COOC k H 2k OH (9)
[0214] wherein k represents an integer of 2-6, and R 8 is a chain hydrocarbon.
[0215] The fatty acid to be esterified in an ester of a C 2 -C 6 glycol and a fatty acid (corresponding to R 8 COOH and R 9 COOH in formula (8) and formula (9)) is not particularly restricted so long as the ester of the C 2 -C 6 glycol and fatty acid satisfies the conditions for the kinematic viscosity, water holding percentage and weight-average molecular weight, and for example, there may be mentioned the fatty acids mentioned above for the “(a 1 ) Ester of a chain hydrocarbon tetraol and at least one fatty acid”, namely saturated fatty acids and unsaturated fatty acids, and in consideration of the potential for degradation by oxidation and the like, it is preferably a saturated fatty acid.
[0216] From the viewpoint of the IOB being from about 0.00 to about 0.60, in a diester of butylene glycol represented by formula (8) (k=4) and a fatty acid, the total number of carbons of the R 9 C and R 9 C portions is preferably about 6 or greater (the IOB is 0.60 when the total number of carbon atoms is 6).
[0217] From the viewpoint of the IOB being from about 0.00 to about 0.60, in a monoester of ethylene glycol represented by formula (9) (k=2) and a fatty acid, the number of carbons of the R 8 C portion is preferably about 12 or greater (the IOB is 0.57 when the number of carbon atoms is 12).
[0218] Considering the potential for degradation by oxidation and the like, the ester of the C 2 -C 6 glycol and fatty acid is preferably a C 2 -C 6 glycol and fatty acid ester derived from a saturated fatty acid, or in other words, an ester of a C 2 -C 6 glycol and a saturated fatty acid.
[0219] Also, from the viewpoint of lowering the water holding percentage, the ester of the C 2 -C 6 glycol and fatty acid is preferably a glycol and fatty acid ester derived from a glycol with a greater number of carbons, such as an ester of a glycol and a fatty acid derived from butylene glycol, pentylene glycol or hexylene glycol.
[0220] Also, from the viewpoint of lowering the water holding percentage, the ester of a C 2 -C 6 glycol and fatty acid is preferably a diester.
[0221] Examples of commercial products of esters of C 2 -C 6 glycols and fatty acids include COMPOL BL and COMPOL BS (both products of NOF Corp.).
[0000] [(B) Ether of (B1) a Compound Having a Chain Hydrocarbon Moiety and 2-4 Hydroxyl Groups Substituting for Hydrogens on the Chain Hydrocarbon Moiety and (B2) a Compound Having a Chain Hydrocarbon Moiety and 1 Hydroxyl Group Substituting for a Hydrogen on the Chain Hydrocarbon Moiety]
[0222] In the (B) ether of (B1) a compound having a chain hydrocarbon moiety and 2-4 hydroxyl groups substituting for hydrogens on the chain hydrocarbon moiety and (B2) a compound having a chain hydrocarbon moiety and 1 hydroxyl group substituting for a hydrogen on the chain hydrocarbon moiety (hereunder also referred to as “compound (B)”), it is not necessary for all of the hydroxyl groups to be etherified so long as the kinematic viscosity, water holding percentage and weight-average molecular weight are within the aforementioned ranges.
[0223] Examples of (B1) a compound having a chain hydrocarbon moiety and 2-4 hydroxyl groups substituting for hydrogens on the chain hydrocarbon moiety (hereunder also referred to as “compound (B1)”) include those mentioned for “compound (A)” as compound (A1), such as pentaerythritol, glycerin and glycol.
[0224] Examples of (B2) a compound having a chain hydrocarbon moiety and 1 hydroxyl group substituting for a hydrogen on the chain hydrocarbon moiety (hereunder also referred to as “compound (B2)”) include compounds wherein 1 hydrogen on the hydrocarbon is substituted with 1 hydroxyl group (—OH), such as aliphatic monohydric alcohols, including saturated aliphatic monohydric alcohols and unsaturated aliphatic monohydric alcohols.
[0225] Examples of saturated aliphatic monohydric alcohols include C 1 -C 20 saturated aliphatic monohydric alcohols, such as methyl alcohol (C 1 ) (C 1 representing the number of carbon atoms, same hereunder), ethyl alcohol (C 2 ), propyl alcohol (C 3 ) and isomers thereof, including isopropyl alcohol (C 3 ), butyl alcohol (C 4 ) and isomers thereof, including sec-butyl alcohol (C 4 ) and tert-butyl alcohol (C 4 ), pentyl alcohol (C 5 ), hexyl alcohol (C 6 ), heptyl alcohol (C 7 ), octyl alcohol (C 8 ) and isomers thereof, including 2-ethylhexyl alcohol (C 8 ), nonyl alcohol (C 9 ), decyl alcohol (C 10 ), dodecyl alcohol (C 12 ), tetradecyl alcohol (C 14 ), hexadecyl alcohol (C 16 ), heptadecyl alcohol (C 17 ), octadecyl alcohol (C 18 ) and eicosyl alcohol (C 20 ), as well as their isomers other than those mentioned.
[0226] Unsaturated aliphatic monohydric alcohols include those wherein 1 C—C single bond of a saturated aliphatic monohydric alcohol mentioned above is replaced with a C═C double bond, such as oleyl alcohol, and for example, such alcohols are commercially available by New Japan Chemical Co., Ltd. as the RIKACOL Series and UNJECOL Series.
[0227] Examples for compound (B) include (b 1 ) an ether of a chain hydrocarbon tetraol and at least one aliphatic monohydric alcohol, such as monoethers, diethers, triethers and tetraethers, preferably diethers, triethers and tetraethers, more preferably triethers and tetraethers and even more preferably tetraethers, (b 2 ) an ether of a chain hydrocarbon triol and at least one aliphatic monohydric alcohol, such as monoethers, diethers and triethers, preferably diethers and triethers and more preferably triethers, and (b 3 ) an ether of a chain hydrocarbon diol and at least one aliphatic monohydric alcohol, such as monoethers and diethers, and preferably diethers.
[0228] Examples of an ether of a chain hydrocarbon tetraol and at least one aliphatic monohydric alcohol include tetraethers, triethers, diethers and monoethers of pentaerythritol and aliphatic monohydric alcohols, represented by the following formulas (10)-(13):
[0000]
[0229] wherein R 10 -R 13 each represent a chain hydrocarbon.
[0230] Examples of an ether of a chain hydrocarbon triol and at least one aliphatic monohydric alcohol include triethers, diethers and monoethers of glycerin and aliphatic monohydric alcohols, represented by the following formulas (14)-(16):
[0000]
[0231] wherein R 14 -R 16 each represent a chain hydrocarbon.
[0232] Examples of an ether of a chain hydrocarbon diol and at least one aliphatic monohydric alcohol include diethers of C 2 -C 6 glycols and aliphatic monohydric alcohols, represented by the following formula (17):
[0000] R 17 OC n H 2n OR 18 (17)
[0233] wherein n is an integer of 2-6, and R 17 and R 18 are each a chain hydrocarbon,
[0234] and monoethers of C 2 -C 6 glycols and aliphatic monohydric alcohols, represented by the following formula (18):
[0000] R 17 OC n H 2n OH (18)
[0235] wherein n is an integer of 2-6, and R 17 is a chain hydrocarbon.
[0236] From the viewpoint of the IOB being between about 0.00 and about 0.60, in a tetraether of pentaerythritol and an aliphatic monohydric alcohol, the total number of carbon atoms of the aliphatic monohydric alcohol composing the tetraether of pentaerythritol and the aliphatic monohydric alcohol, i.e. the total number of carbon atoms of the R 10 , R 11 , R 12 and R 13 portions in formula (10), is preferably about 4 or greater (the IOB is 0.44 when the total number of carbon atoms is 4).
[0237] From the viewpoint of the IOB being between about 0.00 and about 0.60, in a triether of pentaerythritol and an aliphatic monohydric alcohol, the total number of carbon atoms of the aliphatic monohydric alcohol composing the triether of pentaerythritol and the aliphatic monohydric alcohol, i.e. the total number of carbon atoms of the R 10 , R 11 and R 12 portions in formula (11), is preferably about 9 or greater (the IOB is 0.57 when the total number of carbon atoms is 9).
[0238] From the viewpoint of the IOB being between about 0.00 and about 0.60, in a diether of pentaerythritol and an aliphatic monohydric alcohol, the total number of carbon atoms of the aliphatic monohydric alcohol composing the diether of pentaerythritol and the aliphatic monohydric alcohol, i.e. the total number of carbon atoms of the R 10 and R 11 portions in formula (12), is preferably about 15 or greater (the IOB is 0.60 when the total number of carbon atoms is 15).
[0239] From the viewpoint of the IOB being between about 0.00 and about 0.60, in a monoether of pentaerythritol and an aliphatic monohydric alcohol, the number of carbon atoms of the aliphatic monohydric alcohol composing the monoether of pentaerythritol and the aliphatic monohydric alcohol, i.e. the number of carbon atoms of the R 10 portion in formula (13), is preferably about 22 or greater (the IOB is 0.59 when the number of carbon atoms is 22).
[0240] From the viewpoint of the IOB being between about 0.00 and about 0.60, in a triether of glycerin and an aliphatic monohydric alcohol, the total number of carbon atoms of the aliphatic monohydric alcohol composing the triether of glycerin and the aliphatic monohydric alcohol, i.e. the total number of carbon atoms of the R 14 , R 15 and R 16 portions in formula (14), is preferably about 3 or greater (the IOB is 0.50 when the total number of carbon atoms is 3).
[0241] From the viewpoint of the IOB being between about 0.00 and about 0.60, in a diether of glycerin and an aliphatic monohydric alcohol, the total number of carbon atoms of the aliphatic monohydric alcohol composing the diether of glycerin and the aliphatic monohydric alcohol, i.e. the total number of carbon atoms of the R 14 and R 15 portions in formula (15), is preferably about 9 or greater (the IOB is 0.58 when the total number of carbon atoms is 9).
[0242] From the viewpoint of the IOB being between about 0.00 and about 0.60, in a monoether of glycerin and an aliphatic monohydric alcohol, the number of carbon atoms of the aliphatic monohydric alcohol composing the monoether of glycerin and the aliphatic monohydric alcohol, i.e. the number of carbon atoms of the R 14 portion in formula (16), is preferably 16 or greater (the IOB is 0.58 when the number of carbon atoms is 16).
[0243] From the viewpoint of the IOB being from about 0.00 to about 0.60, in a diether of butylene glycol represented by formula (17) (n=4) and an aliphatic monohydric alcohol, the total number of carbon atoms of the R 17 and R 18 portions is preferably about 2 or greater (the IOB is 0.33 when the total number of carbon atoms is 2).
[0244] From the viewpoint of the IOB being from about 0.00 to about 0.60, in a monoether of ethylene glycol represented by formula (18) (n=2) and an aliphatic monohydric alcohol, the number of carbon atoms of the R 17 portion is preferably about 8 or greater (the IOB is 0.60 when the number of carbon atoms is 8).
[0245] Compound (B) may be produced by dehydrating condensation of compound (B1) and compound (B2) in the presence of an acid catalyst.
[0000] [(C) Ester of (C1) a Carboxylic Acid, Hydroxy Acid, Alkoxy Acid or Oxoacid Comprising a Chain Hydrocarbon Moiety and 2-4 Carboxyl Groups Substituting for Hydrogens on the Chain Hydrocarbon Moiety and (C2) a Compound Having a Chain Hydrocarbon Moiety and 1 Hydroxyl Group Substituting for a Hydrogen on the Chain Hydrocarbon Moiety]
[0246] In the (C) ester of (C1) a carboxylic acid, hydroxy acid, alkoxy acid or oxoacid comprising a chain hydrocarbon moiety and 2-4 carboxyl groups substituting for hydrogens on the chain hydrocarbon moiety and (C2) a compound having a chain hydrocarbon moiety and 1 hydroxyl group substituting for a hydrogen on the chain hydrocarbon moiety (hereunder also referred to as “compound (C)”), it is not necessary for all of the carboxyl groups to be esterified so long as the kinematic viscosity, water holding percentage and weight-average molecular weight are within the aforementioned ranges.
[0247] Examples of (C1) a carboxylic acid, hydroxy acid, alkoxy acid or oxoacid comprising a chain hydrocarbon moiety and 2-4 carboxyl groups substituting for hydrogens on the chain hydrocarbon moiety (hereunder also referred to as “compound (C1)”) include chain hydrocarbon carboxylic acids with 2-4 carboxyl groups, such as chain hydrocarbon dicarboxylic acids including alkanedicarboxylic acids, such as ethanedioic acid, propanedioic acid, butanedioic acid, pentanedioic acid, hexanedioic acid, heptanedioic acid, octanedioic acid, nonanedioic acid and decanedioic acid, chain hydrocarbon tricarboxylic acids, including alkanetricarboxylic acids, such as propanetrioic acid, butanetrioic acid, pentanetrioic acid, hexanetrioic acid, heptanetrioic acid, octanetrioic acid, nonanetrioic acid and decanetrioic acid, and chain hydrocarbon tetracarboxylic acids, including alkanetetracarboxylic acids, such as butanetetraoic acid, pentanetetraoic acid, hexanetetraoic acid, heptanetetraoic acid, octanetetraoic acid, nonanetetraoic acid and decanetetraoic acid.
[0248] Compound (C1) includes chain hydrocarbon hydroxy acids with 2-4 carboxyl groups, such as malic acid, tartaric acid, citric acid and isocitric acid, chain hydrocarbon alkoxy acids with 2-4 carboxyl groups, such as O-acetylcitric acid, and chain hydrocarbon oxoacids with 2-4 carboxyl groups.
[0249] (C2) Compound having a chain hydrocarbon moiety and 1 hydroxyl group substituting for a hydrogen on the chain hydrocarbon moiety includes those mentioned for “compound (B)”, such as aliphatic monohydric alcohols.
[0250] Compound (C) may be (c 1 ) an ester, for example a monoester, diester, triester or tetraester, preferably a diester, triester or tetraester, more preferably a triester or tetraester and even more preferably a tetraester, of a chain hydrocarbon tetracarboxylic acid, hydroxy acid, alkoxy acid or oxoacid with 4 carboxyl groups, and at least one aliphatic monohydric alcohol, (c 2 ) an ester, for example, a monoester, diester or triester, preferably a diester or triester and more preferably a triester, of a chain hydrocarbon tricarboxylic acid, hydroxy acid, alkoxy acid or oxoacid with 3 carboxyl groups, and at least one aliphatic monohydric alcohol, or (c 3 ) an ester, for example, a monoester or diester, and preferably a diester, of a chain hydrocarbon dicarboxylic acid, hydroxy acid, alkoxy acid or oxoacid with 2 carboxyl groups, and at least one aliphatic monohydric alcohol.
[0251] Examples for compound (C) include dioctyl adipate, and tributyl O-acetylcitrate, of which commercially available products exist.
[0000] [(D) Compound Having a Chain Hydrocarbon Moiety and One Bond Selected from the Group Consisting of an Ether Bond (—O—), Carbonyl Bond (—CO—), Ester Bond (—COO—) and Carbonate Bond (—OCOO—) Inserted Between a C—C Single Bond of the Chain Hydrocarbon Moiety]
[0252] The (D) compound having a chain hydrocarbon moiety and one bond selected from the group consisting of an ether bond (—O—), carbonyl bond (—CO—), ester bond (—COO—) and carbonate bond (—OCOO—) inserted between a C—C single bond of the chain hydrocarbon moiety (hereunder also referred to as “compound (D)”) may be (d 1 ) an ether of an aliphatic monohydric alcohol and an aliphatic monohydric alcohol, (d 2 ) a dialkyl ketone, (d 3 ) an ester of a fatty acid and an aliphatic monohydric alcohol, or (d 4 ) a dialkyl carbonate.
[0000] [(d 1 ) Ether of an Aliphatic Monohydric Alcohol and an Aliphatic Monohydric Alcohol]
[0253] Ethers of an aliphatic monohydric alcohol and an aliphatic monohydric alcohol include compounds having the following formula (19):
[0000] R 19 OR 20 (19)
[0254] wherein R 19 and R 20 each represent a chain hydrocarbon.
[0255] The aliphatic monohydric alcohol consisting of the ether (corresponding to R 19 OH and R 20 OH in formula (19)) is not particularly restricted so long as the ether satisfies the conditions for the kinematic viscosity, water holding percentage and weight-average molecular weight, and for example, it may be one of the aliphatic monohydric alcohols mentioned for “compound (B)”.
[0000] [(d 2 ) Dialkyl Ketone]
[0256] The dialkyl ketone may be a compound of the following formula (20):
[0000] R 21 COR 22 (20)
[0257] wherein R 21 and R 22 are each an alkyl group.
[0258] The dialkyl ketone may be a commercially available product, or it may be obtained by a known method, such as by oxidation of a secondary alcohol with chromic acid or the like.
[0000] [(d 3 ) Ester of a Fatty Acid and an Aliphatic Monohydric Alcohol]
[0259] Examples of esters of a fatty acid and an aliphatic monohydric alcohol include compounds having the following formula (21):
[0000] R 23 COOR 24 (21)
[0260] wherein R 23 and R 24 each represent a chain hydrocarbon.
[0261] Examples of fatty acids consisting of these esters (corresponding to R 23 COOH in formula (21)) include the fatty acids mentioned for the “(a 1 ) an ester of a chain hydrocarbon tetraol and at least one fatty acids”, and specifically these include saturated fatty acids and unsaturated fatty acids, with saturated fatty acids being preferred in consideration of the potential for degradation by oxidation and the like. The aliphatic monohydric alcohol consisting of the ester (corresponding to R 24 OH in formula (21)) may be one of the aliphatic monohydric alcohols mentioned for “compound (B)”.
[0262] Examples of esters of such fatty acids and aliphatic monohydric alcohols include esters of dodecanoic acid (C 12 ) and dodecyl alcohol (C 12 ) and esters of tetradecanoic acid (C 14 ) and dodecyl alcohol (C 12 ), and examples of commercial products of esters of such fatty acids and aliphatic monohydric alcohols include ELECTOL WE20 and ELECTOL WE40 (both products of NOF Corp.).
[0000] [(d 4 ) Dialkyl Carbonate]
[0263] The dialkyl carbonate may be a compound of the following formula (22):
[0000] R 25 OC(═O)OR 26 (22)
[0264] wherein R 25 and R 26 are each an alkyl group.
[0265] The dialkyl carbonate may be a commercially available product, or it may be synthesized by reaction between phosgene and an alcohol, reaction between formic chloride and an alcohol or alcoholate, or reaction between silver carbonate and an alkyl iodide.
[0266] From the viewpoint of the water holding percentage and vapor pressure, the weight-average molecular weight is preferably about 100 or greater and more preferably about 200 or greater, for (d 1 ) an ether of an aliphatic monohydric alcohol and an aliphatic monohydric alcohol, (d 2 ) a dialkyl ketone, (d 3 ) an ester of a fatty acid and an aliphatic monohydric alcohol, and (d 4 ) a dialkyl carbonate.
[0267] If the total number of carbon atoms is about 8 in a (d 2 ) dialkyl ketone, the melting point will be approximately −50° C. and the vapor pressure will be about 230 Pa at 20° C., in the case of 5-nonanone, for example.
[(E) Polyoxy C 3 -C 6 Alkylene Glycol, or Alkyl Ester or Alkyl Ether Thereof]
[0268] The (E) polyoxy C 3 -C 6 alkylene glycol, or alkyl ester or alkyl ether thereof (hereunder also referred to as “compound (E)”) may be (e 1 ) a polyoxy C 3 -C 6 alkylene glycol, (e 2 ) an ester of a polyoxy C 3 -C 6 alkylene glycol and at least one fatty acid, or (e 3 ) an ether of a polyoxy C 3 -C 6 alkylene glycol and at least one aliphatic monohydric alcohol. These will now be explained.
[0000] [(e 1 ) Polyoxy C 3 -C 6 Alkylene Glycol]
[0269] Polyoxy C 3 -C 6 alkylene glycols refer to i) homopolymers having one unit selected from the group consisting of oxy C 3 -C 6 alkylene units, such as oxypropylene unit, oxybutylene unit, oxypentylene unit and oxyhexylene unit and having hydroxyl groups at both ends, ii) block copolymers having 2 or more units selected from oxy C 3 -C 6 alkylene units described above and oxyhexylene unit and having hydroxyl groups at both ends, or iii) random copolymers having 2 or more units selected from oxy C 3 -C 6 alkylene units described above and having hydroxyl groups at both ends.
[0270] The polyoxy C 3 -C 6 alkylene glycol can be represented by the following formula (23):
[0000] HO—(C m H 2m O) n —H (23)
[0271] wherein m represents an integer of 3-6.
[0272] The present inventors have found that with polypropylene glycol (corresponding to a homopolymer of formula (23) where m=3), the condition for the water holding percentage is not satisfied when the weight-average molecular weight is less than about 1,000. Therefore, polypropylene glycol homopolymer is not included in the scope of the blood slipping agent described above, and propylene glycol should be included in the (e 1 ) polyoxy C 3 -C 6 alkylene glycol only as a copolymer or random polymer with another glycol.
[0273] Incidentally, investigation by the present inventors suggests that with polyethylene glycol (corresponding to a homopolymer of formula (23) where m=2), the condition for the kinematic viscosity and water holding percentage cannot be satisfied when the weight-average molecular weight is less than about 1,000.
[0274] From the viewpoint of the IOB being about 0.00 to about 0.60, when formula (23) is polybutylene glycol (a homopolymer where m=4), for example, preferably n about 7 (when n=7, the IOB is 0.57).
[0275] Examples of commercial products of poly C 3 -C 6 alkylene glycols include UNIOL™ PB-500 and PB-700 (all products of NOF Corp.).
[0000] [(e 2 ) Ester of a Polyoxy C 3 -C 6 Alkylene Glycol and at Least One Fatty Acid]
[0276] Examples of an ester of a polyoxy C 3 -C 6 alkylene glycol and at least one fatty acids include the polyoxy C 3 -C 6 alkylene glycols mentioned for “(e 1 ) Polyoxy C 3 -C 6 alkylene glycol” in which one or both OH ends have been esterified with fatty acids, i.e. monoesters and diesters.
[0277] Examples of fatty acids to be esterified in the ester of a polyoxy C 3 -C 6 alkylene glycol and at least one fatty acid include the fatty acids mentioned for the “(a 1 ) Ester of a chain hydrocarbon tetraol and at least one fatty acid”, and specifically these include saturated fatty acids and unsaturated fatty acids, with saturated fatty acids being preferred in consideration of the potential for degradation by oxidation and the like.
[0000] [(e 3 ) Ether of a Polyoxy C 3 -C 6 Alkylene Glycol and at Least One Aliphatic Monohydric Alcohol]
[0278] Examples of an ether of a polyoxy C 3 -C 6 alkylene glycols and at least one aliphatic monohydric alcohol include the polyoxy C 3 -C 6 alkylene glycols mentioned for “(e 1 ) Polyoxy C 3 -C 6 alkylene glycol” wherein one or both OH ends have been etherified by an aliphatic monohydric alcohol, i.e. monoethers and diethers.
[0279] In an ether of a polyoxy C 3 -C 6 alkylene glycol and at least one aliphatic monohydric alcohol, the aliphatic monohydric alcohol to be etherified may be an aliphatic monohydric alcohol among those mentioned for “compound (B)”.
[(F) Chain Hydrocarbon]
[0280] Examples of chain hydrocarbons include (f 1 ) chain alkanes, such as straight-chain alkanes and branched chain alkanes. Straight-chain alkanes with melting points of about 45° C. or less have up to about 22 carbon atoms, and at a vapor pressure of 1 atmosphere and no greater than about 0.01 Pa at 25° C., the number of carbon atoms is 13 or greater. Branched chain alkanes tend to have lower melting points than chain alkanes, given the same number of carbon atoms. Branched chain alkanes may therefore include those with 22 and more carbon atoms, even with melting points of below about 45° C.
[0281] Examples of commercially available hydrocarbon products include PARLEAM 6 (NOF Corp.).
[0282] In a nonwoven fabric according to one embodiment of this disclosure, the ridges have blood slipping agent-containing regions that contain the aforementioned blood slipping agent. In a nonwoven fabric according to another embodiment of the disclosure, the ridges have blood slipping agent-containing regions that consist entirely of a blood slipping agent. In a nonwoven fabric according to yet another embodiment of this disclosure, the ridges have blood slipping agent-containing regions that comprise a blood slipping agent-containing composition including the aforementioned blood slipping agent and at least one other component.
[0283] In a nonwoven fabric according to one embodiment of this disclosure, the furrows have blood slipping agent-containing regions that contain a blood slipping agent. In a nonwoven fabric according to another embodiment of the disclosure, the furrows have blood slipping agent-containing regions that consist entirely of a blood slipping agent. In a nonwoven fabric according to yet another embodiment of this disclosure, the furrows have blood slipping agent-containing regions that comprise a blood slipping agent-containing composition including the aforementioned blood slipping agent and at least one other component.
[0284] Such a blood slipping agent-containing composition will now be described.
[Blood Slipping Agent-Containing Composition]
[0285] The blood slipping agent-containing composition contains a blood slipping agent and at least one other component. The other component is not particularly restricted so long as it does not inhibit the effect of the present disclosure, and it may be any one commonly employed in absorbent articles of the art, and especially top sheets.
[0286] Examples for the other component(s) include silicone oils, silicones, silicone-based resins and the like.
[0287] Examples for the other component(s) also include antioxidants, such as BHT (2,6-di-t-butyl-p-cresol), BHA (butylated hydroxyanisole) and propyl gallate.
[0288] Further examples for the other component(s) include vitamins, such as natural vitamins and synthetic vitamins. Examples of vitamins include water-soluble vitamins, such as group B vitamins, including vitamin B 1 , vitamin B 2 , vitamin B 3 , vitamin B 5 , vitamin B 6 , vitamin B 7 , vitamin B 9 and vitamin B 12 , and vitamin C.
[0289] Other examples of vitamins include fat-soluble vitamins, such as group A vitamins, group D vitamins, group E vitamins and group K vitamins.
[0290] The derivatives of these vitamins are also included.
[0291] Examples for the other component(s) include amino acids, such as alanine, arginine, lysine, histidine, proline and hydroxyproline, and peptides.
[0292] Other examples for the other component(s) include zeolite, such as natural zeolite, examples of which include analcite, chabazite, heulandite, natrolite, stilbite and thomosonite, and synthetic zeolite.
[0293] Still other examples for the other component(s) include cholesterol, hyaluronic acid, lecithin and ceramide.
[0294] Yet other examples for the other component(s) include drugs, such as skin astringents, anti-pimple medications, anti-wrinkle agents, anti-cellulite agents, skin whiteners, antimicrobial agents and antifungal agents.
[0295] Examples of skin astringents include zinc oxide, aluminum sulfate, tannic acid and the like, and oil-soluble skin astringents, such as fat-soluble polyphenols. Fat-soluble polyphenols include natural fat-soluble polyphenols, such as barley extract, otogiriso extract, white deadnettle extract, chamomilla extract, burdock extract, salvia extract, linden extract, common lime extract, white birch extract, common horsetail extract, sage extract, salvia extract, walnut ( J. regia L. var. orientalis ) extract, hibiscus extract, loquat leaf extract, Miquel's linden extract, hop extract, common horse-chestnut extract and coix seed extract.
[0296] Examples of anti-pimple medications include salicylic acid, benzoyl peroxide, resorcinol, sulfur, erythromycin and zinc.
[0297] Examples of anti-wrinkle agents include lactic acid, salicylic acid, salicylic acid derivatives, glycolic acid, phytic acid, lipoic acid and lysophosphatidic acid.
[0298] Examples of anti-cellulite agents include xanthine compounds, such as aminophylline, caffeine, theophylline and theobromine.
[0299] Examples of skin whiteners include niacinamide, kojic acid, arbutin, glucosamine and its derivatives, phytosterol derivatives, and ascorbic acid and its derivatives, as well as mulberry extract and placenta extract.
[0300] Examples for the other component(s) also include anti-inflammatory components, pH regulators, antimicrobial agents, humectants, aromatics, pigments, dyes, pigments and plant extracts. Examples of anti-inflammatory components include naturally-derived anti-inflammatory drugs, such as peony, golden grass, otogiriso, chamomile, licorice, peach leaf, Japanese mugwort and perilla extract, and synthetic anti-inflammatory drugs, such as allantoin and dipotassium glycyrrhizinate.
[0301] Examples of pH regulators include those that keep the skin weakly acidic, such as malic acid, succinic acid, citric acid, tartaric acid and lactic acid.
[0302] Titanium oxide is an example of a pigment.
[0303] The blood slipping agent-containing composition contains the blood slipping agent and the one or more other components at preferably about 50 to about 99 mass % and about 1 to about 50 mass %, respectively, more preferably about 60 to about 99 mass % and about 1 to about 40 mass %, respectively, even more preferably about 70 to about 99 mass % and about 1 to about 30 mass %, respectively, yet more preferably about 80 to about 99 mass % and about 1 to about 20 mass %, respectively, even yet more preferably about 90 to 99 mass % and about 1 to about 10 mass %, respectively, and even yet more preferably about 95 to 99 mass % and about 1 to about 5 mass %, respectively. These ranges are from the viewpoint of the effect of the present disclosure.
[0304] The blood slipping agent-containing composition preferably contains a surfactant in no greater than the amount from hydrophilicizing treatment of the top sheet or second sheet. More specifically, the blood slipping agent-containing composition contains a surfactant in a basis weight range of preferably about 0.0 to about 1.0 g/m 2 , more preferably about 0.0 to about 0.8 g/m 2 , even more preferably about 0.1 to about 0.5 g/m 2 , and yet more preferably about 0.1 to about 0.3 g/m 2 .
[0305] This is because when the amount of surfactant is increased, menstrual blood will tend to be retained in the top sheet. The surfactant, incidentally, has no water holding percentage. This is because there is no layer of the substance to be measured, due to admixture with water.
[0306] The blood slipping agent-containing composition contains water in a basis weight range of preferably about 0.0 to about 1.0 g/m 2 , more preferably about 0.0 to about 0.8 g/m 2 , even more preferably about 0.1 to about 0.5 g/m 2 , and yet more preferably about 0.1 to about 0.3 g/m 2 .
[0307] Since water lowers the absorption performance of the absorbent article, the amount is preferably low.
[0308] Similar to the blood slipping agent, the blood slipping agent-containing composition, as a composition, has at 40° C., a kinematic viscosity of preferably about 0 to about 80 mm 2 /s, more preferably a kinematic viscosity of about 1 to about 70 mm 2 /s, even more preferably a kinematic viscosity of about 3 to about 60 mm 2 /s, yet more preferably a kinematic viscosity of about 5 to about 50 mm 2 /s, and even yet more preferably a kinematic viscosity of about 7 to about 45 mm 2 /s.
[0309] If the kinematic viscosity of the blood slipping agent-containing composition exceeds 80 mm 2 /s, the viscosity will increase, and the blood slipping agent composition may not slide down into the interior of the absorbent article as easily with menstrual blood that has reached the skin contact surface of the top sheet.
[0310] When the blood slipping agent-containing composition contains a component that is miscible with the blood slipping agent, as at least one other component, the other component preferably has a weight-average molecular weight of less than about 1000, and more preferably a weight-average molecular weight of less than about 900. This is because, if the weight-average molecular weight is about 1000 or higher, tack may result in the blood slipping agent-containing composition itself, tending to create a feeling of unpleasantness for the wearer. If the weight-average molecular weight increases, the viscosity of the blood slipping agent-containing composition will tend to increase, and it will therefore be difficult to lower the viscosity of the blood slipping agent composition by heating to a viscosity suitable for coating, and as a result, the blood slipping agent may need to be diluted with a solvent.
[0311] The blood slipping agent-containing composition, as a composition, has a water holding percentage of about 0.01 to about 4.0 mass %, preferably it has a water holding percentage of about 0.02 to about 3.5 mass %, more preferably it has a water holding percentage of about 0.03 to about 3.0 mass %, even more preferably it has a water holding percentage of about 0.04 to about 2.5 mass %, and yet more preferably it has a water holding percentage of about 0.05 to about 2.0 mass %.
[0312] A low water holding percentage value will tend to lower the affinity between the blood slipping agent composition and menstrual blood, thus inhibiting it from sliding down into the interior of the absorbent article with menstrual blood that has reached the skin contact surface of the top sheet.
[0313] When the blood slipping agent-containing composition contains solid matter, it is preferably removed by filtration for measurement of the kinematic viscosity and water holding percentage.
[0314] The blood slipping agent or blood slipping agent-containing composition may, if desired, be applied as a coating solution containing a volatile solvent, such as an alcohol-based solvent, ester-based solvent or aromatic solvent. If the coating solution includes a volatile solvent, the viscosity of the coating solution containing the blood slipping agent or blood slipping agent-containing composition will be lowered, thereby allowing the application steps to be simplified, facilitating application and making heating during application unnecessary.
[Nonwoven Fabric and Method for Producing Absorbent Article]
[0315] The nonwoven fabric of the disclosure can be produced by a method known in the technical field. The nonwoven fabric of the disclosure can be produced, for example, according to the method described in PTL 1, by forming a nonwoven fabric that is to have through-holes formed therein and that is to be coated with a blood slipping agent, and then providing perforated sections (through-holes) in the ridges by perforation to form a nonwoven fabric that is to be coated with a blood slipping agent, and subsequently coating a blood slipping agent onto the nonwoven fabric that is to be coated with the blood slipping agent. For example, a nonwoven fabric 1 as shown in FIG. 1 to FIG. 4 , prior to formation of perforated sections 4 ′, can be produced according to the “first embodiment” in PTL 1.
[0316] When a nonwoven fabric is to be produced in a nonwoven fabric production apparatus, such as described in PTL 1, using a supporting member, such as shown in FIG. 3 of PTL 1, it is possible to produce a nonwoven fabric having a plurality of ridges and a plurality of furrows, wherein the furrows have a plurality of openings and joints connecting every two adjacent ridges between every two adjacent openings.
[0317] The perforation method may be carried out according to a method known in the technical field, but it is preferred to employ a perforation method, such as shown in FIG. 7 , for example.
[0318] FIG. 7 is a diagram illustrating an example of a method of forming perforated sections.
[0319] A core wrap sheet 122 supplied from a core wrap roll 121 is transported by a belt conveyor 101 in the machine direction MD. Next, ground pulp and an absorbent polymer 131 are supplied from a ground pulp/absorbent polymer supply apparatus (not shown), to a pattern drum 132 . Recesses 133 are formed around the outer periphery of the pattern drum 132 , for molding of the ground pulp and the absorbent polymer. The interior of the pattern drum 132 is aspirated, so that the ground pulp and absorbent polymer 131 supplied to the pattern drum 132 are sucked into the recesses 133 , and they are compacted to form an absorbent core 102 . The absorbent core 102 is then layered onto the core wrap sheet 122 .
[0320] Next, the nonwoven fabric sheet 112 supplied from the nonwoven fabric roll 111 is merged with the core wrap sheet 122 from below the core wrap sheet 122 , and a sealer 141 is used to fold the section of the core wrap sheet 122 that is protruding to the outer side (the widthwise direction perpendicular to the machine direction MD) onto the absorbent core 102 to form an absorbent body 103 on the nonwoven fabric sheet 112 .
[0321] A perforation apparatus 151 is then used to form perforated sections by perforation in the nonwoven fabric sheet 112 and absorbent body 103 . The perforation apparatus 151 includes a protrusion roll 152 having a plurality of protrusions 152 a with shapes, such as needle-like, cylindrical or conical shapes on the outer peripheral surface, and a plain roll 153 having a smooth surface on the outer periphery. The rotational direction of the protrusion roll 152 and the plain roll 153 is the same direction as the direction of movement of the nonwoven fabric sheet 112 and the absorbent body 103 (the machine direction MD).
[0322] The nonwoven fabric sheet 112 and the absorbent body 103 are passed between the protrusion roll 152 and the plain roll 153 , to form perforated sections on the nonwoven fabric sheet 112 and depressed sections in the absorbent body 103 . The perforated sections in the nonwoven fabric sheet 112 and the depressed sections in the absorbent body 103 are formed at matching locations in the thickness direction.
[0323] This method forms a nonwoven fabric that is to be coated with a blood slipping agent.
[0324] FIG. 7 shows an example wherein both the nonwoven fabric sheet 112 and the absorbent body 103 are bored simultaneously, but according to a different embodiment, a perforation apparatus, such as shown in FIG. 7 is used to bore only the nonwoven fabric and form perforated sections in the nonwoven fabric.
[0325] There are no particular restrictions on the method of applying the blood slipping agent or blood slipping agent-containing composition, or the coating solution containing it, and if necessary the blood slipping agent or blood slipping agent-containing composition or the coating solution containing it may be heated, and a coating applicator, for example a non-contact coater, such as a spiral coater, curtain coater, spray coater or dip coater, or a contact coater, may be used for application of the blood slipping agent or blood slipping agent-containing composition or the coating solution containing it. The coating applicator is preferably a non-contact coater, from the viewpoint of uniformly dispersing the droplet or particulate modifying agent throughout, and from the viewpoint of not causing damage in the material.
[0326] The blood slipping agent or blood slipping agent-containing composition, or the coating solution containing it, may be coated directly, if it is a liquid at room temperature, or it may be heated to lower the viscosity, and when it is a solid at room temperature, it may be heated to liquefaction and coated from a control seam HMA (Hot Melt Adhesive) gun. By increasing the air pressure of the control seam HMA gun, it is possible to apply the blood slipping agent or blood slipping agent-containing composition as fine particulates.
[0327] The coating amount of the blood slipping agent or blood slipping agent-containing composition may be adjusted, for example, by increasing or reducing the amount of application from the control seam HMA gun.
[0328] For example, a blood slipping agent or the like may be applied along the ridges from a control seam HMA gun to form blood slipping agent-containing regions in the ridges.
[0329] Alternatively, a blood slipping agent or the like may be applied from a control seam HMA gun onto the entire nonwoven fabric that is to be coated with the blood slipping agent, to form blood slipping agent-containing regions in the ridges and furrows.
[0330] An absorbent article including the nonwoven fabric of this disclosure can be produced by a method known in the technical field. For example, the absorbent article can be produced by layering a liquid-permeable back sheet, an absorbent body and the aforementioned nonwoven fabric with an adhesive between them, and then cutting it into an absorbent article shape.
[0331] The nonwoven fabric of the disclosure may have stamped sections formed by stamping the nonwoven fabric. If the nonwoven fabric of the disclosure has stamped sections, the blood slipping agent will slide down from the projections to the recesses, together with menstrual blood, and menstrual blood will subsequently be able to rapidly migrate into the absorbent body.
[0332] Any liquid-permeable top sheet that is commonly used in the technical field may be employed without any particular restrictions, and for example, it may be a sheet-like material having a structure that allows permeation of liquids, such as a film, woven fabric, nonwoven fabric or the like. The fibers composing such a woven fabric or nonwoven fabric may be natural fibers or chemical fibers, with examples of natural fibers including cellulose, such as ground pulp and cotton, and examples of chemical fibers including regenerated cellulose, such as rayon and fibril rayon, semi-synthetic cellulose, such as acetate and triacetate, thermoplastic hydrophobic chemical fibers, and hydrophilicized thermoplastic hydrophobic chemical fibers.
[0333] Examples of thermoplastic hydrophobic chemical fibers include polyethylene (PE), polypropylene (PP) and polyethylene terephthalate (PET) monofilaments, and fibers including PE and PP graft polymers.
[0334] Examples of nonwoven fabrics include air-through nonwoven fabrics, spunbond nonwoven fabrics, point bond nonwoven fabrics, spunlace nonwoven fabrics, needle punching nonwoven fabrics and meltblown nonwoven fabrics, as well as combinations thereof (such as SMS and the like).
[0335] Liquid-impermeable back sheets include films comprising PE and PP, air-permeable resin films, air-permeable resin films bonded to spunbond or spunlace nonwoven fabrics, and multilayer nonwoven fabrics, such as SMS. In consideration of flexibility of the absorbent article, a low-density polyethylene (LDPE) film with a basis weight of about 15-30 g/m 2 , for example, is preferred.
[0336] An absorbent article according to one embodiment of this disclosure includes a second sheet between the liquid-permeable top sheet and the absorbent body. The second sheet may be any of the same examples as for the liquid-permeable top sheet.
[0337] The first example of the absorbent body is one having an absorbent core covered with a core wrap.
[0338] Examples of components for the absorbent core include hydrophilic fibers, including cellulose, such as ground pulp or cotton, regenerated cellulose, such as rayon or fibril rayon, semi-synthetic cellulose, such as acetate or triacetate, particulate polymers, filamentous polymers, thermoplastic hydrophobic chemical fibers, and hydrophilicized thermoplastic hydrophobic chemical fibers, as well as combinations thereof. The component of the absorbent core may also be a super absorbent polymer, such as granules of a sodium acrylate copolymer or the like.
[0339] The core wrap is not particularly restricted so long as it is a substance that is liquid-permeable and with a barrier property that does not allow permeation of the polymer absorber, and it may be a woven fabric or nonwoven fabric, for example. The woven fabric or nonwoven fabric may be made of a natural fiber, chemical fiber, tissue, or the like.
[0340] A second example of the absorbent body is one formed from an absorbing sheet or polymer sheet, with a thickness of preferably about 0.3 to about 5.0 mm. The absorbing sheet or polymer sheet may usually be used without any particular restrictions so long as it is one that can be used in an absorbent article, such as a sanitary napkin.
[0341] The side sheet may be any of the same examples as for the liquid-permeable top sheet.
[0342] The flap can be formed from a side sheet and a liquid-impermeable back sheet, and optionally it may have a reinforcing sheet, such as paper, between them.
[0343] The blood slipping agent or blood slipping agent-containing composition preferably does not occlude the voids between the fibers of the nonwoven fabric, and the blood slipping agent or blood slipping agent-containing composition may, for example, adhere as droplets or particulates on the surfaces of the fibers of the nonwoven fabric, or it may cover the surfaces of the fibers.
[0344] Furthermore, in order for the blood slipping agent or blood slipping agent-containing composition to slip down together with the absorbed menstrual blood, it preferably has a large surface area, and a blood slipping agent or blood slipping agent-containing composition present as droplets or particulates preferably has a small droplet/particle diameter.
[0345] An absorbent article according to another embodiment of this disclosure has a second sheet containing a blood slipping agent. An absorbent article according to yet another embodiment of this disclosure has an absorbent body containing a blood slipping agent.
[0346] A nonwoven fabric coated with a blood slipping agent or blood slipping agent-containing composition is preferably subjected to hydrophilicizing treatment. The hydrophilicizing treatment may involve coating the surfaces of the fibers of the nonwoven fabric with a hydrophilic agent, or mixing a hydrophilic agent with the synthetic resin used as the starting material for the nonwoven fabric.
[0347] This is because if the nonwoven fabric before coating of the blood slipping agent or blood slipping agent-containing composition is hydrophilic, there will be lipophilic regions due to the blood slipping agent and hydrophilic regions due to the hydrophilic agent, that are sparsely dispersed on the top sheet, and this will allow the blood slipping agent or blood slipping agent-containing composition to exhibit slipping performance and will also facilitate rapid migration of menstrual blood into the absorbent body.
[0348] The blood slipping agent or blood slipping agent-containing composition also has an effect as a lubricant. Thus the blood slipping agent or blood slipping agent-containing composition reduces friction between the fibers of the nonwoven fabric, and improves the flexibility of the nonwoven fabric as a whole.
[0349] An absorbent article according to a preferred embodiment of this disclosure may be one that is intended for absorption of blood, such as a sanitary napkin or panty liner.
[0350] The nonwoven fabric of this disclosure, and the absorbent article comprising the nonwoven fabric, differ from known absorbent articles containing skin care compositions, lotion compositions and the like, in that they do not need components, such as emollients or immobilizing agents, and therefore the nonwoven fabric according to one embodiment of this disclosure, and an absorbent article comprising the nonwoven fabric, do not contain an emollient and/or immobilizing agent.
EXAMPLES
[0351] The present disclosure will now be explained in fuller detail by examples, with the understanding that it is not meant to be limited to the examples.
Example 1
Evaluation of Rewetting Rate and Absorbent Body Migration Rate
[0352] A commercially available sanitary napkin having the shape shown in FIG. 5 (not coated with a blood slipping agent) was prepared. The sanitary napkin was formed from a top sheet, formed of a hydrophilic agent-treated air-through nonwoven fabric (composite fiber composed of polyester and polyethylene terephthalate, basis weight: 35 g/m 2 ), a second sheet, formed of an air-through nonwoven fabric (composite fiber composed of polyester and polyethylene terephthalate, basis weight: 30 g/m 2 ), an absorbent body comprising pulp (basis weight: 150 to 450 g/m 2 , increased at the center section), an acrylic super-absorbent polymer (basis weight: 15 g/m 2 ) and tissue as a core wrap, a water-repellent agent-treated side sheet, and a back sheet composed of a polyethylene film.
[0353] The blood slipping agents used for testing are listed below.
[0000] [(a 1 ) Ester of Chain Hydrocarbon Tetraol and at Least One Fatty Acid]
[0354] UNISTAR H-408BRS, product of NOF Corp.
[0355] Pentaerythritol tetra(2-ethylhexanoate), weight-average molecular weight: approximately 640
[0356] UNISTAR H-2408BRS-22, product of NOF Corp.
[0357] Mixture of pentaerythritol tetra(2-ethylhexanoate) and neopentylglycol di(2-ethylhexanoate) (58:42 as weight ratio), weight-average molecular weight: approximately 520
[0000] [(a 2 ) Ester of Chain Hydrocarbon Triol and at Least One Fatty Acid]
[0358] Cetiol SB45DEO, Cognis Japan
[0359] Glycerin and fatty acid triester, with oleic acid or stearylic acid as the fatty acid.
[0360] SOY42, product of NOF Corp.
[0361] Glycerin and fatty acid triester with C 14 fatty acid:C 16 fatty acid:C 18 fatty acid:C 20 fatty acid (including both saturated fatty acids and unsaturated fatty acids) at a mass ratio of about 0.2:11:88:0.8, weight-average molecular weight: 880
[0362] Tri-C2L oil fatty acid glyceride, product of NOF Corp.
[0363] Glycerin and fatty acid triester with C 8 fatty acid:C 10 fatty acid:C 12 fatty acid at a weight ratio of about 37:7:56, weight-average molecular weight: approximately 570
[0364] Tri-CL oil fatty acid glyceride, product of NOF Corp.
[0365] Glycerin and fatty acid triester with C 8 fatty acid:C 12 fatty acid at a weight ratio of about 44:56, weight-average molecular weight: approximately 570
[0366] PANACET 810s, product of NOF Corp.
[0367] Glycerin and fatty acid triester with C 8 fatty acid:C 10 fatty acid at a mass ratio of about 85:15, weight-average molecular weight: approximately 480
[0368] PANACET 800, product of NOF Corp.
[0369] Glycerin and fatty acid triester with octanoic acid (C 8 ) as the entire fatty acid portion, weight-average molecular weight: approximately 470
[0370] PANACET 800B, product of NOF Corp.
[0371] Glycerin and fatty acid triester with 2-ethylhexanoic acid (C 8 ) as the entire fatty acid portion, weight-average molecular weight: approximately 470
[0372] NA36, product of NOF Corp.
[0373] Glycerin and fatty acid triester with C 16 fatty acid:C 18 fatty acid:C 20 fatty acid (including both saturated fatty acids and unsaturated fatty acids) at a mass ratio of about 5:92:3, weight-average molecular weight: approximately 880
[0374] Tri-coconut fatty acid glyceride, product of NOF Corp.
[0375] Glycerin and fatty acid triester with C 8 fatty acid:C 10 fatty acid:C 12 fatty acid:C 14 fatty acid:C 16 fatty acid (including both saturated fatty acids and unsaturated fatty acids) at a mass ratio of about 4:8:60:25:3, weight-average molecular weight: 670
[0376] Caprylic acid diglyceride, product of NOF Corp.
[0377] Glycerin and fatty acid diester with octanoic acid as the fatty acid, weight-average molecular weight: approximately 340
[0000] [(a 3 ) Ester of a Chain Hydrocarbon Diol and at Least One Fatty Acid]
[0378] UNISTAR H-208BRS, product of NOF Corp.
[0379] Neopentyl glycol di(2-ethylhexanoate), weight-average molecular weight: approximately 360
[0380] COMPOL BL, product of NOF Corp.
[0381] Dodecanoic acid (C 12 ) monoester of butylene glycol, weight-average molecular weight: approximately 270
[0382] COMPOL BS, product of NOF Corp.
[0383] Octadecanoic acid (C 18 ) monoester of butylene glycol, weight-average molecular weight: approximately 350
[0000] [(c 2 ) Ester of a Chain Hydrocarbon Tricarboxylic Acid, Hydroxy Acid, Alkoxy Acid or Oxoacid with 3 Carboxyl Groups, and at Least One Aliphatic Monohydric Alcohol]
[0384] Tributyl 0-acetylcitrate, product of Tokyo Kasei Kogyo Co., Ltd.
[0385] Weight-average molecular weight: approximately 400
[0386] Tributyl citrate, product of Tokyo Kasei Kogyo Co., Ltd.
[0387] Weight-average molecular weight: approximately 360
[0000] [(c 3 ) Ester of a Chain Hydrocarbon Dicarboxylic Acid, Hydroxy Acid, Alkoxy Acid or Oxoacid with 2 Carboxyl Groups, and at Least One Aliphatic Monohydric Alcohol]
[0388] Dioctyl adipate, product of Wako Pure Chemical Industries, Ltd.
[0389] Weight-average molecular weight: approximately 380
[0000] [(d 3 ) Ester of a Fatty Acid and an Aliphatic Monohydric Alcohol]
[0390] ELECTOL WE20, product of NOF Corp.
[0391] Ester of dodecanoic acid (C 12 ) and dodecyl alcohol (C 12 ), weight-average molecular weight: approximately 360
[0392] ELECTOL WE40, product of NOF Corp.
[0393] Ester of tetradecanoic acid (C 14 ) and dodecyl alcohol (C 12 ), weight-average molecular weight: approximately 390
[0000] [(e 1 ) Polyoxy C 3 -C 6 Alkylene Glycol]
[0394] UNIOL PB500, product of NOF Corp.
[0395] Polybutylene glycol, weight-average molecular weight: approximately 500
[0396] UNIOL PB700, product of NOF Corp.
[0397] Polyoxybutylene polyoxypropylene glycol, weight-average molecular weight: approximately 700
[0000] [(f 1 ) Chain Alkane]
[0398] PARLEAM 6, product of NOF Corp.
[0399] Branched chain hydrocarbon, produced by copolymerization of liquid isoparaffin, isobutene and n-butene followed by hydrogen addition, polymerization degree: approximately 5-10, weight-average molecular weight: approximately 330
[Other Materials]
[0400] NA50, product of NOF Corp.
[0401] Glycerin and fatty acid triester obtained by addition of hydrogen to NA36 for reduced proportion of double bonds from unsaturated fatty acid starting material, weight-average molecular weight: approximately 880
[0402] (Caprylic acid/capric acid) monoglyceride, product of NOF Corp.
[0403] Glycerin and fatty acid monoester, with octanoic acid (CO and decanoic acid (C 10 ) at a mass ratio of about 85:15, weight-average molecular weight: approximately 220
[0404] Monomuls 90-L2 lauric acid monoglyceride, product of Cognis Japan
[0405] Isopropyl citrate, product of Tokyo Kasei Kogyo Co., Ltd.
[0406] Weight-average molecular weight: approximately 230
[0407] Diisostearyl Malate
[0408] Weight-average molecular weight: approximately 640
[0409] UNIOL PB1000R, product of NOF Corp.
[0410] Polybutylene glycol, weight-average molecular weight: approximately 1,000
[0411] UNIOL D-250, product of NOF Corp.
[0412] Polypropylene glycol, weight-average molecular weight: approximately 250
[0413] UNIOL D-400, product of NOF Corp.
[0414] Polypropylene glycol, weight-average molecular weight: approximately 400
[0415] UNIOL D-700, product of NOF Corp.
[0416] Polypropylene glycol, weight-average molecular weight: approximately 700
[0417] UNIOL D-1000, product of NOF Corp.
[0418] Polypropylene glycol, weight-average molecular weight: approximately 1,000
[0419] UNIOL D-1200, product of NOF Corp.
[0420] Polypropylene glycol, weight-average molecular weight: approximately 1,160
[0421] UNIOL D-2000, product of NOF Corp.
[0422] Polypropylene glycol, weight-average molecular weight: approximately 2,030
[0423] UNIOL D-3000, product of NOF Corp.
[0424] Polypropylene glycol, weight-average molecular weight: approximately 3,000
[0425] UNIOL D-4000, product of NOF Corp.
[0426] Polypropylene glycol, weight-average molecular weight: approximately 4,000
[0427] PEG1500, product of NOF Corp.
[0428] Polyethylene glycol, weight-average molecular weight: approximately 1,500-1,600
[0429] WILBRITE cp9, product of NOF Corp.
[0430] Polybutylene glycol compound with OH groups at both ends esterified by hexadecanoic acid (C 16 ), weight-average molecular weight: approximately 1,150
[0431] UNILUBE MS-70K, product of NOF Corp.
[0432] Stearyl ether of polypropylene glycol, approximately 15 repeating units, weight-average molecular weight: approximately 1,140
[0433] NONION S-6, product of NOF Corp.
[0434] Polyoxyethylene monostearate, approximately 7 repeating units, weight-average molecular weight: approximately 880
[0435] UNILUBE 5TP-300 KB
[0436] Polyoxyethylene polyoxypropylene pentaerythritol ether, produced by addition of 5 mol of ethylene oxide and 65 mol of propylene oxide to 1 mol of pentaerythritol, weight-average molecular weight: 4,130
[0437] WILBRITE s753, product of NOF Corp.
[0438] Polyoxyethylene polyoxypropylene polyoxybutylene glycerin, weight-average molecular weight: approximately 960
[0439] UNIOL TG-330, product of NOF Corp.
[0440] Glyceryl ether of polypropylene glycol, approximately 6 repeating units, weight-average molecular weight: approximately 330
[0441] UNIOL TG-1000, product of NOF Corp.
[0442] Glyceryl ether of polypropylene glycol, approximately 16 repeating units, weight-average molecular weight: approximately 1,000
[0443] UNIOL TG-3000, product of NOF Corp.
[0444] Glyceryl ether of polypropylene glycol, approximately 16 repeating units, weight-average molecular weight: approximately 3,000
[0445] UNIOL TG-4000, product of NOF Corp.
[0446] Glyceryl ether of polypropylene glycol, approximately 16 repeating units, weight-average molecular weight: approximately 4,000
[0447] UNILUBE DGP-700, product of NOF Corp.
[0448] Diglyceryl ether of polypropylene glycol, approximately 9 repeating units, weight-average molecular weight: approximately 700
[0449] UNIOX HC60, product of NOF Corp.
[0450] Polyoxyethylene hydrogenated castor oil, weight-average molecular weight: approximately 3,570
[0451] Vaseline, product of Cognis Japan
[0452] Petroleum-Derived Hydrocarbon, Semi-Solid
[0453] The kinematic viscosities, water holding percentages, weight-average molecular weights, IOBs and melting points of the samples are shown in Table 2.
[0454] For the melting point, “<45” indicates a melting point of below 45° C.
[0455] Almost the entire skin contact surface of the top sheet of the sanitary napkin was coated with the aforementioned blood slipping agent. Each blood slipping agent was used directly, when the blood slipping agent was liquid at room temperature, or when the blood slipping agent was solid at room temperature it was heated to a temperature of its melting point+20° C., and then a control seam HMA gun was used for atomization of each blood slipping agent and coating onto the skin contact surface of the top sheet to a basis weight of about 5 g/m 2 .
[0456] FIG. 8 is an electron micrograph of the skin contact surface of a top sheet in a sanitary napkin (No. 1-5) wherein the top sheet comprises tri-C2L oil fatty acid glycerides. As clearly seen in FIG. 8 , the tri-C2L oil fatty acid glycerides are present on the fiber surfaces as fine particulates.
[Test Methods]
[0457] An acrylic board with an opened hole (200 mm×100 mm, 125 g, with a 40 mm×10 mm hole opened at the center) was placed on a top sheet comprising each blood slipping agent, and 3.0 g of horse EDTA blood at 37±1° C. (obtained by adding ethylenediaminetetraacetic acid (hereunder, “EDTA”) to horse blood to prevent coagulation) was dropped through the hole using a pipette (once), and after 1 minute, 3.0 g of horse EDTA blood at 37±1° C. was again added dropwise through the acrylic board hole with a pipette (twice).
[0458] After the second dropping of blood, the acrylic board was immediately removed and 10 sheets of filter paper (Qualitative filter paper No. 2, product of Advantech Toyo, Inc., 50 mm×35 mm) (total weight of 10 filter sheets: FW 0 (g)) were placed on the location where the blood had been dropped, and then a weight was placed thereover at a pressure of 30 g/cm 2 . After 1 minute, the filter paper was removed, the total weight FW 1 (g) of the 10 tested filter sheets was measured, and the “rewetting rate” was calculated by the following formula.
[0000] Rewetting rate (mass %)=100×[FW 1 (g)− FW 0 (g)]/6.0(g)
[0459] In addition to the rewetting rate evaluation, the “absorbent body migration rate” was also measured as the time until migration of blood from the top sheet to the absorbent body after the second dropping of blood. The absorbent body migration rate is the time from introducing the blood onto the top sheet, until the redness of the blood could be seen on the surface and in the interior of the top sheet.
[0460] The results for the rewetting rate and absorbent body migration rate are shown below in Table 2.
[0461] The whiteness of the skin contact surface of the top sheet (TS) after the absorbent body migration rate test was visually evaluated on the following scale.
[0462] VG (Very Good): Virtually no redness of blood remaining, and no clear delineation between areas with and without blood.
[0463] G (Good): Slight redness of blood remaining, but difficult to discriminate between areas with and without blood.
[0464] F (Fair): Slight redness of blood remaining, areas with blood discernible.
[0465] P (Poor): Redness of blood completely remaining.
[0466] The tack on the skin contact surface of the top sheet was also measured at 35° C., and evaluated on the following scale.
[0467] G: No tack
[0468] F: Slight tack
[0469] P: Tack
[0470] The results are summarized in Table 2 below.
[0000]
TABLE 2
Kinematic
Water holding
Wt.-
Melting
Rewetting
Absorbent body
viscosity
percentage
average
point
rate
migration rate
TS
No.
Blood slipping agent
(mm 2 /s, 40° C.)
(mass %)
mol. wt.
IOB
(° C.)
(%)
(sec)
whiteness
Tack
1-1
H-408BRS
45
0.7
640
0.13
<−5
1.2
3
VG
G
1-2
H-2408BRS-22
22
0.8
520
0.18
<−5
2.0
3
VG
G
1-3
Cetiol SB45DEO
0.16
44
7.0
6
VG
1-4
SOY42
880
0.16
43
5.8
8
VG
G
1-5
Tri-C2L oil fatty
20
<1.0
570
0.27
37
0.3
3
VG
G
acid glyceride
1-6
Tri-CL oil fatty acid
15
<1.0
570
0.28
38
1.7
3
VG
G
glyceride
1-7
PANACET 810s
9
0.3
480
0.32
−5
2.8
3
VG
G
1-8
PANACET 800
15
0.5
470
0.33
−5
0.3
3
VG
G
1-9
PANACET 800B
20
<1.0
470
0.33
−5
2.0
3
VG
G
1-10
NA36
40
<1.0
880
0.16
37
3.9
5
VG
G
1-11
Tri-coconut oil fatty
25
<1.0
670
0.28
30
4.3
5
VG
G
acid glyceride
1-12
Caprylic acid
25
2.7
340
0.58
<45
4.2
9
G
G
diglyceride
1-13
UNISTAR H-208BRS
8
0.7
360
0.24
<−5
2.0
5
VG
G
1-14
COMPOL BL
10
1.6
270
0.50
2
2.0
5
G
G
1-15
COMPOL BS
35
0.3
350
0.36
37
7.9
9
G
G
1-16
Tributyl O-
15
0.9
400
0.60
<45
6.2
8
VG
G
acetylcitrate
1-17
Tributyl citrate
12
0.6
360
0.78
<45
3.0
6
G
G
1-18
Dioctyl adipate
7
0.4
380
0.27
<45
1.7
6
VG
G
1-19
ELECTOL WE20
10
0.3
360
0.13
29
1.8
5
VG
G
1-20
ELECTOL WE40
15
0.5
390
0.12
37
1.8
4
VG
G
1-21
UNIOL PB500
40
3.6
500
0.44
<45
4.5
4
G
G
1-22
UNIOL PB700
50
2.3
700
0.49
−5
2.8
5
G
G
1-23
PARLEAM 6
5
0.06
330
0.00
−5
6.0
8
VG
G
1-24
NA50
80<<
—*
880
0.18
52
15.5
60
P
G
1-25
(Caprylic acid/Capric
70
4.0<<
220
1.15
<45
4.0
4
P
G
acid) monoglyceride
1-26
90-L2 Lauric acid
80<<
4.0<<
<1,000
0.87
58
6.2
7
P
G
monoglyceride
1-27
Isopropyl citrate
120
4.0<<
230
1.56
<45
12.2
5
G
F
1-28
Diisostearyl malate
450
4.0<<
640
0.28
<45
5.5
8
F
F
1-29
UNIOL PB1000R
70
5.5
1000
0.40
<45
4.0
4
G
F
1-30
UNIOL D-250
20
4.0<<
250
<45
—
—
P
G
1-31
UNIOL D-400
30
4.0<<
400
0.76
<45
8.7
40
P
G
1-32
UNIOL D-700
50
34.6
700
0.58
<45
7.5
—
F
G
1-33
UNIOL D-1000
70
26.7
1,000
0.51
<45
6.8
15
F
F
1-34
UNIOL D-1200
90
16.2
1,160
0.48
<45
0.5
11
F
F
1-35
UNIOL D-2000
160
2,030
<45
—
—
F
P
1-36
UNIOL D-3000
0.6
3,000
0.39
<45
1.7
10
F
P
1-37
UNIOL D-4000
450
0.5
4,000
0.38
<45
1.0
7
G
P
1-38
PEG1500
120
4.0<<
1,500-
0.78
40
11.0
38
P
P
1,600
1-39
WILBRITE CP9
120
0.6
1,150
0.21
35
1.4
3
G
P
1-40
UNILUBE MS-70K
50
2.8
1,140
0.30
<−10
6.7
3
G
F
1-41
NONION S-6
65
4.0<<
880
0.44
37
8.4
7
P
G
1-42
UNILUBE 5TP-300KB
310
3.9
4,130
0.39
<45
2.0
6
G
P
1-43
WILBRITE s753
120
27.3
960
0.67
−5
9.3
9
F
F
1-44
UNIOL TG-330
30
330
1.27
<45
—
—
—
G
1-45
UNIOL TG-1000
100
21.2
1,000
0.61
<45
14.2
7
G
G
1-46
UNIOL TG-3000
230
4.3
3,000
0.42
<45
0.8
6
G
P
1-47
UNIOL TG-4000
300
2.4
4,000
0.40
<45
2.0
6
G
P
1-48
UNILUBE DGP-700
200
4.0<<
700
0.91
<0
8.0
10
F
F
1-49
UNIOX HC60
1150
3,570
0.46
33
14.6
46
P
P
1-50
Vaseline
80<<
0.0
<1,000
0.00
55
9.7
10
F
P
1-51
None
—
—
—
—
—
22.7
60<
P
G
*High viscosity, umeasureable.
[0471] In the absence of a blood slipping agent, the rewetting rate was 22.7% and the absorbent body migration rate was greater than 60 seconds, but the glycerin and fatty acid triesters all produced rewetting rates of no greater than 7.0% and absorbent body migration rates of no longer than 8 seconds, and therefore significantly improved the absorption performance.
[0472] This suggests that, since the blood slipping agent has a high absorbent body migration rate, the blood slipping agent-containing region in the ridges of the nonwoven fabric of this disclosure causes menstrual blood that has reached the ridges to rapidly slip into the absorbent body before being diffused in the longwise direction.
[0473] Similarly, it was found that the absorption performance is greatly improved with a blood slipping agent having a kinematic viscosity of about 0.01 to 80 mm 2 /s at 40° C., a water holding percentage of about 0.01 to about 4.0 mass %, and a weight-average molecular weight of less than about 1,000.
[0474] Next, several volunteer participants were asked to wear sanitary napkins Nos. 1-1 to 1-51, and the obtained responses indicated that with the sanitary napkins comprising blood slipping agent Nos. 1-1 to 1-23, the top sheets had no sticky feel and the top sheets were smooth, even after absorption of menstrual blood.
[0475] Also, with sanitary napkins that comprised blood slipping agent Nos. 1-11, 1-13, 1-16, 1-18 to 1-20 and 1-23, the skin contact surfaces of the top sheets after absorption of menstrual blood was not reddened by the blood and the unpleasantness was minimal.
Example 2
Surface Residue Rate of Menstrual Blood on Top Sheet with Ridge-Furrow Structure
[0476] The surface residue rate of menstrual blood on a top sheet with a ridge-furrow structure was evaluated.
[0477] There were prepared a top sheet, formed of a hydrophilic agent-treated air-through nonwoven fabric (composite fiber composed of polyester and polyethylene terephthalate, basis weight: 35 g/m 2 ), a second sheet, formed of an air-through nonwoven fabric (composite fiber composed of polyester and polyethylene terephthalate, basis weight: 30 g/m 2 ), an absorbent body comprising pulp (basis weight: 150 to 450 g/m 2 , increased at the center section), an acrylic super-absorbent polymer (basis weight: 15 g/m 2 ) and tissue as a core wrap, a water-repellent agent-treated side sheet, and a back sheet composed of a polyethylene film.
[0478] The top sheet was a top sheet produced by the method described in Japanese Unexamined Patent Publication No. 2008-2034, having a ridge-furrow structure, with a ridge thickness of approximately 1.5 mm and a furrow thickness of approximately 0.4 mm, the pitch of the ridge-furrow structure (ridge width+furrow width) was approximately 4 mm, and through-holes (openings) were formed in the furrows at an open area ratio of approximately 15%.
[0479] UNISTAR H-408BRS (product of NOF Corp., tetraester of pentaerythritol and fatty acid) was selected as the blood slipping agent, and it was coated onto the skin contact surface (ridge-furrow side) of the top sheet from a control seam HMA gun at room temperature, to a basis weight of 5.0 g/m 2 . With an electron microscope it was confirmed that the H-408BRS was adhering onto the fiber surfaces as fine particulates.
[0480] A back sheet, an absorbent body, a second sheet, and a top sheet with the ridge-furrow side facing upward, were stacked in that order to form sanitary napkin No. 2-1.
[0481] Sanitary napkins No. 2-2 to No. 2-40 were produced, changing the blood slipping agent from UNISTAR H-408BRS to the ones listed in Table 3. Each blood slipping agent was used directly, when it was liquid at room temperature, or when the blood slipping agent was solid at room temperature it was heated to its melting point of +20° C., and then a control seam HMA gun was used for atomization of the blood slipping agent and coating onto the skin contact surface of the top sheet to a basis weight of about 5 g/m 2 .
[0482] The blood slipping agent was coated onto essentially the entire skin contact surface of the top sheet, and on both the ridges and furrows.
[Test Methods]
[0483] After measuring the weight: W 2 (g) of the top sheet (the weight of the top sheet before the test), an acrylic board with an opened hole (200 mm×100 mm, 125 g, with a 40 mm×10 mm hole opened at the center) was placed on the top sheet, at the center section in the lengthwise direction and widthwise direction of the absorbent article, and 4.0 g of horse EDTA blood at 37±1° C. (obtained by adding ethylenediaminetetraacetic acid (hereunder, “EDTA”) to horse blood to prevent coagulation) was dropped through the hole using a pipette.
[0484] After dropping the horse EDTA blood, the acrylic board was immediately removed, the top sheet was taken off, the mass W 3 (g) (mass of the top sheet after the test) was measured and the “surface residue rate A (mass %)” was calculated by the following formula.
[0000] Surface residue rate (mass %)=100 ×[W 3 (g) −W 2 (g)]/4.0(g)
[0485] The results are shown in Table 3 below.
[0000]
TABLE 3
Surface residue
No.
Blood slipping agent
rate (mass %)
2-1
H-408BRS
0.8
2-2
H-2408BRS-22
0.8
2-3
PANACET 810s
0.8
2-4
PANACET 800
1.8
2-5
Caprylic acid diglyceride
1.0
2-6
UNISTAR H-208BRS
0.5
2-7
COMPOL BL
1.3
2-8
COMPOL BS
2.5
2-9
Tributyl O-acetylcitrate
0.5
2-10
Tributyl citrate
1.8
2-11
Dioctyl adipate
1.5
2-12
ELECTOL WE20
0.5
2-13
ELECTOL WE40
2.3
2-14
UNIOL PB500
2.5
2-15
UNIOL PB700
1.3
2-16
PARLEAM 6
2.0
2-17
NA50
4.3
2-18
(Caprylic acid/capric acid) monoglyceride
5.0
2-19
90-L2 Lauric acid monoglyceride
5.0
2-20
Isopropyl citrate
4.8
2-21
Diisostearyl malate
3.3
2-22
UNIOL PB1000R
2.5
2-23
UNIOL D-250
3.8
2-24
UNIOL D-400
4.8
2-25
UNIOL D-700
4.8
2-26
UNIOL D-1000
3.8
2-27
UNIOL D-1200
3.0
2-28
UNIOL D-3000
3.0
2-29
UNIOL D-4000
2.5
2-30
PEG1500
5.5
2-31
WILBRITE CP9
6.8
2-32
UNILUBE MS-70K
1.5
2-33
UNILUBE 5TP-300KB
2.0
2-34
WILBRITE s753
3.5
2-35
UNIOL TG-1000
3.5
2-36
UNIOL TG-3000
1.0
2-37
UNIOL TG-4000
2.0
2-38
UNILUBE DGP-700
3.5
2-39
Vaseline
4.0
2-40
None
7.5
[0486] With sanitary napkin No. 2-40, which had no blood slipping agent, the surface residue rate was 7.5 mass %, but with sanitary napkins No. 2-1 to No. 2-16 wherein the kinematic viscosity and water holding percentage were within the prescribed ranges, the surface residue rate was 2.5 mass % or lower.
[0487] With sanitary napkins No. 2-1 to No. 2-16, it was observed that the horse EDTA blood that was dropped onto the ridges of the top sheet slipped down from the ridges into the furrows, and was rapidly absorbed from the furrows into the absorbent body. However, with sanitary napkin No. 2-40 which had no blood slipping agent, the dropped horse EDTA blood did not slip down into the furrows but slowly dripped down into the furrows, most of it remaining on the ridges of the top sheet. Also, with the absorbent articles with high water holding percentage, as with No. 2-25, for example, the horse EDTA blood that was dropped onto the ridges of the top sheet did not slip down into the furrows but slowly dripped while partially remaining on the top sheet, and a portion thereof remained on the ridges.
[0488] The following experiment was also conducted in order to confirm the function of the blood slipping agent.
Example 3
Viscosity of Blood Containing Blood Slipping Agent
[0489] The viscosity of the blood slipping agent-containing blood was measured using a Rheometric Expansion System ARES (Rheometric Scientific, Inc.). After adding 2 mass % of PANACET 810s to horse defibrinated blood, the mixture was gently agitated to form a sample, the sample was placed on a 50 mm-diameter parallel plate, with a gap of 100 μm, and the viscosity was measured at 37±0.5° C. The sample was not subjected to a uniform shear rate due to the parallel plate, but the average shear rate indicated by the device was 10 s −1 .
[0490] The viscosity of the horse defibrinated blood containing 2 mass % PANACET 810s was 5.9 mPa·s, while the viscosity of the horse defibrinated blood containing no blood slipping agent was 50.4 mPa·s. Thus, the horse defibrinated blood containing 2 mass % PANACET 810s clearly had an approximately 90% lower viscosity than the blood containing no blood slipping agent.
[0491] It is known that blood contains components, such as blood cells and has a thixotropic nature, and it is believed that the blood slipping agent of the present disclosure has an effect of lowering the viscosity of blood, such as menstrual blood in the low viscosity range. Lowering the blood viscosity presumably allows absorbed menstrual blood to more easily migrate rapidly from the top sheet to the absorbent body.
Example 4
Photomicrograph of Blood Slipping Agent-Containing Blood
[0492] Menstrual blood was sampled from healthy volunteers onto thin plastic wrap, and PANACET 810s dispersed in a 10-fold mass of phosphate-buffered saline was added to a portion thereof to a PANACET 810s concentration of 1 mass %. The menstrual blood was dropped onto a slide glass, a cover glass was placed thereover, and the state of the erythrocytes was observed with an optical microscope. A photomicrograph of menstrual blood containing no blood slipping agent is shown in FIG. 9( a ), and a photomicrograph of menstrual blood containing PANACET 810s is shown in FIG. 9( b ).
[0493] From FIGS. 9( a ) and 9 ( b ), it is seen that the erythrocytes formed aggregates, such as rouleaux in the menstrual blood containing no blood slipping agent, while the erythrocytes were stably dispersed in the menstrual blood containing PANACET 810s. This suggests that the blood slipping agent functions to stabilize erythrocytes in blood.
Example 5
Surface Tension of Blood Containing Blood Slipping Agent
[0494] The surface tension of blood containing a blood slipping agent was measured by the pendant drop method, using a Drop Master500 contact angle meter by Kyowa Interface Science Co., Ltd. The surface tension was measured after adding a prescribed amount of blood slipping agent to sheep defibrinated blood, and thoroughly shaking.
[0495] The measurement was accomplished automatically with a device, and the surface tension y was determined by the following formula (see FIG. 10 ).
[0000] γ=g×ρ×( de ) 2 ×1/ H
[0496] g: Gravitational constant
[0497] 1/H: Correction factor determined from ds/de
[0498] ρ: Density
[0499] de: Maximum diameter
[0500] ds: Diameter at location of increase by de from dropping edge
[0501] The density ρ was measured at the temperatures listed in Table 4, according to JIS K 2249-1995, “Density test methods and density/mass/volume conversion tables”, “5. Vibrating density test method”.
[0502] The measurement was accomplished using a DA-505 by Kyoto Electronics Co., Ltd.
[0503] The results are shown in Table 4 below.
[0000]
TABLE 4
Blood slipping agent
Measuring
Surface
Amount
temperature
tension
No.
Type
(mass %)
(° C.)
(mN/m)
5-1
—
—
35
62.1
5-2
PANACET
0.01
35
61.5
5-3
810s
0.05
35
58.2
5-4
0.10
35
51.2
5-5
ELECTOL
0.10
35
58.8
WE20
5-6
PARLEAM
0.10
35
57.5
6
5-7
—
—
50
56.3
5-8
WILBRITE
0.10
50
49.1
cp9
[0504] Based on Table 4 it is seen that the blood slipping agent has an effect of lowering the surface tension of blood.
[0505] Lowering the surface tension of blood presumably allows absorbed blood to rapidly migrate from the top sheet to the absorbent body, without being retained between the top sheet fibers.
[0506] The present disclosure relates to the following J1 to J10.
[J1]
[0507] A nonwoven fabric for a top sheet of an absorbent article, having a longwise direction and a crosswise direction,
[0508] the nonwoven fabric having a plurality of ridges and a plurality of furrows extending in the longwise direction and alternately disposed in the crosswise direction,
[0509] wherein the plurality of ridges and the plurality of furrows each have a plurality of through-holes,
[0510] each of the ridges has a blood slipping agent-containing region that contains a blood slipping agent with a kinematic viscosity of 0.01 to 80 mm 2 /s at 40° C., a water holding percentage of 0.01 to 4.0 mass % and a weight-average molecular weight of less than 1,000.
[J2]
[0511] The nonwoven fabric according to J1, wherein the blood slipping agent further has an IOB of 0.00 to 0.60.
[J3]
[0512] The nonwoven fabric according to J1 or J2, wherein each of the furrows has, as through-holes, a plurality of openings formed by reducing fibers of the nonwoven fabric at the furrows, and the fabric has joints that connect every two adjacent ridges between every two adjacent openings.
[J4]
[0513] The nonwoven fabric according to J3, wherein at the joints, a content of fibers oriented in the crosswise direction is higher than a content of fibers oriented in the longwise direction.
[J5]
[0514] The nonwoven fabric according to any one of J1 to J4, wherein the through-holes of the ridges include perforated sections formed by perforation.
[J6]
[0515] The nonwoven fabric according to any one of J1 to J5, having 0.5 to 5.0 through-holes per 1 cm 2 area of the nonwoven fabric.
[J7]
[0516] The nonwoven fabric according to any one of J1 to J6, wherein the ridges include a blood slipping agent with a basis weight of 1 to 30 g/m 2 in the blood slipping agent-containing regions.
[J8]
[0517] The nonwoven fabric according to any one of J1 to J7, wherein the blood slipping agent is selected from the group consisting of following items (i) to (iii), and any combination thereof:
[0518] (i) a hydrocarbon;
[0519] (ii) a compound having (ii-1) a hydrocarbon moiety and (ii-2) one or more, same or different groups selected from the group consisting of carbonyl group (—CO—) and oxy group (—O—) inserted between a C—C single bond of the hydrocarbon moiety; and
[0520] (iii) a compound having (iii-1) a hydrocarbon moiety, (iii-2) one or more, same or different groups selected from the group consisting of carbonyl group (—CO—) and oxy group (—O—), inserted between a C—C single bond of the hydrocarbon moiety, and (iii-3) one or more, same or different groups selected from the group consisting of carboxyl group (—COOH) and hydroxyl group (—OH), substituting a hydrogen on the hydrocarbon moiety;
[0521] with the proviso that when two or more oxy groups are inserted in the compound of (ii) or (iii), the oxy groups are not adjacent.
[J9]
[0522] The nonwoven fabric according to any one of J1 to J8, wherein the blood slipping agent is selected from the group consisting of following items (i′) to (iii′), and any combination thereof:
[0523] (i′) a hydrocarbon;
[0524] (ii′) a compound having (ii′-1) a hydrocarbon moiety, and (ii′-2) one or more, same or different bonds selected from the group consisting of carbonyl bond (—CO—), ester bond (—COO—), carbonate bond (—OCOO—), and ether bond (—O—) inserted between a C—C single bond of the hydrocarbon moiety; and
[0525] (iii′) a compound having (iii′-1) a hydrocarbon moiety, (iii′-2) one or more, same or different bonds selected from the group consisting of carbonyl bond (—CO—), ester bond (—COO—), carbonate bond (—OCOO—), and ether bond (—O—) inserted between a C—C single bond of the hydrocarbon moiety, and (iii′-3) one or more, same or different groups selected from the group consisting of carboxyl group (—COOH) and hydroxyl group (—OH) substituting a hydrogen on the hydrocarbon moiety;
[0526] with the proviso that when two or more same or different bonds are inserted in the compound of (ii′) or (iii′), the bonds are not adjacent.
[J10]
[0527] The nonwoven fabric according to any one of J1 to J9, wherein the blood slipping agent is selected from the group consisting of following items (A) to (F), as well as any combination thereof:
[0528] (A) an ester of (A1) a compound having a chain hydrocarbon moiety and 2-4 hydroxyl groups substituting hydrogens on the chain hydrocarbon moiety, and (A2) a compound having a chain hydrocarbon moiety and one carboxyl group substituting a hydrogen on the chain hydrocarbon moiety;
[0529] (B) an ether of (B1) a compound having a chain hydrocarbon moiety and 2-4 hydroxyl groups substituting hydrogens on the chain hydrocarbon moiety, and (B2) a compound having a chain hydrocarbon moiety and one hydroxyl group substituting a hydrogen on the chain hydrocarbon moiety;
[0530] (C) an ester of (C1) a carboxylic acid, hydroxy acid, alkoxy acid or oxoacid containing a chain hydrocarbon moiety and 2-4 carboxyl groups substituting hydrogens on the chain hydrocarbon moiety, and (C2) a compound having a chain hydrocarbon moiety and one hydroxyl group substituting a hydrogen on the chain hydrocarbon moiety;
[0531] (D) a compound having a chain hydrocarbon moiety, and one bond selected from the group consisting of ether bond (—O—), carbonyl bond (—CO—), ester bond (—COO—) and carbonate bond (—OCOO—), inserted between a C—C single bond of the chain hydrocarbon moiety;
[0532] (E) a polyoxy C 3 -C 6 alkylene glycol, or alkyl ester or alkyl ether thereof; and
[0533] (F) a chain hydrocarbon.
[J11]
[0534] The nonwoven fabric according to any one of J1 to J10, wherein the blood slipping agent is selected from the group consisting of (a 1 ) an ester of a chain hydrocarbon tetraol and at least one fatty acid, (a 2 ) an ester of a chain hydrocarbon triol and at least one fatty acid, (a 3 ) an ester of a chain hydrocarbon diol and at least one fatty acid, (b 1 ) an ether of a chain hydrocarbon tetraol and at least one aliphatic monohydric alcohol, (b 2 ) an ether of a chain hydrocarbon triol and at least one aliphatic monohydric alcohol, (b 3 ) an ether of a chain hydrocarbon diol and at least one aliphatic monohydric alcohol, (c 1 ) an ester of a chain hydrocarbon tetracarboxylic acid, hydroxy acid, alkoxy acid or oxoacid with 4 carboxyl groups, and at least one aliphatic monohydric alcohol, (c 2 ) an ester of a chain hydrocarbon tricarboxylic acid, hydroxy acid, alkoxy acid or oxoacid with 3 carboxyl groups, and at least one aliphatic monohydric alcohol, (c 3 ) an ester of a chain hydrocarbon dicarboxylic acid, hydroxy acid, alkoxy acid or oxoacid with 2 carboxyl groups, and at least one aliphatic monohydric alcohol, (d 1 ) an ether of an aliphatic monohydric alcohol and an aliphatic monohydric alcohol, (d 2 ) a dialkyl ketone, (d 3 ) an ester of a fatty acid and an aliphatic monohydric alcohol, (d 4 ) a dialkyl carbonate, (e 1 ) a polyoxy C 3 -C 6 alkylene glycol, (e 2 ) an ester of a polyoxy C 3 -C 6 alkylene glycol and at least one fatty acid, (e 3 ) an ether of a polyoxy C 3 -C 6 alkylene glycol and at least one aliphatic monohydric alcohol, and (f 1 ) a chain alkane, as well as any combination thereof.
[J12]
[0535] The nonwoven fabric according to any one of J1 to J11, wherein the blood slipping agent is adhering to surfaces of fibers of the nonwoven fabric.
[J13]
[0536] An absorbent article comprising a liquid-permeable top sheet, a liquid-impermeable back sheet and an absorbent body between the top sheet and back sheet, wherein
[0537] the top sheet is the nonwoven fabric according to any one of J1 to J12.
[J14]
[0538] The absorbent article according to J13, wherein the longwise direction is parallel to the lengthwise direction of the absorbent article.
[J15]
[0539] The absorbent article according to any one of J1 to J14, which is a sanitary napkin or panty liner.
REFERENCE SIGNS LIST
[0000]
1 Nonwoven fabric
2 Ridge
3 Furrow
4 Through-hole
4 ′ Perforated section
4 ″ Opening
5 Joint
11 Absorbent article
12 Top sheet
13 Absorbent body
14 Side flap
15 Side sheet
16 Embossing
17 Blood slipping agent-containing region
18 Back sheet
21 Projection
22 Recess
23 Skin contact surface
24 Blood slipping agent
25 , 25 ′, 25 ″ Menstrual blood
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The purpose of the present invention is to provide a nonwoven for a top sheet of an absorbent article that is unlikely to stick after having absorbed menstrual blood, that is smooth and dry, and in which the absorbed menstrual blood is unlikely to diffuse on the nonwoven. This nonwoven has the following configuration. A nonwoven for a top sheet of an absorbent article, having a lengthwise direction and a crosswise direction, wherein the nonwoven has a plurality of ridge parts and a plurality of groove parts extending in the lengthwise direction and disposed in alternating fashion in the crosswise direction, the nonwoven being characterized in that the ridge parts and the groove parts have a plurality of through-holes, and the ridge parts have a region containing a blood lubricity-imparting agent that contains a predetermined blood lubricity-imparting agent.
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[0001] This application is a continuation in part of application Ser. No. 11/584,157 filed Oct. 20, 2006 which is herein incorporated by reference in its entirety for all purposes.
FIELD OF THE INVENTION
[0002] This disclosure relates generally to signal lights using light emitting diodes (LED's) to convert electrical energy into light energy.
BACKGROUND INFORMATION
[0003] Light emitting diodes are becoming increasingly prevalent for a variety of lighting functions. They are low cost in terms of use electricity, and now come in a variety of different colors. Not only are they useful in flashlights and automotive uses, but they find additional uses on a regular basis since their cost to operate, brightness, and low heat generation make them useful in a variety of applications.
[0004] It would be useful to have an LED light bulb that may be used in emergency and non-emergency situations to visually identify a condition of interest, and optionally identify that condition with a particular building, or room within a building.
SUMMARY OF THE INVENTION
[0005] One embodiment is a light emitting diode (LED) light bulb. The LED light bulb has multiple groupings of LED's. One LED grouping can have plural LED's that all have a particular light color that is associated with a condition. Another LED grouping has plural LED's that all have a different light color, which is different from the other light colors and is associated with a different condition. The LED light bulb also has control circuitry that selectably addresses the different LED groupings with a supply of electrical power depending upon the condition. A threaded base is connected to supply the control circuitry with electrical power when screwed into a light socket. An envelope connects to the base to house the first LED grouping and the second LED grouping.
[0006] Another embodiment is also a LED light bulb. The LED light bulb has multiple LED boards. One LED board bears plural LED's that all have a particular light color. Another LED board bears plural LED's that all have a different light color. The LED light bulb also has control circuitry that is connected to selectably address the LED boards with a supply of electrical power. A threaded base is connected to supply the control circuitry with electrical power when screwed into a light socket. An envelope connects to the base to house the LED boards.
[0007] Still another embodiment is another light emitting diode (LED) light bulb. The LED light bulb has multiple groupings of LED's. Each LED grouping has plural LED's that all have a similar light color that is associated with a given condition. Other LED groupings have plural LED's that all have a similar light color (different from other groupings), and which is associated with a different condition. The LED light bulb also has control circuitry that is connected to selectably address the different LED groupings or with a supply of electrical power depending upon the condition. In this embodiment a wireless receiver is connected to command selectable address by the control circuitry based upon a received RF signal. A threaded base is connected to supply the control circuitry with electrical power when screwed into a light socket. An envelope connects to the base to house the different LED groupings.
[0008] Yet another embodiment is an emergency alert system. The emergency alert system has first and second alarm sensors. The first alarm sensor is adapted to sense a first emergency condition. The second alarm sensor is adapted to sense a second emergency condition, which is different from the first emergency condition. The emergency alert system also has a system controller connected to receive sensor signals from the first and second alarm sensors and connected to transmit an alarm signal to a command center indicating the first emergency condition or the second emergency condition. The emergency alert system further has a signal conditioner connected to receive an illumination signal from the system controller indicating a first light color corresponding to the first emergency condition or a second light color corresponding to the second emergency condition, the second light color being different from the first light color. The signal conditioner transmits a command signal to selectably illuminate according to the first light color or the second light color, based upon the received illumination signal. A LED light bulb has first and second LED groupings. The first LED grouping has plural light emitting diodes all having the first light color. The second LED grouping has plural light emitting diodes all having the second light color. The LED light bulb further has control circuitry connected to selectably address the first light emitting diode grouping or the second light emitting diode grouping with supply of electrical power based upon the command signal from the signal conditioner.
[0009] The LED light bulb may be implemented with only a single color of LED's or it may have two, three, or more colors of LED's. The number of LED's may vary without departing from the scope of the present invention. Each color (or combination of colors) is associated with a particular condition. For example, and without limitation, emergency conditions and non-emergency conditions may be indicated by different color LED's or combinations thereof, all of which are considered to be within the scope of the present invention.
[0010] The embodiments of the LED light bulb may also be used in conjunction with an automated network notification to emergency responders of the existence of an emergency, as well as a visual indication of the location and type of emergency that has been automatically detected.
[0011] The use of a standard screw in type power contact configuration enables the LED light bulb to be easily retrofitted into existing light bulb sockets. Thus, no new equipment needs to be installed to make the LED light bulb useful.
[0012] In one embodiment, communication between the controller and the LED light bulb is implemented using a wireless connection. According to an alternate embodiment, communication between the controller and the LED light bulb is implemented using existing power wiring and an ×10 protocol (or the like).
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 illustrates a LED light bulb according to a first embodiment with LED color groupings arranged horizontally and stacked atop one another.
[0014] FIG. 2 illustrates a light assembly for a LED light bulb according to a second embodiment with LED's arranged in vertical columns of stacked LED color groupings.
[0015] FIG. 3 illustrates a monitoring system that incorporates use of an LED light bulb.
[0016] FIG. 4 illustrate an LED bulb embodiment
[0017] FIG. 5 illustrates an LED bulb and controller circuit layout.
DETAILED DESCRIPTION
[0018] Referring to FIG. 1 , An LED light bulb 10 according to one embodiment has a light assembly 100 which has plural LED boards 110 , 120 , 130 stacked atop one another. The LED's 114 on the top LED board 110 all radiate light of the same color as one another and are electrically connected so as to illuminate together as a group. The LED's 124 on the middle LED board 120 all radiate light of the same color as one another, but which is of a different color than that radiated by the LED's 114 of the top LED board 110 . The LED's 124 on the middle LED board 120 are electrically connected so as to illuminate together as a group. The LED's 134 on the bottom LED board 130 all radiate light of the same color as one another, but which is of a different color than those radiated by the LED's 114 of the top LED board 110 and the LED's 124 of the middle LED board 120 . The LED's 134 on the bottom LED board 130 are electrically connected so as to illuminate together as a group.
[0019] Control circuitry 200 is disposed inside the bulb 10 and receives power, and in one embodiment a control signal, via the bulb's base 300 . The control circuit 200 controls illumination of the bulb by energizing only one of the LED boards 110 , 120 , 130 , at a given moment. This is accomplished by an addressing circuit that is advantageously implemented as a PIC 16C54 microcontroller. The PIC 16HV540 microcontroller has thirteen input/output (I/O) pins of which twelve are general purpose. These pins are used to address and drive a selected one (or none) of the plural groups of LED's that display light of a selected color characteristic. The PIC is a suitable microcontroller for implementing the invention because it is robust, simple to interface to the outside world, and relatively simple to program.
[0020] The control circuitry 200 also includes a power supply circuit that converts the 120 VAC power received via the bulb's base 300 into a DC voltage appropriate to power the microcontroller, as well as the LED's.
[0021] Bulb 10 has a bulb base 300 that conforms to the same physical dimensions as any standard sizes for incandescent light bulb that use line voltage. In North America, there are four standard sizes of screw-in sockets used for line-voltage lamps:
[0022] E12 candelabra (E10 & E11 in Europe),
[0023] E17 intermediate (E14 in Europe),
[0024] E26 medium or standard (E27 in Europe), and
[0025] E39 mogul (E40 in Europe).
[0026] The LED light bulb base 300 may also be configured according to the standard dimensions of so-called “bayonet” type bulbs having a pair or radially opposed prongs, which are used in low power applications.
[0027] According to an alternate embodiment, the LED light bulb is hardwired to receive power and control signals rather than interfacing with a conventional socket.
[0028] According to another alternate embodiment, the LED light bulb is self-powered with a solar array mounted on the exterior of the bulb and having a battery to store energy gathered via the solar array.
[0029] The base 300 has screw threads 320 formed using a conductive (e.g., metal) material. The threads 320 mechanically engage a standard size bulb socket to retain the bulb 10 in the socket. The threads 320 provide conductive connection between the socket and the control circuitry 200 . The base 300 also has an electrical foot contact 330 formed using a conductive (e.g., metal) material. The electrical foot contact 330 provides conductive connection between the socket and the control circuitry 200 . The threads 320 are electrically isolated from the foot contact 330 by insulation material.
[0030] Not only does electrical power enter through the threads 320 and the electrical foot contact 330 , but according to at least one embodiment these electrical contact points also serve to couple control signals received via the socket into the control circuitry 200 .
[0031] Bulb 10 has an envelope 400 that surrounds the LED boards 110 , 120 , 130 . Although illustrated as having a quasi-spherical shape, the envelope 400 may be formed to have any serviceable shape that provides protection to the LED boards 110 , 120 , 130 and the control circuitry 200 from impact or exposure to ambient conditions (liquids, corrosive materials, salt air, etc.).
[0032] The light assembly 100 , 102 and the control circuitry 200 are housed inside the combination of the envelope 400 and the threaded base 300 . The envelope 400 and the threaded base 300 are integrally joined together to form a protective housing for the internal elements of the bulb. Although a tight fit between the envelope 400 and the threaded base 300 is useful to protect the internal elements of the bulb from ambient conditions, a vacuum seal (as required in incandescent lamps) is not necessary.
[0033] The control circuitry 200 is electrically connected to the threads 320 and the foot contact 330 of the base 300 so as to receive both power and control signals. Each of the LED boards 110 , 120 , 130 connects electrically to the control circuitry 200 to receive electrical power to illuminate addressed groups of the LED's 114 , 124 , 134 . The addressing of the LED's 114 , 124 , 134 is based upon the control signals received by the control circuitry 200 . The control signals may be transmitted via a wireless connection and received via a wireless receiver (explained in detail below) in the control circuitry 200 , or it may be transmitted via the line voltage wiring 546 (refer to FIG. 3 ) and into the base 300 contacts.
[0034] In any of the described embodiments, the number of LED boards illustrated is not meant as a limitation. Further the number of colors represented is similarly not meant as a limitation.
[0035] Referring to FIG. 2 , a structure is illustrated for how LED's may be successfully arranged inside the bulb using an alternative light assembly 102 . This alternative light assembly 102 has plural elongated LED boards 140 , 150 , 160 arrayed in parallel and facing radially outwards away from one another. The LED groupings 142 , 152 , 162 on the top portions of each of the elongated LED boards 140 , 150 , 160 all radiate light of the same color as one another and are electrically connected so as to illuminate together as a group. The LED groupings 144 , 154 , 164 on the middle portions of each of the elongated LED board 140 , 150 , 160 all radiate light of the same color as one another, but which is of a different color than that radiated by the top LED groupings 142 , 152 , 162 . The middle LED groupings 144 , 154 , 164 are electrically connected so as to illuminate together as a group. The LED groupings 146 , 156 , 166 on the bottom portions of each of the elongated LED board 140 , 150 , 160 all radiate light of the same color as one another, but which is of a different color than those radiated by the top LED groupings 142 , 152 , 162 and the middle LED groupings 144 , 154 , 164 . The bottom LED groupings 146 , 156 , 166 are electrically connected so as to illuminate together as a group.
[0036] When powered and controlled to be illuminated, the LED light bulb 10 emits light according to a selected color. For example, the colors may be red, green, and white. These are colors of LED's that are readily commercially available and are easily distinguishable from one another with natural human vision.
[0037] Referring to FIG. 3 , a system for providing alerts to emergency personnel approaching a building is illustrated. One or more sensors 510 , 512 , 514 or signaling systems 520 are connected via a network 530 to a system controller 540 . The system controller 540 continuously monitors the sensors 510 , 512 , 514 and the signaling systems 520 and provides notifications of an alarm condition to a relevant monitoring-dispatching control center 550 . The control center 550 relays, either automatically or at human discretion, alerts to external agencies 560 such as fire/rescue, ambulance, or police.
[0038] Fire detection sensors 510 for use in this system may be embodied as including (without limitation) smoke detectors, flame detectors, carbon monoxide detectors, or a combination of such detectors. Water detection sensors 512 for use in this system may be embodied as including (without limitation) capacitive sensors, conductive sensors, mechanical float switch sensors, or a combination of such sensors. Intrusion detection sensors 514 for use in this system may be embodied as including (without limitation) magnetic proximity switches, motion sensors, pressure switches, or a combination of such devices.
[0039] The system controller 540 also interfaces with a signal conditioner structure that functions to activate the LED light bulb 10 . As illustrated in FIG. 3 , a wireless transmitter 570 serves as the signal conditioner that sends an addressing signal to the LED light bulb 10 commanding it to display a selected color of light.
[0040] When one of the sensors 510 , 512 , 514 or the signaling system 520 notifies the system controller 540 of an alarm condition, the system controller 540 identifies the type of alarm condition (fire, intrusion, medical, etc.) being sensed and forwards commensurate signals onward to both the command center 550 and the wireless transmitter 570 . The system controller 540 sends a signal to the command center 550 that identifies the location of the alarm and the type of alarm condition detected. For example, if a fire condition is sensed the command center 550 is notified of a fire condition at the monitored address. The system controller 540 sends a signal to the wireless transmitter 570 instructing illumination of a color that corresponds to the type of alarm condition detected. For example, if a fire condition is sensed the wireless transmitter 570 is instructed to illuminate with the color red. The wireless transmitter 570 in turn sends a command signal to the LED light bulb 10 to address its red LED's.
[0041] Emergency responders receive information in two ways in this system. The responders receive an external alert 560 from the command center 550 telling them the location and nature of the emergency and, when they approach the location of the alarm, they receive signaling from the LED light bulb 10 illuminating to confirm the precise building to respond to. In the case of an apartment building, the LED light bulb 10 will indicate the location of the building and, optionally, which one of the many units in the apartment building the alarm is originating from. Alternatively, the LED light bulb 10 is augmented by a LED digital numeric display 12 that is also activated by the wireless transmitter 570 to indicate the apartment number the alarm is originating from. For example, when the fire alarm in apartment number 872 is activated, the LED light bulb 10 indicates the building and the LED numeric display 12 indicates that apartment number 872 is the source of the alarm.
[0042] When the system controller 540 receives a notification of an alarm from one of the sensors 510 , 512 , 514 or from an alert device 522 , 524 , 526 via the network 530 , or by monitoring of the telephone 544 line (dial of 911) or dry contact closure 548 from an additional unspecified sensor, the system controller 540 send serial data to the wireless transmitter 570 . The format of the serial data may advantageously take the form:
[0000]
First word
Sync Word
Second word
Unit ID Word (System controller and LED
Light Bulb must have the same Unit ID, for
Led Bulb to be activated)
Third word
Strobe ON or OFF word
[0043] The wireless communication link between the system controller 540 and the LED light bulb 10 can be tested using the telephone. The operator will remove the hand set of the telephone 544 that the system controller 540 is monitoring and dials the test code (for example, #88). The system controller 540 will decode the buttons pushed on the phone and transfer the flash ON code to the LED light bulb 10 .
[0044] The LED light bulb 10 will decode the Sync Word to determine the start of the transmission then verify that the ID Word received is equal to (i.e., matches) the ID Word it has been set to. If the ID Words match the LED light bulb 10 will act on the third word received, either Flash On or Flash OFF.
[0045] To turn the Flash OFF after an emergency condition has been ended or verification that the wireless link is working, the operator will remove the hand set of the telephone 544 that the system controller 540 is monitoring and dials a Stop/Reset code (for example, #55). The system controller 540 will decode the buttons pushed on the phone and transfer the Flash OFF code to the LED light bulb 10 .
[0046] Implementation of the wireless link embodiments can be accomplished using any of various commercially available RF transmitters and receivers hardware. Most any RF transmitter as known in the prior art may be used, since size and power constraints are not a concern at the system controller 540 . On the other hand, at the LED light bulb 10 a compact receiver is useful to fit inside a light bulb form factor package.
EXAMPLE 1
[0047] As a working example, a system controller, wireless transmitter, and LED light bulb wireless receiver have been successfully implemented utilizing RF transmitters and receivers manufactured by LINX Technologies. The LINX RF transmitters and receivers operate on two (2) different carrier frequency ranges depending on the models selected: the low range (nominally 400 MHz) operates at available frequencies including 315, 418 and 433 MHz, and the high range (nominally 900 MHz) operates at available frequencies including 869 and 916 MHz. These devices convert the serial TTL Data stream into RF impulses to be transferred between the two transmitter and receiver components.
[0048] Examples of LINX Technologies manufactured RF receivers of the sort that can be advantageously implemented are receiver model numbers RXM-869-ES (nominally 869 MHz) and RXM916-ES (nominally 916 MHz). Alternatively, receiver model numbers RXM-416-LR or LC (nominally 416 MHz) can be used if lower range frequency use is desired. These models have ultra-compact SMD packages and are set up to perform both analog frequency modulation (FM) and digital frequency shift keying (FSK). These models have high noise immunity, excellent sensitivity, and consume little power. No additional components or tuning are required, other than to provide an antenna of the appropriate impedance (nominally 50 Ω) at the selected operating frequency. These models can operate under conditions as hot as 70° C. and require a regulated power supply of nominal 5 VDC with noise of less than 20 mV. They provide a range of up to 1,000 feet outdoors and up to 500 feet indoors, which is more than plenty for residential applications.
[0049] For additional technical details the component manufacturer, LINX Technologies, may be contacted at 575 S.E. Ashley Place, Grants Pass, Oreg. 97526.
EXAMPLE 2
[0050] As an additional example, the wireless transmitter and receiver components of the disclosed embodiments can be implemented using an RF modem transceiver system, made by Xecom Inc., which operates on AT commands. When data is to be transferred from one modem to the other or a multipoint RF network, the initiating device makes the connection then sends the data. The distant receiving end then sends back to the initiating end an acknowledgment that the data was received error free.
[0051] Examples of Xecom Inc. manufactured RF transceivers of the sort that can be advantageously implemented are model numbers XE900SL10 (low power) and XE900S-500 (high power). These models have compact packages that house spread spectrum transceiver and integrated micro-controller that manages a frequency hopped spread spectrum link and a host system interface. These models each have −100 dBm receiver sensitivity, can operate at temperatures as high as 85° C., require a nominal 3.3 Volt power supply, and operate in a frequency band of about 902 through 928 MHz. The lower power XE900SL10 model has package dimensions of 1 inch square with a 0.26 inch thickness, and has an obstructed signal range of 300 feet. The higher power model has package dimensions of 1.295 inch by 1.410 inch by 0.255 inch, and has an obstructed signal range of 1000 feet.
[0052] For additional technical details the component manufacturer, Xecom Inc., may be contacted at 3374 Turquoise Street, Milpitas, Calif. 95035.
EXAMPLE 3
[0053] When a life threatening emergency occurs, fast response time by emergency personnel is important. Although response times have been shortened substantially via automated alarm systems that provide timely alerts to emergency services organization, many deaths associated with delayed response times are attributable to difficulties in locating the right house, apartment, or business location in a timely manner when responding to emergency calls. Despite rigorous training of emergency personnel to attempt to improve the speed of location of emergency locations, this remains a stubbornly hard-to-eliminate source of delay. Embodiments of the LED light bulb herein described allow responders to quickly find the emergency location via the LED color that is visible.
EXAMPLE 4
[0054] Other embodiments of the LED light bulb may be manually activated in a particular color by a user command. In such a case, a particular color might mean the home is open to “trick-or-treaters” or is a location where pets are located. In summary, the invention can signify any of various non-emergency conditions.
EXAMPLE 5
[0055] An LED light bulb provides signaling regarding various alarm conditions. Each alarm condition is represented by a distinct color profile of light emitted by the LED light bulb. The power connection contacts of the LED bulb are consistent with a standard screw-in type light bulb, although this is not meant as a limitation and other connection interfaces may be used to practice the present invention. The use of a standard screw-in type light bulb base configuration is useful to retrofit the novel structure and function of the present invention easily with existing lighting systems. The bulb incorporates an integrated circuit chip that receives and decodes control signals concerning what signals the LED light bulb is to make. Based on the decoded control signals, the integrated circuit chip controls application of power to a selected one of plural groups of LED's housed inside the bulb. Each of the plural groups of LED's is of a particular color emission characteristic that is distinct from the other LED groups.
EXAMPLE 6
[0056] The LED light bulb can function as part of a security system. Typically a network connects various monitoring subsystems, such as burglary detectors, fire/smoke detectors, medical alert monitors, water intrusion monitors, carbon monoxide sensors, etc. A central controller connects to these various subsystems via the network and provides alert signals to both a remote command center and to one or more of the LED light bulbs at, or near, the premises being monitored. Whereas the remote command center has the discretionary capability to summon emergency personnel (firefighters, police, private security, etc.) the LED light bulbs provide a local visual alert to building occupants, neighbors, passersby, and intruders of an alarm condition.
EXAMPLE 7
[0057] Each of the colors of the LED light bulb may be used to designate a particular condition of either an emergency or non-emergency nature, and when mounted on the exterior of a building (residential or commercial) provides to first responders or passersby information about the nature of the condition, in addition to providing a conspicuous indication of the location of the condition. For example when used in an emergency situation, red might symbolize a fire alarm, green would symbolize a medical alarm (e.g., from a medical alert transmitter), and white would symbolize an intrusion alarm. Other colors may indicate yet other conditions. The illumination may be continuous or modulated to indicate further information, and the frequency and duty cycle of modulation (slow blink, fast blink, strobe, etc.) can also convey information.
[0058] Referring to FIG. 4 a preferred embodiment of the LED light bulb is illustrated. The LED bulb comprises a base 602 that can be a screw type base, pin base, or any other type of base known in the art that allows connection of the bulb to an electrical system. The base 602 provides power to the power supply 600 which in turn provides power to the remainder of the LED bulb embodiment. Day/night sensors 604 , 606 allow the bulb to sense the ambient light and therefore provide greater or lesser power as needed. Once the outside illumination falls below a certain level the day/night sensors will permit the LED bulb to be turned on at a preset level which will not affect the later control or operation of the LED bulb. LED controller 608 is disposed over the power supply and allows both intensity, duration of the flash, and time interval for sequential flashes of the LEDs to be controlled. This controller then controls the LED “sticks” 610 . In a preferred embodiment the LED are disposed in a vertical stick-type arrangement with 8 sticks of LED's connected to the controller. Each stick has 4 LEDS although this is not meant as a limitation. A receiver board/antenna 612 is disposed on top of the LED sticks, although this physical position is not a limitation. The receiver board/antenna 612 allows the LED bulb to receive signals from a wireless controller that instructs the LED bulb to glow in a particular color, to flash in a particular manner, or to operate in other way disclosed herein.
[0059] Referring now to FIG. 5 a vertical view looking down on the LED bulb is illustrated. Note that the antenna board is not seen in this view. Timer circuit 700 controls the LED sticks 704 , 706 , 708 , 710 , 712 , 714 , 716 , and 718 . The timer determines the interval with which the LED sticks will flash (i.e., once every second, sequentially, color, and in other ways disclosed herein). The pulse/flash controller circuit 702 controls the intensity with which the LED sticks will flash at the predetermined interval controlled by the timer circuit 700 .
[0060] This particular layout of LED sticks and controlling circuits is not meant as a limitation. It is illustrated herein for this particular embodiment.
[0061] The embodiments are not limited to the number of colors specifically disclosed, nor to the specific colors mentioned. Practice of the present invention may be effected with as few as one single color of LED in the light bulb, although plural colors are preferred to provide increased versatility. The colors of LED's usable to practice the invention are not limited to those currently commercially available and shall be considered to encompass wavelengths and ranges of wavelengths that may come to be produced in the future. The colors of LED's usable to practice the invention are not limited to visible wavelengths and may include infrared and ultraviolet varieties, for example, for producing radiative alerts that trigger remote sensors or for producing stealthy alerts detectable only to emergency personnel with appropriate equipment to sense non-visible alerts.
[0062] An LED light bulb and an emergency alert system have been described using the LED light bulb. It will be understood by those skilled in the art that the present invention may be embodied in other specific forms without departing from the scope of the invention disclosed and that the examples and embodiments described herein are in all respects illustrative and not restrictive. Those skilled in the art of the present invention will recognize that other embodiments using the concepts described herein are also possible. Further, any reference to claim elements in the singular, for example, using the articles “a,” “an,” or “the” is not to be construed as limiting the element to the singular.
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An LED light bulb having separately addressable groupings of LED's. The LED light bulb can serve as a visual indicator of emergency or non-emergency conditions by selectively illuminating groupings of LED's in a variety of colors, each color corresponding to a predetermined condition.
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This application claims priority, pursuant to 35 U.S.C. §119, to U.S. Provisional Patent Application No. 60/809,046 filed May 30, 2006, the entire content of which is incorporated herein by reference.
FIELD OF THE DISCLOSURE
The present disclosure relates to arrangements, compositions, as well as design and fabrication techniques relating to munitions.
BACKGROUND OF THE INVENTION
In the discussion of the state of the art that follows, reference is made to certain structures and/or methods. However, the following references should not be construed as an admission that these structures and/or methods constitute prior art. Applicant expressly reserves the right to demonstrate that such structures and/or methods do not qualify as prior art.
A conventional blast-frag warhead inflicts damage by two primary methods. The first is the overpressure generated from the detonation of an explosive fill. The second is the formation and acceleration of metal fragments from the warhead case caused by the detonation of an explosive. Different targets exhibit varying degrees of vulnerability to these damage mechanisms. Materiel is more vulnerable to fragments and structures are more vulnerable to blast overpressure. Personnel are vulnerable to both. In light of this, general purpose bombs are usually of the blast-frag variety to ensure that a large target set can be held at risk with a single weapon.
In general, the damage radius for fragmentation is considerably larger than that for blast. Blast damage drops off as a function of distance to the 3rd power. The addition of precision delivery with blast-frag warheads enables a significant weapon system lethality overmatch against many targets. This overmatch has driven our adversaries to attempt to seek cover in civilian populations where our rules of engagement limit our ability to engage them. The rules of engagement are driven by the political motivation to limit collateral damage. Collateral damage is the unintended damage or destruction of life or property near a target. Thus a general purpose warhead that could limit collateral damage without compromising probability of kill would be highly advantageous.
Others have tried to create low collateral damage warheads by eliminating fragment formation by replacing a metal case with a fiber reinforced plastic one. The elimination of the fragments results in a warhead with a primarily blast damage mechanism. However, the permanent elimination of fragments limits the target set against which the weapon is useful and in essence a niche weapon. It increases the logistic trail and mission loadout complexity.
SUMMARY OF THE INVENTION
The disclosed invention includes methods and constructions for selecting between a blast or blast-frag operational mode for a warhead. The selectability is achieved, at least in part, by using a meltable or phase-changeable material in the warhead case. For example, within the case, included as a composite structure or as a discreet layer(s), is a reactive material capable of releasing sufficient thermal energy to melt the meltable material of the case. The case is filled with an explosive payload.
In the blast-frag mode, the warhead is detonated as a conventional warhead, and the metal within the case is fragmented or dispersed naturally or along preformed scribes. In the blast-only mode, a fuze or other initiating component is used to ignite the reactive material in the case. The heat released from the reactive material induces a phase transformation (e.g., melting) of the fragments within the case. Immediately following this reaction the high explosive is initiated allowing the blast to propagate through the molten material.
According to the principles of the present invention, the above-described selectability of the mode of operation of a munition allows the weapon to be used against a broad target set like a general purpose bomb, but when the need arises for reduced collateral effects, the fragments can be selectively eliminated.
According to one aspect, the present invention provides a munition comprising: a casing, the casing comprising a material comprising (i) a meltable or phase-changing material, and (ii) an energetic material; an explosive payload contained within the casing; and a fuze arrangement, the fuze arrangement comprising a main fuze configured and arranged to ignite the high explosive, and at least one secondary fuze configured and arranged to initiate melting or a phase change of the casing material.
According to a further aspect, the present invention provides A method of selectively altering the mode of operation of a munition, the method comprising: forming a casing, the casing comprising a material comprising (i) a meltable or phase-changing, and (ii) an energetic material; introducing an explosive payload into the casing; providing a fuze arrangement comprising a main fuze and at least one secondary fuze configured and arranged to initiate melting or a phase change of the casing material; and selectively activating the main fuze and the at least one secondary fuze in a manner that provides at least a first and a second mode of operation, the first mode of operation comprising blast coupled with fragmentation effects, and the second mode of operation comprising mainly blast effects.
BRIEF DESCRIPTION OF THE DRAWING FIGURES
The following detailed description of preferred embodiments can be read in connection with the accompanying drawings in which like numerals designate like elements and in which:
FIG. 1 is a longitudinal sectional illustration of a munition formed according to the principles of the present invention.
FIG. 2 is a cross-sectional view taken along line 2 - 2 of FIG. 1 .
FIG. 3 is a schematic illustration of different modes of operation of a munition according to the principles of the present invention.
DETAILED DESCRIPTION
FIGS. 1-2 illustrates an exemplary munition 10 formed according to one embodiment of the present invention. As illustrated, the munition 10 may be in form of a warhead comprising a casing 12 carrying an explosive payload 20 . The shape of the casing 12 is not limited to the illustrated embodiment, and may have any suitable geometry and/or size. The casing 12 may optionally include an inner and/or outer liner or shield 14 and/or 16 , respectively. The liner(s) or shield(s) may be provided as a thermal shield. The liner(s) and/or shield(s) can be formed from any suitable material(s). By way of non-limiting example, the shields can be formed from a thermoplastic. Thermoplastics such as polytetrafluoroethylene (PTFE) or polyetheretherketone (PEEK) can be utilized. The linear(s) and/or shield(s) 14 , 16 serve to, at least in part, prevent the transfer of thermal energy to the payload 20 of a magnitude that could cause unwanted detonation thereof.
The main component of the casing 12 is a layered or composite material 18 . This material can be composed mainly of two components: (i) a meltable or phase-changing material, and (ii) an energetic material. The two components can be arranged relative to one another in any suitable fashion. For example, the material can comprise a matrix of the meltable or phase-changing material with the energetic material dispersed therein. Alternatively, the material can comprise one or more layers of the meltable or phase-changing and one or more layers of the energetic material.
The meltable or phase-changing material can be formed from any suitable metal or combination of metals and/or alloys. According to one embodiment, the metal comprises an elemental metal or alloy that when combined with the energetic component (or components); the pressure used to compact and densify the structure is of a magnitude below that which would cause auto ignition of the reactive materials. According to a further embodiment, the metal comprises one or more of: bismuth, lead, tin, aluminum, magnesium, titanium, gallium, indium, and alloys thereof. By way of non-limiting example, suitable alloys include (percentages are by mass): 52.2% In/45% Sn/1.8% Zn; 58% Bi/42% Sn; 60% Sn/40% Bi; 95% Bi/5% Sn; 55% Ge; 45% Al; 88.3% Al/11.7% Si; 92.5% Al/7.5% Si; 95% Al/15% Is; Zn 100%; 4% Al/2.5% Cu/0.04% Mg/Bal Zn; and 11% Al/1% Cu/0.025% Mg/Bal Zn. In addition, the metal may optionally include one or more reinforcing elements or additives. Thus, the metal may optionally include one or more of: an organic material, an inorganic material, a metastable intermolecular compound, and/or a hydride. By way of non-limiting example, one suitable additive could be a polymeric material that releases a gas upon thermal decomposition. The composite can also be reinforced by adding one or more of the following organic and/or inorganic reinforcements: continuous fibers, chopped fibers, whiskers, filaments, a structural preform, a woven fibrous material, a dispersed particulate, or a nonwoven fibrous material. The fragmenting composite may also be partially or full encapsulated within a metal jacket to provide strength and explosive launch survivability. Other suitable reinforcements are contemplated.
The energetic material component may comprise any suitable energetic material, which is dispersed within the meltable or phase-changing binder material, or disposed in one or more layer(s) adjacent to the meltable metal. The energetic material may have any suitable morphology (i.e., powder, flake, crystal, etc.) or composition.
The energetic material may comprise a material, or combination of materials, which upon reaction, release enthalpic or work-producing energy. One example of such a reaction is called a “thermite” reaction. Such reactions can be generally characterized as a reaction between a metal oxide and a reducing metal which upon reaction produces a metal, a different oxide, and energy. There are numerous possible metal oxide and reducing metals which can be utilized to form such reaction products. Suitable combinations include but are not limited to, mixtures of aluminum and copper oxide, aluminum and tungsten oxide, magnesium hydride and copper oxide, magnesium hydride and tungsten oxide, tantalum and copper oxide, titanium hydride and copper oxide, and thin films of aluminum and copper oxide. A generalized formula for the stoichiometry of this reaction can be represented as follows:
M x O y +M Z =M x +M z O y +Energy
wherein M x O y is any of several possible metal oxides, M Z is any of several possible reducing metals, M x is the metal liberated from the original metal oxide, and M z O y is a new metal oxide formed by the reaction. Thus, according to the principles of the present invention, the energetic material 130 may comprise any suitable combination of metal oxide and reducing metal which as described above. For purposes of illustration, suitable metal oxides include: La 2 O 3 , AgO, ThO 2 , SrO, ZrO 2 , UO 2 , BaO, CeO 2 , B 2 O 3 , SiO 2 , V 2 O 5 , Ta 2 O 5 , NiO, Ni 2 O 3 , Cr 2 O 3 , MoO 3 , P 2 O 5 , SnO 2 , WO 2 , WO 3 , Fe 3 O 4 , MoO 3 , NiO, CoO, Co 3 O 4 , Sb 2 O 3 , PbO, Fe 2 O 3 , Bi 2 O 3 , MnO 2 Cu 2 O, and CuO. For purposes of illustration, suitable reducing metals include: Al, Zr, Zn, Th, Ca, Mg, U, B, Ce, Be, Ti, Ta, Hf, and La. The reducing metal may also be in the form of an alloy or intermetallic compound of the above. For purposes of illustration, the metal oxide is an oxide of a transition metal. According to another example, the metal oxide is a copper or tungsten oxide. According to another alternative example, the reducing metal comprises aluminum or an aluminum-containing compound.
As noted above, the energetic material component may have any suitable morphology. Thus, the energetic material may comprise a mixture of fine powders of one or more of the above-mentioned metal oxides and one or more of the reducing metals. This mixture of powders may be dispersed in the metal, which can act like a binder. According to certain embodiments, the metal acts as a partial or complete source of metal fuel for the energetic, or thermite, reaction.
The energetic material may be in the form of a thin film having at least one layer of any of the aforementioned reducing metals and at least one layer of any of the aforementioned metal oxides. The thickness of the alternating layers can vary, and can be selected to impart desirable properties to the energetic material. For purposes of illustration, the thickness of layers and can be about 10 to about 1000 nm. The layers may be formed by any suitable technique, such as chemical or physical deposition, vacuum deposition, sputtering (e.g., magnetron sputtering), or any other suitable thin film deposition technique. Each layer of reducing metal present in the thin-film can be formed from the same metal. Alternatively, the various layers of reducing metal can be composed of different metals, thereby producing a multilayer structure having a plurality of different reducing metals contained therein. Similarly, each layer of metal oxide can be formed from the same metal oxide. Alternatively, the various layers of metal oxide can be composed of different oxides, thereby producing a multilayer structure having different metal oxides contained therein. The ability to vary the composition of the reducing metals and/or metal oxides contained in the thin-film structure advantageously increases the ability to tailor the properties of the detonable energetic material, and thus the properties of the casing material.
The casing 12 of the present invention can be formed according to any suitable method or technique.
Generally speaking, a suitable method for forming a casing according to the present invention includes forming an energetic material, combining the energetic material with a meltable or phase-changing material to form a mixture, and shaping the mixture to form a composite structural component (e.g., casing).
The energetic material can be formed according to any suitable method or technique. For example, when the energetic material is in the form of a thin film, as mentioned above, the thin-film detonable energetic material can be formed as follows. The alternating layers of oxide and reducing metal are deposited on a substrate using a suitable technique, such as vacuum vapor deposition or magnetron sputtering. Other techniques include mechanical rolling and ball milling to produce layered structures that are structurally similar to those produce in vacuum deposition. The deposition or fabrication processes are controlled to provide the desired layer thickness, typically on the order of about 10 to about 1000 nm. The thin-film comprising the above-mentioned alternating layers is then removed form the substrate. Removable can be accomplished by a number of suitable techniques such as photoresist coated substrate lift-off, preferential dissolution of coated substrates, and thermal stock of coating and substrate to cause film delamination. According to one embodiment, the inherent strain at the interface between the substrate and the deposited thin film is such that the thin-film will flake off the substrate with minimal or no effort.
The removed layered material is then reduced in size; preferably, in a manner such that the pieces of thin-film having a reduced size are also substantially uniform. A number of suitable techniques can be utilized to accomplish this. For example, the pieces of thin-film removed from a substrate can be worked to pass them through a screen having a desired mesh size. By way of non-limiting example, a 25-60 size mesh screen can be utilized for this purpose. This accomplishes both objectives of reducing the size of the pieces of thin-film removed from the substrate, and rendering the size of these pieces substantially uniform.
The above-mentioned reduced-size pieces of thin layered film are then combined with metallic matrix or binder material to form a mixture. The metallic binder material can be selected from many of the above-mentioned binder materials. This combination can be accomplished by any suitable technique, such as milling or blending. Additives or additional components can be added to the mixture. As noted above, such additives or additional components may comprise one or more of: an organic material, and inorganic material, a metastable intermolecular compound, and/or a hydride. In addition, one or more reinforcements may also be added. Such reinforcements may include organic and/or inorganic materials in the form of one or more of: continuous fibers, chopped fibers, whiskers, filaments, a structural preform, dispersed particulate, a woven fibrous material, or a nonwoven fibrous material. Optionally, the pieces of layered film, the metallic binder material, the above-mentioned additives and/or the above-mentioned reinforcements can be treated in a manner that functionalizes the surface(s) thereof, thereby promoting wetting of the pieces of thin-film in the matrix of metallic binder. Such treatments are per se known in the art. For example, the particles can be coated with a material that imparts a favorable surface energy thereto.
This mixture can then be shaped thereby forming a structural component having a desired geometrical configuration. The structural component can be shaped by any suitable technique, such as molding or casting, pressing, forging, cold isostatic pressing, hot isostatic pressing. As noted above, the structural component or casing can be provided with any suitable geometry.
As explained above, there are number of potential applications for a structural component according to principles of the present invention. Non-limiting exemplary weapons and/or weapons systems which may incorporate composite structural components formed according to the principles of the present invention include a BLU-109 warhead or other munition such as BLU-109/B, BLU-113, BLU-116, JASSM-1000, J-1000, and the JAST-1000.
As previously noted, one of the advantages of a munition constructed according to the principles of the present invention is that a single weapon can be provided that has a mode of operation that can be selectively changed. Two such selectable alternative modes of operation are illustrated in FIG. 3 . The munition 10 is only schematically illustrated in FIG. 3 , and may take any suitable form. The munition 10 may comprise a casing (e.g., element 12 ; FIGS. 1-2 ) formed at least in part from a meltable or phase-changing energetic material combination as described above (e.g., element 18 ; FIGS. 1-2 ). The munition may also be provided with an inner and/or outer layer or shield, such as heat shields and to provide containment of melted metal in a blast-only mode (e.g., 14 , 16 ; FIGS. 1-2 ). The behavior of the munition 10 is controlled mainly through the selection and operation of the fuze arrangement (e.g., elements 22 , 24 , 26 and 28 ; FIGS. 1-2 ).
As illustrated in FIG. 3 , the mode of operation of the fuze arrangement is selected. According to a first mode, the main fuze is activated which ignites the high explosive contained within the munition. This explosion causes the casing of the munition to fragment along natural or pre-scribed fault lines. The fragments are intended to impact the target. The kinetic energy of the fragments imparts a destructive effect to the target upon impact therewith.
According to a second mode, one or more secondary fuzes are activated, causing the metal of the casing to undergo a phase change (e.g., melt). Subsequently, or simultaneously, the main fuze is activated causing ignition of the high explosive, thereby causing an explosion. However, since the casing has been reduced to a non-solid state, no (or few) solid fragments are produced thereby. Thus, the amount of collateral damage produced by the spreading of and impact of fragments can be greatly reduced, if not eliminated.
All numbers expressing quantities of ingredients, constituents, reaction conditions, and so forth used in the specification are to be understood as being modified in all instances by the term “about”. Notwithstanding that the numerical ranges and parameters setting forth, the broad scope of the subject matter presented herein are approximations, the numerical values set forth are indicated as precisely as possible. Any numerical value, however, inherently contains certain errors necessarily resulting from their respective measurement techniques, as evidenced for example, by the standard deviation associated therewith.
Although the present invention has been described in connection with preferred embodiments thereof, it will be appreciated by those skilled in the art that additions, deletions, modifications, and substitutions not specifically described may be made without department from the spirit and scope of the invention as defined in the appended claims.
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A munition includes a casing, the casing formed at least in part from a material comprising (i) a meltable or phase-changing material, and (ii) an energetic material; an explosive payload contained within the casing; and a fuze arrangement, the fuze arrangement comprising a main fuze configured and arranged to ignite the high explosive, and at least one secondary fuze configured and arranged to cause the casing material to melt or undergo a phase change. A method of selectively altering the mode of operation of a munition includes: forming a casing, the casing comprising a material comprising (i) a meltable or phase-changing material, and (ii) an energetic material; introducing an explosive payload into the casing; providing a fuze arrangement comprising a main fuse and at least one secondary fuze configured and arranged to cause the casing material to melt or undergo a phase change; and selectively activating the main fuze and the at least one secondary fuze in a manner that provided at least a first and a second mode of operation, the first mode of operation comprising blast coupled with fragmentation effects, and the second mode of operation comprising mainly blast effects.
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RELATED APPLICATIONS
[0001] This application is a continuation of PCT/US2010/035331, filed May 18, 2010, which claimed priority to U.S. Provisional Application Ser. No. 61/179,995, filed May 20, 2009, U.S. Provisional Application Ser. No. 61/218,832, filed Jun. 19, 2009, and U.S. Provisional Application Ser. No. 61/226,877, filed Jul. 20, 2009. The complete disclosure of each of these applications is hereby incorporated by reference herein.
BACKGROUND
[0002] Processing hydrocarbon-containing materials can permit useful intermediates or products to be extracted from the materials. Natural hydrocarbon-containing materials can include a variety of other substances in addition to hydrocarbons.
SUMMARY
[0003] Systems and methods are disclosed herein for processing a wide variety of different hydrocarbon-containing materials, such as light and heavy crude oils, natural gas, bitumen, coal, and such materials intermixed with and/or adsorbed onto a solid support, such as an inorganic support. In particular, the systems and methods disclosed herein can be used to process (e.g., crack, convert, isomerize, reform, separate) hydrocarbon-containing materials that are generally thought to be less easily processed, including oil sands, oil shale, tar sands, and other naturally-occurring and synthetic materials that include both hydrocarbon components and solid matter (e.g., solid organic and/or inorganic matter).
[0004] Such materials can be especially difficult to mix with liquids, e.g., with water or a solvent system during processing. For example, if the materials are low density, the materials tend to float to the surface of the liquid, or if the materials are high density they tend to sink to the bottom of the mixing vessel, rather than being dispersed. In some cases, the materials can be hydrophobic, highly crystalline, or otherwise difficult to wet. At the same time, it is desirable to process the feedstock in a relatively high solids level dispersion, for efficiency and in order to obtain a high final concentration of the desired product after processing.
[0005] The inventors have found that dispersion of a feedstock in a liquid mixture can be enhanced, and as a result in some cases the solids level of the mixture can be increased, by the use of certain mixing techniques and equipment. The mixing techniques and equipment disclosed herein also enhance mass transfer. In particular, jet mixing techniques, including for example jet aeration and jet flow agitation, have been found to provide good wetting, dispersion and mechanical disruption. By increasing the solids level of the mixture, the process can proceed more rapidly, more efficiently and more cost-effectively, and the resulting concentration of the intermediate or product can be increased.
[0006] In some implementations, the process further includes treating the feedstock to facilitate recovery of the hydrocarbon. For example, exposure of the materials to particle beams (e.g., beams that include ions and/or electrons and/or neutral particles) or high energy photons (e.g., x-rays or gamma rays) can be used to process the materials. Particle beam exposure can be combined with other techniques such as sonication, mechanical processing, e.g., comminution (for example size reduction), temperature reduction and/or cycling, pyrolysis, chemical processing (e.g., oxidation and/or reduction), and other techniques to further break down, isomerize, or otherwise change the molecular structure of the hydrocarbon components, to separate the components, and to extract useful materials from the components (e.g., directly from the components and/or via one or more additional steps in which the components are converted to other materials). Radiation may be applied from a device that is in a vault. Methods of treating hydrocarbon-containing materials are described in detail in U.S. patent application Ser. Nos. 12/417,786 and 12/417,699, both of which were filed on Apr. 3, 2009, the complete disclosures of which are incorporated herein by reference.
[0007] The systems and methods disclosed herein also provide for the combination of any hydrocarbon-containing materials described herein with additional materials including, for example, solid supporting materials. Solid supporting materials can increase the effectiveness of various material processing techniques. Further, the solid supporting materials can themselves act as catalysts and/or as hosts for catalyst materials such as noble metal particles, e.g., rhodium particles, platinum particles, and/or iridium particles. The catalyst materials can increase still further the rates and selectivity with which particular intermediates or products are obtained from processing the hydrocarbon-containing materials. Such additional materials and their use in processing are described in the above-incorporated U.S. patent application Ser. No. 12/417,786.
[0008] Many of the intermediates or products obtained by the methods disclosed herein, such as petroleum products, can be utilized directly as a fuel or as a blend with other components for powering cars, trucks, tractors, ships or trains. The hydrocarbon products can be further processed via conventional hydrocarbon processing methods. Where hydrocarbons were previously associated with solid components in materials such as oil sands, tar sands, and oil shale, the liberated hydrocarbons are flowable and are therefore amenable to processing in refineries.
[0009] In one aspect, the invention features a method that includes processing a hydrocarbon-containing feedstock by mixing the feedstock with a liquid medium in a vessel, using a jet mixer.
[0010] Some embodiments include one or more of the following features. The jet mixer may include, for example, a jet-flow agitator, a jet aeration type mixer, or a suction chamber jet mixer. If a jet aeration type mixer is used, it may be used without injection of air through the mixer. For example, if the jet aeration type mixer includes a nozzle having a first inlet line and a second inlet line, in some cases both inlet lines are supplied with a liquid. In some cases, mixing comprises adding the feedstock to the liquid medium in increments and mixing between additions. The mixing vessel may be, for example, a tank, rail car or tanker truck. The method may further include adding an emulsifier or surfactant to the mixture in the vessel.
[0011] In some instances, the vessel is or includes a conduit or other structure or carrier for the feedstock. For example, a jet mixer may be disposed in a conduit, e.g., between processing areas. In this case, the jet mixer can serve the dual purpose of mixing and conveying the mixture from one area to another. Additional jet mixers can be disposed in other areas, e.g., in one or more processing tanks, if desired. In some cases, the vessel can be a continuous loop of pipe, tubing, or other structure that defines a bore or lumen, and jet mixing can take place within this loop.
[0012] In another aspect, the invention features processing a hydrocarbon-containing feedstock by mixing the feedstock with a liquid medium in a vessel, using a mixer that produces generally toroidal flow within the vessel.
[0013] In some embodiments, the mixer is configured to limit any increase in the overall temperature of the liquid medium to less than 5° C. over the course of mixing. This aspect may also include, in some embodiments, any of the features discussed above.
[0014] In another aspect, the invention features an apparatus that includes a tank, a jet mixer having a nozzle disposed within the tank, and a delivery device configured to deliver a hydrocarbon-containing feedstock to the tank.
[0015] Some embodiments include one or more of the following features. The jet mixer can further include a motor, and the apparatus can further include a device configured to monitor the torque on the motor during mixing. The apparatus can also include a controller that adjusts the operation of the feedstock delivery device based on input from the torque-monitoring device.
[0016] All publications, patent applications, patents, and other references mentioned herein or attached hereto are incorporated by reference in their entirety for all that they contain.
DESCRIPTION OF THE DRAWINGS
[0017] FIG. 1 is a schematic diagram showing a sequence of steps for processing hydrocarbon-containing materials.
[0018] FIGS. 2 and 2A are diagrams illustrating jet flow exiting a nozzle.
[0019] FIG. 3 is a diagrammatic perspective view of a jet-flow agitator according to one embodiment. FIG. 3A is an enlarged perspective view of the impeller and jet tube of the jet-flow agitator of FIG. 3 . FIG. 3B is an enlarged perspective view of an alternate impeller.
[0020] FIG. 4 is a diagram of a suction chamber jet mixing nozzle according to one embodiment. FIG. 4A is a perspective view of a suction chamber jet mixing system according to another embodiment.
[0021] FIG. 5 is a diagrammatic perspective view of a jet mixing nozzle for a suction chamber jet mixing system according to another alternate embodiment.
[0022] FIG. 6 is a diagrammatic perspective view of a tank and a jet aeration type mixing system positioned in the tank, with the tank being shown as transparent to allow the jet mixer and associated piping to be seen. FIG. 6A is a perspective view of the jet mixer used in the jet aeration system of FIG. 6 . FIG. 6B is a diagrammatic perspective view of a similar system in which an air intake is provided.
[0023] FIG. 7 is a cross-sectional view of a jet aeration type mixer according to one embodiment.
[0024] FIG. 8 is a cross-sectional view of a jet aeration type mixer according to an alternate embodiment.
[0025] FIGS. 9-11 are diagrams illustrating alternative flow patterns in tanks containing different configurations of jet mixers.
[0026] FIG. 12 is a diagram illustrating the flow pattern that occurs in a tank during backflushing according to one embodiment.
[0027] FIG. 13 is a side view of a jet aeration type system according to another embodiment, showing a multi-level arrangement of nozzles in a tank.
[0028] FIGS. 14 and 14A are a diagrammatic top view and a perspective view, respectively, of a device that minimizes hold up along the walls of a tank during mixing.
[0029] FIGS. 15 and 16 are views of water jet devices that provide mixing while also minimizing hold up along the tank walls.
[0030] FIG. 17 is a cross-sectional view of a tank having a domed bottom and two jet mixers extending into the tank from above.
DETAILED DESCRIPTION
[0031] FIG. 1 shows a schematic diagram of a technique 100 for processing hydrocarbon-containing materials such as oil sands, oil shale, tar sands, and other materials that include hydrocarbons intermixed with solid components such as rock, sand, clay, silt, and/or solid organic material. These materials may be in their native form, or may have been previously treated, for example treated in situ with radiation as described below. In a first step of the sequence shown in FIG. 1 , the hydrocarbon-containing material 110 can be subjected to one or more optional mechanical processing steps 120 . The mechanical processing steps can include, for example, grinding, crushing, agitation, centrifugation, rotary cutting and/or chopping, shot-blasting, and various other mechanical processes that can reduce an average size of particles of material 110 , and initiate separation of the hydrocarbons from the remaining solid matter therein. In some embodiments, more than one mechanical processing step can be used. For example, multiple stages of grinding can be used to process material 110 . Alternatively, or in addition, a crushing process followed by a grinding process can be used to treat material 110 . Additional steps such as agitation and/or further crushing and/or grinding can also be used to further reduce the average size of particles of material 110 .
[0032] In a second step 130 of the sequence shown in FIG. 1 , the hydrocarbon-containing material 110 can be subjected to one or more optional cooling and/or temperature-cycling steps. In some embodiments, for example, material 110 can be cooled to a temperature at and/or below a boiling temperature of liquid nitrogen. More generally, the cooling and/or temperature-cycling in step 130 can include, for example, cooling to temperatures well below room temperature (e.g., cooling to 10° C. or less, 0° C. or less, −10° C. or less, −20° C. or less, −30° C. or less, −40° C. or less, −50° C. or less, −100° C. or less, −150° C. or less, −200 ° C. or less, or even lower temperatures). Multiple cooling stages can be performed, with varying intervals between each cooling stage to allow the temperature of material 110 to increase. The effect of cooling and/or temperature-cycling material 110 is to disrupt the physical and/or chemical structure of the material, promoting at least partial dissociation of the hydrocarbon components from the non-hydrocarbon components (e.g., solid non-hydrocarbon materials) in material 110 . Suitable methods and systems for cooling and/or temperature-cycling of material 110 are disclosed, for example, in U.S. Provisional Patent Application Ser. No. 61/081,709, filed on Jul. 17, 2008, and U.S. Ser. No. 12/502,629, filed Jul. 14, 2009, the entire contents of which are incorporated herein by reference.
[0033] In a third step 140 of the sequence of FIG. 1 , the hydrocarbon-containing material 110 can be exposed to charged particles or photons, such as photons having a wavelength between about 0.01 nm and 280 nm. In some embodiments, the photons can have a wavelength between, e.g., 100 nm to 280 nm or between 0.01 nm to 10 nm, or in some cases less than 0.01 nm. The charged particles interact with material 110 , causing further disassociation of the hydrocarbons therein from the non-hydrocarbon materials, and also causing various hydrocarbon chemical processes, including chain scission, bond-formation, and isomerization. These chemical processes convert long-chain hydrocarbons into shorter-chain hydrocarbons, many of which can eventually be extracted from material 110 as products and used directly for various applications. The chemical processes can also lead to conversion of various products into other products, some of which may be more desirable than others. For example, through bond-forming reactions, some short-chain hydrocarbons may be converted to medium-chain-length hydrocarbons, which can be more valuable products. As another example, isomerization can lead to the formation of straight-chain hydrocarbons from cyclic hydrocarbons. Such straight-chain hydrocarbons may be more valuable products than their cyclized counterparts.
[0034] By adjusting an average energy of the charged particles and/or an average current of the charged particles, the total amount of energy delivered or transferred to material 110 by the charged particles can be controlled. In some embodiments, for example, material 110 can be exposed to charged particles so that the energy transferred to material 110 (e.g., the energy dose applied to material 110 ) is 0.3 Mrad or more (e.g., 0.5 Mrad or more, 0.7 Mrad or more, 1.0 Mrad or more, 2.0 Mrad or more, 3.0 Mrad or more, 5.0 Mrad or more, 7.0 Mrad or more, 10.0 Mrad or more, 15.0 Mrad or more, 20.0 Mrad or more, 30.0 Mrad or more, 40.0 Mrad or more, 50.0 Mrad or more, 75.0 Mrad or more, 100.0 Mrad or more, 150.0 Mrad or more, 200.0 Mrad or more, 250.0 Mrad or more, or even 300.0 Mrad or more).
[0035] In general, electrons, ions, photons, and combinations of these can be used as the charged particles in step 140 to process material 110 . A wide variety of different types of ions can be used including, but not limited to, protons, hydride ions, oxygen ions, carbon ions, and nitrogen ions. These charged particles can be used under a variety of conditions; parameters such as particle currents, energy distributions, exposure times, and exposure sequences can be used to ensure that the desired extent of separation of the hydrocarbon components from the non-hydrocarbon components in material 110 , and the extent of the chemical conversion processes among the hydrocarbon components, is reached. Suitable systems and methods for exposing material 110 to charged particles are discussed, for example, in U.S. Ser. No. 12/417,699, filed Apr. 3, 2009, U.S. Ser. No. 12/486,436, filed Oct. 5, 2009, as well as the following U.S. Provisional Patent Applications: Ser. No. 61/049,406, filed on Apr. 30, 2008; Ser. No. 61/073,665, filed on Jun. 18, 2008; and Ser. No. 61/073,680, filed on Jun. 18, 2008. The entire contents of each of the foregoing applications is incorporated herein by reference. In particular, charged particle systems such as inductive linear accelerator (LINAC) systems can be used to deliver large doses of energy (e.g., doses of 50 Mrad or more) to material 110 .
[0036] In the final step of the processing sequence of FIG. 1 , the processed material 110 is subjected to a separation step 150 , which separates the hydrocarbon products 160 and the non-hydrocarbon products 170 . The separation step includes an extraction process that involves agitating the material 110 . For example, tar sands are processed using a hot water extraction process. After mining, the tar sands are transported to an extraction plant, where the hot water extraction process separates bitumen from sand, water and minerals. Hot water is added to the sand, and the resulting slurry is agitated. The combination of hot water and agitation releases bitumen from the oil sand in the form of droplets. Air bubbles attach to the bitumen droplets, causing the droplets to float to the top of the separation tank. The bitumen is then skimmed off and processed to remove residual water and solids. During this extraction process, agitation is performed using the jet mixing techniques discussed below.
[0037] A wide variety of other processing steps can optionally be used to further separate and refine the products. Exemplary processes include, but are not limited to, distillation, centrifugation and filtering.
[0038] The processing sequence shown in FIG. 1 is a flexible sequence, and can be modified as desired for particular materials 110 and/or to recover particular hydrocarbon products 160 . For example, the order of the various steps can be changed in FIG. 1 . Further, additional steps of the types shown, or other types of steps, can be included at any point within the sequence, as desired. For example, additional mechanical processing steps, cooling/temperature-cycling steps, particle beam exposure steps, and/or separation steps can be included at any point in the sequence. Further, other processing steps such as sonication, chemical processing, pyrolysis, oxidation and/or reduction, and radiation exposure can be included in the sequence shown in FIG. 1 prior to, during, and/or following any of the steps shown in FIG. 1 . Many processes suitable for inclusion in the sequence of FIG. 1 are discussed, for example, in PCT Publication No. WO 2008/073186 (e.g., throughout the Detailed Description section).
[0039] Suitable liquids that can be added to material 110 , e.g., during extraction, include, for example, water, various types of liquid hydrocarbons (e.g., hydrocarbon solvents), and other common organic and inorganic solvents.
Agitation
Jet Mixing Characteristics
[0040] Various types of mixing devices which may be used during hydrocarbon processing are described below. Other mixing devices having similar characteristics may be used. Suitable mixers have in common that they produce high velocity circulating flow, for example flow in a toroidal or elliptical pattern. Generally, preferred mixers exhibit a high bulk flow rate. Preferred mixers provide this mixing action with relatively low energy consumption. It is also preferred in some cases that the mixer produce relatively low shear and avoid heating of the liquid medium. As will be discussed in detail below, some preferred mixers draw the mixture through an inlet into a mixing element, which may include a rotor or impeller, and then expel the mixture from the mixing element through an outlet nozzle. This circulating action, and the high velocity of the jet exiting the nozzle, assist in dispersing material that is floating on the surface of the liquid or material that has settled to the bottom of the tank, depending on the orientation of the mixing element. Mixing elements can be positioned in different orientations to disperse both floating and settling material, and the orientation of the mixing elements can in some cases be adjustable.
[0041] For example, in some preferred mixing systems the velocity v o of the jet as meets the ambient fluid is from about 2 to 300 m/s, e.g., about 5 to 150 m/s or about 10 to 100 m/s. The power consumption of the mixing system may be about 20 to 1000 KW, e.g., 30 to 570 KW, 50 to 500 KW, or 150 to 250 KW for a 100,000 L tank. It is generally preferred that the power usage be low for cost-effectiveness.
[0042] Jet mixing involves the discharge of a submerged jet, or a number of submerged jets, of high velocity liquid into a fluid medium, in this case the mixture of feedstock and liquid medium. The jet of liquid penetrates the fluid medium, with its energy being dissipated by turbulence and some initial heat. This turbulence is associated with velocity gradients (fluid shear). The surrounding fluid is accelerated and entrained into the jet flow, with this secondary entrained flow increasing as the distance from the jet nozzle increases. The momentum of the secondary flow remains generally constant as the jet expands, as long as the flow does not hit a wall, floor or other obstacle. The longer the flow continues before it hits any obstacle, the more liquid is entrained into the secondary flow, increasing the bulk flow in the tank or vessel. When it encounters an obstacle, the secondary flow will lose momentum, more or less depending on the geometry of the tank, e.g., the angle at which the flow impinges on the obstacle. It is generally desirable to orient the jets and/or design the tank so that hydraulic losses to the tank walls are minimized. For example, it may be desirable for the tank to have an arcuate bottom (e.g., a domed headplate), and for the jet mixers to be oriented relatively close to the sidewalls, as shown in FIG. 17 . The tank bottom (lower head plate) may have any desired domed configuration, or may have an elliptical or conical geometry.
[0043] Jet mixing differs from most types of liquid/liquid and liquid/solid mixing in that the driving force is hydraulic rather than mechanical. Instead of shearing fluid and propelling it around the mixing vessel, as a mechanical agitator does, a jet mixer forces fluid through one or more nozzles within the tank, creating high-velocity jets that entrain other fluid. The result is shear (fluid against fluid) and circulation, which mix the tank contents efficiently.
[0044] Referring to FIG. 2 , the high velocity gradient between the core flow from a submerged jet and the surrounding fluid causes eddies. FIG. 2A illustrates the general characteristics of a submerged jet. As the submerged jet expands into the surrounding ambient environment the velocity profile flattens as the distance (x) from the nozzle increases. Also, the velocity gradient dv/dr changes with r (the distance from the centerline of the jet) at a given distance x, such that eddies are created which define the mixing zone (the conical expansion from the nozzle).
[0045] In an experimental study of a submerged jet in air (the results of which are applicable to any fluid, including water), Albertson et al. (“Diffusion of Submerged Jets,” Paper 2409, Amer. Soc. of Civil Engineers Transactions, Vol. 115:639-697, 1950, at p. 657) developed dimensionless relationships for v(x) r=0 /v o (centerline velocity), v(r) x /v(x) r−0 (velocity profile at a given x), Q x /Q o (flow entrainment), and E x /E o (energy change with x):
[0046] (1) Centerline velocity, v(x) r=0 /v o :
[0000]
v
(
r
=
0
)
v
o
x
D
o
=
6.2
[0047] (2) velocity profile at any x, v(r) x /v(x) r=0 :
[0000]
log
[
v
(
r
)
x
v
o
x
D
]
=
0.79
-
33
r
2
x
2
[0048] (3) Flow and energy at any x:
[0000]
Q
x
Q
o
=
0.32
x
D
o
(
10.21
)
E
x
E
o
=
4.1
D
o
x
(
10.22
)
[0000] where:
v(r=0)=centerline velocity of submerged jet (m/s), v o =velocity of jet as it emerges from the nozzle (m/s), x=distance from nozzle (m), r=distance from centerline of jet (m), D o =diameter of nozzle (m), Q x =flow of fluid across any given plane at distance x from the nozzle (me/s), Q u =flow of fluid emerging from the nozzle (m3/s), E=energy flux of fluid across any given plane at distance x from the nozzle (m 3 /s), E o =energy flux of fluid emerging from the nozzle (m 3 /s).
[0058] (“Water Treatment Unit Processes: Physical and Chemical,” David W. Hendricks, CRC Press 2006, p. 411.)
[0059] Jet mixing is particularly cost-effective in large-volume (over 1,000 gal) and low-viscosity (under 1,000 cPs) applications. It is also generally advantageous that in most cases a jet mixer has no moving parts submerged, e.g., when a pump is used it is generally located outside the vessel.
[0060] One advantage of jet mixing is that the temperature of the ambient fluid (other than directly adjacent the exit of the nozzle, where there may be some localized heating) is increased only slightly if at all. For example, the temperature may be increased by less than 5° C., less than 1° C., or not to any measureable extent.
Jet-Flow Agitators
[0061] One type of jet-flow agitator is shown in FIGS. 3-3A . This type of mixer is available commercially, e.g., from IKA under the tradename ROTOTRON™. Referring to FIG. 3 , the mixer 200 includes a motor 202 , which rotates a drive shaft 204 . A mixing element 206 is mounted at the end of the drive shaft 204 . As shown in FIG. 3A , the mixing element 206 includes a shroud 208 and, within the shroud, an impeller 210 . As indicated by the arrows, when the impeller is rotated in its “forward” direction, the impeller 210 draws liquid in through the open upper end 212 of the shroud and forces the liquid out through the open lower end 214 . Liquid exiting end 214 is in the form of a high velocity stream or jet. If the direction of rotation of the impeller 210 is reversed, liquid can be drawn in through the lower end 214 and ejected through the upper end 212 . This can be used, for example, to suck in solids that are floating near or on the surface of the liquid in a tank or vessel. (It is noted that “upper” and “lower” refer to the orientation of the mixer in FIG. 3 ; the mixer may be oriented in a tank so that the upper end is below the lower end.)
[0062] The shroud 208 includes flared areas 216 and 218 adjacent its ends. These flared areas are believed to contribute to the generally toroidal flow that is observed with this type of mixer. The geometry of the shroud and impeller also concentrate the flow into a high velocity stream using relatively low power consumption.
[0063] Preferably, the clearance between the shroud 208 and the impeller 210 is sufficient so as to avoid excessive milling of the material as it passes through the shroud. For example, the clearance may be at least 10 times the average particle size of the solids in the mixture, preferably at least 100 times.
[0064] In some implementations, the shaft 204 is configured to allow gas delivery through the shaft. For example, the shaft 204 may include a bore (not shown) through which gas is delivered, and one or more orifices through which gas exits into the mixture. The orifices may be within the shroud 208 , to enhance mixing, and/or at other locations along the length of the shaft 204 .
[0065] The impeller 210 may have any desired geometry that will draw liquid through the shroud at a high velocity. The impeller is preferably a marine impeller, as shown in FIG. 3A , but may have a different design, for example, a Rushton impeller as shown in FIG. 3B , or a modified Rushton impeller, e.g., tilted so as to provide some axial flow.
[0066] In order to generate the high velocity flow through the shroud, the motor 202 is preferably a high speed, high torque motor, e.g., capable of operating at 500 to 20,000 RPM, e.g., 3,000 to 10,000 RPM. However, the larger the mixer (e.g., the larger the shroud and/or the larger the motor) the lower the rotational speed can be. Thus, if a large mixer is used, such as a 5 hp, 10 hp, 20 hp, or 30 hp or greater, the motor may be designed to operate at lower rotational speeds, e.g., less than 2000 RPM, less than 1500 RPM, or even 500 RPM or less. For example, a mixer sized to mix a 10,000-20,000 liter tank may operate at speeds of 900 to 1,200 RPM. The torque of the motor is preferably self-adjusting, to maintain a relatively constant impeller speed as the mixing conditions change over time.
[0067] Advantageously, the mixer can be oriented at any desired angle or location in the tank, to direct the jet flow in a desired direction. Moreover, as discussed above, depending on the direction of rotation of the impeller the mixer can be used to draw fluid from either end of the shroud.
[0068] In some implementations, two or more jet mixers are positioned in the vessel, with one or more being configured to jet fluid upward (“up pump”) and one or more being configured to jet fluid downward (“down pump”). In some cases, an up pumping mixer will be positioned adjacent a down pumping mixer, to enhance the turbulent flow created by the mixers. If desired, one or more mixers may be switched between upward flow and downward flow during processing. It may be advantageous to switch all or most of the mixers to up pumping mode during initial dispersion of the feedstock in the liquid medium, as up pumping creates significant turbulence at the surface.
Suction Chamber Jet Mixers
[0069] Another type of jet mixer includes a primary nozzle that delivers a pressurized fluid from a pump, a suction inlet adjacent the primary nozzle through which ambient fluid is drawn by the pressure drop between the primary nozzle and the wider inlet, and a suction chamber extending between the suction inlet and a secondary nozzle. A jet of high velocity fluid exits the secondary nozzle.
[0070] An example of this type of mixer is shown in FIG. 4 . As shown, in mixer 600 pressurized liquid from a pump (not shown) flows through an inlet passage 602 and exits through a primary nozzle 603 . Ambient liquid is drawn through a suction inlet 604 into suction chamber 606 by the pressure drop caused by the flow of pressurized liquid. The combined flow exits from the suction chamber into the ambient liquid at high velocity through secondary nozzle 608 . Mixing occurs both in the suction chamber and in the ambient liquid due to the jet action of the exiting jet of liquid.
[0071] A mixing system that operates according to a similar principle is shown in FIG. 4A . Mixers embodying this design are commercially available from ITT Water and Wastewater, under the tradename Flygt™ jet mixers. In system 618 , pump 620 generates a primary flow that is delivered to the tank (not shown) through a suction nozzle system 622 . The suction nozzle system 622 includes a primary nozzle 624 which functions in a manner similar to primary nozzle 603 described above, causing ambient fluid to be drawn into the adjacent open end 626 of ejector tube 628 due to the pressure drop induced by the fluid exiting the primary nozzle. The combined flow then exits the other end 630 of ejector tube 628 , which functions as a secondary nozzle, as a high velocity jet.
[0072] The nozzle shown in FIG. 5 , referred to as an eductor nozzle, operates under a similar principle. A nozzle embodying this design is commercially available under the tradename TeeJet®. As shown, in nozzle 700 pressurized liquid flows in through an inlet 702 and exits a primary nozzle 704 , drawing ambient fluid in to the open end 706 of a diffuser 708 . The combined flow exits the opposite open end 710 of the diffuser at a circulation flow rate A+B that is the sum of the inlet flow rate A and the flow rate B of the entrained ambient fluid.
Jet Aeration Type Mixers
[0073] Another type of jet mixing system that can be utilized is referred to in the wastewater industry as “jet aeration mixing.” In the wastewater industry, these mixers are typically used to deliver a jet of a pressurized air and liquid mixture, to provide aeration. However, in the present application in some cases the jet aeration type mixers are utilized without pressurized gas, as will be discussed below. The principles of operation of jet aeration mixers will be initially described in the context of their use with pressurized gas, for clarity.
[0074] An eddy jet mixer, such as the mixer 800 shown in FIGS. 6-6B , includes multiple jets 802 mounted in a radial pattern on a central hub 804 . The radial pattern of the jets uniformly distributes mixing energy throughout the tank. The eddy jet mixer may be centrally positioned in a tank, as shown to provide toroidal flow about the center axis of the tank. The eddy jet mixer may be mounted on piping 806 , which supplies high velocity liquid to the eddy jet mixer. In the embodiment shown in FIG. 6B , air is also supplied to the eddy jet mixer through piping 812 . The high velocity liquid is delivered by a pump 808 which is positioned outside of the tank and which draws liquid in through an inlet 810 in the side wall of the tank.
[0075] FIGS. 7 and 8 show two types of nozzle configurations that are designed to mix a gas and a liquid stream and eject a high velocity jet. These nozzles are configured somewhat differently from the eddy jet mixer shown in FIGS. 6 and 6A but function in a similar manner. In the system 900 shown in FIG. 7 , a primary or motive fluid is directed through a liquid line 902 to inner nozzles 904 through which the liquid travels at high velocity into a mixing area 906 . A second fluid, e.g., a gas, such as compressed air, nitrogen or carbon dioxide, or a liquid, enters the mixing area through a second line 908 and entrained in the motive fluid entering the mixing area 906 through the inner nozzles. In some instances the second fluid is nitrogen or carbon dioxide so as to reduce oxidation of the enzyme. The combined flow from the two lines is jetted into the mixing tank through the outer nozzles 910 . If the second fluid is a gas, tiny bubbles are entrained in the liquid in the mixture. Liquid is supplied to the liquid line 902 by a pump. Gas, if it is used, is provided by compressors. If a liquid is used as the second fluid, it can have the same velocity as the liquid entering through the liquid line 902 , or a different velocity.
[0076] FIG. 8 shows an alternate nozzle design 1000 , in which outer nozzles 1010 (of which only one is shown) are positioned along the length of an elongated member 1011 that includes a liquid line 1002 that is positioned parallel to a second line 1008 . Each nozzle includes a single outer nozzle 1010 and a single inner nozzle 1004 . Mixing of the motive liquid with the second fluid proceeds in the same manner as in the system 900 described above.
[0077] FIGS. 9 and 10 illustrate examples of jet aeration type mixing systems in which nozzles are positioned along the length of an elongated member. In the example shown in FIG. 9 , the elongated member 1102 is positioned along the diameter of the tank 1104 , and the nozzles 1106 extend in opposite directions from the nozzle to produce the indicated flow pattern which includes two areas of generally elliptical flow, one on either side of the central elongated member. In the example shown in FIG. 10 , the tank 1204 is generally rectangular in cross section, and the elongated member 1202 extends along one side wall 1207 of the tank. In this case, the nozzles 1206 all face in the same direction, towards the opposite side wall 1209 . This produces the flow pattern shown, in which flow in the tank is generally elliptical about a major axis extending generally centrally along the length of the tank. In the embodiment shown in FIG. 10 , the nozzles may be canted towards the tank floor, e.g., at an angle of from about 15 to 30 degrees from the horizontal.
[0078] In another embodiment, shown in FIG. 11 , the nozzles 1302 , 1304 , and suction inlet 1306 are arranged to cause the contents of the tank to both revolve and rotate in a toroidal, rolling donut configuration around a central vertical axis of the tank. Flow around the surface of the toroid is drawn down the tank center, along the floor, up the walls and back to the center, creating a rolling helix pattern, which sweeps the center and prevents solids from settling. The toroidal pattern is also effective in moving floating solids to the tank center where they are pulled to the bottom and become homogenous with the tank contents. The result is a continuous helical flow pattern, which minimizes tank dead spots.
Backflushing
[0079] In some instances, the jet nozzles described herein can become plugged, which may cause efficiency and cost effectiveness to be reduced. Plugging of the nozzles may be removed by reversing flow of the motive liquid through the nozzle. For example, in the system shown in FIG. 12 , this is accomplished by closing a valve 1402 between the pump 1404 and the liquid line 1406 flowing to the nozzles 1408 , and activating a secondary pump 1410 . Secondary pump 1410 draws fluid in through the nozzles. The fluid then travels up through vertical pipe 1412 due to valve 1402 being closed. The fluid exits the vertical pipe 1412 at its outlet 1414 for recirculation through the tank.
Mixing in Transit/Portable Mixers
[0080] In some cases processing can take place in part or entirely during transportation of the mixture, e.g., between a first processing plant for treating the feedstock and a second processing plant for production of a final product. In this case, mixing can be conducted using a jet mixer designed for rail car or other portable use. The mixer can be operated using a control system that is external to the tank, which may include for example a motor and a controller configured to control the operation of the mixer. Venting (not shown) may also be provided.
Minimizing Hold Up on Tank Walls
[0081] In some situations, in particular at solids levels approaching a theoretical or practical limit, material may accumulate along the side wall and/or bottom wall of the tank during mixing. This phenomenon, referred to as “hold up,” is undesirable as it can result in inadequate mixing. Several approaches can be taken to minimize hold up and ensure good mixing throughout the tank.
[0082] For example, in addition to the jet mixing device(s), the tank can be outfitted with a scraping device, for example a device having a blade that scrapes the side of the tank in a “squeegee” manner. Such devices are well known, for example in the dairy industry. Suitable agitators include the side and bottom sweep agitators and scraper blade agitators manufactured by Walker Engineered Products, New Lisbon, Wis. As shown in FIG. 14 , a side and bottom sweep agitator 1800 may include a central elongated member 1802 , mounted to rotate about the axis of the tank. Side wall scraper blades 1804 are mounted at each end of the elongated member 1802 and are disposed at an angle with respect to the elongated member. In the embodiment shown, a pair of bottom wall scraper blades 1806 are mounted at an intermediate point on the elongated member 1802 , to scrape up any material accumulating on the tank bottom. These scrapers may be omitted if material is not accumulating on the tank bottom. As shown in FIG. 14A , the scraper blades 1804 may be in the form of a plurality of scraper elements positioned along the side wall. In other embodiments, the scraper blades are continuous, or may have any other desired geometry.
[0083] In other embodiments, the jet mixer itself is configured so as to minimize hold up. For example, the jet mixer may include one or more movable heads and/or flexible portions that move during mixing. For example, the jet mixer may include an elongated rotatable member having a plurality of jet nozzles along its length. The elongated member may be planar, as shown in FIG. 15 , or have a non-planar shape, e.g., it may conform to the shape of the tank walls as shown in FIG. 16 .
[0084] Referring to FIG. 15 , the jet mixer nozzles may be positioned on a rotating elongated member 1900 that is driven by a motor 1902 and shaft 1904 . Water or other fluid is pumped through passageways in the rotating member, e.g., by a pump impeller 1906 , and exits as a plurality of jets through jet orifices 1908 while the member 1900 rotates. To reduce hold up on the tank side walls, orifices 1910 may be provided at the ends of the member 1900 .
[0085] In the embodiment shown in FIG. 16 , to conform to the particular shape of the tank 2000 the elongated member includes horizontally extending arms 2002 , downwardly inclined portions 2004 , outwardly and upwardly inclined portions 2006 , and vertically extending portions 2008 . Fluid is pumped through passageways within the elongated member to a plurality of jet orifices 38 , through which jets are emitted while the elongated member is rotated.
[0086] In both of the embodiments shown in FIGS. 15 and 16 , the jets provide mixing while also washing down the side walls of the tank.
[0087] In some implementations, combinations of the embodiments described above may be used. For example, combinations of planar and non-planar rotating or oscillating elongated members may be used. The moving nozzle arrangements described above can be used in combination with each other and/or in combination with scrapers. A plurality of moving nozzle arrangements can be used together, for example two or more of the rotating members shown in FIG. 15 can be stacked vertically in the tank. When multiple rotating members are used, they can be configured to rotate in the same direction or in opposite directions, and at the same speed or different speeds.
Physical Treatment of Feedstock
[0088] In some implementations, the feedstock is physically treated, e.g., to change its molecular structure. Physical treatment processes can include one or more of any of those described herein, such as mechanical treatment, chemical treatment, irradiation, sonication, oxidation, pyrolysis or steam explosion. Treatment methods can be used in combinations of two, three, four, or even all of these technologies (in any order). When more than one treatment method is used, the methods can be applied at the same time or at different times. Other processes that change a molecular structure of a feedstock may also be used, alone or in combination with the processes disclosed herein.
[0089] Mechanical Treatments
[0090] In some cases, methods can include a mechanical treatment. Mechanical treatments include, for example, cutting, milling, pressing, grinding, shearing and chopping. Milling may include, for example, ball milling, hammer milling, rotor/stator dry or wet milling, or other types of milling. Other mechanical treatments include, e.g., stone grinding, cracking, mechanical ripping or tearing, pin grinding or air attrition milling.
[0091] In some implementations, the feedstock material can first be physically treated by one or more of the other physical treatment methods, e.g., chemical treatment, radiation, sonication, oxidation, pyrolysis or steam explosion, and then mechanically treated. This sequence can be advantageous since materials treated by one or more of the other treatments, e.g., irradiation or pyrolysis, tend to be more brittle and, therefore, it may be easier to further change the molecular structure of the material by mechanical treatment.
[0092] Feed preparation systems can be configured to produce streams with specific characteristics such as, for example, specific maximum sizes or specific surface areas.
[0093] Radiation Treatment
[0094] Irradiation can reduce the molecular weight and/or crystallinity of feedstock. In some embodiments, energy deposited in a material that releases an electron from its atomic orbital is used to irradiate the materials. The radiation may be provided by 1) heavy charged particles, such as alpha particles or protons, 2) electrons, produced, for example, in beta decay or electron beam accelerators, or 3) electromagnetic radiation, for example, gamma rays, x rays, or ultraviolet rays. In one approach, radiation produced by radioactive substances can be used to irradiate the feedstock. In some embodiments, any combination in any order or concurrently of (1) through (3) may be utilized. In another approach, electromagnetic radiation (e.g., produced using electron beam emitters) can be used to irradiate the feedstock. The doses applied depend on the desired effect and the particular feedstock. For example, high doses of radiation can break chemical bonds within feedstock components. In some instances when chain scission is desirable and/or polymer chain functionalization is desirable, particles heavier than electrons, such as protons, helium nuclei, argon ions, silicon ions, neon ions, carbon ions, phosphorus ions, oxygen ions or nitrogen ions can be utilized. When ring-opening chain scission is desired, positively charged particles can be utilized for their Lewis acid properties for enhanced ring-opening chain scission. For example, when maximum oxidation is desired, oxygen ions can be utilized, and when maximum nitration is desired, nitrogen ions can be utilized.
Ionizing Radiation
[0095] Each form of radiation ionizes the carbon-containing material via particular interactions, as determined by the energy of the radiation. Heavy charged particles primarily ionize matter via Coulomb scattering; furthermore, these interactions produce energetic electrons that may further ionize matter. Alpha particles are identical to the nucleus of a helium atom and are produced by the alpha decay of various radioactive nuclei, such as isotopes of bismuth, polonium, astatine, radon, francium, radium, several actinides, such as actinium, thorium, uranium, neptunium, curium, californium, americium, and plutonium.
[0096] When particles are utilized, they can be neutral (uncharged), positively charged or negatively charged. When charged, the charged particles can bear a single positive or negative charge, or multiple charges, e.g., one, two, three or even four or more charges. In instances in which chain scission is desired, positively charged particles may be desirable, in part due to their acidic nature. When particles are utilized, the particles can have the mass of a resting electron, or greater, e.g., 500, 1000, 1500, 2000, 10,000 or even 100,000 times the mass of a resting electron. For example, the particles can have a mass of from about 1 atomic unit to about 150 atomic units, e.g., from about 1 atomic unit to about 50 atomic units, or from about 1 to about 25, e.g., 1, 2, 3, 4, 5, 10, 12 or 15 amu. Accelerators used to accelerate the particles can be electrostatic DC, electrodynamic DC, RF linear, magnetic induction linear or continuous wave. For example, cyclotron type accelerators are available from IBA, Belgium, such as the Rhodotron® system, while DC type accelerators are available from RDI, now IBA Industrial, such as the Dynamitron®. Ions and ion accelerators are discussed in Introductory Nuclear Physics, Kenneth S. Krane, John Wiley & Sons, Inc. (1988), Krsto Prelec, FIZIKA B 6 (1997) 4, 177-206, Chu, William T., “Overview of Light-Ion Beam Therapy” Columbus-Ohio, ICRU-IAEA Meeting, 18-20 Mar. 2006, Iwata, Y. et al., “Alternating-Phase-Focused IH-DTL for Heavy-Ion Medical Accelerators” Proceedings of EPAC 2006, Edinburgh, Scotland and Leaner, C. M. et al., “Status of the Superconducting ECR Ion Source Venus” Proceedings of EPAC 2000, Vienna, Austria.
[0097] Gamma radiation has the advantage of a significant penetration depth into a variety of materials. Sources of gamma rays include radioactive nuclei, such as isotopes of cobalt, calcium, technicium, chromium, gallium, indium, iodine, iron, krypton, samarium, selenium, sodium, thalium, and xenon.
[0098] Sources of x rays include electron beam collision with metal targets, such as tungsten or molybdenum or alloys, or compact light sources, such as those produced commercially by Lyncean.
[0099] Sources for ultraviolet radiation include deuterium or cadmium lamps.
[0100] Sources for infrared radiation include sapphire, zinc, or selenide window ceramic lamps.
[0101] Sources for microwaves include klystrons, Slevin type RF sources, or atom beam sources that employ hydrogen, oxygen, or nitrogen gases.
[0102] In some embodiments, a beam of electrons is used as the radiation source. A beam of electrons has the advantages of high dose rates (e.g., 1, 5, or even 10 Mrad per second), high throughput, less containment, and less confinement equipment. Electrons can also be more efficient at causing chain scission. In addition, electrons having energies of 4-10 MeV can have a penetration depth of 5 to 30 mm or more, such as 40 mm.
[0103] Electron beams can be generated, e.g., by electrostatic generators, cascade generators, transformer generators, low energy accelerators with a scanning system, low energy accelerators with a linear cathode, linear accelerators, and pulsed accelerators. Electrons as an ionizing radiation source can be useful, e.g., for relatively thin piles of materials, e.g., less than 0.5 inch, e.g., less than 0.4 inch, 0.3 inch, 0.2 inch, or less than 0.1 inch. In some embodiments, the energy of each electron of the electron beam is from about 0.3 MeV to about 2.0 MeV (million electron volts), e.g., from about 0.5 MeV to about 1.5 MeV, or from about 0.7 MeV to about 1.25 MeV.
[0104] Electron beam irradiation devices may be procured commercially from Ion Beam Applications, Louvain-la-Neuve, Belgium or the Titan Corporation, San Diego, Calif. Typical electron energies can be 1 MeV, 2 MeV, 4.5 MeV, 7.5 MeV, or 10 MeV. Typical electron beam irradiation device power can be 1 kW, 5 kW, 10 kW, 20 kW, 50 kW, 100 kW, 250 kW, or 500 kW. The level of depolymerization of the feedstock depends on the electron energy used and the dose applied, while exposure time depends on the power and dose. Typical doses may take values of 1 kGy, 5 kGy, 10 kGy, 20 kGy, 50 kGy, 100 kGy, or 200 kGy.
Ion Particle Beams
[0105] Particles heavier than electrons can be utilized to irradiate hydrocarbon-containing materials. For example, protons, helium nuclei, argon ions, silicon ions, neon ions carbon ions, phosphorus ions, oxygen ions or nitrogen ions can be utilized. In some embodiments, particles heavier than electrons can induce higher amounts of chain scission (relative to lighter particles). In some instances, positively charged particles can induce higher amounts of chain scission than negatively charged particles due to their acidity.
[0106] Heavier particle beams can be generated, e.g., using linear accelerators or cyclotrons. In some embodiments, the energy of each particle of the beam is from about 1.0 MeV/atomic unit to about 6,000 MeV/atomic unit, e.g., from about 3 MeV/atomic unit to about 4,800 MeV/atomic unit, or from about 10 MeV/atomic unit to about 1,000 MeV/atomic unit.
[0107] In certain embodiments, ion beams can include more than one type of ion. For example, ion beams can include mixtures of two or more (e.g., three, four or more) different types of ions. Exemplary mixtures can include carbon ions and protons, carbon ions and oxygen ions, nitrogen ions and protons, and iron ions and protons. More generally, mixtures of any of the ions discussed above (or any other ions) can be used to form irradiating ion beams. In particular, mixtures of relatively light and relatively heavier ions can be used in a single ion beam.
[0108] In some embodiments, ion beams for irradiating materials include positively-charged ions. The positively charged ions can include, for example, positively charged hydrogen ions (e.g., protons), noble gas ions (e.g., helium, neon, argon), carbon ions, nitrogen ions, oxygen ions, silicon atoms, phosphorus ions, and metal ions such as sodium ions, calcium ions, and/or iron ions. Without wishing to be bound by any theory, it is believed that such positively-charged ions behave chemically as Lewis acid moieties when exposed to materials, initiating and sustaining cationic ring-opening chain scission reactions in an oxidative environment.
[0109] In certain embodiments, ion beams for irradiating materials include negatively-charged ions. Negatively charged ions can include, for example, negatively charged hydrogen ions (e.g., hydride ions), and negatively charged ions of various relatively electronegative nuclei (e.g., oxygen ions, nitrogen ions, carbon ions, silicon ions, and phosphorus ions). Without wishing to be bound by any theory, it is believed that such negatively-charged ions behave chemically as Lewis base moieties when exposed to materials, causing anionic ring-opening chain scission reactions in a reducing environment.
[0110] In some embodiments, beams for irradiating materials can include neutral atoms. For example, any one or more of hydrogen atoms, helium atoms, carbon atoms, nitrogen atoms, oxygen atoms, neon atoms, silicon atoms, phosphorus atoms, argon atoms, and iron atoms can be included in beams that are used for irradiation of hydrocarbon-containing materials. In general, mixtures of any two or more of the above types of atoms (e.g., three or more, four or more, or even more) can be present in the beams.
[0111] In certain embodiments, ion beams used to irradiate materials include singly-charged ions such as one or more of H + , H − , Hc + , Nc + , Ar + , C + , C − , O + , O − , N + , N − , Si + , Si − , P 1 , P − , Na 1 , Ca + , and Fe 1 . In some embodiments, ion beams can include multiply-charged ions such as one or more of C 2+ , C 3+ , C 4+ , N 3+ , N 5+ , N 3− , O 2+ , O 2− , O 2 2− , Si 2+ , Si 4+ , Si 2− , and Si 4− . In general, the ion beams can also include more complex polynuclear ions that bear multiple positive or negative charges. In certain embodiments, by virtue of the structure of the polynuclear ion, the positive or negative charges can be effectively distributed over substantially the entire structure of the ions. In some embodiments, the positive or negative charges can be somewhat localized over portions of the structure of the ions.
Electromagnetic Radiation
[0112] In embodiments in which the irradiating is performed with electromagnetic radiation, the electromagnetic radiation can have, e.g., energy per photon (in electron volts) of greater than 10 2 eV, e.g., greater than 10 3 , 10 4 , 10 5 , 10 6 , or even greater than 10 7 eV. In some embodiments, the electromagnetic radiation has energy per photon of between 10 4 and 10 7 , e.g., between 10 5 and 10 6 eV. The electromagnetic radiation can have a frequency of, e.g., greater than 10 16 H z, greater than 10 17 Hz, 10 18 , 10 19 , 10 20 , or even greater than 10 21 Hz. In some embodiments, the electromagnetic radiation has a frequency of between 10 18 and 10 22 Hz, e.g., between 10 19 to 10 21 Hz.
Doses
[0113] In some embodiments, the irradiating (with any radiation source or a combination of sources) is performed until the material receives a dose of at least 0.25 Mrad, e.g., at least 1.0 Mrad, at least 2.5 Mrad, at least 5.0 Mrad, or at least 10.0 Mrad. In some embodiments, the irradiating is performed until the material receives a dose of between 1.0 Mrad and 6.0 Mrad, e.g., between 1.5 Mrad and 4.0 Mrad.
[0114] In some embodiments, the irradiating is performed at a dose rate of between 5.0 and 1500.0 kilorads/hour, e.g., between 10.0 and 750.0 kilorads/hour or between 50.0 and 350.0 kilorads/hours.
[0115] In some embodiments, two or more radiation sources are used, such as two or more ionizing radiations. For example, samples can be treated, in any order, with a beam of electrons, followed by gamma radiation and UV light having wavelengths from about 100 nm to about 280 nm. In some embodiments, samples are treated with three ionizing radiation sources, such as a beam of electrons, gamma radiation, and energetic UV light.
Sonication, Pyrolysis and Oxidation
[0116] In addition to radiation treatment, the feedstock may be treated with any one or more of sonication, pyrolysis and oxidation. These treatment processes are described in U.S. Ser. No. 12/417,840, the disclosure of which is incorporated by reference herein.
Other Processes
[0117] Any of the processes of this paragraph can be used alone without any of the processes described herein, or in combination with any of the processes described herein (in any order): steam explosion, acid treatment (including concentrated and dilute acid treatment with mineral acids, such as sulfuric acid, hydrochloric acid and organic acids, such as trifluoroacetic acid), base treatment (e.g., treatment with lime or sodium hydroxide), UV treatment, screw extrusion treatment (see, e.g., U.S. Patent Application Ser. No. 61/073,530, filed Nov. 18, 2008, solvent treatment (e.g., treatment with ionic liquids) and freeze milling (see, e.g., U.S. Patent Application Ser. No. 61/081,709).
Other Embodiments
[0118] A number of embodiments have been described. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the disclosure.
[0119] For example, the jet mixers described herein can be used in any desired combination, and/or in combination with other types of mixers.
[0120] The jet mixer(s) may be mounted in any desired position within the tank. With regard to shaft-mounted jet mixers, the shaft may be collinear with the center axis of the tank or may be offset therefrom. For example, if desired the tank may be provided with a centrally mounted mixer of a different type, e.g., a marine impeller or Rushton impeller, and a jet mixer may be mounted in another area of the tank either offset from the center axis or on the center axis. In the latter case one mixer can extend from the top of the tank while the other extends upward from the floor of the tank. Moreover, as shown in FIG. 13 , two or more jet mixers can be mounted in a multi-level arrangement at different heights within the tank.
[0121] In any of the jet mixing systems described herein, the flow of fluid (liquid and/or gas) through the jet mixer can be continuous or pulsed, or a combination of periods of continuous flow with intervals of pulsed flow. When the flow is pulsed, pulsing can be regular or irregular. In the latter case, the motor that drives the fluid flow can be programmed, for example to provide pulsed flow at intervals to prevent mixing from becoming “stuck.” The frequency of pulsed flow can be, for example, from about 0.5 Hz to about 10 Hz, e.g., about 0.5 Hz, 0.75 Hz, 1.0 Hz, 2.0 Hz, 5 Hz, or 10 Hz. Pulsed flow can be provided by turning the motor on and off, and/or by providing a flow diverter that interrupts flow of the fluid.
[0122] While tanks have been referred to herein, jet mixing may be used in any type of vessel or container, including lagoons, pools, ponds and the like. If the container in which mixing takes place is an in-ground structure such as a lagoon, it may be lined. The container may be covered, e.g., if it is outdoors, or uncovered.
[0123] While hydrocarbon-containing feedstocks have been described herein, other feedstocks and mixtures of hydrocarbon-containing feedstocks with other feedstocks may be used. For example, some implementations may utilize mixtures of hydrocarbon-containing feedstocks with biomass feedstocks such as those disclosed in U.S. Provisional Application No. 61/218,832, filed Jun. 19, 2009, the full disclosure of which is incorporated by reference herein.
[0124] Accordingly, other embodiments are within the scope of the following claims.
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Hydrocarbon-containing feedstocks are processed to produce useful intermediates or products, such as fuels. For example, systems are described that can process a petroleum-containing feedstock, such as oil sands, oil shale, tar sands, and other naturally-occurring and synthetic materials that include both hydrocarbon components and solid matter, to obtain a useful intermediate or product.
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Priority is claimed to the following applications: German Patent Application DE 102 43 085.3, filed on Sep. 16, 2002; German Utility Model DE 203 00 133.8, filed on Jan. 8, 2003; International Patent Application PCT/DE03/01215, filed on Apr. 11, 2003; and International Patent Application PCT/DE03/01214, filed on Apr. 11, 2003. The entire disclosure of each of the aforesaid documents is hereby incorporated by reference herein.
BACKGROUND
The present invention relates to vehicles in general and in particular to convertible tops for vehicles.
In the construction of modern convertible tops which comprise a plurality of hard roof parts and can be deposited automatically in a rear region of the vehicle, the problems generally concern rigid parts which are movable with respect to one another in a manner taking up space.
From the practical experience of constructing convertible vehicles, solutions are known in which a recessed, outer link can be covered by means of a strip-shaped flap which is attached pivotably to a roof part and forms a covering for a roof drip molding.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a top for a convertible vehicle in which an outer roof link is formed in an advantageous manner.
It is a further and/or alternate object of the present invention to provide a convertible top which has an improved appearance.
It is another further and/or alternate object of the present invention to provide a convertible hard top which is easily retractable.
It is yet another further and/or alternate object of the present invention to provide a convertible top with a suitable opening and closing movement.
The present invention provides a convertible vehicle top that includes a first roof part, a second roof part adjoining the first roof part in a closed position of the top, and an outer link pivotably connected to the first roof part and to the second roof part, wherein the outer link, in the closed position of the top, is disposed on an outer side of the first roof part, and wherein the outer link is connected to the first roof part by a first link mechanism.
The present invention also provides a convertible vehicle top that includes a first roof part, a second roof part adjoining the first roof part in a closed position of the top, and a link pivotably connected to the first roof part and to the second roof part, wherein the link is connected to the second roof part by an upper link mechanism.
In addition, the present invention provides a convertible vehicle top that includes a first roof part, a second roof part adjoining the first roof part in a closed position of the top; and an outer link pivotably connected to the first roof part and to the second roof part wherein said outer link is arranged on an outer side of at least one of said first roof part and said second roof part by a link mechanism; and wherein a covering member is arranged on said at least one of said first roof part and said second roof part for at least partially resting over said link mechanism when said top is in a closed position.
The articulation according to the present invention of the outer link by means of the link mechanism has the advantageous effect of making possible a particularly large pivoting angle. A particularly large pivoting angle of virtually 180 degrees is advantageously made possible in this manner.
The link mechanism is preferably designed as a four-bar linkage, the first roof part forming a base of the four-bar linkage and the outer link forming a connecting member of the four-bar linkage. A small-sized and stable link mechanism can thereby be realized in a simple manner.
The outer link is particularly preferably held on the second roof part by means of a second link mechanism. This makes possible an advantageous pivoting of the link over a large angular region. The second link mechanism is particularly preferably likewise designed as a four-bar linkage in this case.
In a preferred embodiment of a top according to the present invention, the outer link is arranged in a groove-like recess of the first roof part in a closed state of the top. The effect, which can advantageously be achieved in this manner, is that the outer link cannot be seen from the outside in the closed state of the top.
In this case, a covering plate is preferably fixed in a pivotable manner in a joint, so that the covering plate can be pivoted essentially parallel to links of the link mechanism. By this means, a visual covering of the link in the form of a conventional roof drip molding can be achieved in a simple manner in the closed state of the top.
In a further preferred embodiment of a top according to the present invention, the outer link is designed as part of a longitudinal body, which protrudes over an outer surface of the top in the closed state of the top. In particular, the outer link can rest on the outer surface of the top in the manner of a trim strip. This enables the outer link to advantageously be used simultaneously as a functional and also as a creative element of the top.
In this case, at least one of the two roof parts is particularly preferably designed as a single-piece shaped part. This makes it possible to produce the roof parts in a simpler and more cost-effective manner. Particularly if the provision of a groove-like recess for holding the outer link in the closed state of the top is essentially omitted, not only is the production of the roof parts simpler and more cost-effective, but also the sealing in the region between the first and second roof part is simplified. This avoids, in particular, the complicated production of the roof parts from a plurality of shaped parts, which are welded to one another in the region of the groove-like recess.
One connecting link of the link mechanism is particularly advantageously a formative component of the longitudinal body in the closed state of the top. By this means, creative and functional elements and a simple manner of construction are combined to a particular extent.
In general, provision can preferably be made in the case of a top according to the present invention for the second roof part to be pivotable essentially parallel over the first roof part. This makes it possible to achieve a favorable packing size of the deposited roof parts in the open state of the top.
In particular, provision is preferably made in the case of a top according to the present invention for the outer link to be pivotable through an angle of at least 150 degrees, particularly preferably through at least 160 degrees.
In a particularly preferred refinement of a top according to the present invention, the first roof part is a middle roof part and the second roof part is a front roof part of a three-part top, a third roof part being arranged behind the first roof part in the direction of travel. In this case, during an opening movement of the top, the second roof part can preferably be moved over the first roof part, and the third roof part can preferably be moved over the first roof part and over the second roof part. This enables a particularly large top to be realized for use in four- and multi-seater vehicles, which nevertheless takes up a particularly small packing size in the open state of the top.
Further advantages and features of a top according to the present invention are revealed in the exemplary embodiments described below and in the dependent claims.
BRIEF DESCRIPTION OF THE DRAWINGS
Two preferred exemplary embodiments of a top according to the present invention will be described below and explained in greater detail with reference to the drawings, in which:
FIG. 1 shows a schematic partial view of a first exemplary embodiment of a top according to the present invention from the side in a closed position of the top;
FIG. 2 shows the top from FIG. 1 in a schematic illustration clarifying the interaction of the components;
FIG. 3 shows a schematic partial view of the top from FIG. 1 from the side in a first step of an opening movement;
FIG. 4 shows the top from FIG. 3 in a schematic illustration clarifying the interaction of the components;
FIG. 5 shows a schematic partial view of the top from FIG. 1 from the side in a second step of an opening movement;
FIG. 6 shows the top from FIG. 5 in a schematic illustration clarifying the interaction of the components;
FIG. 7 shows a schematic partial view of the top from FIG. 1 from the side in a third step of an opening movement;
FIG. 8 shows the top from FIG. 7 in a schematic illustration clarifying the interaction of the components;
FIG. 9 shows a schematic partial view of the top from FIG. 1 from the side in a fourth step of an opening movement;
FIG. 10 shows the top from FIG. 9 in a schematic illustration clarifying the interaction of the components;
FIG. 11 shows a lateral overall view of the top from FIG. 1 ;
FIG. 12 shows a lateral overall view of the top from FIG. 9 ;
FIG. 13 shows the top from FIG. 12 in a further step of an opening movement;
FIG. 14 shows the top from FIG. 12 in a state in which it is completely open and is deposited in a rear region of the vehicle;
FIG. 15 shows a detail view of an outer link of the top from FIG. 1 in a closed position of the top;
FIG. 16 shows the detail view from FIG. 15 in a partially open position;
FIG. 17 shows the detail view from FIG. 15 in a completely open position with the outer link pivoted to the maximum;
FIG. 18 shows a schematic side view of a second exemplary embodiment of a top according to the present invention;
FIG. 19 shows the top from FIG. 18 in a partially open state;
FIG. 20 shows a detail view of an outer roof link of the top from FIG. 18 in a closed state of the top;
FIG. 21 shows a detail view of a front link mechanism for the articulation of the outer roof link from FIG. 20 ;
FIG. 22 shows a detail view of a rear link mechanism for the articulation of the outer roof link from FIG. 20 ;
FIG. 23 shows a detail view of an outer roof link of the top from FIG. 18 in a partially open state of the top;
FIG. 24 shows a detail view of a front link mechanism of the outer roof link from FIG. 23 ;
FIG. 25 shows a detail view of a rear link mechanism of the outer roof link from FIG. 23 ;
FIG. 26 shows a detail view of an outer roof link of the top from FIG. 18 in an open state of the top;
FIG. 27 shows a detail view of a front link mechanism of the outer roof link from FIG. 26 ; and
FIG. 28 shows a detail view of a rear link mechanism of the outer roof link from FIG. 26 .
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
The first preferred exemplary embodiment of a top according to the present invention comprises a front roof part 1 , a rear roof part 2 and a middle roof part 10 , which is arranged between the front and the rear roof parts 1 , 2 in the closed state. The middle roof part 10 is connected fixedly to a middle link 10 a , and so the middle roof part 10 and the middle link 10 a can be regarded as a constructional unit.
The front roof part 1 is connected to the middle roof part 10 via a front four-bar linkage 11 , a front link 11 b of the front four-bar linkage being connected in an articulated manner to the middle link 10 a and an outer link 11 a of the front four-bar linkage 11 being articulated from the outside on the middle roof part 10 . In the closed state according to FIG. 1 , FIG. 2 and FIG. 11 , the outer link bears against the outside of the middle roof part 10 , the outer link being situated in a recess of a roof drip molding or roof channel of the middle roof part 10 .
The rear roof part 2 is articulated on the middle link 10 a by means of a rear four-bar linkage 12 . The rear roof part 2 comprises C-pillars of the top and a fixed rear window. The rear four-bar linkage 12 comprises a first rear link 12 a and a second rear link 12 b.
Overall, the front roof part 1 and the rear roof part 2 can therefore be pivoted in each case over the middle roof part 10 , it also being possible for the rear roof part 2 to be pivoted over the front roof part 1 .
The front four-bar linkage 11 and the rear four-bar linkage 12 are connected to each other via a drivable positive control means 4 , with the result that a position of the front roof part 1 is unambiguously assigned mechanically in each case to a position of the rear roof part 2 .
The positive control means 4 comprises a first linkage 8 which activates the front four-bar linkage 11 , a second linkage 9 which activates the rear four-bar linkage 12 , and a rotary link 7 . The rotary link is connected rotatably to the middle link 10 a in a first joint 7 a . The rotary link 7 can also be rotated in a drivable manner by means of a force-introducing unit 5 , which is designed as a linear hydraulic cylinder and is supported against the middle link 10 a . In the present case, the rotary link is designed as a three-armed link. However, within the context of the present invention, a rotary link may, in particular, also be understood as meaning a rotary disk or control disk. A universally usable perforated disk may, in particular, also be used as the control disk, with the result that the provision of joints in a variable manner on the perforated disk enables a deceleration control means, which can be adapted to different tops to be provided by means of standardized components.
The first linkage 8 comprises a first, front control link 8 a and two front links 8 b , 8 c , in which case, by connecting the front link 11 b to the first control link 8 a by means of the two front links 8 b , 8 c , a particularly large pivoting angle of the front four-bar linkage 11 can be achieved. The first control link 8 a is connected to the rotary link 7 in a second joint 7 b of the rotary link 7 .
The second linkage 9 comprises a second, rear control link 9 a , which is guided with respect to the middle link 10 a via a small supporting link 9 b . The second control link 9 a is articulated on an extension of the second rear link 12 b , thus enabling the rear four-bar linkage 12 to be articulated on the second control link 9 a and to be activatable via the latter.
The middle roof part 10 or the middle link 10 a is connected to a main bearing unit 14 , which is attached in a manner secured on the bodywork, via a main four-bar linkage 13 , the main four-bar linkage 13 comprising a first main link 13 a and a second main link 13 b.
A storage region 16 at the rear of the vehicle can be covered by means of a rear element 15 , it being possible for the rear element 15 to be pivoted up counter to the direction of travel in order to open up a space for the top, which is to be deposited to pass through.
In the case of a top according to the present invention from the first exemplary embodiment, the outer link 11 a , as in particular FIG. 15 to FIG. 17 show, is not articulated on the middle roof part 10 via a conventional rotary joint. On the contrary, the articulation comprises a small four-bar linkage 20 , the middle roof part 10 forming the base of the small four-bar linkage 20 and the outer link 11 a forming the coupling member of the small four-bar linkage 20 . A first connecting link 20 a and a second connecting link 20 b of the small four-bar linkage 20 cross over each other. A short covering plate 21 can be pivoted about its own articulation 21 a essentially parallel to the connecting links 20 a , 20 b of the small four-bar linkage 20 , the covering plate 21 being guided in a sliding manner in the region of its end which lies opposite its articulation 21 a.
Overall, the articulation of the outer link 11 a by means of a small four-bar linkage 20 means that the link mechanism 11 , which connects the front roof part 1 to the middle roof part 10 , is designed as a seven-bar linkage mechanism 11 , the six links of which are formed by the middle link 10 a , the connecting links 20 a and 20 b of the small four-bar linkage 20 , the outer link 11 a , the front roof part 1 and the front link 11 b.
When a link is designed as the outer link, a series of particular features has to be taken into account. As also in the exemplary embodiment shown, an outer link 11 a is advantageously arranged in a roof drip molding recess 10 b , which is provided in any case in most modern vehicle tops. The roof drip molding recess 10 b is covered outside the region of the link 10 a by a roof drip molding cover 10 c . The outer link 11 a expediently comprises a corresponding link covering 22 , which is placed onto the actual link, with the result that the link makes it possible for a roof drip molding 10 c , 22 to appear continuous in the closed state of the top. However, a problem with an arrangement of this type is that, on account of its recessed accommodation in the roof drip molding recess 10 b , the link 11 a would strike against the roof drip molding covering 10 c during a pivoting movement, at least if a large pivoting angle of the link 11 a is required. However, the effect which can be achieved by the advantageous detail solution of the articulation of the link in the small four-bar linkage 20 is that the link 11 a emerges over its entire length together with its roof drip molding covering 22 out of the roof drip molding recess 10 b right at the beginning of its pivoting movement, thus making possible a particularly large pivoting angle. FIGS. 15 to 17 show that a free pivoting angle of the outer link of virtually 180 degrees is made possible in this manner.
The short covering plate 21 which can be pivoted at the same time by the four-bar linkage 20 is used, in the closed state of the top, merely to cover the roof drip molding region above the small four-bar linkage 20 .
The top functions as follows:
Starting from the closed state of the top according to FIG. 1 , FIG. 2 and FIG. 11 , a first part of an opening movement of the top is firstly initiated. For this purpose, the force-introducing unit 5 is actuated, which causes the rotary link 7 to rotate anticlockwise according to the illustrations. From a comparison of FIG. 1 to FIG. 10 , it is clear that in the process first of all the rotary link mainly actuates the first linkage 8 while the position of the third link 7 c with respect to the second linkage 9 means that initially the second linkage 9 is scarcely actuated at all, in particular in the relevant longitudinal direction of the second, rear control link 9 a.
Pivoting of the front roof part 1 over the middle roof part 10 therefore mainly takes place first of all. The pivoting of the front roof part 1 is predominant in the sequence of movement approximately as far as the position illustrated in FIG. 5 and FIG. 6 . During the pivoting of the front roof part over the middle roof part, the outer link 11 a undergoes a rotation through approximately 172 degrees.
The relative movement of the front roof part 1 , which has already been substantially pivoted over the middle roof part 10 , then slows down. At the same time, the movement of the rear roof part 2 increases, since now (approximately from the position shown in FIG. 5 and FIG. 6 ) a very direct conversion of the rotational movement of the rotary link 7 into a longitudinally directed movement of the rear control link 9 a takes place. The described sequence of movement of the two roof parts can therefore be referred to as quasi-sequential.
An end of the first part of the opening movement of the top is reached when the three roof parts 1 , 2 and 10 have been fully arranged to form a stack (see FIG. 9 , FIG. 10 and FIG. 12 ).
A second part of the opening movement of the top is illustrated in the overall views of the top according to FIG. 12 to FIG. 14 . The main four-bar linkage 13 is pivoted here in a manner driven by a second driving device to bring the previously formed package of the roof parts 1 , 2 , 10 into a storage region 16 at the rear of the vehicle. For this purpose, the rear element 15 is first of all pivoted up counter to the direction of travel and then pivoted shut again.
A second exemplary embodiment of a top according to the present invention will be described below in accordance with the drawings FIG. 18 to FIG. 28 :
The top according to the second exemplary embodiment according to the present invention likewise comprises a front roof part 101 , a middle roof part 110 and a rear roof part 102 . This top is preferably connected in a manner identical to the first exemplary embodiment to the vehicle via a link mechanism (not illustrated) which is arranged between the middle roof part 110 and the vehicle bodywork. Similarly, the front roof part 101 can be moved over the middle roof part 110 and the rear roof part 102 can be moved over the front roof part 101 and over the middle roof part 110 . The second preferred exemplary embodiment departs from the first one mainly in the structural and creative design of the outer link 111 a.
The outer link 111 a is connected, firstly, to the middle roof part 110 via a first link mechanism 140 designed as a four-bar linkage and, secondly, is connected to the front roof part 101 via a second link mechanism 120 designed as a four-bar linkage. Since the front roof part 101 is pivoted over the middle roof part 110 , the second link mechanism 120 can be compared to an upper link mechanism, while the first link mechanism 140 corresponds to a lower link mechanism.
In this case, the one middle link 110 a and a roof shell connected fixedly to the latter and incorporating the middle roof part 110 form a base of the first four-bar linkage 140 . Said base is connected by means of two small connecting links 140 a and 140 b to an end region of the outer link 111 a , which forms a connecting member of the first four-bar linkage 140 .
At the same time, the outer link 111 a forms, in its other end region which is at the front in the direction of travel, a base for the second four-bar linkage 120 . The front roof part 101 forms a connecting member of the second four-bar linkage 120 , the base and connecting member of the second four-bar linkage 120 being connected to each other by means of two small connecting links 120 a , 120 b.
The front roof part 101 is furthermore connected via a front link 111 b to the middle link 110 a by means of simple rotary joints in each case. All in all, the kinematics arranged on the supporting middle link 110 a and belonging to the front roof part 101 therefore forms a positively controlled link mechanism 111 in the manner of a ten-bar linkage. The eight individual links of the given or positively controllable ten-bar linkage are: middle link 110 a , first small connecting link 140 a , second small connecting link 140 b , outer link 111 a , first small connecting link 120 a , second small connecting link 120 b , front roof part 101 and front link 111 b.
In this case, by providing the first four-bar linkage 140 and the second four-bar linkage 120 with particularly small dimensions, a very stable chain of links is provided in spite of the relatively large number of links. For the reason mentioned, said chain of links essentially exhibits the stability of a large four-bar linkage comprising outer link 11 a , front roof part 101 , front link 111 b and middle link 110 a and middle roof part 110 .
The connection of the outer link on both sides to the two roof parts adjacent to it enables a large pivoting angle of the outer link to be achieved both with respect to the front roof part and with respect to the rear roof part, as a result of which, in turn, particularly tight stacking of the roof parts, which are deposited one above the other in the same orientation, can be achieved in the open state of the top.
The outer link 111 a particularly preferably rests on an essentially planar, outer surface of the roof parts in the closed state of the top. In particular, the outer link 111 a forms a middle part of a longitudinal body formed as a trim strip. A front part 130 of the longitudinal body is connected fixedly to the front roof part 101 as part of it, and a rear part 131 of the longitudinal body is connected fixedly to the rear roof part 110 as part of it. FIG. 18 and FIG. 19 show the manner in which the parts of the trim-strip-like longitudinal body are arranged on the sheet-metal shaped parts forming the roof parts 101 , 110 . In this case, in the closed state of the top, an elastic intermediate layer 131 a , which may consist, for example, of felt or cellular rubber, is provided between the outer link 111 a and the shell of the middle roof part 110 and prevents the outer roof link from vibrating in the closed state of the top.
The longitudinal body comprising the outer roof link 111 a can be manufactured, for example, from aluminum or stainless steel in order to bring about an appropriate visual decorative effect on the top. As an alternative, it may, however, also consist of steel painted in the color of the vehicle or coated in another way. For creative and aerodynamic purposes, the end regions of the longitudinal body preferably taper conically and are rounded. For the same reasons, the cross section of the longitudinal body or of the outer link 111 a is essentially in the shape of a segment of a circle.
The respective small connecting links 140 a , 140 b , 120 a , 120 b of the first four-bar linkage 140 and of the second four-bar linkage 120 are essentially formed as disk bodies which are fitted into corresponding milled-out sections in the end regions of the mutually adjacent parts of the longitudinal body. The effect thereby achieved is that, in the closed state of the top, the small connecting links 140 a , 140 b , 120 a , 120 b each form part of the surface of the longitudinal body that is visible from the outside (see in particular FIG. 21 and FIG. 22 ) and the complex, multi-part construction of the longitudinal body is covered in a simple manner. The outwardly facing, visible end surfaces of the connecting links 120 a , 120 b , 140 a , 140 b have the same surface structure as the rest of the surface of the longitudinal body 130 , 111 a , 131 that can be seen from the outside. In addition, the end surfaces are matched by corresponding shaping to the generally curved shape of the surface of the longitudinal body; this is expressed in the sectional drawings according to FIG. 21 , FIG. 22 , FIG. 24 , FIG. 25 , FIG. 27 and FIG. 28 in each case by double lines at the corresponding end sides of the links.
All in all, the effect which can be achieved by the above-described integration of the outer link 111 a in a decorative-strip-like longitudinal body which protrudes over the surface of the roof is that groove- or channel-like recesses in side regions of the roof parts for holding the outer roof link in the closed state of the top can be omitted. This makes it possible to achieve, in particular, a cost-reducing simplification of the production of the roof shells from sheet-metal shaped parts, since, if a receiving channel is provided for the roof link, the roof shells generally have to be produced by the welding together of a plurality of sheet-metal parts. In this case, the welding seam is generally situated in the bottom region of the groove-like recess.
A further advantage resulting from the simpler shaping of the roof shells which is therefore made possible is that the roof shells are sealed with respect to one another in a simpler and at the same time more effective manner, since no seals which are shaped in a complex manner and are matched to a groove-like channel are required.
FIG. 20 , FIG. 23 and FIG. 26 show detail views of the decorative-strip-like longitudinal body in various states of the top. A comparison of the open position of the top according to FIG. 26 with the closed position of the top according to FIG. 20 shows that the articulation of the outer link 111 a on both sides by means of the four-bar linkages 140 , 120 makes possible a particularly large pivoting angle of the parts 130 , 131 , 111 a of the longitudinal body with respect to one another. It is also apparent from FIG. 26 that the pivoting angle of the front roof part 1 with respect to the outer link 1111 a and the pivoting angle of the outer link 111 a with respect to the middle roof part 110 can absolutely be greater than 180 degrees and, in the present exemplary embodiment, is restricted merely by the shape of the roof parts themselves and is in each case more than 160 degrees.
The opening movement of the top according to the second exemplary embodiment takes place analogously to the manner described in the first exemplary embodiment.
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A convertible vehicle top includes a first roof part, a second roof part adjoining the first roof part in a closed position of the top, and an outer link pivotably connected to the first roof part and to the second roof part. The outer link is connected to the first roof part by a first link mechanism and is disposed on an outer side of the first roof part in the closed position of the top.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application is a divisional of U.S. patent application Ser. No. 12/657,945, filed Jan. 29, 2010, now U.S. Pat. No. 8,430,900 issued Apr. 30, 2013; which is a divisional of U.S. patent application Ser. No. 11/451,988, filed Jun. 13, 2006, now U.S. Pat. No. 7,669,603 issued Mar. 2, 2010; which is a continuation of U.S. application Ser. No. 10/066,967, filed Feb. 4, 2002, now U.S. Pat. No. 7,146,981 issued Dec. 12, 2006; which applications are incorporated herein by reference.
BACKGROUND
1. Field of the Invention
This invention is directed to methods and apparatuses for treating the pharyngeal wall of a patient. More particularly, this invention pertains to method and apparatus for treating a pharyngeal wall area as part of a sleep apnea treatment.
2. Description of the Prior Art
Sleep apnea and snoring are complex phenomena. Commonly assigned U.S. Pat. No. 6,250,307 describes various prior techniques and discloses a novel treatment for such conditions (including a permanent palatal implant).
These prior art teachings include Huang, et al., “Biomechanics of Snoring”, Endeavour , p. 96-100, Vol. 19, No. 3 (1995). That publication estimates that up to 20% of the adult population snores habitually. Snoring can be a serious cause of marital discord. In addition, snoring can present a serious health risk to the snorer. In 10% of habitual snorers, collapse of the airway during sleep can lead to obstructive sleep apnea syndrome. Id . In addition to describing a model for palatal flutter, that publication also describes a model for collapse of the pharyngeal wall.
Notwithstanding efforts have been made to treat snoring and sleep apnea. These include palatal treatments such as electrical stimulation of the soft palate. See, e.g., Schwartz, et al., “Effects of electrical stimulation to the soft palate on snoring and obstructive sleep apnea”, J. Prosthetic Dentistry , pp. 273-281 (1996). Devices to apply such stimulation are described in U.S. Pat. Nos. 5,284,161 and 5,792,067. Such devices are appliances requiring patient adherence to a regimen of use as well as subjecting the patient to discomfort during sleep. Electrical stimulation to treat sleep apnea is discussed in Wiltfang, et al., “First results on daytime submandibular electrostimulation of suprahyoidal muscles to prevent night-time hypopharyngeal collapse in obstructive sleep apnea syndrome”, International Journal of Oral & Maxillofacial Surgery , pp. 21-25 (1999).
Surgical treatments for the soft palate have also been employed. One such treatment is uvulopalatopharyngoplasty (UPPP) where about 2 cm of the trailing edge of the soft palate is removed to reduce the soft palate's ability to flutter between the tongue and the pharyngeal wall of the throat. See, Huang, et al., supra at 99 and Harries, et al., “The Surgical treatment of snoring”, Journal of Laryngology and Otology , pp. 1105-1106 (1996) which describes removal of up to 1.5 cm of the soft palate. Assessment of snoring treatment is discussed in Cole, et al., “Snoring: A review and a Reassessment”, Journal of Otolaryngology , pp. 303-306 (1995). Huang, et al., propose an alternative to UPPP which proposal includes using a surgical laser to create scar tissue on the surface of the soft palate. The scar is to reduce flexibility of the soft palate to reduce palatal flutter. RF ablation (so-called Somnoplasty as advocated by Somnus Technologies) is also suggested to treat the soft palate. RF ablation has also been suggested for ablation of the tongue base.
In pharyngeal snoring and sleep apnea, the pharyngeal airway collapses in an area between the soft palate and the larynx. One technique for treating airway collapse is continuous positive airway pressure (CPAP). In CPAP air is passed under pressure to maintain a patent airway. However, such equipment is bulky, expensive and generally restricted to patients with obstructive sleep apnea severe enough to threaten general health. Huang, et al. at p. 97.
Treatments of the pharyngeal wall include electrical stimulation is suggested in U.S. Pat. No. 6,240,316 to Richmond et al. issued May 29, 2001, U.S. Pat. No. 4,830,008 to Meer issued May 16, 1989, U.S. Pat. No. 5,158,080 to Kallok issued Oct. 27, 1992, U.S. Pat. No. 5,591,216 to Testerman et al. issued Jan. 7, 1997 and PCT International Publication No. WO 01/23039 published Apr. 5, 2001 (on PCT International Application No. PCT/US00/26616 filed Sep. 28, 2000 with priority to U.S. Ser. No. 09/409,018 filed Sep. 29, 1999). U.S. Pat. No. 5,979,456 to Magovern dated Nov. 9, 1999 teaches an apparatus for modifying the shape of a pharynx. These teachings include a shape-memory structure having an activated shape and a quiescent shape. Dreher et al., “Influence of nasal obstruction on sleep-associated breathing disorders”, So. Laryngo-Rhino-Otologie, pp. 313-317 (June 1999), suggests using nasal stents to treat sleep associated breathing disorders involving nasal obstruction. Upper airway dilating drug treatment is suggested in Aboubakr, et al., “Long-term facilitation in obstructive sleep apnea patients during NREM sleep”, J. Applied Physiology, pp. 2751-2757 (December 2001).
Surgical treatments for sleep apnea are described in Sher et al., “The Efficacy of Surgical Modifications of the Upper Airway in Adults with Obstructive Sleep Apnea Syndrome”, Sleep , Vol. 19, No. 2, pp. 156-177 (1996). Anatomical evaluation of patients with sleep apnea or other sleep disordered breathing are described in Schwab, et al., “Upper Airway and Soft Tissue Anatomy in Normal Subjects and Patients with Sleep-Disordered Breathing”, Am. J. Respir. Crit. Care Med. , Vol. 152, pp. 1673-1689 (1995) (“Schwab I”) and Schwab et al., “Dynamic Upper Airway Imaging During Awake Respiration in Normal Subjects and Patients with Sleep Disordered Breathing”, Am. Rev. Respir. Dis. , Vol. 148, pp. 1385-1400 (1993) (“Schwab II). In Schwab I, it is noted that apneic patients have a smaller airway size and width and a thicker lateral pharyngeal wall. For reviews of pharyngeal wall thickness and other structure and obstructive sleep apnea, see, also, Wheatley, et al., “Mechanical Properties of the Upper Airway”, Current Opinion in Pulmonary Medicine, pp. 363-369 (November 1998); Schwartz et al., “Pharyngeal airway obstruction in obstructive sleep apnea: pathophysiology and clinical implication”, Otolaryngologic Clinics of N. Amer., pp. 911-918 (December 1998); Collard, et al., “Why should we enlarge the pharynx in obstructive sleep apnea?”, Sleep, (9 Suppl.) pp. S85-S87 (November 1996); Winter, et al., “Enlargement of the lateral pharyngeal fat pad space in pigs increases upper airway resistance”, J. Applied Physiology, pp. 726-731 (September 1995); and Stauffer, et al., “Pharyngeal Size and Resistance in Obstructive Sleep Apnea”, Amer. Review of Respiratory Disease, pp. 623-627 (September 1987)
SUMMARY OF THE INVENTION
According to one aspect of the present invention, methods and apparatuses are disclosed for treating a pharyngeal airway having a pharyngeal wall of a patient at least partially surrounding and defining said airway. The method includes inserting an expander member into the airway and positioning an active portion of the expander member in opposition to portions of the wall to be treated. The expander member is activated to urge the wall portions outwardly to an outwardly displaced position. The expander member is then deactivated while leaving the wall portions in the outwardly placed position and the expander member is removed from said airway. A further aspect of the invention includes stabilization of at least a portion of the pharyngeal wall in the outwardly placed position after compression of portions of the wall.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows, in cross-section, a naso-pharyngeal area of an untreated patient;
FIG. 2 is the view of FIG. 1 with the soft palate containing an implant in the form of a bolus of micro-beads deposited in a linear path;
FIG. 3 is a frontal view of the patient of FIG. 3 showing an alternative embodiment with micro-beads deposited as spherical deposits;
FIG. 4 is a schematic representation showing a patch for delivering a bolus of micro-beads through a plurality of needles;
FIG. 5 is a schematic cross-sectional view (taken generally along line 5 - 5 in FIG. 2 ) of a pharyngeal airway at a position in a person with the airway defined by opposing portions of a pharyngeal wall and a base of a tongue;
FIG. 6 is the view of FIG. 5 with a first embodiment of an expander member in position prior to activation;
FIG. 7 is the view of FIG. 6 following activation of the expander member to compress portions of the pharyngeal wall;
FIG. 8 is a side-sectional view of compression pads used in the expander member of FIG. 7 ;
FIG. 9 is the view of FIG. 7 following deactivation and removal of the expander member and showing retention of the pharyngeal wall in an expanded state;
FIG. 10 is the view of FIG. 6 showing an alternative embodiment of the invention;
FIG. 11 is the view of FIG. 6 showing a further alternative embodiment of the invention;
FIG. 12 is the view of FIG. 6 showing a still further alternative embodiment of the invention;
FIG. 13 is a schematic cross-sectional view (taken generally along line 13 - 13 in FIG. 2 ) of a pharyngeal airway at a position in a person distal to the base of the tongue and with the airway defined by the pharyngeal wall;
FIG. 14 is the view of FIG. 13 with a further embodiment of an expander member positioned in the airway in a deactivated state;
FIG. 15 is the view of FIG. 14 with the expander member shown activated compressing the pharyngeal wall;
FIG. 16 is the view of FIG. 15 following deactivation and removal of the expander member and showing retention of the pharyngeal wall in an expanded state;
FIG. 17 is a sectional schematic view of a compressed portion of tissue defining, in part, a pharyngeal airway and stabilized by a biocompatible material in the tissue of the compressed portion;
FIG. 18 is the view of FIG. 17 with the compressed tissue stabilized by suture material;
FIG. 19 is the view of FIG. 17 but with the tissue not being compressed and being stabilized by a suture material;
FIG. 20 is a side-sectional schematic view of a suture material having resorbable and non-resorbable portions;
FIG. 21 is the view of FIG. 18 with the suture material of FIG. 20 prior to resorption of the resorbable portions of the suture material; and
FIG. 22 is the view of FIG. 21 with the suture material of FIG. 20 following resorption of the resorbable portions of the suture material.
DESCRIPTION OF THE PREFERRED EMBODIMENT
A. Physiology Background
Referring now to the several drawing figures, in which identical elements are numbered identically throughout, a description of a preferred embodiment of the present invention will now be provided.
The disclosures of U. S. Pat. No. 6,250,307 and PCT International Publication No. WO 01/19301 (PCT/US00/40830) are incorporated herein by reference.
FIG. 1 shows, in cross-section, a naso-pharyngeal area of an untreated patient. FIG. 1 shows the nose N, mouth M and throat TH. The tongue T is shown in an oral cavity OC of the mouth. A hard palate HP (containing a bone B) separates the oral cavity OC from the nasal cavity NC. The nasal concha C (soft tissue which defines, in part, the nasal sinus—not shown) resides in the nasal cavity NC.
The soft palate SP (a muscle activated soft tissue not supported by bone) depends in cantilevered manner at a leading end LE from the hard palate HP and terminates at a trailing end TE. Below the soft palate SP, the pharyngeal wall PW defines the throat passage TP. A nasal passage NP connects the nasal cavity NC to the pharyngeal wall PW. Below an epiglottis EP, the throat passage TP divides into a trachea TR for passing air to the lungs and an esophagus ES for passing food and drink to the stomach.
The soft palate SP is operated by muscles (not separately shown and labeled) to lift the soft palate SP to urge the trailing edge TE against the rear area of the pharyngeal wall PW. This seals the nasal cavity NC from the oral cavity OC during swallowing. The epiglottis EP closes the trachea TR during swallowing and drinking and opens for breathing.
For purposes of this disclosure, the nasal cavity NC, oral cavity OC and throat passage TP are collectively referred to as the naso-pharyngeal area of the patient (defining, in part, the pharyngeal airway PA in FIGS. 5 and 13 ) with the area including the various body surfaces which cooperate to define the nasal cavity NC, oral cavity OC and throat passage TP. These body surfaces include outer surfaces of the nasal concha C, the upper and lower surfaces of the soft palate SP and outer surfaces of the pharyngeal wall PW. Outer surfaces means surfaces exposed to air. Both the upper and lower surfaces of the soft palate SP are outer surfaces.
Snoring can result from vibration of any one of a number of surfaces or structures of the naso-pharyngeal area. Most commonly, snoring is attributable to vibration of the soft palate SP. However, vibratory action of the nasal concha C and the pharyngeal wall PW can also contribute to snoring sounds. It is not uncommon for vibratory action from more than one region of the naso-pharyngeal area to contribute to snoring sounds. Sleep apnea can result from partial or full collapse of the naso-pharyngeal wall during sleep.
FIG. 5 shows a schematic representation of a cross-section of a throat with the pharyngeal airway PA defined by the pharyngeal wall PW and the tongue T. The anterior-posterior axis is labeled AP to assist in discerning the orientation. The pharyngeal wall PW is shown as including the left lateral pharyngeal wall LLPW, right lateral pharyngeal wall RLPW and posterior pharyngeal wall PPW.
B. Disclosure of Prior Application
In addition to disclosing the teachings of U.S. Pat. No. 6,250,307 and the teachings of selected embodiments of PCT International Publication No. WO 01/19301 (both incorporated herein by reference), commonly assigned and co-pending patent application U.S. Ser. No. 09/636,803, filed Aug. 10, 2000, which is hereby incorporated by reference in its entirety, describes techniques for stiffening tissue of the pharyngeal airway with a bolus of particulate matter. FIGS. 2 and 3 show are taken from the '803 application and show an implant 10 as a bolus of particulate matter. An example of such particulate matter would be micro-beads. An example of such is taught in U.S. Pat. Nos. 5,792,478 and 5,421,406. These patents teach carbon-coated metallic or ceramic particles having cross-sectional dimensions of between 100 and 1,000 microns. The particles are carried in a fluid or gel. These patents state that upon insertion into body tissue, the particles do not migrate significantly and, apparently due to fibrotic response, the tissue into which the particles are injected stiffens.
The particles of U.S. Pat. Nos. 5,792,478 and 5,421,406 are one example of particles for stiffening injection. Such particles can also include ceramic particles or pure carbon or other bio-compatible particles. The particles can be carried in a liquid or gel medium. The particles can have multi-modal particle size distributions (i.e., a mix of two or more sizes of particles with the smaller particles filling interstitial spaces between larger particles).
The bolus 10 of particles can be applied by a needle to inject the bolus 10 into the soft palate SP. The bolus can be the same volume as the volume of the implants 20 of FIGS. 8 and 9 of U.S. Pat. No. 6,250,307. With reference to FIG. 3 , a multiple of bolus injections can be made in the soft palate resulting in deposition of generally spherical deposits 10 ′ of particles. Alternatively, an injecting needle can be withdrawn while simultaneously ejecting particles for the bolus 10 ( FIG. 2 ) to be deposited in a line similar in dimensions to the implants 20 of FIGS. 8 and 9 of U.S. Pat. No. 6,250,307.
The foregoing emphasizes the use of implants to stiffen the soft palate SP. Implants 10 can be placed in any of the tissue of the naso-pharyngeal area (e.g., the concha C, soft palate SP or pharyngeal wall PW) to treat snoring. Also, such a treatment can stiffen the tissue of the throat and treat sleep apnea resulting from airway collapse by stiffening the airway.
While a needle deposition of a bolus of particles may be preferred, the bolus can be applied in other manners. FIG. 4 (which is a reproduction of FIG. 16 of the '803 application) illustrates deposition of particulates through a patch 12 having a volume 14 containing such micro-beads 16 .
One side 12 a of the patch 12 contains an array of micro-needles 18 communicating with the volume 14 . The needles 18 may be small diameter, shallow penetration needles to minimize pain and blood. Examples of shallow, small diameter needles are shown in U.S. Pat. No. 5,582,184 to Erickson et al. Placing the surface 12 a against the tissue (e.g., the pharyngeal wall PW as shown in FIG. 4 ), the needles 18 penetrate the outer surface of the tissue PW. The patch 12 can then be compressed (by finger pressure, roller or the like) to eject the beads 16 from the volume 14 through the plurality of needles 18 . The patch 12 can be provided with interior dividing walls (not shown) so that some of the volume of beads 16 is ejected through each needle 18 . The side 12 a acts as a stop surface to ensure control over the penetration depth of the needles 18 to reduce risk of undesired puncture of underlying structures.
Stiffening of the naso-pharyngeal tissue provides structure to reduce vibration and snoring. Such structure reduces airway collapse as a treatment for sleep apnea.
C. Pharyngeal Wall Compression
FIGS. 5-16 show various methods and apparatus for enlarging the pharyngeal airway PA. As will be described, further disclosure is made for stiffening the tissue or maintaining the enlarged airway size.
FIG. 6 is the view of FIG. 5 showing an expander member 20 positioned within the pharyngeal airway PA for the purpose of treating the pharyngeal wall PW. As will become apparent, the treatment includes enlargement of the pharyngeal airway PA by urging at least portions of the pharyngeal wall PW outwardly. In the embodiment of FIG. 6 , the right and left lateral pharyngeal wall portions RLPW, LLPW are being urged outwardly to increase the area of the airway PA.
The expander member 20 includes left and right supports 22 positioned opposing the right and left lateral pharyngeal wall portions RLPW, LLPW. Compression pads 24 are carried on the supports 22 and in direct opposition to the right and left lateral pharyngeal wall portions RLPW, LLPW. The supports 22 are maintained in fixed spaced apart relation by a spacer bar 26 .
While not shown in the drawings, the spacer bar 26 can be adjustable to permit a physician to modify the spacing between the supports 22 and to permit narrowing the spacing between the supports 22 to facilitate ease of placement of the expander member 20 in the airway PA at a desired treatment area. Preferably, the pads 24 and supports 22 have a length (distance parallel to the longitudinal axis of the airway PA) greater than a width (distance parallel to the opposing surface of the wall PW as indicated by W in FIG. 6 ) to treat an extended length of the wall PW. For example, the pads 24 and supports 22 could be about two centimeters long.
The compression pads 24 are inflatable bladders connected by a tube 28 ( FIG. 8 ) to a source of a pressurized fluid (not shown). Admission of pressurized fluid into the bladders 24 causes the bladders to enlarge urging the right and left lateral pharyngeal wall portions RLPW, LLPW outwardly as illustrated in FIG. 7 . The compression of the tissue of the patient could be compression of the pharyngeal wall PW or compression of tissue surrounding the pharyngeal wall PW (for example, fatty pads). After the compression, the pads 24 are deflated and the expander member 20 is removed from the airway PA as illustrated in FIG. 9 leaving compressed right and left lateral pharyngeal wall portions RLPW, LLPW and an enlarged cross-sectional area of the pharyngeal airway PA.
In addition to compressing the walls of the pharyngeal airway PA, the compressed walls may be stabilized in a compressed state to ensure longer lasting retention of the therapeutic benefits of the enlarged airway PA. This stabilization can include injecting a bio-adhesive or bio-sealants into the tissue adjacent the treated portions of the pharyngeal wall.
An example of bio-adhesives includes cyanoacrylates. Without intending to be a limiting example, these include 2-octyl cyanoacrylate and 2-butyl cyanoacrylate. The 2-octyl cyanoacrylate is developed by Closure Medical Corp., Raleigh, N.C., USA for use to treat topical skin wounds, oral cancers and periodontal disease. It may last 1-2 weeks with faster absorbing products in development. The 2-butyl cyanoacrylate is used as a skin protectant and dental cement and is available from GluStitch, Inc., Delta, BC, Canada
Biocompatible adhesives also include surgical adhesives such as those developed by CryoLife International, Inc., Kennesaw, Ga., USA whose product is composed of purified bovine serum albumin (45%) and cross-linking agent glutaraldehyde (10%). Similar formulations include natural proteins (e.g., collagen, gelatin) with aldehyde or other cross-link agents.
Such bio-sealants may be fibrin sealants. Examples include blood-derived products (e.g., Tisseel™ distributed by Baxter Corp., Deerfield, Ill., USA). Other examples of coatings include hydrogel coatings. An example of these include a photo-curing synthetic sealant developed by Focal, Inc., Lexington, Mass., USA which can adhere to moist or dry tissue and is highly flexible and elastic. This sealant may be absorbable over short or long terms. The sealant is currently used to treat air leaks associated with lung surgery. Other coatings include denture adhesives approved for use in humans.
From the foregoing, it can be seen there are a wide variety of adhesives and other coatings suitable for use with the present invention. The foregoing lists are intended to be illustrative and not exhaustive.
With the description given with respect to FIGS. 6-9 , the bio-stabilizer can be injected into the compressed regions of tissue adjacent the right and left pharyngeal wall. For example, the material can be injected into the compressed portions of the right and left lateral pharyngeal wall portions RLPW, LLPW (mucosal or sub-mucosal or muscular tissue) or into compressed tissue behind the right and left pharyngeal walls, such as compressed fatty tissues. The expander 20 can be left in place while the adhesive as least partially sets such that when the expander 20 is removed, the adhesive helps retain the compressed right and left lateral pharyngeal wall portions RLPW, LLPW in a compressed state.
Bio-adhesives degrade and the therapeutic benefit of the bio-adhesives can be lost over time. Accordingly, a still further embodiment of the present invention includes injecting a fibrosis-inducing agent into the compressed tissue. The fibrosis-inducing agent induces a fibrotic response of the tissue to stiffen the tissue and helping to retain the tissue in a compressed state.
It will be appreciated that the fibrosis-inducing agent may be used in conjunction with the bio-adhesive or the bio-adhesive and fibrosis-inducing agents can be used separately. In the preferred embodiment the fibrosis-inducing agent will be substantially non-biodegradable so as to provide a long lasting, chronic effect maintaining the compressed state of the pharyngeal wall PW.
By way of non-limiting example, a fibrosis-inducing material may be microbeads as described above. While microbeads may be a preferred embodiment, alternative techniques for inducing fibrosis can be in the form of placement in the compressed tissue of polyester material or other foreign bodies which induce a fibrotic response.
In addition to the adhesives or fibrosis-inducing agents, drugs may be admitted into the tissue. Drugs may be injected directly or in microspheres.
FIG. 8 illustrates an embodiment for injecting adhesives or microbeads into the compressed tissue by the use and placement of micro needles 30 on a side of the bladder 24 opposing the tissue similar to the embodiment of FIG. 4 . The fluid from the bladder 24 through the needles 30 contains the bio-adhesives and the microbeads. The micro needles 30 can be of various lengths to vary the depth of distribution of the adhesives and the microbeads.
FIGS. 10-12 show alternative embodiments of the present invention. Elements having functions in common with the fore-going embodiment are numbered identically with the addition of a suffix (“a”, “b” or “c”) to distinguish the embodiments.
In FIGS. 6 and 7 , compression members 24 are shown only opposing the right and left lateral pharyngeal wall portions RLPW, LLPW. In FIG. 12 , four compression members 24 a are shown to cover a wider area of the right and left lateral pharyngeal wall portions RLPW, LLPW. In FIG. 11 , three compression members 24 b are shown for compressing not only the right and left lateral pharyngeal wall portions RLPW, LLPW but also the posterior pharyngeal wall PPW. In FIG. 10 , an arcuate and continuous compression member 24 c is shown for compressing the entire pharyngeal wall PW.
FIGS. 13-15 illustrate use of the method of the present invention in a different region of the pharyngeal airway PA. With respect to FIGS. 6-12 , the embodiments of the invention are shown in use in that portion of the pharyngeal airway PA which is defined in part by the base of the tongue T. Further distal into the pharyngeal airway PA, the pharyngeal airway PA is defined by the pharyngeal wall PW as illustrated in FIG. 13 . The present invention is also applicable to treatment of the naso-pharynx NP ( FIG. 1 ) in which case the airway is defined by lateral and posterior pharyngeal walls and opposing surfaces of the palate. Since this is similar to the shown applications, separate illustrations need not be provided.
FIG. 14 shows a circular airway expander member 20 ′ having a circular support 22 ′ and a circular bladder 24 ′. Since the support 22 ′ is annular-shaped, an unobstructed airway PA remains to permit respiration by the patient during treatment. FIG. 15 shows the device with the bladder 22 ′ in an expanded state to cause compression of the pharyngeal wall PW. FIG. 16 shows the compressed pharyngeal wall following removal of the expander member 20 ′.
FIGS. 17-22 illustrate various examples of techniques for stabilizing the pharyngeal wall PW. FIG. 17 illustrates a region of compressed tissue CT impregnated with a stabilizing material 40 (e.g., adhesive, sealant or microbeads).
The compressed tissue CT may be compressed mucosal tissue or may be compressed muscular tissue. Also, the compressed tissue CT may be compressed fatty pads adjacent the pharyngeal wall PW.
Stabilization could result from a chemical agent (e.g., a sclerosing agent) or by application of energy (e.g., radiofrequency ablation) or any other means (e.g., cryogenic ablation). It will be appreciated that not all of these techniques need provide a permanent stabilization and some of these techniques may result in remodeling over time. Subsequent treatments may then be provided.
FIG. 18 illustrates a mechanical stabilization using suture material 42 to hold the compressed tissue in a compressed state. The suture material may be resorbable or non-resorbable. FIG. 19 is similar to FIG. 18 but the pharyngeal wall is not compressed. Instead, the pharyngeal wall is stabilized by sutures 44 to underlying structure US (e.g., to underlying bucco-pharyngeal fascia, prevertebral fascia, anterior longitudinal ligament or vertebral bodies). Attachment to such bodies may also occur following compression. Stabilization can result from tacking to any sub-mucosal area surrounding the pharyngeal airway.
FIGS. 20-22 illustrate a variation of FIG. 18 where the suture material 46 includes a short non-resorbable core 48 (e.g., poly ester tetrapthalate—PET) covered by a longer outer coating 50 of resorbable suture material. Immediately after the implantation, only the resorbable ends extend out of the pharyngeal wall PW into the airway PA and are tied off (see FIG. 21 ). Following resorption, the non-resorbable portion 48 is fully recessed behind the wall PW as shown in FIG. 22 to limit possibility of later migration of the non-resorbable core 48 into the airway PA. In the foregoing, the term “suture” is not intended to be limited to a thread-like material but can include clips or any other closure mechanism.
The foregoing describes numerous embodiments of a method and apparatus to treat a pharyngeal wall. Having described the invention, alternatives and embodiments may occur to one of skill in the art. For example, a physician may stabilize all or a portion of the pharyngeal wall within the teachings of the foregoing with conventional surgical instruments. It is intended that such modifications and equivalents shall be included within the scope of the following claims.
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A patient's pharyngeal wall is treated by inserting an expander member into the airway and positioning an active portion of the expander member in opposition to portions of the pharyngeal wall to be treated. The expander member is activated to urge the wall portions outwardly to an outwardly displaced position. The expander member is then deactivated while leaving the wall portions in the outwardly placed position and the expander member is removed from said airway. A further aspect of the treatment includes stabilization of at least a portion of the pharyngeal wall after compression of portions of the wall.
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BACKGROUND OF THE INVENTION
The present invention relates to a method and system for performing well operations from a floating installation.
Normally a conventional rig up for performing operations in a well will be comprised of stacked up heave eliminators, which comprises means for keeping the tension in a riser with the movement of a floating vessel or a floating installation, surface flow tree (SFT), equipment for performing wire line or coiled tubing operations into the well or even drilling in the well as for instance through tubing drilling, and a surface blow out preventer (SBOP) on the rig floor as part of the conventional work over riser. There will in some instances also be arranged a telescopic element in the riser below the SBOP. For performing wire line or coiled tubing operations the riser string will normally be depressurized and the rig heave motions vs. the workover riser string are compensated by keeping the upper end of the riser string with the SBOP in relative position in relation to the vessel.
There is in the applicant's own Norwegian patent application No. 20075757 (from which a applicant's pending U.S. patent application Ser. No. 12/734,562 claims priority) described a system where the difficulties with using a pressurized telescopic joint in a high pressure riser and also the situation with having the SBOP located on the top of the riser above the telescopic joint, creating outlets for well fluids at high pressure at a deck creating a situation which is possibly hazardous for personnel working on the floating installation, is solved by positioning an upper workover riser package (UWRP), with means for closing off the passage in the riser and means for cutting any equipment extending down in to the riser, is arranged below a telescopic joint in the riser. The UWRP is thereby arranged to be in a fixed position relative the seabed. The riser is kept in tension by the tensioning system on the floating installation. As the UWRP may be regarded as an extension of the riser, the tension wires are connected to the top of the UWRP to avoid bending forces acting on the UWRP. The system in NO2007575 further describes a system where the UWRP comprises an interface for connection of different kind of workover equipment, such as equipment for performing coiled tubing operations or equipment for wire line operations.
One problem with this system is the need to have the UWRP configured to close the passage and shear equipment that may be present in the passage, resulting in the need to equip the UWRP with several kinds of equipment for the different activities to be performed in the well. Another element is that the valves and shearing functionalities within the UWPR sometimes needs to be replaced or repaired, then the whole riser configurations must be released and taken up on the floating installation.
SUMMARY OF THE INVENTION
An aim with the present invention is to provide a method and system for performing operations in a high pressure riser which gives more flexibility than this known system.
This is achieved with a system as defined in the attached independent method and system claims, with further details and embodiments given in the dependent claims and description below.
According to the invention there is provided a method for performing well operations from a floating installation comprising a high pressure riser connected to the floating installation through a tension system. The riser is connected to a subsea well or installation on the seabed and should be kept in tension to not damage the installation on the seabed. The floating installation may be a floating vessel, floating platform or other floating unit, which would be influenced by wave and weather conditions and also possibly currents in the water etc. The riser according to the invention comprises a housing with an internal diameter larger than an internal diameter of the riser element and the housing is connected at the top of the riser element, wherein the housing is formed with a first connection interface. The housing will normally be kept in a fixed position relative the seabed and the tension system on the floating vessel would normally be connected to an upper part of the housing. According to the invention there is for performing operations made an assembly, having a second connection interface, and wherein the assembly comprises a desired numbers of modules for use in a specific operation, the modules are assembled at the installation, then positioned in the housing. The second connection interface in the assembly is connected to the first connection interface in the housing. The operation is performed through the assembly. The modules will comprise modules for closing the passages of the riser, modules for shearing elements extending in to the riser and also tool specific modules, as for instance modules for closing the passage in the riser around a wire line or coiled tubing, modules for shearing a wire line, and modules for shearing coiled tubing. There may also be extension modules, and control module modules in the assembly. This gives the possibility of adapting equipment for the specific work to be performed in the well. This gives larger flexibility at location for performing the operation as the system is assembled by modules at the installation. Another benefit is since the equipment is operation specific; the load on the riser is kept at a minimum as there for instance will be shearing functionality for a wire line and not a coiled tubing when performing wire line operations. The module functionality may also give the benefit of having the possibility of preparing a new assembly while another is still in use, or replacing some of the modules in an assembly with spare modules when the first ones needs to be repaired or maintained.
According to the invention the method may comprise the step, wherein the assembly of modules is made up of two or more subassemblies, whereof each comprises at least two modules, to position the subassemblies separately in relation to the housing. This gives the possibility of attaching one subassembly within the housing and to the riser which could be used with different other subassemblies, which then could be attached to the one subassembly and thereafter replaced with a different subassembly. Another possibility is to have the whole assembly attached to the riser in one operation. In yet another possibility one may have a subassembly which comprises only one module.
According to another aspect the method may comprise the assembly to be pressure tested at the installation before positioned in the housing or attaching to the riser. This pressure testing may be performed of the whole assembly or one may pressure test subassemblies separately.
According to the invention there is also provided a riser system for performing operations in a well. This riser system comprises a high pressure riser extending from a subsea installation up to and connected to a floating installation through a tension system at a tension connection point. There is at top of the riser arranged a housing. According to the invention the housing is forming part of said riser and is formed with a first connection interface. The housing may also be incorporated as a part of the riser. There is to the connection interface connected an assembly comprising at least two modules, wherein the assembly has a second connection interface for connection of the assembly to the housing through the first connection interface. This assembly would comprise modules with different functionalities needed for the specific operations to be performed in the well.
This riser system gives the possibility of having the assembly specially adapted to the different kinds of operations to the performed in the well with the increased flexibility and benefits this gives.
According to an aspect the assembly, with at least two modules, may comprise a first subassembly comprising at least one modular element and an interface for cooperation with the connection interface of the housing, and a second subassembly for performing the operation in the well, comprising an attachment interface for cooperation with the attachment interface of the first subassembly. The subassemblies may comprise one or more modules each, different numbers of modules, and there may also be more than two subassemblies. A configuration with a subassembly may also be called a split insert BOP.
According to another aspect the internal diameter of the housing is larger than an internal diameter of the riser and adapted to encompass at least a part of the assembly. The housing will be a non-pressure containing housing. The housing can then be made as a relatively thin walled element, compared with the UWRP in the applicant's earlier application. The housing will be formed with the connection interface within the housing and at least a part of the connection interface at a lower part of the housing. The housing will protect the assemblies to be connected to the riser system from the environment. The housing would also be guide for the assembly to be connected to the connection interface in the housing. The housing would in one embodiment also comprise means, i.e. a connection point for connection of the riser system to the tension system at the floating installation. Such a connection point may be positioned at an uppermost part of the housing. The housing may also relatively be positioned within the water but by its configuration keeping the connection interface and also the first subassembly out of water. The housing may extend a distance in the length direction of the riser, from a position in the body of water to a position well above the water level. According to an embodiment the first subassembly may be encompassed by the housing. In another embodiment also part of a second subassembly may be encompassed by the housing.
According to another aspect the riser system may comprise equipment for assemblage of the different assemblies at the installation and a system for pressure testing the assemblies before connecting them to the housing. The riser system may also comprise lifting equipment at the installation for moving the assemblies to and from a deck at the installation and the housing. This gives the possibility of quickly change the assemblies in the riser system and thereby adapting it to different operations. The floating installation will have a set of modules for all different operations and when needed the different modules are assembled, using some of the same modules in the different assemblies. There is also the possibility of providing two modules of the same for the modules that are most frequently used, both to have a spare and also to assemble and test a new assembly while another one is used and removed from the riser system. This gives flexibility and saves time which is cost effective.
According to the invention there may be several modules to be assembled to form the assembly and or subassemblies.
In an embodiment the first subassembly might be a replaceable valve module assembly, and the second subassembly might be a replaceable tool assembly.
A module according to the invention comprises at least an interface, preferably two interfaces on opposite sides of the module, for connection to another module or the connection interface of the housing or an attachment interface for connection to another subassembly, means to allow it to be locked to another module or the housing, and means for sealing the connection between neighboring modules or the connection to the housing. The modules will possibly, dependent on the functionality of the module comprise means for transferring signals and power to elements within the module or through the module to other modules in the assemblies. Such transferring of signals and or power may be done within the modules in a direct line or as a multiplex system within one of the modules. Alternatively the transferring of signals and or power may be done from the outside and into the modules needing signal and or power. Such a system may be arranged outside the modules, possibly at the outside of the housing or possibly at least in part within the housing, and with means for transferring the signals and power through the wall of the housing and into the modules. Such a system may be a direct line system or a system with a multiplex system for at least some of the lines. There is also the possibility of providing the modules with means to orient the modules relative each other and also in relation to the housing, to for instance ensure that the signal and or power transmission is achieved in a correct manner. Activation of the functionality of the modules may be a system within the modules or be a system influencing the modules from the outside. The activation may be achieved by rotational movement, axial movement or radial movement or a combination. Communication for operation of the modules or communication transferred through the modules may be through physical lines as optical, acoustic, electrical, inductive or other means for transferring signals. The communication may also be wireless. A module may also be a control module module, to be positioned in any of the subassemblies or possibly at a position where it only will experience low pressures.
The modules need to be locked to each other to form a sealed connection, where at least some of the modules also should hold high pressure. Such a locking may be configured in several manners. There may be a locking system between each of the modules as such and a locking system for locking the lowermost module of the assembly to the interface of the housing. In an alternative embodiment the modules may be locked to each other by a system which locks several modules together and at the same time locks it to the housing, such a system may comprise locking means at one of the uppermost modules, or the uppermost of the high pressure modules. Such a locking system may then interact with the housing at the position of this module, and by activating this locking system several modules are locked and forming a sealing connection with each other.
In one embodiment the first subassembly, the valve module assembly or part of the assembly may comprise a first connection module, at least one valve module and a cutting module. In another embodiment the first connection module may comprise a valve. In a further embodiment the first connection module may be an extension joint module. In another embodiment the tool assembly may comprise a latch tool module, further the tool assembly may comprise a slip joint module. Alternatively or in addition the tool assembly may comprise a tool catcher module, an annular bag module and a dual stripper module. Alternatively or additionally the tool assembly may comprise a PCH, etc. All the different modules may be connected to form a single assembly or different subassemblies to be connected together to form the riser system.
There is in this description referred to upper and lower parts or elements, and this should be understood to be a part in normal configuration and use of the element in relation to a well operation.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be explained with reference to the attached drawings, where
FIG. 1 shows an overall configuration of a high pressure riser extending from a subsea installation to a floating platform according to the invention.
FIG. 2 is a schematic sketch of a system according to the invention in some more detail
FIG. 3 shows the top of the riser without and assembly according to the invention
FIGS. 4A and 4B shown different embodiments of an assembly and assembly within the top of the riser for wire line operations,
FIGS. 5A and 5B , FIG. 6 and FIG. 7 show assemblies and assemblies arranged at the top of the riser for coiled tubing operations.
FIG. 8 shows an embodiment for drilling operations,
FIG. 9 shown a schematic sketch of a control, communication and power transfer in the assembly,
FIG. 10 shown a detail of a hydraulic system as indicated in FIG. 9
FIGS. 11A and 11B show several alternative modules for use in an assembly according to the invention.
FIG. 12 shows examples of assemblies according to the invention.
DETAILED DESCRIPTION OF THE INVENTION
In FIG. 1 there is shown an overall system sketch of a high pressure riser system extending between a subsea installation, in this case a wellhead 1 with a X-mas tree 2 , and a floating installation, indicated with platform deck, a drill floor 3 and a main deck 4 . A normal configuration of a high pressure riser system would comprise the X-mas tree 2 , a X-mas tree adapter 5 , a low riser package 6 , an emergency disconnect package 7 , a high pressure riser element 8 , a SBOP (Surface Blow Out Preventer) 9 , a connection point 10 for connection to tension equipment at the floating installation, a low pressure slip joint 11 and a diverter or flex joint 12 . A configuration of a high pressure riser system may comprise all of these elements or only some of them and possibly also other element. There are also a kill line 13 and an injection line 14 connected to the riser system just below the SBOP 9 .
In FIG. 2 there is shown a similar system to the one in FIG. 1 in some more detail. There is indicated that the SBOP is comprised of several valve modules 20 , which are configured to form a replaceable modular assembly 15 . The replaceable assembly also comprises a telescopic low pressure extension module 21 , which also can be a slip joint module. The assembly 15 is attached to a first interface 16 A formed within a housing 18 ( FIG. 3 ). The tension equipment is connected to the top of the housing 18 to keep the riser system tension. There are also indicated valves in the kill line 13 and the injection line 14 .
FIGS. 3 , 4 A and 4 B show the upper part of the riser system according to the invention. The riser system comprises the high pressure riser 8 , having an extension in the form of a housing 18 . The housing 18 may have a connection element 17 to be disconnectable from the riser 8 . The housing 18 comprises a first connection interface 16 A, for attaching a replaceable assembly 15 via a second interface 16 B, such that the assembly 15 is securely connected to the high pressure riser 8 . As one can see from the figure the connection point 10 for the tension equipment on the floating installation is arranged at the top of the housing 18 . There is also a low pressure slip joint 11 and a flex joint 12 forming the top of the riser system. The injection line and kill lines are guided on the outside of the housing 18 to a point below the connection point for the tension system.
According to the invention there may to the connection interface ( 16 A) in the housing 18 be attached different assemblies, assembled to perform a specific operation in the well.
In FIG. 4A there is shown one such assembly, for performing wire line operations. The assembly is shown by it self on the left in the figure and attached to the connection interface on the right in the figure. In this assembly there are valve modules, shearing modules, extension modules, extension modules with valves, and a specific wire line module. In this embodiment the assembly is assembled in one piece, pressure tested at the floating installation and then connected to the connection interface within the housing. The assembly is thus positioned fully assembled within the housing.
In FIG. 4B there is shown a somewhat different configuration where the assembly comprises two subassemblies, with a first subassembly, a valve module assembly, comprising of several modules, as an extension module with valve and other valve modules. This first subassembly comprises an interface for connection to the connection interface of the housing and also an attachment interface for attaching a second subassembly to the first subassembly. The second subassembly, a tool assembly comprises also several modules with an extension module and a specific wire line tool module.
In FIG. 5A there is shown a similar system but in this case an assembly for coiled tubing operations, where the assembly comprises several valve modules, shearing modules, extension modules and also a slip joint module. In FIG. 5A the assembly 15 is shown as one assembly, while in FIG. 5B it is shown comprising two subassemblies. There is shown a second configuration of an assembly for of coiled tubing operations in FIG. 6 , and a third configuration of an assembly for coiled tubing operations in FIG. 7 . In FIG. 8 there is shown an assembly configuration for drilling operations, comprised of two subassemblies.
In FIG. 9 there are shown possible details on how to achieve communication between or through the different modules forming an assembly. In the embodiment shown hydraulic fluid is supplied to the modules through the housing, and the connecting interface then also comprising means for transferring hydraulic fluid, signals etc through to the assembly. As indicated in FIG. 10 there may be a number of passages in the wall of the modules for supplying hydraulic fluid to each module where some of the passages terminates (and is used) in the module while others are connected to the nest module(s) up.
In FIG. 11A and FIG. 11B there are shown several different modules which can be connected to each other to form an assembly or possibly a subassembly. Module 70 is a latch tool module that comprises locking means 72 for locking into the lower end of the housing 18 /top end of riser 8 . This module may include ports 73 for the supply of hydraulic fluid to the subassembly, as shown in FIG. 9 . In this embodiment, passages may run through the module and exit at ports 74 that connect to the next module to supply fluid to this module. In the ports 73 and 74 there will preferably be arranged hydraulic couplers having valves that will close the port when the modules are disconnected from each other. In this embodiment it is envisaged that the lower subassembly is locked to the housing 18 with this module. Also note that since this is the lowermost module the locking means 72 is of one type to enable it to fit into the standard interface at the lower end of the housing. The upper end of the module has locking means 76 to lock this module with the module above.
Module 50 is a pipe ram module having rams 52 that can be closed around a pipe and isolate the annular space between the pipe and the inner wall of the module. As above, the module comprises lower 43 and upper 44 ports for hydraulic fluid supply.
Module 60 is a shear ram module having knives 62 to cut through a pipe in an emergency. As this module would normally be the uppermost module in the subassembly there are only supply ports 63 and no ports to connect to a module above.
Module 40 is identical to module 70 but has been modified to include a valve 46 , preferably a ball valve but it may also be any other kind of valves such as gate valve or plug valve. In certain operations it may be desirable to have a valve in the latch tool.
Module 80 is an annular bag-type valve that is used during drilling operations. The bag 82 is designed to close around a rotating drilling string to divert drilling fluids up to the rig.
In FIG. 11B there is shown elements that form the second subassembly. As can be seen in the drawing the bottom module 92 has at its lower end the same interface as the latch tool 70 . As also is shown in FIG. 11A the upper module (in this case modules 60 or 80 ) has at its upper end the same interface as the housing interface 16 A. Therefore the upper subassembly can fit either into the lower subassembly or into the housing and vice versa. Each module 92 , 94 , 96 , 98 has identical interfaces and locking means enabling them to be stacked on top of each other in any order. Module 92 is a latch tool that helps in locking the subassembly into the housing (in reality the lower subassembly), module 94 is a tool catcher, module 96 is a coil tubing annular bag and module 98 is a dual stripper. All these elements are normal equipment in use for drilling and workover operations and as such are well known in the arts.
FIG. 12 shows examples of subassemblies that will be assembled on the rig deck and tested before inserting the assembly into the housing to be locked there.
The invention has now been explained with reference to different embodiment, a skilled person would understand that there may be made alterations and modifications to the shown embodiments that are within the scope of the invention as defined in the attached claims.
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The present invention relates to a method for performing well operations from a floating installation comprising a high pressure riser ( 8 ) connected to the floating installation through a tension system, and where the riser comprises a housing ( 18 ) with an internal diameter larger than an internal diameter of the riser and connected at the top of the riser, where it for performing operations is made an assembly ( 15 ) comprising a desired numbers of modules for use in a specific operation, the modules are assembled at the installation, then positioned in the housing and the operation is performed through the assembly.
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BACKGROUND OF THE INVENTION
This invention relates to foam blowing agent blends of (a) n- and/or i-pentane with (b) 1-chloro-1,1-difluoroethane ("142b") or 2-chloro-1,1,1,2-tetrafluoroethane ("124"), more particularly to blends containing about 10-90 weight % of each of (a) and (b) and to polyol premixes and polyurethane foam compositions containing such blends.
Until now, the leading polyurethane foam blowing agent has been 1,1-dichloro-1-fluoroethane ("141b"), in order to meet the market place requirements for energy, fire performance and cost. At the same time, however, 141b has a high ozone depletion potential ("ODP") of about 0.1. Thus, many foam manufacturers are now investigating cyclopentane as a leading alternative candidate to replace 141b. Cyclopentane has zero ODP, but also has property shortcomings in terms of fire performance and aged k-factor performance (and thus, thermal insulating properties).
It would therefore be useful to provide the industry with a foam blowing agent which overcomes the deficiencies of both 141b and cyclopentane in terms of properties such as ODP, fire performance, k-factor aging and the like.
While articles have been written on the subject of blended blowing agents, such as Research Disclosure 40137 (September 1997) on Hydrochlorofluorocarbon-hydrocarbon Mixtures, the actual data presented is that of blends containing the industry standard, 141b.
BRIEF SUMMARY OF THE INVENTION
Foam blowing agent compositions are provided, which compositions comprise (a) about 10-90 weight % (preferably 60-80%) of n-pentane, i-pentane or mixtures thereof and (b) about 90-10 weight % (preferably 40-20%) of 142b or 124, as well as foam premix compositions, which premix compositions comprise a polyol and the foregoing blowing agent blend, and polyurethane foam compositions, which foam compositions comprise an A-side containing an isocyanate and a B-side containing a polyol and all or a portion of the foregoing blowing agent blend (a portion of the pentane component of the blend preferably being incorporated into the A-side).
DETAILED DESCRIPTION
It has now been found that the foregoing blends of n-pentane and/or i-pentane with 142b or 124 overcome deficiencies associated with 141b or cyclopentane. Thus, relative to 141b, the inventive blends have low ODPs by virtue of the low ODPs of their components, 0 for n-pentane and i-pentane, 0.05 for 142b and 0.02 for 124. Relative to cyclopentane, the use of at least 10% halocarbon (142b or 124) improves the fire performance properties, so that less fire retardant is needed, and provides foams which not only match the initial k-factor of cyclopentane, but surprisingly have a slower aging rate which results in improved thermal insulating properties. The blends also provide advantages in terms of better compressive strength than cyclopentane; better solubility than pure hydrocarbon; less VOC (volalite organic compound) than pure hydrocarbon; and better dimensional stability due to the combination of the high boiling point pentanes and the low boiling point halocarbons.
In the premix compositions, the blowing agent blend is typically present in a concentration range of about 2-60 weight % (preferably 10-40 weight %), based on the weight of the polyol.
In the polyurethane foam compositions, the effective concentrations of the blends are typically about 0.1-25 weight % (preferably 0.5-15%) based on the weight of the total polyurethane foam formulation. In order to help solubilize the blowing agent blend in the polyurethane foam composition, a portion of the pentane component (typically about 50-75%) of the blend is preferably added to the A-side. This also helps to assure that the A-side and the B-side have similar viscosities.
The other components of the premix and foam formulations may be those which are conventionally used, which components and their proportions are well known to those skilled in the art. For example, catalysts, fire retardants and surfactants are typical components of the B-side. Some examples of typical components and mixing procedures are set forth in the Research Disclosure paper referenced above.
The practice of the invention is illustrated in more detail in the following non-limiting examples of n-pentane/142b and n-pentane/124 blown foams in comparison to a cyclopentane blown foam. The formulations used (all having an Iso Index of 300) are set forth in Table I, all listed materials being commercially available. In Table I, M-489 stands for polymeric methane diphenyl diisocyanate, available from Bayer Corporation; T-2541 is a polyester polyol having a hydroxyl number of 240, available from Hoechst Celanese; PC-5 and PC-46 are, respectively, pentamethyldiethylenetriamine and potassium acetate in ethylene glycol, catalysts available from Air Products; K-15 is potassium octoate in dipropylene glycol, a catalyst available from Air Products; B-8462 is a polysiloxane-polyether copolymer, a surfactant available from Goldschmidt Chemical Corporation; and AB-80 is tris(1-chloro-2-propyl)phosphate, a fire retardant available from Albright & Wilson Americas, Inc; all parts are by weight. A-side premix components, containing isocyanate and 75% of the pentane, were mixed and cooled to 10° C. B-side premix components, containing polyol, surfactant, fire retardant, 25% of the pentane and 100%. of any halocarbon, were also mixed and cooled to 10° C.
TABLE I______________________________________ Example 1 Example 2 Comparative (n-pentane/ (n-pentane/ ExampleComponent 142b) 124) (Cyclopentane)______________________________________M-489 170.51 170.51 170.51n-pentane 19.05 21.05 --Cyclo- -- -- 24.08pentaneT-2541 100.00 100.00 100.00PC-5 0.13 0.13 0.13PC-46 0.44 0.44 0.44K-15 3.92 3.92 3.92B-8462 4.32 4.32 4.32AB-80 15.00 15.00 15.00142b 6.36 -- --124 -- 7.04 --______________________________________
In making the foam, the A and B side premixes were mixed for 10 seconds, followed by injection of the catalyst mixture. Mixing is continued for 15 seconds, after which the mixture is poured into a box.
ASTM procedures were then followed to measure (initial and aged) k-factors (ASTM C518) and compressive strengths (ASTM D1621) of the resultant foams, all of which had a density of 1.8 pounds per cubic foot. The results are shown in Tables II and III:
TABLE II______________________________________K-factors (in BTU.in/ft.sup.2.hr. ° F.) Comparative Example 1 Example 2 Example______________________________________Initial 0.160 0.161 0.160After 8 weeks 0.182 0.182 0.189______________________________________
TABLE III______________________________________Compressive Strength (psi) Comparative Example 1 Example 2 Example______________________________________Parallel 27.6 32.3 26.3Perpendicular 17.5 18.9 10.5______________________________________
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Foam blowing agents blends of 10-90% of n- and/or i-pentane with 90-10% of 142b or 124 are provided, as are polyol premixes and polyurethane foam compositions containing such blends.
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BACKGROUND OF THE INVENTION
The invention involves a burner mechanism for a rotary kiln for the production of cement clinker from raw meal, with a burner lance movable in an axial direction, which extends through the stationary kiln outlet housing into the rotary kiln end.
At standard cement clinker production lines, calcined raw meal is burnt to cement clinker in the sintering zone of a rotary kiln by means of a burner lance extended through the kiln outlet housing creating a flame by means of fuel combustion. The red hot cement clinker is discharged through the kiln outlet housing onto a clinker cooler, in most cases grate coolers, and will be cooled down. In modern cement clinker production lines, the hot cooler air collected in the kiln outlet housing is utilized twofold. First, the hot air used as secondary air for the kiln firing and second, as tertiary air for a secondary firing system in the calciner stage installed according to the material flow upstream of the rotary kiln (brochure No. 7-330 KHD Humboldt Wedag AG, page 4 and 5).
The secondary air, which changes flow direction upon entering the kiln outlet end through the stationary kiln outlet housing from below, is loaded with cement clinker dust and has a high temperature of 1,100° C. and higher. Therefore the kiln outlet housing, and especially the burner lance, is exposed to a high mechanical abrasive and thermo/chemical wear. There are cases where the lifetime of a burner lance is extremely short, even if the burner lance is coated with heat resistance material and has a cooling system. An exchange or replacement of the burner lance requires interruption of the kiln operation and consequently an interruption of the whole cement clinker production line.
SUMMARY OF THE INVENTION
The invention has as one of its benefits, to provide a burner mechanism to be used with a burner lance for a rotary kiln for the production of cement clinker, which will extend the lifetime of the burner lance.
With the invented burner mechanism, a removable and replaceable burner protection shield is located at a distance under the burner lance, which means the burner protection shield extends similarly to the burner lance, through the kiln outlet housing into the rotary kiln, from which the red hot clinker discharges through the kiln outlet housing onto the clinker cooler. Especially the bottom side of the burner lance is protected with the burner protection shield against the abrasive dust laden secondary air flowing from below towards the underside of the burner. Furthermore the protection shield protects the burner lance from the extreme heat radiation from the red hot cement clinker.
Due to the protection shield, it is possible to increase the life time of the kiln burner lance to up to a year.
A special feature of the invention is the fact that the burner protection shield is equipped with its own carriage device which makes it movable parallel to the burner lance. Once the protection shield is worn out it can removed from the kiln outlet housing and replaced with a new one. With this feature, the burner lance operation and the operation of the whole cement clinker production line does not have to be interrupted.
To secure the protection of the cylindrical burner lance, the width of the protection shield is greater than the diameter of the burner lance with the advantage that the burner lance is not exposed to the hot air current and radiation.
The burner protection shield is made of heat resistant material. Furthermore the protection shield features at least one cooling channel to introduce a cooling media, for instance cooling air. The heated up cooling air exiting the protection shield will be mixed with secondary air flowing into the rotary kiln or can be vented outside of the kiln hood.
The invention and the special features and advantages are being described using the schematic figures attached.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 illustrates a burner mechanism embodying the principles of the present invention with a protection shield, in a side elevational view.
FIG. 2 illustrates a cross section of the burner device of FIG. 1 taken generally along the line II—II.
FIG. 3 illustrates in detail an enlarged cross section of the burner protection shield of FIG. 2 .
FIG. 4 illustrates a cross section of the burner protection shield, in an embodiment of the invention, taken generally along the line IV—IV of FIG. 3 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
In FIG. 1 , an outlet end of a rotary kiln ( 10 ) of a cement clinker production line is surrounded by a stationary kiln outlet housing ( 11 ). A complete system for manufacturing cement clinker is shown and described in U.S. Pat. Nos. 6,626,662; 6,254,382 and 6,444,026, the disclosures of which are incorporated herein by reference. From the kiln outlet the red hot cement clinker ( 12 ) falls through the kiln outlet housing ( 11 ) down to the not shown clinker cooler. From the clinker cooler, hot cooler air laden with clinker dust flows as secondary air ( 13 ) through the stationary kiln outlet housing ( 1 ) into the rotary kiln ( 10 ). The rotary kiln ( 10 ) will be heated by a flame coming out of a burner lance ( 14 ) which extends through the outlet housing ( 1 ) into the kiln end. The burner lance can be moved in the axial direction with a movable carriage ( 15 ) mounted on rollers.
Positioned at a distance below and parallel to the burner lance ( 14 ) is an exchangeable (removable and replaceable) burner protection shield ( 16 ), which is similar to the burner lance, extends through the kiln outlet housing ( 11 ) into rotary kiln ( 10 ). The protection shield ( 16 ) which is movable parallel to the burner lance ( 14 ) by its own carriage ( 17 ) protects the burner lance ( 14 ), especially at the bottom part, against the flow of the hot clinker dust laden secondary air ( 13 ), as well as against the radiation of the red hot cement clinker ( 12 ). This prolongs the life time of the burner lance considerably.
In FIG. 2 it can clearly be seen that a width (S) of the burner protection shield ( 16 ) is advantageous greater than a diameter (L) of the burner lance ( 14 ) and therefore the lance ( 14 ) is located at the draft side of the of the protection shield with regard to air flow and heat radiation.
As shown in FIG. 3 , the burner protection shield ( 16 ) is comprised of heat resistance material ( 18 ) or coated with this material. This heat resistance material ( 18 ) can contain a metallic reinforcement ( 20 ). Furthermore it can be seen in FIG. 3 that the protection shield ( 16 ) has at least one cooling channel ( 19 ) for passage of cooling media, for example, cooling air. The cooling air passing through the cooling channel ( 19 ) of the protection shield ( 16 ), heats up, and flows out the right end of the protection shield as heated air into the rotary kiln ( 10 ) and mixes with the secondary air.
Alternatively, as shown in FIG. 4 , to decrease false air and improve fuel efficiency, channel ( 19 ) can be re-directed back to the left and out of the kiln outlet housing ( 11 ) through the central segments ( 21 ) of the cooling channel ( 19 ).
As is apparent from the foregoing specification, the invention is susceptible of being embodied with various alterations and modifications which may differ particularly from those that have been described in the preceding specification and description. It should be understood that we wish to embody within the scope of the patent warranted hereon all such modifications as reasonably and properly come within the scope of our contribution to the art.
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A burner protection shield is provided at a distance and in an area below a burner lance that is used in a rotary kiln for the production of cement clinker. Such a mechanism enhances the useful lifetime of the burner lance.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to new Ames-test-negative chain-extension agents or cross-linking agents for polyurethane resins and epoxide resins.
2. Prior Art
The production of polyurethanes according to the isocyanate poly-addition process is known. For example, compounds having hydrogen atoms capable of reaction, such as, polyesters with terminal OH groups, are reacted with diisocyanate to form a prepolymer (German Patent Application No. 1,240,654), which are then made in a second step to react at an elevated temperature with a chain-extension agent or cross-linking agent, which is customarily an aromatic diamine. The developing reaction mass, which is capable of being poured, can then be hardened in a mold over an extended period of time. In that case, it is a prerequisite that all of the prepolymer and the chain extension agents or cross-linking agents do not react too quickly in order that a proper processing time is guaranteed in the fluid phase. For this purpose, the following slow-acting diamines, o-chlorobenzidine, 2,5-dichloro-1,4-phenylene-diamines and especially 3,3'-dichloro-4,4'-diaminodiphenyl methane (MOCA), have proven to be useful.
The production of epoxide resins likewise takes place in a known manner. For example, one can proceed in such a way that an active hydrogen compound, such as, alcohols, phenols or acids, is added to a monoepoxy compound while forming chlorohydrine derivatives, which are then converted to glycidyl compounds under HCl-separation. The latter form the basis for the further conversion into epoxide resins using hardeners, such as, anhydrides, diamines or polyamines (Ullmanns Encyclopedia of Technical Chemistry, 4th Edition, Vol. 10, pp 563 et seq.). The diamines, especially methylene dianiline (MDA) and 3,3'-dichloro-4-4'-diaminodiphenylmethane (MOCA), have been shown to be especially useful for this purpose.
The carcinogeneous and mutagenous characteristics of the hitherto known diamines, which are chain-extension agents or cross-linking agents, are considerable disadvantages. Above all, 3,3'-dichloro-4,4'-diaminodiphenylmethane (MOCA) and methylene dianiline (MDA), have been used on a not very willingly basis because of their suspected carcinogeneous [i.e., Ames-test-positive, see AMES ET AL., PROC. NAT. ACAD. SCI, USA, VOL. 70, 1973, No. 3, pages 782 ff, and No. 8, pages 2281 ff]--their use has even been prohibited in some countries.
A further negative factor is the fact that by the selection of the chain-extension agent or cross-linking agent, the pot time of the elastomer is fixed and can not be varied within a wide range depending upon the use of the elastomer.
BROAD DESCRIPTION OF THE INVENTION
An object of the invention is to provide an amine compound, amine composition, and production process and use process therefor which do not possess the above-mentioned prior art disadvantages. Other objects and advantages of the invention are set out herein or are obvious herefrom to one skilled in the art.
The objects and advantages of the invention are achieved by the compound, compositions and processes of the invention.
The invention involves 2,2'-dichloro-6,6'-diethyl-methylene-bis-aniline or a mixture thereof with at least one compound having the formula: ##STR3## wherein R 1 , R 2 , R 3 , R 4 are the same or different and are straight-chained or branched alkyl radicals having 2 to 4 carbon atoms, or R 1 and/or R 3 are chlorine and the remaining Rs have the above-mentioned definition. Such aniline or mixtures are useful as Ames-test-negative chain-extension agents or cross-linking agents for polyurethane and epoxide resins.
The invention further involves a process for the production of the compound and mixtures of the invention by the condensation of 2-ethyl-6-chloroaniline and at least one aniline having the formula: ##STR4## wherein R 5 and R 6 are the same or different and are straight-chained or branched alkyl radicals having 2 to 4 carbon atoms, with formaldehyde or at least one compound which forms formaldehyde in an acidic medium. 2,2'-dichloro-6,6'-diethylmethylene-bis-aniline results from the condensation of two molecules of the 2-ethyl-6-chloroaniline in an acidic medium with the formaldehyde or compound which forms formaldehyde. The anilines which have both R 1 and R 3 as chlorine are formed from two molecules of the aniline derivatives wherein R 5 is chlorine.
Effective compounds which can occur in the mixture additionally to the 2,2'-dichloro-6,6'-diethylmethylene-bis-aniline, are for example:
TABLE I______________________________________Compounds Ames-Test______________________________________2,6,2'-triethyl-6'-chloro-methylene- -bis-aniline2,2',6,6'-tetraethyl-methylene-bis-aniline -2,2'-diethyl-6-sec.butyl-6'-chloro-methy- -lene-bis-aniline2,6,2'-triethyl-6'-sec.butyl-methylene-bis- -aniline2,2'-diethyl-6,6'-di-sec.butyl-methylene- -bis-aniline2-ethyl-6-chloro-2',6'-diisopropyl- -methylene-bis-aniline2,6,2',6'-tetraisopropyl-methylene- -bis-aniline2,6-diethyl-2',6'-diisopropyl-methylene- -bis-aniline______________________________________
DETAILED DESCRIPTION OF THE INVENTION
As used herein, all parts, ratios, percentages and proportions are on a weight basis unless otherwise stated herein or otherwise obvious herefrom to one ordinarily skilled in the art. Also, as used herein, all temperatures are in degrees Centigrade.
The production of the 2,2'-dichloro-6,6'-diethyl-methylene-bis-aniline or the invention mixtures can take place by the condensation of 2-chloro-6-ethylaniline and dialkyl (or monoalkylmonochloro) anilines of the formula: ##STR5## wherein R 5 and R 6 have the above-stated definition, with formaldehyde or a formaldehyde-forming compound, such as, paraformaldehyde, in the presence of an acidic medium.
Effectively, at least 30 mole percent, preferably at least 80 mole percent, of 2-chloro-6-ethyl aniline is used for the condensation of mixtures with dialkyl aniline of the above-mentioned formula. Formaldehyde is used effectively in a quantity of 0.4 to 0.75 mole, preferably in a quantity of 0.45 to 0.55 mole, per mole of the initial amines. To achieve an acid medium, effectively an inorganic acid, such as, sulfuric acid, is added.
The application of the condensates according to the invention depends on the quantity as well as on the manner of the addition according to the characteristics of the pertinent starting products and according to the type of the end products to be processed.
The incorporation of the Ames-test-negative chain-extension agent or cross-linking agent according to the invention into polyurethanes can take place according to any manner or method customary or known for polyurethane production, for example, by way of the reaction-injection molding process (RIM), or the speading or dipping process, with the customary reaction systems of polyisocyanates, polyhydroxy compounds, catalysts and additional additives. Suitable polyisocyanates for this purpose are aromatic polyisocyanates, such as, methylene phenylene diisocyanate (MDI), tolylene diisocyanate (TDI), naphthaline diisocyanate (NDI), or aliphatic and cycloaliphatic polyisocyanates, such as, isophorone diisocyanate or hexamethylene diisocyanate. Suitable polyhydroxy compounds are, for example, polyglycol, polyether polyols and polyester-polyols. Also all other suitable catalysts, such as, tetramethylbutanediamine (TMBDA), diazabicyclooctane (DABCO) and dibutyl tin dilaurate (DBTC) or combinations of these catalysts and additions such as softeners, driving agents, flame retardant agents, etc., are used.
The chain-extension agents or cross-linking agents of the invention are added effectively in a quantity of 0.4 to 0.6 mole, preferably in a quantity of 0.5 mole, per mole of NCO groups, that is to say, in an equivalent quantity to the reaction system with prepolymers, respectively, proportionally together with the polyols.
The reaction systems can be processed according to a process customary or known for polyurethanes. Thus, one can operate according to the one-shot process or according to the prepolymer process.
As a result of the variation of the compositions of the mixture of the Ames-test-negative chain-extension agents or cross-linking agents according to the invention in the reaction system, the pot time, that is to say, the time T, can be relatively changed until the polyurethane reaction mixture draws threads evenly and horizontally on a dipped-in spatula moved
The following table shows the influence of various effective invention compounds of the Ames-test-negative chain-extension agents or cross-linking agents to the pot time T in comparison with chain-extension agents or cross-linking agents of the above-described prior art in a standard polyurethane elastomer:
TABLE 2______________________________________ OptimalDesignation of T in Hardeningthe product Ames-test Remarks sec. temp.______________________________________diethyltoluoyl- + compar- 9 --diamine ative substance2,2',6,6'-tetra- - compar- 5 --ethyl-methylene- ativebis-aniline substance2,2',6,6'-tetra- - compar- 9 --isopropyl-methy- ativelene-bis-aniline substance2,2'-diethyl-6, - compar- 12 --6'-di-sec.butyl- ativemethylene-bis- substanceaniline2,2'-dichloro- + compar- 105 70° C.methylene-bis- ativeaniline (MOCA) substancecondensate - substance 38 70° C.no. 1 according to inven- tioncondensate - substance 40 70° C.no. 2 according to inven- tioncondensate - substance 13 70° C.no. 3 according to inven- tioncondensate - substance 15 45° C.no. 4 according to inven- tioncondensate - substance 11 45° C.no. 5 according to inven- tioncondensate - substance 10 45° C.no. 6 according to inven- tioncondensate - substance 10 45° C.no. 7 according to inven- tioncondensate - substance 50 40° C.no. 8 according to inven- tioncondensate - substance 40 40° C.no. 9 according to inven- tioncondensate - substance 60 40° C.no. 10 according to inven- tioncondensate - substance 82 70° C.no. 11 according to inven- tion______________________________________ Preferably, condensate no. 1 is used.
When the invention agents are incorporated into a standard polyurethane elastomer, products can be obtained which are still processible at 70° C. on all commonly-used machines.
Moreover, these products have the following advantageous physical characteristics (as compared to MOCA):
TABLE 3______________________________________ with con- with densateCharacteristic test MOCA no. 1 Remarks______________________________________Shore hardness D 54 53tensil stress N/mm.sup.2up to tearing 28.20 27.32up to 3% stretch 5.54 6.09 with con-up to 5% stretch 6.42 7.44 densate no.up to 7% stretch 7.11 8.36 1, 15 to 20up to 10% stretch 7.38 9.24 percent moreup to 100% stretch 15.42 16.39 chargeableelongation at breakN/mm.sup.2 236 246"firmness of structure"ambient temperature 75 51 with con-70° C. 43 44 densate no. 1, at rising tem- perature more sturdy in struc- ture begin- ning with 70° C. superior as compared to MOCA______________________________________
The chain-extension agents or cross-linking agents according to the invention can also be used advantageously as amine hardeners for expoxide resins. The incorporation of the amine hardeners into customary resins such as are formed, for example, from bis-phenol A and epichlorohydrine can be accomplished in a customary or known manner. Effectively, the amine hardeners are added in a quantity of 0.2 to 0.4 equivalent, per equivalent to preferably 0.25 equivalents of epoxy groups in the epoxide resin.
As a result of the use of the Ames-test-negative amine hardeners according to the invention, hardened epoxide resins are achieved with heat stability of shape which is comparable with epoxide resins obtained with the hardeners MOCA and MDA (which are known to be cancerogenic and mutagenic):
TABLE 4______________________________________ Stability of Shape °C. inDiamine Ames-test Heat Epon ® 828 Remarks______________________________________methylene-bis- + 158° comparisonaniline (MDA)2,2'-dichloro- + 155° comparisonmethylene-bis-aniline (MOCA)condensate no. - 159° invention11______________________________________
By way of summary, the invention involves new p,p'-methylene-bis-anilines which are useful as chain-extension agents or cross-linking agents for polyurethanes and epoxide resins.
EXAMPLE 1
Production Of The Condensates According To The Invention.
Always 1 mole of 2-ethyl-6-chloroaniline, or a mixture of it with o-alkylized aromatic amines, was diluted with xylene at a weight ratio of 1:1, was mixed with 3 g or 33 g of 47.8 percent sulfuric acid (33 g was needed in the case of the condensation reaction with diisopropyl aniline) and was brought to reaction with 47.1 g of 30 percent formaldehyde solution (formaline) (which equals 0.472 mole) while stirring and with reflux for 6 hours. It was neutralized with caustic soda solution in excess and was stirred under reflux for an additional 30 minutes. After phase separation at 50° C., the organic phase was washed out once more with 150 ml of water and was separated at 50° C. At about 100 torr, the xylene isomer mixture was now first decanted and the unreacted aniline derivatives were finally removed at a flask temperature of 220° C. and 5 torr. The isolated yields of methylene-bis-compounds were all at above 97 percent of theory or of the CH 2 O used.
Condensate no. 1
92.2 mole of 2-ethyl-6-chloroaniline (CEA) and 7.8 mole percent of 2,6-diethylaniline (DEA) were subjected to condensation in the presence of formaldehyde. A light brown product having a melting range of 100° to 105° C. was obtained with the following composition expressed in mole percent:
______________________________________2,2'-diethyl-6,6'-dichloromethylene-bis-aniline 89.32,6,2'-triethyl-6'-chloromethylene-bis-aniline 10.12,6,2',6'-tetraethylmethylene-bis-aniline 0.65______________________________________
The product showed no mutagenic effect in the Ames-test.
Condensate no. 2
89.6 mole percent of CEA and 10.4 mole percent of DEA were subjected to condensation in the presence of formaldehyde. A brown colored crystalline product having a melting range of 95° to 100° C. was obtained with the following composition expressed in mole percent:
______________________________________2,2'-diethyl-6,6'-dichloromethylene-bis-aniline 80.32,6,2'-triethyl-6'-chloromethylene-bis-aniline 18.62,6,2',6'-tetraethylmethylene-bis-aniline 1.1______________________________________
The product showed no mutagenic effect in the Ames-test.
Condensate no. 3
79.7 mole percent of CEA and 20.3 mole percent of DEA were subjected to condensation in the presence of formaldehyde. A light brown product having a melting range of 91° to 100° C. was obtained with the following composition expressed in mole percent:
______________________________________2,2'-diethyl-6,6'-dichloromethylene-bis-aniline 73.92,6,2'-triethyl-6'-chloromethylene-bis-aniline 21.12,6,2',6'-tetraethylmethylene-bis-aniline 5.0______________________________________
The product showed no mutagenic effect in the Ames-test.
Condensate no. 4
70.3 mole percent of CEA and 29.7 mole percent of DEA were subjected to condensation in the presence of formaldehyde. A light brown product having a melting range of 83° to 94° C. was obtained with the following composition expressed in mole percent:
______________________________________2,2'-diethyl-6,6'-dichloromethylene-bis-aniline 56.72,6,2'-triethyl-6'-chloromethylene-bis-aniline 32.62,6,2',6'-tetraethylmethylene-bis-aniline 10.7______________________________________
The product showed no mutagenic effect in the Ames-test.
Condensate no. 5
64.0 mole percent of CEA and 36.0 mole percent of DEA were subjected to condensation in the presence of formaldehyde. A light brown product having a melting range of 78° to 91° C. was obtained with the following composition expressed in mole percent:
______________________________________2,2'-diethyl-6,6'-dichloromethylene-bis-aniline 43.32,6,2'-triethyl-6'-chloromethylene-bis-aniline 42.52,6,2',6'-tetraethylmethylene-bis-aniline 14.2______________________________________
The product showed no mutagenic effect in the Ames-test.
Condensate no. 6
55.3 mole percent of CEA and 44.7 mole percent of DEA were subjected to condensation in the presence of formaldehyde. A light brown product having a melting range of 70° to 73° C. was obtained with the following composition expressed in mole percent:
______________________________________2,2'-diethyl-6,6'-dichloromethylene-bis-aniline 26.62,6,2'-triethyl-6'-chloromethylene-bis-aniline 54.92,6,2',6'-tetraethylmethylene-bis-aniline 18.4______________________________________
The product showed no mutagenic effect in the Ames-test.
Condensate no. 7
39.8 mole percent of CEA and 60.2 mole percent of DEA were subjected to condensation in the presence of formaldehyde. A brown product having a melting range of 73° to 74° C. was obtained with the following composition expressed in mole percent:
______________________________________2,2'-diethyl-6,6'-dichloromethylene-bis-aniline 12.02,6,2'-triethyl-6'-chloromethylene-bis-aniline 59.02,6,2',6'-tetraethylmethylene-bis-aniline 29.0______________________________________
The product showed no mutagenic effect in the Ames-test.
As a standard starting mixture (if not otherwise stated) for the following condensation reactions, a mixture of:
90 parts of 2-ethyl-6-chloroaniline (89.6 mole percent) and
10 parts of 2,6-diethylaniline (10.4 mole percent) was used.
Condensate no. 8
100 parts of the standard starting mixture was mixed with 40 parts of 2-ethyl-6-sec.butyl aniline and condensed with formaldehyde. The final product had the following composition expressed in mole percent:
______________________________________2,2'-diethyl-6,6'-dichloro-methylene-bis-aniline 43.72,6,2'-triethyl-6'-chloro-methylene-bis-aniline 10.62,2'-diethyl-6-sec.butyl-6'-chloro-methylene-bis- 34.2aniline2,6,2',6'-tetraethyl-methylene-bis-aniline 0.62,6,2'-triethyl-6'-sec.butyl-methylene-bis-aniline 4.12,2'-diethyl-6,6'-di-sec.butyl-methylene-bis-aniline 6.7______________________________________
The product showed no mutagenic effect in the Ames-test.
Condensate no. 9
100 parts of the standard starting mixture was mixed with 80 parts of 2-ethyl-6-sec.butyl aniline and condensed with formaldehyde. The resultant mixture had a content of 2-ethyl-6-chloroaniline of 52.3 mole percent. The final product had the following composition expressed in mole percent:
______________________________________2,2'-diethyl-6,6'-dichloro-methylene-bis-aniline 27.62,6,2'-triethyl-6'-chloro-methylene-bis-aniline 6.72,2'-diethyl-6-sec.butyl-6'-chloro-methylene-bis- 43.2aniline2,6,2',6'-tetraethyl-methylene-bis-aniline 0.42,6,2'-triethyl-6'-sec.butyl-methylene-bis-aniline 5.32,2'-diethyl-6,6'-di-sec.butyl-methylene-bis- 16.9aniline______________________________________
The product showed no mutagenic effect in the Ames-test.
Condensate no. 10
100 parts of the standard starting mixture was mixed with 20 parts of 2,6-diisopropyl aniline and condensed with formaldehyde. The end product had the following composition expressed in mole percent:
______________________________________2,2'-diethyl-6,6'-dichloro-methylene-bis-aniline 57.62,6,2'-triethyl-6'-chloro-methylene-bis-aniline 14.02-ethyl-6-chloro-2',6'-diisopropyl-methylene-bis- 22.6aniline2,6,2',6'-tetraethyl-methylene-bis-aniline 0.82,6,2',6'-tetraisopropyl-methylene-bis-aniline 2.22,6-diethyl-2',6'-diisopropyl-methylene-bis- 2.7aniline______________________________________
The product showed no mutagenic effect in the Ames-test.
Condensate no. 11
2-Chloro-6-ethyl aniline was condensed with formaldehyde. The obtained 2,2'-dichloro-6,6'-diethyl-methylene-bis-aniline had a melting point of 112° C. and was negative in the Ames-test.
Determination of the "pot time" in polyurethane elastomer compositions:
1 mole of polytetramethylene glycol (MG 1000) was heated to 80° C. and was evacuated and dehydrated while stirring for 2 hours at a pressure of 12 mm Hg. Subsequently 2.1 mole of molten methylene diphenyl diisocyanate (so-called MDI pure) with a melting point of 40° C. was added at 45° to 50° C. and was brought to reaction under nitrogen while stirring at 80° C. The prepolymer obtained with an NCO content of 6 percent was degassified in a water jet vacuum for 1 hour at 60° C. prior to its use. This prepolymer was mixed with an equal molar quantity of diamine (or condensate) and was stirred evenly with a spatula for 10 seconds at 50° C. The reaction mixture was poured into an aluminum mold preheated to 100° C. (inside mass 120×10×5 mm). The time in seconds (T), until the mixture drew threads on an evenly-dipped-in spatula, was designated herein as " pot time" (the results are given in Table 2).
The test as hardening agent for epoxide resins:
As the epoxide resin, Epon® 828 (manufacturer SHELL Chemical Co.) was used which is obtained from epichlorohydrine and bis-phenyl H and has an epoxide-equivalent weight of 190 (MG approx. 380). The equivalent weights of the amine hardeners were calculated by dividing their molar weights by 4 (corresponding to the 4 active H atoms). Thus, the equivalent of the above-described 2,2'-diethyl-6,6'-dichloro-methylene-bis-aniline (condensate no. 6) amounted to about 80.8 g. The resin (Epon® 828), heated to 80° C., and the molten hardener were mixed, were degassified by centrifuging and were finally poured into a mold, the inside mass of which amounted to 178×12.7×12.7 mm. The resin-hardener-mixtures were heated over a 2-hour period to 100° C.; they were hardened afterwards during a 1-hour period of heating to 175° C. The hardened formed pieces were tested for their heat form stability according to the ASTM-method D 648-56 (the results are given in Table 4).
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2,2'-Dichloro-6,6'-diethylmethylene-bis-aniline or mixtures thereof with compounds of the formula: ##STR1## wherein R 1 , R 2 , R 3 and R 4 are the same or different and are straight-chained or branched alkyl radicals having 2 to 4 C atoms, or R 1 and/or R 3 are chlorine and the remaining R's have the above-mentioned significance, as chain-extension means or cross-linkage means for polyurethanes or epoxide resins. Process for the production of 2,2'-dichloro-6,6'-diethylmethylene-bis-aniline or such mixtures. 2-ethyl-6-chloroaniline is condensed with itself or an aniline having the formula: ##STR2## wherein R 5 and R 6 are the same or different and are straight-chained or branched having 2 to 4 C atoms, with the proviso that R 5 can also be chlorine, in acidic medium with formaldehyde or compounds which form formaldehyde. The compounds in the mixture can be condensation products of two molecules of such aniline derivatives.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application claims the benefit of the filing date of U.S. Provisional Patent Application Ser. No.60/642,588 filed Jan. 11, 2005.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not applicable.
FIELD OF THE APPLICATION
[0003] The application relates generally to an apparatus for treating a fluid stream flowing inside a pipe or tubing.
BACKGROUND OF THE INVENTION
[0004] It is understood in oil and gas production that heating a downhole fluid stream can (a) lower fluid stream viscosity, (b) reduce tubing friction losses, (c) reduce wellhead pressure requirements, (d) reduce or otherwise eliminate the formation of emulsions, and (e) improve pump efficiency, which in turn, can reduce the energy required to deliver a fluid stream to the surface from downhole and can also reduce the load placed on lift system components. It is also known that maintaining the temperature of a fluid stream above the cloud point (the point at which paraffin, hydrates, bitumen, ashphaltines and other complex hydrocarbons precipitate out of the fluid) can eliminate the build-up of restrictive deposits inside a production tubing string that can restrict fluid flow and lower the production rate of a well.
[0005] Current techniques used to heat and improve the flowability of fluid streams include resistance heating cables, solid resistance heating elements, induction heaters, and steam or hot oil injection. These techniques often have poor heat transfer characteristics and can lead to significant amounts of energy being lost to the surrounding environment and to non-productive parts of the well.
[0006] For instance, with resistance heating cables, which are strapped to the production tubing string to provide heat to the fluid stream inside the tubing during production, a central problem is created because a significant part of the cable is exposed to the surrounding well bore environment. This results in a significant amount of heat energy being lost to the surrounding environment, where it is of little value. Another problem with resistance heating cable systems is that it is extremely difficult to make certain that the heating cable maintains an unbroken contact with the production tubing since gaps where there is no contact will appear at locations where the cable does not lie flat on the tubing. These air gaps significantly lower the efficiency of heat transfer between the cable and the tubing string. Yet another problem with common resistance heating cable systems is that a significant portion of the heat energy, which is delivered to the production tubing, is used to heat the tubing and not the fluid inside. Finally, since none of the heat provided by resistance cable systems is to the fluid below the pump intake, fluid viscosity through the pump is unchanged and there is no benefit to pump performance or efficiency.
[0007] Solid resistance heating elements have also been used at the bottom of a production tubing string in order to heat fluid that passes over and around the heating element. The main problem with this configuration is that they have poor heat transfer characteristics due to a lack of fluid flow through the center resulting in internal and surface element temperatures that are significantly higher. The main result is poor efficiency in the heat transfer process. In order to compensate for this poor efficiency, these types of tools must operate with significantly higher surface temperatures, which can lead to coke formation on the heated surfaces. This build-up of coke further limits heat transfer and exacerbates the problem. Finally these heating elements are exposed to the well annulus with no insulating shroud. This means that a significant portion of the heat energy that they provide is lost to the surrounding environment with limited results.
[0008] Existing products also found in the marketplace include induction heaters, which warm the production casing or tubing using induced current in order to warm the production fluid stream inside the well bore. The main problem with induction heaters is that the clearance between the powered induction coil and the casing or tubing must be very small in order to maintain minimum levels of energy efficiency. Since the induction coil in most designs is located in the path of the production fluid stream, they often add significantly to pressure losses in the fluid stream defeating their purpose. In addition, placing an electrical current inside any component of a producing well such as the tubing or casing will significantly increase the corrosion rate and may cause premature failure.
[0009] Additional products found in the marketplace include steam or hot fluid oil injection products and methods where heated fluid or steam is injected into the well from the surface in order to remove wax and paraffin build-up or to increase the temperature of the fluid contained in the well bore or reservoir. The main problem with steam or hot oil injection products is that significant levels of heat energy are lost in these processes to non-productive parts of the well such as the casing, annulus and portions of the earth in contact with the casing that are not a part of the reservoir. In addition, the surface infrastructure required for permanent steam injection takes considerable space on the surface making this application undesirable in most offshore applications and populated areas.
[0010] An apparatus is needed that can increase the temperature and better regulate and improve the flowability a fluid stream.
SUMMARY OF THE INVENTION
[0011] It is an object of this invention to provide an apparatus and methods of use that regulate and preferably provide regulated increases in the temperature of a hydrocarbon stream produced from an oil and gas well or to preferably increase the temperature of fluid streams introduced into a well for instance light oil, diluents, or any other liquid including water. It is an object of the invention to enhance the efficiency of fluid stream delivery to the surface by conventional lift methods or in a free flowing well, lower operating costs and/or higher producing rates. The invention also preferably features surface controls that assist with regulating, sensing and measuring fluid stream temperature, pressure, rate and other parameters of the lifting system. It is an object of this invention to provide an apparatus and methods of use that regulate temperature to a hydrocarbon fluid stream produced from an oil or gas well or to regulate temperature of fluid streams introduced into a well, for instance in injection operations. It is an object of this invention to enhance efficiency of stream delivery to the surface by conventional lift methods or in a free flowing well, at lower operating costs and at higher producing rates. It is an object of the invention to provide these and other benefits by and through methods and use of an apparatus preferably featuring uniquely adapted heating chamber(s), mixing chamber(s) and preferable shrouds as further shown and described in the specification and figures of this application. The apparatus may be located at a plurality of locations along a wellbore and is preferably used to regulate temperatures of fluids flowing from a reservoir to the surface, or alternatively from the surface to the reservoir. The invention also preferably features surface controls that assist with regulating, sensing and measuring fluid temperatures.
[0012] Another preferable object is to produce an apparatus that can cost effectively provide regulated temperature increases downhole to a fluid stream injected into a well (injection or production) from the surface in order to clean up the near well bore completion zone and/or remove or decrease skin damage in order to restore or increase well productivity. Another preferable object of this invention is to produce an apparatus that can cost effectively provide regulated temperature increases downhole to a fluid stream injected into an injection well located in a hydrocarbon producing field from the surface in order to improve hydrocarbon delivery from the reservoir to one or more producing wells.
[0013] Another preferable object of this invention is to provide apparatus that may be permanently installed in a producing hydrocarbon well that can cost effectively provide regulated temperature increases to a fluid stream downhole, whether said fluid stream is injected from the surface into a producing well, or alternatively produced from a well. It is well understood that injecting hot water, oil or steam from the surface using an injection well into a hydrocarbon reservoir can lower the viscosity of deposits in the reservoir and improve delivery to nearby producing wells. Since significant temperature losses occur in this fluid stream from any surface heating facility to the reservoir, it is clear that providing heat to the fluid stream downhole near the target producing zone in the reservoir will result in energy savings.
[0014] Another preferable object of this invention is to reduce or eliminate the deposits of waxes, paraffins and other hydrocarbon compounds which often form in the near well bore producing zone due to changes in fluid pressure and temperature as hydrocarbons are produced.
[0015] A further preferable object of this invention is to eliminate the need to periodically inject hot fluids into the near well bore area to eliminate the deposits of waxes, paraffins and other hydrocarbon compounds which often form in the near well bore producing zone due to changes in fluid pressure and temperature as hydrocarbons are produced.
[0016] Another preferable object of this invention is to reduce or eliminate the need for existing devices to heat the fluid on the surface, and thus lose efficiency due to heat losses during delivery from the surface to downhole or require removal of the lift system in order to be installed.
[0017] A further preferable object of this invention is to provide a permanently installed downhole apparatus which can heat fluid flowing in either direction, and which would have a significant advantage over existing processes since it would eliminate the need for workover and provide benefits during both (producing and injecting) phases of operation.
[0018] Another preferable object of this invention is to produce an apparatus that accurately and cost effectively regulates increases in the temperature of a hydrocarbon production fluid stream in order to reach and maintain a selected fluid stream viscosity in order to reduce viscous friction losses inside the downhole and surface production tubing and optimize the operating efficiency of the artificial lift system.
[0019] Another preferable object of this invention is to produce an apparatus that accurately and cost effectively regulates increases in the temperature of a hydrocarbon production fluid stream and keeps the temperature of the hydrocarbon production above the temperature at which paraffin and hydrates in the production will precipitate out of the liquid and form on surfaces, restricting flow and increasing pump head requirements.
[0020] Another preferable object of this invention is to produce an apparatus that accurately and cost effectively regulates increases in the temperature of a hydrocarbon production fluid stream to keep paraffin and hydrates in solution during its transport to the stock tank on the surface.
[0021] Another preferable object of this invention is to produce a device that accurately and cost effectively regulates increases in the temperature of a hydrocarbon production fluid stream to destabilize emulsions that may be formed as a result of mixing by a pump or other artificial lift system.
[0022] Another preferable object of this invention is to produce a device that allows the total power required to transport heavy oil from the reservoir to the surface and from the well head to the stock tank to be held at a minimum.
[0023] Another preferable object of this invention is to produce a device that allows increased production rates from existing wells by substituting heat energy for mechanical pumping energy, and to produce a device that allows increased production rates from existing wells by substituting heat energy for lift pressure in free-flowing or gas lifted wells.
[0024] Another preferable object of this invention is to produce a device that keeps an accurate record of the downhole and surface pressures, temperatures and other parameters and the electrical energy used by the heating system during the production of the hydrocarbons from a well.
[0025] Another preferable object of this invention is to produce a device that can remain permanently installed in the well and that does not need to be removed during the production process
[0026] Another preferable object of this invention is to produce a device that communicates between sensors located both at the surface and downhole to keep the temperature of the hydrocarbon production within a specified range.
[0027] Another preferable object of this invention is to produce a device that is robust, cost effective and has a long service life after being installed in a wellbore.
[0028] Another preferable object of this invention is to produce a device that can be economically installed on a single or on a few wells, versus surface located steam injection facilities that are capital intensive and thus whose use is restricted to larger fields.
[0029] Another preferable object of this invention is to produce a device that can be used as a novel form of artificial lift, where heat energy is used instead of mechanical energy such as from a pump or instead of a gas lift system. These and other objects of the invention will be appreciated by those skilled in the arts.
BRIEF DESCRIPTION OF THE DRAWINGS
[0030] FIG. 1A illustrates a perspective view of a solid heating member, which is an optional component of the apparatus.
[0031] FIG. 1B is one depiction of treatment apparatus components, including a heating member and a mixing chamber.
[0032] FIG. 1C illustrates a perspective view of the apparatus including a heating chamber, heating member, mixing chamber and a shroud enveloping the apparatus.
[0033] FIG. 1D illustrates a perspective view of the apparatus including a plurality of heating members, and a mixing chamber formed from and enveloped by a shroud.
[0034] FIG. 1E depicts one embodiment for an enclosure of either a heating or a mixing chamber featuring preferable obstructions or fins that may be used in embodiments of the treatment apparatus to manipulate fluid streams or to enhance heat transfer and/or mixing of the fluid stream.
[0035] FIG. 2A illustrates a perspective view of a preferable enclosure of a heating or mixing chamber including obstructions projecting from an inner surface of a chamber wall.
[0036] FIG. 2B illustrates a perspective view of the apparatus in a casing including a cross-section of a shroud enveloping the apparatus, and further illustrates a preferable embodiment with mixing and heating chambers arranged in a series. Heating members are depicted in parallel form.
[0037] FIG. 3 illustrates a production system and side view of a treatment apparatus for oil and gas production located at a midpoint along the tubing string.
[0038] FIG. 4 illustrates a production system and a side view of a treatment apparatus for oil and gas production located at a lower point of the tubing string.
[0039] FIG. 5 illustrates a production system and a side view of a fluid injection system for oil and gas production including the apparatus at a lowermost point along of the tubing string.
[0040] It is to be noted, however, that the appended drawings illustrate only typical embodiments of this invention and are therefore not to be considered limiting of its scope, for the invention may admit to other equally effective embodiments.
DETAILED DESCRIPTION OF THE INVENTION
[0041] The present application relates to an apparatus suitable for treating fluid streams by:
(a) transferring temperature increases to fluid streams, whether the fluid stream is produced downhole, or is injected from the surface; (b) regulating, and increasing temperature of the downhole fluid stream; (c) being installed downhole in a wellbore whether permanently or temporarily; (d) transferring temperature increases to fluid flowing in any direction; and (e) reaching and maintaining a selected fluid stream viscosity.
[0047] The present application also relates to a system suitable for:
(a) recording downhole pressures and temperatures; (b) recording surface pressures and temperatures; (c) recording and monitoring power usage of the apparatus during treatment of a fluid stream; and (d) communicating surface and downhole fluid stream temperature and pressure and other parameters to the surface in order to monitor the effectiveness of the heating regime.
[0052] In oil and gas production, the apparatus is particularly advantageous for treating fluid streams to:
(a) lower fluid viscosity by heating fluid streams; (b) maintain complex hydrocarbon compounds in solution; (c) eliminate the necessity of removing lift systems to install known surface heating devices; (d) maintain the fluid stream temperature above the temperature at which paraffin and hydrates precipitate out of the fluid stream; (e) maintain the paraffin and hydrates in the fluid stream solution during transport of the fluid stream to a stock tank located on the surface; (f) maintain the fluid stream temperature to destabilize emulsions that can be formed as a result of mixing by a pump or other artificial lift system; and (g) increase production rates from existing wells by substituting heat energy for mechanical pumping energy.
[0060] Other advantages of the apparatus include but are not necessarily limited to the ability to treat fluid streams in oil and gas production brought to the surface by conventional lift methods or fluid streams in free flowing wells; the ability to eliminate the necessity of periodic injections of hot fluids into near well bore areas to remove deposits of waxes, paraffins and other hydrocarbon compounds that can form in near well bore producing zones resulting from changes in fluid pressure and temperature during hydrocarbon production; the ability to minimize the power requirements for producing heavy oil from a reservoir to the surface and from a well head to a stock tank; and the ability to eliminate the necessity of surface located steam injection facilities that are capital intensive and whose use is restricted to large production fields.
[0061] In a first embodiment, the treatment apparatus comprises (1) a heating member for transferring temperature increases to at least one fluid stream, and (2) a mixing chamber in fluid communication with the heating member to mix the heated fluid. In addition, the amount of heat being transferred to the fluid stream from the apparatus can be programmed, monitored and adjusted. The apparatus according to the present application will be described in more detail with reference to the embodiments illustrated in the drawings. The drawings are illustrative only, and are not to be construed as limiting the invention, which is defined in the claims.
[0062] In a simple embodiment of the invention, a heating chamber 11 will contain a single heating member 12 contained within a shroud 32 that forms the heating chamber 11 wall. The heating member 12 will be fixed to the shroud 32 by fastening means 45 , which might include but are not limited to welds, pre-fabricated metal shapes, spokes, or other connectors able to withstand downhole conditions. A shroud 32 makes certain that fluid in the fluid stream passes near to a heating member 12 in order to facilitate heat transfer to the fluid stream and also isolates and insulates the fluid stream from the well bore environment. Ideal forms for heating elements include but are not limited to a thin plate or plates, a solid member or rod ( FIG. 1A ), a simple hollow tube ( FIG. 1B ), or a complex hollow tube ( FIG. 1D ) since these shapes expose a higher percentage of their surface to the fluid stream and improve heat transfer. A preferable benefit is to maximize heated surface exposed to the fluid stream while maintaining a low-pressure drop. Pressure drop is a direct function of the surface area perpendicular to the direction of fluid flow. FIG. 1B demonstrates preferable components of a first embodiment of the apparatus 10 , namely a heating member 12 , and at least one mixing chamber 14 , which as seen if FIG. 1C is in fluid communication with heating chamber 11 . A single heating member(s) 12 preferably comprises a solid heating device, passageway or tube that a fluid stream passes through or over and where one of more of the walls of the heating member(s) 12 are heated in order to provide a heat transfer surface. In its simplest form of design, a heating member 12 preferably comprises an electrically heated member 12 , solid element or hollow structure contained inside the production tubing as shown where fluid passes through and/or around the heating member 12 . A solid heating member 12 is depicted in FIG. 1A where the fluid passes only around an outside diameter of the heating element. In a hollow embodiment of heating member 12 ( FIG. 1B ), there is approximately twice the surface area per foot of length (inner and outer surfaces) exposed to the fluid stream as a respectively sized solid element (outer surface only), therefore, this is a preferable embodiment given that more heat energy will be transferred to the fluid stream than with a solid heating element. With the hollow embodiment, the internal temperature of the heating member walls will be lower under the same operating conditions. Stated another way, this means that in terms of heat transfer capability the hollow heating member 12 embodied in this design is more energy efficient method for fluid stream heating than a solid element. Therefore, a main benefit of a hollow version of heating member 12 is that the fluid stream passes through and around an enclosed area where the sides are comprised of one or more directly (resistance) or indirectly (induction) heated surfaces, which are exposed to the fluid stream on all sides. When fluid passes over any heated surface, the temperature of the portion of the fluid stream immediately adjacent to the heated surface is highest and temperatures further away from the heated surface are lower. Effectively, a fluid stream separates into layers where the fluid closest to the heated surface is warmer and flowing faster than fluids further away from the heated surface. This means that in order to optimize heat transfer rates close attention must be paid to the maximum distance that any portion of the fluid stream may take around the heated surface. If the distance is too large, the result is inefficient and results in uneven temperature regulation. With a heating member 12 , it is possible to precisely control this distance, particularly when one preferable mode is used employing multiple heating members 12 in parallel, as depicted in FIG. 1D .
[0063] In oil and gas production, as fluid passes near or contacts a heated surface, the temperature of that portion of a fluid stream immediately adjacent the heated surface is increased to about the temperature of the heated surface, while the temperature of that portion of the fluid stream further from the heated surface is increased to a lesser degree. Once heated, the fluid stream separates into layers wherein the fluid layer(s) closest to the heated surface comprise a higher temperature and lower viscosity than fluid layer(s) further away from the heated surface. The presence of multiple fluid layer(s) can lead to viscous friction losses inside the downhole and surface tubing string and reduce the operating efficiency of any artificial lift system used during production. The present apparatus 10 overcomes the above concerns by (1) transferring temperature increases to a fluid stream 5 , and (2) mixing the heated fluid stream 5 prior to dispensing the fluid stream 5 from apparatus 10 . In other words, the two or more heated fluid layers can be mixed together within apparatus 10 to equalize the temperature, viscosity, and pressure of fluid stream 5 , and otherwise remove the layers from the fluid stream 5 .
[0064] Following completion of a wellbore, apparatus 10 is transported to a downhole location by attaching apparatus 10 to tubing string 34 as tubing string 34 is being placed into the wellbore. A shroud 32 , which is preferably a continuous tube forming heating chambers 11 and mixing chambers 14 , is connected directly to the tubing string 34 . The apparatus 10 is preferably threaded just like production tubing, but it may also be attached to the tubing string 34 by other means, including but not limited to bolts, welds, or shrink fit.
[0065] A heating member 12 may have an infinite number of shapes varying from the round tube in FIG. 1B to a tube with irregular or polygon surfaces (See FIG. 1E ), and with or without obstructions 30 as depicted in FIG. 2A . Individual heating members 12 may be assembled in a treatment apparatus 10 in series (See FIG. 2B ) or in parallel. In a parallel assembly, the fluid stream must pass through or around at least one of the individual heating members 12 .
[0066] Each of heating members 12 , heating chambers 11 mixing chamber 14 , and shroud 32 can be constructed of any material durable enough to withstand various treatment conditions including but not necessarily limited to chemical environments of varying pH and corrosivity, varying temperatures, varying pressures, and other loads placed upon apparatus 10 . Suitable materials for the heating chambers 11 , mixing chambers 14 , heating members 12 and shroud 32 formed therefrom include but are not limited to steel, aluminum, plastics, steel and other metal alloys, ceramics, rubber, pvc, and combinations thereof. A particularly advantageous and preferable design for heating and mixing chamber and shroud is alloy steel configured to withstand pressures up to 25 MPa or 25,000,000 Pascals and temperatures up to 350 degrees Celsius. Each of heating member(s) 12 , heating chambers 11 and mixing chamber 14 can also be constructed of materials including but not necessarily limited to those materials resistant to chipping, cracking, excessive bending and reshaping as a result of weathering, heat, moisture, other outside mechanical and chemical influences or that are commonly known in the downhole tooling industry.
[0067] Heating chamber 12 can include a solid construction, or in the alternative, heating chamber 12 can be defined by at least one opening therethrough and include at least one outer surface and at least one inner surface thereby increasing the surface area for transferring temperature increases to a fluid stream 5 . Herein, the term “transferring temperature increases” refers to apparatus 10 increasing the temperature of (e.g. transferring heat to) at least one fluid stream 5 from a first temperature prior to treatment of fluid stream 5 by apparatus 10 to a second temperature reached either during or immediately following treatment of fluid stream 5 by apparatus 10 . Herein, the term “fluid” refers to any liquid or gas flowable through and around (1) conventional tubing and (2) the apparatus including at least one heating chamber. Likewise, the fluid can comprise any pressurized conditions and viscosity characteristics suitable to maintain flowability through the tubing and apparatus 10 . The present apparatus 10 is therefore configured to treat fluids including but not necessarily limited to hydrocarbon based liquids and gases, and water based liquid and gases.
[0068] Typical downhole temperatures in oil wells will range from 50° to 95° Celsius. Typically, apparatus 10 can preferably increase the temperature of any given fluid stream 5 up to about 180° C. Of course, the increase in temperature to any given fluid stream 5 depends not only on the amount of heat being transferred to fluid stream 5 from apparatus 10 , but also on the starting temperature of the fluid stream 5 prior to treatment with apparatus 10 .
[0069] The length of the treating apparatus 10 is a function of the flow rate desired temperature change that is expected from the well. Ultimately, the diameter or width of apparatus 10 is determined by the diameter of the hole and/or casing where apparatus 10 is to be positioned during operation. Although apparatus 10 is not limited to any particular size and shape, the length of a one preferable heating chamber 11 on preferable embodiment is approximately 3 feet, with an approximate length of a mixing chamber 14 of 1.5 feet. Although a variety of sizes of treating apparatus 10 are preferable, one preferable range of apparatus 10 lengths (including heating and mixing chambers) is in the range of 30 feet to 120 feet.
[0070] As shown in FIG. 1B , heating member 12 preferably comprises an opening including a first end 16 configured to receive a fluid stream 5 and a second end 18 configured to dispense fluid stream 5 . Second end 18 is configured to be in fluid communication with mixing chamber 14 . As shown in FIG. 1C , heating member 12 is preferably enclosed by shroud 32 , which shroud 32 forms a wall of heating chamber 11 . The portion of shroud 32 forming the wall of heating chamber 11 is alternately referred to as enclosure 20 herein. Enclosure 20 is also configured preferably to envelop the heating member(s) 12 of treatment apparatus 10 .
[0071] Heating chamber 11 comprises one or more heating members 12 aligned in series or in parallel, or both. In addition, heating chambers 11 can include a plurality of configurations. Where heating chamber 12 comprises a tubular configuration, the wall of heating chamber 12 can comprise a plurality of shapes including but not necessarily limited to round, oval or multi-sided shapes including but not necessarily limited to rectangular, polygonal, and irregular shapes. Heating chamber 12 can also include obstructions 30 in similar fashion as mixing chamber 14 projecting from the inner surface of the heating chamber 12 wall, as shown in FIGS. 1E and 2A .
[0072] Even though heating members 11 and mixing chambers 14 can be arranged in any combination and aligned in series or in parallel, it is advantageous for apparatus 10 to be configured so that at least one heating member 12 transfers heat to fluid stream 5 prior to the fluid stream 5 entering a final mixing chamber 14 . For example, a fluid stream 5 may flow from a mixing chamber 14 to a heating member 11 then to another mixing chamber 14 ; a fluid stream 5 may flow through a series of heating members 11 to a series of mixing chambers 14 ; or a fluid stream 5 may cycle through multiple heating member/mixing chamber combinations, so long as long as fluid stream 5 flows lastly from a mixing chamber 14 prior to delivery of fluid stream 5 .
[0073] As depicted in FIG. 1B -D, a principal component of treatment apparatus 10 is a mixing chamber 14 . A mixing chamber 14 is a second section of the treatment apparatus 10 , which is in fluid communication with the heating member 12 and heating chamber 11 . The mixing chamber(s) 14 receive fluid streams flowing over and through one or more heating chambers 11 and heating members 12 to provide a space where the fluid is preferably equalized in terms of temperature and pressure. In terms of structure, this mixing chamber 14 is preferably an unheated passageway that may or may not contain vanes, obstructions 30 or fins ( FIG. 2A ) to rotate and mix the fluid (a heated mixing chamber might also be used). In its simplest form of design, a mixing chamber 14 consists of a hollow tube or chamber that receives fluid flow from one or more heating members 12 in a heating chamber 11 . The mixing chamber 14 should have sufficient length to “mix” these multiple streams in order to equalize the temperature and pressure. The result is that multiple fluid streams from individual fluid paths originating within the heating members 12 and heating chambers 11 are converted into a single fluid steam with a single temperature and pressure. This “mixing” is beneficial to the overall efficiency and operation of a heating element since it eliminates differences in temperature and pressure between individual fluid streams that have passed through differing paths in the heating chamber 11 due to differences in cross sectional and heated surface area. “Mixing” is also beneficial since it reduces the impact if any fluid path inside a heating chamber 11 becomes plugged with foreign material during operation. This makes it possible to design heating chambers 11 with small or complex fluid paths that may be more susceptible to plugging than if there were no mixing chamber 14 included in the design.
[0074] Mixing chamber(s) 14 receive fluid streams from heating chamber(s), however, they may be assembled in variable combinations. For example, a mixing chamber 14 may either deliver the fluid stream to another heating chamber 11 where multiple heating members 12 are assembled in series ( FIG. 2B ) or directly to the production tubing for delivery to the surface. Further, mixing chambers 14 may include fins, or obstructions 30 attached to the inner surface to promote mixing of the fluid and equalization of temperature and pressure (See FIGS. 2A or 1 E). Mixing chambers 14 may also vary from a regular cylindrical shape and incorporate a more complex surface such as a Venturi design to achieve desirable fluid stream pressure objectives.
[0075] Mixing chamber 14 is enveloped by a shroud 32 , which shroud 32 portion over mixing chamber 14 also defines and is referred to herein as enclosure 22 . Mixing chamber 14 includes an enclosure 22 defined by an inlet 24 for receiving fluid stream 5 from heating chamber 11 , and has outlet 26 for dispensing fluid stream 5 from mixing chamber 14 . Enclosure 22 forms a reservoir between inlet 24 and outlet 26 configured to substantially equalize the viscosity, temperature and pressure of fluid stream 5 . In addition, enclosure 22 includes at least one outer surface exposed to the ambient environment, and at least one inner surface exposed to the reservoir of mixing chamber 14 . Suitably, the enclosures of heating chamber 11 and mixing chamber 14 are configured to sealably attach or be formed together for optimum fluid transfer. As depicted in FIG. 2B , a treatment apparatus 10 may preferably comprise one or more heating chambers 11 connected to one or more mixing chambers 14 , preferably enclosed by a shroud 32 so that a fluid stream 5 passes through at least one heating member 11 and one mixing chamber 14 .
[0076] Enclosure 22 can also comprise a plurality of shapes including but not necessarily limited to round, oval or multi-sided shapes. The reservoir of mixing chamber 14 can further include one or more inner walls 28 forming flow channels therebetween and/or include one or more obstructions 30 to mix the fluid received from heating chamber 11 . Suitable obstructions 30 include but are not necessarily limited to protrusions that project out from the inner surface of mixing chamber 14 , such as are preferably depicted in FIGS. 1E and 2A .
[0077] FIG. 2B depicts an important preferable feature of the treatment unit 10 , namely, a shroud 32 . The shroud 32 is another preferable feature of the treatment apparatus and is a covering that surrounds the heating 11 and mixing 14 chambers in order to provide structural integrity and to assure that a fluid stream passes through and around the heating member(s) 12 . The shroud 32 also provides beneficial insulation between the heated fluid stream 5 and the ambient environment, limiting heat loss and improving operating efficiency. A shroud 32 preferably comprises a tube assembled over the outside combination of heating 11 and mixing 14 chambers in order to contain fluid flow, to provide structural integrity, and to reduce heat loss to the environment. Since a heating member 12 preferably allows fluid to flow over both its internal and external surfaces, some type of shroud 32 is preferable to contain and direct the fluid flow. The shroud 32 in this design contains the assembly consisting of one or more heating 11 and mixing 14 chambers and provides structural integrity to the completed assembly ( FIG. 2B ). Finally, the shroud 32 provides temperature insulation between the heated fluid stream and the environment where it is installed.
[0078] In the simplest preferable configuration, a shroud 32 may consist of any thin wall material where the primary function is to direct fluid flow through the heating 11 and mixing 14 chambers without regard to structural or insulating properties. In another preferable configuration, a shroud 32 may be constructed of heavy wall tubing in order to provide structural support to the assembly of heating 11 and mixing 14 chambers and to equipment that may be installed below this assembly. The material used in the shroud 32 may be selected to maximize heat insulation between the production fluid stream and the environment where it is used.
[0079] Apparatus 10 can further comprise a shroud 32 configured to envelop at least part of apparatus 10 . Suitably, shroud 32 is configured to (a) seal and direct fluid flow within apparatus 10 , (b) provide structural integrity to apparatus 10 , and (c) reduce heat lost to the ambient environment. As shown in FIG. 3 , shroud 32 is preferably configured to envelop up to 100% of the length of treatment apparatus 10 . In a particularly advantageous embodiment, shroud 32 envelops at least heating member 12 . Furthermore, shroud 32 can be comprised of any material including but not necessarily limited to thin wall materials and heavy wall materials. Thin wall materials can be defined as those materials configured to direct fluid flow through apparatus 10 without regard to structural or insulating properties of shroud 32 . Heavy wall materials can be defined as those materials that provide structural support to apparatus 10 and/or equipment that can be installed below apparatus 10 downhole. Shroud 32 can further be coated with material(s) to assist with heat insulation.
[0080] As depicted in FIG. 3 , the treatment apparatus 10 preferably features a surface controller 40 . The surface controller 40 regulates voltage supplied to the downhole treatment apparatus 10 in response to signals received from the treatment apparatus 10 sensors 38 , and using electronic components including but not limited to thyristors or Silicon Controlled Rectifiers (SCRs). This regulation is controlled by a microprocessor, which is a major component of the surface controller 40 . The surface controller 40 preferably stores information about well conditions (temperatures, pressures, etc.) for future access and so that engineers may monitor and analyze conditions. Switchboards are commonly used in many applications to control the power delivered to a motor or other electrical device. This system of sensors 38 and regulators preferably maintains temperatures of fluid streams 5 within plus or minus a degree Celsius of a target temperature, although this preferable level of sensitivity is not meant to be limiting of the invention, which may also regulate at lesser sensitivities. These devices ordinarily include some form of on/off switch and some form of overload protection such as fuses. A surface controller 40 is a specialized form of switchboard that preferably provides three additional components not normally found in a switchboard—an electronic device that can modify the voltage of multi-phase power, a device to receive and interpret data received from the downhole sensor 38 , and a microprocessor with software to control the operation of the voltage modifying device in order to achieve the desired results. For this application, the primary objective is to accurately and continuously adjust the voltage delivered to the treatment apparatus 10 in response to signals received from a sensor 38 using electronic voltage regulation components as directed by the program in the microprocessor or as manually directed. There are a number of different known alternatives to continuously electronically regulate voltage including Thyristors, SCRs and other devices. Any of these devices may be suitable for use in a surface controller 40 . Similarly, there are a large number of known alternative microprocessor designs and associated control software to control the operation of a Thyristor or SCR. Any of these devices may be suitable for use in a surface controller 40 .
[0081] As depicted in FIG. 3-5 , this treatment apparatus 10 is preferably positioned at a point along the production tubing string 34 installed in the well, either at the lowest point in the tubing string ( FIG. 4 ) or at some intermediate point ( FIG. 3 ). As shown in FIGS. 3-5 , power is supplied to the treatment apparatus 10 using known power cable 36 suitable for the applications. This power cable 36 is normally attached to the production tubing string 34 using steel bands.
[0082] As shown in FIG. 6 , power is supplied to apparatus 10 from a power source 42 via power cable 36 . In a particularly advantageous embodiment, at least one surface controller 40 is positioned at a point between the power source 42 and the well head 44 , whereby power and other communication can be transferred from power source 42 to surface controller 40 and from surface controller 40 to well head 44 and ultimately to apparatus 10 via power cables 36 . Under normal operating conditions, power cable 36 is attached to tubing string 34 using steel bands, although other means of connection are contemplated. The preferable steel bands that attach the cable to the production tubing are commonly used to attach electric submersible pump power cable. If necessary, a step-up transformer can also be installed between surface controller 40 and well head 44 to increase and level out the voltage applied to apparatus 10 .
[0083] One or more downhole sensors 38 (temperature or pressure/temperature) are preferably installed near the outlet of the treatment apparatus 10 in order to measure the temperature of the fluid stream so that power supplied to the treatment apparatus 10 can be adjusted to achieve desired optimum results. Readings from the sensors 38 are delivered to the surface controller 40 either through the power cable 36 or by other means such as fiber optic lines, or wireless signals, including but not limited to microwave, cellular or radio signals. For production applications, sensors are preferably fixedly connected to apparatus 10 near an outlet toward apparatus top; while for injection applications, sensors are preferably fixedly connected to apparatus 10 at a lower position on apparatus 10 . It is possible to operate the apparatus using a sensor mounted nearly anywhere in the tubing string, but it is preferable to locate the sensors on or near the apparatus 10 .
[0084] As shown in FIG. 4 , one or more downhole temperature and/or temperature/pressure sensors 38 can be installed downstream of heating member 11 . Suitably, sensors 38 measure the temperature and/or pressure of fluid stream 5 so that the power supplied to apparatus 10 can be adjusted, if necessary, to achieve desired fluid stream 5 characteristics. In addition, more than one sensor 38 can be positioned at various points along the tubing string 34 , from the bottom of the well to the stock tank, for either or both of production and injection processes. In some cases, such as when the treatment apparatus 10 is used both for production and for injection or when surface temperature and pressure are important, there multiple sensors 38 located at additional points along the fluid path from the bottom of the well to a stock tank are advantageous.
[0085] The surface controller 40 is preferably located between a power source 42 and the wellhead 44 and is connected using suitable known electric cable both from the power source and to the wellhead and downhole power cable 36 . In most applications, a step-up transformer will also preferably be installed between the surface controller 40 and the wellhead 44 to increase the voltage at a constant ratio.
[0086] As shown in FIG. 4 , alternative variations or methods of using the treatment apparatus 10 are contemplated. In this particular embodiment, the treatment apparatus 10 may be used in a production application such as with a free flowing, pumped, or gas lift well where the primary objective is to reduce fluid stream pressure losses, eliminate paraffin or hydrate deposits, or improve pump operating efficiency by lowering the fluid viscosity. In these applications, the treatment apparatus 10 may be located at the bottom of the tubing string 34 below the pump intake if one is used. The element may also be located elsewhere along the tubing string 34 such as near an operating gas lift valve ( FIG. 3 ) or at the sea bed in an offshore installation in order to provide desired levels of heat to the fluid stream 5 at the most beneficial location. This downhole heating system may also be used as a form of artificial lift in applications where the fluid stream 5 contains sufficient levels of gas in solution and where this gas can be released of brought out of solution by heating to lower the specific gravity of the fluid stream and cause fluid to flow to the surface. In these applications, the downhole element may be located at multiple points where heating will provide the most effective level change in fluid specific gravity. Yet another preferable method of using the apparatus is in offshore applications, particularly in offshore applications, where the water temperature is typically very cold (or near freezing). In these instances, the device can be used (1) to heat fluid in sub sea flow lines to maintain low viscosity and decrease the pressure required to move fluid; and/or (2) installed in the production tubing string as described herein at the sea bed to offset temperature losses to the fluid stream caused by exposure to cold sea water surrounding the riser pipe.
[0087] In yet another embodiment, as depicted in FIG. 5 this treatment apparatus 10 may be used as a downhole heating system and may also be used in an injection application where the primary objective is to improve fluid delivery from the reservoir to the well bore by eliminating near well bore damage, lowering fluid viscosity in the reservoir or near well bore or other similar applications. In these applications, the downhole element may be located close to the casing perforations in order to minimize heat loss between the heating element and the formation.
[0088] This heating system may also be used to increase the temperature of the fluid stream 5 near the surface in order to reduce required well head pressure to deliver fluid from the well head to the stock tank or pipeline. In these applications, the heating element may be located in the well near the surface or even inside the surface production tubing on the surface.
[0089] This heating system may also be used in order to achieve some combination of the above applications in which case, it may be connected differently.
[0090] Apparatus 10 can be positioned at any point along tubing string 34 , either at the lowest point in the tubing string 34 , as shown in FIG. 4 , or at any intermediate point in the tubing string 34 , as shown in FIG. 3 . In at least a second implementation, more than one apparatus 10 can be positioned at multiple points along production tubing string 34 . During production, formation fluids first flow into the wellbore through perforations where fluid stream 5 is introduced to tubing string 34 or apparatus 10 and flows through and/or around apparatus 10 as the fluid stream 5 flows to the surface via tubing string 34 .
[0091] Persons of ordinary skill in the art will recognize that many modifications may be made to the present application without departing from the spirit and scope of the application. The embodiment(s) described herein are meant to be illustrative only and should not be taken as limiting the invention, which is defined in the claims.
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An apparatus and method for increasing and regulating temperature, pressure and fluid viscosities of fluid streams found in oil and gas production. Applicant's apparatus regulates and increases fluid temperatures, by and through improved heating apparatus, which may be placed at one or more locations along a wellbore surface flow line, or subsea flow line. The apparatus preferably either heats fluids flowing from the reservoir to the surface, or alternatively, can heat fluids injected from the surface into the reservoir.
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BACKGROUND OF THE INVENTION
I. Field of the Invention
The invention relates to a laminated, plate-shaped element with position fastening, comprising at least a first and a second substrate, which are joined together, at least indirectly, by adhesive bonding, and also with at least one support element associated with the first substrate in order to fasten the laminated element to an infrastructure and active position fastening of the second substrate, at least in the event of failure of the bonded joint.
II. Description of Related Art
Laminated, plate-shaped elements, which are composed of at least two substrates and of an adhesive layer joining the elements together by surface bonding or of a spacer frame adhesively bonded to the two substrates, may be fastened in a known manner without a frame to structures, by fastening, to the infrastructure, only the substrate facing the building. Examples of such elements and of their fastenings may be found in Documents EP 277 535 A2 and EP 595 062 A1. The Applicant sells and uses support elements of this type (undercut blind hole and anchoring of a support element in the form of a bolt with undercut dowel) with the name SGG Point XS.
For safety reasons, purely adhesive fastening of the substrate placed on the outside is, however, most of the time supplemented with mechanical means, which form at least one position fastening of the external substrate in the event of failure of the bonded joint. According to Document DE 693 10 389 T2 (corresponding to EP 552 101 B1), a substrate close to the building of a curtain wall element made of insulating glazing is fastened by means of discrete supports mounted on the latter, while the outer substrate, away from the building, is held in place only by the spacer frame and the adhesive bonding. In order to ensure the positioning of the outer substrate, metal clips are provided here that are fastened to the discrete supports and catch, underneath, on the lower edges of the two substrates.
Document EP 319 695 A1 discloses position fastening for curtain wall elements made of insulating glazing, which are entirely bonded to the infrastructure in the form of what is called “structural glazing”. In a variant, the position fastening is formed by pins, which catch in undercut blind holes in the outer substrate, away from the building, of the insulating glazing elements and are retained by the infrastructure in the event of failure of the bonded joint.
Document DE 197 51 124 C1 describes a laminated element with supports that pass through one of the substrates and are fastened by means of a undercut dowel in a undercut blind hole in the second substrate. A similar solution is disclosed in Document DE 100 54 816 A1, in which a pin-type support is fastened by means of a curable filling compound in a blind hole in the second substrate.
BRIEF SUMMARY OF THE INVENTION
It is an object of the invention to provide a laminated, plate-shaped element for the building industry, with simple position fastening.
The secure mechanical fastening of the first substrate suffices in principle as the basis for indirect relative position fastening of the second substrate. Preferably, the relative position fastening of the two substrates is provided by fitting at least one fastening element that passes through the joint plane between the two substrates and engages in the two substrates. The fastening acts in a particularly discrete manner and independently of the supports for the laminated element.
It goes without saying that the number of fastening elements to be installed per laminated element depends on the area of the laminated elements, possibly on the mounting position (vertical, inclined or horizontal) and also on the weight of the substrate to be fastened.
In principle, insulating glazing elements could admittedly also be provided with such position fastening elements. A preferred use of these position fastening elements applies, however, to laminated substrates, comprising two substrates and an adhesive layer joining the latter together by surface bonding. The rest of the description therefore relates to this type, without in any way wishing to exclude other forms thereof.
The laminated elements may be equipped with other functional elements, particularly electrical elements, for example solar cells housed between the substrates, heating layers, antenna elements or alarm elements. It goes without saying that the position fastening or alternatively the corresponding fastening elements must always be installed so as not in any way to impede the aforementioned functional elements.
Although this is not absolutely necessary, but nevertheless highly recommended, the actual support for the laminated elements on an infrastructure catches on only one of the substrates, in particular advantageously only that face of the substrate located on the opposite side from the functional elements. Consequently, there may be freedom of choice in where to place them, taking into account the requirements imposed by the static and dynamic loads and also by the infrastructure. The laminated element face left free in the mounting position therefore remains intact.
Laminated or insulating glazing elements, which are in turn adhesively bonded to an infrastructure (structural glazing), may however also be provided with the position fastening according to the invention.
Similarly, staged elements, in which one (larger) substrate is held in place via its edge at discrete points by clips onto an infrastructure or in a frame, while a second (smaller) substrate is only bonded to the first substrate, may receive a position fastening element of the type described here. Another application possibility relates to elements attached at discrete points to the edge, in which elements the substrate to be fastened has, in the region of the supports, only recesses facing the fastened substrate of the same size.
Finally, it is also possible to provide such position fastening directly between a spacer means adhesively bonded to the two substrates, whatever the shape of a peripheral frame, or only in segments, and one or both substrates, that it joins together. This embodiment may be applied not only to the usual spacer means in the form of solid (metal, plastic, ceramic, glass) sections but also to the spacer means, likewise known per se, produced in situ, for example by extrusion or by injection molding. It is even conceivable for the position fastening to be placed again between the two substrates to be fastened, one relative to the other, by passing through the spacer means. Of course, in the case of an insulating glazing element with an intermediate space between the substrates that are sealed off in a gastight manner, measures must be taken to ensure that the position fastening does not compromise the sealing of the arrangement.
It goes without saying that the use of the position fastening according to the invention does not exclude support elements on the infrastructure also supporting the second substrate in addition to the first substrate.
As materials for the laminated elements, it is possible to consider, beside transparent materials like glass, preferably toughened or partially toughened glass, and plastic, other materials such as metal sheets, stone or marble plates, etc. Of course, any pairs of different materials may also form a laminated element of the type discussed here.
It is not absolutely necessary for the fastening elements to be firmly joined to the two substrates (or possibly with the spacing means and the substrate or substrates), even though their simple separation from the laminate must be prevented. In the case of position fastening, a certain initial movement is quite admissible. The fastening elements have only to reliably prevent the propagation of this movement beyond the extent still acceptable. The bond joint will not yield suddenly, but via a creep process, thus retaining a certain residual adhesion. The minimum requirement imposed on the fastening elements is therefore not guaranteeing any more the adhesion of the two substrates perpendicular to their surface extension. However, they may also fulfill this condition with forming and/or appropriate fastening to or in the substrates.
According to a first embodiment, a fastening element is introduced into a drillhole passing through the two substrates, and preferably in such a way that it terminates flush with the outer faces of the two substrates. Modern manufacturing conditions make it possible, even in substrates that are drilled before the manufacture of the laminated element (laminated substrate) and are then thermally toughened in order to increase their mechanical strength, to produce isolated drillholes with sufficient positional precision in such a way that they are aligned along any one axis with small deviations in the laminate of the two substrates. Consequently, it is possible to mount pin-shaped fastening elements of the type considered here a posteriori at little expense in the finished laminated element.
It goes without saying that the adhesive layer between the two substrates must also have a recess for passage of the fastening element. This recess should possibly have already been made before assembly, or subsequently, by appropriate means, when the fastening element has been positioned only after assembly of the substrates.
If for example a thermoplastic adhesive sheet is used, a fastening element may then be heated above the melting point of the adhesive sheet before it is installed and then pushed right in through the adhesive sheet. With this method, it would be unnecessary to make a separate hole in the adhesive sheet and a fastening element would be fastened axially and radially by means of the adhesive layer that adheres thereto.
If the two substrates are bonded together by casting a curable casting resin (as is widely used in the case of solar modules), a fastening element may already have been introduced before the casting and then fastened axially and radially with the casting resin, if sufficient adhesion is guaranteed between the fastening element and the casting resin.
The fastening elements may also be fastened in another manner to at least one of the two substrates, for example by interlocking and/or by separate bonding. If fastening elements made of plastic or soft metal (for example pure aluminum) are used, these may, by intrinsic elastic or plastic deformation, compensate both for any undersize of the drillhole in the substrates and slight lateral offset of the individual drillholes. Elastically or plastically deformable fastening elements are for example collet sleeves (longitudinally slit hollow pins) or pins provided with longitudinal or transverse external ribs. Thanks to their elastic and/or plastic deformation, the respective fastening elements are radially and axially fastened by them being clamped in the recesses provided for this purpose.
According to another embodiment, one of the substrates has a through-drillhole and the other substrate a blind hole in alignment with the latter. The fastening element is introduced before or after the two substrates are assembled, preferably again in such a way that it does not project onto the mouth of the through-drillhole. It may be mounted and/or fastened in the manner described above.
According to yet another embodiment, a fastening element may, according to the invention, be housed entirely in the laminated element, in the manner of a parallel key, which is well known in the construction of machines. The outer faces of the laminated element may in this case remain intact; likewise, it is possible to dispense with special fastening of the fastening element. However, it is necessary to make, in the two inner faces of the two substrates in the laminate, recesses (grooves, blind holes, etc.) with positional precision as high as possible, and the fastening element must have already been introduced before the plates are assembled by bonding. This provides one solution of the problem, which admittedly is particularly attractive looking from the outside, because it is barely perceptible, however its implementation is relatively expensive.
This could be implemented in such a way that, after the recesses have been made in the two substrates to be assembled, the first substrate is initially placed with the recess facing upward, the fastening element is introduced into the recess, then an adhesive film is possibly laid on top, and finally the second substrate is placed in such a way that the fastening element is introduced into the recess in the second substrate. Next, the bonded laminate may be manufactured. During adhesive bonding with a casting resin, a spacer frame is introduced in a known manner between the two substrates, and the intermediate space thus formed is filled with the casting resin.
The fastening elements may themselves be made of any (sufficiently strong) material and have any shape whatsoever, for example with a cylindrical, elliptical or polygonal cross section, they may be hollow or solid, smooth or ribbed, with steps, etc. Of course, the dimensions of the recesses in the substrates and of the fastening elements must be matched to one another in such a way that, should the substrate to be fastened creep, any extraction of the fastening element under a shear load is practically excluded. Moreover, no substantial load is exerted on the individual fastening element, so that it does not have to be exaggeratedly strong.
Other details and advantages of the subject of the invention will become apparent from the drawings of an illustrative example and from its detailed description that follows.
BRIEF DESCRIPTION OF THE DRAWINGS
In these drawings, which are simplified representations with no particular scale:
FIG. 1 is a sectional view of a first embodiment of a laminated element according to the invention, in the region of a support and of a position fastening element; and
FIG. 2 shows a second embodiment, similar to FIG. 1 , with an alternative form of the position fastening element.
DETAILED DESCRIPTION OF THE INVENTION
In FIG. 1 , a laminated element 1 is composed of a first substrate 1 . 1 and a second substrate 1 . 2 , here both made of glass. An adhesive layer 2 joins the two substrates together over their entire area. The substrate 1 . 2 , placed below in the drawing bears, on its face turned toward the adhesive layer 2 , a functional element 3 schematically indicated solely in the form of a coating. In a preferred embodiment of the present invention, the functional element is composed of a number of photovoltaic solar cells, and the laminated element 1 forms or comprises a solar module.
That face of the substrate 1 . 2 which is located to the outside/underneath and on the opposite side from the functional element 3 is provided with an undercut blind hole 4 . Anchored into the latter, in a known manner using an undercut dowel, is a bolt-shaped support element 5 , for example of the SGG Point XS type, with which the laminated element 1 may be fastened to an infrastructure 6 shown solely by a broken double line. The infrastructure may be a building wall, a support framework, a bridge or deck element, and the like.
The support element 5 does not penetrate as far as the plane of the adhesive layer 2 and of the functional element 3 . It can therefore be positioned freely in the region of the surface of the laminated element 1 , which surface is covered by the functional element 3 . It goes without saying that several support elements 5 of this type will be provided, depending on the size and the weight of the laminated element 1 , which support elements together form the mechanical support for the laminated element 1 on the infrastructure 6 .
It is repeated that this discrete fastening indicated by way of example does not exclude the combination of position fastening with other possible ways of fastening laminated elements of this type and with laminated elements that include a spacing means.
In the “solar module” application case, the laminated element 1 is as a rule mounted in an inclined position, obliquely with respect to the solar radiation, as is indicated here, for example on a building roof and/or on a support framework. Consequently, the adhesive layer 2 and the upper substrate 1 . 1 in the mounted state are permanently subjected to a downward sliding force. Of course, this force is taken up by the support elements 5 . However, solar modules may by their nature be very hot in service, so that creep of the adhesive layer 2 cannot be completely excluded.
Close to the right-hand outer edge, to the outside of the surface region covered by the functional element 3 , the substrate 1 . 2 is provided with a through-drillhole 7 . Substantially in axial alignment with the latter is a through-drillhole 8 made in the substrate 1 . 1 . The drillhole 8 has a larger diameter than the drillhole 7 . A fastening element 9 with a thicker head part 9 K and a shank part 9 S is introduced into the two drillholes 7 and 8 in such a way that the step at the transition from the head part 9 K to the shank part 9 S bears on the adhesive layer 2 (or is also embedded in the latter). The shank part 9 S passes through the plane of the adhesive layer 2 and engages in the drillhole 7 in the substrate 1 . 2 . The head part 9 K is located in the larger diameter drillhole 8 in the substrate 1 . 1 .
The length of the fastening element 9 corresponds approximately to the total thickness of the laminated element 1 . Consequently, it ends up at least approximately flush with both external faces of the substrates 1 . 1 and 1 . 2 and does not project beyond them. It is preferably fastened in the drillholes 7 and 8 by means of an adhesive, this fastening constituting only protection against dropping.
In the event of failure of the bonded joint, or alternatively should the adhesive layer 2 creep, the upper substrate 1 . 1 may in any case move relative to the substrate 1 . 2 until the wall of its drillhole 8 touches the fastening element 9 . In this way, mechanical position fastening is established, by shape complementarity, of the bonded assembly held in place by clamping or, depending on the case, by the material, which also meets the requirements regarding the construction.
FIG. 2 shows a variant of the position fastening. Here, only the substrate 1 . 2 has a through-drillhole 7 , while a blind hole 8 ′ is provided in the substrate 1 . 1 . The blind hole is again placed at least approximately in axial alignment with the through drillhole 7 . Here, the two drillholes have substantially the same diameter.
A cylindrical fastening element 9 is again introduced as position fastening into the two drillholes 7 and 8 ′ in such a way that it passes through the plane of the adhesive layer 2 . It is fastened in the drillholes by means of a heat-resistant adhesive. The outer surface of the upper substrate 1 . 1 remains intact, with no hole, in the region of the position fastening. The length of the fastening element 9 is matched to the depth of the drillholes 7 and 8 ′ in such a way that the element can be mounted in the fully pushed-in position without projecting beyond the lower face of the substrate 1 . 2 .
For purely visual masking of the position fastening, the laminated element 1 may be provided, in the region of the edge on the surface of the substrate 1 . 1 , with an opaque colored layer 10 which terminates in a pattern of spots toward the middle of the substrate. The colored layer 10 may for example be deposited by screen printing and baked while the substrate 1 . 1 is being toughened. Of course, in the “solar module” application case, it must be placed on the outside of the region of the surface covered by the solar cells.
In an alternative embodiment shown in FIG. 2 , the blind hole 8 ′ could be placed in the lower substrate 1 . 1 and the through-drillhole in the substrate 1 . 2 . That end face of the fastening element 9 turned toward the outside would then advantageously be colored in the same tint as the colored layer 10 .
According to another embodiment (not shown in FIG. 2 ), the fastening element would even be a little shorter than that shown here, and the drillhole in the substrate 1 . 1 would also be a blind hole. The fastening element 9 must then be placed in the aligned recesses/blind holes before the bonding is carried out.
It goes without saying that, just as was mentioned in the case of the support elements, several individual fastening elements illustrated in the figures as embodiment examples may be provided, when the size and the weight of the laminated elements so require. However, as a general rule two fastening elements will suffice.
One application of the position fastening to a laminated element provided with a spacing means may also be simply accomplished as in FIGS. 1 and 2 .
Instead of bonding over the entire surface with the adhesive layer 2 , in this case a relatively narrow spacing means is formed, this being bonded to the latter only along the edge of the two substrates. The spacer means may either be fully penetrated by a fastening element, just like the adhesive layer 2 , in such a way that there is relative position fastening between the two substrates 1 . 1 and 1 . 2 . However, it is also possible to provide fastening elements only between the spacing means and one or both substrates. In each of these cases, the fastening elements pass through the bonded joint between the spacing means and the substrate in question, and they support the latter should there be any failure of the bonded joint.
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A laminated, plate-shaped element with at least a first and a second substrate, which are joined together at least indirectly by adhesive bonding, and also with at least one support element associated with the first substrate to fasten the laminated element to an infrastructure and active position fastening of the second substrate at least in the event of failure of the bonded joint. The position fastening is active only between the first and second substrates and is placed a certain distance from the edge of the second substrate. The active position fastening is particularly applicable in laminated elements placed in an inclined or vertical mounting position, for example in solar modules with incorporated solar cells.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention relates to a computer program product and method for extracting UML models from legacy applications. More specifically, the invention relates to a method and product for extracting and enhancing a UML model from a legacy application, based on an existing repository containing all necessary information about the legacy application.
[0003] 2. Discussion of the Prior Art
[0004] In modern application development, it is desirable to capture the requirements, functionality and implementation details of an application in the form of design models. One such design model, which is commonly used, is known as the Unified Modeling Language, i.e., UML, which provides a standard which allows for the use of a variety of commercial tools to allow communication between parties.
[0005] For purposes of this description, it is noted that the Unified Modeling Language (UML) is a well-known nonproprietary, object modeling and specification language used in software engineering. UML is a general purpose modeling language that includes a standardized graphical notation that may be used to create an abstract model of a system which is typically known as the UML model.
[0006] In modern application development, UML is primarily used for developing new applications. However, up to now, UML tools have not been used to describe what are known generally as legacy applications which have been designed and built with older technologies.
[0007] Using UML is desirable for new or more modern applications for a number of reasons. First, UML is generally accepted as a language, and any UML description of an application is easy to share between development teams. There are also many commercially available software tools which are capable of forward engineering UML models into program code, all done in a conventional manner as will be readily apparent to those of ordinary skill in the art. Modern day UML tools such as Rational Rose, Together, Sparx, etc. are useful for reverse engineering applications by extracting UML from code in modern languages like Java. However, there are no such tools offering the same reverse engineering capability for use with legacy applications.
[0008] By the term legacy applications is meant applications developed with technologies beginning in the 1960s to date. Such legacy applications have been written in languages such as COBOL, PLI, Natural and RPG. Such applications also include databases such as VSAM, ADABAS, IMS/DB, IDMS, and DMS. Other legacy applications include environments such as CICS, IMS/DC. Most of such applications were developed prior to the development of UML.
[0009] Accordingly, although not completely useful when employed with legacy applications because of the design of current UML tools for use with modern applications, the problems of the use of existing UML tools with older applications is overcome in accordance with the invention in which there is provided a method and system of using UML tools to generate a UML diagram for legacy applications.
BRIEF DESCRIPTION OF THE INVENTION
[0010] Accordingly, in accordance with the invention there is provided a method of extracting UML models from a legacy application. It is assumed that there has already been created a repository of all objects and information about the objects contained in the legacy application. It is also assumed that the repository also contains a collection of business rules implemented in the application. For each legacy application object and for each business rule, the repository keeps pointers to the legacy artifacts or code where they are implemented (such as programs, screens, tables or transactions). Such repositories describing legacy applications may be created using existing legacy analysis commercial tools, as for instance Relativity Modernization Workbench. It is further assumed that the repository is accessible to the system described by this invention through a specialized library of programs, usually called an API (“application public interface”). This interface would allow the system described by the invention to access facts about the legacy application, in particular the association between screens and programs and the transitions or calls between the programs. Such information may be used to create the so-called “screen flows,” which indicate the order in which the screens are navigated by the application user in order to perform a particular task. Once a UML diagram describing the legacy application is created by processing the repository, UML objects in the UML diagram are linked either automatically or manually to the legacy objects and in particular to the business rules which have been extracted from the legacy application, thus creating an enhanced UML model.
[0011] In a more specific aspect, this invention involves the creation of two types of UML diagrams: Use Case diagrams and Activity diagrams. For purposes of describing the invention, the following definitions are provided.
[0012] Activity diagram: Activity diagrams are diagrams are used to model the behaviors of a system and the way in which the behaviors are related in an overall flow of the system. Activity diagrams show the logical paths a process follows based on various conditions, concurrent processing, data access, interruptions and other logical path distinctions which are all used to construct a process, system or procedure.
[0013] Activity: An activity organizes and specifies the participation of subordinate behaviors, such as sub-activities or actions, to reflect the control and data flow of a process. Activities are used for a number of modeling purposes, from procedural-type application development for system design, to business process modeling of organizational structures or workflow.
[0014] Use Case diagram: A Use Case diagram captures use cases and actor interactions. It describes the functional requirements of a system, the manner that outside things (actors) interact at the system boundary, and the response of the system.
[0015] Use Case: A Use Case is a UML modeling element that describes how a user of the proposed system will interact with the system to perform a discreet unit of work. It describes and signifies a single interaction over time that has meaning for the end user (person, machine or other system), and is required to leave the system in a complete state, either with the interaction completed or rolled back to its initial state.
[0016] Business Rule: Business rules describe the operations, definitions and constraints that apply to an organization in achieving its goals. They may be implemented in the code of a computer application serving the organization. In the case of an existing legacy application, business rules may be collected. One example of how such business rules may be collected is described in U.S. patent application Ser. No. 10/827,953, the disclosure of which is incorporated by reference in its entirety.
[0017] In a yet more specific aspect, method involves creating Use Case diagrams from a hierarchy of screens of the legacy application. An Activity diagram is created based on a flow of screens and procedures of the legacy application.
[0018] In the case of the hierarchy of screens, it comprises a tree format starting with the main menu screen and subsequent flows to other screens. The Use Cases are designated by pointing to selected screens and creating a Use Case for each selected screen in a manner in which, if a selected screen is subordinate to another selected screen, then its Use Case either extends or is included in the Use Case derived from the screen to which it is subordinate.
[0019] Yet still further the UML diagrams and UML objects from the legacy application can be manually modified to describe additional information not automatically extracted with the UML mining tool. In a yet still a more specific aspect, the UML diagrams and objects are created in a manner in which they can be exported to and imported from another UML tool through XMI. The enhanced UML model results in part from attaching business rules extracted from the legacy program to the UML model created with the UML mining tool to result in the enhanced model.
[0020] In a yet still further aspect, the invention relates to a computer program product configured for achieving the foregoing. The product is encoded on storage media such as CD, hard drive, USB flash drive, etc. and others as will be readily apparent to those of ordinary skill. It is operable on a computer with screens and other peripherals, as will be readily apparent to those of ordinary skill.
[0021] The program is designed for accessing a repository of all objects and information about the objects which are contained in a legacy application. The program functions to create a UML model of the legacy application by processing the repository. A further function allows linking of UML objects in the UML model to business rules and specifying of additional details about the UML objects, including at least information about the legacy objects and where they were derived.
BRIEF DESCRIPTION OF SEVERAL VIEWS OF THE DRAWINGS
[0022] Having thus briefly described the invention, the same will become more clearly evident from the following detailed discussion of the drawing wherein:
[0023] FIG. 1 is a general flow diagram of a how a refined or enhanced UML model is created from a legacy application, such as an application written in COBOL or other like language; and
[0024] FIG. 2 is a flow diagram in simplified step form of how a diagram representing legacy artifacts can be first adjusted to show the relevant aspects, then a UML diagram is extracted and finally the UML diagram is improved by adding additional specifications.
[0025] FIG. 3 is a screen shot illustrating how a user gives significant business names to all screens;
[0026] FIG. 4 is a screen shot illustrating how the user may click on a screen item in the screen flow diagram and view the layout of the screen;
[0027] FIG. 5 is a screen shot illustrating how an empty Activity diagram is first created, then a screen event is selected for the purpose of designating it as an activity;
[0028] FIG. 6 is a screen shot illustrating how a Use Case diagram is first created as an empty diagram;
[0029] FIG. 7 is a screen shot illustrating how a Use Case is saved;
[0030] FIG. 8 is a screen shot illustrating how the user designates one of the screens of the application as the “root screen,” which is the one from which the user of the application enters the application.
[0031] FIG. 9 is a screen shot illustrating how the tree of screens is reorganized with the “root screen” as the root of the tree of screens, as the result of the action on FIG. 8 .
[0032] FIG. 10 is a screen shot illustrating how a Use Case is created in a Use Case diagram, after the user drags a screen icon from the screen flow diagram into the Use Case diagram.
[0033] FIG. 11 is a screen shot illustrating how when screens are dragged and dropped from the screen navigation tree into a Use Case diagram, the resulting Use Cases appear in the same relation of subordination as the screens.
[0034] FIG. 12 is a screen shot illustrating how a screen event is selected from the screen navigation tree to be dragged and dropped in an Activity Diagram.
[0035] FIG. 13 is a screen shot illustrating how the Activities resulting from the screen events appear in the same order as the order of the events in the screen navigation.
[0036] FIG. 14 is a screen shot illustrating how, when the user chooses two possible navigation paths in the screen flow diagram, a Decision object automatically appears in the Activity Diagram.
DETAILED DESCRIPTION OF THE INVENTION
[0037] In understanding the invention, it is important to appreciate that there are two major functionality aspects of high interest in analyzing a legacy application. The two functionality aspects are a UML model of the legacy application and the business rules embodied in the legacy application. With respect to extracting business rules, reference is made to copending application Ser. No. 10/827,953 filed Apr. 20, 2004 of the same inventor herein. UML, was previously discussed and is well known, and describes the requirements, functionality in terms of processes, structural aspects and implementation of the application. Business rules describe the fundamental restrictions on how the company or organization acts, irrespective of implementation.
EXAMPLE
[0038] This is an example of what kind of functionality is described in an UML model and what kind of functionality is described in business rules. A UML model may describe, for example, how to create an insurance policy by adding information about the customer and the car, in a specific number of steps. The business rules are concerned with the calculation of the premium or the criteria for accepting a particular customer.
[0039] In the past, the two aspects, i.e., UML and business rules were managed by separate technologies such as the previously described modern UML tools or business rules engines as noted with reference to the copending patent application. In accordance with the invention the two are brought together so that one analyzing an application can determine that a specific business rule is invoked during a particular process, which process is defined by the UML model. Thus, in accordance with the invention, some UML objects are able to automatically or manually be linked to business rules.
[0040] In considering how to implement the invention, it is important to understand that there may already exist a high level UML description of the application, for example, in another UML tool. In accordance with the invention, it is important to enrich the existing model by uncovering new details in the current implementation in code, or creating links for references between objects and implementation artifacts. In accordance with the invention, the UML can be extracted by the system of the invention and then exported to another UML tool, or it can also be implemented by first developing the UML model in another UML tool and then importing it into the system of the invention for later enrichment in linkage to legacy code for later reexporting. This is done, in one aspect, by a computer program product as previously described wherein the product is on storage media and functions through a computer as further described herein.
[0041] In one embodiment, a legacy repository has already been created in a manner well known to those of ordinary skill in the art. The legacy repository contains information collected by parsing the sources of a legacy application. The repository includes an inventory of all objects in the application, such as sources, programs, files, tables and screens. Information about the internals of such objects is also contained in the repository such as variable used in the program or the fields which appear on a screen.
[0042] Tools for creating such a repository are available commercially, for example, from Relativity Technologies, Inc. under the name RMW, and the invention involves in part interpreting the information in such a repository.
[0043] Accordingly, in a general aspect as shown FIG. 1 , a mainframe legacy application 101 is analyzed with a legacy analysis tool 103 as previously described to create a legacy repository 105 . Thereafter, a UML mining tool 107 is applied to the repository to create a UML model 109 . As may be appreciated, while a lot of information was extracted from the legacy code, there could exist some UML specifications which could not be found in the code. An example of such a specification is the UML entity Actor which designates an external entity acting on the system. For purposes of this description, an Actor may be a person with a specific role such as a customer or another system which exchanges information with the system being analyzed. The application code in most cases does not make reference to the Actor and the user of the UML mining tool is required to identify and extract the Actor.
[0044] After a UML model is created, a mining tool export facility 111 is applied to the model to create XMI files 113 which are then processed through a UML modeling tool to result in a refined UML model 117 .
[0045] Stated more broadly as shown in FIG. 2 , the invention generally involves starting with a legacy diagram 201 which is then operated on with appropriate tools to create an improved legacy diagram 202 . The improvement refers to giving business names to some of the legacy artifacts or adding some additional information which was not collected by the parsing of the application. The facilities of the system are then applied to create a UML diagram 203 thereafter resulting, after additional processing as discussed hereafter, in an improved UML diagram 204 .
[0046] While a number of UML diagram types may be extracted or built based on a legacy application, the invention is particularly concerned with the extraction of two types of diagrams which have been previously discussed: Use Case diagram and Activity diagram.
[0047] As shown in FIG. 3 , initially, the user gives significant business names to all screens, programs, files or tables. This is necessary because application code uses only technical names while UML diagrams use business names. The assignment of business names may be done by displaying a list of all objects of the application, group to screens, programs, table, etc. When a user clicks on one of the legacy objects, it is displayed. As shown in FIG. 3 , based on display of the object, the user has enough understanding to give it a business name and it is stored by the system.
[0048] In implementing the system and method, when a UML object is derived from an application artifact, the system stores and maintains a pointer to the corresponding this artifact. This allows the system user to explore derived UML diagrams and with a simple click, automatically open a window which shows the legacy objects corresponding to a UML object and even see appropriate code inside a program. This allows the user to view not only the derived diagrams and objects, but where and how they are implemented in the legacy application.
[0049] To extract a Use Case diagram, the user starts by creating a new and empty Use Case diagram, as shown in FIG. 6 . The user also opens a window in which an inventory of all screens in the application is shown. A user then designates as the “root screen,” as in FIG. 8 , which is the first screen encountered by the user of the application when entering the application. Information from the repository is then used to calculate all the screens to which the user of application may transition from the root screen. This step is repeated for each screen reached forming a tree with the root in the root screen as shown in FIG. 5 . If not all screens in the application are reached, the remaining unreached screens are grouped in an unassigned set from which the user may again designate a root screen. This will result in at least one if not multiple trees which are presented graphically in a window defined as a “screen hierarchy,” as shown in FIG. 9 .
[0050] The user then picks a screen from the screen hierarchy and indicates that a use case is to be created from it. This is done by either dragging the screen object from the screen hierachy window and dropping it in the Use Case diagram window, or from a pop up menu shown when the user right clicks on a screen. A use case object automatically appears having the same name as the business name of the screen as shown in FIG. 10 . This action may repeat multiple times, thus creating multiple use cases. If there is a transition from screen A to screen B, then the Use Case from B appears as included in the Use Case from A or extending the Use Case from A as shown in FIG. 11 . The choice of “included or extending” could be made by the user of the system. After all Use Cases desired are included in the diagram, the user of the system may further specify attributes, using a Properties window, which appears when the users clicks on a use case object. The user may also add “Actors” indicating what external agents act on each use case.
[0051] To extract an Activity diagram, the user starts by creating a new Activity diagram. Initially, this diagrams contains just the “initial” and “final” objects, as shown in FIG. 5 . The user also opens a “screen flow” diagram which contains all the screens of the applications and events on the screens, i.e., actions or choices, which lead from one screen to another as also shown in FIG. 5 . Thus, if on a screen A the user of the application presses PF 5 to go to screen B, then the diagram shows a node for screen A connected to a node for event PF 5 , connected to a node to screen B as shown in FIG. 5 . The user may give significant names to these events, overriding the names assigned automatically by the tool.
[0052] By way of example, a screen diagram may be constructed automatically as follows. If a screen A is received by a program A, which then passes exclusive control to program B when an event E is intercepted, and program B sends screen B, then the nodes “screen A”—“event E”—“screen B” are automatically constructed as shown in FIG. 5 . The user of the system clicks on a series of events in the screen flow diagram, designating a flow through the screens. For each event selected (either by drag and drop or by other methods) the system will create an activity object in the activity diagram, corresponding to that event, and initially having the same name as the event. Alternatively, in another implementation, the system may create two interconnected activities for each event, one representing the user action, and the other representing a system response. Thus from an event E, in the activity diagram will be constructed activity “user request E” and “application response to E.” More particularly, as may be appreciated, the activities in the Activity diagram will appear in the same order as the order in which the application user triggers a series of events to navigate from screen to screen in the application, as shown in FIG. 12 . If the user of the application can navigate through the screens on two separate paths, the branching between these paths will appear in the Activity diagram as a decision point.
[0053] Once all UML objects and diagrams are derived, the business rules which were also separately identified in the application may be connected to the UML objects either automatically or manually. As each derived UML object has a pointer to the code showing the program code where it is implemented and each business rule has a pointer to the code showing where the rule is implemented, the system may connect the business rule to the UML object if the code pointed by the business rule intersects the code pointed by the UML object. Thus, the system user may see which business rules are applied in the performance of a particular activity.
[0054] Based on the foregoing description it will be apparent to one of ordinary skill how to program a system such as a computer to result in the methodology described as implemented through the screen shots illustrated herein. In addition, having thus generally described the invention, the same will become better understood from the appended claims from in which it is described in a non-limiting manner.
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A method and computer program product are provided for extracting UML models from legacy applications. The system involves extraction of UML models and importing and exporting than to other commercial UML tools. In a more specific aspect, UML objects are associated with business rules which have been extracted from a legacy application. In particular, UML diagrams are extracted from a legacy application for Use Case diagrams, Activity diagrams from screen flows, and Activity diagrams from program logic.
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BACKGROUND OF THE INVENTION
1. The Field of the Invention
This invention is concerned with the art of providing roadway and other traffic carrying surfaces with traffic regulating signs, such as traffic lane dividing lines and the like and, more particularly, is concerned with means for improving the anti-skid properties and/or the nighttime visibility of the marked area of the road surface.
2. The Prior Art
The art of providing roadway pavements with traffic regulating signs is a well worked one and extensive comments about it are unnecessary. Generally, such signs can be provided by painting or otherwise forming the sign on the roadway pavement, or by applying and adhesively securing on said pavement strips or tape materials. In any case a neatly defined and clearly visible sign has a smooth and compact outer surface which is not receptive to nor retentive of dirt, greasy particles and tiny rubbery particles detached from vehicles' tires, so that the sign will maintain its nearly pure white or clear color. Several compositions are well known for providing suitable and wear resistant signs on traffic carrying surfaces.
It is further known that the thus formed smooth marked areas are undesirably skiddish. Further, the visibility of the markings is undesirably low at nighttime when substantially one source of light only is provided by a vehicle's headlamps, expecially in rainy weather, when a film or thin layer of water exists on the road pavement and forms a mirror-like surface thereon.
Various means have been heretofore proposed for at least partially avoiding the undesirable characteristics of the conventionally formed signs. In the prior U.S. Pat. No. 3,587,415 it has been proposed to provide on the smooth highly visible marking area a plurality of spaced plates or reliefs having coarse upper faces to improve the overall anti-skid character of the sign. Such plates are formed of aggregates including resin bonded retroreflective glass beads for improving also the nighttime visibility of the sign.
In my prior U.S. Pat. No. 3,746,425 there has been described a manner for providing aggregates of the above character which include an exceedingly high multiplicity of glass beads for correspondingly increasing the number of the "light spots" contributing to a better nighttime visibility.
With a view towards improving the anti-skid properties of the marked areas, for a substantial contribution to traffic safety, my Canadian Pat. No. 929,696 (U.S. patent application Ser. No. 153,218, filed June 15, 1971, now U.S. Pat. No. 3,782,843) proposes to add to and partially embed in the marking composition a multiplicity of very hard crystals, such as of corundum, to provide on the marked area a multiplicity of hard, sharp and upwardly projecting points adapted to frictionally engage the tire treads and to prevent skidding even if the vehicle is engaged in speeding around a curve or in an emergency braking action.
Reference is hereby made to the disclosures of the above patent literature as to the various compositions, binders, fillers, retroreflective beads, crystalline particles and other substances which, individually considered, can be made use of for carrying out the present invention and which, therefore, will not be described and specified in detail as this description proceeds.
THE PRINCIPAL OBJECTS OF THE INVENTION
The heretofore proposed means, while generally satisfying, are however subject to certain serious limitations. For example, the spaced reliefs of U.S. Pat. No. 3,587,415 are not wholly satisfying. They are required to be pre-formed and pre-positioned and secured to a marking material in tape form. As the marking material becomes thinner and thinner by traffic wear, the aggregate plates can be entirely or partially tripped off. The reliefs also spoil the desirable generally planar upper face of the sign.
Similarly the very efficient anti-skid means consisting of partially embedded hard crystals are torn off as the base sign layer is thinned by wear. Further, such crystals are subject to breakage or splitting apart by flaking under violent shearing stresses (such as that promoted by an emergency braking of the vehicle) and under certain high frequency vibrations which have been found to sometimes occur in a road marking material in service. Additionally, relatively big crystals of the order of one millimeter or so, as necessary for obtaining a substantial jutting up from the sign surface and for an efficient rooting in the marking layer, are undesirably costly on a volume basis.
It is therefore a principal object of this invention to provide new and advantageous elements designed to with be associated to road surface marking materials and which are capable of improving the surface properties of the sign, and are not subject to the above and other objections.
Another object of the present invention is to provide new elements as above adapted to be progressively worn off by the traffic, concurrently with the progressive wearing off of the marking material, while maintaining their efficiency as far as the anti-skid properties and/or the nighttime visibility of the marking sign are concerned.
A further object of the invention is to provide new elements as above which can be firmly secured to the marking layer even if not deeply embedded or rooted therein.
Other important objects and advantages of the invention will be made apparent as this description proceeds.
SUMMARY OF THE INVENTION
Essentially, according to the invention, each new element consists of an aggregate comprising a multiplicity of particles individually adapted for imparting the desired anti-skid or retroreflective properties to the sign surface, from which some particles extend upwardly when the aggregate is partially embedded, and a resinous binder firmly securing said particles to each other, the particles positioned at the surface of the aggregate jointly forming a coarse anti-skid surface and at least some of the thus-positioned particles being capable of reflecting light rays impinging thereon in a direction forming a small angle with the said sign surface.
Said particles consist of tiny hard crystals or of reflective microspheres or tiny glass beads. Preferably, the aggregate comprises both tiny crystals and tiny reflective beads. Also preferably, the aggregate is formed about a core body. In one embodiment, such core body consists of a hard crystal and the aggregate has an approximately spheroidal configuration. In another embodiment of the invention, the core body consists of a small flat disk and the aggregate has an approximately disk-like or flattened configuration.
Most preferably, the resinous binder comprises an epoxy resin or a polyurethane resin, and the aggregate is so formed that the binder completely fills even minimal interspaces between the particles to provide a strong coherent physically unitary structure.
It has been surprisingly found that the resulting composite structure, while capable of acting as an extremely efficient means for imparting the desired anti-skid properties to the surface of the traffic regulating sign, by taking advantage of its coarse outer surface, and while capable of providing the desired improved visibility, by taking advantage of the reflectivity of the uncoated particles located at its said outer surface, is extremely resistant to shearing stresses and violent impacts. Further the said structure is subject to progressive wear upon detachment of particles located at its uppermost portion, such detachment leaving the particles located at the next lower level uncovered and thus positioned for providing the desired effect.
The said structure consists of closely spaced particles embedded in a network of very hard resinous material.
The said network forms, at the outer surface of the aggregate, in the interspaces between the particles, an indented structure which efficiently contributes to the provision of a frictional adherence with vehicle tires. The new element provides therefore an efficient anti-skidding action even if the particles embedded in the said network are not sharply pointed, such as is the case with reflective glass beads.
On the other hand, when the particles are such as to provide the best frictional resistance, such as when the aggregate comprises hard, pointed microcrystals, the multiplicity of such crystals which are partially uncovered and located at the exposed surface of an element which is only partially embedded in the marking composition, provides a noticeable reflection of the light due to the refractivity and the internal reflection of the crystalline particles, a part of said reflection of the differently oriented crystals being directed towards the source of light, thus providing substantial retroreflectivity and nighttime visibility.
Further, the above discussed properties of the new element, that is, the ability to provide good frictional resistance for vehicle tires even if not provided with sharply pointed particles, and the ability to provide an exceptionally good resistance to shearing forces, leads to the new advantage that very good and durable anti-skid elements can be manufactured by making use of crystalline or nearly crystalline particles of hard but not very hard materials and compounds. It has been found that exceptionally efficient anti-skid aggregate elements can be made by providing the same with crystals or crushed crystalline scraps of any known substance or compound having a hardness of not less than 6 on the Mohs' Hardness Scale.
These and other objects and advantages of the invention will be apparent from the following detailed description of a few exemplary embodiments of the same invention, shown in the accompanying drawings.
THE SEVERAL VIEWS OF THE DRAWINGS
FIG. 1 is a diagrammatic fragmentary perspective view of a marked road having greatly improved visibility and anti-skid properties due to the provision of the marking material with a multiplicity of the new elements, which are scattered on and protrude above the surface facing away from the roadway pavement;
FIG. 2 is a diagrammatic sectional view, taken in the plane indicated at II--II in FIG. 1, illustrating a new element in service on an enlarged scale, in an embodiment particularly adapted for providing nighttime visibility;
FIG. 3 is a diametral sectional view, in very enlarged scale, of the same element;
FIG. 4 illustrates diagrammatically and perspectively the essential steps of a procedure for constructing the same element;
FIG. 5 is a very enlarged diagrammatic sectional view of another embodiment, taken in the plane indicated at V--V in FIG. 1;
FIG. 6 is a similar view of another embodiment as partially embedded in freshly laid or formed marking material;
FIG. 7 is a view similar to that of FIG. 6, but showing the same element and marking material after a substantial wearing off due to severe traffic; and
FIG. 8 is a view similar to that of FIG. 7, showing a further and preferred embodiment of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 generally visualizes the field and the objects of the invention. A strip or layer of marking material is laid on and secured to the surface of the pavement 12 of a roadway. The layer is generally indicated at 16 and its composition, mode of formation and the manner of securing the same to the pavement form no part of this invention as such art is widely known. Reference is herein made to the above indicated patent literature. Of course, such material is to be chosen from the known types which can receive and embed discrete elements, when the material is in its liquid or viscous state, and then strongly retain such elements when completely cured or set.
Generally, the elements are dropped on and if necessary pressed into the layer 16 of the marking material, either during the production thereof, if in tape form, or before setting thereof on the road pavement, if the marking has been painted or otherwise formed on the pavement. The elements are located on the marked area with spacing in an at least approximately evenly distributed manner and in such number as to provide a convenient average population of protruding parts as necessary to impart the desired nighttime visibility and anti-skid properties to the marked area. Advantageously, as diagrammatically indicated in FIG. 1, elements of different types are combined to provide the best compromise of the said properties. Thus, in the marked areas, specifically "good adherence" elements Ea are mixed with specifically "good reflectivity" elements Er. As described below, elements Ear (FIG. 8) possessing both said properties can be provided and made use of according to the invention.
FIG. 2 illustrates how a "good reflectivity" element Er is partly embedded and firmly secured in the layer 16 of the marking material over the road pavement 12. This element Er has however an upper exposed coarse face which provides also a noticeable improvement in the anti-skid property. As shown in FIG. 3, this element has a resinous core body 20 and a multi-layer coating 22 of retroreflective beads, having diameters known type, of from a few microns to say 100 microns, preferably from 20 to 50 microns, such dimensions not being limiting for the invention.
The rounded edge portion of the element, protruding above the surface S of the marked area, provides a multiplicity of particles (the beads), each capable of retroreflection. The arrow Rr diagrammatically indicates how a light ray is returned essentially in the direction of light impingement.
The provision of even a relatively few retroreflective elements provides an exceptionally improved nighttime visibility in rainy weather, when a film or thin layer of water exists over the road pavement and marked areas, said watery layer being indicated at A in FIG. 2. As is well known to motorists, in rainy weather, and when essentially the sole source of light is provided by the vehicle's headlamps, the traffic dividing lines and other signs on the roadway pavement seem to "disappear" with serious prejudice for the traffic safety.
FIG. 2 visualizes this undesirable phenomenon. The watery layer A provides a mirror-like reflective surface. An incident light ray such as indicated at Ri impinges say at point P under an angle of incidence near 90° and corresponds to that emitted by a headlamp at a distance of 10-20 meters from point P. This ray is completely reflected away from the vehicle, as indicated by the reflected ray Rf and therefore in such weather conditions the indicia formed on a roadway pavement cannot actually be seen by the motorist from beyond an undesirably short distance away therefrom. A light ray which however impinges, from the same direction, on the rounded protruding edge of the element Er, or more properly on the watery layer A which conforms to the protrusion and which, evidently impinges at a much smaller angle of incidence, passes back and forth through the layer, e.g., by reflection from point Pe, and is nearly entirely retrocollimated as indicated at Rr, thus providing the desired visibility of the marking.
This element Er can be manufactured by cutting or punching small disks 20 (of from 1 to 3 millimeters diameter, for example) from a calendered tape 24 of a suitable resinous material, such as an epoxy or a polyurethane resin, having a thickness of 0.1 to 0.5 millimeter, for example, and preferably but not necessarily having some tiny reflective beads incorporated therein, as shown in FIG. 4. This disk 20 is coated with a layer 26 of a resinous binder and, before setting of such layer 26, with a first monolayer 28 of reflective beads. Upon substantial setting of the binder (suitable heating can provide a very fast curing, as is well known), a further layer 30 of binder and a further monolayer of beads are applied. These steps are repeated until the desired coating of beads 22 of FIG. 3 is provided. Tiny crystals or crystalline scraps or chips can be mixed with the beads for improving the adherence property.
Upon the provision of a flat core body such as the tiny disk 20, an essentially flat element Er is formed. Such flatness provides both a relatively large upper face for good adherence (provided by the coarseness of such face) and a tendency of the element to spontaneously lay flat on the marking material, whether the element is dropped on and pressed into the marking material or whether the element is applied to marking material which is prefabricated in tape form.
The element Er as above described is serviceable and efficient until the multi-layer 22 of beads on its core body 20 is completely worn off by the traffic due to progressive detachment of its individual beads.
According to the embodiment of FIG. 5, a bonded multi-layer of retroreflective beads is formed about a crystalline core 32. The layers 28 of beads are much more closely spaced than illustrated in FIG. 5 (as are the reflective and crystalline particles in FIGS. 6 to 8), the views being enlarged for a better showing of the resinous network formed by the binder. This element has a generally spheroidal configuration and therefore provides a more sharply protruding body when not worn, for better engagement with the vehicle tires. As its uppermost portion is worn off (thus leading to a flatter protrusion having less grip for a tire) the upper point of the crystalline core body 32 will be uncovered thus providing a sharply pointed protrusion. This element might therefore be considered as a combined "good visibility and good adherence" aggregate. Reflective beads can however be mixed with sharp crystalline particles when such an element is manufactured.
A specifically "good adherence" element Ea is shown in FIG. 6. A metric scale associated with said FIG. 6 exemplifies the dimensions of the element and its components. In such element Ea a smaller crystalline core 32 is coated with a multi-layer 34 of tiny crystals or chips of a hard crystalline substance. This element in shown in FIG. 6 as being rather deeply embedded in a layer 16 of still unworn marking material on a roadway pavement 12. This element however protrudes considerably above the surface S of the marking layer 16 for imparting the desired properties thereto.
FIG. 7 illustrates the same element after a substantial wearing away of the same, concurrently with the wearing away of the marking layer 16, the profile of the unworn element and layer being indicated by a dot-and-dash line in FIG. 7. Assuming that a substantial portion U of the marking layer 16 has been worn away by the traffic (while the marking efficiency of the layer is not, or not substantially, affected), the element Ea, if it was not physically and dimensionally modified, would remain proportionately insufficiently embedded below the worn surface Su of the layer 16. If an element was be made of an integrally formed body, such as a monocrystal of similar overall dimensions, it would be entirely torn off from the marking layer 16, well before the wearing away of said layer to the extent indicated at U.
On the contrary, the new aggregate structure of the element Ea wears away concurrently with the the marking layer 16. The thus progressively worn away element, such as indicated at Eu in FIG. 7, (a) protrudes above the worn away surface Su of the marking layer, forming an essentially conical protrusion with a portion of the core 32 constituting the tip thereof, and (b) remains embedded within the layer 16 to a depth which, proportionately, is well related to the extent of its protrusion. The indented coarse lower face of the element ensures a firm bond with the composition of the layer 16, even if the element hardly projects therein. FIG. 7 is an enlarged realistic representation of a partially worn but still quite efficient element, still firmly bound to a nearly completely worn marking layer of a polyurethane resin based composition.
It is therefore evident that the invention provides an extremely advantageous means for sharply improving the visibility and anti-skid properties of a compact and smooth road surface marking material, having a surface S which is not receptive to dirt, and where the layer having such surface is subject to progressive wear and thinning, said properties being unaffected by said wear and being maintained for essentially the entire service life-time of the road marking material.
FIG. 8 illustrates how the element of FIGS. 6 and 7 can be modified for a better contribution to the above discussed nighttime visibility. Layers of retrocollimating beads can be altered with layers of hard and pointed crystalline particles or chips. For example, a first layer 36 of beads can be formed about a crystalline core 32 followed by a plurality of layers 34 of tiny crystals or crystalline chips, and this then followed by a further monolayer or even a multilayer 38 of beads about the aggregate of crystalline particles.
While not substantially worn, the thus provided combined "good visibility and good adherence" element Ear of FIG. 8 behaves as the element of FIG. 5 does. As soon as its convex protruding tip is flattened by traffic, the hard crystalline particles begin to be uncovered for improving the adherence, this being promoted by such flattening. The desired combined properties are maintained and even improved by the wearing down, as is illustrated in FIG. 8, where the double pointed arrows R indicate impinging and retrocollimated light rays, and as is also illustrated in FIG. 7, until the road surface marking is no longer serviceable.
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There are described elements designed to be partially embedded and secured in a marking layer on a roadway pavement. Each element consists of an aggregate including a multiplicity of tiny hard and sharp particles, such as crystalline chips, and/or light reflective particles, such as retrocollimating glass beads, in a high cohesion resinous binder network, such as of an epoxy or a polyurethane resin. The elements are exceptionally resistant to shocks and to shearing stresses and are capable of being progressively worn off by traffic, concurrently with the wearing off of the marking layer, while their ability to improve anti-skid proper and the nighttime visibility of the marked areas is unaffected by such wearing off.
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BACKGROUND OF THE INVENTION
This invention relates to a drum-equipped apparatus for the batch-wise wet treatment of textiles, particularly a washing machine. The apparatus includes a horizontally oriented, driven drum which has central inlet and outlet openings in the end walls and further has an internal conveying impeller. The latter is provided with a lifting wall for the radial displacement of the batch during the rotation of the impeller in the "treating direction" and a slide for the axial discharge of the batch during the rotation of the impeller in the opposite, "conveying direction". The drum is supported in stationary external vessel and is partially submerged in the treating liquid contained in the vessel.
German Laid-Open Application (Offenlegungsschrift) No. 23 45 943 discloses a continuous washing machine for laundry batches. The drum of the washing machine is formed of axially juxtapositioned length portions which, in turn, are supported in respective outer chambers (also arranged serially) each containing the wash liquid. The end walls of the drum length portions projecting radially beyond the abutment faces of the length portions extend into annular spaces of the outer chambers adjoining the abutment faces. Between the end wall of the drum length portion and the annular chamber wall there is provided a sliding seal for separating the adjacent wash baths from one another. Such sliding seals are, however, continuously exposed to mechanical wear as well as chemical and thermal effects of the wash liquid so that a loss of a satisfactory seal and resulting leaks are likely to occur. Such leaks, in turn, lead to an undesirable mixing of the wash baths, particularly during longer periods of standstill (at night or over weakends). Thus, a satisfactory and safe wash zone separation cannot be ensured. Although the drum has apertures only along three-fourths of its circumference, the non-apertured zone, nevertheless, is situated at the location where the lifting wall of the conveying impeller joins the drum surface and thus it has no effect on the guidance of the wash liquid and the laundry batch.
German Utility Model Patent (Gebrauchsmuster) No. 73 07 294 discloses a continuous washing machine for laundry loads which has a drum provided with apertures only in certain zones of the drum. The aperture zones are connected with one another by a channel-like, sealed hollow space at the outer side of the drum. This arrangement seeks to achieve that the washing liquid contained in the hollow space remains, during the conveying phase, in the respective chamber and thus does not flow with the laundry load into the successive chamber. Since this arrangement is a single-drum apparatus, whose radially closed drum accommodates laundry and washing liquid, it is, to be sure, possible to achieve a full separation of the individual wash baths by the internal radial separating walls. A separate control of the individual baths, however, such as control of temperature, concentration of wash detergent and additives can be effected only with difficulty and in a time consuming manner. Thus, the washing process cannot be adapted to non-homogeneous laundry in an optimal manner.
SUMMARY OF THE INVENTION
It is an object of the invention to provide an improved drum for an apparatus of the above-outlined type to ensure in a reliable manner the full separation of the wash baths from one another even in case of lengthy idle periods and to further ensure that each wash bath can be readily controlled and altered.
This object and others to become apparent as the specification progresses, are accomplished by the invention, according to which, briefly stated, the drum-equipped apparatus for the wet treatment of batches of material has a horizontally oriented, rotatably supported drum including a drum shell bounded by end walls and including a central inlet opening and a central outlet opening provided in the one and the other end wall, respectively. The apparatus further has a drive for selectively rotating the drum in a treating direction and in an opposite, conveying direction. A lifting wall is secured to the drum in the inside thereof for displacing the material batch radially with respect to the rotary axis of the drum during the rotation thereof in the treating direction. Further, a slide is secured to the drum in the inside thereof for displacing the material batch in the axial direction of the drum towards the outlet opening during the rotation thereof in the conveying direction. The drum is supported in an external vessel which receives treating liquid into which the drum is partially submerged. The drum shell has an apertured zone oriented towards the slide face of the slide and an aperture-free zone oriented towards the reverse side of the slide.
According to a particularly advantageous feature of the invention, the length of the non-apertured (aperture-free) zone in the circumferential direction is such that in the submerged state of the aperture-free zone, both ends thereof are above the liquid level.
The invention is particularly advantageous in that the drum shell provided with an apertured zone and an aperture-free zone of predetermined magnitude and circumferential orientation, there is obtained, in a certain angular position of the drum, an outwardly closed space into which no liquid can penetrate from the outside even during extended idle periods and further, liquids can also not flow from the inside outwardly. During the treating operation, on the other hand, the liquid may normally flow in either direction (inwardly and outwardly). Since the aperture-free zone of the drum shell is smooth and therefore has favorable sliding properties, there is obtained a substantial conveying component for the batches; this circumstance, in turn, results in a forceful liquid penetration with a vigorous treating effect. The liquid penetration is further amplified by the division of the apertured and the non-apertured zones in the drum shell, resulting in a practically forced guidance in certain angular positions of the drum. Further, during the rotation of the drum in the "conveying direction", the batch is first lumped together as a whole and then conveyed again as a whole. In this manner, the parts forming the batch always remain together and leave the apparatus in the same composition as they entered it.
With a drum-equipped apparatus, particularly a washing machine, having a drum structured according to the invention, there is thus achieved not only a continuous and absolute bath separation (including a biological bath separation, so that no recontamination is possible), but also, due to the mechanical conveyance of the articles in a single direction of drum rotation, there is achieved an intensive, yet gentle handling and it is further ensured that the bath separation is securely maintained even during the conveying phase.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic elevational end view of a drum structured according to a preferred embodiment of the invention.
FIG. 2 is a side elevational view of the structure illustrated in FIG. 1.
FIGS. 3, 4 and 5 are elevational end views, on a reduced scale, of the preferred embodiment, showing the same in different angular positions during the treating phase.
FIG. 6 is an elevational end view of the same embodiment illustrating the same during the conveying phase.
FIG. 7 is a sectional side elevational view of an apparatus incorporating a plurality of drums structured according to the invention.
FIG. 8 is a sectional view taken along line VIII--VIII of FIG. 7.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Turning now to FIGS. 1 and 2, there is shown a drum 1 of an otherwise conventional, drum-equipped apparatus for the wet treatment of textiles, particularly for washing the same. It is to be understood, however, that the term "wet treatment" is not intended to be limited to washing processes, it may include such treatments as cleaning, dyeing or the like.
The drum 1 is formed of a drum shell 2 which is closed at both ends by radial end walls 3 and 4, respectively, to thus obtain a generally closed inner drum space. The end wall 3 has a central inlet opening 5, while the end wall 4 has a central outlet opening 6. Both openings 5 and 6 are surrounded by a respective ring 7. In other aspects too, the end walls 3 and 4 with their respective inlet and outlet openings 5 and 6 are of identical configuration. In the inner space of the drum there is secured a conveying impeller or vane 8 for moving the batches. The impeller 8 is formed of an obliquely oriented slide 9 which, in the position of the drum as shown in FIGS. 1 and 2, extends downwardly from the upper edge of the inlet opening 5 (where it is attached to the end wall 3 along the linear edge 10) to the end wall 4 and which has the shape of a gradually downwardly deepening, upwardly open channel. The slide 9 is surrounded along its lower circumferential half (as viewed in the position depicted in FIG. 2) by the outlet opening 6 and extends linearly upwardly to the diametral height of the outlet opening 6. In this manner there is obtained, at one side, an edge 11 which extends parallel to the drum axis between the two end walls 3 and 4. On the other side, this upwardly extending wall of the impeller slide 9 is extended up to the junction 12' with the drum shell 2 and thus forms a lifting wall 12 which merges with a gradual transition, in the impeller slide 9.
The drum shell 2 has an apertured zone 13 and a non-apertured (that is, aperture-free) zone 14. Each zone 13 and 14 extends in the circumferential direction approximately along one-half of the drum circumference. The apertured zone 13 is situated on that part of the drum shell which is oriented towards the work face (slide face) of the slide 9, while the aperture-free zone 14 is oriented towards the backside (reverse side) of the slide 9. The junction edge 12' of the lifting wall 12 at the drum shell 2 extends axially parallel, at least approximately in the middle of the apertured zone 13, thus dividing the latter into an apertured part zone 13' and an apertured part zone 13" arranged on either side of the lifting wall 12. The two end walls 3 and 4 are, at least in the aperture-free zone 14, connected in the liquidtight manner (for example, by welding) with the drum shell 2. Further, the inner face of the drum shell 2 is smooth, that is, it has no ribs or other protrusions.
The operation of the drum 1 will now be described with reference to FIGS. 3, 4, 5 and 6.
The drum 1 is supported in a stationary outer vessel 15 and is partially submerged into the treating liquid 18. Supply and discharge conduits as well as heating devices (neither shown) serve for maintaining the liquid 18 in its desired effective condition. During the wet treatment (such as washing) of a batch 17, the drum 1 rotates clockwise in the direction of the arrow 16. When the lifting wall 12 reaches its lowermost position as shown in FIG. 3, the entire batch 17 is held together in the wedge-shaped space between a portion of the drum shell 2 and the lifting wall 12. In this position of the drum, the liquid 18 still dwelling on the batch 17 flows through the batch 17 downwardly and, passing through the holes 19 of the apertured part zone 13', flows into the space between the outer vessel 15 and the drum shell 2. In that space the liquid then flows past the junction 12' and flows back into the drum 1 through the holes 19 of the other apertured part zone 13". During the course of further rotation in the treating direction 16, the batch 17 is moved upwardly by the lifting wall 12, as depicted in FIG. 4. During the entire batch lifting step, the liquid 18 flows out of the drum through the openings 19 of the part zone 13' and then flows back into the drum 1 through the holes 19 of the other part zone 13" as shown by the arrows drawn through the openings 19 in FIG. 4. In this manner liquid is continuously drawn from the batch 17. Upon further clockwise rotation, as the inclination of the lifting wall 12 increases, the batch 17 slides and falls downwardly into the liquid 18 which has accumulated in the drum 1 above the aperture-free zone 14 which, by this time, has assumed its lower position as shown in FIG. 5. By means of the impact speed of the batch 17 with which it splashes into the stationary liquid 18 and by virtue of the circumstance that the liquid 18 can be displaced neither upwardly because of the impeller slide 9 nor downwardly because of the non-apertured zone 14, an intensive liquid penetration is achieved. This liquid penetration is further enhanced by the sinking leading portion of the apertured part zone 13'. In this manner, by means of the then occurring exit of the liquid 18, a drop in the liquid level and thus an intensive penetration of the batch 17 is maintained. Upon further rotation in the treating direction 16, the drum 1 again assumes its position shown in FIG. 3 and the cycle is repeated.
Upon termination of the treating phase, the conveying phase begins, for which the drum 1 is rotated in the opposite, "conveying" direction as indicated with the arrow 20 in FIG. 6. During this counterclockwise rotation, first the lifting wall 12 engages the batch 17, whereby the liquid 18 flows through the bores 19 of the apertured part zone 13" out of the drum 1 and onto the outer vessel 15 and then, passing the junction 12', it flows again back into the drum 1 through the bores 19 of the other apertured part zone 13'. Thus, during the subsequent lifting of the batch 17 by the lifting wall 12, a substantial part of the liquid 18 is withdrawn from the batch. This liquid remains in the drum 1 or, as the case may be, in the outer vessel 15 while the batch 17 is further lifted. As, during the rotation of the drum 1 in the conveying direction 20, the wall 12 attains a sufficient inclination, the batch 17 slides on the lifting wall 12 downwardly onto the impeller slide 9 and further slides on the latter in the conveying direction from the left to the right as viewed in FIG. 2, to thus exit through the outlet opening 6 and to be then introduced into the successive drum 1.
Turning now to FIG. 7, there is illustrated therein a drum-equipped washing machine in which the drums are structured according to the invention. The washing machine has three drums 1. The outer vessels 15 are formed of a housing portion 21 which, at its opposite ends, is provided with radially outwardly extending annular flanges 22. To these flanges there are secured, by means of bolts 24 or the like, radial separating walls 23 in a fluidtight manner. The housing shell 21 of an adjoining outer vessel 15 may engage directly the opposite side of the separating wall 23, so that, in each instance, only a single separating wall 23 is arranged between any two adjoining drums 1. Each separating wall 23 is provided with a central opening accommodating a slide bearing ring 25 which surrounds and supports two adjoining rings 7 belonging, respectively, to the outlet opening 6 of one drum 1 and the inlet opening 5 of the adjoining, successive drum 1. Each drum 1 is provided with a gear ring 26 arranged circumferentially on the outside of the respective drum shell 2. Each gear ring 26 meshes with a respective pinion 27 of a reversible drive motor 28 supported externally of the respective outer vessel 15. It may be observed in FIG. 7 that each drum 1 can be rotated, during operation, either in the treating direction or in the conveying direction. The batches which are introduced into the machine through a hopper 29 arranged at the left side of the machine (as viewed in FIG. 7) are thus, after each washing phase, conveyed towards the right into the successive drum and thus batchwise leave the last drum 1 situated at the right. For supporting the outer vessels 15 there is provided a machine frame 30. The supply and control of wash detergents and additives as well as the supply and control of heat for the liquid 18 are effected in a conventional manner. Also, at the same time, the liquid quantity is controlled as indicated at 18' showing non-uniform liquid levels in the several drums 1.
When the washing machine is switched off, a control arrangement in the drum drive ensures that the drums 1 come to rest in a "parking" position in which the two ends 14' of the aperture-free zone 14 are situated above a horizontal plane that corresponds to the normal operational liquid level 18' , while the remainder of the zone 14 is underneth that plane, as indicated in FIG. 8. Stated differently, in the "parking" position the lower circumferential half of the drum shell is its aperture-free zone 14 and the liquid level 18' is such that it does not project beyond the aperture-free zone 14 into the apertured zone 13. In this manner, underneath the ends 14' there is provided a liquidtight space inside the drum 1 so that liquid can flow neither out of the drum nor thereinto when the machine is at standstill. Thus, at standstill, the condition of the liquid 18 and the batch 17 present in the drum 1 is, apart from changes in temperature, maintained constant irrespective of the time lapsed. The control arrangement for achieving such a predetermined parking position includes known elements, for example, a contact 32 which is mounted on the gear ring 26 and the position of which is sensed by contacting or contactless means to achieve a predetermined parking position subsequent to to the shutoff of the washing machine.
It is to be understood that the distribution of the apertured and aperture-free zones 13 and 14, respectively, may be different from that disclosed above, but should be so designed that the opposite ends 14' of the aperture-free zone 14 project upwardly beyond the horizontal plane representing the liquid level 18' in the position of rest (parking position) of the drum 1. Thus, it is feasible to provide different distributions of the zones 13 and 14 from drum to drum to thus adopt the liquid penetration to the particular treating phase. It is further feasible to provide a single drive for all drums 1 of the drum-equipped apparatus, for example, by providing, for the pinions 27, a throughgoing common shaft driven by a single motor. In such a case, the conveying positions of the drums 1 are expediently angularly staggered with respect to one another, while care is taken that in the parking position the drums 1 are separated liquidtight from one another as described above.
It is to be understood that the above description of the present invention is susceptible to various modifications, changes and adaptations and the same are intended to be comprehended within the meaning and range of equivalents of the appended claims.
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A drum-equipped apparatus for the wet treatment of batches of material has a horizontally oriented rotatably supported drum including a drum shell bounded by end walls and including a central inlet opening and a central outlet opening provided in the one and the other end wall, respectively. The apparatus further has a drive for selectively rotating the drum in a treating direction and in an opposite, conveying direction. A lifting wall is secured to the drum in the inside thereof for displacing the material batch radially with respect to the rotary axis of the drum during the rotation thereof in the treating direction. Further, a slide is secured to the drum in the inside thereof for displacing the material batch in the axial direction of the drum towards the outlet opening during the rotation thereof in the conveying direction. The drum is supported in an external vessel which receives treating liquid into which the drum is partially submerged. The drum shell has an apertured zone oriented towards the slide face of the slide and an aperture-free zone oriented towards the reverse side of the slide.
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TECHNICAL FIELD
[0001] The present invention relates to a system and method for providing refrigeration to a cryogenic separation unit, and more specifically, to a system and method which incorporates both warm and cold turbine arrangements that are configured to provide the refrigeration required to enable increased liquid product make.
BACKGROUND
[0002] Cryogenic air separation is a very energy intensive process due to the need to generate very low temperature refrigeration and separate feed constituents of low relative volatility. The cryogenic air separation process is further complicated when it is integrated with a liquefaction process to recover substantial flows of liquid products from the air separation unit. In cryogenic air separation units designed to produce a large amount of liquid products, such as liquid oxygen, liquid nitrogen and liquid argon, a large amount of refrigeration must be provided, typically through the use of multi-turbine process arrangements.
[0003] A broad set of refrigeration configurations are designed to expand the feed air. Feed air expansion arrangements are often referred to as air pre-expansion configurations. High pressure feed air may be first cooled and then expanded in whole or in part to any one of the nitrogen rectification sections of the column system. In many instances, the demand for liquid products eclipses the potential production from air pre-expansion. In such circumstances, a warm turbine may be configured to expand air or another fluid for purposes of warm end fore-cooling. Such arrangements can be configured as open or semi-closed recycle systems. Such configurations impart refrigeration to the cryogenic air distillation column system via indirect heat exchange with the pre-purified, compressed feed air in the primary heat exchanger or in an auxiliary heat exchanger.
[0004] In the air pre-expansion arrangement, a portion of the pre-purified, compressed feed air is often further compressed in a boosted air compressor, partially cooled in the primary heat exchanger, and then all or a portion of this further compressed, partially cooled stream is diverted to a turbine. The expanded gas stream or exhaust stream is then directed to the higher pressure column of a dual pressure cryogenic air distillation column system. In some air pre-expansion arrangements, a portion of the compressed and purified air is diverted to a turbine without further compression in a booster air compressor,
[0005] Alternatively, a portion of the pre-purified, compressed feed air is partially cooled in the primary heat exchanger; a portion of this partially cooled stream is diverted to a second turbo-expander. The expanded gas stream or exhaust stream may be optionally cooled via direct or indirect heat exchange and directed to into a lower pressure column in the a thermally linked dual pressure distillation column system such as a two-column or three column distillation column system of a cryogenic air separation unit. The turbo-expansion of various column feed streams serves to refrigerate the distillation process. The work of expansion provides the refrigeration necessary to offset warm end temperature loss, process heat leak and to generate liquid products. In general, when column feed streams are expanded prior to column entry the refrigeration generated is subsequently recouped by the warming of the various product streams. The indirect heat exchange of warming column products provides then necessary cooling of the various feed air streams prior to column entry.
[0006] In order to increase the fraction of liquefied products extracted from the column system to above approximately 40% of the incoming feed air, refrigeration must be imparted to the cold end of the primary heat exchanger. Prior art processes have addressed this need by recycling a portion of the cold turbo-expanded gas stream through the primary heat exchanger.
[0007] Prior art cryogenic air separation processes have dealt with this issue by further turbo-expand the portion of air recycled to the cold turbine in an air separation unit to pressures at or near ambient pressure, as disclosed in U.S. Pat. No. 5,157,926. Such an approach, however suffers due to increased costs required to handle the near ambient pressure stream in the primary heat exchanger. In addition, the warm expansion turbine is constrained to operate between the pressure of the lower column and near ambient pressure. In addition such processes substantially increase the pre-purification demands on the process.
[0008] Accordingly, there is a need to reduce the costs associated with high liquid make cryogenic air separation units while maintaining high thermodynamic efficiency of the integrated cryogenic air separation and liquefaction system. Such solutions must also maintain the simplicity, reliability and relatively low cost of the rotating machinery used in the cold and warm turbines as well as the associated booster compression.
SUMMARY OF THE INVENTION
[0009] The present invention may be characterized as a method for air separation and liquefaction, the method comprising the steps of: (a) compressing at least a portion of a feed stream, such as air, in a multi-stage main feed compression system to a first pressure; (b) purifying the compressed feed stream to remove high boiling contaminants and other impurities; (c) further compressing at least a portion of the purified, compressed feed stream in a booster compression system to a second pressure; (d) still further compressing at least a portion of the further compressed feed stream at the second pressure in the booster compression system to a third pressure; (e) cooling a first portion of the further compressed feed stream at the third pressure in a primary heat exchanger and expanding the cooled first portion of the feed stream in a first turbine to a pressure suitable for introduction into the cryogenic separation unit; (f) cooling and substantially condensing a second portion of the further compressed feed stream at the third pressure and feeding the condensed second portion to a distillation column system of the cryogenic separation unit; (g) directing a first portion of the exhaust stream from the first turbine to a distillation column system of the cryogenic separation unit where it is separated to produce at least one liquefied product, such as liquid oxygen, liquid nitrogen, liquid argon or combinations thereof; (h) warming a second portion of the exhaust stream from the first turbine and compressing the warmed second portion of the exhaust stream from the first turbine in a recycle compression system to produce a recycle stream at a recycle pressure between the first pressure and the second pressure; (i) recycling the recycle stream to the purified, compressed feed stream; (j) diverting a portion of the purified, compressed feed stream between the first pressure and the third pressure to a second turbine and expanding the diverted portion of the purified, compressed feed stream to a pressure between the first pressure and the second pressure; and (k) warming the exhaust stream from the second turbine in the primary heat exchanger and recycling the warmed exhaust stream from the second turbine to the purified, compressed feed stream. Preferably, the pressure of the warmed exhaust stream from the second turbine is roughly the same as the recycle pressure.
[0010] The present invention may also be characterized as a cryogenic separation unit comprising: (i) a multi-stage main feed compression system configured for compressing at least a portion of a feed stream to a first pressure; (ii) a pre-purifier unit disposed downstream of the main feed compression system and configured for purifying the compressed feed stream to remove impurities; (iii) a booster compression system disposed downstream of the pre-purifier unit and configured for further compressing the purified, compressed feed stream to a second pressure and then further compressing a portion of the purified, compressed feed stream at the second pressure to a third pressure; (iv) a primary heat exchanger configured to receive a first portion and a second portion of the compressed, purified feed stream at the third pressure, partially cool the first portion of the compressed, purified feed stream at the third pressure, and substantially condense the second portion of the compressed, purified feed stream at the third pressure to temperatures suitable for rectification in a distillation column system; (v) a first turbine arrangement configured to receive the partially cooled first portion of the compressed, purified feed stream at the third pressure, expand such first portion to provide refrigeration, wherein a portion of the expanded stream is directed to the distillation column system where it is separated to produce at least one liquefied product and wherein another portion of the expanded stream is directed to the primary heat exchanger where it is warmed; (vi) a recycle compression circuit configured to receive another portion of the expanded stream from the first turbine arrangement, warm the another portion of the expanded stream in the primary heat exchanger, further compress the warmed expanded stream in a recycle compressor to produce a recycle stream at a recycle pressure between the first pressure and the second pressure, wherein the recycle stream is recycled to a location upstream of the boosted compression system; (vii) a second turbine arrangement configured to receive a portion of the purified, compressed feed stream at the second pressure and expand such portion to provide refrigeration, wherein the expanded stream from the second turbine arrangement is warmed in the primary heat exchanger and recycled to a location upstream of the boosted compression system; and (viii) a warm turbine recycle circuit configured to receive the expanded stream from the second turbine arrangement, warm the expanded stream in the primary heat exchanger, and recycle the warmed expanded stream from the second turbine arrangement to a location upstream of the boosted compression system.
[0011] In the present system and method, the first turbine or first turbine arrangement is preferably configured as a lower column turbine which directs a portion of the exhaust stream to the higher pressure column of the distillation column system. The first turbine and/or the second turbine may be further configured or arranged such that the shaft work of expansion from the first turbine and/or the second turbine drives one or more stages of compression in the booster compression system and/or the recycle compression system. Optionally, where the exhaust stream of the first turbine is a two-phase stream, a phase separator may be employed downstream of the first turbine to separate the phases and direct the separated streams to the distillation column system.
BRIEF DESCRIPTION OF THE DRAWING
[0012] While the specification concludes with claims specifically pointing out the subject matter that Applicant regards as the invention, it is believed that the invention will be better understood when taken in connection with the accompanying drawing in which
[0013] FIG. 1 is a schematic illustration of an embodiment of an integrated cryogenic separation and liquefaction system outlining a process or method for cryogenic separation and liquefaction in accordance with the present invention.
DETAILED DESCRIPTION
[0014] Turning now to FIG. 1 , there is shown a simplified illustration of the present cryogenic separation system 10 and process. In a broad sense, the present system and method comprises: a multi-stage main feed compression train 20 ; one or more booster compression circuits 30 , a main or primary heat exchange section 40 ; two or more turbine based refrigeration circuits 70 A and 70 B, and a distillation column system 50 .
[0015] In the main feed compression train 20 shown in FIG. 1 , the incoming feed air 11 is compressed in a multi-stage main air compressor arrangement 12 to a pressure P 1 generally in the range of about 130 psia to about 190 psia. The compressed air feed 13 is then purified in a pre-purification unit 14 to remove high boiling contaminants from the incoming feed air. Such a pre-purification unit 14 typically has beds of adsorbents to adsorb such contaminants as water vapor, carbon dioxide, and hydrocarbons.
[0016] As described in more detail below, the compressed, purified feed air stream 15 is separated into oxygen-rich, nitrogen-rich, and argon-rich fractions in a plurality of distillation columns including a higher pressure column 52 , a lower pressure column 54 , and optionally, argon column (not shown). Prior to such distillation however, the compressed, pre-purified feed air stream 15 is split into a plurality of feed air streams that are cooled to temperatures suitable for rectification. Cooling the compressed, purified feed air streams is accomplished by way of indirect heat exchanger with the warming column system 50 streams which include the oxygen, nitrogen and/or argon waste. Refrigeration is generated by the cold and warm turbine arrangements disposed within the turbine based refrigeration circuits.
[0017] In the present embodiment, the compressed, pre-purified air stream 15 is further compressed in a recycle air compressor (RAC) 22 to a pressure P 2 in range of about 450 psia to about 550 psia. A first portion of this warm, further compressed, pre-purified air 23 A is still further compressed by way of a boosted air compressor 24 preferably powered by way of the shaft work of expansion from a first turbo-expander 32 to a third pressure P 3 . As illustrated, the first turbo-expander 32 providing the shaft work is preferably one of the turbo-expanders associated with the cold-turbine arrangement 72 , and preferably a lower column turbine (LCT). The resulting pressure, P 3 , of this first portion of compressed, pre-purified feed air 23 A is preferably in the range of about 650 psia to about 850 psia. A second portion of the warm, further compressed, pre-purified air 23 B is diverted to the refrigeration circuits 70 B, and more particularly to the warm recycle turbine (WRT) arrangement 74 as a warm recycle air stream 23 B, described below.
[0018] The first portion of compressed, pre-purified feed air 23 A is high pressure feed air stream that is further split into a first subportion high pressure feed air stream 37 and a second subportion high pressure feed air stream 39 . The first subportion high pressure feed air stream 37 is partially cooled in the primary heat exchanger 42 and expanded in the first turbo-expander 32 associated with the LCT cold turbine arrangement 72 , while the second subportion high pressure feed air stream 39 is liquefied in the primary heat exchanger 42 and fed to the distillation column system 50 . As illustrated, part of the second subportion high pressure feed air stream 39 is liquefied in the primary heat exchanger 42 and the resulting liquid air stream 41 is expanded in valve 46 and introduced at an intermediate location of the higher pressure column 52 while another part of the second subportion high pressure feed air stream 39 is liquefied in the primary heat exchanger 42 and the resulting liquid air stream 43 is expanded in valve 44 and introduced as liquid air to the lower pressure column 54 . The splitting of the high pressure feed air stream 23 A may be accomplished either upstream of the primary heat exchanger 42 or within the primary heat exchanger at selected locations to achieve the desired cooling profiles of the different portions and subportions of the high pressure feed air stream.
[0019] Part of the exhaust stream 36 A from the first turbo-expander 32 of the LCT based cold turbine arrangement 72 is fed directly to the distillation column system 50 , and more preferably to the higher pressure column 52 while another part of the exhaust stream 36 B from the first turbo-expander 32 of the LCT based cold turbine arrangement 72 is diverted to the primary heat exchanger 42 where it is warmed to near ambient temperatures and the resulting LCT recycle stream 45 is compressed in the WRT booster compressor 79 . Stream 36 A may be optionally subcooled against a waste nitrogen stream and/or phase separated prior to column entry. The compressed LCT recycle stream 76 is then combined with the warmed WRT exhaust stream 78 and recycled back to the compressed and purified feed air stream 15 , preferably at a location upstream of the RAC 22 . One of the key aspects or features of the present system and method is this recompression of the LCT recycle stream 45 to a pressure, P 4 , that is not less than the pressure P 1 of the compressed air feed exiting the multi-stage main feed air compressor 12 or pre-purification unit 14 .
[0020] In the illustrated embodiment, between about 50% and 70%, and more preferably about 60% of the exhaust stream 36 from the first turbo-expander 32 of the LCT based cold-turbine arrangement 72 is recycled back through the primary heat exchanger 42 while the remaining 30% to 50% of the exhaust stream 36 from the first turbo-expander 32 of the LCT based cold turbine arrangement 72 is fed to the distillation column system 50 . In a preferred mode of operation, the remaining exhaust stream 36 A is fed directly to the higher pressure column 52 . In cases where the exhaust stream is a two phase stream, the exhaust stream may also be directed to a phase separator either upstream or downstream of the LCT exhaust split to further condition the stream prior to introduction into the distillation column system.
[0021] Within the illustrated distillation column system 50 , the various feed air streams in both gaseous and liquid forms are separated in manners well known to those persons skilled in the art into various product streams, kettle streams, and waste streams, including a liquid nitrogen product stream 62 and a liquid oxygen product stream 64 , which are preferably directed to suitable storage vessels (not shown). A portion of the liquid nitrogen stream 67 may be used to reflux the lower pressure column 54 . Likewise, a portion of the kettle stream 65 may be re-introduced to the lower pressure column 54 .
[0022] The waste streams comprised of excess gaseous oxygen 66 and lower pressure column overhead gaseous nitrogen 68 are preferably returned to the primary heat exchanger 42 where they are warmed to temperatures at or near ambient temperature and indirectly cooling the high pressure incoming air feed streams. Optionally, the gaseous nitrogen overhead stream 68 may be used as a source of subcooling streams entering the distillation column system 50 . Optionally, the gaseous oxygen stream 66 and gaseous nitrogen overhead stream 68 may be combined into a single waste stream 69 prior to warming in the primary heat exchanger 42 .
[0023] Key features of the present system and method are derived from the management of the various warming recycle streams obtained from both the cold and warm turbines. In the illustrated embodiment, a warm recycle air stream 23 B is extracted from the discharge of the RAC 23 and directed via a warm recycle circuit to the primary heat exchanger 42 , partially cooled in the primary heat exchanger 42 and expanded in a second turbo-expander 75 of the warm recycle turbine (WRT) arrangement 74 to a pressure not less than the pressure of the compressed air feed exiting the multi-stage main feed air compressor 12 or pre-purification unit 14 . While the stream 23 B is shown as being partially cooled in the primary heat exchanger, the stream 23 B could alternatively be cooled by other cooling means such as a refrigeration system. The exhaust 77 from the second turbo-expander 75 is then warmed in the primary heat exchanger 42 thereby producing WRT recycle stream 78 which is returned or recycled back to the compressed, purified feed air stream 15 , preferably at a location upstream of the RAC 22 .
[0024] While the present invention has been described with reference to a preferred embodiment and operating method associated therewith, it should be understood that numerous additions, changes and omissions to the disclosed system and method can be made without departing from the spirit and scope of the present invention as set forth in the appended claims.
[0025] For example, the warm recycle air stream 23 B may be extracted or diverted from the discharge of the LCT booster compressor 24 , partially cooled in the primary heat exchanger 42 and subsequently expanded in the second turbo-expander 75 of the warm recycle turbine (WRT) arrangement 74 to generate refrigeration.
[0026] Also, the warm booster compressor discharge pressure and the WRT exhaust pressure are preferably equivalent so that the streams 76 and 78 may be combined prior to recycling the combined stream 78 to the purified, compressed feed air stream 15 . However, in arrangements where the warm booster compressor discharge pressure and the WRT exhaust pressure differ, the LCT recycle stream 76 and the warmed WRT exhaust stream 78 may be returned or recycled separately to selected locations in the purified, compressed feed streams 15 or 23 .
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A system and method for providing refrigeration to a cryogenic separation unit is provided. The disclosed system and associated methods employ both a warm recycle turbine arrangement and cold turbine arrangement to provide the refrigeration required to produce a large amount of liquid products, such as liquid oxygen, liquid nitrogen and liquid argon when used in a cryogenic air separation unit.
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BACKGROUND OF THE INVENTION
The present application is related generally to the field of underground directional drilling and, more particularly, to an advanced underground homing system, apparatus and method for directing a drill head to a homing target.
A boring tool is well-known as a steerable drill head that can carry sensors, transmitters and associated electronics. The boring tool is usually controlled through a drill string that is extendable from a drill rig. The drill string is most often formed of drill pipe sections, which may be referred to hereinafter as drill rods, that are selectively attachable with one another for purposes of advancing and retracting the drill string. Steering is often accomplished using a beveled face on the drill head. Advancing the drill string while rotating should result in the boring tool traveling straight forward, whereas advancing the drill string with the bevel oriented at some fixed angle will result in deflecting the boring tool in some direction. A number of approaches have been seen in the prior art for purposes of attempting to guide the boring tool to a desired location, a few of which will be discussed immediately hereinafter.
In one approach, the boring tool transmits an electromagnetic locating signal. Above ground, a portable detection device, known as a walkover detector, is movable so as to characterize the positional relationship between the walkover detector and the boring tool at a given time. The boring tool can be located, for example, by moving the walkover detector to a position that is directly overhead of the boring tool or at least to some unique point in the field of the electromagnetic locating signal. In some cases, however, a walkover locator is not particularly practical when drilling beneath some sort of obstacle such as, for example, a river, freeway or building. In such cases, other approaches may be more practical.
Another approach that has been taken by the prior art, which may be better adapted for coping with obstacles which prevent access to the surface of the ground above the boring tool, resides in what is commonly referred to as a “steering tool.” This term has come to describe an overall system which essentially predicts the position of the boring tool, as it is advanced through the ground using a drill string, such that the boring tool can be steered from a starting location while the location of the boring tool is tracked in an appropriate coordinate system relative to the starting position. Arrival at a target location is generally determined by comparing the determined position of the boring tool with the position of the desired target in the coordinate system.
Steering tool systems are considered as being distinct from other types of locating systems used in horizontal directional drilling at least for the reason that the position of the boring tool is determined in a step-wise fashion as it progresses through the ground. Generally, in a traditional steering tool system, pitch and yaw angles of the drill-head are measured in coordination with extension of the drill string. From this, the drill-head position coordinates are obtained by numerical integration step-by-step from one location to the next. Nominal or measured drill rod lengths can serve as a step size during integration. One concern with respect to conventional steering tools is a tendency for positional error to accumulate with increasing progress through the ground up to unacceptable levels. This accumulation of positional error is attributable to measurement error in determining the pitch and yaw angles at each measurement location. One technique in the prior art in attempting to cope with the accumulation of positional error resides in attempting to measure the pitch and yaw parameters with the highest possible precision, for example, using an optical gyroscope in an inertial guidance system. Unfortunately, such gyroscopes are generally expensive.
Another approach that has been taken by the prior art, which is also able to cope with drilling beneath obstacles, is a homing type system. In traditional homing systems, the boring tool includes a homing transmitter that transmits an electromagnetic signal. A homing receiver is positioned at a target location or at least proximate to a target location such as, for example, directly above the target location. The homing receiver is used to receive the electromagnetic signal and to generate homing commands based on characteristics of the electromagnetic signal which indicate whether the boring tool is on a course that would ultimately cause it to be directed to the target location. Generally, identifying the particular location of the boring tool is not of interest since the boring tool will ultimately arrive at the target location if the operator follows the homing commands as they are issued by the system. Applicants recognize, however, that such traditional homing systems are problematic with respect to use at relatively long ranges between the homing receiver and the boring tool, as will be discussed in detail below.
The foregoing examples of the related art and limitations related therewith are intended to be illustrative and not exclusive. Other limitations of the related art will become apparent to those of skill in the art upon a reading of the specification and a study of the drawings.
SUMMARY
The following embodiments and aspects thereof are described and illustrated in conjunction with systems, tools and methods which are meant to be exemplary and illustrative, not limiting in scope. In various embodiments, one or more of the above-described problems have been reduced or eliminated, while other embodiments are directed to other improvements.
In general, a system includes a boring tool that is moved by a drill string using a drill rig that selectively extends the drill string to the boring tool to form an underground bore such that the drill string is characterized by a drill string length which is determinable. In one aspect, a homing apparatus includes a transmitter, forming part of the boring tool, for transmitting a time varying dipole field as a homing field. A pitch sensor is located in the boring tool for detecting a pitch orientation of the boring tool. A homing receiver is positionable at least proximate to a target location for detecting the homing field to produce a set of flux measurements. A processing arrangement is configured for using the detected pitch orientation and the set of flux measurements in conjunction with a determined length of the drill string to determine a vertical homing command for use in controlling depth in directing the boring tool to the target location such that the vertical homing command is generated with a particular accuracy at a given range between the transmitter and the homing receiver and which would otherwise be generated with the particular accuracy for a standard range, that is different from the particular range, without using the determined length of the drill string. A display indicates the vertical homing command to a user. In one feature, the boring tool is sequentially advanced through a series of positions along the underground bore and, at each one of the positions (i) the pitch orientation is detected by the pitch sensor, (ii) the homing receiver produces the flux measurements and (iii) the drill string is of the determined length such that at least the set of flux measurements is subject to a measurement error and the processing arrangement is configured for determining the vertical homing command, at least in part, by compensating for the measurement error, which measurement error would otherwise accumulate from each one of the series of positions to a next one of the series of positions, to cause the particular range to be greater than the standard range.
In another aspect, a system includes a boring tool that is moved by a drill string using a drill rig that selectively extends the drill string to the boring tool to form an underground bore such that the drill string is characterized by a drill string length. One embodiment of a method includes transmitting a time varying dipole field from the boring tool as a homing field. A pitch orientation of the boring tool is detected using a pitch sensor located in the boring tool. A homing receiver is positioned at least proximate to a target location for detecting the homing field to produce a set of flux measurements. A length of the drill string is determined. A processor is configured for using the detected pitch orientation and the set of flux measurements in conjunction with the established length of the drill string to determine a vertical homing command for use in controlling depth in directing the boring tool to the target location such that the vertical homing command is generated with a particular accuracy at a given range between the transmitter and the homing receiver and which would be generated with the particular accuracy for a standard range, that is different from the particular range, without using the determined length of the drill string, and indicating the vertical homing command to a user. In one feature, the boring tool is sequentially advanced through a series of positions along the underground bore and, at each one of the positions (i) the pitch orientation is detected using the pitch sensor, (ii) the flux measurements are produced by the homing receiver and (iii) establishing the determined length of the drill string is established such that at least the set of flux measurements is subject to a measurement error. The vertical homing command is determined, at least in part, by compensating for the measurement error, which measurement error would otherwise accumulate from each one of the series of positions to a next one of the series of positions, to cause the particular range to be greater than the standard range.
In still another aspect, a system includes a boring tool that is moved by a drill string using a drill rig that selectively extends the drill string to the boring tool to form an underground bore such that the drill string is characterized by a drill string length which is determinable. A homing apparatus includes a transmitter, forming part of the boring tool, for transmitting a time varying electromagnetic homing field. A pitch sensor is located in the boring tool for detecting a pitch orientation of the boring tool. A homing receiver is provided that is positionable at least proximate to a target location for detecting the homing field to produce a set of flux measurements. A processing arrangement is configured for using the detected pitch orientation and the set of flux measurements in conjunction with a determined length of the drill string to determine a vertical homing command and a horizontal homing command such that the vertical homing command has a particular accuracy that is different from another accuracy associated with the horizontal homing command for use in controlling depth in directing the boring tool to the target location. In one feature, the particular accuracy of the vertical homing command is greater than the other accuracy of the horizontal homing command.
In yet another aspect, a system includes a boring tool that is moved by a drill string using a drill rig that selectively extends the drill string to the boring tool to form an underground bore such that the drill string is characterized by a drill string length which is determinable. A method includes transmitting a time varying electromagnetic homing field from the boring tool. A pitch orientation of the boring tool is detected. A homing receiver is positioned at least proximate to a target location for detecting the homing field to produce a set of flux measurements. The detected pitch orientation and the set of flux measurements are used in conjunction with a determined length of the drill string to determine a vertical homing command and a horizontal homing command such that the vertical homing command has a particular accuracy that is different from another accuracy associated with the horizontal homing command for use in controlling depth in directing the boring tool to the target location. In one feature, the particular accuracy of the vertical homing command is generated as being more accurate than the other accuracy of the horizontal homing command.
In a further aspect, a system includes a boring tool that is moved by a drill string using a drill rig that selectively extends the drill string to the boring tool to form an underground bore such that the drill string is characterized by a drill string length which is determinable and in which the boring tool is configured for transmitting an electromagnetic homing field. An improvement includes configuring an arrangement for using at least the electromagnetic homing field to determine a vertical homing command and a horizontal homing command such that the vertical homing command has a particular accuracy that is different from another accuracy associated with the horizontal homing command for use in controlling depth in directing the boring tool to the target location. In one feature, the arrangement is further configured for generating the particular accuracy of the vertical homing command as being more accurate than the other accuracy of the horizontal homing command.
In addition to the exemplary aspects and embodiments described above, further aspects and embodiments will become apparent by reference to the drawings and by study of the following descriptions.
BRIEF DESCRIPTION OF THE DRAWINGS
Exemplary embodiments are illustrated in referenced figures of the drawings. It is intended that the embodiments and figures disclosed herein are to be illustrative rather than limiting.
FIG. 1 is a diagrammatic view, in elevation, of a region in which a homing apparatus and associated method, according to the present disclosure, are used in a homing operation for purposes of causing a boring tool to home in on a target location.
FIG. 2 is a diagrammatic plan view of the region of FIG. 1 in which the homing apparatus and associated method are employed.
FIG. 3 is a diagrammatic view, in perspective, of a portable homing receiver that is produced according to the present disclosure, shown here to illustrate the various components of the homing receiver.
FIG. 4 is a flow diagram which illustrates one embodiment of a homing method according to the present disclosure.
FIG. 5 is a diagrammatic illustration of one embodiment of the appearance of a screen for displaying a homing command generated according to the present disclosure.
FIG. 6 a is a plot which illustrates a simulated drill path in an elevational view for use in demonstrating the accuracy of vertical homing commands produced according to the present disclosure.
FIG. 6 b is a plot of the vertical homing command along the simulated drill path of FIG. 6 a , which vertical homing command is produced according to the present disclosure.
FIG. 6 c is a plot of X axis error along the X axis illustrating a difference between actual position along the X axis and determined position for the drill path of FIG. 6 a.
FIG. 6 d is a plot of Z axis error along the X axis illustrating a difference between actual position along the Z axis and determined position for the drill path of FIG. 6 a.
FIG. 7 a is a another plot which illustrates another simulated drill path in an elevational view for use in demonstrating the accuracy of vertical homing commands produced according to the present disclosure.
FIG. 7 b is a plot of the vertical homing command along the simulated drill path of FIG. 7 a , which vertical homing command is produced according to the present disclosure.
FIG. 7 c is a plot of X axis error along the X axis illustrating a difference between actual position along the X axis and determined position for the drillpath of FIG. 7 a.
FIG. 7 d is a plot of Z axis error along the X axis illustrating a difference between actual position along the Z axis and determined position for the drillpath of FIG. 7 a.
FIG. 8 a is a plot which illustrates a simulated drill path in a plan view which is used in conjunction with the elevational view of FIG. 6 a to form an overall three-dimensional simulated drill path for use in demonstrating the effectiveness of vertical homing commands produced according to the present disclosure in view of significant yaw and lateral diversion of the boring tool.
FIG. 8 b is a plot of the vertical homing command along the simulated drill path cooperatively defined by FIGS. 6 a and 8 a , which vertical homing command is produced according to the present disclosure and with the vertical homing command of FIG. 6 b shown as a dashed line for purposes of comparison.
FIG. 8 c is a plot of Z axis error along the X axis illustrating a difference between actual position along the Z axis and determined position for the drillpath cooperatively defined by FIGS. 6 a and 8 a and with the Z axis error of FIG. 6 d shown as a dashed line for purposes of comparison.
FIG. 9 is a plot of the vertical homing command along the X axis, shown here for purposes of comparing the accuracy of the homing commands of a conventional homing system with the accuracy of vertical homing commands generated according to the present disclosure.
DETAILED DESCRIPTION
The following description is presented to enable one of ordinary skill in the art to make and use the invention and is provided in the context of a patent application and its requirements. Various modifications to the described embodiments will be readily apparent to those skilled in the art and the generic principles taught herein may be applied to other embodiments. Thus, the present invention is not intended to be limited to the embodiment shown, but is to be accorded the widest scope consistent with the principles and features described herein including modifications and equivalents, as defined within the scope of the appended claims. It is noted that the drawings are not to scale and are diagrammatic in nature in a way that is thought to best illustrate features of interest. Descriptive terminology such as, for example, upper/lower, front/rear, vertically/horizontally, inward/outward, left/right and the like may be adopted for purposes of enhancing the reader's understanding, with respect to the various views provided in the figures, and is in no way intended as being limiting.
Turning now to the figures, wherein like components are designated by like reference numbers whenever practical, attention is immediately directed to FIGS. 1 and 2 , which illustrate an advanced homing tool system that is generally indicated by the reference number 10 and produced according to the present disclosure. FIG. 1 is a diagrammatic elevational view of the system, whereas FIG. 2 is a diagrammatic plan view of the system, each figure showing a region 12 in which a homing operation is underway. System 10 includes a drill rig 18 having a carriage 20 received for movement along the length of an opposing pair of rails 22 which are, in turn, mounted on a frame 24 . A conventional arrangement (not shown) is provided for moving carriage 20 along rails 22 . A boring tool 26 includes an asymmetric face 28 ( FIG. 1 ) and is attached to a drill string 30 which is composed of a plurality of drill pipe sections 32 , several of which are indicated. It is noted that the drill string is partially shown due to illustrative constraints. Generally, the drill rig hydraulically pushes the drill string into the ground with selective rotation. Pushing with rotation is intended to cause the boring tool to travel straight ahead while pushing without rotation is intended to cause the boring tool to turn, based on the orientation of asymmetric face 28 . A path 40 of the boring tool includes a series of positions that are designated as k=1, 2, 3, 4 etc. as the boring tool is advanced through the ground. The current position of the boring tool is position k with the next position to be position k+1. The portion of path 40 along which the boring tool has already traveled is shown as a solid line while a dashed line 40 ′, in FIG. 1 , illustrates the potential appearance of the path ahead of the boring tool resulting from the homing procedure. The increment between the positions k and k+1 can correspond to the length of one pipe section, although this is not a requirement. Boring tool 26 enters the ground at 42 , however, the subject homing process can begin at position k=1 at a depth D 1 below a surface 44 of the ground, where a point 45 on the surface of the ground serves as the origin of a coordinate system. As will be seen, the homing operation can be initiated at point 42 where the boring tool initially enters the ground. While a Cartesian coordinate system is used as the basis for the coordinate system employed by the various embodiments disclosed herein, it is to be understood that this terminology is used in the specification and claims for descriptive purposes and that any suitable coordinate system may be used.
As the drilling operation proceeds, respective drill pipe sections, which may be referred to interchangeably as drill rods, are added to the drill string at the drill rig. A most recently added drill rod 32 a is shown on the drill rig. An upper end 50 of drill rod 32 a is held by a locking arrangement (not shown) which forms part of carriage 20 such that movement of the carriage in the direction indicated by an arrow 52 ( FIG. 1 ) causes section 32 a to move therewith, which pushes the drill string into the ground thereby advancing the boring operation. A clamping arrangement 54 is used to facilitate the addition of drill pipe sections to the drill string. The drilling operation can be controlled by an operator (not shown) at a control console 60 which itself can include a telemetry section 62 connected with a telemetry antenna 64 , a display screen 66 , an input device such as a keyboard 68 , a processor 70 , and a plurality of control levers 72 which, for example, control movement of carriage 20 .
Still referring to FIGS. 1 and 2 , in one embodiment, system 10 can include a drill string measuring arrangement having a stationary ultrasonic transmitter 202 positioned on drill frame 24 and an ultrasonic receiver 204 with an air temperature sensor 206 ( FIG. 2 ) positioned on carriage 20 . It should be noted that the positions of the ultrasonic transmitter and receiver may be interchanged with no effect on measurement capabilities. Transmitter 202 and receiver 204 are each coupled to processor 70 or a separate dedicated processor (not shown). In a manner well known in the art, transmitter 202 emits an ultrasonic wave 208 that is picked up at receiver 204 such that the distance between the receiver and the transmitter may be determined to within a fraction of an inch by processor 70 using time delay and temperature measurements. By monitoring movements of carriage 20 , in which drill string 30 is either pushed into or pulled out of the ground, and clamping arrangement 54 , processor 70 can accurately track the length of drill string 30 throughout a drilling operation to within a particular measurement accuracy. While it is convenient to perform measurements in the context of the length of the drill rods, with measurement positions corresponding to the ends of the drill rods, it should be appreciated that this is not a requirement and the ultrasonic arrangement can provide the total length of the drill string at any given moment in time. Further, in another embodiment, the length of the drill string can be determined according to the number of drill rods multiplied by nominal rod length. In this case, the rod length may be of a nominal value subject to some manufacturing tolerance at least with respect to its length. In one version of this embodiment, the drill string measurement arrangement can count the drill rods. In another version of this embodiment, the operator can count the drill rods. Of course, in either case, the number of drill rods that is counted can be correlated to the length that is determined by ultrasonic measurement, although there is no requirement for precision overall drill string length measurement.
Referring to FIG. 1 , boring tool 26 includes a mono-axial antenna (not shown) such as a dipole antenna oriented along an elongation axis of the boring tool and which is driven to emit a dipole magnetic homing signal 250 (only one flux line of which is partially shown). As an example of a boring tool incorporating such a mono-axial antenna in its transmitter arrangement, see FIG. 9 of U.S. Pat. No. 5,155,442 (hereinafter, the '442 patent) entitled POSITION AND ORIENTATION LOCATOR/MONITOR and its associated description. This latter patent is commonly owned with the present application and hereby incorporated by reference. As will be described in detail hereinafter, homing signal 250 is monitored by a homing receiver 260 which will be described in detail at an appropriate point hereinafter. The boring tool is equipped with a pitch sensor (not shown) for measurement of its pitch orientation as is described, for example, in the '442 patent. As is also well known, the pitch orientation and other parameters of interest can be modulated onto the homing signal for remote reception and decoding. In other embodiments, measured parameters can be transferred to the drill rig using a wire-in-pipe configuration such as is described, for example, in U.S. Pat. No. 7,150,329 entitled AUTO-EXTENDING/RETRACTING ELECTRICALLY ISOLATED CONDUCTORS IN A SEGMENTED DRILL STRING, which is commonly owned with the present application and incorporated herein by reference. The parameters may be used at the drill rig and/or transferred to a remote location, for example, by telemetry section 62 . It is noted, however, that the measurement of yaw is not necessary and, therefore, there is no need for a yaw sensor in the boring tool. It is well known that yaw angle is a parameter that is generally significantly more difficult to measure, as compared to pitch orientation. Accordingly, there is some benefit associated with techniques such as described herein which do not rely on measured yaw orientation.
FIG. 3 is a diagrammatic view, in perspective, which illustrates details of one embodiment of portable homing receiver 260 . The homing receiver includes a three-axis antenna cluster 262 for measuring three orthogonally arranged components of magnetic flux in a coordinate system that can be fixed to the homing receiver itself having axes designated as b X , b y and b Z and, of course, transformed to another coordinate system such as what may be referred to as a global coordinate system in the context of which the homing operation can be performed. In one embodiment, the global coordinate system can be the X,Y,Z. One useful antenna cluster contemplated for use herein is disclosed by U.S. Pat. No. 6,005,532 entitled ORTHOGONAL ANTENNA ARRANGEMENT AND METHOD which is commonly owned with the present application and is incorporated herein by reference. Antenna 262 is electrically connected to a receiver section 264 which can include amplification and filtering circuitry, as needed. Homing receiver 260 further may include a graphics display 266 , a telemetry arrangement 268 having an antenna 270 and a processing section 272 interconnected appropriately with the various components. The processing section can include one or more microprocessors, DSP units, memory and other components, as needed. It is noted that, for the most part, inter-component cabling has not been illustrated in order to maintain illustrative clarity, but is understood to be present and may readily be implemented by one having ordinary skill in the art in view of this overall disclosure. It should be appreciated that graphics display 266 can be a touch screen in order to facilitate operator selection of various buttons that are defined on the screen and/or scrolling can be facilitated between various buttons that are defined on the screen to provide for operator selections. Such a touch screen can be used alone or in combination with an input device 274 such as, for example, a keypad. The latter can be used without the need for a touch screen. Moreover, many variations of the input device may be employed and can use scroll wheels and other suitable well-known forms of selection device. The telemetry arrangement and associated antenna are optional. The processing section can include components such as, for example, one or more processors, memory of any appropriate type and analog to digital converters. Generally, the homing receiver can be configured for direct placement on surface 44 of the ground, however, an ultrasonic transducer (not shown) can be provided for measuring the height of the homing receiver above the surface of the ground. One highly advantageous ultrasonic transducer arrangement is described, for example, in the above incorporated '442 patent.
As will be further described, Applicant recognizes that the accuracy of homing commands depends directly on the accuracy of fluxes measured at the homing receiver. Since dipole field signal strength (see item 250 , in FIG. 1 ) decreases in inverse proportion to distance to the third power, homing accuracy can diminish rapidly with relatively larger distances between the homing transmitter of boring tool 26 and homing receiver 260 . In this regard, it should appreciated that the weakest signal and, hence, the lowest accuracy in a typical homing procedure will be encountered at the start of the operation when separation between the homing transmitter and the homing receiver is usually at a maximum. In a conventional homing system, this initial separation can be beyond the range at which the homing receiver is capable of receiving the homing signal.
The homing technique and apparatus disclosed herein increases the range over which vertical homing is accurate. Accurate and useful homing commands can be generated over distances much larger than the typical range of 40 feet or so, using a typical battery powered homing transmitter. At a given range between the boring tool and the homing receiver, vertical homing accuracy is remarkably enhanced by using flux measurements in conjunction with integrating pitch for a determined drill string length, as will be further discussed at an appropriate point below.
Nomenclature
The following nomenclature is used in embodiments of the homing procedure described herein and is provided here as a convenience for the reader.
b = flux magnitude for unit boring tool transmitter dipole strength b X , b Z = flux components in the X, Z - directions D 1 = initial boring tool transmitter depth D T = target depth below homing receiver H = observation coefficient matrix I = identity matrix K = Kalman gain L R = average drill rod length P = error covariance matrix Q k = discrete process noise covariance matrix R M = observation error covariance matrix {right arrow over (R)} = position vector from boring tool transmitter antenna center to the center of the homing receiver antenna s = arc length along drill string axis {right arrow over (v)} b = vector of flux measurement error {right arrow over (v)} hr = vector of homing receiver position error {right arrow over (x)} = state variables vector x hr = homing receiver x -position in boring tool transmitter coordinates X, Z = coordinate axes of vertical plane in which homing commands are generated or position coordinates in this plane X hr , Z hr = homing receiver position X T , Z T = target position {right arrow over (w)} k = process noise vector {right arrow over (z)} = measurement vector δX, δZ = position state variables δX hr , δZ hr = homing receiver antenna position increments δφ = pitch angle increment ΔY, ΔZ = horizontal and vertical homing commands φ = pitch angle Φ k = discrete state equation transition matrix σ = standard deviation σ φ = pitch measurement error σ b X , σ b Y = flux measurement errors σ X hr , σ Z hr = homing receiver position measurement errors σ X 1 , σ Z 1 = initial boring tool transmitter position error σ 2 = variance, square of standard deviation
Subscripts
est estimated value ex exact value hr Homing receiver k k -th transmitter position m measured T target 1 initial position of boring tool where homing is initiated
Superscripts
( • )
ⅆ
ⅆ
s
( ) −
indicates last available estimate
( )′
transpose
( ) *
nominal drill path
x
→
^
state variables vector estimate
Referring to FIG. 1 , prior to homing, the user may place homing receiver 260 on the ground ahead of the homing transmitter and above a specified target location T, pointing in the drilling direction in one embodiment. Note that the receiver x axis faces to the right in the view of FIG. 1 . That is, the x axis of the receiver, along which flux b X is measured, faces away from the drill rig at least approximately in the drilling direction. In another embodiment, the center of tri-axial antenna 262 of the homing receiver may be chosen as a target T′. This set-up procedure determines an X,Z coordinate system used during homing ( FIG. 2 ) where X is horizontal and Z is vertical. A Y axis extends horizontally and orthogonal to the X,Z plane completing a right handed Cartesian coordinate system. The use of this particular coordinate system which may be referred to herein as a master or global coordinate system, should be considered as exemplary and not limiting. Any suitable coordinate system may be used including Cartesian coordinate systems having different orientations and polar coordinate systems. It should be appreciated that the drill path is not physically confined to the X,Z plane such that homing along a curved path can be performed. The technique described herein, however, does not account for divergence of the boring tool out of the X,Z plane or for yaw angles out of the X,Z plane as represented by boring tool 26 ′ (shown in phantom in FIG. 2 ) for purposes of producing enhanced vertical homing commands while still producing remarkable results. At the time of setup, the X,Z axes define a vertical plane that contains the center of the transmitter antenna at the start of homing and the center of antenna 262 of homing receiver 260 . These axes can remain so defined for the remainder of the homing procedure. In the present example, the origin of this system is located at point 45 on the surface of the ground above the center of the homing transmitter antenna in boring tool 26 at position k=1 with the boring tool at a depth D 1 . The depth at D 1 can be measured, for example, by a walk-over locator or using a tape-measure if the initial position of the boring tool has been exposed. Hence, the initial homing transmitter position becomes
X 1 =0 (1)
Z 1 =−D 1 (2)
In an embodiment where the origin of the coordinate system is defined at point 42 , where the boring tool enters the enters the ground, the origin of the coordinate system is at the center of the transmitter antenna with D 1 =0.
Homing receiver position coordinates designated as X hr ,Z hr can be measured before homing begins. In addition, the average length of drill rods L R can determined for use in embodiments where the drill rig does not monitor the length of the drill string. For purposes of the present description, it will be assumed that drill rods are to be counted and that homing command determinations are made on a rod by rod basis such that the average drill rod length is relevant. The user can specify the depth of the target D T below the homing receiver so that target position coordinates, designated as X T ,Z T , can be obtained from
X T =X hr (3)
Z T =Z hr −D T (4)
During homing, flux components are measured using antenna 262 of the homing receiver for use in conjunction with the measured pitch, designated as φ, of the boring tool at each k position. The homing system utilizes an estimate of pitch measurement uncertainty a σ φ and of the measurement uncertainties of the 2 fluxes in the vertical X,Z plane which are denominated as σ b X ,σ b Z , respectively. In addition, measurement uncertainties σ Z i ,σ X hr ,σ Z hr are utilized where σ Z 1 is the measurement uncertainty of depth Z 1 at position k 1 , the value σ X dr is the measurement uncertainty of the position of homing receiver 260 on the X axis, and the value σ Z hr is the measurement uncertainty of the position of homing receiver 260 on the Z axis. Note that σ X 1 =0 since X 1 =0 according to the definition above of the selected coordinate system. It should be appreciated that the various measurement uncertainties can be empirically obtained in a straightforward manner by evaluating and comparing repeat measurements of the quantity of interest. The uncertainty of locator position measurements is readily available from the manufacturer of distance measuring devices. Although the position of the homing receiver can be determined in any suitable manner, suitable handheld or tripod mounted laser devices are readily commercially available for measuring the homing receiver position coordinates. For example, the Leica Disto™ D5 can be used which has a range of over 300 feet and a built-in pitch sensor. In other embodiments, standard surveyor instrumentation can be used to determine the homing receiver position/coordinates prior to homing.
In one embodiment, the method is based on two types of equations, referred to as process equations and measurement equations. The following process equations are chosen where the dot symbol denotes derivatives with respect to arc length s along the axis of the drill rod or drill string:
{dot over (X)}=cos φ (5)
Ż=sin φ (6)
For vertical homing, the flux components b X ,b Z induced at the homing receiver are measured. They can be expressed in terms of transmitter position X,Z, homing receiver position X hr ,Z hr and pitchφ. This leads to the following measurement equation written in vector form as
{right arrow over (B)}= 3 x hr R −5 {right arrow over (R)}−R −3 {right arrow over (u)} (7)
where
{right arrow over ( B )}=( b X ,b Z )′ (8)
{right arrow over ( R )}=( X hr −X,Z hr −Z )′ (9)
R=|{right arrow over (R)}| (10)
{right arrow over ( u )}=(cos φ, sin φ)′ (11)
x hr ={right arrow over (e)}′{right arrow over (R)} (12)
Above, the prime symbol denotes the transpose of a vector.
Equations (5) and (6) are ordinary differential equations for the two unknown transmitter position coordinates X,Z. Vector Equation (7) can be written as two scalar equations for the flux components b X and b Z along the X and Z axes. It should be appreciated that these equations represent an initial value problem since Equations (5) and (6) can be integrated along arc length S starting from known initial values X 1 ,Z 1 at k=1. Equations (5), (6) and (7) couple flux measurements at the homing receiver to the transmitter position such that enhanced accuracy homing commands can be generated as compared to homing commands that are generated based solely on flux measurements, as in a conventional homing system.
Nonlinear Solution Procedures
The foregoing initial value problem can be solved using either a nonlinear solution procedure, such as the method of nonlinear least squares, the SIMPLEX method, or can be based on Kalman filtering. The latter will be discussed in detail beginning at an appropriate point below. Initially, however, an application of the SIMPLEX method will be described where the description is limited to the derivation of the nonlinear algebraic equations that are to be solved at each drill-path position. Details of the solver itself are well-known and considered as within the skill of one having ordinary skill in the art in view of this overall disclosure.
SIMPLEX Method
The present technique and other solution methods can replace the derivatives X, Z in Equations (5) and (6) with finite differences that are here written as:
X
.
=
X
k
+
1
-
X
k
L
R
(
13
)
Z
.
=
Z
k
+
1
-
Z
k
L
R
(
14
)
Resulting algebraic equations read:
f 1 =X k+1 −X k −L R cos φ k =0 (15)
f 2 =Z k+1 −Z k −L R sin φ k =0 (16)
The flux measurement Equations (7-12) provide two additional algebraic equations written as:
f 3 =b X k+1 −3 x hr R k+1 −5 ( X hr −X k+1 )+ R k+1 −3 cos φ k+1 =0 (17)
f 4 =b Z k+1 −3 x hr R k+1 −5 ( z hr −Z k+1 )+ R k+1 −3 sin φ k+1 =0 (18)
Here, transmitter pitch and fluxes are measured at the (k+1) st position. The distance between transmitter and homing receiver is obtained from the corresponding distance vector which reads
{right arrow over (R)} k+1 =( X hr −X k+1 ,Z hr −Z k+1 )′ (19)
Furthermore, we use
R k+1 =|{right arrow over (R)} k+1 | (20)
{right arrow over (u)} k+1 =(cos φ k+1 , sin φ k+1 )′ (21)
x hr ={right arrow over (u)}′ k+1 {right arrow over (R)} k+1 (22)
Starting with the known initial values (Equations 1 and 2) at drill begin, the coordinates of subsequent positions along the drill path can be obtained by solving the above set of nonlinear algebraic equations (15-22) for each new tool position. The coordinates of position k+1 are determined iteratively beginning with some assumed initial solution estimate that is sufficiently close to the actual location to assure convergence to the correct position. One suitable estimate will be described immediately hereinafter.
An initial solution estimate is given by linear extrapolation of the previously predicted/last determined position to a predicted position. The linear extrapolation is based on Equations 5 and 6 and a given incremental movement L R of the homing tool from a k th position where:
( X k+1 ) est =X k +L R cos φ k (23)
( Z k+1 ) est =Z k +L R sin φ k (24)
Where the subscript (est) represents an estimated position. Application of the SIMPLEX method requires definition of a function that is to be minimized during the solution procedure. An example of such a function that is suitable in the present application reads:
F
=
∑
p
=
1
4
f
p
2
(
25
)
As noted above, it is considered that one having ordinary skill can conclude the solution procedure under SIMPLEX in view of the foregoing.
Kalman Filter Solution
In another embodiment, a method is described for solving the homing command by employing Kalman filtering. The filter reduces the position error uncertainties caused by measurement minimizing the uncertainty of the vertical homing command in a least square sense thereby increasing the accuracy of the vertical homing command. The Kalman filter is applied in a way that couples flux measurements on a position-by-position basis with integration of pitch readings that are indicative of position coordinates in the X,Z plane, while accounting for error estimates relating to both flux measurement and pitch measurement.
It is worthwhile to note that a Kalman filter merges the solutions of two types of equations in order to obtain a single set of transmitter position coordinates along the drill path. In the present application, one set of equations (Equations 5 and 6) defines the rate of change of transmitter position along the drill path as a function of measured pitch angle. Equation (7) is based on the equations of a magnetic dipole inducing a flux at the homing receiver antenna. The Kalman filter provides enhanced homing commands by reducing the effect of errors in measuring fluxes, pitch, and homing receiver position.
The homing procedure can be initiated at a known boring tool position, as described above. Advancing the boring tool to the next location by one rod length provides an estimate of the new transmitter position that is limited to the X,Z plane by integrating measured pitch for known drill rod length increment. Consequently, this position estimate is improved by incorporating dipole flux equations. Accordingly, enhanced homing commands are generated responsive to both the flux measurements and the position of the boring tool in the vertical X,Z plane. This process is repeated along the drill path until the drill head has reached the target. It should be mentioned that the strength of the homing signal is generally initially weakest at the start of the homing procedure and increases in signal strength as the boring tool approaches the boring tool. The present disclosure serves not only to increase the accuracy of the homing signal but to increase homing range to distances that are unattainable in a conventional homing system for a given signal strength, as transmitted from the boring tool.
It is noted that the Kalman filter addresses random measurement errors. Therefore, fixed errors can be addressed prior to homing. For example, any significant misalignment of the pitch sensor in the boring tool with the elongation axis of the boring tool can be corrected. Such a correction can generally be performed easily by applying a suitable level such as, for example, a digital level to the housing of the boring tool and recording the difference between measured pitch and the pitch that is indicated by the pitch signal generated by the boring tool. Systematic error such as pitch sensor misalignment can be addressed in another way by using an identical roll orientation of the boring tool each time the pitch orientation is measured.
Nominal Drill Path
Assuming that the coordinates X k ,Z k are known for a current position of the boring tool whether by measurement of the initial position or by processing determinations on a position-by-position basis, an estimate for the next position of the boring tool can be obtained by linear extrapolation from k to k+1 for the incremental distance that is being used between adjacent positions. This estimate is a point on what is referred to herein as the nominal drill path, indicated by the superscript (*). In the present example, the incremental distance is taken as the average rod length, although this is not a requirement. The nominal drill path falls within the X,Z plane and ignores any out of plane travel of the boring tool. Hence, the coordinates for the estimated position become:
X* k+1 =X k +L R cos φ k (26)
Z* k+1 =Z k +L R sin φ k (27)
Here, the symbols L R ,φ k denote average rod length and boring tool transmitter pitch at position k, respectively. It is noted that L R can correspond to any selected incremental distance between positions and may even vary from position to position.
While drill path positions can be found in one way by integrating Equations (5) and (6) starting from a specified initial guess without making use of flux Equation (7), solution accuracy may suffer from the following errors:
Integration errors due to pitch measurement errors, especially at relatively long ranges between the homing receiver and the initial transmitter position,
Numerical integration errors, and
Modeling inaccuracy since process Equations (5) and (6) might serve only as an approximation for some drilling scenarios.
State Variables
The Kalman Filter adds correction terms δX,δZ to the nominal drill path so that the transmitter position coordinates become:
X k+1 =X* k+1 +δX k+1 (28)
Z k+1 =Z* k+1 +δZ k+1 (29)
The vector containing δX,δZ is denominated as the vector of state variables, given as:
{right arrow over (x)} =(δ X,δZ )′ (30)
The vector of state variables is governed by a set of state equations derived from Equations (5) and (6) by linearization, given as:
{right arrow over (x)} k+1 =Φ k {right arrow over (x)} k +{right arrow over (w)} k (31)
where
{right arrow over (w)} k =L R {right arrow over (G)} k δφ k (32)
Φ k =I (33)
{right arrow over (G)} k =(−sin φ k , cos φ k )′ (34)
Above, the vector {right arrow over (w)} k of Equation (19) is the process noise that depends on pitch measurement error and on vector {right arrow over (G)} k which in turn is a function of pitch. The covariance of {right arrow over (w)} k is the so-called discrete process noise covariance matrix Q k which plays an important role in Kalman filter analysis, given as:
Q k =cov ( {right arrow over (w)} k ) (35)
Q k =L R 2 {right arrow over (G)} k σ φ 2 {right arrow over (G)}′ k (36)
Even though Q k is defined analytically it could be manipulated empirically in order to increase solution accuracy for some applications. One convenient method to achieve this is to multiply Q k by the factor F E whose value is determined empirically by numerical experimentation. The best value of F E provides the most accurate predictions of the vertical homing command.
Linearization of the flux measurement equations about the nominal drill path results in the so-called observation equations, given in vector notation as:
{right arrow over (z)}=H{right arrow over (x)}+{right arrow over (ν)} b +{right arrow over (ν)} hr (37)
Application to Equations (7-12) provides the following details of vector {right arrow over (z)} and matrix H:
{right arrow over (z)} =( b X m −b X *,b Z m −b Z *)′ (38)
H= 3 x hr R −7 (5 {right arrow over (R)}{right arrow over (R)}′−R 2 I )−3 R −5 ( {right arrow over (R)}{right arrow over (u)}′+{right arrow over (u)}{right arrow over (R)} ′) (39)
x hr ={right arrow over (u)}′{right arrow over (R)} (40)
{right arrow over ( u )}=(cos φ, sin φ)′ (41)
{right arrow over (R)} =( X hr −X*,Z hr −Z *) (42)
R=|{right arrow over (R)}| (43)
Note that b* X ,b* Z are the fluxes induced at the homing receiver by the transmitter on the nominal drill path X*,Z*. These fluxes can be determined using Equations (7-12) with {right arrow over (R)}=(X hr −X*,Z hr −Z*)′. Fluxes b X m ,b Z m are the actual fluxes measured at the homing receiver with the boring tool transmitter in its actual position along the borehole, which can be yawed and/or positioned out of the X,Z plane.
The terms {right arrow over (ν)} b ,{right arrow over (ν)} hr represent vectors of flux measurement errors and homing receiver position errors, respectively. The observation error covariance matrix R M , also used by the Kalman filter loop, is given by:
R M =cov ({right arrow over (ν)} b +{right arrow over (ν)} hr ) (44)
R
M
=
[
σ
b
X
2
0
0
σ
b
Z
2
]
+
H
[
σ
X
hr
2
0
0
σ
Z
hr
2
]
H
′
(
45
)
State variables {right arrow over (x)} and error covariance matrix P are initialized at the new position along the drill path by setting
{circumflex over ({right arrow over (x)} k+1 =(0,0)′ (46)
P k+1 − =P k +Q k (47)
Here, the superscript ( ) − indicates the last available estimate of P.
The process of updating P begins with P 1 at the initial homing position X 1 ,Z 1 . Its value is given as
P
1
=
[
σ
X
1
2
0
0
σ
Z
1
2
]
(
48
)
The classical, well documented version of the Kalman filter loop is chosen as a basis for the current homing tool embodiment. It is made up of three steps:
Kalman gain is given as:
K=P − H ′( HP − H′+R M ) −1 (49)
Update state variables:
{circumflex over ({right arrow over (x)}={circumflex over ({right arrow over (x)} − +K ( {right arrow over (z)}−H{circumflex over ({right arrow over (x)} − ) (50)
Update error covariance matrix:
P =( I−KH ) P − (51)
Above, the symbol {circumflex over ({right arrow over (x)} denotes a state variables estimate.
Equations (36-38) define a standard Kalman filter loop, for instance, as documented by Brown and Hwang, “Introduction to Random Signals and Applied Kalman Filtering”, 1997.
Homing Commands
The vertical homing command in this embodiment is given by the vertical distance between transmitter and target:
Δ Z=Z−Z T (52)
The horizontal homing command is defined as the ratio of horizontal fluxes measured at the homing receiver.
Δ
Y
=
b
Y
m
b
X
m
(
53
)
Attention is now directed to FIG. 4 which illustrates one exemplary embodiment of a method according to the present disclosure, generally indicated by the reference number 300 . The method begins at step 302 in which various set-up information is provided. It is noted that these items have been described above insofar as their determination and the reader is referred to these descriptions. The information includes the position of the homing receiver, the depth of the target, the average length of the drill rods to be used in an embodiment which relies on the drill rod length as an incremental movement distance; the initial transmitter depth; measurement uncertainties of pitch readings, flux measurements, homing receiver position and the initial transmitter depth; and the pitch bias error, if any.
At 304 , for the current position of the boring tool, the pitch is measured as well as fluxes at the homing receiver using antenna 262 . Note that the boring tool can be oriented at an identical roll orientation each time a pitch reading is taken if such a technique is in use for purposes of compensating for pitch bias error.
At 306 , the selected nonlinear solution procedure such as, for example, the aforedescribed Kalman filter analysis is performed for the current position of the boring tool.
At 308 , the homing commands are determined based on the nonlinear solution procedure and the homing commands are displayed to the user.
At 310 , a determination is made as to whether the boring tool has arrived at the target position. If not, the boring tool is moved by step 312 to the next position and the process repeats by returning to step 304 . If, on the other hand, the determination is made that the boring tool has arrived at the target, the procedure ends at 314 .
The homing commands can be displayed, for example, as seen in FIG. 5 where the objective is to minimize ΔY,ΔZ when the target is approached. In particular, a screen shot of one embodiment of the appearance of display 266 is shown having a crosshair arrangement 400 with a homing pointer 402 . In the present example, the boring tool should be steered down and the left by the operator of the system according to homing pointer 402 . That is, pointer 402 shows the direction in which the boring tool should be directed to home in on the homing receiver. The position of the homing indicator on the display is to be established by the determined values of ΔY and ΔZ, as described above. When homing indicator 402 is centered on cross-hairs 404 , the boring tool is on course and no steering is required.
Numerical simulations of vertical homing, according to the disclosure above, are now presented assuming pitch, fluxes and homing receiver position can be measured with the following accuracies:
σ φ =0.5 deg (54)
σ b X =2.4 e −6 ft −3 (55)
σ b Z =2.4 e −6 ft −3 (56)
σ X hr =0.1 ft (57)
σ Z hr =0.1 ft (58)
The chosen initial position accuracy depends on the location where homing begins.
σ X 1 =0 for X 1 =0 (59)
σ Z 1 =0 for Z 1 =0 (60)
or
σ Z 1 =0.1 ft for Z 1 =−D 1 (61)
Referring to FIGS. 6 a - 6 d , a numerical simulation is provided based on the Kalman filter embodiment described above and the accuracies set forth by Equations (54-61), as applicable. FIG. 6 a is a plot, in elevation, showing the X, Z plane and an exact path in the plane that is indicated by the reference number 600 . The homing procedure is initiated at coordinates (0,−10) and target T is located at coordinates (100,−4). The equation of this exemplary drill path is given as:
Z ex =−10+(6 e −4) X ex 2 , ft (62)
Here the subscript (ex) stands for “exact.” The example represents homing with a 100 foot range of effective vertical homing and a ten foot average drill rod length. It should be appreciated that this drill path is representative of a homing distance that is generally well beyond the standard range of a conventional homing system at the start of drilling. The range of a conventional homing system is typically about 40 feet with a typical transmitter and a typical receiver. FIG. 6 b is another plot of the X, Z plane showing a plot 602 of the value of the vertical homing command. It should be appreciated that the magnitude of the homing command controls the amount of steering that is needed. Thus, the magnitude of the homing command starts decreasing significantly at around X=40 feet and has the value zero at X=100 feet, where the boring tool arrives at the target. FIG. 6 c shows a plot of the value of X error 604 along the length of the drill path. The X error is the difference between the actual position of the boring tool along this axis and the determined position of the boring tool along the X axis. FIG. 6 d shows a plot of Z error 606 along the length of the drill path. The Z error is the difference between the actual position of the boring tool along this axis and the determined position of the boring tool along the Z axis. It is noted that a negative going peak 610 is present in plot 606 at X=60 feet, representing a maximum vertical position error of approximately 7 inches at a distance equivalent to 4 rod length laterally away from the target. This distance provides sufficient steering reserves to accurately reach the target. The X position error along the drill path is less than 1 inch. Note in this example that homing started at a depth of 10 ft. At X=100 feet, the Z error value is near zero.
Referring to FIGS. 7 a - 7 d , another numerical simulation is provided based on the Kalman filter embodiment described above and the accuracies set forth by Equations (54-61), as applicable. FIG. 7 a is a plot, in elevation, showing the X,Z plane and an exact path in the plane that is indicated by the reference number 700 . The homing procedure is initiated at coordinates (0,0) and target T is located at coordinates (80,−10). Again, at the incept of drilling, this example illustrates a range that is generally well beyond the range that is available in a conventional homing system. The equation of this exemplary drill path is given as:
Z ex =−0.25 X ex +0.0015625 X ex 2 (63)
Where the subscript (ex) again stands for “exact.” The example represents homing with an 80 foot range of effective vertical homing and a five foot average drill rod length. FIG. 7 b is another plot of the X, Z plane showing a plot 702 of the value of the vertical homing command. As is the case in all of the examples presented here, the magnitude of the homing command controls the amount of steering that is needed. Thus, the magnitude of the homing command starts decreasing significantly at around X=50 feet and has the value zero at X=80 feet, where the boring tool arrives at the target. FIG. 7 c shows a plot of the value of X error 704 along the length of the drill path. It is noted that the X error is less than approximately 2 inches for the entire length of the drill path. FIG. 7 d shows a plot of Z error 706 along the length of the drill path. It is noted that a negative going peak 710 is present in plot 706 at X=48 feet representing a maximum Z error of about 6 inches at around 30 feet from the target. At X=80 feet, the Z error value is near zero.
The previous examples assume that during the homing process the transmitter moves in the vertical X,Z plane and that any three-dimensional effect on vertical homing commands is negligible. In the next example, it will be shown that homing commands remain accurate even when the transmitter leaves the vertical plane and/or yaws with respect to the vertical plane. The lateral offset may reduce lateral homing effectiveness at initial, greater range from the target but lateral effectiveness improves when the transmitter approaches the target, as will be seen.
Turning to FIG. 8 a - d , a three-dimensional test case will now be described. FIG. 8 a illustrates a plot of a horizontal drill path 800 that is added to the vertical drill path of FIG. 6 a and given by Equation (49). A ten foot average drill rod length is used in the present example. The lateral drill path is given by:
Y ex =0.2 X ex −(2 e −3) X ex 2 (64)
The three-dimensional effect is mainly due to changes in transmitter yaw and to the lateral offset resulting in slightly different fluxes measured by the homing receiver antennas. Minor changes of measured pitch can also contribute to this effect. The lateral offset reaches a maximum of five feet at a point 802 in plot 800 . FIG. 8 b is a plot of the vertical homing command 806 as further influenced by the lateral deviation in FIG. 8 a . For purposes of comparison, homing command plot 602 of FIG. 6 b is shown as a dashed line. It is noted that the difference between plots 602 and 806 is not viewed as significant in terms of overall results of the homing procedure. FIG. 8 c illustrates the Z error 810 along the X axis which includes the effects of yaw and lateral deviation from the X, Z plane with Z error plot 606 of FIG. 6 d shown as a dashed line for purposes of comparison. Even for a significant 5 foot lateral deviation, as seen in FIG. 8 a , the accuracy of the vertical homing command is near that of the two-dimensional test case of FIG. 6 a , as is evidenced by FIG. 8 c . That is, the maximum Z error is approximately 7 inches in each case but the three-dimensional effect of the lateral transmitter offset, shown in FIG. 8 a , causes the maximum Z error to move closer to the target. Thus, the present example confirms that homing according to the present disclosure is highly effective with relatively large amounts of yaw and lateral deviation from the X,Z plane. Accordingly, a relatively reduced accuracy of the horizontal component of the homing command at long range is confirmed by this example as acceptable.
FIG. 9 illustrates the vertical homing command, ΔZ versus X based on the drill path depicted in FIG. 6 a . A first plot 900 , shown as a dotted line, illustrates the vertical homing command for the exact drill path (see also, plot 602 of FIG. 6 b ). A second plot 902 , shown as a dashed line, illustrates the vertical homing command derived based on a conventional system which generates the homing command based solely on flux measurements. A third plot 904 , shown as a solid line, illustrates the homing command based on the use of the Kalman filter. It should be appreciated that the homing receiver is located at X=100 feet such that positions to the left in the view of the figure are relatively further from the homing receiver. It can be seen that the Kalman filter plot 902 and the conventional plot 904 agree well with the exact homing command plot 900 when the transmitter is within 40 feet or so of the homing receiver. That is, the value of X is greater than 60 feet in the plot. At larger distances from the homing receiver (i.e., below X=60 feet, the conventional system becomes increasingly unreliable and eventually fails to provide any meaningful homing guidance, for example, proximate to X=40 feet. Kalman filter plot 904 , however, closely tracks the exact homing command values of plot 900 along the entire drill path, even at greater distances from the homing receiver, including proximate to X=40 feet at which the conventional system is essentially unusable. It should be appreciated that attempting to use the conventional system at long range would result in dramatically oversteering the boring tool upward.
In view of the foregoing, it should be appreciated that a homing apparatus and associated method have been described which can advantageously use a measured parameter in the form of the drill string length in conjunction with measured flux values to generate a vertical homing command. Further, a nonlinear solution procedure can be employed in order to remarkably enhance vertical homing command accuracy and homing range as compared to conventional homing implementations that rely only on flux measurements.
While a number of exemplary aspects and embodiments have been discussed above, those of skill in the art will recognize certain modifications, permutations, additions and sub-combinations thereof. It is therefore intended that the following appended claims and claims hereafter introduced are interpreted to include all such modifications, permutations, additions and sub-combinations as are within their true spirit and scope.
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A boring tool that is moved by a drill string to form an underground bore. A transmitter transmits a time varying dipole field as a homing field from the boring tool. A pitch sensor detects a pitch orientation of the boring tool. A homing receiver is positionable at a target location for detecting the homing field to produce a set of flux measurements. A processing arrangement uses the pitch orientation and flux measurements with a determined length of the drill string to determine a vertical homing command for use in controlling depth in directing the boring tool to the target location such that the vertical homing command is generated with a particular accuracy at a given range between the transmitter and the homing receiver and which would otherwise be generated with the particular accuracy for a standard range, different from the particular range. An associated system and method are described.
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This is a division of application Ser. No. 553,105, filed Nov. 18, 1983.
BACKGROUND OF THE INVENTION
This invention relates broadly to fasteners for apparel, and more particularly to bra-back fasteners, especially bra-back repair parts, and shoulder strap guards.
Prior bra-back fasteners, and especially bra-back repair parts, have metal hook and eye fasteners stitched in place, the stitching operations increasing the cost of manufacture. They are also difficult to fasten for some women, e.g., women suffering from arthritis, and the metal may cause irritation rubbing against the skin. Similarly, prior shoulder strap guards (lingerie guards) have metal snap fasteners, attachment of which and quality control over which increase the manufacturing cost.
SUMMARY OF THE INVENTION
Among the several objects of the invention may be noted the provision of improved fasteners for apparel, particularly bra-back fasteners, and especially bra-back repair parts, and shoulder strap guards, which do not have metal fastener elements such as metal hooks and eyes, or metal snap fastener elements, and which are relatively easy to use even by women with arthritis; and the provision of methods of manufacturing such fasteners at reduced cost.
In general, the method of this invention for making fastener elements for use with apparel comprises feeding forward a continuous base strip of material which is heat-sealable at least on one surface thereof, feeding forward a continuous fastener tape constituting one of a hook tape or a plush tape adapted to be releasably fastened together by pressing them together, said fastener tape being heat-sealable to the base strip, combining the fastener tape with the base strip as they are fed forward with the fastener tape extending longitudinally of the base strip on said surface of the latter, heat-sealing the fastener tape to the base strip on relatively narrow seals extending longitudinally of the fastener tape spaced transversely of the fastener strip, and segmenting the combined base strip and fastener tape on transverse lines at intervals spaced longitudinally thereof to form individual fastener elements each comprising a band of the base material having a segment of fastener tape material heat-sealed on one surface of the band by relatively narrow seals extending across the element from one side edge thereof to the other.
A fastener element of the invention for use with apparel comprises a band of flexible base material which is heat-sealable at least at one surface thereof and a segment of fastener tape material constituting one of a hook tape or a plush tape of heat-sealable material heat-sealed to said surface by relatively narrow seals extending across the element from one side thereof to the other.
Other objects and features will be in part apparent and in part pointed out hereinafter.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a view illustrating the manufacture in accordance with this invention of a first part of a bra-back fastener or repair of the invention;
FIG. 2 is a view illustrating said first part;
FIG. 3 is a view illustrating the manufacture in accordance with this invention of a second part of the bra-back fastener or repair of the invention;
FIG. 4 is a view illustrating said second part;
FIG. 5 is a view on edge of the two parts fastened together;
FIG. 6 is a view illustrating the manufacture in accordance with this invention of a shoulder strap guard of the invention; and
FIG. 7 is a view of the shoulder strap guard as completed.
Corresponding reference characters indicate corresponding parts throughout the several views of the drawings.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1, there is generally indicated at 1 a continuous base strip of flexible material, which is ultrasonically heat-sealable at least on one surface thereof, being fed forward (from left to right). This strip is preferably a laminated strip comprising a central layer of polyurethane film laminated (under heat and pressure) between two outer layers of non-woven polyester material. As shown, this base strip is folded generally in half on fold line 2 extending longitudinally thereof to have two plies 3 and 5 which are open at one edge 7 of the folded strip and integrally joined along the fold line 2 at the other side edge thereof. Ply 3 is the lower ply and ply 5 is the upper ply as the strip feeds forward. Preferably the strip is supplied unfolded in a roll 9 and folded in half on line 2 as it is unwound from the roll and fed forward.
A continuous fastener tape 11, more particularly a VELCRO or VELCRO type hook fastener tape, is unwound from a roll 13, fed forward along with the base strip 1, and combined with the strip as the strip and tape are fed forward with the tape extending longitudinally of the strip on the bottom of the strip and with its hooks 15 on the underside. Tape 11 is ultrasonically heat-sealable for being ultrasonically heat-sealed to the strip 1, preferably being a nylon hook tape as is commercially available. It is narrower than the folded strip 1 and is combined with the folded strip 1 on the bottom of the folded strip extending generally centrally of the folded strip.
The combined folded base strip 1 and hook tape 11 feed forward between the horn 17 and wheel 19 of an ultrasonic sealing apparatus of the type shown in U.S. Pat. No. 3,666,599 and sold by Branson Sonic Power Company of Danburg, Conn. The wheel is formed with two annular peripheral ridges each designated 21 on its cylindrical surface spaced axially of the wheel a distance somewhat less than the width of the tape 11. The tape is generally centered transversely with respect to the two ridges so that it becomes ultrasonically sealed to the folded strip 1 on two lines of seal each designated 23 adjacent the side edges of the tape, leaving an unsealed portion 25 of the tape between the two lines of seal where the hooks 15 of the tape are intact.
The composite of the strip 1 and tape 11 produced as above-described is then segmented into individual fastener elements or parts such as indicated at P1 in FIG. 2 by cutting the composite on transverse lines at intervals spaced longitudinally thereof, as by means of a cutter such as indicated at 27 in FIG. 1. Each such part comprises a band 29 of the base material 1 and a segment 31 of the fastener tape material heat-sealed on one surface of the band by the relatively narrow lines of seal 23 extending across the part from one side edge thereof to the other.
The two plies 3 and 5 of the band 29 are free of one another at the side edge 7 opposite the fold 2. The seals at 23 secure the plies together. The part P1 has free margins 33 of the plies at edge 7 adapting it for being stitched as indicated at 35 in FIG. 2 to a back part 37 of a bra with the latter sandwiched between said free margins.
Referring to FIG. 3, there is generally indicated at 41 a continuous base strip of flexible material, which is ultrasonically heat-sealable at least on one surface thereof, being fed forward (from left to right). This strip is preferably a laminated strip like strip 1 but wider, comprising a central layer of polyurethane film laminated (under heat and pressure) between two outer layers of non-woven polyester material. As shown in FIG. 3, base strip 41 is folded generally in half on fold line 42 extending longitudinally thereof to have two plies 43 and 45 which are open at one edge 47 of the folded strip and integrally joined along the fold line 42 at the other side edge thereof. Ply 43 is the lower ply and ply 45 is the upper ply as the strip feeds forward. Preferably the strip is supplied unfolded in a roll 49 and folded in half on line 42 as it is unwound from the roll and fed forward.
A continuous fastener tape 51, more particularly a VELCRO or VELCRO type plush fastener tape, is unwound from a roll 53, fed forward along with the base strip 41, and combined with the strip as the strip 41 and tape 51 are fed forward with the tape extending longitudinally of the strip on the bottom of the strip and with its plush 55 on the underside. Tape 51 is ultrasonically heat-sealable for being ultrasonically heat-sealed to the strip 1, preferably being a nylon plush tape as is commercially available. It is somewhat narrower than the folded strip 41 and is combined with the folded strip 41 on the bottom of the folded strip extending generally in centered relation with respect to folded strip 41.
The combined folded base strip 41 and plush tape 51 feed forward between the horn 57 and wheel 59 of an ultrasonic sealing apparatus again of the above-mentioned type. The wheel is shown as formed with four annular peripheral ridges each designated 61 on its cylindrical surface spaced axially of the wheel. The tape, generally centered with respect to the folded strip 41, becomes ultrasonically sealed to the folded strip 41 on four lines of seal each designated 63 leaving three unsealed portions 65 of the tape between the four lines of seal where the plush 55 of the tape are intact.
The composite of the strip 41 and tape 51 produced as above-described is then segmented into individual fastener parts such as indicated at P2 in FIG. 4 by cutting the composite on transverse lines at intervals spaced longitudinally thereof, as by means of a cutter such as indicated at 67 in FIG. 3. Each such part comprises a band 69 of the base material 41 and a segment 71 of the plush tape material heat-sealed on a surface of the band by the relatively narrow lines of seal 63 extending across the part from one side edge thereof to the other, these lines of seal dividing the segment into three side-by-side plush zones 71a, 71b and 71c.
The two plies 43 and 45 of the band 69 are free of one another at the side edge 47 opposite the fold 42. The seals at 63 secure the plies together. The part P2 has free margins 73 of the plies at edge 47 and a band 75 of elastic material is sandwiched between these free margins and stitched thereto as indicated at 77 in FIG. 4.
For bra repair, or for original bra manufacture, the repair part P1 is stitched as indicated at 33 to the back of a bra at one side and the elastic band 75 of the repair part P2 is stitched to the back of the bra at the other side. The wearer may readily press together the hook zone 31 of part P1 and one of the plush zones 71a, 71b, 71c of part P2 as shown in FIG. 5 to fasten these parts together, the provision of the three plush zones providing for adjustment to fit the wearer.
Of special note is that the hook tape segment or zone 31 and the plush zones 71a, 71b and 71c are secured to the bands 29, 69 only by the seals 23, 63 extending transversely of the bands and are otherwise free of the bands throughout their extent from one side edge to the other. It has been observed that with the hook and plush zones free from the bands except at the seals (23, 63) extending transversely of the bands, the parts cling better together and are less prone to separate, in relation to an arrangement in which the hook and plush zones are secured completely around their edges (i.e., at the ends as well as the sides) to the bands.
Referring now to FIG. 6, there is generally indicated at 81 a continuous base strip of flexible material, which is ultrasonically heat-sealable on both surfaces thereof, being fed forward (from left to right). This strip may be of the same material as above-described three-layer laminate used for the manufacture of the bra-back repair parts, but is substantially wider than the strips used in the manufacture of the bra-back repair parts. As strip 81 is fed forward, it is folded on a fold line 83 to have a relatively narrow margin 85 folded under on the bottom of the strip at one side of the strip. The strip is supplied unfolded in a roll 87 and folded on the line 83 as it is unwound from the roll and fed forward. A continuous VELCRO or VELCRO type hook fastener tape 89 and a continuous VELCRO or VELCRO type plush fastener tape 91 are unwound from respective rolls 93 and 95, fed forward along with the base strip 81 and combined with the strip as the strip and tapes are fed forward, with the tapes extending longitudinally of the strip on the bottom of the strip and with the hook and plush sides 97 and 99 of the tapes facing down. Each tape is ultrasonically heat-sealable for being ultrasonically heat-sealed to the strip 81, preferably being nylon hook and plush tapes as are commercially available. Each tape is relatively narrow. One of them, e.g., the hook tape 89 is combined with the strip 81 up against the folded-under margin 85 overlapping the edge of the latter and extending inwardly therefrom. The other tape, i.e., the plush tape 91, is combined with the strip 81 on the underside of strip 81 adjacent the edge 81a of strip 81 opposite the fold 83.
The combined base strip 81 (with the folded-under margin 85) and the tapes 89 and 91 feed forward between the horn 107 and wheel 109 of an ultrasonic sealing apparatus as above-described. The wheel is formed with two circular peripheral ridges each designed 111 on its cylindrical surface adjacent one end of the wheel for sealing the hook tape 89 to the strip, and with two annular peripheral ridges each designated 113 on its cylindrical surface adjacent the other end of the wheel for sealing the plush tape 91 to the strip. The tape 89 is generally centered transversely with respect to ridges 111, which are spaced axially a distance somewhat less than the width of tape 89, so that the tape 89 becomes sealed to the strip on two lines of seal 115 adjacent the side edges of the tape, leaving an unsealed portion 117 of the tape between the two lines of seal where the hooks of the tape are intact. The outer one of these two lines of seal 115 seals the folded-under margin 85 to the strip 81 proper. The tape 91 is generally centered transversely with respect to the ridges 113, which are spaced axially a distance less than the width of the tape 91, so that the tape becomes sealed to the strip 81 on two lines of seal 119, leaving an unsealed portion 121 of the tape between the two lines of seal where the plush of the tape is intact.
The composite of the strip 81 and the tapes 89 and 91 produced as above-described is segmented into individual shoulder strap guards such as indicated at 123 in FIGS. 6 and 7 by cutting the composite on transverse lines at relatively narrow intervals spaced longitudinally thereof, as by means of a cutter such as indicated at 125 in FIG. 6. Referring to FIGS. 6 and 7, each such guard is shown to comprise the relatively narrow band 127 of heat-sealable material (derived from strip 81), an end portion 129 of which (derived from margin 85) is folded over on the fold line 83 extending across the band adjacent one end of the band and overlying one face of the band, said fold line constituting one end of the guard. A segment 131 of the heat-sealable hook fastener material (derived from tape 93) and a segment 133 of the heat-sealable plush fastener material (derived from tape 95) are heat-sealed to the band. One of said segments, namely the segment 127, overlies said folded-over end portion 129 of the band and is heat-sealed thereto by heat seal 135 spaced inwardly from said fold line 83, said folded-over end portion being heat-sealed to the band at this heat seal, and by a heat seal 137. The folded-over end portion 129 forms a loop at said one end of the guard for receiving a safety pin 139. The other of said segments, namely 133, is heat-sealed to said band adjacent the other end of the band on lines 119. The band is adapted to be folded around a shoulder strap on a fold line extending across the band between the two segments 131, 133 to bring the hook material and plush material segments together, and the band is adapted to be secured around the strap by pressing together the said hook material and plush material segments. The safety pin is used to pin the band to the user's dress, as will be readily understood.
In view of the above, it will be seen that the several objects of the invention are achieved and other advantageous results attained.
As various changes could be made in the above constructions without departing from the scope of the invention, it is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense.
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Bra-back fasteners parts and shoulder strap guards having hook and plush fastener elements, and methods of manufacturing them.
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BACKGROUND
[0001] This version of the invention is concerned with the field of self-charging direct current power devises such as batteries; where said power source does not need an external charging source for its continual normal use. This application also covers some of the uses and applications of the said power modules. These uses includes the following: DC-rectifying transformer packages, for building AC-power stations, and DC and AC transforming generators for converting DC-power to AC-power for general use; DC/HVAC systems to help alleviate present power shortages, and save money to consumers; DC-electric cars and trucks, AC-electric bus and DC-electric Air craft, DC-marine craft and DC and AC-trains, also to be used in power plants, and module racks for increasing volts and amps. These power modules will also be used to develop a thermal air pump module, which will be used to propel new land, marine, And aircraft engines. All of these products will save money for consumers, because they will use no fossil fuel.
[0002] The present invention will save the environment because there will be no pollution created by said devices. The ecology will also be helped because the present invention would lead to less drilling for oil and oil spills. The present invention will also help to free the nations from dependence on imported oil. The present invention will also help to save lives because automobile and aircraft wrecks will result in fewer fires, caused by gasoline and fuel oil. This is especially important since the tragic events of Sep. 11, 2001. The present invention will also save business from the spiraling cost of fuel and the lack of enough power to operate. The said mentioned products will be explained in continuation, divisional and daughter and granddaughter applications.
DISCUSSION OF THE PRIOR ART
[0003] When batteries are being used as a power source they cannot be relied on for continued use without dependence on a separate charging source. This greatly limits how batteries can be used as a power source, since they must work in conjunction with a separate charging source. To overcome this limitation an attempt has been made to install solar plates inside a flashlight, to charge the batteries automatically. This design is disclosed in U.S. Pat. No. 4,648,013, issued to Raymond f. Curiel on 3 Mar. 1987. This attempt falls short of its intended goal as the above mentioned device depends on the Sun for its recharging power. When the Sun is not shining the charging source cannot be depended on.
[0004] As illustrated by background art, efforts are continuously being made in an attempt to develop an internal re-charging mechanism for battery powered devices. No prior effort, however, provides the benefits attendant with the present invention. As such, it may be appreciated that there is a continuing need for a new and improved method to re-cycle the charging energy within battery operated devices, eliminating the need for a separate battery charging system or operation. In these respects, the present version of the invention substantially departs from the conventional concepts and designs of the prior art, and in so doing provides an apparatus that substantially fulfills this need. Additionally, the prior patent and commercial techniques do not suggest the present inventive combination of component elements arraigned and configured as disclosed herein.
[0005] The present invention achieves its intended purposes, objects, and advantages through a new, useful and unobvious combination of methods steps and component elements, with the use of a minimum number of functioning parts, at a reasonable cost to manufacture, and by employing only readily available materials.
SUMMARY
[0006] The present version of the invention, which will be described in greater detail hereinafter, relates to the field of continuous DC power devices such as self-charging battery devices. This version of the invention is concerned with devices that are designed to power other devisees without need to re-charge the batteries for normal operation. In some instances the device can also deliver torque which can be used for a verity of uses. My version of the invention overcomes all of the shortcomings listed previously, in addition to novel aspects that will be described in detail hereinafter.
[0007] Described briefly, according to a typical embodiment, the invention prevents a self-contained self-charging power module to deliver a steady continuous source of DC power and toque. The said module can be used by its self, or in conjunction with other modules to create the power source needed for various activities. A 36-volt module consist of three 12-volt batteries connected in series. A 24-volt module has two 12-volt, and a 12-volt module has two 6-volt batteries each connected in series to achieve the desired voltage and amperage for that module. Motor or motors are installed in each unit with means to operate a current re-cycling component with volts and amps and sensors enough to refurbish said batteries on a as needed basis. This process eliminates the need for any external energy source for said modules' normal operation. Another version called a torque-box power module can also deliver turning motion along with current. This makes the present invention a more practical energy source than just batteries alone, which must depend on some external charging source for its continued operation. Module racks also can be used to increase volts and amps. A service monitor also controls said modules' operation, and alerts user of potential problems.
[0008] My invention, therefore, resides not in any one of these features per se, but rather in the particular combination of all of them herein disclosed. It is distinguished from the prior art in this particular combination of all its structures for the functions specified.
[0009] In as much as the forgoing has outlined rather broadly the more pertinent and important features of the present invention in order that the detailed description of the invention that follows may be better understood, so that the present contribution to the art can be more fully appreciated, Additional features of the invention will be described hereinafter. It should be appreciated by those skilled in the art that the conception and the disclosed specific methods and structures may be readily utilized as a basis for modifying or designing other structures for carrying out the same purposes of the present invention. It should be realized by those skilled in the art that such equivalent methods and structures do not depart from the spirit and scope of the invention.
[0010] In this respect, before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and to the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein are for the purpose of description and should not be regarded as limiting.
[0011] As such, those skilled in the art will appreciate that the conception, upon which the disclosure is based is based, may readily be utilized as a basis for designing of other structures, methods and systems for carrying out the several purposes of the present invention.
[0012] Further, the purpose of the foregoing abstract is to enable the U.S. Patent and Trademark Office and the public generally, and especially the scientists, engineers and practitioners in the art who are not familiar with patent or legal terms or phraseology, to determine quickly from a cursory inspection the nature and essence of the technical disclosure of the application. The abstract is neither intended to define the invention of the application nor is it intended to be limiting as to the scope of the invention in any way.
[0013] Accordingly, it is an object of my version of the invention to provide a low-cost, easy-to-manufacture, and easy-to-market self-charging power module.
[0014] A further object of my version of the invention is to provide an easy-to-use and versatile power module and torque box.
[0015] A significant object of the invention is to provide a self-charging power module and torque box that can be used in a variety of ways, to produce power for land, marine and air crafts, and power generators, and HV/AC systems.
[0016] Another important object of the invention is to save money to consumers, and to alleviate air and water pollution caused by the use of fossil fuel, and to deliver the nations from dependence on imported oil.
[0017] A final but very significant object of the invention is to provide a self-charging power module that will save lives, as automobile and aircraft wrecks will result in fewer fires due to the fact that said power modules will replace fossil fuel uses.
[0018] For a better understanding of the invention, its operating advantages and the specific objects attained by its uses, reference should be made to the accompanying drawings and descriptive matter in which there is illustrated preferred and alternate embodiments of the invention. The foregoing has outlined some of the more pertinent objects of the invention. These objects should be construed to be merely illustrative of some of the more prominent features and applications of the present invention. Many other beneficial results can be attained by applying the disclosed invention in a different manner or by modifying the disclosed invention within the scope of the disclosure. Accordingly, other objects and a fuller understanding of the invention may be had by referring to the summary of the invention and the detailed description of the preferred and alternate embodiments in addition to the scope of the invention illustrated by the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] The foregoing and other objects, features, and advantages of the inventions will become more fully understood from the following description of the preferred and alternate embodiments of the invention as illustrated in the accompanying drawings, in which reference characters refer to the same parts throughout different views. The drawings are not necessarily to scale, emphasis is instead being placed upon illustrating the principles of the invention.
[0020] [0020]FIG. 1 is a plan view of a 36-volt power module; also showing future service monitor, and remote voice communicator/controller and remote volt/amp meter and anunciator/beeper.
[0021] [0021]FIG. 2 is an elevational view of a module rack showing front and rear elevations, and illustrating a 216-volt and a 440-amp wiring configuration, also a 216-volt and 220-amp wiring configuration.
[0022] [0022]FIG. 3 is an elevational view of a module rack showing front and rear elevations, and illustrating a 432-volt and a 220-amp wiring configuration, also illustrating a 108-volt and 220-amp configuration.
[0023] [0023]FIG. 4 is an elevational view of a 432-volt and a 440-amp module rack showing front and rear elevations, and a 432-volt and a 440-amp wiring configuration.
[0024] [0024]FIG. 5 is a perspective view of a 24-volt 62-amp torque-box power module alternate embodiment in accordance with the present version of the invention.
[0025] [0025]FIG. 5A is a perspective view of a wiring configuration for a 24-volt and 100-amp power module in accordance with the present version of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0026] Description Referring now to the drawings and, in particular to FIG. 1 wherein there is illustrated a typical embodiment of a 36-volt automatic-self-charging-power module 22 . The present version of the invention 22 is constructed of materials and components that are light weight and durable, and resistant to corrosion and oxidation, such as plastic, aluminum, carbon steel, various composite materials or a combination thereof: including the possibilities of conductive polymers.
[0027] The device 22 consists in a main housing 40 of the following: three batteries 70 , a motor and pulley assembly 68 , a generator assembly 30 , a motor drive belt 54 , a sensor switch 32 , a test push button 50 , a volt meter 52 , a remote on/off sensor switch 76 , a fuse 42 , terminals 34 & 36 , a voltage regulator 63 , two carrying handles 38 , a future service monitor 72 , a service monitor battery charger connection 46 , a remote voice communicator/controller 56 , and a remote annunciator/beeper 48 .
[0028] Referring again to FIG. 1, batteries 70 are connected in series, to give 36-volts. Motor assembly 68 , and generator assembly 30 are positioned with drive belt 54 , in such a way that when powered by sensor switch 32 , when there is a 1-volt drop in device 22 , the batteries 70 are refurbished by generator 30 (generator 30 is a 38-volt motor operated counter-clockwise by motor 68 ). When 38-volts are reached in device 22 , sensor switch 32 opens the circuit to motor 68 , thereby stopping the charging process. This cycle is repeated on a as needed basis, weather the device 22 is in use or not. Thereby eliminating the need for any external energy source to keep the device 22 in operation.
[0029] Referring again to FIG. 1 service monitor(SM) 72 has its own 36-volt internal battery which is re-charged via connection 46 . The voltage in power module(PM) 22 is controlled by voltage regulator 63 . Unit SM. 72 monitors the condition of PM 22 and alerts the operator of any potential or immediate problems. This information is conveyed either by voice prompts or numerically. Said messages can be heard over speaker 98 , or by remote voice communicator. controller (RVCC) 56 . RVCC 56 can also work as a cellular phone or two-way radio controlled by button 60 . RVCC 56 is battery operated, and is re-charged through cord 64 , by standard 12-volt battery charger. RVCC 56 can also be used to turn PM 22 on or off, through sensor switch 76 by pressing button 59 .
[0030] Continuing with FIG. 1 remote annunciator/beeper(RA) 48 , can display messages transmitted by SM. 72 , a beep alerts user to a new message. RA 48 can also be connected to SM. 72 by plug 49 and receptor 51 .
Description of Module Racks
[0031] Referring now to FIG. 2 wherein there is illustrated a typical embodiment of power module racks 23 and 23 A. The present version of the invention is constructed of mild steel or aluminum depending on its' use. The device 23 consist of main outer frame 244 , with intermediate shelves 248 sturdy enough to support the weight of said power modules. Some units are constructed with center support 241 to support shelves on either side of outer frame 244 . The device 23 is equip with a set of lifting lugs 242 , and wheels 246 . Also illustrated by FIG. 2 is a proposed wiring configuration for a 216-volt and 440-amp module rack 23 , and a 216-volts and 220-amps DC module rack 23 A.
[0032] [0032]FIG. 3 illustrates a typical embodiment of a module rack 23 B, and 23 D showing proposed wiring configuration for a 432-volt and 220-amps, and a 108-volt and 220-amps DC module rack respectively.
[0033] [0033]FIG. 4 illustrates a typical embodiment of a module rack 23 C showing proposed wiring configuration for a 432-volt and 440-amps DC module rack.
[0034] Description of Alternate Embodiment
[0035] Referring again to the drawings and in particular to FIG. 5 wherein there is illustrated an alternate embodiment of a 24-volt torque-box power module 27 . The present version of the invention 27 , is constructed of materials and components that are light weight, durable and resistant to corrosion and oxidation such as plastic, malleable iron, wood, carbon steel, composite materials, or a combination thereof: including the possibilities of conductive polymers. The device 27 consist in a main housing 120 of the following major parts: Two 1 HP motors (M 1 ) 90 and (M 2 ) 92 , two 12-volt batteries(B 1 & B 2 ) 88 , two chain & sprocket drive assembly 112 (12 to 1 ratio) and 114 (7 to 1ratio), and two bearing and drive shaft assembly 108 main and 110 auxiliary, and two relays 41 & 41 A, one volt meter 84 , and one tachometer speed switch 82 , and one 150-amp-24-volt alternator 98 , and alternator drive pulley 100 , and service monitor 72 , and on/off switch 103 , and torque drive extension shaft 111 .
[0036] When switch 103 is closed power goes to motors M 1 and M 2 , instrument gauges 82 and 84 and alternator 98 . This action permits alternator 98 to re-furbish battery 88 , in response to internal voltage regulator of alternator 98 . The said process will allow torque-box power module 27 to operate perpetually. When switch 103 is in the off position service monitor(SM.) 73 monitors the condition of torque-box power module(TPM) 27 . When there is a drop in voltage SM. 73 transmits a signal to motors 90 & 92 via wires 102 . When the desired voltage and current is achieved SM. 73 turns said motors off, thereby keeping said batteries continuously re-furbished, weather said module is in use or not.
[0037] Extension torque drive-shaft 111 can be extended outside housing 120 , and used for desired turning motion. In addition to that 62-amps will be available from terminals 34 & 36 .
[0038] Description of Alternate Wiring
[0039] Referring now to FIG. 5A wherein there is illustrated a wiring configuration for a 24-volt-100-amp power module 27 A. This version of the invention 27 A only allows one motor to operate at a time; therefore the amperage at terminals 34 and 36 (FIG. 5) will be higher than the TPM 27 . Power module(PM) 27 A cannot be operated as a torque-box. This version of the invention 27 A is designed for DC power only, although PM 27 A has all the components of the TPM 27 , and functions under the same principle.
[0040] Referring again to FIG. 5A when switch 101 is closed, motor 90 is energized, and instrument gauges 82 and 84 receives power. Alternator 98 is set in motion (see FIG. 5). Alternator 98 has an internal tachometer that operate in concert with tachometer speed switch 82 . When the set speed is satisfied on tachometer speed switch 82 (see FIG. 5A), power goes to relay coils 41 and 41 A. This said action transfers power to motor 92 , and stops motor 90 . Power also is transmitted to alternator 98 , thereby allowing the charging process to begin. A 12-volt module would operate under any of the previously mentioned principles.
[0041] Ramifications
[0042] The amperage and voltage specified in the present application of the invention are merely for exemplification and should not be considered to be limitations upon the scope of the invention in any way. Accordingly all suitable volts and amps may be resorted to. The specifications of motor ratings speed ratios, charging components and such like, should not be construed to be limitations upon the present invention; Therefore all other equivalent or suitable components, or rating, may be resorted to without departing from the spirit and scope of the invention.
[0043] Conclusion and Scope of Invention
[0044] From the foregoing, it will be understood by persons skilled in the art that an improved DC power device has been provided. The invention is relatively simple and easy to manufacture, yet affords a variety of uses. While my description contains many specifications, these should not be construed as limitations on the scope of the version of the invention but rather as an exemplification of the preferred embodiment thereof. The foregoing is considered as illustrative only of the principles of the invention. Further, since numerous modifications and changes will readily occur to those skilled in the art, it is not to be sired to limit the invention to the exact construction and operation shown and described, accordingly all suitable modifications and equivalents may be resorted to, falling within the scope of the invention.
[0045] Although this invention has been described in its preferred form with a certain degree of particularity, it is to be understood that the present disclosure of the preferred form has been made only by way of example, and numerous changes in details of construction and combination, and arrangements of parts may be resorted to without departing from the spirit and scope of the invention.
[0046] Drawing Reference Numbers
[0047] [0047] 30 38-volt generator
[0048] [0048] 32 Sensor on/off switch
[0049] [0049] 34 Negative terminal connection
[0050] [0050] 36 positive terminal connection
[0051] [0051] 38 Carrying handle
[0052] [0052] 40 Module housing
[0053] [0053] 41 24-volt tachometer relay
[0054] [0054] 41 A 24-volt tachometer relay
[0055] [0055] 42 Main module fuse
[0056] [0056] 43 Re-cycle charging wire
[0057] [0057] 44 External speaker connection
[0058] [0058] 45 Motor fuse
[0059] [0059] 46 SM battery charger connection
[0060] [0060] 47 Positive lead wire to SM
[0061] [0061] 48 Remote annunciator/beeper(RA)
[0062] [0062] 49 RA connector to SM
[0063] [0063] 50 Voltage test push button
[0064] [0064] 51 RA receptacle
[0065] [0065] 52 Volt meter for PM 22
[0066] [0066] 54 Generator drive-pulley belt
[0067] [0067] 56 Remote voice communicator/controller(RVCC)
[0068] [0068] 58 RVCC on/off switch
[0069] [0069] 59 Remote on/off switch
[0070] [0070] 60 Two-way radio control
[0071] [0071] 62 Antenna for RVCC
[0072] [0072] 63 Voltage regulator
[0073] [0073] 64 RVCC battery charger connection
[0074] [0074] 66 RVCC display screen
[0075] [0075] 68 36-volt drive motor & pulley assembly
[0076] [0076] 70 12-volt re-chargeable batteries(B 1 ,B 2 ,B 3 )
[0077] [0077] 72 Service monitor with 36 to 12-volt internal battery charger
[0078] [0078] 73 Service monitor with 24 to 12-volt internal battery charger
[0079] [0079] 76 RVCC speaker
[0080] [0080] 82 24-volt tachometer
[0081] [0081] 84 24-volt, volt-meter
[0082] [0082] 86 Instrument fuse
[0083] [0083] 88 12-volt re-chargeable batteries(B 1 ,B 2 )
[0084] [0084] 90 24-volt motor(M 1 )
[0085] [0085] 91 Negative lead re-cycle wire
[0086] [0086] 92 24-volt motor(M 2 )
[0087] [0087] 93 Negative lead to instrument gauges
[0088] [0088] 94 Tachometer sensor wire
[0089] [0089] 96 Service monitor speaker
[0090] [0090] 98 24-volt alternator
[0091] [0091] 100 Alternator drive pulley
[0092] [0092] 101 Double throw switch
[0093] [0093] 102 Motor power lead from SM 73
[0094] [0094] 103 Triple throw switch
[0095] [0095] 104 Air vent louvers
[0096] [0096] 106 Motor coupler
[0097] [0097] 108 Main drive shaft assembly
[0098] [0098] 110 Auxiliary drive shaft assembly
[0099] [0099] 111 Extension torque drive shaft
[0100] [0100] 112 Chain & sprocket assembly( 12 - 1 )
[0101] [0101] 114 Chain & sprocket assembly( 7 - 1 )
[0102] [0102] 116 Bridge supports for pillow blocks
[0103] [0103] 119 SM 73 charger wire connection
[0104] [0104] 120 Module housing without cover
[0105] [0105] 241 Center support
[0106] [0106] 242 Lifting lugs
[0107] [0107] 244 Outer frame
[0108] [0108] 246 Wheels
[0109] [0109] 248 Shelf
[0110] [0110] 250 Module lock
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A self-contained DC-self-charging power module of 12 to 36-volts that could be used to power land, marine, and air, crafts and also to build electrical power generators and HV/AC systems is disclosed. These modules could be connected in series and or parallel circuits in order to achieve a desired voltage and amperage, for almost any task.
This can be accomplished by installing batteries in series to give the desired volts and amps. Motor or motors with means to operate a energy re-cycling component to re-charge the batteries, could be installed. A computerized monitoring system could be installed, to control and monitor said power device, so that the batteries are re-charged automatically weather the device is in use or not.
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BACKGROUND OF THE INVENTION
One of the most important advances in the area of electronic integrated circuit (IC) design over the past few years has been the development of logic synthesis as part of the overall IC design process. In a nutshell, logic synthesis allows IC designers to more fully utilize the ever-increasing number of transistors available in an IC while ignoring the tedious complexities associated with direct gate-level design. Thus, logic synthesis has allowed the designer to concentrate on the functionality of an IC while, at the same time, reducing its associated time-to-market.
As shown in FIG. 1, logic synthesis currently is a vital part of a typical IC design process 1 . An IC designer initially generates a high-level behavioral or register-transfer-level (RTL) description (step 100 ) of the functionality of a proposed IC, which is normally written in a hardware design language (HDL), with VHDL and Verilog being the two most popular examples. Often, a functional simulation of the behavioral or RTL description is performed thereafter to determine if the circuit logically operates as was intended (step 110 ). If this simulation (step 110 ) yields no unpleasant surprises, the designer then uses a set of software tools that performs logic synthesis (step 120 ) to transform the behavioral or RTL description into a schematic representation of circuit elements, such as logic gates, transistors, resistors, and the like, along with the associated logical connections between elements. The synthesized circuit elements and logical connections are then simulated once again (step 130 ) at the logic gate level to check the operation of the circuit against previously specified voltage and timing constraints. If the gate-level simulation (step 130 ) executes successfully, the schematic of circuit elements and connections is then passed to a “place-and-route” tool (step 140 ), which determines the actual location of the circuit elements and connections within the space available on the IC. A final simulation (step 150 ) is then performed, this time on the circuit generated by the place-and-route tool, in order to determine if the chip meets all functional and timing constraints, given the actual physical layout of the circuit.
As can be seen in FIG. 1, successful completion of a step of the IC design process brings the IC design one step closer to being a viable IC. Conversely, any problems or failures discovered in any of the steps results in some portion of the design process to be repeated. (FIG. 1 indicates a few of the possible “repeating” paths.) In the past, a reasonable number of failures were expected early on in the process, such as during functional simulation (step 110 ) or gate-level simulation (step 130 ), with relatively few problems encountered at final simulation (step 150 ).
However, with the decreasing size in the IC geometries being used, and the correspondingly higher number of transistors available on an IC, the standard design process described above has proven inadequate at times, with a significant number of IC failures not being discovered until final simulation (step 150 ). This is especially problematic considering that the manufacturing process for the IC is oftentimes begun prior to final simulation, since that simulation (step 150 ) is quite a time-consuming task due to the complex nature of the circuit models and current waveforms involved. Unlike before, when logic gate timing delays contributed the overwhelming majority of the overall timing delay of a signal, the latest advances in IC manufacturing technology have caused the connections between logic gates to be the single largest contributor to signal delay in most cases. Since the signal delay in a connection is dependent upon the length of that connection, the placement and routing of the connection must be known with a high degree of certainty in order to accurately model the signal delay involved. Unfortunately, under typical IC design process 1 , the place-and-route information is not known until well after the RTL design and synthesis steps have been performed.
Recently, companies such as Synopsis Inc. and Avant! Corporation have devised new IC design tool strategies to deal with this problem. Although the various strategies differ in the details, they basically involve the addition of “quick,” or non-final, types of synthesis and place-and-route functions earlier in the design process to determine within certain error limits the lengths of the interconnections in the IC. In FIG. 2, an updated IC design process 2 is shown, with a quick synthesis and place-and-route step (step 200 ) essentially being added early in the design flow. (Frequently, the “quick” place-and-route function is termed “floorplanning”.) As a result, timing simulations at the gate level are carried out using preliminary physical layout information, thereby giving the IC designer greater confidence that the IC will actually perform as expected prior to final place-and-route. In other words, the “logical” design steps of RTL definition and logic synthesis are more tightly coupled with the “physical” design steps of placing and routing under updated IC design process 2 . Potential timing problems are thus discovered earlier in the design process, saving development time that would otherwise be wasted during place-and-route (step 140 ) and final simulation (step 150 ). Therefore, the problems involved with meeting timing constraints under the older process have been mitigated somewhat with the newer IC design approaches.
However, the latest advances in design methodology do not appear to address all of the problems associated with the typical separation of the logical and physical portions of IC design. For example, some currently available IC design tools allow analysis of the average magnitude of the loads placed on the on-chip power grid during the logical portion of the design cycle to determine power requirements for the various areas of the IC. However, the IC power supply circuitry, which includes both the on-chip power circuitry and the IC package power circuitry, is generally not taken into account during the design of the IC core logic. As a result, incompatibilities between the IC power supply circuitry and the IC core logic circuitry can cause problems not easily identified until final simulation (step 150 ).
Even if fluctuations of the power supply at the pins of an IC package are insignificant, the power still has a significant amount of circuitry to traverse before it reaches the on-chip logic circuitry of an IC, as can be seen in the diagrammatic representation of FIG. 3 . More specifically, package power supply pins 320 , typically labeled VDD and GND, are the entry points of the power and ground connections into an IC package 300 . Ordinarily, on LSI components, multiple VDD and GND power supply pins 320 are supplied to allow a sufficient amount of current to pass between IC package 300 and a circuit board power supply circuit 310 to operate the chip properly. Power supply pins 320 are, in turn, connected to a package power supply circuit 330 , which is made up primarily of, but not limited to, a network of metal planes, grids, and bypass capacitors inside the IC package. Package power supply circuit 330 , in turn, provides power to an on-chip power supply circuit 340 , which is made up mainly of metal grids and more bypass capacitors. It is on-chip power supply circuit 340 that is attached via multiple connection points to an IC core logic circuit 350 , which performs the logical functions expected of the IC. As is well-known in the art, the bypass capacitors in package power supply circuit 330 and on-chip power supply circuit 340 are placed across the power and ground planes and grids to help stabilize the power supply voltage levels by providing charge during short time periods of high current demand by core logic circuit 350 .
As can be appreciated by someone of skill in the art, the IC designer pays much attention to the problem of providing adequate and stable power to core logic circuit 350 by investing a significant amount of time and resources into the design of both package power supply circuit 330 and on-chip power supply circuit 340 . However, depending on the physical and operational characteristics of core logic circuit 350 , problems in the power supplied at the core may still exist, leading to faults in the operation of the logic circuitry. For example, package power supply circuit 330 , with its network of planes, grids, and bypass capacitors, usually exhibits a resonant frequency at which the impedance of that circuitry increases substantially. If at least some portion of core logic circuit 350 is operated in a periodic fashion at or near that resonant frequency, package power supply circuit 330 will exhibit the increased impedance, thereby resulting in a reduced power supply voltage at core logic circuit 350 during that time. Such an unstable power supply voltage, in turn, causes the voltage trigger points of core logic circuit 350 to fall, possibly allowing small amounts of noise on a signal line to trigger a logic gate input falsely, thereby causing operational failure of the IC. On-chip or externally provided clock signals are typical determinants of the operational frequency of the clock. However, even clock signals with primary frequencies less than that of the resonant frequency of the IC package may cause problems, since many harmonics are present in such clock signals, especially those clock signals with extremely short rise and falls times. Oppositely, clock signal frequencies greater than the package resonant frequency may also cause failures, as some large portions of core logic circuit 350 may trigger in response to multiple periods of a clock signal, resulting in operational frequencies that are some fraction of that of the original clock signal.
Package power supply circuit 330 is not the only source of power supply impedance. On-chip power supply circuit 340 , with its power supply grid and bypass capacitors on the IC chip itself, also contributes to this effect, often generating a more prominent resonance point at a higher frequency than its package counterpart. With two resonance points in the power supply circuit, it can be appreciated by those skilled in the art that the power supply resonances are potential barriers to designing a chip that works correctly for all combinations of temperature, timing, and supply voltage constraints that are specified for the IC.
In addition to the periodic nature of core logic circuit 350 , and its interaction with the resonant frequencies of package and on-chip power supply circuits 330 and 340 , core logic circuit 350 may also exhibit substantial non-periodic current demands on the power supply circuitry in the form of current “spikes,” or short, non-periodic instances of extremely high current demand. These spikes occur, for example, as a result of the response of core logic circuit 350 to a change in state of one of the IC input signal lines driven by circuitry external to IC package 300 . Logic signal changes within IC package 300 may also cause current spikes to occur. Spikes of sufficiently large magnitude cause temporary failure in the portion of the power supply circuitry that is in close proximity to the section of core logic circuit 350 responsible for that current demand. Unfortunately, in order to detect such problems prior to final simulation 150 , more information concerning the structure of package and on-chip power supply circuits 330 and 340 is required earlier in IC design processes 1 and 2 . For example, the nature of the power supply circuitry must be known sufficiently to determine the level of current demand necessary at various locations within core logic circuit 350 to cause a drop in supply voltage that would cause core logic circuit 350 to fail.
Unfortunately, the electrical characteristics of the package and on-chip power supply circuits, including the identity of the power supply circuit resonant frequencies, and their resultant effects on the operation of core logic circuit 350 , are currently not known with sufficient accuracy during the logic description ( 100 ) and synthesis ( 120 ) steps of either of design processes 1 and 2 described above to prevent design problems early in the IC design cycle. Typically, such problems are not found until final simulation, which is rather late in the design process, impacting time-to-market adversely.
Thus, it would be advantageous to utilize information concerning the power supply circuitry of the package and the chip earlier in the IC design cycle to modify the synthesis of the IC core logic. Such modification would help avoid operational faults related to the periodic and non-periodic interaction of the core logic and the power supply circuitry.
SUMMARY OF THE INVENTION
The embodiments of the invention, to be discussed in detail below, allow the use of the package and on-chip chip power supply circuit models and associated resonant frequencies as input to the initial IC RTL description and synthesis process. These additional inputs, when used properly, help prevent the core logic from placing too high a periodic current demand at the resonant frequencies, and too high a non-periodic current spike that exceeds the capabilities of the package and on-chip power supply circuits. Without specific information concerning the electrical characteristics of the power supply circuits, valuable time-to-market is often wasted during the initial description, synthesis, and simulation of the IC in creating a logic core that is incompatible with the power supply circuitry that will be used to drive the chip.
According to an embodiment of the invention, a method of adjusting the core logic of an IC based on the electrical characteristics of the package and on-chip power supply circuits begins with developing electrical models of those power supply circuits. As will be discussed later, on-chip power supply SPICE models for ICs recently have become available prior to initial floorplanning activity. Similarly, package power supply circuitry for a particular package size is also available, with the associated SPICE model. Circuit simulations are then performed on each of these two models in order to determine the primary resonant frequencies identified with each of the power supply circuits. The resonant frequency of the on-chip power supply circuit is then used as input to initial floorplanning, or “first chip route,” for the IC. Positional current waveforms, each specific to various locations on the IC core logic, are then developed from an analysis of the initial floorplan. The positional current waveforms are, in turn, used in conjunction with the previously generated power supply circuit models to run power supply integrity simulations. The results of these power supply integrity simulations, along with the two previously identified resonant frequencies, are then used to generate design constraints associated with the power supply circuitry and its interaction with the core logic circuitry. The design constraints are then used to either manually modify the core logic by way of the RTL description language, or to automatically modify the logic synthesis process. Whether the manual or automatic approach is taken, the core logic of the IC is modified according to techniques known in the art so that the primary frequency components of the electrical current demands of the logic are “pushed away” from those resonant frequencies. Also, problematic core logic current waveforms are also “smoothed out” so that the magnitude of current frequencies coinciding with the resonant frequencies, and the magnitude of non-periodic current demands, are reduced to a level that will not cause power supply voltage failures.
In some cases, either the package or on-chip power supply circuit model is not obtained before the RTL description of the core logic circuit has been synthesized. Embodiments of the invention exist which allow the model of either the package or on-chip power supply circuit to be utilized for adjustment of the core logic gate-level description.
Another embodiment of the invention is a system which produces a set of design constraints that mitigate problems associated with the interaction of the package and on-chip power supply circuits and the core logic circuit. One portion of the system is a circuit simulator, which takes the package and on-chip power supply circuit models as input, and determines the primary resonant frequencies for those models. Also included in the system is an initial floorplanner, which takes as input the on-chip power supply resonant frequency and the initial block-level description of the core logic circuit as input, and generates a set of positional current waveforms. A power supply integrity simulator then utilizes the positional waveforms and the power supply circuit models to generate a set of design constraints associated with the power supply circuits. The design constraints, in addition to the identity of the power supply resonant frequencies, are then either used as input to a logic synthesis tool to adjust the synthesis of the core logic circuit, or used manually by an IC designer to adjust the high-level description of the core logic.
Additionally, alternate system embodiments allow the use of either the package or on-chip power supply circuit model alone, thus allowing the absence of one of the power supply circuit models while adjusting the IC core logic using information about the known power supply circuit model.
Other aspects and advantages of the invention will become apparent from the following detailed description, taken in conjunction with the accompanying drawings, illustrating by way of example the principles of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a flow chart of a standard IC design process.
FIG. 2 is a flow chart of an updated IC design process that more closely couples the logical and physical aspects of the process.
FIG. 3 is a block diagram of the power supply and core logic circuitry of a typical IC.
FIG. 4 is a flow chart of a logic synthesis adjustment method according to an embodiment of the invention in which both the package and on-chip power supply circuits are previously known, and the resulting design constraints are input directly into a logic synthesis tool.
FIG. 5 is a flow chart of a logic synthesis adjustment method according to an embodiment of the invention in which both the package and on-chip power supply circuits are previously known, and the resulting design constraints are used to manually modify the high-level description of the IC.
FIG. 6 is a flow chart of a logic synthesis adjustment method according to an embodiment of the invention in which only the on-chip power supply circuit is previously known, and the resulting design constraints are input directly into a logic synthesis tool.
FIG. 7 is a flow chart of a logic synthesis adjustment method according to an embodiment of the invention in which only the on-chip power supply circuit is previously known, and the resulting design constraints are used to manually modify the high-level description of the IC.
FIG. 8 is a flow chart of a logic synthesis adjustment method according to an embodiment of the invention in which only the package power supply circuit is previously known, and the resulting design constraints are input directly into a logic synthesis tool.
FIG. 9 is a flow chart of a logic synthesis adjustment method according to an embodiment of the invention in which only the package power supply circuit is previously known, and the resulting design constraints are used to manually modify the high-level description of the IC.
FIG. 10 is a flow chart of a system, with associated input and output data, according to an embodiment of the invention in which both the package and on-chip power supply circuits are previously known, and the resulting design constraints are input directly into a logic synthesis tool.
DETAILED DESCRIPTION
An embodiment of a method according to the invention is shown in the block diagram of FIG. 4 . The synthesis adjustment process shown in the diagram is started by separately developing both the on-chip power supply circuit (step 400 ) and the package power supply circuit (step 415 ). Generally, ICs that utilize the same package size and technology will also utilize very similar on-chip and package power supply circuits. As a result, the designs for those two power supply circuits for a given package/technology combination will tend to be quite stable, having been generated initially by hand, and subsequently modified through many design cycles during the development of other ICs. If the package and associated IC technology for a new IC to be designed have been previously utilized, the designs for the package and on-chip power supplies will already be completed before the design of the core logic begins, allowing knowledge of the power supply circuits to influence the synthesis process of the IC core logic, as seen below.
Once good power supply circuits have been achieved, it becomes advantageous to dedicate resources to generate the complex SPICE models of the on-chip power supply circuit (step 405 ) and the package power supply circuit (step 420 ). Once the SPICE models have been generated, simulations are run on the on-chip power supply circuit (step 410 ) and the package power supply circuit (step 425 ) to determine resonant frequencies ω 1 and ω 2 , respectively, with ω 1 generally being greater than ω 2 . The on-chip design libraries used during the IC design process would also use these power supply circuit SPICE models for gate-level and final simulations.
Once on-chip power supply resonant frequency ω 1 has been determined, that information can be used as input to the “first chip route” process (step 430 ). First chip route, in one embodiment, is an initial type of floorplanning that allows the designer to estimate the space and location to be used for the various functional “blocks” to be implemented within the chip. Generally, this initial floorplanning is accomplished by using as input block-level information about the IC, such as the identity of the functional blocks to be utilized (RAM, ROM, and processor core, for example) and their basic capabilities (processor speed, RAM size and speed, and so on). The use of resonant frequency ω 1 in early floorplanning aids in identifying potential conflicts between ω 1 and parameters of the chip design that may be known at the early floorplanning stage, such as the primary IC clock frequency, and the associated clock driver and repeater scheme. For example, if the primary IC clock frequency is the same as ω 1 , the clock frequency may be changed (if allowed by the chip specification) so that the clock frequency and ω 1 do not coincide. Similarly, the chip clock driver and repeater scheme may be modified so that not all drivers and repeaters are triggering at the same instant, thus “smoothing out” the current spikes so that the current demand of the IC at frequency ω 1 is reduced to an acceptable level. The smoothing of the waveform can be accomplished, for example, by modifying the lengths of the traces in the driver and repeater circuit so that the gates involved do not all trigger at precisely the same instant.
As a result of the early floorplanning (step 430 ), simulated positional current waveforms may then be generated (step 435 ). These waveforms represent the expected amplitude and frequency of the periodic and non-periodic aspects of the electrical current being drawn at numerous locations within the core logic circuitry of the IC under various operating conditions. These positional current waveforms are then used, in turn, to drive both the on-chip and package power supply circuit SPICE models generated earlier in the synthesis adjustment process via a power supply signal integrity simulation (step 440 ). The results of power supply integrity simulation 440 will indicate if a compatibility problem exists between the core logic circuitry and the on-chip and package power supply circuits. This information is then used as a set of design constraints into a logic synthesis process (step 445 ) to guide the actual synthesis of the high-level description to the gate level. (The high-level description, in an alternate embodiment, has already been analyzed by functional simulation 110 , of FIG. 1, prior to logic synthesis (step 445 ).) The nature of such constraints is similar to those already used in a typical synthesis process, such as the timing requirements of the logic, the area limitations of the IC, and the overall power limits under which the IC must operate. For example, an area of the core logic circuit may be identified as potentially causing too high a current spike on the power supply during certain input signal states. In another case, a portion of core logic may be operating at a magnitude and frequency that would cause failure of the power supply to sustain the supplied voltage within acceptable limits. The design constraints would thus indicate these potential situations to the logic synthesis tool, indicating that the resulting gate-level description of the core logic must address these issues.
In an alternate embodiment, shown in FIG. 5, the identity of ω 1 and ω 2 and the results of the power supply signal integrity simulation are used to manually modify the high-level description of the logic to remedy the power supply resonance problems that were identified (step 100 ). The high-level description is then synthesized as part of a normal IC design process.
Whether the problems are handled manually in the high-level description, or automatically during synthesis, the methods used to mitigate the identified problems are known to those skilled in the art. In addition to the clock circuit modification techniques discussed earlier, other ways of reducing the amount of current drawn by the core logic at a particular instant exist. For example, instead of clocking all portions of a circuit on the same positive or negative edge of a clock signal, it is possible in some circuits to use a mix of positive- and negative-edge clocking to spread out the current demands more evenly throughout the cycle period.
In some cases, the IC designer may only know the physical structure of the on-chip power supply circuitry prior to the design and synthesis of the core logic. In that case, the information from the on-chip power supply SPICE model may be used in the absence of the corresponding data for the package power supply to modify the core logic circuitry, as shown in FIG. 6 and FIG. 7 . FIG. 6 shows an embodiment whereby the information concerning the on-chip power supply circuitry is input to the logic synthesis tool, which automatically takes that information into account during the synthesis process. FIG. 7, on the other hand, depicts the use of that information by the IC designer to manually adjust the high-level description of the core logic prior to synthesis. Such a method is implemented so that as much as is known about the power supply circuitry is incorporated as early as possible into the design of the core logic circuitry. Similarly, as shown in FIG. 8 and FIG. 9, if only the package power supply circuitry is known prior to the design and synthesis of the core logic, information concerning the package can be used to influence the early portions of the IC design process. FIG. 8 shows the automatic use of the package power supply information within the synthesis tool, while FIG. 9 illustrates the use of that information within the high-level description of the core logic. In general, incorporating any physical information regarding the power supply circuitry into the early stages of the design process is beneficial because of the fewer design and simulation iterations that result later in the design cycle.
The invention is also embodied as a system of incorporating the physical information of the package and on-chip power supply circuits into the synthesis of the core logic circuitry of an IC. As shown in FIG. 10, an on-chip power supply SPICE model 1000 and a package power supply SPICE model 1005 are each used as input to a circuit simulator 1010 which identifies the resonant frequencies associated with the on-chip and package power supply circuits ( 1015 and 1020 , respectively). An initial floorplanner 1030 uses initial, block-level information 1025 about the core logic, as well as on-chip power supply circuit resonant frequency 1015 , to generate a set of positional current waveforms 1035 that indicate the current load caused by the IC core logic at various locations on the chip. (Of course, initial floorplanner 1030 develops an initial floorplan of the IC core logic, as well, which is not shown in FIG. 10.) A power supply integrity simulator 1040 uses positional current waveforms 1035 , on-chip power supply SPICE model 1000 , and package power supply SPICE model 1005 to determine any periodic and non-periodic conflicts between the core logic current waveforms and the power supply circuits. As a result of its work, power supply integrity simulator 1040 generates a set of design constraints 1045 associated with the power supply circuits that cause the discovered conflicts to be resolved. A logic synthesis tool 1050 then uses design constraints 1045 and resonant frequencies 1015 and 1020 from circuit simulator 1010 as input to be added to a high-level description 1055 of the core logic. High-level description 1055 may or may not have been simulated at the functional level prior to being passed to logic synthesis tool 1050 . The resulting output of logic synthesis tool 1050 is a gate-level description of the IC that exhibits no compatibility problems with the package and on-chip power supply circuits of the IC.
Additional system embodiments of the invention are analogous to the embodiment methods described earlier. For example, it is possible that either (but not both) SPICE model 1000 or 1005 (from FIG. 10) will not be available prior to the design of the core logic. If that is the case, only one SPICE model ( 1000 or 1005 ) and one resonant frequency ( 1015 or 1020 ) will be available to be used in the remainder of the system. Additionally, design constraints 1045 may be used by the IC designer to manually modify the high-level description 1055 of the core logic. This embodiment is useful in the case that logic synthesizer 1050 does not have the capability to use that information to automatically modify the synthesis process.
From the foregoing, it will be apparent that the invention provides a useful and effective system and method for adjusting the logic synthesis of the core logic of an integrated circuit to account for the physical characteristics of both the on-chip and IC package power supply circuits. Accounting for the interaction between the power supply circuits and the core logic circuit prior to logic synthesis in this manner prevents the late discovery of potential power supply problems that adversely impact the time-to-market of the IC and the functional operation of the IC after being delivered to the customer.
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A system and method of adjusting the logic synthesis process of the design of an integrated circuit takes into account the interaction between the IC core logic circuitry, the on-chip power supply circuitry, and the package power supply circuitry. In IC package/circuit technology combinations that have been employed in previous IC designs, the associated package and on-chip power supply circuit designs are stable and well-defined, thus allowing the generating of simulation models for those power supply circuits. Those models are used to identify resonant frequencies and other characteristics of the power supply circuitry. By using the identity of the power supply resonant frequencies and the power supply models themselves, design constraints are developed that are supplied as input, either directly or indirectly, to the logic synthesis process to avoid incompatibilities of a periodic and non-periodic nature between the IC core logic and the power supply circuitry.
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PRIORITY & CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation application of U.S. patent application Ser. No. 10/072,603 filed Feb. 7, 2002 now U.S. Pat. No. 6,609,646, which claims the benefit of U.S. Provisional Application No. 60/267,359, filed Feb. 8, 2001.
FIELD OF THE INVENTION
The present invention generally relates to a fastening tool for dispensing fasteners from a magazine assembly into a workpiece and more specifically to an improved magazine assembly for a fastening tool.
BACKGROUND OF THE INVENTION
A number of pneumatically operated devices have been developed for use in driving fasteners, such as staples and nails, into workpieces. These tools typically employ a magazine assembly for holding a plurality of the fasteners and feeding the fasteners into the nose of the tool prior to the installation of the fasteners into a workpiece.
Despite the wide spread use of such tools, several drawbacks have been noted. One such drawback concerns the dry-firing of the tool when an insufficient number of fasteners are contained in the magazine assembly. As is known in the art, the dry-firing of such tools tends to be harmful to the tool.
Another drawback relates to situations wherein one or more fasteners are jammed in the nose of the tool. In such situations, the magazine assembly is typically removed from the fastening tool so as to provide sufficient space to permit the operator to remove the jammed fasteners from the nose of the fastening tool. Often times, tools, such as pliers, are employed in this task, so that the amount of space that is required for servicing the nose of the tool can be significant. Unfortunately, the complete removal of the magazine assembly from the remainder of the tool is often times very time consuming and may also require the use of additional tools to physically disconnect the magazine assembly.
SUMMARY OF THE INVENTION
In one preferred form, the present invention provides a fastening tool for holding a plurality of fasteners and selectively setting a first one of the fasteners into a workpiece. The fastening tool includes a fastening tool portion and a magazine assembly. The fastening tool portion has a dispensing portion for dispensing a first one of the fasteners and the magazine assembly is configured to hold a portion of the fasteners. The magazine assembly is coupled to the fastening tool portion and positionable between a first position, wherein the magazine assembly is positioned to dispense the portion of fasteners into the dispensing portion, and a second position, wherein the magazine assembly is positioned so as to be incapable of dispensing the portion of the fasteners into the dispensing portion.
In another preferred form, the present invention provides a fastening tool for holding a plurality of fasteners and selectively installing a first one of the fasteners into a workpiece. The fastening tool includes a fastening tool portion having a dispensing portion for dispensing a first one of the fasteners, wherein the dispensing portion includes a lock-out aperture. The fastening tool also includes a magazine assembly for holding a portion of the fasteners. The magazine assembly, which is coupled to the fastening tool portion, includes a lock-out dog that extends into the lock-out aperture and inhibits the fastening tool portion from operating when the magazine assembly is positioned in a condition which permits the magazine assembly to feed the portion of the fasteners into the dispensing portion and a quantity of the fasteners in the magazine assembly is less than a predetermined quantity.
In yet another preferred form, the present invention provides a fastening tool for holding a plurality of fasteners and selectively installing a first one of the fasteners into a workpiece. The fastening tool includes a fastening tool portion, a magazine assembly coupled to the fastening tool portion, a guide post coupled to one of the fastening tool portion and the magazine assembly, and a guide port formed in the other one of the fastening tool portion and the magazine assembly, the guide port slidingly receiving the guide post.
Further areas of applicability of the present invention will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while indicating the preferred embodiment of the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
Additional advantages and features of the present invention will become apparent from the subsequent description and the appended claims, taken in conjunction with the accompanying drawings, wherein:
FIG. 1 is a left side view of a tool constructed in accordance with the teachings of a preferred embodiment of the present invention;
FIG. 2 is a right side view of the tool of FIG. 1 ;
FIG. 3 is an exploded perspective view of the tool of FIG. 1 ;
FIG. 4 is a sectional view of the tool of FIG. 1 taken through its longitudinal axis;
FIG. 4 a is a section view taken along the line 4 a — 4 a of FIG. 4 ;
FIG. 5 is a top view of the tool of FIG. 1 ;
FIG. 6 is a sectional view taken along the line 6 — 6 of FIG. 5 ;
FIG. 7 is an enlarged portion of FIG. 4 illustrating the nose assembly in greater detail;
FIG. 8 is a front view of a portion of the tool of FIG. 1 illustrating the nose body and the contact tip in greater detail;
FIG. 9 is a sectional view taken along the line 9 — 9 of FIG. 2 ;
FIG. 9 a is sectional view of a portion of the magazine clamp assembly illustrating the spring collar in greater detail;
FIG. 9 b is a sectional view of a portion of the magazine clamp assembly illustrating the clamp pin in greater detail;
FIG. 10 is an enlarged portion of FIG. 4 illustrating the trigger assembly in greater detail;
FIG. 11 is an exploded view of the tool of FIG. 1 ;
FIG. 12 is an enlarged portion of FIG. 4 illustrating the rear of tool in greater detail;
FIG. 13 is a sectional view of a portion of the exhaust manifold illustrating the construction of the exhaust ports in greater detail;
FIG. 14 is an enlarged portion of FIG. 4 illustrating the engine assembly in greater detail;
FIG. 15 is an enlarged portion of FIG. 11 illustrating the engine assembly in greater detail;
FIG. 16 is a sectional view of the sleeve taken along its longitudinal axis;
FIG. 17 is a sectional view taken along the line 17 — 17 of FIG. 16 ;
FIG. 18 is a sectional view similar to that of FIG. 10 but illustrating the trigger assembly in an actuated condition;
FIG. 19 is an exploded perspective view of the magazine assembly;
FIG. 20 is a sectional view taken along the line 20 — 20 of FIG. 1 and illustrating the construction of the magazine body assembly;
FIG. 21 is a rear view of a portion of the magazine body assembly;
FIG. 22 is a side view of a portion of the magazine body assembly illustrating the L-shaped pin aperture in greater detail;
FIG. 23 is a top view of a guide structure;
FIG. 24 is a front view of the bracket structure;
FIG. 25 is a rear view of a portion of the bracket structure;
FIG. 26 is a side view of a portion of the bracket structure;
FIG. 27 is a side view of the follower structure;
FIG. 28 is a top view of a portion of the follower structure illustrating the construction of a portion of the follower body, the follower guide and the actuating lever;
FIG. 29 is a view of a portion of the follower structure illustrating the configuration of the forward leg of the follower body;
FIG. 30 is a view of a portion of the follower structure illustrating the configuration of the rearward leg of the follower body;
FIG. 31 is a front view of a portion of the follower structure;
FIG. 32 is a partial view of the follower structure from a side opposite the side which is illustrated in FIG. 27 ;
FIG. 33 is a side view of the follower spring;
FIG. 34 is a side view of the magazine end cap assembly;
FIG. 35 is a sectional view of a portion of the end cap structure taken along the line 35 — 35 in FIG. 34 ;
FIG. 36 is a sectional view of a portion of the end cap structure taken along the line 36 — 36 in FIG. 35 ;
FIG. 37 is a top view of a portion of the end cap structure;
FIG. 38 is a front view of the cam follower;
FIG. 39 is a partial side view of the cam follower;
FIG. 40 is an enlarged portion of the cam follower illustrated in FIG. 38 ;
FIG. 41 is a partial side view of the cam follower illustrating the follower hook in greater detail;
FIG. 42 is a partial section view illustrating the position of the cam follower on the pivot structure just prior to contact between the loading cam and the follower hook;
FIG. 43 is a partial section view similar to that of FIG. 42 but illustrating the cam follower when the follower hook is contacting the first loading cam portion;
FIG. 44 is a side view of the follower structure engaged to the magazine end cap assembly;
FIG. 45 is a section view taken along the line 45 — 45 illustrating the follower hook disposed within the capture aperture;
FIG. 46 is a side view of a portion of a tool constructed in accordance with the teachings of the an alternate embodiment of the present invention illustrating the magazine assembly removed from the tool; and
FIG. 47 is a side view similar to that of FIG. 46 but illustrating the magazine assembly coupled to the tool.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
With reference to FIG. 1 of the drawings, a fastening tool constructed in accordance with the teachings of the present invention is generally indicated by reference numeral 10 . Fastening tool 10 is illustrated to include a detachable magazine assembly 20 and a fastening tool portion 30 . The fastening tool portion 30 includes a nose assembly 40 , a housing assembly 42 , a cap assembly 44 , an engine assembly 46 and a trigger assembly 48 .
Nose Assembly
With reference to FIGS. 1 through 9 , the nose assembly 40 is illustrated to include a nose structure 50 , a contact trip 52 , a trigger lever 54 and a contact trip-return spring 56 . The nose structure 50 includes a nose body 60 , a pair of magazine stabilizing tabs 62 , a magazine flange 64 , a pair of magazine guide posts 66 , a mounting base 68 , a spring post 70 and a pair of contact trip guides 72 . The nose body 60 is generally U-shaped, with the legs 80 of the “U” being inwardly offset to form a semi-circular blade cavity 82 . The inwardly offset legs 80 of the nose body 60 also serve as a guide surface 84 for guiding the lower front portion 86 of the contact trip 52 . The contact trip guides 72 are coupled to the top of the nose body 60 and form a guide surface for guiding the portion 88 of the contact trip 52 that extends over the nose body 60 .
The magazine stabilizing tabs 62 are situated on opposite sides of the nose body 60 and are spaced apart by a predetermined distance. The magazine flange 64 is a generally flat structure that is coupled to the bottom of the nose body 60 and that includes a lock-out dog aperture 90 . The magazine guide posts 66 , which are cylindrically shaped in the particular embodiment illustrated, extend downwardly and rearwardly from the magazine flange 64 . The magazine stabilizing tabs 62 , magazine flange 64 and magazine guide posts 66 are discussed in greater detail, below.
The mounting base 68 is coupled to the magazine flange 64 and the nose body 60 and includes a pair of mounting apertures 94 , a nose seal groove 96 and a nose guide 98 . The nose guide 98 is generally cylindrically shaped and includes an internal cavity 100 that having a cross-section that is configured to receive the fastener F and which may include a fastener stop 102 which is configured to prevent the fasteners F from traveling rearwardly toward the engine assembly 46 . In the embodiment illustrated, the internal cavity 100 is generally semi-circular in shape but which includes a key-shaped fastener stop 102 . The nose seal groove 96 is formed around the outer perimeter of the nose guide 98 and is sized to receive a nose seal 104 , which is an O-ring seal in the particular embodiment illustrated. The spring post 70 is coupled to the top of the mounting base 68 and includes a boss 108 that is sized to fit within the contact trip-return spring 56 .
The contact trip 52 is fit over and slides on the nose body 60 , being guided thereon by the inwardly offset legs 80 of the nose body 60 and the contact trip guides 72 . Preferably, the effective length of the contact trip 52 is adjustable so as to permit the tool operator to vary the depth at which the tool 10 sets the fasteners F. A spring protrusion 110 , which is sized to engage the inside diameter of the contact trip-return spring 56 , is formed in the rear of the contact trip 52 . The contact trip-return spring 56 is set over the boss 108 on the spring post 70 and the spring protrusion 110 on the contact trip 52 and exerts a spring force that biases the contact trip 52 away from the spring post 70 . Forward motion of the contact trip 52 is checked by a contract trip stop 114 that is formed onto a side of the nose body 60 and which contacts the contact trip 52 at a predetermined point.
The trigger lever 54 is fixedly coupled to the contact trip 52 at a first end 120 and extends rearwardly from the nose structure 50 where a second end 122 engages the trigger assembly 48 in a conventional manner that is well known in the art. Briefly, the trigger assembly 48 includes a primary trigger 126 , a secondary trigger 128 and a trigger valve 130 that selectively controls the flow of compressed air to the engine assembly 46 . The primary trigger 126 is pivotably mounted to the housing assembly 42 and movable in response to the tool operator's finger. Movement of the primary trigger 126 will not, in and of itself, alter the state of the trigger valve 130 . Rather, the second end 122 of the trigger lever 54 must also move rearwardly and into contact with the secondary trigger 128 before the state of the trigger valve 130 is changed to permit compressed air to flow to the engine assembly 46 . A stop member 134 , which is configured to interact with the magazine assembly 20 in a matter that will be discussed in greater detail below, is coupled to the trigger lever 54 below the magazine flange 64 and extends inwardly toward the nose body 60 . In the particular embodiment illustrated, the stop member 134 is die-punched into the trigger lever 54 and is offset inwardly therefrom toward the nose body 60 .
Housing Assembly
Housing assembly 42 includes a unitarily formed housing 150 , a piston bumper 152 , a magazine clamp assembly 154 and a housing seal 156 , which is illustrated to be an O-ring seal in the example provided. The housing 150 includes a housing body 160 , a trigger housing 162 , a nose housing 164 and a handle portion 166 . The housing body 160 is a container-like structure having a front base 170 and an outwardly tapering sidewall 172 that cooperate to form a housing cavity 174 . The outwardly tapering sidewall 172 terminates at the rear of the housing body 160 at a rear housing face 176 , which in the particular embodiment illustrated, includes a housing seal groove 178 that is configured to receive the housing seal 156 . A guide bore 180 is formed into the inside face 182 of the housing cavity 174 and terminates at its forward end at a guide stop 184 . A nose guide aperture 188 is formed through the front base 170 of the housing body 160 .
The nose housing 164 is coupled to the front base 170 of the housing body 160 and extends forwardly therefrom. The nose housing 164 includes an upper shroud 200 , a pair of sidewalls 202 and a pair of spaced apart bosses 204 , each of which having a threaded aperture 206 . The upper shroud 200 , sidewalls 202 and spaced apart bosses 204 cooperate to locate the nose assembly 40 to the housing 150 and the nose guide 98 is inserted into the nose guide aperture 188 . Threaded fasteners 210 are placed through each of the mounting apertures 94 in the mounting base 68 and threadably engaged to the threaded apertures 206 in the spaced apart bosses 204 to fixedly but removably couple the nose assembly 40 to the housing 150 . The axis 212 of the threaded fasteners 210 is skewed toward the rear of the tool 10 , causing the threaded fasteners 210 to exert a clamping force that pushes the nose assembly 40 downwardly onto the spaced apart bosses 204 and rearwardly against the front face of the front base 170 to thereby compress the nose seal 104 and sealingly engage the nose structure 50 to the housing body 160 . The upper shroud covers the spring post 70 , the contact trip-return spring 56 and a portion of the rear of the contact trip 52 to prevent foreign objects from lodging between the rear of the contact trip 52 and the spring post 70 .
The handle portion 166 is preferably non-circular in shape and contoured to comfortably fit the hand of a tool operator. The distal end 250 of the handle portion 166 is enlarged so as to render the handle portion 166 less prone to slipping out of the tool operator's hand. With additional reference to FIG. 4 a , a clamp boss 252 is coupled to the forward face of the distal end 250 of the handle portion 166 . The clamp boss 252 includes a clamp boss base 254 that extends toward the front of the tool 10 , a clamp boss sidewall 256 that wraps around the perimeter of the clamp boss base 254 and an annular intermediate clamp boss wall 258 that cooperates with a portion of the clamp boss sidewall 256 to form a circular spring cavity 260 . The clamp boss base 254 and the clamp boss sidewall 256 cooperate to form a clamp cavity 262 into which the magazine clamp assembly 154 is disposed. A pair of U-shaped pin apertures 264 , which will be discussed in further detail below, are formed into an end of the clamp boss sidewall 256 .
The handle portion 166 intersects both the housing body 160 and the trigger housing 162 and includes an air inlet cavity 270 which extends through the distal end 250 of the handle portion 166 to receive a supply of compressed air. The air inlet cavity 270 extends through the handle portion 166 and into both the housing cavity 174 and the trigger housing 162 to permit the compressed air to be directed through the tool 10 in a predetermined manner that will be described in detail, below.
In the example provided, the magazine clamp assembly 154 is illustrated to include a clamp pin 300 , a compression spring 302 , a spring collar 304 , an actuating cam 306 and a coupling pin 308 . The clamp pin 300 includes a head portion 322 , a first body section 324 , which is coupled to the head portion 322 , and a second body section 326 that is coupled to the opposite end of the first body section 324 . The first body section 324 is generally cylindrically shaped and includes a pair of parallel flats 328 . The second body section 326 is generally cylindrically shaped but has an outer diameter that is smaller than that of the first body section 324 . The head portion 322 includes a frusto-conical abutting face 330 .
The spring collar 304 includes a first annular portion 340 having a diameter that is sized to fit within the compression spring 302 , and a second annular portion 342 that is relatively larger in diameter than the compression spring 302 and which has a flat contact surface 344 . A pin aperture 346 is formed through the spring collar 304 that is sized to receive the second body section 326 of the clamp pin 300 .
The actuating cam 306 has a base portion 350 and a leg portion 352 which are arranged relative to one another in an L-shape. The end of the base portion 350 opposite the intersection point 354 between the base and leg portions 350 and 352 includes a coupling pin aperture (not specifically shown) which is sized to engage the coupling pin 308 . The leg portion 352 of the actuating cam 306 is arcuate in shape and includes a plurality of gripping protrusions 356 or is otherwise textured on its inside surface so as to improve the tool operator's ability to move the actuating cam 306 in a desired direction. A slot 358 , which is sized to engage the second body segment 326 of the clamp pin 300 in a slip-fit manner, is formed into the actuating cam 306 through the base portion 350 and a portion of the leg portion 352 .
The clamp pin 300 extends through a pin aperture 360 formed into the clamp boss base 254 of the clamp boss 252 such that the second body section 326 extends into the spring cavity 260 . The compression spring 302 is positioned over the second body section 326 and into the spring cavity 260 . The spring collar 304 is placed over the second body section 326 such that the first annular portion 340 is disposed inside the compression spring 302 . The base portion 350 of the actuating cam 306 is positioned into contact with the flat contact surface 344 such that the second body segment 326 extends into the portion of the slot 358 that is formed into the base portion 350 of the actuating cam 306 . The coupling pin 308 , which is a roll-pin in the example illustrated, is positioned into one of the U-shaped pin apertures 264 and driven through the base portion 350 of the actuating cam 306 and into engagement with a pin aperture 364 in the second body segment 326 of the clamp pin 300 . Accordingly, the coupling pin 308 pivotably couples the actuating cam 306 to the clamp pin 300 . Rotation of the actuating cam 306 about the coupling pin 308 places the intersection point 354 into contact with the flat contact surface 344 , causing the spring collar 304 to compress the compression spring 302 and transmit a clamping force to the head portion 322 of the clamp pin 300 . When the actuating cam 306 has been pivoted sufficiently so as to place the leg portion 352 into contact with the flat contact surface 344 , the force exerted by the compression spring 302 urges the spring collar 304 against the leg portion 352 to releasably lock the actuating cam 306 in place. The clamp cavity 262 protects the actuating cam 306 from being contacted during the operation of the tool 10 , thereby guarding against the inadvertent unlocking or releasing of the actuating cam 306 .
In FIG. 10 , the trigger housing 162 is configured to receive the trigger assembly 48 and includes a supply port 370 , which is coupled to the air inlet cavity 270 to provide the trigger assembly 48 with a source of compressed air. A biasing port 372 extends from the trigger housing 162 through the guide bore 180 in the housing cavity 174 that permits the trigger assembly 48 to direct air to or exhaust air from the housing cavity 174 .
As shown in FIGS. 7 and 11 , the piston bumper 152 is a unitarily formed molded elastomeric structure. In the particular example illustrated, the piston bumper 152 has a cylindrical body portion 390 and an annular lip 392 . The cylindrical body portion 390 preferably includes a first annular bumper portion 396 and a second annular bumper portion 398 that is generally larger in diameter than the first annular bumper portion 396 and which is disposed between the first annular bumper portion 396 and the annular lip 392 . The annular lip 392 extends radially outwardly of the body portion 390 and includes a front abutting face 400 that is configured to abut the inside surface 402 of the housing body 160 and sealingly engage the front base 170 of the housing body 160 . The annular lip 392 also includes a rear abutting face 404 having a first annular lip portion 406 and a second annular lip portion 408 that that lies radially outwardly of and recessed forwardly relative to the first annular lip portion 406 . The rear abutting face 404 and a cylindrically-shaped driver blade aperture 410 that extends through the center of the piston bumper 152 will be described in detail, below.
Cap Assembly
With reference to FIGS. 11 and 12 , the cap assembly 44 includes a cap housing 420 , an exhaust manifold 422 and a top bumper 424 . The cap housing 420 includes an outer cap wall 430 that is generally flat at the rear of the tool 10 , but folds over on its sides to form a cup-like container having a generally flat forward face 432 that is configured to engage the housing seal 156 to permit the cap housing 420 to be sealingly coupled to the rear of the housing 150 .
The cap housing 420 also includes a plurality of foot tabs 434 , a plurality of strengthening gussets (not specifically shown), an annular exhaust port wall 438 , an exhaust button 440 and a cylindrical locating hub 442 having a threaded aperture 444 formed therethrough. The foot tabs 434 extend forwardly from the flat portion of the outer cap wall 430 beyond the front face 432 by a predetermined distance. The outside diameter of the foot tabs 434 is sized such that the foot tabs 434 fit within the housing cavity 174 . The foot tabs 434 will be discussed in greater detail, below. The strengthening gussets are employed to couple both the foot tabs 434 or the outer cap wall 430 to the annular exhaust port wall 438 , which extends forwardly from the flat rear portion 446 of the outer cap wall 430 . The exhaust button 440 is an annular member that also extends forwardly from the flat rear portion 446 of the outer cap wall 430 but which is spaced apart from the annular exhaust port wall 438 and the locating hub 442 . A plurality of primary exhaust ports 450 are formed through the exhaust button 440 and a plurality of secondary exhaust ports 452 are formed through the portion of the outer cap wall 430 between the annular exhaust port wall 438 and the exhaust button 440 .
The exhaust manifold 422 is preferably unitarily formed from a molded from a plastic material and includes a center hub 460 , an annular spacing wall 462 and an annular manifold wall 464 . The center hub 460 is configured to fit between the exhaust button 440 and the locating hub 442 and includes a hub aperture 468 that is configured to engage the locating hub 442 in a slip fit manner. The annular spacing wall 462 is coupled to the forward-most portion of the center hub 460 and is spaced apart from the exhaust button 440 . The annular manifold wall 464 is coupled to the outer perimeter of the annular spacing wall 462 and includes a plurality of circumferentially extending exhaust slots 470 that are spaced around the circumference of the annular manifold wall 464 . The exhaust slots 470 are generally U-shaped and as best shown in FIG. 13 , have a rear edge 472 that tapers rearwardly and inwardly toward the center hub 460 .
Returning to FIGS. 11 and 12 , the top bumper 424 preferably includes a dampening member 480 that is molded from an elastomeric material, such as urethane, and a structural member 482 , such as a washer, that is molded into the dampening member 480 . The dampening member 480 is a cup-shaped structure that is sized to fit within the center hub 460 of the exhaust manifold 422 . The dampening member 480 includes an annular wall 484 that extends forwardly from the base 486 of the dampening member 480 . A ridge 488 is formed into the forward end of the annular wall 484 , thereby creating a groove 490 between the base 486 of the dampening member 480 and the ridge 488 . A plurality of slits 492 are formed into the annular wall 484 , creating a plurality of wall segments 494 that are flexibly coupled to the base 486 . A threaded fastener 496 is threadably engaged to the threaded aperture 444 in the locating hub 442 to fixedly but removably couple the top bumper 424 to the cap housing 420 . The structural member 482 is employed so as to permit the clamping force that is exerted by the threaded fastener 496 to be transmitted through the top bumper 424 without crushing the base 486 of the dampening member 480 . A portion of the clamping force is transmitted through the base 486 of the dampening member 480 and into the center hub 460 of the exhaust manifold 422 to maintain the exhaust manifold 422 in a stationary position relative to the cap housing 420 .
Engine Assembly
Engine assembly 46 is shown to include a cylinder assembly 500 , a piston assembly 502 , a rod or driver blade 504 . The cylinder assembly 500 includes a hollow, cylindrical, and unitarily constructed sleeve 510 , an inner exhaust port seal 512 , an outer exhaust port seal 514 , a cap flange seal 516 , rear and front guide seals 518 and 520 , a guide assembly 522 , a compensating valve 524 , a rear spring flange 526 , a spring 528 , a front spring flange 530 and a front spring flange seal 532 . In the particular embodiment illustrated, inner exhaust port seal 512 , outer exhaust port seal 514 , rear and front guide seals 518 and 520 and front spring flange seal 532 are conventional, commercially available O-ring seals. The cap flange seal 516 is a molded elastomeric seal having an outside surface with a generally flat seal face 540 and first and second radially inwardly extending flanges 542 and 544 , respectively, that are spaced apart from one another to form an engagement groove 546 therebetween.
With additional reference to FIG. 16 , the sleeve 510 is shown to include a first sleeve body portion 550 , an annular sleeve flange 552 , a second sleeve body portion 554 having a maximum outer diameter that is generally the same as that of the first sleeve body portion 550 and a third sleeve body portion 556 having a maximum outer diameter that is generally larger than that of the first sleeve body portion 550 . The first sleeve body portion 550 includes a first U-shaped seal groove 560 , which is sized to receive the front spring flange seal 532 , a plurality of circumferentially-spaced front exhausting ports 562 , a spring flange groove 564 , which is sized to receive the rear spring flange 526 , a valve groove 566 , which is discussed in greater detail, below, and a second U-shaped seal groove 568 , which is sized to receive the front guide seal 520 .
The valve groove 566 has a first U-shaped portion 570 , a second U-shaped portion 572 and a plurality of valve apertures 574 . The first U-shaped portion 570 is sized to receive the compensating valve 524 , which in the particular embodiment illustrated, is a flat elastomeric band 580 . The second U-shaped portion 572 is disposed within the first U-shaped portion 570 , but has a diameter that is somewhat smaller than that of the first U-shaped portion 570 so as to define an annular ring that extends around the circumference of the first U-shaped portion 570 . In the particular embodiment illustrated, the diameter of the second U-shaped portion 572 is about 0.010 inches to about 0.030 inches smaller in diameter than the first U-shaped portion 570 . The valve apertures 574 are illustrated to be relatively small diameter holes that are located within the second U-shaped portion 572 and which are drilled through the sleeve 510 . The valve apertures 574 will be discussed in greater detail, below, as will the set of front exhausting ports 562 that are located between the first U-shaped seal groove 560 and the spring flange groove 564 .
The annular sleeve flange 552 extends radially outwardly from the first sleeve body portion 550 of the sleeve 510 and separates the first and second sleeve body portions 550 and 554 from one another. A third U-shaped seal groove 584 , which is sized to receive the rear guide seal 518 is formed into the outer surface of the annular sleeve flange 552 .
The majority of the second sleeve body portion 554 of the sleeve 510 is of approximately the same outer diameter as the first sleeve body portion 550 . The rear end of the second sleeve body portion 554 , however, includes a flange portion 590 that extends radially outwardly to form a seal lip 592 and a fourth U-shaped seal groove 594 prior to its connection with the third sleeve body portion 556 . The seal lip 592 is configured to engage the engagement groove 546 formed into the cap flange seal 516 and abut the first and second radially inwardly extending flanges 542 and 544 . The fourth U-shaped seal groove 594 is configured to receive a portion of the first radially inwardly extending flange 542 .
The third sleeve body portion 556 is fixedly coupled to the end of the second sleeve body portion 554 and is larger in diameter than the outer diameter of the first sleeve body portion 550 . A fifth U-shaped seal groove 600 is formed into the outer surface of the third sleeve body portion 556 and is sized to receive the outer exhaust port seal 514 . A plurality of circumferentially extending rear exhaust slots 604 are disposed around the perimeter of the third sleeve body portion 556 . The rear exhaust slots 604 are located between the fourth and fifth U-shaped seal grooves 594 and 600 . A sixth U-shaped seal groove 608 , which is configured to receive the inner exhaust port seal 512 , is formed into the inner diameter of the third sleeve body portion 556 .
The hollow cavity 610 that is formed through the sleeve 510 has a first cavity portion 612 that is generally of a constant diameter over the portion of its length that includes the first and second sleeve body portions 550 and 554 and the annular sleeve flange 552 . The hollow cavity 610 also has a second cavity portion 614 having a larger diameter than that of the first cavity portion 612 .
In FIG. 14 , the guide assembly 522 is shown to include a guide 650 and first and second housing seals 652 and 654 , which in the particular embodiment illustrated, are O-ring seals. The guide 650 is a molded plastic component, having a stepped-diameter body portion 660 , a plurality of longitudinally extending legs 662 , a locating tab 664 and a plurality of stop tabs 668 . The stepped-diameter body portion 660 includes a flange bore 670 , which is sized to receive the annular sleeve flange 552 and sealingly engage the rear guide seal 518 , a body bore 672 , which is sized to receive the first sleeve body portion 550 and sealingly engage the front guide seal 520 , and an abutting flange 676 that forms the transition between the flange bore 670 and the body bore 672 .
The longitudinally extending legs 662 extend away from the stepped-diameter body portion 660 and are spaced apart circumferentially in equal amounts. The locating tab 664 is positioned on the same side of the stepped-diameter body portion 660 as the longitudinally extending legs 662 between two of the longitudinally extending legs 662 . The locating tab 664 is employed to signify the presence of an air gallery 680 and locate the guide assembly 522 relative to the housing assembly 42 . The air gallery 680 is configured to permit air to flow through the stepped-diameter body portion 660 from a point between the first and second housing seals 652 and 654 through the stepped-diameter body portion 660 and out the abutting flange 676 .
The rear and front guide seals 518 and 520 and the elastomeric band 580 that forms a portion of the compensating valve 524 are initially installed to the sleeve 510 . Thereafter, the guide assembly 522 is positioned over the first sleeve body portion 550 and pushed onto the sleeve 510 such that the flange bore 670 and body bore 672 are sealingly engaged to the rear and front guide seals 518 and 520 , respectively, and the abutting flange 676 abuts the annular sleeve flange 552 .
The rear spring flange 526 is next installed to the sleeve 510 . The rear spring flange 526 is a plastic collar that is split on one side to permit the ends of the rear spring flange 526 to be spread apart so that it may be loaded onto the first sleeve body portion 550 of the sleeve 510 and into the spring flange groove 564 . The rear spring flange 526 has a cylindrically shaped body portion 690 and a flange portion 692 that extends radially-outwardly from the body portion 590 in a manner that provides the rear spring flange 526 with a L-shaped cross-section. The rear spring flange 526 is located to the spring flange groove 564 such that the flange portion 692 is nearest the annular sleeve flange 552 .
The front spring flange 530 is a plastic collar having a tapering outside diameter 596 and a generally flat rear face 698 . The inside surface 700 of the front spring flange 530 is generally cylindrical, but includes an annular protrusion 702 that extends radially inwardly of the remainder of the inside surface 700 and which engages the first sleeve body portion 550 of the sleeve 510 in a slip-fit manner.
The spring 528 is a conventional compression spring having both ends ground flat. The spring 528 is disposed over the first sleeve body portion 550 of the sleeve 510 such that its rear end abuts the flange portion 692 of the rear spring flange 526 . Thereafter, the front spring flange 530 is positioned such that its rear face 698 contacts the second end of the spring 528 . The front spring flange 530 is pushed toward the annular sleeve flange 552 to compress the spring 528 a sufficient distance to permit the front spring flange seal 532 to be inserted into the first U-shaped seal groove 560 . Thereafter, the front spring flange 530 is moved toward the front of the sleeve 510 such that the front spring flange seal 532 is sealingly engaged with the inside surface 700 of the front spring flange 530 . The rear side of the front spring flange seal 532 contacts the annular protrusion 702 to limit the forward travel of the front spring flange 530 prior to the installation of the engine assembly 46 to the housing assembly 42 . Forward motion of the guide assembly 522 along the sleeve 510 is checked by contact between the stop tabs 668 and the rear surface of the flange portion 692 of the rear spring flange 526 to thereby prevent the guide 650 from becoming disengaged from the rear and front guide seals 518 and 520 . Construction in this manner is highly advantageous in that it permits the entire cylinder assembly 500 to be pre-assembled outside of the housing assembly 42 in a relatively easy and cost efficient manner.
The piston assembly 502 includes a piston 720 and a ring 722 . In the example provided, the piston 720 is shown to include a first piston portion 730 and a second piston portion 732 . The first piston portion 730 in an annular member that is smaller in diameter than the first cavity portion 612 of the hollow cavity 610 in the sleeve 510 . A U-shaped annular ring groove 734 is formed around the circumference of the first piston portion 730 that is sized to receive the ring 722 . In the embodiment illustrated, the ring 722 is shown to be fabricated from a plastic material and have a rectangular cross-section. The ring 722 is split to permit its ends of the ring 722 to be spread apart so that it may be loaded around the first piston portion 730 and into the ring groove 734 . The second piston portion 732 is an annular member that is smaller in diameter than the first piston portion 730 . The second piston portion 732 is coupled to the rear end of the first piston portion 730 and includes a pair of wrench flats 740 and a locking protrusion 744 , both of which will be discussed in more detail, below. A generous fillet radius 746 is employed at the intersection between the first and second piston portions 730 and 732 so as to reduce the concentration of stress within the piston 720 .
The construction of the driver blade 504 is largely conventional and as such, a detailed discussion of it is neither required nor within the scope of this disclosure. Briefly, the driver blade 504 is shown to include a coupling portion 760 and a driver body 762 . In the example provided, the coupling portion 760 includes a collar 764 and a threaded portion 766 which are formed into the rear end of the driver blade 504 . The wrench flats 740 on the second piston portion 732 are employed to facilitate relative rotation between the driver blade 504 and the piston 720 to permit the threaded portion 766 to threadably engage a threaded aperture 768 that is formed through the piston 720 and to permit the collar 764 to engage the front surface 770 of the piston 720 to generate a clamping force that fixedly but removably couples the piston 720 and the driver blade 504 together. Coupling of the piston 720 and the driver blade 504 via a threaded connection is presently preferred so as to permit the servicing and replacement of the driver blade 504 , since this portion of the tool 10 is essentially perishable. Those skilled in the art will understand, however, that other coupling mechanisms, such as press-fitting, shrink fitting, welding, or any other mechanical coupling method may also be employed.
The driver body 762 is sized to fit in the blade cavity 82 and is shown to include a keyway 774 , a slide surface 776 , a loading groove 778 and a tip portion 780 . The keyway 774 is illustrated to be a cut that is formed into the surface of the driver body 762 along its longitudinal axis. The fastener stop 102 that is formed into the internal cavity 100 in the nose guide 98 is disposed within the keyway 782 to guard against a situation wherein fasteners F feed rearwardly into the tool 10 . The slide surface 776 is generally flat and provides the driver body 762 with a relatively large surface that will consistently slide over the fasteners F that are loaded into the magazine assembly 20 . The tip portion 780 is formed at the front end of the driver body 762 and is operable for contacting the fasteners F and driving them into a workpiece. The loading groove 778 is cylindrically shaped and is formed along an axis that is skewed to the longitudinal axis of the driver blade 504 such that it intersects both the tip portion 780 and the slide surface 776 . The loading groove 778 is tapered such that it is deepest at the front of the driver blade 504 . The loading groove 778 ensures that only one fastener F is sheared from the remaining fasteners F in the magazine assembly 20 . The loading groove 778 also permits the fasteners F in the magazine assembly 20 to move upwardly toward the nose body 60 of the tool 10 prior to the time at which the driver blade 504 has stroked back to its rear-most (i.e., retracted) position to thereby minimize the lag time between the point at which the driver blade 504 has moved to its retracted position and the point at which the driver blade 504 can be moved forwardly to drive another fastener F.
With additional reference to FIGS. 16 and 17 , the driver blade 504 and the piston assembly 502 , once coupled to one another, are inserted into the second cavity portion 614 of the hollow cavity 610 in the sleeve 510 . The diameter of the second cavity portion 614 is larger than the diameter of the piston assembly 502 (with the ring 722 in an expanded condition). A chamfer 790 is employed at the front of the second cavity portion 614 to facilitate the transition to the smaller-diameter first cavity portion 612 . With the exertion of light force onto the rear of the piston assembly 502 , the piston assembly 502 is moved forwardly in the hollow cavity 610 and into contact with the chamfer 790 . The chamfer 790 is operable for compressing the ring 722 to permit the piston assembly 502 to travel into the first cavity portion 612 .
Once assembled, the engine assembly 46 is placed into the housing cavity 174 such that the locating tab 664 is aligned to a tab slot 800 formed into the housing cavity 174 and the driver blade 504 is inserted through the driver blade aperture 410 in the piston bumper 152 and into the internal cavity 100 in the nose guide 98 . The engine assembly 46 is pushed forwardly into the housing cavity 174 to engage the guide assembly 522 against the guide stop 184 . In this position, the first and second housing seals 652 and 654 sealingly engage the guide bore 180 that is formed into the inside surface 182 of the outwardly tapering sidewall 172 . The first and second annular bumper portions 396 and 398 extend through the front face 810 of the sleeve 510 and into the hollow cavity 610 . The front face 820 of the front spring flange 530 sealingly contacts the second annular lip portion 408 on the piston bumper 152 . The cap assembly 44 is thereafter placed onto the rear end of the housing assembly 42 such that each of the longitudinally extending legs 662 contacts one of the foot tabs 434 . The foot tabs 434 cooperate with the longitudinally extending legs 662 to prevent the guide assembly 522 from moving along the longitudinal axis of the tool 10 . The sleeve 510 , however, is slidable within the guide assembly 522 , as will be discussed in greater detail, below.
Alternatively, the piston assembly 502 and driver blade 504 may be inserted into the housing cavity 174 such that the driver blade 504 is inserted through the driver blade aperture 410 in the piston bumper 152 and into the internal cavity 100 in the nose guide 98 . The cylinder assembly 500 is then loaded into the housing cavity 174 in the manner discussed above. A lead L formed into the front face 810 of the sleeve 510 that permits the ring 722 to be compressed so that the piston assembly 502 can travel rearwardly into the first cavity portion 612 of the hollow cavity 610 in the sleeve 510 .
Engine Operation
With reference to FIGS. 10 , 14 and 16 , when the tool 10 has been coupled to a source of compressed air, the trigger assembly 48 maintains the trigger valve 130 in an unactuated state wherein compressed air is directed from the supply port 370 to the biasing port 372 where it enters the air gallery 680 at a point between the first and second housing seals 652 and 654 . Compressed air flows through the stepped-diameter body portion 660 and exits from the abutting flange 676 where it enters a sleeve return chamber 850 that is defined by the forward face 852 of the annular sleeve flange 552 , the rear guide seal 518 , the flange bore 670 , the body bore 672 , the front guide seal 520 and the first sleeve body portion 550 of the sleeve 510 . As the guide 650 is not movable within the housing 150 , the pressure of the air that is in the sleeve return chamber 850 is exerted against the front face 852 of the annular sleeve flange 552 to bias the sleeve 510 in a rearward direction.
The air inlet cavity 270 also provides compressed air to a sleeve extend chamber 860 that is defined by the rearward face 862 of the annular sleeve flange 552 , the rear guide seal 518 , the guide 650 , the second housing seal 654 , the portion of the outwardly tapering sidewall 172 that is situated rearwardly of the second housing seal 654 , the outer portion of the cap housing 420 that includes the annular exhaust port wall 438 , the cap flange seal 516 and the second sleeve body portion 554 of the sleeve 510 . Compressed air in the sleeve extend chamber 860 directs force to both the rearward face 862 of the annular sleeve flange 552 and the front face 864 of the flange portion 590 of the second sleeve body portion 554 of the sleeve 510 .
The forces that act on the annular sleeve flange 552 and the front face 864 of the flange portion 590 , in cooperation with the force that is exerted by the spring 528 , bias the sleeve 510 in a rearward direction into its retracted position such that the flat seal face 540 of the cap flange seal 516 sealingly engages the front face 866 of the annular exhaust port wall 438 .
With reference to FIGS. 10 and 12 , when the sleeve 510 is in the retracted position, a primary exhaust chamber 870 is defined by the cap flange seal 516 , the inside surface 872 of the annular exhaust port wall 438 , the outer exhaust port seal 514 , the third sleeve body portion 556 of the sleeve 510 , the inner exhaust port seal 512 , the exhaust manifold 422 , the second sleeve body portion 554 of the sleeve 510 , the piston assembly 502 and the driver blade 504 . The position of the sleeve 510 relative to the cap assembly 44 is such that the air that is in the primary exhaust chamber 870 is permitted to flow between the third sleeve body portion 556 and exhaust manifold 422 , through the exhaust slots 470 in the exhaust manifold 422 and out the primary exhaust ports 450 in the exhaust button 440 where this air is vented to atmosphere.
With the sleeve 510 in the retracted position, a secondary exhaust chamber 880 is formed by the annular exhaust port wall 438 , the outer exhaust port seal 514 , the third sleeve body portion 556 of the sleeve 510 , the inner exhaust port seal 512 , the exhaust manifold 422 , the exhaust button 440 and the portion of the outer cap wall 430 between the annular exhaust port wall 438 and the exhaust button 440 . Air that is in the secondary exhaust chamber 880 is vented to the atmosphere through the primary exhaust ports 450 in the exhaust button 440 and through the secondary exhaust ports 452 in the portion of the outer cap wall 430 between the annular exhaust port wall 438 and the exhaust button 440 .
With reference to FIGS. 12 , 14 and 18 , when the trigger assembly 48 is actuated to change the state of the trigger valve 130 to an actuated state, air in the sleeve return chamber 850 is vented through the trigger assembly 48 to the atmosphere. Consequently, the force that is exerted onto the rear face 862 of the annular sleeve flange 552 causes the sleeve 510 to slide forwardly relative to the housing assembly 42 . When the sleeve 510 slides in a forward direction, the seal between the cap flange seal 516 and the front face 866 of the annular exhaust port wall 438 is broken, permitting compressed air to flow through the rear exhaust slots 604 in the third sleeve body portion 556 of the sleeve 510 . As the area of the front surface 900 of the rear exhaust slots 604 is larger than the area of its rear surface 902 , the pressure of the air flowing through the rear exhaust slots 604 also tends to push the sleeve 510 in a forward direction. The piston bumper 152 checks forward travel of the sleeve 510 . More specifically, forward travel of the sleeve 510 is checked when the front face 810 of the sleeve 510 contacts the first annular lip portion 406 of the piston bumper 152 .
Simultaneous with the forward motion of the sleeve 510 , the inner exhaust port seal 512 slides forwardly by an equal amount to sealingly engage the outer circumference 910 of the exhaust manifold 422 at a point forward of the exhaust slots 470 to thereby prevent air from flowing to the atmosphere through the exhaust slots 470 . Pressure acts on the rear surface 920 of the piston assembly 502 to disengage the locking protrusion 744 in the second piston portion 732 from the groove 490 in the top bumper 424 . The pressure acts on the piston assembly 502 to drive the piston assembly 502 and the driver blade 504 forwardly through the first cavity portion 612 of the hollow cavity 610 in the sleeve 510 . Air in the first cavity portion 612 is compressed by the forward motion of the piston assembly 502 , causing it to be expelled from the hollow cavity 610 through the internal cavity 100 in the nose guide 98 , as well as through the front exhausting ports 562 and into a frontal air chamber 940 . The frontal air chamber 940 is defined by the first sleeve body portion 550 of the sleeve 510 , the front guide seal 520 , the guide 650 , the first housing seal 652 , the outwardly tapering wall 172 of the housing body 160 , the second annular lip portion 408 of the annular lip 392 in the piston bumper 152 , the front spring flange 530 and the front spring flange seal 532 .
The piston bumper 152 checks the forward motion of the sleeve 510 . Thereafter, the piston assembly 502 pushes the driver blade 504 forwardly so that the tip portion 780 drives a fastener F into a workpiece (not shown). With the piston bumper 152 also checks the forward motion of the piston assembly 502 and effectively seals against the front surface 770 of the piston assembly 502 to seal the frontal air chamber 940 . In this condition, the piston assembly 502 is positioned forwardly of the valve apertures 574 in the first sleeve body portion 550 of the sleeve 510 . Accordingly, if the pressure of the air in the portion of the hollow cavity 610 that is rearward of the piston assembly 502 is greater than the pressure of the air in the frontal air chamber 940 , the compensating valve 524 permits air to flow through the sleeve 510 and into the frontal air chamber 940 so as to balance the air pressure that is acting on the front and rear surfaces 770 and 920 of the piston assembly 502 . The compensating valve 524 , however, is a one-way valve that does not permit air to flow from the frontal air chamber 940 through the valve apertures 574 and into the hollow cavity 610 .
Referring back to FIGS. 10 , 12 , 14 and 16 , when the state of the trigger valve 130 is changed to its unactuated state, compressed air is once again routed to the sleeve return chamber 850 where it applies a force against the front face 852 of the annular sleeve flange 552 . The balance of the forces on the sleeve 510 is such that the sleeve 510 is pushed in a rearward direction until the cap flange seal 516 sealingly engages the front face 866 of the annular exhaust port wall 438 . Air in the primary and secondary exhaust chambers 870 and 880 is then vented to the atmosphere in the manner discussed above.
The piston assembly 502 , immediately prior to the exhausting of the air in the primary and secondary exhaust chambers 870 and 880 , was such that it remained in sealed engagement with the piston bumper 152 . When the air in the primary exhaust chamber 870 is vented to the atmosphere, however, the pressure in the frontal air chamber 940 generates a force on the front surface 770 of the piston assembly 502 that exceeds the force that is acting on its rear face 920 . As mentioned above, the compensating valve 524 is a one-way valve that prevents air from flowing through the valve apertures 574 and into the hollow cavity 610 and as such, the pressure of the air to the rear of the piston assembly 502 is less than the pressure of the air in the frontal air chamber 940 . Accordingly, the pressure acting on the front surface 770 of the piston assembly 502 drives the piston assembly 502 rearwardly until the locking protrusion 744 in the second piston portion 732 engages the groove 490 in the top bumper 424 .
Those skilled in the art will understand that while the above-described configuration of the engine assembly 46 results in a relatively lighter-weight tool as compared with pneumatic fastening devices that employ a conventional head valve, the reduction in the weight of the tool 10 does not come at the expense of increased recoil that is felt by the tool operator. In this regard, the felt force that is exerted onto the cap assembly 44 when a fastener F is driven into a workpiece is counteracted by the felt force that is exerted by the sliding of the sleeve 510 in a forward direction.
Magazine Assembly
The magazine assembly 20 is shown to include a magazine body assembly 1000 , a follower structure 1002 , a follower spring 1004 and a magazine endcap assembly 1006 . The magazine body assembly 1000 includes a magazine housing 1010 , a pair of guide structures 1012 a and 1012 b and a coupling bracket 1014 . In the example illustrated, the magazine housing 1010 is extruded from a lightweight material, such as aluminum and includes a wall member 1020 that defines a fastener head portion 1022 , a follower housing portion 1024 , a pair of guide housing portions 1026 and a fastener body portion 1028 .
The fastener head portion 1022 is generally rectangular in shape, defining a fastener head chamber 1030 that is open at its top and bottom ends so as to permit the head portion H of the fasteners F to travel through the fastener head portion 1022 . The fastener head portion 1022 is also open along a portion of one of its sides 1032 so as to permit the follower structure 1002 to travel upwardly within the magazine housing 1010 . With additional reference to FIG. 21 , a threaded fastener 1034 is threadably engaged to the wall member 1020 , forming a contact surface 1036 that checks the upward travel of the follower structure 1002 .
As shown in FIGS. 19 , 20 and 22 , the follower housing portion 1024 is coupled to the forward side of the fastener head portion 1022 and defines a generally rectangular follower cavity 1040 that is sized to receive the follower structure 1002 and the follower spring 1004 . A slot 1042 is formed into the rear surface 1044 of the follower housing portion 1024 . The slot 1042 interconnects the follower cavity 1040 to the fastener head chamber 1030 . An L-shaped pin aperture 1050 is formed into a side of the follower housing portion 1024 . The L-shaped pin aperture 1050 includes a relatively narrow first portion 1052 that extends generally parallel the longitudinal axis of the follower housing portion 1024 and a second portion 1054 that is skewed to the first portion 1052 . The L-shaped pin aperture 1050 will be discussed in greater detail, below.
In FIGS. 19 and 20 , each guide housing portion 1026 is shown to include a pair of spaced apart and arcuate protrusions 1060 a and 1060 b that are coupled to the wall member 1020 . The arcuate protrusions 1060 a and 1060 b cooperate with the wall member 1020 to define a guide structure cavity 1062 that extends over the length of the magazine housing 1010 and which is configured to receive one of the guide structures 1012 a and 1012 b. In the particular embodiment illustrated, the guide structure cavity 1062 includes a first cavity portion 1064 that is generally cylindrically shaped and located proximate the follower housing portion 1024 , and a second cavity portion 1066 that is shaped as a generally flat void that is generally tangent to the cylindrically shaped first cavity portion 1064 .
The fastener body portion 1028 is generally U-shaped, being coupled to the forward portion of the pair of guide housing portions 1026 . The fastener body portion 1028 includes a U-shaped fastener body cavity 1070 that is configured to receive the body B of the fasteners F. A plurality of oval windows 1072 are formed into the sides 1074 of the fastener body portion 1028 which permit the tool operator to monitor the quantity of fasteners F that are housed in the magazine assembly 20 , as well as to reduce the overall weight of the magazine assembly 20 .
As guide structures 1012 a and 1012 b are generally identical in construction, reference numerals may occasionally be shown on only of the guide structure 1012 a and 1012 b. Those skilled in the art will understand, however, that guide structure 1012 b is a mirror image of guide structure 1012 a. In the embodiment illustrated in FIGS. 19 , 20 and 23 , each of the guide structures 1012 a and 1012 b includes a cylindrically-shaped guide port 1100 , first and second retention tabs 1102 and 1104 , respectively, an intermediate member 1106 and an end member 1108 . The guide port 1100 is generally hollow, having an outside diameter that is sized to slip fit into the first cavity portion 1064 of an associated one of the guide housing portions 1026 and an inside diameter that is to engage an associated one of the magazine guide posts 66 . The first retention tab 1102 is coupled to the guide port 1100 on one side and to the intermediate member 1106 on the opposite side. The second retention tab 1104 is coupled to the intermediate member 1106 on the side opposite the first retention tab 1102 . The intermediate member 1106 is sized to fit between the arcuate protrusions 1060 a and 1060 b in the guide housing portion 1026 as well as to space the first and second retention tabs 1102 and 1104 apart from one another by a predetermined distance that permits the first and second retention tabs 1102 and 1104 to engage the arcuate protrusions 1060 a and 1060 b when the guide structures 1012 a and 1012 b are inserted into the guide structure cavities 1062 . The inner surface 1110 of the second retention tab 1104 extends inwardly further toward the centerline 1112 of the magazine housing 1010 than the inside surfaces of the U-shaped fastener body cavity 1070 so as to form a wear surface 1114 against which the body B of the fastener F is permitted to rub. The end member 1108 is coupled to the end of the guide structures 1012 a and 1012 b opposite the end to which the guide port 1100 is coupled. The end member 1108 is configured to abut the ends of the arcuate protrusions 1060 a and 1060 b so as to prevent the guide structures 1012 a and 1012 b from moving upwardly out of the top of the magazine housing 1010 .
In FIGS. 24 and 25 , the coupling bracket 1014 is shown to have a pair of threaded bushings 1200 and a bracket structure 1202 having a pair of mounting flanges 1204 and a U-shaped body portion 1206 that is coupled to one of the mounting flanges 1204 at each of its opposite ends. Each of the threaded bushings 1200 is coupled to one of the mounting flanges 1204 . The mounting flanges 1204 abut the side of the follower housing portion 1024 and threaded fasteners 1210 ( FIG. 2 ) are employed to engage the threaded bushings 1200 to fixedly but removably couple the coupling bracket 1014 to the magazine housing 1010 .
The U-shaped body portion 1206 includes a base 1220 and a plurality of legs 1222 , with each of the legs 1222 coupling a side of the base 1220 to an associated one of the mounting flanges 1204 . The base 1220 includes a slotted pin aperture 1230 that includes a circular portion 1232 , a slotted portion 1234 that is spaced apart from the circular portion 1232 , and a necked-down slotted portion 1236 having a width that is smaller than that of the slotted portion 1234 and which interconnects the circular and slotted portions 1232 and 1234 . The circular portion 1232 is sized to receive the head portion 322 of the clamp pin 300 , the slotted portion 1234 is sized to slidingly receive the first body section 324 of the clamp pin 300 , and the necked-down slotted portion 1236 is sized to receive the second body section 326 of the clamp pin 300 but not the first body section 324 . With specific reference to FIG. 25 , the back side of the base 1220 is illustrated in pertinent detail. The end of the slotted portion 1234 is shown to include a conical detent 1238 which is configured to confront the frusto-conical abutting face 330 of the head portion 322 of the clamp pin 300 .
With reference to FIGS. 19 , 20 and 27 through 32 , the follower structure 1002 is illustrated to have a follower body 1300 , a front guide tab 1302 , a lock-out dog 1304 , a loading cam 1306 , a follower guide 1308 and an actuating lever 1310 . The follower body 1300 is generally U-shaped, having a base 1320 and a pair of follower legs 1322 a and 1322 b. The lock-out dog 1304 extends upwardly from the base 1320 in a direction opposite that of the follower legs 1322 a and 1322 b. The front guide tab 1302 is also coupled to the base 1320 but extends upwardly and forwardly therefrom in the same plane as the base 1320 . Accordingly, when the follower structure 1002 is installed to the magazine housing 1010 , the front guide tab 1302 extends forwardly from the follower housing portion 1024 , past the pair of guide housing portions 1026 and into the fastener body portion 1028 where the U-shaped tip portion 1330 of the front guide tab 1302 supports the body B of the fasteners F.
The loading cam 1306 is formed into follower leg 1322 a and includes a first loading cam portion 1350 , a second loading cam portion 1352 and a third loading cam portion 1354 . The first loading cam portion 1350 is a tapered ramp that extends outwardly and upwardly from the distal end of the follower leg 1322 a. The second loading cam portion 1352 includes an oval follower capturing portion 1360 , a downwardly and forwardly extending intermediate portion 1362 and a forwardly and upwardly extending catch portion 1364 and a catch aperture 1368 that is formed at the lower-most portion of the catch portion 1364 . The follower capturing portion 1360 and the intermediate portion 1362 are formed into a first side of the follower leg 1322 a at a first depth, and the catch portion 1364 is formed into the first side of the follower leg 1322 a at a second depth that is greater than the first depth. The third loading cam portion 1354 is a generally flat portion of the front surface 1370 of the follower leg 1322 a.
The follower guide 1308 is formed onto the outside surface of follower leg 1322 b. The follower guide 1308 includes a V-shaped flange 1380 , an end member 1382 and a connector portion 1384 that couples the V-shaped flange 1380 and the end member 1382 . The connector portion 1384 is configured to fit into the slot 1042 in the follower housing portion 1024 such that the V-shaped flange 1380 and the end member 1382 confront the rear inside surface 1044 and the rear outside surface 1388 , respectively, of the follower housing portion 1024 .
The actuating lever 1310 extends outwardly from the end member 1382 and thereafter bends inwardly toward the follower legs 1322 a and 1322 b. The distal end of the actuating lever 1310 forms an engagement surface 1390 that is configured for receiving an input from the tool operator's thumb. A protrusion 1392 that is configured to contact the contact surface 1036 in the fastener head portion 1022 is also formed onto the actuating lever 1310 .
With reference to FIGS. 19 , 20 , 29 , 30 and 33 , the follower spring 1004 is illustrated to include a spring hook 1400 , a coiled, flat band spring 1402 , a cylindrically-shaped spring roller body 1404 and a spring roller pin 1406 . The spring roller pin 1406 extends through and rotatably supports the spring roller body 1404 . The band spring 1402 is a type of torsion spring, being coupled to and wound around the spring roller body 1404 . The free end of the band spring 1402 is coupled to the spring hook 1400 . Each end of the spring roller pin 1406 is set into a generally U-shaped spring roller slot 1410 that is formed into each inside surface of the follower legs 1322 a and 1322 b to couple the follower spring 1004 to the follower structure 1002 .
When the follower structure 1002 is disposed within the follower housing portion 1024 , the band spring 1402 is unwound to permit the C-shaped spring hook 1400 to be engaged to the side of the follower housing portion 1024 opposite the side in which the L-shaped pin aperture 1050 is formed. The torsion exerted by the band spring 1402 is converted to a force that is exerted through the spring roller pin 1406 to the follower structure 1002 , thereby biasing the follower structure 1002 in an upward direction toward the spring hook 1400 .
In the particular embodiment illustrated in FIGS. 1 , 19 and 35 through 45 , the magazine endcap assembly 1006 includes a molded end cap structure 1600 , a crush tube 1602 , a pivot structure 1604 , a cam follower 1606 , a cam follower spring 1608 and a thrust member 1610 . The end cap structure 1600 is configured to mate against the bottom of the magazine housing 1010 to close off the follower housing portion 1024 and the fastener body portion 1028 .
The end cap structure 1600 includes a bushing trunnion 1620 for receiving the crush tube 1602 , a fastener trunnion 1622 for receiving a fastener 1623 a ( FIG. 1 ) that couples the nose 1623 b of the end cap structure 1600 to the fastener body portion 1028 and a pair of pivot trunnions 1624 for receiving the pivot structure 1604 , which is illustrated to be a threaded fastener 1626 that is secured to the end cap structure 1600 via a threaded nut 1628 in the example provided. The crush tube 1602 , which is retained by the bushing trunnion 1620 , prevents the end cap structure 1600 form being overstressed as well as the follower housing portion 1024 from being deformed as a result of the clamping force that is exerted by the threaded fastener 1630 ( FIG. 1 ) that couples the end cap structure 1600 to the follower housing portion 1024 .
The end cap structure 1600 also includes a follower directing wall 1640 , a thrust flange 1642 and a spring flange 1644 . The follower directing wall 1640 extends upwardly from the base 1646 of the end cap structure 1600 and includes a ramped portion 1650 , which tapers outwardly and downwardly from the top end 1652 of the follower directing wall 1640 , and a generally flat portion 1654 that interconnects the ramped portion 1650 to the base 1646 of the end cap structure 1600 . The spring flange 1644 is located proximate one of the pivot trunnions 1624 , extending upwardly from the base 1646 of the end cap structure 1600 behind one of the pivot trunnions 1624 . The thrust flange 1642 is located between the spring flange 1644 and the follower directing wall 1640 and includes a first U-shaped aperture 1660 that is configured to receive the pivot structure 1604 and a second U-shaped aperture 1662 that is configured to receive the hollow thrust member 1610 .
In the particular embodiment illustrated, the cam follower 1606 includes a lever 1670 and a follower hook 1672 . The lever 1670 includes a slotted pivot aperture 1680 that is sized to receive and rotate as well as pivot in a lateral (side-to-side) direction on a portion of the pivot structure 1604 . The lever 1670 extends beyond the slotted pivot aperture 1680 to form a spring follower hook 1672 that can be employed during the assembly of the magazine endcap assembly 1006 . The follower hook 1672 includes a cylindrical body portion 1690 that is coupled to the distal end of the lever 1670 and a leg member 1692 that is coupled to the outer end of the body portion 1690 and which extends downwardly from the body portion 1690 generally parallel to the lever 1670 . The outside face 1694 of the leg member 1692 is heavily chamfered such that the leg member 1692 terminates at a rounded tip portion 1696 . The intersection between the body portion 1690 and the leg member 1692 is undercut by a radius 1698 .
The cam follower spring 1608 is illustrated to be a combination compression and torsion spring having a spring body 1700 that wraps around a portion of the pivot structure 1604 , a bent end 1702 for contacting the front face of the lever 1670 and a straight end 1704 for contacting the spring flange 1644 . The cam follower spring 1608 is operable for exerting a rotational biasing force onto the cam follower 1606 which biases the cam follower 1606 toward the rear of the tool 10 . The cam follower spring 1608 is also operable for exerting a lateral force onto the cam follower 1606 which biases the cam follower 1606 toward the thrust member 1610 .
The pivot structure 1604 is positioned through the pivot trunnion 1624 that is adjacent the spring flange 1644 . The cam follower spring 1608 is positioned over a portion of the pivot structure 1604 such that the straight end 1704 is in contact with the spring flange 1644 . The cam follower 1606 is positioned into the end cap structure 1600 such that the lever 1670 will contact the thrust member 1610 and the follower hook 1672 will be proximate the follower directing wall 1640 . The spring follower hook 1672 of the cam follower 1606 is employed to lift the bent end 1702 of the cam follower spring 1608 onto the lever 1670 . The pivot structure 1604 is then pushed through the slotted pivot aperture 1680 . The hollow thrust member 1610 , which is a washer in the embodiment illustrated, is positioned in the second U-shaped aperture 1662 in the thrust flange 1642 and the pivot structure 1604 is pushed entirely through the end cap structure 1600 and secured in place with the threaded nut 1628 .
With additional reference to FIGS. 27 , 31 and 32 , when fasteners F are to be loaded into the magazine assembly 20 , the tool operator presses the engagement surface 1390 of the actuating lever 1310 to move the follower structure 1002 downward toward the end cap structure 1600 . The ramped portion 1650 of the follower directing wall 1640 directs the follower leg 1322 a of the follower structure 1002 toward the cam follower 1606 and the flat portion 1654 of the follower directing wall 1640 ensure that proper contact is established and maintained between the loading cam 1306 and the cam follower 1606 .
When the first loading cam portion 1350 of the loading cam 1306 contacts the leg member 1692 of the follower hook 1672 on the cam follower 1606 , the ramp of the first loading cam portion 1350 pushes the follower hook 1672 in a side-to-side motion along the axis of the pivot structure 1604 in the direction of Arrow R (FIG. 43 ), permitting the leg member 1692 to travel over the first loading cam portion 1350 and into the oval follower capturing portion 1360 of the second loading cam portion 1352 of the loading cam 1306 . With the leg member 1692 being positioned in the oval follower capturing portion 1360 , the follower structure 1002 cannot be moved further down the magazine housing 1010 . When pressure on the engagement surface 1390 of the actuating lever 1310 is released, the force generated by the follower spring 1004 is employed to lift the follower structure 1002 within the magazine housing 1010 so as to simultaneously cause the cam follower 1606 to pivot about the axis of the pivot structure 1604 , thereby permitting the leg member 1692 to travel through the intermediate portion 1362 and into the catch portion 1364 of the second loading cam portion 1352 of the loading cam 1306 . When the leg member 1692 is positioned in the catch portion 1364 of the loading cam 1306 , the leg member 1692 extends through the catch aperture 1368 and around the follower leg 1322 a of the follower structure 1002 thereby securely coupling the cam follower 1606 to the follower structure 1002 and inhibiting upward travel of the follower structure 1002 within the magazine housing 1010 . In this condition, fasteners F may be readily loaded into the magazine assembly 20 .
If the magazine assembly 20 is not already coupled to the fastening tool portion 30 , this operation is performed next. This is accomplished by positioning the top end of the magazine assembly 20 relative to the nose assembly 40 such that the holes in the guide ports 1100 are proximate an associated one of the magazine guide posts 66 , the stop member 134 on the trigger lever 54 is positioned directly above the first portion 1052 of the L-shaped pin aperture 1050 , and the head portion 322 of the clamp pin 300 is engaged to the circular portion 1232 of the slotted pin aperture 1230 in the base 1220 of the bracket structure 1202 . The actuating cam 306 is then pushed toward the clamp boss 252 to compress the compression spring 302 and extend the clamp pin 300 in an outward direction so that the second body section 326 of the clamp pin 300 extends through the slotted pin aperture 1230 . With the clamp pin 300 in this condition, the magazine assembly 20 is slid upwardly until the clamp pin 300 is fully positioned into the slotted portion 1234 of the slotted pin aperture 1230 . Simultaneously, the guide ports 1100 are slid further onto the magazine guide posts 66 so that the top of the magazine assembly 20 cannot pivot relative to the nose assembly 40 and the stop member 134 on the trigger lever 54 is disposed in the second portion 1054 of the L-shaped pin aperture 1050 .
Thereafter, the tool operator releases the actuating cam 306 , causing the compression spring 302 to retract the clamp pin 300 somewhat so that the first body section 324 of the clamp pin 300 is disposed within the slotted portion 1234 of the slotted pin aperture 1230 . In this condition, the parallel flats 328 that are formed onto the first body section 324 abut the parallel sides of the slotted portion 1234 of the slotted pin aperture 1230 , thereby permitting the magazine assembly 20 to be slid along an axis defined by the magazine guide posts 66 and the slotted portion 1234 of the slotted pin aperture 1230 . The magazine assembly 20 is pushed upwardly into contact with the magazine flange 64 that is formed into the nose structure 50 . The actuating cam 306 is then pivoted to place the leg portion 352 in contact with the flat contact surface 344 . More specifically, the frusto-conical abutting face 330 of the head portion 322 of the clamp pin 300 engages the conical detent 1238 that is formed into the end of the slotted portion 1234 to both locate the magazine assembly 20 relative to the tool portion 30 as well as to mechanically lock the clamp pin 300 to the coupling bracket 1014 .
In this condition, the compression spring 302 exerts a clamping force that is transmitted through the clamp pin 300 to fixedly but removably couple the coupling bracket 1014 to the clamp boss 252 . The magazine stabilizing tabs 62 extend downwardly from the magazine flange 64 and abut the opposite sides of the fastener body portion 1028 of the magazine housing 1010 to inhibit excessive rotation of the magazine assembly 20 relative to the nose assembly 40 .
With the magazine assembly 20 attached, the fasteners F are fed into the magazine assembly 20 such that the body B of the fasteners F enter the follower cavity 1040 via the slot 1042 . Typically, the fasteners F are collated (usually at an angle of 20° or 31°) in “sticks”, which permits the magazine assembly 20 to be loaded relatively rapidly.
The follower structure 1002 is released from the cam follower 1606 by pressing downwardly on the engagement surface 1390 of the actuating lever 1310 . The body portion 1690 of the follower hook 1672 rides on the upper surface of the forwardly and upwardly extending catch portion 1364 , causing the cam follower 1606 to rotate forwardly. The simultaneous downward movement of the follower structure 1002 and the forward rotation of the cam follower 1606 continues until the leg member 1692 slips out of the catch portion 1364 and the body portion 1690 of the follower hook 1672 slides onto the third loading cam portion 1354 of the loading cam 1306 . As the leg member 1692 of the follower hook 1672 is not contacting the side of the leg 1322 a of the follower structure 1002 , the follower spring 1004 exerts a force against the lever 1670 that pushes the follower hook 1672 in a side-to-side motion so that the lever 1670 abuts the thrust member 1610 . With the body 1690 of the follower hook 1672 engaged against the third loading cam portion 1354 of the loading cam 1306 , the body 1690 of the follower hook 1672 prevents the cam follower 1606 from engaging the follower structure 1002 and the upward motion of the follower structure 1002 is controlled by the follower spring 1004 . The upward movement of the follower structure 1002 brings the tip portion 1330 of the front guide tab 1302 into contact with the bottom-most fastener F in the magazine assembly 20 which urges the fasteners F upwardly and into the nose assembly 40 . The force exerted by the follower structure 1002 onto the fasteners F, along with the configuration of the fastener head portion 1022 , ensures that fasteners F will not slip rearwardly out of the magazine assembly 20 during the operation of the tool 10 .
As discussed above, the tool operator must push the contact trip 52 against the workpiece to cause the trigger lever 54 to push the secondary trigger 128 in to contact with the trigger valve 130 to permit the state of the trigger valve 130 to be changed. With the magazine assembly 20 fully engaged against the magazine flange 64 , the stop member 134 on the trigger lever 54 is free to move in a direction parallel to the longitudinal axis of the tool 10 (i.e., rearwardly-forwardly) within the second portion 1054 of the L-shaped pin aperture 1050 .
In the event of a “jam” condition wherein fasteners F have not fed properly through the nose assembly 40 , the tool operator need only rotate the actuating cam 306 such that its base portion 350 is abutted against the flat contact surface 344 to release the clamping force that is exerted through the clamp pin 300 . The magazine assembly 20 may then be slid downwardly from the magazine flange 64 to permit the tool operator to service the nose assembly 40 . The magazine assembly 20 , however, is constrained by the magazine guide posts 66 and the clamp pin 300 so that it can only move in a predetermined linear direction. The predetermined linear direction is cooperatively defined by the magazine guide posts 66 , which remain engaged in the holes 1800 in the guide ports 1100 , and the first body section 324 of the clamp pin 300 , which remains engaged in the slotted portion 1234 of the slotted pin aperture 1230 . Downward movement of the magazine assembly 20 is checked when the first body section 324 of the clamp pin 300 contacts the necked-down slotted portion 1236 of the slotted pin aperture 1230 . Accordingly, the nose assembly 40 may be serviced without completely removing the magazine assembly 20 from the magazine flange 64 . Furthermore, when the magazine assembly 20 is moved downwardly into this condition, the stop member 134 is moved out of the second portion 1054 of the L-shaped pin aperture 1050 and into the first portion 1052 of the L-shaped pin aperture 1050 . With the stop member 134 located in this manner, rearward motion of the contact trip 52 relative to the nose body 60 is limited such that the stop member 134 contacts the rearward edge 1820 of the first portion 1052 of the L-shaped pin aperture 1050 , thereby preventing the trigger lever 54 from pushing the secondary trigger 128 sufficiently rearward so that the state of the trigger valve 130 cannot be changed (i.e., actuated). Accordingly, the stop member 134 and the L-shaped pin aperture 1050 cooperate to selectively prevent the trigger valve 130 from being actuated depending upon the position of the magazine assembly 20 relative to the magazine flange 64 .
Those skilled in the art will understand that as fasteners F are dispensed from the tool 10 , the follower spring 1004 will force the follower structure 1002 in an upwardly direction so as to continue to feed fasteners F into the nose body 60 . When the magazine assembly 20 is empty of fasteners F, the follower structure 1002 will be raised within the magazine housing 1010 to a point wherein the lock-out dog 1304 extends through the lock-out dog aperture 90 that is formed into the magazine flange 64 so that it inhibits sufficient rearward motion of the contact trip 52 so as to prevent the trigger lever 54 from changing the state of the trigger valve 130 . Accordingly, the lockout dog 1304 inhibits the tool 10 from cycling when the magazine assembly 20 is empty of fasteners F and coupled to the magazine flange 64 .
In an alternate embodiment of the present invention illustrated in FIGS. 46 and 47 , the nose assembly 40 includes a pivoting lock-out tab 2000 that is rotatably coupled to the nose structure 50 and pivotable between a first position, which is illustrated in FIG. 47 , that permits the contact trip 52 to move rearwardly a sufficient amount that permits the trigger lever 54 to change the state of the trigger valve 130 , and a second position, which is shown in FIG. 46 , that inhibits rearward motion of the contact trip 52 by an amount wherein the trigger lever 54 cannot change the state of the trigger valve 130 . As illustrated in FIG. 47 , when the magazine assembly 20 abuts the magazine flange 64 , the top surface 2010 of the magazine housing 1010 contacts the lock-out tab 2000 and rotates it into the first position. When the magazine assembly 20 is not abutted against the magazine flange 64 as illustrated in FIG. 46 , however, the lock-out tab 2000 is rotated by a torsion spring (not specifically shown) into the second position to prevent the tool 10 from being cycled.
While the invention has been described in the specification and illustrated in the drawings with reference to a preferred embodiment, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention as defined in the claims. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment illustrated by the drawings and described in the specification as the best mode presently contemplated for carrying out this invention, but that the invention will include any embodiments falling within the foregoing description and the appended claims.
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A magazine assembly for a fastening tool. The magazine assembly slides on guide posts that are formed into the nose assembly of the fastening tool and is clamped to the fastening tool via a magazine clamp assembly that requires no tools to operate. The magazine clamp assembly may be partially released to permit the magazine assembly to be partially withdrawn from the nose assembly so that the nose assembly may be maintained without the complete removal of the magazine assembly. The construction of the nose assembly is such that when the magazine assembly is placed in a partially withdrawn state, a portion of the nose assembly mechanically inhibits actuation of the fastening tool trigger system.
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Cross-reference to Related Applications:
This Application is a National Phase of PCT/MX2007/000121, filed 17 Oct. 2007.
BACKGROUND
A. Field of the Invention
This invention is related to glass melting furnaces and more specifically to glass melting furnaces for the manufacture of glass containers or flat glass, entirely built with refractory concrete.
B. Description of the Related Art
The conventional design of furnaces for the glass production includes the use of masonry, that is to say, the use of bricks and blocks assembled using mortar and/or cement to build each one of the sections that constitute the unit. These refractory materials are chosen in order to attain an useful life of at least 12 years before requiring a total reconstruction.
The repairing of conventional furnaces used to produce glass, has been traditionally developed, by replacing the damaged or worn-out sections, using new bricks or blocks, incorporating them to the furnace's sections using mortar and/or cement.
However, when refractory concretes appeared, the repairing of furnace's sections was simplified because now it is only needed to remove the refractory bricks or blocks from the affected areas and to fill in these areas directly with refractory cement, being not required to place refractory bricks.
Examples of refractory cements for glass melting furnaces, are described in the U.S. Pat. No. 7,176,153 of Anderson, for an alumina, zirconium and silica refractory system that, as it is set forth in the said patent, can be used to produce blocks or can be used directly in a worn-out portion of the furnace; U.S. Pat. No. 6,313,057 of Brown et al, for a melted silica refractory material made up of granulated quartz, that contains a calcium oxide binder; U.S. Pat. No. 6,158,248 of Beppu, for a melted cast refractory of alumina, zirconium and silica; U.S. Pat. No. 6,554,058 among others.
Nevertheless, all these refractory cements have been used only to manufacture blocks and for repairing worn-out areas of furnace's sections.
This invention considers the design of a furnace with sections entirely built with refractory concretes that are total and hermetically joined forming a monolithic furnace. The achieved benefits hereof are the following: higher airtightness that improves the thermal efficiency, thus saving fuel; more durability of critical areas due to a reduction in the chemical erosion and corrosion, as a result of the absence of joints among the structural components. It is possible to achieve an important reduction in construction time due to the design of large elements, because the sections are directly shaped at the construction site, likewise, an important reduction is achieved in the warm-up and the operation startup time.
OBJECTIVES OF THE INVENTION
Thus, one main objective of this invention is to provide a glass melting furnace, entirely built with refractory concrete.
It is an additional objective of this invention is to provide a glass melting furnace, of the above described characteristics, with better airtightness that improves its thermal efficiency resulting in a fuel saving.
It is a further main objective of this invention, to provide a glass melting furnace, with the above described characteristics that has a longer durability of its critical areas, due to the reduction of chemical erosion and corrosion, as a result of the lack of joints among the structural components.
It is jet an additional objective of this invention, to provide a glass melting furnace, with the above described characteristics, with which because of the design of large elements, it is possible to achieve an important reduction in its construction time, as well as in its warm-up time at the operation startup stage.
These and other objectives and advantages of the glass melting furnace, built with refractory concrete, of this invention, can be viewed by the experts in the area in the following detailed description of the preferred embodiments of the invention, which will be within the scope of the invention claimed.
DESCRIPTION OF THE DRAWINGS
FIG. 1 , is a cross section view of a side elevation a glass melting furnace for the manufacturing of containers, schematized, showing its several sections made up of several materials according to its coding, according to this invention;
FIG. 2 , is an upper plant cross section view of the furnace in FIG. 1 , showing several sections made up of several materials according to its coding;
FIG. 3 , is a conventional perspective view of the regeneration section, showing its regenerating chambers with its side, front and rear walls and vaults.
FIG. 4 , is a conventional perspective view of the throat connecting the regeneration section with the melting section.
FIG. 5 , is a conventional perspective view showing the melting section of the monolithic furnace of this invention;
FIG. 6 , is a detailed, enlarged cross section of a side elevation view, of the refining section of FIG. 1 ; and,
FIG. 7 , is a diagram of the codes of the materials that form part of the furnace.
DETAILED DESCRIPTION OF THE INVENTION
The glass melting furnace of this invention will be described below making reference to the specific embodiments of the same and to the drawings enclosed as figures, where the same signs refer to the same parts of the shown figures.
A typical glass melting furnace, known as Regenerative Furnace with “End Port” includes sections that have specific functions such as: one melting section SF, one refining section SR and one regeneration section SRG ( FIGS. 1 and 2 ), each of which, according to this invention, is built entirely with refractory concrete made of specific materials and features and they will be described in detail below in the sequence in which this type of furnace is built.
Regarding to the type of materials used to build the furnace to be described in the following, it is important to state that the calculated thickness according to the design is such that the useful life of the operative unit is the same as the one of a conventional furnace, that is, at least 12 years of useful life until its next repairing, during this period of useful life minor maintenance services in warm conditions are considered to preserve the unit, as it is a common practice in current glass furnaces.
Regeneration Section:
Regenerative Chambers.
The regenerative chambers CRG 1 and CRG 2 ( FIGS. 2 and 3 ) of the furnace H are subject to thermal changes due to the burn cycle from one side to another of the furnace H, also, they are subject to differential temperatures from the combustion gas exhaust 1 of the melting section SF of approximately 1550° C. to the base 2 of the regenerative chambers CRG 1 and CRG 2 from about 400 to 500° C., therefore materials that remain stable under this operation conditions were chosen.
Also, due to the changing condition of combustion air intake (21% O2) and gases exhaust (4-5% O2) they are exposed to oxidation-reduction changes of state, at the same time that they present the above mentioned thermal gradient.
The following alumina-silica refractory materials were chosen to build the regenerative chambers CRL 1 and CRL 2 , which, because of their amphoteric characteristic, are able to resist the acid environments which are present due to the combustion and basic gases of the materials of the side and central walls of the regenerators.
The lower area, side walls 3 a and 3 b , front wall 4 a , rear wall 5 a and central wall 6 a ( FIG. 3 ) which are exposed to temperatures from about 400 to 800° C., are built with alumino-silicate refractory concrete. The middle area, side walls 3 c and 3 d , front wall 4 b , rear wall 5 b and central wall 6 b ( FIG. 3 ), which are exposed to temperatures from about 800 to 1100° C., are built with high alumina and low calcium oxide refractory concrete. The upper area, side walls 3 e and 3 f , front wall 4 c , rear wall 5 c and central wall 6 c ( FIG. 3 ), which are exposed to operation temperatures from about 1100 to 1500° C., are built with high alumina and low calcium oxide refractory concrete. Finally, the vault 7 and overvault 8 that seals the regenerative chambers CRG ( FIG. 3 ), are built with high silica and low calcium oxide silicon refractory concrete.
These refractory materials offer high resistance to pressure under burning conditions and high resistance to sudden temperature changes due to changes in burning cycles. Also, at work temperatures they have a high chemical resistance to condensable gases and steams, such as the sodium sulphate.
Ports:
In order to build ports 10 a and 10 b that connect regenerative chambers CRG 1 and CRL 2 ( FIGS. 2 and 4 ) to the melting section SF, a high alumina (>99.0%) and low calcium oxide (<0.2%) refractory was considered, the chemical stability of the alpha alumina used, prevents the reactivity with other materials, also, the presence of low calcium oxide content prevents the reactivity with other compounds such as heavy metals from fossil fuels, making a high chemical resistance monolithic refractory. In addition, the thermal stability provided by the low expansion coefficient, allows an excellent behavior as a joining piece between the melting section and the regenerative chambers CRG 1 and CRG 2 due to the change of thermal cycles during the furnace operation, therefore:
each of the ports 10 a and 10 b , their side walls 11 a and 11 b, vault 12 and floor 13 ( FIG. 4 ) are built in a monolithic form with high alumina refractory concrete.
Melting Section:
Refractory in Contact with Glass:
The refractory materials in contact with glass are of the zirconium-alumina-silica type, which include zirconium oxide in their chemical composition because, due to the presence of the same, it provides to the the products a higher resistance to corrosion, abrasion and compression. For this reason, the materials that are in contact with glass in the furnace H ( FIGS. 1 , 2 and 5 ) of this invention, include the use of refractory concrete to form monolithic pieces with zirconium-alumina-silica refractory material with 20-24% of zirconium oxide content, as it is set forth in U.S. Pat. No. 4,053,321, therefore:
Floor:
The lower layer 20 of floor P of the melting section SF ( FIG. 5 ) is built with alumino-silicate refractory concrete;
The middle layer 21 of floor P ( FIG. 5 ) is built with high alumina refractory concrete; and
The upper layer 22 of floor P ( FIG. 5 ) is built with zirconium-alumina-silica refractory concrete. This last layer is the one that is in contact with the glass.
Cup:
The cup 23 of melting section SF ( FIG. 5 ), including both side chargers 24 a and 24 b , are built with zirconium-alumina-silica refractory concrete.
Superstructure:
The superstructure SS of the furnace H, that comprises the overcup 25 , front wall 26 , rear wall 27 and side walls 28 a and 28 b of furnace H ( FIG. 5 ), requires high temperature resistant materials, because they are exposed to flames, and that provide resistance to combustion gases and gas and volatile compounds environment which come from glass manufacturing, such as the raw material dragging “carry over”, sodium oxide, sodium hydroxide, etc. That is why when choosing the materials to form the superstructure SE, high alumina refractory materials were used, which provide a high fusion point and chemical resistance to the corrosion of the alkaline environment of the glass and to the acid environment of the combustion gases because of its neutral feature. Also, more specifically, due to its low calcium oxide concentration in its structure, the possibility of forming liquid phases is reduced, avoiding any dripping problem and generation of defects in the melted glass, therefore:
The overcup 25 , front wall 26 , rear wall 27 and side walls 28 a and 28 b of the melting section SF ( FIG. 5 ), are built with high alumina and low calcium oxide refractory concrete.
Vault:
The vault 29 is the structural element of the melting section SF ( FIG. 5 ) that closes the upper space of the glass melting furnace H and this design considers refractory concretes with high SiO2 (>99%) and low calcium oxide (<0.2%) concentrations different from the common refractory which uses from 2.5 to 3.5% CaO. The manufacture in only one piece of the vault 29 prevents all kind of union joints among blocks and permits a better airtightness with the furnace walls, significantly reducing the appearance of joints and cracks. This condition together with the high SiO2 content and low CaO concentration reduces the potential reactivity between the volatile phases of alkalis of furnace H and the silica, preventing the reactivity between these compounds. On the other hand, it reduces the potential generation of corrosion points among joints because of the lack of heat and steam leaks that prevent the formation of liquid phases which form the “rat holes”.
Also, the sealing of the vault 29 , called overvault 30 installed once the heating process of the Furnace H has finished ( FIG. 5 ), eliminates any crack or leak of heat left in the vault during the heating of the same, maintaining the airthickness of the system, therefore:
The vault 29 and sealing overvault 30 ( FIG. 5 ) are built with silicon refractory concrete with high silica and low calcium oxide contents;
Throat:
The Throat 31 ( FIGS. 1 and 2 ) is built with zirconium-alumina-silica refractory concrete.
Refining Section:
The base 40 of the refiner cup floor RC is built with alumina-silicate refractory concrete; and The upper body 41 of the refiner cup RC and the upper layer 42 in contact with the glass, are built with zirconium-alumina-silica refractory concrete.
The chosen group of refractory concretes permits the construction of a monolithic glass furnace reducing its construction time compared against common furnaces made up of preformed blocks, as well as a low manufacture cost due to the low cost of the materials used while the design and calculation of the thickness of the involved materials provides an equal or longer useful life than the one of conventional furnaces, that is at least 12 years, it can also be mentioned that an additional advantage is the considerable reduction of time spent repairing the unit after the useful life of the furnace, since there is a fixed base of the previous furnace, thus allowing important savings in materials and time reduction to restart the unit's operation.
This development considers the design of monolithic pieces (see table of parts) to form the glass furnace, and the calculation of the thickness of the materials of each part to keep the useful life of the glass furnace the same as a conventional furnace.
Preferred Sample of Embodiment with Materials and Thicknesses Used in a 220-Ton/Day Furnace Regeneration Section.
Regenerative Chambers:
In the lower area, the side walls 3 a and 3 b , front wall 4 a and rear wall 5 a were built with alumina-silicate refractory concrete which contains 36-38% alumina with a thickness of 28.5″ in the lower part and 24″ in the upper part, and central wall 6 a with a thickness of 33″ in the lower part and 24″ in the upper part respectively, that are exposed to a temperature of around 400 to 800° C.
In the middle area, the side walls 3 c and 3 d , front wall 4 b , rear wall 5 b and central wall 6 b , that are exposed to temperatures of around 800 to 1100° C., were built with high alumina refractory concrete with Al 2 O 3 content with a thickness of 24″.
In the upper area, the side walls 3 e and 3 f , front wall 4 c , rear wall 5 c and central wall 6 c , that are exposed to temperatures of around 1100 to 1500° C., were built with high alumina refractory concrete with a 85 to 91% content of Al 2 O 3 , with a thickness of 24″.
Vault 7 and Sealing Overvault 8 , were built with silicon refractory concrete with high silica and low calcium oxide content, with a thickness of 13.5″ in the vault 7 and a thickness of 2″ in the sealing overvault.
Ports:
Each of the ports 10 a and 10 b were built in a monolithic form with high alumina refractory concrete with Al 2 O 3 contents of 85 to 91%, with side walls 11 a and 11 b with a thickness of 9″, with a vault 12 thickness of 12″, and a floor 13 with a variable thickness of 9″ next to chambers and 4.5″ in the nose of the floor of the port.
Melting Section.
Refractory in Contact with Glass:
Floor:
The lower layer 20 of floor P was built with alumino-silicate refractory concrete with a 47-52.5% alumina content with a thickness of 18″;
The middle layer 21 of floor P was built with high alumina refractory concrete with a 85-91% Al 2 O 3 content with a thickness of 8″; and
The upper layer 22 of floor P was built with zirconium-alumina-silica refractory concrete with a 20-24% zirconium oxide content with a thickness of 6″.
Cup:
The cup 23 was built with zirconium-alumina-silica refractory concrete with a 20-24% zirconium oxide content with a thickness of 18″ including both chargers.
Superstructure:
The overcup 25 , its front wall 26 , rear wall 27 and side walls 28 a and 28 b were built with high alumina refractory concrete with a 85-91% Al 2 O 3 content and low calcium content, with an overcup thickness of 8″ and side walls 28 a and 28 b , front wall 26 and rear wall 27 with a thickness of 12 ″.
Vault:
The vault 29 and sealing overvault 30 were built with silicon refractory concrete with high silica content and low calcium oxide content. with a thickness of 13.5″ in the vault in the vault 29 , and a thickness of 2″ in the sealing overvault.
Throat:
The throat 31 was built with zirconium-alumina-silica refractory concrete with a 20-24% zirconium oxide content.
Refining Section.
The Base 40 of the cup floor was built with alumino-silicate refractory concrete with a 47-52.5% alumina content and with a thickness of 7.5″.
The upper body 41 of the cup and the upper layer 42 in contact with glass, were built with zirconium-alumina-silica refractory concrete with a 20-24% zirconium oxide content with a thickness of 10″ in the upper body 41 and with a thickness of 6″ in the upper layer 42 in contact with glass.
All of the above is in the understanding that the aforesaid description of the invention, is only provided in order to show the specific embodiments of the same and the better way to develop it as of the time when this application for patent is filed and the invention will not be limited to these, but its scope must be considered regarding the enclosed claims.
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Glass melting furnace comprised by several sections which are built entirely with refractory concrete of diverse refractory materials according to operation conditions, chemical environment, temperature, and mechanical load to which its several sections are exposed, as well as to the material thickness required, to assure an structural integrity and durability similar to the ones of furnaces of conventional design as well as a lower investment cost.
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This application claims the benefit of U.S. Provisional Application Serial No. 60/032,098 filed on Dec. 4, 1996.
TECHNICAL FIELD
The present invention is in the field of ladders and scaffolds, such are used in the building, painting and cleaning trades, and for household use; and is used for holding items while using ladders and scaffolds.
BACKGROUND
Ladders and scaffolds find applications in many trades, such as the building, painting and cleaning trades. Also, ladders are commonly used in the household for a wide variety of tasks.
Both commercial and household uses of ladders and scaffolds typically involve the use of tools and/or chemical agents, such as cleaners and paints.
Naturally, it is desirable to be able to hold tools and other materials on a ladder or scaffold securely and easily within reach of the user. Many ladders come equipped with fold-out shelves that are part of a folding ladder structure near the top of the ladder and opposite the ladder stairs or rungs. These shelves are difficult to use because they require the user to reach around or through the ladder, they remain only at one height, and they require that the folding ladder be completely unfolded to be operative. Straight ladders typically do not come equipped with shelves.
Accordingly, an object of the present invention is to provide an adjustable shelf that can be used at a variety of heights and on a wide variety of ladders or scaffolds.
It is also an object of the present invention to provide such a shelf which is convenient to use and which cannot be used improperly as a step.
The present invention also has as an object to provide a shelf or other holder that can be used without interfering with the ascent or descent of the user on the ladder or scaffold.
SUMMARY OF THE INVENTION
In broadest terms, the present invention includes a holding device adapted to attach to a ladder having rungs, the holding device comprising: (a) a substantially flat holder member defining a holder plane; (b) a hook adapted to engage one of the rungs, the hook being adjustable with respect to the holder plane, and lockable in at least two orientations with respect to the holder plane.
It is preferred that the hook be lockable in a plurality of orientations with respect to the holder plane. This may be accomplished by the holder member and the hook each being provided with orientating surfaces which are adapted to be releasably engaged so as to allow the hook to be lockable in a plurality of orientations with respect to the holder plane. The ability of the hook to be lockable in a plurality of orientations with respect to the holder plane allows the holder to be adjusted so as to accommodate any angle of the ladder staves (or sidepieces) when the ladder is being used. The hook is preferably attached at a point that will allow the holder to bear against the ladder stave. For instance, the hook may be oriented along one side of the holder so as to allow the holder to rest against the ladder stave and extend from the side of the ladder, clearing the path of the ladder rungs. The holder portion may have an extension portion that may be adjustable so as to bear against the ladder stave below the position of the holder plane in order to stabilize the holder once the hook has been placed in position on the stave. In an alternative embodiment, the adjustable hook itself may have an extension rod that is designed to bear against the ladder stave below the position of the holder plane in order to stabilize the holder once the hook has been placed in position on the stave. The description of the preferred embodiment shows this in more detail.
In another preferred embodiment, the holding device may be such that the holder member additionally includes at least one drawer that might be used for holding painting supplies or tools. In another embodiment, the holder member is provided with at least one drain hole that may be used to allow spilled paint or other liquids to drain.
The holder member and the hook may be made of any appropriate dimensionally stable material, such as wood, plastics and metals.
The present invention is a versatile device that may be attached to any extension ladder, straight ladder, folding ladder, scaffolding, etc., and can be used as a tool stand, paint or paint brush holder etc. For instance, one use of the present invention is as a paint rack for holding a gallon paint can, paint brushes (that may be put in holes in the holder plate) and a few tools that may be placed in an optional drawer or shelf beneath the holder table itself. Such a drawer or shelf may be removable.
The dimensions of the table intended for use in painting should be just large enough square to accommodate the gallon paint can and the optional lower shelf may be approximately 2 inches deep. For example, if the table is eight inches by eight inches with a 0.75 inch lip around the perimeter the removable shelf may be about 7.75 inches square and 2" deep and may rest on a lower extension of the table.
The shelf may be removable and would fit securely into the top of holder plate so it could be opened and the tools could be used in a convenient manner.
The present invention may be made of any appropriate material(s) such as heavy gage aluminum or plastic. For instance, the entire mechanism except for the locking screw may be made of high density, high impact plastic and would be able to withstand the weight of at least two full gallons of paint and a drawer full of tools.
Additional optional features may include a mechanism that adjusts and maintains the angle of the table in discrete positions, such as through an intermeshing series of radial grooves with "V" cross-sections which extend and expand radially, that could be locked into one another in a plurality of orientations (typically 5, 10 or even 30 possible orientations). Other such arrangements may include such variations of mechanical arrangements and surfaces that are adjustable and lockable by pressure of mechanical opposition, such as opposed peg-and-hole arrangements, opposed cooperating rib arrangements, and simple opposing roughened surfaces; all of which can be applied to make the ladder table adjustable.
One or more drawers or shelves (with or without doors) may be attached to the ladder table, such as just below the table itself, to contain brushes, screwdrivers, and other tools or fasteners, such as screws, nails, etc., for use as a storage area when working on the ladder.
The attaching hook could be on a pivot so as to be able to engage the rung of the ladder onto which the holder table is to be attached. The stabilizing lug that contacts the bottom of the attachment area of the ladder may be made so as to provide an asymmetrical rotating ring on the end that could be rotated and act as a cam to tighten the table to the ladder for better stability.
Appropriate cautionary legends, such as the words "DO NOT STAND ON OR HANG FROM THIS DEVICE" and a weight limit may be printed or molded into the holder plate's rim so as to be visible to the user during use.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an elevational, environmental view of a ladder table in accordance with one embodiment of the present invention.
FIG. 2 is a lateral, elevational, environmental view of a ladder table in accordance with one embodiment of the present invention.
FIG. 3 is a side, elevational view of the attachment portion of a ladder table in accordance with one embodiment of the present invention.
FIG. 4 is an end-on, elevational view of an attachment portion of a ladder table in accordance with one embodiment of the present invention.
FIG. 5 is a side, elevational view of the table portion of a ladder table in accordance with one embodiment of the present invention.
FIG. 6 is a detailed view of a nut, bolt and extension handle that may be used in accordance with one embodiment of the present invention.
FIG. 7 is a plan view of the table portion of a ladder table in accordance with one embodiment of the present invention.
FIG. 8 is an elevational, partially sectioned environmental view of a ladder table in accordance with one embodiment of the present invention.
FIG. 9 is an elevational view of the ladder table device shown in FIG. 8 as viewed along line 9--9 of FIG. 8.
FIG. 10 is a side elevational view of the hooking component in accordance with one embodiment of the present invention.
FIG. 11 is a front exploded elevational view of the hooking component in accordance with one embodiment of the present invention.
FIG. 11a is a detailed plan of view of flange lock in accordance with one embodiment of the present invention.
FIG. 11b is a detailed view of screw lock in accordance with one embodiment of the present invention.
FIG. 11c is a detailed view of screw component in accordance with one embodiment of the present invention.
FIG. 11d is a detailed view of screw cap in accordance with one embodiment of the present invention.
FIG. 11e is a detailed view of a pivot boss in accordance with one embodiment of the present invention.
FIG. 11f is a detailed view of a locking bolt in accordance with one embodiment of the present invention.
FIG. 11g is a detailed view of locator pin in accordance with one embodiment of the present invention.
FIG. 12 is a side exploded elevational view of an optional screw component in accordance with one embodiment of the present invention.
FIG. 13 is a side elevational view of connecting bracket in accordance with one embodiment of the present invention.
FIG. 14 shows ladder table having recessed table surface in accordance with one embodiment of the present invention.
FIG. 14a shows the open drawer end of the one-piece ladder table in accordance with one embodiment of the present invention.
FIG. 14b shows a side view of a one-piece ladder table in accordance with one embodiment of the present invention.
FIG. 15 is a side view of ladder table showing drawer slot in accordance with one embodiment of the present invention.
FIG. 15a is a frontal view of ladder table showing drawer in accordance with one embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
In accordance with the foregoing summary of the invention the following presents a detailed description of the preferred embodiment of the invention, presently considered to be the best made of the invention when applied to the painting trades.
FIG. 1 shows an elevational view of the ladder table in accordance with the preferred embodiment of the invention seen as it would appear by the operator viewing the ladder table in place along one lateral support of a straight ladder. FIG. 1 shows ladder rung (1) on ladder support (2). The attachment portion (3) comprises a hook portion (4) which is adapted to engage ladder rung (1). The attachment portion (3) also includes an abutting portion (5) which is adapted to abut against the facing side of ladder support (2) to maintain it from swinging about ladder rung (1). Abutment portion (5) may also be provided with a swivel cam (19) that is rotatable about the abutment portion and which will oppose the static force of the attachment portion (4), thus locking the entire arrangement onto the ladder. Attachment portion (3) also is provided with a discreet positioning mating portion (6) and an aperture (7) through which bolt (8) extends so as to attach to and be locked in positional relationship with table portion (9). Table portion (9) also includes a discreet positioning mating portion (10). In the shown embodiment the discreet positioning portions (6 and 10) are disks with an equal number of radially extending v-grooves which mate with one another so that the attachment portion and table portion can be locked in a desired orientation (normally with the table portion held substantially normal to the pull of gravity with the attachment portion positioned to correspond to the angle of the ladder in the working position). The two discreet positioning portions are held in mated relationship through the action of bolt (8) with nut portion (11) which in turn, is provided with an extension handle (12) so that the operator may conveniently slightly loosen and then re-tighten the nut and bolt combination in order to be able to turn the table portion with respect to the attachment portion to achieve the desired angular orientation. In the shown embodiment, the table portion may optionally be provided with a hollowed top to form a well portion (13) as is indicated by dotted lines, which provides walls along the sides of the table top so as to help prevent spillage or the dropping of tools during use of the table for holding paints, varnishes or stains, or when holding tools such as paint brushes, hand tools, etc. The embodiment shown in FIG. 1 also shows that the table portion may be provided with one or more drawer spaces which can be provided with a drawer to help contain tools and small work items such as fasteners, such as hooks, nails, screws, etc. In this embodiment, the drawer portion (14) may be supplied with drawer (14a) or, in an alternative embodiment, may be fitted with a door (18).
FIG. 2 is a view of the preferred embodiment of the present invention as seen as viewed along line 2--2. All of the numerical references in FIG. 2 are the same those taken from FIG. 1. FIG. 2 more clearly shows the position of the attachment portion (3) with its hook (4) extending over rung (1) attached to ladder support (2). Also shown is the abutting portion (5) which abuts atop ladder support (2). The discreet positioning portions (6 and 10) can be seen as they would appear when viewed through table portion (9) and drawer portion (14) which, in this embodiment, is shown as having well portion (13) and optional drawer portion (14) (optional drawer (14a) and door (18) not shown). This view also shows extension portion (12) as described in FIG. 1.
FIG. 3 shows a side elevational view of the attachment portion (3) used in accordance with the preferred embodiment of the present invention. FIG. 3 shows hook portion (4) and abutment portion (5) as well as discreet positioning portion (6) (shown in phantom). The dimensions and radii given in FIG. 3 are expressed in inches. FIG. 4 is a rear elevational view of the attachment portion (3), as it would be viewed in the orientation as seen in FIG. 1. FIG. 4 shows attachment portion (3) with hook portion (4) and abutment portion (5). FIG. 4 also shows aperture (7) which is adapted to accept the bolt (8) shown in FIG. 1.
FIG. 5 shows a side elevational view of the table portion (9) of the present invention as it would be viewed along line 5--5 of FIG. 1 (i.e., as seen from the engagement side that faces the attachment portion (3)) without the bolt (8) or nut (11) in place. FIG. 5 shows table portion (9) having hollow portion (13) and a drawer portion (14). Also shown is discreet positioning portion (10) and aperture (15) through which bolt (8) passes (as shown in FIG. 1). The dimensions and radii given in FIG. 5 are expressed in inches.
FIG. 6 is a detailed view of the bolt (8) and extension handle (12) as shown in FIG. 1. This Figure also shows how bolt (8) fits into nut (11). The bolt (8) may be made of plastic or metal, and could be molded into the hook mechanism itself. The nut portion (11) may also be made of a wear-resistant material and contain internal threads to match the locking bolt (8). The extension arm (12) may be made of metal to extend below the ladder table for easy access and to provide a sufficient amount of leverage to ease the locking of nut portion (11) onto locking bolt (8). The throw of the locking arm (12) may be 140°. The bolt may be a very coarse 4 TPI for locking, and the combined bolt and nut naturally must fit into the space between the drawer space (if provided) and the table side face with the discreet positioning portion.
FIG. 7 is a plan view taken along line 7--7 of FIG. 1. FIG. 7 shows table portion (9) having hollow well (13) which is provided with texturing portions (16) to prevent slippage of a paint can placed thereupon. FIG. 7 also shows optional drain holes (17) that might be applied in an embodiment of the present invention that either uses no drawer, or are used in portions of the table portion that do not reside above the drawer (where the drawer is not as wide as the table portion, allowing spilled paint to drip through the table in the case of spills, if desired).
FIGS. 8 through 15a show an alternative embodiment of the present invention.
FIG. 8 is an elevational, partially sectioned environmental view of a ladder table in accordance with one embodiment of the present invention shown as it would be attached to a simple metal ladder with rung 20 perpendicular to its sidepiece support 21. FIG. 8 shows an embodiment of the invention that involves the ladder attachment portion being rendered in two pieces, a hooking component 22 and a bracket component 23. FIG. 8 shows that hooking component 22 engages rung 20 and includes a screw component 24 which may be attached by screw 25 (which preferably allows pivotal orientation to be changed and locked into place by tightening screw 25), or otherwise, such as by welding it onto hooking component 22. The screw component 24 is used to attach hooking component 22 to bracket component 23 by passing though an aperture in bracket component 23 and being releasably locked into place by screw lock 26 and optional flange lock 27 (which may be used with a ladder such as an aluminum ladder which may have shaping along the ladder edge, such as the recess indicated by the dotted lines running along the ladder edge shown in FIG. 8). In similar fashion, the screw component 28 is used to urge bracket component 23 against the outboard side of sidepiece support 2 by passing though an aperture in bracket component 23 and being releasably locked into place by screw lock 29 and optional flange lock 30 which functions as described with respect to optional flange lock 27. The screw component 28 may be a simple screw or bolt, or may have a screw cap 31 which is held in place by screw 32.
The ladder table 33 (with or without provision for one or more drawers, such as may be supported by drawer slots 33a) may be held in place by attachment to bracket component such as screw 34 which allows the ladder table to be pivoted, and by bolt 35 and wing nut 36 that allow the ladder table to be locked into an orientation on the pivot arc (see FIG. 9) through arc slot 41.
FIG. 9 is an elevational view of the ladder table device shown in FIG. 8 as viewed along line 9--9 of FIG. 8. The same reference numerals used in FIG. 8 apply to FIG. 9.
FIG. 9 also shows ladder flange 37 engaged by the locking flanges 27 and 30.
FIG. 9 also shows that screw components 24 and 28 optionally may be flat-sided bolts or similar flat-sided attachments that allow them to rest securely against the ladder edge 21.
Also visible in FIG. 9 is the pivot boss 38 into which screw 34 fits to allow ladder table 33 to pivot and be locked into place. FIG. 9 also shows locator pin 39 and corresponding shaping 40 of a portion of the side of the bracket component 23, that function to orient the ladder table with respect to the bracket component (and ultimately the ladder itself once all of the joints are fixed).
This arrangement allows the ladder table to be held in position both by action of the hook (preventing downward vertical displacement and horizontal displacement toward the user) and the clamping action of the multi-piece hook (principally additionally preventing lateral displacement to the side of the ladder).
FIG. 10 is a side elevational view of the hooking component 22 showing screw component 24.
FIG. 11 is a front exploded elevational view of the hooking component 22 showing screw component 24, the locking flange 27 and screw lock 26.
FIG. 11a is a detailed plan of view of flange lock 27 which may also be used as flange lock 30.
FIG. 11b is a detailed view of screw lock 26 which may also be used as screw lock 29.
FIG. 11c is a detailed view of screw component 28a showing the pivot hole 28b into which screw 32 fits.
FIG. 11d is a detailed view of screw cap 31 showing aperture 31a through which screw 32 passes.
FIG. 11e is a detailed view of pivot boss 38.
FIG. 11f is a detailed view of locking bolt 35.
FIG. 11g is a detailed view of locator pin 39.
FIG. 12 is a side exploded elevational view of an optional screw component 28a used as an alternative to screw component 28 to urge bracket component 23 against the outboard side of sidepiece support 2 as described above. FIG. 12 shows screw lock 29a and optional flange lock 30a which functions as screw lock 29 and optional flange lock 30 as described above. The screw component 28a as shown is a simple bolt, as opposed to the arrangement of a screw cap 31 which is held in place by screw 32, as described above.
FIG. 13 is a side elevational view of connecting bracket 23 showing apertures 23a and 23b through which pass screw components 24 and 28, respectively as described above. Also shown are shaping 40 of a portion of the side of the bracket component 23 and arc slot 41.
FIG. 14 shows ladder table 33 having recessed table surface 33b, and featuring pivot boss 38, hole 42 for receiving locating bolt 35, and wedge-shaped locator portion 43, as an alternative to locator pin 39.
FIG. 14a shows the open drawer end of the one-piece ladder table 33 showing drawer slots 33a and ladder table surface 33b.
FIG. 14b shows a side view of a one-piece ladder table 33 which shows table surface 33b, drawer slot 33a and pivot boss 38.
FIG. 15 is a side view of ladder table 33 showing drawer slot 33a and pivot boss 38. FIG. 15 also shows drawer portion 44 which engages drawer slots 33a through mounting-slider pegs 45.
FIG. 15a is a frontal view of ladder table 33 showing drawer 44 in a closed position engaging ladder table 33 through mounting lighter peas 45 engaging drawer slots 33a.
The components of the ladder table of the present invention may be made of any appropriate dimensionally stable material taking into account the stress likely to be brought to bare during use. In this regard, the ladder table for instance may be made from machined metal or may be injection molded as a single piece from a plastic material. In the case where metals are used, it is preferred that the components of the ladder table of the present invention be made of lightweight materials such as aluminum which may be machined, and which provide for sufficient operating strength with a minimum of weight.
The ladder table of the present invention typically will be operated by placing the hooking component 22 over ladder rung 20 followed by tightening screw locks 26 and 29 in order that the hooking component and connecting bracket are urged against, respectively, the inboard side and outboard side surfaces of sidepiece support 2 (and where used, the flange locks 27 and 30 engage the ladder flange 21a where present). The ladder table 33 can then be leveled by adjusting its pitch orientation and fixing that orientation by tightening wing nut 36.
In view of the foregoing disclosure, it will be within the ability of one skilled in the art to make alterations and variations to the present invention, such as through the substitution of equivalent materials and mechanical arrangements, such as the integration and disintegration of component parts, without departing from the spirit of the invention as reflected in the following claims.
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The invention relates to holding device adapted to attach to a ladder having rungs. The holding device comprises: (a) a substantially flat holder member defining a holder plane; (b) a hook adapted to engage one of the rungs, the hook being adjustable with respect to the holder plane, and lockable in at least two orientations with respect to the holder plane.
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[0001] Priority is claimed to Swiss Patent Application No. CH 00504/05, filed on Mar. 23, 2005, the entire disclosure of which is incorporated by reference herein.
[0002] The present invention relates to the field of rotating machines. It refers to a rotor shaft, in particular for a gas turbine.
BACKGROUND
[0003] Where machines subjected to high thermal and mechanical load are concerned, such as for example, compressors, gas turbines or steam turbines, it is desirable to reduce mechanical stresses by means of a suitable design of the individual machine and plant parts.
[0004] Thus, from the prior art, it is known, for example (see EP-A1-0 945 594 or U.S. Pat. No. 6,478,539 B1), in the moving blades of gas turbines, to design the transition from the blade leaf to the adjoining blade platform lying beneath it with a predetermined, preferably elliptic curvature contour, the major axis running in the radial direction and the minor axis being oriented parallel to the surface of the platform.
[0005] Furthermore, it is known from U.S. Pat. No. 6,237,558 B1 to provide specific locations of the crankcase of an internal combustion engine which are critical in terms of mechanical stresses with a curvature which follows a conic section (ellipse, hyperbola, parabola).
[0006] Not only the moving blades of turbines are exposed to high mechanical loads on account of the high rotational speeds, but also the rotor shaft itself. Critical locations are in this case, above all, the grooves in the rotor shaft which are arranged on the outer circumference and which, running in the axial direction or running around annularly, may be provided, for example, for receiving the blade roots of the moving blades or as part of a shaft seal. Where such grooves are concerned, the stresses arising in the groove depend critically on the cross-sectional contour. GB-A-2 265 671 or U.S. Pat. No. 4,818,182 discloses grooves running around annularly for the fastening of moving blades, said grooves having a rounded cross-sectional contour. No information is given on the nature of the curvature profile or on the influence of the contour on the stresses in the groove.
[0007] In the rotor parts subjected to particularly high thermal load, the turbine part, additional cooling measures are often provided, in order, at the high hot-gas temperatures, to achieve a sufficient service life of the material used. Cooling measures of this kind include cooling air ducts which run approximately in the radial direction from the inside outward through the rotor shaft and lead cooling air from an inner cooling air supply to the surface of the rotor shaft. Cooling air ducts of this type, however, constitute mechanical weakenings of the rotor shaft which may have an adverse effect in the case of the high temperatures and centrifugal forces and under the changing loads.
SUMMARY OF THE INVENTION
[0008] An object of the present invention is to provide such a rotor shaft equipped with radial cooling air ducts, in such a way that the weakenings of the rotor shaft due to the cooling air ducts are minimized or at least markedly reduced.
[0009] The present invention provides a rotor shaft, in particular for a gas turbine, in which cooling air ducts are provided, which run from the inside outward essentially in the radial direction and are connected to a cooling air supply present inside the rotor shaft, characterized in that the cooling air ducts have an elliptic cross section for the reduction of mechanical stresses.
[0010] A refinement of the invention is characterized in that the cooling air ducts are arranged so as to be distributed over the circumference of the rotor shaft, and in that the elliptic cross section of the cooling air ducts is in each case oriented such that the major axis is oriented in the circumferential direction and the minor axis is oriented in the axial direction.
[0011] Preferably, the rotor shaft has a compressor part and a turbine part, and the cooling air ducts are arranged in the turbine part.
[0012] Another refinement of the invention is distinguished in that the turbine part has a plurality of rotor disks arranged one behind the other in the axial direction, for the fastening of moving blades, and in that the cooling air ducts are arranged between adjacent rotor disks.
[0013] In particular, it is conceivable that cavities are formed, concentrically with respect to the rotor axis, inside the rotor shaft, and that the cooling air ducts emanate from at least one of the cavities and are connected to the cooling air supply via this cavity. It is then especially beneficial that the cavities have, at least partially, an elliptic cross-sectional contour on the outer circumference for the reduction of mechanical stresses, preferably the cross-sectional contour on the outer circumference being composed of two elliptic segments of two ellipses which are tilted with respect to one another and the major axes of which are oriented approximately in the radial direction.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] The invention will be explained in more detail below by means of exemplary embodiments in conjunction with the drawings, in which:
[0015] FIG. 1 shows a perspective side view of a rotor shaft (without blading) with cooling air ducts in the turbine part according to an exemplary embodiment of the present invention;
[0016] FIG. 2 shows a longitudinal section through the rotor shaft from FIG. 1 in the region of the turbine part;
[0017] FIG. 3 shows a view of the turbine part of a rotor shaft, said turbine part being equipped with conventional cooling air ducts;
[0018] FIG. 4 shows an illustration, comparable to FIG. 3 , of a rotor shaft according to an exemplary embodiment of the invention; and
[0019] FIG. 5 shows, in longitudinal section, a rotor shaft with inner cavities which, according to another exemplary embodiment of the invention, are provided on the outer circumference with a partially elliptic cross-sectional contour.
DETAILED DESCRIPTION
[0020] FIG. 1 reproduces a perspective side view of a rotor shaft 10 (without blading) of a gas turbine. The rotor shaft 10 , rotationally symmetric with respect to the rotor axis ( 17 in FIG. 2 ), is subdivided into a compressor part 11 and a turbine part 12 . Between the two parts 11 and 12 , inside the gas turbine, the combustion chamber is arranged, into which the air compressed in the compressor part 11 is introduced and out of which the hot gas flows through the turbine part 12 . The turbine part 12 has, arranged one behind the other in the axial direction, a plurality of rotor disks 13 , in which, according to FIG. 3, 4 , axially oriented reception slots 21 for the reception of corresponding moving blades are formed so as to be distributed over the circumference. The blade roots are held in the reception slots 21 in the customary way by positive connection by means of a pinetree-like cross-sectional contour. According to FIG. 5 , in the compressor part 1 1 , circumferential grooves 18 running around are provided, in which the blading of the compressor part is fastened.
[0021] In the turbine part 12 subjected to high thermal load, a multiplicity of cooling air ducts 14 are provided, distributed over the circumference, between adjacent rotor disks, which cooling air ducts emanate approximately radially outward from a cavity 15 formed inside the rotor shaft 10 and issue into the outside space on the surface of the rotor shaft 10 ( FIG. 2 ). The cavity 15 is connected to a central cooling air supply 16 running in the axial direction. Whereas, in earlier designs ( FIG. 3 ), the cooling air ducts ( 14 ′) had a circular cross section, in the novel configuration of FIG. 4 the cooling air ducts 14 have an elliptic cross section for reasons of mechanical stability. The elliptic cross section of the cooling air ducts 14 may be predetermined even during the casting of the rotor shaft. It is also conceivable, however, to introduce such a cross section into the rotor shaft 10 by means of special machining methods, such as erosion.
[0022] As can be seen clearly in FIG. 4 , the ellipses of the duct cross section of the cooling air ducts 14 are oriented such that the major axes are oriented in the circumferential direction, while the minor axes lie parallel to the rotor axis 17 . A maximum reduction of the mechanical stresses is thereby achieved. It goes without saying that the advantages of an elliptic cross section are not restricted to cooling air ducts in the rotor shaft itself, but also apply to cooling air ducts which are arranged on other parts of the rotor, such as moving blades or the like.
[0023] The cavity 15 formed concentrically with respect to the rotor axis 17 is likewise optimized in its cross-sectional profile in terms of the mechanical stresses which arise. The optimization of the cross-sectional profile takes place in the way illustrated in FIG. 5 in further cavities 19 , 20 in the compressor part 11 , in such a way that the edge contour on the outer circumference of the cavity 15 , 19 , 20 is at least partially of elliptic design. In particular, as is illustrated for the cavity 20 in FIG. 5 , the cross-sectional contour on the outer circumference is composed of two elliptic segments of two ellipses E 1 , E 2 (depicted by dashes in FIG. 5 ) which are tilted with respect to one another and the major axes of which are oriented approximately in the radial direction. Such a shaping of the cavities present inside the rotor shaft 10 is not only advantageous in connection with the cooling air ducts 14 in the turbine part, but may also be used in other cavities 19 , 20 which are located, for example, in the compressor part 11 of the rotor shaft 10 .
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A rotor shaft, particularly for a gas turbine, includes a cooling air supply disposed inside the rotor shaft and a plurality of cooling air ducts connected to the cooling air supply and extending essentially radially outward toward an outside of the shaft, wherein each of the cooling air ducts has an elliptic cross section.
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RELATED APPLICATIONS
[0001] Applicant claims priority to Provisional Application No. 60/355,443, filed Feb. 7, 2002 in the United States Patent and Trademark Office.
FIELD OF THE INVENTION
[0002] This application relates generally to the field of electrical fixtures, and more specifically to backlighting for electrical cover plates and embodiments of same using techniques such as electroluminescence.
BACKGROUND OF THE INVENTION
[0003] In both homes and commercial establishments, cover plates are conventionally attached to the walls or other surfaces to cover the electrical connections of switches and power outlets. Securing of the cover plate is well known in the art. Typically, the cover plate is secured to the receiving surface by two screws. In an example of a light switch, as is well known, a light is typically turned on and off by flipping the light switch in the appropriate on or off position. It is common for several switches to be located in one general region, such as a door. In order to visually identify which light is turned on or off by a certain light switch, a stick-on label such as a “Dymo” label may need to be affixed to the cover plate identifying the particular light controlled by that light switch. Further, if a light is not working when the controlling light switch is in the on position, a problem is presented because a person entering a darkened space cannot visually identify whether the problem is the light bulb or the circuit connected to the light switch. The light bulb must be changed to determine if the problem is the light bulb. If the light still does not work after changing the light bulb, the breaker must be checked to determine whether electricity is being supplied to the light switch. If the breaker has not interrupted the flow of electricity to the light switch, one may not be able to determine whether the source of the problem is the light switch or the light without further inquiry.
[0004] With a power outlet, typically a power cord of an electrical device is plugged into one of the outlets of the power outlet through openings in the wall plate. Through this connection, electricity is supplied to the electrical device. If the electrical device is not operating when turned on, a problem is presented because one cannot visually identify whether the electrical device is malfunctioning or the electrical circuit at the power outlet is not providing electricity. Typically, one tests the power outlet or the electrical device to determine the source of the problem. In addition, a person may not be able to visually identify at the power outlet which electrical device is plugged into a particular outlet. Typically, one follows the power cord to the particular electrical device. The person may also affix a label to the wall plate identifying the particular electrical device.
SUMMARY OF THE INVENTION
[0005] A backlit cover plate for use with an electrical supply addresses these and other needs in the art. The backlit cover plate comprises a plate, the plate including a window therein, and backlighting powered by the electrical supply, the backlighting disposed to be mounted on the plate so as to shine through the window. The backlit cover plate may optionally further comprise a switch on the electrical supply, the switch having an operating mechanism to alternatively connect or interrupt the electrical supply, the plate further comprising an opening, the operating mechanism of the switch receivable in the opening, the backlighting connected to the power supply so as to be energized when the switch interrupts the power supply. In addition, the backlit cover plate may optionally further comprise a label, the label including a translucent background and an opaque foreground comprising data to be communicated, the label disposed to be mounted so that the backlighting shines through the window and the label. It will be seen that a technical advantage of the invention includes backlighting a portion of a cover plate, addressing some of the problems encountered by conventional cover plates. For instance, embodiments of the invention allow visual monitoring of an electrical circuit at a light switch or power outlet.
[0006] Further technical advantages include visual identification of light switches and power outlets, which, especially in conjunction with a backlit label, assists an individual in not turning on the wrong light or plugging an appliance into the wrong power outlet by mistake. When in use with a power outlet, a further technical advantage includes freeing up all available outlets of a power outlet, without using up one outlet to illuminate the cover plate itself. The invention also allows an individual to use the proper light switch or power outlet when lighting is poor, which enhances convenience and improves safety to the individual. The invention further allows different colors to be used for the backlighting, which allows an individual to use the invention for aesthetics or color coding. Although the invention is conveniently embodied on a cover plate for use with standard household AC electrical supply, the invention is not limited. In this regard, it will be appreciated that other embodiments are possible for any type of power supply in any environment. Note also that the invention is not limited to AC embodiments. Although the invention is described herein with respect to embodiments using electroluminescence for backlighting powered by AC supply, it will be seen that the principles of the invention apply with equivalent enabling effect to embodiments relying on DC power supply. The foregoing has outlined the features and technical advantages of the present invention in order that the detailed description of the invention that follows may be better understood. Additional features and advantages of the invention will be described hereinafter which form the subject of the claims of the invention. It should be appreciated by those skilled in the art that the conception and the specific embodiment disclosed may be readily utilized as a basis for modifying or designing other structures for carrying out the same purposes of the present invention. It should also be realized by those skilled in the art that such equivalent constructions do not depart from the spirit and scope of the invention as set forth in the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] For a more complete understanding of the present invention, and the advantages thereof, reference is now made to the following descriptions taken in conjunction with the accompanying drawings, in which:
[0008] FIG. 1 illustrates an embodiment of the invention showing a switch cover plate with electroluminescent backlighting.
[0009] FIG. 2 is a plane view of the embodiment of switch cover plate invention illustrated from the reverse side of FIG. 1 .
[0010] FIG. 3 illustrates another embodiment of the invention showing an outlet cover plate with electroluminescent backlighting.
[0011] FIG. 4 is a plane view of the embodiment of the outlet cover plate of FIG. 3 from the reverse side.
DETAILED DESCRIPTION OF THE INVENTION
[0012] An embodiment of the invention is described with respect to FIG. 1 , in which a backlit cover plate 5 comprises a plate 10 , a window cover 15 , which cover engages the edges of the window 30 thereby permitting the electroluminescent (EL) backlighting 20 , more clearly shown in FIG. 2 , to emit light through the window 30 . Label 45 , which displays either text or symbols, is positioned between the EL backlighting 20 and window cover 15 is thereby contrasted and highlighted. Plate 10 has a switch opening 25 , a window 30 , and at least one plate-securing opening 35 . As shown, screws, nails or any other suitable fasteners may be used to secure the plate 10 to a surface through plate-securing openings 35 . As previously noted, window 30 is an opening in plate 10 , but may also be formed with transparent material (not shown) in lieu of window cover 15 . The contrasting text or symbols on label 45 would then be attached to the top of the backlit window 30 without departing from the spirit or intent of the invention.
[0013] In the embodiment illustrated in FIG. 1 , label 45 containing either text or symbols or both, can be mounted within window 30 . Label 45 comprises a foreground and a background. Label 45 is secured within the window 30 by glue, snap fitting, or any other suitable securing method. The background of the label 45 is advantageously comprised of any semirigid, translucent material, preferably clear plastic. The foreground comprises data to be communicated. A variety of lettered or numbered labels known in the art may be used for the data, but preferably individual letters or numbers that have adhesive backing may be used. The opaque letters or numbers in such embodiments are affixed to the background. Window cover 15 covers window 30 and label 45 . Window cover 15 is secured to plate 10 by snap fitting within the interior edges of window 30 or any other suitable securing method. Window cover 15 is also comprised of any semi-rigid, translucent material, preferably clear plastic.
[0014] FIG. 2 is an plane view of the embodiment of the invention shown on FIG. 1 from the reverse side more clearly disclosing the disposition of the EL backlighting 20 . FIG. 2 illustrates the backlit cover plate 5 having a back plate 50 . As shown, EL backlight 20 is secured to plate 10 on the backside of the window 30 . EL backlight 20 is secured to the plate 10 by snap fitting, glue, or any other suitable securing method. The materials to form EL backlight 20 are well known in the art. Examples of available electroluminescent materials which can be used for backlight 20 include Durel A3, NEC, and Indiglo. EL backlight 20 illuminates plate 10 , window 30 , and label 45 and provides at least two EL electrodes 55 through which a potential across the phosphor is provided to illuminate the EL backlight 20 , all in a manner well known in the art. A back plate (not shown) can be fashioned to enclose EL backlight 20 and secured to the back side of plate 10 , although is not required. This back plate can be secured to plate 10 by glue, snap fitting, or any other suitable securing methods. Alternatively, the electroluminescent material could be molded into the plate 10 and provide a recessed area or window to allow text or symbols to be inserted in the recess or window without departing from the scope of the disclosure contained herein. The backlighting color can be varied by an appropriate choice of phosphor materials, in a manner well known in the industry to provide a variety of colors or hues. Additionally, the backlighting may be accomplished with the use of light emitting diodes (LEDs) which are readily available in the marketplace and which are well known in the industry.
[0015] The following describes an exemplary application of the present invention as embodied and illustrated on FIGS. 1 and 2 . In operation, connectors 55 are connected to a power source at a light switch on a wall. The light switch controls a light. The power source at the light switch forms an electrical circuit with the light. Plate 10 is then secured to the wall at the light switch. Plate 10 is disposed to enable a light switch to pass through switch opening 25 . Screws are inserted through the plate securing openings 35 and are used to secure plate 10 to the light switch and the wall. Through the connectors 55 , electricity from the power source flows through the back plate electrodes and to the opposed plates sandwiching the phosphor of the backlight 20 . The light switch controls the flow of electricity to the light and EL backlight 20 . When the light switch is in the off position, EL backlight 20 is energized, while the electrical circuit to the light is interrupted. The line voltage from the electrical power source potentiates EL backlight 20 via the connectors 55 . The light switch is then visually identifiable in the dark via the EL backlighting 20 .
[0016] When the light switch is in the on position, the electrical circuit to the light is connected, and electricity flows directly to the light, which becomes illuminated. EL backlight 20 is no longer illuminated. If the light does not illuminate when the light switch is turned to the on position, the electrical circuit at the light switch may be checked by viewing backlit cover plate 5 . If EL backlight 20 illuminates when the switch is in the off position, voltage is present across EL backlight 20 and the electrical circuit from the power source is functioning properly, and one may conclude the light bulb or light is not functioning properly. The light bulb may then be replaced or the light may be serviced. If EL backlight 20 does not illuminate, no voltage has reached the EL backlight 20 and the electrical circuit at the power source is not functioning properly, which signifies, from an absence of electrical power at the appropriate outlet, that the light switch or power supply may need service.
[0017] To identify which particular light the switch controls, window cover 15 may be removed from the plate 10 , and label 45 may be mounted within the window 30 . The foreground data may be affixed to the background of label 45 in any word, number, or symbol order that identifies the particular light. Window cover 15 is then secured again to plate 10 . Label 45 can visually identify the light corresponding to the light switch at all times. When the light switch is turned to the on position, the illumination provided by the light allows a person to view the label 45 and identify the light. When the light switch is turned to the off position and no other external light is available, the illumination of EL backlight 20 illuminates label 45 and allows one to clearly view label 45 , which can be fabricated from a variety of colors or hues as previously noted.
[0018] Even though the above disclosure describes the backlit cover plate 5 in assembled form, backlit cover plate 5 is also available disassembled (not illustrated), with the following components disassembled from the backlit cover plate 5 , plate 10 , EL backlight 20 , label 45 , and window cover 15 . In addition, the disassembled components of the backlit cover plate 5 may be packaged together in a kit (not illustrated). The kit may be in any form that is packaged together and available to a consumer.
[0019] Even though the above disclosure describes incorporating EL backlight 20 into a light switch plate, the present invention is expressly not limited to such applications, and may be useful in various other applications. The present invention would prove useful in illuminating and identifying power outlets, telephone jacks, and internet jacks.
[0020] For example, FIG. 3 discloses another embodiment of the present invention for an electrical outlet plate. Plate 10 is formed from molded plastic in a manner well known to the industry and provides an opening 35 for attaching such plate to an electrical junction box mounted in a wall, all in a manner well known to the electrical trades. The outlet plate of FIG. 3 also provides a window 30 , through which text or symbols 45 may be viewed, covered with window cover 15 , all as previously described in the description of FIGS. 1 and 2 above. Plate 10 of FIG. 3 provides additional openings 26 for standard electrical receptacles.
[0021] FIG. 4 discloses the reverse of outlet cover plate 10 of FIG. 3 . FIG. 4 further discloses the EL backlight 20 connected to two conductors 65 which provided clips 66 for connection to the electrical service provided to the outlet junction box previously described. A person skilled in the electrical trades can easily substitute any number of available electrical connectors to the conductors which provide the potential to the EL backlight 20 and still remain within the scope of the disclosure made herein. Further, the conductors to the EL backlight can provide appropriate fusing to prevent shortcircuiting of EL backlight 20 . When the backligting is on, the outlet is shown to be provided with electrical service. If the backlighting is off, the electrical service to the outlet has been interrupted and one can readily determine the cause of the absence of the service at the outlet.
[0022] The present invention is further not limited to use in electrical outlets disposed in walls. The invention is further not limited to use of electroluminescence for backlighting. Other types of backlighting are known in the art, such as conventional filament lighting or light emitting diodes. It will be further appreciated that the invention may incorporate backlighting into a power plate in any technology or application calling for such functionality.
[0023] As described above in the summary sections, it will also be understood that the embodiments are possible covering structures or surfaces other than walls. Further, it will be appreciated that the invention is not limited to embodiments working off AC supply. The invention is equally enabled by embodiments working off DC supply. Any application which specifies the application of an electric field to a dielectric phosphor to release light in a switch or outlet plate for identification of the switch or outlet may be accomplished by the present disclosure.
[0024] Although the present invention and its advantages have been described in detail, it should be understood that various changes, substitutions and alterations can be made herein without departing from the spirit and scope of the invention as defined by the appended claims.
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A cover plate ( 5 ) for use with an electrical supply. In one embodiment, the backlit cover plate comprises a plate ( 5 ), the plate ( 5 ) including a window ( 15 ) therein; and backlighting, the backlighting powered by the electrical supply ( 55 ), the backlighting ( 20 ) disposed to be mounted on the plate ( 5 ) so as to shine through the window ( 15 ). Optional labels ( 45 ) may be provided through which the backlighting may shine, thereby illuminating data on the labels ( 45 ) from behind. In a disclosed embodiment, the backlighting ( 20 ) comprises electroluminescent lighting.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation-in-part of U.S. application Ser. No. 09/759,980 entitled Test Probe and Connector, filed Jan. 12, 2001, the disclosure of which is incorporated by reference herein.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] N/A
BACKGROUND OF THE INVENTION
[0003] The present invention relates to probes that are used in printed circuit board test fixtures and more particularly, to a socketless, leaktight replaceable probe for use in a test fixture.
[0004] It is known to provide testing fixtures for printed circuits boards (PCBs) and the like, for testing the integrity of the electrical connectivity of the circuit boards. A conventional embodiment of a testing apparatus is shown in FIG. 1, and includes a fixed, stationary substantially horizontal probe plate 10 and an overlying vertically spaced movable top plate 12 . Top plate 12 is linked to probe plate 10 by means of a peripheral elastomeric spacer 14 which allows top plate 12 to vertically move towards probe plate 10 upon a vacuum being created inside the sealed enclosure formed by probe plate 10 , spacer 14 , top plate 12 , and an overlying pressure plate (not shown) sealingly engaging the upper face of top plate 12 . The downward movement of top plate 12 is accomplished by elastomeric spacer 14 partly collapsing under the movable top plate 12 being sucked downwards by the vacuum.
[0005] Top plate 12 holds on its upper surface a printed circuit board 18 which is securely anchored thereto by the above-mentioned pressure plate upon the vacuum being created. Circuit board 18 is spaced from top plate 12 by means of rigid spacers 20 , 22 and is aligned, relative to probe plate 10 , by means of a number of alignment rods 16 which are fixedly attached to probe plate 10 and which upwardly extend through and loosely engage respective vertically registering channels 23 provided in top plate 12 to engage alignment holes provided in circuit board 18 .
[0006] A number of tapered channels 24 extend transversely through top plate 12 , with a test probe 26 being located under and vertically registering with each channel 24 . Each test probe 26 is fixedly attached to probe plate 10 in a manner described hereinafter, and vertically extends above and below probe plate 10 . Top plate channels 24 further vertically register with electrical contact points 28 to be tested on printed circuit board 18 upon engagement with the probe tip of the test probe 26 . Thus, upon top plate 12 moving downward, the probe tip of the test probe 26 abuts the selected contact point 28 to be tested on the printed circuit board 18 . Through the instrumentality of known software, electric current is transmitted sequentially through selected probes to test the integrity of the electrical connectivity of the printed circuit board 18 .
[0007] The probes 26 of known construction are removably inserted in a sleeve (socket) 30 fixedly anchored to the probe plate 10 . Sleeve 30 in turn is connected to a computer-controlled circuit which allows electrical current to be selectively transmitted therethrough. Probe 26 includes a tube in which a plunger is vertically movable under the bias of a spring, between a lower and an upper limit position. The plunger, the tube and the sleeve are all electrically connected to each other, for allowing the electric current to be transmitted to the printed circuit board. The movable plunger is continuously biased upwardly, and is downwardly forced against the bias of the spring when the printed circuit board downwardly moves against the upper tips of the probes when the vacuum is created inside the sealed enclosure. The purpose of providing a probe which is distinct from its holding sleeve is that the probe has a limited life span, and will thus have to be changed after a certain number of uses because of wear.
[0008] Three important problems exist with the above-described conventional circuit board testing apparatus:
[0009] a) The first problem is that the stationary sleeves holding the probes prevent the use of more sturdy probes for any given probe spacing. In fact, the contact points of the probes on the printed circuit boards are closely adjacent to one another, and thus the probes need to be positioned in a closely adjacent fashion. This is becoming more and more important as the miniaturization of the printed circuit boards evolves. Thus, if the contact points of the probes on a printed circuit board are very close to one another, probes of a smaller diameter need to be used to allow the probes to be positioned closer to each other. Since the sleeves carrying the probes have a larger diameter than the probes themselves, circuit board contact points which are closer to one another require sleeves of smaller diameter, and consequently probes of even smaller diameter. Probes having a very small diameter are less sturdy and more prone to accidental breakage. b) The second problem is that the vertical alignment of the probe tips with their respective registering circuit board contact points is in practice not always achieved. Indeed, when inserting the probes inside their respective sleeves, a certain vertical angular offset may occur. The top plate channels are tapered to promote self-alignment of the probes therein; however, the probe tips may still be slightly misaligned when they protrude beyond their respective channels in the space between the top plate and the printed circuit board. The consequence of this misalignment is that the probe tips may be allowed to contact the printed circuit board in a slightly offset fashion relative to their intended respective contact points, which may result in electric current not being transmitted to the circuit board. Thus, the testing software could falsely indicate a connection error.
[0010] c) The third problem also relates to a possible misalignment between the probe tips and their corresponding intended circuit board contact points, due to the fact that the alignment rods, which are used to position the circuit board, are fixed to the probe plate. Indeed, it is possible that a misalignment of the top plate relative to the probe plate may result in the top plate through-channels being laterally offset relative to their corresponding underlying probes, since the circuit board position is determined by the alignment rods which are integrally attached to the probe plate, while the position of the through-channels depends on the position of the top plate. If the through-channels are laterally offset relative to their corresponding probes, then certain probes may be laterally deflected by the edges of their corresponding through-channels when the top plate is lowered, which may result in the tips of these deflected probes abutting against the circuit board aside from their intended position. Again, the testing software would then detect a connection error on the printed circuit board where there is none.
[0011] Reference is here also made to U.S. Pat. No. 4,885,533 assigned to the assignee of the present application which discloses a probe which, in use, is firmly engaged in an electrically conductive socket mounted tightly in a dielectric plate of a PCB testing fixture.
BRIEF SUMMARY OF THE INVENTION
[0012] In accordance with the present invention an improved probe and connector are disclosed that are adapted for use in a printed circuit board test fixture. The probe includes a conductive tubular housing or body and a conductive plunger that is contained and movable within the housing. The plunger includes a contact tip that extends out one end of the housing. The plunger and tip are urged to a normally outward position by a bias force created by a coil spring disposed within the housing. At the opposing end of the probe from the contact tip, the probe end defines a bore that is suitable sized to receive a cooperative pin located at one end of a connector.
[0013] The connector includes a tubular body that may be mounted in a through-hole within a fixture plate. The connector may be fixedly retained within the fixture plate via an annular barb or a plurality of annular beads located on the tubular body. In a preferred embodiment, the connector includes the connector pin at one end and a terminal of a desired configuration at the opposing end. The terminal may include a wire-wrap pin, a crimp type terminal or wire jack for attachment to a wire, or a spring loaded plunger for wireless conductive engagement with an electrical contact such as is located on a printed circuit board. The connector pin receiving end of the probe may contain one or more detents for retaining in the end to retain the probe on the connector once the connector pin is disposed in assembled relation with the probe bore.
[0014] Additionally, the connector includes a tapered portion between the connector pin and the connector body. The tapered portion increases in diameter from the connector pin to the connector body so that an air tight seal is created between the probe and the connector upon seating of the pin receiving end of the probe over the connector pin.
[0015] Other features, aspects and advantages of the presently disclosed probe and connector will be apparent from the Detailed Description of the Invention that follows.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
[0016] The invention will be more fully understood by reference to the following Detailed Description of the Invention in conjunction with the drawings, of which:
[0017] [0017]FIG. 1 is a schematic side elevation showing a prior art circuit board testing fixture;
[0018] [0018]FIG. 2 is a schematic elevation showing a circuit board testing fixture according to the present invention;
[0019] [0019]FIG. 3 is a cross-sectional side elevation of a sleeveless testing probe according to the present invention;
[0020] [0020]FIG. 4 is an under view of the probe of FIG. 3;
[0021] [0021]FIG. 5 is an elevation of one embodiment of connector for connecting and supporting the probe of FIGS. 3;
[0022] [0022]FIG. 6 is a sectional elevation of an alternative embodiment to the connector of FIG. 5;
[0023] [0023]FIG. 7 is an illustrative arrangement showing various probe and connector implementations;
[0024] [0024]FIG. 8 is a partial side view of the probe plunger of FIG. 3 illustrating alternative embodiments of probe tips that may be employed;
[0025] [0025]FIG. 9 is a schematic side elevation illustrating one embodiment of a connector for use with the test probe depicted in FIG. 3;
[0026] [0026]FIG. 10 is a schematic side elevation illustrating another embodiment of a connector for use with the test probe depicted in FIG. 3;
[0027] [0027]FIG. 11 is an elevation view of a further embodiment of the connector having a wire jack;
[0028] [0028]FIG. 12 is a cross-sectional view of the connector of FIG. 11 at the wire jack receptacle end;
[0029] [0029]FIG. 13 is an elevation view of another embodiment of the connector having a wire jack; and
[0030] [0030]FIG. 14 is a cross sectional view of the embodiment of FIG. 13 at the wire jack receptacle end.
DETAILED DESCRIPTION OF THE INVENTION
[0031] [0031]FIG. 2 depicts a circuit board testing fixture 40 with a probe and one embodiment of probe connector in accordance with the present invention. A testing fixture 40 includes a movable dielectric top plate 42 provided with a number of bores 44 which transversely extend through the top plate 42 . These will be detailed hereinafter. Testing fixture 40 further comprises a dielectric intermediate alignment plate 46 which is spaced from top plate 42 by a peripheral elastomeric spacer 48 of known construction. A dielectric lower probe plate 52 is located spaced under intermediate plate 46 by a rigid peripheral wall 54 . A printed circuit board 58 to be tested is installed so as to rest on the top surface of top plate 42 and is properly positioned relative to top plate 42 by means of alignment rods 60 , 62 which protrude from and are fixed to top plate 42 and which engage holes (not shown) in printed circuit board 58 . As known in the art, a pressure plate 64 is positioned spacedly over printed circuit board 58 , plate 64 being supported by a rigid peripheral wall 66 provided with an underlying peripheral elastomeric pad 70 . Downwardly projecting fingers 74 , 76 are integrally carried by an intermediate portion of pressure plate 64 .
[0032] A number of testing probes 78 (only one testing probe being shown in FIG. 2) are provided on testing fixture 40 . Referring to FIGS. 3 and 4, each testing probe 78 comprises a gold clad electrically conductive hollow tube 80 which is engaged by a vertically slidable gold-plated electrically conductive plunger 82 continuously upwardly biased by a coil spring 84 . Plunger 82 has a gold-plated probe tip 85 and is provided at its intermediate portion with an annular shoulder 86 which abuts a complementary upper annular seat 88 , adjacent the upper end of tube 80 , to prevent plunger 82 from moving beyond an upper limit position under the bias of spring 84 . Between the seat 88 and the open end 89 of the tube 80 , through which the plunger 82 extends to the tip 85 , is a reduced diameter elongate retaining and sliding bearing region 90 produced by swaging or rolling the tube 80 radially inwardly against a reduced diameter outer portion 91 of the plunger 82 connecting the annular shoulder 86 with the tip 85 . This bearing region 90 has a close clearance with the outer portion 91 to provide excellent tolerance to side loading forces and smooth long life reciprocal axial movement of the plunger 82 against the bias of the spring 84 with no edges or corners to contact, scrape and wear the plunger 82 . Additionally, the swaging or rolling of the tube 80 against the outer portion 91 of the plunger 82 produces the desired clearance between the bearing region 90 and the outer portion 91 as a result of material spring back (hysteresis) following the swaging or rolling operation.
[0033] Tube 80 also has a lower annular spring seat 92 against which rests the lower end of spring 84 . Plunger 82 preferably has an inclined lower surface 93 which is engaged by the upper end of spring 84 , to simultaneously bias plunger 82 upwardly and radially against tube 80 to ensure a reliable electrical connection between plunger 82 and tube 80 . The lower end of tube 80 comprises an axial bore 94 for sealed resilient connection between tube 80 and a connector 96 (see FIG. 5) providing good electric transmissibility and probe support.
[0034] [0034]FIG. 2 show that probe 78 is carried by a connector 96 fixedly anchored in probe plate 52 , and more particularly that connector 96 engages bore 94 , as will be detailed hereinafter. Moreover, probe 78 , and more particularly tube 80 , extends through intermediate plate 46 in a registering guiding channel 81 provided therein.
[0035] A sealed enclosure is formed between lower probe plate 52 and pressure plate 64 , with channels 81 and 44 providing for fluid communication the areas between plates 52 , 46 , 42 and 64 . A vacuum port (not shown) is provided in probe plate 52 , to allow a vacuum to be created in the sealed enclosure.
[0036] In use, a vacuum is created in the sealed enclosure, wherein the elastomeric peripheral spacer 48 will gradually collapse to allow top plate 42 to downwardly move towards intermediate plate 46 for the probe tips 85 to come into contact with selected registering contact points on printed circuit board 58 ; and wherein the peripheral elastomeric pad 70 will also collapse to allow pressure plate 64 to move towards top plate 42 whereby the fingers 74 , 76 of pressure plate 64 will abut against and firmly support printed circuit board 58 against the upward bias of the numerous probe plungers 82 .
[0037] The guiding channels 81 provided in intermediate plate 46 will correctly vertically align probes 78 so that they register with the contact points on circuit board 58 which they are intended to contact. Moreover, the top plate throughbores 44 also promote proper self-alignment of probes 78 relative to the corresponding circuit board contact points. Indeed, the top plate bores 44 each have a lower portion 44 a of increased diameter, which allows the corresponding probe tip 85 to engage the bore 44 even if the probe tip is slightly misaligned; a tapered intermediate neck portion 44 b, which allows the probe tip orientation to be corrected if it is slightly misaligned; and an elongate upper portion 44 c which extends up to the printed circuit board 58 and which has a diameter to guide the corresponding probe tip 85 to the circuit board contact point.
[0038] Additionally, the fact that circuit board 58 rests directly on top plate 42 and is positioned thereon by means of the alignment rods 60 , 62 which are fixedly attached to the top plate 42 , ensures that the contact points of circuit board 58 which are intended to come into contact with respective probe tips 85 , will be properly aligned relative to the top plate bores 44 . Thus, in view of these improvements over prior art devices, misalignment of the probe tips 85 relative to their corresponding intended circuit board contact points is very unlikely, if not almost completely obviated.
[0039] Also, according to the invention, the testing probe 78 is not installed in a socket or sleeve, as with prior art devices. Indeed, probe 78 engages a connector 96 directly, through the instrumentality of its axial bore 94 . The intermediate plate guiding channel 81 allows vertical alignment of the probe to be achieved even though no elongate supporting socket or sleeve is present.
[0040] The axial bore 94 is an elongate cylindrical bore defined by a cylindrical tubular extension 98 of the tube 80 opposite the elongate bearing 90 . The tubular extension 98 extends from an annular shoulder forming the spring seat 92 and is coaxial with the longitudinal axis 99 of the tube 80 , spring 84 and plunger 82 . The tubular extension 98 defines a circular connector pin receiving opening 100 which is itself defined by a smooth circular inner edge 101 .
[0041] The tubular extension 98 , as with the bearing region 90 , is integral with the remainder of the tube 80 and may be formed by rolling or swaging.
[0042] At least one detent 102 is pressed or stamped inwardly into the wall of the extension 98 intermediate the length of the extension 98 between the shoulder for the spring seat 92 and the opening 100 . Preferably there are three such detents 102 evenly spaced about the circumference of the extension and in a plane normal to the axis 99 . The detents 102 do not perforate the tubular extension 98 .
[0043] Alternatively, the one or more detents can be provided in a separate tube, rather than the extension of the main tube.
[0044] Referring now to FIG. 5, a first embodiment of connector 96 is described. The connector 96 is gold plated, electrically conductive and includes a connector pin 103 terminating in an annular curved tip, to facilitate entry into probe bore 94 (FIG. 3) through opening 100 and a parallel portion 104 to closely fit within the probe bore 94 and to engage the detent(s) 102 to resiliently and firmly, but removably, support and retain the probe 78 on the connector 96 in good electrical contact therewith.
[0045] The inner end of pin 103 remote from the curved tip terminates with an annular taper 105 sized to sealingly engage the smooth circular edge 101 of the probe extension opening 100 when the connector pin 103 is fully engaged in the bore 94 .
[0046] The connector pin 103 is connected to a wire-wrap pin 109 by way of a plate connector portion 106 sized to extend through plate 52 (FIG. 2) and to be fixedly mounted in a circular opening extending through the plate 52 . The fixed mounting is, as shown, by an interference fit aided by an annular plate engaging ridge 107 . Alternative fixed mountings could be provided by splines on the portion 106 , the use of adhesives, molding-in, etc., as would be well known to those skilled in this technology.
[0047] A positive stop flange 108 is designed to control the degree of insertion of the connector 96 into the plate 52 .
[0048] Typically, by way of example, for a probe having an O.D. of 0.054 inch, the bore 94 has an I.D. of 0.0265 inch and the pin 103 has a parallel portion 104 with an O.D. of 0.025±0.0003 inch, a taper 105 increasing from the parallel portion 104 to a maximum O.D. of 0.028±0.001 inch with an included angle of 15±2 degrees. Probes of these dimensions with sleeve mounting would require probe spacing in a fixture of 0.100 inch, whereas with the present invention a center spacing for the probes without sleeves may be reduced to 0.075 inch. Similarly, center to center reductions apply also to probes of other sizes.
[0049] [0049]FIG. 6 illustrates a second embodiment of connector 97 . In this embodiment features common with those of the first embodiment of connector will not be described again. The connector 97 is a two-part assembly for connecting an insulated wire 110 to the probe 78 by way of a gold plated electrically conducting pin 111 externally similar to pin 103 but hollow to receive the electrical conductor 112 of the wire 110 which is crimped at 113 in the hollow interior of the pin 111 to provide good electrical interconnection. A polyester (nylon) sleeve 114 is attached to the pin 111 by an annular protrusion 115 on an extension of the pin 111 . The sleeve 114 covers the junction of the pin 111 and the insulation 116 of the wire 110 and provides for the fixed engagement of the connector 97 in a circular opening in plate 52 .
[0050] The connector(s) 96 , 97 are sealingly engaged with the plate 52 to provide an air tight mounting such that air and any contaminants cannot be drawn through the fixture or the body of the probe when a vacuum is applied during a testing phase.
[0051] [0051]FIG. 7 illustrates a variety of probe arrangements providing differing probe heights achieved by varying the length of protruding outer portions 91 of the plungers 82 and/or the axial length of the stop flange 108 of the connectors 96 (or 97 ). Additionally, this figure shows two connectors 117 , the ends 118 of which include wireless terminations for engaging a printed circuit test board. An exemplary connector that provides a wireless termination is illustrated in greater detail in FIG. 10 and is discussed below.
[0052] The probe 78 may be provided with a probe tip of configurations that differ from the probe tip 85 depicted in FIG. 3. Referring to FIG. 8, exemplary alternative probe tips are shown. For example, a spherical probe tip 130 , a spear probe tip 132 or a chisel probe tip 134 may be provided on the end of the plunger 91 intended to contact the printed circuit board 58 . Probe tips of other configurations may also be used.
[0053] Referring to FIG. 9 an alternative embodiment of a connector 140 having a wirewrap pin termination is depicted installed in the lower probe plate 52 . The connector 140 includes a connector pin 142 , a plate connector portion 144 and an annular tapered portion 146 between the connector pin 142 and the plate connector portion 144 . Additionally, the connector 140 includes a wire wrap pin 148 at the opposite end of the plate connector portion 144 from the connector pin 142 . Two annular beads 150 are provided on the plate connector portion 144 . The diameter of the annular beads 150 is specified to provide an interference fit with the respective hole in the lower probe plate 52 . Upon insertion of the connector 140 within the respective hole in the probe plate 52 , the annular beads 150 secure the connector within the probe plate 52 and maintain vertical alignment of the connector 140 within the probe plate 52 .
[0054] Referring to FIG. 10 a further embodiment of a connector 160 that provides a wireless termination is depicted both with a printed circuit board 162 present beneath the connector 160 and absent beneath the connector 160 . The connector 160 , in one embodiment, is fabricated in first and second connector portions 164 and 166 respectively. The first portion 164 includes a connector pin 168 for insertion within the axial bore 94 of the testing probe 78 (FIG. 3). Additionally, the first portion includes a body 170 and the connector pin 168 extends from one end of the body 170 . A tapered annulus is provided between the connector pin 168 and the body 170 to provide a seal when the connector pin 168 is disposed within the axial bore 94 as discussed hereinabove. An axial bore 174 is provided in the end of the first portion 164 opposite the connector pin 168 to receive a cooperative mating pin 176 at one end of the second portion 166 of the connector 160 . The mating pin 176 extends from one end of a tube 178 . A probe 180 having a probe tip 182 is disposed within the tube 178 and is urged outward via a coiled bias spring (not shown). As shown in the connector 160 on the left in FIG. 10, the probe is disposed in an extended position the absence of the printed circuit board. As shown in the connector 160 on the right of FIG. 10, the probe tip 182 is urged into contact with the printed circuit board 162 so as to make an electrical connection with a contact point located on the printed circuit board 162 . The first connector portion 164 includes two annular beads 184 for securing the first connector portion 164 within the lower probe plate 52 and maintaining vertical alignment of the connector 160 within the probe plate 52 .
[0055] While the connector 160 is illustrated as being fabricated in first and second portions 164 and 166 , in an alternative embodiment, a connector that permits wireless termination may be fabricated as a component that includes a tubular body portion having a connector pin at one end that is sized for insertion within the axial bore 94 of the testing probe 78 . A probe is disposed within the tubular body and includes a probe tip that extends from the end of the body opposite the connector pin. A plurality of annular beads may be provided on the body to secure the connector within the lower probe plate 52 . In this manner, the electrical connection between the mating pin 176 and the bore 174 of the first connector portion 164 depicted in FIG. 10 is eliminated.
[0056] Another embodiment of the connector is shown in FIG. 11 which provides a wire jack termination by which a wire can be pluggably mated to the connector. The connector 200 includes a connector pin 202 , a plate connector portion 204 and an annular tapered portion 206 between the connector pin 202 and the plate connector portion 204 . Two annular beads 208 are provided on the plate connector portion as in the above embodiment, the diameter of the annular beads being such to provide an interference fit with the respective hole in the probe plate 52 . As in the connector embodiment described above, alternative fixed mountings can be provided by an annular plate engaging ridge, as in FIG. 5, or by splines, adhesives, molding-in, etc., as would be well known to those skilled in the technology. Upon insertion of the connector 200 within a respective hole in the probe plate, the annular beads secure the connector within the probe plate and maintain vertical alignment of the connector within the probe plate, in the same manner as described above. At the opposite end of the connector from the connector pin 202 , there is provided a wire jack receptacle 210 which can pluggably receive a terminal pin 212 attached to a wire 214 . The wire jack receptacle is formed by a blind hole drilled or otherwise provided in the end of the connector body and typically by a pair of diametrically opposite slots 216 through the wall of the wire jack end. The slots are typically formed by saw cuts. The slots provide crimpable walls of the receptacle end to provide a non-circular and typically slightly oval cross-section for interference fit of an inserted wire jack pin. The oval cross-section is illustrated in FIG. 12. It is seen that the receptacle end is crimped along an axis which is transverse to the slots. The slots also serve to allow flow of a plating solution during nickel or other plating of the receptacle end.
[0057] [0057]FIG. 13 illustrates an alternative embodiment of the wire jack receptacle 310 of the connector 300 . The wire jack receptacle is formed by a blind hole drilled or otherwise provided in the end of the connector body and by at least one detent 302 pressed or stamped inwardly into the wall of the connector 308 between the end 312 of the connector and the inner end of the blind hole 314 . The detents 302 do not penetrate the wall of the connector 308 . Preferably, there are three such detents 302 evenly spaced about the circumference of the connector between the end of the connector 312 and the end of the blind hole 314 . At least one opening 304 is provided near the inner end of the blind hole 314 to facilitate the flow of a plating solution during nickel or other plating of the receptacle end. FIG. 14 illustrates an end view of this embodiment of the wire jack receptacle.
[0058] These embodiments having a wire jack termination permits the pluggable insertion of connecting wires into the test probe connector, and also permits smaller spacing between probes since clearance for wire wrapping of wire wrap pins is not needed. While the connector 200 (or 300 ) is illustrated as being fabricated as a single component, in an alternative embodiment, a connector having a wire jack receptacle 210 on the end opposite the connector pin 202 , may also be fabricated as an assemblage of two or more components.
[0059] An advantage of the presently described probe and connector is that no sleeves or sockets are used for holding and vertically aligning the probes. Indeed, the probes are positioned on their corresponding connectors which engage detents in the probe that resiliently and releasably hold and support the probe. This prevents the probes from being accidentally released e.g. during assembly of the fixture. Moreover, the intermediate plate allows the probes to be substantially vertically aligned. The absence of the probecarrying sockets or sleeves allow the use of probes of larger diameters, for a given required probe spacing, which will consequently be more sturdy and less likely to be accidentally damaged and which will resist wear longer than probes using sleeves or sockets.
[0060] Also, the alignment of the probes with their respective contact tips on the printed circuit board is enhanced by the presence of the top plate throughbores which extend from the probe tip up to the printed circuit board, thus preventing the probe tip from being laterally offset and to contact the printed circuit board elsewhere than on its intended contact point thereon. The intermediate plate throughbores, and the fact that the alignment rods are fixed to the top plate instead of the probe plate, also help improve alignment of the probes with their respective intended contact points on the printed circuit board.
[0061] It should be noted that the presently disclosed test probes and connectors may be fabricated of any suitable metal such as berylium copper and may be plated with gold or other suitable material to enhance conductivity and/or to reduce corrosion.
[0062] It will be appreciated by those of ordinary skill in the art that modifications to and variations of the above described socketless probe may be made without departing from the inventive concepts described herein. Accordingly, the invention should not be viewed as limited except as by the scope and spirit of the appended claims.
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An improved probe includes a conductive tubular housing or body containing a coil spring and a conductive plunger movable in the housing and having a contact tip outwardly extending from one end of the housing. The plunger and tip are urged to a normally outward position by the bias force of the spring. The opposite end of the housing has an opening for mating with a conductive pin of a connector. The connector is retained in a mounting plate of an associated fixture and has terminal ends of desired configuration. The terminal end may include a wire-wrap pin, a crimp type terminal or wire jack for attachment to a wire, or the terminal may include a spring loaded pin for engagement with an associated electrical contact. An air tight seal may be provided between the probe and the connector and the connector may be mounted in a mounting such that when vacuum is applied to an associated test fixture, air cannot be drawn through the fixture or through the body of the probe.
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RELATED INVENTIONS
[0001] The current application is the continuation of a related pending application, Ser. No. 14/685,648, filed 14 Apr. 2015, now allowed, which is the continuation of a related pending application Ser. No. 12/969,588, filed 16 Dec. 2010, now as U.S. Pat. No. 9,020,636, issued Apr. 28, 2015. We have incorporated all of the teachings of the above applications by reference. We claim the priority date of the above applications.
BACKGROUND OF THE INVENTION
[0002] The solar energy and solar farms are used to generate energy and reduce dependence on oil, or for other environmental purposes. Some of the prior art for solar farms/energy are:
US patent application or patent number 20030034062, Theodore Garry Stern et al teaches clean panel. 20050103409, Hugo Weber teaches cleaning. 20080264411, Gerald Beranek teaches protective pane. 20090223510, Theodore E. Larsen teaches optimization. 20100000570, Max Mertins et al teaches washing. 20090288691, Gene Hunt et al teaches cleaning. 20090288679, Anton Pietsch et al teaches cleaning. 20090266353, Han-Lung Lee teaches cleaning. 20090241994, Han-Lung Lee teaches cleaning. 20100043851, Mitch Levy et al teaches cleaning and solar panels. U.S. Pat. No. 7,834,303, Fatehi et al teaches concentrators, solar cells, array of small devices, tracking system, multi-element concentrator system, and coating and cleaning techniques, to protect/clean surfaces for the devices. U.S. Pat. No. 4,908,903, Mori teaches cleaning. U.S. Pat. No. 4,275,711, Dumbeck teaches solar energy. U.S. Pat. No. 4,324,947, Dumbeck teaches solar energy/system. U.S. Pat. No. 4,321,419, Hanafin teaches cleaning/solar panel. U.S. Pat. No. 5,242,827, Chaumont et al teaches cleaning.
[0019] However, none of the prior art teaches the features that we taught below, in this disclosure.
SUMMARY OF THE INVENTION
[0020] The maintenance and repairs in big farms become very difficult, expensive, and inefficient, using human technicians. Thus, here, we teach using the robots with various functions and components in various settings, for various purposes, to improve operations in big or hard-to-access farms, to automate, save money, reduce human mistakes, or scale the solutions to very large scale or areas.
[0021] The cleaning robots and inspector robots are discussed here, as examples. Other variations or types are also discussed (for methods, systems, devices, and materials), for various other functions and tasks in the farm, for installation, optimization, maintenance, and daily operation of the farm.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] The following figures are just some examples/embodiments, to explain better:
[0023] FIGS. 1 a - e show robot functioning and moving around in a solar farm, consisting of various tracks or rails in a matrix form.
[0024] FIGS. 2 a - b show different types of robots, flat bed carrier and lifter.
[0025] FIGS. 3 a - i show robot(s) functioning and moving around in a solar farm, consisting of various tracks or rails in a matrix form.
[0026] FIG. 4 shows flat bed carrier robot, with lifter or fork lift or blade.
[0027] FIGS. 5 a - f show robot(s) functioning different tasks and moving around in a solar farm, consisting of various tracks or rails in a matrix form.
[0028] FIG. 6 shows the pusher robot.
[0029] FIG. 7 shows changing directions on the tracks using different sets of wheels, engaged at different times, perpendicular to each other.
[0030] FIG. 8 shows wheels arrangements for rails or tracks or conduits, for robot movements.
[0031] FIG. 9 shows wheels arrangements for rails or tracks or conduits, for robot movements.
[0032] FIG. 10 shows wheels arrangements for rails or tracks or conduits, for robot movements.
[0033] FIG. 11 shows wheels arrangements for rails or tracks or conduits, for robot movements.
[0034] FIG. 12 shows a mechanism for robot movements, similar to a tank.
[0035] FIG. 13 shows rails or tracks or conduits or canals, for robot movements, with stations (e.g. for repair or supplies), multiple loops, and parking spaces, along the tracks.
[0036] FIG. 14 shows rails or tracks or conduits or canals, for robot movements, around or between the panels.
[0037] FIG. 15 shows a robot moving on a rail(s) near a panel, and/or working on a panel, performing tasks, assigned by HQ or central processor(s).
[0038] FIGS. 16 a - c show a robot with a brush, on a curved panel.
[0039] FIG. 17 shows a robot with a wiper tool.
[0040] FIGS. 18 a - b show a robot with a grip tool, fingers, holder, clamp, or hand.
[0041] FIGS. 19 a - c show a robot with rails on different sides of a panel, functioning with different tools or tool heads/tips or arms or tool handles.
[0042] FIGS. 20 a - b show a robot with a moveable section/sweeper, with respect to the body/trunk/main section of the robot, sweeping across the panel, to cover all areas on the panel, functioning on its tasks, with its tool(s).
[0043] FIGS. 21 a - c show a robot with a jack/lifting tool, probe, cables, rail(s), hinges, and adjusting mechanism/tool for the angle for the panel, with respect to the horizontal or vertical planes, for Sun tracking or focusing or other purposes.
[0044] FIGS. 22 a - e show a robot with spherical joints/hinges, lifter(s)/jacks, gears, angle adjusters, engaging mechanism, motor(s), and tracking mechanism.
[0045] FIG. 23 shows a mother robot with a baby robot.
[0046] FIGS. 24 a - b show a panel with calibration cell or sensors or markers or beacons, positioned randomly or in a pattern, located on top, over, below, behind, or sides (on a blank plate or surface, or on a panel full of devices or solar cells), for electrical, optical, or positional measurements, to optimize the performance or test the performance or normalize the performance of the devices, cells, panels, sub-panels, or sections of panels. One example is for the measurements and analysis during the cloudy days, in which case the performance is normalized to consider (take that into the account) the overall reduction in energy absorbed across the farm, due to cloud absorption, to have a better comparison on the performance of the panels during different days or seasons, such as using electrical/voltage/current measurements, to calculate solar cell or panel's efficiency, or find defects on panels/devices/cells more efficiently or precisely, or evaluate panels, normalized to the degree or effect of cloudiness/cloud.
[0047] FIG. 25 shows a mother robot puts a baby robot on a curved panel, for various tasks, e.g. cleaning or brushing the surface.
[0048] FIG. 26 shows flow chart/method for monitoring panels, e.g. for cleaning or repairs.
[0049] FIGS. 27 a - c show a robot with an optical device, with its details.
[0050] FIG. 28 shows a nozzle used for panels and other applications/locations.
[0051] FIG. 29 shows an array or matrix or 2-D (two-dimensional) set for a farm.
[0052] FIG. 30 shows an array or matrix or 2-D (two-dimensional) set for a farm, plus a network.
[0053] FIGS. 31 a - b show rotating tool holder.
[0054] FIG. 32 shows tool box, tools, holder/partitions/separators/compartments/shelves/holes.
[0055] FIG. 33 a shows robot accessories and attachments, for tools and other purposes.
[0056] FIGS. 33 b - c show robot components or subsystems, as a block diagram and regular model drawings.
[0057] FIG. 34 shows the farm structure and connections.
[0058] FIG. 35 shows adjusting the panel.
[0059] FIGS. 36 a - c show coarse and fine adjustments for the panel.
[0060] FIG. 37 shows adjusting with coarse and fine markers.
[0061] FIG. 38 shows adjusting with coarse and fine markers.
[0062] FIG. 39 shows dispatching the robots.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0063] In one embodiment, the robots are divided based on the types of work they perform. For example, one robot is the repairing robot (to repair the panels), another one is inspector robot (to inspect the panels), another one is carrying robot (for carrying panels or parts for the repairs or other operations), another one is the mechanics robot (for repairing other robots or the whole system, such as rails), another one is cleaning robot (for cleaning the panels), another one is the mother robot (see FIG. 23 ) (for carrying smaller robots to the panels or other locations, such as to repair depot), supervising robot (for monitoring other robots or removing/solving the problems on spot, real-time), electrical robot (for electrical measurements on the panels, such as spot checking on voltage, current, resistivity, electrical conductivity, Hall multi-probe measurement, microwave measurements, mobility of carrier measurement (holes and electrons), defect analysis, doping analysis, defect levels in the bandgap, doping and defect concentrations, surface analysis, surface states, surface analysis, surface bondings, surface cleanliness, and other electrical parameters, for different devices, cells, or panels), recording robot (for recording the measurements and other parameters or events, including logs and timings/scheduling), night robot (for performing the tasks at night, with no Sun), day robot (for performing the tasks during the day), optical robot (for optical measurements on the panels, such as spot checking on photo-luminescence (at room/ambient or low temperature), electro-luminescence, Raman Spectroscopy, X-ray, any spectroscopy, semiconductor bandgap measurement, defect analysis, crystal analysis, doping analysis, surface roughness analysis, and surface monitoring for cleanliness or debris), adjustment robot (for adjusting the position or angle of panels, or tracking the Sun for panels), or tool robot (for providing tools such as screw driver or wrench, to adjust the position or angle for panels, or to fix or tighten a loose connection or screw on a panel or subsystem). In one embodiment, one robot has one or more functions, capabilities, or equipment, as mentioned in the list above. For example, an inspector robot can also be equipped with tools, such that it can use tools for repairs, as well, once a defective panel is detected and marked.
[0064] In an embodiment, an inspector robot moves on the rails or its own wheels, to get close enough to a panel, one-by-one, with the coarse adjustment or accuracy with respect to the position of the robot, relative to the edges and boundaries of the panel under inspection. Then, the sensors or detectors on the robot detect the markers, flags, or beacons on or around the panels, to fine-adjust the position of the robot (e.g. a few cm or mm of movements, or small angle of rotation), with respect to the panel. The markers may be a symbol, a magnetic ink or object, color-marked print, tag, pattern, or an RFID (radio-frequency identification) device, which can be detected by a camera, pattern recognition module, magnetic detector, antenna, or RFID detector or module.
[0065] In one embodiment, once the robot is in correct position with respect to the panel, the robot inspects the panel with its cameras, detectors, measurement tools, and sensors, such as two-probes, multiple-probes, thermocouple, thermometer, power meter, frequency analyzer, ohm meter, voltmeter, and ammeter. For example, the inspector robot takes measurements on the electrical behavior of the solar cell, single device, or panel, to measure the current, voltage, power, resistivity, electrical conductivity, or heat conductivity (as an example), to measure the performance, efficiency, quality, and estimate remaining lifetime of the device or panel(s).
[0066] In one embodiment, this can be accomplished using the predetermined data and patterns on the normal or expected value or magnitude, or range, or acceptable standard deviation, of the normal device under a specific condition (such as time of day, or date/season, or degree of cloudiness, or outside temperature, or angle of panels, with respect to the horizontal plane). This data can be the history or prior data collected on the same or different device or panel (general or average or expected values). When comparing with the expected value(s), if the measured value(s) are very different (more than a threshold or difference or deviation, in absolute value or relatively or percentage-wise or number of standard deviations), then the measured value is classified as a suspected value.
[0067] In one embodiment, once a suspected value is found, then we repeat the same measurement(s) or do another measurement, to confirm, correlate, or verify the accuracy, percentage, or degree of confidence, of the suspected value, to further classify that value as either “passed” or “failed”. That means that the device or panel is either “accepted” or “rejected” (i.e. determining that a panel or device is “good” or “bad”).
[0068] In one embodiment, the robot can also use a camera(s) or sensor(s) for optical measurements. For example, it can take a picture of the surface of the device or panel, to see the roughness of the surface, or measure the reflectivity changes (by shining the light on the surface, and measuring the reflection using a detector or sensor nearby, on the path of reflection), to detect the debris, dirt, snow, or ice on the panel or device, when comparing to the pictures of the typical sample or calibration device or clean device or the original/new device, using a pattern recognition software or comparison of the pictures (e.g. bit-wise) or values, for the relative or absolute values of the differences (or deltas or changes or variations). Anything above a threshold or having a specific pattern(s) is considered as unacceptable debris, dirt, snow, or ice on the panel or device, as an example. The photo-luminescence and other optical measurements (mentioned above) may require a detector (for light or particle detector), plus a computer and/or frequency analyzer, as an example.
[0069] In one embodiment, the sampling of the devices or panels are done randomly, or periodically, or based on the history. For example, any area of the panel with an exceptional history of defects or large problems or low quality devices can be targeted or designated to be examined more often or continuously (as a sampling scheme), to get the potential problems (and solve them) faster (and with higher percentages).
[0070] In one embodiment, the robot may have a light source or infrared source, for better illumination and detection, on the panel, at different times of the day/night. The robot may have self-calibration module to calibrate itself, for positioning and various functions. The robot can have a calibration module to calibrate devices, panels, cells, or other instruments (in another embodiment), on the spot. That saves a lot of time and money for fixing the problem on spot (without removing the panels for repair or adjustments, from its original position in the solar farm, for example).
[0071] In one embodiment, after the determination of the defective (or non-efficient or old or dirty) panel (or device or circuit), the inspector robot moves out of the way, and a repair robot comes in, close to the defective panel. Then, the repair robot repairs the panel (for example, solder/connect/repair a metal wire or connection, or adjust an angle for the panel plane, with respect to the horizontal plane). Then, the repair robot moves out of the way, and the inspector robot comes in again, for another inspection, as a follow-up. If the results of the inspection are satisfactory, the repair is complete, and the robots will go to their next assignment in their queue or task lists.
[0072] In one embodiment, however, if the repair was not good enough or incomplete, then the inspector robot moves out and let the repair robot come in again, for further repair. This loop or cycle can be repeated N times (where N is an integer, larger than or equal to one, e.g. 3), until the N is reached or until a satisfactory result is obtained, within a margin of tolerance, by inspector robot.
[0073] In one embodiment, however, if the repair was still not good enough or incomplete, and if N is reached (as the repeated loop/procedure), then the inspector robot refers the problem to the central computer/control unit, or headquarters, which will send a carrying robot (e.g. having a fork lift or tray or box or bag or container or storage) to come and disengage the panel (e.g. unscrew the panel, with its own screw driver in its tool box, that has an exchangeable head/tip, on a common tool bar or handle, for multiple purposes/functions, for example) from the solar farm or system (or backbone structure, frames, casings, jackets, or holders). Then, the carrying robot lifts and puts the defective panel on its tray (for example).
[0074] In one embodiment, then, the supply robot (or the same carrying robot) puts a new (or clean or refurbished or restored) panel in the place of the old/defective panel, with a fork lift, clamp, vice, holder, artificial/robotic fingers, arm, lifter, crane, chain, belt, bar, cable, string, tie, suction cup, vacuum hose sucking/holding the object, magnetic pull/push using a permanent magnet (or a coil with a current going through it, acting as a magnet/with magnetic field), hooks, rings, hook-and-loop straps, fasteners, or tapes, tapes, fasteners, glues, screws, bolts, or any other attachment devices or means (located on the robot, or as its tools). Then, the supply robot screws the panel to the frame (or secures the position in any other way).
[0075] In one embodiment, then, the inspector robot comes in again, for inspection and measurements on the new panel. The flow chart/procedure/loop/steps/functions described above will repeat again, in case the new panel is defective already.
[0076] In one embodiment, all the procedures we mentioned above for the repair robot also apply to the cleaning robot and cleaning procedures. For example, the inspector robot inspects a panel, by taking pictures of the surface for debris detection, using a pattern recognition software (or comparing to the clean surface's picture stored previously, as a baseline or calibration/test sample), located at the central unit/location/HQ (headquarters), or on the robot's computer. The whole decision making or computer/processing/recognition/detection unit/software can be distributed, or can be centralized, using commands and data going back and forth.
[0077] Or, in one embodiment, the inspector robot inspects a panel, by taking electrical or optical measurements, as mentioned above, e.g. to find the low current or voltage, as an indication of the dirty surface or ice on the surface. In case of ice, another/heating robot can come and heat up the panel, using a hair-dryer style device on the arm of the robot, or use any chemical for de-icing. Alternatively, the heating wires under/close to the panel can heat up to de-ice the panel. In case of multiple measurements by different methods, the HQ combines all of the results for higher confidence on detection accuracy, to make sure a defect or dirt is detected.
[0078] In one embodiment, in case of the dirty panel, the cleaning robot comes in, near the dirty panel, and it uses the brush, water, soap, chemicals, razor blade, broom, or combinations of them, as its tools, in its tool box, being put on its exchangeable tool handle (which snaps in or screws in or clamps in, to secure the tool on the tool handle), with one or more robot arms, using one or more tools and tool handles, e.g. one tool per one arm, to clean up the surface. Then, the inspector robot inspects again. If the dirt persists, the cleaning robot cleans again for N times in this loop/repeated procedure/steps, until it gets clean, within some acceptable threshold, or range for cleanliness of panel/degree of cleanliness (e.g. expressed as percentage of cleanliness, such as above 80 percent clean, or 80 percent area clean), or N number of loops is exhausted/reached.
[0079] In one embodiment, in case that the dirty panel still persists (i.e. cannot be cleaned after N times), the harsh chemicals or harsh brushes are used, or the panel is replaced altogether, with a new panel, using a carrying robot. Then, an inspector robot inspects the panel again. This can be the same or different inspector robot, depending on the scheduling, or optimum locations of multiple robots with respect to the panel, to optimize the scheduling (e.g. to reduce travel time and cost, or avoid collision on tracks/delays/waiting time, on parking robots, waiting on queue or line, or parking spots along the tracks (similar to metro or train system, with parallel tracks on the side, for parking, or for passing incoming train on the same track), to get back on the tracks or rails again, as an active or moving robots, to do their functions, per schedule or plan or queue, from the HQ).
[0080] In one embodiment, the HQ has the flexibility in re-scheduling all the robots, in case of unexpected event, such as ice storm, to re-define or re-arrange or re-order or re-prioritize the tasks for robots, as a linear optimizer or scheduling optimizer or using any other mathematical optimizer, to save time and cost for scheduling/moving robots around the farm for different tasks. These tasks are listed on the task and priority list for the specific robot and/or for the whole farm, as one system, with multiple subsystems, such as tracks, parkings for robots (to open the tracks or rails for moving/other robots, so that they can pass and get to their destinations, on a 1-way track or limited-capacity track or rails), depot for storing robots, shop for repairing robots, and other locations for robots.
[0081] In one embodiment, the HQ can convert a repairing robot to a cleaning robot, in emergency, if needed, for example, in cases that not much repairing is needed, but a lot of cleaning is needed very fast, in a short term, such as after a dust storm covering panels with dust and sand, which requires broom and clean up with power wash. The tools are replaced on the arm of the robot, to modify or convert the robot, in the robot shop or depot, or at the stations near each track in predetermined intervals, as a faster way to convert robots without sending them all the way to the shop or depot, far away, to save time and cost. The conversion can be done by another machine/robot at the station, or by robot itself, as a self-service, modifying itself, by engaging its own arms and tools to change the tools at the end of the tool handles or change the tool box or storage altogether, to fit for the other tasks or functions.
[0082] In one embodiment, the cleaning liquid, water, recycled water, solid, liquid, or powdered soap, chemicals for cleaning or de-icing, anti-rust for joints or parts (to prevent rust or oxidation or degradation), or oil for lubrications of the joints (using a nozzle, spray, valve, or tube), to be used by a cleaning or repair robot, with corresponding pump or motor and its container or storage(s), are placed in the main body of robot, or arm of robot, or in the localized or central storages feeding the robot near the tracks, or in long pipes along the rails or tracks with supply far away, but feed through those pipes, by suction or motor, to be used by a robot, when the robot hooks/connects to the input valve and then opens the valve for the flow of the liquid, gas, fluid, water, steam, pressurized gas, compound, mixtures, sand, or powder, through the pipes, nozzles, manifolds, or valves, used by the repair or cleaning robot.
[0083] In addition, a supply robot can carry those tanks or capsules or cylinders for gas or liquid along, for the use of another nearby robot (the repair or cleaning robot). The supplies or cylinders or containers can be changed or added to, using another robot, by robot itself, e.g. at a station or depot (central supply depot/location), using a valve at a station along the track at some intervals or at the main/central depot, automatically controlled by a computer (when there is a short supply remaining, or indicated by robot or sensors), or by a human/user/operator at a station or depot.
[0084] In one embodiment, the robot washes with water and quickly dries the panel with a jet or air flow/nozzle to prevent water residue on the panels (or use spotless solution or de-ionized water or rinse-free solution). The robot may have a windshield wiper as a tool (or windshield wiper attached on a panel, for each panel). The cleaning robot sprays and wipes clean/dries very quickly, with absorbing clothing material or air pressure.
[0085] In one embodiment, the repair robot has tools for soldering (solder tip), welding (torch), and sand blasting (nozzle or pipes or valves), with another arm or fingers holding the material or objects close by for proper operation, and a container (connected through the pipes or conduits or channels or ducks, to the tip of the tool or finger or arm) holding the material for usage by the soldering, welding, or sand blasting (surface cleaning). The sandblasting harshness and strength for cleaning the surfaces are adjusted using the motor speed, grain size for sands, type of sand, nozzle opening size/diameter, pressure of gas, speed of the gas, and size of the cross section for the air/sand jet.
[0086] In one embodiment, the measuring or inspection robot uses voltages, currents, and other optical or electrical characteristics/measurements of the devices and panels, for cleanliness scale and calibration, to quantify the cleanliness, in scale of 0 to 10 (or to 100, or as percentage), as an example. That has a direct effect and relationship to the effectiveness and efficiency of the solar cells, semiconductor devices, or panels, to convert the photon or light to electricity, because the dirty or covered panels are very inefficient. Thus, beforehand, on predetermined surfaces, these surfaces are calibrated and tabulated, based on the measured current, voltage, and power generated, to map them to the cleanliness scale, for calibration, for future comparison. In addition, the data from a specific panel can be compared to its prior history, or other panels nearby or similar, to get a standard deviation and acceptable range or threshold/values, for acceptability criteria and cleanliness/efficiency of solar panels/devices.
[0087] In one embodiment, one or more cameras can be used for the inspections, for back side and front side for the panels, or different parts of the panels, or move the cameras on a rail on the robot, for better coverage of the panel in 2-D (dimensional) space, on the panel. Two or more cameras focusing on a panel can be used for depth and position detection/determination, as stereo-cameras for measuring depth and lengths, for example, finding the size of dust or particle/ice sheet on the panels.
[0088] In one embodiment, the thickness of the ice can be estimated by optical manners, as well, using the reflection or transmission of the light across or through the ice sheet, and measuring the brightness, angles and distances deviated due to the ice sheet, instead of usual air, on top of the panel, based on refraction, reflection, and transmission (optics/laws in physics), for a material with an index of refraction (n) and thickness (L), which can be calibrated beforehand, as well. The calibration/test data is expressed as a formula, table, curve, or as points in a database, expressing the relationship between L and refraction, reflection, and transmission of the light, in terms of distances and angles deviated, due to the ice sheet or layer on the panel.
[0089] In one embodiment, other devices attached to or carried by a repair or optical robot for repair and optical inspection comprises: mirror (concave or convex), lens (concave or convex), light reflector, night vision, light source(s), flash light, flood light, color light, laser, diode light, halogen light, anti-fog light, concentrator for light, video recorder, still-image digital or analog recorder/camera, pattern recognition module/software, antenna for transmission of data, or memory storage for storing the data, such as magnetic or optical disk, CD, hard drive, and memory stick.
[0090] In one embodiment, the depot is the place for storing the robots. Parking spaces are extra tracks or rail systems, parallel and close to the main tracks or rails, for the incoming or potentially colliding robots avoid each other, or two or more robots use a single lane, rail, or track, without collision. For example, the first robot pulls out from the main track and waits in the nearby parking space, as a detour or waiting/queue location, until the incoming robots in the same lane or track pass. Then, the first robot comes out from the parking space, and continues in the opposite direction, as originally intended.
[0091] In one embodiment, one or more baby robots are carried by a mother robot, to put them in a right place, e.g. for a repair task on a panel. The mother robot can push or pull or control the movements of the baby robot, by remote control, such as wired or wireless controller/antenna. The mother robot can supply electricity or power to the baby robot, such as charging the battery. Or, baby robot can get energized, such as recharging battery, through power lines on the side of the tracks and rails (by hooking up and connecting to them, directly, or through mother robot). The transformer or AC-DC conversion or battery can be placed on the baby robot, mother robot, stations along the railing system, or a combination of them.
[0092] In one embodiment, the energy and electricity can also come from the solar farm/nearby panels itself, wireless electromagnetic transmission of power, wired transmission of power, batteries, heavy flywheels storing energy mechanically, spring-powered mechanical gears (wound up), power grid, betavoltaic sources/batteries, wind generators, nuclear plants, ocean waves, tidal movement of water, or any other sources.
[0093] In one embodiment, the baby robot is autonomous and independent both in decision making or functions it performs (or both). In one embodiment, the baby robot needs the help of mother robot (or HQ), to make decisions (such as scheduling, detection, or recognition), or do the functions. For example, the mother robot carries a baby robot to a dirty panel, and puts the baby robot on top of the panel's surface. Then, for example, the baby robot uses its small brush to clean up the curvature (e.g. concave) or flat surface of the panel, by going in rows and columns, or zig-zag, to cover all the surface, or at least the dirty section of the surface for the panel (which is marked and tagged in the memory of the inspector robot beforehand, and the data transmitted to the HQ already, to be instructed/transmitted to the cleaning baby robot).
[0094] In one embodiment, the baby robot has its own motor, 3 or 4 wheels, tank-like chain moving mechanism, rotating mechanism, reverse moving mechanism (such as gearbox and gears), tool box, arms, handles for tools, tool tips (exchangeable tips, such as screw driver at different shapes and sizes, oil dispenser for lubrication the gears for the system, hammer for repair functions, or soldering tip), carrying bag for tools or pieces, vacuum bag for vacuuming and cleaning the surface, different brushes of various sizes and softness for cleaning, razor blade or ice blades for scrapping the ice or dirt off the panel, and various other tools.
[0095] In one embodiment, multiple baby robots do the cleaning faster. The collision avoidance mechanism can be central, using scheduling program by HQ, and also, to make sure they all cover the entire surface, with minimal overlap/waste. The collision avoidance mechanism can be local, based on the detecting or locating other baby robots, by baby robots themselves, or by a panel vision system nearby (cameras attached near the panel), so that they either avoid each other by stopping or changing direction/speed, or by softly hitting each other (softly bumping to each other, without any damage to the baby robots or system, with low speed and good shock-absorbent bumpers, like cars) and changing direction (going reverse) immediately, without major supervision/control from HQ or outside.
[0096] In one embodiment, when baby robot reaches to the edge of the panel, it stops and comes back/changes direction, to avoid the fall (and damage to the baby robot). This can be done by a raised edge of the panel, as a mechanical railing or barrier around the panel, or by markers/beacons (as described elsewhere in this invention) that the baby robot detects, to stop or slow down or change direction, to avoid falling off the edge of the panel.
[0097] In one embodiment, the mother robot can wait for the baby robot to finish its task, to remove it to the next needed panel. Or, the mother robot can go to other locations for other work/tasks, and especially, if it takes too long for cleaning by the baby robot, later on, the same or different mother robot is scheduled to come and pick up the cleaning baby robot, to be moved to another panel for more cleaning. The scheduling of the mother robots for pick-up or drop-off are done by HQ, in one example, to optimize the resources, reduce cost and delay/waiting, and improve efficiency of the whole system/solar farm.
[0098] The baby robot can be detected and grabbed by the mother robot using markers, color, tags, RFID, any beacons, sound source, light source at specific color, laser source, by object recognition, or by shape recognition. Alternatively, the baby robot can measure and detect its own coordinate with respect to the coordinates of the panels, and its corners, and the information is transmitted to the mother robot, via HQ, or wirelessly or by cable, such that the mother robot can grab the baby robot from any location on the panel, or alternatively, from a specific location on the panel, designated for the pickup, which baby robot can indicate its readiness, to be picked up by the mother robot, when the baby robot reaches to that pickup location on the panel.
[0099] In one embodiment, the adjustment robot adjusts the angle or slope of the plane for the frame that holds the panel, so that it tracks the Sun, as much as possible, regularly, periodically, or at some specific times/intervals, determined by HQ, to optimize the efficiency of solar cells and obtain more energy from Sun per day. The Sun tracking can be done or Sun's position detected by outside entity such as HQ or inspector robot. Alternatively, it can be done using the sensors on the panel itself, such as photodetectors, for measuring the intensity of light. Alternatively, it can be done using historical data or data from nearby (or same) panels, for comparison. Alternatively, it can be done using current and voltage measured from the panels or devices, to calculate the efficiency, and try to optimize that by trial-and-error technique (i.e. adjust the angle and measure, in a loop/repeated procedure, until it does not get any better. Then, stop at that point, which is the optimum angle for our setup, for the panel for solar cell efficiency.). Or, HQ can use prior data (and use a software) to optimize the angle/position of panel, based on how close the current and voltage get to the expected/optimum value(s).
[0100] In one embodiment, the adjustment robot adjusts the angle or slope of the plane for the frame that holds the panel, using a screw driver or wrench, on its tool handle, on its arm, using proper tool tip (exchangeable) to fit the screws and nuts, stored in a tool box or tray or bag, attached to or carried by the repair robot, and properly stored in small compartments in the toolbox for easy access and pickup by the repair robot. The size of the nuts and screws are known already from the system specification, which is stored in the HQ database/magnetic data storage, as an example. Alternatively, the small camera installed near the screw, or on the arm of the robot, can pick up the image of screw, and by the pattern recognition module, at the HQ or on robot itself, it determines the exact size and type of screw, for proper tool or tool tip, to be selected by the repair robot, from the toolbox.
[0101] In one embodiment, the pattern recognition module can be a normalizer unit that normalizes the size of the digital image. Then, the output goes to the analyzer for comparison to a database, for size determination, such as bit-by-bit comparison of the 2 images, plus considering of the factor for normalization, to get the absolute value of the size of the screw or nut, in terms of inch or cm or mm.
[0102] The following figures and corresponding descriptions are just some examples and embodiments for the teaching the many different aspects of this invention:
[0103] In one embodiment, FIG. 1 is an example of the sequence of 2 robots carrying a task together, designated as Robot 1 (lifter robot, with a fork lift, magnet, chains, bars, arm, fingers, suction cups (or hose with a pump or motor), bracket, frame, holder, spoon-shaped container, fork-shaped container, or crane (with a ring and a hook)) and Robot 2 (flat-bed carrier robot). The solar farm comprises some arrays of 2-D or matrix or columns/rows of panels, with rails or tracks (or paths or streets, for some robots having 3, 4, or more wheels, that can move around on wheels, without the rails), located in between panels, for robots to move around in 2 directions/dimensions/perpendicular paths, or 1 direction, as shown in FIG. 1 a . The rails are useful for repair robots or inspector robots to move around and do their functions/tasks, as explained above, without or with minimal human intervention or supervision.
[0104] In one embodiment, the array of mirrors or panels is rectangular-shaped. In one embodiment, the array of mirrors or panels is not rectangular-shaped. Rather, they are positioned in a curve arrangement (concentric, radially, or any arbitrary shape), e.g. focusing on one point, as is common in the concave mirror farms, all focusing on a small area on a tower, to heat up a container on the tower.
[0105] FIGS. 1 a -1 b show, for example, once a defective panel is detected and marked by an inspector robot, as explained above, Robot 1 and Robot 2 approach the panel on the rails or tracks. Then, Robot 1 lifts the panel and puts it on/inside the tray, container, box, plate, or bag of Robot 2 , as in FIGS. 1 c - d . Then, Robot 2 moves away to repair shop or depot or storage, for storing or repairing the defective panel, as in FIG. 1 e . Consequently, a new or refurbished panel, or a new or better version of the panel, will be brought by the robots (and gets installed, as explained above), as an example.
[0106] FIG. 2 a shows one carrier robot with a flat bed or tray, with (optional) hinge(s), with multiple piece arm(s), which can go up and down (e.g. through a rail, cavity, or conduit), with respect to the robot main body or trunk. FIG. 2 b shows a lifter robot, with a fork-lift structure, or a shovel-like structure, for lifting purposes, from its side view.
[0107] FIG. 3 ( FIGS. 3 a - i ) shows a sequence of (an example) of a robot removing a defective panel to the depot or repair shop. However, in this case, one robot has both a lifter and a flat bed. Thus, only one robot can do the same functions/tasks performed by the 2 robots, above, as the one shown in FIG. 1 sequence. The rotation at the corners, or between rows and columns, for change of direction, e.g. at 90 degree, for the robot, is done by short curved interconnecting rails (similar to the one shown in FIG. 13 , or those used on train or metro rail/track systems, for many years, as they are well-known in the art).
[0108] Alternatively, it can be done using different sets of wheels (e.g. 2, 4, 6, or more wheels) under the robot (e.g. fitted to rails or tracks) that can be brought up and down in the following manner: to get engaged with the tracks 90 degrees perpendicular to the current tracks (perpendicular-direction wheels brought down), and then to get disengaged from the current tracks (current wheels brought up). Then, the active wheels are working on the perpendicular direction (with respect to the original direction/tracks). Thus, the robot now moves in the perpendicular direction or tracks, as in FIG. 7 . Alternatively, only one set of the wheels can be brought up/down, and for the other direction, the wheels can be fixed or stationary, in height. In one embodiment, there is a gear to change the direction of the robot in the reverse direction, on the same track, similar to a car or train or metro system.
[0109] Alternatively, it can be done using hinges on the wheel sets (to rotate them), or using a differential system at the curves for the pair of wheels on both sides (similar to those of the cars or trains or underground metros), or using ball-bearings (for low friction rotations), or a combination of those techniques.
[0110] FIG. 4 shows a typical side view of the robot having a lifter and a flat-bed/tray, which is adjustable in terms of height, for the sequence of FIG. 3 .
[0111] FIG. 6 shows a pusher robot with a wide or narrow hand or frame or perpendicular tray or extensions or blade (similar to a bulldozer), on an arm(s), with optional hinges, for pushing/moving the panels (e.g. panels moving on wheels, on tracks), as shown in the sequence of FIG. 5 (for Robot 1 and Robot 2 ). FIGS. 5 a - d show the removal sequence for an old/defective panel. FIGS. 5 e - f show the placing or installing sequence of a new panel.
[0112] The rails and tracks and wheels are generally protected against the natural elements, such as water, sand, and ice, by having a cover on them, at least partially (such as FIG. 8 ), and having a gutter underneath, or holes, to move the water out of the railing system, as is conventional in the railing technology, e.g. for the protection of the high-voltage line/power lines for metro or train systems.
[0113] FIG. 8 shows the 2 rails coming out of the page, perpendicular to page of the figure, and the wheels rotate on those rails, causing the robot to move on those rails. It also has an optional cover for a better protection of the rail system.
[0114] FIG. 9 shows another rail system, with wheels situated horizontally. However, for better support, one can add a vertical wheel under the horizontal wheels, to hold the weight better. That vertical wheel can be on a hinge (or flexible connection), so that at the curved places, for rotation, e.g. at the corners, it can work properly, without breaking the wheels. The connection between the horizontal wheels can also be on a flexible basis, rather than a fixed rod, similar to the conventional car steering system, with differential system, for steering the vehicle, with one wheel moving much more than that of the other pair/wheel, without breaking the whole system under stress (of being asymmetric movement, between the pair of wheels). In one embodiment, there is an extra wheel for balance, to keep the robot on the track, and to prevent the fall of robot. In one embodiment, there is a gyroscope for adjusting the balance of the robot on tracks.
[0115] The power line can be fed through a cable or brush or broom or hook, on the side of the track, as shown in FIG. 9 , very similar to the conventional power supply/connections for electric trains and subways/metros/undergrounds. In addition, a spring-loaded or telescopic-arm contact or brush can be used for electrical connections, e.g. for commands, data, or electrical connectivity, for inbound and outbound directions.
[0116] FIG. 10 shows another system for rails, where a moving or pulling cable moves, and when a robot is done with its tasks and wants to move to another location or next panel, the robot can engage (attach itself to) (latch to) (or grip) the moving cable, to move to the desired location. Then, once it is getting close to the destination location, the robot disengages the moving cable, to stop at the desired location, by friction, or by applying a brake system.
[0117] FIG. 11 shows another system for rails, with one pair of vertical and one pair of horizontal wheels on each side (per track). FIG. 12 shows another system without rails (free-movement robot) that employs the moving mechanism of a conventional tank or a bulldozer. Alternatively, the robot can move on 3-4 wheels, or more, similar to the conventional car or vehicle. Alternatively, the robot can move based on hovercraft mechanism, jet, gasoline engine, electric motor, or any other system conventionally used in the prior art.
[0118] In one embodiment, the robot puts a cover on the panels during/before sand storm or ice storm, for example, for protection, such as a plastic cover or heavy duty flexible material. The cover can be built-in, on the side of each panel structure/frame. Or, the cover can be carried by a protective robot, in its bag or container or basket, located inside, on top, bottom, or on side of a robot. The cover can be Venetian-type curtain or spring-loaded curtain. The cover can be opened/closed by HQ, by panel itself, or by robot intervention/help (or all of the above), using motor, spring, lever, air pressure, magnet, electrical coil magnet, or any similar methods.
[0119] Solar farm in this invention applies to the farms with panels for solar cells. Also, it applies to the solar heating panel farms (or solar heating sheets or containers or collectors or tanks or storages), which use liquid, water, or oil, to heat up and absorbs the Sun energy, to move a turbine or heat up a water tank for use of hot water, for water usage or heat up a house or room. All the teachings in this disclosure also apply to the mirror farms, in which the panels are huge mirrors for the reflection of the Sun, to concentrate on a small space for heating up a container. It also applies to any reflector surface farms, curved or flat, or mirror or lenses, metal or glass, or concentrator farms, with any types of surface, to absorb, direct, re-direct, or concentrate the Sun light, using semiconductor or direct heat/energy from photons/light (or from phonons, as lattice vibrations, due to heat, sound, or other energy sources, caused by Sun energy). In general, it applies to any farm or array of devices and panels, or in matrix form, in 1-D, 2-D, or 3-D arrangements, in any shape, even curved and non-rectangular, or circular, or symmetric, or irregular, using the power of Sun.
[0120] In one embodiment, FIG. 13 shows another system for rails, in which a robot can go from one loop to another loop or subsystem, using a common track, e.g. to move solar panels, e.g. from the installation point to depot. It also shows a side track extension, for (or as) a parking space, to store the robots temporarily, or for multiple robots using the same track, moving in different directions, to be able to pass each other without collision. It also shows 2 stations near the tracks and near the parking space, as an example. FIG. 14 shows an arrangement of the loops, with a curved rail, which can be cascaded with many more loops, on each side.
[0121] In one embodiment, FIG. 15 shows a robot which moves on a side rail, on the side of the panel structure, which has camera(s) and light source(s) (for example for night vision and repairs at night), plus one or more arms and tool holder(s), so that multiple functions are possible simultaneously, or one at a time. The tool handle can be added to the tool holder, which has multiple tips for various tools, e.g. different screw drivers. Tool holder can also function with tools directly, without tool handle, with tools from its own toolbox, or a toolbox at or near the rail, stations along the rail, or near/on a panel, e.g. as a box or container.
[0122] In one embodiment, FIG. 16 a shows a robot on the side rail, that includes cables, wires, pipes, or conduits, for control wires, power wires, air pump, air supply, vacuum suction, water jet, air jet (e.g. for the nozzle at the tip of the tool holder), soap, chemicals, cleaner liquid, and other material supply to the tip of the tool holder, e.g. for welding or sputtering or sand-blasting. In one embodiment, tool holder has an exchangeable tip, with different tools attached to the tip, such as brush, to be changed or installed by a human user, same robot, a machine at a station, or different robot. In one embodiment, tool holder has a fixed tip, e.g. with a single handle and a single tool attached permanently.
[0123] In one embodiment, the brush may have a tilt, curvature, multiple mini-brushes at different or flexible angles, or telescopic arm/extension, or flexible/spring-loaded plate(s), to be fitted on (hugging or leaning against or touching) the surface of the curved plane, panel, mirror, or lens.
[0124] In one embodiment, to change the tool tips, the robot puts its arm or tool tip into a hole (located at a station, or depot, or on another robot, or on itself), so that a jaw or hand grabs the tool, and a wrench disengages and separates the tool from the arm. Then, the robot withdraws its arm from the hole. Then, optionally, the robot puts its arm into another hole (located at a station, or depot, or on another robot, or on itself), and a wrench attaches a tool tip (which is a tool with no handle) to the robot's arm (or attaches a tool tip to the tool handle, which is attached to an arm of a robot). Then, optionally, the jaw (or hand or gripper or holder) that holds the tool tip (if any) will let go (opens its jaw), so that the robot arm can take the new tool tip and withdraw from the second hole. In some embodiments, there is no jaw to hold the tool tip, and the tool tip simply sits in a hole or horizontal cylindrical cavity, until it is picked up by a robot arm, as described above.
[0125] In one embodiment, to change the tool tips, the robot has 2 or more arms, or alternatively, uses an arm of another robot, to grab and engage/disengage (attach/separate) the tool tips. Alternatively, the second or extra arms or hands are coming from a machine located at a depot or station or near a panel or near rails.
[0126] In one embodiment, FIG. 16 b shows a robot in action/cleaning, which is monitored in real-time or on-spot, using a camera connected to HQ, with a light illuminating the panel for inspection, analyzing the images at HQ, for pattern recognition or surface analysis, to stop the cleaning or do more, depending the quality (status) of the surface, if needed, based on some threshold or range of cleanliness, as a number, percentage, or parameter for quantization of surface status. The brush can have a sensor, e.g. on the back, such as using piezoelectric sensor, to measure pressure, for adjustment of the force behind the arm/brush, for good attachment to the surface, without too much force, as a feedback, to prevent damage to the brush or robot or panel.
[0127] In one embodiment, FIG. 16 c shows a robot in action/cleaning, up to an edge, so that it stops at that point or line or boundary, due to a beacon, flag, marker, or mechanical barrier, using pressure sensor, switches (similar to toy cars, bumping to objects, and reversing their directions), light sensors (similar to the garage door openers), or cameras (for digital images or pattern recognitions). Alternatively, it can be done using the already-known dimensions of the panel, to limit the movements of the brush or arm of the robot accordingly, with respect to angle or size of the ranges for the arm or brush movements.
[0128] In one embodiment, FIG. 17 shows a robot in action/cleaning, using a wiper tool, such as those on windshield wipers. In one embodiment, FIGS. 18 a - b show a robot in action/grabbing, using a grip tool or fingers or vice grip or hand or clamp or jaws, to (e.g.) remove or put or replace a part or component on the panel, for repair purposes.
[0129] In one embodiment, the robot is not on a track or rail. Instead, it is on 2 or more wheels (or using wheel/chain combination, belt/wheel combination, horizontal cylindrical roller, ball-roller mechanism, or bulldozer or tank moving mechanism), moving through the solar farm for different tasks, without railing. The movement of the robot is based on, e.g.: (1) a pattern (for the routes it uses, on the ground of the farm, e.g. using a GPS/global positioning system, or marker/flags around/along the routes) instructed from HQ, or (2) direct vision/camera and pattern recognition to analyze and recognize objects, targets, panels, routes, and landmarks to perform its tasks, or (3) using markers or dots or color/paints, on the floor of the farm/ground, as a guide for a camera or detector, to follow the marker, to go from point A to point B in the farm, for different panels, for different tasks, assigned or scheduled by HQ or other processors.
[0130] In one embodiment, FIG. 19 a shows a robot on 2 rails on 2 sides of the panel, going from panel to panel, with multiple cameras for various position inspections, and multiple lights/flashes/flood lights/LEDs/Halogen lamps/fluorescent lamps, at different wavelengths for various illuminations at different times of the day, and various sensors or detectors, such as for X-ray or backscattering or photomultipliers or photodetectors, to measure or detect or distinguish parts, thresholds, optical characteristics, parameters, problems, dirt, ice, or defects, for the panel or surface or devices or farm or whole system or tracks. The robot has 2 or more telescopic arms (e.g. hydraulic or pump or motor or chain-driven) to move the robot up and down with respect to the panel to do various tasks, or change the angle of the robot with respect to the plane of the panel to do various tasks, for maneuverability, e.g. for big tools.
[0131] In one embodiment, FIG. 19 b shows the robot in action. FIG. 19 c shows that the whole assembly for camera or tools can be installed on a rail on a robot, to move and scan or sweep or cover one range/area, such as a sweeper, in 3 different directions, as 3-D movements/axes, in Cartesian coordinates, or using/changing angles of rotations and radius of rotations in cylindrical or spherical coordinates, such as a telescopic structure or extension or antenna for changing radius, with a ball at the base as a hinge for changing angle in 3-D space, as is well-known in the art.
[0132] In one embodiment, FIG. 20 a shows the robot in action, with a wiper (tool tip) attached to a tool handle or holder, for cleaning purposes or de-icing the surface/30 panel. In one embodiment, FIG. 20 b shows the tool holder extended for performing the task, as needed on some parts of the surface.
[0133] In one embodiment, FIG. 21 a shows the robot in action, with the following components and features:
[0134] 2110 : Power and Signal Connector to the solar panel for measurement and calibration.
[0135] 2112 : Power and Signal Connector carried by panel arm of the robot, or the electrical probe for electrical measurements on the panels or devices or cells.
[0136] 2115 : Tilt Adjuster Wrench Driver or motor
[0137] 2120 : crank axel
[0138] 2125 : Lift or jack
[0139] 2130 , 2132 : Lift support (e.g., axial or spherical joint) coupler
[0140] 2135 : Joint (e.g., spherical), hinge, or ball-joint
[0141] The robot is located at the side of the panel, with one or more rails on the side, perpendicular to the plane of the picture, with flexible arm, connecting electrically to the panel, for (e.g. electrical) measurements and power supply/power gathering and transfer from the panels, or to the panels. The robot uses 2115 motor to crank the shaft 2120 to lift the jack or lift (e.g. screw-shaped/design), to change the angle of the panel, for tracking the Sun, cleaning, repairing, adjusting, storing/protecting during storm, or optimization of the position and angle for the panel, using feedback from the electrical measurements (or optical), as described above. Various contacts, hinges, or ball-hinges are used, e.g. at 2130 and 2135 , to make the lift of the panel possible. The lift of the panel can be done with one or more jacks/lifts, from one or more sides, as an embodiment.
[0142] In one embodiment, FIG. 21 b shows the lifting process, and 2112 engaging and connecting to 2110 , for electrical connections, as mentioned above. In one embodiment, FIG. 21 c shows the lifting, and stretching at the hinge or ball-hinge or spherical-hinge 2132 and 2130 , by moving the jack up, using 2115 and 2120 .
[0143] In one embodiment, FIG. 22 a shows a robot on rail or rails, moving around, with wrench driver, cranking axel to lift the jack, to lift the solar panel, from one or more points or directions (or lowering the panel, in the reverse direction, using the same jack). The relative angle and slope of the panel (with respect to the horizontal plane) can be changed using the relative height of one or more jacks, under the panel. The spherical joints, ball joints, or ball hinges are used to connect to the panel, to enable the one or more jacks being applied to the panel, to change the height and slope/angle of said panel, e.g. for tracking the Sun.
[0144] In one embodiment, FIG. 22 b shows a robot in which the arm is engaged with the crank axel, to lift or lower the jack, for one or more jacks. The arm is moved/rotated, to connect to the crank axel. In one embodiment, FIG. 22 c shows a robot in action, in reverse direction, to lower/bring down the panel or one side of the panel, changing the slope/angle of the plane of the panel.
[0145] In one embodiment, FIG. 22 d shows a case in which one side rotates faster for crank axel, lifting faster for that side, by engaging the gears inside the chain, bar, belt, or jack, to tilt the panel toward one direction or the other. In one embodiment, FIG. 22 e shows the disengagement of the arm(s) from the crank axel(s), to leave the panel in the same position and angle/slope.
[0146] In one embodiment, FIG. 24 a or 24 b shows calibrations cells or sensors, for calibration or analyzing or testing the panel, located in patterns, in order, or randomly, to find the ice or dirt or problems or defects on the panel. For example, if the day is cloudy, one can get that information, about loss of energy/reduction in efficiency, using the calibrated/calibration cells or devices on various panels in the whole farm/system, as a pattern observed across the board. The calibration devices may be among other regular devices. Or, alternatively, they may be isolated/located on separate panels/panel.
[0147] In one embodiment, supplies (e.g. water, chemicals for de-icing, soap, or electricity, e.g. using battery or outlet, from grid or from solar farm itself) can be held by the robot itself, or by another/carrying robot or supply robot, or at a station near tracks at some intervals (inside containers or cylinders or tanks or storages), or using a hose, outlet, valve, or switch at a station with supply on pipes or conduits along the track at intervals (or at specific distances), coming from a “central location” at the farm, with huge supply or containers, distributed/used along the tracks to different panels or robots for various tasks, such as repair, soldering, welding, cleaning, or de-icing.
[0148] In one embodiment, the same concept (mentioned above, for supplies) also applies to the deposits. For example, for deposits such as collecting garbage or dirt, a cleaning robot empties its vacuum cleaner bag (periodically or when it is full) at a (local) station along the tracks (depositing locally), for future pickups, by a garbage robot, to carry all of the collected garbage and dirt, to a “central place” at the farm, e.g. for disposal out of the farm area at a later time. Or, the station is connected to the central place via a vacuum hose(s), so that a motor can suck the dirt and move that to the central place, through the vacuum hose(s).
[0149] In one embodiment, the water or soap or chemicals used, e.g. for cleaning, are separated and recycled through some trays (under the panels or robots), for recycling and re-usage. The recycling unit can be centralized or localized. The recycling unit can have a small motor for carrying the material through the pipes or conduits. The recycling unit can have storages, for storing or recycling different components and materials.
[0150] In one embodiment, FIG. 25 shows a curved/concave/mirror/reflector as a panel, tilted on a base/supporting structure, with a mother robot coming to it, on a rail(s) on the side, with one or more baby robots on the mother robot, inside the pouch, pocket, purse, bag, container, or storage(s). For example, a baby robot is picked up/grabbed by the mother robot, using tool holder and arm, from the pouch, and either released or directed/moved around on the surface of the panel, to do a task or function, such as cleaning task, e.g. using a brush, soap, or air.
[0151] In one embodiment, FIG. 26 shows monitoring the panel or surface based on many methods mentioned above or at 2610 . The measurements are normalized based on the season and weather conditions and other parameters affecting the output, 2615 , e.g. voltage, current, or power from a panel or device (or solar panel efficiency or performance). That is, for example, if the weather is cloudy, the calibration devices, mentioned above, will register less current or power, indicating the there is less Sun and energy at this time or day, which means that the low power is not due to the ice or dirt, which means that the surface is still clean, and no cleaning is needed now.
[0152] In one embodiment, the temperature sensors, thermometer, or thermocouple(s) can also help to indicate the temperature outside at the panel surface, to guess/determine if there is an ice forming on the panel. The humidity and wind speed can also be measured by any method of prior art, to help to guess/determine if there is an ice forming on the panel.
[0153] In one embodiment, the result(s) is compared to a baseline ( 2620 ), theory, history, prior data, similar panels at different locations at the same time, or simulations stored or done real-time/on-spot, to find that there is an unusual data/output, to determine if that is indicating dirty surface, ice, defective panel, component, device, wiring, cable, or solder, broken glass or cover, or any other problem in cell, device, arrays, panel, system, panels, farm, connection, transmission of power, or grid, 2625 , using a threshold or criteria, 2630 . In case the result is satisfactory and acceptable, it moves to the next panel or task, or retire the subroutine, software, or robot for the moment, or for the rest of the day, 2635 .
[0154] In one embodiment, if the result (from further measurements and monitoring) is indicating that a repair, exchange, cleaning, or adjustment is needed, 2630 , then the cleaning or repair is initiated. Then, the panel is monitored again, to determine this is acceptable, so far. Otherwise, the cleaning or repair is continued or modified. For example, a harsher cleaning or brush, or different or stronger/weaker soap or method ( 2660 ), is needed (or being sufficient), to do the job/finish the cleaning procedure or routine, as shown in the loop ( 2645 , 2650 , 2655 , and 2660 ). Once the repair or cleaning or the task is finished/performed, the robot moves to the next panel, 2665 .
[0155] In one embodiment, the robot does the adjustment on the panel, such as Sun tracking, using jacks to lift one side of the panel, for optimum angle of Sun rays on the panel, for higher electrical or energy generation/conversion efficiency. In one embodiment, the robot does the protection, by pulling a cover on the panel, or using an umbrella, from/stored in its bag, over the panel, to protect against hail, frozen rain, storm, or dust.
[0156] In one embodiment, the farm consists of a main processor(s) at HQ and multiple smaller processors locally for local/simple decisions on the robot (e.g. local pattern recognition for finding defects or problems on a panel) that do not require the coordination of all system or robots together (such as scheduling, prioritizing, robot movements, movement on tracks, parking scheduling, or emergency situations, e.g. storms prevention/protection and repairs).
[0157] In one embodiment, everything is done at one place, at HQ, “central location”, for all decisions. The communications in-between HQ and robots (or stations or depot or storages or grid or switches or tracking movers (to move tracks for re-routing the robots, such as those in railroads) or parking or garages (multiple level track system on multiple floors, to store robots, similar to those used for cars)) can be done wirelessly (e.g. antennas or satellite dishes/receivers), by wire, by cable, by Internet, remotely, optically, by laser, electromagnetic waves, Morse code, sound, voice, notes, marked papers, marks on papers, computer instructions on papers or cardboards or plastic cards, magnetic cards or memory, optical memory or disk or devices or storages, or computer-readable instructions on any media.
[0158] In one embodiment, the robot can move freely on its feet (2 or more), without wheels or rails. In one embodiment, the statistics or history of the measurements and data indicates the repair needed or scheduled maintenance, as preventive maintenance. In one embodiment, the robot or farm have redundancies in operations and functions, e.g. for preventive maintenance (e.g. lubrication, cleaning, or parts exchange), or for the sake of efficiency, or less down-time during the day or noon-time. Most repairs are done at night, to have more efficiency during the day/Sun exposure/day operation. In one embodiment, the robot uses infrared camera, heat sensitive detectors, X-ray to find defects, or ultrasonic waves/detectors to find defects, e.g. cracks in material or structures or panels.
[0159] In one embodiment, the robot is self-repairing, e.g. use screw driver to tighten or replace screws or parts/components, on itself. In one embodiment, the location of robot is determined wirelessly, e.g. by (active or passive) RFID and WiFi, or by magnet, GPS, triangulations, sensors near the track(s), tags, flags, acknowledgement messages, commands to HQ, message at tracks or stations, antennas, or codes, for scheduling, collision avoidance, overlap coverage, redundancy, or area of coverage, e.g. for task assignment/management, based on the location of all robots active in the field.
[0160] In one embodiment, the robot is on one rail, two rails, or more than 2 rails. In one embodiment, the rail is on the ground, on the air, underneath, over, suspended, or on the side of the robot. In one embodiment, the HQ does the risk analysis for time-to-failure analysis, for preventive maintenance. In one embodiment, the brush, spray, jet, soap dispenser, and camera are located in series, in the order they are needed. In one embodiment, the brush, spray, jet, soap dispenser, and camera are located in parallel. In one embodiment, the brush, spray, jet, soap dispenser, and camera are moved in/out of the sight, or front, to do their functions, one at a time.
[0161] In one embodiment, the wheels on the track have independent axis or shaft for rotation. In one embodiment, the wheels on the track have multiple diameter wheels attached to each other, as a single concentric unit. Then, like trains, it can be used on tracks on the curved paths, for better rotation/support at the curves. The electrical power can be supplied through the wheels, or through the metal brush structure along the wheels and tracks, or through the small wheel rotating or touching on another track(s) that carries the voltage V (located along the tracks), similar to electrical tram's or trolley's system.
[0162] In one embodiment, for aligning the panel with respect to robot, or vice versa, or with respect to Sun (for Sun tracking), knobs, levers, or hinges can be used, with screw drivers or screws for adjustments, and cameras or sensors (e.g. electrical or magnetic or optical) for detecting the edges or positions/markers/beacons (e.g. RFID or magnetic stripe or painted stripe), on the panel or sides of the panel.
[0163] In one embodiment, for changing the defective panels, it can be used in serial procedure or parallel procedure, using multiple robots on multiple tracks from 2 sides of the panel (left and right sides). The carrying robot has multiple shelves, to store the good and bad panels, separately, on different shelves or drawers or trays. For different heights for panels on the ground, the rails are located at multiple heights, and thus, they can be used on bridges, tunnels, and overpasses (over another track), similar to a train track/rail system.
[0164] In one embodiment, the panels have holes on them, for draining water from rain to ground, or for recycling water. The robot or base support system can have a small motor to shake/move the plates slightly, to prevent the formation of ice, for de-icing purpose. The cover for ice or sand or dirt can be screen, plastic cover, metal accordion shape cover that folds and unfolds, umbrella similar to the ones people use during rain that can fold and put aside (or similar to the ones near the beach and swimming pools on the tables), roller shape curtain similar to the curtain on the windows, folding or rolling curtains (similar to the ones for house windows, operating vertically or horizontally), or Venetian Blind type curtain. The robot can have its own umbrella or cover, for its own cover/protection, if needed, e.g. in bad weather.
[0165] In one embodiment, the panels or other parts are adjusted using gears, step-motors, motors, levers, bars, screws (e.g. for engaging or disengaging the panels), latches (e.g. for engaging or disengaging the panels), screw/inclined curling/rotating surface mechanism (e.g. an Archimedean Screw or the screw-pump mechanism, which is historically used for transferring water) (e.g. to lift the panel by a jack or lift, using such a mechanism, by a gear or lever/rod or small motor), gear-boxes, clutches, engines (similar to a car), or combination of them. In one embodiment, the major problems/repairs/defects are solved in the depot, for the robot or panel (e.g. using the carrying robot, or transferring to the depot), and minor problems are fixed on spot at the panel site, to save cost and time.
[0166] In one embodiment, this invention/panels are used on other planets (or deserts in Africa, or North or South Pole, or on a ship floating on the sea, with extreme weather conditions) for generating electricity, where the stations need electricity, and where the dust/snow storms are possible. However, the robots are much cheaper and more practical than human repair person, to do the repair and cleaning in the remote/harsh/extreme places.
[0167] In one embodiment, the robot is controlled remotely, as an option, from HQ, by a computer or a human operator, who can see the whole operation and read the sensors, using cameras and sensors on the robot. In one embodiment, the robot and panels are moved on the same tracks. Alternatively, they can be moved on different tracks. In one embodiment, the robot has a siren or bell to notify others that it is approaching, similar to a train. In one embodiment, the robot has a brake, to stop, similar to a train or car.
[0168] In one embodiment, the robot goes to a station for calibration, for itself or a panel, e.g. electrical or optical measurements. In one embodiment, the robot moves by a conveyer belt or chain, with pulley or gear, hooked to it by a latch, grip, or hook, pulled on a track, by the force exerted from belt or chain. In one embodiment, the rails/cross sections look like a dove-tail and notch combination. In one embodiment, the installer robot is used to install the tracks and whole farm initially. In one embodiment, the robot does self-diagnosis, self-repair, self-assembly, and self-test.
[0169] In one embodiment, the HQ keeps track of the lifetime and defects to analyze which manufacturer or batch of panels are more defective, for future feedback to correct the problems at the panel factory, or change components periodically to prevent major shut-down. In one embodiment, the robot, panel, and HQ share knowledge, intelligence, data, and processor for decision makings or coordination with other panels and robots, as centralized, distributed, or somewhere in-between. By distributing responsibilities and functions (e.g. modularizing/re-using the system, farm, robots, components, and functions), the repairs and changes are much faster, focused, and cheaper, to maintain the farm operational.
[0170] In one embodiment, the robot has a hand or suction tube or sharp pointed bar, to pick up garbage on the track or panel. In one embodiment, the robot has a leak detector (for pipes or containers, for gas, liquid, or solid), or detector for inspecting the rails with camera or ultrasound, to inspect the defects for prevention or repairs. In one embodiment, the baby robot moves on the panel the same way as that the mechanism of the print-head for ink-jet printers, during printing on a sheet of paper.
[0171] In one embodiment, the robot has the motor and/or pump(s), rather than the panel having them (which is another embodiment (or both robot and panel having them, which is yet another embodiment, as well)), which saves the user a lot of money, due to having less number of pumps and motors (used for adjustments and repairs) for the whole farm, for future repairs or initial installation costs.
[0172] In one embodiment, the robot has a Swiss Army Knife type device for all tool tips needed. In one embodiment, the baby robot has a suction foot, using pump or motor, for a baby robot to walk (e.g. using feet similar to a human) on the panel, without falling off the panel, to prevent damage to the baby robot. In one embodiment, the HQ uses redundancies, backups, and schedule optimization, for tasking robots at different locations at a big farm, to reduce downtime and unnecessary movements of robots (for shortest or fastest route, as an example), using any optimization or scheduling module and software in the prior art/market.
[0173] In one embodiment, the robot has a hydraulic for lifting panel/adjustment of the angles for the panel, with respect to the Sun and season, for tracking Sun/optimization. In one embodiment, the robot has a siren or bell or sound box, to scare the birds away, or animals, for cleaner farm, which requires less maintenance. In one embodiment, the robot has an ultrasonic device for surface cleaning, similar to those of the dentists for cleaning the teeth, by vibration (or the vibration used in semiconductor cleaning process, to clean the substrate, using liquid chemicals and cleaners, or using de-ionized or regular or recycled or clean water).
[0174] In one embodiment, the panels or robots have gutters, recycling bins, recycling tray, and recycling bags, for water and other objects, such as used and defective screws/metals. In one embodiment, the robot shines a laser (that it has) on a target, to focus and adjust panels, for optimization, e.g. in mirror farms, focusing on a small area on a tower, or focusing on a water or liquid or fluid pipe or container. In one embodiment, one/single panel, or subpanel, or device, or row, or column, or matrix, or solar cell, or cell is inspected, and only the defective part(s) or devices or panels or subpanels are replaced/repaired.
[0175] In one embodiment, FIG. 27 a , the solar cells on a solar panel may be monitored by a robot by shining light (e.g., a white source or monochromatic), on a solar cell, and measure the output of the cell (or panel or a row of cells). The light source may be previously calibrated. Various calibration checks for the light source may be achieved, e.g., 1) by moving the robot over a calibration panel and measuring the consistency of the light source, 2) using calibration cells on the solar panel itself, and 3) using the calibration light detector on the robot, e.g., by diverting it (e.g., reflecting the light from the light source onto a calibration photo cell, or placing a photo cell at proximity of the light source to capture portion of the incident rays from the light source). A location that the visual or output level indications point to an obstruction or a residue, the affected solar cell/panel may be tested against calibrated light source to determine the effect of obstruction (e.g., by comparing to the baseline/historical values).
[0176] In one embodiment, testing and monitoring the solar cells may be done at night, early morning, or late afternoon, when there is no substantial Sun rays to capture by the panel, so the monitoring would not interfere with power production of the solar panel. The telescopic arms of the robot can change the inclined angle of the robot, as well as the height of the robot, by moving the sides of the robot up or down, e.g. to make the robot substantially parallel to the current inclination or position of the solar panel.
[0177] In one embodiment, the robot on top shines light on the panel/sensors, and measures the output (and compares against the calibration/baseline). Also, it needs to perform self-calibration, e.g., reflecting light on its own sensor and/or measuring Sun light intensity with its own photo-detector. This will help adjusting for variations in Sun light, as clouds interfere, or as other elements affecting the measured parameter/output/efficiency.
[0178] FIG. 27 a also shows a solar cell/small panel on robot itself, for power supply for the robot. It has a light source and lens assembly. The robot has telescopic arm(s) for height and angle adjustment for moving, repairs, Sun tracking, optimization, and other functions. The robot moves on multiple rails on both sides. The retractable plug is useful for electrical connections or disengagement, for electricity in/out, and/or measurements/signal/data collected (e.g. electrical/optical), through probes connected to the panel, at the side of the panel.
[0179] FIG. 27 b shows the optical setup shown in FIG. 27 a , as an example. The light source shines light on the solar panel, and using an actuated hinge, to open/close the shutter with a mirror, the robot can divert the light to a small local photocell sheet/plane/bracket/piece, in the assembly, for calibration purposes, for comparison, to normalize, and get a better result for variations, to calculate panel efficiency, or finding the defects or problems or dirt on the panels. Once the shutter is open, using a motor, step motor, or a rod from robot, the light shines onto the panel/solar cells again, through the focusing lens and transparent cover.
[0180] FIG. 27 c shows the optical setup shown in FIG. 27 a , as an example, similar to FIG. 27 b . The difference with FIG. 27 b is that the moveable shutter is replaced with a stationary semi-transparent mirror, which can reflect and transmit partially the incident light (mostly transmitted), to remove the need for the mechanical mechanism shown in FIG. 27 b for the shutter.
[0181] FIG. 28 shows another example for the use of gas (e.g., air or compressed/pressurized air or hot air, from a tank/cylinder/pipe/valve/manifold, from station, HQ, central location, robot supply tank, panel supply tank, or pipes along the tracks), to dry or clean the solar cells or solar panel, from water, rain, dust or debris. Or, one can use a streak free liquid or cleaning detergent, or multiple liquids in a sequence applied to the surface of the panel, from one or more nozzles or valves, one-by-one, one at a time, or pre-mixed, or mixed at the surface, or simultaneously at the same time, in parallel. Or, one can use a nozzle (through the nozzle), after positioning the nozzle above the solar cell/panel. The nozzle may be moved laterally or be tilted to run the water or debris off of the solar cells/panel, in a direction closer to the edge of the panel, as determined by the robot on a case by case basis, or push them in the direction of the slope of the panel, for easier pushing to the edge of the panel, to get rid of the water or debris.
[0182] In one embodiment, the nozzle may be attached to the tool holder. The gas may be supplied directly to the nozzle or through the tool holder and the robot. The gas may be switched on/off at the tool holder by, for example, a relay or at its source by a controllable valve, or via a valve in the robot. The robot or HQ can control the on/off switch/valve. The robot may carry multiple containers for detergent, water, and gas. Multiple nozzles may be used to dispense or spray various materials (e.g., liquids or gas or powder or mixture or compound or fluid or detergent or chemicals, e.g. for de-icing or cleaning). A nozzle may be used to dispense multiple materials.
[0183] For FIG. 29 , it teaches multiple small antennas (similar to LoJack system for stolen car recovery and e.g. 3-4 antennas on the police cars) or GPS (similar to GPS system for the cars or other vehicles or phones) or RFID (similar to the ones for inventory tracking in a big warehouse, such as those used by Walmart Corporation, e.g. for tags or IDs, passive or active RFID systems) on a robot, used for GPS or triangulations, interacting with satellite or local stationary antennas or markers, distributed in the farm, to find the (relative or absolute) position of the robot or panels. Multiple positioning stations are located in the farm (e.g., 2910 at corner, 2920 at side, and 2930 in the middle), for robots to determine their positions in the farm. In the farm, the solar panels (e.g., 2900 ) may be arranged in an array. A robot may determine its position via one or more of the positioning stations. The stations may wirelessly communicate with the robot, each other, and/or a network infrastructure. The stations may use a line of sight technology, such as infrared, to detect an obstruction (e.g., a robot) crossing the line of site (or using a motion detector, or a pattern recognition module). Each positioning station may compromise of two or more positioning elements that provide boundaries, and either detect or let robot detect when it is crossing the boundary, e.g., by using line of sight beams (e.g. that are crossed, similar to the automatic garage door opener safety feature). The position of the robot can be used by the robot or other robots or HQ, to find the optimum route to the next assignment, to reduce time delay and cost, using any scheduling and optimizing module available in the market.
[0184] FIG. 30 represents the structure for supply routes, such as wires, cables, pipes, or conduits, e.g. for water and soap and electricity and data and gas. It can also be for electricity in/out of the robot or panel, or measurement connections for data and calibration or status of a panel or robot, such as efficiency data, repair data inbound/outbound, analysis, scheduling, tasking commands for robots, reports by robots, acknowledgement signals by robots or stations, any wired or wireless communications transmitted (along with cables and wires or probe wires for those purposes), voltages, powers, or currents measured data, optical data, or any other measured parameters from panels/cells/devices/solar panels/subpanels/rows of devices. The HQ or main supply tank or depot 3002 is connected through the lines or conduits or pipes 3008 , 3006 , and 3004 , to supply or communicate with stations or nodes 3010 at corners of the farm (and 3020 at the boundary stations or nodes, or 3030 in-between stations or nodes along the tracks or routes), inbound/outbound, in multiple directions, for the whole farm for communication and supply and power management, for the panels management and repair, e.g. 3000 . In one example, wireless devices or antennas can also be added to the stations or nodes for communications or data or power transmission, in addition to wires and cables.
[0185] FIG. 31 a teaches rotating tool holder with axis of rotation parallel to the plane of solar panel, as an example, connected to the panel or robot or at a station along the tracks. It can also be inside the body of the robot. The holder rotates to a correct position, for a robot to pick up a needed tool, from the j-th position/hole/shelf on the holder.
[0186] FIG. 31 b teaches rotating tool holder with axis of rotation not parallel to the plane of solar panel, as an example, connected to the panel or robot or at a station along the tracks. It can also be inside the body of the robot. The holder rotates to a correct position, for a robot to pick up a needed tool, from the j-th position/hole/shelf on the holder. Alternatively, the tool can be engaged on the surface of the panel, directly, without being picked up by the robot, e.g. a screw driver tip, out of the tool holder, can engage a screw on the panel, and tighten the screw, using the tool holder as a tool handle or arm of the robot.
[0187] FIG. 32 shows a toolbox, holder, tools, and various slots to store them, connected to the panel or robot or at a station along the tracks. It can also be inside the body of the robot. The holder can move on a rail, or the robot arm can move to the right slot/slit/opening/gap, to position the arm or robot to pick up/exchange/return the intended and needed tool.
[0188] FIG. 33 a shows robot accessories and attachments/tools, which can be connected or attached to robot, or panel, or station, as a box or holder or container or hook or bag or deposit box or shelf, for example as shown in FIG. 33 c for bag, container, or toolbox. Some examples are: holders or grips to hold objects, wiper for cleaning, manifold/valves/mixer/separators/filters for gases or fluids or mixtures, spare parts for repairs, covers for protection against storm or rain or sand or dust, battery for charging or operation of devices on the robot or elsewhere, measurement or analysis tools (such as camera, sensors, probes, voltmeters, detectors, and photodetectors), or recycling tray or bag for recycling objects such as water or purifying for re-use (to conserve water, to reduce cost, located under the robot or panel, and pumped back up using a floating or regular pump or motor, for re-use for cleaning with brush or nozzle, as an example).
[0189] The probe for measurements, as one example for a tool, can be electrical, mechanical, magnetic, piezoelectric, X-ray, ultrasonic, or acoustic probe. The probes can be located under the panel or front of the panel, for transmission or backscattering or reflection signals, coming from one or more sources at top, side, or back of the panels, and resulting signals being detected on the front, side, or back, as the signal gets transmitted, refracted, reflected, or backscattered, accordingly, based on the geometry of the source(s) with respect to the panel/detectors. The position of the detectors can be self-adjusted by sensor itself, e.g. on a small rail with a small motor or wheel, or by robot moving the angle or position of the sensors, accordingly, with robot using an arm or hand, and sensor located on a rail(s) or between 2 bars or on a slide scale/track or with a screw and nut system between a narrow gap for holding that sensor, to maximize/optimize the measurements/position sensors correctly for measurements.
[0190] FIG. 33 b shows robot components, connected electrically or data-wise, wirelessly or by wire or optically, communicating or sending data/information to each other. For example, they are: memory, processor unit or microprocessor for analysis, connected to HQ for further processing, communication devices or antennas or optical for sending data in/out, controllers e.g. to adjust air pressure, ADC/DAC for analog to digital or vice versa conversions e.g. for sensors or data or commands, navigation e.g. GPS or tags or IDs to find and locate objects, robots, or panels (or find the best/fastest/shortest route to get to a destination/panel), servo-motor units for moving objects and operations, sensors for detections, and accessories for tools or measurements or operations.
[0191] FIG. 33 c shows an example of a robot with attached, or holding, a toolbox, bag, or container/tray/shelf/box/package/carton/envelop/attachment/extension.
[0192] FIG. 34 shows an example of a solar farm with components and units shown:
depot having repair facility for robots and components, with calibration units for measurements, and user/human being present, as operator, with parts and supply to be picked up by robots, and waste collected or recycled from/to robots, with communication wired or wirelessly to other locations and units or HQ (main processor for decisions). tracks and power lines across the farm, and connected to depot and stations. solar panels connected to the local grid, and also to the outside power grid through some central power management facility for monitoring and interface purposes, e.g. with DC/AC current convertors, or surge protectors for protection of the grids and panels/system/farm. HQ with an operator, with Internet or network access. monitors/PCs/computers, with operators, with servers and databases, for control station, for history, analysis, and information, also communicating with HQ, power management facility, and depot/stations/panels/robots.
[0198] FIG. 35 shows an example of method/steps of determining the angular position of the panel:
[0199] 1) Old position is in DB/database/memory.
[0200] 2) Position is now determined by the position of the panel support.
[0201] 3) Retrieve or receive data from panel (calculated by panel). For example, panel or central server gets locality and time information and Sun position, to determine its own position, after multiple measurements.
[0202] 4) Robot places its own probe on the panel. Or, a panel having such probe is integrated with it. For example, it is containing a level device for measuring horizontal plane (with liquid, similar to the ones for house constructions), in 3 dimensions. Or, one can use MEMS (small sensors, or Micro-Electro-Mechanical Systems), or inclinometer sensors.
[0203] To determine the position of the Sun, with respect to the panel, here are some examples/embodiments/methods:
[0204] 1) Analytically, based on the time of day and year, and geographical latitude, plus the position of panel.
[0205] 2) Measured via a ray-tracer aligned (or attached) to the panel.
[0206] 3) Maximizing the output of solar cell sensor or panel, by varying the panel angular position, i.e., via a negative feedback.
[0207] To adjust the coarse/fine movements of the panel, the panel is set on a frame that is set on the support and base. The coarse movement is done via adjusting the position of the supports, while the fine movement is done by adjusting the relative position of the frame and panel, as depicted in steps 3510 , 3515 , 3520 , and 3525 , as an example.
[0208] FIG. 36 a shows a panel on a frame, with leg(s) support with coarse adjustments, and moving/adjusting up/down for the legs, e.g. using a jack, lift, or screw system, e.g. using robot or motor/actuator, using hinge/joint/spherical hinge(s) for connectivity, stability, and flexibility. Then, the fine adjustments can be done between frame and panel using screw and bars or nuts, or spring loaded plates, using the lever or screw driver by the robot, to adjust small heights and angles in 3-D space, for the plane of the panel. In another embodiment, a slightly-loose cable through the frame (e.g. as a loop/closed long ellipse shape) can also be used for the adjustment of the angle for the panel, e.g. by securing one end of the cable, and pulling the other end (or the middle portion of the loop), using a motor, bar, or chain, e.g. by the robot.
[0209] In another embodiment, only one side of the panel is moved up/down, using actuator/motor, and the other side just follows, as for alignment. In another embodiment, each leg (e.g. 4-6 legs) can be moved up/down, both for coarse and fine adjustments, as an option, giving multiple degrees of freedom for better adjustments, with minimum effort/feedback/re-adjustments (faster adjustments).
[0210] FIG. 36 b shows a new system for hinge or movement support, comprising multiple hinges and connections. Connection (or connector) 1 is connected to hinge 1 , and connection 2 is connected to hinge 2 . There is a cross bar between hinges 1 and 2 . The overall system has 2 angles of freedom in 3-D space for flexibility, similar to the spherical hinges or connectors. Connectors 1 and 2 can move, with hinges 1 and 2 rotating, similar to a spherical hinge movement/support/flexibility. Thus, this new system in FIG. 36 b is very useful for most of our figures in this invention related to the movements of objects, e.g. to be used in FIG. 36 a , as a replacement for spherical hinge or connector.
[0211] FIG. 36 c shows a new system for jack or lifter, with a shaft/driver, driving through a gearbox and multiple gears, to do reverse or multiple speeds, for coarse and fine movements for the legs, for different adjustments.
[0212] FIG. 37 shows the adjustment of the position by coarse movements using “coarse-movement” markers, e.g. on the panel, 3730 and 3735 , after determining the position and path of the robot 3710 and 3720 , and moving other robots out of the way 3725 . Then, the fine adjustments/movement is done using “fine-movement” marker(s), in a loop, 3740 and 3745 , until it is satisfactory (in the logic decision loop). Then, it applies the brake or slide to final position slowly 3750 , or using a grip/holder. This logic can be used for all adjustments in this invention, including height and angles, to do coarse, semi-coarse, and fine adjustments (e.g. in N times/steps), in multiple steps/loops, so that it will adjust more efficiently. The Fuzzy Logic module can be added to this system, to stop/adjust more efficiently/faster (to avoid abrupt braking and accelerations, to reduce waste of energy/money and time).
[0213] FIG. 38 shows an example for FIG. 37 system. A robot moving on a path (e.g. to the right direction, e.g. on rail or land or hanged from a top overhead rail or floating on air cushion on a rail, as in hovercraft, or floating on a magnetic-driven rail, as in high-speed trains), with multiple (e.g. 2) sensors looking for markers, to sense coarse marker(s) and fine markers (in this order), first in the coarse vicinity region, then in the fine vicinity region(s), with one or combination of sensors, starting with coarse speed (faster) and then with fine speed (movement) (slower), going back and forth, as a logic loop, until threshold or requirement is reached/satisfied, with aligned position, with respect to the panel, for each loop separately. Instead of 2 degrees of adjustment (coarse and fine), we can have 3 or more, e.g. N (an integer), for more efficiency. However, at one point, higher N values are counterproductive, due to overhead/computational/adjustment delays, and usually N=3 or 4 may be enough, for all practical purposes.
[0214] FIG. 39 shows an example of the dispatching and scheduling for robots. The inspector robot inspects a panel or another object in the farm, to find defects and problems, 3910 , using all methods described above. Then, to fix the problems 3915 , the HQ helps the robot determine supply and inventories/locations of depots or stations holding them 3920 , which is an optimization problem, using any optimization/scheduling module in the prior art. Then, based on the locations of robots 3925 working in the field and their availabilities (e.g. if they need 5 minutes to finish the current task, and 10 minutes to get to the next task/panel, or if they need to retire themselves for repair of the robot itself at the depot, as the indication of the unavailability of the robot e.g. for the next 5 hours, or if another robot is nearby for the backup, or do the task, instead), then HQ will decide which robot goes where and do what task, based on type of robot/location, so that the total delays in the farm is minimized. Another embodiment is that the delay for an individual/single robot is optimized/minimized, which may be generally different for overall delays/expenses/optimizations for the whole farm/all robots, as a whole. That is another optimization problem, with linear optimization or other solutions in the market.
[0215] Dispatching (D) to different robots for different tasks is done by HQ, after optimization/scheduling, to command to move specific robots (R) to specific locations (L) for specific tasks (T), from current location (L 0 ), which have estimated length of time corresponding to each task, which HQ takes into account for scheduling purpose, for series of repairs by the same robot. In addition, e.g., for one/the first robot washing the panel with water and 2 nd robot cleaning and drying the panel, we need the first robot scheduled first for the panel, and after that, the second robot comes to the panel. This way, there may be a margin of error in timing/delay between these processes/steps. Thus, we should order the robots' arrivals accordingly, with enough margin of time in-between, so that they do not interfere with each other, or wait unnecessarily for another robot, or to avoid collision of robots on the same track, if there is no parking space nearby, parallel to the tracks. All these timing requirements/constraints come in to the optimization problem/equation, for dispatching 3930 , 3940 , 3935 .
[0216] For one embodiment, mathematically, for the measurements (e.g. electrical, optical, magnetic, or other parameters) (M), by sensors and detectors (S), based on parameters (voltage (V), current (C), or others), we have the functions F and G:
[0000] M 1 =F ( S 1 ,S 2 , . . . ,S N )= G ( V,C , . . . )
[0217] (with N being a positive integer bigger than 1.)
[0218] When calibrating using calibration sensors (S C ) or devices (e.g. resulting in voltage V C and current C C ) to normalize (Q) the measurements, then we will have the corresponding functions F 1 and G 1 :
[0000] Q 1 =F 1 ( S 1 ,S 2 , . . . ,S N ,S C )= G 1 ( V,C, . . . ,V C ,C C , . . . )
[0219] The defect Y is distinguished/analyzed based on normalized measurements, Q 1 , Q 2 , Q 3 , . . . , and comparing to the history data (or comparison/calibration/test data), Q H , as a function of B:
[0000] Y=B ( Q H ,Q 1 ,Q 2 ,Q 3 , . . . )
[0220] For dispatch optimization D, as a function H, we will have:
[0000] D=H ( R,L,T,L 0 ,Y , . . . )
[0221] For all robots or whole farm, the optimization shall be (D F ):
[0000] D F =Z ( D 1 ,D 2 ,D 3 , . . . ,D i ),
[0222] where i is a positive integer, and Z is the optimization function/operator, such as linear optimizer, located at the processor at the HQ or main processor or CPU.
[0223] where D 1 , D 2 , D 3 , . . . , D i refer to dispatch functions for i different robots active/working in the farm, at a given time.
[0224] Basically, we have a function (or more functions (objective function)), that we want to minimize or maximize (optimize), with all parameters/dependencies/functions/relationships/constraints mentioned above. Therefore, now, we solve for dispatching and scheduling function for the whole farm D F .
[0225] Any variations of the above teaching are also intended to be covered by this patent application.
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The solar energy and solar farms are used to generate energy and reduce dependence on oil (or for environmental purposes). The maintenance, operation, optimization, and repairs in big farms become very difficult, expensive, and inefficient, using human technicians. Thus, here, we teach using the robots with various functions and components, in various settings, for various purposes, to improve operations in big (or hard-to-access) farms, to automate, save money, reduce human mistakes, increase efficiency, or scale the solutions to very large scales or areas, e.g., for repair, operation, calibration, testing, maintenance, adjustment, cleaning, improving the efficiency, and tracking the Sun.
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CROSS-REFERENCE TO RELATED APPLICATION
This application claims priority from Provisional Application No. 61/912,524 filed Dec. 5, 2013, the contents of which are hereby incorporated by reference.
BACKGROUND OF THE INVENTION
This invention relates in general to the removal of mercury present as an impurity in hydrocarbon streams, and more particularly to the removal and the recovery of mercury from gaseous and liquid hydrocarbons.
Mercury is an undesirable impurity found in many petrochemical process streams and in much of the natural gas found throughout the world. The mercury impurity present in such streams is generally in the form of elemental mercury, but in some instances the mercury is in the form of mercury compounds, including organic mercury compounds. Mercury impurities in process streams, particularly light hydrocarbon streams, that is, where the light hydrocarbons comprise methane (C 1 ) through C 10 hydrocarbons, may cause corrosion problems in process equipment or poison sensitive downstream catalytic and mechanical processes that produce either natural gas liquids (typically C 2 -C 4 paraffins) or liquefied natural gas. The mercury can condense to the liquid state which is corrosive to the aluminum heat exchangers typically used in the cryogenic process. To remove mercury, several products have been produced such as mixed metal oxides (non-regenerative removal). Recently, with the advent of hydraulic fracturing (fracking) and horizontal drilling, the natural gas can contain small amounts of oxygen. This oxygen can have an adverse affect on some adsorbents and in particular on the mixed metal oxide adsorbents used for mercury removal. A considerable number of methods and schemes have been devised to selectively remove the mercury. The purification processes are most often based on adsorption technology where the mercury is selectively adsorbed on to the adsorbent. Some of these processes involve the use of non-regenerable adsorbents, but technology based on non-regenerable adsorbents usually results in the production of a solid adsorbent loaded with mercury and thus presents a hazardous waste disposal problem. One of the commonly used adsorbents for the removal of mercury is an activated carbon as a support for a mercury reactive material such as potassium triodide, sulfur, sulfuric acid, chlorine, silver, copper, or various salts of silver or copper. Other supports for mercury reactive materials include silicas, aluminas, silica-aluminas, and zeolitic aluminosilicates. Ion-exchange resins, particularly the strong basic anion-exchange types which have been reacted with a polysulfide, have also been reported as useful mercury adsorbents. See U.S. Pat. No. 4,591,490 (Horton) in this latter regard. The disclosures of U.S. Pat. No. 4,500,327 (Nishino) and U.S. Pat. No. 4,196,173 (de Jong et al.) are relevant to the use of activated carbon support for mercury reactive materials. U.S. Pat. No. 5,523,067 relates to processing both gas and liquid hydrocarbon streams containing mercury.
U.S. Pat. No. 5,281, 258 to Markovs discloses a process for removing mercury vapor from a natural gas stream which comprises mercury and water. The natural gas stream is passed through a first fixed bed adsorber containing a regenerable adsorbent which adsorbs mercury and water and a purified effluent is recovered. The flow of the natural gas stream to the first adsorber bed is terminated and a heated purge desorbent stream is passed through the first adsorbent bed to desorb mercury and water to produce a spent regenerant. The spent regenerant is cooled and condensed to recover liquid mercury and water. The remainder of the spent regenerant is passed to a second fixed bed adsorber containing a regenerable adsorbent with a strong affinity for adsorbing water to produce a second effluent, decreased in water. The second effluent is cooled and condensed to condense out a portion of the mercury from the second effluent. The second fixed bed adsorber is regenerated with a portion of the heated purge desorbent and is not recovered. The second fixed bed adsorber is required to remove water prior to the condensing out of the mercury to prevent hydrate formation.
U.S. Pat. No. 5,281,259 to Markovs discloses a process for the removal of mercury from a natural gas stream wherein the mercury vapor contained in the purge gas used to regenerate the adsorption beds is recovered as liquid mercury. In this scheme, a primary spent purge desorbent from a primary bed undergoing desorption is cooled and condensed to recover mercury and water and the remaining material is passed to a secondary bed containing a regenerable adsorbent for mercury to produce a second effluent stream depleted in mercury. Another secondary bed undergoing regeneration at the same time as the primary bed is purged with a portion of the purge desorbent to produce a secondary spent regenerant. The secondary spent regenerant is combined with the primary spent desorbent prior to the cooling and condensing step.
U.S. Pat. No. 5,271,760 to Markovs discloses a process for the removal of mercury from a process feedstream containing liquid mercury. The process comprises the passing of the feedstream periodically in sequence through two fixed beds containing a regenerable adsorbent selective for the adsorption of mercury. Each of the beds cyclically undergoes an adsorption step wherein the feedstream is passed through the bed to selectively adsorb mercury and to produce an effluent stream, and a purge desorption step wherein the adsorbed mercury is desorbed by passing a regeneration fluid through the bed to produce a second effluent. The improvement comprises the tandem operation of the beds so that as one bed is operating in the adsorption step, the other bed is operating in the purge desorption step and the second effluent is cooled and condensed to recover a portion of the mercury. Markovs further discloses that the remainder of the second effluent is recombined with the feedstream and passed to the bed undergoing adsorption. The above U.S. Pat. Nos. 5,281,258, 5,281,259, and U.S. Pat. No. 5,271,760 are hereby incorporated by reference.
The majority of natural gas being produced in the United States is from wells that are being hydraulically fractured. In a typical well, the fracturing liquid is about 99.5% water and sand with the remainder being common chemicals. Oxygen is also known to be introduced into the well through the use of these fracturing liquids. Currently metal oxide adsorbents are being used for mercury removal. However, oxygen can have an adverse effect on the removal of mercury. Purification processes and adsorbents are needed for the removal of mercury from hydrocarbon streams, including natural gas streams, containing oxygen.
Elemental mercury is a known contaminant in natural gas deposits. When natural gas is subjected to cryogenic processes to produce either natural gas liquids (typically C 2 -C 4 paraffins) or liquefied natural gas, the mercury can condense to the liquid state. Mercury in the liquid state is corrosive to the aluminum heat exchangers typically used in the cryogenic process. To remove mercury, several products have been produced such as mixed metal oxides (non-regenerative removal) and UOP HgSIV products (regenerable removal). Recently, with the advent of fracking and horizontal drilling, the natural gas can contain small amounts of oxygen. This oxygen can have an adverse affect on the mixed metal oxide adsorbents used for mercury removal.
Purification processes are sought for the high recovery of mercury from both gaseous and liquid hydrocarbon streams that contain oxygen.
SUMMARY OF THE INVENTION
The invention provides a process for the removal and recovery of mercury as a liquid stream from a hydrocarbon feedstream that contains oxygen.
It has been found that silver-containing zeolites for the selective removal of mercury from fluid streams containing oxygen can be achieved without a corresponding reduction in the effectiveness of the process as compared to fluid streams that do not contain oxygen. It is quite unexpected that the adsorbents that were used maintained their effectiveness in the presence of oxygen.
UOP HgSIV is a unique regenerable adsorbent which uses silver to amalgam the mercury and remove it from the gas stream. Since the silver is used in the reduced metal form, one may expect that the silver when exposed to oxygen would oxidize and become ineffective. Laboratory testing with air (21% O 2 ) proved that the silver metal is stable to air and removes mercury with the same efficiency as in a natural gas stream that does not contain small amounts of oxygen. Therefore, even if there is a small amount of oxygen present in the natural gas, the silver containing adsorbent is still effective at removing the mercury and the adsorbent can then be regenerated.
BRIEF DESCRIPTION OF THE DRAWING
The FIGURE represents a schematic block flow diagram of the process of the present invention wherein a hydrocarbon feedstream is separated into a gaseous portion and a liquid portion and both portions are separately treated for removal of mercury while adsorption zones for such treatment are regenerated with common heating and mercury recovery.
DETAILED DESCRIPTION OF THE INVENTION
Preferred adsorbents are those which comprise constituents chemically reactive with mercury or mercury compounds. Various cationic forms of several zeolite species, including both naturally occurring and synthesized compositions, have been reported by Barrer et al., J. CHEM. Soc. (1967) pp. 19-25, to exhibit appreciable capacities for mercury adsorption due to the chemisorption of metallic mercury at the cation sites. Some of these zeolitic adsorbents reversibly adsorb mercury and others exhibit less than full, but nevertheless significant, reversibility. An especially effective adsorbent for use in the present process is one of the zeolite-based compositions containing cationic or finely dispersed elemental forms of silver, gold, platinum or palladium. A particularly preferred adsorbent of this type is disclosed in U.S. Pat. No. 4,874,525 (Markovs) wherein the silver is concentrated on the outermost portions of the zeolite crystallites. This adsorbent, as well as the other zeolite-based adsorbents containing ionic or elemental gold, platinum, or palladium, is capable of selectively adsorbing and sequestering organic mercury compounds as well as elemental mercury. Zeolite A containing elemental gold is disclosed as an adsorbent for mercury in the later issued U.S. Pat. No. 4,892,567 (Yan). The specific mention of these materials is not intended to be limiting, the composition actually selected being a matter deemed most advantageous by the practitioner given the particular circumstances to which the process is applied.
The temperature and pressure conditions for the filtration and the adsorption purification steps are not critical and depend to some degree upon the particular feedstock being purified and whether the adsorption step is to be carried out in the liquid or in the vapor phase. Temperatures typically range from about 16° to 60° C. in the beds during the adsorption-purification step. If the adsorption bed is to be regenerated, the purge medium is heated to approximately 200° C. or more. Pressure conditions can range from about 140 kPa to about 17.5 Mpa (20 to 2500 psia) and are generally not critical, except of course during liquid phase operation wherein it is necessary to maintain sufficient pressure at the operating temperature to avoid vaporization of the feedstock.
DETAILED DESCRIPTION OF THE DRAWING
The following is one embodiment of the invention. Modifications within the scope of one skilled in the art may also be employed. With reference to the FIGURE, a hydrocarbon feedstream comprising C 1 to C 10 hydrocarbons, mercury, oxygen and water is passed via line 10 to a separation zone 101 wherein the hydrocarbon feedstream is separated to produce a gaseous stream 12 comprising primarily C 1 -C 3 hydrocarbons, mercury and water, and a liquid hydrocarbon stream 14 comprising primarily C 3 + hydrocarbons, mercury, and water. The gaseous stream 12 is passed to a first gas purifier bed 102 of typically two gas purifier beds ( 102 and 104 ), and a treated gas effluent stream having a reduced amount of mercury relative to the gaseous stream is withdrawn in line 16 . Gas purifier bed 102 is shown operating in the adsorption mode while gas purifier bed 104 is shown in the desorption mode. Prior to mercury breakthrough, the operation is switched by techniques well known in the gas adsorption art and the first gas purifier bed 102 is regenerated while the other gas purifier bed 104 is placed in the adsorption mode. Each of the gas purifier beds typically comprises fixed beds containing a first adsorbent zone selective for the reversible adsorption of water and a second adsorbent zone for the reversible adsorption of water and mercury from the gaseous stream 12 . Preferably, the first adsorbent zone contains a zeolite adsorbent selected from the group consisting of zeolite A, zeolite X, and the second adsorbent zone contains an adsorbent selected from the group consisting of zeolite A, zeolite X, and zeolite Y containing cationic or finely dispersed elemental forms of a metal selected from the group consisting of silver, gold, platinum, palladium, and mixtures thereof. More preferably, the first adsorbent zone contains a desiccant comprising zeolite A, or zeolite X, and a second adsorbent layer comprising zeolite A or zeolite X containing ionic or elemental silver.
The liquid hydrocarbon stream 14 is passed to a first liquid purifier bed 106 which is the first liquid purifier bed of typically at least two liquid purifier beds ( 106 and 108 ) and a treated liquid effluent having a reduced amount of mercury relative to the liquid hydrocarbon stream is withdrawn in line 18 . Each of the liquid purifier beds, like the gas purifier beds, typically comprises a fixed bed containing a first adsorbent zone containing a desiccant such as zeolite A or X, and a second adsorbent zone selective for the reversible adsorption of water and mercury such as a molecular sieve zeolite selected from the group consisting of zeolite A, zeolite X, and zeolite Y containing cationic or finely dispersed elemental forms of a metal selected from the group consisting of silver, gold, platinum, palladium, and mixtures thereof. Preferably the second adsorbent zone of the liquid purifier bed comprises a zeolite A or zeolite X containing ionic or elemental silver. Liquid purifier bed 106 is shown in the adsorption mode while liquid purifier bed 108 is shown in a desorption mode. The operation of the liquid purifier beds 106 and 108 is periodically switched between adsorption and desorption mode prior to the breakthrough of mercury into the treated liquid effluent stream 18 .
In the regeneration mode, a regenerant stream 20 typically comprising C 1 -C 2 hydrocarbons is passed via line 20 and 21 to heater 109 to provide a heated regenerant stream 22 . Preferably, the heated regenerant stream is heated to a regeneration temperature greater than about 200° C., and more preferably, the heated regenerant stream is heated to a regeneration temperature between about 200° and about 350° C. According to the present invention, the gas purifier bed 104 and the liquid purifier bed 108 are regenerated in a sequential manner using a common mercury recovery zone. The heated regenerant stream 22 is passed to gas purifier 104 in a direction countercurrent to the flow of gas during the adsorption mode to desorb mercury and water and to produce a spent regenerant stream 32 comprising mercury and water. The spent regenerant stream 32 is passed via lines 32 , 34 , and 38 to a cooler/separator comprising cooler 110 and separator 116 , connected by line 40 . Cooler 110 cools the spent regenerant stream to condense a portion of the mercury and a portion of the water desorbed from the first adsorbent zone to produce a cooled regenerant stream 46 , a water stream 44 , and a mercury stream 42 . In some embodiments mercury will instead be removed in its gaseous form. The cooled regenerant stream 46 is passed to a first secondary adsorption bed 114 of at least two secondary adsorption beds ( 114 and 112 ) to produce a purified gas stream 47 containing less than about 0.1 μg/Nm 3 of mercury. Each of the secondary adsorption beds like the gas purifier beds, and the liquid purifier beds comprises a fixed bed containing a first adsorbent zone containing a desiccant such as zeolite A or X, and a second adsorbent zone selective for the reversible adsorption of water and mercury such as a molecular sieve zeolite selected from the group consisting of zeolite A, zeolite X, and zeolite Y containing cationic or finely dispersed elemental forms of a metal selected from the group consisting of silver, gold, platinum, palladium, and mixtures thereof. Preferably the second adsorbent zone of the liquid purifier bed comprises a zeolite A or zeolite X containing ionic or elemental silver. The purified gas stream 47 is withdrawn for use as plant fuel via line 48 . At least a portion of the purified gas stream 47 may be combined with the regenerant stream 20 ′ via line 20 . When the mercury has been removed from the first gas purifier bed 104 , the passing of heated regenerant 26 to bed 104 and the passing of the spent regenerant stream 32 are terminated and the heated regenerant 28 is passed to the liquid purifier 108 in a direction countercurrent to the liquid flow during the adsorption mode to produce a second spent regenerant stream 33 which has approximately the same composition as the spent regeneration stream 32 comprising mercury and water. The second spent regenerant stream 33 is passed to the cooler/separator via lines 33 , 34 , and 38 to produce the cooled regenerant stream 46 , the water stream 44 , and the mercury stream 42 . The cooled regenerant stream 46 continues to be passed to the first secondary adsorbent bed 114 for the production of the purified gas stream 47 . Preferably the temperature of the cooled regenerant stream ranges between about 20° and about 45° C., and more preferably the temperature of the cooled regenerant steam is less than about 25° C. When the liquid purifier bed 108 has been regenerated, the passing of the heated regenerant stream thereto and the passing of the second spent regenerant stream 33 are terminated and the heated regenerant stream 22 is passed to the other secondary adsorbent bed 112 via line 30 in a direction countercurrent to the gas flow during the adsorption mode to desorb mercury and water and to produce the third spent regenerant stream 36 . The third spent regenerant stream 36 is passed to the cooler 110 /separator 116 to provide the cooled regenerant stream 46 , the water stream 44 , and the mercury stream 42 . The cooled regenerant stream is passed to the first secondary adsorbent bed 114 to produce the purified gas stream 47 . Thus, the regeneration of the gas purifier bed 104 , the liquid purifier bed 108 , and the secondary adsorbent bed 112 is carried out sequentially with a common cooler 110 /separator 116 to provide a continuous process and a continuous regeneration cycle. Preferably, the total regeneration cycle time including cooling the beds to adsorption conditions comprises 30-60 percent for the regeneration of the gas purifier bed, 20-50 percent for the regeneration of the liquid purifier bed, and 5-20 percent for the regeneration of the secondary adsorbent bed. Following the termination of passing heated regenerant to each of the beds undergoing regeneration, the beds are cooled by the passing of unheated regenerant or purified gas in the conventional manner.
EXAMPLE
Two samples were compared, one sample was in nitrogen feed gas and the other sample was in air. In both samples, 10 g of adsorbent used. The bed height was 10 cm, bed volume 7.2 mL and the nominal feed flowrate was 1200 mL/min. In the first sample, using nitrogen, the nominal inlet Hg concentration was 802 μg/m 3 and in the sample containing air, the nominal inlet Hg concentration was 975 μg/m 3 . It was found that the loading of Hg vs. time of stream was about the same for both the sample in nitrogen and the sample in air.
SPECIFIC EMBODIMENTS
While the following is described in conjunction with specific embodiments, it will be understood that this description is intended to illustrate and not limit the scope of the preceding description and the appended claims.
A first embodiment of the invention is a process for the removal of mercury vapor from a fluid stream containing hydrocarbons and oxygen comprising passing the stream through an adsorbent bed containing particles comprised of crystallites of a zeolitic molecular sieve having pore diameters of at least 3.0 angstroms and in which the zeolite crystallites are formed into an aggregate as pellets or beads with clay which contain elemental silver, whereby at least a major proportion of the mercury is adsorbed and a purified effluent fluid stream is recovered. An embodiment of the invention is one, any or all of prior embodiments in this paragraph up through the first embodiment in this paragraph wherein the zeolite crystallites of the adsorbent particles containing silver comprise zeolite X or zeolite Y or zeolite A. An embodiment of the invention is one, any or all of prior embodiments in this paragraph up through the first embodiment in this paragraph wherein the fluid stream being treated for mercury removal comprises natural gas. An embodiment of the invention is one, any or all of prior embodiments in this paragraph up through the first embodiment in this paragraph wherein the natural gas contains both water vapor and mercury as impurity constituents and both impurities are removed by passage of the stream through a compound bed containing a desiccant adsorbent and the silver-containing adsorbent, and thereafter regenerating both adsorbent materials by passage through the compound bed of a non-sorbable purge gas at a temperature higher than employed during the adsorption stage. An embodiment of the invention is one, any or all of prior embodiments in this paragraph up through the first embodiment in this paragraph wherein the silver-containing adsorbent is contained within a discrete zone of the compound bed. An embodiment of the invention is one, any or all of prior embodiments in this paragraph up through the first embodiment in this paragraph wherein the hydrocarbon stream is treated in the liquid phase.
A second embodiment of the invention is a process for removing mercury from a feedstock fluid stream containing the mercury and containing oxygen which comprises (a) passing the stream in the liquid phase through an adsorbent bed containing as an adsorbent particles comprised of crystallites of a zeolitic molecular sieve having pore diameters of at least 3.0 angstroms and in which the zeolite crystallites are formed into an aggregate shape (cylindrical or beads) that contain elemental silver, whereby mercury is adsorbed and a purified product stream is recovered as an effluent from the bed; (b) periodically regenerating the bed by the passage as a purge gas therethrough of a portion of the purified product in the vapor phase; and (c) condensing the effluent from the bed during regeneration and recovering the liquid phase mercury for the liquefied purge gas. An embodiment of the invention is one, any or all of prior embodiments in this paragraph up through the second embodiment in this paragraph wherein the bed regeneration is carried out by passing the purge gas stream through the bed in a direction counter-current to the direction of flow through the bed during the purification adsorption step. An embodiment of the invention is one, any or all of prior embodiments in this paragraph up through the second embodiment in this paragraph wherein the feedstock being purified is naphtha.
Without further elaboration, it is believed that using the preceding description that one skilled in the art can utilize the present invention to its fullest extent and easily ascertain the essential characteristics of this invention, without departing from the spirit and scope thereof, to make various changes and modifications of the invention and to adapt it to various usages and conditions. The preceding preferred specific embodiments are, therefore, to be construed as merely illustrative, and not limiting the remainder of the disclosure in any way whatsoever, and that it is intended to cover various modifications and equivalent arrangements included within the scope of the appended claims.
In the foregoing, all temperatures are set forth in degrees Celsius and, all parts and percentages are by weight, unless otherwise indicated.
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The invention relates to a process for removing and recovering mercury, an impurity, from a hydrocarbon feedstream containing oxygen, such as introduced during hydraulic fracturing. Mercury is selectively removed to very low levels of concentration from fluid streams such as natural gas, cracked gas, hydrogen or naphtha by passage of the stream through an adsorbent bed containing particles of a zeolitic molecular sieve preferably having pore diameters of at least 3.0 angstroms and in which the zeolite crystallites are formed into an aggregate (cylindrical or beads) which contain ionic or elemental silver. These adsorbent particles maintain their capacity for removal of mercury despite the presence of oxygen.
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This application claims benefit of application Ser. No. 60/102,836 filed Oct. 2, 1998.
FIELD OF THE INVENTION
The present invention relates to haptens and conjugate labels having improved specificity for anti-cortisol antibodies, methods for their preparation and use in immunoassays for the detection of cortisol. More particularly, the present invention relates to conjugates comprising horseradish peroxidase and reduced cortisol.
BACKGROUND OF THE INVENTION
Cortisol is the major glucocorticoid in humans. It is synthesized and secreted by the zona fasciculata and the zona reticularis of the adrenal cortex. It is involved in the regulation of carbohydrate, protein, and lipid metabolism. Cortisol levels can rise ten fold following surgery or other major trauma, as the steroid acts to prevent vascular collapse, reduce inflammation, and suppress the immune system.
There are three primary medical disorders associated with hyperadrenalism: Cushing's syndrome, hyperaldosteronism, and congenital adrenal hyperplasia. Cushing's syndrome is the term used to describe any condition resulting from an increased concentration of circulating glucocorticoid, usually cortisol ( Clinical Chemistry: Theory, Analysis, and Correlation; Lawrence A. Kaplan, Amadeo J. Pesce, C V Mosby Company, 1989, pp 673-4).
The detection and quantification of cortisol in human serum, plasma or urine is required for proper diagnosis, treatment and follow-up of cortisol related conditions.
Competitive binding immunoassays for cortisol comprise anti-cortisol antibody, usually bound to an immobilized or immobilizable substrate and labeled cortisol, or labeled analogs (derivatives) of cortisol. It shall be understood that whenever reference is made to labeled cortisol, unless otherwise indicated, the term is intended to encompass labeled analogs (derivatives) of cortisol. Labeled cortisol competes with cortisol for a limited number of anti-cortisol antibody binding sites. Signal derived from free or bound labeled cortisol is determined as a measure of the amount of cortisol.
The sensitivity and specificity of an immunoassay for cortisol are dependent on the labeled cortisol. It is important that labeled cortisol effectively compete for the limited number of anti-cortisol binding sites with steroids structurally similar to cortisol that may be present in a sample. Otherwise, a clinically acceptable determination of the amount of cortisol in the sample will not be obtained.
Individuals having a deficiency of the enzyme 11β-hydroxylase, or who receive metyrapone will have greatly increased levels of 11-deoxycortisol, which is structurally similar to cortisol ( Fundamentals of Clinical Chemistry, Tietz,N. W., W. B. Saunders Co., 1987,p 569) and potentially can compete with labeled cortisol for binding to anti-cortisol antibody. Other cortisol-like steroids that may be present in a sample, which potentially can compete with labeled cortisol for anti-cortisol antibody, include prednisolone, cortisone, and corticosterone. Such competition with labeled cortisol for anti-cortisol antibody is termed cross-reactivity.
Commercial cortisol assays can exhibit cross-reactivity with all the above-identified steroids. For example, a cross-reactivity with 11-deoxycortisol of greater than 10 percent has been observed; seriously compromising the accuracy of the assay for cortisol.
SUMMARY OF THE INVENTION
The problems associated with prior art assays for cortisol have been overcome using the conjugate labels described hereinbelow.
The present invention relates to compositions comprising novel reduced cortisol conjugates, methods for their preparation and use in immunoassays for cortisol.
In another aspect, it relates to conjugates of reduced cortisol as immunogens or haptens for eliciting anti-cortisol or anti-reduced cortisol antibodies.
It was found unexpectedly that labeled reduced cortisol conjugates of the present invention effectively compete with cortisol-like steroids for binding to anti-cortisol antibodies, thereby exhibiting significantly less cross-reactivity compared with prior art labeled cortisol conjugates. Immunoassays for cortisol comprising labeled reduced cortisol conjugates of the present invention exhibit both improved specificity and sensitivity for the determination of cortisol.
Accordingly, the present invention provides a reduced cortisol conjugate of formula:
wherein X is O, S, sufonyl, or phosphono; X 1 is a labeled or unlabeled natural or synthetic polymer or a label; Y 1 is a linking group or a bond; X 2 is a labeled or unlabeled natural or synthetic polymer or a label; Y 2 is a linking group or a bond; A 1 and A 2 are each hydrogen or A 1 and A 2 together form a single bond, B 1 and B 2 are each hydrogen or B 1 and B 2 together form a single bond, E 1 and E 2 are each hydrogen or E 1 and E 2 together form a single bond provided at least one of A 1 and A 2 , or B 1 and B 2 , or E 1 and E 2 are each hydrogen.
In another aspect, the present invention relates to methods for the preparation of reduced cortisol conjugates. Accordingly, we provide a method for preparing a reduced cortisol conjugate of formula
wherein X, X 1 , Y 1 , X 2 , Y 2 , A 1 , A 2 , B 1 , B 2 , E 1 and E 2 are as defined above, comprising:
reacting a compound of formula
with a reducing agent.
An alternative method is provided for preparing a reduced cortisol conjugate of formula
wherein X, X 1 , Y 1 , X 2 , Y 2 , A 1 , A 2 , B 1 , B 2 , E 1 and E 2 are as defined above, comprising the steps of:
(i) reacting a compound of formula
with a reducing agent, thereby forming compound IA or IC; and
ii) with a first coupling agent, thereby forming a compound of formula
wherein G 1 is a coupling group;
(iii) optionally, reacting X 2 with a second coupling agent, thereby forming X 2 —G 2 , wherein G 2 is a coupling group capable of forming a covalent bond with the coupling group G 1 , and wherein G 1 and G 2 may be the same;
(iv) optionally reacting compound IA or IC with X 2 —G 2 wherein G 2 is capable of forming a covalent bond with a functional group of X 1 , thereby forming reduced cortisol conjugate IB or ID;
(v) optionally reacting compound IIIA or IIIC with X 2 wherein G 1 is capable of forming a covalent bond with a functional group of X 2 , thereby forming reduced cortisol conjugate IB or ID;
(vi) optionally reacting compound IIIA or IIIC with X 2 —G 2 , thereby forming reduced cortisol conjugate IB or ID.
In yet another aspect, the present invention relates to methods for the qualitative or quantitative determination of cortisol that utilize the novel labeled reduced cortisol conjugates.
Accordingly, we provide a method for performing a competitive assay for cortisol comprising the steps of:
A) contacting a sample suspected of containing cortisol with
(i) an immobilized or immobilizable receptor that binds cortisol, thereby forming cortisol that is bound and cortisol that is not bound to the immobilized or immobilizable receptor,
(ii) a labeled reduced cortisol conjugate of formula IA, IB, IC or ID as defined above, thereby forming labeled reduced cortisol conjugate that is bound and labeled reduced cortisol conjugate that is not bound to the immobilized or immobilizable receptor;
B) detecting either the labeled reduced cortisol conjugate that is bound or the labeled reduced cortisol conjugate that is not bound to the immobilized or immobilizable receptor as a measure of the amount of cortisol in the sample.
In an alternative ebodiment, the assay method described above may be combined with a step wherein the labeled reduced cortisol conjugate that is bound is separated from the labeled reduced cortisol conjugate that is not bound to the immobilized or immobilizable receptor;
An alternative method for performing a competitive assay for cortisol using a dry analytical element is also provided, the dry analytical element comprising
a) a spreading zone,
b) one or more reagent zones,
c) a support, and
together or separately in one or more of the zones, an immobilized receptor that binds cortisol and optionally, a labeled reduced cortisol conjugate of formula IA, IB, IC or ID defined above, wherein the method comprises the steps of:
A) contacting the spreading zone of the dry analytical element with
i) a sample suspected of containing cortisol, thereby forming cortisol that is bound and cortisol that is not bound to the immobilized receptor,
ii) labeled reduced cortisol conjugate if it is not present in the dry analytical element, thereby forming labeled reduced cortisol conjugate that is bound and labeled reduced cortisol conjugate that is not bound to the immobilized receptor,
B) optionally, separating the labeled reduced cortisol conjugate that is bound from the labeled reduced cortisol conjugate that is not bound to the immobilized receptor; and
C) detecting either the labeled reduced cortisol conjugate that is bound or the labeled reduced cortisol conjugate that is not bound to the immobilized receptor as a measure of the amount of cortisol in the sample.
In another sense, the present invention relates to haptens or immunogens of formula IA, IB, IC or ID as defined above and compositions comprising the immunogens. It also relates to methods of producing anti-cortisol antibodies using the immunogens of the present invention, by immunizing a host animal, removing blood from the host, and separating antibodies that bind cortisol from the host animal's blood serum or plasma. In another related method, the spleen, thymus or other organ that is populated with antibody producing cells is removed from the immunized host animal, antibody secreting hybridomas are prepared using antibody producing cells of the spleen, thymus or other organ so removed, and antibodies that bind cortisol are selected therefrom.
In yet another sense, the present invention relates to methods of reducing cross-reactivity in immunoassays for cortisol using labeled reduced cortisol conjugates of formula IA, IB, IC or ID.
The labeled reduced cortisol conjugates of the present invention, as stated, effectively compete with cortisol-like steroids for binding to anti-cortisol antibodies, thereby exhibiting significantly less cross-reactivity compared with prior art labeled cortisol conjugates.
DETAILED DESCRIPTION
The invention is described in detail with respect to a specific reduced cortisol conjugate comprising bovine serum albumin and horseradish peroxidase. This has been done to illustrate the present invention and is not intended in any way to limit the invention to this specific example. Other reduced cortisol conjugates, their syntheses and use as immunogens, or as reduced cortisol labels in competitive and noncompetitive immunoassay and in other aspects that are evident from the teachings presented herein or would be known to the skilled artisan are also contemplated.
A “natural polymer” for the purpose of the present invention is herein defined as one that originates from a biological source including but not limited to: microorganisms, fungi, viruses, human, cow, pig, mouse, cat, dog, rat, or insect. Such natural polymers include proteins, peptides, glycoproteins, lipoproteins and recombinant and chemically modified species thereof, polysaccharides, celluloses, collagens, and latexes. Somewhat more specific examples include, dextrans, porcine, human, mouse, rat and bovine serum albumins or globulins, strepavidin, antibodies, enzymes such as peroxidase, β-galactosidase, and alkaline phosphatase.
A “synthetic polymer” is defined herein as a polymer that does not necessarily directly originate from a biological source. It is one that is prepared by methods well known to the skilled artisan. For example, by way of monomer condensation using emulsion polymerization, ionic chain polymerization, carbonyl polymerization, radical chain polymerization and the like. It includes homopolymers such as polyacrylamides, polymethacrylates, polystyrenes, substitited polyacrylamides, polymethacrylates, and polystyrenes, and copolymers comprising two or more different monomeric units, such as acrylamide or substituted acrylamide, styrene and substituted styrene, and the like, as would be well known to one skilled in the art. It includes blockcopolymers, graftcopolymers, aqueous soluble and aqueous insoluble polymers and covalent and non-covalent combinations with natural polymers.
The term “label” as defined herein includes: chemical elements, compounds, and enzymes that are capable of being detected directly or indirectly using, for example, absorption, fluorescence, or reflectance spectrophotometry, or radiation detection methods. A label may be a natural or synthetic polymer. For example, horseradish peroxidase is both a label and a natural polymer. But a label is not necessarily a natural or synthetic polymer.
A label capable of direct detection is one that is intrinsically capable of producing a detectable signal. Such labels include organic and inorganic substances capable of fluorscence, or phosphoresence, such as but not limited to fluorescein, and derivatives thereof, and N-(3-fluoranthyl)-maleimide, radionucleides, such as carbon 14, tritium and phosporus 32, and the like. Included are substances having appropriate spectral absorption such as but not limited to, azo-oxo, azo-tetrazo, azine, oxazine, thiazine, quinoline, indamine, pyrone and pyrazolone dyes.
A label that is capable of indirect detection requires the presence of one or more additional substances for production of the detectable signal. Such labels typically include but are not limited to enzymes that require the presence of a substrate(s), co-factor(s), metal(s) and the like. Peroxidases, most particularly, horseradish peroxidase, a common label, requires an electron donor and an oxidizing agent, such as luminol, di- or triarylimidazole leucodyes and hydrogen peroxide to produce a chemiluminescent product or dye, respectively. Other enzymes, such as β-galactosidase, glucose oxidase and alkaline phosphatase, and the like, are also contemplated.
In general, labels include radioactive tags, enzymes, chromophores, fluorophores, stable free radicals, and enzyme cofactors, inhibitors and allosteric effectors.
A “reducing agent”, for the purpose of the present invention, is any compound or reagent admixture that is capable of hydrogenating a double bond, such as carbon-carbon, carbon-nitrogen, carbon-oxygen and carbon-sulfur double bonds.
Useful reducing agents include but are not limited to: aluminum hydride, lithium aluminum hydride, borohydride and salts thereof. Catalytic hydrogenation over paladium, platinum or nickel or other hydrogenation methods can also be used. Sodium borohydride is a preferred reducing agent.
A “linking group” is defined herein, as a chemical group comprising one or more atoms. A linking group connects one molecule to another, such as a natural polymer to a natural polymer, a synthetic polymer to a synthetic polymer, a natural polymer to a synthetic polymer, a label to a natural or synthetic polymer, a label to reduced cortisol, a label to cortisol, and so on, through formation of a covalent bond with each of the molecules it joins.
The linking group can comprise a substituted or unsubstituted straight chain or branched alkyl or heteroalkyl, such as oxyalkyl, thioalkyl, aminoalkyl, substituted or unsubstituted alkenyl, one or more substituted or unsubstituted hydrocarbon heterocyclic rings, one or more substituted or unsubstituted aryl or heteroaryl rings such as but not limited to, imidazoyl, isoxazolyl, pyridyl, piperidyl, piperazinyl, pyrazolyl,triazolyl, oxadiazolyl, pyridazinyl, pyrimidyl, pyrazinyl, quinolinyl, and quinazolinyl.
Linking or coupling of macromolecules, such as natural and synthetic polymers to other macromolecules, or linking small molecules, such as cortisol or analogs of cortisol, to macromolecules is well known in the art. Specifically with respect to cortisol, carbon 3(C3)is reactive with nucleophiles including, amines, oximes, and thio-oximes and others known in the art. The nucleophilic species may be a coupling (linking) agent, a label, a natural or synthetic polymer. If it is a coupling agent or other species having a reactive functional group (a label, etc.), upon covalently bonding to the C3 of cortisol it may be reacted further with another coupling agent or other species having an appropriately reactive functional group. Cortisol so derivatized can be used as the starting point for preparing the reduced cortisol compounds of the instant invention. Details of coupling chemistry and linking groups may be found in numerous publications, including, U.S. Pat. Nos. 3,654,090; 3,791,932; 3,875,011; 4,016,043; 4,040,907; 4,092,479; 4,213,894; 4,243,749; 4,376,165; 4,410,643; 4,752,658; 4,828,978; 4,879,249; 4,997,772; 5,053,497; 5,106,732; 5,147,777; 5,155,166; 5,162,219; 5,177,023; 5,284,948; 5,298,403; 5,308,749; 5,374,516; 5,391,483; 5,397,695; 5,401,633; 5,527,709; 5,543,311; 5,578,457; 5,652,346; 5,763,588; 5,770,390 and references identified therein; Yoshitake et al. Eur. J. Biochem., 101, 395, (1979) and Tjssen, in Laboratory Techniques in Biochemistry and Molecular Biology, pp 221-278 (1985) and references therein.
In brief, a linking group and molecule to which it is covalently attached can be connected through amide, ester, ether, thioester, and disulfide bonds. For example coupling or linking chemistry that includes reacting the molecules to be coupled with condensing agents such as carbodiimides, maleimides, ethylchloroformate, and glutaraldehyde is well known in the art.
The term “sample” refers to any substance that may contain the analyte of interest. A sample can be a biological fluid, such as cerebral spinal fluid, semen, vaginal secretions, sputum, ascites fluid, lacrimal fluid, sweat, serum, plasma, urine, whole blood or whole blood components including red and white blood cells, platelets, and other fluids or tissues of the body that may contain the analyte of interest. Optionally, samples may be obtained from water, soil and plants.
Immunoassays, which take advantage of natural immunological reactions, have found wide-spread use as analytical techniques in clinical chemistry. Because of the specificity of the reactions, they are particularly advantageous in quantifying biological analytes, that are present in very low concentration in biological fluids. Such analytes include, for example, antibodies, therapeutic drugs, narcotics, enzymes, hormones, proteins, etc.
In competitive binding immunoassays, a labeled analyte (the term includes immunocompetent analogs of the analyte) is placed in competition with unlabeled analyte for reaction with a fixed amount of an appropriate receptor, which is often immobilized on a solid susbstrate, or is capable of immobilization thereto. The labeled analyte that is bound to the receptor is separated from free labeled analyte. Unknown concentrations of the analyte can be determined from the measured signal of either the bound or free labeled analyte. The reaction proceeds as follows:
Analyte+labeled analyte+receptor⇄analyte−receptor+labeled analyte−receptor.
Immunoassays can be carried out in solution, in test devices where soluble and insoluble components can be separated, or in dry analytical elements. Immunoassays can be heterogeneous or homogeneous as those terms are known in the art. In heterogeneous assays, bound and free labeled immunoreactants (labeled analyte or labeled receptor for an analyte) are separated prior to signal measurement; whereas, in homogeneous assays separation of free from bound labeled immunoreactant is not required. The reduced cortisol conjugates of the instant invention can used in both homogeneous and heterogeneous assays.
Numerous publications relating to immunoassays and immunoassay methods, which include many of the above-cited publications relating to linking groups and coupling chemistry, are available to the practitioner. Additional publications include: U.S. Pat. Nos. 4,372,745; 4,670,381; 4,483,921; 4,517,288; 4,822,747; 4,824,778; 4,829,012; 4,839,299; 4,847,194; 4,847,195; 4,853,335; 4,855,226; 4,857,453; 4,857,454; 4,859,610; 4,863,876; 4,868,106; 4,868,130; 4,879,219; 5,663,054; 5,776,933 and all references cited therein; and Immunoassays in the Clinical Laboratory, Nakamura et al, eds., Alan R. Liss, Inc., (1979); Quantitative Enzyme Immunoassay, Engvall et al., eds, Blackwell Scientific Publications, (1978; Clinical Chemistry, Sommer et al., v.32,p. 1770-1774, (1986); Clinical Chemistry, Sommeret al., p 201-206 (1990); A Primer for Multilayer Immunoassay, Berke, American Chemical Society Conference Proceeding, p.303-312, Plenum Press, (1988); and all references cited therein.
In competitive immunoassays labeled analyte and sample containing free analyte can be added simultaneously or separately to an admixture comprising immobilized or immobilizable receptor that binds the analyte.
In the case of dry analytical elements, labeled analyte and immobilized receptor when present together in the element prior to contact with sample, are preferably present in separate zones.
Conventional materials and means for assembling dry-film analytical elements are described, for example, in U.S. Pat. Nos. 3,867,258; 3,992,158; 4,042,435; 4,050,898; 4,066,403; 4,153,668; 4,258,001; 4,292,272 and 4,430,436.
Methods to obtain antibodies that bind a specific molecule by immunizing suitable host animals is well known. Such methods are well documented and are described, for example, in the following publications: Methods in Immunology, Garvey,J. S., Cremer,N. E. and Sussdorf,D. H., W. A. Benjamin,Inc., Third Ed. (1977)and Handbook of Experimental Immunology, edited by Weir,D. M., Blackwell Scientific Publications, Third Ed., (1978)
Methods of producing hybridoma cell lines for secretion of antibodies is also well known, and are provided, for example, in U.S. Pat. Nos. 4,950,592; 5,338,671 and 5,650,324.
Preparation of HRP Labeled Reduced Cortisol-3-CMO-BSA
A method is provided below illustrating the preparation of a horseradish peroxidase (HRP) labeled reduced cortisol conjugate. In this method the reduction of a bovine serum albumin cortisol oxime conjugate (Cortisol-3-CMO-BSA) with sodium borohydride was carried out prior to conjugation with HRP; however, reduction of cortisol can be carried out subsequent to coupling with HRP.
There are three sites for reduction of Cortisol-3-CMO-BSA that are marked by an asterisk in the structure shown below
Any or all of these sites can be reduced by treatment with a reducing agent or reducing admixture that is capable of hydrogenating a double bond, yielding products having a single site reduced as in the structures shown below.
as well as, compounds having any two of the sites reduced, yielding three different reduced species, and all three sites reduced, as is readily apparent to the skilled artisan. Other conjugates comprising cortisol, which upon reduction produce the compounds generically defined in structures 1A, 1B, 1C and 1D, analogously will form different reduced cortisol species as exemplified above with Cortisol-3-CMO-BSA. Compounds having a covalent bond to C3 of cortisol that is not capable of being hydrogenated will be reduced only at the ring carbon-carbon double bond and/or the carbon-oxygen double bond (carbonyl group) of cortisol. All reduced forms individually or in any combination are contemplated in the present invention.
EXAMPLE 1
Preparation of 3-Cortisolcarboxymethyl Oxime Conjugated to Bovine Serum Albumin (3-CMO-BSA)
Hydrocortisone-3-(O-Carboxymethyl)oxime
Bovine Serum Albumin (Cortisol-3-CMO-BSA) was prepared as described below. Alternatively, it can be purchased from Sigma Chemical Co., St. Louis, Mo.
A stock solution of N-hydroxysuccimide (NHS) was prepared by dissolving 20 mg of NHS in 3.0 mL of dioxane. A stock solution of dicyclohexylcarbodiimide (DCC) was also prepared by dissolving 30 mg of DCC in 2.50 ml of dioxane. To a glass vial containing 40 mg of Cortisol-3-carboxymethyl oxime (Cortisol-3-CMO) was added 1.744 mL of the NHS stock and 1.744 mL of the DCC stock. The mixture was stirred and incubated for three hours at ambient room temperature. To 1.00 gram of Bovine Serum Albumin (BSA) was added 12 mL of 0.1M sodium hydrogen carbonate solution. The solution was mixed until clear and at the end of the three hour incubation, 3.0 ml of the activated Cortisol-3-CMO was added to the BSA solution. The mixture was stirred and incubated at ambient temperature for two hours. After the two hour incubation, 15 mL of 0.1M sodium phosphate, 0.3M sodium chloride (pH 6.0) buffer was added. The mixture was filtered through a 5.0 um and 0.45 um Sartorius Minisarts and then cromatographed on a 5×70 cm Superdex 200PG column at a flow rate of 8.0 mL/min. The first tube corresponding to the major peak and the following ten (one minute) fractions were collected and pooled. Pool the fractions. The pooled fractions were dialyzed against water for approximately fifteen hours. The dialysis was repeated. The dialysate was filtered through a 0.2 um Sartorius Minsart and lyophilized in small aliquots and kept frozen until needed.
EXAMPLE 2
Reduction and Activation of Cortisol-3-CMO-BSA
Cortisol-3-CMO-BSA (24 mg) was dissolved in 4 mL of a solution of 50 mM sodium carbonate and 100 mM sodium chloride at pH 9.5. An aliquot, 0.60 mL, of an aqueous solution of sodium borohydride (4 mg per mL) was added to the cortisol-3-CMO-BSA solution, which was then mixed continuously for thirty minutes at 20° C. The pH was then adjusted, using about 200 μL of a 0.5 M sodium phosphate solution, to a value in a range between pH 7.2 to 7.5 to decompose any excess borohydride. The solution was gently mixed until effervescence ceased and allowed to stand for about fifteen minutes. The reaction mixture was then filtered through a 0.45μ filter and chromatographed on a Sephadex G25 1.6×14.5 cm column pre-equilibrated with 0.02 M phosphate, pH 7.0, at a flow rate of about 40 mL/hr. The fraction size collected was about 0.67 mL (1 min). Fifteen of the most concentrated fractions, that is, those fractions having a large absorption at 280 nm were pooled.
Succinimidyl 4-(N-maleimidomethyl) cyclohexane-1-carboxylate (SMCC) was dissolved in N,N-dimethylformamide (DMF) at a final concentration of 9.6 mg/mL. To 10 mL of the reduced cortisol-3-CMO-BSA collected from the chromatography step above, was added 186 μL of the SMCC solution. The solution was mixed gently then incubated for one hour at 20° C. The reaction was quenched with 800 μL of an aqueous solution of glycine (10 percent, weight/voume). The quenched reaction mixture was then chromatographed on a 3.2×10 cm column filled with Sephadex G25 pre-equilibrated with a solution of 0.1 M phosphate and 5 mM ethylenediaminetetraacetic acid (EDTA), pH 6.0, at a flow rate of about 161 mL/hr. One milliliter fractions were collected. Eight of the most concentrated fractions (having a large absorption at 280 nm) were pooled and used for conjugation to activated HRP.
EXAMPLE 3
Activation of HRP
Horseradish peroxidase was dissolved in 0.1 M phosphate, pH 7.5, at a final HRP concentration of 10 mg/mL. Five milliliters of the HRP solution were transferred to a 20 mL reaction vial. A 0.5 mL aliquot of S-acetylthioacetic acid, N-hydroxysuccinimidyl ester (SATA) in DMF (25 mg/mL) was added to the reaction vial containing the HRP solution. The solution was mixed gently then incubated at 20° C. for sixty minutes. An aliquot (500 μL) of a solution containing 0.05 M EDTA and 2.5 M hydroxylamine at pH 7.0, was added to the reaction mixture, mixed gently, and then incubated at 20° C. for 15 minutes. The mixture was then chromatographed on a 2.0×10 cm column of Sephadex G25 pre-equilibrated with a solution of 0.1 M phosphate and 5 mM EDTA at pH 6.0, using a flow rate of about 63 mL per hour. One minute fractions were collected. Eleven of the most concentrated fractions (having a large absorption at 403 nm) were pooled.
EXAMPLE 4
Coupling of Activated HRP and Reduced and Activated Cortisol-3-CMO-BSA
The activated, reduced cortisol-3-CMO-BSA 21.47 mL was combined with 11.55 mL of activated HRP. The solution was mixed gently, and incubated at 20° C. for twenty hours. An aliquot (224 μL) of a solution containing mercaptoethanol in water (1 percent of the thiol by volume) was added to the reaction mixture and the solution was mixed gently and allowed to stand for about 15 minutes. A 476 μL aliquot of a solution containing 10 mg/mL N-ethylmaleimide in DMF, was then added to the reaction mixture, and incubated an additional twenty minutes after mixing. The reaction mixture was then chromatographed on a 4.4×50 cm column containing Superdex 200 pre-equilibrated with a solution of 0.1 M phosphate and 0.3 M NaCl at pH 6.0 using a flow rate of about 344 mL per hour. One minute fractions were collected. Twenty six of the most concentrated fractions centered around the first eluates having a maximum absorption at 280 nm were pooled.
The absorption of the conjugate pool (cj)and the HRP solution (in Example 2 above, prior to activation and sufficiently diluted in phosphate buffer to obtain an accurate absorption measurement)were determined at 280 nm and 403 nm, A 403 cj, A 280 cj and A 403 HRP, A 280 HRP respectively. The concentration of the reduced cortisol-3-CMO-BSA-HRP conjugate based on the BSA concentration was determined from these measurements using the following formula:
BSA (mg/mL)= A 280 cj −( A 403 cj/[A 403 HRP/A 280 HRP ])/0.76
EXAMPLE 4
Evaluation of Conjugate
Evaluation of the HRP labeled reduced cortisol-3-CMO-BSA (hereinafter referred to as HRP-RC conjugate) was evaluated using an Ortho-Clinical Diagnostic VITROS ECi chemiluminesence-based assay methodology.
The following reagents were prepared for use with the VITROS ECi system.
Label Solution
100 ng/mL reduced cortisol-3-CMO-BSA-HRP (or 20 ng/mL of a comparative HRP-cortisol conjugate label, which is not a conjugate label of the present invention, but which was carried through the same procedures as the label of the invention except for the reduction step)
2.86 g/L sodium phosphate dibasic,anhydrous
7.3 g/L sodium phosphate monobasic, monohydrate
0.01 g/L potassium ferricyanide
2.5 g/L 8-anilino-1-naphthalenesulfonic acid
20 g/L bovine serum slbumin
0.03 g/L apo-horseradish peroxidase
0.2% bovine alpha globulin(Cohn fraction IV-I)
1 g/L bovine gamma globulin
5 g/L normal sheep serum
100 g/L charcoal stripped human plasma
20 g/L Kathon (a preservative comprising 5-chloro-2-methyl-4-isothiazolin-3-one and 2-methyl-4-isothiazolin-3-one)
pH 6.4
Biotinylated Sheep Polyclonal Anti-Cortisol Solution
1.5 μg/mL biotinylated sheep anti-cortisol gamma globulin
21 g/L sodium phosphate dibasic,anhydrous
1.8 g/L sodium chloride
1.1 g/L citric acid
20 g/L bovine serum albumin
20 g/L Kathon
pH 5.4
Wash Reagent
0.39 g/L boric acid
0.35 g/L disodium tetraborate
0.58 g/L sodium chloride
0.50 g/L TRITON X-100 (octylphenoxypolyethoxy ethanol)
0.5% w/w BRONIDOX (a preservative comprising 5-bromo-5-nitro-1,3-dioxane)
pH 8.4
Signal Reagent
Part A
3.88 g/L boric acid
14.2 g/L sodium tetraborate
1.06 g/L sodium citrate
0.08 g/L sodium benzoate
0.10 g/L sodium azide
0.008 g/L diethylenetriaminepentaacetic acid
0.58 g/L glycine
0.40 g/L luminol
Part B
0.90 g/L citric acid
1.68 g/L sodium citrate
0.08 g/L sodium benzoate
0.62 g/L sodium perborate
0.06 g/L 3-chloro-4-hydroxyacetanilide
5.84 g/L sodium chloride
An aliquot (75 μL) of anti-cortisol biotinylated sheep antibody, 30 μL of sample, serum comprising cortisol or a steroid structurally similar to cortisol (below), and 75 μL of HRP-RC conjugate were added to an VITROS ECi sample container to which strepavidin had been prebound. The solution was incubated at 37° C. for 30 minutes, then washed using the above-indicated wash reagent.
A 200 μL aliquot of the above-indicated signal reagent solution (100 μL of part A and 100 μL of part B combined just prior to use) was then added to the sample container. The solution was incubated for 5 minutes at 37° C., and the chemiluminesence intensity was then determined.
EXAMPLE 5
Cross Reactivity
The above method was used to determine the concentration of potential cross reactant (steroid that is structurally similar to cortisol: 11-deoxycortisol, prednisolone, corticosterone and cortisone) that displaced fifty percent of a fixed amount of a comparative HRP labeled cortisol conjugate (nonreduced cortisol, HRP-NRC) or HRP-RC conjugate bound to a fixed amount of anti-cortisol antibody.
Varied levels of the potential cross reactant were added to sample containers containing either the comparative labeled cortisol conjugate (nonreduced cortisol, HRP-NRC) or HRP-RC conjugate of the instant invention, as described above.
The concentration of cross reactant resulting in a light signal measurement corresponding to 50% of the maximum attainable (all conjugate displaced) was determined and used to calculate the percent cross reactivity as described below and whose results are listed in Table 1.
Percent cross-reactivity is defined as The concentration of cortisol that displaced 50% of the HRP-NRC comparative conjugate (or the HRP-RC conjugate) divided by the concentration of cross-reactant that displaced 50% of the HRP-NRC comparative conjugate (or the HRP-RC conjugate) multiplied by 100 as determined per the assay method described hereinabove.
TABLE 1
Percent Cross-Reactivity
HRP-NRC
HRP-RC
Comparative
Invention
Compound
Label
Label
cortisol
100
100
prednisolone
34.8
24.6
11-deoxycortisol
28.4
2.2
cortisone
5.5
1.8
corticosterone
4.4
3.3
These data clearly show that the representative HRP-RC conjugate of the present invention provides significantly less cross-reactivity in an immunoassay for cortisol. Accordingly, cortisol assays utilizing labeled reduced cortisol as described in the present invention will exhibit improved accuracy; resulting in improved diagnosis, treatment and follow-up.
The present invention has been described in detail with particular reference to certain preferred embodiments thereof. It will be understood that variations and modifications can be effected within the spirit and scope of the invention. All cited publications are incorporated herein by reference.
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The present invention relates to compositions comprising novel reduced cortisol conjugates, methods for their preparation and use in immunoassays for cortisol.
In another aspect, it relates to conjugates of reduced cortisol as immunogens or haptens for eliciting anti-cortisol or anti-reduced cortisol antibodies.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to U.S. Provisional Patent Application No. 61/944,677 filed on Feb. 26, 2014.
STATEMENT OF GOVERNMENT RIGHTS
[0002] This invention was made with government support under N000140911118 awarded by the Office of Naval Research, 1104373 awarded by the National Science Foundation, and W911NF-11-1-0137 awarded by the Army Research Office. The government has certain rights in the invention.
FIELD OF THE INVENTION
[0003] This disclosure relates to the field of nanotechnology and more particularly to the engineering of wireframe architectures and scaffolds using DNA structures.
BACKGROUND OF THE INVENTION
[0004] Self-assembling nucleic acid molecules have shown merit as versatile materials for organizing and constructing complex nano-scale structures. Methods are known for generation of complex DNA origami nanostructures with addressable surface features. For example, a long scaffold strand, most often the 7429-nucleotide (nt) circular genome of the M13mp18 bacteriophage, is organized and folded by interactions with a large number of short, synthetic, staple strands. The path of the scaffold strand in this approach has been restricted to discrete domains of parallel lines because it is based on the double crossover unit motif to link adjacent helices.
[0005] Because engineering wireframe architectures and scaffolds of increasing complexity is an important challenge in nanotechology, methods and compositions for achieving same are very useful and inventive.
SUMMARY OF THE INVENTION
[0006] We present a design strategy that uses an unusual set of immobile Holliday junction analogs (four-arm junctions) as the basic structural unit of DNA origami nanostructures and as joints to construct a variety of two-dimensional (2D) and 3D gridiron structures, in which the scaffold strand and corresponding double helices are not restricted to a 1D parallel, raster-fill pattern. By programming the connection between individual joints with DNA segments of variable lengths, we constructed complex wireframe geometries.
[0007] These and other aspects of the invention will be apparent upon reference to the following detailed description and figures. To that end, any patent and other documents cited herein are hereby incorporated by reference in their entirety.
BRIEF DESCRIPTION OF THE FIGURES
[0008] FIG. 1 . (A) (Left) Geometry and strand polarity of a single gridiron unit formed from four four-arm junctions. (Right) Geometry and polarity of a double-crossover molecule motif used in conventional DNA origami structures. For both structures, the ssDNAs depicted in red are components of DNA double helices that serve as the scaffold strands. The ssDNA depicted in gray represents staple strands. (B) Models of four four-arm junction molecules in their relaxed conformation. The orientation of the upper two junctions differs from that of the lower two by a 180° in-plane rotation. Thus, the polarities of the continuous red strands in the upper and lower layers of the horizontally oriented helices are antiparallel to one another. (C) Models illustrating the deviation from a relaxed conformation required of the four individual junctions to form a gridiron unit. The blue arrows indicate that the top helix of the junctions in the upper-left and lower-right corners must be rotated ˜150° clockwise, whereas in the upper-right and lower-left junctions they must be rotated ˜30° counterclockwise. (D and E) Helical models illustrating a complete gridiron unit. (F and G) Schematics illustrating a typical scaffold-folding path for a 2D DNA gridiron pattern.
[0009] FIG. 2 . (A to D) Images for a 2D gridiron structures with 21-bp cavities with AFM [(A) and (B)] and TEM images [(C) and (D)]. (E and F) Images for a 2D gridiron with 63-bp cavities with AFM (E) and TEM images (F). (G to J) Schematics (left), TEM images (middle), and histogram analysis (right) of the angle distributions for angle control. All scale bars indicate 200 nm, and all zoom-in images (images without scale bars) are 200 by 200 nm.
[0010] FIG. 3 . Multilayer gridiron design strategies. (A and B) Strategy 1 is stacked layers. (A) A portion of a double-layer gridiron lattice with 52-bp cavity size. The yellow circles designate the permissible connection points to a third layer. The dashed lines correspond to possible connection points to form additional layers. (B) Given the double-layer gridiron lattice (X and Y lengths) and the distance between crossover points in the third layer, the angle q can be calculated as 180°−cos−1[(X2+Y2−L2)/2XY]. (C) Strategy 2 is intertwining gridiron planes. (D to F) Schematics (left), AFM (middle), and TEM (right) images of (D) a three-layer hexagonal gridiron design, q=120°; (E) a four-layer gridiron design, q is not controlled because the dashed green line in (A) represents a connection strategy that cannot fix the angle; and (F) a 3D gridiron assembled by using strategy 2. All scale bars indicate 200 nm, and all zoom-in images (images without scale bars) are 200 by 200 nm.
[0011] FIG. 4 . Schematics (left), AFM (middle), and TEM images (right) of (A) an S-shaped structure, (B) a sphere, and (C) a screw. All scale bars indicate 200 nm, and all zoom-in images (images without scale bars) are 200 by 200 nm. In (B) and (C), the diameter and the width, respectively, appear to be larger in the AFM images compared with the TEM images. This difference is probably a result of flattening of the 3D objects into two-layer structures and AFM tip convolution.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0012] Although intuitively one could imagine threading a single-stranded scaffold through a number of four-arm junction units in both horizontal and vertical directions to create gridiron like patterns, the structural properties of traditional Holliday junction impose certain challenges that require unconventional rearrangement of the junction unit conformation, as revealed by the design principles described below.
[0013] We compared a gridiron unit to a double crossover motif ( FIG. 1A ), and the DNA strands are abstracted to display only their polarity with the arrows pointing from 5′ to 3′. In the gridiron unit, four four-arm junctions are linked together to form a two-layer square frame in which the helices on opposite sides lie in the same plane. An antiparallel arrangement between opposite sides of the square frame permits a single, central strand to traverse each of the helices.
[0014] Each of the four junctions is depicted in its relaxed conformation ( FIG. 1B ) such that the helices form a right-handed twist with a 60° torsion angle. Deviation from a relaxed conformation is required of each junction to form the gridiron unit cell. First, the red strands in the horizontally oriented helices (both top and bottom images) can be linked together to produce continuous strands without reversing the 5′-to-3′ polarity ( FIG. 1 , B and C). Next, the vertically oriented helices need to be rotated in the plane about the junction points ( FIG. 1C ) to allow the formation of continuous 5′-to-3′ connections between upper and lower junctions ( FIG. 1 , D and E).
[0015] Connecting a number of gridiron units leads to the formation of a variety of 2D lattices ( FIG. 1 , F and G). The red lines represent the DNA strands that are expected to retain an unperturbed helical structure with continuous base stacking. Meanwhile, the short strands (in gray) form the crossovers between helical domains and function as staples. A long scaffold strand is created by connecting the termini of the red strands with short single-stranded DNA (ssDNA) loops. In the most basic design, the scaffold begins at one corner, fills the first changes direction at the opposite corner, and then fills the second layer to produce a structure in which the helices within the two layers are oriented perpendicularly with respect to each other. Lastly, the scaffold returns to its initial position to form a closed loop ( FIG. 1G ).
[0016] The cavity size of gridiron structures can be tailored by altering the number of base pairs between the adjacent junction points. An 11-by-11 gridiron structure (11 vertical helices by 11 horizontal helices) with 21 base pairs (bp) between junctions in both directions uses 5301 of 7249 nt of the M13mp18 ssDNA scaffold strand and contains 120 staple strands (42 nt each). The remaining 1948 nt of the scaffold form a single-stranded loop at one corner that is visible in atomic force microscope (AFM, FIG. 2 , A and B) and transmission electron microscope (TEM) images ( FIG. 2 , C and D). Gridiron structures with 63-by-63-bp cavities ( FIG. 2 , E and F) were assembled to demonstrate the programmability of the design strategy.
[0017] To test whether the ssDNA scaffold is required to force the junction to rotate and form the intended gridiron structures, we designed and successfully constructed a scaffold-free 11-by-11 gridiron structure. We also found that scaffolded and scaffold-free gridiron elements can be combined within a single structure. Further, a scaffold-free gridiron unit was examined by native gel electrophoresis to verify its formation when the component strands were mixed in equal stoichiometric ratios. Although the schematic diagram in FIG. 1D depicts 90° angles between the helices in the upper and lower layers, the angles are not fixed because the junctions are flexible. The experimental results reveal the formation of rhomboid rather than square structures; the junctions most likely behave cooperatively in order to maintain optimized base-stacking interactions and the lowest overall free energy. The single-stranded scaffold loop in one corner serves as an intrinsic marker to determine the angles adopted by the gridiron, and the angles display a bimodal distribution with nearly equal amplitudes, centered at 76° T 7° (SD) and 103° T 7°.
[0018] The flexibility of the joints makes it possible to control or reconfigure the conformation of the gridiron structure by exerting external forces on selected corners of a gridiron. A modified version of a 15-by-15 gridiron structure with 21-bp cavities has about one quadrant of the gridiron unfolded and forms a randomly coiled 836-nt single-stranded loop between two “arms” of tweezers ( FIG. 2G ). The ssDNA loop is long enough to allow the structure to adopt a relaxed conformation. The observed distribution of the inner angle (q) of the tweezers (measured from 309 individual structures) is broad and centered at 80° to 90°.
[0019] We could contract and extend the ssDNA loop by introducing secondary or tertiary structures that generate enough force to control the angle. Sets of staple strands were designed to either contract the ssDNA loop and fix an acute angle (a narrow distribution centered at 41° T 7°) via the formation of a two-helix bundle ( FIG. 2H ) or to extend the loop to secure a right ( FIG. 2I ) or obtuse angle ( FIG. 2J ) via the formation of a three-helix bundle of specific length. The design with the right angle shows a narrow and symmetrical distribution centered at 94° T 10°, and the design with the obtuse angle has a broader angle distribution centered at 102° and exhibits an asymmetry that is more heavily weighted toward smaller angles.
[0020] We extended the gridiron design into the third dimension by three different strategies. The first involves stacking multiple layers of 2D gridiron lattices at selected connection points ( FIG. 3 , A and B). The second relies on intertwining several gridiron planes in x-y-z directions ( FIG. 3C ). The third method has its basis in distorting a single layer of DNA gridiron into 3D structures by controlling their curvatures ( FIG. 4 ). By using the first strategy, we constructed a three-layer hexagonal ( FIG. 3D ), a four-layer rectangular gridiron ( FIG. 3E ), and a three-layer parallelogram structure. For all multilayer gridiron structures, the scaffold strand raster fills each layer, with an off-set in the angle formed between the helices of adjacent layers. The three-layer hexagonal and four-layer rectangular structures maintained 60° and 90° offsets between layers, respectively.
[0021] Varying the location and distance between connection points will yield differently patterned multilayer structures. In contrast to the angle flexibility present in the quasi-2D structures, the addition of a third layer fixes the angles at junction points. The only exception to this is for connections through the center of the same unit motif, as shown by the green dashed line ( FIG. 3A ). In a 3D model of an eight-by-eight-by-eight three-layer hexagonal gridiron structure ( FIG. 3D ), neighboring junctions in the top and bottom layers are 52 bp apart, and neighboring junctions in the middle layer (alternating connections to the top and bottom layers) are 26 bp apart. Because X=Y=L ( FIG. 3B ), each junction should adopt a 60° torsion angle. A four-layer rectangular gridiron structure ( FIG. 3E ) can be broken down into two six-by-five double-layer gridirons (with 52-bp cavities) stacked on top of one another with a 26-bp offset in the connections between the first and third, and second and fourth, layers.
[0022] The relations of the lattice planes in gridiron structures are not restricted to stacked multilayer structures. The 3D gridiron structures can also be assembled by integrating gridiron lattices with scaffold-free elements. FIG. 3F presents such a design in which a nine-by-nine gridiron plane (shown in blue) is intertwined with an eight-by-eight scaffold-free gridiron plane (shown in yellow). The complex, interwoven topology of this particular structure required combining scaffolded and scaffold-free components.
[0023] Gridiron designs can allow assembly of even more complex structures by inducing a desired curvature in the basic structural unit described in nonparallel helices. The relation between adjacent linear helices (the angles formed by their theoretical intersection) between adjacent linear helices was varied. Some 3D gridiron structures that contain curvature were also achieved, such as the sphere shown in FIG. 4B . The helices in concentric ring and radial spoke layers are stretched in the center and shrunk at the edges, forming a latitudinal and longitudinal framework, respectively. This is realized by progressively adjusting the distance between junctions in latitudinal directions. Additional modifications to the basic structural motif can be used to produce other complex structures. In the screw structure ( FIG. 4C ), the polarity of the DNA strands in the square unit motif differs from what is illustrated in FIG. 1B (where adjacent scaffold helices have an antiparallel polarity in one direction and the same polarity in the other direction). The scaffold strand is arranged in an antiparallel configuration to form a wireframe cylinder structure (11 helices are arranged axially) and subsequently wraps around the cylinder (analogous to a left-handed screw) until the two ends meet. The distance between adjacent axial helices is 21 bp, the interthread distance is 42 bp, and the AFM and TEM images display the expected left-handed conformation.
[0024] The design principles of creating gridiron units allow scaffold strands to travel in multiple directions, which represent an important departure from certain aspects of the previous DNA origami methods. Traditional Holliday junctions do not naturally adopt conformations that would allow them to be connected in such a way, and it was unexpected to find that these motifs could (within a larger network of crossovers) endure a 150° rotation of one of the arms while simultaneously maintaining their integrity. Indeed, the flexible and dynamic behavior of these motifs may have excluded these types of junction conformations for consideration in scaffolded structures. Yield analysis from agarose gel and TEM images shows that the structures, even without purification, form with reasonably high yield (from ˜36% for the gridiron tweezers to ˜85% for the gridiron screw, estimated from agarose gels; from ˜51% for the gridiron sphere to ˜89% for the four-layer gridiron, estimated from TEM images; see supplementary materials for yield analysis). The ability to engineer DNA gridirons that are analogous to vector-based objects, where a series of points with defined positions in 3D space are connected by lines, is an important milestone in the development of synthetic nucleic acid structures. In particular, this opens up new opportunities to implement the design of complex wireframe structures that are amenable to dynamic controls. A future challenge in DNA origami is to achieve true folding, starting from a 2D sheet (miura ori), rather than the 1D M13 scaffolds commonly used in traditional DNA origami construction. The loose 2D networks and freely rotating hinges between different planes of DNA gridirons provide the design features necessary to implement Miura on type of origami.
EXAMPLES
[0025] It should be understood that these Examples, while indicating preferred embodiments of the invention, are given by way of illustration only. From the above discussion and these following Examples, one skilled in the art can ascertain the essential characteristics of this invention, and without departing from the spirit and scope thereof, can make various changes and modifications of the invention to adapt it to various uses and conditions.
Materials and Methods
[0026] All staple strands were purchased from Integrated DNA Technologies Inc. (www.IDTDNA.com) in the format of 96-well plates at a 25 nmole synthesis scale. All the strands were normalized to 200 μM×100 μL and were used without further purification. M13mp18 single stranded DNA was purchased from New England Biolabs (NEB, Catalog number: #N4040S) and was used as received.
[0027] Assembly of 2D and 3D DNA nanostructures. The design and sequences of the DNA oligos used to form a particular structure are listed below. For each design, 10 nM of single stranded M13mp18 DNA (7,249 nucleotides) was mixed with a 10 times molar excess of staple strands in TAE Mg2+ buffer (40 mM Tris, 20 mM Acetic acid, 2 mM EDTA and 12.5 mM Magnesium acetate, pH 8.0). The resulting solutions were annealed from 95° C. to 4° C. to form the designed structures. The exact temperature steps for the slow anneal are as follows: 94 to 86° C. at 4° C. per 5 minutes; 85 to 70° C. at 1° C. per 5 minutes; 70 to 40° C. at 1° C. per 15 minutes; 40 to 25° C. at 1° C. per 10 minutes. The exact temperature steps for the fast anneal are as follows: 90 to 76° C. at 2° C. per 5 minutes; 76 to 24° C. at 4° C. per 5 minutes. All structures form in both anneal protocols. All samples are then subjected to AFM imaging and TEM imaging without further purification.
[0028] AFM imaging. For AFM imaging, the sample (2 L) was deposited onto a freshly cleaved mica surface (Ted Pella, Inc.) and left to adsorb for 2 min. 50 L buffer (1×TAE−Mg2+, plus 2 L 100 mM NiC12) was added onto the mica, and the sample was scanned on a Veeco 8 AFM in the Scanasyst in Fluid mode using scanasyst in fluid+tips (Veeco, Inc.).
[0029] TEM imaging: TEM samples were prepared by dropping 2 μL of the sample solution on a carbon-coated grid (400 mesh, Ted Pella). Before depositing the sample, the grids were negatively glow discharged (Emitech K100X). After 1 minute, the excess sample was wicked away from the grid with a piece of filter paper. To remove the excess salt, the grid was washed with a drop of nanopure water and the excess water was wicked away with filter paper. For staining, the grid was treated with a drop of 0.7% uranyl formate solution and the excess solution was removed with filter paper. The grid was treated with a second drop of uranyl formate solution for 20 seconds, and the excess solution was removed with filter paper. The grid was subsequently held at room temperature in air to evaporate the excess solution. TEM studies were conducted with a Philips CM12 transmission electron microscope, operated at 80 kV in bright field mode.
[0030] Agarose Gel electrophoresis: The folding products were subject to native gel electrophoresis on 0.75% agarose gel (1×TAE−Mg2+, preloaded in the gel with 0.5 μg/mL ethidium bromide) at 75-80 V for two to three hours and the gels were visualized under UV light.
[0031] Page Gel electrophoresis: The folding products were subject to native gel electrophoresis on 6% Native PAGE gel (polyacrymide; 1×TAE−Mg2+) at 200V for 2 hours at 20 degree and the gels were visualized under UV light.
[0032] Design details and sequences of assembled structures. “Tiamat” software was used to design all DNA Gridiron structures. Tiamat is a basic DNA drawing software program (similar programs also exist) and no special algorithms were used to design the DNA Gridiron structures. Most of the design tasks were performed manually and Tiamat was primarily used to generate Maple strands sequences according to the scaffold strand sequence.
[0033] Below are illustrated the design details and staple strand sequences of some example DNA Gridiron structures. Tiamat software and files for all designs are available for downloading at the following website: skydrive.live.com/redir?resid=2416F4B1C095AF65!152&authkey=!AELrUerdPdo1P1w.
[0000]
TABLE 1
Sequences of the staples in the 21 bps Gridiron structure
Name (No.)
Sequence
21bpsGridiron-1
GAAAATTCATAAGTAAGCGTCATACATGGCTTAGACGGGAGA (SEQ ID NO. 1)
21bpsGridiron-2
ATATTCACAAAATAAAAACAGGGAAGCGCATTTTGATGATAC (SEQ ID NO. 2)
21bpsGridiron-3
AGGAGTGTACTAATAAACAGCCATATTATTTAATTGGCCTTG (SEQ ID NO. 3)
21bpsGridiron-4
GCCAGTTACAAGGTAATAAGTTTTAACGGGGTGTCCTGAACA (SEQ ID NO. 4)
21bpsGridiron-5
GOADAACGCGCGAGGTTGAGGCAGGTCAGACGTCCCAATCCA (SEQ ID NO. 5)
21bpsGridiron-6
AATAAGAAACGGACTTGAGCCATTTGGGAATTTTCAGCTAAT (SEQ ID NO. 6)
21bpsGridiron-7
GAGAGAATAACCAAATAAATCCTCATTAAAGCAAGGGCGA (SEQ ID NO. 7)
21bpsGridiron-8
AGCATTGACAGCTGTTTATCAACAATAGATAACNTTGCCTTG (SEQ ID NO. 8)
21bpsGridiron-9
AGTAACAGTGCCCAGTAATAAGAGAATATAAAAGCCGCCGCC (SEQ ID NO. 9)
21bpsGridiron-10
GCATTTTCGAGCCGTATAAACAGTTAATGCCCTATCAAAATC (SEQ ID NO. 10)
21bpsGridiron-11
ATTAAGACGCTCGCCACCAGAACCACCACCAGGTACCGACAA (SEQ ID NO. 11)
21bpsGridiron-12
AAGGTAAAGTAAGCACCATTACCATTAGCAAGGATAGCTTAG (SEQ ID NO. 12)
21bpsGridiron-13
TTTACCGTTCCTGGTTTACCAGCGCCAAAGACCAGAATGGAAAG (SEQ ID NO. 13)
21bpsGridiron-14
CATTCAACCGATTGACGGAAATTATTCATTAAAGCCTTTACA (SEQ ID NO. 14)
21bpsGridiron-15
GAAAATAGCAGGTGAATTATCACCGTCACCATTTTTTGTT (SEQ ID NO. 15)
21bpsGridiron-16
GCAAAGACACCGTAAATGAATTTTCTGTATGGTAATTGAGCG (SEQ ID NO. 16)
21bpsGridiron-17
TAGCATTCCACACCCTGAACAAAGTCAGAGGGGATTTTGCTA (SEQ ID NO. 17)
21bpsGridiron-18
AAGAACTTTCACGCTAACGAGCGTCTTTCCAGACAACGCCTG (SEQ ID NO. 18)
21bpsGridiron-19
AATCTTACCAAACAGTTTCAGCGGAGTGAGAAATGTAGAAAC (SEQ ID NO. 19)
21bpsGridiron-20
AGAAAAATAATGTTTCGTCACCAGTACAAACTAGCCTAATTT (SEQ ID NO. 20)
21bpsGridiron-21
ATTAACTGAACAGACAGCCCTCATAGTTAGCGACAATCAATA (SEQ ID NO. 21)
21bpsGridiron-22
AACAACATGAGAGCCAGCAAAATCACCAGTATTCTGTCCA (SEQ ID NO. 22)
21bpsGridiron-23
CGTAACACTGAATCCCATCCTAATTTACGAGCTAGAAAGGAA (SEQ ID NO. 23)
21bpsGridiron-24
CAACTAAAGGATTAACAACGCCAACATGTAATACCCATGTAC (SEQ ID NO. 24)
21bpsGridiron-25
AATCGCCATATATTGCGAATAATAATTTTTTCGCTTAGGTTG (SEQ ID NO. 25)
21bpsGridiron-26
ATAGGTCTGAGGGGATAGCAAGCCCAATAGGATTAGGCAGAG (SEQ ID NO. 26)
21bpsGridiron-27
TCCAGACGTTAACGGAATAAGTTTATTTTGTCTAACGATCTAAA (SEQ ID NO. 27)
21bpsGridiron-28
TCGCCCACGCAGCCATTGCAACAGGAAAAATGCGCCGACA (SEQ ID NO. 28)
21bpsGridiron-29
CCTCATTTTCAAGACTACCTTTTTAACCTCCGACGTTGAAAA (SEQ ID NO. 29)
21bpsGridiron-30
TCTCCAAAAAATGAATTACCTTTTTTAATGGAGAGCCACCAC (SEQ ID NO. 30)
21bpsGridiron-31
ATATAAGTATTTGACGCTCAATCGTCTGAAGATAAGTGCC (SEQ ID NO. 31)
21bpsGridiron-32
ACCCTCAGAGCGAGAAGAGTCAATAGTGAATTCCTGCCTATT (SEQ ID NO. 32)
21bpsGridiron-33
TCGGAACCTATTGTGAGTGAATAACCTTGCTTCAGAGCCACC (SEQ ID NO. 33)
21bpsGridiron-34
CGTTTGCCAATTCACCAGTCACACGACCAGTTCGGTCATA (SEQ ID NO. 34)
21bpsGridiron-35
AAACATAGCGCCGGAAACGTCACCAATGAATAATTTTCCC (SEQ ID NO. 35)
21bpsGridiron-36
ACAATTTCATTAAGGCTCCAAAAGGAGCCTTTTATACTTCTG (SEQ ID NO. 36)
21bpsGridiron-37
GAACAAAGAATCAGTAGCGACAGAATCAAGTTGAGTAACA (SEQ ID NO. 37)
21bpsGridiron-38
GATAATACATTTGCTTTCGAGGTGAATTTCTTAGCCCTAAAA (SEQ ID NO. 38)
21bpsGridiron-39
ACAGAGATATAGCGCGTTTTCATCGGCATTTAATAAAAGG (SEQ ID NO. 39)
21bpsGridiron-40
ATTTTAAAAGTTTTGCCTTTAGCGTCAGACTGGAACCCTTCT (SEQ ID NO. 40)
21bpsGridiron-41
GACCTGAAAGCCGGAACCAGAGCCACCTACCGGAACGTTATTA (SEQ ID NO. 41)
21bpsGridiron-42
ATCAAAATCACGTAAGAATACGTGGCACAGACGGTTTTGCTC (SEQ ID NO. 42)
21bpsGridiron-43
AGTACCAGGCGATGGATTATTTACATTGGCAGTCTTTTCATA (SEQ ID NO. 43)
21bpsGridiron-44
AATTCGACAACGAGAAGGATTAGGATTAGCGGAATATTTTTG (SEQ ID NO. 44)
21bpsGridiron-45
AATGGCTATTACCGTACTCAGGAGGTTTAGTACTTTACAAAC (SEQ ID NO. 45)
21bpsGridiron-46
TAGGTGTATCAGTCTTTAATGCGCGAACTGATAAACAGCTTG (SEQ ID NO. 46)
21bpsGridiron-47
ATACCGATAGTCGCTCATGGAAATACCTACATTAGCCCGGAA (SEQ ID NO. 47)
21bpsGridiron-48
GTTTATCAGCTTGAGGATTTAGAAGTATTAGACCGCCACCCT (SEQ ID NO. 48)
21bpsGridiron-49
CAGAACCGCCATATAATCCTGATTGTTTGGATAATTGTATCG (SEQ ID NO. 49)
21bpsGridiron-50
AGACTCCTCAATCGTATTAAATCCTTTGCCCGAACCGCCTCC (SEQ ID NO. 50)
21bpsGridiron-51
CTCAGAGCCGCTATCATCATATTCCTGATTATTAAGAGGCTG (SEQ ID NO. 51)
21bpsGridiron-52
TCGCTATTAATACCATCGATAGCAGCACCGTAAACCACCAGA (SEQ ID NO. 52)
21bpsGridiron-53
AGGAGCGGAATCACCCTCAGAACCGCCACCCTCTGTAAATCG (SEQ ID NO. 53)
21bpsGridiron-54
AAATCAATATATATTCTGAAACATGAAAGTATCAGATGATGG (SEQ ID NO. 54)
21bpsGridiron-55
CAATTCATCAACCCTCAGAACCGCCACCCTCAAACAGTACAT (SEQ ID NO. 55)
21bpsGridiron-56
GGTTATATAACCGGCTACAGAGGCTTTGAGGACTTAATTGAG (SEQ ID NO. 56)
21bpsGridiron-57
TAAGGCGTTCCCAATTCTGCGAACGAGTAGTGAAATACCG (SEQ ID NO. 57)
21bpsGridiron-58
GCTTAATTGCTAACGCAATAATAACGGAATAGAGGTCATTTTTG (SEQ ID NO. 58)
21bpsGridiron-59
TAATTTCATCTACTTCAAATATCGCGTTTTAATCATAATTAC (SEQ ID NO. 59)
21bpsGridiron-60
TAGAAAAAGCCGTTTACCAGACGACGATAAAAATATTTTAGT (SEQ ID NO. 60)
21bpsGridiron-61
AGTTGAGATTTAGACTCCTTATTACGCAGTATATTATTACAGGT (SEQ ID NO. 61)
21bpsGridiron-62
AAGACAAAGAATAATCATTGTGAATTACCTTATACAAATTCT (SEQ ID NO. 62)
21bpsGridiron-63
TACCAGTATAATCCATGTTACTTAGCCGGAACATCCAATCGC (SEQ ID NO. 63)
21bpsGridiron-64
ATCTTTGACCCATACATAAAGGTGGCAACATAGGCAAAAGAATA (SEQ ID NO. 64)
21bpsGridiron-65
AACCGAGGAGAATATAATGCTGTAGCTGAAGCCGAACAAA (SEQ ID NO. 65)
21bpsGridiron-66
CTAATATCAGAGCACCAACCTAAAACGAAAGATAAAAGAAAC (SEQ ID NO. 66)
21bpsGridiron-67
CCACTAGGAAGGAGATAACCCACAAGAATTGAACAAAGTA (SEQ ID NO. 67)
21bpsGridiron-68
CAACGGAGATTGTATTTTGCACCGAGCTACAAATACGTAATG (SEQ ID NO. 68)
21bpsGridiron-69
TAGAAGGCTAAGTACGGTGTCTGGAAGTTTCCCAATAGCA (SEQ ID NO. 69)
21bpsGridiron-70
CAATCAATAATAGTTTCCATTAAACGGGTAAATTTTATCCTG (SEQ ID NO. 70)
21bpsGridiron-71
TTTCATGAGGACGGCTGTCTTTGCTTATCATTGTGTCGAAAT (SEQ ID NO. 71)
21bpsGridiron-72
CCGCGACCTGCAGCCAACGCTCAACAGTAGGGCTAAAGACTT (SEQ ID NO. 72)
21bpsGridiron-73
AAGATTAGTTGTGTATCATCGCCTGATAAATTCCAAGAACGG (SEQ ID NO. 73)
21bpsGridiron-74
GTATTAAACCAATTATACCAGTCAGGACGTTGGGCTTAAATC (SEQ ID NO. 74)
21bpsGridiron-75
AGAACTGGCTCAGTACCGCACTCATCGAGAACAGCAACACTA (SEQ ID NO. 75)
21bpsGridiron-76
TCATAACCCTCTGTTTAGTATCATATGCGTTATGCGATTTTA (SEQ ID NO. 76)
21bpsGridiron-77
AGCGAACCTCCGGAATTACGAGGCATAGTAAGAAGGAAGGCG (SEQ ID NO. 77)
21bpsGridiron-78
TTTTTATTTTCGACCGGAAGCAAACTCCAACAGAGGCGTTTT (SEQ ID NO. 78)
21bpsGridiron-79
AAAGCGAACCAATCGTAGGAATCATTACCGCGCATTCCATAT (SEQ ID NO. 79)
21bpsGridiron-80
AACAGTTGATTAAATAAGAATAAACACCGGAATTCGAGCTTC (SEQ ID NO. 80)
21bpsGridiron-81
ATATGCAACTATATCCGGTATTCTAAGAACGCCGTCAGGATT (SEQ ID NO. 81)
21bpsGridiron-82
AGAGAGTACGTTTTAAGAAAAGTAAGCAGATACATGTTTTAA (SEQ ID NO. 82)
21bpsGridiron-83
TAACGCCAAAACGACTTGCGGGAGGTTTTGAAGGAAGAAAAA (SEQ ID NO. 83)
21bpsGridiron-84
TCTACGTTAATAAGAAACAATGAAATAGCAATTGCAGATACA (SEQ ID NO. 84)
21bpsGridiron-85
GTAGAAAATACCCAGCGATTATACCAAGCGCGGTTAAGCCCA (SEQ ID NO. 85)
21bpsGridiron-86
ATAATAAGAGCAAAACGAACTAACGGAACAACGTTAGCAAAC (SEQ ID NO. 86)
21bpsGridiron-87
TGGCATGATTAAGGAATACCACATTCAACTAAAGCTATCTTA (SEQ ID NO. 87)
21bpsGridiron-88
CCGAAGCCCTTTTAATTGCTCCTTTTGATAAGCCAAAAGAAC (SEQ ID NO. 88)
21bpsGridiron-89
AAGCCCGAAAGTCTGACCTAAATTTAATGGTTATTTAGTTTG (SEQ ID NO. 89)
21bpsGridiron-90
ACCATTAGATAGATTGCTTTGAATACCAAGTTGATTAAGAGG (SEQ ID NO. 90)
21bpsGridiron-91
TAAACTAGTTTTTGATTAGTAATAACATCACCATTGAATCC (SEQ ID NO. 91)
21bpsGridiron-92
AATTTCAACTTCGCGAGAAAACTTTTTCAAATACCAAAATAG (SEQ ID NO. 92)
21bpsGridiron-93
CGAGAGGCTTTTTATTCATTTCAATTACCTGAGAGATGGTTT (SEQ ID NO. 93)
21bpsGridiron-94
ATTCATTACAACTATCGGCCTTGCTGGTAAAGTAATCTTG (SEQ ID NO. 94)
21bpsGridiron-95
GAGGGTAGCAATATATGTAAATGCTGATGCAAGAGGCGCAGA (SEQ ID NO. 95)
21bpsGridiron-96
CGGTCAATCATAACATCAAGAAAACAAAATTAGCATCGGAAC (SEQ ID NO. 96)
21bpsGridiron-97
GATTCGCCTCATTTCGCAAATGGTCAATAATTACATCGGG (SEQ ID NO. 97)
21bpsGridiron-98
AATAATGGAAGCACCCTCAGCAGCGAAAGACAATTACATTTA (SEQ ID NO. 98)
21bpsGridiron-99
TGCGGGATCGTGGTTAGAACCTACCATATCAATTTGAAAGAG (SEQ ID NO. 99)
21bpsGridiron-100
GACAGATGAACACTAACAACTAATAGATTAGAAGGCCGCTTT (SEQ ID NO. 100)
21bpsGridiron-101
CTCAAATATTTGGGGCGCGAGCTGAAAAGGTCTAAAGCAT (SEQ ID NO. 101)
21bpsGridiron-102
CATCGCCATTACTGAGGCTTGCAGGGAGTTAAGCCGTCAATA (SEQ ID NO. 102)
21bpsGridiron-103
ATATTCGGTCGAAAATACCGAACGAACCACCAGGCTGGCTGA (SEQ ID NO. 103)
21bpsGridiron-104
CCTTCATCAAGTATCCAGAACAATATTACCGCCATAACCGAT (SEQ ID NO. 104)
21bpsGridiron-105
TCTTTAGGAGCGGTGTACAGACCAGGCGCATAGCAGAAGATA (SEQ ID NO. 105)
21bpsGridiron-106
AAACAGAGGTGGCTCATTCAGTGAATAAGGCTATCTAAAATA (SEQ ID NO. 106)
21bpsGridiron-107
GTAACAAAGCTAGGCGGTCAGTATTAACACCGTGCGGAATCG (SEQ ID NO. 107)
21bpsGridiron-108
TGATAAATATTTTGCCTGAGTAGAAGAACTCACCAAATCAAC (SEQ ID NO. 108)
21bpsGridiron-109
AAATCAACAGTAGACTGGATAGCGTCCAATACCCTGCAACAG (SEQ ID NO. 109)
21bpsGridiron-110
TGCCACGCTGAAATCAAAAATCAGGTCTTTACGTCAGTTGGC (SEQ ID NO. 110)
21bpsGridiron-111
GAATGACCATAGAGCCAGCAGCAAATGAAAAATGGCATCAAT (SEQ ID NO. 111)
21bpsGridiron-112
TCTACTAATAGTAACCGTTGTAGCAATACTTCCAGAAAACGA (SEQ ID NO. 112)
21bpsGridiron-113
TATATTTTCATCAAACCCTCAATCAATATCTGCCTGACTATT (SEQ ID NO. 113)
21bpsGridiron-114
ATAGTCAGAAGAATATACAGTAACAGTACCTTCCTGTTTAGC (SEQ ID NO. 114)
21bpsGridiron-115
GTAAAATGTTTTGAAAGGAATTGAGGAAGGTTTGCCCTGACG (SEQ ID NO. 115)
21bpsGridiron-116
AGAAACACCAGAAATAAAGAAATTGCGTAGATGGGGGTAATA (SEQ ID NO. 116)
21bpsGridiron-117
ATGATGAAACAAAGGGAACCGAACTGACCAACAATTATTTGC (SEQ ID NO. 117)
21bpsGridiron-118
ACGTAAAACAGAACGAGTAGTAAATTGGGCTTGCAAAAGAAG (SEQ ID NO. 118)
21bpsGridiron-119
GCAGAGGCGAATGCAAAAGAAGTTTTGCCAGATTTCAGGTTT (SEQ ID NO. 119)
21bpsGridiron-120
AACGTCAGATGCAAAGCGGATTGCATCAAAAAACAAAATCGC (SEQ ID NO. 120)
[0000] TABLE 2 Sequences of the staples in the 42 bps Gridiron structure Name (No.) Sequence 42bpsGridiron-1 CCTCCCGACTTGCGGGAGGTTCTGCATTAATGAATCGGCCAA (SEQ ID NO. 121) 42bpsGridiron-2 TAACTCACATTAATTGCGTTGAGAATTAACTGAACACCCTGA (SEQ ID NO. 122) 42bpsGridiron-3 AAAATGAAAATAGCAGCCTTTTTAAATTTTTGTTAAATCAGC (SEQ ID NO. 123) 42bpsGridiron-4 AACAGGAAGATTGTATAAGCATACAATTTTATCCTGAATCTT (SEQ ID NO. 124) 42bpsGridiron-5 AGTTGCTATTTTGCACCCAGCAATATTTAAATTGTAAACGTT (SEQ ID NO. 125) 42bpsGridiron-6 AATATTTTGTTAAAATTCGCAACAGAGAGAATAACATAAAAA (SEQ ID NO. 126) 42bpsGridiron-7 CAGGGAAGCGCATTAGACGGGCGCTCACTGCCCGCTTTCCAG (SEQ ID NO. 127) 42bpsGridiron-8 TCGGGAAACCTGTCGTGCCAGTTGAAGCCTTAAATCAAGATT (SEQ ID NO. 128) 42bpsGridiron-9 ACCAACGCTAACGAGCGTCTTTGTCAATCATATGTACCCCGG (SEQ ID NO. 129) 42bpsGridiron-10 GGTCATTGCCTGAGAGTCTGGACGATTTTTTGTTTAACGTCA (SEQ ID NO. 130) 42bpsGridiron-11 TTATCCCAATCCAAATAAGAAAGCAAACAAGAGAATCGATGA (SEQ ID NO. 131) 42bpsGridiron-12 ACGGTAATCGTAAAACTAGCATCCAGAGCCTAATTTGCCAGT (SEQ ID NO. 132) 42bpsGridiron-13 CCGCCACCCTCAGAGCCACCATTTCATCAACATTAAATGTGA (SEQ ID NO. 133) 42bpsGridiron-14 TCATTTTTTAACCAATAGGAAGTAGCGCGTTTTCATCGGCAT (SEQ ID NO. 134) 42bpsGridiron-15 AACCATCGATAGCAGCACCGTTGGDGTGCCTAATGAGTGAGC (SEQ ID NO. 135) 42bpsGridiron-16 AGCTTGCATGCCTGCAGGTCGTAGTTGCGCCGACAATGACAA (SEQ ID NO. 136) 42bpsGridiron-17 TTTCGGTCATAGCCCCCTTATAGAGATCTACAAAGGCTATCA (SEQ ID NO. 137) 42bpsGridiron-18 CCTCATATATTTTAAATGCAAAAAAAAGGCTCCAAAAGGAGC (SEQ ID NO. 138) 42bpsGridiron-19 TTTCACGTTGAAAATCTCCAATGCCTGAGTAATGTGTAGGTA (SEQ ID NO. 139) 42bpsGridiron-20 AAGATTCAAAAGGGTGAGAAATGAGAATAGAAAGGAACAACT (SEQ ID NO. 140) 42bpsGridiron-21 TCATAGTTAGCGTAACGATCTTGGTCATAGCTGTTTCCTGTG (SEQ ID NO. 141) 42bpsGridiron-22 CCGAGCTCGAATTCGTAATCAAAAGTTTTGTCGTCTTTCCAG (SEQ ID NO. 142) 42bpsGridiron-23 ACGTTAGTAAATGAATTTTCTTCTCCGTGGGAACAAACGGCG (SEQ ID NO. 143) 42bpsGridiron-24 GCGAGTAACAACCCGTCGGATGTATGGGATTTTGCTAAACAA (SEQ ID NO. 144) 42bpsGridiron-25 CTTTAATTGTATCGGTTTATCTCACGTTGGTGTAGATGGGCG (SEQ ID NO. 145) 42bpsGridiron-26 GATTGACCGTAATGGGATAGGAGCTTGCTTTCGAGGTGAATT (SEQ ID NO. 146) 42bpsGridiron-27 CTTTCAACAGTTTCAGCGGAGGGCCGGAGACAGTCAAATCAC (SEQ ID NO. 147) 42bpsGridiron-28 CATCAATATGATATTCAACCGTCAGAGCCGCCACCCTCAGAA (SEQ ID NO. 148) 42bpsGridiron-29 CCACCACCGGAACCGCCTCCCTTCTAGCTGATAAATTAATGC (SEQ ID NO. 149) 42bpsGridiron-30 TGAAATTGTTATCCGCTCACAGCATTGAGAGGAGGTTGAGGC (SEQ ID NO. 150) 42bpsGridiron-31 CCACCACCAGAGCCGCCGCCAATTCCACACAACATACGAGCC (SEQ ID NO. 151) 42bpsGridiron-32 TCTGGCCTTCCTGTAGCCAGCCCCTCAGAGCCGCCACCAGAA (SEQ ID NO. 152) 42bpsGridiron-33 CGGAGAGGGTAGCTATTTTTGTAGCGTTTGCCATCTTTTCAT (SEQ ID NO. 153) 42bpsGridiron-34 TCTTAAACAGCTTGATACCGAACTCTAGAGGATCCCCGGGTA (SEQ ID NO. 154) 42bpsGridiron-35 GGAAGCATAAAGTGTAAAGCCAATCAGTAGCGACAGAATCAA (SEQ ID NO. 155) 42bpsGridiron-36 GTTTGCCTTTAGCGTCAGACTCGCCATCAAAAATAATTCGCG (SEQ ID NO. 156) 42bpsGridiron-37 ACAGGTAGAAAGATTCATCAGACTCCAGCCAGCTTTCCGGCA (SEQ ID NO. 157) 42bpsGridiron-38 CATCGTAACCGTGCATCTGCCTGGTTTAATTTCAACTTTAAT (SEQ ID NO. 158) 42bpsGridiron-39 ATTCAGTGAATAAGGCTTGCCGTAAAACGACGGCCAGTGCCA (SEQ ID NO. 159) 42bpsGridiron-40 CATTGTGAATTACCTTATGCGAAGGATAAAAATTTTTAGAAC (SEQ ID NO. 160) 42bpsGridiron-41 TAGCAAAATTAAGCAATAAAGTCTACTAATAGTAGTAGCATT (SEQ ID NO. 161) 42bpsGridiron-42 CGAACGAGTAGATTTAGTTTGCGCTATTACGCCAGCTGGCGA (SEQ ID NO. 162) 42bpsGridiron-43 GGCGATCGGTGCGGGCCTCTTACCATTAGATACATTTCGCAA (SEQ ID NO. 163) 42bpsGridiron-44 ATGGTCAATAACCTGTTTAGCAGGCAAAGCGCCATTCGCCAT (SEQ ID NO. 164) 42bpsGridiron-45 CCGCTTCTGGTGCCGGAAACCTATATTTTCATTTGGGGCGCG (SEQ ID NO. 165) 42bpsGridiron-46 AGCTGAAAAGGTGGCATCAATCCTCAGAGCATAAAGCTAAAT (SEQ ID NO. 166) 42bpsGridiron-47 CGGTTGTACCAAAAACATTATAACTAACGGAACAACATTATT (SEQ ID NO. 167) 42bpsGridiron-48 AAAATCTACGTTAATAAAACGGACCCTGTAATACTTTTGCGG (SEQ ID NO. 168) 42bpsGridiron-49 AAGGGGGATGTGCTGCAAGGCACGCCAAAAGGAATTACGAGG (SEQ ID NO. 169) 42bpsGridiron-50 TTCAACTAATGCAGATACATAGATTAAGTTGGGTAACGCCAG (SEQ ID NO. 170) 42bpsGridiron-51 TATCGGCCTCAGGAAGATCGCTTGAGATTTAGGAATACCACA (SEQ ID NO. 171) 42bpsGridiron-52 GAGAAGCCTTTATTTCAACGCATTTTAAGAACTGGCTCATTA (SEQ ID NO. 172) 42bpsGridiron-53 GGTTTTCCCAGTCACGACGTTCTGACGAGAAGCACCAGAACG (SEQ ID NO. 173) 42bpsGridiron-54 AGTAGTAAATTGGGCTTGAGAAGTTTGAGGGGACGACGACAG (SEQ ID NO. 174) 42bpsGridiron-55 TCTTTCCTTATCATTCCAAGACGTAAAACAGAAATAAAGAAA (SEQ ID NO. 175) 42bpsGridiron-56 TTGTTTGGATTATACTTCTGAAAAGTTACCAGAAGGAAACCG (SEQ ID NO. 176) 42bpsGridiron-57 AATGAAATAGCAATAGCTATCAATGGATTATTTACATTGGCA (SEQ ID NO. 177) 42bpsGridiron-58 CCAGCCATTGCAACAGGAAAAGCCGTTTTTATTTTCATCGTA (SEQ ID NO. 178) 42bpsGridiron-59 GCACTCATCGAGAACAAGCAAACGCTCATGGAAATACCTACA (SEQ ID NO. 179) 42bpsGridiron-60 TTTTGACGCTCAATCGTCTGATTACCGAAGCCCTTTTTAAGA (SEQ ID NO. 180) 42bpsGridiron-61 AAAGTAAGCAGATAGCCGAACATAATGGAAGGGTTAGAACCT (SEQ ID NO. 181) 42bpsGridiron-62 ACCATATCAAAATTATTTGCAACGGGTATTAAACCAAGTACC (SEQ ID NO. 182) 42bpsGridiron-63 GGAATCATTACCGCGCCCAATTCAAACTATCGGCCTTGCTGG (SEQ ID NO. 133) 42bpsGridiron-64 AATTAACCGTTGTAGCAATACCCAATAATAAGAGCAAGAAAC (SEQ ID NO. 184) 42bpsGridiron-65 ACAAAGTCAGAGGGTAATTGACCGCCTGGCCCTGAGAGAGTT (SEQ ID NO. 185) 42bpsGridiron-66 TATTGGGCGCCAGGGTGGTTTAACGCGAGGCGTTTTAGCGAA (SEQ ID NO. 136) 42bpsGridiron-67 AGGCTTATCCGGTATTCTAAGTTCTTTTCACCAGTGAGACGG (SEQ ID NO. 187) 42bpsGridiron-68 GCAACAGCTGATTGCCCTTCAGCGCTAATATCAGAGAGATAA (SEQ ID NO. 188) 42bpsGridiron-69 CCCACAAGAATTGAGTTAAGCTTCTTTGATTAGTAATAACAT (SEQ ID NO. 139) 42bpsGridiron-70 CACTTGCCTGAGTAGAAGAACAGCAAGCAAATCAGATATAGA (SEQ ID NO. 190) 42bpsGridiron-71 TTCCAGTAAGCGTCATACATGTGACCTGAAAGCGTAAGAATA (SEQ ID NO. 191) 42bpsGridiron-72 GATTCACCAGTCACACGACCAAAGGTGAATTATCACCGTCAC (SEQ ID NO. 192) 42bpsGridiron-73 CAAAACCCCGACATTCAACCGAGTTCATCAATATAATCCTGA (SEQ ID NO. 193) 42bpsGridiron-74 TTTACAAAAAATTCGACAACTACTTTTTCATGAGGAAGTTTC (SEQ ID NO. 194) 42bpsGridiron-75 CAACCATCGCCCACGCATAACAAAGAACGTGGACTCCAACGT (SEQ ID NO. 195) 42bpsGridiron-76 GCAGCAAGCGGTCCACGCTGGGGCCGGAAACGTCACCAATGA (SEQ ID NO. 196) 42bpsGridiron-77 CGACTTGAGCCATTTGGGAATAAAGAGTCTGTCCATCACGCA (SEQ ID NO. 197) 42bpsGridiron-78 TGGTTGCTTTGACGAGCACGTCTTTTGCGGGATCGTCACCCT (SEQ ID NO. 193) 42bpsGridiron-79 CTTGCACCCAGTTAAAGGCCGATAACGTGCTTTCCTCGTTAG (SEQ ID NO. 199) 42bpsGridiron-80 AATCAGAGCGGGAGCTAAACACCGTAACACTGAGTTTCGTCA (SEQ ID NO. 200) 42bpsGridiron-81 GGAGGTTTAGTACCGCCACCCTGAGTAACATTATCATTTTGC (SEQ ID NO. 201) 42bpsGridiron-82 ACGTTATTAATTTTAAAAGTTTCAGAACCGCCACCCTCAGAA (SEQ ID NO. 202) 42bpsGridiron-83 CCGCCACCCTCAGAGCCACCAGAATGGCTATTAGTCTTTAAT (SEQ ID NO. 203) 42bpsGridiron-84 CGTGGCACAGACAATATTTTTCCCTCATTTTCAGGGATAGCA (SEQ ID NO. 204) 42bpsGridiron-85 CAGCAGCGAAAGACAGCATCGACATCGCCATTAAAAATACCG (SEQ ID NO. 205) 42bpsGridiron-86 GCGCGAACTGATAGCCCTAAAGAACGAGGGTAGCAACGGCTA (SEQ ID NO. 206) 42bpsGridiron-87 AGCCCAATAGGAACCCATGTAGGAGGCCGATTAAAGGGATTT (SEQ ID NO. 207) 42bpsGridiron-88 ATCAAAAGAATAGCCCGAGATGTAGCATTCCACAGACAGCCC (SEQ ID NO. 208) 42bpsGridiron-89 CCAGTACAAACTACAACGCCTAGGGTTGAGTGTTGTTCCAGT (SEQ ID NO. 209) 42bpsGridiron-90 TAGACAGGAACGGTACGCCAGGCGCAGTCTCTGAATTTACCG (SEQ ID NO. 210) 42bpsGridiron-91 AGGTCAGACGATTGGCCTTGAAATCGGCAAAATCCCTTATAA (SEQ ID NO. 211) 42bpsGridiron-92 CCTGTTTGATGGTGGTTCCGATATTCACAAACAAATAAATCC (SEQ ID NO. 212) 42bpsGridiron-93 TCATTAATGCCAGAATGGAAAAATCCTGAGAAGTGTTTTTAT (SEQ ID NO. 213) 42bpsGridiron-94 GGAACAAAGAAACCACCAGAAGGGTCAGTGCCTTGAGTAACA (SEQ ID NO. 214) 42bpsGridiron-95 TACTGGTAATAAGTTTTAACGGGAGCGGAATTATCATCATAT (SEQ ID NO. 215) 42bpsGridiron-96 CCAACAGAGATAGAACCCTTCGCTTTTGATGATACAGGAGTG (SEQ ID NO. 216) 42bpsGridiron-97 AATCAGTGAGGCCACCGAGTATAGAGCCAGCAAAATCACCAG (SEQ ID NO. 217) 42bpsGridiron-98 TAGCACCATTACCATTAGCAATTTGCCCCAGCAGGCGAAAAT (SEQ ID NO. 218) 42bpsGridiron-99 TTGGAACAAGAGTCCACTATTCGATATATTCGGTCGCTGAGG (SEQ ID NO. 219) 42bpsGridiron-100 CAGAGGCTTTGAGGACTAAAGCGTATTAAATCCTTTGCCCGA (SEQ ID NO. 220) 42bpsGridiron-101 TCCTGATTATCAGATGATGGCATTGAGGGAGGGAAGGTAAAT (SEQ ID NO. 221) 42bpsGridiron-102 ATTGACGGAAATTATTCATTAGTAATAAAAGGGACATTCTGG (SEQ ID NO. 222) 42bpsGridiron-103 TTTGCCAGAGGGGGTAATAGTGTGCCACGCTGAGAGCCAGCA (SEQ ID NO. 223) 42bpsGridiron-104 AACGAACCACCAGCAGAAGATATGAACGGTGTACAGACCAGG (SEQ ID NO. 224) 42bpsGridiron-105 CGGAACGAGGCGCAGACGGTCGAGGATTTAGAAGTATTAGAC (SEQ ID NO. 225) 42bpsGridiron-106 CAAAGGGCGAAAAACCGTCTAATCAACGTAACAAAGCTGCTC (SEQ ID NO. 226) 42bpsGridiron-107 CGCATAGGCTGGCTGACCTTCGCCGCTACAGGGCGCGTACTA (SEQ ID NO. 227) 42bpsGridiron-108 CGTGGCGAGAAAGGAAGGGAAATATGCAACTAAAGTACGGTG (SEQ ID NO. 228) 42bpsGridiron-109 AGGATTAGAGAGTACCTTTAAGAAAGGAATTGAGGAAGGTTA (SEQ ID NO. 229) 42bpsGridiron-110 TCAGTTGGCAAATCAACAGTTTTGCTCCTTTTGATAAGAGGT (SEQ ID NO. 230) 42bpsGridiron-111 CATTTTTGCGGATGGCTTAGATCACCTTGCTGAACCTCAAAT (SEQ ID NO. 231) 42bpsGridiron-112 GCAAATGAAAAATCTAAAGCAGCTTAATTGCTGAATATAATG (SEQ ID NO. 232) 42bpsGridiron-113 CTGTAGCTCAACATGTTTTAAGAAAGCGAAAGGAGCGGGCGC (SEQ ID NO. 233) 42bpsGridiron-114 TAAAGCACTAAATCGGAACCCAACAGTTGATTCCCAATTCTG (SEQ ID NO. 234) 42bpsGridiron-115 TCTGGAAGTTTCATTCCATATTAAAGGGAGCCCCCGATTTAG (SEQ ID NO. 235) 42bpsGridiron-116 TAGGGCGCTGGCAAGTGTAGCAGAGGCTTTTGCAAAAGAAGT (SEQ ID NO. 236) 42bpsGridiron-117 CATAGTAAGAGCAACACTATCTTTTTTGGGGTCGAGGTGCCG (SEQ ID NO. 237) 42bpsGridiron-118 TGAACCATCACCCAAATCAAGATAACCCTCGTTTACCAGACG (SEQ ID NO. 238) 42bpsGridiron-119 ACGATAAAAACCAAAATAGCGGGTCACGCTGCGCGTAACCAC (SEQ ID NO. 239) 42bpsGridiron-120 TCTAAAATATCTTTAGGAGCAATAAATATTCATTGAATCCCC (SEQ ID NO. 240) 42bpsGridiron-121 GTCCAATACTGCGGAATCGTCCTAACAACTAATAGATTAGAG (SEQ ID NO. 241) 42bpsGridiron-122 GTATTAACACCGCCTGCAACAAAAATGTTTAGACTGGATAGC (SEQ ID NO. 242) 42bpsGridiron-123 CACACCCGCCGCGCTTAATGCATCAAGAGTAATCTTGACAAG (SEQ ID NO. 243) 42bpsGridiron-124 AACCGGATATTCATTACCCAATCAGGGCGATGGCCCACTACG (SEQ ID NO. 244) 42bpsGridiron-125 CCGTCAATAGATAATACATTTAATCATAAGGGAACCGAACTG (SEQ ID NO. 245) 42bpsGridiron-126 ACCAACTTTGAAAGAGGACAGAAAACAGAGGTGAGGCGGTCA (SEQ ID NO. 246) 42bpsGridiron-127 ATCAACAATAGATAAGTCCTGTGTCCAGACGACGACAATAAA (SEQ ID NO. 247) 42bpsGridiron-128 GCAGAGGCATTTTCGAGCCAGGTATGTTAGCAAACGTAGAAA (SEQ ID NO. 248) 42bpsGridiron-129 AGGAAACGCAATAATAACGGATTGCTTTGAATACCAAGTTAC (SEQ ID NO. 249) 42bpsGridiron-130 GTCAGATGAATATACAGTAACAAACCAATCAATAATCGGCTG (SEQ ID NO. 250) 42bpsGridiron-131 TCCTAATTTACGAGCATGTAGAGTACCTTTTACATCGGGAGA (SEQ ID NO. 251) 42bpsGridiron-132 AACAATAACGGATTCGCCTGAATACCCAAAAGAACTGGCATG (SEQ ID NO. 252) 42bpsGridiron-133 ATTAAGACTCCTTATTACGCATAATAAGAGAATATAAAGTAC (SEQ ID NO. 253) 42bpsGridiron-134 CGACAAAAGGTAAAGTAATTCAACAAGAAAAATAATATCCCA (SEQ ID NO. 254) 42bpsGridiron-135 CATTAAACGGGTAPAATACGTTGAGTGAATAACCTTGCTTCT (SEQ ID NO. 255) 42bpsGridiron-136 AAAATCGCGCAGAGGCGAATTATGGTTTACCAGCGCCAAAGA (SEQ ID NO. 256) 42bpsGridiron-137 ATAAAAGAAACGCAAAGACACCAACGCCAACATGTAATTTAG (SEQ ID NO. 257) 42bpsGridiron-138 GIGATAAATAAGGCGTTAAATAGAATACACTAAAACACTCAT (SEQ ID NO. 258) 42bpsGridiron-139 ACCTAAAACGAAAGAGGCAAAAAGAATAAACACCGGAATCAT (SEQ ID NO. 259) 42bpsGridiron-140 AATTACTAGAAAAAGCCTGTTGGATAAGTGCCGTCGAGAGGG (SEQ ID NO. 260) 42bpsGridiron-141 GGGTTTTGCTCAGTACCAGGCTAGTATCATATGCGTTATACA (SEQ ID NO. 261) 42bpsGridiron-142 TACATTTAACAATTTCATTTGATAGGTGTATCACCGTACTCA (SEQ ID NO. 262) 42bpsGridiron-143 TTGATATAAGTATAGCCCGGAAATTACCTTTTTTAATGGAAA (SEQ ID NO. 263) 42bpsGridiron-144 AATTCTTACCAGTATAAAGCCGTATTAAGAGGCTGAGACTCC (SEQ ID NO. 264) 42bpsGridiron-145 GTGCCCGTATAAACAGTTAATCATCAAGAAPACAAPATTAAT (SEQ ID NO. 265) 42bpsGridiron-146 AAAAGAAGATGATGAAACAAAGCCCCCTGCCTATTTCGGAAC (SEQ ID NO. 266) 42bpsGridiron-147 CTATTATTCTGAAACATGAAAAAGCGTCAACAGTAGGGCTTA (SEQ ID NO. 267) 42bpsGridiron-148 ATTGAGAATCGCCATATTTAACACGGAATAAGTTTATTTTGT (SEQ ID NO. 268) 42bpsGridiron-149 CACAATCAATAGAAAATTCATATTCATTTCAATTACCTGAGC (SEQ ID NO. 269) 42bpsGridiron-150 CAGTACATAAATCAATATATGAATGCCACTACGAAGGCACCA (SEQ ID NO. 270) 42bpsGridiron-151 CTAAATCGTCGCTATTAATTAACCTGCTCCATGTTACTTAGC (SEQ ID NO. 271) 42bpsGridiron-152 AGCGCGAAACAAAGTACAACGATGGTTTGAAATACCGACCGT (SEQ ID NO. 272) 42bpsGridiron-153 TATAACTATATGTAAATGCTGCAAATATCGCGTTTTAATTCG (SEQ ID NO. 273) 42bpsGridiron-154 AAGAGGAAGCCCGAAAGACTTATGCAAATCCAATCGCAAGAC (SEQ ID NO. 274) 42bpsGridiron-155 TAGTGAATTTATCAAAATCATGGAAGCAAACTCCAACAGGTC (SEQ ID NO. 275) 42bpsGridiron-156 AGCTTCAAAGCGAACCAGACCAGGTCTGAGAGACTACCTTTT (SEQ ID NO. 276) 42bpsGridiron-157 AAAGAACGCGAGAAAACTTTTCTGACTATTATAGTCAGAAGC (SEQ ID NO. 277) 42bpsGridiron-158 CTCAAATGCTTTAAACAGTTCTAAGACGCTGAGAAGAGTCAA (SEQ ID NO. 278) 42bpsGridiron-159 AAACATAGCGATAGCTTAGATAGAAAACGAGAATGACCATAA (SEQ ID NO. 279) 42bpsGridiron-160 ATCAAAAATCAGGTCTTTACCTCAAATATATTTTAGTTAATT (SEQ ID NO. 280) 42bpsGridiron-161 TCATCTTCTGACCTAAATTTAGAGATTTGTATCATCGCCTGA (SEQ ID NO. 281) 42bpsGridiron-162 TAAATTGTGTCGAAATCCGCGATTTTCCCTTAGAATCCTTGA (SEQ ID NO. 282)
The claims are not intended to be limited to the embodiments and examples described herein.
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Novel compositions and methods for engineering wireframe architectures and scaffolds of increasing complexity by creating gridiron-like DNA structures (FIG. 1 ). A series of four-arm junctions are used as vertices within a network of double-helical DNA fragments. Deliberate distortion of the junctions from their most relaxed conformations ensures that a scaffold strand can traverse through individual vertices in multiple directions. DNA gridirons, ranging from two-dimensional arrays with reconfigurability to multilayer and three-dimensional structures and curved objects, can be assembled according the methods presented herein.
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CROSS REFERENCE TO RELATED APPLICATION
This application claims priority from Japanese Patent Application No. 2005-021991, filed Jan. 28, 2005, the contents of which are hereby incorporated by reference into the present application.
TECHNICAL FIELD
The disclosure relates to an image forming device such as a laser printer, and a process cartridge and a developer cartridge which are, in use, mounted on the image forming device.
BACKGROUND
Conventional image forming devices such as a laser printer use a photosensitive cartridge in which a photosensitive drum is rotatably supported. A developer cartridge is also used therein for supplying the photosensitive drum with toner. The photosensitive cartridge and the developer cartridge are mountable to and detachable from the main body of the device. Only necessary one or ones of the cartridges can be replaced with a new one when the lifetime of the cartridge is ended.
Japanese Patent Application Publication No. 2000-267547 discloses a photosensitive cartridge, for use in an image forming device. The photosensitive cartridge has a flat lower surface facilitating to place the cartridge removed from the image forming device on a flat table.
With the photosensitive cartridge according to the proposal described above, the cartridge can be placed stably on a flat plane. However, the shape of the upper surface of the cartridge does not allow another photosensitive cartridge to be stacked thereon. Typically, a manufacturer collects and stores, in a stock room, old photosensitive cartridges or developer cartridges detached from the main body of the device for recycling In this case, it is convenient if the cartridges can be stacked one on the other. Otherwise, inconvenience is caused in handling the old cartridges and a large space is required for storage.
SUMMARY
In view of the foregoing, it is an object of the present invention to provide a process cartridge and a developer cartridge which can be stacked stably, without packing the cartridges in boxes, and an image forming device including such a process cartridge or developer cartridge.
In order to attain the above and other objects, the present invention provides a process cartridge being detachably mountable in an image-forming device. The process cartridge includes a main casing. The main casing includes a first wall, a second wall, and a third wall. The first wall is formed with at least one first engagement part. The second wall is formed with at least one second engagement part. The second wall is disposed in confronting relation with the first wall. The third wall connects the first wall and the second wall. When a plurality of the process cartridges are stacked one on the other with the first wall being downside with respect to the second wall, the first engagement part in one process cartridge engages the second engagement part in another process cartridge disposed just below the one process cartridge.
According to another aspect of the present invention provides a developer cartridge, detachably mountable in an image-bearing member cartridge. The developer cartridge includes a developer main casing. The developer main casing includes a first developer wall and a second developer wall. The first developer wall is formed with a convex part. The second developer wall is formed with an insertion portion inserted by the convex part when the developer cartridge is mounted on the image-bearing member cartridge. The second developer wall is disposed in confronting relation with the first developer wall.
According to another aspect of the present invention provides a developer cartridge being detachably mountable in an image-bearing member cartridge. The developer cartridge includes a developer main casing. The developer main casing includes a first developer wall and a second developer wall. The first developer wall is formed with a first developer engagement part. The second developer wall is formed with a second developer engagement part. The second developer wall is disposed in confronting relation with the first developer wall. When a plurality of the developer cartridges are stacked one on the other with the first developer wall being downside with respect to the second developer wall facing upward, the first developer engagement part in one process cartridge engages the second developer engagement part in another developer cartridge disposed just below the one developer cartridge.
According to another aspect, of the present invention provides an image-forming device. The image-forming device includes a process cartridge. The process cartridge includes a main casing. The main casing includes a first wall, a second wall, and a third wall. The first wall is formed with at least one first engagement part. The second wall is formed with at least one second engagement part. The second wall is disposed in confronting relation with the first wall. The third wall connects the first wall and the second wall. When a plurality of the process cartridges are stacked one on the other with the first wall being downside with respect to the second wall, the first engagement part in one process cartridge engages the second engagement part in another process cartridge disposed just below the one process cartridge.
According to another aspect of the present invention provides an image-forming device. The image-forming device includes a developer cartridge being detachably mountable in an image-bearing member cartridge. The developer cartridge includes a developer main casing. The developer main casing includes a first developer wall and a second developer wall. The first developer wall is formed with a convex part. The second developer wall is formed with an insertion portion into which the convex part is inserted when the developer cartridge is mounted on the image-bearing member cartridge. The second developer wall is disposed in confronting relation with the first developer wall.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings:
FIG. 1 is a side cross-sectional view of a main part of a laser printer according to a preferred embodiment of the present invention;
FIG. 2 is a side cross-sectional view of a process cartridge shown in FIG. 1 ;
FIG. 3 is a plan view of a drum cartridge shown in FIG. 1 ;
FIG. 4 is a bottom view of the drum cartridge shown in FIG. 1 ;
FIG. 5 is a side view of the drum cartridge shown in FIG. 1 ;
FIG. 6 is a plan view of a developer cartridge shown in FIG. 1 ;
FIG. 7 is a bottom view of the developer cartridge shown in FIG. 1 ;
FIG. 8 is a side view of the developer cartridge shown in FIG. 1 ;
FIG. 9 is a side view of the process cartridge shown in FIG. 1 when the developer cartridge is mounted on the drum cartridge;
FIG. 10 is a bottom view of the process cartridge shown in FIG. 1 , when the developer cartridge is mounted on the drum cartridge;
FIG. 11 is a side view of the process cartridge shown in FIG. 1 , when the drum cartridges are stacked;
FIG. 12 is a side view of stacked process cartridges each shown in FIG. 1 , when each developer cartridge is mounted on the drum cartridge; and
FIG. 13 is a side view of stacked developer cartridges each shown in FIG. 1 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
A preferred embodiment of the present invention will be described while referring to the accompanying drawings wherein like parts and components are designated by the same reference numerals to avoid duplicating description.
<Overall Structure of Laser Printer>
FIG. 1 is a side cross-sectional view showing a laser printer as an image forming device according to an embodiment of the present invention. In FIG. 1 , the laser printer 1 has a feeder section 4 and an image forming section 5 , in a body casing 2 . The feeder section 4 serves to feed a paper sheet 3 as a recording medium. The image forming section 5 serves to form an image on the paper sheet 3 .
<Structure of Body Casing 2 >
A sheet discharge tray 6 for receiving the paper sheet 3 on which an image has been formed is formed on the upper surface of the body casing 2 . On one side of the sheet discharge tray 6 , an operation panel having operation keys, and an LED display portion are provided. Further, an opening 7 through which a process cartridge 22 to be described in detail is detachably mounted is formed on the side wall at the operation panel side in the body casing 2 . A front cover 8 is provided for opening and closing the opening 7 . The front cover 8 is pivotably movably supported by a cover shaft (not shown) inserted in a lower end portion of the front cover 8 . The front cover 8 is pivotably moved to selectively open and close the opening. Specifically when the front cover 8 is opened (tilted), the opening 7 is opened whereas when the front cover 8 is closed, the opening 7 is closed. Through the opening 7 , the process cartridge 22 can be mounted on and detached from the body casing 2 .
In the description below, the side in which the front cover is provided is defined as the “front side” of this laser printer 1 , and the opposite side is as the “rear side”. The direction perpendicular to sheet of drawing in FIG. 1 is defined as the widthwise direction of the laser printer 1 .
<Structure of Feeder Section>
The feeder section 4 includes a sheet feed tray 9 , a sheet press plate 10 , a sheet feed roller 11 , a sheet feed pad 12 , paper powder removal rollers 13 and 14 , and registration rollers 15 . The sheet feed tray 9 is detachably mounted on a bottom portion of the body casing 2 . The sheet press plate 10 is provided in the sheet feed tray 9 . The sheet feed roller 11 and sheet feed pad 12 are provided in the front and upper side of the sheet feed tray 9 . The paper powder removal roller 13 is disposed in opposition to the sheet feed roller 11 with the paper sheet conveying path intervened therebetween. Another paper powder removal rollers 14 are disposed in the downstream side of the sheet feed roller 11 in the conveying direction of a paper sheet 3 . The registration rollers 15 are disposed in the downstream side of the paper powder removal rollers 13 and 14 in the conveying direction of the paper sheet 3 .
The sheet press plate 10 adapted to receive paper sheets 3 to be stacked thereon. When the paper sheets 3 are stacked on the sheet press plate 10 , an end portion of the sheet press plate 10 moves away from the sheet feed roller 11 . The sheet press plate 10 is urged upwardly by a spring (not shown) from the back side thereof. Therefore, as the number of stacked paper sheets 3 increases, the sheet press plate 10 is moved downwardly against the pressing force of the spring. The sheet feed roller 11 is disposed in confronting relation with the sheet feed pad 12 . The sheet feed pad 12 is pressed against the sheet feed roller 11 by a spring 16 provided on the back side of sheet feed pad 12 .
The paper sheet 3 stacked at the uppermost position on the sheet press plate 10 is pressed against the sheet feed roller 11 by the pressing force of the spring from the back side of the sheet press plate 10 . The uppermost paper sheet 3 is sandwiched between the sheet feed roller 11 and the sheet feed pad 12 and fed by rotation of the sheet feed roller 11 upon being separated from the remaining paper sheets 3 .
Further, paper powder is removed by the paper powder removal rollers 13 and 14 . Thereafter, the paper sheet 3 is conveyed by the registration rollers 15 .
The registration rollers 15 consist of a pair of rollers opposed to each other. After registration of the paper sheet 3 is completed, the registration rollers 15 convey the paper sheet 3 to a transfer position between a photosensitive drum 32 and a transfer roller 34 where a toner image on the photosensitive drum 32 is transferred to the paper sheet 3 .
The feeder section 4 further includes a multipurpose tray 17 , a multipurpose tray side sheet feed roller 18 , and a multipurpose tray side sheet feed pad 19 . The multipurpose tray side sheet feed roller 18 and multipurpose tray side sheet feed pad 19 serve to feed paper sheets 3 stacked on the multipurpose tray 17 . The multipurpose tray side sheet feed roller 18 and the multipurpose tray side sheet feed pad 19 are disposed in opposition to each other. The multipurpose tray side sheet feed pad 19 is pressed toward the multipurpose tray side sheet feed roller 18 by a spring 20 provided in the back side of the multipurpose tray side sheet feed pad 19 .
The paper sheets 3 stacked on the multipurpose tray 17 are separated one after another and fed into a nip between the multipurpose tray side sheet feed roller 18 and the multipurpose tray side sheet feed pad 19 . The paper sheet 3 is fed by rotation of the multipurpose tray side sheet feed roller 18 .
<Structure of Image Forming Section>
The image forming section 5 includes a scanner section 21 , a process cartridge 22 , a fixing section 23 .
<Structure of Scanner Section>
The scanner section 21 is disposed at an upper portion inside the body casing 2 . The scanner section 21 includes a laser light emission section (not shown), a polygon mirror 24 , lenses 25 and 26 , and reflection mirrors 27 , 28 , and 29 . A laser beam modulated based on image data emitted from the laser light emission section. Then the modulated laser beam is reflected by the polygon mirror 24 , passes through the lens 25 , and reflected by or passes through reflection mirrors 27 and 28 , lens 26 , and reflection mirror 29 in this order, as indicated by a chain line in FIG. 1 . The laser beam is thus irradiated onto the surface of the photosensitive drum 32 contained in the process cartridge 22 .
<Structure of Process Cartridge>
FIG. 2 is a side cross-sectional view of the process cartridge 22 .
The process cartridge 22 is detachably mounted on the body casing 2 and disposed below the scanner section 21 . This process cartridge 22 includes a drum cartridge 30 , and a developer cartridge 31 which is detachably mounted on the drum cartridge 30 .
<Structure of Drum Cartridge>
As shown in FIG. 2 , the drum cartridge 30 includes a cartridge frame 103 , a photosensitive drum 32 disposed in the cartridge frame 103 , a scorotron charger 33 , a transfer roller 34 , and a cleaning brush 35 .
FIG. 3 is a plan view of a drum cartridge 30 . FIG. 4 is a bottom view of the drum cartridge 30 . FIG. 5 is a side view of the drum cartridge 30 .
As shown in FIG. 3 , a cartridge frame 103 integrally has a left side wall 36 , a right side wall 37 , a bottom wall 38 , a front wall 39 , and a rear upper wall 40 .
The left side wall 36 and the right side wall 37 are opposed to each other with an interval in the widthwise direction therebetween. Further, the left side wall 36 and the right side wall 37 have substantially symmetrical structures in the widthwise direction. As shown in FIG. 5 , each of the left side wall 36 and right side wall 37 has a rear side wall portion 41 having a substantially bow-side like shape when viewed from a side, and a front side wall portion 42 extending frontwardly from the rear side wall portion 41 .
In the front side wall portion 42 , a roller shaft guide portion 43 , and a roller shaft receiving portion 44 are formed. The roller shaft guide portion 43 guides a shaft end portion of a developer roller shaft 91 described later when the developer cartridge 31 is attached to the drum cartridge 30 . The roller shaft receiving portion 44 is formed continuously with a rear end of the roller shaft guide portion 43 , and receives the end portion of the developer roller shaft 91 guided by the roller shaft guide portion 43 .
The roller shaft guide portion 43 is formed as a part of an upper end edge of the front side wall portion 42 . That is, the roller shaft guide portion 43 extends obliquely downwardly toward the rear side from the middle of the front side wall portion 42 . The roller shaft guide portion 43 is downwardly shaped and gradually flattened toward the rear side.
The roller shaft receiving portion 44 is formed below a protruding wall 45 and continuous to the rear side of the roller shaft guide portion 43 . The roller shaft receiving portion 44 is a substantially in a rectangular shape when viewed from a side. A lower end edge of the protruding wall 45 is formed continuously with the rear end edge of the roller shaft guide portion 43 .
Also, the front side wall portion 42 has a front engagement convex portion 46 . When plural drum cartridges 30 are stacked one on the other, the front engagement convex portion 46 of the lower drum cartridge 30 is engageable with a front engagement concave portion 49 of the upper drum cartridge 30 , described later This front engagement convex portion 46 is flat at the top and formed as a part of the upper end edge of the front side wall portion 42 . Further, the upper front end portion 47 of the front side wall portion 42 extends obliquely downwardly toward the front side, the front engagement convex portion 46 is higher than the top flat portion of the front end portion 47 and the roller shaft guide portion 43 .
As shown in FIG. 3 , the bottom wall 38 is substantially flat in shape, and is provided to connect lower end edges of the left side wall 36 and the right side wall 37 in the front-to-rear direction. As shown in FIGS. 4 and 5 , the bottom wall 38 has a pair of rear engagement convex portions 48 , at a position below the drum shaft 56 of a photosensitive drum 32 and right and left side end portions. When plural drum cartridges 30 are stacked one on the other, the rear engagement convex portions 48 are engaged with (inserted in) rear engagement concave portions 52 (described later) of an upper drum cartridge 30 . Each of the rear engagement convex portions 48 is formed of a thin plate which is curved to protrude downwardly. When a drum cartridge 30 is put on a flat mount surface S, each of the rear engagement convex portions 48 contacts the mount surface S, and supports the drum cartridge 30 such that the rear upper wall 40 and the front engagement convex portion 46 are substantially parallel to the mount surface S.
Also, a pair of front engagement concave portions 49 is formed in the bottom wall 38 at positions opposed in the widthwise direction. When plural drum cartridges 30 are stacked one on the other, the front engagement concave portions 49 are engaged with (receive) the front engagement convex portions 46 of an upper drum cartridge 30 . The front engagement concave portion 49 is substantially in a rectangular shape when viewed from the bottom.
Further, as shown in FIG. 4 , a pair of insertion portions 62 is formed at the left and right side end portions of the bottom wall 38 . When a plurality of the drum cartridge 30 is stacked one on the other, the developer engagement convex portion 80 , described later, of the lower drum cartridge 30 can be inserted in the insertion portion 62 of upper drum cartridge 30 . Each of the insertion portions 62 is provided at a position near the center with respect to the front-to-rear direction, ie., between the rear engagement convex portion 48 and the front engagement concave portion 49 . The insertion portions 62 are in the form of a through-hole having a substantially rectangular shape when viewed from the bottom.
The front wall 39 is bent upwardly from the front end edge of the bottom wall 38 . This front wall 39 is substantially in a rectangular shape. Both end portions of the front wall 39 in the widthwise direction are bent perpendicularly and are formed continuously with the left side wall 36 and right side wall 37 .
As shown in FIGS. 3 and 5 , the rear upper wall 40 is a flat, plate-like member and is provided so as to connect to the upper end edges of the rear side wall portions 41 of the left side wall 36 and the right side wall 37 . At the front portion of the rear upper wall 40 , a laser input window 50 is formed which is substantially rectangular in shape when viewed from the top extends in the widthwise direction, as shown in FIG. 3 . The rear upper wall 40 has a charger support portion 51 for supporting a Scorotron charger 33 , which is disposed behind the laser input window 50 .
Further, in the rear upper wall 40 , a pair of rear engagement concave portions 52 is formed. When plural drum cartridges 30 are stacked one on the other, the pair of rear engagement concave portions 52 of the lower drum cartridge 30 is engageable with the pair of the rear engagement convex portions 48 at the left and right side end portions of the rear upper wall 40 of the upper drum cartridge 30 . Each of the rear engagement concave portions 52 is provided at a position opposed in the vertical direction to the rear engagement convex portions 48 .
Further, in the cartridge frame 103 , a drum accommodating section 53 which accommodates the photosensitive drum 32 , is formed by the rear side wall portions 41 of the left and right side walls 36 and 37 , the rear upper wall 40 , and the rear portion of the bottom wall 38 which is opposed in the vertical direction to the rear upper wall 40 . The drum accommodating section 53 is open to the front. A developer cartridge accommodating section 54 which accommodates the developer cartridge 31 is formed by the front side wall portions 42 of the left and right side walls 36 and 37 , and the front portion of the bottom wall 38 formed continuously with each of the front side wall portions 42 in the widthwise direction. The developer cartridge accommodating section 54 is open in the upper side and communicates with the drum accommodating section 53 in the rear side.
As shown in FIG. 2 , the photosensitive drum 32 has a cylindrical drum body 55 and a metal-made drum shaft 56 . The drum body 55 is formed of a photosensitive layer having positive charges. A surface layer of the drum body 55 is made of polycarbonate. The drum shaft 56 extends in the longitudinal direction of the drum body 55 through the center of the drum body 55 to be loosely rotatable about the drum body 55 . The drum shaft 56 is fixedly supported by the left and right side walls 36 and 37 of the drum cartridge 30 . Thus, the photosensitive drum 32 , disposed between the left and the right side walls 36 and 37 is rotatable around the drum shaft 56 .
The Scorotron charger 33 is disposed above the photosensitive drum 32 and supported by the charger support portion 51 . The Scorotron charger 33 is disposed opposite to the photosensitive drum 32 without contacting each other. A predetermined interval is maintained between the Scorotron charger 33 and the photosensitive drum 32 . This Scorotron charger 33 has a wire 57 , grid 58 , and a wire cleaner 59 .
The wire 57 is stretched between the left and right side walls 36 and 37 while imparting a predetermined tension therebetween.
The grid 58 extends in the widthwise direction to surround the lower side of the wire 57 . The grid 58 is bridged between the left and right side walls 36 and 37 .
A wire cleaner 59 (see FIG. 3 ) is provided to be slidably movable in the widthwise direction of the charger support portion 51 , while sandwiching and contacting the wire 57 . The sliding movement of the wire cleaner 59 cleans the wire 57 .
A transfer roller 34 is rotatably supported between the left and right side walls 36 and 37 . As shown in FIG. 2 , the transfer roller 34 is opposed to and contacts the photosensitive drum 32 , thereby forming a nip between the transfer roller 34 and the photosensitive drum 32 . This transfer roller 34 includes a transfer roller shaft 60 made of metal, and a roller 61 made of a conductive rubber material.
A cleaning brush 35 is disposed at the rear side of the photosensitive drum 32 . A lot of bristles of the cleaning brush 35 are supported on a support plate having an elongated rectangular shape extending in the widthwise direction. The cleaning brush 35 is opposed to the photosensitive drum 32 in the front-to-rear direction, such that the bristles contact the surface of the photosensitive drum 32 along the widthwise direction.
<Structure of Developer Cartridge>
FIG. 6 is a plan view of the developer cartridge 31 . FIG. 7 is a bottom view of the developer cartridge 31 . FIG. 8 is a side view of the developer cartridge 31 .
The developer cartridge 31 is detachably mounted in the developer cartridge accommodating section 54 . As shown in FIG. 2 , the developer cartridge 31 includes a box-like developer casing 63 open in the rear side, a feed roller 64 , a developer roller 65 , and a layer-thickness regulation blade 66 .
As shown in FIGS. 6 and 7 , the developer casing 63 is defined by a left side wall 67 , a right side wall 68 , a lower wall 69 , and an upper wall 70 . The left side wall 67 and the right side wall 68 are disposed opposed to each other, with an interval therebetween in the widthwise direction. The lower wall 69 and the upper wall 70 are connected to the left and right side walls 67 and 68 . As shown in FIG. 9 , when the developer cartridge 31 is mounted in the developer cartridge accommodating section 54 of the drum cartridge 30 and the drum cartridge 30 on which the developer cartridge 31 is mounted is put on the mount surface S, the upper surface (upper wall 70 ) is held substantially at the same height as the upper surface of the rear upper wall 40 .
The left and right side walls 67 and 68 are in a plate-like shape extending in the front-to-rear direction. The upper wall 70 is bridged between upper end edges of both walls. The left and right side walls 67 and 68 sandwich the lower wall 69 , and are provided such that inner surfaces of the walls 67 and 68 are opposed to each other.
As shown in FIG. 8 , the left side wall 67 is provided with an intermediate gear 72 , an agitator drive gear 73 , a developer roller drive gear 74 , and a feed roller drive gear 75 . The intermediate gear 72 is toothed with an input gear 71 . The agitator drive gear 73 is provided in the front side of the intermediate gear 72 , and is meshingly engaged with the intermediate gear 72 . The developer roller drive gear 74 is positioned obliquely below the input gear 71 in the rear side of the input gear 71 , and is meshingly engaged with the input gear 71 . The feed roller drive gear 75 is provided below the input gear 71 and is meshingly engaged with the input gear 71 . Drive force from a motor (not shown) is applied to the input gear 71 .
As shown in FIG. 8 , a toner filling port 76 for filling toner in a toner accommodating section 85 is formed in the left side wall 67 obliquely above the agitator drive gear 73 . The toner filling port 76 is circular in shape, penetrating the left side wall 67 in the thickness direction at the position corresponding to the toner accommodating section 85 . The toner filling port 76 is closed by a cap 77 for preventing toner in the toner accommodating section 85 from leaking out of the toner filling port 76 .
The lower wall 69 is a plate-like member extending in the front-to-rear direction and the widthwise direction (see FIG. 7 ), and includes a rear lower wall portion 78 and a front lower wall portion 79 . The rear lower wall portion 78 serves for partitioning a developer room 84 described later. The front lower wall portion 79 is continuous to the front end edge of the rear lower wall portion 78 , and has a substantially arcuate cross-sectional shape along the rotation orbit of an agitator 87 described later. The lower wall 69 is held between the left side wall 67 and the right side wall 68 .
At each of the left and right end side portions of the rear lower wall portion 78 (both side end portions in the widthwise direction), a developer engagement convex portion 80 is provided. The developer engagement convex portion 80 is inserted in insertion portions 62 of the drum cartridge 30 when the developer cartridge 31 is mounted in the drum cartridge 30 . Each of the developer engagement convex portions 80 is in a substantially rectangular shape when viewed from a side. Each of the developer engagement convex portions 80 is provided outside an area through which a paper sheet 3 entering between the photosensitive drum 32 and the transfer roller 34 passes. As shown in FIG. 8 , when the developer cartridge 31 is put on the flat mount surface S, the developer engagement convex portions 80 contact the mount surface S and support the developer cartridge 31 such that the upper wall 70 is substantially parallel to the mount surface S.
As shown in FIG. 2 , a lower partition portion 81 having a substantially triangular cross-sectional shape and protruding upwardly is formed along the widthwise direction, at the boundary between the rear lower wall portion 78 and the front lower wall portion 79 .
As shown in FIG. 6 , the upper wall 70 is a plate-like member and is bridged between upper end edges of the left and right side walls 67 and 68 . At the rear end portions of the upper wall 70 , developer engagement concave portions 82 are formed at the left and right side end portions of the upper wall 70 . When plural developer cartridges 31 are stacked one on the other, the developer engagement concave portions 82 of the lower developer cartridge are engageable with the developer engagement convex portions 80 of the upper developer cartridge 31 . The developer engagement concave portion 82 in the left side is substantially rectangular in shape when viewed from the top. The concave portion 82 in left side is engaged with the lower end portion of the left developer engagement convex portion 80 of an upper developer cartridge 31 when plural developer cartridges 31 are stacked. On the other side, the right developer engagement concave portion 82 is formed in the form of a stepped portion lower in level by one step than the upper surface of the upper wall 70 . The right side concave portion 82 is also engaged with the lower end portion of the right developer engagement convex portion 80 of the upper developer cartridge 31 when plural developer cartridges 31 are stacked.
As shown in FIG. 2 , an upper partition plate 83 protruding downwardly is formed along the widthwise direction on the lower surface of the upper wall 70 , opposed to the lower partition portion 81 of the lower wall 69 .
Further, in this developer casing 63 , an inner space at the front side from the upper and lower partition portions 83 and 81 , is partitioned and formed as developer room 84 . Another inner space at the rear side is partitioned and formed as a toner accommodating section 85 .
In the toner accommodating section 85 , toner made from electrically positive, non-magnetic component is accommodated as a developer. Used as the toner is polymerized toner which is obtained by a known copolymerization method by which a polymerization monomer, for example, a styrene monomer such as styrene or an acrylic monomer such as an acrylic acid, alkyl (C1 to C4) acrylate, or alkyl (C1 to C4) methacrylate are coplymerized. This kind of polymerized toner grains is spherical shape and has very excellent fluidity. Therefore, images can be formed with high image quality.
Toner of this kind is mixed with a coloring agent such as carbon-black, wax, or the like. In order to improve fluidity, an external additive agent such as silica is added. The grain diameter of the external additive agent is about 6 to 10 μm.
In the toner accommodating section 85 , an agitator 87 for stirring toner in the toner accommodating section 85 is provided. At the central portion of the toner accommodating section 85 , the agitator 87 is supported by an agitator rotation shaft 88 extending in the widthwise direction.
A feed roller 64 is provided in the front lower side in the developer room 84 , and is rotatably supported between the left and right side walls 67 and 68 of the developer casing 63 . This feed roller 64 is formed of a metal-made feed roller shaft 89 , and a sponge roller 90 . The feed roller shaft 89 extends in the widthwise direction. The sponge roller 90 made of an electrically conductive foaming material covers the circumference of the feed roller shaft 89 .
The developer roller 65 is provided in the rear lower side in the developer room 84 . The developer roller 65 and the feed roller 64 are pressed against each other. The rear portion of the developer roller 65 is partially exposed rearward from the developer casing 63 . A rear part of the developer roller 65 has a metal-made developer roller shaft 91 , which is covered with a rubber roller 92 made of electrically conductive rubber material, the rubber covering the circumference of the developer roller shaft 91 . More specifically, the rubber roller 92 is made of electrically conductive urethane rubber or silicone rubber containing fine carbon grains. The surface of the rubber roller 92 is covered with urethane rubber or silicon rubber containing fluorine. As shown in FIGS. 6 and 7 , end portions of the developer roller shaft 91 in both sides extend outwardly in the widthwise direction beyond the side plates of the developer casing 63 .
As shown in FIG. 2 , the layer-thickness regulation blade 66 is formed of a metal leaf spring. The layer-thickness regulation blade 66 is provided, at the top end portion thereof with a press rubber member 93 having a semi-circular cross-section made of an electrically insulating silicone rubber. Further, the layer-thickness regulation blade 66 is supported by the developer casing 63 at a position above the developer roller 65 . The lower end portion of the layer-thickness regulation blade 66 is in contact with the rubber roller 92 of the developer roller 65 . The press rubber member 93 is pressed against the surface of the rubber roller 92 by elastic force of the layer-thickness regulation blade 66 .
FIG. 9 is a side view of a process cartridge 22 in which the developer cartridge 31 is mounted on the drum cartridge 30 . FIG. 10 is a bottom view of the process cartridge 22 .
The developer cartridge 31 is attached to the developer cartridge accommodating section 54 of the drum cartridge 30 in the following manner. That is, the developer cartridge 31 is located above the developer cartridge accommodating section 54 of the drum cartridge 30 . Further, both end portions of the developer roller shaft 91 protruding outwardly from both sides of the developer casing 63 are guided along the roller shaft guide portions 43 of the cartridge frame 103 of the drum cartridge 30 , the developer cartridge 31 is moved down. Further, both end portions of the developer roller shaft 91 are brought into contact with the rear end edges of the roller shaft receiving portions 44 , and are respectively received in the roller shaft receiving portions 44 . Then, the developer cartridge 31 is completely mounted in the drum cartridge 30 .
In this mounting process, the developer engagement convex portions 80 of the developer cartridge 31 are inserted in the insertion portions 62 of the drum cartridge 30 , as shown in FIG. 10 . Therefore, each of the developer engagement convex portions 80 does not obstruct mounting the developer cartridge 31 in the drum cartridge 30 . As a result, smooth mount of the developer cartridge 31 to the drum cartridge 30 is ensured.
Referring to FIGS. 2 and 8 , a drive force is applied to the input gear 71 of the developer cartridge 31 . By this drive force, the agitator 87 is rotated around the agitator rotation shaft 88 . Then, toner in the toner accommodating section 85 is stirred and expelled toward the developer room 84 through a section between the upper partition plate 83 and the lower partition portion 81 . Further, the toner supplied to the developer room 84 is conveyed onto the developer roller 65 by the rotation of the feed roller 64 . At this time, toner is frictionally positively charged when passing through a nip between the sponge roller 90 of the feed roller 64 and the rubber roller 92 of the developer roller 65 . The toner supplied onto the developer roller 65 enters a nip between the developer roller 65 and the press rubber member 93 of the layer-thickness regulation blade 66 along with the rotation of the developer roller 65 , thereby forming a thin toner layer having a constant thickness. The layer is carried on the developer roller 65 .
Meanwhile, the surface of the photosensitive drum 32 is positively charged uniformly by the Scorotron charger 33 . Thereafter, the surface of the photosensitive drum 32 is exposed to a laser beam from the scanner section 21 . An electrostatic latent image based on image data is formed on the photosensitive drum 32 .
Next, the positively charged toner carried on the developer roller 65 is supplied to the electrostatic latent image formed on the photosensitive drum 32 . That is, of the photosensitive drum uniformly charged positively, toner is attracted to the exposed parts that have been exposed to the laser beam and have a lowered potential. Accordingly, the toner is selectively carried on the photosensitive drum 32 , and the latent image is thus visualized.
The paper sheet 3 is fed between the photosensitive drum 32 and the transfer roller 34 . A toner image carried on the surface of the photosensitive drum 32 is transferred to the paper sheet 3 .
<Structure of Fixing Section>
As shown in FIG. 1 , the fixing section 23 is provided in the rear side of the process cartridge 22 and in the downstream side in the conveying direction of the paper sheet 3 . The fixing section 23 includes a heating roller 94 , a press roller 95 which presses the heating roller 94 , and a pair of conveyer rollers 96 . The press roller 95 is opposed to the heating roller 94 . The pair of conveyer rollers 96 is provided in the downstream side of the press roller 95 in the conveying direction of the paper sheet 3 .
The heating roller 94 houses a halogen lamp and is made of metal for heating. In the fixing section 23 , the toner image transferred to the paper sheet 3 is thermally fixed while the paper sheet 3 passes between the heating roller 94 and the press roller 95 . Thereafter, the paper sheet 3 is conveyed to a sheet discharge path 97 by the conveyer rollers 96 . The paper sheet 3 is discharged onto the sheet discharge tray 6 by the sheet discharge rollers 98 .
In this laser printer 1 , residual toner remaining on the surface of the photosensitive drum 32 after transferring the toner image to the paper sheet 3 is collected by the developer roller 65 . If the toner remaining on the photosensitive drum 32 is collected by such a cleanerless method, neither a toner cleaner device nor a storage portion of waste toner are necessary. The structure of the device can thus be simplified.
<Structure of Reverse Conveyer Section>
The laser printer 1 is provided with a reverse conveyer section 99 to form images on both sides of the paper sheet 3 . This reverse conveyer section 99 includes sheet discharge rollers 98 , a reverse conveying path 100 , a flapper 101 , and plural reverse conveyer rollers 102 .
The sheet discharge rollers 98 are constituted by a pair of rollers and is constructed such that forward and reverse rotations can be switched to each other. In discharging the paper sheet 3 onto the sheet discharge tray 6 , the sheet discharge rollers 98 rotate in the forward direction. Otherwise, in reversing the paper sheet 3 , the sheet discharge rollers 98 rotate in the reverse direction.
The reverse conveying path 100 is arranged along the vertical direction so that the paper sheet 3 can be conveyed from the sheet discharge rollers 98 to the plural reverse conveyer rollers 102 provided below the image forming position. An end portion of the reverse conveying path 100 in the upstream side is positioned near the sheet discharge rollers 98 . Another end thereof in the downstream side is positioned near the reverse conveyer rollers 102 .
The flapper 101 is pivotally disposed in a branch portion between the sheet discharge path 97 and the reverse conveying path 100 . By energization or de-energization of a solenoid (not shown), the conveying direction can be switched from the direction toward the sheet discharge path 97 to the direction toward the reverse conveying path 100 .
Plural reverse conveyer rollers 102 are provided in the front-to-rear direction, above the sheet feed tray 9 . The reverse conveyer roller 102 in the most upstream side is positioned near the rear end portion of the reverse conveying path 100 . The reverse conveyer rollers 102 in the most downstream side is positioned below the registration rollers 15 .
Further, to form images on both sides of the paper sheet 3 , this reverse conveyer section 99 is operated as follows. A paper sheet 3 having a surface on which an image has been formed is conveyed from the sheet discharge path 97 to the sheet discharge rollers 98 by the conveyer rollers 96 . Then, the sheet discharge rollers 98 forwardly rotate with the paper sheet 3 sandwiched therebetween, and convey the paper sheet 3 to the outside (the side of the sheet discharge tray 6 ). When most part of the paper sheet 3 is fed to the outside and the rear end of the paper sheet 3 is sandwiched between the sheet discharge rollers 98 , the sheet discharge rollers 98 stop rotating. Subsequently, the sheet discharge rollers 98 rotate in the reverse direction, and the flapper 101 pivots to switch the conveying direction such that the paper sheet 3 is conveyed to the reverse conveying path 100 . The paper sheet 3 is conveyed to the reverse conveying path 100 with the top and bottom of the paper sheet 3 reversed. After conveyance of the paper sheet 3 is completed, the flapper 101 is switched to an original state, i.e., a state in which the paper sheet 3 fed from the conveyer rollers 96 is sent to the sheet discharge rollers 98 .
Subsequently, the paper sheet 3 conveyed to the reverse conveying path 100 in the opposite direction is further conveyed to the reverse conveyer rollers 102 . From the reverse conveyer rollers 102 , the paper sheet 3 is conveyed upwardly and further reversed, and sent to the registration rollers 15 . The paper sheet 3 conveyed to the registration rollers 15 is subjected to registration again. Thereafter, the paper sheet 3 is fed to the image forming position. Images are thus formed on both sides of the paper sheet 3 .
<Stacking of Process Cartridges>
FIG. 11 is a side view showing a state in which two drum cartridges 30 are stacked. FIG. 12 is a side view showing a state in which developer cartridges 31 are mounted in the drum cartridges 30 . FIG. 13 is a side view showing a state in which two developer cartridges 31 are stacked.
According to the structure as described above, the rear engagement convex portions 48 are formed on the bottom wall 38 of the cartridge frame 103 of the drum cartridge 30 . Formed on the rear upper wall 40 are the rear engagement concave portions 52 engageable with the rear engagement convex portion 48 . The front engagement concave portions 49 are also formed on the bottom wall 38 . Formed on the front side wall portions 42 of the left and right side walls 36 and 37 are the front engagement convex portions 46 each being engageable with the front engagement concave portion 49 . Therefore, another drum cartridge 30 is provided on a drum cartridge 30 as shown in FIG. 11 , or another process cartridge 22 is provided on a process cartridge 22 as shown in FIG. 12 . Then, the rear engagement convex portions 48 of the upper drum cartridge 30 (process cartridge 22 ) can be engaged with the rear engagement concave portions 52 of the lower drum cartridge 30 (process cartridge 22 ). Simultaneously, the front engagement concave portions 49 of the upper drum cartridge 30 (process cartridge 22 ) can be engaged with the front engagement convex portions 46 of the lower drum cartridge 30 (process cartridge 22 ). Likewise, another drum cartridge 30 (process cartridge 22 ) may be stacked on the upper drum cartridge 30 (process cartridge 22 ), may be stacked on the upper drum cartridge 30 (process cartridge 22 ). Then, the rear engagement convex portions 48 and the front engagement concave portions 49 of the upper drum cartridge 30 (process cartridge 22 ) can be engaged with the rear engagement concave portion 52 and the front engagement convex portion 46 of the lower drum cartridge 30 (process cartridge 22 ) respectively.
As a result, plural drum cartridges 30 can be stacked stably by concave-convex engagement between the individual drum cartridges 30 . When drum cartridges 30 are detached from the laser printer 1 (body casing 2 ), the drum cartridges 30 can be handled easily. In addition, the space for storing the drum cartridge 30 can be reduced.
Also, plural process cartridges 22 can be stacked stably by concave-convex engagement between the individual process cartridges 22 . When process cartridges 22 are detached from the laser printer 1 (body casing 2 ), the process cartridges 22 can be handled easily. And, the space for storing the process cartridge 22 can be reduced.
As shown in FIG. 4 , the rear engagement convex portions 48 , front engagement concave portions 49 , rear engagement concave portions 52 , and front engagement convex portions 46 are provided in both the left and right sides (both sides in the widthwise direction). Therefore, by concave-convex engagement between these portions, plural drum cartridges 30 can be stacked more stably. Similarly, by concave-convex engagement between these portions, plural process cartridges 22 can be stacked more stably.
In addition, when a drum cartridge 30 (see FIG. 5 ) or a process cartridge 22 (see FIG. 9 ) is put on the flat mount surface S, each of the rear engagement convex portions 48 contacts the mount surface S, and supports the drum cartridge 30 or process cartridge 22 such that the rear upper wall 40 and the front engagement convex portion 46 are substantially parallel to the mount surface S. On the drum cartridge 30 put on the mount surface S, plural drum cartridges 30 can be stacked much more stably. Similarly, on the process cartridge 22 put on the mount surface S, plural process cartridges 22 can also be stacked much more stably.
The rear engagement concave portions 52 and the front engagement convex portions 46 are at such positions that are opposed to the rear engagement convex portions 48 and the front engagement concave portions 49 in the vertical direction. Therefore, plural drum cartridges 30 can be stacked in the vertical direction. As a result, the plural drum cartridges 30 can be stacked more stably. Similarly, plural process cartridges 22 can be stacked in the vertical direction. As a result, the plural process cartridges can be stacked more stably.
Further, the rear engagement concave portions 52 and the front engagement convex portions 46 are spaced apart therebetween in the front-to-rear direction. The rear engagement convex portions 48 and the front engagement concave portions 49 are space apart therebetween in the front-to-rear direction.
Therefore, the state in which plural drum cartridges 30 are stacked can be kept more stably in the front-to-rear direction, by concave-convex engagement between the respective cartridges. As a result, plural drum cartridges 30 can be stacked more stably.
Also, the state in which plural process cartridges 22 are stacked can be kept more stably in the front-to-rear direction, by concave-convex engagement between the respective cartridges. As a result, plural process cartridges 22 can be stacked more stably.
In other words, the rear engagement concave portion 52 and the rear engagement convex portions 48 which are opposed to each other in the vertical direction are considered as one set. The front engagement convex portion 46 and the front engagement concave portion 49 which are opposed to each other in the vertical direction are considered as one set. These sets spaced apart in the front-to-rear direction. For each set, two sets are provided in the widthwise direction. Therefore, in the front-to-rear direction and in the widthwise direction, the plural drum cartridges 30 can be stacked one on the other, kept stable in the vertical direction. Similarly, in the front-to-rear direction and in the widthwise direction, the plural process cartridges 30 can be stacked one on the other, kept stable in the vertical direction.
In the present embodiment, as shown in FIG. 9 , when the developer cartridge 31 is mounted on the developer cartridge accommodating section 54 of the drum cartridge 30 , and these cartridges are put on the mount surface S, a height from the mount surface S to the upper surface (the upper wall 70 ) of the developer casing 63 of the developer cartridge 31 is substantially equal to the height from the mount surface S to the upper surface of the rear upper wall 40 . As shown in FIG. 12 , when the developer cartridge 31 is mounted on the drum cartridge 30 , the plurality of process cartridge 22 (the drum cartridge with the developer cartridge) can be stacked stably.
As shown in FIG. 8 , the developer cartridge 31 is provided with the developer engagement convex portions 80 . When the developer cartridge 31 is put on a flat mount surface S, the developer engagement convex portions 80 contact the mount surface S and support the developer cartridge 31 such that the upper wall 70 of the developer casing 63 is substantially parallel to the mount surface S. Therefore, as shown in FIG. 13 , another developer cartridge 31 can be stacked on a developer cartridge 31 put on the mount surface S.
In addition, the developer engagement convex portions 80 are provided in both the left and right sides of the developer cartridge 31 . When the developer cartridge 31 is put on a mount surface S, the upper wall 70 of the developer casing 63 substantially parallel to the mount surface S in the widthwise direction. Therefore, another developer cartridge 31 can be stacked stably on the developer cartridge 31 put on the mount surface S.
The insertion portions 62 are formed in the drum cartridge 30 . When the developer cartridge 31 is mounted on the drum cartridge 30 , the developer engagement convex portions 80 are inserted in the corresponding insertion portions 62 . Therefore, the developer engagement convex portions 80 are prevented from obstructing mounting of the developer cartridge 31 in the drum cartridge 30 . As a result, smooth mounting of the developer cartridge 31 to the drum cartridge 30 can be ensured.
Besides, each of the insertion portions 62 is provided outside the area through which the paper sheet 3 entering between the photosensitive drum 32 and the transfer roller 34 passes. Therefore, when the developer cartridge 31 is mounted on the drum cartridge 30 , the developer engagement convex portions 80 inserted in the corresponding insertion portions 62 are prevented from obstructing passage of the paper sheet 3 .
In addition, the developer engagement concave portions 82 each being engageable with the developer engagement convex portion 80 are formed in the upper wall 70 of the developer casing 63 of the developer cartridge 31 . Therefore, when developer cartridge 31 can be put on the developer cartridge 31 , the developer engagement convex portions 80 of the upper developer cartridge 31 can be engaged with the developer engagement concave portions 82 of the lower developer cartridge 31 . Likewise, when further developer cartridge 31 can be put on the upper developer cartridge 31 , and the developer engagement convex portions 80 of the upper developer cartridge 31 can be engaged with the developer engagement concave portions 82 of the lower developer cartridge 31 . As a result, plural developer cartridges 31 can be put, stacked stably, by engaging the developer engagement convex portions 80 with the corresponding developer engagement concave portions 82 . Therefore, when developer cartridges 31 are put out of the laser printer 1 (body casing 2 ), handling of the developer cartridges 31 can be facilitated. In addition, the space for storing the developer cartridges 31 can be reduced.
The developer cartridge 31 has a toner accommodating section 85 for accommodating toner. When the developer cartridge 31 is mounted on the drum cartridge 30 , the developer cartridge 31 can supply the photosensitive drum 32 supported by the drum cartridge 30 with the toner accommodated in the toner accommodating section 85 .
The laser printer 1 has a drum cartridge 30 (process cartridge 22 ) and a developer cartridge 31 as described above. Therefore, in case where the manufacturer of the laser printer 1 recycles process cartridges 22 , handling of drum cartridges 30 and developer cartridges 31 is facilitated. In addition, the space for storing the drum cartridges 30 and developer cartridges 31 can be reduced.
While the invention has been described in detail with reference to the specific embodiment thereof, it would be apparent to those skilled in the art that various changes and modifications may be made therein without departing from the spirit of the invention.
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A developer cartridge includes a first developer wall formed with a convex part and a second developer wall disposed in confronting relation with the first developer wall. The convex part of the first developer wall is insertable into an insertion portion of an image-bearing member cartridge when the developer cartridge is mounted on the image-bearing member cartridge. When a plurality of the developer cartridges are stacked one on the other with the first developer wall being downside with respect to the second developer wall facing upward, the first developer engagement part in one developer cartridge engages the second developer engagement part in another developer cartridge disposed just below the one developer cartridge.
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FIELD OF THE INVENTION
The present invention relates to a projectile or gripper shuttle loom having a weft-thread delivery unit which includes a stationary drum, a withdrawal eye and a yarn brake, and to a delivery unit having a storage drum from which weft yarn can be withdrawn through a yarn eye.
BACKGROUND OF THE RELATED ART
In a projectile loom known from U.S. Pat. No. 3,411,548 (FIGS. 1 to 5), the weft yarn is drawn from the drum below a cylindrical annular body, which encloses the face end of the drum, into the withdrawal eye which has arranged downstream thereof a controlled yarn brake. It is true that the annular body limits the size of the yarn balloon that forms during withdrawal, but only within a narrow axial range. A strong yarn balloon which performs braking, thereby increasing the tension level in the yarn in an inexpedient manner, is respectively formed in front and behind the annular body. Furthermore, when the yarn brake is being closed, the kinetic energy of the yarn balloon is released, whereby yarn is subsequently pulled from the windings on the drum until one or several loops of loose yarn are formed, resulting in disturbances during the next feeding operation, above all when these get caught on the annular body or on the withdrawal eye.
In a projectile loom known from DE-B-20 28 543, an internally smooth withdrawal cone is pulled on a delivery unit over a conical front nose of the drum with an intermediate spacing to limit ballooning. The withdrawal cone can be axially adjusted. The effect of the internally smooth withdrawal cone is not sufficient at the high yarn speeds in modern looms of this type. However, there might be formed a spatially limited balloon which in the cone stores a great length of yarn that relaxes upon braking, leading to the formation of loops and tangles.
Therefore, according to the above-mentioned U.S. Pat. No. 3,411,548 (FIGS. 8 to 13), it was already suggested about 30 years ago that an additional brake should be arranged on the drum, for instance a brush-type ring or a felt ring which touches the drum and fixes the yarn by clamping. This is supposed to counteract any subsequent pulling of yarn from the windings on the drum when kinetic energy is released in the yarn balloon after braking of the yarn by the controlled yarn clamp. However, such an additional brake on the drum has the serious disadvantage of a braking action which progressively increases considerably in response to the yarn speed and which inadmissibly increases the tension level in the yarn. That is why U.S. Pat. No. 3,411,548 provides for an axial temporary adjustment of the additional brake to reduce the influence thereof temporarily. Such a motional control is extremely troublesome and sluggish from a technical point of view because of the great masses to be moved.
Modern projectile looms operate at very high yarn speeds, e.g. up to 1500 m/min. Without an additional brake on the drum of the delivery unit, loops leading to frequent disturbances will be formed upon braking of the yarn by the controlled yarn clamp. Therefore, the provision of an additional brake on the drum, e.g. of the type shown in FIGS. 8 to 15 of U.S. Pat. No. 3,411,548, has generally been accepted in practice, the additional brake remaining, however, passive in a preselected position because an axial motional control of the additional brake can hardly be implemented technically in today's high-speed looms. The brake actively touches the drum with bristles, teeth or lamellae. The resultant yarn speed-dependent braking action, however, leads to an inacceptably high tension level in the yarn and is a cause for frequent yarn breakages and disturbances.
It is therefore the object of the present invention to provide a projectile or gripper shuttle loom as well as a delivery unit for such a loom wherein, despite high yarn speeds, the risk of operational malfunctions caused by loose yarn loops is considerably reduced.
SUMMARY OF THE INVENTION
This object is achieved by providing a hollow body over the storage drum which has inwardly protruding elements or projections for ballooning, disturbing and braking the yarn being withdrawn.
The hollow body permits the formation of only one yarn balloon or only a plurality of extremely small yarn balloons in which a relatively small amount of excess yarn length is stored. In addition, the projections permanently withdraw kinetic energy from the balloon. Surprisingly enough, the tension level in the withdrawn yarn becomes very low in modern looms of this type due to the combinatory effect, i.e., even at high yarn speeds. During or after braking of the yarn by the controlled yarn brake downstream of the delivery unit, it is of special advantage that the amount of kinetic energy contained in the small yarn balloon is so small that virtually no yarn is subsequently pulled from the windings on the drum on the one hand and the small amount of energy released by the activation of the controlled yarn brake is very rapidly and efficiently consumed by collision of the yarn with the projections on the other hand. The yarn which possibly relaxes does not form downwardly hanging loops any more, but is deposited on one of the deposit surfaces in orderly fashion, so that the next feeding operation starts without any trouble. In a surprisingly simple manner, the combination of the brake-free drum of the delivery unit with the hollow body eliminates the need for an additional brake in modern looms of this type, which additional brake is used for preventing dangerous loop formation after activation of the controlled yarn brake, whereby the drawback of a high yarn tension level for the major part of the feeding operation need not be put up with.
It is true that it is common practice in the yarn spooling technique (DE-A-26 23 916) to arrange a hollow truncated cone with internal projections on a face side for keeping the yarn balloon so small that it requires little space even at a high unwinding speed, and exhibits only a small braking action (low yarn tension). However, it is here irrelevant because of the continuous operation how the yarn behaves in case of a sudden delay or stop.
According to U.S. Pat. No. 3,958,404, it also is customary during spinning, doubling and twisting of spun yarn material by means of a high-speed spindle to make a balloon limitation ring enclose the spindle. This ring has inwardly protruding projections which are additionally inclined to avoid the locally concentrated heating of the yarn until melting by an enlarged contact surface during contact with the yarn. However, the process is performed continuously, so that it is irrelevant how the yarn material behaves when abruptly stopped.
Where the hollow body has a straight, concave or convex generatrix which may be parallel or inclined relative to a drum axis the hollow body may be a rotary body relative to the drum axis and can then be produced in a simple manner. A circumferentially uniform disturbance can be set for the yarn during ballooning. Along the generatrix of the hollow body, there are long deposit surfaces for the delayed or stopped yarn.
Where the hollow body has a polygonal inner cross-section, the hollow body is a rotationally symmetrical body relative to the drum axis. The projections and the deposit surfaces are solely produced by the cross-sectional shape of the hollow body.
In another embodiment, a star-shaped inner cross-section is expediently suited for disturbing purposes and for depositing the yarn.
In the star-shaped hollow body, the inner wall portions which define basic projections may have provided thereon further projections to produce a mixed form of projections which have been produced geometrically through the cross-section and of additional projections.
Where the hollow body extends from a side of a withdrawal eye over an edge of the drum from which the yarn is withdrawn, the yarn is disturbingly influenced during ballooning when being lifted from the circumferential face of the drum.
The drum may have an inner cross-section which is smaller than the drum circumference at least between the withdrawal edge and the withdrawal eye such that the hollow body is located in front of the withdrawal edge of the drum. Other disturbing measures are optionally taken in the area of the drum, e.g. where the hollow body surrounds the drum circumference with a radial space formed therebetween, by an annular body which may have a smooth inner surface.
The annular body can be an integral cylindrical extension of the hollow body which continues the hollow body in a constructionally simple manner.
Projections which are identical with or similar to the projections on the hollow body may also be provided on the inside of the annular body. It is also possible to select a different type, a different number or a different distribution of the projections in the annular body as compared with the hollow body.
At least one of the hollow body and the annular body can be mounted to a mounting on a delivery unit such that the hollow body and optionally the annular body are supported in a stable manner. The effect of the hollow body on the respective yarn quality and the respective operating conditions can be set through axial adjustability.
The hollow body can be formed of light metal, or plastics which are virtually suited for all possible yarn qualities. The hollow body or the hollow body with its annular body is lightweight, stable and resistant to wear.
Preferably, the drum diameter is about 100 mm, and the conical hollow body has a cone angle of about 120°, a large end diameter of about 110 mm, a small end diameter of about 41 mm and an axial height of about 30 mm. Further, the withdrawal eye is spaced from an end face of the drum by approximately 47 mm, and has an axial length of about 44 mm, an inner diameter of about 100 mm, and protrusions having a height of between 2 and 5 mm. The hollow body is adapted to the shape and size of the drum.
Where a controlled yarn brake is disposed directly next to the withdrawal eye, a short free yarn length is ensured between the withdrawal eye and the controlled yarn brake, so that the yarn cannot escape laterally. In a very expedient variant, the yarn brake is even arranged on the withdrawal eye.
The withdrawal eye can be replaced by the feeding eye of the controlled yarn brake.
The delivery unit which includes a hollow body coaxial to the drum permits a trouble-free supply of the weft yarn at high yarn speeds to the projectile or gripper shuttle loom, resulting in a low yarn tension level over the major part of the feeding operation because of the small balloon, while no dangerous excess length of the yarn is formed during or after braking of the yarn by the controlled yarn brake, and dangerous loops are suppressed. An additional passive brake on the drum of the delivery device, as has so far been necessary, can be dispensed with.
The delivery unit according to claim 17 is compact and operationally reliable.
BRIEF DESCRIPTION OF THE DRAWINGS
Embodiments of the invention will be explained with reference to the drawing, in which:
FIG. 1 is a diagrammatic side view of a projectile or gripper shuttle loom;
FIG. 2A shows a front elevational view of a hollow body of FIG. 1;
FIG. 2B shows a cross-sectional side view of the hollow body;
FIG. 3 shows a modified detail in a longitudinal side elevational section view;
FIG. 4A is an enlarged front elevational view of a weft-thread delivery device;
FIG. 4B is an enlarged side elevational view of the delivery device;
FIG. 5 is a partial side elevational view of the delivery device;
FIG. 6 is a partial side elevational view of a second embodiment of the delivery device;
FIG. 7 is a partial side elevational view of a third embodiment of the delivery device;
FIG. 8 is a front elevational view of the hollow body of FIG. 7;
FIG. 9A is a partial side elevational view of the hollow body of a fourth embodiment of the delivery device;
FIG. 9B is a front elevational view of the hollow body of FIG. 9A;
FIG. 10A is a partial side elevational view of the hollow body of a fifth embodiment of the delivery device;
FIG. 10B is a front elevational view of the hollow body of FIG. 10A;
FIG. 11A is a partial side elevational view of the hollow body of a sixth embodiment of the delivery device;
FIG. 11B is a front elevational view of the hollow body of FIG. 11A;
FIG. 12A is a partial side elevational view of the hollow body of a seventh embodiment of the delivery device; and
FIG. 12B is a front elevational view of the hollow body of FIG. 12A.
DETAILED DESCRIPTION
A weft-yarn delivery device S is mounted on a projectile or gripper shuttle loom L in FIG. 1. Although a plurality of delivery devices S are most of the time provided for alternate operation, a single delivery device is illustrated. The delivery device S includes a delivery unit F for a weft yarn Y and is equipped with a hollow body K comprising projections V on the inside and with a withdrawal eye E. A yarn brake B which is either retained as such or fixedly mounted on delivery unit F is provided downstream of withdrawal eye E.
The weft yarn Y is introduced from a supply coil 1 into a housing 2 approximately coaxially with an axis X. A rotationally drivable winding unit 3 forms windings W on a drum 4 with an approximately cylindrical circumferential or enveloping surface. On an extension arm 5, the hollow body K is fixed in a mounting 6, preferably in an axially adjustable manner, at the free face end of drum 4. The withdrawal eye E is secured to the extension arm 5 by means of a holder 7. The controlled yarn brake B is positioned at a short distance behind the withdrawal eye E or directly follows said withdrawal eye E which can then form the feeding eye of the yarn brake at the same time. The yarn brake B is, e.g., controlled via a control line 10 by a control device C in response to the weaving cycle of loom L, so that the weft yarn Y is braked at the end of a feeding operation (in the case of a projectile loom) when the projectile 12 is stopped in a catching device 14. In a gripper shuttle loom L, a braking operation is performed at the feed end and additionally in a transition phase in which a supplying gripper 12 hands over the weft yarn to a receiving gripper in a transition portion 15 (shown in broken line) in shed 13. A transfer device 11 hands over the weft yarn Y to the gripper or projectile 12. For the major part of the feeding operation the controlled yarn brake B is opened.
The hollow body K as illustrated in FIGS. 1, 2A and 2B has the shape of a frustoconical cover with a thin wall 16, a large-diameter end 17 and a small-diameter end 18 which defines a passage opening 19. The conical axis of the hollow body K corresponds to the axis X of the delivery unit F. Evenly or unevenly distributed projections V which are, for instance, shaped in the form of warts, domes, pyramids or also ribs (as outlined at 22) project inwards on the inside of the hollow body K.
The hollow body K according to FIGS. 1, 2A, 2B, 4A and 4B grips with the large-diameter end 17 over a rounded or tapered withdrawal edge 26 on the face end of drum 4. An end section of the circumferential surface of drum 4 is enclosed by a cylindrical annular body R (annular gap) which is an extension of the hollow body K in the illustrated embodiment. The inner wall 24 of the annular body R is either smooth or also provided with internally protruding projections V (FIG. 6). 23 is the transition line from the conical hollow body K to the annular body R. The annular body R is optionally retained such that it is separated and spaced apart from the hollow body K.
As becomes apparent from FIGS. 4A and 4B, hollow body K is secured with annular body R to a ring 127 which is seated with a tightening strap 128 in mounting 6 on extension arm 5. An adjusting screw 125 serves to axially adjust the hollow body K. For instance with a straight yarn path, yarn Y runs from withdrawal edge 26 to withdrawal eye E without contacting the small-diameter end of hollow body K. The controlled yarn brake B is arranged in FIGS. 4A and 4B directly behind the withdrawal eye E or on said eye. Like the annular body R, the hollow body K expediently consists of light metal. The projections V are externally impressed or indented recesses.
In the embodiment of FIGS. 4A and 4B, the annular body R extends over about 44 mm from withdrawal edge 26 rearwards, i.e. over the portion in which windings W are located on drum 4. The annular gap provided between the annular body R and the circumferential surface of drum 4 has a width of about 5 mm. The conical part of hollow body K has a cone angle of about 120°. The height of the projections V above the inner wall is between 2 and 5 mm, the diameter of the wart-shaped projections V being approximately 10 to 20 mm in the case of a cone angle of about 120°.
FIG. 3 illustrates a conical hollow body K whose shape corresponds to that of the hollow body K in FIGS. 1, 2 and 4. I illustrates a straight generatrix of the hollow body K. Alternatively, the generatrix could also be a bow line II which is convex relative to drum axis X, or a concave bow line III.
As outlined in FIGS. 5 and 6, the hollow body K grips over the face end of drum 4. In such a case, the outer diameter of drum 4 is smaller than the inner diameter at the large-diameter end of hollow body K. However, it is also possible to position the hollow body K according to FIG. 5 at some distance in front of drum 4. The large-diameter end of hollow body K is then expediently approximately equal to or smaller than the drum diameter.
According to FIG. 6, the hollow body K grips with the integrated annular body R either over the face end of drum 4 (outlined in broken line), or it is arranged at some distance in front of the face end of drum 4. In the first-mentioned case, the diameter of the annular body R and of the large-diameter end of the conical part of the hollow body K is larger than the outer diameter of drum 4. In the second case, the diameter is either equal to or preferably smaller than the drum diameter. As further outlined in FIG. 6, the hollow body K forms deposit surfaces A for the weft yarn Y on which the weft yarn Y is temporarily deposited after a braking operation in such a manner that it does not hang freely downwards anywhere.
FIG. 7 shows, in full lines, a modified embodiment of a hollow body K which is, for instance, a section of a profile tube 20 having a polygonal inner cross-section (there is shown a cross-section in the form of an equilateral triangle) and is positioned in front of the face end of drum 4 (outlined in broken line) with longitudinal edges parallel to drum axis X. Drum axis X expediently extends through the area center of gravity of the inner cross-section of hollow body K. Straight or optionally curved inner wall portions 23 which serve as inwardly protruding projections to influence the movement of the weft yarn in the circumferential direction about the drum axis are positioned between the corners of the inner cross-section, which are designated by 21. Additional projections 22, V are optionally provided on the inner wall portions 23 according to the projections of the conical hollow body K according to FIG. 5.
Furthermore, as shown in broken line in FIG. 7, the hollow body K has a conically enlarged extension 24 which is continued with the same inner cross-section and optionally grips over the face end of drum 4 or is opposite to said end at some distance. The inner cross-section of the hollow body K or of the conical extension 24 is expediently smaller than the cross-section of the drum enveloping surface. This is not an imperative prerequisite. The hollow body K according to FIGS. 7 and 8 could also, as shown at II and III, extend in arcuately retracted fashion or arcuately curved fashion.
In FIGS. 9A and 9B, the hollow body K is similar to that of FIGS. 7 and 8, the body being conically tapered towards the withdrawal eye E. The inner wall portions 23 which connect corners 21 form the projections V in the hollow body K formed with a cover 25. Furthermore, the inner wall portions 23 define deposit surfaces A for the relaxed and braked weft yarn. Inside the conical extension of the hollow body K according to FIGS. 9A and 9B, there might also be a narrowed portion or bulging portion in the course of the longitudinal edges according to the dash-dotted lines II and III with inwardly directed inclination towards the withdrawal eye.
In FIGS. 10A and 10B, the inner cross-section of the hollow body K is star-shaped with inner wall portions 28 which are set in zigzag-shaped fashion relative to each other and which define the projections V and the deposit surfaces A. The hollow body K according to FIGS. 10A and 10B could be a tubular section 27 with constant inner cross-section, or conical, as outlined at 27'.
In FIGS. 11A and 11B, the hollow body K is a cylindrical tubular section 30 with axially defined inwardly protruding projections V, e.g. on the front and rear ends. The inner wall forms deposit surfaces A. The hollow body K according to FIGS. 11A and 11B could be conical or curved or narrowed.
FIGS. 12A and 12B show an annular hollow body K which has a basic body 29 with inwardly protruding projections V between which deposit surfaces A are disposed. The hollow body K according to FIG. 12 is coaxial to the drum axis. The projections V could also be rounded or formed differently. Furthermore, they could be bent outwards from the plane of basic body 29 either towards the drum or to the withdrawal eye or alternately. A plurality of such hollow bodies might also be arranged subsequently.
The withdrawal eye E could be supported in the end of hollow body E, or the end of hollow body A might be formed as a withdrawal eye. The controlled yarn brake B could then be mounted on the hollow body K directly. A yarn brake B which clamps the yarn is used as a controlled yarn brake B, as is common in projectile looms.
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A projectile or gripper shuttle loom includes a weft-yarn delivery device with an overend-unwinding delivery unit that has a stationary, brakeless drum, a withdrawal eye arranged coaxially downstream of the drum and a yarn brake controlled in accordance with the loom cycle. The thread path is enclosed by at least one hollow body extending from the circumferential face of the drum to the withdrawal eye at least in one axially limited segment. The hollow body has on its inner side coaxial to the drum axis a plurality of ballooning, disturbing and braking elements which protrude inwards without touching the drum while forming projections and deposit surfaces for the weft yarn.
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RELATED APPLICATIONS
[0001] This application claims priority to Taiwan Application Serial Number 97139343, filed Oct. 14, 2008, which is herein incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of Invention
[0003] The present invention relates to an encoding/decoding method, and particularly relates to an encoding/decoding method of the Berger Code.
[0004] 2. Description of Related Art
[0005] The first prior art reference about the Berger codes occurs in the article “A note on error detection codes for asymmetric channels” by J. M. Berger in volume 4 of Information and Control at pp. 68-73 in March 1961. In the later prior arts, the asymmetric channels can be generalized to data storage. All of them are related to a binary digital system where for each bit, the probability of an error from the unstable state to the stable state is higher than the probability of the opposite one. Particularly, the probability of an error from the stable state to the unstable state is zero in a fully asymmetric communication or storage system. The unstable state may be in a higher or lower voltage, current or other signals and can be represented in logic value 0 or 1 while the stable state can be represented in the alternative logic value.
[0006] To introduce the prior arts, FIG. 1 shows an implementation of the traditional Berger Codes applied in communication, where the stable and unstable states are respectively represented by logic values 0 and 1. An n-bit codeword w transmitted to an asymmetric communication channel 100 from the transmitter 110 to the receiver 120 . The m-bit stable-bit count c is obtained by a parallel counter 111 , represented as #0's for a 0's counter, and transmitted along with the codeword w as the check bits 112 . While the data is received, the stable-bit count of the received codeword w′ is calculated again by a parallel counter 122 and compared with the received checkbits c′ by a comparator 123 . If the binary number represented by the received checkbits 121 is less than the stable-bit count, i.e. c′<#0's(w′), the output 124 indicates an error.
[0007] Unidirectional fault detecting methods including the m-out-of-n codes, the two-rail codes and the Berger Codes have been used for more than 50 years in fully asymmetric communication systems. However, most previous work has been devoted to enhancing the totally self-checking (TSC), reducing the area overhead and decreasing the decoding time, but ignores the improvement of the reliability.
SUMMARY OF THE INVENTION
[0008] A Berger invert code encoding and decoding method is disclosed. The method includes steps: Selecting logic value 0 or 1 to represent the stable and unstable states respectively. Calculating the stable bit count and the unstable-bit count of the codeword. Checking whether the unstable bit count is larger than the stable bit count or not. Setting the Invert Bit to the unstable state for indicating the inversion when the unstable bit count is larger than the stable bit count. Resetting the Invert Bit to the stable state for indicating the non-inversion when the unstable bit count is not larger than the stable bit count. Concatenating the Invert Bit to the codeword as a new codeword.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] The invention can be more fully understood by reading the following detailed description of the embodiment, with reference made to the accompanying drawings as follows:
[0010] FIG. 1 is a circuit diagram view of the prior arts.
[0011] FIG. 2 is the flowchart diagram of the method of the invention.
[0012] FIG. 3 is the circuit diagram of one embodiment to realize the method shown in FIG. 2 .
DETAILED DESCRIPTION
The Embodiment of the Method of the Invention
[0013] Refer to FIG. 2 for a flowchart diagram of the method of the present invention. The Berger Invert Code encoding and decoding method is applied to an error-asymmetric channel that can be also generalized to an asymmetric binary data transmission, communication or storage. In the asymmetric channel, the data is transferred or saved by a binary signal that can be the voltage, current, frequency or others, and the probabilities of error occurrence from one state to the other are not equal to each other. For usual applications, the probability of each bit disturbed from the stable state s to the unstable state n is much less than that in the other direction and particularly zero in a fully asymmetric channel.
[0014] The embodiment of the method in the present invention includes the steps of following:
[0015] First, as shown in step 210 , the embodiment selects logic value 0 or 1 to represent the unstable state u and the other logic value for the stable state s.
[0016] Second, as shown in step 211 , the embodiment calculates the stable bit count S and the unstable-bit count U of the n-bit codeword w. For convenience of description, let #b(w) represents the bit-b count in codeword w. Therefore, S=#s(w) and U=#u(w) in this step. Note that one of them can be easily obtained by each other with respect to S+U=n.
[0017] For most voltage-mode electronic systems, low voltage state is more stable than the high voltage state. Namely, in such a system, the high voltage state may be disturbed by hazard in the channel and be lowered thereof. The fully asymmetric communication system may recognize the bit as being in a low voltage state, and generate bit errors.
[0018] Third, as shown in step 212 , the embodiment checks whether the unstable bit count U, is larger than the stable bit count S, U>S, or not. If the unstable bit count is larger than the stable bit count as shown in step 213 , a flag bit, called the Invert Bit I, is set to the unstable state for indicating the inversion. Otherwise as shown in step 214 , the Invert Bit I is reset to the stable state for indicating the non-inversion. The Invert Bit I is then concatenated to the codeword w as a new codeword x={I, w} for transmitting or storing in step 215 .
[0019] The encoding method for the traditional Berger codes is then followed in steps 216 - 217 and decoding method in steps 220 - 223 . Namely for the new codeword x, the stable-bit count is calculated in step 216 , c=#s(x) and both of them, {c, x}, are transmitted to the channel or saved in a storage in step 217 .
[0020] Similar to the traditional checker of the Berger codes, the checker receives or reads the codeword x′ with the associated checkbits c′ in step 220 . The stable bit count #s(x′) is then calculated again in step 221 and compared with c′ in step 222 . For most preferred applications where the unstable state is represented by logic value 1, the case #s(x′)>c′ will indicate an error in step 223 . Once the unstable state is represented by logic value 0, the error should be indicated by #s(x′)<c′.
[0021] In the method of the present invention, the Invert bit will be separated from the received codeword to check the inversion in step 224 . If the Invert bit indicated that the remaining codeword bits have been inverted, the remaining bits will be inverted again in step 225 . Finally the recovered codeword is then used in the corresponding application as shown in step 226 .
[0022] In the foregoing embodiment, the codewords with more unstable bits are transferred to those with less ones so that the error rate can then be reduced. Because the probability of the transitions is also lowered between successive codewords, about one quarter of power is also reduced.
The Embodiment of the Apparatus to Achieve the Method
[0023] FIG. 3 shows an electronic schematic diagram for an embodiment of the apparatus where the unstable state ii is represented by logic value 1 and s=0 in the positive logic system. The codeword error rate and energy of the information can be improved through an error-asymmetric channel 300 from the transmitter 310 to the receiver 320 .
[0024] First, the n-bit codeword w is inputted into 311. For convenience of explanation, two 6 bit codewords, w 1 =“001000” and w 2 =“101111” are taken as examples in difference cases.
[0025] Second, the 0's count and the 1's count are calculated in a parallel counter 312 which can be implemented by only a 1's counter for #1's along with a m-bit subtractor for #0's where m can be the ceiling number of log 2 n.
[0026] Next, the 0's count and the 1's count are compared by an m-bit comparator 313 to generate the Invert Bit I at 314 . In one case, I is reset to 0 because U=#1's (001000)=1 and S=n−U=5. In the other case, I is set to 1 since U=#1's(101111)=5 and S=n−U=1.
[0027] In the following step, the codeword w is inverted by the set of XOR gates 315 while I=1, otherwise, it will stay as is. Concatenated with the Invert Bit, the transmitted codeword x will be {I, w} at 316 if I=0, or {1, w } if I=1.
[0028] In the non-inverting case, due to the extra bit I=0, #0's(x) will be #0's(w)+1, therefore a simple increment circuit 317 is added. The checkbits c are chosen by the selector 318 . For example 1, #0's(x)=#0's(0 — 01000)=6 thus c will be 110 2 .
[0029] For the inverting case, #0's(x)=#1's(w) is selected by the selector 318 as the checkbits c. For example 2, the submitted checkbits c will be 010 2 since #0's(x)=#1's(1 — 010000).
[0030] When the codeword x′ at 321 are read from the storage or received from the channel, the 0's count is calculated again by the parallel counter 322 and then compared with the received checkbits c′ at 323 by a comparator 324 . If the 0's count of the received codeword is larger than the binary number represented by the received checkbits, an error signal is sent out at 325 . Taking the codeword w 1 as an example, either the 0's count increased by collapsing down the bit 1 in the received codewords, “0 — 001000”, or the binary number of the received checkbits, c′=110 2 , decreased by changing any one to zero in c′, the 0's count of the received codeword will be greater than the binary number of the checkbits. The error is then detected.
[0031] Otherwise, the Invert Bit split form the received codeword at 326 is used to recover the codeword to the recovered codeword w′ at 327 by the set of XOR gates 328 . For instance in example 2, the received codeword will be x′=1 — 010000 and the recovered codeword w′ can then be recovered to 101111=w by inverting 01000.
[0032] It will be apparent to those skilled in the art that various modifications and variations can be made to the structure of the present invention without departing from the scope or spirit of the invention. In view of the foregoing, it is intended that the present invention cover modifications and variations of this invention provided they fall within the scope of the following claims.
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A Berger invert code encoding and decoding method is disclosed. The method includes steps: Selecting logic value 0 or 1 to represent the stable and unstable states respectively. Calculating the stable bit count and the unstable-bit count of the codeword. Checking whether the unstable bit count is larger than the stable bit count or not. Setting the Invert Bit to the unstable state for indicating the inversion when the unstable bit count is larger than the stable bit count. Resetting the Invert Bit to the stable state for indicating the non-inversion when the unstable bit count is not larger than the stable bit count. Concatenating the Invert Bit to the codeword as a new codeword.
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BACKGROUND OF INVENTION
1. Field of the Invention
The present invention relates to a radiator, and more specifically, to a radiator having a fan in variable rotation speed.
2. Description of the Prior Art
Common radiators include cooling fins and fans. Most of the cooling fins are composed of aluminum alloy while a small number uses other materials, but all of them have almost the same heat conductivity. Besides composing materials, the performance of a cooling fin depends also on its surface area. A cooling fin conducts heat to its surface so that the air can bring the heat away, thus the larger the surface area is, the better the performance of the cooling fin is. However, the cooling fin does not work well if the air flow is insufficient even if it has a large surface area, thus for a better performance, a fan promoting air flow is necessary. Generally, the higher the rotation speed, the better the performance of the fan. That is because the fan accelerates the air flow in high rotation speed so that the air can bring more heat away. The rotation speed of the fan can be known by its power consumption. A fan consuming more power rotates faster.
Please refer to FIG. 1 showing a conventional radiator 10 . The radiator 10 includes a thermal sensor 12 , a microcontroller 14 , a driver circuit 16 and a fan 18 . The interconnection between devices of the radiator 10 is shown in FIG. 10 . Generally the radiator 10 is installed in a system, the thermal sensor 12 is for sensing the temperature of the system, the microcontroller 14 compares the temperature sensed by the thermal sensor 12 with a predetermined temperature, and the driver circuit 16 turns on the fan when the temperature sensed by the thermal sensor 12 exceeds the predetermined temperature. The driver circuit 16 can output different voltages according to the requirements by the microcontroller 14 to control the rotation speed of the fan 18 , and the fan 18 has a signal line connected to the driver circuit 16 for outputting a speed signal of the fan 18 . Whenever the thermal sensor 12 senses a temperature raising, the microcontroller 14 requires the driver circuit 16 to speed up the fan 18 , so that the driver circuit 16 raises up the output voltage to the fan 18 , and when the speed of the fan 18 is raised up, the signal line transmits the speed signal back to the driver circuit 16 . And if the thermal sensor 12 senses a decrease in temperature, the speed of the fan 18 should be lowered down to conserve power, so that the microcontroller 14 requires the driver circuit 16 to lower down the output voltage to the fan 18 , and the driver circuit 16 knows the speed of the fan 18 by the signal line.
As mentioned above, the conventional radiator capable of controlling the rotation speed of the fan 18 uses the thermal sensor 12 to sense the environmental temperature, the microcontroller 14 compares the temperature sensed by the thermal sensor 12 with the predetermined temperature and requires the driver circuit 16 to control the speed of the fan, and the driver circuit 16 to compare the feedback speed signal of the fan 18 with the speed signal required by the microcontroller 14 in order to control the output voltage to the fan 18 to change its rotation speed, so that the speed of the fan 18 can be adjusted according to the environmental temperature. However, the radiator 10 requires the thermal sensor 12 , the microcontroller 14 and the driver circuit 16 which raise the cost. In addition, the temperature comparison by the microcontroller 14 and the rotation speed comparison by the driver circuit 16 also lower down the sensibility of the radiator 10 .
SUMMARY OF INVENTION
It is therefore a primary objective of the present invention to provide a radiator having a fan with variable rotation speed in order to solve the problems mentioned above.
Briefly summarized, a radiator includes a voltage regulator for providing a reference voltage, a fan including a power end connected to the reference voltage via a first resistor and a feedback end for outputting a pulse signal indicating the rotation speed of the fan, an integration circuit including an output end, and an input end connected to the feedback end of the fan for converting the pulse signal from the feedback end into a voltage signal, and a thermistor connected between the output end of the integration circuit and the reference voltage, for detecting temperature change in order to adjust the rotation speed of the fan.
These and other objectives of the present invention will no doubt become obvious to those of ordinary skill in the art after reading the following detailed description of the preferred embodiment that is illustrated in the various figures and drawings.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 illustrates a conventional radiator.
FIG. 2 is a circuit diagram of a radiator according to the present invention.
FIG. 3 illustrates the relationship between Vo and Vx.
FIG. 4 illustrates the relationship between Vo and Rt.
DETAILED DESCRIPTION
Please refer to FIG. 2 showing a circuit diagram of a radiator 20 according to the present invention. The radiator 20 includes a voltage regulator 22 , a fan 24 , a first resistor 26 , a second resistor 28 , a third resistor 30 , a capacitor 32 and a thermistor 34 . The interconnection of these devices is shown in FIG. 2 . An output end of the voltage regulator 22 provides a stable reference voltage, first ends of the first resistor 26 , the second resistor 28 and the thermistor 34 are connected to the output end of the voltage regulator 22 , and a second end of the second resistor 28 is grounded for providing a stable current. The fan 24 has a power end, a ground end and a feed back end, a second end of the first resistor 26 is connected to the power end of the fan 24 for providing operational voltage to the fan 24 . A first end of the third resistor 30 is connected to a first end of the capacitor 32 , and a second end of the capacitor 32 is grounded to form an integration circuit 36 . An output end of the integration circuit 36 is the first end of the third resistor 30 connected to a second end of the thermistor 34 , and an input end of the integration circuit 36 is a second end of the third resistor 30 connected to the feedback end of the fan 24 . A speed pulse signal of the fan 24 outputted by the integration circuit 36 becomes direct current (DC) voltage. On node r in FIG. 2 , a formula can be obtained according to Kirchhoff s current law (KCL):
( Vo−Vr )/ R 1 +( Vx−Vr )/ Rt−Vr/R 2 =0 formula (1)
Vo, Vr, Vx are voltages of node o, r and x. Vo is an input voltage of the fan 24 , Vr is an output voltage of the voltage regulator 22 , Vx is a feedback voltage output by the integration circuit 36 . R 1 , Rt, R 2 are resistances of the first resistor 26 , the thermistor 34 and the second resistor 28 . Under a fixed temperature, Rt is also fixed so that formula (1) can be simplified as follows:
Vo =(1 +R 1 / Rt+R 1 /R 2 ) Vr −( R 1 / Rt ) Vx formula (2)
If the rotation speed of the fan 24 is fixed, Vx is also fixed so that formula (1) can be simplified as follows:
Vo =(1 +R 1 /R 2 ) Vr −( R 1 / Rt )( Vx−Vr ) formula (3)
Please refer to FIG. 3 showing the relationship between Vo and Vx, and FIG. 4 showing the relationship between Vo and Rt. Under a fixed temperature, Rt is also fixed and formula (2) has only two variables, which are Vo and Vx, while other parameters can be regarded as constants. Define a=(1+R 1 /Rt+R 1 /R 2 )Vr, b=(R 1 /Rt), and formula (2) can be simplified as Vo=a−bVx. The relationship between Vo and Vx is shown in FIG. 3 , when Vo increases, Vx decreases, that means when the fan 24 rotates fast, the feedback end of the fan 24 will output pulse signals in longer period and a smaller voltage will output the integration circuit 36 , and when the fan 24 rotates slowly, the feedback end of the fan 24 will output pulse signals in shorter period and a larger voltage will output the integration circuit 36 . In such a manner the relationship between the rotation speed of the fan 24 and the output signal from the feedback end can be known. And if the rotation speed of the fan 24 is fixed, Vx is also fixed so that formula (3) has only two variables, which are Vo and Rt, while other parameters can be regarded as constants. Define c=(1+R 1 /R 2 )Vr, d=R 1 (Vx−Vr), and formula (3) can be simplified as Vo=c−d/Rt. The relationship between Vo and Rt is shown in FIG. 4 , when Rt increases, Vo also increases, that means the resistance of the thermistor 34 increases according to the temperature, because the fan 24 speeds up when Vo increases. In such a manner the relationship between the thermistor 34 and the temperature can be known. FIG. 3 and FIG. 4 indicate the characteristics of the fan 24 and the thermistor 34 of the radiator 20 . First, the pulse signals from the feedback end of the fan 24 decreases when the rotation speed increases. Second, the resistance of the thermistor 34 increases according to the temperature.
The operation of the radiator 20 is described as follows. The radiator 20 is installed in a system in order to keep the temperature T of the system in a reasonable range. When the radiator is activated, the voltage regulator 22 provides the reference voltage Vr, and the input voltage Vo 1 of the fan 24 is generated. The speed signal Vx 1 of the fan 24 can be obtained by formula (2), and the initial temperature T 0 of the system determines the resistance Rt 0 of the thermistor 34 . The input voltage Vo 2 of the fan 24 can be obtained by formula (3), and under the initial temperature T 0 . The speed signal Vx 2 of the fan 24 can be obtained by formula (2), and the input voltage Vo 2 of the fan 24 keeps the fan 24 rotate in a fixed speed. When the system operates, the temperature rises from T 0 to T 1 , and accordingly, the resistance of the thermistor 34 rises from Rt 0 to Rt 1 . By formula (3) we can know Vo 2 >Vo 1 , so that the input voltage of the fan 24 rises from Vo 1 to Vo 2 , that means the fan 24 rotates faster, and by formula (2) we know Vx 2 <Vx 1 . After the fan 24 is accelerated for a while, the temperature of the system falls down from T 1 to T 0 , and accordingly the resistance of the thermistor 34 falls down from Rt 2 to Rt 1 , and the input voltage of the fan 24 falls down to Vo 1 , the speed signal of the fan 24 returns to Vx 1 . After the fan 24 lowers down, since the system keeps on operating, the temperature rises again after a period of time. With such kind of operation, the system can be prevented from overheating and the efficiency of the fan 24 is also increased. As mentioned above, the flow of the operation is as follows: T increases=>Rt increases=>Vo increases=>Vx decreases=>T decreases=>Rt decreases=>Vo decreases=>Vx increases=>T increases
The resistance increase of the thermistor 34 according to the temperature is analog. Whenever the resistance rises up or falls down, the input voltage of the fan 24 will changes accordingly so that the rotation speed of the fan 24 changes precisely according to the temperature. However, if the thermistor 34 reacts only when a larger temperature change occurs, the input voltage of the fan 24 and the speed signal will keep balance by formula (2).
As described above, the radiator 20 uses the thermistor 34 for sensing the temperature, and since the thermistor 34 changes its resistance according to the temperature, the input voltage of the fan 24 can be changed according to the temperature in order to have the fan 24 rotate in different speeds according to different temperatures. In the present invention, the radiator 20 uses the thermistor 34 with its resistance increasing according to the temperature, and the fan 24 with the feedback end. The feedback end of the fan 24 lowers the pulse signal down when the rotation speed increases, and the integration circuit 36 puts the pulse signal as the feedback voltage out. By the first resistor 26 and the second resistor 28 , the input voltage of the fan 24 changes according to the feedback voltage. When the temperature rises up, the input voltage of the fan 24 also rises up so that the fan 24 rotates faster for better heat dissipation. When the temperature goes down, the input voltage of the fan 24 lowers down so that the fan 24 rotates slower in order to conserve power.
In contrast to the prior art, the radiator, according to the present invention, utilizes the thermistor with resistance changing according to the temperature to change the input voltage of the fan according to the temperature, so that the fan rotates faster as the temperature increases. On the other hand, the conventional radiator requires the thermal sensor, the microcontroller and the driver circuit and also changes the rotation speed by comparing the temperature with the rotation speed. These active devices not only increase the cost, but also raise the probability of misjudgment. The radiator, according to the present invention, uses low cost passive devices such as the resistor and the capacitor. Furthermore, the thermistor changes its resistance according to the temperature by its own material characteristics, so that misjudgment may not be done.
Those skilled in the art will readily observe that numerous modifications and alterations of the method may be made while retaining the teachings of the 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 radiator includes a voltage regulator for providing a reference voltage, a fan including a power end connected to the reference voltage via a first resistor and a feedback end for outputting a pulse signal indicating the rotation speed of the fan, an integration circuit including an output end, and an input end connected to the feedback end of the fan for converting the pulse signal from the feedback end into a voltage signal, and a thermistor connected between the output end of the integration circuit and the reference voltage, for detecting temperature changes in order to adjust the rotation speed of the fan.
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This application is related to the following U.S. patent applications: U.S. patent application Ser. No. 08/919,105, entitled “System and Method for Displaying Dispatch and Work Order Information,” filed Aug. 28, 1997; U.S. patent application Ser. No. 08/919,475, entitled “System and Method for Computer-Aided Technician Dispatch,” filed Aug. 28, 1997; U.S. patent application Ser. No. 08/919,474, entitled “System and Method for Dispatch List and Map Interaction,” filed Aug. 28, 1997; U.S. patent application Ser. No. 08/919,218, entitled “System and Method for Automatic Work Order Routing,” filed Aug. 28, 1997; and U.S. patent application Ser. No. 08/919,215, entitled “System and Method for Computer-Aided Technician Dispatch and Tracking,” filed Aug. 28, 1997.
FIELD OF THE INVENTION
This invention relates to the field of technician dispatch and more particularly to a system and method for computer-aided technician dispatch and communication.
BACKGROUND OF THE INVENTION
Cable television and subscriber programming systems are well-known in the art. These systems typically consist of a service center and a plurality of subscriber locations, all serviced by a team of technicians. The service center includes a service representative, who is responsible for receiving incoming calls and requests for service. A dispatcher, who is responsible for ensuring that technicians are dispatched to subscriber locations that require service and for monitoring the technicians' progress, coordinates with the customer service representative at the service center site, or may be located at a different location.
As subscribers need assistance, they call the service representative. The service representative typically screens the request, and determines whether or not technician assistance is required. Should technician assistance be required, the service representative generates a work order request. This work order request includes the customer's name, address, telephone number, date of service appointment, current service status, service requested, and other desirable service information. A computer may be used to aid in the input, storage, and transfer of this information. This work order is then forwarded to the dispatcher to assign the work order to a technician.
Typically, the problem of assigning technicians to subscribers and tracking the technicians' progress is solved manually. In a conventional system, the information received by the dispatcher is in a list-based format and not formatted graphically. In the prior art, dispatchers use a conventional map and colored pins to represent the location of work orders and the location of technicians on the map. However, it is difficult to maintain the accuracy of this map throughout the day, as unexpected events may occur that interfere with the tracking of work orders. Further, there is a limit to the amount of information that a dispatcher can import from the map and from a list of job orders. As the day progresses, work order information, such as status, location, technician assigned, etc., may change, and, although this information may be entered in a computer immediately, it may be some time before the map is updated to reflect changes.
SUMMARY OF THE INVENTION
It is therefore an object of this invention to automate both the assignment of technicians to subscribers and monitoring the technician's progress throughout the day. This objective is achieved by providing an integrated computer and display system for conveying information regarding the location of technicians and the status of work orders to a dispatcher graphically.
It is a further object of this invention to represent a work orders as an icon on a display system.
It is a further object of this invention to represent different statuses of a work order as different icons on a display system.
It is a further object of this invention to quickly allow a dispatcher to discern whether a work order represents a specific type of service request such as an outage.
In another embodiment, a system for computer-aided technician dispatch and communication is disclosed. The system comprises a communications system linking a plurality of subscribers, a team of technicians, a service representative, and a user; an input terminal for receiving information, the information comprising service request information from the plurality of subscribers, and work order information from the team of technicians, a server coupled to the input terminals for processing the information and generating a graphical representation of the information, and, a display for receiving the graphical representation and presenting the graphical representation to a user.
In another embodiment, a method for computer aided technician dispatch and communication in accordance with the invention comprises five steps. Those steps are (1) communicating with a plurality of subscribers and a team of technicians; (2) receiving information, the information comprising service request information from the subscriber and work order information from the team of technicians, (3) entering the information in an input terminal, the input terminal coupled to a server; (4) processing the information, the processing resulting in a graphical representation of the information; and (5) displaying the graphical representation to a user.
A technical advantage of the present invention is that a system and method for computer-aided technician dispatch and communication is provided. Another technical advantage is that the invention displays graphical representations of service requests or work orders on a map in accordance with their actual positions. Another technical advantage is that the invention automatically updates the graphical representations as changes to their statuses are recognized. Another technical advantage is that the invention allows technician information to be entered into the database. Another technical advantage is that the invention automatically routes pending, unassigned service requests or work orders in accordance with a predefined algorithm to account for skill and distance factors.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of a system for computer-aided technician dispatch.
FIG. 2 shows a representation of the map display window.
FIG. 3 illustrates an example of a digitized map used in accordance with one embodiment of the present invention.
FIG. 4 shows a tree diagram of the menu structure according to one embodiment of the present invention.
FIG. 5 shows a tree diagram of the Admin. Mode menu structure.
FIG. 6 shows a tree diagram of the Routing and Dispatch menu structure.
FIG. 7 illustrates a preferred embodiment of the routing process.
FIG. 8 illustrates the assignment process according to one embodiment of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1 , which illustrates a block diagram of a system for computer-aided technician dispatch, a subscriber service request input terminal 100 is provided for a user, such as a service representative 112 or dispatcher 114 . Work order/technician information input terminal 102 may also be provided for a user. Both subscriber service request input terminal 100 and work order/technician information input terminal 102 are coupled to server 116 . Server 116 may comprise map generation means 118 , service request/work order processing means 120 , routing means 122 , and a database 124 . In one embodiment, a separate work order generating means may be provided. In another embodiment, a separate work order processing means may be provided to process technician information. Other processors and databases may be provided as required. In the preferred embodiment, map generation means, service request/work order processing means 120 , routing means 122 and database 124 are integrated applications running under a common operating system, such as Windows 95 or UNIX.
Display 104 is provided for displaying information to a user. A plurality of displays may be provided throughout the system. In a preferred embodiment, display 104 comprises an input window (not shown) and a map window (not shown). Other windows may be provided as necessary.
Subscribers 108 are linked by communications system 106 to service representative 112 , dispatcher 114 , and a team of technicians 110 . Communications system 106 may be a standard telephone, a cellular phone, a facsimile, pager, e-mail, or any other means of communicating. Technicians may communicate over communications system 106 by telephone, cellular telephone, radio, wireless computer, or any other means of communicating. In a preferred embodiment, subscribers 108 communicate solely with service representative 112 , while the technicians 110 communicate primarily with dispatcher 114 . Occasionally, the technicians 110 may be required to communicate with subscribers 108 for various reasons, such as to confirm an appointment, to change an appointment, to get directions, etc.
In a preferred embodiment of the invention, service representative 112 may comprise an automated call answering system 113 to record and enter subscriber service requests. For example, by using the numeric keypad on a telephone, a subscriber 108 may be able to request a service call by navigating a series of menus without actually speaking to service representative 112 . Service representative 112 may be required to contact subscribers 108 in the event of scheduling difficulties or for other reasons. In an alternate embodiment, service representative 112 may further comprise an e-mail mailbox that receives and processes electronic service request via e-mail.
In a preferred embodiment, team of technicians 110 may be able to access server 116 directly in order to enter work order information.
Subscribers typically communicate service requests to service representative 112 . These service requests may include reception difficulty, disconnection requests, addition or deletion of channels, or any other service request. Technicians typically communicate work order status, including completed, in service, or not completed; location information; scheduling information; or any other required information. In a preferred embodiment, technician location may be tracked using a global positioning system sensor, which transmits the technician location to the server directly. Other means of transmitting location or data to the server may also be used.
Referring to FIG. 2 , which depicts a flowchart of the method for computer-aided technician dispatch, in step 200 , a service request is received. Typically this will be from a subscriber or a potential subscriber, but it may also be from a technician. In step 202 , the service representative determines whether or not the service request is for a current subscriber or not. If it is not, in step 204 the service representative may have the potential subscriber give necessary subscriber information, which may include name, address, telephone number, etc. If the service request is from a current subscriber, in step 206 , the server retrieves the subscriber information from the database. In step 208 , the service request is entered into the service request input terminal 100 . Next, in step 210 , the information is processed, and a graphical representation of the service request is created. In order to develop this, the service status of the service request may be considered. Once the graphical representation is complete, the map and graphical representations of service requests are displayed in step 212 .
Referring again to FIG. 1 , in a preferred embodiment, once the service request information is entered into input terminal 100 , a work order is created. A work order is a compilation of all information for use either by team of technicians 110 , dispatcher 114 , or service representative 112 . Typically, a work order may be assigned a number to facilitate reference by team of technicians 110 or dispatcher 114 . Work order information may be entered, updated, deleted, or otherwise accessed through work order input terminal 102 .
Referring now to FIG. 3 , which illustrates an example of a display means 301 comprised of a digitized map in accordance with one embodiment of the present invention, a representation of a service area is shown in map window 300 . Map window 300 may be moved up, down, left, or right using the pan buttons 350 . Further, the amount of the service area that is displayed in map window 300 may be adjusted using zoom control 352 . Zoom control 352 may provide a plurality of levels of detail. Service requests are represented in map window 300 by using graphical representations of the service request. In a preferred embodiment, icons 302 , 304 , 306 , 308 , 310 , and 312 are used as graphical representations. A different icon may be used to represent the various statuses of a service request. For example, a service request that is assigned to a technician may be shown as 302 . A service request that has been canceled may be shown as 304 . A service request that has been completed by a technician may be shown as 306 . A service request that is currently being serviced by a technician may be shown as 308 . A service request that is unassigned may be shown as 310 . A service request that represents an outage may be shown as 312 . Other graphical representations may be used to show these and other service request statuses.
Other information may be conveyed through the properties of the graphical representations of the service requests. For instance, the color of the graphical representation of the service request may mean different things. A red graphical representation of a service request may indicate that the technician is late for a scheduled appointment; a flashing graphical icon may indicate that a technician is spending more time that was allotted for a certain service request, etc. Other properties of the graphical representations may be used to convey other information as well.
A user may have the ability to have all outages that have been reported and entered displayed at once using the Outages: Show button 354 . This will cause outages, indicated by graphical representation 312 , to be shown on the map.
Referring to FIG. 4 , which shows a tree diagram of the menu structure according to one embodiment of the present invention, the system starts by having the user log on to the system 400 . In this step, the user may be required to enter a user name and password. Once this is complete, the user selects a service area or fulfillment center in step 402 . This may be especially useful when one service center serves several service areas. Once the fulfillment center is chosen, the user is launched into the dispatch work space 404 . From this platform, the user may select either the Admin. Mode 406 or the Dispatch Mode 408 . The Admin. Mode 406 allows the user to run administrative functions, such as functions dealing with technicians 410 , work orders 412 , quota 419 , which are defined as the effort needed to complete a work product or task on a work order, or scheduled areas 416 , which are defined as the boundaries that subdivide a service area. Each Admin. Mode 406 area will be discussed in detail below.
Referring to FIG. 5 , which shows a tree diagram of the Admin. Mode menu structure, Techs window 410 gives the user two options. They are the Add Tech option 502 and the Edit option 504 . The Add Tech option 502 allows the user to enter information about a technician, which may include the technician's name, phone number, start date, and termination date. Other information may be added if required.
The Edit option 504 provides the ability to edit information that already exists. From Edit 504 , the user may edit Shift information 506 , edit Skills information 508 , edit Driver information 506 , and edit Private information 512 . From the edit shift information 510 the user may enter and update information dealing with the technician's Scheduled Hours 514 , the Scheduled Areas 516 that the technician may be assigned jobs from, and the daily Start/End Location 518 for a technician. The Start/End Location 518 information may be entered as an address, as a longitude/latitude position, or any other positioning system.
The edit Skills information 508 allows the user to update and add new skills to a particular technician's record. This may involve assigning a number of points to a technician based on his or her assessed skill level. The edit Driver information 510 allows the user to enter information such as a commercial driver license information, height, weight, eye color, birth date, gender, etc. Comments may be added as necessary.
The edit Private information 512 may be used to record miscellaneous comments about a particular technician.
The Admin. Mode 406 also allows a user to define Schedule Areas 416 . As discussed earlier, schedule areas are defined as the boundaries that subdivide a service area. These subdivisions may be defined by a franchise tax area, zip codes, geographical codes, or any other means for dividing a service area. The user may define the schedule areas based on these methods. New schedule areas may be added as appropriate.
Quota 414 may be set in Admin. Mode 406 . The user may assign a particular number of points to a particular task depending on the difficulty of the task. For example, connecting a customer to cable in a pre-wired apartment may be worth 20 points, indicating a low skill requirement and a low time requirement, while installing cable to a home that has not been pre-wired may be worth 50 points. These points are used to determine how many jobs a technician may complete in a given work day, and the amount of skill required to complete them.
Referring to FIG. 6 , which shows a tree diagram of the Routing and Dispatch menu structure, from the Routing and Dispatch window 408 , the user may use the automatic routing feature 418 , enter the Work Order Processing window 420 , or view the fulfillment center map 422 . The automatic routing feature 418 is used to automatically route unassigned work orders or service requests to available technicians. If the user does not desire to use the automatic routing feature 418 , the user may manually assign the service request or work order from the Routing and Dispatch window 408 .
From the Routing and Dispatch window 408 the user may select the Work Order Processing window 420 . This window allows the user to choose to update Job information 602 , Equipment information 604 , and Comments 606 . From the Job information window 602 , the user may enter and edit information regarding the particular work that was done or is pending, what products or services have been requested and their current statuses, and the current products that the subscriber has. The user may also launch into the Customer window 608 , the Service Location window 610 , the Work Order window 612 , and the Products window 614 .
Customer window 608 allows the user to update or enter information such as the customer type (e.g., regular, corporate, school, etc.), customer language preference, customer birth date, customer title, customer name, customer social security number, customer phone number, and any other information that may be required. Service Location window 610 allows the user to update or enter information regarding a particular service location, such as the address of the service location, postal route information, service location unit type (e.g., apartment, house, etc.) Work Order window 612 displays a schedule for a particular technician for a given time period, and may be used to cancel assigned work orders. Products window 614 allows unrequested equipment to be added to a customer's records.
From the Equipment information window 604 , the user may update information regarding the subscriber's current equipment and any requested equipment. The user may Add a converter box 616 , Remove a converter box 618 , Swap a converter box 620 , or refresh a converter box 622 .
Comments window 606 allows comments to be entered as necessary.
The user may also view the map 422 from the Routing and Dispatch window. This feature may be available from every menu for convenience. From the view map 422 option, the user may select a particular service request or work order that has been plotted on the map and have the Work Order Processing window 420 for that particular request displayed. Referring to FIG. 3 , the user may also view outages by selecting the “Show Outages” option 354 .
Referring again to FIG. 6 , the user may also select the “Show Tech” option 424 from the Routing and Dispatch window 408 . This will bring up the map window and show all jobs that are assigned to a particular technician.
Referring now to FIG. 7 , which is a diagram representing the routing process, first the input is received in step 701 . Next, a list of all unassigned work orders is created in step 702 . This may be done for a particular day, or any other time period. Next, in step 704 , a list of available technicians to complete the work orders, which, as discussed earlier, contain service request information and may include additional information, is created. In step 706 , a determination of the technicians that are qualified to complete the pending work orders is made. This may be done based on a skill rating that each technician may be assigned, and may include comparing the required time for the work order to a technician's available time. This list is temporarily associated with the work order record. Next, in step 708 , the number of qualified technicians is counted and this number x is also temporarily associated with the record. At the completion of step 708 , each work order record should have a corresponding list of qualified technicians and number of qualified technicians associated with it.
In step 710 , a determination is made as to whether or not there are any work orders that do not have any qualified technicians. To make this determination, a counter n which is initially set to 0 is compared to the number of qualified technicians associated with each work order, generated in step 706 . If there are any work orders that do not have any qualified technicians, a message indicating such is sent to the user in step 712 .
If there is at least one qualified technician for each work order, or a message has been sent to the user in step 712 , a determination is next made as to whether or not any unassigned work orders remain to be assigned in step 714 . If there are not, a message indicating such is displayed in step 728 and the process is completed in step 730 . If there are, in step 716 a determination is made of whether or not any of the unassigned work orders have qualified technicians still available. If there are not any qualified technicians available (i.e., all of the available time for the qualified technicians is allocated), a message indicating this is sent to the user via a display in step 718 , the remaining work orders are classified as “unassigned” in step 720 and the process is completed in step 730 . If there are qualified technicians available for the unassigned work orders, in step 722 the counter n, which was originally set at 0, is incremented by 1. A determination is then made in step 724 if there are any work orders that have n qualified technicians associated. If there are not, the process loops back to step 722 . If there are, the process assigns the work orders having n qualified technicians available in step 726 . Next, in step 732 , the process again creates a list of unassigned work orders. This list will not include the work orders previously assigned by step 726 . The assignment in step 726 will be discussed in view of FIG. 8 . Once the work orders having n qualified technicians are complete, the process loops back to step 714 .
Referring to FIG. 8 , which illustrates the assignment process, in step 801 , input is received. In step 802 , the process counts the number of work orders having n qualified technicians available and then assigns this a number to a variable, i. In step 804 , the process arranges the work orders in decreasing time-to-complete order. In this step, each work order is assigned a number from i to 1, where the work order that takes the longest to complete is assigned i and the work order that takes the shortest amount of time is assigned 1. The process, in step 806 , then determines whether the number of qualified technicians, n, is equal to 1. If it is, the process, in step 808 starting with work order i assigns the work orders to the qualified technicians. If the technician does not have time available to complete the work order, determined in step 810 , the work order is classified as “unassigned” in step 812 and, in step 814 , a message is sent to the user indicating such. If it is determined in step 810 that the technician does have enough available time to complete the work, the work order is classified as “assigned,” in step 816 , and the technician's schedule is updated in step 818 . In step 820 , i is decremented by 1, and in step 822 , if i=0, indicating that all work orders having n technicians have been reviewed, the process returns to step 732 of FIG. 7 . If i is not equal to 0, the process loops back to step 808 to continue reviewing these work orders.
If, in step 806 , n does not equal 1, distance will determine which of the at least one qualified technician will be assigned the work order. In step 826 , a distance comparison for work order i is made. The comparison is made between work order i's location and the qualified technicians' assigned start and end points, as well as to other previously assigned work orders. The technician having the minimum distance in any of these comparisons will be assigned the work order. In step 828 , a determination is made as to whether or not the technician has time available to complete the work order. If he does, in step 830 , the work order is classified as “assigned” and in step 832 the technician's schedule is adjusted to include the work order. If the technician does not have time available to complete the work order, that technician is removed from the qualified technician list for work order i in step 834 . A check is then made in step 836 to determine if any of the qualified technicians have available time to complete the work order i. If they do not, the work order is classified as “unassigned” in step 838 . In step 840 , a message is displayed to the user indicating such. If at least one technician has available time, the process loops back to step 826 . Once the work order is classified as either “assigned” or “unassigned,” the process decrements i by 1 in step 842 . In step 844 , if i=0, indicating that all work orders have been reviewed, the process, in step 826 , returns to step 714 of FIG. 7 . If i is greater than 0, the process loops back to step 826 .
As an example of how this process works according to one embodiment of the invention, assume that there are 6 work orders (W 1 , W 2 , W 3 , W 4 , W 5 , and W 6 ) to complete and 3 technicians (T 1 , T 2 , and T 3 ) available. Referring to FIGS. 7 and 8 and Table 1, step 702 would return the data in the column entitled “Unassigned Work Order” and step 706 would return the data in the column entitled “Qualified Technicians.” Next, the step 708 would return the data in the column entitled “Number of Qualified Technicians.” The data in these columns would then be associated with the particular work order(s). For instance, work order W 2 would have T 1 and T 2 associated with it, as well as the number of technicians that can complete the job, which is 2.
TABLE 1
Unassigned Work Order
Number of Qualified
(time to complete)
Qualified Technicians
Technicians
W 1 (4)
T 1
1
W 2 (3)
T 1 , T 2
2
W 3 (2)
T 2
1
W 4 (4)
T 1 , T 2 , T 3
3
W 5 (1)
T 1 , T 2
2
W 6 (5)
None
0
Next, in step 710 , the process determines that W 6 does not have any qualified technicians. This would cause a message to be sent to the user in step 712 . Since there are unassigned work orders (step 714 ), and there are qualified technicians for the unassigned work orders (step 716 ), the process looks at work orders with n=1 qualified technicians (step 724 ). Thus, the assignment process begins (step 726 ). Referring to FIG. 8 and Table 1, there are two work orders that have n equal to 1, W 1 and W 3 . Thus, in step 802 i is equal to 2. The result of step 804 would be W 1 followed by W 3 , with W 1 assigned i=2 and W 3 assigned i=1. Assuming that both technicians had available time to complete the work orders, step 816 would first assign W 1 to T 1 , and, after decrementing i in step 820 and looping back to step 808 , step 816 would then assign W 3 to T 2 .
Next, the process would loop back to step 732 of FIG. 7 and would look for work orders with n=2. Referring to Table 1, there are two work orders, W 2 and W 5 , that have two qualified technicians. Step 804 of FIG. 8 would put the work orders in the order W 2 followed by W 5 .
The process, in step 826 , considers the distance from the start location, the end location, or any previously assigned work order locations to the work order location in question. For example, referring to Tables 2 and 3, the distance data relative to the two qualified technicians for W 2 is considered. Since the minimum distance for W 2 from a previous point is 5 miles (from W 1 ), T 1 is selected to complete W 2 .
TABLE 2
Technician 1
Location
Miles To W 2
W 1
5
Start Location
16
End Location
20
TABLE 3
Technician 2
Location
Miles To W 2
W 3
7
Start Location
6
End Location
14
Once a technician is selected, the process confirms that the selected technician has available time to complete the work order (step 828 ). Here, assuming T 1 that T 1 has available time (at least 3 hours) to complete W 2 , T 1 is assigned W 2 (step 830 ) and T 1 's schedule is updated to reflect this (step 832 ). After i is decremented (step 842 ), the same type of analysis is repeated for W 5 .
The process then considers the work orders that have n=3 qualified technicians available using a similar type of analysis.
Although the present invention has been described in detail, it should be understood that various changes, substitutions, and alterations can be made without departing from the intended scope as defined by the appended claims.
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A system for computer aided technician dispatch and communication includes a communications system linking a plurality of subscribers, a team of technicians, a service representative, and a user. An input terminal receives information, the information includes service request information from the plurality of subscribers ( 116 ), and work order information from the team of technicians. The system, also includes a server coupled to the input terminals for processing the information and generating a graphical representation of the information, and, a display for receiving the graphical representation and presenting the graphical representation to a user. A method for computer aided technician dispatch and communication includes communicating with a plurality of subscribers and a team of technicians and receiving information, the information including service request information from the subscriber and work order information from the team of technicians. The method also includes entering the information in an input terminal coupled to a server processing the information, the processing resulting in a graphical representation of the information and displaying the graphical representation to a user.
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BACKGROUND
[0001] In the downhole drilling and completion industry, there is often need to contain fluid within a formation during various operations. Conventionally, a mechanical barrier is put in the system that can be closed to contain the formation fluid when necessary. One example of a system known in the art will use a valve in operable communication with an Electric Submersible Pump (ESP) so that if/when the ESP is pulled from the downhole environment, formation fluids will be contained by the valve. While such systems are successfully used and have been for decades, in an age of increasing oversight and fail safe/failure tolerant requirements, additional systems will be well received by the art.
SUMMARY
[0002] Disclosed herein is a multi-barrier system including a first valve in fluid communication with a lower completion, and a second valve in fluid communication with the lower completion. The first valve and the second valve are positioned proximate an uphole extent of the lower completion, and a packer located proximate the first valve and the second valve is closable in response to retrieving an upper completion.
[0003] Also disclosed herein is a method of redundantly closing a wellbore nonpermanently upon retrieval of an upper completion, including disengaging an upper completion from a lower completion, closing a first valve in response to the disengaging, closing a second valve in response to the disengaging, reengaging an upper completion with the lower completion, opening the first valve, and opening the second valve.
BRIEF DESCRIPTION OF THE DRAWINGS
[0004] Referring now to the drawings wherein like elements are numbered alike in the several Figures:
[0005] FIG. 1 is a schematic view of a stackable multi-barrier system;
[0006] FIG. 2 is a schematic view of the system of FIG. 1 in partial withdrawal from the borehole;
[0007] FIG. 3 is a schematic view of a new stackable multi-barrier system engaged with the remains of the system illustrated in FIG. 1 ; and
[0008] FIG. 4 depicts a quarter cross sectional view of a portion of a hydraulically actuated valve employed in the stackable multi-barrier system of FIGS. 1-3 .
DETAILED DESCRIPTION
[0009] Referring to FIG. 1 , a stackable multi-barrier system 10 is illustrated. Illustrated is a portion of a lower completion 12 , a packer 14 and a portion of an upper completion 16 . One of ordinary skill in the art will be familiar with the lower completion 12 and the packer 14 and the concept of an upper completion 16 in operable communication therewith. In the illustrated embodiment an electric submersible pump (ESP) 18 is included in the upper completion 16 , which is a device well known to the art. Between the illustrated ESP 18 and the lower completion 12 however, one of ordinary skill in the art will be surprised to see a number of mechanical barriers 20 , 22 (sometimes referred to herein as “valves”) that is greater than one. As illustrated in the figures hereof there are two but nothing in this disclosure should be construed as limiting the number of mechanical barriers to two. Rather more could also be added, if desired.
[0010] In one embodiment the more downhole valve 20 is a hydraulically actuated valve such as an ORBIT™ valve available commercially from Baker Hughes Incorporated, Houston Texas and the more uphole valve 22 is a mechanically actuated valve such as a HALO™ valve available from the same source. It will be appreciated that these particular valves are merely exemplary and may be substituted for by other valves without departing from the invention.
[0011] Control lines 24 are provided to the valve 20 for hydraulic operation thereof. In the illustrated embodiment the lines also have a releasable control line device 28 in line therewith to allow for retrieval of the upper completion 16 apart from the lower completion 12 . Also included in this embodiment of the system 10 is a stroker 30 that may be a hydraulic stroker in some iterations.
[0012] The components described function together to manage flow between the lower completion 12 and the upper completion 16 . This is accomplished in that the valve 20 is settable to an open or closed position (and may be variable in some iterations) based upon hydraulic fluid pressure in the control line 24 . The valve 22 is opened or closed based upon mechanical input generated by movement of the upper completion 16 , or in the case of the illustration in FIG. 1 , based upon mechanical movement caused by the stroker 30 that is itself powered by hydraulic fluid pressure. Of course, the stroker 30 could be electrically driven or otherwise in other embodiments. In any condition, the valve 22 is configured to close upon withdrawal of the upper completion 16 . In normal production, both of the valves 20 and 22 will remain open unless there is a reason to close them. Such a reason occurs, for example, when it is required to retrieve the upper completion 16 for some reason. One such reason is to replace the ESP 18 . Regardless of the reason for closure, employment of the system 10 in a completion string provides more than one mechanical barrier 20 , 22 at an uphole extent of the lower completion 12 . The barriers when closed prevent fluid flow after the upper completion is retrieved.
[0013] Attention is directed to releasable control line devices 28 and FIG. 2 . During a withdrawal of the upper completion 16 , the control lines 24 are subjected to a tensile load. The releasable control line devices will release at a threshold tensile load and seal the portion of the control lines 24 that will remain in the downhole environment as a part of the lower completion string 12 . The valve 20 , if not already closed, is configured to close in response to this release of the control lines 24 . This will complete the separation of the upper completion 16 from the lower completion 12 and allow retrieval of the upper completion 16 to the surface. With more than one mechanical barrier 20 , 22 in place at the uphole extent of the lower completion 12 , there is improved confidence that fluids will not escape from the lower completion 12 . Important to note here briefly is that the system 10 also includes provision 44 for allowing the reopening of the valve 20 using tubing pressure after the upper completion 16 is reinstalled. This will be addressed further hereunder.
[0014] In order to restore production, another system 110 is attached at a downhole end of upper completion 16 and run in the hole. This is illustrated in FIG. 3 . The original system 10 has components such as packer 14 , valves 20 and 22 and control lines 24 are seen at the bottom of the drawing and a new system 110 stackable on the last is shown. The new system 110 includes a packer 114 valve 120 , valve 122 , lines 124 , stroker 13 , ESP 118 and releasable hydraulic line device 128 . In essence each of the components of system 10 is duplicated in system 110 . Moreover, it should be understood that the process of pulling out and stabbing in with new systems can go on ad infinitum (or at least until practicality dictates otherwise).
[0015] Since the valves 20 and 22 will be in the closed position, having been intentionally closed upon preparing to retrieve the upper completion 16 , they will need to be opened upon installation of the new system 110 . This is accomplished by stabbing a mechanical shiftdown 142 into valve 22 and setting packer 114 . The mechanical shiftdown 142 mechanically shifts the valve 22 to the open position. It should be pointed out that, in this embodiment, the mechanical shiftdown 142 does not seal to the valve 22 and as such the inside of the upper completion 16 is in fluidic communication with annular space 146 defined between the packers 14 and 114 . Applying pressure to the tubing at this point will result in a pressure buildup that will act on the valve 20 through the string uphole thereof since all valves thereabove, 22 , 120 and 122 are in the open position. Referring to FIG. 4 , a view of valve 20 illustrates the provision 44 that includes a port 52 in operable communication with an optional shifter 50 . The shifter 50 is configured to open the port 52 in response to retrieval of the upper completion 16 . As illustrated the shifter 50 in this embodiment is a sleeve that is automatically actuated upon retrieval of the upper completion 16 . More specifically, when upper completion 16 begins to move uphole, the provision 44 is shifted to the open position. When the provision 44 is in the open position tubular fluid pressure is in communication with the port 52 . The port 52 includes an openable member 54 such as a burst disk or similar that when opened provides fluid access to an atmospheric chamber 56 . The member 54 opens upon increased tubing pressure and allows fluid to fill the atmospheric chamber 56 . Fluid in the atmospheric chamber causes one or more pistons 58 to urge the valve 20 to the open position. In one embodiment, ratcheting devices (not shown) may be provided in operable communication with the one or more pistons 58 to prevent the pistons from moving in a direction to allow the valve to close by serendipity at some later time. It may also be that the valve 20 itself is configured to be locked permanently open by other means if the atmospheric chamber floods.
[0016] The foregoing apparatus and method for its use allows for the retrieval and replacement of an upper completion without the need for a wet connection.
[0017] While one or more embodiments have been shown and described, 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 illustrations and not limitation.
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A multi-barrier system includes a first valve in fluid communication with a lower completion, and a second valve in fluid communication with the lower completion. The first valve and the second valve are positioned proximate an uphole extent of the lower completion, and a packer located proximate the first valve and the second valve is closable in response to retrieving an upper completion.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention relates broadly to sculptured articles of manufacture and methods for making them. More particularly, this invention relates to turned figures based on a profile or a stylized representation of a figure. In addition, the invention relates to arrangements of said sculptured articles.
[0003] 2. State of the Art
[0004] Decorative representations and methods for creating them have been granted utility patent protection since at least the nineteenth century. U.S. Pat. No. 629,312 to Beidler (issued in 1899) discloses a campaign torch with a three dimensional representation of two human heads, presumably candidates. U.S. Pat. No. 1,555,644 to Duncan (issued in 1925) discloses a multiple face doll, as does U.S. Pat. No. 1,618,772 to Merseburger (issued in 1927). U.S. Pat. No. 2,197,577 discloses a three dimensional ornament for use on a Christmas tree as well as a method for making it. In 1973 U.S. Pat. No. 3,762,084 issued to Jones for a fish mobile and a method for making the fish.
[0005] In 1980 DiMatteo was granted U.S. Pat. No. 4,180,930 for a reflected three dimensional display wherein half of two symmetrical portions of an object is cut or embedded in one surface of a block of transparent material with a reflective surface such that the cut or embedded image is reflected to give the appearance of the complete object.
[0006] U.S. Pat. No. 4,858,425 to Cheredaryk et al. (issued in 1989) discloses a reflecting ornament string in which a plurality of reflecting members are connected with a thin cord so as to permit free rotation of each member relative to others.
[0007] More recently, U.S. Pat. No. 6,858,422 to Spaar discloses a three dimensional hanging decoration which is made from a flat, lightweight sheet of flexible material.
[0008] It is therefore clear from the foregoing that art and technology have combined many times to produce something ornamental or artistic.
[0009] The history of the art of sculpture dates from the stone age when small statues were made of soft stone, ivory, or clay. These statues have been found and dated by archeologists. As the art progressed, different materials were employed including metals such as copper, gold and silver. Different methods of making sculptured articles were employed depending on the material used and the size of the sculpture. The sphinx was carved out of living rock whereas the Mount Rushmore sculpture was created with the aid of explosives. The most common methods of sculpture today include carving, casting, and molding. However, some metal sculpture is created by torch cutting and welding or by assembly with fasteners such as screws or rivets.
[0010] In 2004, a Colorado craftsman named Tom Beshara created a wooden object which is turned on a lathe. The object is a solid artifact which resembles an urn or a table leg or a candle holder. However, it creates, in negative space, on opposite sides of the artifact two identical two-dimensional profiles facing each other. The effect is based on an old optical illusion which requires you to look not at the object but to look at the negative space surrounding it. Thus, it is not really a sculpture of any thing. It is an object which defines a negative space wherein a human profile can be perceived.
[0011] For many years, the present inventor has been creating different art forms that express human identity. In recent years, the present inventor began to contemplate turned figures illustrating human identity. Before learning about Mr. Beshra's products, the present inventor conceived of the invention described and claimed herein.
SUMMARY OF THE INVENTION
[0012] It is therefore an object of the invention to provide new methods for creating sculptured articles.
[0013] It is another object of the invention to provide artistic displays utilizing these new methods.
[0014] It is a further object of the invention to create sculptured articles which represent or suggest human identity.
[0015] In accord with these objects, which will be discussed in detail below, the methods of the invention include first creating a profile, either manually by drawing it or with the aid of backlit photography. The profile may be a realistic representation or an impressionistic representation. The profile is then used to create a solid sculpture which is a positive rotation of the profile about an axis. The resulting sculpture shows the profile on its three dimensional surface not in negative space. According to one method of the invention, the profile is used to create a CNC (computer numeric control) file which is used to operate a CNC equipped lathe. Suitable materials for use with the lathe include stone, metal, or wood depending on the cutting tool used in the lathe. The resulting article is a three dimensional object having a generally convex profile revolved about a longitudinal axis. When viewed, the profile can be seen in positive space over the entire surface of the object. According to another method of the invention, the profile is used to create a 3D printer file and a 3D printer is used to build an acrylic photopolymer sculpture. The resulting article is a three dimensional object having a generally convex profile revolved about a longitudinal axis. When viewed, the profile can be seen in positive space over the entire surface of the object.
[0016] In a first embodiment, a realistic profile of a human face is used and the resulting article resembles a bust but with only the features of the profile which are seen in positive space over the entire surface of the object. According to a second embodiment, a plurality of realistic human face profiles are acquired and connected to each other so that when the sculpture is complete one profile is atop the other somewhat like a totem pole. According to a preferred aspect of this embodiment, each of the faces are from members of the same family and the product is called the Family Totem™ or Revolutionary Family Toten™.
[0017] According to a third embodiment, a profile is obtained and a sculpture is created according to one of the methods described above. A plurality of objects are created in this manner and are suspended in a three dimensional field defined by a frame. According to a preferred aspect of this embodiment, the profiles are impressionistic profiles of nude female figures.
[0018] According to other embodiments of the invention, other profiles depicting or suggesting human identity are created and turned into solid objects according to one of the methods of the invention. Examples of profiles which depict or suggest human identity include, a profile of a city skyline (of the city where the person lives), a profile of a person's automobile, a profile of a person's hands, a profile of a person's pet, etc.
[0019] 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
[0020] FIG. 1 is a simplified flowchart showing a first method according to the invention;
[0021] FIG. 2 is a profile of a subject for a sculpture according to the invention;
[0022] FIG. 3 is a schematic illustration of a backlit photo of the subject of FIG. 2 ;
[0023] FIG. 4 is an illustration of the back lit profile with the rear of the head profile removed;
[0024] FIG. 5 is an illustration of the profile of FIG. 4 duplicated and the duplicate flipped;
[0025] FIG. 6 is an illustration of the two copies of the profile joined and a suitable base below them;
[0026] FIG. 7 is an illustration of the two copies of the profile and base all joined together providing a two dimensional representation of how the finished sculpture will appear;
[0027] FIG. 8 is an illustration of the profile which will be used to generate an appropriate computer file to complete the sculpture either with a printer or a lathe;
[0028] FIG. 9 is an illustration of a finished sculpture according to the invention where the shading illustrates shadow;
[0029] FIG. 10 is a simplified flow chart illustrating another method for making the sculpture of FIG. 9 ;
[0030] FIGS. 11 through 13 illustrate some of the steps in the process of making a totem sculpture according to the invention;
[0031] FIGS. 14 through 16 are computer generated images which illustrate impressionistic turned figures based on the human female body;
[0032] FIG. 17 is a photograph which illustrates a plurality of impressionistic figures arranged in a three dimensional space defined by a metal frame with the figures suspended by thin transparent filaments;
[0033] FIG. 18 is a two dimensional representation of a sculpture according to the invention of the profile of a city skyline;
[0034] FIG. 19 is a two dimensional representation of a sculpture according to the invention of the profile of a dog's head;
[0035] FIG. 20 is a two dimensional representation of a sculpture according to the invention of the profile of a penguin;
[0036] FIG. 21 is a two dimensional representation of a sculpture according to the invention of the profile of a horse head;
[0037] FIG. 22 is a three dimensional computer rendering of the expected appearance of a finished sculpture according to the invention; and
[0038] FIG. 23 is a photograph of three marble sculptures according to the invention.
DETAILED DESCRIPTION
[0039] Turning now to FIG. 1 and with reference to FIGS. 2 through 9 , a method of making a sculpture begins with obtaining a profile. One way of doing this is to obtain a backlit photograph of the subject as indicated at 10 in FIG. 1 . FIG. 2 illustrates a person's head and FIG. 3 schematically illustrates what a backlit photograph of the head looks like, i.e. no detail of the hairline, eye, ear, nose or mouth, just the outline or “profile”. FIG. 3 is schematic because in a backlit photograph the profile would be filled with black. According to presently preferred methods, the photograph is either digital or digitized with a scanner and processed with image editing software such as Adobe® Photoshop® from Adobe Systems, Incorporated. This is indicated at 12 in FIG. 1 . The processing steps include removing the black fill from the photo to obtain an image that looks like FIG. 3 . Alternatively, the black filled profile can be traced in a separate layer. In either case, the back of the profile is removed to create an image like that shown in FIG. 4 . The image of FIG. 4 is then copied and the copy is flipped horizontally as illustrated in FIG. 5 . The two copies are joined and an aesthetically suitable base is drawn as shown in FIG. 6 . The base is joined to the joined profiles as illustrated in FIG. 7 . FIG. 7 is a two dimensional approximation of what the final product will look like.
[0040] According to the invention, the profile will be revolved about an axis. Therefore, only half the profile is needed and thus, half may be removed leaving the profile of the head and base as shown in FIG. 8 . Those skilled in the arts of computer graphics and computer aided manufacturing (CAM) will appreciate that image editing software such as Adobe® Photoshop® create and manipulate “bitmap” images and that CAM machines work with “vector” images or numeric representations of an image. The bitmap image of FIG. 8 is thus converted to a vector image. This can be accomplished by importing it into a vector drawing program such as Adobe® Illustrator®. This step in the method is indicated at 14 in FIG. 1 .
[0041] A vector image such as an Adobe® Illustrator® file can then be imported into a 3D graphic modeling program such as Rhino™ from the McNeel Company. Thus, the vectorized image of FIG. 8 is imported into Rhino 3D as indicated at 16 in FIG. 1 . Using the vector information, the 3D modeling program can be given a command and will “render” an image on the computer screen that appears three dimensional. In this case, the command is “revolve” and the resulting image looks like FIG. 9 . The application of the revolve command is indicated at 18 in FIG. 1 . This step in the method will show the artist an approximation of what the finished product will look like at this point, the artist can go back and alter the profile in the vector drawing program to alter the look of the sculpture if desired.
[0042] Many 3D modeling programs allow for the creation of a CAM file such as an .stl (stereo lithography) file which can be used by a 3D printer. Thus, such a file is created as indicated at 20 in FIG. 1 .
[0043] According to the method illustrated in FIG. 1 , a rapid prototyping and manufacturing (RP&M) program, such as Magics X from Materialize, Leuven, Belgium, is used to control a 3D printer, such as the InVision™ 3-D Printers from 3D Systems, Inc. Thus, the file created at 20 in FIG. 1 is opened at 22 with Magics and sent to the 3D printer at 24 . These printers typically build acrylic photopolymer on a support to create the three dimensional article described by the computer file as indicated at 26 in FIG. 1 . When the printing is complete, the support is removed as indicated at 28 in FIG. 1 .
[0044] The method described with reference to FIG. 1 will produce an acrylic three dimensional object. However, the invention aims to create sculpture in different types of media and not just acrylic polymer. Thus, a second similar method is described in FIG. 10 which utilizes a CNC Lathe such as those available from Mori Seki Co. Ltd. and Nakamura-Tome Co. The method is substantially the same as that illustrated in FIG. 1 for method steps 110 through 118 . The method differs starting at 120 where a step file (.stp) is created and optionally converted at 122 to an ASCII G code file. The G code (or the .stp file) is sent to a CNC lathe at 124 which uses it to cut a block of spinning material at 126 . When the code is completed, the finished piece is removed at 128 . CNC lathes can be used to cut metal, wood, marble, and stone. Thus, the method of FIG. 10 provides a wider choice of materials for the sculptures.
[0045] FIGS. 11 through 13 illustrate some of the steps used to create a Family Totem™ according to the invention. The process described above with reference steps 10 and 12 in FIG. 1 are repeated for several profiles shown in FIG. 11 and the profiles are joined together and vectorized as shown in FIG. 12 . The vectorized image of FIG. 12 is then used in the process of either FIG. 1 or FIG. 10 to produce a solid turned sculpture as shown in FIG. 13 which is similar in some respects to a totem pole. According to the presently preferred embodiment, the totem comprises the profiles of several family members. Those skilled in the art may appreciate that the interface between the neck/shoulder/chest of one profile with the head of the profile below it may need to be “finessed” to achieve an aesthetically pleasing result.
[0046] Turning now to FIGS. 14-17 , another embodiment of the invention involves impressionistic profiles and a three dimensional arrangement of a plurality of sculptures. The turned sculptures shown in FIGS. 14-16 are based on an impressionistic representation of human female nude figures. As such, they are preferably drawn by hand rather than captured with digital photography. Alternatively, they may be captured with digital photography and then, after vectorizing, manipulated substantially. Because these figures lack a base, they are preferably displayed by suspending them. It is conceivable that a single such figure could be suspended or provided with a base, but an aspect of the invention shows a plurality of figures suspended in a three dimensional space which is defined by a frame as shown in FIG. 17 . It is not necessary that all of the figures be unique, nor is it necessary that they all be made of the same material or be the same color. Other sculpture made according to the methods of the invention may also benefit from a suspended display such as that shown in FIG. 17 .
[0047] FIG. 18 shows a two dimensional representation of a sculpture made according to the methods of the invention which is based on a city skyline. This can be more readily seen by viewing the sculpture with its axis or rotation aligned horizontally. Those familiar with the city will appreciate that the sculpture of FIG. 18 is based on the skyline of mid-town Manhattan, NYC. The sculpture of FIG. 18 is not shown with a base. A base may be provided or the sculpture may be suspended or it may be suspended in a three dimensional array with other related sculptures.
[0048] FIG. 19 shows a two dimensional representation of a sculpture made according to the methods of the invention which is based on a dog's profile. This sculpture could be provided with a base or made part of a totem.
[0049] FIG. 20 shows a two dimensional representation of a sculpture made according to the methods of the invention which is based on the profile of a penguin. This could identify a person who lives or has lived where penguins live.
[0050] FIG. 21 shows a two dimensional representation of a sculpture made according to the methods of the invention which is based on a horse's head.
[0051] FIG. 22 is a computer generated image such as the image generated at step 18 in FIG. 1 .
[0052] FIG. 23 is a photograph of three marble sculptures made according to the methods of the invention. Here the three “busts” are of family members
[0053] There have been described and illustrated herein several embodiments of methods for creating sculptures and sculptures created according to the methods. 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. 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 spirit and scope as claimed.
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A method for creating a sculpture includes obtaining a profile of a person or thing, using the profile to create a three dimensional object in which the profile is revolved about an axis. The resulting sculpture shows the profile in positive space over its entire surface. Exemplary apparatus for carrying out the method include 3 D printers and CNC lathes.
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CROSS-REFERENCE TO RELATED APPLICATION
This application claims the benefit of U.S. Provisional Patent Application Ser. No. 61/886,075, filed Oct. 3, 2013, and entitled “Evacuation Slide Readiness Indicator Concept,” the entire contents of which application are incorporated herein by this reference.
FIELD OF THE INVENTION
This application relates to systems for evacuating passenger vessels such as aircraft and more particularly, but not exclusively, to inflatable evacuation slides with indicators that the slides are inflated and ready for use.
BACKGROUND OF THE INVENTION
U.S. Pat. No. 4,333,546 to Fisher describes inflatable evacuation or escape slides intended principally for off-wing (or “over-wing”) use. Because the wing may block view of the ground or other support surface from within the aircraft, passengers and crew may be unable to ascertain visually whether an off-wing evacuation slide has inflated sufficient for use. As noted in the Fisher patent:
It is . . . important for the flight attendant to know whether or not the slide is properly extended without walking to the edge of the wing and looking down. This is important because the attendant must have this information without leaving the fuselage of the aircraft in order to direct the passengers to the escape slides which are operable.
See Fisher, col. 1, 11. 13-19. Accordingly, the escape slides of the Fisher patent include two additional indicator tubes designed to inflate upwardly into the line of sight of a flight attendant positioned at the corresponding fuselage access door. The indicator tubes further may include marking tape wrapped around their uppermost ends to enhance their visibility. See id. at col. 3, 11. 38-61. After presumed inflation of a slide, “[t]he attendant then can look out the access door of the fuselage and by observing the positions of the indicator tubes determine if the slide portion, which is not visible from the fuselage, is in condition for evacuating passengers.” See id. at 11. 64-68 (numerals omitted).
U.S. Pat. No. 6,443,259 to Oley discloses a different mechanism for indicating readiness for use of an off-wing evacuation slide. Instead of using the two upwardly-inflatable tubes of the Fisher patent, slides of the Oley patent include
a conventional red, octagonal “stop” sign that is releasably mounted to the guard rail. The stop sign is removed (to indicate that it is safe to proceed) when the evacuation slide has properly deployed by means of a [lanyard] connected to [the] toe end of the evacuation slide. As the evacuation slide unfurls, the lanyard is paid out until, at the last stage, when the toe end unfurls the lanyard pulls the stop sign off the guard rail, so that it is no longer visible to a disembarking passenger.
See Oley, Abstract, 11. 9-17.
Such a stop sign of the Oley patent is made of fabric and removably attached to the guard rail by hook-and-loop fasteners. See id., col. 3, 11. 61-64. Full deployment of the corresponding slide “yank[s the sign] off its mountings” and pulls it into a sheath for concealment and stowage. See id., col. 4, 11. 25-33. Alternatively, the stop sign may be replaced by “a permanent sign which is concealed by a cover operated by a lanyard, or a conventional yellow ‘police tape’ stretching across the entrance [of the slide], which is removed by a lanyard.” See id., col. 4, 11. 53-57. The contents of the Fisher and Oley patents are incorporated herein in their entireties by this reference.
As criticized in the Oley patent, the inflatable, upwardly-extending “barber poles” of the Fisher patent are disadvantageous at least because “they use valuable inflation gasses to effect their deployment.” Additionally, they “are not intuitive,” as “self-disembarking passengers will not know to look for the barber poles to determine the status of the evacuation slide and may attempt to exit the plane before the slide is properly deployed.” See id., col. 1, 1. 59 through col. 2, 1. 6. Nor are the stop signs of the Oley patent wholly advantageous, however. Passengers and crew receive no affirmative indication of slide readiness, for example; mere absence of a “stop” sign might not be understood to mean “go,” leading to possible confusion among evacuees as to whether evacuation is yet proper. Additionally, failure of the lanyard to overcome the mechanical strength of the hook-and-loop fasteners, tearing of the fabric of the stop sign, or lack of complete stowage of the stop sign in its sheath may result in continued visibility of some or all of the stop sign even though the corresponding slide is ready for use. This too could confuse passengers and crew, incorrectly inhibiting evacuation when it would be proper to do so.
SUMMARY OF THE INVENTION
The present invention provides alternatives to the readiness indicators of the Fisher and Oley patents. The indicators not only are intuitive, but also furnish affirmative information as to when evacuation is proper. No valuable inflation gas is needed for operation of the indicators of the present invention, nor is any “yanking” of fabric signs necessary to change states of the indicators from “stop” to “go.” The present invention thus is designed to reduce, if not wholly avoid, evacuee confusion as to readiness of (particularly) off-wing inflatable evacuation slides for use without impeding inflation of the slides in any way. It further may be simple and reliable and use pre-existing electrical power.
Presently preferred versions of the invention may comprise colored lights indicating slide statuses. Although such lighting may be supplied in any suitable manner, at least some embodiments of the invention utilize red and green light-emitting diodes (LEDs) to furnish the colored lighting. Nearly universally understood by humans is that a red light is synonymous with a stop command, whereas a green light indicates the contrary (i.e. “go”). Depending on which light is illuminated at any given time, passengers and crew receive clear information—whether negative or affirmative—as to the readiness for use of the corresponding slide.
Moreover, some versions of the invention may place the lights on a background shaped like a conventional traffic signal. The signal-shaped background additionally may be of a color contrasting with red and green (e.g. yellow or orange). The effect is to clarify further the function and nature of the lighting as providing stop and go commands for slide usage.
Enhanced visibility of the indicator lighting may, if desired, be provided by mounting it on an outboard rail tube at the entrance to the ramp of the slide. This mounting position typically permits easy viewing of the lighting from the fuselage access door or an adjacent window, even in low-light conditions sometimes present in emergency evacuation situations.
Readiness indicator lighting of the invention may be powered by, for example, emergency power of the aircraft. Alternatively, batteries used for other aspects of slide lighting may power the indicator lighting of the present invention. No additional power thus is needed to operate the indicator lighting. However, if desired for any reason, the indicator lighting may have a dedicated power supply independent from those typically already present on-board an aircraft.
Certain versions of the invention may include a switching module mounted on a lower section of a slide. Upon commencement of slide deployment, electrical power may be supplied to the switching module, whose normal (default) state causes illumination of (only) the red LED. Normal slide inflation causes restraint links to separate sequentially to stage proper unfolding of the slide. As the slide continues to deploy normally, the restraint links continue to separate until a final link remains in the lower section of the slide. If the switching module is connected to or included as part of the final link, separation of the final link may cause the switching module to change state so as to extinguish the red LED and illuminate the green LED instead. Such change in illumination supplies an affirmative signal to passengers and crew that the slide has fully inflated. By contrast, if for any reason the final link does not separate—indicative of improper or incomplete deployment of the slide—the switching module will not change state and the red LED will remain illuminated.
Some switching modules may be designed to effect state change through removal of a pin. If the pin is attached to a lanyard in turn attached to a separable portion of the final link, separation of the final link will tension the lanyard and pull the pin from the switching module. As the pin is removed, the switching module changes from its default state (in which the red LED is illuminated) to a state in which the green LED is active and the red LED is inactive.
In some circumstances, it might be possible for a slide to deploy completely, hence activating the green LED, yet soon thereafter deflate sufficiently to be unusable. Some versions of the invention, therefore, also may include a pressure sensor which must register satisfactory pressure in the slide before the green LED may illuminate. If at any time slide pressure drops below a minimum acceptable value, the sensor prevents illumination of the green LED or, if the green LED is illuminated, causes a state change so that the red LED becomes active instead. The pressure sensor, if present, preferably is electrically powered, although other sensors of inflation pressure, including transducer-type sensors which may produce electrical signals, may be used instead.
It thus is an optional, non-exclusive object of the present invention to provide improved systems for evacuating persons from vessels or other objects.
It is also an optional, non-exclusive object of the present invention to provide evacuation systems in which indication of slide readiness is furnished.
It is another optional, non-exclusive object of the present invention to provide evacuation systems in which colored indicators of slide readiness are configured to be visible to passengers and crew within aircraft.
It is a further optional, non-exclusive object of the present invention to provide evacuation systems not requiring inflation gas or yanking of a fabric sign for purposes of indicating slide readiness.
It is, moreover, an optional, non-exclusive object of the present invention to provide evacuation systems in which red and green lights signal, alternatively, “stop” and “go” commands for slide usage.
It is an additional optional, non-exclusive object of the present invention to provide evacuation systems in which the signal lights may be positioned on an outboard rail tube at the entrance to a slide ramp and, optionally, with a background of contrasting color shaped as a traffic signal.
It is yet another optional, non-exclusive object of the present invention to provide evacuation systems in which indicator lights may be powered by pre-existing sources of electricity.
It is also an optional, non-exclusive object of the present invention to provide evacuation systems having switching modules whose states determine which one of a plurality of indicator lights present on a slide is to be illuminated.
It is a further optional, non-exclusive object of the present invention to provide evacuation systems in which a switching module is associated with a final restraint link of a slide such that separation of the final link causes the switching module to change states.
It is, moreover, an optional, non-exclusive object of the present invention to provide evacuation systems in which the switching module is configured to change states when a pin is pulled therefrom, as by a lanyard tensioned by separation of the final restraint link.
It is also an optional, non-exclusive object of the present invention to provide evacuation systems optionally including a sensor for determining that inflation pressure of a slide is (or remains) satisfactory for use.
Other objects, features, and advantages of the present invention will be apparent to those skilled in the art with reference to the remaining text and drawings of this application.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1-3 provide various, partly-schematic views of an exemplary inflatable off-wing slide as deployed for purposes of evacuating an aircraft.
FIG. 4 illustrates an outboard rail tube of the slide of FIGS. 1-3 together with an exemplary readiness indicator of the present invention.
FIG. 5 is another view of portions of the slide and the readiness indicator of FIGS. 1-4 .
FIG. 6 provides an example of a switching module and final restraint link useful as parts of the slide and readiness indicator of FIGS. 1-5 , with the final restraint link intact and the switching module in its normal (default) state.
FIG. 7 illustrates the exemplary switching module and final restraint link of FIG. 6 , with the final restraint link separated (i.e. not intact) thereby causing the switching module to change to a state differing from its normal state.
DETAILED DESCRIPTION
Depicted in FIGS. 1-3 is exemplary evacuation slide assembly 10 . Slide assembly 10 is shown positioned in part on wing W of aircraft A and thus is commonly called an “off wing” (or “over wing”) assembly. Slide assembly 10 may comprise multiple inflatable tubes 14 and sliding surface 18 and be divided into a generally horizontal entrance section 22 and a ramped section 26 having lower section 28 terminating at toe end 30 . Beneficially, when slide assembly 10 is deployed for evacuation of aircraft A, toe end 30 will be adjacent ground G or some other surface capable of supporting evacuees.
However, as illustrated especially in FIG. 3 , view of lower section 28 (including toe end 30 ) from within aircraft A may be blocked by wing W. Thus, absent exiting the aircraft A via hatch door D and walking to entrance section 22 , passengers and crew may be unable to ascertain whether, in particular, toe end 30 is inflated and positioned properly for use. In darkness or low-light conditions, furthermore, it may be impossible to assess the condition and positioning of lower section 28 even after exiting aircraft A onto entrance section 22 .
FIGS. 4-5 show a solution to this issue in the form of readiness indicator 34 . Indicator 34 preferably (although not necessarily) provides visible indication of the deployment status of slide assembly 10 ; visible indications further are preferably of high brightness to counteract external darkness or low-light conditions. Indicator 34 may be mounted, or otherwise attached or connected, to slide assembly 10 in any appropriate manner. As illustrated in FIG. 4 , indicator 34 preferably is permanently attached to an outboard rail 38 of entrance section 22 so as to be readily visible from hatch door D or nearby windows of the fuselage of aircraft A.
At least some versions of indicator 34 include first and second components in the form of lights 42 and 46 . One of these lights beneficially may be a red LED ( 42 ), whereas the other may be a green LED ( 46 ). The colors red and green may be chosen because of their near-universal signification of the commands “stop” and “go,” respectively. Those skilled in the art will, though, recognize that indicator 34 need not provide visual indication or, if it does, that such visual indication need not necessarily be in the form of red and green lighting. Nevertheless, if present, lights 42 and 46 optionally may be backed by a contrasting colored structure or material 50 shaped in the form of a traffic signal, thereby reinforcing the “stop” and “go” command meanings of the red and green colors.
Lights 42 and 46 may be powered in any appropriate manner. Aircraft emergency power may be used, for example, as may power potentially available for lighting other aspects of slide assembly 10 . Alternatively, one or more batteries or other power sources may be dedicated to powering lights 42 and 46 . Switching module 54 (see FIGS. 6-7 ) may be employed to illuminate one or the other of lights 42 and 46 —but preferably not both concurrently—depending on a condition of slide assembly 10 . For example, switching module 54 may have a default state in which, upon deployment of slide assembly 10 , power passes to illuminate red light 42 . When slide assembly 10 is inflated sufficiently for use, switching module 54 may be caused to change state such that power passes to illuminate green light 46 instead. In this way, passengers and crew can be made to comprehend not to evacuate aircraft A when red light 42 is illuminated and to begin evacuating when the red light 42 is extinguished and green light 46 is illuminated.
Switching module 54 , while directly or indirectly electrically connected to lights 42 and 46 , beneficially may be mechanically connected to final restraint link 58 of slide assembly 10 . As assembly 10 inflates for deployment, multiple restraint links may separate sequentially in controlled fashion so as properly to stage the unfolding of the assembly 10 . By associating switching module 54 with final restraint link 58 , allowing separation of that final restraint link 58 to effect a change of switching module 54 helps ensure such change occurs only when slide assembly 10 has inflated properly.
As shown in FIG. 6 , final restraint link 58 is intact, and lanyard 62 is connected to pin 66 of switching module 54 . As final restraint link 58 separates ( FIG. 7 ), lanyard 66 is tensioned until the force pulls pin 66 from switching module 54 . Switching module 54 is configured such that removal of pin 66 effects the state change (i.e. toggles the switch), removing power from red light 42 and supplying power to green light 46 . By contrast, should slide assembly 10 not deploy properly such that final restraint link 58 does not separate, power never will be furnished to green light 46 but instead will be provided to red light 42 as long as power is available to switch module 54 .
The foregoing is provided for purposes of illustrating, explaining, and describing embodiments of the present invention. Modifications and adaptations to these embodiments will be apparent to those skilled in the art and may be made without departing from the scope or spirit of the invention. As a non-limiting example of an acceptable adaptation, embodiments optionally may include a pressure sensor which must register satisfactory pressure in the slide to commence or maintain illumination of green light 46 .
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Evacuation systems including slide readiness indicators are detailed. The indicators may include lights colored, preferably, red and green and powered using either pre-existing or dedicated electricity sources. Associated switching equipment defaults to illumination of a red light until a slide is satisfactorily inflated and deployed, at which time the red light is extinguished and a green light is illuminated to provide affirmative indication that evacuation via the slide may commence.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation-in-part application of patent application Ser. No. 10/262,965, filed Oct. 3, 2002, which claims the priority of provisional application serial Nos. 60/326,958, filed Oct. 3, 2001, 60/334,316, filed Nov. 29, 2001 and 60/354,939, filed Feb. 11, 2002, and patent application Ser. No. 10/263,192, filed Oct. 3, 2002. The entire content of each of these applications is incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to methods for purifying levofloxacin. In a preferred embodiment, the levofloxacin is prepared with anitoxidants.
BACKGROUND OF THE INVENTION
[0003] Levofloxacin is a broad spectrum synthetic antibiotic. Levofloxacin is the S-enantiomer of the racemate, ofloxacin, a fluoroquinolone antimicrobial agent. The antibacterial activity of ofloxacin resides primarily in the S-enantiomer. The mechanism of action of levofloxacin and other fluoroquinolone antimicrobials involves the inhibition of DNA gyrase (bacterial topoisomerase II), an enzyme required for DNA replication, transcription repair and recombination. Levofloxacin is available as LEVAQUIN® which may be orally administered or administered intravenously.
[0004] Levofloxacin is a chiral fluorinated carboxyquinolone. Its chemical name is (S)-9-fluoro-2,3-dihydro-3-methyl-10-(4-methyl-1-piperazinyl)-7-oxo-7H-pyrido[1,2,3-de]-1,4-benzoxazine-6-carboxylic acid hemihydrate (CAS Registry No. 100986-85-4). The chemical structure of levofloxacin is shown as Formula I.
[0005] U.S. Pat. No. 4,382,892 is directed toward pyrido[1,2,3-de][1,4]benzoxazine derivatives and methods of preparing them.
[0006] U.S. Pat. No. 5,053,407 is directed toward optically active pyridobenzoxazine derivatives, processes for preparing the same, and intermediates useful for preparing such derivatives.
[0007] U.S. Pat. No. 5,051,505 is directed toward processes for preparing piperazinyl quinolone derivatives. The process comprises reacting dihaloquinolones with piperazine derivatives and tetraalkyl ammonium halides in the presence of a polar solvent such as acetonitrile, dimethylformamide, pyridine, sulfolane and dimethyl sulfoxide.
[0008] U.S. Pat. No. 5,155,223 is directed toward the preparation of quinolinecarboxylic acids.
[0009] U.S. Pat. No. 5,545,737 discloses selectively producing a levofloxacin hemihydrate or monohydrate by controlling the water content of an aqueous solvent in which levofloxacin is dissolved during a crystallization. Arutla et al., Arzneimittelforschung (October 1998) 48(10):1024-7, asserts that the racemic mixture ofloxacin has an antioxidant property. One disadvantage of the prior art methods for purifying levofloxacin is that they often produce an unsatisfactory yield. For example, 45-65% yields are typical. There remains a need for novel methods for purifying levofloxacin, particularly purified preparations having diminished impurities, such as anti-levofloxacin, desmethyl levofloxacin, N-oxide levofloxacin, desfluoro-levofloxacin and/or decarboxy-levofloxacin.
SUMMARY OF THE INVENTION
[0010] The present invention provides novel processes for purifying levofloxacin. Levofloxacin is dissolved in a polar solvent, preferably one selected from the group consisting of DMSO, methyl ethyl ketone, acetonitrile, an alcohol (preferably butanol), a ketone, mixtures thereof, and aqueous mixtures thereof, at an elevated temperature and crystallized to form levofloxacin. In one embodiment, the solvent is anhydrous. In another embodiment, an antioxidant is added, resulting in a more pure levofloxacin product.
DETAILED DESCRIPTION OF THE INVENTION
[0011] Crude and semi-pure preparations of levofloxacin can be prepared by methods known in the art. Alternatively, levofloxacin crude can be prepared, for example, by the following method: In a 1-liter reactor equipped with a mechanical stirrer, a condenser and a thermometer, heated at 80° C. is charged 87.5 g (0.31 mole) of (S)-(−)-9,10-difluoro-3-methyl-7-oxo-2,3-dihydro-7H-pyrido[1,2,3-de][1,4]benzoxazine-6-carboxylic acid, 61.3 mL DMSO and 86.3 mL (0.77 mole) of N-methylpiperazine. The slurry is stirred at a rate of 250 rpm under nitrogen atmosphere at 80° C. until completion of the reaction (monitoring by HPLC). Then the slurry is cooled to 75° C. and a mixture of isopropanol (675 mL) and water (25 mL) is added dropwise at this temperature over 2 hours. The slurry is then cooled to 5° C. over 4 hours, maintained at this temperature for 2 hours and filtrated under vacuum at this temperature. The solid is then washed with 175 mL of isopropanol (2 rinses) and dried under vacuum to obtain levofloxacin crude.
[0012] In one embodiment of the present invention, crude levofloxacin is purified. As used herein, “purified levofloxacin” is a relative term meaning more pure. As used herein, “crude levofloxacin” refers to levofloxacin that has not undergone a purifying crystallization step. A crude preparation of levofloxacin is mixed with a suitable solvent to form a mixture that is typically a suspension. The temperature of the mixture is then elevated to enhance dissolution of the levofloxacin in the solvent. Typically, the elevated temperature ranges from about 80° C. to about 110° C. Preferably, the mixture is refluxed. Preferably, once the levofloxacin is dissolved in the solvent, the mixture is filtrated while hot. Purified levofloxacin is then precipitated, preferably by slow cooling, and preferably recovered. The purified levofloxacin preferably has a purity of about 99% or greater, more preferably about 99.5% or greater.
[0013] Polar solvents are generally suitable. Preferably, the solvent is DMSO, methyl ethyl ketone, butanol, acetonitrile, mixtures thereof, or aqueous mixtures thereof. As used herein, the term “polar solvent” is intended as a relative term to mean relatively more polar than another solvent.
[0014] The solvent may be anhydrous or may contain a small amount of water. The solvent preferably contains water when a water-soluble antioxidant, such as sodium metabisulfite, is used. The amount of water should be less than about 20% (v/v) and preferably about 10% (v/v) or less. Greater amounts of water tends to decrease the yield. n-BuOH:H 2 O (9:1) and acetonitrile:H 2 O (99:1) are examples of suitable water-containing solvents. Acetonitrile and acetonitrile:H 2 O (99:1) are the most preferred solvents for purifying levofloxacin.
[0015] In another embodiment, an antioxidant is added to the mixture prior to precipitation. The antioxidant may be any that prevents the formation of N-oxide levofloxacin, particularly during crystallization. Examples include ascorbic acid, sodium ascorbate, calcium ascorbate, ascorbic palmitate, butylated hydroxyanisole, butylated hydroxytoluene, 2,4,5-trihydroxybutyrophenone, 4-hydroxymethyl-2,6-di-tert-butylphenol, erythorbic acid, gum guaiac, propyl gallate, thiodipropionic acid, dilauryl thiodipropionate, tert-butylhydroquinone, tocopherols (such as vitamin E), and pharmaceutically acceptable salts and mixtures thereof. Preferably, the antioxidant includes sodium metabisulfite or ascorbic acid.
[0016] An antioxdiant, if used, can be added at various points in the purification process. For example, in one embodiment, an antioxidant is admixed with levofloxacin before or during the crystallization step or before the dissolution step. In another embodiment, an antioxidant is admixed with (S)-(−)-9,10-Difluoro-3-Methyl-7-oxo-2,3-Dihydro-7H-Pyrido[1,2,3-de][1,4]Benzoxazine-6-Carboxylic Acid, a levofloxacin precursor, prior to its conversion to levofloxacin at an elevated temperature.
[0017] The amount of antioxidant, when present, is preferably about 0.2% to about 5% by weight, more preferably about 0.2% to about 1%.
[0018] The function and advantages of these and other embodiments of the present invention will be more fully understood from the examples below. The following examples are intended to illustrate the benefits of the present invention, but do not exemplify the full scope of the invention.
EXAMPLES
[0019] The following Table 1 summarizes the results of the experiments described in the Examples below. The percentage of each component in Table 1 was determined by HPLC using a method based on the European Pharmacopea method for related substances in Ofloxacin.
TABLE 1 Purification During Crystallization Impurity Profile Crude Purified Solvent Imp. D Imp. E Imp. F Imp. D Imp. E Imp. F Ex. System Levo Anti DesMe N-Oxide Levo Anti DesMe N-Oxide 1 n-Bu—OH 99.44 ND 0.11 0.19 99.60 ND 0.09 0.19 2 n-BuOH 99.58 ND 0.11 0.21 99.78 ND 0.08 ND Asc. acid (2.4%) 3 n-BuOH/ 99.58 ND 0.11 0.21 99.85 ND 0.08 ND H 2 O Na 2 S 2 O 5 (0.6%) 4 ACN 99.44 ND 0.11 0.19 99.67 ND 0.04 0.15 5 ACN:H 2 O 99.64 0.08 0.09 <0.03 99.85 ND 0.06 <0.03 6 ACN:H 2 O 99.77 <0.03 0.05 <0.03 99.93 ND <0.03 ND Na 2 S 2 O 5 (0.2%) 7 ACN 99.58 ND 0.11 0.21 99.70 ND 0.06 0.1 Na 2 S 2 O 5 (0.5%) 8 DMSO: 99.44 ND 0.11 0.19 99.75 ND 0.06 0.13 H 2 O 9 MEK 99.44 ND 0.11 0.19 99.58 ND ND 0.26 10 ACN:H 2 O 99.58 ND 0.11 0.21 99.69 ND 0.08 ND (90:10) Na 2 S 2 O 5 (0.5%) 11 ACN:H 2 O 99.58 ND 0.11 0.21 99.74 ND 0.06 ND (95:5) Na 2 S 2 O 5 (0.5%) 12 ACN:H 2 O 99.58 ND 0.11 0.21 99.81 ND 0.08 ND (95:5) Na 2 S 2 O 5 (0.25%) 13 DMSO 99.80 ND 0.03 0.02 — — — — Asc. Acid (0.6%) 14 DMSO 99.77 0.04 0.10 <0.03 — — — — Na 2 S 2 O 5 (0.5 eq.)
Example 1
n-BuOH
[0020] 1 g of levofloxacin crude was put in suspension in 7 ml of n-BuOH. The mixture was heated to reflux temperature until complete dissolution of the material. Then the solution was cooled to RT over a period of 2.5 hours. The precipitate was filtrated under vacuum, washed with n-BuOH and dried at 60° C. in a vacuum oven to give 810 mg (81%) of purified levofloxacin hemihydrate.
Example2
n-BuOH/Ascorbic acid
[0021] 1.5 g of levofloxacin crude and 36 mg of ascorbic acid were put in suspension in 9.5 ml of n-BuOH under inert atmosphere. The mixture was heated to reflux temperature and a hot filtration was performed. The solution was then evaporated to dryness and n-BuOH (10 ml) was added. The mixture was heated to reflux until complete dissolution and then cooled to RT over a period of 1.5 hour. The precipitate was filtrated under vacuum, washed with n-BuOH (4 ml) and dried at 60° C. in a vacuum oven to give 840 mg (56%) of purified levofloxacin hemihydrate.
Example 3
n-BuOH:H 2 O (9:1)/Metabisulfite
[0022] 1.5 g of levofloxacin crude and 10 mg of sodium metabisulfite were put in suspension in 6 ml of a mixture n-BuOH:H 2 O (9:1) under nitrogen atmosphere. The mixture was heated to reflux temperature until complete dissolution of the material. Then the solution was cooled to RT over a period of 1.5 hours. The precipitate was filtrated under vacuum, washed with a mixture n-BuOH:H 2 O (9:1) (4 ml) and dried at 60° C. in a vacuum oven to give 1.2 g (81%) of purified levofloxacin hemihydrate. The purified levofloxacin hemihydrate contained virtually no N-oxide levofloxacin.
Example 4
ACN
[0023] 1.5 g of levofloxacin crude was put in suspension in 10.5 ml of ACN. The mixture was heated to reflux temperature until complete dissolution of the material. Then the solution was cooled to 0° C. over a period of 20 minutes. The precipitate was filtrated under vacuum, washed with ACN (1.5 ml) and dried at 30° C. in a vacuum oven to give 1.15 g (77%) of purified levofloxacin (hemihydrate/monohydrate mixture). The purified levofloxacin contained approximately half the amount of desmethyl levofloxacin as that in the crude sample.
Example 5
ACN:H 2 O (99:1)
[0024] 25 g of wet levofloxacin crude (about 22.17 g or dry levofloxacin) was put in suspension in 225 mL of mixture ACN:H 2 O (99:1) under nitrogen atmosphere. The mixture was heated to reflux during 1 hour and then filtrated under vacuum with Hyflow when still hot. Then the solution was heated again to reflux and cooled to 0° C. over a period of 1 hour. The precipitate was filtrated under vacuum, washed with ACN:H 2 O (2×12 mL) and dried in a vacuum oven to give 18.6 g (84%) of purified levofloxacin hemihydrate. The purified levofloxacin hemihydrate contained approximately one-third less desmethyl levofloxacin than in the crude sample.
Example 6
ACN:H 2 O (99:1)/Metabisulfite
[0025] 8 g of wet levofloxacin crude (about 5.6 g of dry levofloxacin) and 14 mg of sodium metabisulfite were put in suspension in 39 ml of a mixture ACN:H 2 O (99:1) under nitrogen atmosphere. The mixture was heated to reflux during 1 hour, 0.65 g of Hyflo was added and the reflux was continued for an additional half an hour. The mixture was filtrated under vacuum when still hot. Then the solution was cooled to 3° C. over a period of 30 minutes. The precipitate was filtrated under vacuum, washed with a mixture ACN:H 2 O (99:1) (5 ml) and dried at 60° C. in a vacuum oven to give 1.77 g (31%) of purified levofloxacin. Technical problems during the hot filtration decreased the yield.
Example 7
ACN/Metabisulfite
[0026] 1.5 g of levofloxacin crude and 8 mg of sodium metabisulfite were put in suspension in 10.5 ml of ACN under nitrogen atmosphere. The mixture was heated to reflux temperature and a hot filtration was performed. Then the solution was heated again to reflux temperature until complete dissolution of the material. The solution was then cooled to 0° C. over a period of 30 minutes. The precipitate was filtrated under vacuum and dried at 60° C. in a vacuum oven to give 1.04 g (69%) of purified levofloxacin. The purified levofloxacin contained approximately half the amount of N-oxide levofloxacin as that in the crude sample.
Example 8
DMSO/H 2 O
[0027] 1 g of levofloxacin crude was put in suspension in 1.5 ml of DMSO. The mixture was heated to 108° C. until complete dissolution of the material. Then H 2 O (7.5 ml) was added over 10 minutes and the mixture was cooled to RT. The precipitate was filtrated under vacuum, washed with 1 ml of a mixture DMSO:H 2 O 1:5 and dried at 60° C. in an air-flow oven to give 840 mg (84%) of purified levofloxacin hemihydrate.
Example 9
MEK
[0028] 1.5 g of levofloxacin crude was put in suspension in 15 ml of MEK. The mixture was heated to reflux temperature until complete dissolution of the material. Then the solution was cooled to −5° C. over a period of 3 hours. The precipitate was filtrated under vacuum, washed with 1.5 ml of MEK and dried at 30° C. in a vacuum oven to give 840 mg (84%) of purified levofloxacin hemihydrate.
Example 10
ACN:H2O (9:1)/Metabisulfite
[0029] 1.5 g of levofloxacin crude and 8 mg of sodium metabisulfite were put in suspension in 10.5 ml of a mixture ACN:H 2 O 9:1 under nitrogen atmosphere. The mixture was heated to reflux temperature until complete dissolution of the material. Then the solution was cooled to RT over a period of 30 minutes. The precipitate was filtrated under vacuum, washed with a mixture ACN:H 2 O 9:1 (4 ml) and dried at 60° C. in a vacuum oven to give 1.16 g (77%) of pure levofloxacin.
Example 11
ACN:H2O (95:5)/Metabisulfite (8 mg)
[0030] 1.5 g of levofloxacin crude and 8 mg of sodium metabisulfite were put in suspension in 10.5 ml of a mixture ACN:H 2 O 95:5 under nitrogen atmosphere. The mixture was heated to reflux temperature and a hot filtration was performed. The solution was heated again to reflux temperature then cooled to 3° C. in 30 minutes. The precipitate was filtrated under vacuum and dried at 60° C. in a vacuum oven to give 500 mg (33%) of pure levofloxacin.
Example 12
ACN:H2O (95:5)/Metabisulfite (4 mg)
[0031] 1.5 g of levofloxacin crude and 4 mg of sodium metabisulfite were put in suspension in 15 ml of a mixture ACN:H 2 O 95:5 under nitrogen atmosphere. The mixture was heated to reflux temperature until complete dissolution of the material. Then the solution was cooled to 3° C. over a period of 2 hours. The precipitate was filtrated under vacuum and dried at 60° C. in a vacuum oven to give 1.3 g (86.7%) of pure Levofloxacin.
Example 13
DMSO/Ascorbic Acid
[0032] In a three necks flask equipped of a condenser were put in suspension in 3.5 ml of DMSO at 80° C. under nitrogen atmosphere 5 g (17.8 mmol) of (S)-(−)-9,10-Difluoro-3-Methyl-7-oxo-2,3-Dihydro-7H-Pyrido[1,2,3-de][1,4]Benzoxazine-6-Carboxylic Acid, 4.46 g (44.6 mmol), 31 mg (0.17 mmol) of ascorbic acid. The reaction mixture was heated at this temperature (4h30) until completion of the reaction. Then the solution was cooled to 70° C. and IPA (40 ml) was added dropwise. The mixture was cooled to 0° C. in 1 hour and then stirred at this temperature for 30 minutes. The precipitate was filtrated under vacuum, washed with IPA (10 ml) and dried at 60° C. in a vacuum oven to give 5.63 g (87.6%) of pure levofloxacin.
Example 14
DMSO/Metabisulfite
[0033] In a three necks flask equipped of a condenser were put in suspension in 7 ml of DMSO at 80° C. under nitrogen atmosphere 10 g (35.5 mmol) of (S)-(−)-9,10-Difluoro-3-Methyl-7-oxo-2,3-Dihydro-7H-Pyrido[1,2,3-de][1,4]Benzoxazine-6-Carboxylic Acid, 9.0 g (90 mmol), 34 mg (0.17 mmol) of sodium metabisulfite. The reaction mixture was heated at this temperature (5h30) until completion of the reaction. Then the solution was cooled to 70° C. and IPA (40 ml) was added dropwise. The mixture was cooled to 0° C. in 1 hour and then stirred at this temperature for 30 minutes. The precipitate was filtrated under vacuum, washed with IPA (10 ml) and dried at 60° C. in a vacuum oven to give 11.8 g (92.4%) of pure levofloxacin.
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Levofloxacin has been purified by dissolving levofloxacin in a polar solvent at an elevated temperature and crystallizing purified levofloxacin. Preferably, an antioxidant is added to increase the purity.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to and is a continuation in part of International Application No. PCT/US2016/054475, filed Sep. 29, 2016, entitled “Methods and Articles of Manufacture for the Treatment of Animals,” which claims priority to and benefit of U.S. Provisional Patent Application No. 62/234,354, filed Sep. 29, 2015, of the same title. The contents of these applications are incorporated herein by reference in their entirety.
STATEMENT REGARDING FEDERAL SPONSORSHIP
[0002] Inventions described herein were not conceived or reduced to practice with Federal sponsorship.
FIELD OF THE INVENTION
[0003] The present disclosure provides processed fetal tissues and cells suitable for reducing the effects of aging seen on skin and methods of using these fetal tissues and cells to promote a cosmetically appealing aspect to skin.
BACKGROUND OF THE INVENTION
[0004] The effects of aging on the human skin produce cosmetically undesirable appearance. These effects include wrinkles, creases, sags, hair loss, spots, loss of flexibility, thinning, loss of color and others. These effects are often addressed with surgical intervention such as face lifts, dermal fillers, onabutulinumtoxinA (sold under the tradename BOTOX®, Allergan, Inc., Irvine, Calif.). However, these interventions subject the subject receiving the intervention with risks and the effects may be of short duration, incomplete or produce unsatisfactory results.
[0005] It would be useful to have methods and articles of manufacture that reduce the undesirable effects of aging on skin. As used herein, unless the context requires otherwise, the term “subject” encompasses and includes humans and animals receiving intervention for the effects of aging on skin.
SUMMARY OF THE INVENTION
[0006] Embodiments of the present invention feature methods and articles of manufacture that reduce the effects of aging on skin in humans and in animals.
[0007] The fetal tissue and cellular compositions disclosed herein have many advantages for use in intervening with normal aging processes including promoting healing of injuries, immune privilege, an absence of associated ethical issues, and no requirement of invasive procedures for harvesting the cells and tissues. In addition, the treatment regimen disclosed herein is remarkably effective at promoting the rapid healing of open wounds within one to two weeks.
[0008] One embodiment is directed to an article of manufacture. The article comprises aesthetic modifier comprising a dried particulate mixture of mechanically decellularized amnion obtained from one or more animals compatible with a subject animal. The dried particulate mixture is capable of reconstitution to form a reconstituted aesthetic modifier for administration to the subject animal to produce a cosmetic result.
[0009] By way of example, without limitation, a cosmetically effective amount of the reconstituted medicament is applied by injecting at or around the periphery of or under or into wrinkles, creases, sags, hair loss, spots, loss of flexibility, thinning, loss of color and others, or applied to a subject by way of dropper or spray, cream, ointment, slurry, paste, wash, mask, dermal patch, powder, solution or suspension to the skin of a subject or into a dermal layer of the skin of a subject, or the like to a cosmetic result. As used herein, the term “cosmetic result” means a aesthetically pleasing result suggesting a more youthful or healthy appearance. Such appearance can mean one or more of the following including fuller skin, decreased appearance of wrinkles, creases, sagging, hair loss and spots, greater flexibility, healthier color, hair regeneration and the like. As used herein, the term “subject” refers to the person or animal receiving the aesthetic modifier.
[0010] In one aspect, one milliliter of reconstituted aesthetic modifier is the amount of particulate matter obtained from the mechanically decellularized amnion of about 1.5 10 −2 cm 3 to 5 10 −2 cm 3 of amnion. In one aspect, the mechanically decellularized amnion is filtered to contain particles of less than about 100 microns in diameter.
[0011] Embodiments of the present invention feature a particulate mixture comprising particles. The particles have an approximate diameter of less than 500μ, or less than 400μ, or less than 300μ, or less than 200μ, or less than 150μ, or less than 100μ, or less 90μ, or less than 80μ, or less than 70μ, or less than 60μ, or less than 50μ, or less than 40μ, or less than 30μ, or less than 20μ, or less than 10μ. In other embodiments, the particles have a diameter of more than 10μ, or more than 20μ, or more than 30μ, or more than 40μ, or more than 50μ, or more than 60μ, or more than 70μ, or more than 80μ, or more than 90μ, or more than 100μ, or more than 200μ, or more than 300μ, or more than 400μ, or more than 500μ. In other embodiments, the particles have an approximate diameter of about 500μ, or about 400μ, or about 300μ, or about 200μ, or about 150μ, or about 100μ, or about 50μ, or about 25μ.
[0012] In certain embodiments, the article comprises a dried particulate mixture of mechanically decellularized amnion obtained from one or more animals compatible with a subject, and fetal cells obtained from one or more animals compatible with a subject to form a particulate cellular suspension. The particulate cellular suspension is administered to a subject to produce a cosmetic result.
[0013] By way of example, without limitation, a cosmetically effective amount of the aesthetic modifier comprising a particulate cellular suspension medicament can be injected around the periphery of or under or into wrinkles, creases, sags, hair loss, spots, loss of flexibility, thinning, loss of color and others, or applied to a subject by way of dropper or spray, cream, ointment, slurry, paste, wash, mask, dermal patch, powder, solution or suspension to the skin of a subject or into a dermal layer of the skin of a subject, or the like to a cosmetic result.
[0014] A cosmetically effective amount of the particulate cellular suspension medicament comprises about 10 1 to 10 20 cells per mL. Other embodiments feature about 10 3 to about 10 7 cells per mL.
[0015] A further embodiment of the article further comprises a fetal tissue wrap. The tissue wrap can comprise amnion tissue obtained from one or more animals compatible with a subject. The wrap is constructed and arranged for placement in juxtaposition with a site of wrinkles, creases, sags, hair loss, spots, loss of flexibility, thinning, loss of color to promote a cosmetic result. For facial applications, the wrap is shaped or contoured to the shape and contour of the face.
[0016] The wrap, comprising fetal tissue, can be air-dried for about 1 minute to about 48 or more. In another embodiment, the wrap is air-dried for about 1 hour to about 12 hours. In another embodiment, the wrap is air-dried for about 1 hour to about 6 hours. In another embodiment, the wrap is air-dried for about 1 hour to about 3 hours. In another embodiment, the wrap is air-dried for about 1 hour to about 2 hours.
[0017] In another aspect of the invention, one embodiment features a kit for producing a cosmetic result in a subject. One kit comprises aesthetic modifier comprising a dried particulate mixture of mechanically decellularized amnion obtained from one or more animals compatible with a subject. The aesthetic modifier is directly applied or incorporated in one or more of the carriers such as a spray, cream, ointment, slurry, paste, wash, mask, dermal patch, powder, solution or suspension. The dried particulate mixture may be held as a powder that can be capable of reconstitution to form a reconstituted aesthetic modifier.
[0018] A further embodiment of the kit comprises fetal cells obtained from one or more animals compatible with a subject that are compatible with a particulate mixture obtained from the mechanical decellularization of amnion isolated from one or more animals. The fetal cells are applied in cooperation or concurrently with the reconstituted aesthetic modifier or form a combined aesthetic modifier comprising a particulate cellular suspension and/or amniotic liquid for administration to the subject to produce a cosmetic result.
[0019] A further embodiment of the kit comprises a tissue wrap obtained from one or more animals compatible with a subject. The tissue wrap comprises amnion tissue constructed and arranged for placement in juxtaposition with the site of wrinkles, creases, sags, hair loss, spots, loss of flexibility, thinning, loss of color to promote a cosmetic result. The tissue wrap is applied in cooperation or concurrently with the reconstituted aesthetic modifier or a combined medicament comprising a particulate cellular or acellular suspension medicament with or without mechanically decellularized amnion and/or amniotic liquid for administration to the subject to produce a cosmetic result.
[0020] A further embodiment of the present invention features an inflammation inducing means selected from the group comprising keratolytics, irritants, rubefacients, abrasives, phototherapy, dermal microneedle devices for application prior to or during administration of the aesthetic modifier. For example, without limitation, one or more keratolytics, irritants, rubefacients, or abrasives are carried in a spray, cream, ointment, slurry, paste, wash, mask, dermal patch, powder, solution or suspension for application before or carried with with the aesthetic modifier and applied with the aesthetic modifier.
[0021] A further embodiment of the present invention is directed to a method of producing a cosmetic result in a subject. One embodiment of the present method features the steps of administering to the site of wrinkles, creases, sags, hair loss, spots, loss of flexibility, thinning, loss of color an injury at least one of the group consisting of a reconstituted aesthetic modifier, a reconstituted amnion suspension with or without cells and a tissue wrap all of which have been previously described.
[0022] For example, without limitation, in one embodiment, a method comprises the step of applying a reconstituted aesthetic modifier. The reconstituted aesthetic modifier is made from a dried particulate mixture of mechanically decellularized amnion obtained from one or more animals compatible with a subject.
[0023] Another method features the step of applying, by way of injection, an aesthetic modifier comprising a particulate cellular suspension medicament to the periphery or under or into the site of wrinkles, creases, sags, hair loss, spots, loss of flexibility, thinning, loss of color to promote a cosmetic result. The particulate cellular suspension comprises particles derived from the mechanical decellularization of amnion obtained from one or more animals compatible with the subject animal, and isolated amniotic fluid cells obtained from the one or more animals compatible with the subject.
[0024] In one aspect, the method further comprises the step of applying a tissue wrap to the site wrinkles, creases, sags, hair loss, spots, loss of flexibility, thinning, loss of color to promote a cosmetic result. The wrap comprises amnion tissue compatible with the subject constructed and arranged for placement in juxtaposition with the site of wrinkles, creases, sags, hair loss, spots, loss of flexibility, thinning, loss of color. The amnion tissue is air-dried for about 1 minute to about 48 hours or more. In another embodiment the amnion tissue is air-dried for about 1 hour to about 12 hours. In another embodiment, the amnion tissue is air-dried for about 1 hour to about 6 hours. In another embodiment, the amnion tissue is air-dried for about 1 hour to about 3 hours. In another embodiment, the amnion tissue is air-dried for about 1 hour to about 2 hours. One embodiment features a wrap shaped to the contours of the face for facial application in the nature of a mask.
[0025] In one aspect of the method, the site of wrinkles, creases, sags, hair loss, spots, loss of flexibility, thinning, loss of color to promote a cosmetic result is prepared prior to or with the applying of one or more of the group consisting of a cellular reconstituted suspension, or a reconstituted acellular suspension medicament and a tissue wrap. The preparation creates an inflammation response which improves the effectiveness of the aesthetic modifier. For example without limitation, an inflammation inducing means selected from the group comprising keratolytics, irritants, rubefacients, abrasives, phototherapy, dermal microneedle devices is applied prior to or during administration of the aesthetic modifier. The one or more keratolytics, irritants, rubefacients, or abrasives are carried in a spray, cream, ointment, slurry, paste, wash, mask, dermal patch, powder, solution or suspension for application before or carried with with the aesthetic modifier and applied with the aesthetic modifier.
[0026] A further embodiment is directed to a method of making a dried particulate mixture of mechanically decellularized fetal tissue obtained from one or more animals compatible with a subject. The dried particulate mixture is capable of reconstitution to form a reconstituted medicament for administration to the subject to produce a cosmetic result. The method comprises the step of mechanically decellularizing amnion tissue to form particles capable of reconstitution.
[0027] A further embodiment is directed to a method of making a aesthetic modifier comprising a particulate cellular suspension. The method comprises the steps of providing a dried particulate mixture of mechanically decellularized amnion obtained from one or more animals compatible with a subject, and fetal cells obtained from one or more animals compatible with a subject animal and forming a particulate cellular suspension. The aesthetic modifier comprising a particulate cellular suspension is administered to a subject to produce a cosmetic result.
[0028] A further embodiment of the present invention features methods of making a tissue wrap, a particulate mixture medicament and a particulate cellular suspension medicament. One embodiment of the method of making the tissue wrap comprises the steps of applying amnion tissue to a support to form a supported amnion. The supported amnion is next air dried to form the tissue wrap which is placed in a suitable containment means until applied. One embodiment features a mask. The mask is formed by shaping the wrap to the contours of the face.
[0029] A further embodiment is directed to a method of making an aesthetic modifier for effecting a cosmetic result comprising the steps of mechanically decellularizing fetal tissue obtained from one or more animals compatible with a subject animal and drying the decellularized fetal tissue to form a dried particulate mixture for reconstitution and administration.
[0030] These and other features and advantages will be apparent upon viewing the Figures that are briefly described below and upon reading the detailed description that follows.
BRIEF DESCRIPTION OF THE FIGURES
[0031] FIG. 1 depicts a kit embodying features of the present invention;
[0032] FIG. 2 depicts a tissue wrap embodying features of the present invention;
[0033] FIG. 3 shows a tissue wrap embodying features of the present invention in a container; and,
[0034] FIG. 4 depicts a tissue wrap having facial contours and shape embodying features of the present invention.
DETAILED DESCRIPTION
[0035] Unless otherwise defined herein, scientific and technical terms used herein have the meanings that are commonly understood by those of ordinary skill in the art. In the event of any latent ambiguity, definitions provided herein take precedence over any dictionary or extrinsic definition. Unless otherwise required by context, singular terms shall include pluralities and plural terms shall include the singular. The use of “or” means “and/or” unless stated otherwise. The use of the term “including”, as well as other forms, such as “includes” and “included”, is not limiting.
[0036] It is noted here that as used in this specification and the appended claims, the singular forms “a”, “an”, and “the” also include plural reference, unless the context clearly dictates otherwise.
[0037] The term “about” or “approximately” means within 10%, and more preferably within 5% (or 1% or less) of a given value or range.
[0038] As used herein, the term “isolated cell” refers to a cell that has been removed from its in-vivo location.
[0039] As used herein, the term “decellularization” refers to a process that removes cells from a tissue while preserving the native ultrastructure and composition of the extracellular matrix (ECM). For example, an amnion particulate mixture can be obtained by decellularizing a fetal tissue comprising amnion.
[0040] There are a number of methods of decellularization of tissue known in the art, including, but not limited to, chemical agents, hypotonic and hypertonic solutions, detergents (e.g., Triton-X), alcohols, solvents (e.g., tributyl phosphate (TBP), biologic agents (e.g., collagenase, trypsin, lipase, nucleases, α-galactosidase), non-enzymatic agents (e.g., chelating agents such as EDTA or EGTA), physical agents (e.g., temperature, force and pressure, non-thermal irreversible, mechanical, electroporation (NTIRE) (see, for example, Crapo et al., Biomaterials. 2011; 32(12): 3233-3243). In certain embodiments, one or a combination of the aforementioned methods may be used to decellularize a tissue. However, methods that preserve the complex composition and three-dimensional ultrastructure of the extracellular matrix (ECM) are preferred.
[0041] In one embodiment, a tissue is mechanically decellularized, e.g., by cryofractionation, a procedure in which a tissue is frozen and ground in a cryomill to produce a mixture of particles. Such particles are obtained from the cryofractionation of about 0.5 cm 2 , or about 1 cm 2 , or about 1.5 cm 2 , or about 2 cm 2 , or about 2.5 cm 2 , or about 3 cm 2 , or about 3.5 cm 2 or about 4 cm 2 , or about 4.5 cm 2 to about 5 cm 2 of amnion or more. The amnion can have a thickness of from about 500 to 50 or from 400 to about 50 , or from about 300 to 50 or from about 200 to about 50 or from about 150 to about 50 from about 100 to about 50 or from about 50 to about 25 or less. n another embodiment the amnion has a thickness of about 500 or about 400 or about 300 or about 200 or about 150 or about 100 or about 50 or about 25 or less.
[0042] The term “amnion” refers to a thin, cellular, extra-embryonic membrane that forms the inner membrane of a closed sac surrounding and protecting an embryo in reptiles, birds, and mammals. The sac contains the fetus and amniotic fluid, in which the embryo is immersed, nourished and protected. Typically, the amnion is a tough, transparent, nerve-free, and nonvascular membrane consisting of two layers of cells: an inner, single-cell-thick layer of ectodermal epithelium and an outer covering of mesodermal, connective, and specialized smooth muscular tissue. In the later stages of pregnancy, the amnion expands to come in contact with the inner wall of the chorion creating the appearance of a thin wall of the sac extending from the margin of the placenta. The amnion and chorion are closely applied, though not fused, to one another and to the wall of the uterus. Thus, at the later stage of gestation, the fetal membranes are composed of two principal layers: the outer chorion that is in contact with maternal cells and the inner amnion that is bathed by amniotic fluid. The amnion has multiple functions, e.g., as a covering epithelium, as an active secretary epithelium, and for intense intercellular and transcellular transport.
[0043] As used herein, the term “tissue” refers to an aggregate of similar cells and associated extracellular matrix (ECM) forming a definite kind of organized material with a specific function, in a multicellular organism.
[0044] As used herein, an “amnion tissue” refers to the isolated cellular, extra-embryonic amnion membrane that is detached from the chorion. In one embodiment, the amnion tissue is air-dried. In another embodiment, the amnion is air-dried for about 60 to about 90 minutes or more at ambient temperature (i.e. about 18 to 24° C.).
[0045] As used herein, a “particulate mixture” refers to the powder or particles obtained from the cryofractionation of amnion.
[0046] As used herein, the term “fetal tissue” refers to extra-embryonic tissues including, but not limited to, amnion, chorion, yolk sac, the allantois, umbilical cord and/or fetal placenta (villous chorion).
[0047] As used herein, the term “fetal cells” refers to cells resident in the extra-embryonic tissues including, but not limited to, amnion, chorion, yolk sac, the allantois, umbilical cord, fetal placenta (villous chorion) and/or amniotic fluid. In certain embodiments, the term “fetal cells” refer to isolated fetal cells.
[0048] In certain embodiments, the term “fetal cells” refers to unfractionated cells of the amniotic fluid including epithelial and/or amniotic fluid or membrane-derived mesenchymal stem cells (see U.S. Patent Publication No. US 2013/0230924, which is incorporated by reference herein in its entirety).
[0049] The term “injury” means a pathological condition, such as, by way of example, without limitation, a wound, incision, a break in the skin, bone, tendon, ligament, muscle, neoplasia, eye, and soft tissues, an inflammation, infection, or other disease condition.
[0050] The term “promoting healing” refers to causing a favorable result compared to no treatment. The favorable result comprises any one or more of the following such as reduction of scarring, reduction of inflammation, regrowth of normal tissue or growth of scar tissue, improved load bearing on a limb movement, closure of wound, reduction in infection and reduction in mortality associated with the underlying pathology.
[0051] The term “aesthetic modifier” refers to a material that produces a cosmetic effect on skin. This effect is not clearly a healing of an injury but is in the nature of ordinary and common aging, or exposure to long-term environmental conditions such as light. As used herein, the term “cosmetic effect” refers to a more pleasing younger appearance, in the nature of fewer or shallower wrinkles or creases, less sagging, less hair loss, hair regeneration, tighter fuller skin, thicker and more flexible skin, improved coloring, fewer or smaller or lighter spots.
[0052] The term “compatible with a subject” denotes the origin of the tissue as being from the same species or closely related species or a species that does not elicit a strong immune response.
[0053] In other embodiments, the term “compatible with a subject” refers to an xenograft, i.e., a tissue graft from different species.
[0054] In another embodiment, the term “compatible with a subject” refers to allografts, i.e., a tissue from one individual to another of the same species with a different genotype.
[0055] As used herein, an “animal” refers to living multi-cellular vertebrate organisms, a category that includes, for example, mammals, birds, reptiles, and amphibians. The term mammal includes both human and non-human mammals. Similarly, the term “subject” includes both human and non-human subjects. In a cosmetic sense, the term “subject” refers to an individual human which has a site having wrinkles, creases, sags, hair loss, spots, loss of flexibility, thinning, loss of color or other effects of aging.
[0056] As used herein, a non-human animal can refer to a mammal including, but not limited to, a domesticated animal such as a dog, a racing dog, sheep, a pig, a goat, cattle, a zebu, a cat, a guinea pig, a donkey, water buffalo, including “river buffalo” and “swamp buffalo”, a horse, a racing horse, a dromedary camel, a yak, a bactrian camel, a llama, an alpaca, a ferret, a mouse, a bali cattle, a gayal, a rabbit, a rat and a lab rat, a silver fox or a hedgehog.
[0057] In certain embodiments, a non-human animal can refer to mammals kept in zoos including, but not limited to, zebra, gazelle, wolves, wild swine (pigs & hogs), wild cattle, warthogs, vervet monkeys, two-toed sloths, tree pangolins, tigers, tapirs, tamandua or lesser anteaters, takins, sun bears, striped hyena, spotted hyena, spiral-horned antelope, somali wild ass, snow leopards, small cats, sloth bears, singing dogs, siamang, serval, sea lions, rock hyrax, rhinoceros, reindeer, red pandas, pygmy marmosets, pygmy hippopotamus, przewalski's horses, pronghorns, prairie dogs, porcupines, polar bears, painted dogs, otters, oryx, orangutan, okapi, ocelot, nubian ibex, nile lechwe, naked mole-rats, mountain lions (puma, cougar), monkeys, meerkat, mangabey, mandrill, lynx and bobcats, lions, leopards, lemur, jaguars, honey badgers (ratel), hippos, hamadryas baboons, guenon, guanaco, gorillas, giraffe, giant pandas, giant anteaters, gelada baboons, fossa, fishing cats, elephants, echidna, dhole, coquerel's sifaka, clouded leopards, chimpanzees, cheetahs, tigers, caracals, capybara, camels, brown bears, bonobos, binturongs, bat-eared fox, bats, armadillos, antelope, andean (spectacled) bears, birds and agouti.
[0058] In certain other embodiments, a non-human animal can refer to mammals considered by the World Wildlife Fund to be endangered including, but not limited to, the amur leopard, black rhino, cross river gorilla, javan rhino, mountain gorilla, pangolin, saola, south china tiger, sumatran elephant, sumatran orangutan, sumatran rhino, sumatran tiger, vaquita, western lowland gorilla, yangtze finless porpoise, african wild dog, amur tiger, asian elephant, bengal tiger, black spider monkey, black-footed ferret, blue whale, bonobo, bornean orangutan, borneo pygmy elephant, chimpanzee, eastern lowland gorilla, fin whale, ganges river dolphin, giant panda, hector's dolphin, indian elephant, indochinese tiger, indus river dolphin, malayan tiger, north atlantic right whale, orangutan, sea lions, sei whale, snow leopard, Sri Lankan elephant, tigers and whales.
[0059] In certain embodiments, a non-human animal can refer to marsupials, including, but not limited to, wallabies, koalas, possums, opossums, kangaroos, bandicoots, wombats, bettongs, bilbys, quolls, quokkas and the Tasmanian devil.
[0060] The term “reconstituted” means that that an aqueous liquid is added to make the material. A liquid for reconstitution comprises a biocompatible solution such as normal saline, e.g. phosphate buffered saline (PBS) or amniotic fluid. A preferred liquid for reconstitution is calcium-free sterile, non-pyrogenic isotonic solution suitable for intravenous administration. For example, without limitation, one such liquid is sold under the trademark PlasmaLyte A™ in a single dose container for intravenous administration. Each 100 mL contains 526 mg of Sodium Chloride, USP (NaCl); 502 mg of Sodium Gluconate (C 6 H 11 NaO 7 ); 368 mg of Sodium Acetate Trihydrate, USP (C 2 H 3 NaO 2 .3H 2 O); 37 mg of Potassium Chloride, USP (KCl); and 30 mg of Magnesium Chloride, USP (MgCl 2 .6H 2 O). It contains no antimicrobial agents. The pH is 7.4.
[0061] The term “administering” means applying or injecting or ingesting the material. The term “applying” is used broadly and includes uses such as washes, placing and massaging into the skin as performed with conventional creams, ointments lotions and pastes and implantation.
[0062] Connective soft tissue defects or injuries often occur by damage to the extra-cellular matrix (ECM) that forms muscles, ligaments or tendons in mammals. Collagen is the most abundant structural protein in the connective tissue (ECM) and acts as a natural scaffold for cellular attachment in the body.
[0063] Amnion is an abundant source of collagen, as well as the other proteins, carbohydrates, lipids, hyaluronic acid, laminin, fibronectin, pluripotent mesenchymal stem cells (MSC) and other complex growth factors that are essential for fetal growth and development. In particular, amnion has a complete lack of surface antigens, thus it does not induce an immune response when implanted into a ‘foreign’ body, which is in contrast to most other allograft implants. Amnion also markedly suppresses the expression of the pro-inflammatory cytokines, IL-1α and IL-1β (Solomon et al., 2001, Br. J. Ophthalmol. 85 (4):444-9) and produces natural inhibitors of matrix metalloproteases (MMPs) expressed by infiltrating polymorphonuclear cells and macrophages (Hao et al., 2000, Cornea, 19 (3):348-52; Kim et al., 2000, Exp. Eye Res. 70 (3):329-37). Amnion also down-regulates TGF-β and its receptor expression by fibroblasts leading to the ability to modulate the healing of a wound by promoting tissue reconstruction. Furthermore, amnion has a broad spectrum of antimicrobial activity against bacteria, fungi, protozoa, and viruses for reduced risk of post-operative infection.
[0064] Amnion derived tissues are therefore immune-privileged and ideally suited for cosmetic purposes.
[0065] A “kit” is an assembly of parts, materials, and compositions of matter packaged together to facilitate a procedure. Kits commonly comprise instructions for the use of the parts, materials and compositions.
[0066] Turning now to FIG. 1 , a kit embodying features of the present invention, generally designated by the numeral 11 is depicted. Kit 11 has the following major elements: a first vial 15 , a second vial 17 , a container for a tissue wrap 21 , a syringe 23 , and instructions 25 . The kit 11 is held in suitable packaging, as depicted, a box 27 . Suitable packaging may comprise any means for holding the collection of parts, materials and compositions. For example, without limitation, bags, wraps, containers, ties and the like.
[0067] The first vial 15 contains a aesthetic modifier comprising a dried particulate mixture of mechanically decellularized amnion obtained from one or more animals compatible with a subject. Upon reconstitution, the aesthetic modifier forms a reconstituted aesthetic modifier. The kit 11 may contain a vial containing such liquid for reconstitution [not shown] or the liquid for reconstitution may be derived from other sources.
[0068] The second vial contains fetal cells obtained from one or more animals compatible with a subject and compatible with a particulate mixture in the first vial 15 . The fetal cells are applied in cooperation or concurrently with the reconstituted aesthetic modifier or form a combined aesthetic modifier comprising a particulate cellular suspension and fetal cells for application to the subject to produce a cosmetic effect. In forming a combined aesthetic modifier, the dried particulate mixture of the first vial 15 is reconstituted with or combined with the fetal cells of the second vial 17 , supplemented as needed with further liquid for reconstitution. For example, the dried particulate mixture can be reconstituted by suspension in a solution of 50% solution for reconstitution, such as PlasmaLyte A′, and 50% amniotic fluid containing fetal cells.
[0069] The combined aesthetic modifier is injected into or around the site of at least one of the group of sites comprising creases, wrinkles, inconsistent pigment, sags, hair loss, spots, loss of flexibility, thinning, and voids injury with syringe 23 .
[0070] The kit 11 may also contain cream or ointment or lotion or paste bases in a third vial or jar [not shown] to which the combined aesthetic modifier and/or the aesthetic modifier comprising the dried particulate cellular and/or the reconstituted aesthetic modifier is incorporated by agitation and or levigation. Cream and lotion bases are sold under a variety of tradenames such as Eucerin® and Nivea® (Beiersdorf, Inc., Hamburg, Germany). Ointment bases are sold under a number of tradenames and comprise white petrolatum as a major constituent. Pastes can be made readily by adjusting the water content of the fluids used for reconstitution or by adding inert builders such as carboxymethycellulose. The cream, lotion, ointment or paste can be made just prior to application or premade. Although reference is made to commercially available cream and ointment bases, the aesthetic modifier, reconstituted aesthetic modifier and combined aesthetic modifier may be incorporated in similar creams, ointments, lotion and pastes during the manufacture of the base.
[0071] The kit 11 may also contain an inflammation inducing means {not shown]. Inflammation inducing means creates an inflammation creates an inflammation response which improves the effectiveness of the aesthetic modifier. For example without limitation, a inflammation inducing means selected from the group comprising keratolytics, irritants, rubefacients, abrasives, phototherapy, dermal microneedle devices is applied prior to or during administration of the aesthetic modifier. The one or more keratolytics, irritants, rubefacients, or abrasives are carried in a spray, cream, ointment, slurry, paste, wash, mask, dermal patch, powder, solution or suspension held in a vial [not shown] similar to the vials depicted or in a jar. The one or more keratolytics, irritants, rubefacients, or abrasives are applied before or carried with the aesthetic modifier and applied with the aesthetic modifier. Irritants, rubefacients and vesicants are know in the art and include, by way of example, without limitation, anthralin, camphor, cantharidin, capsicum , coal tar, ichthammol, juniper tar, menthol, Peruvian balsam, and pine tar. Keratolytics are known in the art and include by way of example, without limitation, benzoyl peroxide, salicylic acid, retinoic acid and other vitamin A derivatives. Keratolytic compounds are commonly found in acne treatment products. The kit 11 may also comprise photo or light devices to create an inflammatory response. Photo or light devices are known in the art as sun lamps and tuned lazer devices.
[0072] The container for a tissue wrap 21 contains a tissue wrap derived from amnion tissue obtained from one or more animals compatible with a subject. The tissue wrap comprises amnion tissue constructed and arranged for placement in juxtaposition with at least one of the group of sites comprising creases, wrinkles, inconsistent pigment, sags, hair loss, spots, loss of flexibility, thinning, and voids. The tissue wrap is applied in cooperation or concurrently with the aesthetic modifier, reconstituted aesthetic modifer or a combined aesthetic modifier to create a cosmetic result.
[0073] Turning now to FIG. 2 the container for tissue wrap 21 is depicted as a transparent bag through which the tissue wrap designated by numeral 31 can be seen. As seen in FIG. 3 , tissue wrap 31 is formed by affixing amnion tissue to a first support 33 on one side of the amnion and a second support on the other side of the amnion [not shown] and air drying the tissue for thirty minutes to three hours or more, based on humidity, and, most preferably, for about one hour. The supports, of which first support 33 is depicted, maintain the shape of the tissue during the drying process. The supports are preferably removed prior to placement of the tissue in container 21 . One embodiment of the present invention features a first support 33 and second support constructed and arranged to have facial features [not shown]. The first support 33 and the second support are sculpted to resemble a human face in shape and contour such that the tissue wrap 21 , when placed on the face of a subject will readily conform to the shape and contours of the subject's face as best seen in FIG. 4 .
[0074] FIG. 4 depicts a subject 23 to which a tissue wrap 21 in the form of a mask 25 is being applied. Mask 25 has openings 27 (only one is visable) for the eyes and openings 31 (only one is visable) for nasal passages and an opening 35 for the mouth. Mask 25 is removed from the container and placed over the face to create a cosmetic result.
[0075] Returning now to FIG. 1 , the dried particulate mixture is obtained from the mechanical decellularization or cryofractionation of about 1.5 10 −2 cm 3 to 5 10 −2 cm 3 of amnion/mL of reconstituted medicament and include particles greater than 20-100 microns in diameter. Upon reconstitution of the dried particulate mixture by suspension in a solution of amniotic fluid and/or PlasmaLyte A™, the reconstituted medicament can be administered to the subject animal to promote the healing of superficial wounds.
[0076] The dried particulate mixture obtained from the cryofractionation comprises about 1.5×10 −2 cm 3 to about 5×10 −2 cm 3 of amnion/mL of reconstituted medicament.
[0077] The fetal cells can comprise amniotic fluid cells and the particulate matter can be filtered to contain particles that are less than 100 microns in diameter. The fetal cells can have a concentration from 10 3 to 10 20 /mL mesyschimal and/or epithelial stem cells. In another embodiment, fetal cells can have a concentration of 10 3 to 10 12 /mL. In another embodiment, fetal cells can have a concentration of 10 4 to 10 12 /mL. In another embodiment, fetal cells can have a concentration of 10 4 to 10 11 /mL. In another embodiment, fetal cells can have a concentration of 10 4 to 10 10 /mL. In another embodiment, fetal cells can have a concentration of 10 4 to 10 9 /mL. In another embodiment, fetal cells can have a concentration of 10 4 to 10 8 /mL. In another embodiment, fetal cells can have a concentration of 10 4 to 10 7 /mL. In another embodiment, fetal cells can have a concentration of 10 4 to 10 6 /mL. In another embodiment, fetal cells can have a concentration of 10 3 to 10 6 /mL. In another embodiment, fetal cells can have a concentration of 10 3 to 10 7 /mL.
[0078] In one example, the fetal cells can have a concentration of about 0.8×10 6 to 1.2×10 6 cells/mL of the particulate cellular suspension. The dried particulate mixture can contain particles obtained from the cryofractionation of from about 1.5×10 −2 cm 3 to about 5×10 −2 cm 3 amnion per mL of the particulate cellular suspension. In one example, the particulate cellular suspension comprises a particulate matter obtained from the cryofractionation about 1.5×10 −2 cm 3 to about 5×10 −2 cm 3 amnion for every 10 6 plus or minus 2×10 5 amnion fluid cells.
[0079] Features of the present invention are further described with respect to the following Examples. These examples feature equine subjects and materials. However, materials derived from other animals species, for example, without limitation, canine, feline, bovine, porcine and other animal species materials and subjects can be prepared in a similar manner as outlined below. The equine materials have been utilized with avian, reptilian and other animal groups.
EXAMPLES
Example 1: Amniotic Material Processing
[0080] This procedure defines the aseptic collection of amniotic material (amnion and amniotic fluid) for injection at the site of an injury.
[0081] Amnion Tissue
[0082] The amnion container was picked up and sampled for Bioburden. The amnion was aseptically transferred into the sterile field (laminar flow hood). The amnion transport packaging (previously disinfected, i.e. with 70% ETOH) was opened.
[0083] A 50 mL sample of the Amnion Transport Solution was aseptically transferred into a 30 to 60 mL conical tube for pre-processing bioburden testing. The vial was labeled with sample description, batch number, date and time and placed in a designated refrigerator.
[0084] (1) Amnion Preparation
[0085] The amnion from the incoming container was transferred into approximately 200 mL of Plasma Lyte-A in a sterile bioassay dish where it was gently rinsed. A piece of amnion was then spread evenly on a sterile cutting board carefully avoiding any overlaps. A record was made of the amnion preparation start time. Sterile gauze or laps were used to remove any remaining debris/blood from the surface of the amnion. The amnion was inverted and the surface of the opposite site was similarly washed. Any chorion was removed by blunt dissection to separate it from the amnion. After washing and cleaning, the amnion pieces were returned to the bioassay dish containing Plasma Lyte-A. Using a sterile scissors/scalpel, the amnion was cut into 2 to 10 sections. The approximate area of each piece (50-450 cm 2 ) was measured and recorded using a sterile stainless steel ruler.
[0086] The cleaned pieces of the amnion were placed back on the sterile cutting board and the amnion was spread out on the board taking care to not overlap. A sterile nylon mesh was placed over the surface of the amnion again taking care to overlap them. The amnion and mesh were then placed onto a sterile drying rack and allowed to air dry for a minimum of one hour. Start and stop times for drying were recorded.
[0087] (2) Amniotic Fluid
[0088] (a) Amnion Fluid Preparation
[0089] A large sterile pan was first placed into the sterile field (laminar flow hood) and filled with cold packs from a −80° C. freezer. The aspiration containers with the amniotic fluid were disinfected with 70% ethanol (ETOH), inspected for integrity and placed on the cold packs in the laminar flow hood. The source of the amniotic fluid was confirmed by looking at the Donor animal ID number. The 2.0 mL of amniotic fluid was then aseptically pipeted into a 2 mL sterile microcentrifuge tube for bioburden testing. The vial was labeled with the sample number, batch number, date and time and placed in the designated refrigerator.
[0090] Using a 50 mL sterile disposable serological pipette all the remaining amniotic fluid was transferred into 1 liter sterile disposable bottles and placed on the cold pack. The total volume of the amniotic fluid and the color were recorded.
[0091] (3) Amniotic Fluid Cell Count and Determination of the Number of Viable Cells
[0092] Each amniotic fluid bottle was gently mixed and 1.0 mL of the fluid was collected using a 1 mL micropipette and transferred into a 2 mL Eppendorf microcentrifuge tube. A total of 50 of cell suspension was then added to 50 μL of trypan blue (0.4%) in an Eppendorf microcentrifuge tube and vortexed for 5 seconds. The sample was placed on a rack for 5 minutes.
[0093] A Neubauer chamber (hemocytometer) was rinsed with distilled water, and then sprayed with ETOH 70% and wiped clean and dried with paper towels. A cover slip was placed on the top of the micro-grids of the chamber. The trypan blue-cell suspension was gently mixed and used to fill both sides of the hemocytometer with 10 μL by capillary action. The cells were allowed to settle down for at least 30 seconds. The hemocytometer was placed under the microscope and all cells in the four 1 mm corner squares and one 1 mm center square were counted. For accuracy the total number of cells counted was greater than 100. The cells were re-counted if >10% of the cells appeared clustered, by vigorously pipetting in the original cell suspension as well as in the trypan blue cell suspension mixture. Using a double cell counter, the number of viable and non-viable cells was determined. The cells in both chambers were counted and an average was calculated. For the trypan blue test, live cells did not take up the dye, whereas dead (non-viable) cells did. Thus non-viable cells stained blue and viable cells remained opaque. “Ghost” cells, which appeared as flattened pale blue cells were not counted.
[0094] The number of cells was determined as follows: Each square represented a total volume of 0.1 mm 3 or 1×10 −4 mL (0.1 mm depth×1 mm width×1 mm height=0.1 mm 3 ). The number of cells per mL was then deduced from the average viable cell count per 1 mm square×2×10 4 . The total cell number was therefore equal to the number of cells per mL multiplied by the original volume of sample fluid. The cells were then diluted to the desired concentration.
Example 2: Aseptic Processing of the Amniotic Material
[0095] (1) Aseptic Cryofractionation of Amnion
[0096] After at least one hour, the amnion was removed from the drying rack and transferred into the milling chambers having an impactor. The milling chambers were placed into the Cryomill and cryofractionated using the following settings:
[0097] Number of Cycles: 4
[0098] Frequency 1/s: 10 CPS —
[0099] Precooling Time: 10 minutes
[0100] Grinding Time: 4 minutes
[0101] Intermediate Cooling: 3 minutes
[0102] Once grinding was complete, the milling chambers were allowed to warm to room temperature for approximately two hours. The start and stop times were recorded.
[0103] Approximately 50 mL of the amnion suspension solution was dispensed into each milling chamber. The inside milling chamber and the impactor were rinsed with the solution multiple times until the ground amnion (dried particulate mixture) was re-suspended and collected in the bottom of the chamber. The impactor was removed using the magnet pen. The cryofractionated amnion solution was then transferred to the amnion suspension container and placed on cold packs in the sterile field and diluted to the desired amount.
[0104] (2) Aseptic Processing of Amniotic Fluid
[0105] The amniotic fluid was aliquoted evenly into 50 mL sterile centrifuge tubes and centrifuged at 200-400×g (1100-1600 rpm) for approximately 5-10 minutes at room temperature. The supernatant was then removed from each tube using a 25 mL sterile serological pipette. The amniotic liquid was kept in new container and the pellet was re-suspended in Plasma Lyte-A™ to a total volume of 25 mL in each tube. The re-suspended cells in any two different tubes were vortexed for approximately 3 to 5 sec and consolidated into a single tube prior to centrifugation at 200-400×g (1100-1600 rpm) for approximately 5-10 minutes at ambient temperature. The preceding steps were repeated as necessary.
[0106] The supernatant from each tube was removed using a sterile pipette and the pellet was again re-suspended in a cell suspension solution (amniotic fluid and/or an isotononic solution, e.g., PlasmaLyte A™) to bring the volume in each tube to about 10 mL and vortexed for approximately 3 to 5 seconds. A 1 mL aliquot was removed and the cell count and viability was determined using the above-described trypan blue test.
[0107] If red blood cells were present in the amniotic fluid cell suspension, they were removed using a RBC Lysing Solution. A 10× concentration was prepared as follows: NH 4 Cl (ammonium chloride)=8.02 gm+NaHCO 3 (sodium bicarbonate)=0.84 gm adjusted to a total volume of 100 mL with Millipore filtered water. 10 mL of the 10× concentrate was added to 90 mL Millipore filtered water and refrigerated until use. The amount needed of Erythrolysis solution (15 mL per tube centrifuged) was removed from the refrigerator and kept for a period of 0.5 hours in the stabilization incubator. After centrifuging the amniotic fluid at 400×g for 10 minutes, the supernatant was removed and the pellet was re-suspended in Erythrolysis solution (minimum of 50 mL per tube). The contents of all the tubes were consolidated into one tube that was rocked for ˜10 minutes at room temperature until the liquid was clear red. The cells were again centrifuged for 5 minutes at 250 to 400×g. The supernatant was decanted. The pellet was washed with 50 mL of PBS or PlasmaLyte A™ before centrifugation again for 10 minutes at 250 to 400×g. The washing of the pellet was repeated as needed. The amniotic fluid cells were then filtered through a 100 μm cell strainer, and re-suspended in PBS or PlasmaLyte A™. The cells were again centrifuged for 10 minutes at 250 to 400×g. The supernatant was decanted and the pellet was left in the 50 mL conical centrifuge tube.
[0108] (3) Procedure for Cryopreservation of Cryofractionated Amnion with Amnion Fluid Cells
[0109] Appropriate size cryovials that were previously labeled and their corresponding size of CoolCell™ freezer (CCF) racks were placed in the hood. CryoStor 10™, the Cell Suspension Solution and the Amnion Suspension Solution were also placed on cold packs in the hood. Cryostor 10™ is commercially available from Biolife Solutions.
[0110] The cell suspension solution and the amnion suspension solution were then combined into the cell suspension solution container. Using 50 mL serological pipettes, the solutions were homogenized several times. The container was again placed on the cold packs on the sterile field. Empty cryovials were placed in the CCF racks on cold packs and their caps were removed inside the hood (sterile field). The mix of cell/amnion suspension solution was pipeted into an empty Amnion Suspension container and a same volume of CryoStor 10™ was added and homogenized before being placed on the cold packs. A 50 mL pipette Combitip was fitted on to a repeat pipetor set to dispensing mode. The fill volume was adjusted and 50 mL of the Cell/Amnion solution was aspirated and then adjusted to the desired dispense volume (1 or 2 mL). The cryovials in the CCF were then filled and the vial caps were replaced securely and the rack of filled vials was placed on cold packs for QC inspection.
[0111] Cell freezing was achieved by cooling the cells at a cooling rate of 1° C. per minute from 4° C. to −80° C., using a passive cooling controlled-rate freezer CoolCell™ (commercially available from Biocision.)
[0112] The cell suspension in cryoprotective freezing medium was aliquoted into each of the cryovials and the cells were gently mixed to maintain a homogeneous cell suspension. The solid core of the CoolCell (black ring) at room temperature was seated in the bottom of the central cavity and the vials containing the cell suspension were placed in each well. The lid of the CoolCell™ was fully sealed and the Coolcell™ was placed into a −80° C. freezer for at least 4 hours prior to transfer on dry ice to long term storage. Cell viability and QA/QC were evaluated by thawing one vial after short term storage.
Example 3: Amniotic Tissue Wrap Preparation
[0113] After confirming the amniotic tissue source and donor mare ID and recording the time of receipt, the amnion transport packaging (previously disinfected, i.e. with 70% ethanol, methanol, etc.) was aseptically transferred into the sterile field (a laminar flow hood). A sample of the Amnion Transport Solution was first transferred into a 50 mL conical tube for Bioburden testing. The vial was then labeled with sample description, batch number, date and time and placed in designated refrigerator.
[0114] (1) Amniotic Membrane Wrap Preparation
[0115] Saline was aseptically added into a second receiving pan in the sterile field (i.e. laminar flow hood) and the amnion tissue was taken from incoming receiving pan to the second receiving pan containing the sterile saline. Any remaining blood was rinsed with sterile saline. After documenting the amnion preparation start time, sterile gauze or laps was used to remove any remaining debris/blood from the surface of the amnion. The amnion was then inverted and the other side was rinsed and washed. Any remaining chorion was removed by blunt dissection to separate it from the amnion. The amnion was kept wet with sterile saline. The tissue was blocked off by cutting away any stringy ends and checked for holes or tears. After repositioning the amnion on the cutting board with the chorion side up, the approximate area of each piece of amnion was measured and recorded in cm 2 using a sterile stainless steel ruler.
[0116] The amnion (chorion side up) was covered with a sterile mesh (e.g., a nylon mesh) wetted with sterile saline. For the purpose of this discussion, there is a first steel mesh which is denoted by a first visible indicia, the color white, and a second steel mesh, to be discussed below, which is denoted by a second visible indicia, the color blue. Any reference to the colors white or blue are directed to these visible indicia. Those skilled in the art will recognize that such visible indicia is matter of choice. The mesh was cut to size and was allowed to slightly overlap the amnion. The mesh-covered amnion was then gently lifted, turned over and placed back on the cutting board. Caution was used as to not disturb the mesh/amnion interface. The newly exposed side of the amnion was wiped with sterile wipes or gauze pads to remove any remaining blood or small tissue particles. The newly exposed side of the amnion was covered with a second steel mesh, BLUE sterile mesh (e.g., a nylon mesh) wetted with sterile saline. The mesh was cut to size and was allowed to slightly overlap the amnion.
[0117] The amnion tissue sandwiched between the white and blue mesh was placed on the drying rack where the amnion tissue was allowed to dry for 60 to 90 minutes at ambient temperature (65° to 70° F.). Caution was used as to not disturb the mesh/amnion interface. The amnion was kept unfolded and as flat as possible during this step. Additional drying racks were used as needed. The total drying time was recorded. The dried tissue was then removed from the rack(s) and laid flat on the cutting board, WHITE side up. The WHITE mesh was carefully removed from the entire sheet of amnion which was checked for holes or tears. With the BLUE mesh side up on the cutting board, each section was cut using a scalpel or rotary cutting blade and the sizes and surface areas were recorded as 5×5 cm, 10×10 cm, round 15 mm diameter and round 22 mm diameter. Those skilled in the art will recognize that the sections can be cut and sized to fit particular needs and these sizes and shapes are only exemplary. For example, the supports may be constructed and arranged to resemble facival features to produce a mask as previously described.
[0118] (2) Amniotic Membrane Wrap Pre-Packing
Pouches, Sealing Test and Labeling
[0119] The sterile field was set up for packaging including a sealer for packing pouches (Sealer settings: Temperature=177±9° C. (350±15° F.)). Three (3) empty pouches were sealed for visual inspection and retention and then labeled. Packing pouches are available from numerous vendors. One suitable pouch is sold under the trademark KAPAK™.
Amniotic Membrane Wrap Packing
[0120] Pouches were transferred onto the sterile field (previously disinfected laminar flow hood). Using sterile forceps, each individual tissue membrane was inserted into the inner pouch. Large membranes were folded if necessary. The pouches were sealed with the dried amnion tissue on a mesh (see, for example, FIGS. 2 and 3 ) and inspected for a broken seal, impurities, and defects. Upon passing the inspection, the pouches were labeled with date and packaged in large pouches according to size and stored in the refrigerator or at room temperature. The donor ID, size, date, time, and initials were documented.
Example 4: Implantation of Cryofractionated Amnion and Isolated Amniotic Fluid Cells
[0121] (1) Thawing Vials
[0122] A container was ¾ filled with hot tap water with a thermometer and cold water was added until a temperature of 37° C. was reached. A vial of cryofractionated amnion with amniotic fluid cells was taken from the −80° C. freezer. Holding the cap, the vial was partial immersed in the water bath for approximately 2 to 3 minutes with gentle agitation until the contents were melted. The vial was removed from the water bath and the exterior was wiped with sterile gauze saturated with 70% ethanol. The thawed contents were then ready for immediate use.
[0123] (2) Implantation Procedure
[0124] The site for the product implantation would be processed as a surgically prepared area. After cleaning or clipping of any gross contamination, the complete the area would be scrubbed with chlorhexidine for 5 to 7 minutes and then wiped down with alcohol swabs. Before proceeding, the area would be cleaned until the alcohol swabs used on the scrubbed area were dirt-free. Antibiotics would be administered prior to starting the procedure, if needed.
[0125] The contents of the 2 mL vial would be split into multiple doses (0.50 to 0.67 mL) and loaded into syringes (for example, 1 mL syringes) with sterile hypodermic needles (for example 22 gauge, 1.5 inch needles). The sites comprising creases, wrinkles, inconsistent pigment, sags, hair loss, spots, loss of flexibility, thinning, and voids are injected with small volumes of combined aesthetic modifier. After injection, the site was bandaged with sterile swabs and adhesive bandage, if needed.
Example 5: Implantation of Cryofractionated Amnion and Isolated Amniotic Fluid Cells in Combination with the Amnion Tissue Wrap
[0126] (1) Materials
[0127] A kit comprising sterile hypodermic needles (18 and 23 gauge), syringes (3 to 5 mL), vials of thawed cryofractionated amnion and amniotic fetal cells as well as packaged amnion tissue wrap of the appropriate size were assembled (see FIG. 1 ) together with sterile gloves, 1% lidocaine, saline and sedatives and/or anesthetics.
[0128] (2) Surface Preparation
[0129] The site would be initially pre-cleaned to remove dirt, scrubbed with chlorhexidine for 5 to 7 minutes and then wiped down with alcohol swabs.
[0130] (3) Inflammation:
[0131] A subject would create a mild inflammatory response by applying one or more inflammation means comprising keratolytics, irritants, rubefacients, abrasives, phototherapy, dermal microneedle devices prior to or during administration of the aesthetic modifier. The one or more keratolytics, irritants, rubefacients, or abrasives are carried in a spray, cream, ointment, slurry, paste, wash, mask, dermal patch, powder, solution or suspension. The one or more keratolytics, irritants, rubefacients, or abrasives are applied before or carried with with the aesthetic modifier and applied with the aesthetic modifier. Irritants, rubefacients and vesicants are know in the art and include, by way of example, without limitation, anthralin, camphor, cantharidin, capsicum , coal tar, ichthammol, juniper tar, menthol, Peruvian balsam, and pine tar. Keratolytics are known in the art and include by way of example, without limitation, benzoyl peroxide, salicylic acid, retinoic acid and other vitamin A derivatives. Keratolytic compounds are commonly found in acne treatment products. The kit 11 may also comprise photo or light devices to create an inflammatory response. Photo or light devices are known in the art as sun lamps and tuned lazer devices.
[0132] This step created a relatively clean wound bed and generated an inflammatory signal that induced the migration and proliferation of stem cells and growth factors (from the amniotic material and subject's own immune system). Systemic antibiotics were administered prior to starting the procedure.
[0133] (4) Application of Amniotic Tissue Wrap
[0134] Amniotic tissue wrap shaped as a mask for facial application would be applied to the face of the subject.
[0135] After the application of the amnion tissue wrap as described above, the approximate volume of the would be estimated and the amount of cryofractionated amnion and isolated amnion fluid cells to be injected were determined in accordance with guidelines shown in Table 3.
[0000]
TABLE 3
Amount of cryofractionated amnion and isolated amnion fluid cells
to be injected as a function of volume crease or voids or wrinkles.
Amount of cryofractionated amnion/
Area
amnion fluid cell suspension to use
<12.5 cm 2
1.0 mL
>12.5 cm 2 but <25 cm 2
1.5 mL
>25 cm 2
2.0 mL
[0136] After application of the inflammation means, the cryofractionated amnion/amnion fluid cell suspension would be injected into the skin below the features which modifiecation is desired.
[0137] To minimize discomfort and to ensure an adequate spread of the amniotic material, the cryofractionated amnion/amnion fluid cell suspension would be mixed with 1% plain lidocaine in a 1:1 ratio. After the completion of the procedure, the site was dressed with a nonporous dressing followed by application of a nonstick dressing and a dry sterile dressing of gauze. Five to seven days after implant of the amnion allograft, the area would be redressed, and standard wound care consisting of saline wet to dry sterile gauze dressing would be resumed.
[0138] Any patent, patent application, publication, or other disclosure material identified in the specification is hereby incorporated by reference in its entirety and for all purposes to the same extent as if each such individual reference (e.g., patent, patent application, publication, or other disclosure material) was specifically and individually indicated to be incorporated by reference in its entirety for all purposes. Any material, or portion thereof, that is said to be incorporated by reference herein, but which conflicts with existing definitions, statements, or other disclosure material set forth herein, is only incorporated by reference to the extent that no conflict arises between that incorporated by reference material and the present disclosure material.
[0139] Other embodiments are within the following claims.
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Methods are disclosed for the collection and processing of amniotic material in animals. These methods involve collection of amniotic material directly during parturition or cesariean section in animals for the processing of regenerative wound treatments and tissue repairs without culturing or utilization of any excess manipulation of tissue. These materials are used to effect a cosmetic result.
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BACKGROUND OF THE INVENTION
An overhead door of the type, according to the present invention, is known from German 3 726 699 Al. During the transition from the closed state to the open state and vice versa, the panels of such a door, especially a sectional door, which are articulated to one another along the direction the door moves in, travel along a curved track between a more or less vertical and straight section that accommodates the open door and a more or less horizontal section that accommodates the open door. The panels are for this purpose articulated together with hinges with an axis that extends along the interior surface of the door, the surface of the door, that is, that faces the space inside the building or other structure to be closed off with the door. Gaps can appear between adjacent panels in the tilted position that occurs while they are traveling through the curved section of the track. Fingers could be inserted into these gaps by accident or due to improper handling of the door by hand. To prevent such gaps, the facing edges of adjacent panels are curved in cross-section more or less in the arc of a circle with its center more or less on the axis of the hinge. There is a gap between each pair of facing curved edges that extends uninterruptedly between the outside and the inside of the door, ignoring any specially provided elastic sealing strips. An articulation between the adjacent panels that incorporates this gap is ensured by the use of appropriate hinges which must be precisely positioned because of the sealing strip. This requirement is difficult to comply with when establishing the hinges between the panels.
This state of the art in contrast to such other known designs as those disclosed in French Patent 1 310 605 and German GM 8 800 956, has shoulders adjacent to the convex and concave surfaces that engage each other when the door is in the closed state. The shoulders turn the gap into some-what of a labyrinth seal, and prevent the panels from shifting perpendicular to the plane of the closed door, when blown by the wind, for example, the shoulders also provide an appropriate surface for the wings of the hinges, which are better proportioned, to rest against.
The object of the present invention is to provide an overhead door of the aforesaid type whereby the adjacent panels can be simply, precisely, and more tightly secured together.
SUMMARY OF THE INVENTION To achieve this object, the facing edges of each pair of panels are designed in accordance with the invention such that the gap created between them is interrupted while the door is extending more or less in a single plane, when, that is, it is in the vicinity of the ceiling and in the open state or, as is important in the present context, when it is in the closed state, such that the two edges rest against each other in one section of and along the gap extending from the outer to the interior surface of the door with each panel resting on the panel just below it. It accordingly becomes possible not only to produce a seal between the panels in this section of the gap or area of contact but above all to precisely establish the position of the panels in relation to each other when the door is in the closed state. A seal in the remaining section of the gap can, due to the prescribed width and shape of the gap at that point, accordingly be dimensioned precisely enough and provided with a resilience that is precise enough to ensure minimum wear and resistance to friction. One particular advantage is that the distance between adjacent panels can be precisely defined due to intervention in the contact area of the gap section before the articulation between the panels is established by the hinged connection, especially separate hinges distributed across the direction the door moves in, whereby the correct positioning of the hinges is considerably facilitated. Furthermore, the panels can rest one on top of another when the door is in the closed state practically without stressing the hinged connection between them to the extent that the hinges are subjected only to tension and that there will be no interactive stress that could deteriorate the long-term security of the hinges.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic side view of one embodiment FIGS. 2a and 2b are schematic partly sectional side views of the edges of two adjacent panels from one embodiment employing a hinge both with the door closed and in the maximally flexed state in the vicinity of the curved transition between the straight more or less horizontal section of, track occupied by the open sectional door (FIG. 2b) and the straight more or less vertical section occupied by the closed door (FIG. 2a),
FIGS. 3a and 3b comprise illustrations similar to those in FIGS. 2a and 2b of another embodiment of the panels,
FIGS. 4a and 4b comprise illustrations similar to those in FIGS. 3a and 3of somewhat thicker panels,
FIGS. 5a and 5b comprise illustrations similar to those in FIGS. 2a and 2b of a fourth embodiment of the panels,
FIGS. 6a and 6b comprise illustrations similar to those in FIGS. 5a and 5b of a different embodiment of the panels,
FIGS. 7a and 7b comprise illustrations similar to those in FIGS. 2a and 2b with another embodiment of the hinges, FIGS. 8a and 8b comprise illustrations similar to those in FIGS. 2a and 2b of another embodiment of the panels,
FIG. 9a and 9b comprise illustrations similar to those in FIGS. 8a and 8b of a thicker embodiment of the panels, and
FIG. 10 is a side view of a hollow panel made out of a transparent material.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The schematic side view in FIG. 1 represents a sectional door 1 or its panels with solid lines in the closed state 2 and with broken lines in the open state 3 below the ceiling of an interior that it is intended to close off. The door when closed comprises a bottommost panel 4', one or more intermediate panels 4, and a topmost panel 4". The articulations between the panels rest against rollers 5 that engage tracks 6 as is generally known in doors of this type. Each track consists of a straight, more or less vertical section that accommodates the door when it is in a closed state 2, of a curved transitional section, and of a straight, more or less horizontal section that accommodates the door when it is in open state 3. The topmost roller, which is associated with the panel that is topmost when the door is in the closed state, has a special horizontal track with a sloping transitional section 6' for shifting the topmost panel into the closed state at a lower drop, as will be evident from FIG. 1. When it is in closed state 2, door 1 presents an outwardly facing outer surface 17 and an interior surface 18 that faces the interior being closed off.
FIGS. 2 through 9 show the articulation between two adjacent panels 4 and 4', with the drawing on the left representing the two panels in the same plane, in closed state 2 in the present case, and the drawing on the right representing them at their greatest mutual angle 16 at the transition between closed state 2 and open state 3. When the door is in the closed state, the upper edge 8 of bottommost panel 4' faces the lower edge 9 of intermediate panel 4. Upper edge 8 has a convex area 10 and lower edge 9 a concave area 11. These areas can be curved, especially along the arc of a circle with its center more or less on the axis 13 of articulation. Both the convex area 10 and the concave area 11 in the embodiments however, are comprised of several polygonal sections. The focus of the polygonal reflections corresponding to the intersections, of the perpendiculars to the midpoints of the sides of the polygon, however is at a point or spot in or near axis 13 of articulation and at least facing the adjacent axis 13 of articulation. Between the convex areas 10 and concave areas 11 created by polygonal sides 48 and 49 and 50, 51, and 52 of the facing edges 8 and 9 of the panels in closed state 2 as illustrated on the left of the drawing is a gap section 15 that varies in width along the thickness of the panels in the embodiments now being considered. The convex area 10 of the lower edge 9 of upper panel 4 can also be rectangular, with the downward side of the rectangle extending along the outer surface of the door and with its freely projecting edge displaced against the upwardly convex area 10 of lower panel 4' in imitation of the gap area while the panels are flexed. It is important in this context for gap section 15 to remain so narrow at any angle dictated between panels 4 and 4' by the operating conditions that fingers cannot be inserted into it. This applies to all embodiments of the convex and concave areas addressed herein and to any similar embodiments. The concave area 11 of each lower edge 9 terminates in a ridge 23, and the convex area 10 of upper edge 8 extends from outer surface 17 into the interior of the panel, where it terminates in a truncation 22. As will be evident from the right side of each FIG. 2 through 9, since the overlapping of areas 10 and 11 concludes by way of a complementary angle as the flexion increases, a gap 21 will occur between ridge 23 and truncation 22 that is too narrow to admit a finger into the space between the edges 8 and 9 of panels 4 and 4'. Gap 21 will preferably be narrower than 4 mm.
Left between the outer surfaces of panels 4 and 4' in the vicinity of the gap in outer surface 17 (facing left in FIGS. 2 through 9), is a joint that merges into gap section 15. This joint resembles one of several unillustrated beads on the panels.
Whereas the gap section 15 between the areas 10 and 11 of edges 8 and 9 opens, with the exception of a seal 33, toward outer surface 17 when the door is in closed state 2, the gap, or rather the plane of separation, between edges 8 and 9 terminates at interior surface 18 in a shoulder that is created between a shoulder area 19 extending down from upper edge 8 and hence into associated panel 4' and a shoulder area 20 extending down from lower edge 9 and hence from associated panel 4. Shoulder areas 19 and 20 constitute in conjunction with convex and concave areas 10 and 11 an interlocking engagement between the facing edges 8 and 9 of adjacent panels, preventing the panels from shifting in relation to one another subject to such forces as that of the wind perpendicular to their most extensive surface and accordingly allow any opening to form in the closed door. They also accommodate the leaves 26 and 27 of hinges 12, the axis of which is accommodated in one particularly preferred embodiment more or less securely between the sections 63 and 64 of shoulder areas 19 and 20 when the door is in the closed state.
The downward-extending shoulder area 20 of lower edge 9 extends in conjunction with the ridge 23 that is positioned on the same panel 4 where gap section 15 opens into the outer surface of the door within a plane perpendicular to the most extensive surface of the panels and allows reliable deposition of the panel upright on a level floor.
The walls demarcating the constant cross-sections of the panels illustrated along the axis of the hinges in FIGS. 2 through 9 and in the remaining figures all extend over the total length of the panel, over the total width of the door, that is, perpendicular to the direction that the door moves in.
The characteristics described heretofore are common to the described embodiments and are to some extent known from the initially described state of the art. The following description of individual embodiments relates to their individual designs and to the design and mounting of the specific type of hinge, especially to the shape of a gap 60 wherein the adjacent panels are in contact with or rest one on top of the other when the door is in the closed position. The latter situation in particular is of great advantage in that the mutually contacting panels become optimally distributed while the door is being manufactured as the result of one resting on top of the other, in consequence of which it becomes especially easy to correctly position the hinges and hence attain optimum orientation and distribution of the panels in the finished door. When different embodiments incorporate the same particular designs and groups of characteristics, their description will not be repeated in what follows.
FIG. 2 illustrates one embodiment of a panel 4 in the form of a single skin 29, with one extensive surface facing the outer surface 17 of the door in the form of an outer panel surface 35. As viewed from the interior surface 18 of the door, the panels are "open" between upper and lower margins 24 and 25 that are bent back against themselves to provide a reinforced area for securing the halves 26 and 27 of the hinged connection with screws 36. The hinged connection consists of several individual hinges 12 distributed over the length of the panels and along their axis. Skin 29, which is made of thin sheet metal, is reinforced with struts 39 that have tongue-shaped ends 40 resting against the outside of upper margins 24 in the vicinity of halves 26 and 27. Tongue-shaped ends 40 are also penetrated by screws 36.
The edges 8 (of lower panel 4') and 9 (of upper panel 4) comprise various sections. Upper edge 8 consists as viewed from outer surface 17 of an angle that faces the ridge 23 on upper panel 4 and resembles one of the beads, followed by a convex area 10 consisting of the sides 50, 51, and 52 of a polygon, followed toward interior surface 18 by an edge area 61 that merges inward in the same direction into a surface that extends more or less parallel to the interior surface of the door. The latter two surfaces constitute the shoulder area 19 of upper edge 8 that extends into the associated panel. Lower edge 9 is constituted as viewed from outer surface 17 by the polygonal sides 48 and 49 that constitute concave area 11 adjacent to ridge 23 followed toward interior surface 18 by an edge area 62 that merges,. in the same direction into a surface that substantially parallels the interior surface of the door and is in turn followed by a surface 64 that slopes in to interior surface 18. The latter two surfaces constitute in conjunction with one area of the panel surface facing interior surface 18, the shoulder area 20 of lower edge 9, that faces away from inside the panel and engages, with the door in the closed state represented on the left, the shoulder area 19 of the adjacent panel, which accordingly constitutes a recess.
The areas 10 and 11 of edges 8 and 9 demarcate, when the door is in the closed state, the gap section 15 wherein the edges are separated.
The areas 61 and 62 of edges 8 and 9 on the other hand rest against each other and constitute the gap section 60 wherein the distance of the gap from the outer surface 17 to the interior surface 18 of the door is accordingly interrupted. Gap section 60 constitutes to this extent a supporting section with supporting or contact areas 61 and 62. Farther in toward interior surface 18, a gap distance occurs again between the surfaces of the two shoulder areas 19 and 20, that are more or less parallel to each other, and the interior surface of the door, and opens between their surface sections 63 and 64, which constitute the sides of a trapezoid that opens toward interior surface 18. The cross-section of adjacent panels when the door is in the closed state, accordingly, does not exhibit a gap that continues with no point of contact from outer surface 17 to interior surface 18, but one that is interrupted at gap section 60, so that it is more accurate to speak of a line of separation between edges 8 and 9, which represents the cross-section in the drawing and suggests the contour of an equivalent plane extension along the length of the panels.
The drawing represents the preferred shape of gap section 20 or of edge or contact areas 61 and 62 in the form of flat surfaces that extend parallel to axis 13 of articulation and parallel to the plane or most extensive surface of the panels. The edge areas of the gap section can, on the other hand, also be angled or curved in toward the axis in cross-section and/or need not be precisely perpendicular to the plane of the panels. Here, as in the embodiments illustrated in FIGS. 3 through 7, the previously described extent of the edge areas 61 and 62 of gap section 60 is located between the concave or convex area and the surfaces of shoulder areas 19 and 20 are that more or less parallel to the plane of the panels, or in other words, at the end of the gap area adjacent to the shoulder area. In this case the gap section can to this extent be considered part of gap section 15 and it can also be said with reference to the position of the gap section in these embodiments that edge areas 61 and 62 constitute parts of the polygonal section of areas 10 and 11 and are accordingly adjacent to polygonal section 50 or polygonal section 48. The gap section can however also basically be shifted further toward the midpoint of areas 10 and 11, or be included in the polygonal sections existing at that location.
The axis of articulation of hinges 12, the actual pin-like shaft 13 of the hinges in the present case, is accommodated along with the sections 78 that it rolls along between the lateral sections 63 and 64 of shoulder areas 19 and 20. The halves 26 and 27 of the hinges are connected to rollover sections 73 by way of intermediate webs 72 that parallel sections 63 and 64 as well as being adjacent to the tongue-shaped ends 40 of struts 39 and hence to the margins 24 and 25 of skin 29, extending within the same plane as the panels on interior surface 18. In this way the axis of articulation of shaft 13 arrives in a position shifted from interior surface 18 toward the inside of the panel as illustrated in the figure. This is an especially preferred embodiment that positively affects the shaping of edges 8 and 9 with respect to allowing rotation to a maximum angle 16 of rotation. The distance, perpendicular to the thickness of the panel, between axis 13 of hinge articulation and the midpoint of gap section 60 in the same direction is approximately one fourth of the total thickness of the panels and hence of the door.
Also evident from FIG. 2 is a seal 33 in the gap section 15 between areas 10 and 11 at the end of the overlap and at the transition between the tilted positions of the adjacent panels from the open and into the closed state in the form of a strip extending perpendicular to the motion of the door and accordingly along the length of panels 4. The strip is inserted in a parallel seal-accommodation groove 34 in the convex area 10 of upper edge 8. The result is that the friction produced by the engagement on the part of seal 33 with the other and opposite concave area 11 on the lower edge 9 of the panel 4 that is at the top when the door is in the closed state, will occur only over a relatively short terminal pivoting angle between the panels.
The panels in the embodiment illustrated in FIG. 3 are all in two halves. One half 30 incorporates outer panel surface 35, edges 8 and 9, and the adjacent upper margin 24. The other half 42 comprises a rear wall 41. The margin 43 of half 42 is bent back against itself for reinforcement and applied to the upper margin 24 of half 30, reinforced in turn by the folded-down lower margin 25, such that the halves 26 and 27 of the hinges are secured to reinforced margin 43 and to reinforced margins 24 and 25 by the threaded connections 26 represented by dot-and-dash lines. The borders of the margin 43 of rear wall 41 that extend into the associated panel 4 or 4' are provided with resilient snap-in edges 45 that overlap the folded-back regions between upper margin 24 and the folded-back lower margin 25 in the manner of a clip. Half 30 and rear wall 41 can accordingly be provided before being screwed together with hinge halves 2 and 27, so as to constitute a simple prefabrication. The panels can be filled with insulating foam 32, for example. Otherwise edges 8 and 9, the hinges, and the seal are similar in design and function to those in the embodiment illustrated in FIG. 2.
The embodiment illustrated in FIG. 4 differs from the embodiment illustrated in FIG. 3 in that the panels are thicker, with skin 59 longer in the vicinity of the sections 63 and 64 of shoulder areas 19 and 20. Otherwise skin 59 again incorporates outer panel surface 35 and upper margin 24 along with its folded layers as described in conjunction with FIG. 3. Due to the longer sections 63 and 64, axis 13 of hinge articulation extends farther into the panel as will be evident from FIG. 4. The result is the same relationships during the pivoting motion between the shape of areas 10 and 11 as in the embodiments illustrated in FIGS. 2 and 3, as also applies to seal 33. These panels can also be occupied by insulating foam 32. The design and distribution of the various components in the vicinity of the connection between the two halves of the skin are similar to those illustrated in FIG. 3, and the design of the hinge differs only in that intermediate webs 72 are long enough to match sections 63 and 64.
The panels 4 and 4' in the embodiment illustrated in FIG. 5 accommodate a frame 47 that is comprised of one edgewise section of outer panel surface 35, edges 8 and 9, and upper margin 24 or an edge section of rear wall 41 that represents it. The frame acts as a mount for hinge halves 26 and 27. The shape of the panel edges and the shape and distribution of hinges 12 correspond, like those of seal 33, to the conditions characteristic of the embodiment illustrated in FIGS. 2 and 3. Inserted into the space enclosed in frame 47 is a pane of glass or a diaphragm. Frame 47 can be made out of metal (sheet metal or a light-weight metal), plastic, and/or wood, for example.
The embodiment illustrated in FIG. 6 differs extensively from that illustrated in FIG. 5 in that no heat can travel from one side of the door to the other. For this purpose the frame 47 in each panel 4 or 4' has a section 74 on outer surface 17 and another section 75 on interior surface 18. Frame sections 74 and 75 are attached and fastened together through the thickness of the panel by heat-insulating plastic webs 76 inserted in the form of bridges. These webs are resistant to high temperatures. Between the sections 74 and 75 that constitute frame 47 is an insulating mass 77 that comprises part of the polygonal section of convex area 10 that demarcates gap section 15 and at least part of the edge section or contact area 61 of gap section 60. Since the insulating mass simultaneously functions as a sealing strip, no separate sealing strip is necessary at the end of gap section 15 that faces outer surface 17. Nor does the exit from gap section 15 at interior surface 18 resemble a bead because no beads are repeated along the door in the direction of motion in the version of the panels being considered in the present context.
The embodiment illustrated in FIG. 7 differs from that illustrated in FIG. 2 in the design of the hinge mechanism or of hinges 12. Each half 26 and 27 of the hinges in the embodiment illustrated in FIG. 2 has a securing area 71 paralleling the interior surface 18 of the panel 4 or 4' that is to be attached. A facing intermediate web 72 that slopes, at an angle greater than 30° for example, out of the plane of securing area 71 and toward outer surface 17, and an adjacent rollover section 43 that surrounds the axis 13 of hinge articulation and, adjacent to intermediate web 72, extends into an envelope of axis 13 that faces outer surface 17. The halves 26' and 27' of the hinges 12' in the embodiment illustrated in FIG. 7, on the other hand, have a securing area 71' that parallels the interior surface 18 of the adjacent panel 4 or 4'. An intermediate web 72' extends in the same plane or slopes into the panel, and an adjacent rollover section 73' surrounds the axis 13' of hinge articulation with an initial area adjacent to the intermediate web merging into an axial envelope that faces away from outer surface 17. Recesses are, of course, provided in the intermediate webs of the hinge halves to allow them to pivot around their axis to the maximum angle of rotation.
The embodiment illustrated in FIG. 8 is similar to that illustrated in FIG. 3 with respect to the design and distribution of the hinges, although the design of convex and concave areas 10 and 11 and the position of gap section 20 are different. The convex area 10 of the upper edge 8 of lower panel 4' extensively exhibits not only polygonal sides 50, 51, and 52 but also the groove 34 for accommodating seal 33. The concave area 11 of the lower edge 9 of upper panel 4, on the other hand, consists of two sections 48 and 49 directly adjacent to the surface of the shoulder area 20 on that edge. These areas accordingly constitute in conjunction with that surface an almost U-shaped channel. Ridge 23, however, is still present and pivots toward convex area 10 as in the embodiments illustrated in FIGS. 2 and 3. Gap section 20 has been shifted into the vicinity of shoulder areas 19 and 20, meaning that the lateral-edge area or the contact area of gap section 20 is constituted by part 62' of the edge surface 64 of shoulder area 20 and engages part 61' of the edge surface 63 of shoulder area 19. Edge surface 63 is for this purpose graduated such that the hinge vicinity of hinge mechanism 12 can be accommodated in an approximately U-shaped channel, whereas the adjacent areas of edge surfaces 63 and 64 in gap section 20 are above the axis 13 of articulation as will be evident from the figure, to which attention is expressly directed.
FIG. 9 illustrates a variation of the embodiment illustrated in FIG. 8 with thicker panels. The areas 10 and 11 of edges 8 and 9 are comparable to those in the embodiment in FIG. 8. Gap section 20 is also in the area engaged by shoulder areas 19 and 20 although again, with respect to the surface areas 61' and 62' that are adjacent in gap section 20, by way of graduations in the surfaces of shoulder areas 19 and 20 that face each other along the thickness of the panels. Shoulders 19 and 20 are accordingly double, as will be particularly evident from FIG. 9. Gap section 20 is definitely above the axis of articulation, which is an additional advantage in preventing fingers from entering the gap.
The hinges 12 employed in this embodiment are, in one especially simple version, provided with a shaft 13 that has an axis extending within interior surface 18, so that the hinge engages only to some extent between the interior sections of the sections 63 and 64 of shoulder areas 19 and 20. A hinge of this type can also be employed with the embodiments previously described and hinges of types previously described can on the other hand be employed with the last embodiment to be described, whereby the convex and concave surface areas can, if necessary, be designed somewhat different, retaining the resemblance between ridge 23 and gap section 15 when the panels are pivoted toward one another to prevent insertion of a finger between the panels. The intervals between the individual hinges on interior surface 18 are small enough to prevent insertion of a finger and to prevent a finger from getting squeezed when the panels are pivoted.
FIG. 10 is an edge-on view or axial cross-section of a panel 4 made out of, (extruded for example), two halves of translucent or transparent plastic. The cross-section exhibits appropriate reinforcements or hollows where the hinges attach, and the panel is also provided with reinforcing webs that extend along its thickness. A panel of this type could basically be made out of a single structure if thick enough or adequately reinforced. A number of such light-permeable panels can be combined into a door, or a few light-permeable panels can be employed with a number of opaque panels to obtain a type of window and/or admit light.
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An overhead door having a number of panels secured together by hinges, in which the insertion of a finger into a gap between the consecutive panels is prevented. Facing edges of ajdacent panels have areas that curve around an axis of the hinges to eliminate the occurrence of a gap as wide as a finger at any angle between the panels. Shoulder areas engage each other when the door is in the closed state, and they are located in the vicinity of the interior surface of the door and outside the curved edge areas that extend from the outer surface of the door. To facilitate manufacture of panels that will ensure that the door is tight, well supported, and precisely positioned when in the closed state, there is a section in the area of the gap between the facing edges of adjacent panels as viewed from the outer surface and toward the interior surface of the door. The gap distance is interrupted and the panels rest one on top of another when the door is in the closed state.
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FIELD
This invention relates to simple, easy-to-use precision tools that precisely locate the mid-line, or center line, of any symmetrical geometric shape, such as squares, circles, rectangles, parallelograms, and trapezoids. The invention is a single object wherein contact members locate or check the center of a hole or the location of a center line, without the need for measurements or mathematical calculations.
BACKGROUND OF THE INVENTION
There is a need for a simple-to-use, precision tool that accurately identifies the center lines and center points of a variety of geometric shapes, requiring no more than simple manual manipulations by the user to determine the center lines with mathematical precision.
Precision tools exist that can be used to identify the center lines of different geometric shapes, but those instruments are limited in several ways. Similar instruments that are easy to operate incorporate sophisticated construction or automation to identify center lines with mathematical precision. Some manually operated tools yield imprecise approximations of center lines or center points. Other manually operated tools identify center lines or center points with mathematical precision, but require precise measurements or mathematical calculations by the user. Accordingly, there is an urgent need for a simple, manually operated precision tool that will identify the center lines of symmetrical geometric shapes with mathematical precision, without requiring the user to make mathematically precise measurements or calculations.
Other similar precision tools are complex constructions requiring power gears and additional pieces for assembly and function. There is a need for a precision tool that determines center lines without the use of automated parts, such as a power-screw mechanism. By simply placing the positioning legs of the precision tool on the edges of a geometric shape, the center is immediately indicated without any further adjustments to position the centering leg or by means of an adjustment screw. This provides a precision tool that is easier to use, and has a design that requires only a few, non-automated parts. Furthermore, this precision tool does not require a power source for operation.
There also exist other instruments that could be adapted to identifying the precise center lines of only a few geometric shapes, or only one geometric shape. There exists a need for a precision tool that identifies the center lines of a variety of different symmetrical geometric shapes.
Precision tools that identify the center lines of symmetrical geometric shapes operate in a plane that is substantially perpendicular to the geometric shapes. There exists a further need for precision tools that are operated in a plane that is substantially parallel to the geometric shapes, particularly in circumstances where space limitations prevent the use of a substantially perpendicular tool.
SUMMARY OF THE INVENTION
The disclosed embodiments include a precision tool comprising a base leg, two slidingly adjustable positioning legs, and a means of orienting the positioning legs relative to the base leg so that the base leg forms the center line between the two portioning legs. Accordingly, when the positioning legs are placed upon two separate points on the edge of a geometric shape, the base leg identifies the center line of that geometric shape between those two points, without additional measurements, manipulations, or mathematical calculations.
The disclosed invention relates to precision tools that precisely locate the center line of a geometric shape. Unlike a compass, which is a two-legged instrument, the disclosed precision tools comprise a central base leg with two flanking positioning legs that are slidingly attached to the base leg. When the ends of the positioning legs are placed upon two separate points on the edge of the geometric shape, the base leg defines the center line of the geometric shape, without further measurements or mathematical calculations.
To precisely define the center line of a geometric shape, the base leg is maintained in a particular orientation relative to the two positioning legs. The base leg is restricted to maintaining an orientation in which the base leg bisects the angle formed by its two flanking positioning legs. As the positioning legs move outward from the base leg (or inward toward it), the first positioning leg forms an angle with the base leg that is the same as the angle formed by the second positioning leg and the base leg. This feature ensures the mathematical precision of the center line identified by the disclosed invention.
The precision tool can be used to identify multiple center lines for the same geometric shape, and can identify the center line for every axis of symmetry that a geometric shape possesses. In addition, by plotting two or more center lines, the center point of a geometric shape is identified by the intersection of those center lines, with mathematical precision.
One embodiment of the invention further comprises a central leg. The central leg provides means to maintain the positioning legs in a particular orientation relative to the base leg, so that the precision tool accurately identifies the center line between the two separate points on the edge of a geometric shape that are indicated with the positioning legs.
Another embodiment of the invention further comprises a simple planetary gear system, instead of a central leg, to ensure that the positioning legs maintain the correct orientation relative to the base leg. In this way, the base leg and positioning legs maintain the necessary orientation so that the precision tool accurately identifies the center line between two separate points on the edge of a geometric shape. The planetary gear system provides an alternative means of adjusting the positioning legs to maintain the required orientation relative to the base leg.
Another embodiment of the invention further comprises gears to ensure that the positioning legs maintain the correct orientation relative to the base leg. The interlocking gears maintain the required orientation that ensures that the base leg of the precision tool accurately identifies the center line between two separate points on the edge of a geometric shape.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an illustration of a precision tool with a central leg according to the disclosed embodiments, where the positioning legs are in an opened position.
FIG. 2 is an illustration of a precision tool with a central leg according to the disclosed embodiments, where the positioning legs are in a closed position.
FIG. 3 is a side view of the precision tool with a central leg.
FIGS. 4A-4B are top and side views of a positioning leg of the precision tool.
FIGS. 5A-5B are top and side views of the central leg of the precision tool.
FIGS. 6A-6B illustrate a top and side view of the base leg of the precision tool.
FIG. 7 is an illustration of a further embodiment of a precision tool containing a planetary gear system.
FIGS. 8A-8B illustrate a further embodiment of a precision tool containing gears in an opened position and a closed position.
DETAILED DESCRIPTION
A “geometric shape” is any closed, two-dimensional shape having at least one axis of symmetry. Examples of geometric shapes include, but are not limited to, squares, rectangles, parallelograms, trapezoids, ellipses, ovals, and circles. Other examples include pentagons, hexagons, and other polygons, as long as they have at least one axis of symmetry.
A “center line” is any line which forms an axis of symmetry in a geometric shape. A center line divides a geometric shape into two halves. Each half possesses equal area to each other and is a mirror image of the other half.
The disclosed embodiments of the invention relate to a precision tool that readily identifies the center line between two separate points on the edge of a geometric shape.
Embodiment 1
FIGS. 1-6 illustrate one embodiment of a precision tool of the disclosure. The embodiment shown in FIGS. 1-2 includes a base leg 10 , two positioning legs 21 , 22 attached next to each other atop the base leg 10 , and a central leg 31 atop the two positioning legs 21 , 22 .
The base leg 10 is shown in greater detail in FIGS. 6A-6B . The base leg 10 contains a thru slot 11 positioned in its midline and four openings 12 - 15 .
The two positioning legs 21 , 22 are identical in structure and shown in greater detail in FIGS. 4A-4B . Each positioning leg 21 , 22 has three openings 23 - 25 . The first positioning leg 21 is slidingly attached atop the base leg 10 by a fastening means through opening 12 of the base leg 10 and opening 23 of the first positioning leg 21 . The second positioning leg 22 is slidingly attached atop the base leg 10 by a fastening means through opening 13 of the base leg 10 and opening 23 of the second positioning leg 22 .
The first positioning leg 21 slidingly attaches to the base leg 10 at opening 12 . The second positioning leg 22 slidingly attaches to the base leg 10 at opening 13 .
This embodiment of the precision tool also includes a central leg 31 , which is shown in greater detail in FIGS. 5A-5B . The central leg 31 is shaped like an capital letter “H” with elongated arms 33 - 36 . There is an open section 37 between elongated arms 33 and 35 . There is another open section 38 between elongated arms 34 and 36 . The crosspiece 32 of the central leg contains an opening 39 .
This embodiment is assembled as the base leg 10 , two positioning legs 21 , 22 attached next to each other atop the base leg 10 , and a central leg 31 atop the two positioning legs 21 , 22 .
FIGS. 2-3 further illustrate the assembled precision tool. When assembled, first positioning leg 21 and second positioning leg 22 lie atop the base leg 10 , with thru slot 11 between them ( FIG. 2 ). Opening 23 of the first positioning leg 21 will be slidingly fastened to opening 12 of the base leg 10 and opening 23 of the second positioning leg 22 will be slidingly fastened to opening 13 of the base leg 10 . Opening 24 of the first positioning leg 21 will align to opening 14 of the base leg 10 and opening 24 of the second positioning leg 22 will align to opening 15 of the base leg 10 . Opening 25 of each positioning leg 21 , 22 will extend past the base leg 10 .
The central leg 31 slidingly attaches to the base leg 10 by a fastening means through opening 39 of the central leg 31 and thru slot 11 of the base leg 10 . The fastening means, for example, a pin, allows the central leg 31 to move laterally along the thru slot 11 , along the midline of the base leg 10 . ( FIG. 2 ).
As the two positioning legs 21 , 22 move outward from the midline of the base leg 10 (or inward toward it), opening 24 of the first positioning leg 21 must be kept in alignment with opening 24 of the second positioning leg 22 , so that a line formed between the two openings is perpendicular to thru slot 11 of the base leg 10 . This restriction maintains the two positioning legs 21 , 22 in proper alignment with the base leg 10 ( FIGS. 2-3 ), so that the angles formed between the base leg and each positioning leg are angles of equal size and, accordingly, the base leg 10 identifies the center line of a geometric shape.
This embodiment of the precision tool can be used to find the center line between two separate points on a geometric shape. To do so, opening 25 of the first positioning leg must be positioned above one point along the edge of the geometric shape and opening 25 of the second positioning leg must be positioned above another point along the edge of the geometric shape. The central leg must be positioned such that opening 24 of the first positioning leg is contained within open section 37 of the central leg and opening 24 of the second positioning leg is contained within open section 38 of the central leg. With the precision tool thus aligned, the base leg will identify the center line between the two points of the geometric figure with mathematical precision.
Embodiment 2
FIG. 7 illustrates an example of an alternative embodiment of a precision tool of the disclosure. In this embodiment, the relative alignment of the base leg and two positioning legs are maintained by means of simple planetary gear system, instead of the central leg piece described in Embodiment 1.
This precision tool is made of a base leg 60 , a first positioning leg 70 , and a second positioning leg 80 that are aligned by a simple planetary system. The simple planetary system has a sun gear 71 , planet gear 61 , curved groove 72 , and ring gear 82 .
The base leg 60 forms the bottom piece of the precision tool. The planet gear 61 is attached atop the base leg 60 near the base leg's apex. The planet gear 61 is attached at point 62 so that the planet gear can only rotate around its own center.
First positioning leg 70 contains a curved groove 72 near its apex. A sun gear 71 is fastened atop first positioning leg 70 , positioned closer to the apex than the curved groove 72 . The curved groove 72 describes a partial orbit around the sun gear 71 .
First positioning leg 70 is placed atop base leg 60 so that the planet gear 61 protrudes upward through the curved groove 72 . The teeth of planet gear 61 contact the teeth of the sun gear 71 . The ring gear 82 encircles the sun gear 71 , the planet gear 61 , and the curved groove 72 . The inner teeth of the ring gear 82 contact the teeth of the planet gear 61 .
The second positioning leg 80 is placed atop the first positioning leg 70 and the ring gear 82 , near the apex of the second positioning leg 80 . The precision tool is fastened together at a single point 84 , attached by a fastening means through the second positioning leg 80 , the center of the sun gear 71 , the first positioning leg 70 , and the base leg 60 .
The planetary gear system functions to restrict the movement of the first positioning leg 70 and second positioning leg 80 so that whenever one positioning leg is moved away (or toward) the base leg, the other positioning leg also moves the same distance away (or toward) the base leg 60 . Thus, the unattached ends of the first positioning leg 70 and the second positioning leg 80 always remain equidistant from the base leg 60 . Also, the interior angle between the base leg 60 and the first positioning leg 70 always remains the same size as the interior angle between the base leg 60 and the second positioning leg 80 . Accordingly, the planetary gear system maintains the required orientation between the base leg and the two positioning legs to ensure that the precision tool identifies a geometric shape's center line with mathematical precision.
This embodiment of the precision tool can be used to find the center line between two separate points on a geometric shape. To do so, the unattached ends of the first positioning leg 70 and the second positioning leg 80 are extended outward and placed on two separate points along the edge of the geometric shape. With the precision tool thus aligned, the base leg 60 will identify the center line between the two points of the geometric figure.
Embodiment 3
FIGS. 8A-8B illustrate an example of an alternative embodiment of a precision tool of the disclosure. In this embodiment, the relative alignment of the base leg and two positioning legs are maintained by means of gears, instead of the central leg piece described in Embodiment 1 or the simple planetary gear system described in Embodiment 2 .
This precision tool is made of a base leg 91 , a first positioning leg 92 , and a second positioning leg 93 that are aligned with gears 94 , 95 . The first positioning leg 92 is slidingly attached atop the base leg 91 near its apex by means of a gear 94 sandwiched between them. The second positioning leg 93 is slidingly attached atop the base leg 91 near its apex by means of a gear 95 sandwiched between them. Gear 94 is identical to gear 95 and the teeth of the two gears contact each other. The first positioning leg 92 and second positioning leg 93 are the same length.
The gears function to restrict the movement of the first positioning leg 92 and second positioning leg 93 so that whenever one positioning leg is moved away (or toward) the base leg 91 , the other positioning leg also moves the same distance away (or toward) the base leg. Thus, the unattached ends of the first positioning leg 92 and the second positioning leg 93 always remain equidistant from the base leg 91 . Also, the interior angle between the base leg 91 and the first positioning leg 92 always remains the same size as the interior angle between the base leg 91 and the second positioning leg 93 . Accordingly, the gears maintain the required orientation between the base leg and the two positioning legs to ensure that the precision tool identifies a geometric shape's center line with mathematical precision.
This embodiment of the precision tool can be used to find the center line between two separate points on a geometric shape. To do so, the unattached ends of the first positioning leg 92 and the second positioning leg 93 are placed on two separate points along the edge of the geometric shape. With the precision tool thus aligned, the base leg 91 will identify the center line between the two points of the geometric figure.
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The disclosed invention relates to easy-to-use precision tools that locate the mid-line, or center line, of any symmetrical geometric shape, such as triangles, squares, circles, rectangles, parallelograms, trapezoids, and symmetrical polygons. Given two separate points on the edge of a symmetrical geometric shape, these precision tools identify the center line of the geometric shape between those two points, without the need for additional measurements or mathematical calculations. The precision tools can also be used to identify the center points of symmetrical geometric shapes.
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This Application claims the benefit of U.S. Provisional Application No. 60/430,583 filed on Dec. 4, 2002.
BACKGROUND OF INVENTION
1. Field of the Invention
The present invention relates to a method and apparatus for determining the vibration damping characteristics of an automotive component such as a brake structure, e.g. a brake pad or brake shoe.
2. Disclosure Information
Automotive brake systems present unique challenges to designers inasmuch as such systems must be capable of stopping a vehicle reliably during a long service life. Vibration-induced noise in disc brake pads is an issue which asserted itself since the dawn of the disc-brake age in the annals of mass produced automobiles.
The production of audible noise by automotive disc-brake systems is greatly affected by the presence (or absence) of self-damping capability offered by the disc-brake pads themselves. Not surprisingly, it is therefore desirable to produce pads having self-damping characteristics in the vibration regimes which would otherwise produce noise. The assessment of a brake pad's self-damping characteristics have been the subject of previous inventive activity. As a result, several test methods and types of apparatus have been proposed, such as that shown in U.S. Pat. No. 6,382,027. The method and apparatus of the '027 patent uses an exciter which is pulsed on and off, with the actual vibration damping being measured while the exciter is in the deactivated mode. This type of operation is not suitable for high speed assessment of parts because the vibration assessment must be accomplished serially. In other words, the vibration response is not measured while the exciter is providing vibratory energy to the disc-brake pad. Thus, more time is required to obtain the assessment. Moreover, the capabilities of the method disclosed in the '027 patent are wanting because of limitations inherent in the time decay process. Moreover, other test methods such as the Oberst Bar test are capable of measuring damping only at lower frequencies.
It is advantageous that a method and apparatus according to the present invention overcomes problems associated with prior art methods and apparatus for determining the inherent damping characteristics of automotive brake structures, including brake pads, as well as other components.
SUMMARY OF INVENTION
As used herein, the term “insulator” means the friction material applied to the backing plate of either a disc brake pad or a drum brake shoe. According to the present invention, a method for determining the vibration damping characteristics of an automotive brake structure includes the steps of resiliently setting or mounting the brake structure to a stationary base, applying broadband random-frequency vibratory excitation to the brake structure, measuring the vibration response of the brake structure during application of the random-frequency excitation, including responsive vibration occurring at not less than one modal frequency, and applying a confined bandwidth random-frequency vibrator excitation to the brake structure, with the confined bandwidth being selected to correspond to at least one modal frequency. The present method further includes the steps of measuring the vibration response of the brake structure during application of the confined bandwidth signal, and using the measured vibration response of the brake structure to the confined bandwidth signal to calculate the damping value of the brake structure.
A method according to the present invention preferably utilizes broadband random-frequency excitation in the frequency range from 10 Hz to about 15 kHz. The brake structure is preferably excited by a variable reluctance actuator, which is a non-contacting actuator. The vibration response of the brake structure is preferably measured by a non-contacting sensor system such as a laser velocimeter. The confined bandwidth excitation preferably has a bandwidth of about 200 Hz to about 400 Hz, and a center frequency equal to one of the observed modal frequencies develop during broadband sweep.
According to another aspect of the present invention, a system for determining the vibration damping characteristics of an automotive component such as a brake structure includes a broadband, random-frequency vibratory exciter for inducing vibration in the component, and a non-contacting vibration measuring device for determining the frequency response of the component during the vibratory excitation, with the frequency response including the identification of a plurality of modal frequencies. A confined bandwidth random-frequency vibratory exciter then induces vibration in the test component at frequencies corresponding to the plurality of modal frequencies. Then, a processor determines the vibration damping characteristic of the component as the ratio of the difference in the frequency of the vibrations at a 3 dB vibration magnitude bandwidth, as a fraction of the frequency of vibration at the center of the confined bandwidth.
The present test apparatus may further include an environmental chamber for housing the component being tested, with the chamber having a ports for accommodating the vibratory exciter and the vibration measuring device.
The present vibration testing method and apparatus is advantageous because the time required to perform an assessment of the vibration is sufficiently brief that the present system may be used to assess high-volume production parts.
It is a further advantage of the present invention that the present method and system may be employed to nondestructively determine whether a disc brake pad insulator or shim friction material is properly bonded, or otherwise attached to a brake backing plate. This is important because the bonding characteristics of the pad insulator are an important determinator of brake pad vibration damping.
Other advantages, as well as objects and features of the present invention, will become apparent to the reader of this specification.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a systematic representation of a vibration damping test system according to the present invention.
FIG. 2 is a frequency vibration plot developed during a broadband sweep of an automotive component according to the present invention.
FIG. 3 is a frequency vibration plot produce by a confined bandwidth random-frequency vibratory excitation according to an aspect of the present invention.
FIG. 4 illustrates a brake pad having modal vibration pattern indicating a consistent bonding pattern between the pad insulator and the brake backing plate.
FIG. 5 illustrates a brake pad having an irregular distribution of bonding between the pad insulator and the backing plate.
DETAILED DESCRIPTION
As shown in FIG. 1 , brake pad 20 is placed on stand 24 within environmental chamber 22 , which may be used to provide heat for conducting a vibration assessment according to the present invention, at a variety of temperatures. Those skilled in the art will appreciate in view of this disclosure that the present method and system could be used for the purpose of determining vibration damping and component material bonding for parts other than automotive brake parts. As used herein, the term “mounting” means placing the part to be tested upon supports located within chamber 22 so that the part merely rests on the supports, or alternatively, attaching the part to the supports.
Brake pad 20 is placed upon stand 24 , comprising silicone rubber supports, within environmental chamber 22 . Exciter 36 passes into the interior of environmental chamber 22 through port 32 . Exciter 36 is preferably a non-contact magnetic actuator which generates magnetic force. This type of device, sometimes termed a variable reluctance actuator, is sold by Electro Corporation under the model number 3030HTB. Exciter 36 is driven by high output amplifier 30 , which may comprise a single-channel high output amplifier such as an AVC 790A01 model power amplifier. The amplifier's controls are operated by controller 28 drawn from a universe of such controllers known to those skilled in the art of vibration testing and suggested by this disclosure.
Vibrations of pad 20 are sensed by means of laser doppler velocimeter 26 , which preferably comprises a laser velocimeter such as a Polytech PDV-100 or Polytech PSV-400 having a Class 2 visible helium/neon laser. Controller 28 includes a two-channel signal analyzer drawn from the class of such analyzers known to those skilled in the art and suggested by this disclosure, such as a Hewlett Packard model 35670A.
According to the present invention, the experimental method begins as shown in FIG. 2 with a broadband excitation of pad 20 at frequencies of up to, or even exceeding, 15 kHz. The resulting vibration of pad 20 is measured by laser velocimeter 26 , and a series of modal frequencies is developed, as shown in the FIG. 2 . After the broadband sweep has been performed as shown in FIG. 2 , controller 28 performs the assessment shown in FIG. 3 , wherein a confined bandwidth random-frequency vibratory excitation is applied to pad 20 . This excitation is selected to correspond to at least one of the previously developed modal frequencies. The narrow band random excitation signal preferably has a bandwidth of 200 Hz to 400 Hz, with the center frequency being equal to one of the modal frequencies. Then, the modal damping value is calculated using the half powered principle according to the following equation:
η = f + 3 dB - f - 3 dB f peak
Where η is damping loss factor, f+3 dB is the frequency of vibration at 3 dB less than the peak magnitude of vibration at the right side of the power spectra plot, and f−3 dB is 3 dB down from the peak magnitude of vibration on the left side of the power spectra plot. This is termed a “half power” calculation because 3 dB attenuation corresponds to a halving of the vibration power. As seen from the formula, the modal damping value increases as the slopes to and from the peak vibration value become increasingly smaller. In essence, controller 28 determines, for at least one of the modal frequencies, the vibration damping characteristic of a component as the ratio of the difference in the frequencies of the vibrations, at a predetermined off-peak magnitude (in the above example, at a vibration magnitude which is 3 dB less than the peak magnitude), to the value of the modal frequency.
As noted above, the present system may be used for assessing the structural integrity of a brake structure by comparing a pattern of modal lines developed at a fixed frequency with a predetermined pattern of such modal lines. FIG. 4 shows a well-developed pattern of modal lines, M, detected by sweeping velocimeter 26 over the surface of pad 20 while exciter 36 providing constant frequency vibratory excitement to pad 20 . The pad shown in FIG. 4 has proper bonding between the pad's insulator and backing plate. In contrast with the situation of FIG. 4 , the pad illustrated at FIG. 5 does not have proper bonding between the insulator and the backing plate, as shown by the absence of any coherent modal lines at the center region of the pad. The present invention allows the testing of pad in a non-destructive fashion, which can be used to more easily assess insulator bonding processes and materials.
Although the present invention has been described in connection with particular embodiments thereof, it is to be understood that various modifications, alterations, and adaptations may be made by those skilled in the art without departing from the spirit and scope of the invention set forth in the following claims.
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A method and apparatus for determining the vibration damping characteristics of an automotive brake structure measures the vibration response of a brake structure during application of random-frequency wide spectrum excitation, followed by measuring vibration of the structure at particularly noted modal frequencies, using a confined bandwidth random-frequency vibratory excitation. The method and apparatus may be used also to assess the bonding or attachment characteristics of damping materials.
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BACKGROUND
The control of multiple, accurately-spaced clock phases operating at one frequency is important to the design of many high-performance, high-speed chip-to-chip interconnect systems. While some interconnect systems use just two phases, e.g., the rising and falling edges of a single very high-speed clock, there are drawbacks to that approach, such as the difficulty of accurately controlling the duty-cycle of such a high-speed clock, as well as the necessity and difficulty of operating the high speed clock at a high frequency equal to ½ the data rate. The use of multiple clock signals with accurately spaced clock phases overcomes the disadvantages of a single clock approach. For example, because there are more clock phases, the frequency of these multi-phase clocks can be a fraction of the data rate, such as ½, ¼, ⅛, or 1/10. However, with multiple clock signals, problems can develop if the phase relationship among the various clock signals is not properly and accurately maintained.
SUMMARY
The present invention is directed to a multi-phase correction circuit that can adjust the phase relationship among multiple clock signals having rising edges that are nominally spaced equidistant in time from one another, yet may have substantial errors in this spacing, such that these spacing errors are substantially reduced. In one embodiment, each of four input clock signals operating at the same frequency and nominally spaced equidistant in time from one another, yet with spacing errors, are buffered so as to generate output clock signals whose rising edges are equidistant in time from one another and have substantially reduced spacing errors. In particular, the circuit measures the relative time-position of the rising edges of each of the output clock signals and adjusts their time positions such that the rising edge of each successive clock signal trails the rising edge of the preceding clock signal by the same amount.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing summary and the following detailed description are better understood when read in conjunction with the appended drawings. For the purpose of illustrating the multi-phase correction circuit, there is shown in the drawings exemplary embodiments of various aspects of the circuit; however, the invention is not limited to the specific circuitry, methods and instrumentalities disclosed. In the drawings:
FIG. 1 is a diagram illustrating the adjustment of the phases of a set of clock signals in accordance with an embodiment of the present invention;
FIG. 2 is a circuit diagram illustrating one embodiment of a multi-phase correction circuit;
FIG. 3 is a circuit diagram illustrating one embodiment of a multi-phase measurement circuit which is used in the multi-phase correction circuit;
FIG. 4 is a circuit diagram illustrating one embodiment of a delay measurement subcircuit which is used in the multi-phase measurement circuit;
FIG. 5 is a circuit diagram illustrating one embodiment of a delay circuit which is used in the multi-phase correction circuit; and
FIG. 6 is a circuit diagram illustrating one embodiment of bias generators which are used in connection with the multi-phase correction circuit; and FIG. 7 is a circuit diagram illustrating one embodiment of a loop filter capacitor used in the multi-phase correction circuit.
DETAILED DESCRIPTION
FIG. 1 is a diagram illustrating the adjustment of the phases of a set of clock signals in accordance with an embodiment of the present invention. In the example shown, four input signals, IN 0 , IN 1 , IN 2 and IN 3 , each have substantially the same frequency. The respective rising edges 102 , 104 , 106 and 108 of these input signals are not, however, equally spaced. The multi-phase correction circuit of the present invention, one embodiment of which is illustrated in the following figures, generates output clock signals OUT 0 , OUT 1 , OUT 2 , and OUT 3 from input signals IN 0 , IN 1 , IN 2 , and IN 3 and having respective rising edges 112 , 114 , 116 and 118 that are substantially equidistant in time from one another.
As one example, each of the four input clock signals IN 0 , IN 1 , IN 2 and IN 3 may switch at 2.7 GHz (period=370 ps). The multi-phase correction circuit of FIG. 2 may buffer the input signals to generate the output clock signals OUT 0 , OUT 1 , OUT 2 and OUT 3 . A portion of the multi-phase correction circuit may measure a relative time-position of the rising edges of each of the output clock signals and, by means of negative feedback, adjust the relative time positions such that the rising edge of OUT 1 trails the rising edge of OUT 0 by 370/4=92.5 ps, the rising edge of OUT 2 trails the rising edge of OUT 1 by 370/4=92.5 ps, the rising edge of OUT 3 trails the rising edge of OUT 2 by 370/4=92.5 ps, and the next rising edge of OUT 0 trails the rising edge of CLK 3 by 370/4=92.5 ps.
FIG. 2 is a circuit diagram illustrating one embodiment of the multi-phase correction circuit. In this embodiment, voltage-controlled delay circuits 220 , 221 , 222 , and 223 each accept two of four multi-phase input signals IN 0 , IN 1 , IN 2 , and IN 3 and generate multi-phase output signals OUT 0 , OUT 1 , OUT 2 , and OUT 3 . Signal delay through each delay circuit from IN and /IN to OUT is controlled by a respective one of four delay control bias voltages BIASP 0 , BIASP 1 , BIASP 2 , and BIASP 3 . A multi-phase measurement circuit 210 generates the delay control bias voltages in response to measured phase relationships between the output signals. The combined action of the delay circuits and the multi-phase measurement circuit forms four phase control loops having negative feedback, substantial open-loop gain, a loop frequency response compensated with capacitors C 0 , C 1 , C 2 , and C 3 , and results in substantially lower phase errors in the output signals, compared to those which may exist in the input signals.
FIG. 3 illustrates further details of one embodiment 300 of the multi-phase measurement circuit 210 of FIG. 2 . In this circuit, delay measurement subcircuit 301 , transistors M 2 , M 3 , and M 4 , and inverter 311 work together to draw a current from BIASP 0 which is inversely proportional to the time between a rising edge of OUT 3 and a rising edge of OUT 0 . Similarly, delay measurement subcircuit 302 , transistors M 6 , M 7 , and M 8 , and inverter 312 work together to draw a current from BIASP 0 which is inversely proportional to the time between a rising edge of OUT 0 and a rising edge of OUT 1 , delay measurement subcircuit 303 , transistors M 10 , M 11 , and M 12 , and inverter 313 work together to draw a current from BIASP 0 which is inversely proportional to the time between a rising edge of OUT 1 and a rising edge of OUT 2 , and delay measurement subcircuit 304 , transistors M 14 , M 15 , and M 16 , and inverter 314 work together to draw a current from BIASP 0 which is inversely proportional to the time between a rising edge of OUT 2 and a rising edge of OUT 3 .
To cause an average voltage of BIASP 0 , BIASP 1 , BIASP 2 , and BIASP 3 to be substantially equal to a common mode reference voltage CMREF, transistors M 1 , M 5 , M 9 , and M 13 each source a substantially equal current onto BIASP 0 , BIASP 1 , BIASP 2 , and BIASP 3 , respectively, whereas a magnitude of the equal current is set by a common-mode feedback voltage CMFB. The CMFB voltage is set by combined action of delay measurement subcircuits 301 , 302 , 303 , and 304 .
When the multi-phase measurement circuit 300 is coupled to four delay circuits as illustrated in FIG. 2 , four control loops result, each of which has negative feedback and substantial open-loop gain. Appropriately sized loop filter capacitors C 0 , C 1 , C 2 , and C 3 of the phase correction circuit in FIG. 2 integrate current from four instances of transistor M 31 of FIG. 4 (see below) and transistors M 1 , M 5 , M 9 , and M 13 of FIG. 3 (see below) that are coupled to BIASP 0 , BIASP 1 , BIASP 2 , and BIASP 3 , respectively, and also provide for control loop stability. As shown in FIG. 7 , in one embodiment, each loop filter capacitor comprises a p-type field effect transistor (PFET) M 70 having a gate coupled to the respective BIASPn node [n=0,1,2,3] and a source and drain coupled to a first power supply terminal VDD.
FIG. 4 is a circuit diagram illustrating one embodiment 400 of the delay measurement subcircuit, four instances of which are used in the multi-phase measurement circuit of FIG. 3 at 301 , 302 , 303 , and 304 . Common-gate transistors M 30 and M 31 are configured to operate as switched current sources which conduct when input IN is shorted to a second power supply terminal VSS by transistors in the multi-phase measurement circuit. Transistors M 32 , M 33 , M 34 , M 35 , and M 36 work together to generate a voltage on common-mode feedback control node CMFB such that the average voltage of BIASP 0 , BIASP 1 , BIASP 2 , and BIASP 3 of the phase measurement circuit is substantially equal to the voltage of CMREF. In a preferred embodiment, all transistors of FIG. 4 but M 37 have a width and length substantially larger than the minimum allowed by the technology so as to provide for good matching. By asserting RESET high, transistor M 37 , having a gate coupled to RESET, a source coupled to power supply terminal VSS and a drain coupled to BIASP, provides a means to exit an invalid yet potentially stable control loop state in which the voltage at BIASP is substantially equal to power supply voltage VDD.
FIG. 5 is a circuit diagram illustrating one embodiment 500 of the voltage-controlled delay circuit, four instances of which are placed in FIG. 2 at 220 , 221 , 222 and 223 . The delay circuit operates as a buffer having complementary signal inputs IN and /IN, a single-ended signal output OUT, a controllable insertion delay defined as a delay from a transition on the complementary inputs to a transition on the output, a third input BIASP to control the insertion delay, and a static fourth input CMREF to set the maximum insertion delay. PFET transistors M 41 and M 43 each control a current conducted to PFET switches M 42 and M 44 , respectively, and the sum of these currents is mirrored to /OUT as a pull-down current by n-type field effect transistors (NFETs) M 49 and M 50 . Similarly, PFET transistors M 45 and M 47 each control a current conducted to PFET switches M 46 and M 48 , respectively, and the sum of these currents form a pull-up current on /OUT. Through adjustment of the voltage of BIASP, the pull-up and pull-down currents are adjusted proportionately, thereby also adjusting the rise and fall time of /OUT, and ultimately, the insertion delay. Static input CMREF and PFETS M 43 , M 44 , M 47 , and M 48 are optional, and when used, set a maximum insertion delay and a maximum phase control open loop gain so as to assist in the stability of the phase control loops of the phase correction circuit.
FIG. 6 is a circuit diagram illustrating one embodiment of the bias generators used to generate a voltage at BIASN and a voltage at CMREF in FIG. 2 . Each generator comprises a diode-connected transistor and a resistor. Those skilled in the art will recognize the operation of these circuits, and will further recognize the appropriate choice of resistor value and transistor size. In a preferred embodiment, and to provide for good transistor matching and bandwidth, a resistance value of R 1 and a transistor size of M 1 are chosen so as to provide for a substantial gate bias above threshold of transistors M 30 and M 31 of FIG. 4 . Further, in the preferred embodiment, and to provide for good transistor matching, a resistance value of R 2 and a transistor size of M 2 are chosen so as to provide for a substantial gate bias above threshold of transistors M 1 , M 5 , M 9 , and M 13 of FIG. 3 , and of transistors M 33 , M 34 , M 35 , and M 36 of FIG. 4 . Finally, in the preferred embodiment, a resistance value of R 2 and a transistor size of M 2 are chosen so as to provide for a voltage at CMREF being neither too close to power supply voltage VSS nor too close to power supply voltage VDD, thereby providing for an appropriate control voltage range at BIASPn [n=0,1,2,3] and an appropriate range of insertion delay control for delay circuits 220 , 221 , 222 , and 223 of FIG. 2 .
While circuitry has been described and illustrated with reference to specific embodiments, those skilled in the art will recognize that modification and variations may be made without departing from the principles described above and set forth in the following claims. For example, although in the embodiments described above, four clock signals are processed, the circuitry disclosed above may be scaled to process any even number of fewer or more clock signals. For example, the circuitry may be scaled to process as few as two clock signals or may be scaled to process any even number of clock signals more than four. Accordingly, reference should be made to the following claims as describing the scope of the present invention.
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A multi-phase correction circuit adjusts the phase relationship among multiple clock signals such that their rising edges are equidistant in time from one another.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a YUV-RGB digital conversion circuit which converts a digital luminance signal Y and digital color-difference signals U and V into digital color signals R, G, and B, an image display apparatus using the same, and an electronic apparatus using the image display apparatus.
2. Description of Related Art
As an electronic apparatus using an image display apparatus, for example, a projector will be given as an example.
A liquid-crystal display apparatus of this projector includes a liquid-crystal panel having a liquid crystal sealed between a pair of substrates, a signal processing circuit for performing signal processing, such as gamma correction or polarity inversion, suitable for driving the liquid-crystal panel, on an input RGB signal, and a driving circuit for driving the liquid-crystal panel on the basis of an output of this signal processing circuit.
Here, because of a demand for a liquid-crystal display apparatus with a smaller size, the signal processing circuit must be formed into an IC. Therefore, a digital RGB signal must be provided to the signal processing circuit of the liquid-crystal display apparatus.
The RGB signal provided to this liquid-crystal display apparatus is output from the control board of the main unit of the projector. This control board is provided with a YUV-RGB conversion circuit for converting a luminance signal Y and color-difference signals U and V into RGB signals. Here, in the control board, it is necessary to perform various processing on the RGB signal, and since a memory, such as a VRAM, is used for this processing, digital processing is suitable for the signal processing by the control board. If YUV-RGB conversion by the YUV-RGB conversion circuit is performed digitally, the efficiency is high.
The YUV signal and the RGB signal have the following relationship when each signal is assumed to be of 8 bits (=256 gradations):
R=Y+(V−128)×1.371 (1)
G=Y−(V−128)×0.337−(U−128)×0.698 (2)
B=Y+(U−128)×1.733 (3)
The value of 128, which is subtracted from the color-difference signals U or V, is the middle value of 256 gradations and differs depending upon the total number of gradations. The reason why the middle value of the total gradation value is subtracted from the color-difference signals U and V as described above is that each coefficient shown in equations (1) to (3) must be multiplied by a color-difference signal which becomes positive or negative, assuming to be zero when it has the middle value of the full gradation value.
Here, each of the coefficients multiplied by (V−128) and (U−128) includes a decimal, such as 1.371, 0.337, 0.698, or 1.733.
To realize a product of such decimals by logic, a method is known in which this decimal is expanded into the sum of 2 −n (n is a natural number) and computed. For example, (V−128)×0.5=(V−128)×2 −1 can be determined by shifting the digital value of(V−128) by one bit to the lower order. Similarly, (V−128)×2 −n can be computed easily for each coefficient (−n) by shifting the digital value of (V−128) by n bits to the lower order.
Each of the above-described coefficients is expanded to the sum of 2 −n as described below.
1.371≈2 0 +2 −2 +2 −4 +2 −5 +2 −6 +2 −7 +2 −9 +2 −10 +2 −11 +2 −12 +2 −13 +2 −16 + . . .
0.337≈2 −2 +2 −4 +2 −6 +2 −7 +2 −10 +2 −14 +2 −16 +2 −17 +2 −19 +2 −24 +2 −25 + . . .
0.698≈2 −1 +2 −3 +2 −4 +2 −7 +2 −9 +2 −11 +2 −12 +2 −19 +2 −25 +2 −26 +2 −30 + . . .
1.733≈2 0 +2 −1 +2 −3 +2 −4 +2 −5 +2 −7 +2 −8 +2 −9 +2 −11 +2 −14 +2 −16 +2 −17 + . . .
Regarding the above-described coefficients, only approximated coefficients can be used as long as the number of expansion terms is finite. Here, if this coefficient is expanded to multiple terms, a more accurate value can be used, but the scale of the circuit becomes large. On the other hand, if the number of expansion terms is decreased too much in order to reduce the scale of the circuit, the computation error becomes larger. As described above, the number of expansion terms of the coefficient must be determined by taking both the scale of the circuit and the computation error into consideration.
Next, the scale of the computation circuit is considered after the number of expansion terms is determined. In the case where, for example, the coefficient 1.371 is expanded to seven terms and approximated in equation (1) described above, if each of these terms is added in sequence, six adders are required, and the scale of the circuit increases. Also, if, for example, the data is of 8 bits, the 2 0 term of the highest order requires 8 bits for only the integer part, and the 2 −8 term of the lowest order requires 8 bits for only the decimal part. During the computation process, 16 bits are required for the total of the integer part and the decimal part, and this causes the scale of the circuit to increase.
SUMMARY OF THE INVENTION
Accordingly, an object of the present invention is to provide a YUV-RGB digital conversion circuit capable of reducing the scale of a circuit by decreasing a number of adders for adding the terms such that a coefficient including a decimal to be multiplied by a digital color-difference signal is approximately expanded to a finite number of 2 −n terms in each conversion section for converting a digital YUV signal to a digital RGB signal, and an image display apparatus and an electronic apparatus using the YUV-RGB digital conversion circuit.
Another object of the present invention is to provide a YUV-RGB digital conversion circuit capable of reducing the scale of a circuit by truncating unnecessary bits in a computation process in which each term of 2 −n is added together, and an image display apparatus and an electronic apparatus using the same.
Still another object of the present invention is to provide a YUV-RGB digital conversion circuit capable of outputting an RGB signal such that the display is not inverted even if there is an input value other than a theoretical specified value, and an image display apparatus and an electronic apparatus using the same.
The invention is characterized in that, a YUV-RGB digital conversion circuit for converting a digital luminance signal Y and digital color-difference signals U and V into digital color signals R, G, and B includes a YV-R conversion section for converting a digital luminance signal Y and a digital color-difference signal V into a color signal R,
a YUV-G conversion section for converting a digital luminance signal Y and digital color-difference signals U and V into a color signal G, and
a YU-B conversion section for converting a digital luminance signal Y and a digital color-difference signal U into a color signal B,
each conversion section includes a plurality of bit-shift circuits, provided in each stage, for outputting an input signal×2 −k (k is a natural number such that k≦n) by bit-shifting an input signal by one or a plurality of bit-shifting in order to add the terms such that a coefficient including a decimal multiplied by a digital color-difference signal is approximately expanded to a finite number of terms of 2 −n (n is a natural number); and
a plurality of adders, provided in each stage, for performing addition of the terms of two sets of an input signal×2 −k , whose value of the multiplier k is different, and
the addition of a combination such that the difference of each multiplier k of the two sets of terms to be added becomes the same is shared by one adder.
According to the invention, when, for example, a YV signal is converted into an R signal, for example, V×(2 0 +2 −2 +2 −4 +2 −5 +2 −6 +2 −7 +2 −8 ) is computed, and of this, for example, both 2 −7 +2 −8 and 2 −5 +2 −6 are additions of a first-power difference. Accordingly, initially, after V×2 −1 is obtained by using a bit-shift circuit of the first stage, the addition of V×2 −1 and V×2 0 such that the difference of each multiplier k becomes a first-power difference is performed. If this V(2 0 +2 −1 ) is shifted by the bit-shift circuit by five bits to the lower-order side, 2 −5 +2 −6 is obtained. If it is shifted by another bit-shift circuit by seven bits to the lower-order side, 2 −7 +2 −8 is obtained. As described above, since one adder can be shared for the addition of terms such that the power difference is equal, it is possible to reduce the scale of the circuit.
The invention is characterized in that, the plurality of adders are connected to multiple stages so that the addition of terms corresponding to a smaller term from among a plurality of terms of 2 −n is performed with priority, and when the output of the adder of a previous stage is bit-shifted by a bit-shift circuit, a plurality of additions are performed while dropping the low-order bits such that there is no addend to be added in the addition or subsequent additions by the adder of the next stage.
According to the invention, since digits which are not related to the carry-over to the digit of the data of the final output can be truncated during computation, the number of computation bits is reduced, and the scale of the circuit can be reduced.
The invention is characterized in that, the YUV-G conversion section includes a plurality of adders for adding two sets of terms, the term of a color-difference signal U×2 −i (i is a natural number such that i≦n) and the term of a color-difference signal V×2 −j is a natural number such that j≦n), and the addition of a combination such that the difference (i−j) of each multiplier of two sets of terms is the same is shared by one adder.
In the YUV-RGB conversion section, U and V are used as the color-difference signals, and an adder for adding, for example, the first-power difference term of the digital color-difference signals U, and an adder for adding the first-power difference term of the color-difference signals V cannot be shared in this case because the input data are different from U and V. If it is constructed in accordance with the invention, since the color-difference signal U×2 −i and the color-difference signal V×2 −j can be input commonly to one adder, the number of adders is decreased, and the scale of the circuit is reduced.
The invention is characterized in that,
a carry-over signal, together with an addition output of predetermined bits, is output from the adder of the final stage, and
there is further provided a luminance-limit circuit for inputting an output of the adder of the final stage and for forcibly setting the addition output of predetermined bits to all 1 in accordance with the carry-over signal.
According to the invention, even if a value out of the specified range, exceeding a maximum value of the adder of the final stage, is output, the value can be forcibly corrected to a maximum value by the luminance-limit circuit, and the image quality can be improved.
The invention also provides a YUV-RGB digital conversion circuit characterized in that,
each conversion section includes a computation unit for subtracting a predetermined gradation value from a color-difference signal U or V, a negative-sign signal indicating that the output of the computation unit is negative, together with an addition output of predetermined bits and a carry-over signal, is output from the adder of the final stage, and the luminance-limit circuit forcibly sets the addition output of predetermined bits to all 0 in accordance with the negative-sign signal.
According to the invention, even if the output of the adder of the final stage becomes a negative value as a result of an input that is out of the specified range, since the output is forcibly corrected to a minimum luminance value by the luminance-limit circuit, the image quality can be improved.
The invention is characterized in that, the total number of expansion terms in which a coefficient to be multiplied by a digital color-difference signal is approximately expanded to a plurality of terms of 2 −n is set to a finite number such that the SN ratio of each signal of RGB is 60 dB or more.
According to the invention, even if the number of expansion terms is finite, accuracy such that the SN ratio is 60 dB or more can be obtained, and an image having an image quality of a predetermined level or greater can be reproduced while YUV-RGB conversion is being performed digitally.
The invention also provides an image display apparatus and an electronic apparatus including a YUV-RGB digital conversion circuit in accordance with the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram showing a circuit section required for a liquid-crystal display of an electronic apparatus according to an embodiment of the present invention.
FIG. 2 is a block diagram of a digital chroma circuit and a YUV-RGB conversion circuit of the circuit shown in FIG. 1 .
FIG. 3 is a schematic view illustrating a bit expansion of each 8-bit term of V×2 −n used in a YV-R conversion.
FIG. 4 is a block diagram showing an example of the YV-R conversion circuit.
FIG. 5 is a schematic view illustrating output data of each circuit of FIG. 4 .
FIG. 6 is a circuit diagram showing an example of a clipping circuit shown in FIG. 3 .
FIGS. 7 (A) to 7 (C) are schematic views which show schematically the technique of YV-R conversion, YU-B conversion, and YUV-G conversion.
FIG. 8 is a block diagram of the YV-R conversion circuit designed d in accordance with the technique shown in FIG. 7 (A).
FIG. 9 is a schematic view illustrating output data of each circuit of FIG. 8 .
FIG. 10 is a block diagram of the YU-B conversion circuit designed in accordance with the technique shown in FIG. 7 (B).
FIG. 11 is a block diagram of the YUV-G conversion circuit designed in accordance with the technique shown in FIG. 7 (C).
FIG. 12 is a block diagram of an electronic apparatus.
FIG. 13 is a schematic view of a projector which is an example of an electronic apparatus.
FIG. 14 is an exterior view of a personal computer which is an example of an electronic apparatus.
FIG. 15 is an exploded perspective view of a pager which is an example of an electronic apparatus.
FIG. 16 is a schematic perspective view showing an example of a liquid-crystal display apparatus provided with an external circuit.
FIG. 17 is a timing chart showing an operation separated by a YUV signal.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
With reference to the embodiments of the present invention shown in the figures, a description will be given below in more detail.
(Construction of the entire apparatus)
FIG. 1 shows a block diagram of the elements involved in a liquid-crystal display of an electronic apparatus, such as a projector, according to an embodiment of the present invention. In FIG. 1, a control board 10 of the electronic apparatus includes an analog-digital converter (ADC) 12 to which is input a composite video signal and which converts it from analog to digital form. A digital chroma circuit 14 is provided in a stage behind the ADC 12 . This digital chroma circuit 14 separates the digitized video signal into a luminance signal Y and a U/V signal which is a time-division composite signal. The output of the digital chroma circuit 14 is shown in FIG. 17 . The numeric value shown in FIG. 17 indicates a pixel number, and the luminance signal Y has 8-bits of information per one pixel. On the other hand, for the composite signal U/V of the color-difference signal, the same signal is commonly used for the U signal and the V signal for two adjacent pixels, and each of U and V signals has 8-bits of information per two pixels.
The YUV-RGB conversion circuit 16 , to which this signal Y and the U/V signal are input, converts a YUV signal into an RGB signal. As shown in FIG. 2, the YUV-RGB conversion circuit 16 includes a delay circuit 16 A which delays the luminance signal Y, and a U/V separation circuit 16 B which separates the U/V signal, which is a time-division composite signal, into parallel U and V signals. The Y signal output from the delay circuit 16 A, and the U and V signals output from the U/V separation circuit 16 B are output in parallel, as shown in FIG. 17 .
Further, as shown in FIG. 2, this YUV-RGB conversion circuit 16 includes a YV-R conversion circuit 16 C, a YUV-G conversion circuit 16 D, and a YU-B conversion circuit 16 E, the details of which will be described later.
This control board 10 is provided with an ADC 18 to which is input an analog PC (personal computer) signal, and this ADC 18 converts an analog RGB signal into a digital signal and outputs it.
A graphic controller 20 to which is input a digital RGB signal from the YUV-RGB conversion circuit 16 or the ADC 18 performs various digital processing for graphic display. For this purpose, the graphic controller 20 has a VRAM and stores a digital RGB signal in the VRAM, and performs various processing. For example, since the video signal which is input via the ADC 12 has been subjected to gamma correction for CRT, a gamma correction process for returning this to the original signal is performed by the graphic controller 20 . Further, a process for interlace scanning is performed by the graphic controller 20 .
The output from the graphic controller 20 is provided to an LCD controller 32 for driving and controlling the LCD 30 shown in FIG. 1 . Also in this LCD controller 32 , digital processing is performed on the RGB signal. For example, in this LCD controller 32 , the following are performed: a gamma correction process according to the applied voltage—transmittance characteristics of the LCD 30 , a signal inversion process for driving of polarity inversion, a signal process for decreasing the driving frequency, and a signal process for reducing the effect of amplifier variations on the viewed image.
For the LCD 30 , various types of liquid-crystal panels can be used, for example, a simple matrix liquid-crystal display panel which does not use switching elements, an active matrix liquid-crystal display panel which uses three-terminal switching elements typified by a TFT or two-terminal switching elements typified by an HIM, or a ferroelectric liquid-crystal display panel.
Next, the YUV-RGB digital conversion circuit 16 , which is a feature element of the present invention, will be described with reference to FIG. 3 and subsequent figures.
(The number of expansion terms of 2 −n of a coefficient to be multiplied by a color-difference signal)
The YUV-RGB digital conversion circuit 16 respectively computes each of the RGB color signal on the basis of equations (1) to (3) described above, and outputs it. The number of expansion terms of 2 −n of a coefficient to be multiplied with a color-difference signal will be examined first.
Knowing the extent n of 2 −n , the terms of which are obtained by expanding each coefficient shown in equations (1) to (3), makes it possible to compute the SN ratio of each color RGB when a computation circuit is designed in accordance with the approximated coefficient. The relationship between the number of expansion terms and the SN ratio is shown in Table 1 below.
TABLE 1
n ≦
n ≦
n ≦
n ≦
n ≦
n ≦
n ≦
n ≦
7
8
9
10
11
12
13
14
S/N of R
57.6
87.5
87.5
87.5
87.5
87.5
87.5
87.5
S/N of G
60.7
60.7
67.8
72.5
81.3
91.0
91.0
100.0
S/N of B
64.9
64.9
80.0
80.0
85.4
85.4
85.4
85.4
Here, as is clear from Table 1 described above, the smaller the number of expansion terms, the less the computation accuracy becomes. Since noise increases because of a decrease in this computation accuracy, the SN ratio decreases. The reason why the SN ratio does not vary even though the number n is varied in Table 1 described above, is that no term is present which falls within the upper limit of n and which makes the error smaller.
According to the investigations of the inventors of the present invention, it can be seen that when the SN ratio of the computation circuit is 60 [dB] or more, there is no problem with the image quality on the liquid-crystal display. When it is considered that the SN ratio of a laser disk at present is 40 [dB], the validity of this fact is supported. Here, in this embodiment, when considering that this YUV-RGB conversion circuit 16 is formed of an IC and this YUV-RGB conversion IC will be used for a long period of time in the future, the lower limit of the SN ratio of the circuit is set to 70 [dB]. The expansion of each coefficient in this case is as in equations (4) to (7) described below.
1.371≈2 0 +2 −2 +2 −4 +2 −5 +2 −6 +2 −7 +2 −8 (4)
0.337≈2 −2 +2 −4 +2 −6 +2 −7 +2 −10 (5)
0.698≈2 −1 +2 −3 +2 −4 +2 −7 +2 −9 (6)
1.733≈2 0 +2 −1 +2 −2 +2 −3 +2 −4 +2 −5 +2 −7 +2 −8 +2 −9 (7)
The number of expansion terms in the case where the low limit of the SN ratio of the circuit is changed can be determined by taking Table 1 described above into consideration.
(Construction principle of the YUV-RGB conversion circuit)
Next, the technique of the construction of the conversion circuit of the present invention will be described by using a circuit for converting a luminance signal Y and a color-difference signal V into a R signal in accordance with the computation equation (1) and the expansion equation (4) described above as an example.
FIG. 3 shows a bit expansion of each term of the result in which (V−128) of 8 bits to be multiplied by 2 −n used for the expansion equation (4) is multiplied.
Here, the points that the inventors of the present invention have taken note of are the final output of the result of equation (4) multiplied by the (V−128) of equation (1) has 8 bits of the digits 2 0 to 2 7 in FIG. 3, and for the digits other than those, only the digits which are carried over to 2 0 to 2 −7 in the middle of the addition of equation (4) may be considered.
Therefore, even if the terms that do not influence any of the digits 2 0 to 2 7 are ignored during computation, the computation accuracy can be secured, and by decreasing the number of bits in the middle of the computation, the scale of the circuit can be reduced.
Here, if the seven terms shown in FIG. 3 are added in sequence starting from the upper-order term with a large value, the digit equal to or less than 2 −1 may be carried over to the 2 0 digit or more in the final computation. Under this condition, it is not possible to omit the low-order side bits in the middle of computation, and the scale of circuit cannot be reduced.
Therefore, the inventors of the present invention have decided to add starting from the low-order term with a small value of the seven terms shown in FIG. 3 with priority given thereto.
A case is considered in which, for example, the 2 −8 term plus the 2 −7 term, which are two terms of the low-order side of FIG. 3, are added first. It can be seen that the 2 −8 digit, which is the lowest-order bit of the 2 −8 term, has no addend to be added from now on, and it is a digit which is not related to carry-over and which is not required for computation. Further, it can be seen that after the computation of the 2 −8 term plus the 2 −7 term is completed, the 2 −7 digit of the computation result also has no addend to be added from now on, and it is a digit which is not related to carry-over and which is not required for computation.
As described above, by adding starting from the low-order term with a small value of the seven terms shown in FIG. 3 with priority, it is possible to truncate the digits of the low-order side which are not used for the computation, and a fewer number of bits of the adder is required, making it possible to reduce the scale of the circuit.
Next, an adder for adding the seven terms shown in FIG. 3 is considered. If it is assumed to add starting from the low-order term with a small value in sequence of the seven terms shown in FIG. 3, six adders are required.
Here, as the characteristics of a digital value, the computation of 8 bits×2 −k can be realized by a bit-shift circuit which shifts the 8-bit data to the low-order side by k bits, as stated above.
The inventors of the present invention have taken note of the fact that a plurality of sets of combinations of the addition is present such that the difference in the multiplier (−n) of 2 −n is the same within the seven terms shown in FIG. 3 . For example, as a combination of addition such that the difference in the multiplier (−n) becomes a first-power difference, there are two sets, namely a combination of (the 2 −8 term and the 2 −7 term), and a combination of (the 2 −6 term and the 2 −5 term).
At this time, if the input of the adder is assumed to be two inputs of (V−128) before and after passing through a 1-bit-shift circuit, this adder can output (V−128)×(2 0 +2 −1 ). If the output of this adder is shifted by seven bits to the low-order side, the computation result of (the 2 −8 term plus the 2 −7 term) is obtained, and if the output of this adder is shifted by five bits to the low-order side, (the 2 −6 term plus the 2 −5 term) is obtained.
As described above, if the difference in the multiplier (−n) of 2 −n is the same, this adder can be shared regardless of the value of n. In the embodiment below, the number of adders is reduced by this technique.
(Example of the construction of the YV-R conversion circuit)
The YUV-RGB conversion circuit produced in accordance with the above-described construction principle includes three conversion circuits as in the equations (1) to (3) described above. An example thereof will be described by using the YV-R conversion circuit shown in FIG. 4 as an example.
An input to the YV-R conversion circuit shown in FIG. 4 is an 8-bit luminance signal Y and a color-difference signal V. The color-difference signal V is input to a (V−128) computation unit 40 where the computation of V−128 is performed. This computation can be performed only by inverting the highest-order bit of the 8-bit color-difference signal V with respect to a digital value. This value is indicated by A as shown in FIG. 5 . This 8-bit data A becomes a positive or negative value of −128 to +127, and the data itself can be represented by 8 bits. Here, since the maximum value of the positive value of the data A is 127, if the data A is positive, the bit of 2 7 is always “0”. When the data A is negative, for example, when A=−1, the data is represented in such a way that each of the bits of 2 0 to 2 7 becomes “1”, and when A=−2, only the 2 0 bit becomes “0”. Therefore, when the data A is negative, the bit of 2 7 is always “1”. As described above, in this embodiment, the value of the highest-order bit of the data A represents a code bit, as shown in FIG. 5 . By using this fact, a gradation-limit process based on the code is performed by a clipping circuit 64 to be described later. The information of the data A is not limited to that described above, and the information of the data A may be set in such a way that, when, for example, A=−128, each of the bits of 2 0 to 2 7 is set to “0”, when A =+127, each of the bits of 2 0 to 2 7 is set to “1”, when the data A is positive, the 2 7 bit is always “1”, and when the data A is negative, the 2 7 bit is always “0”.
In the circuit shown in FIG. 4, the conversion from YV to R is performed in such a manner as to be divided into the first to fourth terms as in equation (8) described below. R = Y + ( V - 128 ) × ( 2 0 + 2 - 2 + 2 - 4 + 2 - 5 + 2 - 6 + 2 - 7 + 2 - 8 ) = first term + second term + third term + fourth term
where
the first term=[(V−128)×(2 −7 +2 −8 )]
the second term=[(V−128)×(2 −5 +2 −6 )]
the third term=[(V−128)×(2 −2 +2 −4 )]
the fourth term=[Y+(V−128)×2 0 ] (8)
Then, in FIG. 4, in order to perform the computation of first term plus second term=[(V−128)×(2 −7 +2 −8 )]+[(V−128)×(2 −5 +2 −6 )], a 1-bit shift circuit 42 is provided in the first stage, a first-power difference adder 44 is provided in the second stage, a 2-bit shift circuit 46 is provided in the third stage, an adder 48 is provided in the fourth stage, and a 5-bit shift circuit 50 is provided in the fifth stage.
For the above-described first and second terms, the difference in the multiplier (−n) of 2 −n is a first-power difference, and the first-power difference adder 44 is shared to compute these two sets. This computation of the first term plus the second term will be described with reference to FIGS. 4 and 5. By causing the above-described data A to pass through the 1-bit shift circuit 42 , as shown in FIG. 5, a data B such that the data A is shifted by one bit to the low-order side is obtained. During this 1-bit shift, the value of the code bit of the highest-order bit of the data A is added to the bit of 2 7 of the data B, and code extension is performed. Therefore, the data B becomes 9 bits (see FIG. 5 ). Also during the subsequent k-bit shift, code extension is performed such that the sign bit of the highest-order bit before being bit shifted is added to the k digits of the upper-order side of the data after being bit shifted.
Next, as an output C of the first-power difference adder 44 which computes A+B, (V−128)×(2 0 +2 −1 ) is obtained. All of the addition computations, including this computation of A+B, are performed by adding the bit values of the same digit (including the digits of the carry-over bit and the code bit) and by taking the carry-over into consideration. When there is no data in the same digit (the 2 −1 digit in the case of A+B), 0 is added.
This data C becomes 8-bit data such that the lowest-order digit of the data part is 2 −1 and the highest-order digit of the data part is 2 6 , as shown in FIG. 5 . Since a carry-over occurs during this addition, the 2 7 digit becomes a carry-over bit, and the 2 8 digit of the data C becomes a code bit, becoming 10 bits in total.
As a result of this data C being shifted by two bits to the low-order side by the 2-bit shift circuit 46 , a data D=(V−128)×(2 −2 +2 −3 ) is obtained. As shown in FIG. 5, this data D is such that, in addition to 8-bit data such that the lowest-order digit of the data part is 2 −3 and the highest-order digit of the data part is 2 4 , the 2 5 digit becomes a carry-over bit, and the three bits 2 6 to 2 8 are code-extended to become a code bit, becoming 12 bits in total.
Meanwhile, this data D is added to the data C by the adder 48 . For this and subsequent addition, the data of the digits 2 −3 and 2 −2 of the two low-order digits of the data D has no addend to be added. Therefore, the data of the two low-order digits of the data D can be truncated as shown in FIG. 5 .
As a result of the above, for the C+D=E=(V−128)×(2 0 +2 −1 +2 −2 +2 −3 ), which is the computation result of the adder 48 , as shown in FIG. 5, the data part becomes 8 bits in the same manner as the data C. In this case, the two digits 2 7 and 2 8 are required as carry-over bits, and the 2 9 digit becomes a code bit.
Next, a data E is shifted by the 5-bit shift circuit 48 by five bits to the low-order side, and a data F is obtained. This data F is such that, in addition to the 8-bit data such that the lowest-order digit of the data part is 2 −6 and the highest-order digit of the data part is 2 −1 , the two digits of 2 2 and 2 3 become carry-over bits, and the five digits of 2 4 to 2 9 are code-extended to become code bits, becoming 16 bits in total. Meanwhile, this data F is to be added to another data by an adder 62 to be described later. For this and subsequent additions, the data of the digits 2 −6 and 2 −5 of the two low-order digits of the data F have no addend to be added. Therefore, the data of the two low-order digits of the data F can be truncated as shown in FIG. 5 . As a result, the data F becomes 14 bits in total.
Next, the computation of the above-described third and fourth terms of equation (8) is described below. As circuits for performing the computation of the third term, as in FIG. 4, a 2-bit shift circuit 52 of the first stage, a second-power difference adder 54 of the second stage, and a 2-bit shift circuit 56 of the third stage are provided.
Further, a 0-power difference adder 58 is provided for the computation of the fourth stage. Further, an adder 60 is provided to perform the addition of the third term and the fourth term.
The computation of the fourth term will be described first. The output A of the (V−128) computation unit 40 and the luminance signal Y are input to the 0-power difference adder 58 , and a data G=Y+(V−128)×2 0 shown in FIG. 5 is obtained as the output thereof. This data G is such that, in addition to the 8-bit data such that the lowest-order digit of the data part is 2 0 , and the highest-order digit of the data part is 2 7 , the 2 8 digit becomes a carry-over bit, and the 2 9 digit becomes a code bit, becoming 10 bits in total.
Next, the computation of the third term will be described. Initially, the data A from the (V−128) computation unit 40 is shifted by the 2-bit shift circuit 52 by two bits to the low-order side, and a data H shown in FIG. 5 is obtained. This data H is such that, in addition to 7-bit data such that the lowest-order digit of the data part is 2 −2 and the highest-order digit of the data part is 2 4 , the digits 2 5 to 2 7 are code-extended to become code bits, becoming 10 bits in total. The second-power difference adder 54 adds this data H and the data A together and obtains a data I shown in FIG. 5 as A+H (V−128)×(2 0 +2 −2 ). This data I has 9-bit data such that the lowest-order digit of the data is 2 −2 and the highest-order digit of the data is 2 6 , the 2 7 digit becomes a carry-over bit, and the 2 8 digit becomes a code bit, becoming 11 bits in total. This data I is further shifted by the 2-bit shift circuit 56 by two bits to the low-order side and becomes a data J. Therefore, this data J is such that, in addition to the 9-bit data such that the lowest-order digit of the data part is 2 −4 and the highest-order digit of the data part is 2 4 , the 2 5 digit becomes a carry-over bit, digits 2 6 to 2 8 are code-extended to become code bits, becoming 13 bits in total.
As the output of the adder 60 which performs the computation of the third term plus the fourth term, a data K is obtained as shown in FIG. 5 . This data K is such that, in addition to the 12-bit data such that the lowest-order digit of the data is 2 −4 and the highest-order digit of the data is 2 7 , the digit of 2 8 becomes a carry-over bit, and the digit of 2 9 becomes a code bit, becoming 14 bits in total. In the data K, since a carry-over of the 2 9 bit or more is not required as data, it is not necessary to provide carry-over data in the 2 9 digit.
Finally, as an output of the adder 62 of the final stage for performing the computation of the first term plus the second term plus the third term plus the fourth term, a data L is obtained as shown in FIG. 5 . Since the data part of this final output may be 8 bits, the four low-order bits are truncated as in FIG. 5, in addition to the data part of 2 0 to 2 7 , the 2 8 digit becomes a carry-over bit, and the 2 9 digit becomes a core bit.
When there is an input YV within the specified range, the minimum value of the 8-bit output data L is 0 (all the 8 bits are 0) and the maximum value is 255 (all the 8 bits are 1). However, when there is an input out of the specified range, there is a case in which, for example, the value of the data L is 256 (all the 8 bits are 0), and the data L has a carry-over bit in preparation for a malfunction in this case. In another example, there is a case in which, for example, the output data L=−1 (all of the 8-bit data are 1), and the data L has a code bit in preparation for a malfunction in this case.
(Clipping circuit)
As shown in FIG. 4, the clipping circuit 64 functioning as a luminance limit circuit is provided in a stage behind the adder 62 of the final stage. This clipping circuit 64 has two functions. One of them is to resolve a malfunction when a code bit indicates negative as described above. In this case, since the data L may be assumed to be “0”, all the 8 bits of each digit of 2 0 to 2 7 of the data L are forcibly set to “0”.
The other function of the clipping circuit 64 is to resolve a malfunction when there is a carry-over in the data L. At this time, since the data L may be assumed to be “255”, all the 8 bits of each digit of 2 0 to 2 7 of the data L are forcibly set to “1”.
An example of this clipping circuit 62 is shown in FIG. 6 . As shown in the figure, when the code bit is “1”, since “0” is input to the eight AND gates via an inverter, the output of each digit of the 8 bits is forcibly set to “0”. Here, when the code bit is “0”, since “1” is always input to one of the input ends of the AND gates, as long as the carry-over bit is “0”, the 8 bits of the output data L are output via an OR gate and the AND gates unchanged. On the other hand, when the carry-over bit becomes “1”, since “1”is input to the other input ends of all the AND gates via the OR circuit, the output of each digit of the 8 bits is forcibly set to “1”.
(Another example of the construction of the YV-R conversion section)
FIG. 7 (A) shows schematically a modification of the YV-R conversion circuit. Unlike the embodiment of FIG. 4, FIG. 7 (A) shows an example in which a second-power difference adder 72 is shared for the addition of three types of second-power differences, [(V−128)×(2 −2 +2 −4 )], [(V−128)×(2 −5 +2 −7 )], and [(V−128)×(2 −6 +2 −8 )].
The details of the YV-R conversion circuit of FIG. 7 (A) are shown in FIG. 8, and signals A to J in FIG. 8 are shown in FIG. 9 . The code bit and the carry-over bit shown in FIG. 9 are the same as those of the embodiment of FIGS. 4 and 5. In FIGS. 8 and 9, the output data A from the (V−128) computation unit 40 is the same as that of FIG. 4, and the output data B of a 2-bit shift circuit 70 becomes
B=(V−128)×2 −2 .
The output data C from the second-power difference adder 72 in a subsequent stage becomes
C=(V−128)×(2 0 +2 −2 ).
The output data D from a 1-bit shift circuit 76 in a stage behind that becomes
D=(V−128)×(2 −1 +2 −3 ).
The output data E from an adder 78 in a stage behind that becomes
E=(V−128)×(2 0 +2 −1 +2 −2 +2 −3 ).
The output data F from a 3-bit shift circuit 80 in a stage behind that becomes
F=(V−128)×(2 −3 +2 −4 +2 −5 +2 −6 )
Here, one of the data C input to an adder 84 must be delayed by the amount of time that the other data F is obtained after passing through the adder 78 , therefore, it is delayed by a delay circuit 82 , and synchronization is obtained. The output data G of the adder 84 becomes
G=(V−128)×(2 0 +2 −2 +2 −3 +2 −4 +2 −5 +2 −6 )
The output data H from a 2-bit shift circuit 86 behind that becomes
H=(V-128)×(2 −2 +2 −4 +2 −5 +2 −6 +2 −7 +2 −8 ).
On the other hand, the output data I from a 0-power difference adder 88 becomes
I=Y+(V−128),
this is delayed by a delay circuit 90 , synchronization with the output data H from the 2-bit shift circuit 86 is obtained, and it is input to an adder 92 of the final stage. Then, as output data J from this adder 92 of the final stage,
J=Y+(V−128)×(2 0 +2 −2 +2 −4 +2 −5 +2 −6 +2 −7 +2 −8 )
is obtained, and the same result as that of the embodiment of FIGS. 4 and 5 is obtained. This output data J is supplied to the clipping circuit 64 shown in FIG. 6 .
(An example of the construction of the YU-B conversion circuit)
FIG. 7 (B) schematically shows the YU-B conversion circuit. The details of the YU-B conversion circuit of FIG. 7 (B) are shown in FIG. 10 . Each data shown in FIG. 10 also has a sign bit and a carry-over bit in the same manner as in the above-described embodiment, but the details thereof have been omitted. In the embodiment of FIG. 10, a first-power difference adder 102 is shared for the computation of three types of first-power difference.
In FIG. 10, the output data A from a (U- 128 ) computation unit 41 is the same as that of FIGS. 4 and 8. The output data B of a 1-bit shift circuit 100 becomes
B=(U−128)×2 −1 .
The output data C from the first-power difference adder 102 in a stage behind that becomes
C=(U−128)×(2 0 +2 −1 ).
The output data D from the 3-bit shift circuit 104 in a stage behind that becomes
D=(U−128)×(2 −3 +2 −4 ).
The output data E from an adder 106 in a stage behind that becomes
E=(U−128)×(2 0 +2 −1 +2 −3 +2 −4 ).
On the other hand, the output data A from the (U−128) computation unit 41 is also input to a 2-bit shift circuit 108 , and the output data F becomes
F=(U−128)×2 −2 .
The output data G from a second-power difference adder 110 in a stage behind that becomes
G=(U−128)×(2 0 +2 −2 ).
The data D and G are input to an adder 112 after that, and the output data H becomes
H=(U−128)×(2 0 +2 −2 +2 −3 +2 −4 ).
As the output data I of a 5-bit shift circuit 114 in a stage after that,
I=(U−128)×(2 −5 +2 −7 +2 −8 +2 −9 )
is obtained. The output data J of an adder 116 to which the data H and I are input becomes
J=(U−128)×(2 0 +2 −1 +2 −3 +2 −4 +2 −5 +2 −7 +2 −8 +2 −9 ).
Further, the luminance signal Y is delayed by a delay circuit 118 , obtaining synchronization with the data J, it is input to an adder 120 of the final stage, and as the output data K,
K=Y+(U−128)×(2 0 +2 −1 +2 −3 +2 −4 +2 −5 +2 −7 +2 −8 +2 −9 )
is obtained. The same result as that of equation (7) is obtained. This output data K is supplied to the clipping circuit 64 shown in FIG. 6 .
(Example of the construction of the YUV-G conversion circuit)
FIG. 7 (C) schematically shows an example of the YUV-G conversion circuit.
In the example of FIG. 7 (C), a first-power difference adder is shared for the addition of three types of first-power difference terms. Here, the feature which differs from the above-described embodiment is that when adding together a color-difference signal U×2 −i and a color-difference signal U×2 −j , an adder is shared for the combination such that the difference (i−j) of each multiplier becomes the same (a first-power difference in this example). The reason for this is as follows: in this embodiment, an adder for adding the term of a first-power difference of the color-difference signals U, and an adder for adding the term of a first-power difference of the color-difference signals V cannot be shared because the input data are different from U and V.
The details of this circuit of FIG. 7 (C) are shown in FIG. 11 . In FIG. 11, the output data A of the (V−128) computation unit 40 is input to a 2-bit shift circuit 204 and a 0-power difference adder 212 , and the output data B of the (U−128) computation unit 41 is input to a 1-bit shift circuit 202 and the 0-power difference adder 212 .
The computation of the route of a first-power difference adder 210 will be described first. The output data C from the 1-bit shift circuit 202 to which the data B is input becomes
C=(U−128)×2 −1 .
The output data D of the 2-bit shift circuit 204 to which the data A is input becomes
D=(V−128)×2 −2 .
The output data E from the first-power difference adder 210 to which the data C and D are input becomes
E=(U−128)×2 −1 +(V−128)×2 −2 .
This data E is shifted by a 2-bit shift circuit 216 by two bits to the low-order side, and as the output data F,
F=(U−128)×2 3 +(V−128)× 2 −4
is obtained. Further, as the output data G from an adder 224 to which the data E and F are input,
G=(U−128)×(2 −1 +2 −3 )+(V−128)×(2 −2 +2 −4 )
is obtained.
Next, the computation route of the 0-power difference adder 212 is described. As output data H from the 0-power difference adder 212 to which data A and B are input,
H=(U−128)+(V−128)
is obtained. This data G is shifted by a 7-bit shift circuit 220 by seven bits to the low-order side, and as the output data I,
I=(U−128)×2 −7 +(V−128)×2 −7
is obtained. On the other hand, the output data E from the first-power difference adder 210 is also input to a 8-bit shift circuit 218 , and as the output data J,
J=(U−128)×2 −9 +(V−128)×2 −10
is obtained.
As output data K from an adder 226 to which these data I and J are input,
K=(U−128)×(2 −7 +2 −9 )+(V−128)×(2 −7 +2 −10 )
is obtained.
Next, the computation route of a second-power difference adder 214 is described. As output data L from the second-power difference adder 214 to which data B and D are input,
L=(U−128)+(V−128)×2 −2
is obtained. This data L is shifted by a 4-bit shift circuit 222 by four bits to the low-order side, and as the output data M,
M=(U−128)×2 −4 +(V−128)×2 −6
is obtained. This data M is delayed by a delay circuit 228 , obtaining synchronization with the data K, and the data is input to an adder 230 . The output data N from the adder 230 becomes
N=(U−128)×(2 −4 +2 −7 +2 −9 )+(V−128)×(2 −6 +2 −7 +2 −10 )
Further, the data G from the adder 224 is delayed by a delay circuit 232 and input to an adder 234 together with the data N from the adder 230 . The output data O from this adder 234 becomes
O=(U−128)×(2 −1 +2 −3 +2 −4 +2 −7+2 −9 )+(V−128)×(2 −2 +2 −4 +2 −6 +2 −7 +2 −10).
This data O is input to a sign inversion circuit 238 where all of the 10 bits formed of the 8-bit data part, the carry-over bit, and the sign bit are inverted. Further, “1” is added to the lowest-order bit, and data P on which a data inversion process has been performed is output.
Finally, the luminance signal Y is delayed by a delay circuit 236 so as to be synchronized with the data P, and this signal Y and the data P are input to the adder 24 . Since the data P has been inverted in advance, data P is subtracted from the signal Y, and as the output data Q from this adder 24 ,
Q=Y-(U−128)×(2 −1 +2 −3 +2 −4 +2 −7 +2 −9 )−(V−128)×(2 −2 +2 −4 +2 −6 +2 −7 +2 −10 )
is obtained. The feature that this data Q is also supplied to the clipping circuit 64 is the same as in each of the above-described embodiments.
The present invention is not limited to the above-described embodiments, and various modifications are possible within the spirit and scope of the present invention.
For example, although omitted in each of the above-described embodiments, preferably, a circuit formed of, for example, a D-type flip-flop, for obtaining synchronization of two inputs, is inserted into the stage before the adder. In this case, as in the above-described embodiment, by truncating unused low-order bits, the number of D-type flip-flops required for each bit can be decreased, and this contributes to a circuit having a reduced scale.
The electronic apparatus constructed by using the liquid-crystal display apparatus of the above-described embodiment comprises a display information output source 1000 , a display information processing circuit 1002 , a display driving circuit 1004 , a display panel 1006 , such as a liquid-crystal panel, a clock generation circuit 1008 , and a power-supply circuit 1010 , which are shown in FIG. 12 . The display information output source 1000 , which comprises a memory, such as a ROM and/or a RAM, and a tuning circuit for tuning to a television signal and outputting it, outputs display information, such as a video signal, in accordance with the clock from the clock generation circuit 1008 . This display information output source 1000 includes a YUV-RGB conversion circuit of each of the above-described embodiments. The display information processing circuit 1002 processes display information in accordance with the clock from the clock generation circuit 1008 and outputs it. This display information processing circuit 1002 may include, for example, an amplification/polarity inversion circuit, a gamma correction circuit, and a clamping circuit. The display driving circuit 1004 , which comprises a scanning-side driving circuit and a data-side driving circuit, causes the liquid-crystal panel 1006 to be driven and displayed. The power-supply circuit 1010 supplies power to each of the above-described circuits.
Examples of the electronic apparatus having such a construction, in which it is assumed that YUV data is handled, include a liquid-crystal projector shown in FIG. 13, a personal computer (PC) and an engineering workstation (EWS), shown in FIG. 14, which can handle multimedia, a pager shown in FIG. 15, or a portable telephone, a word processor, a television, a view-finder-type or monitor-direct-view-type video tape recorder, an electronic notebook, an electronic desktop calculator, a car navigation apparatus, a POS terminal, and an apparatus with a touch panel.
The liquid-crystal projector shown in FIG. 13 is a projection-type projector using a transmission-type liquid-crystal panel as a light valve, which uses an optical system, for example, of a three-plate prism method. In FIG. 13, in the projector 1100 , projection light emitted from a lamp unit 1102 as a white light source is separated into the three primary colors of R, G, and B by a plurality of mirrors 1106 and two dichroic mirrors 1108 inside a light guide 1104 , and are guided to three liquid-crystal panels 1110 R, 1110 G, and 1110 B which display an image of each color. Then, the light which is modulated by the respective liquid-crystal panels 1110 R, 1110 G, and 1110 B is made to enter a dichroic prism 1112 from three directions. In the dichroic prism 1112 , since the light of red R and blue B is bent by 90°, and light of green G travels straight, the images of each color are synthesized, and a color image is projected onto a screen or the like through a projection lens 1114 .
The personal computer 1200 shown in FIG. 14 includes a main section 1204 having a keyboard 1202 , and a liquid-crystal display screen 1206 .
The pager shown in FIG. 15 includes, inside a metallic frame 1302 , a light guide 1306 with a liquid-crystal display panel 1304 and a back light 1306 a , a circuit substrate 1308 , first and second shield plates 1310 and 1312 , two elastic conductors 1314 and 1316 , and a film carrier tape 1318 . The two elastic conductors 1314 and 1316 , and the film carrier tape 1318 are used to connect the liquid-crystal display panel 1304 to the circuit substrate 1308 .
Here, the liquid-crystal display panel 1304 has a liquid crystal sealed between two transparent substrates 1304 a and 1304 b , and as a result, at least a dot-matrix-type liquid-crystal display panel is constructed. On one transparent substrate, the display driving circuit 1004 shown in FIG. 12, or in addition to this, a display information processing circuit 1002 can be formed. The circuit which is not mounted on the liquid-crystal display panel 1304 is made as an external circuit of the liquid-crystal display panel, and in the case of FIG. 15, it can be mounted onto the circuit substrate 1308 .
Since FIG. 15 shows the construction of the pager, in addition to the liquid-crystal display panel 1304 , the circuit substrate 1308 is required. When the liquid-crystal display apparatus is used as a component for the electronic apparatus and when a display driving circuit or the like is mounted onto the transparent substrate, the minimum unit of the liquid-crystal display apparatus is the liquid-crystal display panel 1304 . Alternatively, the liquid-crystal display panel 1304 fixed to a metal frame 1302 as a housing may be used as a liquid-crystal display apparatus which is a component for the electronic apparatus. Further, in the case of a backlight type, the liquid-crystal display panel 1304 , and the light guide 1306 with a backlight 1306 a may be incorporated within the metallic frame 1302 , thus a liquid-crystal display apparatus can be constructed. In place of these, as shown in FIG. 16, a TCP (Tape Carrier Package) 1320 such that an IC chip 1324 is mounted onto a polymide tape 1322 formed with a metallic conductive film is connected to one of the two transparent substrates 1304 a and 1304 b which form the liquid-crystal display panel 1304 , making it possible to be used as a liquid-crystal display apparatus which is a component for the electronic apparatus.
The present invention is not limited to the above-described embodiments, and various modifications are possible within the spirit and scope of the present invention. For example, the present invention is not limited to an apparatus for driving the above-described various liquid-crystal panels, and can be applied to other image display apparatuses, such as an electroluminescence, or a plasma display apparatus.
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A YUV-RGB digital conversion circuit which can be reduced in circuit scale. The YV-R conversion circuit in the YUV-RGB conversion circuit which converts digital luminance signal (Y) and digital color difference signals (U and V) into digital chrominance signals (R, G, and B) computes the R signal by approximately developing the coefficient 1.371 in the expression of R=Y+(V−128)×1.371 in terms of a finite number, 2 −n (n: a natural number). The YV-R conversion circuit is provided with a plurality of bit shift circuits ( 42, 46, 50, 52 and 56 ) which output the products of input signals and 2 −k (k: a natural number of ≦n) by bit-shifting the input signals. A plurality of adders ( 44, 48, 54, 58, 60 , and 62 ) which perform addition on terms of two sets of products of the input signals and 2 −k (k: a multiplier), with the (k) having different values. Of the adders, the adder ( 44 ) is commonly used for the addition of a plurality of sets having k's with difference equal to one. The adders, in addition, are connected so that the adders can preferentially perform addition on the terms of 2 −n with a small value and a corresponding pair of values. When the output of a preceding adder is to be bit-shifted by means of a bit shift circuit, the addition is performed by a plurality of number of times by omitting low-order bits having no paired augend in the addition by means of the adders of the next and farther stages.
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FIELD OF THE INVENTION
The present invention relates to a method of directing a vehicle, in particular a motor vehicle, a plane or a ship, from at least one starting point to at least one destination.
BACKGROUND INFORMATION
Navigation systems installed in vehicles, such as, for example, motor vehicles, aircraft or ships may direct the driver of the vehicle rapidly, easily and reliably from a current location to a desired destination by visual or acoustic output of driving instructions without the driver of the vehicle or manner of locomotion having to plan a route before starting a trip or having to complete the remaining charting of the route on the basis of a map during the trip. For this, appropriate navigation data, based on road maps or other maps, for example, is stored in a memory in the navigation device, which may be on CD-ROM. The navigation device uses trip sensors and a compass plus optionally the signals of a GPS (global positioning system) transmitted by satellite to determine an instantaneous location of the vehicle and to calculate appropriate navigation instructions leading to a predefined destination.
With navigation devices from Blaupunkt-Werke GmbH, after the user makes appropriate entries, it is possible in calculating a route to eliminate sections of the route having a certain property. Thus, a menu item provided in an operating menu in the above-mentioned devices intended for motor vehicles allows the calculation of trip routes that do not include toll roads. With these devices, however, all toll roads used in calculating a route may be allowed or excluded.
SUMMARY OF THE INVENTION
The exemplary device according to the present invention is believed to have the advantage that individual route sections having a given property can be selected or deselected by the user on an individual basis. This may yield the further advantage that the user can determine an optimal route, such as, for example, in the sense of making an evaluation between the lowest possible trip cost, which might suggest avoiding toll roads as much as possible, and a minimized travel time, which would in turn make the use of toll roads seem appropriate.
It is believed to be especially advantageous here if route sections, such as, for example, toll roads, having a given property defined as part of the route calculation are output together with an available detour. This allows the user to make a direct comparison of the route section having the given property with the alternative route section, thus facilitating a decision for one of the two routes suggested.
Furthermore, it is believed to be advantageous if additional information characterizing the route section with the given property or the alternative route section is also output in addition to the route section having the given property and the alternative route section. This should make it easier for the user to make a decision about selection or deselection of a route section having the given property on the basis of a comparison between the toll road route section and the detour route, for example.
It is likewise believed to be advantageous if traffic congestion or other traffic obstacles such as construction sites or roadblocks can be preselected as a property characterizing a route section, so that the user can, if desired, detour route sections characterized in this way.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 shows a block diagram of an exemplary navigation device according to the present invention for carrying out or performing the exemplary method according to the present invention.
DETAILED DESCRIPTION
FIG. 1 shows a block diagram of an exemplary navigation device according to the present invention for carrying out or performing the exemplary method according to the present invention. The apparatuses, arrangements or structures 30 , 35 , 40 , which provide information regarding the location, the direction of movement and the movement status of the vehicle, are connected to device control 20 of navigation device 10 , which also includes the actual navigation computer.
In the exemplary embodiment, these apparatuses, arrangements or structures include a rotational rate sensor 30 with the help of which the orientation of the vehicle in which the navigation device is installed is defined with respect to the cardinal directions by integration via the detected changes in rotational rate. In addition, they include a trip odometer 35 which detects pulses delivered by wheel sensors in an anti-skid system for the vehicle brakes, for example, and determines the distance traveled on the basis of the defined pulse count and a known wheel circumference. Finally, they include a GPS (global positioning system) receiver 40 for receiving and analyzing radio signals which are emitted by GPS satellites and can be used to determine the position of the vehicle.
In addition, a memory 60 for storing map information in digital form is connected to control 20 . In the exemplary embodiment, memory 60 is in the form of a CD-ROM drive into which is inserted a CD-ROM as the data medium for the map information. Likewise, however, memory 60 may also be implemented in the form of a RAM or ROM semiconductor memory.
In addition, an output unit 50 , which is a display device in the present case, is also connected to control 20 . During the actual navigation operation, driving instructions for the driver of the vehicle are displayed there, such as, for example, in the form of a directional arrow in the case of pending turns and a remaining distance display up to the turn. As an alternative or in addition to the visual display, it is also possible for output device 50 to include an acoustic output device for output of acoustic driving instructions, such as “turn right after 100 meters” or the like.
Finally, an input unit 45 having operating elements such as pushbuttons 47 or some other input apparatus, arrangement or structure, such as rotary knobs, is connected to control 20 for input of a navigation destination and for operation of other functions of the device.
The exemplary navigation device according to the present invention and the exemplary navigation method according to the present invention function as follows.
After switching on navigation device 10 , sensors 30 , 35 , 40 , namely rotational rate sensor 30 , trip odometer 35 and GPS receiver 40 supply information from which control 20 , that is, the navigation computer contained in the control, determines the current position of the vehicle in which the navigation device according to the present invention is installed. The control optionally also takes into account data from the map stored in memory 60 in the context of a plausibility check for correction of the vehicle's position calculated on the basis of the sensor data. This type of correction of the vehicle's defined position is also known by the term “map matching.”
After or even during the determination of the current location of the vehicle, a navigation destination is input as described below, for example.
First, for interregional trips, the name of the city or town is entered as the destination on input unit 45 by scrolling through the alphabet, such as, for example, by using a rocker key 47 or a rotary knob, the first letter of the name of the city is selected and then confirmed. Then a selection list of names of cities and towns beginning with the letter entered appears on display unit 50 of the navigation device. For further selection of the name of the town, the available list of town names may be scrolled through by using rocker keys until discovering the desired town name. As an alternative, however, it is also possible to enter the town name by entering the second letter and optionally other letters by the exemplary method described above.
Then by a similar method in a second step, the street name of the desired destination is entered. If the city selected as a destination is a small city or town, it is also possible for a list of street names to be output over the output device immediately after input of the name of the city or town, so the user can then select the correct street name.
In the case of very long streets where the name remains the same, there may also be a third step in which a house number, an intersection with another street or another landmark along the street is also entered by the user to define the navigation destination more precisely.
As an alternative to the form of destination input described here, the navigation destination may be entered by a number assigned to the destination address, such as, for example, a telephone number. Therefore, the navigation device has a memory in which a list of telephone numbers is stored together with a respective address list, thus permitting an unambiguous correlation of a telephone number with a destination address.
In addition, navigation device 10 may also have a chip card reader, and the navigation destination may be read from a chip card inserted into the chip card reader. To do so, first the navigation destination is written into a rewritable memory of the chip card by using a suitable device such as a personal computer having a chip card reader.
A destination may also be input by marking and selecting the destination on a map shown on a display unit by using cursor keys, for example, and then on the basis of the information stored in memory 60 of navigation device 10 , assigning destination coordinates to the destination thus marked.
In the exemplary methods for inputting a destination described so far, it has been assumed that only a single destination is input. According to another exemplary embodiment of the present invention, however, multiple destinations may be entered so the navigation computer calculates an optimal route from the standpoint of minimal driving time or distance. For example, this may be appropriate for delivery vehicles, for example, of a package delivery service that must drive to multiple delivery addresses within a single delivery trip.
After determining the starting point and destination (if the navigation device does not have any self-locating system, the starting location must also be entered in the manner described here), according to the exemplary embodiment and/or exemplary method of the present invention the user (the driver of the vehicle in the present case of a navigation device for a motor vehicle) can enter a preselectable property for a route section potentially to be avoided, such as, for example, a route section with a road use fee. A certain property of a route section can be entered, for example, by scrolling through a list of properties by using rocker key 47 .
This is based on whether the driver of the vehicle might want to exclude certain route sections having a specific property, such as toll roads, from planning of the route.
If, however, the user has detailed knowledge of the traffic volume on certain route sections, such as, for example, because of updated traffic information broadcast by radio, it may be appropriate to allow the driver of the vehicle to intervene in the planning of the route by not automatically excluding route sections having the given property from planning of the route and instead allowing the user to decide whether or not to include a certain route section.
According to the exemplary embodiment and/or exemplary method of the present invention, in the course of route planning, the driver of the vehicle is informed of such route sections having a previously selected property, such as, for example, toll roads, such as, for example, in the form of a display on display unit 50 . The driver of the vehicle may then accept the route section output, so that it is included in planning the route, or may reject it as undesirable, whereupon an alternative route section is defined in planning the route.
Since, however, bypassing toll road sections, for example, may entail a considerable detour or a much longer trip time, in an exemplary embodiment, the driver of the vehicle may exclude the toll road, for example, from planning the route when a route section having the given property occurs, or include it if bypassing it would lead to an unacceptably long travel time or would entail other disadvantages.
In addition to the route section having the given property, an alternative route section is also defined, and both the route section having the given property as well as the alternative section are output, such as, for example, on a display unit. Furthermore, additional information characterizing the alternative route section in addition to at least the alternative route section or the section having the given property is output. The features characterizing the alternative route section may include, for example, additional driving time required, an additional driving distance or the road toll saved.
In another exemplary embodiment of the-present invention, features characterizing the route section having the given property, such as a road use fee, roadblocks, construction sites or traffic jams are also output in addition to the properties characterizing the alternative route section.
To obtain current information, such as, for example, regarding traffic jams, construction sites or roadblocks not included in map memory 60 , navigation device 10 according to an exemplary embodiment of the present invention has a receiver, which may be in the form of a radio receiver 65 connected to control 20 .
According to a first exemplary embodiment, the radio receiver may be a TMC radio receiver suitable for analysis of digitally coded traffic information according to the TMC (traffic message channel) standard transmitted over a radio broadcast frequency as part of the radio data signal in a known way. The received traffic information is linked to map data from memory 60 according to the exemplary embodiment and/or exemplary method of the present invention so that the respective current traffic information, such as traffic jams, roadblocks and construction sites is allocated as characteristic properties to specific route sections.
In another exemplary embodiment, the radio receiver may be a mobile cellular telephone, so that after dialing a service provider and establishing the connection, for example, the service provider provides current or updated information about route sections affected. This information is then linked to the map data for characterization of the route sections affected.
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A method of directing a driver of a vehicle, in particular a motor vehicle, aircraft or ship, from at least one starting point to at least one destination is described, a trip route being defined from the at least one starting point to the at least one destination. Once a certain property is specified, the driver of the vehicle is informed of which sections along the trip route have the given property. This allows the user or the driver of the vehicle to intervene specifically in the trip planning by including route sections having the given property in the route planning or by initiating the determination of an alternative route section.
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BACKGROUND OF THE INVENTION
The present invention relates to a new and improved construction of multi-ply headbox.
In its more particular aspects, the present invention relates to a new and improved multi-ply headbox comprising a number of headbox elements, each of which contains an infeed member provided with turbulence elements for the fiber stock suspension and a nozzle chamber connected after the infeed member. The nozzle chambers of the headbox elements are bounded or delimited by outer lips or lip members and at least one intermediate lip or lip member located between the nozzle chambers. At least part of the lips is adjustable or displaceable for adjustment of the size of the outlet slice of the nozzle chambers.
In such general type of a multi-ply headbox as known, for example, from German Pat. No. 899,896, the intermediate lip has the shape of a tongue member which is pivotable within the nozzle chamber. Additionally, also one of the outer lips is pivotably arranged.
In such prior art headbox a precise adjustment of the size of the outlet slice, by pivoting an inner intermediate lip, can only be obtained with great difficulty, particularly considering the deformation of the lip which is to be expected across the width of the machine and considering the accuracy required for the adjustment. Furthermore, in the known headbox construction an adjustment of the intermediate lip not only affects the size of one of the outlet slices, but at the same time the size of the other outlet slice, and specifically in the converse sense. Due to the risk of deformation by torsion or twisting and the related change in the size of the two outlet slices separated from each other by the intermediate lip, such a pivotable intermediate lip must be equally loaded at both sides or faces thereof, i.e., the pressures prevailing in the two nozzle chambers must be equal.
SUMMARY OF THE INVENTION
Therefore, with the foregoing in mind it is a primary object of the present invention to provide a new and improved construction of multi-ply headbox for a papermaking machine which enables the nozzle chambers to be charged with liquid fiber stock suspensions having flow rates and pressures which are mutually independent of each other.
Another important object of the present invention is directed to the provision of a new and improved construction of multi-ply headbox for a papermaking machine which enables using only part of the headbox elements in the event that paper containing a smaller number of plies or layers is to be produced in comparison to the number of plies or layers for which the headbox is normally intended or designed.
Still a further significant object of the present invention is directed to a new and improved construction of a multi-ply headbox for a papermaking machine which permits precise adjustment of the size of the outlet slices of such headbox.
Another very important object of the present invention is directed to a new and improved construction of a multi-ply headbox for a papermaking machine which permits the size of one outlet slice of the headbox to be adjusted without affecting the size of an adjacent outlet slice thereof.
Now in order to implement these and still further objects of the invention, which will become more readily apparent as the description proceeds, the multi-ply headbox of the present development is manifested by the features that, the infeed members comprise substantially wedge-like converging side walls and are provided with distributor or distributing channels or passages for the stock suspension arranged substantially parallel to each other. Moreover, at least the intermediate lips or lip members are arranged for displacement along the side walls between the infeed members in the flow direction of the fiber stock suspension.
By virtue of the aforementioned measures there is obtained a simple construction of the inventive headbox in which the intermediate lips or lip members can assume the form or shape of plates or plate members which can be precisely adjusted by means of a simple adjusting or adjustment mechanism. The adjustment of one lip will only affect the size of one of the outlet slices, namely that one which is bounded by the lip. Additionally, the intermediate lips or lip members can be designed to be sufficiently rigid and can be sufficiently rigidly guided so as to withstand significant pressure differences between the individual nozzle chambers.
In a preferred embodiment of the multi-ply headbox according to the invention, the outer lips or lip members are also arranged for displacement along substantially flat or planar side walls of the outer infeed members. A simplification in the design of the headbox is thereby achieved, since the outer lips and their associated adjusting mechanism may be constructed substantially identical to the intermediate lips.
Preferably, the lips or lip members may have the shape of plates bounded or delimited by parallel planar surfaces. Consequently, there is obtained a particularly simple design of the lips or lip members which can be fabricated from sheet metal plates or metal plating.
It is preferred to associate a guide or guiding member with each lip. The guiding member is secured to the related infeed member and forms mechanical guiding or guide means for the relevant plate forming the lip or lip member. A further simplification in the design of the headbox is thus obtained, since the infeed members may be constructed more simply by locating the guiding means for the plate forming the lip upon an essentially planar or flat guiding or guide member.
However, a modification of the headbox is also conceivable in which the outer lips or lip members are pivotably supported at the region of the outer walls of the outer infeed members and in which the outer lips are pivotable in order to adjust or set the size of the outlet slice.
In a preferred design of the headbox the outer lips can contain outwardly bent ends which are flexed or bent such that the outlet slices formed between the outer lips and the intermediate lips are bounded by surfaces which extend substantially parallel to each other. In this manner there is obtained an improved guiding of the flow of the stock suspension in the outlet slices bounded by the outer lips or lip members.
Preferably the infeed members may comprise blocks formed of a solid material and possessing in each such block a plurality of preferably parallel bores constituting the distributing channels or passages. Such a design is known as such from the commonly assigned U.S. Pat. No. 4,087,321, granted May 2, 1978, and has the advantage of particular simplicity and rigidity. Significant in this regard is also the commonly assigned U.S. Pat. No. 4,089,739, granted May 16, 1978.
It is particularly advantageous to provide the distributing or distributor channels passages formed in the block with step-shaped widening or widened portions which are also known from the aforementioned U.S. Pat. Nos. 4,087,321 and 4,089,739.
Furthermore, the intermediate lips or lip members may be provided with flexible foils which extend beyond the outlet slices.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be better understood and objects other than those set forth above, will become apparent when consideration is given to the following detailed description thereof. Such description makes reference to the annexed drawings wherein:
FIG. 1 is a cross-section through a first embodiment of a multi-ply headbox constructed according to the present invention;
FIG. 1a shows a detail, on an enlarged scale, of the headbox shown in FIG. 1;
FIG. 2 is a partial sectional view, taken substantially along the line II-II of FIG. 1;
FIG. 3 is an illustration of a second embodiment of headbox according to the invention, showing a part thereof in a view corresponding to FIG. 1;
FIG. 4 is a view of the headbox shown in FIG. 3 looking essentially in the direction of the arrow P thereof; and
FIG. 5 is a sectional view showing a modified design of the terminal regions or the ends of the intermediate lips or lip members and the outer lips or lip members of the headbox shown in FIG. 1.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Describing now the drawings, it is to be understood that only enough of the construction of the multi-ply headbox has been shown as needed for those skilled in the art to readily understand the underlying principles and concepts of the present development, while simplifying the showing of the drawings. Turning attention now specifically to FIG. 1, there has been illustrated therein in section a headbox suitable for for use with a conventional twin-wire papermaking machine, which therefore only has been generally indicated by two wire rollers or cylinders 1 equipped with wires or sieves 2. The headbox contains three headbox elements, each of which comprises an infeed member 3 containing distributing or distributor channels or passages 4 for the stock suspension as well as a nozzle chamber 5. The nozzle chambers 5 of the headbox elements communicate with the related infeed members 3 and are bounded or delimited by outer lips or lip members 6 and by intermediate lips or lip members 7. The illustrated infeed members 3 are shaped as blocks formed from solid material containing bores formed therein in order to provide the distributor or distributing channels 4 equipped with step-like widening or widened portions 4' defining turbulence elements.
The infeed members 3 possess wedge-like converging side walls 8, and the outer lip members 6 and the intermediate lip members 7 are guided along these side walls 8. By means of an adjustment mechanism 10 each outer lip member 6 and intermediate lip member 7 is displaceably arranged in the flow direction of the stock suspension in the distributor channels or passages 4, i.e., in the showing of FIG. 1 at an angle or inclination downwardly or upwardly, wherein this adjustment or displacement mechanism 10 has been shown in front view in FIG. 2.
In the embodiment of headbox shown in FIG. 1, the outer lip members 6 and the intermediate lip members 7 have the shape of plates which are bounded by parallel planar or flat surfaces 8' at the region between these infeed members 3 such that these lips or lip members may be fabricated, for example, from sheet material or metal plating.
Outer guiding or guide members 11 are operatively associated with the outer lip members 6 and mounted by, for example, threaded bolts 12 or equivalent structure to the related infeed member 3. Guiding or guide members 13 are operatively associated with the intermediate lip members 7 and are mounted to the outer infeed members 3 by threaded bolts 14 or equivalent structure. The guiding or guide members 13 simultaneously serve to connect the related outer infeed member 3 to which they are connected to the inner infeed member 3 as shown in FIG. 1. For this purpose the guiding members 13 are provided with projections 15 and 16 and with threaded bolts 15', the arrangement of which will also be evident from FIG. 2. The central or intermediate infeed member 3, on the other hand, is provided with projections 17 and 18 which cooperate with the projections 15 and 16, as shown.
As will be evident from FIG. 2, the intermediate lip members 7 are provided with slots 20 into which extend the projections 15, 16, 17 and 18. These projections serve as spacers and as guides for the intermediate lip members 7. Each intermediate lip member 7 is displaceable in the direction of the double-headed arrow S. These projections 15, 16, 17, 18 may contain inclined surfaces as shown, and advantageously serve to provide a so-called dovetail connection arrangement for interconnecting the infeed members 3.
The adjustment or displacement mechanism 10 for thusly displacing the related intermediate lip member 7 comprises a bell-crank or angle lever 21 which is pivotable about a pivot pin 22 and carries at one arm or leg thereof a pin 23 which engages by means of a sliding block 24 a recess formed in an adjustment or displacing rod or rod means 25 defining a transversely extending rod member. The adjustment or displacing rod 25 is displaceable in the direction of the double-headed arrow T in accordance with the illustration of FIG. 2. The other arm or leg of the bell-crank or angle lever 21 is provided with a pin 26 surrounded by a sliding block 27 which is movable in a not particularly referenced groove formed in a member or part 28 which is secured by, for instance, bolts to the related outer lip member 6 or intermediate lip member 7. The adjustment or displacing rod 25 is guided in eyelets 30 or the like which are mounted together with the pins or pin members 22 at a supporting structure 31.
The supporting or support structure 31 simultaneously serves to attach a plate or plate member 32 to which there are connected plate-shaped connecting members 33 of manifold or distributor tubes 34. Connecting pipes or lines 35 lead from the distributor tubes 34 to the individual distributor or distributing channels 4 provided in the infeed members 3.
A further embodiment of headbox designed according to the teachings of the invention is shown in FIG. 3, and components or parts thereof which correspond to the same or identical parts shown in FIG. 1 have been conveniently designated by the same reference numerals. This embodiment differs from the first described embodiment primarily in that here the outer lip members 6 are pivotably mounted at the region of the side walls 8 of the outer infeed members 3. The adjustment of the size of the outlet slice A is effected by pivoting the outer lip members 6 by using a conventional adjustment or adjusting mechanism 39. The desired size of the central or intermediate outlet slice B is obtained by appropriately displacing the intermediate lip members 7 as described with reference to the first embodiment shown in FIG. 1.
A further difference in relation to the first embodiment depicted in FIG. 1 is that here the distributing or distributor channels 4 comprise end or terminal sections 40 configured in the form of continuous slots in which, in accordance with the showing FIG. 4, a lattice-shaped honeycomb member 41 is arranged. These end or terminal sections 40 of the individual distributor channels 4 thus have imparted thereto a substantially rectangular cross-sectional configuration.
In the first embodiment of the headbox according to the invention, as shown in FIG. 1, the intermediate lip members 7 are provided with planar or flat outer surfaces 8' which simultaneously form the inner boundaries of the outlet slices or gaps A. The ends 6' of the outer lip members 6 are bent or flexed as shown in FIG. 1 such that the outlet slices A between the outer lip members 6 and the intermediate lip members 7 are bounded by surfaces 9 extending substantially parallel to each other. In the case of surfaces converging in the flow direction of the stock suspension their angle α may, for example, be in a range of between 0° and 10° (see FIG. 1a).
As will still be evident from FIG. 1, the intermediate lip members 7 are provided with flexible foils 42 or the like mounted at the guiding or guide members 13. These flexible foils 42 extend past the outlet slices A and B and serve to guide the stock suspension jets effluxing from the individual headbox elements at regions extending beyond the outlet slices A and B.
Finally, FIG. 5 shows a possible design of the ends or terminal regions of the outer lip members 6 and of the intermediate lip members 7 at the region of the outlet slices A and B. In this case, not only the outer lip members 6 have bent-off ends 6', but here also the intermediate lip members 7 are provided with bent-out ends 7'. With such an arrangement there is moderated the collision or impact of the stock flows exiting from the outlet slices A with the stock flow exiting from the outlet slice B.
Although the multi-ply headbox according to the invention has been illustrated and described, by way of example, with reference to a headbox containing three headbox elements, it will be obvious and should be expressly understood that the headbox may be equipped in the same way with a different number like, for example, two or four headbox elements.
While there are shown and described present preferred embodiments of the invention, it is to be distinctly understood that the invention is not limited thereto, but may be otherwise variously embodied and practiced within the scope of the following claims. Accordingly,
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The multi-ply headbox has a number of, for example, three headbox elements comprising block-like infeed members containing mutually parallel distributor passages for the fiber stock suspension which open each into a nozzle chamber. Plate-like intermediate lip members or lips bound the nozzle chambers and are provided between the headbox elements. The plate-like intermediate lips are displaceably arranged between the infeed members. There are also provided outer lips or lip members which either can be structured as displaceable plates or may be constructed to be pivotable. One of the outlet slices can be altered without affecting the size of the other slices.
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This is a Continuation-In-Part of U.S. patent application Ser. No. 09/620,250 filed on Jul. 20, 2000, now U.S. Pat. No. 6,506,360.
FIELD OF THE INVENTION
This invention relates to the production of hydrogen gas from the reaction of aluminum with water in the presence of sodium hydroxide as catalyst.
BACKGROUND OF THE INVENTION
Hydrogen energy is environment-friendly. Because of the actual human ecology concerns, the exploitation of hydrogen as an universal fuel would be greatly acclaimed. During the last two decades or so, the elaboration of a hydrogen-based economy has made important progress on account of numerous research projects such as the hydrogen fuel cell and the hydrogen car. Although these important discoveries constitute milestones toward a pollution-free society, more research is needed to obtain the hydrogen easily and economically.
A convenient source of hydrogen is a reaction of aluminum with water to split the water molecules into hydrogen and oxygen. The hydrogen is released as a gas and the oxygen combines with the aluminum to form aluminum oxide compounds. Aluminum is the third most abundant element after oxygen and silicon in the earth's crust, and constitutes approximately 8% by weight of the earth's crust. Aluminum is a safe material and is commonly used in the food, cosmetics and medical fields. Water is also abundant. Therefore, the reaction of these two elements to produce hydrogen represents an interesting proposal to replace fossil fuels.
Generally speaking, it is known that under certain conditions, aluminum reacts with water to generate hydrogen and heat. It is also known, however, that this type of reaction is not sustainable at ambient temperature. It is believed that a protective oxide layer forms on a metal surface in contact with water at ambient temperature and hinders the reaction. Therefore, it has been accepted by those skilled in the art that the use of aluminum in a reaction with water to generate hydrogen gas requires that the protective oxide layer is efficiently and continuously removed, and that the reaction is kept at an elevated temperature.
A number of hydrogen generators have been developed in the past. The following patent documents constitute a good inventory of the devices and methods of the prior art in the field of hydrogen gas generation using the reaction of aluminum or alloys of aluminum with water.
U.S. Pat. No. 909,536 issued on Jan. 12, 1909, and U.S. Pat. No. 934,036 issued on Sep. 14, 1909, both issued to G. F. Brindley et al. These documents disclose several compositions for generating hydrogen. The compositions comprise any metal which can form an hydroxide when it is brought into contact with a solution of a suitable hydroxide. For example, aluminum is reacted with sodium hydroxide to release hydrogen and to produce sodium aluminate.
U.S. Pat. No. 2,721,789, issued on Oct. 25, 1955 to Q. C. Gill. This document discloses the structure of an hydrogen generator for reacting water with a measured dry charge of aluminum particles and flakes of sodium hydroxide. The reaction releases hydrogen gas and produces sodium aluminate.
U.S. Pat. No. 3,554,707 issued on Jan. 12, 1971 to W. A. Holmes et al. This document discloses a gas generator having bellows to raise or lower the level of water in response to the pressure inside the generator. As the level of water drops, the contact surface between the fuel cartridge and the water is lost and the reaction is terminated.
U.S. Pat. No. 3,957,483 issued on May 18, 1976 to M. Suzuki. This patent discloses a magnesium composition which produces hydrogen upon contact with water. The preferred magnesium composition comprises magnesium, and one or more metals selected from the group consisting of iron, zinc, chromium, aluminum and manganese.
U.S. Pat. No. 3,975,913 issued on Aug. 24, 1976 to D. C. Erickson. This document discloses a hydrogen generator wherein molten aluminum is reacted with water. The generator is kept at a very high temperature to keep the metal in a molten condition.
U.S. Pat. No. 4,643,166 issued on Feb. 17, 1987, and
U.S. Pat. No. 4,730,601 issued on Mar. 15, 1988 both to H. D. Hubele et al. These documents disclose the structure of a fuel cell for producing heat energy and hydrogen gas. The device has a reaction chamber containing a fuel composition that is reactive with water. The fuel composition includes a main fuel part of magnesium and aluminum in a molar ratio of 1:2, and the second part is composed of lithium hydride, magnesium and aluminum in equal molar ratio.
U.S. Pat. No. 4,670,018 issued on Jun. 2, 1987, and
U.S. Pat. No. 4,769,044 issued on Sep. 6, 1988, both to J. H. Cornwell. These documents describe a log made of compressed wood waste and paper. The log is coated with aluminum particles. Upon burning, the aluminum particles react with moisture in the log to emit heat due to the generation of hydrogen gas.
U.S. Pat. No. 4,752,463 issued on Jun. 21, 1988 to K. Nagira et al. This document discloses an alloy which reacts with water for producing hydrogen gas. The alloy material comprises essentially aluminum and 5 to 50% tin.
U.S. Pat. No. 5,143,047 issued on Sep. 1, 1992 to W. W. Lee. This document discloses an apparatus and a method for generating steam and hydrogen gas. In this apparatus, an aluminum or aluminum alloy powder is reacted with water to generate hydrogen gas. An electric power source is used to start the reaction. The electric power source is used to explode an aluminum conductor and to disperse pieces of molten aluminum into a mixture of water and aluminum powder. A heat exchanger is provided to extract useful heat.
U.S. Pat. No. 5,867,978 issued on Feb. 9, 1999 to M. Klanchar et al. This document discloses another hydrogen gas generator using a charge of fuel selected from the group consisting of lithium, alloys of lithium and aluminum. The charge of fuel is molten and mixed with water to generate hydrogen gas.
JP 401,208,30 issued to Mito on Aug. 22, 1989. This document discloses a process for producing hydrogen. Aluminum is reacted with water under an inactive gas or a vacuum to produce hydrogen gas.
CA 2,225,978 published on Jun. 29, 1999 by J. H. Checketts. This patent application discloses a hydrogen generation system wherein a coating on reactive pellets is selectively removed to expose the reactive material to water for producing hydrogen gas on demand. In one embodiment, aluminum and sodium hydroxide are reacted with water to release hydrogen gas and produce sodium aluminate.
DE 3,401,194 published in Jul. 18, 1985 by Werner Schweikert. This document discloses a device for utilizing energy from a chemical reaction between various aluminum alloys and sodium hydroxide. The chemical reaction occurring in this device generates heat, hydrogen gas, a direct current and sodium aluminate as a residue.
FR 2,465,683 published in Mar. 27, 1981 by Guy Ecolasse. This document also discloses a process for producing hydrogen by the reaction of aluminum on sodium hydroxide solution in water. A by-product of this reaction is sodium aluminate.
Belitskus, David. 1970. Technical Note: “Reaction of Aluminum With Sodium Hydroxide Solution as a Source of Hydrogen” J. Electrochem Soc. (1970), (August), Vol. 117. No. 8, pp.1097-9, XP-002180270. This technical paper.describes several experiments wherein aluminum samples including a cylindrical block, uncompacted powders and pellets of various densities have been reacted with aqueous solutions of sodium hydroxide at various concentrations to generate hydrogen gas. In these experiments, the formation of sodium aluminate was observed, as well as the regeneration of sodium hydroxide through the precipitation of aluminum hydroxide.
Stockburger, D. et al. 1991. “On-Line Hydrogen Generation from Aluminum in an Alkaline Solution”. Proc.-Electrochem. Soc. (1992), Vol. 92-5 (Proc. Symp. Hydrogen Storage Mater., Batteries, Electrochem., pp. 431-44, 1992, XP-001032928. This technical paper describes three sizes of hydrogen generators in which aluminum is reacted with an aqueous solution of 5.75 M sodium hydroxide. This technical paper also notes the formation of sodium aluminate and the precipitation of aluminum hydroxide that regenerates sodium hydroxide.
Although the chemical reactions of aluminum with water in the presence of sodium hydroxide have been demonstrated in various projects in the past, these reactions were not considered as being safe for use by the general public. Sodium hydroxide is extremely corrosive and must be handled according to particular safety procedures. Therefore, any chemical reaction wherein sodium hydroxide is a consumable would not represent an attractive source of hydrogen for use in vehicles or in household power systems, for examples. As such, it is believed that a need still exists for a method to produce hydrogen gas by the reaction of aluminum and water, wherein the consumables are limited to aluminum and water.
SUMMARY OF THE INVENTION
Broadly stated, the process for producing hydrogen gas according to the present invention consists of reacting aluminum with water in the presence of sodium hydroxide acting as a catalyst.
In accordance with one aspect of the present invention, there is provided a process for producing hydrogen gas, comprising the initial step of: providing an aqueous solution in a vessel. The aqueous solution contains sodium hydroxide in a concentration between 0.26 M and 19 M NaOH.
The next step consists of reacting aluminum with water at the surface of the solution thereby generating a region of effervescence at the surface of the solution and a precipitate sinking to the bottom region of the vessel. The process also includes the step of maintaining the region of effervescence separated from the precipitate at the bottom the vessel, to prevent the precipitate from swirling and mixing with the aluminum in the reaction zone at the surface of the solution. This process is advantageous because it proceeds catalytically with the sodium hydroxide acting as the catalyst.
The process mentioned above is best carried out with an aqueous solution containing between about 5M and 10 M NaOH. The process is also more efficient when makeup water is added only after an initial amount of aluminum has been consumed, and when the temperature of the aqueous solution has reached a peak or 75° C.
In accordance with another aspect of the present invention, there is provided a process for initiating and maintaining a catalytic reaction of aluminum with water for producing hydrogen gas. The process comprises the initial step of providing an aqueous solution in a vessel. This aqueous solution contains a portion of NaOH and a portion of water. The next steps consist of introducing a portion of aluminum in the aqueous solution, and reacting that portion of aluminum with the portion of water. The process also includes the steps of maintaining constant the portion of NaOH in the vessel and adding additional portions of water and additional portions of aluminum in the vessel according to the rates of consumption of the aluminum and the water in the reaction.
Again, this process is best carried out with an aqueous solution of between 1.2 M and 19 M NaOH and at a temperature between 4° C. and 170° C.
In yet another aspect of the present invention, there is provided a process for simultaneously producing hydrogen gas and alumina (Al 2 O 3 ). This process firstly comprises the step of providing an aqueous solution in a vessel. The aqueous solution contains sodium hydroxide in a concentration between 0.26 M and 19 M NaOH. The next step consists of reacting aluminum with water at a surface of the aqueous solution and generating hydrogen gas and alumina. The process also includes the step of recovering hydrogen gas from the surface of the aqueous solution and alumina from a bottom region of the vessel.
Other advantages and novel features of the present invention will become apparent from the following detailed description,.
BRIEF DESCRIPTION OF THE DRAWINGS
A preferred embodiment of the process according to the present invention selected by way of examples will now be described with reference to the accompanying drawings, in which:
FIG. 1 is graph illustrating a first reaction of aluminum with water to produce hydrogen gas, in a 5.0 M sodium hydroxide solution, carried out over a period of about 130 minutes;
FIG. 2 is a graph illustrating a second reaction of aluminum with water to produce hydrogen gas, in a 4.95 M sodium hydroxide solution, carried out over a period of about 100 minutes;
FIG. 3 is a graph illustrating a third reaction of aluminum with water in a 4.5 M sodium hydroxide solution, while keeping the temperature relatively low;
FIG. 4 is a graph illustrating a fourth reaction of aluminum with water in a 4.5 M sodium hydroxide solution, while keeping the temperature relatively low;
FIG. 5 is a graph illustrating a reaction of aluminum with water in a 1.2 M NaOH solution;
FIG. 6 is a graph illustrating a reaction of aluminum with water in a 2.5 M NaOH solution;
FIG. 7 is a graph illustrating a reaction of aluminum with water in a 3.9 M NaOH solution;
FIG. 8 is a graph illustrating a reaction of aluminum with water in a 4.8 M NaOH solution;
FIG. 9 is a graph illustrating a reaction of aluminum with water in a 5.5 M NaOH solution;
FIG. 10 is a graph illustrating a reaction of aluminum with water in a 6 M NaOH solution;
FIG. 11 is a graph illustrating a reaction of aluminum with water in a 6.03 M NaOH solution;
FIG. 12 is a graph illustrating a reaction of aluminum with water in a 6.1 M NaOH solution;
FIG. 13 is a graph illustrating a reaction of aluminum with water in a 6 M NaOH solution, wherein the water was added continuously;
FIG. 14 is a graph illustrating a reaction of aluminum with water in a 6 M NaOH solution, wherein the aluminum was added quickly;
FIG. 15 is a graph illustrating a reaction of aluminum with water in a 6.7 M NaOH solution;
FIG. 16 is a graph illustrating a reaction of aluminum with water in a 11.3 M NaOH solution;
FIG. 17 is a graph illustrating a reaction of aluminum with water in a saturated 19 M NaOH solution;
FIG. 18 is graph illustrating maximum reaction temperatures obtained with aqueous solutions of various concentrations, and the responsiveness of the reaction for solutions of various concentrations;
FIG. 19 is a graph showing the effects of adding water to the reaction as, opposed to adding a fixed-molar NaOH solution to the reaction,
FIG. 20 is a partial cross-section view of an apparatus to produce hydrogen gas, embodying some of the preferred conditions to carry out the process according to the present invention;
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
In the present invention it is believed that aluminum reacts with water under certain conditions in the presence of sodium hydroxide as a catalyst. It is believed that the reaction is carried out according to the equation (1) or possibly (2), or some combination of the two, as follows;
2Al+3H 2 O→Al 2 O 3 +3H 2 (1)
catalyst=NaOH
2Al+6H 2 O→Al 2 (OH) 3 +3H 2 (2)
catalyst=NaOH
In one of the most pertinent prior art documents, the U.S. Pat. No. 934,036, it is taught that aluminum reacts with water and sodium hydroxide according to one of the following formulas;
2Al+2NaOH+ x H 2 O→Na 2 Al 2 O 4 +x H 2 O+3H 2 (3)
2Al+6NaOH+ x H 2 O→Na 6 Al 2 O 6 +x H 2 O+3H 2 (4)
In other relevant prior art documents, Stockburger and Belitskus teach that aluminum reacts with an alkaline solution of NaOH and that NaOH is subsequently regenerated by the precipitation of Al(OH) 3 as described by the formulas (5) and (6) respectively.
2Al+2NaOH+6H 2 O→2NaAl(OH) 4 +3H 2 (5)
2NaAl(OH) 4 →2NaOH+2Al(OH) 3 ↓ (6)
It is also taught in Stockburger, that an optimum concentration of the alkaline solution should be maintained at 5.75 M NaOH for an acceptable reaction rate, and in Belitskus that the rate of precipitation of Al(OH) 3 and the regeneration of NaOH is insufficient to support rapid reaction rates.
The following experiments were carried out to demonstrate that under certain conditions, the sodium hydroxide is not consumed in the reaction but acts as a catalyst to the reaction as described in equation (1) or (2).
Experiments 1-1 to 1-8
A first series of eight experiments was carried out to measure the volume of hydrogen gas produced in a typical reaction. In these experiments, aluminum foil from Reynolds Aluminum Company of Canada was loosely crumpled and placed in a one liter plastic bottle containing 500 ml of catalytic solution of about 4.5M NaOH. The bottle was quickly capped with a cover fitted with a tube which led to an inverted volumetric cylinder filled with water. The bottle was immersed in a water bath to prevent overheating.
The volume of water displaced by the gas produced was measured and corrected to a gas volume at standard temperature and pressure (STP). Atmospheric pressure on that day was obtained from a local weather office. The corrected volume of gas produced was compared to the theoretical quantity of hydrogen gas, which would be obtained according to the equation,
2Al+3H 2 O→Al 2 O 3 +3H 2 (1)
These experiments were carried out at a room temperature of 21° C. and an atmospheric pressure of 758 mm of Hg. In all cases the reaction started in few seconds and continued for few minutes, until depletion of the aluminum foil. It was noticed that a typical reaction with less than 5 grams of loosely crumpled aluminum foil, is complete in less than 5 minutes. The results of these experiments are shown in Table 1 below.
TABLE 1
Hydrogen Gas Production from Aluminum Foil
Exp.
Al
H 2
H 2 (l)
H 2 (l)
Yield
Deviation
(#)
(g.)
(l)
(STP)
Theoretical
(%)
(+/− %)
1-1
2.08
2.94
2.71
2.59
104
2.6
1-2
2.03
2.85
2.62
2.53
104
2.6
1-3
2.21
3.05
2.81
2.75
102
2.5
1-4
2.16
2.9
2.67
2.69
99
2.6
1-5
2.2
3.04
2.8
2.74
102
2.5
1-6
2.21
3.04
2.8
2.76
102
2.5
1-7
0.73
1.03
0.94
0.91
103
2.4
1-8
0.83
1.15
1.05
1.03
102
2.2
Ave.
102
2.47
The results from Table 1 show that the reaction is reproducible and produces stoichiometric quantities of hydrogen gas. The 102% average yield of hydrogen gas is considered to be within the measurement uncertainty; however, there are at least two factors which might have contributed to a slightly higher hydrogen yield. Firstly, the volume of gas produced was corrected to STP. It is possible that the exhausted fume hood in which the experiments were carried out could have lowered the reaction pressure below the atmospheric pressure of 758 mm of Hg. This would have increased the observed value for the volume of gas produced. An exhaust bench typically runs at 1 inch or 2 inches of water pressure. At a maximum, this could have increased the measured volume by about 0.5%.
Secondly, the water used was tap water in all cases, in which dissolved air may have been present. If any of this air had been released in the presence of the warm hydrogen gas, this would have increased the volume of gas; measured. This would have affected the results by less than 1%. Since the results are within the measurement error, and quantification of these two sources of error would not significantly affect the results, no further experiment was carried out in this area.
Experiments 1-9 and 1-10
The procedure used in the above experiments was repeated, with the exception that the tube leading from the top of the reaction bottle was connected to a gas sampling bag. Two samples of gas were obtained and, analysed. The results are presented in Table 2.
TABLE 2
Gas Analysis
Hydrogen
Oxygen &
Sample
Concentration
Nitrogen
1 (1-9)
92%
balance
2 (1-10)
98%
balance
Table 2 shows that the purity of the hydrogen collected in the second sample was 98%. This is close to what was theoretically expected. The lower 92% concentration observed in the first sample was probably due to the fact the system was not completely purged with hydrogen before the sample was taken. By the time the second sample was taken, most of the air had been purged from the tube and the reaction bottle.
Experiment 1-11
The procedure used in the first mentioned experiments was repeated except that the reaction bottle was placed in a water bath before the aluminum was added to the water, and the hydrogen produced was bubbled through the bath water. The temperature of the bath and the catalytic solution were measured before and after the reaction, and at about four minutes after the reaction was completed.
The water equivalent of the plastic containers for absorbing heat and their specific heat were determined experimentally by adding a known quantity of hot water to the reaction system at room temperature and then calculating the heat transfer based on the final temperature.
The quantity of heat produced by the reaction was determined and compared with the theoretical values. The results are shown in Table 3.
TABLE 3
Heat of the Reaction
Temp.
Temp. ° C.
Temp. ° C.
Temp. ° C.
° C.
Reactor
Bath
Reactor
Bath
Readings
Start
Start
Finish
Finish
Time
1 (1-11)
21.1
20.2
45.5
24.4
5.29
2 (1-11)
21.1
20.2
38.3
25.3
5.33
Heat
Heats of
Heat of
Heat
Output
Formation
Formation
Output
Theo-
Effi-
Al
Al 2 O 3
H 2 O
Actual
retical
ciency
Readings
(g)
kcal/mole
kcal/mole
kcal
kcal
(%)
1 (1-11)
9.52
−400.5
−68.3
33.3
34.5
96
2 (1-11)
9.52
−400.5
−68.3
32.5
34.5
94
The results in Table 3 show that the observed heat released in the production of hydrogen was 96% of the theoretical value. The 94% value from the second reading can be attributed to the heat lost to the surroundings during the time that lapsed between the readings.
The reaction has a net maximum heat production during hydrogen generation of 195.6 kCal/mole. A further 204.9 kCal/mole will be released if the hydrogen is burned with oxygen. Stated another way, 51% of the reaction energy is used to form hydrogen gas and 49% goes into the production of heat.
Experiment 2-1
With 5.00 M NaOH Alkaline Solution
Sodium hydroxide (NaOH) pellets (40.63 g) from Wiler Fine Chemicals were placed in a two liter Erlenmeyer flask. Tap water (200 ml) was added to the flask. The mixture was swirled and allowed to stand on the lab bench. The lab temperature was 25° C. After about an hour, aluminum (Al) foil (30.72 g) was added in two portions. The first addition of aluminum is referred to as time zero, the start of the reaction. The temperature of the vapour coming from the top of the flask was measured using a thermometer and was found to be 93° C. four minutes after the first half of the Al had been added. The flask was open to the atmosphere. The reaction was carried out for a period of 130 minutes. Additional quantities of Al and water were added at regular intervals, and the temperature was observed and recorded. The flask was swirled periodically to ensure the solution was in contact with the Al. No further NaOH was added.
During this first experiment, a total amount of 98.7 g of aluminum was added, and 650 ml of water was added to the initial volume. A graphic illustration of this Experiment 2-1 is shown in FIG. 1 . In this illustration, the heavy curve labelled as ‘T’ indicates the temperature of the vapour coming out of the flask; the medium density curve labelled ‘A’ indicates the amount of aluminum added; and the lighter curve ‘W’ indicates the water added. The same labelling is used for all the experiments illustrated herein.
The addition of Al to the NaOH solution resulted in the production of vapour which issued from the neck of the flask at temperatures above 90° C. Furthermore, this production of hot vapour started within a few minutes (less than 4 minutes) of the Al being added. The reaction proceeded vigorously with the addition of each charge of Al. Furthermore, even when there was a delay between charges, such as at the 36 minute and 44 minute additions, the reaction proceeded. Indeed, even when the addition of Al was delayed for 41 minutes and the reaction mixture had been allowed to cool, the reaction still proceeded vigorously (at about 128 minutes) when Al was added and the mixture was swirled.
It is to be noted that the amount of aluminum consumed in this reaction is about 3.6 times the amount predicted by the formulas (3) and (5), and about 10.8 times the amount predicted by the equation (4). These findings confirm the catalytic nature of the reaction according to the present invention.
Experiment 2-2
With 4.95 M NaOH Alkaline Solution.
To tap water (100 ml) in a one liter suction flask was added NaOH pellets (20.12 g) from Willer Fine Chemicals. The mixture was swirled to aid solvation. The lab temperature was 23° C. Two thermocouples were inserted through the suction inlet on the flask. The flask was open to the atmosphere. Thermocouple 1 (TC 1 ) was placed in the NaOH solution about one centimeter from the bottom of the flask. The junction of thermocouple 2 (TC 2 ) was placed in the flask neck at the same level as, the suction inlet. The thermocouples were read by a Scimetric System 200 data recorder which stored the temperature readings at five second intervals. After about half an hour TC 1 and TC 2 read 31° C. and 21° C. respectively After 53 minutes, TC 1 and TC 2 read 26° C. and 22° C., respectively, and heavy duty Al foil (4.90 g) from Alcan Aluminum Limited was added to the solution. There was vigorous reaction. This is referred to as time zero, the start of the reaction.
After four minutes, water (35 ml) was added to the solution. Al foil and water were added at five minutes intervals. The flask was swirled periodically. No further NaOH was added. FIG. 2 illustrates the response of this reaction in Experiment 2-2.
The reaction was monitored for about 90 minutes. During that period a total of 53.32 grams of aluminum was consumed and 350 ml of water was added to the initial quantity. The quantity of aluminum added corresponds to about 3.9 times the amount predicted by formulas (3) and (5), and about 11.8 times the amount predicted by equation (4). Again this confirms that the reaction according to the present invention proceeds according to equation (1) or (2). In this experiment, there was no occasion in which Al was added that the temperature of the vapour being emitted did not increase two to three minutes of the Al being added. A sharp drop in the temperature was observed about one minute after the addition of water. This is to be expected since the water was at room temperature (˜23° C.) and it was poured in through the top of the flask. Thus, it would cool the system momentarily.
In both Experiments 2-1 and 2-2, there was no indication that the reaction would not have proceeded indefinitely if more Al had been added. The regular addition of Al and the fact that the temperature of the vapour remained above 80° C., except when water was added, indicate that the reaction proceeded directly and no time was there a pause in the reaction to permit the regeneration of any reagent species as predicted by the formula (6).
The following Experiments 2-3 and 2-4 were carried out at temperature of 45° C. or less to determine whether the reaction would be sustainable at these temperatures. The composition of the precipitate forming in the reaction at these temperatures, as well as the composition of the gases emitted were also analysed.
Experiment 2-3
Collection of Precipitate at an Early Stage of the Reaction
Sodium hydroxide (NaOH) pellets (39.92 g) from Wiler Fine Chemicals, Lot #14449, were placed in a two liter Erlenmeyer flask. Tap water (182 ml) was added to the flask. The mixture was swirled and allowed to stand on the lab bench over night. Then it was swirled again to dissolve the remaining NaOH and mix the solution. The solution was then transferred to a 400 ml beaker.
Commercial aluminum foil (24.23 g), namely Reynolds Wrap™, a Registered Trade Mark of Canadian Reynolds Metal Company, Ltd., was>weighed, folded, and cut into portions that ranged in weight from 0.5 g to 1.5 g. The beaker containing the NaOH solution was placed in a water bath which was cooled with ice cubes. Thermometers were placed in both the water bath and the beaker. Care was taken to ensure the temperature of the solution in the beaker was kept at or below about 45° C. In each case, the temperatures of the solutions were read and recorded just before the portions of Al were added. At 29, 44, and 50 minute the reaction beaker was removed from the water bath to try to keep the reaction temperature as close to 45° C. as possible.
The Al foil was added in portions over a 59 minute period. When the Al was added to the initial reaction mixture, gas bubbles were observed to form after about 45 seconds. It was noted that when gas bubbles formed on the surface of the Al, the piece of Al floated at or near the top of the reaction mixture. A small amount of fine black material was observed to float in the reaction mixture after all the Al has been dissolved. By the 44 th minute, the reaction mixture was observed to be very viscous because of the formation of a solid material. At 50 minute, tap water (30 ml) was added to the reaction mixture. This Experiment 2-3 is explained graphically in FIG. 3 .
The solution was allowed to cool to room temperature, then it was filtered through a porcelain suction funnel without any filter paper to ensure there was no un-reacted Al present in the reaction mixture which could distort the analysis of the precipitate. The cloudy, grey, viscous material which passed through the funnel was filtered using a paper towel. It was washed with tap water. The final precipitate, a light grey solid, was allowed to stand in the fume hood overnight, then a portion of it, labelled P 3 - 1 , was dried in an oven at 102° C. After 45 minutes the sample was sealed in a plastic bag and taken to an Electron Microscopy Unit for analysis. The results of this analysis are presented in Table 4.
Experiment 2-4
Collection of Precipitate at an Advanced Stage of the Reaction
A 400 ml beaker containing tap water (175 ml) in which NaOH pellets (38.11 g) had been dissolved was placed in a water bath which was cooled by ice cubes. Al foil (39.26 g) was weighed, folded and cut into portions ranging up to 2 g. Both the NaOH and the Al came from the same source as described in Experiment 2-3. The Al foil was added to the NaOH solution over a 148 minute period following the same procedure as in Experiment 2-3. Additional water, totalling 70 ml, was added in four portions during the Experiment 2-4 at the times shown in FIG. 4 .
The reaction mixture was allowed to stand in the fume hood for about two hours after the addition of the last portion of Al, by which time the mixture had stopped bubbling. Part of the mixture was then filtered through a fine plastic mesh to ensure no un-reacted Al could contaminate the sample to be analysed. The mixture which passed through the mesh was then filtered by suction using qualitative filter paper. A sample of this grey precipitate was taken without washing and labelled P 4 - 1 . The remainder of the precipitate was removed from the filter paper and swirled with tap water in a flask, then it was re-filtered and washed with tap water.
A sample of the washed precipitate was taken and labelled P 4 - 2 . Both samples were dried in an oven at 102° C. for about an hour then they were sealed in a plastic bag and taken to the Electron Microscopy Unit for analysis. The results of the analysis are given in Tables 5 and 6.
The samples taken from Experiments 2-3 and 2-4 were analysed using a JEOL-6400 Scanning Electron Microscope (SEM) equipped with a Link eXL x-ray microanalyser. An accelerating voltage of 15 kV and a probe current of 1.5 nA were employed, and spectral collection times were 200s for sample P 3 - 1 and 120s for samples P 4 - 1 and P 4 - 2 . The results are; reported as oxide weight percent values, although oxygen was not analysed. Oxide values were calculated from elemental analyses using specified oxide stoichiometries. The minimum detection limits for NaOH under these conditions are approximately 0.38 wt. % for sample P 3 - 1 and 0.5 wt. % for samples P 4 - 1 and P 4 - 2 .
TABLE 4
Sample P3-1.
SiO 2
n.d.
n.d.
0.23
0.32
0.18
TiO 2
n.d.
n.d.
n.d.
n.d.
n.d.
Al 2 O 3
59.71
67.63
80.08
57.50
70.11
FeO
0.27
0.28
0.33
0.30
0.44
MnO
n.d
n.d.
n.d.
n.d.
n.d.
MgO
n.d.
n.d.
n.d.
n.d.
n.d.
CaO
0.26
0.28
0.35
0.41
0.18
Na 2 O
0.39
n.d.
n.d.
n.d.
n.d.
K 2 O
n.d.
n.d.
n.d.
n.d.
n.d.
CuO
0.38
0.46
0.42
0.70
0.41
Total
61.01
68.65
81.41
59.23
71.32
n.d. = not detected
TABLE 5
Sample P4-1.
SiO 2
0.21
0.27
n.d.
n.d.
n.d.
TiO 2
n.d.
n.d.
n.d.
n.d.
n.d.
Al 2 O 3
63.05
54.87
62.40
63.02
74.57
FeO
0.26
0.26
n.d
0.29
0.32
MnO
n.d
n.d.
n.d.
n.d.
n.d.
MgO
n.d.
n.d.
n.d.
n.d.
n.d.
CaO
n.d.
n.d.
n.d.
n.d.
n.d.
Na 2 O
8.03
11.21
9.46
4.02
4.25
K 2 O
n.d.
n.d.
n.d.
n.d.
n.d.
CuO
n.d.
n.d.
n.d.
0.37
n.d.
Total
71.55
66.61
71.86
67.70
79.14
n.d. = not detected
TABLE 6
Sample P4-2.
SiO 2
n.d.
0.29
n.d.
n.d.
0.22
TiO 2
n.d.
n.d.
n.d.
n.d.
n.d.
Al 2 O 3
70.96
72.01
63.77
69.72
65.80
FeO
0.30
0.35
0.32
0.23
0.28
MnO
n.d
n.d.
n.d.
n.d.
n.d.
MgO
n.d.
n.d.
n.d.
n.d.
n.d.
CaO
0.18
0.10
0.16
n.d.
0.14
Na 2 O
n.d.
0.69
n.d.
n.d.
n.d.
K 2 O
n.d.
n.d.
n.d.
n.d.
n.d.
CuO
0.42
0.37
0.30
0.42
0.51
Total
71.86
73.81
64.55
70.37
66.95
n.d. = not detected
The results presented in Tables 4-6 show the precipitate formed does not contain sodium beyond what could reasonably be expected to be present in an impure material precipitated from a concentrated NaOH solution. In no case was the quantity of sodium in the precipitate present in amounts exceeding 1.1% of that required by the reaction products specified in equation (3), (4) or (5). Therefore it may be concluded that the precipitate formed is not Na/Al moiety, but is rather primarily an Al/Oxygen material, which may contain some hydrogen in the form of hydroxyl groups or water molecules.
The two samples collected and analysed in Experiment 2-4 show two things, namely, the washing of the precipitate with water removes significant amounts of Na; and that none of the five measurements on the unwashed precipitate showed levels of Na which exceeded more than 34% of that necessary to form the compounds given in equation (3), (4) or (5). Indeed, the average sodium content of the five measurements was less than one-fifth of that necessary to form the compounds given in equation (3), (4), or (5). This removes any possibility that the Na/Al substances as shown in equation (3), (4) or (5) was at one time present in the reaction precipitate and was subsequently changed to an aluminum/oxygen species by washing. If such were the case the Na:Al ratio from sample P 4 - 1 would have had to be at least 1:1. This was not observed. Therefore, it may be concluded that even in the unwashed state the precipitate is primarily an aluminum based compound.
The fact that washing with water readily removes most of the sodium confirms that the sodium species present is water soluble as would be expected for an ionic species containing sodium.
Experiment 2-5
Activeness of the Filtrate
To a small amount (˜50 ml) of the filtrate from the first filtration in Experiment 2-4, was added Al foil (0.5 g). Within about 60 seconds, bubbling started and the Al completely dissolved, and a grey precipitate formed in this previously clear solution.
Experiment 2-6
Collection of Gases.
To tap water (182 ml) in a four liter plastic bottle was added NaOH pellets (40.15 g). The bottle was covered, shaken and-the solution allowed to come to room temperature after the NaOH had dissolved. The bottle was then placed in a water bath at 18° C. Al foil (14.8 g) was added in three portions of about 5 g each. Both the Al and NaOH came from the same source as described in Experiment 2-3. After the first portion of Al (4.63 g) was added, the bottle was capped with a lid fitted with a hose. Bubbles started to form on the surface of the Al after about 10 seconds. Bubbles came out of the hose, which was submerged in the water bath, after about 40 seconds. The Al had completely reacted within about three minutes. The lid was removed from the bottle and a second portion of Al foil (4.98 g) was added and the bottle recapped. Bubbling from the hose started after about 30 seconds, the hose was connected to a gas sampling bag and sample P 6 - 1 was collected. The addition of Al foil (5.19 g) was repeated and gas sample P 6 - 2 was collected. Both gas samples were analysed. The analytic data and the normalized results are summarized in Table 7.
TABLE 7
Gas Analysis.
Observed
Normalized
Concentrations
Concentrations
Sample #
P6-1
P6-2
P6-1
P6-2
Oxygen
2%
1%
2%
1%
Nitrogen
7%
2%
7%
2%
Hydrogen
86%
92%
91%
97%
Total
95%
95%
100%
100%
Experiments 3-1 to 3-15
A series of fifteen experiments was carried out using NaOH concentrations which ranged from about 0.25M to a saturated solution of NaOH in water at room temperature. The saturated solution was about 19M. Thirteen of these experiments were recorded on graphs, and are shown in the accompanying FIGS. 5-17. On these graphs, the labels ‘T’, ‘A’ and ‘W’ designate the temperature of the reaction, and the aluminum and water added respectively as in the previous graphs. The label ‘S’ has been added, however. The line ‘S’ across each graph designates the amount of aluminum that would react with the initial amount of NaOH if the reaction would proceed according to the equation (3), (4) or (5). This amount is also referred to herein as the stoichiometric amount of aluminum.
Solutions of NaOH were typically cooled before starting the reactions. The starting temperature for each reaction was often in the range of 4-10° C. The reactions were carried out in glass vessels ranging in size from 25 ml to 500 ml. Solutions of NaOH were prepared by dissolving NaOH pellets from BDH Inc., Toronto, Ontario, Canada, M8Z 1K5, Lot #128142-125228, in tap water at room temperature. The heat of solvation was allowed to dissipate and the portion of the solution to be used in the experiment was cooled in an ice bath in the reaction vessel.
A thermocouple junction was placed in the solution about one centimeter below the surface. The thermocouple reading was monitored continually and recorded on a computer file every 15 seconds.
Aluminum foil (Reynolds Wrap from Canadian Reynolds Metals Company Ltd., Montreal, Toronto, Calgary, Canada) was crumpled or folded and added in portions ranging from 0.2 g to 1.1 g. Each portion of Al foil was initially submerged in the solution using a glass stirring rod. Then it was allowed to float to the top of the solution. The start time for every experiment was the time when the first aluminum was added. Aluminum was added in amounts to keep the temperature above 60° C.
Water was added in amounts up to 20 ml. Water was only added when the reaction mixture became viscous and foamed more than one centimeter. In most of the experiments, the addition of water started after about 75% of the stoichiometric amount of Al was added. Water was added in sufficient quantities to ensure that the level of the solution was at least one centimeter above the level of the precipitate. In most cases, water was added only after the temperature had reached a peak or a value of at least 75° C. The portions of water were also controlled so that the temperature of the top of the solution did not drop more than 60° C. when the water was added. Aluminum and water were added until at least two times the stoichiometric amount, based on equation (3), had been reached.
After the reaction had ceased the solution was cooled and the precipitate was suction-filtered, and rinsed while still in the suction funnel with about 250 ml of tap water. Samples from the Experiments 3-1 to 3-15 were sent for elemental analysis of the precipitate and the hydrogen gas. The results of these analyses are shown in Table 8.
TABLE 8
Catalytic Ratios and Product Analysis.
[NaOH]
Catalytic
[Al 2 O 3 ]
[Na 2 O]
H 2
Test (#)
(M)
Ratio
(%)
(%)
(%)
3-1
0.26
3.0
98.3
<0.71
3-2
0.60
3.1
98.9
<0.71
3-3
1.2
4.2
96.3
1.14
3-4
2.5
3.3
98.7
0.7
3-5
3.9
3.9
96.8
<0.71
3-6
4.8
3.4
3-7
5.5
4.5
98.6
<0.71
3-8
6.0
2.6
3-9
6.0
3.3
98.6
<0.71
97
3-10
6.1
4.2
3-11
6.1
3.2
99.3
<0.71
3-12
6.1
3.8
98.3
<0.71
3-13
6.7
3.3
99.1
<0.71
3-14
11.3
2.7
97.3
<0.71
98
3-15
19
2.7
99.1
0.79
97
The expression “catalytic ratio” in the above table is calculated by dividing the amount of Al that actually reacted by the amount that would have reacted if the reaction were stoichiometric with respect to NaOH as in equation (3), (4) or (5).
Table 8 also shows the results of the analyses of the precipitates filtered from twelve of the experiments. In every case the concentration of the Al species is larger than 96%. Sodium was detectable in only three of the samples, and then at a maximum concentration of only 1.14% or less. Thus, aluminum is present in the precipitate at levels that are two orders of magnitude above sodium.
It may be concluded that the reaction according to the present invention is catalytic in aqueous solutions from 0.26 M NaOH to 19 M NaOH. It should be noted that although the 0.26 M and 0.60 M solutions showed a catalytic reaction, the reaction temperature did not rise above 30° C. during those experiments. However, FIG. 5 shows that the temperature of the 1.2 M solution rose above 45° C. even though the Al was added very slowly and only after the previous portion had dissolved.
The results in FIGS. 5-17 show that the reaction can and does occur over a temperature range from 4° C. to 165° C. In one experiment with the saturated solution a temperature of 170° C. was observed. The molal boiling point elevation constant will result in a higher boiling point for the more concentrated solutions, ensuring that water does not boil off until the higher boiling point is reached. In the case of the saturated solution from Experiment 3-15, the boiling point elevation would have contributed to the high boiling point of the solution. It was also noted that NaOH did not precipitate from the solution even at the higher concentration, probably because of the known higher solubility of NaOH in hot aqueous solutions.
It was found that at about 75% of the stoichiometric amount the solution would become viscous and foaming with large longer-lasting bubbles. Water was added at this point and often the addition of Al had to be slowed down or an excess of un-reacted aluminum could be observed.
The formation of a greyish-white precipitate would start between 75% and 100% of the stoichiometric amount. Once the precipitate started to form it was necessary to keep the reaction zone above the precipitate a distance of about I cm, or the precipitate would mix with the bubbling aluminum and form a more viscous foam which on occasion overflowed the reaction vessel.
Based on all the experiments described herein, it will be appreciated that the present process to produce hydrogen is reproducible with aqueous solutions from 1.2 M NaOH to 19 M NaOH and over a temperature range from 4° C. to greater than 170° C. Furthermore, the reaction is catalytic over the same temperature range and over a NaOH concentration range of 0.26 M to above 19 M. The reaction's by-product comprises high-purity alumina (Al 2 O 3 ).
Referring now to the graph in FIG. 18, there is shown therein a first curve 30 showing the maximum temperatures obtained with different NaOH concentrations. This best-fit curve was plotted from the data shown in FIGS. 5-17, and is presented herein for illustrating the effect of NaOH concentration on the maximum temperature of the reaction. FIG. 18 shows another curve 32 which represents the responsiveness of the reaction to aluminum and water additions. This curve has been prepared by plotting the time required to reach the initial maximum temperature of the reactions, against the different NaOH concentrations studied. The resulting best-fit curve is a complex inverted hyperbolic curve centred on a concentration of about 8 M NaOH. This curve indicates that the reaction is highly responsive to fuel additions, when the NaOH concentration is between about 5 M and 10 M, and that the responsiveness decreases rapidly when the NaOH concentration is adjusted away from this median region.
Referring now the FIG. 19, there is illustrated therein two curves. The first curve 34 represents the effect of adding plain water to the catalytic reaction of equation ( 1 ) or ( 2 ). As the reaction proceeds, the water is consumed, and therefore, the concentration of NaOH increases, as shown by the segment: 36 , from its initial concentration 38 . When water is added, as indicated by segment 40 , the concentration drops back to or below the initial concentration 38 . If water is added in portions to maintain a certain level in a reaction vessel for example, the solution concentration fluctuates up and down from the initial concentration 38 , as generally represented by the curve 34 .
If someone is led to believe that the reaction proceeds as in equation (3), (4) or (5), that person would logically add NaOH into the reaction vessel with the makeup water. If NaOH is added to a reaction that actually proceeds according to equation (1) or (2), however, the resulting NaOH concentration of the aqueous solution in the reaction vessel would increase as represented by curve 44 . Whether the NaOH is added alone or in a fixed-molar NaOH solution, as represented by segment 46 , the NaOH concentration of the solution in the reaction vessel would move quickly toward saturation.
Reference is made again to the curve 32 in FIG. 18 . It will be appreciated that a regular addition of a fixed-molar NaOH solution to a reaction that proceeds according to equation (1) or (2) would cause the responsiveness of the reaction to move along the curve 32 as indicated by the series of arrows 48 , and quickly reach a region of very low responsiveness. Such migration of the NaOH concentration toward a region of low responsiveness would cause the reaction to cease or to appear to have ceased. The addition of plain water, however, as taught herein, causes the responsiveness of the reaction (1) or (2) to oscillate back and forth along the curve 32 toward and away from a more reactive state, as shown by arrows 50 and 52 . These oscillations 50 , 52 are believe to stimulate the reaction, and to contribute to some degrees to the catalytic feature of the reaction according to the present invention.
The arrows 50 , 52 and the corresponding theory explain the facts that in some experiments, a water addition has caused the reaction to slow down, according to the arrow 50 , and in other experiments, the addition of water caused an immediate response, as in 52 . The same theory explains why both events can occur in a same experiment, such as when the NaOH concentration is maintained substantially in the median region, between 5 and 10 M NaOH. The curve 44 and arrows 48 on the other hand, explain why prior inventors may have failed to observe a catalytic reaction with the same elements.
It has been found that the reaction proceeds better when water is added after an initial amount of aluminum has been consumed. This phenomenon can also be explained using the curve 32 in FIG. 18 . In a low concentration solution, any delay in adding water causes the NaOH concentration to move toward a highly responsive state, such as around 8M for example. An addition of water at that time and a subsequent addition of makeup water causes the NaOH concentration to oscillate within this highly responsive region. On the other hand, if the initial concentration is above 8 M for example, an addition of water brings the concentration back to a highly responsive state, and therefore immediate results can be observed.
Additional Experiments
Additional experiments were carried out using aluminum wire of different gauge sizes and aluminum flakes from the helical casing of armoured electrical wire. Although these additional experiments were not recorded in details, the catalytic effect was observed. Therefore, it is believed that the reaction (1) or (2) is reproducible with aluminum flakes from beverage cans and food packages, aluminum chips, shavings and sawdust found in machine shop waste, and aluminum powder available commercially for different purposes including fireworks, or other small aluminum particles of the like. It is to be expected that the intensity of the reaction depends upon the surface of contact between the aluminum and water. Aluminum foil for example reacts faster than a heavy gauge aluminum wire, and aluminum powder would react almost instantly to produce hydrogen gas.
Preferred Apparatus
A preferred hydrogen generator 60 is illustrated in FIG. 20 . The hydrogen generator 60 , comprises a reaction vessel 62 made of non-corrosive material, in which the reaction is carried out. A minimum amount of an alkaline solution 64 is maintained in this vessel. During the operation of the generator, it has been found that aluminum particles reacts with water at the surface 66 of the alkaline solution and defines at and near the surface 66 , a region of substantial effervescence. This region is defined as the reaction zone ‘F’. The height of the reaction zone ‘F’ vary with the intensity of the reaction, and extends above and below the surface 66 of the alkaline solution 64 . During the operation of the generator, a precipitate 68 accumulates at the bottom of the reaction vessel 62 . It is recommended to maintain the reaction zone ‘F’ at a height ‘H’ of at least about 1 cm above the precipitate 68 , to prevent the precipitate from swirling into the reaction zone and mixing with the aluminum particles. Although this dimension can be reduced in some installations, a dimension of one centimeter is suggested herein to enable those skilled in the art to readily use the process according to the present invention successfully.
A water bottle 70 is affixed to the side of the reaction vessel 62 and has a piping system 72 connected to an array of nozzles 74 in the bottom of the reaction vessel 62 . Only one nozzle is shown for clarity. The introduction of water through the bottom of the vessel 62 has the effect of capturing some of the heat in the precipitate 68 to preheat the water entering the reaction vessel. A second purpose for the feeding of water through the bottom of the reaction vessel 62 is to entrain to the reaction zone ‘F’, any sodium hydroxide which may be present in the precipitate 68 .
While the distance ‘H’ of the reaction zone ‘F’ above the precipitate 68 defines a low limit to the water content in the reaction vessel, the upper limit should be defined as to maintain the concentration of the alkaline solution over about 1M NaOH, and more preferably, a concentration of 5M NaOH. A sight glass 76 on the side of the reaction vessel 62 is provided to monitor the minimum distance ‘H’ of the reaction zone ‘F’ above the precipitate 68 .
Aluminum particles 78 are delivered into the reaction vessel 62 from a hopper 80 mounted on the top of the vessel 62 , though an airlock™ rotary feeder 84 and through a drop pipe 86 at the center of the reaction vessel 62 . A deflector 88 is mounted at the end of the drop pipe 86 to disperse the aluminum particles 78 over the entire surface of the alkaline solution 64 . The hydrogen generated in the reaction vessel exits through the drop pipe 86 and the spout 90 .
The drop pipe 86 is preferably mounted through a large openable cap 92 on the top of the reaction vessel. This cap 92 preferably covers a substantial portion of the upper end of the reaction vessel 62 and provides access to the reaction vessel for periodically cleaning the vessel. A bung 94 is provided in the bottom surface of the reaction vessel 62 to recover the precipitate 68 .
The aluminum particles 78 are preferably flakes, sawdust, milling shavings and chips, powder or other similar small particles having a large surface over volume ratio. It has been noticed that aluminum foil fragments for example, have a tendency to float at the surface 66 of the alkaline solution 64 . This is preferable and is explained by the buoyancy created by the foam 96 and the bubbling action generate in the reaction zone ‘F’. It is believed that the bubbling action and the high temperature in this reaction zone is ideal to prevent or reduce the formation of a protective oxide layer on the surface of the aluminum particles. It is believed that the retention of the aluminum particles in this reaction zone contributes largely to maintaining the catalytic effect.
When relatively dense aluminum particles are used, it is recommended to install a floating screen 98 at the surface of the alkaline solution 64 , to retain the aluminum particles in the reaction zone ‘F’.
As to other manner of usage and operation of the process according to the present invention, the same should be apparent from the above description and accompanying drawings, and accordingly further discussion relative to these aspects is deemed unnecessary.
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The process for producing hydrogen gas according to the present invention consists of reacting aluminum with water in the presence of sodium hydroxide as a catalyst. In one aspect of the present invention, there is provided a process for producing hydrogen gas, comprising the steps of: providing an aqueous solution containing between 0.26 M and 19 M NaOH in a vessel. The next step consists of reacting aluminum with water at the surface of the solution to generate a region of effervescence at the surface of the solution and a precipitate sinking from the region of effervescence to the bottom of the vessel. The region of effervescence is kept separated from the precipitate at the bottom the vessel, to prevent any precipitate from mixing with the aluminum therein.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a liquid crystal display (LCD) device, and more particularly, to a LCD device having a design of a bonding pad between a LCD panel and a flexible printed circuit.
2. Description of the Prior Art
Owing to their low-profile, thin, and lightweight features, LCD devices have replaced cathode ray tubes (CRTs) in many applications and becomes the mainstream display devices in recent years. LCD panels are widely used in electronic devices such as mobile phones, personal digital assistants (PDAs), digital cameras, computer screens, notebook screens, etc.
A conventional liquid crystal display (LCD) device comprises a LCD panel and external driving chips. The external driving chips transmit scan or data signals to pixels of the LCD panel to display images via metallic wires on the LCD panel.
The external driving chips and the LCD panel are coupled through a flexible printed circuit (FPC) on which metallic wires are set up. One end of each metallic wire on the FPC is coupled to output of the external driving chips, and the other end of each metallic wire on the FPC is coupled to each metallic wire of the LCD panel. Due to the arrangement, the driving chips can output signals to the LCD panel successfully.
In addition, the metallic wires of the FPC are bonded to the metallic wires of the LCD panel. In the prior art, there is a convex FPC bonding pad at the end of each metallic wire on the FPC, and there is also a convex panel bonding pad at the end of each metallic wire on the LCD panel. In the process of bonding, anisotropic conductive film (ACF) is coated on the surface of the LCD panel. Then the FPC bonding pads target at and stick to the panel bonding pads. Conductive particles in the ACF are crushed by pressing and heating, so that the FPC bonding pads couples the panel bonding pads.
Please refer to FIG. 1 . FIG. 1 is a local diagram of a LCD device 100 in the prior art. To facilitate the description, FIG. 1 only shows bonding areas of the FPC and the LCD panel. The panel bonding pad 110 is designed as one section. Every bonding pad 110 has the same area. All pitches between any two neighboring bonding pads 110 are identical. The FPC bonding pad 120 is also designed correspondingly to the panel bonding pad 110 for bonding.
Owing to panel resolution being getting higher, more data lines are needed to be disposed on the LCD panel. Hence it is necessary to set up more bonding pads. The measure of bonding area, however, is actually limited. Therefore, the solution is to reduce the areas of the bonding pad/FPC bonding pad and to reduce a pitch between two neighboring panel bonding pads and between two neighboring FPC bonding pad. But it is ineffective to mass production because machine precision leads to misalignment of the panel bonding pad and FPC bonding pad of probably the to cause abnormal signal transmission.
SUMMARY OF THE INVENTION
Accordingly, the present invention proposes a design of a bonding pad of a LCD panel and a flexible printed circuit (FPC). Each bonding pad is divided into three sections. Therefore, more bonding pads can be disposed on a high resolution panel without reducing total bonding width. Furthermore, the bonding pad with three sections, the FPC bonding pad and the panel bonding pad which are coupled with each other have different area so that misalignment is avoided in the process of bonding of the FPC and panel bonding pad.
According to the present invention, a liquid crystal display (LCD) panel comprising a glass substrate, a plurality of metallic wires and a plurality of panel bonding pads. Each metallic wire is coupled to one of the plurality of panel bonding pads. The plurality of panel bonding pads further comprise: a first set of panel bonding pads placed in a first section; a second set of panel bonding pads placed in a second section; and a third set of panel bonding pads placed in a third section. Each area of the first set of panel bonding pads is different from that of the second set of panel bonding pads.
In one aspect of the present invention, each area of the first set of panel bonding pads is smaller than that of the second set of panel bonding pads, and each area of the second set of panel bonding pads equals to that of the third set of panel bonding pads.
In one aspect of the present invention, a distance from the pixel area of the LCD panel to the second section is closer than that from the pixel area of the LCD panel to the first section.
In one aspect of the present invention, each panel bonding pad comprises: a first metallic layer, formed on the glass substrate, for coupling to one of the metallic wires; an insulating layer, formed on the first metallic layer; a second metallic layer, formed on the insulating layer; a passivation layer, formed on the second metallic layer; and a transparent conducting layer, formed on the passivation layer, for electrically connecting to a first metallic layer and a second metallic layer through a via defined on the passivation layer and the insulating layer.
According to the present invention, a flexible circuit board comprises a substrate, a plurality of metallic wires and a plurality of FPC bonding pads. Each of the metallic wires is coupled to one of the FPC bonding pads. The plurality of FPC bonding pads further comprise: a first set of FPC bonding pads placed in a first section; a second set of FPC bonding pads placed in a second section; and a third set of FPC bonding pads placed in a third section. Each area of the first set of FPC bonding pads is different from that of the second set of FPC bonding pads.
In one aspect of the present invention, each area of the first set of FPC bonding pads is greater than that of the second set of FPC bonding pads, and each area of the second set of FPC bonding pads equals to that of the third set of FPC bonding pads.
In one aspect of the present invention, the FPC is used for coupling a LCD panel to a driving chip, and a distance from the second section to a pixel area of the LCD panel is closer than that from the first section to the pixel area of the LCD panel after the FPC is coupled to the LCD panel.
According to the present invention, a liquid crystal display (LCD) device comprising an LCD panel and a flexible circuit board for linking the LCD panel and an external driving chip. The LCD device further comprises: a glass substrate, a plurality of first metallic wires formed on the glass substrate, and a plurality of panel bonding pads. Each panel bonding pad is coupled to one of the plurality of first metallic wires. The plurality of panel bonding pads further comprises a first set of panel bonding pads placed in a first section; a second set of panel bonding pads placed in a second section; and a third set of panel bonding pads placed in a third section. The flexible printed circuit comprises a substrate, a plurality of second metallic wires formed on the substrate, and a plurality of FPC bonding pads. Each FPC bonding pad is coupled to one of the plurality of second metallic wires. The plurality of FPC bonding pads comprise a first set of FPC bonding pads placed in a fourth section, a second set of FPC bonding pads placed in a fifth section, and a third set of FPC bonding pads placed in a sixth section. Each area of the first set of panel bonding pads is different from that of the second set of panel bonding pads. The first section corresponds to the fourth section, the second section corresponds to the fifth section, and the third section corresponds to the sixth section when the flexible circuit board couples to the LCD panel.
In one aspect of the present invention, each area of the first set of panel bonding pads is smaller than that of the second set of panel bonding pads, and each area of the second set of panel bonding pads equals to that of the third set of panel bonding pads.
In one aspect of the present invention, a distance from the pixel area of the LCD panel to the second section is closer than that from the pixel area of the LCD panel to the first section.
In one aspect of the present invention, each panel bonding pad comprises a first metallic layer, formed on the glass substrate, for coupling to one of the first metallic wires, an insulating layer, formed on the first metallic layer, a second metallic layer formed on the insulating layer, a passivation layer, formed on the second metallic layer, and a transparent conducting layer, formed on the passivation layer, for electrically connecting to a first metallic layer and a second metallic layer through a via defined on the passivation layer and the insulating layer.
In one aspect of the present invention, each area of the first set of FPC bonding pads is greater than that of the second set of FPC bonding pads, and each area of the second set of FPC bonding pads equals to that of the third set of FPC bonding pads.
In one aspect of the present invention, each area of the second set of panel bonding pads is identical with each area of the first set of FPC bonding pads.
In one aspect of the present invention, each area of the first set of panel bonding pads is identical with each area of the second set of FPC bonding pads.
In one aspect of the present invention, each area of the plurality of panel bonding pads is identical with each area of the plurality of FPC bonding pads.
Compared to the prior art, the present invention provides a design of a bonding pad of a LCD panel and a flexible printed circuit (FPC). Each bonding pad is divided into three sections. Therefore, more bonding pads can be disposed on a high resolution panel without reducing total bonding width. Furthermore, the bonding pad with three sections, the FPC bonding pad and the panel bonding pad which are coupled with each other have different area so that misalignment is avoided in the process of bonding of the FPC and panel bonding pad. Besides that, a bonding area of each FPC bonding pad and panel bonding pad are substantially the same to assure resistance.
These and other features, aspects and advantages of the present disclosure will become understood with reference to the following description, appended claims and accompanying figures.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a local diagram of a LCD device in the prior art.
FIG. 2 is a local diagram of a LCD according to the present invention.
FIG. 3 to FIG. 6 are a manufacture diagram of the panel bonding pad of the LCD according to the present invention.
FIG. 7 is a sectional diagram of the panel bonding pad along with the X section in the present invention.
FIG. 8 is a sectional diagram of the panel bonding pad along with the Y section in the present invention.
FIG. 9 is a diagram of the panel bonding pad in FIG. 6 bonded with the FPC bonding pad.
FIG. 10 is a local enlarged diagram of FIG. 9 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Please refer to FIG. 2 . FIG. 2 is a local diagram of a LCD 200 according to the present invention. For brevity, FIG. 2 only shows bonding areas of the FPC and LCD panel in the LCD 200 .
As shown in FIG. 2 , the LCD panel 200 comprises a plurality of metallic wires 210 and a plurality of panel bonding pads 220 each of which is at an end of each metallic wire 210 . The metallic wire 210 serves as a data line or a scan line on an LCD panel which is coupled to pixel (not shown) for transmitting signals from external driving chip to drive pixels. Furthermore, the FPC correspondingly has a plurality of metallic wires 230 as well, and there is a FPC bonding pad 240 at the end of each metallic wire 230 .
The arrangement of the bonding pad of the LCD 200 in the present invention is different. The panel bonding pad 220 /FPC bonding pad 240 is arranged in three sections L 1 , L 2 and L 3 (separating by dotted sections). Noted that each panel bonding pad 220 /FPC bonding pad 240 is divided into three sections L 1 , L 2 , L 3 . Therefore, such design decreases width of area of whole bonding pads so that there is no need to reduce area of bonding pads or decrease pitch between bonding pads. For instance, the two metallic wires which are coupled between the section L 2 and the section L 3 substitute for a bonding pad of the section L 2 and the section L 3 between two adjacent bonding pads of the section L 1 . In hence, it is able to narrow width of whole bonding pads on account of the width of metallic wires being narrower than that of bonding pads.
In another aspect of the embodiment, each area of the sections L 1 , L 2 and L 3 of the panel bonding pad 220 is different. As FIG. 2 shows, an area of the section L 1 of the panel bonding pad 220 is smaller than that of the section L 2 of the panel bonding pad 220 , and an area of the section L 2 of the panel bonding pad 220 is approximately equal to that of the section L 3 of the panel bonding pad 220 . On the other hand, each section L 1 , L 2 and L 3 of the FPC bonding pad 240 has corresponding area. In the embodiment, measure of the FPC bonding pad 240 of the section L 1 is smaller than that of the FPC bonding pad 240 of the section L 2 , and measure of the FPC bonding pad 240 of the section L 2 is approximately equal to that of the FPC bonding pad 240 of the section L 3 . In addition, measure of the FPC bonding pad 240 of the section L 2 is approximately equal to that of the panel bonding pad 220 of the section L 1 , and measure of the FPC bonding pad 240 of the section L 1 is approximately equal to that of the FPC bonding pad 220 of the section L 2 .
As FIG. 2 shows, such design is able to make sure that bonding area of the FPC bonding pad 240 and the panel bonding pad 220 in each section L 1 , L 2 and L 3 is the same with each other. In hence, the contact resistance is assured.
Please refer to FIG. 3 to FIG. 8 . FIG. 3 to FIG. 6 are diagrams of forming the panel bonding pad 220 of the LCD according to the present invention. FIG. 7 is a sectional diagram of the panel bonding pad along with the X section in the present invention. FIG. 8 is a sectional diagram of the panel bonding pad along with the Y section in the present invention. As FIG. 3 shows, taking the first metallic layer M 1 the processes, such as lithography etching, to form the structure of the bonding pad 220 in three sections and the metallic wires. Area of the bonding pad 220 in the first section L 1 is smaller than that of the bonding pad 220 in the second section L 2 /the third section L 3 .
And then, an insulting layer 250 (illustrated in FIG. 7 and FIG. 8 ) is deposited on the first metallic layer M 1 .
As FIG. 4 shows, the second metallic layer M 2 is formed on the first metallic layer M 1 by lithography etching to form the structure of fan-out. In other words, each metallic wire coupled to the pixel area form a two-layer structure. The metallic wires at the one end of the bonding pad 220 and not coupled to the panel utilizes the first metallic layer M 1 , and the second metallic layer M 2 just occupies a half of the bonding pad 220 . And then, a passivation layer 252 is deposited on the insulating layer 250 (illustrated in FIG. 7 and FIG. 8 ).
As FIG. 5 shows, the insulating layer 250 on the first metallic layer M 1 is etched to form a via 254 . Furthermore, a passivation layer 252 over the second metallic layer M 2 is etched to form a via 256 .
Finally, as FIG. 6 to FIG. 8 show, a transparent conducting layer 258 which covers the passivation layer 252 and the gate insulating 250 is sputtered at the position of the bonding pad 220 for electrically connecting the first metallic layer M 1 to the second metallic layer M 2 through the via 254 , 256 by the transparent conducting layer 258 .
Noted that the insulating layer 250 is between the first metallic layer M 1 and the second metallic layer M 2 , and the passivation layer 252 is formed on the second metallic layer M 2 . However, for clarify, the insulting layer and the passivation layer in FIG. 3 to FIG. 6 are not shown. Therefore, the first metallic layer M 1 /the second metallic layer M 2 be coupled to external driving chips or data lines or scan lines of a LCD panel through the vias 254 , 256 which penetrate the passivation layer/insulating layer, respectively.
Please refer to FIG. 7 and FIG. 8 . FIG. 7 is a cross section view of the panel bonding pad 220 in a horizontal direction according to the present invention. And FIG. 8 is a section view of the panel bonding pad 220 in a vertical direction according to the present invention.
Please refer to FIG. 7 and FIG. 8 first. The bonding pad 220 comprises a first metallic layer M 1 , an insulating layer 250 , a second metallic layer M 2 , a passivation layer 252 and an transparent conducting layer 258 . The insulating layer 250 is placed between the first metallic layer M 1 and the second metallic layer M 2 , and the passivation layer 252 is on the second metallic layer M 2 . In addition, the insulating layer 250 and the passivation layer 252 open the via 254 and 256 respectively for laying the transparent conducting layer 258 through the via 254 and 256 to make the first metallic layer M 1 and the second metallic layer M 2 transmit electrical signals by the connection of the transparent conducting layer 258 .
Please refer to FIG. 9 . FIG. 9 is a diagram of the panel bonding pad 220 in FIG. 6 bonded with the FPC bonding pad 240 . As mentioned before, according to proper bonding pad position and measure, the FPC bonding pad 240 in the first section L 1 is larger while the panel bonding pad 220 in the first section L 1 is smaller, and meanwhile, width of the FPC bonding pad 240 in the first section L 1 is equal to that of the panel bonding pad 220 in the second/third section. On the other hand, the FPC bonding pad 240 in the second/third section is smaller but width is equal to the panel bonding pad 220 in the first section, and length of the FPC bonding pad 240 in three sections are the same. Such design assures the bonding area of the FPC bonding pad 240 and the panel bonding pad 220 in each section the same, so that there is equal contact resistance in each section.
Please refer to FIG. 10 . FIG. 10 is a local enlarged diagram of FIG. 9 . Since different sizes of the bonding pads 220 , 240 in three sections L 1 , L 2 , and L 3 , the pitch A between the first section L 1 of the FPC bonding pad 240 and the nearby metallic wire is shorter than the pitch B between the second/third sections L 2 , L 3 of the FPC bonding pad 240 and the nearby metallic wire in FIG. 10 Please note that the pitch B is set to be greater than a width complying with accuracy of alignment using a machine. Therefore, even if misalignment occurs, the FPC bonding pad 240 in the second/third section is avoided to be bonded to metallic wires, preventing from signal transmission errors. The pitch A between the FPC bonding pads 240 in the first section L 1 is narrower. If an offset, due to misalignment, exceeds the pitch A, the FPC bonding pad 240 may be located over the metallic wires. However, since the metallic wires on bottom of the FPC bonding pad 240 in the first section L 1 , are made of the first metallic layer M 1 , and the insulating layer 250 and the passivation layer 252 are between the metallic wires and the FPC bonding pad 240 , conductive particles of anisotropic conductive film (ACF) are not capable of penetrating the first metallic layer M 1 to cause abnormal signal transmission.
Please take notice that, the bonding pad 220 / 240 adopts three sections in the embodiments. Practically, the use of four or more sections is also allowed and in the scope of the present invention.
While the present invention has been described in connection with what is considered the most practical and preferred embodiments, it is understood that this invention is not limited to the disclosed embodiments but is intended to cover various arrangements made without departing from the scope of the broadest interpretation of the appended claims.
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The present invention provides a design of a bonding pad of a LCD panel and a flexible printed circuit (FPC). Each bonding pad is divided into three sections. Therefore, more bonding pads can be disposed on a high resolution panel without reducing total bonding width. Furthermore, the bonding pad with three sections, the FPC bonding pad and the panel bonding pad which are coupled with each other have different area so that misalignment is avoided in the process of bonding of the FPC and panel bonding pad. Besides that, a bonding area of each FPC bonding pad and panel bonding pad are substantially the same to assure resistance.
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BACKGROUND OF THE INVENTION
This application is a continuation in part of application Ser. No. 10/397,498, filed Mar. 26, 2003.
This invention concerns the composition, structure and fabrication of a high voltage cable that leads to and is connected to a miniature x-ray source, for applications including post-operative radiation of breast tissue and treatment within various lumens of the human body, including blood vessels.
Miniature or small x-ray tubes for human therapeutic treatment are discussed in several prior patents, including U.S. Pat. Nos. 5,854,822, 5,621,780 and 6,319,188, as well as co-pending application Ser. No. 10/397,498, commonly owned with this application. Such small x-rays tubes have been proposed or developed for the purpose of treating tumors within surgical openings in the body, for treatment within blood vessels using a catheter that contains the tube, and for other radiation treatments within the body. The cited pending application describes a cathode assembly with a cathode manufactured by MEMS technology and discloses a means of forming an extractor cup and electrically connecting the extractor cup to high voltage. The application also discloses several configurations for the high voltage cable of the device, which also carries cathode heating current on multiple inner conductors, in configurations that maximize dielectric properties to prevent arcing to a ground at an outer position on the cable. The application discloses several embodiments, and shows a form of connection of the cable to the cathode end of an x-ray tube.
The x-ray tube potential contemplated for such miniature x-ray devices is greater than 25 kV, and preferably greater than 40 kV and may be 50 kV or greater. The insulation and components in the cable, which must be quite flexible and small in diameter, preferably smaller than the x-ray tube, are required to withstand very high dielectric fields. Effective insulating material must surround and encapsulate the high voltage interior conductors, insulating them from the exterior ground. Providing enough insulating protection within a very small profile, so as to prevent arcing and cable failure, is a challenge. Placing as much insulating protection in as small a profile as possible must be achieved, while lowering the field gradient as much as possible. Such a challenge involving high voltage and extremely small size has not previously been undertaken, because the typical HV cable situation has involved much larger size or much lower voltages. Materials and design are critical, and become much more critical with reductions in size, to the order of about 1 mm external diameter, often with a requirement to pass through tight radius curves.
High voltage is divided along any path between conductors at different potentials whether or not there is a gas, solid or liquid between the conductors. The division of voltage can be proportional to the distance (linear division) or some other distribution. If the distribution is not linear, there will be a place where the voltage gradient is higher than the average linear gradient. This distribution can change with time as well as due to breakdown and material damage. When the distribution is higher than the dielectric being used can support an arc can occur.
If a solid insulator is used as the dielectric, it is normally very high resistance material. The voltage divides between the conductors based mostly on capacitance of the dielectric.
Some polymers have excellent insulating properties, rated better than glass as dielectrics. However, glass can be the ultimate insulator because it can be drawn nearly flaw free. When the glass is nearly perfect it is the optimum dielectric material for a miniature HV cable. If glass is used, sealing of the glass to the conductors is critical. In the present invention described below, glass is used as a primary insulator in several embodiments, but the use of polymers is also disclosed in several embodiments.
At the cathode end of the x-ray tube, the HV cable must be connected in a way that is rugged, that does not greatly reduce flexibility of the device so as to be capable of travel through a tight design radius, and in a way that makes effective connections of the HV conductors, including the ground, without introducing conditions that would promote arcing and breakdown.
Solutions to these problems are the subject matter of the current invention described below.
SUMMARY OF THE INVENTION
In a miniature x-ray tube, on the order of approximately 1–4 mm in diameter, preferably 2 mm or 1 mm or even less, a high voltage cable is provided in various embodiments for conducting current and high voltages to the cathode of the x-ray tube and for providing ground to anode of the tube. For many radiation procedures in patient lumens or tissue, the cable must have sufficient flexibility to pass through tight curves. In preferred embodiments the cable of the invention can pass through curves having radius at least as small as 10 times the outside diameter of the cable preferably about 8 times the OD.
In various embodiments of the cable, at least two conductors occupy a center region of the cable, packed as closely together as possible, in various shapes that are compact and present as smooth as possible an external shape for maximizing dielectric properties against the exterior high voltage ground, surrounding and generally concentric with the inner conductors. The inner conductors, which carry high voltage in opposition to the outer ground, can be in opposed D shapes, coaxial, two flattened conductors side by side, or simply a pair of cylindrical wires positioned as closely as possible. The space between the inner conductors and the outer ground can be occupied by a glass insulator, a mixture of polymers and dielectric fillers, polymer, successive layers of polymers and adhesive, air, gas, vacuum or other dielectrics.
If the dielectric is loaded so that it is a semiconductor, and a nominal amount of current is allowed to flow between the conductors, the voltage gradient that is established will be due to the resistive divider rather than the capacitance of the insulator material. When a flaw is present that might defeat part of the dielectric withstand of the insulator, the resistive divider will work to smooth out the voltage distribution due to the parallel nature of the linear resistor.
Polymers are traditionally used to electrically insulate conductors in a cable from each other and from external influences. However, because of the nature of the x-ray tube and its requirements to be capable of sustaining high vacuum and bake out temperature environments, polymer seals on the x-ray tube are not possible. An alternative to insulating conductors with the polymers is to insulate them with glass. While glass provides an effective electrical insulation, it is susceptible to fracture at low stress levels unless protected. When protection is applied at the time of insulating glass manufacture, strength of the glass is up to 100 times that typically observed. This high initial strength can be preserved through the application of surface protective coatings onto the glass. This technology is utilized in the manufacture of fiber optic cables to allow fibers to tolerate the high stresses that occur during fiber bending and handling. Herein, the concept of surface protection of glass insulated metallic conductors is disclosed.
To be effective the seal between the metal conductors and the glass insulator must be good enough as to not compromise the vacuum integrity of the x-ray tube device. Also at all locations the seal between the metal conductors and glass must be adequate to avoid HV corona breakdown at the interface. These are considerations in the choice of materials, configuration and construction of the HV cables.
It is thus an object of the invention to provide efficient HV cables in very small diameters, in some embodiments not larger than about 4 mm and in some embodiments down to about 1 mm or even less, the cables exhibiting ruggedness, reliability, high dielectric strength and the ability to turn about tight radii. These and other objects, advantages and features of the invention will be apparent from the following description of a preferred embodiment, considered along with the accompanying drawings.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a view showing a high voltage cable of the invention connected to an x-ray source at its distal end, and indicating a control unit.
FIG. 2 is a schematic cross-sectional view showing one embodiment of the high voltage cable, with a pair of spaced apart, generally cylindrical conductor wires as inner conductors.
FIG. 3 is a cross-sectional view similar to FIG. 2 with conductors similar to FIG. 2 but including a resistive/partially conductive coating or composite over the two inner conductors.
FIG. 4 is another cross-sectional view similar to FIG. 2 , and showing a pair of back-to-back D-shaped conductors as the inner conductors.
FIG. 5 is a view similar to FIG. 4 and with similar conductors, but including a resistive/partially conductive coating or composite over the inner conductors.
FIG. 6 is another cross-sectional view showing a high voltage cable, in this case with flattened conductors each of elongated cross-section.
FIG. 7 is a cross-sectional view similar to FIG. 6 , and with similar inner conductors, but with a resistive/partially conductive coating or composite over the inner conductors.
FIG. 8 is a cross-sectional view of a high voltage cable, in this embodiment showing a pair of inner conductors that are coaxial.
FIG. 9 is a cross-sectional view showing coaxial inner conductors in accordance with another embodiment, in this case with the inner conductor having insulative coating and the outer conductor comprising a further coating of partially resistive material.
FIG. 10 is a cross-sectional view schematically showing another embodiment of a high voltage cable, in this case with two generally cylindrical and spaced apart inner conductors as in FIG. 3 , with a resistive/partially conductive coating or composite around the conductors, but in this case with an insulative coating over one of the inner conductors.
FIGS. 11 and 12 are similar perspective views showing high voltage cables formed of clad glass insulated wires in somewhat modified embodiments.
FIG. 13 is a perspective view showing a high voltage cable construction with multiple layers of polymer and adhesive.
DESCRIPTION OF PREFERRED EMBODIMENTS
In the drawings, FIG. 1 shows schematically a system 10 according to the invention for administering x-rays using a switchable x-ray source. The system includes a miniature x-ray source 12 at the distal end of a cable 14 , connected to a controller 16 . The cable and x-ray source 14 , 12 have important uses inside the human body, for various purposes discussed above. A connector 18 preferably is included, at a position which will remain outside a patient's body.
The cable 14 leading to the x-ray source 12 carries high voltage potential, up to about 50–60 kV, as well as carrying a low voltage cathode filament heater circuit. The low voltage conductors preferably also carry high voltage potential. The construction of such a cable, which must be small in diameter, flexible to travel around tight-radius curves and having a high dielectric property so as to resist breakdown, is the primary subject of the remaining drawings and of the discussion below.
FIG. 2 shows one embodiment of a high voltage cable 14 . The cable 14 has a pair of inner conductors 20 and 22 , which in this embodiment are positioned side by side and spaced apart so as not to short the low voltage carried by these two inner conductors for heating the cathode. The two inner conductors 20 , 22 may be held in position appropriately while being clad with a resistive dielectric 24 surrounding the inner conductors. On the outside of this resistive dielectric 24 is an outer, coaxial conductor 26 which carries high voltage ground potential.
If the resistive dielectric 24 is glass, it is most preferably nearly flaw free drawn glass, preferably fiber optic quality.
As an alternative, the dielectric material 24 can comprise a polymer material of high dielectric strength. Such insulating polymers can be effective for this purpose, but generally are not as effective as nearly-pure drawn glass, and may require a larger overall diameter in order to achieve sufficient separation between inner conductors and the outer conductor to prevent arcing and breakdown.
In the assembly of FIG. 2 , the two inner conductors may be coated with a thin layer of insulation, or only one of the conductors may be so coated, and the two conductors may then be in contact. Otherwise, the two conductors 20 and 22 are held in a slightly spaced apart relationship as they are assembled with the insulation 24 .
The ground layer 26 just outside the dielectric 24 can be made up of many very small diameter conductors, wrapped in a spiral or in a braid pattern around the dielectric. Alternatively, this ground can be formed of a conductive metallic material which is sputtered or evaporative coated onto the outside surface of the dielectric 24 .
A jacket layer 28 is shown surrounding the ground layer 26 on the cable 14 .
FIG. 3 shows a modified high voltage cable construction. The modified cable 14 a has construction similar to that of FIG. 2 with a pair of inner conductors 20 and 22 , but in this case the inner conductors, one or both of which may have a thin insulated coating, are together covered with a resistive/partially conductive coating 30 . The layer 30 is in a circular or slightly oval or elliptical shape and helps avoid breakdown in a very small cable carrying high voltage leading to the miniature x-ray tube. The coating 30 enshrouding the conductors 20 and 22 can have two advantages. First, this presents a smooth and round, circular or nearly-circular transition as an interface where arcing from the high potential must be held off from the opposing HV conductor, the ground 26 . Arcing is more likely to occur if the inner HV conductors present an irregular surface toward the outer ground. Second, there is advantage to having a field-softening transition between the central area, where the cathode heater wires are located, and the outer ground.
The dielectric strength of the insulator in the cable has some intrinsic breakdown voltage and if the gradient across it is uniform and is very near that breakdown voltage, the cable is being used to its maximum or optimized extent. If the actual gradient between the high voltage center conductor and the ground is not uniform, then wherever it is higher than the average it potentially will break down that dielectric causing a cascade of voltage breakdown which will cause the cable to fail. So, rather than allowing the very high resistivity of the material—something typically on the order of 10 15 ohm-cm for these materials—to define the gradient, if one puts a dopant in the dielectric it allows the cable to be somewhat lossy, especially around the center. This will establish a desired gradient and thereby insure that the gradient is always optimized.
Thus, the dielectric 24 is loaded so that it becomes a semi-conductor in the inner region 30 surrounding the center conductors, and a nominal amount of current is allowed to flow between the center conductors, assuming neither of them has an insulative coating. The voltage gradient that is established will be due to the resistive divider rather than the capacitance of the insulator material. When a flaw is present that might defeat part of the dielectric withstand of the insulator 24 the resistive divider will work to smooth out the voltage distribution due to the transition and due to the parallel nature of the linear resistor.
The only negative effect of this resistive/partially conductive coating or region theory is that the cable becomes somewhat lossy, and some power is dissipated in the cable, as a small amount of heat. This can be extremely small compared to the power that is put through the cable and thus is a reasonable tradeoff for the cable's not being perfectly insulated.
In a similar geometric approach to FIG. 3 , conductors 20 and 22 may be insulated to prevent any substantial resistive divider network to develop. In this case the resistive region 30 is made up of a polymer/conductor or polymer/semi-conductor or a glass/conductor or a glass/semi-conductor such that the composite acts as a semi-conductor. By selection of the semi-condcutor additive, AC field absorbing attributes can be developed which results in an advantage that allows the cable to better tolerate transient changes (for example, caused by arcs in the x-ray source) that occur during operation. Both carbon conductors and ferrite semi-conductors are useful in this regard.
In FIG. 3 , the resistive/partially conductive coating or region 30 , which masks the non-circular symmetry of the center conductors can be consistent in resistivity/conductivity throughout the region 30 where it is present, with an abrupt change to the very high resistance of the dielectric insulative material 24 , or it can be in a diminishing gradient outward from the center. In the latter case, the conductivity tapers off gradually, due to any distribution of dopant in the insulator diminishing with increasing radius, and this can continue all the way to the outer ground 26 . This eliminates any hard boundary and may have the effect of eliminating any sharp wall from which breakdown could occur.
FIG. 4 shows in cross section another HV cable construction, in this case with inner conductors 20 a and 22 a being back to back D-shaped conductors as shown. Again, the goals are to present a smooth surface at the composite high-voltage carrier and to make the pair of conductors together as small as possible, leaving more distance for dielectric material 24 between these center conductors and the outer ground 26 . The two D-shaped conductors, if separated by a very thin insulator, present a nearly cylindrical surface toward the ground. The remaining construction of the cable 14 b of FIG. 4 can be, as in FIG. 2 , with the outer jacket (not shown) and with a high dielectric polymer as the insulative material 24 , or more preferably, nearly perfect drawn glass as the insulator 24 .
In FIG. 5 , a HV cable 14 c is similar to the cable 14 b of FIG. 4 , but in this case a resistive/partially conductive coating or region 30 a is included surrounding the D-shaped center conductors 20 a and 22 a . Thus, the cable 14 c gains the advantages discussed above relative to the constructions of both FIGS. 3 and 4 and can be even more effective in preventing breakdown.
In FIG. 6 partially flattened center conductors 20 b and 22 b are shown, in an HV cable 14 d . The two flattened conductors, which can be rolled cylindrical conductors to the flattened shape, again make compact the pair of center conductors, in a simple and easily executed configuration. The conductors 20 b and 22 b can be spaced apart slightly or one or both can have a thin coat of insulation, holding off the low differential voltage required for cathode heating. As in the previous embodiments described above, the ground 26 at the outer surface of the dielectric 24 can be formed by dipping the formed cable with dielectric 24 into molten metal, such as aluminum. It can also be formed as a braided sheet of very small wires, or by helical wrapping of wires, preferably in two counter-directions.
FIG. 7 shows a modification of the construction of FIG. 6 in which an HV cable 14 e has flattened center conductors 20 b , 22 b that are coated with a resistive/partially conductive coating 30 b , as in FIGS. 3 and 5 , and with similar advantages.
In FIG. 8 , a HV cable 14 f has a coaxial pair of inner conductors 35 and 36 . This can be an optimal design for presenting a smooth surface of the inner conductors collectively to the outer ground 26 , as an efficient design for holding off arcing and breakdown. The two conductors 35 and 36 may be closer together than what is represented in the not-to-scale drawings, the only requirement being a thin layer of insulation 38 between center conductor 35 and the coaxially arranged second conductor 36 surrounding the inner conductor. Such insulation layer 38 can be of a polymer or glass material.
FIG. 9 is another cross-sectional view that schematically indicates a further form of HV cable 14 g . In this case, the inner conductors 35 and 36 again are coaxial, but the assembly includes an outer layer 40 of resistive/partially conductive material 40 generally as was applied in FIGS. 3 , 5 and 7 . Again, as in FIGS. 3 , 5 and 7 , this layer 40 can have a sharply defined boundary 40 a or it can be on a gradient, from most conductive adjacent to the coaxial conductor 36 to least conductive and very highly resistive at a location such as shown at 40 a , or extending substantially entirely out to the ground 26 . This particular construction provides essentially a maximum protection against breakdown in the cable.
FIG. 10 shows another embodiment of a HV cable 14 h , in this case with two generally cylindrical and spaced apart inner conductors 20 c and 22 c as in FIG. 3 , and with a resistive/partially conductive coating 30 c surrounding the two inner conductors. In this case an insulative coating 42 , which may be of glass, surrounds one inner conductor 20 c (the drawings are not to scale). The two inner conductors 20 c and 22 c can thus be held tightly together with one of them insulated. The resistive/partially conductive coating 30 c may be as described above with respect to other embodiments.
It should be understood that in all embodiments described above, the dielectric material 24 can be a polymer material with very good insulative properties, rather than glass. However, in general the smaller the outside diameter of the HV cable, the more it becomes important to use a nearly perfect drawn glass as the dielectric 24 , for maximum withstand properties.
In the event a resistive/partially conductive layer or region is included surrounding the inner conductors, as in FIGS. 3 , 5 , 7 , 9 and 10 as described above, this layer or region can be formed in various ways. One way is to dope the center region with semiconductive particles such as titanium or an oxide of titanium (oxidation may occur during processing) when the glass is in a molten state, form the insulator around the inner conductive wires, whether this is done by drawing a glass preform on the wires or by providing a glass tube within which the wires are placed, and then filled under vacuum with a low viscosity curable material (such as by light). With the doping material in place, the partially conductive region can have a fixed boundary at a particular radius, or it can be heated to the point of flowing so as to fuse the glass and cause the doping to spread outwardly, forming the gradient-placed conductive material which is advantageous as discussed above. Alternatively, multiple layers can be assembled, each having different resistance. The resistive/partially conductive layer or region can be extruded, with the conductors captured in the extrusion. If desired to establish a gradient of conductivity, layers of extrusion can be formed successively, each with less conductive doping. If desired the composite structure could then later be heated to fuse the layers together.
As reviewed above, the dielectric material surrounding the inner conductors can take several forms, and can be assembled onto the conductors in several different ways. Generally, the smaller the diameter (e.g. down to 1 mm or even down to about 0.5 mm) the more it becomes necessary to use drawn glass substantially of fiber optic quality, which is nearly perfect and is an excellent dielectric. Nonetheless, various methods and materials for constructing a small HV cable are discussed below.
One method is to use a glass tubing into which the conductors are inserted. The conductors can be overcoated with a polymer before insertion to prevent damage to the glass tube inside surface, and they can be potted into the glass tubing internal diameter with a dielectric polymer such as one of several silicone products. The conductors could be pre-overcoated with glass, followed by a polymer overcoat, and then with a polymer potting the coated conductors into the interior of the glass tube.
In another method of fabrication, glass is drawn around the metallic conductors. The metallic conductors can be bare, and held apart appropriately, or more preferably, the metallic conductors, or one of them, can be precoated with a glass coating. The inclusion of a thin insulative coating on one of the conductors allows the conductors to be placed tightly and compactly together within the insulator surrounding the conductors. Various glasses have been investigated and developed to allow a heat seal to be successfully made between the HV cable and the x-ray tube envelope (shown schematically at 12 in FIG. 1 ). These include silica glass clad with polymer; silica glass clad with aluminum; borosilicate glass (e.g. from Corning), either as tubing within which the conductors are placed, or with the glass drawn around the conductors; and alumino silicate glass (e.g. Schott 8250 or 8253 or Kimble N51A), drawn around conductors. The cladding acts as a buffer to protect the essentially fiber optic quality glass which otherwise will begin to degrade by developing surface micro cracking very quickly after drawing, if the buffer is not added to protect the surface. These glass types can be used with any of the disclosed embodiments in FIGS. 2 through 10 .
FIGS. 11 and 12 show in perspective two different examples of clad glass insulated inner conductive wires in an HV cable. In FIG. 11 an HV cable 50 has a pair of conductors 20 d , 22 d that are shown spaced apart but which can actually be very close together. In this case they are shown not individually coated with insulation, although one or both can be clad with an insulative material such as glass. Preferred materials for the conductors are molybdenum, tungsten, or gold/palladium/platinum clad versions. The wires can also be niobium or osmium, or similarly clad versions of these materials. Glass insulation is shown at 24 a , surrounding the 2 conductors 20 d and 22 d . Fabrication and material can be by the various techniques described above.
As discussed above, a metal or polymer protective cladding 52 is secured on the outside of the insulator 24 a . This protective cladding can be, for example, any of the metals aluminum, nickel, gold, platinum or palladium or alloys thereof. Polymers for this purpose include polyimide. Surrounding this protective cladding, if the cladding is of an insulative material such as polymer, will be the ground conductor (not shown). The ground conductor is indicated at 26 in some of the drawings discussed above. As discussed earlier, it can be formed of fine braided wire or fine wires wrapped helically around the cladding and repeated in the opposite direction, covering almost the entire surface; or the ground could be solid metal, deposited as by coating or plating.
In FIG. 12 a variation is shown of the construction in FIG. 11 . Here, the metallic conductors 20 d , 22 d are first covered with insulation, or preferably only one of them is covered with insulation. This can be a glass cladding, very thin, and the conductors can then be positioned tightly together. If desired, the cladding can be a polymer, since the assembly will not be heated to a high temperature. The insulator 24 b in this case is a pre-formed tube as discussed above, within which the metallic conductors 20 d , 22 d are placed, and are potted therein with an infiltrated polymer dielectric 54 . The dielectric 54 is added by squeezing it in after the wires are inserted. The polymer chosen must wet the surfaces to exclude adherent air bubbles. A vacuum can be used to remove air prior to adding the polymer dielectric.
At the outside of the glass insulation tube 24 b in the HV cable 50 a is a metal or polymer cladding 52 a , which can be configured and constructed as discussed above relative to FIG. 11 . Again, if the cladding is non-conductive, then a braided or other type of ground is placed around the outside of the cladding 52 a . As an alternative, a metal coating can be applied for the ground, as by dipping or drawing the cable into or through a molten bath of metal.
As outlined above, high dielectric polymers can be used as the insulator in many cases. One method of preparing the cable is to co-extrude the inner conductors with the polymer insulation. The insulating material must surround and encapsulate the high voltage (inner) conductors, with minimized voids between the inner conductors and the insulating material. Co-extrusion can accomplish this purpose. The inner conductors are small gauge metal wires, which may be about 33 gauge or smaller. The inner conductors are sent through a circular extrusion die and are surrounded by molten polymer. In a similar way, the extrusion can be accomplished in two steps for cables with semi-conductive inner layers like those shown in FIG. 3 . The inner layer polymer would contain semi-conductive additives, where the outer layer would act as the HV dielectric. In either case, following extrusion, the polymer and conductor assembly is cooled and hardens to a solid state, leaving virtually no gaps or voids between the inner conductors and the insulation. This assembly can withstand a high voltage as is contemplated by the invention (50 kV or higher), provided the outer diameter of the cable is not too small. This assembly works well for outer diameters of about 3 mm. In one specific embodiment the OD of the polymer is about 2.2 mm and OD of the cable is about 3.2 mm, in a 50 kV cable.
FIG. 13 shows in perspective an alternative construction for an HV cable 55 . Here, a pair of conductors 56 and 57 , shown spaced apart but preferably with at least one of the conductor wires pre-coated with a high dielectric polymer material, are shown at the center of the HV cable assembly. In this case the insulator for the cable is formed of a series of layers of TEFLON grade heat shrink material, and adhesive. Shown schematically (not to scale) at 58 , 60 , 62 , and 64 are layers of TEFLON grade heat shrink material. These layers, as the name implies, are applied by heat shrinking them onto the previous layer. Shown at 65 , 67 , 69 and 71 are adhesive layers, preferably a high dielectric silicon material. The outer layer 72 indicates further layers as desired.
The adhesive/silicon layers provide for HV creep and bond the layers together substantially without voids. The TEFLON grade heat shrink can be the same material or different heat shrink materials in different layers. These multiple layers provide for high dielectric withstand; minimize effects of any localized defects on the heat shrink layers by offsetting them using the layering format; and provide optimum electric field control by carefully choosing the desired combination of different grades of heat shrink materials. When adhesive is used between layers of heat shrink to remove trapped air pockets, the heat shrink tubing is chemically etched or plasma etched to increase the bondability of the plastic surface. In some cases, silicon layers applied between the heat shrink layers will provide high voltage creep resistance as noted above. Choosing the adequate heat shrink material is important. Some preferred materials are high quality FEP and/or PFA, both being TEFLON grade. Certain heat shrink FEP polymers were specially processed to rid them of insoluble particulate impurities to reduce the tendency of internal corona formation during high voltage stress. The construction shown in FIG. 13 can be effective down to about 2 mm OD of the outer layer 72 .
The above described preferred embodiments are intended to illustrate the principles of the invention, but not to limit its scope. Other embodiments and variations to these preferred embodiments will be apparent to those skilled in the art and may be made without departing from the spirit and scope of the invention as defined in the following claims.
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In a miniature x-ray tube, which may be on the order of approximately 1 mm in diameter or even less, a high voltage cable is provided in various embodiments for conducting current to the cathode of the x-ray tube and for conducting high voltage to the cathode and anode of the tube. In various embodiments of the cable, two conductors occupy a center region of the cable, packed as closely together as possible, in various shapes that are compact and present as smooth as possible an external shape for maximizing dielectric properties against the exterior high voltage ground, surrounding and generally concentric with the inner conductors. The inner conductors, which carry high voltage in opposition to the outer ground, can be in opposed D shapes, coaxial, two flattened conductors side by side, or simply a pair of cylindrical wires positioned as closely as possible. The space between the inner conductors and the outer ground can be occupied by a glass insulator, polymer, successive layers of polymers and adhesive, air, gas, vacuum or other dielectrics. A partially conductive region can surround the inner conductors.
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