description
stringlengths 2.98k
3.35M
| abstract
stringlengths 94
10.6k
| cpc
int64 0
8
|
|---|---|---|
BACKGROUND
This invention is directed to a locking mechanism which requires both a key and a corresponding combination wheel position to open the locking mechanism. A recorder records the combination wheel setting each time the lock is opened.
One of the types of mechanisms which has been developed to limit access to a designated space is the combination lock. In this case, one or more lock members must be set into an unlocking position by manipulation of one or more manual input elements. The numbered dial is often used, and either one dial is sequentially turned to successive positions or a plurality of dials is each set to a particular position to cause unlocking. The advantage of a combination lock is that a key may be lost or stolen, but a memorized combination is secure until disclosed by the person having the combination.
Another common type of lock is the key lock wherein a specially shaped key is inserted into the lock. The key causes mechanical action in the lock to position tumblers so that the lock is unlocked. Key locks may have a very complicated key-tumbler structure to increase the difficulty of lock-picking. However, loss of the key to another person permits access to the lock-protected space by that person. Furthermore, such keys can and sometimes must be duplicated so that many persons have access, with a greater chance of loss of control. Additionally, when many persons have keys and thus access to protected space, it is not known which of those among the authorized key holders have had access to that space. In order to identify the key user, U.S. Pat. No. 1,253,051 provides a key which has a first set of notches for properly positioning locking tumblers into the unlocked position and has a second set of notches which are peculiar to that key for actuating a recording device for recording which key has been used to open the lock and thus, presumably, identify the key user. However, such a key can be lost, duplicated, or the identifying portion can be altered or defaced to reduce the security of its recording system.
Another type of lock is the key-controlled combination lock. An example of this type of lock is shown in U.S. Pat. No. 3,383,886. In this type of lock, a key is used to unlock the combination dial, and once unlocked, the combination dial then is actuated to unlock the secured space. This type of lock provides the security of having possession of a key and possession of a combination to provide access to the secured space. Thus, loss or duplication of the key does not compromise the space because both knowledge of the combination and possession of the key are necessary for access. When a plurality of persons is permitted access, then the chances of compromise are compounded because the combination can be obtained from one holder and a key from another or by duplication. Furthermore, such a locking structure cannot provide for identification of the user so that, if compromised, that person cannot be identified.
Therefore, there is need of a locking mechanism which can be arranged so that it may be opened by a large number of people, but recording of the user can be achieved. Furthermore, it is desirable to maximize security of such a system by providing a structure wherein each user has two sets of unique information which cooperate together in the locking mechanism to permit access to the secured space and, at the same time, record information related to the user.
SUMMARY
In order to aid in the understanding of this invention, it can be stated in essentially summary form that it is directed to a locking mechanism which has a first input mechanism that is set to a first position unique to that user and also has a second input mechanism which is set to a second position unique to that user. When both mechanisms are set, the positioning of one of them identifies the user, and the related positioning of the two of them permits unlocking so that first and second unique inputs are required of a user for unlocking a lock. Many different keys and combinations are possible for each lock.
Accordingly, it is an object of this invention to provide a locking mechanism which requires first and second inputs, the inputs being unique to the user and related to each other so that, when they are both input into the locking mechanism, the locking mechanism not only is unlocked but records at least one of the unique inputs to identify the lock user. It is another object to provide a locking mechanism where one unique input is a key and the related unique input is a numeral combination so that, when both of them are placed into the lock, the lock is opened and at least one of the unique inputs is recorded. It is a further object to provide a locking mechanism wherein tumblers are positioned by a key and combination wheels are located adjacent to the tumblers so that, when the combination wheels are correctly rotarily positioned, the lock barrel is unlocked for unlocking the mechanism.
It is another object to provide a locking mechanism which is particularly useful for locking a secure space to which access by many different persons is required so that recording of lock opening can be achieved. It is a further object to provide a locking mechanism which is particularly useful for high security controlled areas requiring access by more than one person. Applications include dangerous drug storage or secret files.
Other objects and advantages of this invention will become apparent from a study of the following portion of the specification, the claims, and the attached drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an isometric view of a preferred embodiment of the lock and key mechanism of this invention.
FIG. 2 is an enlarged section taken generally along the line 2--2 of FIG. 1.
FIG. 3 is a section taken generally along the line 3--3 of FIG. 2.
FIG. 4 is a section taken generally along the line 4--4 of FIG. 2.
FIG. 5 is a section taken generally along the line 5--5 of FIG. 4.
FIG. 6 is an exploded view of a preferred embodiment of the locking mechanism of this invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
A preferred embodiment of the locking mechanism of this invention is generally indicated at 10 in FIGS. 2, 4 and 6. It is a locking mechanism which can be employed to permit the locking and unlocking of any desired type of restricted space. In the present example, it is associated with lock housing 12 which is arranged to lock and unlock small chamber 14 in the lock housing itself. As seen in FIGS. 1, 2, 5 and 6, lock housing 12 has front 16 integrally formed with sides 18 and 20. Back 22 has top 24 integrally formed therewith. Back 22 is hinged to the sides with hinge pin 26.
As can be seen in FIG. 6, back 22 with its top 24 can be hinged away from the remainder of the lock housing. It can also be swung forward to the closed position and locked in place with separate lock 28. Lock 28 is conventional and has locking flange 30 which engages behind striker plate 31. By unlocking lock 28, the lock housing 12 can be moved from the closed position illustrated in FIGS. 1, 2 and 5 to the open position illustrated in FIG. 6 for access to the interior of lock housing 12. Thereupon, the lock housing can be closed and locked by key lock 28. Hasp 32 has oppositely bevelled tangs which can enter down through holes in top 24. The tangs also carry latching slots therein so that, when the hasp is pushed down through the openings illustrated in FIG. 6, lock plate 34 engages in the slots to hold the hasp in place, see FIGS. 2 and 5. In this way, the lock housing can be locked onto any solid device, such as a doorknob, an eye, or a post. The lock housing can be closed and locked at a central location where the lock use records are maintained and key 36 is kept. It can then be locked in its use location by insertion of hasp 32. By opening lock housing 12 by means of key lock 28, latch plate 34 can be released to release hasp 32 for removal. In this way, lock housing 12 can be secured at any location desired, and the holder of key 36 which operates key lock 28 is the person with access to the interior of the lock housing and can remove the lock housing.
Locking mechanism 10 controls access to chamber 14. When actuated, a recording of the combination used for access is made. The recording mechanism is within lock housing 12 so that the access information is available to the holder of the key 36. While the locking mechanism 10 will be described with respect to access to chamber 14, it is clear that the locking mechanism 10 can be employed for controlling access to and recording access to another chamber.
Locking mechanism 10 requires two separate and related inputs for its actuation. Furthermore, for any first input, the second input which causes opening is unique to that first input. In the illustrated preferred embodiment of the locking mechanism 10 shown in the drawings, the first input to the locking mechanism is presented by key 38, and the second input is presented by combination mechanism 40, see FIGS. 4 and 6. Locking mechanism 10 has barrel 42 in which is formed key slot 44. The key slot is illustrated as being a plane rectangular slot opening, but it may carry therein (on at least one side thereof) particular longitudinal shaping to limit the shape of the key that may be inserted. Key 38 has a shank 46 which can be longitudinally inserted into key slot 44. Shank 46 has a notch 48 which interacts with cup 50 so that key 38 cannot be turned until it is fully inserted. Key shank 46 carries cam groove 52 on the side thereof to act as a tumbler driver. Groove 52 has a wide, funnel-shaped open front end 54 to catch the pins on the tumblers as the key is inserted. The key serves to program the lock and is a first means or program input.
There is a plurality of tumblers of which each is slidably positioned in a tumbler slot which is oriented transversely to key slot 44. Five tumblers and five tumbler slots are shown. Tumblers 56 and 58 are specifically indicated in FIGS. 4 and 6. Tumbler pins 60 and 62 are respectively secured on these tumblers intermediate the ends thereof. The tumbler pins of each of the tumblers extend into key slot 44 to be controlled by cam groove 52. When the key 38 is inserted, the pins on the tumblers are picked up by the funnel-shaped front end 54 of the cam groove, and the tumblers are shifted in accordance with the shape of the cam groove. For convenience of manufacture, the cam groove can be shaped with a particular number of discrete tumbler positions, as is common in tumbler-type locks. For example, there can be five discrete positions of each of the tumblers along its tumbler slot normal to the direction of the insertion. In the present embodiment, it is seen that the tumblers are single-piece and double-ended; that is, they extend out of barrel 42 on both ends of the tumbler in all of the intermediate positions of the tumbler. Since the tumblers are positively driven, no springs are needed, and this reduces the pickability of the lock. Each tumbler must be positively set in its correct tumbler position in order to be in the desired unlocking position. When the key 38 is fully inserted, it can be turned to the right by the agency of notch 48 in the key shank cooperating with the opening in cup 50. This turning of the key does not unlock the mechanism, but permits the next stage of unlocking to be pursued.
Combination mechanism 40 comprises a plurality of combination wheels. Five combination wheels are shown and are indicated at 64, 66, 68, 70 and 72. The combination wheels provide a second input and thus are a second means. Combination wheels 66 and 68 are associated with tumblers 56 and 58. There is the same number of combination wheels as there are tumblers, and one of the tumblers is associated with each of the combination wheels, as is seen in FIG. 4. Each of the combination wheels has an interior hole 74 which engages directly around barrel 42. Each of them has a rim, of which rim 76 of combination wheel 66 is illustrative. The rims extend partly out through an opening at 78 in the front of lock housing 12 so that the rims are manually accessible, see FIGS. 1, 2 and 6. Thus, the lock operator can turn each rim and thus each combination wheel to a selected relative position. Numbers on the rims aid in selecting the desired position, although other types of indicia could alternatively be used. As is seen in FIGS. 2, 4 and 6, each of the combination wheels has a web, with the web 80 of wheel 64 illustrated in FIGS. 4 and 6, and the web of wheel 66 illustrated in FIGS. 2 and 6. Each of the webs of each of the combination wheels 64 through 72 lie adjacent to and on the left side of the tumblers when the locking mechanism 10 is in its locked position, as seen in FIG. 4. Each of the webs has a plurality of slots or radially positioned notches therein, each of the slots being related to a rotary position of the combination wheel and each being related to a particular axial position of its corresponding tumbler. The plural nature of the angularly positioned slots is illustrated in FIGS. 2 and 6 where different pairs of slots are positioned in accordance with the rotary setting of each combination wheel. The plurality of slots in web 80 is generally indicated at 84 in FIG. 6, and the plurality of slots in web 82 is generally indicated at 86 in FIG. 2. The diametrically opposed radial slots in the webs are dimensioned so that their ends are spaced apart just slightly longer than the length of the corresponding tumbler. Thus, when each combination wheel is properly angularly positioned with the proper indicia showing, than a slot (second member) of particular dimensional position is arranged adjacent a tumbler (first member) having a particular position. Blind shallow recesses of differing depths such as shown at 87 in FIGS. 2 and 4 are provided in the shape of tumblers at all angular positions of the wheels. This renders it impossible to "pick" the lock using a key for which the corresponding combination is not known, as for instance in the case of a key being found by an unauthorized person. Any attempt to pick the lock by loading the wheel with the key and testing for stiffness (which would indicate a wrong position) would be foiled because different recesses would "feel" like a correct wheel setting.
When all of the tumblers are arranged in a particular position as required (first means) by key 38 and each of the combination wheels (second means) is properly angularly set, then the tumblers are each lined up in the preselected position with a slot through a web at the same position. Now, barrel 42 can move to the left from the locked position of FIG. 4 to an unlocked position. In the unlocked position, movement of the barrel to the left places grooves 88 and 90 in the barrel adjacent side plates 92 and 94 on latching frame 96. Latching frame 96 is pivoted at 98 onto the pin 100 on back 22, see FIGS. 2 and 6. Spring 102 urges latching frame 96 toward the unlocked position.
As previously noted, notch 48 prevents turning of key 38 until it is fully inserted. Spring 104 urges barrel 42 to the right toward the unlocking position but, in order to prevent the moving tumblers from engaging upon the webs during key insertion (possibly by overcoming the force of spring 104), pin 106 (see FIG. 4) engages on the inside of cap 108 to take up the thrust until the key is fully inserted. After full insertion, cup 50 permits clockwise turning of key 38 through a small angle, for example 45 degrees, so that pin 106 lines up with aperture 110 in cap 108. In this orientation, with the combination wheels turned to the correct position, further thrust on key 38 moves the barrel 42 to the left in FIG. 4 to the unlocked position. When the unlocked position is reached, latching frame 96 swings forward.
As is seen in FIGS. 2, 5 and 6, latching frame 96 has sear 112 on its bottom. In FIG. 2, latching frame 96 is shown in its locked position wherein sear 112 is in the narrow portion of slot 114 to hold small chamber 14 in the raised position. When latching frame 96 swings to the unlocked position of FIG. 5, sear 112 is in the large part of slot 114 to permit the descent and opening of small chamber 14, as is shown in FIG. 5. In this way, small chamber 14 is unlocked and opened.
The swinging forward of latching frame 96 from the locked to the unlocked position, in addition to opening small chamber 14, also records the position of the combination wheels. Hence, a sequential record of the position of the combination wheels as the lock is opened is maintained which can be used to trace the persons who were issued those combinations. Recording is accomplished by projections 116 on the periphery of the combination wheels. The projections are patterned so that a specific pattern represents a specific angular orientation of each combination wheel. The projections face press pad 118 which is secured to locking frame 96. Supply roll 120 and takeup roll 122 feed film-like recording medium 122 across press pad 118. Pawl 126 on back 122 in cooperation with a ratchet wheel on takeup roll 122 causes advance of the recording medium each time latching frame 96 swings from the unlocked position to the locked position. Thus, each key provides a different program and the sequence of use is recorded. Takeup roll 122 with its sequentially recorded information is available to the holder of key 36.
In locking up, first chamber 14 must be closed. Reset lever 128, see FIG. 6, extends out of window 130 in the side of the lock housing. Reset lever 128 is manually engaged to swing latching frame 96 rearward to lock small chamber 14. Swinging latching frame 96 back also pulls side plates 92 and 94 out of grooves 88 and 90 so that barrel 42 can move to the right under the force of spring 104. This also pulls pin 106 out of aperture 110 so that key 38 can be turned to the upright position to remove notch 48 from the constraints of cup 50 so that key 38 can be withdrawn. Thus, key 38 can only be withdrawn when the secured chamber (small chamber 14) is again closed.
From this description, it can be seen that locking mechanism 10 can be unlocked with a plurality of keys 38 each having a different shape of cam grooves 52, providing that the corresponding positioning of the combination mechanism is achieved at the same time. Thus, different key shapes of key 38 can be distributed to different potential users of the secured or controlled space, and, with each key 38, a corresponding combination is provided. Thus, each unique key has a unique combination by which the locking mechanism can be unlocked. For security purposes, it is desirable to employ a key and a combination in conjunction with each other, for a key can be lost or stolen but, without the combination, cannot be employed. Furthermore, a combination can become compromised, but without the corresponding key, it cannot unlock the secured space. For this reason, the described mechanism is the preferred embodiment. However, the structure could be arranged with first and second combinations, the first uniquely setting a first portion of the mechanism, and the second uniquely unlocking the locking mechanism from that position. Similarly, two keys could be employed, the first uniquely setting the first portion of the mechanism and the second uniquely unlocking the mechanism from that position. Thus, first and second unique inputs permit recording of the lock user. Furthermore, while the locking mechanism is described in conjunction with a small secure chamber 14, it is clear that the swinging of the locking frame 96 can secure and release other types of secure chambers. In a real estate sales operation, a door key to a house for sale can be stored in chamber 14, and each real estate person can have a unique key 38 and a unique combination. By requiring two inputs to the locking mechanism and by recording each combination used, security is enhanced.
This invention has been described in its presently preferred mode, and it is clear that it is susceptible to numerous modifications and embodiments within the ability of those skilled in the art and without the exercise of the inventive faculty. Accordingly, the scope of this invention is defined by the scope of the following claims.
|
Locking mechanism has both a key setting multiple tumblers to unique positions and a combination wheel for each tumbler so that opening of the lock requires setting each wheel to correspond to its tumbler position. For a single lock, different keys require different combinations. A mechanical recorder records the wheel positions with each lock opening so that all combinations used for access can be read, if necessary.
| 4
|
BACKGROUND OF THE INVENTION
This invention concerns a stabilizer for deep well drilling tools.
With a known stabilizer of this type (U.S. Pat. No. 4,407,377), the ribbed bodies fit tightly in the slit openings of the outer casing and are sealed with respect to the slit openings. The outer longitudinal and end faces of the ribbed bodies thus form guide faces that are in sliding engagement with the inside faces of the slit openings opposite them as mating faces. The ribbed bodies are provided with projections that extend outward along the internal longitudinal edges and act as stops together with the casing to set an outer limit position for the ribbed bodies. The ribbed bodies move radially outward out of a flush starting position in the slit openings into a working position or an outer end position against the force of leaf springs that are braced on the casing and tend to push the ribbed bodies back into their flush starting position. With such a stabilizer, the ribbed bodies have a tendency to stick in the slit openings and fail to return to their starting position because even minor tilting leads to jamming, and furthermore there is the danger that solids such as rock particles in the oil well fluid might stick between the guide faces and block the shifting movements of the ribbed bodies.
SUMMARY OF THE INVENTION
This invention is based on the goal of creating a stabilizer whose ribbed bodies can be moved out reliably into working position even under unfavorable operating conditions and can be retracted into the starting position.
The gap openings between the opposing longitudinal sides of the slit openings and the ribbed bodies create a free space that safely prevents jamming of the ribbed bodies in the slit openings in this area. Nevertheless, the ribbed bodies are guided with sufficient accuracy by the guide projections extending axially at their ends with reduced dimensions, and they are also secured against tilting in the peripheral direction. The ribbed bodies can be inserted easily and rapidly into the outer casing from the outside and are held in position by securing pieces that are also inserted from the outside into the outer casing so they can execute tilting movements when the wedge faces of the adjusting mandrel are lifted away from the rear wedge faces of the ribbed bodies in their longitudinal direction so these tilting movements facilitate shifting of the ribbed body back into their starting position.
BRIEF DESCRIPTION OF THE DRAWINGS
Additional details, versions and advantages derive from the following description and the figures which illustrate several practical examples of the object of this invention in the form of diagrams. The figures show the following:
FIG. 1 shows a first version of a stabilizer according to this invention by areas in sectional view or axial section.
FIG. 2 shows a cutaway view of the stabilizer in the direction of arrow II--II in FIG. 2.
FIG. 3 shows a section according to line III--III in FIG. 1.
FIG. 4 shows a second version of the stabilizer according to this invention in a diagram like that in FIG. 1.
FIG. 5 shows a cutaway view of the stabilizer in the direction of arrow V in FIG. 4.
FIG. 6 shows a cutaway perspective view of a third version of the stabilizer according to this invention.
FIG. 7 shows a schematic sectional view according to line VII--VII in FIG. 6.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
The stabilizer for deep well drilling tools illustrated in the figures has a tubular outer casing 3 which has screw thread connections 1, 2 on its ends and in the example shown here consists of two casing parts 5, 6 screwed together at 4. Casing 3 can be inserted and screwed into a drilling shaft and includes a central axially continuous flow channel 7 for a drilling medium which is usually pumped through the drilling shaft to the deep well drilling tool, e.g., a rotary drill bit positioned centrally or eccentrically with the axis of the drill casing.
Casing 3 has slit openings 8 distributed around the periphery, but only one is illustrated in each case here. Casing 3 has at least two diametrically opposed slit openings 8 but may also have three or four slit openings 8 which form a group at one level. Furthermore, the stabilizer may also have groups of slit openings 8 positioned axially at some distance apart and in turn formed by at least two slit openings.
With the stabilizer versions shown here, slit openings 8 extend axially and have a linear main axis 9. Instead of this the slit openings may also run at an acute angle to the longitudinal middle axis 10 of casing 3 and regardless of their alignment, instead of having a straight design they may also have a curved or helical shape of the main axis 9.
With the stabilizer versions according to FIGS. 1 to 5, the slit openings 8 end in an enlargement 11 which is bordered by an arc whose diameter somewhat exceeds the distance between the longitudinal sides 12, 13 of slit opening 8. Slit openings 8 together with enlargements 11 are located in the area of housing elevations 3' on the outside, increasing the holding space and at the same time forming reinforcements for housing 3.
There is an elongated ribbed body 14 in each slit opening 8, and in the versions shown according to FIGS. 1 to 5, the ribbed body is in the form of a straight rod that has a rear wedge face 15 near each end. FIGS. 1 to 5 show the ribbed bodies in the extended working end position (14a in FIG. 3) from which they can be returned into a starting position flush with casing 3 (14b in FIG. 3).
Longitudinal sides 16, 17 of ribbed body 14, that are parallel to each other and to the longitudinal sides 12, 13 of slit openings 8, are a distance apart which is somewhat smaller than the distance between the longitudinal sides 12, 13 of slit openings 8. Therefore, gap openings 18, 19 remain between longitudinal sides 12, 16 and 13, 17, and these gap openings 18, 19 have a width that assures that ribbed bodies 14 cannot become stuck in slit openings 8 either due to direct jamming action between longitudinal sides 12, 16 and 13, 17 of the parts or due to deposition of solid particles from the oil well fluid between the parts. The width of gap openings 18, 19 can accordingly reach the millimeter size range depending on the diameter of casing 3 and the other dimensions of slit openings 8 and ribbed body 14, which in turn depend on the diameter of casing 3, and when the casing diameter is 120.65 mm, for example, the width of the gap opening may be about 3 mm.
Ribbed bodies 14 have a coating 20 of an especially wear-resistant material such as sintered metal on their outer surface and at their ends they have a taper 20, 22 that reduces the radial dimensions toward the ends and they also have axially projecting guide projections 24 over their end faces 23. These guide projections 24 have a width measured in the circumferential direction of casing 3 such that the width is smaller than the width of the ribbed bodies 14, e.g., is reduced by one-half. The guide projections 24 that are symmetrical with the longitudinal midplane of each ribbed body 14 have parallel side guide faces 25, 26, a front side 27, 28 that is graduated in height and faces outward and a rear side 29 that is flush with the rear side 30 of ribbed body 14. In the area beneath part 28 of the front side, guide projections 24 have a height which when measured in radial direction corresponds approximately to half the height of the guide projections 24 in the area below part 27 of the front side. In this way, guide projections 24 have an outer part 31 which in addition to a guide function also fulfills the function of a stop lug as described in greater detail below.
The rear wedge faces 15 near the ends of ribbed body 14 are opposite mating wedge faces 32 which are on the outside of the tubular adjusting mandrel 33, e.g., on rotating elevations. Adjusting mandrel 33 is designed as the differential pressure piston exposed to the oil well fluid and having a larger piston area at the top, in the version according to FIG. 1, and a smaller piston area at the bottom and is under pretension from a restoring spring 34 that tries to press the adjusting mandrel 33 into an upper starting position.
Specifically, adjusting mandrel 33 has a ring-shaped outer piston extension 35 on its upper end which is in sliding engagement with the inside face of part 6 of casing 3 and is sealed by means of gaskets 36 with respect to this inside face. Piston projection 35 forms a lower shoulder 37 on which restoring spring 34 (which is designed as a helical spring), rests with its upper end. The lower end of restoring spring 34 is braced on a supporting ring 38 which is secured on the inside of part 6 of casing 3 at a suitable distance below piston extension 35.
In the area of its lower end, adjusting mandrel 33 is guided by a guide ring 39 which rests on a shoulder 40 on part 6 of casing 3, is secured on it and has gaskets 41 to seal it with respect to the outer face of adjusting mandrel 33.
The hydrostatic pressure acting on the differential area between two gasket diameters, "D" and "d," exerts a downward adjusting force on adjusting mandrel 33 which counteracts the upward restoring force of restoring spring 34. When the downward adjusting force exceeds the restoring force of restoring spring 34 depending on the pressure in the oil well fluid in flow channel 7, adjusting mandrel 33 is moved downward so ribbed bodies 14 execute a parallel outward movement over wedge faces 32 and wedge faces 15 until they reach an outer working end position.
If the restoring force exceeds the adjusting force, the adjusting mandrel 33 moves upward so the wedge faces 32 come out of pressure contact or adjusting engagement with wedge faces 15 of ribbed bodies 14 which are then free to return to their flush starting position in casing 3.
The return of ribbed bodies 14 to their starting position takes place in the versions according to FIGS. 1 to 5 with upward or downward movements of the stabilizer in the borehole in interaction with the borehole wall as soon as the taper 21 or 22 comes into engaged position with the borehole wall and causes the upper or lower end of the ribbed body to snap into position before a greatly facilitated inward shifting of the ribbed bodies 14 along their entire length through the borehole wall is then induced.
The desired conditions can be established above ground by varying the delivery pressure of the oil well fluid pump. In addition, a difference between the pressure with which the oil well fluid acts on the upper piston area of the adjusting body 33 in FIG. 1 and the pressure in the oil well fluid acting on the lower piston area of the adjusting body 33 can be created by means of a nozzle ring body 42 mounted interchangeably on the upper edge of the adjusting body 33. This increases the adjusting force regardless of the diameter ratio D/d.
The ribbed bodies 14 are held in their slit openings 8 in casing 3 by securing pieces 44 that can be inserted into the casing from the outside and have the basic shape of the cylindrical segment in the stabilizer versions according to FIGS. 1 to 5. These securing pieces 44 are countersunk in the enlargements 11 at the ends of slit openings 8 and are fixed in their installed position by tangential locking pins 45. Securing pieces 44 reach over guide projections 24 but only into the area of the outside parts 31 in the versions according to FIGS. 1 to 5. To this end each securing piece 44 is provided with a recess 46 that is gradated in longitudinal section and is fitted to the corresponding shape of guide projections 24 with outside part 31 and presents side guide mating faces 47, 48 that work together with guide faces 25, 26 of a guide projection 24 and forms a shoulder 49 which extends over the outside part 31 of guide projection 24. This shoulder 49 forms a stop for part 28 of front side 27, 28 of guide projection 24 by which the working end position of ribbed bodies 14 is defined.
Such a design for guiding and securing ribbed bodies 14 in their slit openings 8 permits a simple and rapid method of assembling ribbed bodies 14 from the outside of casing 3, it secures a sufficiently precise guidance of ribbed bodies 14 in their extension and retraction and furthermore secures ribbed bodies 14 adequately against tilting due to forces acting in the peripheral direction of casing 3 on ribbed bodies 14 during operation of the stabilizer. The guide engagement faces are so small that jamming effects that occur in their area due to deposits of solid particles from the oil well fluid, for example, can only be of such a small extent that they cannot block the inward and outward movements of ribbed bodies 14.
In the design of slit openings 8, ribbed bodies 14 and securing pieces 44, the stabilizer version according to FIGS. 4 and 5 corresponds essentially to that according to FIGS. 1 to 3. This is also true of casing 3 and adjusting mandrel 33 but with the difference that the casing and adjusting body have an installed position that is tilted by 180., i.e., it is stood on its head, with the result that the upper screw thread connection 1 is on part 6 of casing 3 and the lower screw thread connection 2 is on part 5 of casing 3. The reference numbers from FIGS. 1 to 3 have therefore also been used for corresponding parts with no change in FIGS. 4 and 5.
Functionally, the inverted fitting position (on its head) has the effect that the hydraulic adjusting force for adjusting mandrel 33 is directed upward and the restoring force of restoring spring 34 is directed downward. Therefore, lowering the pressure of the oil well fluid causes adjusting mandrel 33 to move downward as soon as the restoring force exceeds the adjusting force and thus the ribbed bodies 14 are released for an inward movement.
Nozzle ring 42 on the lower end of adjusting mandrel 33 in the version according to FIG. 4 not only fulfills the function of reducing the adjusting force derived from the oil well fluid pressure for adjusting mandrel 33 but also fulfills the special function of forming a valve seat for an insertion valve body designed as a valve ball 50.
If after reducing the pressure of the oil well fluid the restoring force has moved adjusting mandrel 33 into the release position, indicated by 33a, where the ribbed bodies 14 can move back into their starting position in casing 3 due to inward directed forces acting on them, and if a valve body 50 is then inserted, a strong downward force is exerted by the oil well fluid on the adjusting mandrel in addition to the restoring force due to the fact that flow channel 7 is blocked at the lower end, and this downward force causes adjusting mandrel 33 to move into the lower end position illustrated by 33b. In this end position, the oil well fluid is forced to flow out of flow channel 7 at the upper end of adjusting mandrel 33 and past gasket 39 through slit openings 8 with the result that the oil well fluid flushes out any solid particles that might be deposited in the gap openings 18, 19.
With such a downward movement induced by valve body 50, the lower end of adjusting mandrel 33 comes into engagement with a stop element which in the practical example according to FIG. 4 is also designed as a fixing element, namely as a slotted radially expandable fixing ring which rests in an internal groove 52 in part 6 of casing 3. This stop and fixing element which may also have any other suitable design defines the lower end position for adjusting mandrel 33 and also secures it when the pumping of oil well fluid is concluded so the oil well fluid present in the drilling shaft above valve body 50 can escape into the borehole for the sake of drainage when the drilling shaft is pulled up. For the next operation of the deep well drilling tool, valve body 50 is removed from the stabilizer and the adjusting mandrel 33 is pushed up out of engagement with the stop and fixing ring 51, which can be accomplished, for example, as part of an above-ground maintenance job by a tool inserted from beneath after unscrewing casing part 5.
Finally, FIGS. 6 and 7 show in diagram form a third stabilizer design whereby the ribbed bodies 114 are designed as swing wings that can pivot about axial (at least essentially axial) articulated axles 54' at the forward edge in the direction of rotation 53. Guide stops 124 here are designed as pivot pins located near the front edge 54 of ribbed bodies 114 as seen in the direction of rotation 53 of casing 3 in operation and they project upward and downward beyond their contour. To receive these pivot pins 124, slit opening 108 where ribbed body 114 is illustrated here in the fully inserted flush starting position is provided with axial enlargements 111 that are cup shaped and are located in the area of the front corners as seen in the direction of rotation 53 in operation. Securing pieces 144 are designed as mold caps that can be inserted into the enlargements 111, secured there by means of bolts 55 and hold pivot pins 124 in position in enlargements 111 extending over them.
Since ribbed bodies 114 execute inward and outward movements to shift them out of the flush starting position into their operating position, ribbed bodies 114 are provided with wedge faces 115 on their rear side or inside only near their edge 56 that is to the rear in the direction of rotation 53 of casing 3 in operation, and these wedge faces essentially correspond to wedge faces 15 in the versions according to FIGS. 1 to 5 and work together with mating faces 32 on an adjusting mandrel which may have a design like that of adjusting mandrel 33 in the version according to FIGS. 4 and 5. Moreover, a gap opening 118 is left between slit opening 108 and ribbed body 114, preferably extending around the entire ribbed body 114.
|
A stabilizer for deep well drilling tools is disclosed which includes a tubular outer casing having a plurality of slit openings distributed around its periphery with a tubular adjusting mandrel supported in the casing for relative axial movement therewith in response to well fluid pressure applied to the well. A separate elongated ribbed body is movably mounted in each slit opening. Each of the ribbed bodies has a rear wedge face facing opposite to the relative motion of the mandrel which cooperates with a separate mating wedge face on the mandrel such that the ribbed body moves radially outwardly in its respective slit opening upon contact between said mating wedges upon axial movement of the mandrel relative to the casing in response to well fluid pressure applied to the well. Also, each end of each ribbed body has an axially projecting guide projection which terminates in a reduced dimension at its end. Each guide projection has a separate securing piece adapted to be inserted through a slit from outside the casing to hold its guide projection in the casing. Each securing piece has the basic shape of a cylindrical segment and can be inserted into the casing so it is flush therewith. A separate locking pin secures each securing piece in the casing.
| 4
|
BACKGROUND OF THE INVENTION
The present invention relates to a roof paver element and a roof paver system including a plurality of interconnected roof paver elements for covering roofs and, especially, for covering the membranes of single-ply roofing systems.
For most types of low-slope roofs, roof ballast is used to hold down the roofing membrane against the roof deck when wind conditions may create negative pressures tending to lift the membranes. The ballast also protects the membranes from ultraviolet radiation and puncture or impact damage by maintenance crews and windblown objects. The standard form for roof ballast has traditionally been a smooth, round "river wash" type of gravel which is spread uniformly to produce a minimum of 10 lb/sf load on the membrane. However, the use of gravel as roof ballast has been reviewed in recent years in light of the development of new single-ply roofing systems and the extensive damage caused to buildings near gravel ballast roofs as the result of flying gravel in hurricane type conditions. New single-ply roofing membranes, as opposed to the conventional multi-ply "built up" roofing systems, do not use hot bitumen for holding the membranes in place, and in some cases, the single-ply membranes are laid loosely on the roof deck without fasteners other than at the perimeter, which means that heavier than usual ballast is desirable to keep the membrane down. In addition, because the gravel ballast does not adhere to the single-ply membranes as it adhered to the bitumen in the asphalt-based systems, there is a greater potential hazard of gravel flying under extreme wind conditions.
In order to overcome the drawbacks of gravel ballast, flat concrete paver elements and systems have been developed which provide adequate ballast to hold down the roof membrane and protect it from ultraviolet radiation and impact damage, but each suffers from at least one of several disadvantages. Some of the prior art roof paver elements require special concrete molding equipment, drying racks and handling equipment, even though they are produced by manufacturers already having conventional equipment of the same types for producing standard concrete blocks. This is due to the fact that the designs of the known paver elements require the elements to have non-standard dimensions to provide roof drainage or for other purposes, and even with such special dimensions, the provision for roof drainage is not always adequate and/or permits drainage in only one direction. Some roof paver elements have flat upper surfaces which allow air to flow uninterrupted across the elements at high speeds, producing negative pressures which can lift and displace the elements. In addition, known roof paver systems do not provide a convenient arrangement for aligning and anchoring the paver elements in courses around the perimeter of the roof or a system for preventing the paver elements from sliding when they are installed in roofs having higher slopes.
SUMMARY OF THE INVENTION
In accordance with the present invention, a roof paver system includes roof paver elements which can be produced in a standard concrete block mold machine, dried on standard drying racks and handled with conventional concrete block material handling equipment. The length and width of the paver elements correspond to two of the dimensions of a standard concrete block mold machine, and the height of the elements is such that a plurality of such elements can be accommodated at one time in the mold.
Each roof paver element has a larger footprint than previously known roof pavers, that is, a larger proportion of its surface area contacts the roof to provide a greater weight distribution and a reduced likelihood of damage to the roof membrane. The roof paver elements according to the present invention allow a far greater drainage volume than other roof paver elements by providing more and larger drainage grooves, and they permit the drainage in two directions. The elements have a higher thermal insulating value than previously known roof paver elements by their ability to trap a larger volume of air in the drainage grooves, and, by tapering alternate drainage grooves, the roof paver elements provide a mechanism for immediately breaking the vacuum between the elements and the concrete mold when the elements are formed, thereby reducing forces which retain completed elements in the mold and increasing the speed and ease with which the elements can be molded.
The ends of the elements cooperate with one another to define composite drainage grooves for receiving and retaining separate connecting members for interlocking the elements to provide an integrated roof paver system, thereby preventing individual elements from being lifted and moved out of position by high winds. The drainage grooves within each element which are not tapered are shaped like the composite grooves, providing a relatively narrow space at the roof membrane but increased area above for greater drainage. The effect of high winds is also diminished by the provision of raised portions on the top surface of each roof paver element for generating air vortexes to break up the smooth flow of air which tends to lift the elements as it moves across them. The raised portions also define a safety tread which helps prevent workmen from slipping.
For some installations, such as those having a low fascia, the roof paver system employs clips along its perimeter for aligning the roof paver elements at the start of laying and for anchoring them to the roof. For roofs having high slopes, the system includes elongate battens securable to the roof membrane and shaped to be slid into and retained in the shaped alternate grooves of the paver elements, the battens having apertures to accommodate transverse stop members for abutting the downslope edge of the paver elements.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a roof paver system in place on a roof;
FIG. 2 is a perspective view of a roof paver element according to the present invention;
FIG. 3 is a top view of the roof paver element of FIG. 2;
FIG. 4 is a partial front view of the roof paver element of FIG. 2;
FIG. 5 is a cross-section taken along the line 5--5 in FIG. 4;
FIG. 6 is a side view of a perimeter clip according to the present invention;
FIG. 7 is a schematic cross section of a roof paver system installation employing the perimeter clips of FIG. 6;
FIG. 8 is a schematic cross section of another roof paver system installation; and
FIG. 9 is an end view of a batten according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In FIG. 1 of the drawings, a exemplary embodiment of an integrated roof paver system 10 according to the present invention is shown in place on a roof 12, such as a flat or low-slope roof, in which a roof membrane 14 overlies insulation 16 on top of a roof deck 18. The roof paver system 10 includes a plurality of roof paver elements 20, four of which are shown, each of which contains a plurality of tapered grooves 22 and alternating dovetail-shaped grooves 24 on the underside to allow the drainage of water and to trap air for thermal insulation. In addition, the dovetail grooves 24 receive connector members 26, such as standard one-inch plastic tube connectors, to positively interlock the roof paver elements 20 in the system 10, and dovetail-shaped battens 28 to secure the paver elements 20 to the roof 12 and to keep the paver elements from sliding on roofs having a relatively high slope. In the embodiment illustrated, the courses of roof paver elements 20 are staggered to permit total interlocking of the roof paver system 10, but it is understood that the roof paver elements 20 of adjacent courses can be in alignment if desired.
As can be seen from FIG. 2, the roof paver element 20 is a thin shell block element preferably made of concrete and having dimensions which permit it to be molded readily in a standard concrete block mold box. For this reason, a preferred embodiment of the roof paver element has nominal dimensions of 16 in.×8 in.×2.5 in. so that a mold box which can produce, for example, three standard concrete blocks at a time can produce six thin shell roof paver elements at a time. A roof paver element 20 according to the present invention having the above dimensions has a ballast weight of 11 pounds per square foot, a coverage of 0.88 square feet, a footprint of 81.5 square inches per square foot of coverage, and an insulating value of 1.6 R (sf). The roof paver element 20 includes an elongate planar portion 30 which defines the upper portion of the paver element 20 when it is in place on a roof, and projecting from the planar portion 30 are a plurality of spaced ribs 32 terminating in broadened feet 34 and 36 which include toe portions 34a and 36a, respectively, and heel portions 34b and 36b. The area of the feet 24 and 26 which contacts the roof, that is, the footprint, is made greater than the cross-sectional area of the ribs 32 to provide increased weight distribution and to diminish the likelihood of damage to the roof membrane. The dovetail grooves 24 are defined between adjacent ribs 32 and facing toe portions 34a and 36a of the feet 34 and 36, so that the region above the toe portions 34a and 36a has an increased cross sectional area to accommodate a large volume of drainage. The tapered grooves 22, which are defined between adjacent ribs 32 and the heel portions 34b and 36b of the feet 34 and 36, taper longitudinally to provide a mechanism for breaking the vacuum between the tapered grooves 22 and the mold as the roof paver elements 20 are slid out of the mold in a direction parallel to the grooves 22 and 24. The breaking of the vacuum between the tapered grooves 22 and the portions of the mold they contact reduces the overall forces retaining the paver elements 20 in the mold so that the elements can be slid out easily.
The feet 34 and 36 are shorter than the parallel dimension of the planar portion 30, each foot having a flush end 38 which is coplanar with an edge of the planar portion 30 and a recessed end 40 which is connected by a beveled portion 42 of the ribs 32 to an opposite edge of the planar portion 30, as can best be seen from FIGS. 1 and 2. When the paver elements 20 are in place on a roof, the space between the recessed ends 40 of the feet 34 and 36 and the adjacent edge of the planar portion 30 define with the beveled portions 42 of the ribs 32 a drainage passage which is transverse to the drainage provided by the dovetail grooves 24 and the tapered grooves 22. FIG. 1 shows in dotted lines a transverse drainage passage 44 of double width defined by the juxtaposition of the recessed ends 40 of the feet 34 and 36 of one paver element 20 with the recessed ends 40 of the paver elements 20 in the adjacent course. By this arrangement, a double width transverse drainage passage 44 is defined after every two courses of paver elements 20, there being no significant transverse drainage at the abutment of the paver elements between the drainage passages 44. The paver elements 20 can also be laid with the recessed ends 40 in each paver element 20 juxtaposed with the flush ends 38 of the feet 34 and 36 of paver elements 20, so that a transverse drainage passage of single width is defined after every course of paver elements 20.
As can best be seen from FIGS. 1 and 3, the roof paver elements 20 have bar-shaped raised portions 46 on their upper surfaces, so that when the roof paver elements 20 are in place on a roof, the raised portions 46 provide a tread for roof traffic, such as maintenance crews and repairmen, and also constitute vortex generators which break up the flow of air along the roof paver elements, which can cause uplift and displacement of the elements, by creating swirls of air which destroy the negative pressure causing the uplift.
Each paver element 20 terminates at its ends with structure defining one half of a dovetail groove 24. Specifically, each end of the paver element 20 includes a rib 32 spaced inward from the lateral edge of the planar portion 30 by a distance equal to one half the width of a dovetail groove 24 and a foot 34 or 36 having an outwardly directed toe 34a or 36a, so that when the end of the paver element 20 is laid in abutment with the end of the adjacent paver element, a composite dovetail groove 24 for receiving the connector members 26 is defined, as can be seen in FIG. 1. The connector members 26, which are received snugly between aligned dovetail grooves 24 in adjacent roof paver elements 20 further prevent the displacement of the elements. The dovetail grooves 24 which lie entirely within one roof paver element 20 also can receive the connector members 26, as shown in FIG. 1, so that a connector member can have one end inserted in a composite dovetail groove 24 and the other end inserted in a dovetail groove 24 lying entirely within one roof paver element 20. The connector members 26 can also connect two dovetail grooves 24 lying entirely within their respective roof paver elements 20 and, where the roof paver elements of adjacent courses are in alignment, the connector members 26 can connect two composite dovetail grooves 24.
Especially in cases where the connector members 26 are used in dovetail grooves 24 defined entirely by one roof paver element 20, stops, such as radial projections 37, for engaging the ends of the ribs 22 or feet 34 and 36 are contemplated to prevent the connector members 26 from being pushed too far into the dovetail grooves 24 in a roof paver element 20 in one course by the element in the next course as it is being moved into abutment with the element in the first course. Although connector members 26 are employed in only two of the dovetail grooves 24 in each roof paver element 20 illustrated in the embodiment of FIG. 1, any number of the remaining dovetail grooves 24 can be employed to receive additional connector members 26 if stronger integration of the roof paver elements 20 is desired.
In order to allow the alignment of the roof paver elements 20 at the perimeter of the roof paver system 10, and to anchor the elements in place, anchoring and alignment devices such as the clip 48 illustrated in FIG. 6 are provided. The clip 48, which can be made, for example, of metal or plastic, includes a base portion 50 having at least one aperture 52 for receiving nails or other fasteners, and an angular portion 54 shaped to mate with the outwardly directed toe 36a at the end of a roof paver element 20'. As can best be seen from FIG. 7, in which a portion of the roof paver system 10 is shown on a roof having a low gravel stop fascia 56, the clips 48 can be nailed to a nailer 58 at the top of a wall 60 to which the fascia 56 is also nailed. A membrane 62, which overlies insulation 64 on top of a roof deck 66, can also overlie the base portion 50 of the clips 48 which have been secured to the nailer 58. The clips 48 constrain the end of the perimeter course roof paver element 20', which in this case is one half of the element 20 shown in FIG. 2 and is laid perpendicular to the course of roof paver elements inside of the perimeter course. The dovetail grooves 24 of the roof paver elements 20' in the perimeter course can be secured to one another by the connector members 26, and the elements 20' of the perimeter course can be connected to the inner elements 20 by connector members extending from the dovetail grooves 24 of the inner members and received perpendicularly in the one half dovetail groove, between the toe 34a and the lower surface of the planar portion 30, defined at the inner end of the elements 20'. FIG. 8 shows another installation of a roof paver system 10' on a roof having a parapet 68, including flashing 70 and counterflashing 72, for which the perimeter clips 48 are not needed.
As is illustrated in FIG. 1, the roof paver system 10 can also include the elongate battens 28 for holding down the roof paver elements 20 and for preventing them from sliding, especially on roofs having a relatively high slope. The battens 28 can be made of metal or plastic, for example, like the clips 48 and include a base portion 76 including a plurality of spaced apertures 78 for receiving nails or other fasteners to secure the battens 28 to the roof. The dovetail shaped grooves 24 of the roof paver elements 20 are slidingly received on the battens 28, which have a complementary portion 80 dovetail shaped in cross section, by which the battens 28 hold the paver elements 20 down. The battens 28 include a plurality of spaced transverse openings 82 defined, for example, in the dovetail portion 80 and sized to receive a nail 84 or other thin element which engages the ends of the ribs 32 or feet 34 and 36, thereby preventing the paver elements from sliding along the battens 28.
Although the roof paver element is described herein as being made of concrete, other suitable materials may be employed, such as ceramics or plastics. Furthermore, the roof paver elements may be employed in structures other than as part of a roof paver system.
Thus, it will be appreciated that as a result of the invention, a highly effective roof paver element and system is provided for covering roofs, and that it will be apparent to those skilled in the art and it is contemplated that variations and/or changes in the embodiments illustrated and described herein may be made without departure from the present invention. Accordingly, it is intended that the foregoing description is illustrative only, not limiting, and that the true spirit and scope of the present invention will be determined by the appended claims.
|
A roof paver system includes a plurality of roof paver elements having alternating dovetail-shaped and tapered grooves and an upper surface having raised portions to generate vortexes for preventing wind from lifting the elements and to provide a safety tread. Connecting members are provided in some of the dovetail grooves to interconnect the roof paver elements and further prevent their displacement. The tapered grooves break the vacuum between the roof paver elements and the molds in which they are formed. Clips are provided to mate with outwardly projecting toes on the roof paver elements in perimeter courses to align and anchor them, and elongate battens, which are dovetail-shaped in cross section, are received in the dovetail grooves and include openings for receiving thin elements transverse to the battens to engage the concrete elements at the ends of the grooves.
| 4
|
BACKGROUND
[0001] This invention relates to data security.
[0002] In today's digital world, information is more readily accessible than ever. Businesses are increasingly dependent on digital communications. However, the promulgation and ease of use of digital communication technologies has come at some price: increased exposure to security threats. Conventional digital communication technologies allow for easy storage, retrieval and transfer of information. What is needed are equally easy means for securing valuable information.
[0003] Referring to FIG. 1 , a conventional host computer 20 is in communication with a mass storage device 40 for storing data. Often, a user of the host computer 20 wishes to keep data stored on the mass storage device 40 secure, so that only authorized users can access the data. The user can select from a number of conventional ways to protect the data. For example, the user can password protect access to the data. However, if the hard disk is removed from the mass storage device 40 and installed into an unprotected computer, password protection may be lost and the data may be exposed. Another conventional way of protecting the data is through the use of software or hardware (or a combination of both) encryption technologies. Some of the disadvantages associated with software encryption include memory resource requirements and non-real time processing. Some hardware encryption technologies require storing a key in a hardware device, such as on storage media, for example, on a hard disk, floppy disk, EEPROM, flash or optical recordable disk. However, known hardware encryption technologies do not protect the key when the key is stored or loaded to and from the hardware device. Hardware devices can also be susceptible to spy programs. More robust ways of protecting critical data are therefore desirable.
SUMMARY
[0004] In some implementations, methods of providing data security in a security device are provided. The method includes coupling a plug-in device to a security device, the security device controlling an encryption or decryption of data to or from an associated storage device. When a data encryption or decryption operation is required, a secret is retrieved from a plug-in device. A host seed is recovered from the secret. A key is generated from the host seed to be used in the encryption or decryption of data.
[0005] In some implementations, methods of providing data security include receiving a request to facilitate secure encryption or decryption operations; providing a randomly generated number; receiving a secret created from the randomly generated number and a host seed; and storing the secret until run-time.
[0006] In some implementations, a plug-in device for providing data security includes a random number generator to generate a random number; an encryption engine to encrypt the random number; a matching engine to compare the encrypted random number to a received encrypted random number; and a memory for storing a secret to be shared with a security device if the matching engine determines a match has been made.
[0007] In some implementations, a security device includes a means for connecting to a host computer for receiving a host seed; a memory configured to store at least one of a device seed or a random number; and a processor configured to hide the host key in a secret, extract the host seed from the secret and create a key from the host seed, but only when coupled to an authenticated device that stores the secret.
[0008] In some implementations, a system for securing data includes a host computer, a security device, an authenticatable device and data storage. The security device includes a means for connecting to the host computer for receiving a host seed, a memory for storing at least one of a device seed or a random number and a processor configured to hide the host key in a secret, extract the host seed from the secret and create a key from the host seed but only when coupled to an authenticatable device that stores the secret. The authenticatable device is configured to generate the random number and to store the secret. The data storage stores encrypted data.
[0009] The methods and devices described herein may provide none, one or more of the following advantages. Together, a plug-in device in combination with a data security device can provide a robust data security method. Secret information, such as a mixed seed, can be stored on the plug-in device. The mixed seed and/or the plug-in device may be required to create a key for encryption or decryption of critical data. However, possession of the plug-in device alone is insufficient for creating the key. Information stored on the security device is also required to construct the encryption/decryption key. Because both the plug-in device and the security device are required to create the key, possession of the security device alone is also insufficient for creating the encryption/decryption key. If either the plug-in device or the security device are compromised, the key is not compromised.
[0010] The details of one or more embodiments of the invention are set forth in the accompanying drawings and the description below. Other features, objects, and advantages of the invention will be apparent from the description and drawings, and from the claims.
DESCRIPTION OF DRAWINGS
[0011] FIG. 1 is a schematic of a host computer in communication with a storage device.
[0012] FIG. 2 includes a schematic of a security device configured to communicate with a plug-in device.
[0013] FIG. 3 is a flow diagram for preparing and using a plug-in device for security.
[0014] FIG. 4 is a flow diagram describing publishing a secret to the plug-in device.
[0015] FIG. 5 is a flow diagram for authorizing and verifying the plug-in device and the security device.
[0016] FIG. 6 is a flow diagram for loading the secret from the plug-in device to generate a key.
[0017] Like reference symbols in the various drawings indicate like elements.
DETAILED DESCRIPTION
[0018] Referring to FIG. 2 , a data security device and plug-in device together can protect data stored on a storage device. A data security device 10 is connected to a host device (e.g., host computer 20 ), a plug-in device 30 and a storage device (e.g., mass storage device 40 ) by various communication mediums. The communication mediums form signal paths between the respective devices and can be of the form of electrical, optical, radio frequency or other communication media.
[0019] The host device can be of the form, and is shown, as a computer. The storage device can be of the form, and is shown, as a mass storage device. While reference is made to a host computer 20 and a mass storage device 40 , this reference is merely exemplary. The security device 10 and plug-in device 30 can be associated with other host devices (e.g., personal computer, laptop computer, personal digital assistant, access point, portable electronic device, game console, set-top box, or other information processing device) and other storage devices (e.g., hard drive, optical drive, flash drive, etc.). Similarly, while reference is made to individual components one or more of the host device, plug-in device, security device, and storage device can be integrated. For example, in one implementation, a security device 10 can be integrated with mass storage device 40 in a disk key device (e.g., a flash or disk USB drive) that is configured to be coupled to one or more host devices.
Data Security Device
[0020] Data security device 10 operates to work with the host device and the plug-in device to create one or more keys for use in encrypting and decrypting data to be stored on (and/or retrieved from) the storage device. Accordingly, data security device 10 includes three primary interfaces: a host interface (e.g., host port 11 for communicating with the host computer 20 ), a plug-in device interface (e.g., plug-in device port 16 ), and a storage device interface (e.g., device port 15 for communicating with the mass storage device 40 ). In the particular implementation shown the data security device 10 includes a plug-in device port 16 for directly accessing a plug-in device 30 . Other communication configurations between the data security device 10 and the plug-in device, host device and storage device are possible. As will be discussed in greater detail below, the plug-in device 30 stores and retrieves secret information that is required for creating a key used to encrypt and decrypt data stored in the mass storage device 40 . In one implementation, the data security device 10 also includes a host-device data flow controller 12 , which directs data going to or coming from the host computer 20 , an encryption/decryption engine 13 , for encrypting data going to the mass storage device 40 or decrypting data coming from the mass storage device 40 , a microprocessor 14 and memory 17 .
[0021] The host port 11 is in communication with host computer 20 and the host-device data flow controller 12 . The host port 11 receives commands and data from the host computer 20 and communicates the commands and data to the host-device data flow controller 12 for processing. The host port 11 also communicates the status of executed commands and returned data from the mass storage device 40 to the host computer 20 . In one implementation, the host computer 20 and the security device 10 are connected with a host side bus of any suitable type, such as PCI, PCI express, USB, 1394, ATA, serial ATA, SCSI, or FiberChannel.
[0022] The host-device data flow controller 12 is in communication with the host port 11 , the encryption/decryption engine 13 and the microprocessor 14 . The host-device data flow controller 12 receives commands and data from the host port 11 and processes the commands and data in two categories. A first category includes commands for accessing the mass storage device 40 . A second category includes key management commands. Other categories of commands are possible. The host device data flow controller 12 communicates commands for accessing the mass storage device 40 and associated data to the encryption/decryption engine 13 . The host-device data flow controller 12 communicates key management commands and associated data to the microprocessor 14 . The host-device data flow controller 12 also receives returned status information and data from the encryption/decryption engine 13 and the microprocessor 14 and provides these as required to the host computer using the host port 11 .
[0023] The encryption/decryption engine 13 is in communication with the host-device data flow controller 12 and the microprocessor 14 . The encryption/decryption engine 13 encrypts data traveling from host computer 20 to mass storage device 40 and decrypts data traveling from mass storage device 40 to host computer 20 . In one implementation, the encryption/decryption engine 13 does not process commands and associated returned status information (i.e., can pass the information through as required unchanged). As will be discussed in greater detail below, the microprocessor 14 creates the key used by the encryption/decryption engine 13 to encrypt/decrypt data. The encryption/decryption engine 13 can use an encryption/decryption algorithm selected from published and verified algorithms, such as AES and DES, or other suitable algorithms.
[0024] The microprocessor 14 is in communication with the host-device data flow controller 12 , the encryption/decryption engine 13 , the plug-in device port 16 and the memory 17 . Though reference is made to a microprocessor, other processing devices are possible including microcontrollers, or other controllers. In one implementation, the microprocessor 14 controls various operational processes of the data security device 10 , including sending a response to requests from the host computer 20 (e.g., to store or retrieve data or process a host seed) and storing and loading data to and from the plug-in device 30 . The microprocessor 14 also controls the generation of a key for encryption and decryption.
[0025] The microprocessor 14 can retrieve instructions from the memory 17 or store data in the memory 17 . Memory 17 can include volatile and/or non-volatile memory including random access memory, read only memory (including EPROMs and the like), flash memory, etc.
[0026] The device port 15 is in communication with the encryption/decryption engine 13 and mass storage device 40 . The device port 15 receives reported command status and data from mass storage device 40 and communicates the command status and data to the encryption/decryption engine 13 . In the reverse direction, the device port 15 also receives commands and data from the encryption/decryption engine 13 and communicates the commands and data to the mass storage device 40 . The device side bus connecting the security device 10 to the mass storage device 40 can be the same type as the host side bus or of a different type. Either bus can also be defined as a vendor specific bus.
[0027] The plug-in device port 16 communicates with a plug-in device 30 and the microprocessor 14 . Though reference is made to a plug-in port, other means of communicating with the plug-in device are possible. As will be discussed in detail below, plug-in device 30 may be otherwise coupled to the security device (i.e., not by a plug-in connection). Accordingly, the description provided here is merely exemplary. The plug-in device port 16 can be controlled by the microprocessor 14 allowing for access to the plug-in device 30 , such as writing to and reading from the plug-in device 30 . In some implementations, the data security device 10 has an interface configured to conform to a specific plug-in device standard, such as ISO-7816. In one implementation, the plug-in device port 16 provides a secure channel for transmitting information between the security device 10 and the plug-in device 30 . In some implementations, data is transferred securely to and from the plug-in device 30 using a specified plug-in device data transfer protocol. The data moving between the plug-in device 30 and the security device 10 can also be encrypted, such as by DES, AES or 3DES. The plug-in device 30 can be physically located in very close proximity to the security device 10 . In some implementations, the plug-in device 30 plugs into a receptacle in the security device 10 .
Plug-In Device
[0028] By way of example, reference is made to a plug-in device as being a device that interfaces with the security device 10 and stores a secret which is required to enable the encryption and/or decryption of data stored on the mass storage device. Those of ordinary skill in the art will recognize that the device can be coupled by other means to the security device 10 . Characteristics of the plug-in device include its ability to be removed from the security device (e.g., communicatively and/or physically disconnected), authentication capabilities and ability to store a secret. One example of a plug-in device that can be used is a smart card. Other types of devices are possible including a USB device, a chip card, EEPROM, flash, or an IC (integrated circuit) card. In one implementation, the plug-in device 30 includes a random number generator 18 , an encryption engine 21 , a matching engine 23 and a memory 25 .
[0029] Random number generator 18 can be used to generate a random or pseudo random number for use in an authentication protocol between the plug-in device 30 and the security device 10 . Authentication protocols are discussed in greater detail below.
[0030] Encryption engine 21 can be used to encrypt a random number generated by the random number generator 18 using a key that is provided at the time the plug-in device is created (e.g., an authentication key). Details of the use of the encryption engine are discussed below.
[0031] The matching engine 23 can be used as part of the authentication protocol and determine whether a number or a string of data received by the plug-in device 30 from security device 10 matches a number or string of data generated or stored by the plug-in device 30 (e.g., matches data produced by encryption engine 21 ). Matching engine 23 processes and authentication protocols are discussed in greater detail below.
[0032] A system including the components described above is used to store and access encrypted data. Secure encryption and decryption methods are described further herein.
[0033] Referring to FIG. 3 , a method is shown for securely encrypting or decrypting data. The method can be executed in a processing device that is in communication with various other components of a secure communication system. The process begins with the receipt of a host seed (e.g., by the data security device 10 from the host computer 20 ) (step 110 ). A secret is created from the host seed (e.g., the security device 10 can create a mixed seed from the host seed and a random number) (step 120 ). As used herein, a mixed seed refers to a data structure that is constructed from the host seed that can be used to hide the host seed in the event of compromise. One method for creating the mixed seed includes mixing the host seed with a mixing element (e.g., a random or pseudo random number). The mixed seed can be stored securely and the host seed recovered when required using a inverse operation (e.g. using the mixing element). The details of creating a mixed seed are discussed in greater detail below. The secret (e.g., mixed seed) is then provided and stored in a separate secure device (e.g., the mix seed is provided to the plug-in device 30 for storage) (step 130 ).
[0034] The separate secure device can be decoupled as desired. When coupled (e.g., when the plug-in device 30 is coupled to the security device 10 ) an authentication process can be performed (e.g., the security device 10 authenticates the plug-in device 30 ) (step 140 ). Authentication protocols are discussed in greater detail below. At run time (e.g., when encryption or decryption of data is required), the secret (e.g., mixed seed) can be retrieved (e.g., the security device 10 recalls the mixed seed from the plug-in device 30 ) (step 150 ). The secret is used to create a encryption/decryption (E/D) key (step 160 ). The creation of the E/D key can include the recovery of the host seed from the secret and the mixing or otherwise of the host seed with a device seed to create the E/D key. Creation of the E/D key will be discussed in greater detail below. Thereafter, the E/D key can be used (e.g., by the security engine 10 ) to encrypt and decrypt data (e.g., moving between the host computer 20 and the mass storage device 40 ) (step 170 ). The process described allows a security device to create the E/D key on-the-fly and only after authenticating of the plug-in device. In one implementation, the E/D key that is used for encryption and decryption is maintained only as long as required for a specific encryption or decryption operation. Alternatively, the E/D key can be maintained as long as the plug-in card 30 is connected to the security device 10 . Once the plug-in device 30 is disconnected from the security device 10 , the E/D key is either erased from memory, or the encryption/decryption engine 12 is disabled. Many of the foregoing steps are described further herein. The foregoing steps will be described with reference to the communication system shown in FIG. 2 , though those of ordinary skill in the art will recognize that the methods describe can be performed by other individual or integrated systems.
Creating a Secret
[0035] Referring to FIG. 4 , a method is shown for processing a host seed received from a host device and the creation of a secret to be stored in a separate device. The process includes the security device 10 publishing the secret (e.g., the mixed seed) to the plug-in device 30 for the plug-in device 30 to store. The security device 10 may detect that a plug-in device 30 is connected to the plug-in device port 16 or may receive a request from the host computer 20 to start the publication process. In either event, the security device 10 receives a host seed from the host device (e.g., host computer 20 ) (step 210 ). In one implementation, the host computer 20 encrypts the host seed and sends the encrypted host seed to the security device 10 . Alternatively, the host seed may not be encrypted and may be transmitted over a secure communication link without separate encryption. If the host seed is encrypted, the security device 10 (e.g., microprocessor 14 ) decrypts the encrypted host seed to recover the host seed (step 220 ). Thereafter, a secret is created (step 230 ).
[0036] In one implementation the secret is a mixture of a data generated by the plug-in card 30 (e.g., a random or pseudo random number generated by the plug-in card 30 ) and the host seed. In some implementations, the microprocessor 14 sends a request to the plug-in device 30 to generate a random number. The plug-in device's random number generator 18 generates the random number and the plug-in device 30 sends the number to the microprocessor 14 . In other implementations, the security device generates the random number or retrieves the random number from memory 17 . The random number can be random or pseudo random. The microprocessor 14 then scrambles the host seed with the random number to produce the secret (referred to herein as the mixed seed).
[0037] Thereafter, the secret (e.g., mixed seed) can be communicated to the plug-in device 30 for storage (e.g., the microprocessor 14 can send the mixed seed to the plug-in device's memory 25 ) (step 240 ). In some implementations, only one mixed seed can be stored on a plug-in device 30 .
[0038] In some implementations, the system can allow the publication of the secret to a new plug-in device 30 if the original plug-in device 30 is corrupted or lost. For example, if a new plug-in device 30 is required to store the secret, the security device 10 can recall the random number from its own memory, request the host seed from the host device and re-create the secret (e.g., mixed seed). The security device 10 can then publish the mixed seed to the new plug-in device 30 .
Communicating with the Plug-In Device
[0039] As described above, the security device 10 can communicate with the plug-in device 30 including transferring the secret. The communications can include an authentication routine as will be discussed below. The authentication can be performed each time the plug-in device 30 is coupled to the security device 10 . Reference is made to one protocol for authenticating the security device 10 and the plug-in device 30 . The one protocol is exemplary, and other protocols can be used. Reference as well will be made to an authentication key that can be used in the authentication protocol. The authentication key can be made known to both the plug-in device 30 and security device 10 by various means, including at a time of manufacture or otherwise. The authentication key is stored by both the security device 10 and plug-in device 30 to be used during an authentication process. In some implementations, the authentication key is assigned by the host computer 20 . Optionally, for additional security, a PIN can also be assigned to the plug-in device 30 and the security device 10 . The PIN can be a number that is not known to the host computer 20 , but only known to the security device 10 and the plug-in device 30 .
[0040] In some implementations, the security device 10 authenticates the plug-in device 30 prior to publishing the secret (e.g., the mixed seed) to the plug-in device 30 . The authentication process can be used each time a plug-in device 30 is connected to the security device 10 and the security device 10 is used to encrypt or decrypt data. When a user couples the plug-in device 30 to the port (e.g., plug-in device port 16 ) of the security device 10 , the security device 10 detects the plug-in device 30 . The plug-in device 30 and the security device 10 can then take part in a one or two-way challenge to ensure data security. In some implementations, a request from the host computer 20 begins the authentication process.
[0041] Referring to FIG. 5 , one implementation for a combined authentication and secret sharing method are shown where the security device 10 (whose steps are shown in solid line) and the plug-in device 30 (whose steps are shown in dashed line) each perform steps in the authentication and sharing method. The process begins with the security device 10 sending a request to the plug-in device 30 for a random number (step 405 ). The plug-in device 30 receives the request (step 410 ) and generates a random number (step 415 ). The random number can be the same number as the number used to create the secret (e.g., mixed seed) or a different number (e.g., as part of an authentication process, the plug-in device may generate a random number which is used to authenticate that the plug-in device and the security device both have the correct authentication key and PIN as discussed in further detail below (this process may it self be separate from the secret sharing process described above)). The plug-in device 30 sends a response including the random number to the device 10 (step 420 ). The transmission of the random number can be on a secure communication link or otherwise be secured.
[0042] The device 10 receives the random number (step 425 ) and encrypts the received random number (step 430 ). The security device 10 uses an authentication key that is known to both the security device 10 and the plug-in device 30 to encrypt the random number. In one implementation, the authentication key is written to the plug-in device 30 during publication. The security device 10 can use a standard, such as DES, 3DES, or AES for encrypting the random number. Other suitable keys or algorithms may also be used, as long as both are known to the plug-in device 30 and the security device 10 .
[0043] The security device 10 sends an external authentication request with the encrypted random number back to the plug-in device 30 (step 435 ). In parallel or in response to the received communication from the security device 10 , the plug-in device's encryption engine 21 also encrypts the random number using its authentication key and encryption algorithm (assuming these to be the same as those used in the security device 10 ) (step 440 ). Thereafter, the plug-in device 30 checks whether the plug-in device's encrypted random number matches the security device's encrypted random number (step 445 ). If the two encrypted numbers do not match, the plug-in device 30 sends a failure response to the security device 10 and the challenge ends. If the two encrypted numbers match, the plug-in device can send a success response (step 450 ). This completes the authentication process.
[0044] Optionally, the security device 10 performs a further validation of the plug-in device 30 after authentication. The validation step can ensure that the plug-in device 30 is bonded to the security device 10 . In the validation portion, the security device 10 sends a personal identification number (i.e., PIN) verification request with a PIN to the plug-in device 30 (step 455 ). The plug-in device 30 checks whether its stored PIN is equal to the received PIN (step 455 ). If the PINs do not match, the plug-in device 30 sends a failure response and the challenge ends. If the PINs match, the plug-in device 30 sends a success response and the challenge ends successfully. The PIN verification can be used to tie a particular plug-in device 30 to a particular security device 10 . In one implementation, the PIN is created when the plug-in device is initialized by host request.
[0045] While reference is made to a particular authentication protocol above, other authentication schemes are possible, including ones that verify one or both of the communicating parties. Further, while reference is made to particular actions being performed by either the plug-in device 30 or the security device 10 , those actions can be performed by the other in alternative implementations using alternative authentication protocols.
Encryption/Decryption Process
[0046] Once the plug-in device 30 and security device 10 have successfully completed the authentication (including PIN validation as required), security device 10 can create a key (the E/D key) and initiate the encryption/decryption process, as shown in FIG. 6 . In one implementation, the security device must authenticate a plug-in device 30 prior to creating the E/D key. The security device 10 retrieves (or receives) the secret (e.g., mixed seed) from-plug-in device 30 (step 510 ). The host seed then is recovered from the secret (step 520 ). Where a mixed seed is used, the security device 10 (e.g., the microprocessor 14 of the security device 10 ) can restore the host seed from the mixed seed by descrambling the mixed seed with the previously received random number. In some implementations, the security device 10 stores the random number for retrieval to extract the host seed as required. Thereafter the E/D key is created (step 530 ). In one implementation, the microprocessor 14 combines the host seed with a device seed to generate the E/D key. In one implementation, the device seed is created when the security device 10 is initialized. In one implementation, each security device has a unique device seed. The device seed can be stored in memory 17 for subsequent retrieval. Finally, the encryption/decryption engine 12 can be enabled that is, the engine can begin encrypting or decrypting once in possession of the E/D key (step 540 ).
[0047] In some implementations, the security device 10 is able to detect when the plug-in device 30 is removed or disconnected. The security device 10 can shut down the encryption/decryption engine 13 and prevent the host computer 20 from storing or accessing any further data to or from the mass storage device 40 . In some implementations, when the security device 10 detects that the plug-in device 30 has been removed, the security device wipes the E/D key from memory.
[0048] Although the system has been described as having one host, multiple hosts can be in communication with the security device 10 . The security device 10 can allow each of the hosts to access or store data securely, as long as the plug-in device 30 is in communication with the security device 10 .
[0049] In some implementations, the configuration of the system is modified from the system shown in FIG. 2 . The host computer 20 can connect to the plug-in device 30 , the mass storage device 40 and the security device 10 . The host computer 20 can pass the data to be encrypted or decrypted to and from the security device 10 and the mass storage device 40 , as required.
[0050] Methods are described for performing encryption and decryption of data with a highly secure key management technology. The methods described herein create a key that is only in existence at run time. The key is not stored in memory and is not transferred to or from a security device. Thus, the key cannot be retrieved from memory when the plug-in device and the security device are not in use together, such as when the plug-in device or the security device are individually stolen. This prevents the key from being accessed by someone who does not have both the proper security device and the proper plug-in device.
[0051] In one implementation, the plug-in device does not store the E/D key, but rather stores a mixed seed, that is, a hybrid of a host seed and a random number. The host seed is first extracted from the mixed seed before being combined with a device seed to create the E/D key. Gaining control of only the device only provides access to the device seed, which is insufficient for creating the E/D key. Gaining control of the plug-in device only provides the mixed seed, which is also insufficient for re-constructing the E/D key. Thus, both the correct plug-in device and the correct security device are needed together to produce the desired E/D key. If the plug-in device, the data connection between the mass storage device and the security device, or security device are compromised individually, the data is still safe.
[0052] The mass storage device 40 need not be located physically close to the security device 10 . Because any information that is transmitted between the mass storage device 40 and the security device 10 is encrypted, access by an outsider, that is, someone other than a user of the host computer 20 , only permits access to encrypted data.
[0053] A number of embodiments of the invention have been described. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the invention. For example, the plug-in device can be replaced by a different readable medium that includes an integrated circuit or is in a compact size that is easy for a user to transport and carry. Alternative or additional verification steps can be initiated before the mixed seed is transferred from the plug-in device to the security device. Any random numbers or PINs described herein can be exchanged for passwords or strings of text including both symbols, letters, numbers or a combination thereof. Accordingly, other embodiments are within the scope of the following claims.
|
Methods for providing data security are described. A security device ( 10 ) and a plug-in device ( 30 ) work in conjunction to enable encryption and decryption of data. A secret is stored by one of the security device ( 10 ) or the plug-in device ( 30 ). While the secret is required for constructing a key, the key cannot be constructed from the secret alone. Unauthorized devices or users are thereby prevented from accessing the key.
| 7
|
FIELD OF THE INVENTION
The present invention relates to hypodermic needles and more particularly a safety needle sheath that is adapted to be used with a reusable VACUTAINER holder and a non-reusable syringe.
BACKGROUND OF THE INVENTION
In Hollister U.S. Pat. No. 4,982,842, there is disclosed a safety needle container, to be used with a syringe, that protects a user from being accidentally pricked by the sharp end of a needle. In Hollister U.S. Pat. No. 5,139,489, the safety sheath disclosed in the '842 patent is taught to be mated to a VACUTAINER holder (tube holder). In Hollister U.S. Pat. No. 5,154,285, the '842 safety needle sheath is taught to rotatably mount about neck of a tube holder. The disclosures of the '842, '489 and '285 patents are hereby incorporated to this application by reference.
There is further disclosed in the '489 patent a variant of the invention in which the safety needle sheath is removable from the tube holder. However, this variant (shown in FIG. 4 of the '489 patent) requires that a specially designed safety needle sheath adapter be threadedly mated to a tube holder; and that after use, the housing be removed from the tube holder. This variant was found to be impractical due to its dimensional requirements.
SUMMARY OF THE PRESENT INVENTION
To provide ease of use, the present invention safety needle sheath has a base to which there is flexibly connected a safety sheath (housing) pivotable to enclose an exposed cannula of a two-ended needle mated to the base. To the end of the base away from the pivotable sheath is a cap, or skirt, that is fittable over a corresponding end of a tube holder. The lower edge of the cap portion of the base is notched at several places to mate with corresponding extensions integrated to the tube holder. In operation, a user fits the cap of the safety needle sheath over the appropriate end of the tube holder, and turns the cap to secure the same to the tube holder. After use, the safety sheath portion is twisted off from the tube holder and discarded. The tube holder can then be reused after sterilization. A second embodiment of the present invention adapts the removable safety sheath to a syringe.
It is an objective of the instant invention to provide a safety needle sheath to be conveniently used with a reusable tube holder.
It is another objective of the instant invention to provide a safety needle sheath adapted to be used with a syringe.
BRIEF DESCRIPTION OF THE DRAWINGS
The above-mentioned objectives and advantages of the present invention will become more apparent and the invention itself will be best understood by reference to the following description of embodiments of the present invention taken in conjunction with the accompanying drawings, wherein:
FIG. 1 is a semi-cutaway cross-sectional view of the present invention;
FIG. 2 is a semi-cutaway cross-sectional view of a second embodiment of the present invention; and
FIG. 3 is a semi-cutaway cross-sectional view of additional variations of the FIG. 1 embodiment of the instant invention.
DETAILED DESCRIPTION OF THE INVENTION
As shown in FIG. 1, a safety device 2 has a base 4. Connected to base 4 via a flexible connection or living hinge 6 is a sheath or housing 8, which is pivotable along the direction indicated by directional arrow 10 to be in substantial alignment along longitudinal axis 12 of cannula 14. For the FIG. 1 embodiment, cannula 14 is a first end of a double ended needle 16 whose other cannula is designated 18. Cannula 18 is enclosed by a rubber sheath 20. As shown, double ended needle 16 is threadedly mated to base 4 via its threaded portion 22 extending from its hub 24.
Extending from the lower portion of base 4 is a skirt or cap 26 whose inner circumference matches the outer circumference of a tube holder 28. Cap 26 has at its lower end a number of notches 29, configured to lockingly mate with a corresponding number of fingers 30 extending from tube holder 28. As is well known, a fluid container, such as for example a vacuum tube, can be inserted to space 32 of tube holder 28 to be in fluid communication with double ended needle 16. As shown, unlike the conventional VACUTAINER holder, tube holder 28 may be opened at both ends. Of course, it should be appreciated that end 34 of tube holder 28 may be configured to have a smaller opening than end 36, inasmuch as the size of the opening at end 34 is not that significant, so long as rubber sheath 20 can be fitted thereat. In any event, once cap 26 is fitted over tube holder 28 and is turned clockwise approximately one quarter turn so that notches 29 are lockingly secured to fingers 30, the device shown in FIG. 1 is ready for use. Further, the length of cap 26 along axis 12 extending from base 4 is sufficiently long (i.e., at least as long as cannula 18) such that the tip of cannula 18 would not be exposed when cap 26 is removed from tube holder 28.
After use, i.e., after cannula 14 has been withdrawn from the patient, sheath 8 is pivoted along directional arrow 10 to a position in substantial alignment along longitudinal axis 12 to thereby envelop cannula 14. As was disclosed in the aforenoted '842 patent, a locking mechanism, such as a number of hooks, may be formed in sheath 8 to snap onto cannula 14 to thereby fixedly retain cannula 14 within sheath 8. Thereafter, device 2 is removed from tube holder 28, by twisting cap 26 in a counterclockwise fashion so that it no longer is secured by fingers 30. Safety device 2 can then be safely disposed of. Tube holder 28, inasmuch as it is to be constructed from a sturdy polymer material, can be reused after it has been sterilized.
FIG. 2 illustrates the adaptation of the safety device 2 shown in the FIG. 1 embodiment to a syringe 38. As shown, syringe 38, fitted with a needle assembly 40, is mated to a safety device 2 via its cap 26. A number of fingers 30 extending from syringe 38 secures cap 26 to syringe 38 by means of notches 29. The operation of the syringe of FIG. 2 is the same as that discussed with reference to the tube holder of FIG. 1. Thus, after use, safety device 2 is twisted off syringe 38 and disposed of. Syringe 38 is likewise disposed of.
For the FIGS. 1 and 2 embodiments, tube holder 28 and syringe 38 are special manufactured to include the respective extending fingers 30.
Variants of the instant invention are shown in FIG. 3. It should be appreciated that these variants are equally applicable to the syringe embodiment shown in FIG. 2. Components in FIG. 3 which are the same as those shown in FIG. 1 are labeled the same.
As shown, the FIG. 3 embodiment illustrates the rotatable mounting of sheath 8 to base 4 by means of a non-enclosed ring 42, such as that disclosed in the '285 patent. Accordingly, sheath 8 is rotatable about base 4 so that the user can always ascertain the orientation of tip 14t of cannula 14.
A second variant of the FIG. 1 invention, as shown in FIG. 3, encompasses the inclusion of a fluid absorbable material 44 adapted to the end portion of sheath 8. Such fluid absorbable material 44 may include, for example, foam, paper, sponge or other materials that can readily absorb fluid, such as blood that may be formed at the tip of cannula 14, after it is withdrawn from a patient. Fluid absorbent material 44 is configured at sheath 8 in such a manner that it contacts cannula 14 before any hook 9 integrated within sheath 8 (see FIG. 2 and the disclosure of the '842 patent). Thus, as sheath 8 is pivoted toward axis 12, if a hook is present within sheath 8, fluid absorbable material 44 would absorb any fluid formed at tip 14t of cannula 14 before hook 9 contacts cannula 14. Thus, even were hook 9 to impart a motion to cannula 14 to cause it to shake, there is no danger of any fluid being flicked into the environment since such fluid would have been absorbed by material 44 prior to the contact between cannula 14 and hook 9. Material 44 does of course have the characteristic of readily yielding to cannula 14 as it contacts the same.
Yet another variant of the present invention uses a cooperating locking mechanism between sheath 8 and base 4 to prevent further relative movement between sheath 8 and base 4 once the former is pivoted to a position substantially in alignment along axis 12. For this variant, instead of hook 9 integrated to sheath 8, an opening 46 is provided at the lower portion of sheath 8 and an extension 48 appropriately at base 4 (assuming that sheath 8 is no longer rotatable about base 4). Extension 48 has a front end 50 that is mushroom shaped, with the tip and base portion of front end 50 being respectively configured to be smaller and larger than that of opening 46. Thus, as sheath 8 is pivoted toward the alignment position at axis 12, front end 50 would penetrate through opening 46. And after sheath 8 is positioned in alignment with axis 12, the base portion of front end 50 would prevent sheath 8 from pivoting backwards, to thereby prevent any further relative movement between sheath 8 and base 4. Other types of locking mechanisms based on cooperation between means at the base and sheath are also envisioned. For example, a plurality of openings may be formed at the sheath to cooperatively coact with and lock onto corresponding tabs formed at the base.
Inasmuch as the present invention is subject to many variation, modifications and changes in detail, it is intended that all matter described throughout this specification and shown in the accompanying drawings be interpreted as illustrative only and not in a limiting sense. Accordingly, it is intended that the invention be limited only by the spirit and scope of the hereto appended claims.
|
A safety needle device adaptable to fit over a tube holder includes a skirt that fittingly mates to the front end of the tube holder. A housing flexibly attached to the base of the safety device is pivotable to a position in alignment with the needle mated to the device so as to cover the same.
| 0
|
BACKGROUND AND SUMMARY
The prior art contains patents which relate to the subject matter of this invention, and U.S. patents known to applicant are listed below: Nos.
______________________________________1 751 841 Pickens Mar 25, 19302 389 433 Hough Nov 20, 19452 399 555 Locke Apr 30, 19463 068 360 Sholin Nov 30, 19623 066 423 Solem Dec 4, 19623 157 391 Angelone Nov 17, 19643 197 886 Brame et al Aug 3, 19653 289 313 Lechner Jr. et al Dec 6, 19663 673 701 Albertson Jul 4, 1972______________________________________
However, such prior art constructions are cumbersome and relatively complicated and because of this have apparently not found much commercial use. Some of the prior art constructions were used as auxiliary heaters in conjunction with a conventional clothes dryer but were not used during a clothes drying cycle, and therefore effected no savings in energy.
In contrast to the prior art, my improved device is simple in construction and low in manufacturing cost, and may be easily inserted into the normal duct from a conventional clothes dryer, which duct heretofore was always used to vent the warm, moist air from the dryer to the outside atmosphere.
In the winter season, the heat in most homes is very dry and homeowners frequently resorted to installation of a humidifier in the air duct of the heating system, or used portable humidifiers to supply sufficient humidity. My invention provides moist, warm air, without the need of a humidifier, and thus not only saves the cost of a humidifier but also utilizes the heated air which is normally vented to the atmosphere during a clothes-drying cycle.
My improved device comprises a relatively low-cost housing, preferably in the form of a Y fitting. One leg of the fitting is connected to the air exhaust of the clothes dryer. The second or opposite leg is connected to the normal vent to the atmosphere and the third leg directs heated air into the household room. A simple damper is disposed within the fitting to selectively direct heated air to the second or third leg, or both simultaneously, as desired.
DESCRIPTION OF THE DRAWING
In the drawing accompanying this specification and forming a part of this application, there is shown, for purpose of illustration, an embodiment which my invention may assume, and in this drawing:
FIG. 1 is a small scale side view of a preferred embodiment of my invention, with a conventional clothes dryer and conventional duct work shown in dot-dash lines,
FIG. 2 is an enlarged view of the embodiment, parts being broken away to show interior construction,
FIG. 3 is an enlarged, fragmentary sectional view corresponding generally to the line 3--3 of FIG. 2, and
FIG. 4 is a face view of a detail corresponding generally to the line 4--4 of FIG. 3.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The clothes dryer 1, shown in FIG. 1, may be any one of a number of dryers now on the market and may utilize either gas or electric as the means of producing heat for the drying of clothes placed in the dryer. A vent pipe 2 is normally connected to the dryer to vent moist, heated air to a vent cover 3 which is usually located outside the house. In the usual method of drying clothes, the wet clothes are loaded into the dryer through an access door (not shown). The dryer cycle is started and heat generated by the heating unit (not shown) disposed within the dryer is effective to drying the clothes. A high capacity fan (not shown) draws heated air through the clothes in the revolving drum in the dryer, and this air is normally blown and exhausted by the fan to the atmosphere through the vent pipe 2.
My invention comprises a housing 4 which is preferably in the form of a Y fitting molded of heat-resistant plastic, or formed aluminum, or a combination of both, and is serially inserted within the vent pipe 2, as seen in FIG. 1. One open end 4a of the fitting is connected to that portion of the vent pipe 2 which leads from the dryer. The opposite or second open end 4b of the fitting is connected to part of the vent pipe 2 which leads to the vent cover 3. The third open end 4c of the fitting is adapted to communicate with the interior of a room in which the dryer is located, or by suitable duct work, to another room, or several rooms.
The conventional clothes dryer normally has a built-in air filter to remove lint and the like from the air vented from the dryer. However, to insure complete lint removal, I prefer to install an additional air filter in connection with the fitting leg 4c. If the leg 4c vents directly into a room, a removable bag-like filter 5 may be clamped around the opening of a leg 4c by means of an elastic band or endless coil spring 6, as seen in FIG. 2. This bag-like filter may be removed for cleaning as required.
Located within the fitting 4 is a damper 7 which may be swung to various positions, as shown in full and dot-dash lines in FIG. 2, to either close off air flow to the fitting leg 4c, or to leg 4b, or provide for divided air flow to both legs. The damper 7 is carried by a shaft 8 which has round portions 8a and 8b journalled in bosses provided within the fitting 4. An intermediate non-circular shaft portion 8c (preferably square in cross-section) engages in a complementary opening in the damper so that the latter is constrained to rotative movements of the shaft 8.
A manually operable knob 9 is integral with the shaft 8. Built into the knob 9 is a pointer 9a, which is in line with the damper 7, to indicate the damper position. A collar 10 is connected to an outwardly extending end of the shaft 8, preferably be means of a pin 11. On an inner face, the collar 10 has serrations 10a which co-operate with serrations 4d formed on the fitting 4, or on a washer (not shown) secured to the fitting.
A coil spring 12 is interposed between the knob 9 and an adjacent outer surface of the fitting 4 to normally urge the shaft 8 to the left, as viewed in FIG. 3, so as to hold the serrations 4d and 10a in interengaging relation and thus prevent rotation of the shaft 8. A slight push on the knob 9 will move the shaft 8 to the right and disengage the serrations 4d and 10a and thus permit rotation of the shaft 8, and connected damper 7, by manual rotation of the knob 9.
The vent pipe 2 may be either a rigid sheet aluminum pipe, or a flexible conduit and, in case of the latter, it is preferable to firmly connect the fitting 4 to a wall through use of fasteners such as the screws 13, which pass through ears formed on the fitting.
During warm weather, when no additional heat or moisture is required in a room, the damper is moved to a position in which it fully closes air flow to the fitting leg 4c. In this position all air is vented to the outside atmosphere. In cold weather, the damper 7 may be moved to a position to provide for full or partial air flow to the fitting leg 4c.
|
An improved valve device adapted to be used in conjunction with a conventional clothes dryer, either gas or electric, to selectively divert into a room of a household the heated air that is normally vented to the atmosphere.
| 3
|
This application is a filing under 35 U.S.C. 371 of international application number PCT/IB2006/000028, filed Jan. 11, 2006, which claims priority to application number 60/643,453 filed Jan. 13, 2005, in the United States the entire disclosure of which is hereby incorporated by reference.
FIELD OF THE INVENTION
This invention relates to 11 C-labeled compounds, their preparation, and their use as radiopharmaceuticals for positron emission tomography (“PET”).
BACKGROUND OF THE INVENTION
Serotonin plays a role in several psychiatric disorders, including anxiety, Alzheimer's disease, depression, nausea and vomiting, sleep, pain, eating disorders, and migraine headache. Serotonin also plays a role in both the positive and negative symptoms of schizophrenia. The central nervous system (“CNS”) distribution of serotonin and one of its receptors, the serotonin type 1B (“5HT 1B ”) receptor, coupled with the functional effects of serotonin suggest that 5HT 1B receptor antagonists can exert important neurological and behavioral effects. In addition, 5HT 1B antagonists have been shown to have antidepressant properties. Agents that selectively inhibit the 5HT 1B receptor, therefore, represent a useful approach to the treatment of psychiatric disorders including major depressive disorder.
A difficulty in the development of compounds useful for the treatment of psychiatric disorders has been the lack of appropriate animal models, the limited accessibility to the brain for pharmacokinetic measurements and lack of adequate direct biomarkers relating to action on the target system. Therefore, more accurate models for performing pharmacokinetic (“PK”) and pharmacodynamic (“PD”) modeling would be achievable if central pharmacokinetic parameters such as receptor occupancy are used instead of plasma exposures.
PET is a non-invasive imaging technique that has been widely used in neuropsychopharmacological drug development. In particular, measuring the degree of receptor occupancy in the brain has been used to guide dose-selection for antidepressant and antipsychotic drugs. Additionally, PET can be used to determine the appropriate dosing regimen for a centrally acting agent by determining the rate of onset, magnitude and duration of CNS target interaction versus the plasma half-life. See, e.g., Andree B, Nyberg S, Ito H, Ginovart N, Brunner F, Jaquet F, Halldin C and Farde L. Positron emission tomographic analysis of dose-dependent MDL 100,907 binding to 5-hydroxytryptamine-2A receptors in the human brain. Journal of Clinical Psychopharmacology 18: 317-323, 1998. PET is based on the external detection and recording of the decay of positron emitters incorporated in compounds administered to in a subject. For example, molecules of biological interest (water, sugars, amino acids or synthetic compounds) have been labeled with short-lived positron emitter isotopes of biological nuclei (e.g., 11 C), providing radiotracers having high specific activity and preserved biochemical properties.
Recently developed PET instruments allow one to obtain time-varying three-dimensional maps of the absolute radioactivity concentration distribution following compound administration. By applying tracer-kinetic modeling to these PET regional time activity curves (“TACs”), it is possible to estimate absolute values of the physiological parameters that determine the interactions and fate of the radiotracer compound. PET can be used for assessing in vivo the transport and binding regional parameters of a given drug in the tissue of a mammal, or for investigating the regional effects of a drug on physiological parameters, such as blood flow, energy metabolism, or protein synthesis rate.
The utility of radioactive agents with affinity for receptors, such as serotonin receptors, for imaging tissue, either directly or indirectly, is known. For example, C.-Y. Shiue et al., Synapse, 1997, 25, 147 and S. Houle et al., Can. Nucl. Med. Commun., 1997, 18, 1130, describe the use of 5HT 1A receptor ligands to image 5HT 1A receptors in the human brain using PET. See also C. Halldin et al., Curr. Pharm. Design, 2001, 7(18) 1907-29.
There is a great need for CNS ligands, including 5HT 1B ligands, that can be labeled with PET radionuclide and used for imaging tissue expression of this receptor system.
SUMMARY OF THE INVENTION
The present invention relates to compounds of the formula I:
and pharmaceutically acceptable salts thereof,
wherein X is CH or N;
Y is —C(OR 1 )(R 2 ) 2 or —N(R 3 ) 2 ;
R 1 is H or C 1 -C 6 alkyl;
each R 2 is independently C 1 -C 6 alkyl, or both R 2 groups are taken together to form —(CH 2 ) n —, where n is an integer ranging from 2 to 7;
each R 3 is independently C 1 -C 6 alkyl, or both R 3 groups are taken together to form —(CH 2 ) 2 —O—(CH 2 ) 2 —, —(CH 2 ) 2 —(NR 4 )—(CH 2 ) 2 — or —(CH 2 ) m —, where m is an integer ranging from 2 to 7;
R 4 is H or CH 3 ; and
* is a chiral carbon atom, wherein said carbon is a racemate, an (R)-enantiomer, an (S)-enantiomer, or a mixture thereof.
A compound of Formula I or a pharmaceutically acceptable salt thereof (each being a “ 11 C-labeled compound”) is useful for radiopharmaceuticals for positron emission tomography in a mammal. Herein a 11 C-labeled compound of Formula I or a pharmaceutically acceptable salt thereof is also referred to as a 11 C-labeled compound; the descriptions are used interchangeably.
The invention also relates to compositions comprising an effective amount of a 11 C-labeled compound and a physiologically acceptable carrier or vehicle.
The invention further relates to compounds of formula II:
wherein X is CH or N;
Y is —C(OR 1 )(R 2 ) 2 or —N(R 3 ) 2 ;
R 1 is H or C 1 -C 6 alkyl;
each R 2 is independently C 1 -C 6 alkyl, or both R 2 groups are taken together to form —(CH 2 ) n —, where n is an integer ranging from 2 to 7;
each R 3 is independently C 1 -C 6 alkyl, or both R 3 groups are taken together to form —(CH 2 ) 2 —O—(CH 2 ) 2 —, —(CH 2 ) 2 —(NR 4 )—(CH 2 ) 2 — or —(CH 2 ) m —, where m is an integer ranging from 2 to 7;
R 4 is H or CH 3 ; and
* is a chiral carbon atom, wherein said carbon is a racemate, an (R)-enantiomer, an (S)-enantiomer, or a mixture thereof.
The compounds of Formula II are useful as chemical intermediates for the synthesis of 11 C-labeled compounds.
The invention also relates to methods for synthesizing a 11 C-labeled compound, comprising allowing a compound of Formula II to react with [ 11 C]methyl iodide under conditions that are sufficient to synthesize a 11 C-labeled compound.
The present invention may be understood more fully by reference to the following detailed description and illustrative examples, which are intended to exemplify non-limiting embodiments of the invention.
DETAILED DESCRIPTION OF THE INVENTION
The term “C 1 -C 6 alkyl” as used herein refers to a straight or branched chain, saturated hydrocarbon having from 1 to 6 carbon atoms. Representative C 1 -C 6 alkyl groups include, but are not limited to, methyl, ethyl, n-propyl, iso-propyl, n-butyl, iso-butyl, sec-butyl, tert-butyl, n-pentyl, iso-pentyl, neopentyl, n-hexyl, iso-hexyl, and neohexyl.
Examples of a mammal include, but are not limited to, a human, mouse, rat, guinea pig, horse, dog, cat, cow, pig, monkey, chimpanzee, and baboon.
The term “substantially free of its corresponding (S)-enantiomer” as used herein means that the 11 C-labeled compound or compound of Formula II contains no more than about 10% by weight of its corresponding (S)-enantiomer, in another embodiment, no more than about 5% by weight of its corresponding (S)-enantiomer, in another embodiment no more than about 1% by weight of its corresponding (S)-enantiomer, in another embodiment no more than about 0.5% by weight of its corresponding (S)-enantiomer, and in another embodiment no more than about 0.1% by weight of its corresponding (S)-enantiomer.
The term “substantially free of its corresponding (R)-enantiomer” as used herein means that the 11 C-labeled compound or compound of Formula II contains no more than about 10% by weight of its corresponding (R)-enantiomer, in another embodiment, no more than about 5% by weight of its corresponding (R)-enantiomer, in another embodiment no more than about 1% by weight of its corresponding (R)-enantiomer, in another embodiment no more than about 0.5% by weight of its corresponding (R)-enantiomer, and in another embodiment no more than about 0.1% by weight of its corresponding (R)-enantiomer.
Examples of a pharmaceutically acceptable salt include, but are not limited to, a hydrochloride, a hydrobromide, a hydroiodide, a nitrate, a sulfate, a bisulfate, a phosphate, an acid phosphate, an isonicotinate, an acetate, a lactate, a salicylate, a citrate, an acid citrate, a tartrate, a pantothenate, a bitartrate, an ascorbate, a succinate, a maleate, a fumarate, a gluconate, a glucaronate, a saccharate, a formate, a benzoate, a glutamate, a methanesulfonate, an ethanesulfonate, a benzenesulfonate, and a p-toluenesulfonate salt.
As used herein, the term “effective amount” refers to an amount of a 11 C-labeled compound of Formula I that is effective for imaging tissue or labeling tissue in a mammal.
The invention provides 11 C-labeled compounds of Formula I:
wherein X is CH or N;
Y is —C(OR 1 )(R 2 ) 2 or —N(R 3 ) 2 ;
R 1 is H or C 1 -C 6 alkyl;
each R 2 is independently C 1 -C 6 alkyl, or both R 2 groups are taken together form —(CH 2 ) n —, where n is an integer ranging from 2 to 7;
each R 3 is independently C 1 -C 6 alkyl, or both R 3 groups are taken together to form —(CH 2 ) 2 —O—(CH 2 ) 2 —, —(CH 2 ) 2 —(NR 4 )—(CH 2 ) 2 — or —(CH 2 ) m —, where m is an integer ranging from 2 to 7;
R 4 is H or CH 3 ; and
* is a chiral carbon atom, wherein said carbon is a racemate, an (R)-enantiomer, an (S)-enantiomer, or a mixture thereof.
The present invention also provides compositions comprising an effective amount of a 11 C-labeled compound and a physiologically acceptable carrier or vehicle.
The present invention also provides methods or uses for quantitatively imaging tissue, comprising administering an effective amount of a 11 C-labeled compound to a mammal and detecting binding of the 11 C-labeled compound in the mammal. This includes quantitatively imaging tissue that contains the 5HT 1B receptor.
The present invention also provides methods or uses for labeling tissue, comprising administering an effective amount of a 11 C-labeled compound to a mammal. This includes labeling tissue that contains the 5HT 1B receptor.
In one embodiment, X is CH. In another embodiment, X is N.
In one embodiment, Y is —C(OR 1 )(R 2 ) 2 . In another embodiment, Y is —N(R 3 ) 2 .
In one embodiment, R 1 and each R 2 group are —CH 3 . In another embodiment, R 1 is H and each R 2 group is —CH 2 CH 3 . In another embodiment, R 1 is H and both R 2 groups are taken together to form —(CH 2 ) 4 —.
In another embodiment, both R 3 groups are taken together to form —(CH 2 ) 2 —O—(CH 2 ) 2 —.
In one embodiment, X is CH, Y is —C(OR 1 )(R 2 ) 2 and R 1 and each R 2 group are —CH 3 .
It is understood that each variable of Formula I may have any definition described herein.
Formula I depicts an (*)-denoted carbon atom, which is chiral. With respect to the (*)-denoted carbon atom, Formula I encompasses a racemate, an (R)-enantiomer, an (S)-enantiomer, or a mixture thereof.
In one embodiment, the 11 C-labeled compound is racemic with respect to the (*)-denoted carbon atom.
A 11 C-labeled compound that is racemic with respect to the (*)-denoted carbon atom has the formula:
where X and Y are as defined above.
In another embodiment, a 11 C-labeled compound is an (R)-enantiomer with respect to the (*)-denoted carbon atom and is substantially free of its corresponding (S)-enantiomer with respect to the (*)-denoted carbon atom.
A 11 C-labeled compound that is an (R)-enantiomer with respect to the (*)-denoted carbon atom and that is substantially free of its corresponding (S)-enantiomer with respect to the (*)-denoted carbon atom has the formula:
where X and Y are defined above.
In another embodiment, a 11 C-labeled compound is an (S)-enantiomer with respect to the (*)-denoted carbon atom and is substantially free of its corresponding (R)-enantiomer with respect to the (*)-denoted carbon atom.
A 11 C-labeled compound that is an (S)-enantiomer with respect to the (*)-denoted carbon atom and that is substantially free of its corresponding (R)-enantiomer with respect to the (*)-denoted carbon atom has the formula:
where X and Y are defined above.
In one embodiment, the 11 C-labeled compound is independently any one or more of the following:
or, a pharmaceutically acceptable salt thereof.
In one embodiment, the 11 C-labeled compound binds to a serotonin receptor. In another embodiment, the 11 C-labeled compound binds to a 5HT 1B receptor. In another embodiment, the 11 C-labeled compound is a 5HT 1B -receptor antagonist.
The invention also provides compounds of Formula II:
wherein X is CH or N;
Y is —C(OR 1 )(R 2 ) 2 or —N(R 3 ) 2 ;
R 1 is H or C 1 -C 6 alkyl;
each R 2 is independently C 1 -C 6 alkyl, or both R 2 groups are taken together form —(CH 2 ) n —, where n is an integer ranging from 2 to 7;
each R 3 is independently C 1 -C 6 alkyl, or both R 3 groups are taken together to form —(CH 2 ) 2 —O—(CH 2 ) 2 —, —(CH 2 ) 2 —(NR 4 )—(CH 2 ) 2 — or —(CH 2 ) m —, where m is an integer ranging from 2 to 7;
R 4 is H or CH 3 ; and
* is a chiral carbon atom, wherein said carbon is a racemate, an (R)-enantiomer, an (S)-enantiomer, or a mixture thereof.
In one embodiment, X is CH. In another embodiment, X is N.
In one embodiment, Y is —C(OR 1 )(R 2 ) 2 . In another embodiment, Y is —N(R 3 ) 2 .
In one embodiment, R 1 is H and each R 2 group is —CH 2 CH 3 . In another embodiment, R 1 is H and both R 2 groups are taken together to form —(CH 2 ) 4 —.
In another embodiment, both R 3 groups are taken together to form —(CH 2 ) 2 —O—(CH 2 ) 2 —.
In one embodiment, X is CH, Y is —C(OR 1 )(R 2 ) 2 and R 1 and each R 2 group are —CH 3 .
It is understood that each variable of Formula II may have any definition described herein.
Formula II depicts an (*)-denoted carbon atom, which is chiral. With respect to the (*)-denoted carbon atom, Formula II encompasses a racemate, an (R)-enantiomer, an (S)-enantiomer, and a mixture thereof.
In one embodiment, a compound of Formula II is racemic with respect to the (*)-denoted carbon atom.
A compound of Formula II that is racemic with respect to the (*)-denoted carbon atom has the formula:
where X and Y are as defined above.
In another embodiment, a compound of Formula II is an (R)-enantiomer with respect to the (*)-denoted carbon atom and is substantially free of its corresponding (S)-enantiomer with respect to the (*)-denoted carbon atom.
A compound of Formula II that is an (R)-enantiomer with respect to the (*)-denoted carbon atom and that is substantially free of its corresponding (S)-enantiomer with respect to the (*)-denoted carbon atom has the formula:
where X and Y are defined above.
In another embodiment, a compound of Formula II is an (S)-enantiomer with respect to the (*)-denoted carbon atom and is substantially free of its corresponding (R)-enantiomer with respect to the (*)-denoted carbon atom.
A compound of Formula II that is an (S)-enantiomer with respect to the (*)-denoted carbon atom and that is substantially free of its corresponding (R)-enantiomer with respect to the (*)-denoted carbon atom has the formula:
where X and Y are defined above.
In one embodiment, the compound of Formula II is independently any one or more of the following:
The compounds of Formula II and 11 C-labeled compounds can be synthesized as shown generally in Schemes 1 and 2. Scheme 1 illustrates a synthesis of a pyrrolidin-2-one intermediate, 3-(2-piperazin-1-yl-benzyl)-pyrrolidin-2-one (6).
In Scheme 1, benzylpiperazine (1) and 2-fluorobenzaldehyde (2) are allowed to react in the presence of a suitable base, such as, for example, an alkali metal or alkaline earth base, including K 2 CO 3 and Na 2 CO 3 , in the presence of a polar organic solvent, such as dioxane, water, acetone, tetrahydrofuran (“THF”), dimethylsulfoxide (“DMSO”), dimethylformamide (“DMF”), N-methylpyrrolidine (“NMP”), pyridine, dichloromethane, or a mixture thereof to provide the benzaldehyde derivative 3. Reaction of the benzaldehyde 3 in the presence of N-acetylpyrrolidinone (4) and hydride base such as sodium hydride, lithium aluminum hydride, or sodium aluminum hydride provides 5. Treatment of 5 with H 2 in the presence of palladium on carbon removes the benzyl protecting group and reduces the double bond of 5 to provide the racemic pyrrolidinone derivative 6. The skilled worker will understand that similar procedures would be efficacious in performing the aldol condensation wherein groups other than acyl are present on the pyrrolidinone ring, such as pivaloyl.
As shown in Scheme 2, the racemic pyrrolidinone derivative 6 can be coupled with the desired phenyl- or pyridyl-bromide derivative 7 in the presence of a copper catalyst such as copper iodide, copper bromide, copper chloride, copper triflate, or copper acetate, a suitable ligand such as dimethylethylenediamine, ethylenediamine, or 2,2′-bipyridine, in the presence of a suitable base such as cesium carbonate, potassium carbonate, or sodium carbonate, in a non-polar solvent such as toluene, carbon tetrachloride, octane, hexane, or cyclohexane, to form a racemic compound of Formula II.
The racemic compound of Formula II can then be subjected to chiral resolution to provide an (R)-enantiomer with respect to the (*)-denoted carbon atom of Formula II that is substantially free of its (S)-enantiomer with respect to the (*)-denoted carbon atom, or an (S)-enantiomer with respect to the (*)-denoted carbon atom of Formula II that is substantially free of its (R)-enantiomer with respect to the (*)-denoted carbon atom, using techniques known to those of skill in the art. For example, the racemic compound of Formula II can be subjected to chiral liquid chromatography (“LC”) using a preparatory column appropriate for separating racemic compounds, including, for example, CHIRALCEL OD-H column, CHIRALPAK AD-H column, CHIRALPAK AS-H column, and CHIRALCEL OJ-H column, available commercially from Chiral Technologies, Inc., using solvent systems such as, for example, 0 to 40% methanol or ethanol in heptane, hexane, or acetonitrile (“ACN”); optionally including less than about 0.5% trifluoroacetic acid or less than about 0.5% diethylamine or triethylamine.
As shown in Scheme 3, compounds of Formula II are N-methylated with [ 11 C]methyl iodide to provide the 11 C-labeled compounds of the present invention. N-methylation can occur in a suitable polar aprotic solvent such as DMF, DMSO, ACN, or acetone. Methods for generating [ 11 C]methyl iodide are known to those of ordinary skill in the art. One example is disclosed in Långström B. and Lundqvist H., Int. J. Appl. Radiat. Isot., 1976, 27, 357-363.
The present invention also provides compositions comprising an effective amount of a compound of Formula I and a physiologically acceptable carrier or vehicle. The compounds of Formula I may be administered by any means that achieve their intended purpose. For example, administration may be by parenteral, including subcutaneous, intravenous, intramuscular, intraperitoneal, transdermal, or buccal, routes. Alternatively, or concurrently, oral administration may be employed. A preferred route of administration of the compounds of Formula I for imaging is the intravenous route. The compounds of Formula I can be administered in a single bolus, or by gradual perfusion, which is preferably intravenous, using peristaltic means to accomplish the gradual perfusion.
The compounds of Formula I may be formulated in biocompatible solubilizing media for enteral or parenteral administration. The PET formulations of the invention may contain conventional pharmaceutical carriers and excipients appropriate for the type of administration contemplated. Formulations for enteral administration may vary widely, as is well-known in the art. In general, such formulations include a diagnostically effective amount of a ligand of the invention (compounds of Formula I) in an aqueous solution or suspension. Such enteral compositions may optionally include buffers, surfactants, adjuvants, thixotropic agents, and the like. Parenteral formulations advantageously contain a sterile aqueous or non-aqueous solution or suspension or emulsion of a ligand according to this invention. Various techniques for preparing suitable pharmaceutical solutions and suspensions are known in the art. Such solutions also may contain pharmaceutically acceptable buffers, stabilizers, antioxidants, and electrolytes, such as sodium chloride. Parenteral compositions may be injected directly or mixed with a large volume parenteral composition for systemic administration. Examples of non-aqueous solvents are propyleneglycol, polyethyleneglycol, vegetable oil, such as olive oil, and injectable organic esters, such as ethyl oleate. Aqueous carriers include water, alcoholic/aqueous solutions, emulsions or suspensions, including saline and buffered media, parenteral vehicles including sodium chloride solution, Ringer's dextrose, dextrose and sodium chloride, lactated Ringer's, or fixed oils. Intravenous vehicles include fluid and nutrient replenishers, electrolyte replenishers, such as those based on Ringer's dextrose, and the like. Preservatives and other additives may also present, such as, for example, antimicrobials, anti-oxidants, chelating agents, and inert gases. See, generally, Remington's Pharmaceutical Science, 16th ed., 1980.
The labeled compositions within the scope of the present invention are administered in doses effective to achieve the desired PET image. Such doses may vary widely, depending upon the activity level of the C-11 generated, the organs or tissues which are the subject of the imaging procedure, the PET equipment being used, etc. Typical doses of the diagnostic compositions are in the range from about 4 to about 400 pmol/kg body weight, and preferably about 200 pmol/kg body weight.
The invention is also useful as a means to evaluate the efficacy of, and responses to, therapeutic treatment of various CNS disorders such as depression and anxiety. In such a utility, the compounds of Formula I are used in a conventional manner in PET imaging procedures.
In one embodiment, the dose of a 11 C-labeled compound is an amount that has sufficient radioactivity to enable labeling or imaging of tissue or an organ's expression of the receptor system using a technique such as PET. A dose useful for labeling or imaging a tissue typically ranges from about 1 MBq/kg to about 20 MBq/kg, but can vary according to factors such as the general health, age, and sex of the mammal and the particular application.
In one embodiment, the present methods further comprise administering an effective amount of a serotonin reuptake inhibitor (“SRI”) (e.g., sertraline, fluoxetine, fenfluramine, or fluvoxamine) to the mammal. In this embodiment, the 11 C-labeled compound and the SRI can be administered within the same composition, or separately. Where the 11 C-labeled compound and SRI are administered separately, the administration is such that the SRI is inhibiting the reuptake of serotonin during a time where the 11 C-labeled compound is labeling tissue in a mammal.
An effective dose of the SRI is generally within the range of about 1 mg to about 400 mg/mammal/day.
In one embodiment, the present methods further comprise administering an effective amount of a serotonin-2 (“5HT 2 ”) receptor antagonist (e.g., ketanserin, pelanserin, pipamperone, spiperone, pirenperin or ritanserin) to the mammal. In this embodiment, the 11 C-labeled compound and the 5HT 2 receptor antagonist can be administered within the same composition, or separately. Where the 11 C-labeled compound and 5HT 2 receptor antagonist are administered separately, administration is such that the 5HT 2 receptor antagonist is inhibiting the 5HT 2 receptor during a time where the 11 C-labeled compound is labeling a tissue in a mammal.
An effective amount of the 5HT 2 antagonist is generally within the range of about 1 mg to about 400 mg/mammal/day.
In one embodiment, the present methods further comprise administering an effective amount of a serotonin-1 (“5HT 1 ”) receptor antagonist (e.g., a 5HT 1B antagonist) to the mammal. In this embodiment, the 11 C-labeled compound and the 5HT 1B receptor antagonist can be administered within the same composition, or separately. Where the 11 C-labeled compound and 5HT 1B receptor antagonist are administered separately, administration is such that the 5HT 1B receptor antagonist is inhibiting the 5HT 1B receptor during a time where the 11 C-labeled compound is labeling a tissue in a mammal.
An effective amount of the 5HT 1B antagonist is generally within the range of about 1 mg to about 400 mg/mammal/day.
The invention also encompasses methods for imaging tissue, comprising administering an effective amount of a 11 C-labeled compound to a mammal and detecting binding of the 11 C-labeled compound in the mammal.
In one embodiment, detecting binding comprises detecting a radioactive emission from the 11 C-labeled compound. The tissue can be epithelial tissue, connective tissue, muscle tissue, or nerve tissue. In one embodiment, the tissue is an organ.
Representative tissue includes brain, spinal cord, nerve, heart, blood vessel, blood, mouth, esophagus, stomach, small intestine, large intestine, colon, liver, lung, skin, eye, nose, trachea, kidney, bladder, urethra, ovary, uterus, vagina, breast, or testicle. In one embodiment, the tissue is brain. In another embodiment, the brain is globus pallidus, ventral pallidum, lentiform nucleus, striatum, substantia nigra, frontal lobe, temporal lobe, occipital cortex, cerebrum, or cerebellum.
In one embodiment, the tissue expresses serotonin receptors. In another embodiment, the tissue expresses 5HT 1B receptors. There are specifically high levels of 5HT 1B expression in the globus pallidus and substantia nigra, but significant expression is observed in all brain grey matter except cerebellar grey matter.
In one embodiment, the mammal is a human.
Imaging can be carried out using any appropriate apparatus. Imaging can be carried out on a conscious or unconscious mammal using standard imaging techniques in order to evaluate, for example, blood flow, pharmacokinetic parameters, and pharmacodynamic parameters before and after administration of a 11 C-labeled compound. Physiological parameters that can be evaluated include, for example, F v (vascular fraction), K 1 , k 2 (plasma/free compartment exchange rate), k off , k on /V r (association and dissociation rate), B max (receptor concentration), and K d (apparent equilibrium dissociation rate) of a 11 C-labeled compound. Imaging can also be used to examine metabolic routes of a 11 C-labeled compound.
Methods for PET imaging are described in, for example, C. Halldin et al., Curr. Pharm. Design, 2001, 7(18) 1907-29; C.-Y. Shiue et al., Synapse, 1997, 25, 147; and S. Houle et al., Can. Nucl. Med. Commun., 1997, 18, 1130.
Therefore, the following examples further describe and demonstrate certain embodiments within the scope of the present invention. The examples are given solely for the purpose of illustration, and are not to be construed as limitations of the present invention since many variations of the present invention are possible without departing from its spirit and scope.
EXAMPLES
Example 1
Synthesis of 1-acetyl-pyrrolidin-2-one
A mixture of 112 g of 2-pyrrolidinone (9) and 249 mL of acetic anhydride was heated at reflux for 2 hours. The resultant mixture was allowed to cool to room temperature, was concentrated in vacuo, and was distilled (0.8 mm Hg, 68° C.) to provide 160 g of N-acetyl-2-pyrrolidinone (4) in 96% yield.
Example 2
Synthesis of 1-bromo-4-(1-methoxy-1-methyl-ethyl)-benzene
A mixture of 6.87 g of ethyl 4-bromobenzoate (10) was allowed to react with 64 mL (1.4 M in toluene) of methyl magnesium bromide in THF at −40° C. for 1 hour, and the reaction mixture was gradually warmed to 0° C. The reaction was quenched with saturated aqueous ammonium chloride solution and the resultant mixture was extracted with ethyl acetate. The organic layer was washed with brine, was dried over magnesium sulfate, was filtered, and the solvent was removed in vacuo. Purification by silica gel chromatography (50:1 to 10:1 hexanes-ethyl acetate) afforded 6.44 g (99% yield) of 2-(4-bromophenyl)propan-2-o1; MS (AP/CI) observed: 199.1 (M+H−H 2 O) + , 100%; 213.1, 215.1 (M−H) − , 60%, 80%. 2-(4-Bromophenyl)propan-2-o1 (1.77 g) and iodomethane (1.16 g) in THF (100 mL) were treated with sodium hydride, 60% in mineral oil (328 mg). After stirring for 24 h at room temperature, the reaction mixture was quenched with dilute aqueous hydrochloric acid, was extracted with ethyl acetate, and the organic layer was washed with brine, was dried over magnesium sulfate, was filtered, and the solvent was removed in vacuo. The resultant oil was purified by silica gel chromatography (200:1 hexanes-ethylacetate) to afford 0.5 g of 1-bromo-4-(1-methoxy-1-methyl-ethyl)-benzene; 13 C NMR (400 MHz, CDCl 3 ) δ 145.35, 131.53, 127.91, 121.00, 50.90, 28.60.
Example 3
Synthesis of 1-[4-(1-methoxy-1-methyl-ethyl)-phenyl]-3-(2-piperazin-1-yl-benzyl)-pyrrolidin-2-one (compound 12)
A mixture of 25 g of benzylpiperazine (1) and 10 g of 2-fluorobenzaldehyde (2) were allowed to react in refluxing dioxane/water (1:2, 90 mL total volume) for 24 hours in the presence of 17 g K 2 CO 3 . The resultant reaction mixture was allowed to cool to room temperature, was extracted with methylene chloride and the organic layer was then washed with water, 5% hydrochloric acid, brine, and was then dried over magnesium sulfate, was filtered, and the solvent was removed in vacuo. Purification by silica gel chromatography (5:1 hexanes-ethyl acetate) afforded 20 g of the benzaldehyde 3 in 89% yield; MS (AP/CI) observed: 281.1 (M+H) + (100%). The benzaldehyde 3 (8 g) was subsequently allowed to react with 7.3 g of 1-acetyl-pyrrolidin-2-one (4) in the presence of 4.6 g of NaH (60% in mineral oil) at 0° C. for 1 hour followed by warming to room temperature and stirring for 2 hours. After quenching carefully with methanol at 0° C., the solvent was removed in vacuo, the residue was diluted with water, was extracted with methylene chloride and the organic extracts were washed with brine and were dried over magnesium sulfate and were filtered. The solvent was removed in vacuo and the residue was purified by silica gel chromatography (40:1 chloroform-methanol) to provide 7.9 g of 3-[2-(4-benzyl -piperazin-1-yl)-benzylidene]-pyrrolidin-2-one (5) in 80% yield; MS (AP/CI) observed: 348.1 (M+H) + , 100%. Hydrogenation of 6.3 g of 5 with 1.5 g of Pd/C in 100 mL of methanol under 50 p.s.i. of pressure at 60° C. provided 3.8 g (82% yield) of 3-(2-piperazin-1-yl-benzyl)-pyrrolidin-2-one (6) following filtration, removal of solvent in vacuo, and purification by silica gel chromatography (30:1:0.3 chloroform-methanol-ammonium hydroxide); MS (AP/CI) observed: 260.1 (M+H) + , 100%.
3-(2-piperazin-1-yl-benzyl)-pyrrolidin-2-one (6) (1.2 grams) was subsequently allowed to react with 1.27 g of 1-bromo-4-(1-methoxy-1-methyl-ethyl)-benzene (11) in the presence of 0.041 grams of N,N′-dimethylethylenediamine, 0.088 g of CuI and 0.96 grams of K 2 CO 3 in toluene (6 mL) at 110° C. for 17 hours to provide 1.2 grams of the racemate 1-[4-(1-methoxy-1-methyl-ethyl)-phenyl]-3-(2-piperazin-1-yl-benzyl)-pyrrolidin-2-one (12) (64% yield) following silica gel chromatography (40:1:0.5 chloroform-methanol-ammonium hydroxide); MS (AP/CI) observed: 408.2 (M+H) + .
Example 4
Synthesis of R-1-[4-(1-methoxy-1-methyl-ethyl)-phenyl]-3-(2-piperazin-1-yl-benzyl)-pyrrolidin-2-one (compound 13)
The racemic compound 12 (1137 milligrams) was subjected to chiral liquid chromatography separation using a CHIRALPAK AD 10×25 cm column, with a mobile phase of heptane/ethanol in a 75:25 ratio and a flow rate of 275 mL/min. Compound 13 exhibited a retention time of approximately 29 minutes and a UV max of 250 nM. The relevant fractions were collected and concentrated in vacuo to provide 0.488 grams of compound 13 (diagnostic 13 C NMR (400 MHz, CDCl 3 ) δ 175.93, 152.53, 142.09, 138.54, 135.30, 130.56, 127.63, 126.55, 124.54, 120.86, 119.62, 76.72, 54.16, 50.85, 46.98, 46.77, 44.99, 32.49, 28.17, 28.13, 24.69), which contained no more than about 0.5% by weight of its corresponding (S)-enantiomer.
Example 5
Synthesis of S-1-[4-(1-methoxy-1-methyl-ethyl)-phenyl]-3-(2-piperazin-1-yl-benzyl)-pyrrolidin-2-one (compound 14)
The racemic compound 12 (1137 milligrams) was subjected to chiral liquid chromatography separation using a CHIRALPAK AD 10×25 cm column, with a mobile phase of heptane/ethanol in a 75:25 ratio and a flow rate of 275 mL/min. Compound 14 exhibited a retention time of approximately 48 minutes and a UV max of 250 nM. The relevant fractions were collected and concentrated in vacuo to provide 0.70 grams of compound 14 (diagnostic 13 C NMR (400 MHz, CDCl 3 ) δ 175.93, 152.54, 142.10, 138.54, 135.30, 130.56, 127.62, 126.55, 124.53, 120.86, 119.62, 76.72, 54.19, 50.84, 46.98, 46.80, 44.99, 32.48, 28.17, 28.13, 24.67), which contained no more than about 4% by weight of its corresponding (R)-enantiomer.
Example 6
Synthesis of R-1-[4-(2-methoxy-isopropyl)-phenyl]-3-[2-(4-[ 11 C]methyl-piperazin-1-yl)benzyl]-pyrrolidin-2-one (compound I-B)
[ 11 C]Carbon dioxide was generated using a Scanditronix MC-17 cyclotron using an 14 N(p,α) 11 C reaction with 17 MeV protons in a gas target containing nitrogen (AGA, Nitrogen 6.0) and 0.1% oxygen (AGA, Oxygen 4.8). Schlyer, D. J. (2003). Production of Radionuclides in Accelerators. Handbook of Radiopharmaceuticals. Radiochemistry & Applications . M. J. Welch and C. S. Redvanly. Chichester, John Wiley & Sons, Ltd., 1-70.
Liquid chromatographic purification and analysis were performed using a Beckman 126 gradient pump and a Beckman 166 variable-wavelength UV detector in series with β + -flow detector. The following mobile phases were used for semi-preparative LC: saline (9 mg/mL) and acetonitrile/H 2 O (50:7); for analytical LC: 0.05 M ammonium formate, pH 3.5 and acetonitrile/H 2 O (50:7). A Jones Chromatography Genesis C 18 column (250×4.6 mm, i.d.) was used for analytical liquid chromatography at a flow rate of 2 mL/min. For semi-preparative LC, a Jones Chromatography Genesis C 18 column (4 μm, 250×10 mm, i.d.) was used at a flow rate of 6 mL/min. Synthia, an automated synthesis system available from Uppsala Imanet, was used for LC injection and fraction collection. Data collection and LC control were performed using a Beckman System Gold chromatography software package.
Radioactivity was measured using a Veenstra Instrumenten by VDC-202 ion chamber.
Synthesis of [ 11 C]methyl iodide
The trapped [ 11 C]carbon dioxide was released by heating the trap to 50° C. Once released, the [ 11 C]carbon dioxide was carried in a stream of nitrogen gas via stainless steel lines to a hot-cell and trapped in a suitably designed reaction vessel containing lithium aluminium hydride (0.2M) in tetrahydrofuran (200 μL). After transfer of the [ 11 C]carbon dioxide, the THF was evaporated by heating it to about 120° C. in a stream of dry nitrogen gas. Hydroiodic acid (1.5 mL, 54%) was added, and the resultant [ 11 C]methyl iodide was transferred in a stream of nitrogen gas via a drying tower (SICAPENT) to the reaction vessel.
Synthesis of Compound I-B
The [ 11 C]methyl iodide obtained above was trapped at ambient temperature into a DMF (200 μL) and DMSO (100 μL) solution of compound 13 (1 mg) in a pear-shape stoppered vial, and the resultant reaction mixture was heated at about 130° C. for 5 min. The reaction mixture was allowed to cool to room temperature and diluted with saline/acetonitrile (300 μL) and injected into the semi-preparative HPLC column. Fractions were collected, transferred to a rotary-evaporator flask, and concentrated by heating at 95° C. under vacuum. A sterile phosphate buffer solution (pH 7, 2.4 mL) and ethanol (0.6 mL, 99.5%) was transferred to the flask and subsequently transferred to a sterile injection vial containing 0.1 M sterile phosphate buffer solution (3 mL) by helium gas using a 0.22 μm filter. Standard chemical characterization methods verified the structure of compound I-B. Compound I-B contains no more than about 1.5% of its corresponding (S)-enantiomer, compound I-C.
Example 7
Receptor-Binding Experiments with Compound I-B
Experiments performed with compound I-B, including in-vitro autoradiographies and ex-vivo experiments in Guinea pig, and in-vivo PET-experiments in Rhesus monkeys, indicate a specific uptake of compound I-B mainly in the external globus pallidus and ventral pallidum. This uptake is sensitive to blocking by other 5HT 1B antagonists in a dose dependent manner.
Example 8
Administration of Compound I-B for Imaging Tissue
Compound I-B is a 5HT 1B receptor antagonist having physiochemical properties that make it useful for labeling or imaging tissue in a mammal. Compound I-B is also useful for measuring 5HT 1B receptor occupancy.
Less than about 20 μg of compound I-B, which corresponds to approximately 250-500 MBq in 0.1 M phosphate buffer (pH 7.4) containing <8% ethanol, is administered intravenously.
Screening takes place over a two-day trial period. On day 1, a single intravenous dose of about 10 mL of the phosphate-buffered compound I-B is administered to the mammal over about 30 seconds, and is followed by performing PET for 90 minutes. Arterial plasma samples are continuously withdrawn for 7 minutes with an on-line radioactivity detector. Arterial blood sampling provides a plasma input function for calculating specific brain regional uptake of compound I-B. This is followed by the taking of discrete arterial blood samples at 2, 5, 10, 20, 40, 60 and 90 minutes, to determine levels of plasma 11 C due to compound I-B and its metabolites. Subject symptoms and adverse events are monitored. On day 2, subjects are assessed within 1-10 days to repeat the assessments outlined above in Day 1.
The projected blood volume to be collected is approximately 175 mL.
Arterial blood samples are continuously withdrawn for 7 minutes with an on-line radioactivity detector at a speed of 4 mL/min, and discrete samples of 7 mL each are taken at 2, 5, 10, 20, 40, 60 and 90 minutes following dosing. HPLC analysis of arterial blood samples to determine levels of 11 C due to parent tracer and its metabolites is also performed.
Subjects receive an intravenous injection of compound I-B in up to 10 mL 0.1 M phosphate buffer (pH 7.4) containing <8% ethanol over approximately 30 seconds at the onset of the PET scan with a duration of 90 minutes. During PET, arterial blood sampling is performed to provide a plasma input function for calculating specific brain regional uptake of compound I-B. Initially, whole blood 11 C radioactivity is continuously monitored for 7 minutes using an on-line radioactivity detector to obtain peak activity levels. Also, discrete arterial blood samples are taken at 2, 5, 10, 20, 40, 60, and 90 minutes to determine levels of plasma 11 C radioactivity due to the parent tracer and its metabolites.
Subjects are placed in the scanner with transaxial planes orientated parallel to the orbito-meatal line. Dynamic compound I-B PET data are acquired in 3D mode for all subjects using either of the two identical ECAT EXACT HR+ (Siemens/CTI) scanners, which have a 15.5 cm axial field of view and generates 63 transaxial planes. The tomographs have a reconstructed spatial resolution of about 5-6 mm after image reconstruction. A transmission scan, which corrects for attenuation of emitted radiation by skull and tissue, is acquired during 10 minutes using three retractable 68 Ge line sources. An emission scan is then started simultaneously with start of tracer injection, and data are acquired over 90 minutes (divided into 18 successive time frames). Dynamic images are reconstructed using a filtered back projection algorithm with a Hanning filter.
For the analysis of the images, initially an average over the sequence is made and images are co-aligned with the subjects MRI images acquired at screening. A set of volumes of interest (“VOIs”) are created and placed bilaterally over the globus pallidus (part of lentiform nucleus, striatum), (medial) frontal, lateral temporal and occipital cortex and cerebellum (cortex) to sample tracer uptake in these regions.
Depending on the actual pattern of tracer distribution in the human brain additional regions are also included.
The VOIs are applied to the uptake data, and dynamic TACs are generated. Various modeling exercises are undertaken in the work of verifying a suitable modeling approach. A metabolite-corrected plasma input function is generated and used.
The defined VOIs are then used to generate TACs from the dynamic time series. Patlak and Logan linear graphical methods are used to quantify tracer uptake as an influx constant K i in areas of irreversible binding (striatum) and specific volumes of distribution (V d ) in areas of reversible binding (cortex, thalamus) during the time course of PET. Assuming the cerebellum demonstrates rapid uptake and then washout, suggesting an absence of specific binding, the cerebellar time activity curve is used as a reference tissue input function. Alternatively, a metabolite-corrected arterial plasma input function is employed. The slope (K i ) obtained for an irreversibly trapped tracer and the V d obtained for a reversibly binding agent are both proportional to the binding potential (B max /K d in the absence of cold ligand) of the tracer. The influx constant, K i , has units of min −1 .
The tracer uptake is described and presented as TAC data combined with blood and plasma data as well as metabolite data.
Descriptive statistics for pharmacodynamic variables such as counts per second and specific to non-specific uptake ratio are tabulated. Satisfactory tracer measures a count rate in the head (decayed to time of tracer injection) of not less than 50,000 counts per second. Satisfactory tracer also has specific to non-specific uptake ratio greater than 0.5.
Plasma levels of 11 C due to compound I-B and its metabolites at 2 (only total 11 C measured), 5 (only total 11 C measured), 10, 20, 40, 60 and 90 minutes are determined.
Compound I-B can also be employed to measure the degree of brain 5HT 1B receptor occupancy of 5HT 1B receptor antagonists in development, which assists in the determination of efficacious dose. Gefvert O, et al. Eur Neuropsychopharmacol., 2001, 11, 105-110; Bergström M, et al., Biological Psychiatry, 2004, 55, 1007-1012.
Throughout this application, various publications are referenced. The disclosures of these publications in their entireties are hereby incorporated by reference into this application.
|
The invention relates to “C-labeled compounds, their preparation, compositions comprising an effective amount of a “C-labeled compound, and the use of a “C-labeled compound as a radiopharmaceutical for positron emission tomography.
| 2
|
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The invention relates to synthetic sports surfaces and to a method of manufacturing an artificial turf as well as other types of surfaces constructed of synthetic fibers.
[0003] 2. Description of the Prior Art
[0004] Tufted surface coverings are employed indoors as floor coverings in the form of carpeting, area rugs, floor, gym, barrier and crash mats, as well as outdoors, in the form of carpeting, artificial turf, cushioned sport and play surfaces and sport mats. Surface coverings for sporting use are generally constructed by stitching into a preformed fabric backing layer to form tufts, and then bonding the primary backing layer to an impact-absorbing resilient lower layer or shock pad, by means of a thin, laminating layer.
[0005] Conventional tufting machines employ rows of needles, which are threaded with a suitable yarn fed from a ball or creel through an aperture adjacent the tip of each needle. The tufting machine forces the rows of needles through a backing fabric. The needles pierce the fabric from back to front, pushing the yarn through the backing. Looping tools catch the yarn loops on the face of the backing as the needles are withdrawn. Once tufting of the primary backing is completed, the loops of face yarn are generally cut to form a pile surface or “face”. While the loops may be left uncut for indoor carpet surfaces, the loops of surfaces intended for outdoor usage are generally cut in order to produce a covering more closely resembling grass. The diameter of the yarn, the number of yarn strands in each tuft, and the spacing of the tufts determine the density of the final surface.
[0006] Conventional tufting machines use a reciprocating needle bar carrying a plurality of aligned needles of a predetermined gauge, the needles being constructed and arranged to reciprocally penetrate a backing material passing beneath the needle bar and over a bedrail. As the needles penetrate the backing materials they each carry a separate yarn which yarn is caught either by a looper to create a looped pile article, or by a hook moving, in timed relationship with a knife to create a loop of tufted material which is then cut to create a cut pile article. It is by these well known processes, that loop pile and cut pile carpeting is made. Typical of the tufting machines currently employed in the art are those disclosed in U.S. Pat. Nos. 2,057,920; 3,026,830; 3,142,276; 3,361,096; 3,645,219 4,132,182; 4,173,192; 4,419,944; 4,440,102; 4,586,445; 4,665,845; 4,829,917; 5,513,586; 5,224,434; 5,706,745; 5,979,344 and British Patents Nos. 1,507,201 and 1,304,151.
[0007] Synthetic turf was originally developed in response to a need for a sports playing surface which could overcome some of the limitations of natural grass turf. The advent of the covered, multipurpose stadium was the impetus of the original development. In its infancy the artificial grass market was almost exclusively limited to textured nylon yams constructed into a carpet like material. The advantages of these systems were as follows:
[0008] (1) Provided excellent traction for the athletes.
[0009] (2) Extremely durability to wear and tear from sports activities.
[0010] (3) Lower maintenance costs compared to traditional grass fields.
[0011] However, these systems also had several major disadvantages as follows:
[0012] (1) Extremely abrasiveness to skin surfaces, requiring athletes to wear special padding and equipment.
[0013] (2) The systems did not have the appearance of natural grass.
[0014] (3) Athletes performing on the surfaces typically required special shoes.
[0015] These disadvantages eventually led to the development of artificial turf systems that consisted of high pile, non-textured polyethylene (PE) yarn which were filled at the job sight with sand and/or rubber particles [U.S. Pat. No. 5,958,527]. The advantage of these systems are as follows:
[0016] (1) The systems have more of an appearance of a real grass playing field.
[0017] (2) The yarn was thought to be less abrasive and typically, it was surmised, did not require special padding for the individual athletes. This misapprehension was based on the misconception that the construction of the nylon fibers in the first generation systems made them abrasive. It was later learned that the lack of texture in the PE fiber lowered their abrasive characteristics more than the change in fiber composition.
[0018] (3) Most systems were sold under the impression that special shoes would not be required, i.e., that the traditional cleats typically used for real grass could be worn.
[0019] However, these systems also suffered from the following disadvantages:
[0020] (1) The requirement for infill material created additional maintenance costs when compared to non-infilled materials.
[0021] (2) The infill material tends to fragment and be pulverized and/or compact during normal wear.
[0022] (3) The infill material, e.g., sand could be abrasive, or, if it were a rubber like material, it would tend to migrate.
[0023] (4) The PE fiber is less durable to wear and tear when compared to nylon fiber.
[0024] (5) One of the characteristics of PE fiber is lower resiliency when compared to nylon, i.e., as the fibers are worn they tend to lay flat and create a surface that becomes slippery thereby requiring the use of special shoes.
[0025] One solution of the above noted problems is suggested in published U.S. application Ser. No. 20030099787. That application utilizes alternating thread-ups of yarn systems for constructing artificial turf systems. The publication discloses a sports surface made of a flexible backing tufted with a combination of yarns of different final lengths and textures. A first yarn is tufted at spaced intervals in the backing to provide first yam segments extending upwardly from the backing suggestive of blades of grass. A second type of yarn is tufted in the intervals between said first yarn, to provide second yarn segments. The second yam segments may be of a conventional texturized yam having a length under tension approximately equal to that of the first yam segments. In the finished surface the second yam segments return to a sinusoidal or kinked form and constitute an under layer having a lower vertical height than the first yam segments.
[0026] It is an object of the present invention to provide a novel synthetic sports surfaces (artificial turf) or other types of carpet surfaces constructed of synthetic fibers that does not suffer from the disadvantages discussed above.
[0027] It is a further object of the invention to provide a novel method for constructing synthetic sports surfaces (artificial turf) or other types of carpet surfaces utilizing synthetic fibers.
SUMMARY OF THE INVENTION
[0028] The foregoing and other objects are realized by the present invention, one embodiment of which relates to an improved method of constructing a synthetic sports surface or other type of carpet surface by means of a needle tufting operation in which at least one needle is caused to penetrate a backing material and tuft synthetic yam therethrough, the improvement comprising delivering a plurality of synthetic yams of differing texture to the same needle for simultaneous insertion through the backing material.
[0029] Other embodiments of the invention relate to the surfaces produced by the above-described method.
[0030] Other objects, features and advantages of the present invention will become apparent to those skilled in the art from the following detailed description. It should be understood, however, that the detailed description and specific examples, while indicating preferred embodiments of the present invention, are given by way of illustration and not limitation. Many changes and modifications within the scope of the present invention may be made without departing from the spirit thereof, and the invention includes all such modifications.
BRIEF DESCRIPTION OF THE DRAWINGS
[0031] FIG. 1 is a side elevation of a prior art sports surface based on FIG. 2 of U.S. Pat. No. 5,958,527;
[0032] FIG. 2 is a side elevation of a prior art sports surface based on marketing literature;
[0033] FIG. 3 is a side elevation of a prior art sports surface based on FIG. 3 of U.S. Patent Application, Pub. No. 20030099787;
[0034] FIG. 4 is a side elevation of a prior art sports surface based on FIG. 4 of U.S. Patent Application, Pub. No. 20030099787;
[0035] FIG. 5 is a stylized side elevation of an embodiment of the present invention;
[0036] FIG. 6 is a stylized side elevation of another embodiment of the present invention.
DETAILED DESCRIPTION OF THE DRAWINGS
[0037] FIGS. 1 and 2 illustrate various prior art sports surfaces using in-fill techniques.
[0038] FIG. 1 is a side elevation of a prior art synthetic grass turf assembly as depicted in FIG. 2 of U.S. Pat. No. 5,958,527. The grass turf assembly 10 includes a flexible open weave backing 12 and upstanding synthetic ribbons 14 , which are tufted in spaced-apart rows. An in-fill layer 16 is disposed between the ribbons. The in-fill is made up of sand granules 18 and resilient rubber granules 20 , arranged in layers of different sand-rubber proportions.
[0039] FIG. 2 is a side elevation of a prior art turf system (AstroPlay™) as depicted in marketing literature for the product. The turf system product 20 includes a fiberglass backing 32 and polyethylene fibers 34 . A 100% particulate rubber in-fill 36 is used. Texturized nylon fibers 38 are said to stabilize the fill.
[0040] FIGS. 3 and 4 are side elevation views of the prior art turf systems depicted in FIGS. 3 and 4 of U.S. Patent Application, Pub. No. 20030099787. The sports surface 100 includes a suitable flexible backing such as the open weave flexible backing 102 of a weight sufficient to withstand forces encountered when the surface is in use and to maintain the sports surface in contact with, for example, an adhesive coated playing field substrate surface. A first yam 104 is tufted at spaced intervals in the backing and provides generally upwardly extending segments suggestive of blades of grass. A second yam 106 (and in the case of the product of FIG. 4 , a third yam 108 ) provides yarn segments in supporting layer 110 below the tops of the first yam segments. In preferred embodiments, the second yam segments 106 (and third yam segments 108 ) are made of a heavy denier knit-deknit yam and have a length under tension approximately equal to the length L of the first yarn segments. The second (and third) yam segments form a layer having a vertical height less than L. The second (and third) yarn segments are sufficiently numerous and of sufficient bulk to maintain the first yarn segments in an approximately vertical orientation in the layer without requiring the addition of particulate fill.
[0041] In contrast to the above, in the present invention, a synthetic sports surface or other type of carpet surface is constructed by means of a needle tufting operation in which a plurality of synthetic yams of differing texture are delivered to the same needle for simultaneous insertion through the backing material. The sports surface of the present invention can be made on conventional carpet tufting machinery. The general tuft arrangement will now be discussed with reference to the side elevations of FIGS. 5 and 6 which have been simplified to illustrate the tufting procedure. The sports surface 200 includes a suitable flexible backing such as the open weave flexible backing 201 of a weight sufficient to withstand forces encountered when the surface is in use and to maintain the sports surface in contact with, for example, an adhesive coated playing field substrate surface. A first yarn 202 and a second yarn 203 are tufted simultaneously through a single needle at spaced intervals in the backing and provide generally upwardly extending segments 202 suggestive of blades of grass and shorter segments 203 forming a layer having a vertical height less than that of 202 . The second yarn segments are sufficiently numerous and of sufficient bulk to maintain the first yarn segments in an approximately vertical orientation in the layer without requiring the addition of particulate fill. Upper portions of the first yarn segments may lay over somewhat.
DETAILED DESCRIPTION OF THE INVENTION
[0042] The invention is predicated on the discovery that the disadvantages of the prior art systems can be overcome by utilizing synthetic fibers of different textures in the construction of the artificial turf surface and that such systems may be constructed by tufting the synthetic fibers of differing textures through a single needle. The fibers preferably comprise a straight yarn and a highly textured yarn. The straight yarn provides a less abrasive fiber for athletes to slide upon while the textured yarn provides superior traction as the cleat of the athlete's shoe penetrates into the turf. The resiliency of the straight nylon fiber and the texturized nature of the second nylon fiber, which offers additional support to the straight nylon fiber, work together to eliminate the need for a particulate infill.
[0043] Although polypropylene, polyethylene or other synthetic yarns can be employed, it is preferred to utilize nylon fibers due to their superior durability characteristics. It is a critical feature of the invention that one of the yarn components comprises a straight non-textured yarn. This contributes to: (1) the artificial turf having the appearance of real blades of grass (2) a low degree of abrasiveness to human skin and (3) a high degree of resiliency such that the turf surface will not easily deform or lay flat. The second yam component comprises a highly textured yam. It will be understood that the second yam component may comprise fibers having one or more texture configurations. The textured component contributes to (1) additional support for the straight non-textured yarn (2) superior shoe traction and (3) a cushion effect and resistance to downward forces, which does away with the requirement for infill particulate.
[0044] It is a further critical feature of the invention that both yarns, the straight non-textured and the highly textured yarns are tufted through the same needle to form the artificial turf. This unique aspect of the method of the invention permits the construction of a novel turf system wherein the texture yarn is positioned adjacent to the non-textured yarn thereby enhancing the above-noted advantageous characteristics of the mixed-yarn turf product. After being tufted together through the tufting needle and cut, the textured yarn which has a length under tension approximately equal to that of the non-textured yarn segments regains its original textured shape by returning to a sinusoidal or kinked form thereby forming an under layer having a lower vertical height than the non-textured yarn segments and wrapping around the non-textured yarn which retains its original length and remains straight and upright. This re-assumption of its original textured shape by the textured yarn provides added support for the non-textured yarn. The textured yarn segments are sufficiently numerous and of sufficient dimension and texture so as to maintain the bases of the nontextured yarn segments in an approximately vertical orientation without requiring the provision of a particulate fill.
[0045] Any conventional tufting machine (such as those disclosed and discussed above) that produces the fibrous face of tufted articles, for example carpets, by tufting individual yarns through a primary backing material or substrate may be used in the practice of the invention. The tufting machine typically has a frame supporting at least one elongate needle bar on which at least one series of spaced tufting needles is disposed. A continuous web of backing material is continuously fed in a warp, i.e., a longitudinal or lengthwise, direction through the tufting machine during the tufting process. Each of the tufting needles is threaded with a suitable combination of yarns to be tufted in the backing material, and the needles are passed together through the backing material by the reciprocating motion of the needle bar as the backing material is moved or carried past the needle bar during machine operation to form tufts in the “face” of the backing material. If so desired, and as known, the tufting machine may be provided with two spaced and parallel needle bars, each of which being provided with a separate series of spaced tufting needles.
[0046] The needle bar is driven through a suitable drive arrangement such that it is reciprocated vertically with respect to the backing material as it is passed beneath the needle bar during a continuous tufting operation. As appropriate, a looper and/or a knife may be placed on the face side of the backing material, in registry with each respective needle, so that loops or cut piles of tufted yarn are formed and remain in the backing material once the tufting needles are drawn by the needle bar back out of the backing material.
EXAMPLE
[0047] The yarn used for this trial was 100% nylon and was purchased from Syntec Industries. The yarn is an eight-filament yarn with each filament having a denier [a universal method for measuring and expressing the size of yarn] of 525. Therefore, the entire package has denier of 8×525 or 4200/2 ply.
[0048] The yarn is divided 1) into its natural or untextured state and 2) a textured state. The texture rising was done by processing it through a Dietz. This equipment uses mechanical gears to impact a permanent crimp into the yarn.
[0049] The yarn was put on a creel and fed to a ⅜ gauge tufting machine located at [Intergrated Tufting Center]. The “gauge” of the machine is determined by the number of needles that are positioned on the machine across the width. In this particular case the needles are ⅜ of an inch apart. The width of the machine is 180 inches wide yielding 480 needles. Each needle was fed one texturized fiber and one non-texturized fiber. The fiber pile height was 1-¾ inches. Stitches per inch were 5¼ per inch. Fiber denier, fiber height and the number of stitches per inch equaled 56 ounces per square yard of nylon fiber weight.
[0050] The fibers were tufted into a primary comprising “SportsBac” (Synthetic Industries). This is a woven 15-pic polypropylene. It has a polyester fiber needled into it and an open mesh fiberglass attached also by the needling process.
[0051] The last step consists of coating the backstitches. Approximately 20 ounces per square yard of polyurethane adhesive was used. It was cured and then an 8-millimeter thick polyurethane foam was applied (approximately 80 ounces per square yard) with a non-woven polyester secondary. Holes were drilled in the composite to allow water to pass through the finished synthetic playing surface.
[0052] It will be understood that various combinations of yarn tufts and tuft spacings can be obtained by feeding the appropriate yarn types to selected ones of the tufting needles of a conventional tufting machine.
[0053] Those skilled in the art will be familiar with the types of texturized or textured yarns suitable for use in the present invention. Generally, any texturized yarn suitable for use in the manufacture of carpet or sports surfaces may be used in the practice of the invention. Typical of such textured yarns are those disclosed in U.S. Pats. Nos. 3,298,079; 3,861,133; 4,169,707; 6,076,345 and 4,096,226; European Patent Application, Publication No. EP .0784109 A2; European Patent document EP 485 871B1; German Patent 32 10 784—Japanese Patent Publication No. Showa 45(1970)-24699, Japanese Patent Publication No. Showa 44(1969)-13226, Japanese Patent Application Laid-Open Specification No. Showa 46(1971)-2180 and Japanese Patent Publication No. Showa 46(1971)-23766; German Published Application No. 1,902,213; U.K. Pat. No. 1,170,749; French Pat. No. 1,535,468) and French Pat. No. 1,555,112.
[0054] From the foregoing description, various modifications and changes in the composition and method will occur to those skilled in the art. All such modifications coming within the scope of the appended claims are intended to be included therein. The entire disclosures and contents of each and all references cited and discussed herein are expressly incorporated herein by reference. All percentages expressed herein are by weight unless otherwise indicated.
|
In a needle tufting operation in which at least one needle is caused to penetrate a backing material and tuft synthetic yarn therethrough to form a surface thereon comprising the synthetic yarn, the improvement comprising delivering a plurality of synthetic yarns of differing texture to the same needle for simultaneous insertion through the backing material such that the tuft formed thereby comprises the plurality of yarns of differing texture and the articles produced thereby.
| 3
|
METHOD AND APPARATUS OF COATING SUBSTRATES
1. Field of the Invention
The invention relates to a method of coating substrates in which the layer to be applied is produced by condensing particles of a plasma generated by means of a gas discharge which are incident on the substrates.
The invention further relates to an apparatus for carrying out the method.
2. Background of the Invention
The technology of surface treatment and the production of thin films has become extremely significant in recent years, particularly with respect to its industrial application. The numerous known vacuum methods for the production of thin films or for the treatment of material surfaces primarily include methods which relate to vaporization in furnaces, boats, and crucibles, etc. In these methods the vaporization takes place for example through electrical heating, or by electron bombardment by means of an anodic or cathodic arc, or by eddy current heating of conductive material in an induced AC field. Moreover, the large area sputtering of cathodes is known in various embodiments of cathode sputtering, with or without magnetic enhancement of the ionization in the DC or AC glow discharge.
In the known and customary ion assisted vaporization methods the kinetic energies of the atoms, ions and/or particles which are incident on the substrate are distributed such that the highly energetic particles create defects in the crystal lattice of the condensing layer which lead to compressive stresses and embrittlement of the layer, or trigger effects which lead to an undesired reverse sputtering or resputtering of the condensing layer. On the other hand, the incident particles of lower energy often hardly attain the kinetic energy required at the surface to ensure a homogeneous layer build-up. A particularly broad and therefore unfavorable distribution of the kinetic energies of the atoms and ions which are incident on the substrate is present with arc vaporizers in particular. Moreover, macroparticles, termed "droplets", frequently arise with the various forms of arc vaporizers and can be extremely disturbing if a corrosion resistant material coating is required, or if the coefficient of friction of the layer material is intended to be particularly low.
With cathode sputtering, the low concentration of ionized particles compared with arc vaporization is unfavorable, particularly in the direct environment of the substrates to be coated. This frequently leads to the condensing layers not being sufficiently dense, particularly when depositing layers of high melting point such as is the case with hard material coatings.
Moreover, it has been shown that layers deposited by means of cathode sputtering are inferior with respect to bond strength to those deposited by arc vaporization. On the other hand, with cathode sputtering, it is possible to precisely set the kinetic energy of the incident ionized particles in the range of some few electron volts, for example 10 eV up to 1000 eV and more, through a suitable choice of the negative substrate bias, whereas the majority of the non-ionized atoms have a kinetic energy which is typically smaller than 10 eV.
OBJECT OF THE INVENTION
An object of the invention is to develop a method which, on the one hand, ensures the deposition of layers which are as free as possible of defects and which are simultaneously well bonded, i.e. which are of high quality layers, and which, on the other hand, offers adequate possibilities for ideally and precisely matching the layer growth to the required circumstances through a suitable choice of the deposition parameters.
SUMMARY OF THE INVENTION
This object is accomplished in accordance with the invention in that both an arc discharge vaporization process and a cathode sputtering process are performed, with the arc discharge vaporization being carried out before the cathode sputtering; i.e. in the first phase of the coating process, arc vaporization is used and the coating is then continued or terminated by means of cathode sputtering.
As a result of the arc discharge vaporization which precedes the cathode sputtering, a transition layer is generated on the substrate surface with highly energetic ions which ensures a good bond of the layer to be applied on the substrate, whereas, during the subsequent cathode sputtering, it is possible to sensitively control both the speed of condensation at low particle energy over wide ranges, corresponding to the desired crystal growth and the desired crystal structure of the layer to be applied, and also the bias voltage at the substrate. As a result of the short mean free path of the vaporized particles a uniform thickness distribution of the layer arises, even around the corners.
The cathode sputtering can be carried out such that the vapor of the cathode material and also the gas atoms which participate in the cathode sputtering can be ionized to a substantially higher degree in the space between the cathode and the substrate or substrates with the aid of magnetic fields, which are additionally provided as compared with customary known methods of cathode sputtering, such as DC sputtering or magnetron sputtering, whereby a dense layer deposition is made possible. This is achieved by the scattering fields of specially mounted magnetic arrangements, which consist in particular of coils, which can be formed in accordance with the known principles of magnetic field assisted sputtering, and of the imbalanced magnetron (see the literature references 1-6).
As the major portion of the particles which condense on the substrate during arc discharge vaporization is ionized, the kinetic energies can, for example, be advantageously controlled without problem by means of a negative bias on the substrate. With the combination in accordance with the invention of arc discharge vaporization and cathode sputtering, in particular cathode sputtering by means of an imbalanced magnetron, the advantages of the two coating methods, namely the good bond strength and high layer quality which can be achieved, are exploited in an ideal manner without having to tolerate the above described disadvantages of the individual methods.
The substrate is preferably first bombarded during the arc discharge vaporization process with Ti ions of optimized energy and corresponding ion current density such that the substrate surface is cleaned by ion etching, i.e. is partly removed in a known manner. The high ion energy required for this surface cleaning can be generated relatively easily, for example by the application of a negative substrate bias in the range from 1500 V to 2000 V.
The transition zone which is important for the inventive combination of arc discharge vaporization and cathode sputtering is subsequently likewise formed with the aid of arc discharge vaporization in the region directly beneath the substrate surface. For this, the fact is exploited that the multiply ionized Ti-atoms produced during arc discharge vaporization can be implanted into the substrate surface under certain conditions. For this purpose the energy of the Ti-ions must, on the one hand, be sufficiently high, but on the other hand, not too high in order to avoid the above described etching process being initiated. This can be achieved, for example, with substrates of differently alloyed steels, when the negative substrate bias potential lies in the region between 1000 and 1500 V, preferably between 1100 and 1200 V. In the case of iron containing substrates, Ti-Fe mixed crystals then form, by way of example, and ensure a particularly advantageous anchoring of a TiN layer which, for example, grows during coating. Similar favorable results can be achieved if one uses Zr-, Hf-, Cr-, Ta-, Nb or V-ions for the pretreatment in place of Ti-ions. In these cases a zone of, for example, 200 to 400Å thickness and rich in mixed crystals first forms directly beneath the substrate surface, whereas a diffusion profile of the implanted foreign ions occurs beneath it which extends into the substrate thickness to a depth of 1500 to 2000Å. This transition layer then brings about a support function of, for example, the very hard and relatively brittle TiN coating during mechanical loading when the ion energy, for example, of the Ti-vapor, is correspondingly optimized.
The continuation of the coating process can be effected in accordance with two methods:
On the one hand, the negative bias at the substrate can be reduced while retaining the arc discharge vaporization until a majority of the metal atoms and ions arriving at the substrate condense in the presence of nitrogen atoms and ions. This is, for example, the case when the negative substrate bias lies in the range from 10 to 200 V, preferably between 50 and 100 V. The coating is then interrupted when, for example, up to 20% of the desired layer thickness of, for example, TiN has been achieved. The process is then switched over to cathode sputtering.
On the other hand, an even better design of the transition from the substrate to the coating layer can be brought about if one, directly after manufacturing the transition layer by means of arc discharge vaporization, directly switches over the ion implantation to coating by means of cathode sputtering, particularly by using an imbalanced magnetron. In the case of deposition of, for example, TiN, it is advantageous to apply a negative substrate bias voltage during cathode sputtering in the range from 40 V to 200 V, preferably 50±225 V. In doing so it should be ensured that the ion bombardment is carried out with an ion current density greater than 2 mÅ/cm 2 in order to attain an adequate layer thickness (see literature reference 7).
The processes of arc discharge vaporization and cathode sputtering can be carried out from the same cathode. It is, however, also possible to use separate or respective cathodes for the two process steps. This leads, on the one hand, to the system concept becoming more expensive but, on the other hand, also opens the possibility of being able to construct the transition layer with materials which differ from the actual coating.
An apparatus for carrying out the method in accordance with the invention includes a chamber which receives the respective working gas, a substrate holder arranged in the chamber, and various electrical circuits which are required to carry out the different method steps. The chamber which is used is in this arrangement is constructed such that it can be pumped out with customary vacuum pumps to 10 -5 mbar. The chamber is electrically grounded.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be explained in the following in more detail with reference to the drawing in which are shown:
FIG. 1 is a diagram of the typical distribution of the kinetic energies of the particles which are incident on the substrate when coating a substrate by means of a customary arc discharge vaporization method,
FIGS. 2A and 2B show basic circuit diagrams to explain the arc discharge vaporization and cathode sputtering processes,
FIG. 3 is a schematic illustration of an apparatus for carrying out the method of the invention,
FIG. 4 is a schematic representation of a magnetron cathode,
FIG. 5 is a cross-sectional representation of a multi-cathode system,
FIG. 6 is a schematic cross-sectional representation of an imbalanced magnetron,
FIGS. 7 and 8 show an example of a layer build-up and of the associated process steps in a schematic illustration, and
FIGS. 9 and 10 depict a schematic representation of a preferred layer sequence and the temporal course or time sequence of the associated process steps.
DETAILED DESCRIPTION OF THE INVENTION
The diagram of FIG. 1 shows the typical distribution of the kinetic energies of the particles which are incident on a substrate to be coated by means of a customary arc discharge vaporization method. The kinetic energy is plotted along the abscissa and the frequency of incidence of the condensing particles is plotted along the ordinate.
As can be seen from this diagram, the ideal energy range lies, in accordance with experience, at around 40 to 80 eV. Smaller or larger energies lead to defect mechanisms which are set forth in the diagram.
Basic circuit diagrams for arc discharge vaporization and for cathode sputtering are shown in FIGS. 2A and 2B, respectively.
In either case a cathode 2 is arranged in a vacuum chamber 1. In the case of arc discharge vaporization the cathode is held at a potential of -20 V to -50 V. The arc current forms between the cathode 2 and the anode 3.
The anode 3 is at a typical potential in the region between 0 and +50 V. The arc current can amount to several hundreds of amperes. A part of the current propagates in the space in the direction towards the substrates 4. The substrates are maintained, as required, at a negative bias of up to 2000 V in the case of an etching process and, for example, between 1100 and 1200 V in the case of forming the transition layer, or at ca. 100 V during coating.
The substrates 4 are fixedly connected to the substrate holder 5. The latter is positioned inside the chamber 1 in electrically insulated manner and can be connected with a suitable power supply.
In the case of conventional cathode sputtering, the negative bias on the cathode is in the range from 3000 to 4000 V. Typical values for magnetron sputtering lie between 400 and 700 V. The space filling plasma of the conventional cathode sputtering process is schematically indicated with the reference numeral 6. The same conditions apply to the substrates 4 and the substrate holder 5 as in the case of arc discharge vaporization.
FIG. 3 shows a block diagram of an example of an apparatus for carrying out the method of the invention. In this arrangement, a common cathode 2 is provided for the arc discharge vaporization and the cathode sputtering.
The cathode 2 is surrounded by a dark field screen 7 held at ground potential or at a floating potential, or insulative material. Cathode 2 and anode 3 are connected together in the circuit 8. The power supply 9 for maintaining the arc discharge and the switch 10 for selectively actuating the arc discharge vaporization are in power circuit 8.
Parallel to the power circuit 8 is the power circuit 11 which connects the power supply 12 to the cathode 2 via the switch 13 for selective maintenance of the cathode sputtering discharge. The positive output of the power supply 12 is, in known manner, at ground potential. Finally, a circuit 14 connects the substrate holder 5 with the negative output of power supply 16 via a switch 15. The positive output in this case is either held at ground potential or at the potential of the chamber. Two possible embodiments of magnetization devices for the plasma (reference numeral 6 in FIG. 2) are indicated by the reference numerals 17 and 18. Depending on the particular apparatus, these magnetization devices 17 and 18 consisting of scattering field coils are electrically connected with DC power supplies 19 and 20, respectively. The level of the coil current is selected such that the ion current density at the substrates 4 is above 2 mÅ/cm 2 under the action of the negative bias originating from the power supply 16.
FIG. 4 shows a known embodiment of a magnetron cathode. Reference numeral 2 designates the target of a conventional or magnetron cathode. Reference numeral 21 designates a special magnet arrangement. A scattering field coil 17 such as shown in FIG. 3 surrounds the arrangement in the region of the target 2. The double arrow indicates that the magnetic field is displaceable relative to the target 2. This is of practical significance because it is of advantage to selectively allow the arc discharge vaporization to proceed on its own with or without the influence of the magnetic field, whereas during cathode sputtering the magnetic field is of importance for the magnetron operation of the cathode.
FIG. 5 shows a cross-section of a multi-cathode system. Here two conventional cathodes and the magnetron cathode are located in the chamber 1. One of the conventional cathodes can in this case be used as an arc discharge vaporizer, whereas the other serves as a sputtering source. Finally, FIG. 6 shows the shape most frequently represented in the relevant literature for a magnetron in cross-section. In this arrangement the coil 17 again serves to increase the ionization of the space and acts in conjunction with the magnet arrangement consisting of permanent magnets, preferably of SmCo or NdFeB, as an imbalanced magnetron.
FIGS. 7 and 8 schematically show the various coating layers and the individual process steps.
FIG. 7 shows a typical substrate of steel, the surface of which is characterized by the transition layer which quasi operates as an "anchoring zone". When using Ti as a coating material, intermetallic phases arise in this region, consisting, for example, of TiFe. A first layer of TiN then lies on this transition zone and is formed through reactive vapor deposition by means of arc discharge vaporization. This layer is then followed by a second TiN layer deposited by cathode sputtering.
FIG. 8 shows the time sequence of the characteristic electrical method parameters in a schematic representation.
During the etching process, the bias potential applied to the substrate is at its highest value (typically -1600 V) and is reduced stepwise to form the transition zone (typically -1100 V) and during coating with the aid of the power supply 16. The current at the substrates is initially very high and is reduced during the formation of the transition layer.
During the coating by means of arc discharge vaporization, and also during the phase of cathode sputtering, the negative substrate bias can be held at a constant level, i.e. typically 50 V±25 V.
To achieve an adequate ion current at the substrate the arc current (power supply 9) is increased.
The cathode potential is held almost constant (typically -20 V) during the first process steps by means of the power supply 9 and is increased by means of the power supply 12 to typically -500 V during the coating by cathode sputtering, for example when using magnetron cathodes.
The cathode current during cathode sputtering is current controlled by means of power supply 12 and remains constant during the course of the further coating process.
The ion current to the substrates (bias current) is correspondingly high through the use of additional magnetic ionization (for example, by means of the magnetizing devices 17, 18) and is greater than 2 mÅ/cm 2 .
FIGS. 9 and 10 represent a preferred method with reference to the example of TiN coating.
FIG. 9 shows the layer sequence. The TiN-layer lies directly above the "anchoring zone".
FIG. 10 shows the time sequence of the process steps. In comparison to FIG. 8, the phase of arc discharge vaporization for the production of a first TiN-layer is missing.
The most important process parameters for the method of the invention are set forth in the following table:
TABLE__________________________________________________________________________Process parametersProcess step Process parameter Unit Operational range Preferred range__________________________________________________________________________Etching Arc potential V 15-50 20-40 Arc current A 40-400 50-250 Pressure 10.sup.-5 mbar 0.1-2 0 5-1 Neg. substrate bias V 1300-2000 1500-1600 Etching time min 1-10 2-5Transition zone Arc potential V 15-50 20-40(Ion implant- Arc current A 40-400 50-250ation) Pressure 10.sup.-5 mbar 0.1-2 0.5-1 Neg. substrate bias V 1000-1500 1000-1200 Implantation time min 1-20 5-10Coating Discharge potential V 300-750 500-600(imbalanced Discharge power W/cm.sup.2 5-30 10-15magnetron) Total pressure 10.sup.-3 mbar 0.5-50 1-3 Neg. substrate bias V 0-500 50 ± 25 Bias current density mA/cm.sup.2 1-10 2-4 Rate nm/sec 0.5-10 1-1.5 Layer thickness μm 1-10 3-5 Substrate temperature °C. 250-600 350-450__________________________________________________________________________
LITERATURE:
1. L. Maissel, "Handbook of Thin Film Technology" McGraw-Hill Book Company, 1970, p. 4.8
2. T. Hata, R. Noda, O. Morimoto, T. Hada Appl. Phys. Lett., 37 (3) 1980, p. 633
3. B. Window, F. Sharples, N. Savvides Vac. Sci. Technol., A 3 (6) 1985, p. 2368
4. B. Window, N. Savvides Vac. Sci. Technol., A 4 (2) 1986, p. 196
5. B. Window, N. Savvides Vac. Sci. Technol., A 4 (3) 1985, p. 453
6. S. Kadlec, V. Musil, W.-D. Manz, G. Hakanssot E. Sundgren, 16th ICMC, San Diego, U.S.A., 1989
7. H. Freller, H. P. Lorenz Vac. Sci. Technol., A 4 (1986), p. 2691
8. H. Freller Proc. SURTEC, Berlin '89, Carl Hanser Verlag, Munich, 133
|
A method and an apparatus for coating substrates is described in which the layer to be applied is produced by the condensing particles of a plasma generated by a gas discharge which are incident on the substrates. Both an arc discharge vaporization coating process and a cathode sputtering coating process are effected in the same apparatus, and the arc discharge vaporization process is carried out before the cathode sputtering process.
| 2
|
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims priority to German Patent Application No. 202013007803.0 filed Sep. 3, 2013, which is incorporated herein by reference in its entirety.
TECHNICAL FIELD
[0002] The technical field relates to an anchorage device for anchoring a portable seat on a vehicle seat of a motor vehicle, in particular for anchoring a child seat.
BACKGROUND
[0003] Anchorage devices for the detachable fastening of portable seats, such as for example child seats in motor vehicles are generally known. Accordingly, various child restraint systems for transporting children or infants in motor vehicles exist. In addition to restraint systems, in which exclusively the occupant belt is provided for fastening and fixing child seats, child restraint systems with anchorage devices on the body side are also known. In the case of the so-called “ISOFIX system,” restraint shackles are provided in defined locations of the body, in the region of a motor vehicle seat, for example in the transition from the seat cushion and backrest to which fastening latches provided on the child seat side can be releasably connected.
[0004] For improved fastening of child seats individual anchorage devices can also be provided in the region of a parcel shelf located in travelling direction behind the back seat bench, on which a child seat can be fastened, for example by means of a fastening belt. In the case of Sedan versions of motor vehicles, such restraint shackles can be provided in the region of a parcel shelf, while in the case of minivans or Kombi-type motor vehicles such anchorage devices can be integrated fin the back of a backrest part of a motor vehicle seat.
[0005] For fastening on the body side, generic anchorage devices include a shackle with two legs, which is welded to a mounting plate that is substantially designed flat. Such a connection of two legs 14 , 16 oriented approximately parallel to one another of a shackle on a mounting plate 8 is sketched in FIG. 3 . For this purpose, the mounting plate 8 includes two sockets 20 designed as passage opening, through which the free ends of the legs 14 , 16 are passed and are welded to the mounting plate 8 on a bottom side 9 of the mounting plate 8 by means of a gas-shielded welding method, for example by means of MIG-welding.
[0006] The welding process provided here generates a weld bead 7 encircling the legs 14 , 16 . To provide an adequately strong and secure connection of the legs 14 , 16 to the mounting plate, it is required that the end faces 15 of the two legs 14 , 16 projecting downward through the mounting plate 8 have a certain minimum spacing D from the bottom side 9 of the mounting plate 8 . Typically, that spacing D amounts to between 5 mm and 10 mm in order to be able to provide an adequately secure connection of the legs 14 , 16 to the mounting plate 8 with the gas-shielded welding method provided here.
[0007] However, because of the fact that the free ends of the legs 14 , 16 projecting downwards protrude from the bottom side 9 of the mounting plate 8 it is required for the connection of such anchorage devices on the body side, to provide corresponding recesses or depressions on a support structure on the body side provided for fastening those anchorage devices, so that the mounting plate 8 with its bottom side 9 can be fastened to the support structure, in particular welded to the same.
[0008] Forming such passage openings in the support structure of the body sometimes contributes to a structural weakening of the body. In addition, providing such passage openings requires additional operations and accordingly increased production and assembly effort.
SUMMARY
[0009] In accordance with an embodiment of the present disclosure an improved anchorage device for anchoring portable seats on motor vehicle seats is provided which contributes to an improvement of the structural stiffness of the body, can be mounted particularly cost-effectively, easily and can provide a particularly stable fastening for the portable seat. An anchorage device for anchoring a portable seat, in particular of a child seat or a support shell on a vehicle seat of a motor vehicle is provided. The anchorage device includes a shackle with two legs and a mounting plate. The mounting plate is equipped with two sockets, with which the legs of the shackle are laser-welded. Laser-welding of shackle and mounting plate makes possible a mutual arrangement of shackle and mounting plate in such a manner that the legs of the shackle to be directly connected to the mounting plate no longer protrude from a bottom side of the mounting plate but come to lie at the most surface-flush with the bottom side of the mounting plate.
[0010] Such an arrangement of shackle and mounting plate makes possible, furthermore, to largely configure the support structure on the body side for fastening the anchorage device flat or without depression, recess or passage opening. For connecting the anchorage device to the motor vehicle body, the support structure on the body side can be formed passage opening-free so that the body in this region can undergo structural reinforcement. The free ends of the legs of the shackle no longer protrude from the bottom side of the mounting plate because of the laser welding, and the mounting plate furthermore can be connected, in particular welded to the support structure on the body side almost over the full area. In this regard, the laser welding of shackle and mounting plate is also advantageous for a particularly strong, loadable and durable connection of mounting plate and support structure on the body side.
[0011] The shackle of the anchorage device is substantially formed U-shaped, wherein the two legs are typically oriented parallel to one another and are approximately identical in length. The sockets for the legs of the mounting plate are spaced from one another, which spacing substantially corresponds to the spacing of the two leg ends.
[0012] According to a first embodiment, at least one of the sockets of the mounting plate is formed as a blind hole or as a corresponding depression in the mounting plate. The blind hole can be formed through a bore or through a local stamping of the mounting plate. Advantageously, the bottom side of the mounting plate in this case is substantially formed flat in order to be able to form a mutual contact position on the support structure on the body side preferably over the full area of the mounting plate.
[0013] According to a further configuration, at least one of the sockets of the mounting plate is formed as passage opening in the mounting plate. In this way, at least one of the legs can be introduced into or through the passage opening of the mounting plate or be passed through the same and subsequently laser-welded to the mounting plate from a bottom side of the mounting plate, in particular to the inner wall of the passage opening of the socket. The bottom side of the mounting plate in this case corresponds to the sides of the mounting plate facing away from the shackle. The provision of a passage opening in the mounting plate makes possible in particular to connect the leg projecting into the passage opening or projecting through the passage opening to the mounting plate over the entire material thickness of the mounting plate. The thickness of the weld can be maximized in this regard without a welding bead worth mentioning being formed on the top or bottom side of the mounting plate.
[0014] It can be provided in particular that both sockets of the mounting plate are formed as blind hole or as passage opening. It is conceivable furthermore to form one of the sockets as a blind hole while the other socket has a passage opening for the corresponding leg of the shackle.
[0015] According to a further configuration, the free ends of the legs are arranged with their end faces substantially surface-flush with a bottom side of the mounting plate. In this regard, the legs can close the passage openings provided in the mounting plate substantially over the full area and thus contribute to configuring a substantially flat bottom side of the mounting plate. Laser welding of shackle and mounting plate is particularly well suited for a weld bead-free or weld burr-free configuration of the bottom side of the mounting plate.
[0016] The surface-flush arrangement of the legs regarding the bottom side of the mounting plate additionally leads to a direct support of the legs, thus of the shackle on the support structure on the body side when the mounting plate is connected, in particular welded to that support structure in the final assembly state of the motor vehicle. Because of this, direct force transmission from the shackle into the support structure on the body side can be provided.
[0017] According to a further configuration, the mounting plate includes a bead-like stamping in the region of at least one of the sockets. The mounting plate is locally formed in that connecting region. Such forming can contribute to the torsional and structural stiffness of the mounting plate and in this regard bring about a structural reinforcement of the mounting plate. As the bead-like stamping extends towards the shackle and in this regard constitutes a recess or a depression relative to the bottom side of the mounting plate, a hollow space can be formed between mounting plate and support structure upon connecting the anchorage device to the support structure on the body side, in which the connecting region of the shackle comes to lie. In this way, it can be made possible in particular when configuring the socket formed as a passage opening so that the free end of the leg or its end face protrudes at least slightly from the bottom side of the mounting plate. Any weld burr or weld bead thus comes to lie in that hollow space in this regard so that through the welded connection of shackle and mounting plate, areal fastening of mounting plate and support structure on the body side is not impaired or only to a negligible degree.
[0018] According to a further configuration, the mounting plate has a stamping each in the region of both sockets. A corresponding mounting plate provided with multiple stampings can have an even further improved structural stiffness. The bead-like stampings can be adapted to the geometry or the cross section of the legs or of the shackle. The bead-like stampings can be formed circular but also angular in this regard in the plane of the mounting plate. It is conceivable, furthermore that both sockets for the shackle come to lie within one and the same bead-like stamping.
[0019] According to a further configuration, the at least one socket is arranged in the region of a flat bottom portion of the stamping or in the region of such a bead bottom. The bead bottom typically extends parallel to the bottom side of the mounting plate and merges into an angled or sloping bead edge into the bottom side of the support plate which is substantially configured flat. As the at least one socket or as both sockets are arranged in the region of one or multiple bottom portions of one or multiple stampings, the end face of the free end of the leg in each case comes to lie spaced from the support structure of the motor vehicle body. In this way, any welding burrs created during the course of the laser welding can come to lie correspondingly spaced from the support structure.
[0020] According to a further configuration, the bottom portion of the stamping is recessed with respect to a substantially flat bottom side of the mounting plate. The bottom portion or bead bottom in this regard is located above the bottom side of the mounting plate projecting downwards. The recessed configuration of the bottom portion with respect to the mounting plate bottom side makes possible in particular the formation of a hollow space between mounting plate and support structure on the body side despite a substantially full-area contact position of mounting plate and support structure.
[0021] According to a further configuration, the laser weld of shackle and mounting plate is formed radially between an inner wall of the socket and an outer circumference of the legs. The materially joined connection of leg and mounting plate is located within the material thickness of the mounting plate. For connecting shackle and mounting plate, a laser deep welding process can be provided in particular, which utilizes comparatively high radiation intensities in the region of several megawatt per square centimeter.
[0022] In the process, a so-called keyhole can form in the depth of the mounting plate. In the melt formed by the laser beam a vapor capillary is formed in the process in radiation direction of the laser beam, i.e. a hose-shaped hollow space filled with metal vapor or part-ionized metal vapor is formed. By means of a laser deep welding process, the material of the mounting plate, typically steel plate, can be melted in the depth or in the material thickness so that across the entire material thickness of the mounting plate a materially joined connection to the respective leg of the shackle can be created.
[0023] According to a further aspect, a motor vehicle body is finally provided which includes at least one support structure, on which at least one anchorage device described before is fastened.
[0024] In a further development, the mounting plate of the anchorage device can be welded to the support structure with its bottom side facing away from the shackle. Here, a surrounding welding of mounting plate and support structure is provided in particular in order to provide a particularly stable and durable connection of anchorage device and motor vehicle body.
[0025] Through the laser welding of shackle and mounting plate of the anchorage device, the support structure of the motor vehicle body according to a further configuration can be formed passage opening-free in the region of the anchorage device. In this regard, the support structure need not have any passage openings for receiving the leg ends projecting through the mounting plate. Through the omission of such passage openings in the support structure, the dimensional stability of the support structure on the whole can be improved and correspondingly increased.
[0026] According to a further configuration, the support structure is formed as a parcel shelf panel or as a cross member of a parcel shelf, which extends approximately adjoining an upper end of a seat backrest of a motor vehicle back seat bench opposite the travelling direction in vehicle longitudinal direction and in vehicle transverse direction. The anchorage device in this case can be formed in particular in a cross member profile portion of the support structure or of the parcel shelf panel. For the individual seats of the motor vehicle back seat bench, at least one previously described anchorage device each can be arranged based on the vehicle transverse direction (y) approximately in the middle regarding the respective seat.
[0027] After all that a vehicle is finally provided which includes a motor vehicle body described before and/or at least one anchorage device described before.
BRIEF DESCRIPTION OF THE DRAWINGS
[0028] The present disclosure will hereinafter be described in conjunction with the following drawing figures, wherein like numerals denote like elements.
[0029] FIG. 1 shows a support structure on the body side designed as a parcel shelf panel;
[0030] FIG. 2 shows a perspective representation of an anchorage device according to a first configuration;
[0031] FIG. 3 shows a cross section through a conventional anchorage device in the region of the shackle connection to a mounting plate;
[0032] FIG. 4 shows a further configuration of the anchorage device in cross section; and
[0033] FIG. 5 shows a schematic representation of a motor vehicle equipped with the anchorage device.
DETAILED DESCRIPTION
[0034] The following detailed description is merely exemplary in nature and is not intended to limit the present disclosure or the application and uses of the present disclosure. Furthermore, there is no intention to be bound by any theory presented in the preceding background or the following detailed description.
[0035] The anchorage device 10 shown in perspective representation in FIG. 2 includes a shackle 12 formed approximately U-shaped, which has two legs 14 , 16 substantially running parallel to one another. The free ends of the legs 14 , 16 projecting downwards in FIG. 2 are inserted in the sockets 20 sketched in FIG. 2 of a mounting plate 18 substantially falls flat and laser-welded there to the mounting plate 18 . Through a laser welding process, the formation of welding beads or welding burrs on the top side 17 and also on the bottom side 19 of the mounting plate 18 can be largely avoided.
[0036] In a final assembly configuration, such as is schematically shown for example in FIG. 1 , the anchorage device 10 shown in FIG. 2 can be arranged on a cross member profile portion 6 of a support structure 5 located in travelling direction at the front via the mounting plate 18 , in particular welded to the cross member profile portion 6 . The support structure 5 on the body side schematically shown in FIG. 1 is configured as a parcel shelf panel, which extends approximately from the upper end of a backrest of a rear seat bench of the motor vehicle against the travelling direction, in the plane substantially defined by vehicle longitudinal direction (x) and vehicle transverse direction (y).
[0037] As shown in FIG. 1 , multiple anchorage devices 10 approximately spaced equidistantly in vehicle transverse direction (y) are arranged on the cross member profile portion 6 of the support structure 5 .
[0038] By laser welding shackle 12 and mounting plate 18 , a substantially flat bottom side 19 of the mounting plate or of the anchorage device 10 without elevations can be formed, which makes possible supporting and resting of the mounting plate 18 on the support structure 5 on the body side over a largely full area.
[0039] In the embodiment shown in cross section in FIG. 4 , the mounting plate 28 is provided with a bead-like stamping 24 each in the region of the connection of the two legs 14 , 16 of the shackle 12 . The stamping 24 is recessed with respect to the bottom side 29 of the mounting plate 28 . The stamping 24 thus projects upwards and extends to the upper portion of the shackle 12 which is configured closed. The stamping 24 has a bottom portion 25 , which extends substantially parallel to the bottom side 29 of the mounting plate 28 . That bottom portion 25 furthermore is formed substantially flat. Furthermore, the bottom portion 25 into the adjoining bottom side 29 of the mounting plate 28 substantially configured flat via a stamping edge 26 which follows a sloping or inclined course.
[0040] The sockets 20 for the free ends of the legs 14 , 16 in this case are formed as passage openings. The legs 14 , 16 are inserted into those sockets 20 in such a manner that the end faces 15 of the legs 14 , 16 projecting downwards come to lie substantially surface-flush with the bottom portion 25 of the stamping 24 . The weld 22 for the materially joined connection of shackle 12 and mounting plate 28 extends radially adjoining or radially between the outer circumference of the legs 14 , 16 and the inner wall 21 of the sockets 20 . Typically, the weld 22 or the region of the mounting plate 18 or of the shackle 12 melted through the laser welding process extends approximately over the entire material thickness of the mounting plate 28 .
[0041] The forming of the stamping 24 on the one hand can improve and accordingly reinforce the structural stiffness of the mounting plate 28 . In addition, through the stamping 24 , a hollow space is formed between the bottom portion 25 and the top side of the support structure 5 so that any welding burrs or welding beads which are invariably created through the welding process project from the bottom portion 25 downwards remain contact-free regarding the support structure 5 when the mounting plate 28 is welded to the support structure 5 with its bottom side 29 .
[0042] The shackle 12 as well as the mounting plates 18 , 28 are typically produced from steel or a steel plate. The extension of the weld 22 between shackle 12 and mounting plate 28 and 18 respectively can be at least 50%, at least 75%, at least 85%, 95% or even 100% of the material thickness of the mounting plate 18 and 28 respectively in the direction of the surface normal of the mounting plate 28 , 18 . In configurations, in which the extension of the weld 22 is smaller than the material thickness of the mounting plate 18 , 28 , the top side of the mounting plate 17 , 27 in particular when the bottom side 19 , 29 is exposed to laser radiation, can remain largely unworked, so that the type of the weld or the mutual fastening of shackle 12 and mounting plate 18 , 28 in the final assembly state is not noticeable on the support structure 5 on the body side.
[0043] FIG. 5 finally shows a motor vehicle 1 with a motor vehicle body having at least the support structure 5 provided with multiple anchorages 10 in FIG. 1 .
[0044] While at least one exemplary embodiment has been presented in the foregoing detailed description, it should be appreciated that a vast number of variations exist. It should also be appreciated that the exemplary embodiment is only an example, and are not intended to limit the scope, applicability, or configuration of the present disclosure in any way. Rather, the foregoing detailed description will provide those skilled in the art with a convenient road map for implementing an exemplary embodiment, it being understood that various changes may be made in the function and arrangement of elements described in an exemplary embodiment without departing from the scope of the present disclosure as set forth in the appended claims and their legal equivalents.
|
An anchorage device for anchoring a portable seat is disclosed. The anchorage device includes a shackle with two legs and a mounting plate equipped with two sockets receiving end of the legs. The shackle and mounting plate are laser welded in such a manner that the legs of the shackle are directly connected to the mounting plate and lie at the most surface-flush with the bottom side of the mounting plate.
| 1
|
BACKGROUND OF THE INVENTION
The invention herein described was made in the course of work under a contract or subcontract thereunder with the Department of Defense.
This invention relates to turbine nozzle guide vane assemblies and more particularly to such assemblies wherein individual ones of the vanes are radially removable from the assembly without removing an associated high pressue turbine wheel and blade assembly.
In gas turbine engines it is desirable that individual vanes or complete vane rows be replaced without removing a downstream high pressure turbine wheel and blade assembly in order to maintain a desired axially set rotor position.
Furthermore, it is recognized that radially replaceable guide vane assemblies further enable special air flow configurations to be included upstream of a turbine nozzle guide vane assembly to produce a smooth transition for flow from the combustion liner of a gas turbine engine into the nozzle guide vane row upstream of a high pressure turbine stage. Various proposals have been suggested to support stator units within a gas turbine engine in a way that they can be removed without disturbing a downstream turbine wheel and blade assembly. An example of such an arrangement is set forth in the U.S. Pat. No. 2,654,566, issued Oct. 6, 1953 to W. Boyd et al. It discloses an arrangment wherein individual guide vanes can be removed separately and replaced if they become worn or damaged. In such an arrangement a clamping band encircles all blades. It requires adjustment to maintain a desired snug fit under both cold and hot operation of the engine.
Another arrangement that permits an individual stator vane removable in a direction upstream of a downstream turbine wheel and vane assembly is set forth in the U.S. Pat. No. 2,984,454, issued May 16, 1961 to B. M. Fiori. However, in this arrangement it is necessary to remove a transition duct 104 thereby disturbing the set relationship of it with respect to the remaining portions of the gas turbine engine.
An object of the present invention is to provide an improved gas turbine nozzle guide vane construction in which individual vanes or a complete vane row can be replaced from the gas turbine engine without disturbing the set of a downstream turbine wheel and blade assembly or an upstream guide air foil configuration for providing a smooth transition from an upstream combustor into the turbine nozzle guide vane inlet.
Another object of the present invention is to provide an improved turbine vane stator assembly including means for radially removing individual vanes or a complete vane row from upstream of a turbine wheel and blade assembly without disturbing it and to do so by a first index vane secured to an inner support band by a single axially loaded pin and by the further porvision of individual vanes each having side slotted base portions thereon engageable with a fixed pin on the inner band for preventing radial shift of the individual vanes while enabling each of the other individual vanes to be rotated in a direction opposite to tangential gas loads on the vanes to free them for removal radially of the gas turbine engine.
Further objects and advantages of the present invention will be apparent from the following description, reference being had to the accompanying drawings wherein a preferred embodiment of the present invention is clearly shown.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a fragmentary view in vertical section showing one vane of the improved turbine nozzle guide vane assembly of the present invention;
FIG. 2 is a fragmentary, front elevational view of an arcuate segment of the vane row construction of the present invention;
FIG. 3 is a top elevational view, partially broken away, and in cross section to show an axially loaded lock pin and side slot and fixed retainer pin components of the present invention; and
FIG. 4 is a view in elevation showing one of the side slotted vane components of the present invention in a location prior to radially directed removal.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In FIG. 1, a fragmentary segment of a gas turbine engine is illustrated including a turbine vane case 10 having a peripheral flange 12 thereon located in juxtaposed engagement with a peripheral flange 14 of an outer combustion case 16 of the gas turbine engine. Additionally, the structure includes an inner vane case 18 and an associated air seal ring 20.
The inner vane case 18 includes an axially forwardly facing slot 22 therein and a plurality of circumferentially spaced tangs 24 interlocked with respect to radially outwardly directed tabs 26 on the air seal ring 20. Additionally, the inner vane case 18 includes a second plurality of circumferentially spaced tangs 28 thereon each axially positioned within a slot 30 on the outer radial flange 32 of an index vane 34 in a turbine vane nozzle construction 36 in accordance with the present invention. Upstream of the vane nozzle assembly 36 is located a combustor discharge air foil configured guide assembly 38 that includes an outer radial segment 40 thereon which supportingly receives a forward flange segment 42 of the air seal ring 20 which is secured to the segment 40 by means of a threaded screw element 44 and nut 46.
The air foil configured guide assembly 38 includes a pair of convergent wall segments 48, 50 defining a passage 52 from the combustor through an outlet 54 into the nozzle assembly 36. The outlet 54 includes a circumferentially formed, radially outwardly facing slot 56 which supportingly receives a dependent flange 58 on the air seal ring 20.
The outlet 54 includes an axially downstream facing slot 60 therein which receives one leg 62 of an inner support ring 64, ring 64 has a slot 66 to receive a flange 68 on the outlet 54 thereby to support the inner support ring 64 with respect to the combustor discharge air foil configured guide assembly 38.
The assembly 38 is therefore axially and radially fixed with respect to the nozzle assembly 36.
More particularly the inner support ring 64 is secured to a brace 70 by a plurality of fasteners 72 each including a threaded end 74 seated within a tapped opening 76 on a downstream surface of the inner support ring 64 as best seen in FIG. 1. Fasteners 72 further include a head 78 thereon press fitted within a bore 80 in the outer radial flange 82 of the brace 70. Additionally, the inner support ring 64 is secured to a turbine seal frame 84 by means of a plurality of studs 86 having a head portion 88 in engagement with the inboard face of the frame 84 and including a threaded outer end connected by means of a nut 90 to the upstream face of the inner support ring 64.
The frame 84 includes an annular, forwardly facing surface 92 thereon that supportingly receives a rear flange 94 on the base 96 of the index vane 34.
In the illustrated arrangement the index vane 34 is the key index point for a row of vanes in the vane nozzle assembly, a sector of which is illustrated in FIG. 2. The index vane 34 includes a front flange 98 thereon having a bore 100 into which a plunger head 102 on a release or lock pin 104 of a release mechanism 105 is positioned. The release mechanism 105 also includes a recessed end segment 106 located below an access port 108 defined by opposed walls 110, 112 having an air foil curvature formed as part of the upstream combustor discharge air foil configured guide assembly 38.
The port 108 serves as an entrance for a tool to operate the mechanism 105. The pin 104 further includes a stop flange 114 thereon spring biased against a retention ring 116 fixedly secured within a bore 118 in the inner support ring 64. A coil spring 120 located within the bore is biased against the flange 114 to hold the pin 104 so that the plunger head 102 thereon will be in interlocked engagement with the bore 100 as best seen in FIG. 1.
When the vane 34 is in its indexed position as shown in FIGS. 1 and 2, it locates each of a plurality of circumferentially located, nozzle or indexed vanes 122 in an interlocked relationship with the inner support ring 64.
More particularly, when in their locked position, each of the vanes 122 is located so as to position a side slot 124 in a base 125 thereon with respect to a fixed retainer or retention pin 126 on the ring 64 as shown in FIG. 2. At this point, each of the retainer pins 126 is located against a semicircular end segment 128 of the groove 124 and has a diameter corresponding to the height of the groove 124 at the end segment 128 thereon to serve as a stop against radial movement of a vane 122 with respect to the inner support ring 64.
Additionally, the slot 124 is undercut at 130, a distance corresponding to that between a reference surface 132 on the right hand side of each vane 122 as viewed in FIG. 2 and a point of contact 134 on a clockwise located reference portion of an adjacent fixed fastener 126. In the illustrated arrangement, as shown in FIG. 2 the ring 64 is formed as a plurality of sectors each being held in place by means of the studs 86 and nuts 90 as shown in FIG. 2.
The base 125 on each of the vanes 122 is seated between the reference surface 92 and the ring 64. These surfaces serve as a means for slidably guiding the individual vanes 122 from a locked position on the support ring 64 to a release position as shown in FIG. 3.
It engines of the aforesaid type the turbine vane case 10, outer combustion case 16, inner vane case 18 and air seal ring 20 are removed from exteriorly of the engine to provide access to the vane nozzle assembly 36. Such removal does not disturb the set of the upstream combustor air foil configured guide assembly 38 as well as that of a downstream turbine stage 136. This is the case since individual vanes or complete vane rows can be replaced without removing the downstream turbine stage 136 or otherwise disturbing the axial set of the rotor components thereof.
Furthermore, the special air foil configured guide assembly 38 defining a smooth transition from the combustion liner into the turbine stage 136 can be maintained set behind existing radial struts in the engine.
The arrangment is such that there are no additional air leakage paths into the gas stream because the mechanism 105 can be tripped by means of a tool directed through the access port 108 in an area away the gas stream flow through the engine.
In practicing the present invention, once the outer casing components are removed the spring biased release pin 104 is pulled to the left as viewed in FIG. 1 until the plunger head 102 is removed from the bore 100. At this point the index vane 34 can be removed radially outwardly of the vane row 36. Thereafter, the remainder of the vanes 122 can be removed one at a time by rotating each of the vanes 122 in a direction opposite to the tangential gas load direction on each of the vanes 122 under operating conditions. As each of the vanes 122 is shifted one at a time in a clockwise direction the slot 124 clears the fixed retainer pin 126 and the reference surface 132 as indexed against the next adjacent retainer pin so that, once shifted in a circumferential direction as seen in FIGS. 2 and 3, the individual nozzle vanes 122 can be removed from the inner support ring 64. This sequence can be repeated in order to provide ready removal of burned out or worn individual parts in the overall assembly.
As stated above, each of the side slots 124 and the fixed retainer pins 126 release in a direction opposite to the gas loading on the individual vanes 122. Conversely, during gas turbine engine operation the tangential gas load on each of the individual vanes 122 is in a direction to cause the base 125 to be pressure biased in a direction to seat the fixed retainer pin 126 against the adjacent end segment 128 of each slot 124 to assure a radial interlock of each of the individual vanes 122 with respect to the inner support ring 64. When the index vane 34 is in place and the spring biased release mechanism 105 is locked as shown in FIG. 1, the full assembly is interlocked with respect to the support ring 64 to maintain a spring biased and pressure loaded configuration wherein each of the individual vane segments of the nozzle assembly 36 is secured against separation from the support ring 64 while retaining the capability of selective and quick removal of any or all of the vanes in the assembly.
While the embodiments of the present invention, as herein disclosed, constitute a preferred form, it is to be understood that other forms might be adopted.
|
A gas turbine engine has a turbine vane case, an outer combustion case and inner vane case along with an air seal located in circumferential surrounding relationship to a circumferential row of stator vanes defining a turbine nozzle assembly upstream of a high pressure turbine stage. Individual stator vanes can be replaced without removing the high pressure turbine stage by configuring an index vane to be removably secured to an inner support band by means of a spring loaded pin and configuring each of the remaining vanes in the vane row to have a side slotted base secured to the inner band and removable therefrom by rotation of each of the individual vanes in a direction opposite to the tangential gas load thereon.
| 5
|
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is based on, claims the benefit of, and incorporates by reference U.S. Provisional Application Ser. No. 61/125,691 filed Apr. 28, 2008, and entitled “Method and Apparatus for Assessing Atrial Electrical Stability” and U.S. Provisional Application Ser. No. 61/134,325 filed Jul. 9, 2008, and entitled “Method and Apparatus for Assessing Atrial Electrical Stability.”
BACKGROUND
[0002] Cardiovascular disease is the greatest cause of morbidity and mortality in the industrialized world. It not only strikes down a significant fraction of the population without warning but also causes prolonged suffering and disability in an even larger number.
[0003] Atrial fibrillation (AF) is a common arrhythmia, affecting approximately 1% of the general population and 8% of those over the age of 80. As a result, AF places a substantial financial burden on the healthcare system, accounting for over $6 billion in direct treatment costs in the United States in 2006. More importantly, AF is associated with substantial morbidity and mortality. For example, several studies have documented a two-fold increase in mortality and a 2 to 7-fold increase in stroke rate for patients in AF compared to age-matched controls in normal sinus rhythm. Unfortunately, current pharmacologic therapy for the prevention of AF (anti-arrhythmic drugs) is hampered by major dose-limiting toxicities and high rates of arrhythmia recurrence.
[0004] In some cases, radio-frequency catheter ablation of the pulmonary veins is used to isolate unorganized electrical activity generated therein to prevent AF. Current catheter based techniques generally use an anatomic approach to identify ablation targets—regions targeted for radio-frequency ablation are identified largely based on their anatomic proximity to the pulmonary veins resulting in the same basic set of ablation lesions being generated in all patients. Using this approach, however, long-term success has been limited with an AF recurrence rate of up to 50% within 12 months following a single ablation procedure. The limited efficacy of pulmonary vein ablation is at least partly due to the fact that atrial fibrillation is a heterogeneous disease and arises from different sites in different patients.
[0005] In fact, many non-pulmonary vein sites have been identified as potential triggers for AF. Unfortunately, methods to identify these other sites during ablation procedures are lacking. In addition to the pulmonary veins, other cardiac veins are potentially arrhythmogenic, and may also be involved in the initiation and perpetuation of AF.
[0006] More recent techniques for AF ablation have used complex electroanatomic mapping systems to identify non-pulmonary vein sites as targets for ablation. These newer methods are technically complex, difficult to apply broadly and still do not provide an easily applied measure for defining the adequacy of ablation.
[0007] Pulmonary vein ablation is hampered by safety concerns with a major complication rate around 6%, including stroke, pulmonary vein stenosis, cardiac tamponade, atrio-esophageal fistula and death. In most cases, complications of catheter ablation occur as a result of thermal injury to the atrium and surrounding structures. Limiting the amount of tissue targeted for ablation may prevent complications from thermal injury but may also compromise efficacy by leaving behind un-ablated sites that later serve as the substrate for recurrent AF. One of the major limitations of the anatomic approach to pulmonary vein ablation has been the inability to determine, in real-time, when enough tissue has been ablated to achieve a successful outcome—that is no recurrence of AF.
SUMMARY OF THE INVENTION
[0008] The present invention involves a method for recording a multiplicity of electrocardiographic signals in and/or on the heart and/or tissues and blood vessels that are connected to the heart and/or on the body surface, to determine susceptibility to atrial-rhythm disturbances.
[0009] In one embodiment, the present invention is a method for identifying a susceptibility of a subject to atrial-rhythm disturbances. The method includes a) placing a plurality of sensors on the subject to measure a physiologic signal of the subject, and b) recording the physiologic signal from the sensor. The physiologic signal includes an atrial electrical activity of the subject. The method includes c) determining a beat-to-beat variability in the atrial electrical activity of the subject. The beat-to-beat variability includes alternans of electrocardiographic waveforms of a predetermined number of a sequence of heart beats. The method includes d) determining a susceptibility to atrial-rhythm disturbances of the subject using the beat-to-beat variability in the atrial electrical activity determined in step c), and e) generating a report of the susceptibility to atrial-rhythm disturbances of the subject.
[0010] In another embodiment, the present invention is a method for identifying a susceptibility of a subject to atrial-rhythm disturbances. The method includes a) placing a sensor on the subject to measure a physiologic signal of the subject, and b) recording the physiologic signal from the sensor. The physiologic signal includes an electrical activity of a heart of the subject. The method includes c) determining a beat-to-beat variability in the atrial electrical activity of the subject during a sequence of heart beats, d) determining a susceptibility to atrial-rhythm disturbances of the subject using the beat-to-beat variability in the atrial electrical activity, and e) generating a report of the susceptibility to atrial-rhythm disturbances of the subject.
[0011] In another embodiment, the present invention is a system for identifying susceptibility to atrial-rhythm disturbances. The system includes a plurality of sensors configured to measure a physiologic signal of a subject, and a computer for recording the physiologic signal from the sensor. The physiologic signal includes an atrial electrical activity of the subject. The computer is configured to determine a beat-to-beat variability in the atrial electrical activity of the subject. The beat-to-beat variability includes alternans of electrocardiographic waveforms of a predetermined number of a sequence of heart beats. The computer is configured to use the beat-to-beat variability in the atrial electrical activity to determine a susceptibility to atrial-rhythm disturbances of the subject. The system includes a user interface for displaying the susceptibility to atrial-rhythm disturbances of the subject.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] For a more complete understanding of this disclosure, reference is now made to the following brief description, taken in connection with the accompanying drawings and detailed description, wherein like reference numerals represent like parts.
[0013] FIG. 1 is a schematic diagram illustrating the formation of spatial alternans in cardiac tissue leading to a dispersion of recovery, wave front fractionation, and reentry;
[0014] FIG. 2 is a flow chart setting forth the steps of a method for determining a subject's susceptibility to atrial-rhythm disturbances and for treating the subject to minimize the occurrences of atrial-rhythm disturbances;
[0015] FIG. 3 is a three dimensional (3D) illustration of an anterior view of the left atrium and pulmonary veins of a heart indicating potential catheter lead locations;
[0016] FIG. 4 is a 3D illustration of a posterior view of the left atrium and pulmonary veins of a heart indicating potential catheter lead locations;
[0017] FIG. 5 is a 3D illustration of a top view of the left atrium and pulmonary veins of a heart indicating potential catheter lead locations.
[0018] FIG. 6 is an exemplary electrocardiographic waveform including annotations identifying a plurality of portions of the electrocardiographic waveform;
[0019] FIG. 7 is a flow chart illustrating the steps of an algorithm for estimating alternans of atrial electrocardiographic waveforms;
[0020] FIG. 8 shows a plurality of exemplary electrocardiographic waveforms illustrating time-aligned samples within the P-wave used for the depolarization alternans of atrial electrocardiographic waveforms estimation; and
[0021] FIG. 9 is a schematic diagram of a system for assessing atrial electrical stability.
DETAILED DESCRIPTION
[0022] The present invention is directed to a system and method for assessing atrial electrical stability. More specifically, a system and method are provided for guiding radio-frequency catheter ablation to minimize instances of atrial fibrillation (AF). In one implementation, catheter ablation procedures are guided using measurements and analysis of atrial alternans, a beat-to-beat variation in the morphology of the atrial electrocardiographic (ECG) waveform. In some cases, atrial alternans are associated with the same myocardial substrate that gives rise to AF.
[0023] Electrical alternans are a pattern of variation in the shape of electrocardiographic waveform that appears on an every other beat basis. In humans, visible (macroscopic) alternations in ventricular repolarization have been associated with an increased vulnerability to ventricular arrhythmias under diverse pathophysiologic conditions.
[0024] A Fast Fourier Transform (FFT) spectral method may be used to detect microvolt level T-Wave Alternans (TWA) and the establishment of a relationship between TWA and Ventricular Fibrillation (VF) threshold (VFT). An increased dispersion of repolarization (DR) is an important condition for the development of reentrant arrhythmias and may be associated with both VT/VF and concordant or discordant alternans (DR is greater at sites of discordant vs. concordant alternans). In some cases, action potential (AP) duration (APD) alternans can provide the substrate for reentry, indicating that TWA is also a short-term predictor of arrhythmia susceptibility. Accordingly, the mechanisms that generate VRA (functional spatial dispersion of refractoriness) are likely to also lead to VT/VF, requiring that the heart pass through a VRA stage on the way to VT/VF or VRA occurs in conjunction with developing VT/VF.
[0025] Action potential alternans involve an alternating sequence in which the shape of the action potential (the wave-like pattern of variation of a cell's transmembrane potential) associated with an individual cardiac cell changes on an every other beat basis. If the duration of the action potential alternates on an every other beat basis, then the duration of the refractory period also alternates in duration because the refractory period is generally comparable to the duration of the action potential. Thus, action potential alternans create a situation in which a region of the myocardium has a long refractory period on an every other beat basis. Referring to FIG. 1 , on these alternate beats, regions 2 with long action potential duration alternans can create islands of refractory tissue with respect to areas 4 of short action potential duration alternans. These variations between the regions 2 , 4 cause fractionation of activation wavefronts 6 and promote the development of reentry.
[0026] A major factor leading to the creation of ventricular arrhythmias during ischemia is dispersion of refractoriness. Dispersion of refractoriness is a measure of non-homogeneous recovery of excitability in a given mass of cardiac tissue (tissue is called refractory when it cannot be re-stimulated until it has recovered). In normal myocardium, the excitability is strictly proportional to the duration of repolarization. Reentry is the most likely mechanism of arrhythmia facilitated by enhanced dispersion of repolarization. The elements that are most often represented in the experimental or clinical models of arrhythmias attributed to reentry include non-uniform conduction, non-uniform excitability, and non-uniform refractoriness. An important mechanism for enhancing dispersion of the refractory period is alternation of the action potential from beat to beat.
[0027] Thus, as illustrated in FIG. 1 , action potential alternans 2 , 4 , which generally occur in diseased tissue, can promote the formation of islands of refractory tissue which promote the development of reentry. Therefore, localized cardiac alternans may be reflected in the surface ECG as TWA. Concomitantly, localized regions of AP alternans that exhibit delayed recovery on an every other beat basis are intrinsically linked or even lead to increased repolarization gradients sufficient to produce unidirectional block and reentry. Therefore, localized AP alternans lead to TWA as well as to increased DR, wavefront fractionation, reentry and VT/VF.
[0028] Similarly to ventricular alternans, localized regions of atrial APD heterogeneity can be identified on the ECG waveform as atrial (depolarization and/or repolarization) alternans, and the presence of alternans of atrial electrocardiographic waveforms is linked to the gradients of repolarization that give rise to multiple-wavelets and AF. Furthermore, by identifying local regions and/or periods of heightened alternans of atrial electrocardiographic waveforms in the heart and/or tissues that are connected to the heart and targeting them, catheter ablation can sufficiently modify the electrical substrate to prevent AF. Suppression of alternans of atrial electrocardiographic waveforms may also be used as a marker for identifying a suitable end-point for ablation and limiting further thermal injury.
[0029] The use of alternans of atrial electrocardiographic waveforms to guide catheter ablation procedures of AF and verify and confirm its success, provides several advantages, such as: (i) a real-time, rapid and highly efficient method for identifying ablation targets based on electrophysiologic properties, not just anatomic markers; (ii) an approach that would limit thermal injury by preventing ablation of “non-culprit” atrial tissue; (iii) a marker to define the success of ablation and identify a procedural end point; (iv) a marker to predict long-term risk of arrhythmia recurrence; and (v) a broadly applicable approach to meet the substantial demand for AF therapy.
[0030] Heart rate variability (HRV), a variability of ventricular depolarization times, also acts as an indicator of sudden cardiac death in post myocardial infarction patients. As such, a mathematical model has been developed for describing HRV. In an analogous manner to measuring variability of ventricular depolarization times, the altered variability of atrial depolarization times and/or variability in the duration of atrial depolarization and/or variability in the duration from the onset of atrial depolarization to the offset of atrial repolarization and/or parameters of the signal averaged P-wave, may be intrinsically linked to periods of increased susceptibility of atrial arrhythmias and AF. Furthermore, identifying local regions and/or periods of altered variability of atrial depolarization times and/or variability in the duration of atrial depolarization and/or variability in the duration from the onset of atrial depolarization to the offset of atrial repolarization and/or parameters of the signal averaged P-wave and/or the tissues that it is connected, and targeting them for catheter ablation can sufficiently modify the electrical substrate to prevent AF.
[0031] As will be described, the present method involves recording electrocardiographic signals associated with the heart, tissues or blood vessels that are connected to the heart, and/or the body surface, to determine a susceptibility to atrial-rhythm disturbances. The atrial-rhythm disturbances may involve atrial tachycardia, atrial fibrillation, atrial flutter, or other disturbances to the operation of the atria. Using the present method, sites that originate atrial-rhythm disturbances are identified in the atria or tissues and blood vessels that are connected to the heart. After identifying the sites originating atrial-rhythm disturbances, appropriate medical treatments such as the delivery of a chemical or biochemical substance, or the application of electrical energy are guided to those sites. The present method may also involve determining the risk or likelihood of a subject to develop atrial-rhythm disturbances.
[0032] FIG. 2 is a flow chart setting for the steps of an exemplary method 100 for determining a subject's susceptibility to atrial-rhythm disturbances and treating the subject to minimize the occurrences of atrial-rhythm disturbances. Using method 100 , electrical activity originating in and/or on the heart and/or tissues and blood vessels that are connected to the heart and/or on the body surface are collected and processed. After processing, the system assesses a susceptibility to atrial-rhythm disturbances by further processing of atrial electrical activity data.
[0033] In step 102 , atrial activity of the heart is recorded using one or more electrodes connected to a subject to collect electrical data describing the activity of the heart tissue of the subject. The electrodes may include passive electrodes and may be placed in the atria, pulmonary veins, the coronary sinus, or any other tissue or blood vessels attached to the heart. FIGS. 3-5 illustrate a heart 10 of a subject having example placements of electrode or sensors 12 around a proximity of heart 10 . FIG. 3 illustrates an anterior view of the left atrium and pulmonary veins of heart 10 . FIG. 4 illustrates a posterior view of the left atrium and pulmonary veins of heart 10 . FIG. 5 illustrates a top view of the left atrium and pulmonary veins of heart 10 . In FIGS. 3-5 , dots 12 indicate exemplary placement positions for the sensors or catheter leads.
[0034] The electrodes or sensors may be in a bipolar configuration for recording localized atrial electrical activity, or in a unipolar configuration for recording remote or global atrial electrical activity. Alternatively, atrial activity data may be collected using catheters similar to those used as part of the atrial fibrillation ablation procedure and the detected signals, following amplification, filtering and conditioning, are used for further analysis.
[0035] Depending upon system requirements, placement of the electrodes may optionally be guided or facilitated by the use of various imaging modalities, such as magnetic resonance imaging (MRI), computed tomography (CT) or ultrasound. The catheter lead location placement with respect to each other may be circular or straight. In one implementation, catheter leads in the heart (see, for example, FIGS. 3-5 ) may be positioned at or close to the pulmonary veins, in the high and/or low, anterior and/or posterior surfaces of the left atrium, or at any other tissue close to the atria, such as the coronary sinus. Catheter leads in the heart may be positioned at the corresponding sites in the right atrium and may occur sequentially at the aforementioned or different locations providing a detailed spatio-temporal (time-dependent anatomical) characterization of the beat-to-beat variability of atrial electrical activity.
[0036] In an alternative implementation, the leads for acquiring the electrocardiographic waveforms within or on the body may include Frank orthogonal leads or may be mathematically combined to form Frank orthogonal leads. In that case, the selected atrial waveforms of the three orthogonal bipolar leads (X, Y, Z) may be combined into a vector magnitude by the formula (X 2 +Y 2 +Z 2 ) 1/2 .
[0037] Referring again to FIG. 2 , step 102 may be implemented using leads of an implanted device such as an implantable cardioverter defibrillator or cardiac pacemaker. The devices may contain micro-processors or other electronic circuitry capable of performing the computations necessary for the measurement. Furthermore, the devices can also serve as a cardioverter defibrillator or pacemaker during the therapy portions of the present method.
[0038] At step 103 , the signals representing the collected atrial activity data are stored in a computer or other electronic storage medium using an analog to digital card. In one implementation, the data is stored in a database, or other electronic storage medium on a computer's hard disk. After storage, the data is further processed to determine susceptibility to atrial-rhythm disturbances.
[0039] In one implementation, the method continues by manipulating the data stored in step 103 to determine beat-to-beat variability in step 104 . For example, the beat-to-beat variability may include atrial depolarization and/or repolarization alternans, or alternans of the PQ interval, as illustrated in FIG. 6 . After determining beat-to-beat variability, the method includes estimating alternans of atrial electrocardiographic waveforms in step 106 . Further detail of step 106 will be described with respect to FIG. 7 .
[0040] After determining the alternans of atrial electrocardiographic waveforms, in step 108 , output data is generated that may be used for treatment of the atrial-rhythm disturbances. For example, when the level of alternans of the selected atrial waveform estimated from one or more leads, exceeds a threshold value over some period of time (such as for example, one minute), susceptibility to atrial-rhythm disturbances may be indicated at step 108 . Furthermore, when the level of alternans of the selected atrial waveform estimated from one lead, but not all leads, exceeds a threshold value over a predetermined period of time (such as for example, one minute), it may be determined that the site of origin of the atrial abnormal heart rhythm is close and/or around that lead, and susceptibility to atrial-rhythm disturbances may be indicated at that particular location. Successful elimination, interruption and/or isolation of the atrial heart-rhythm disturbances may be manifested by suppression and/or elimination of the alternans level of the selected atrial waveform. After detecting an on-going susceptibility to atrial-rhythm disturbances, various treatments or therapy are provided in step 110 .
[0041] Referring now to FIG. 7 , in one exemplary implementation, the process for estimating alternans of atrial electrocardiographic waveforms described with respect to step 106 of FIG. 2 , may use 128 electrocardiographic waveforms and may be updated or shifted forward with every new electrocardiographic waveform recorded. The algorithm for estimating alternans of atrial electrocardiographic waveforms may be triggered either from the ventricular R-wave (R v ) of the QRS complex or the P-wave (seen in FIG. 6 ) in a double triggering approach in step 602 . Double triggering first identifies the high amplitude ventricular R v -wave and then a backwards algorithm may be applied to trigger on the P-wave. Alternatively, the algorithm for estimating alternans of atrial electrocardiographic waveforms may be triggered from the atrial R a -wave.
[0042] The R v -wave (indicating ventricular depolarization, as illustrated in FIG. 6 ) detection occurs in the electrocardiographic waveform obtained from any of the sensors placed in or on the patients' heart or tissues and blood vessels attached to the heart or on the patient's body surface. Following R v -wave detection, the “baseline” for each beat (considered to be the mean or median value of the electrocardiographic waveform during the PQ interval seen in FIG. 6 ), may be adjusted by subtracting the baseline value from the value of the electrocardiographic waveform segment used for further analysis in step 604 .
[0043] In another implementation, however, the PQ interval baseline can be adjusted by high-pass filtering. For example, to filter the effect of respiration at a rate of 9 breaths per minute on the ECG signal, a 128 order digital finite impulse response filter with a low cut-off frequency of 0.16 Hz with a normalized gain at that frequency at a magnitude of approximately −6 dB and having magnitude 1 at the pass-band may be used. Alternatively, the low cut-off frequency of the filter to reduce the effect of respiration on the ECG signal may be dynamically adjusted based on a real-time estimate of the respiration rate. In one implementation, for example, a high-pass filter impulse response is windowed with a 129 point length window (for example, Hamming or Hanning).
[0044] Following PQ interval baseline adjustment in step 604 , an average or median ventricular QRS complex (for example, 70 milliseconds long) is formed and each ventricular QRS complex in the 128-beat sequence is repeatedly cross-correlated (convoluted) and shifted against the average or median ventricular QRS complex of that sequence of beats in step 606 . The sample point at which the cross-correlation takes its maximum value is considered the true R v -wave (fiducial point). To make the fiducial point as accurate as possible, an additional interpolation may optionally be performed to determine the fiducial point to the nearest sample point.
[0045] Following refinement in identifying the peak of the ventricular QRS complexes, erroneous ventricular QRS complexes are detected in step 608 based on at least one of two criteria: (i) the morphology criterion, in which the correlation coefficient between the present beat ventricular QRS complex and the average or median ventricular QRS complex of the, for example, 128-beat sequence, is less than a threshold value of, for example, 0.95; and (ii) the R v -to-R v (R v R v ) interval criterion, in which the present beat's R v R v interval minus the mean R v R v interval of the previous, for example, 5 beats is less/more than a threshold value of, for example, 50 milliseconds.
[0046] A beat may be classified as good if both the morphology (indicated as “1” in Table 1) and the R v R v -interval (indicated as “1” in Table 1) criteria are satisfied, as indicated in a decision matrix that may help classify beats. After the erroneous beats are detected, for each erroneous beat, the appropriate number of atrial electrocardiographic waveforms are removed from that sequence of beats, as indicated in Table 1 and step 610 .
[0000]
TABLE 1
Decision matrix for beat classification based
on analysis of the ventricular QRS complex.
Morphology
R V R V
Removed
Case
Criterion
Criterion
Outcome
Beats
Classification
1
0
0
0
3
Premature
(previous +
Ventricular
present + next)
Contraction
2
0
1
0
2
Supraventricular
(present + next)
3
1
0
0
2
Aberrantly
(previous +
conducted sinus
present)
beat (i.e. bundle
branch block)
4
1
1
1
0
Normal
[0047] In one implementation, the fiducial point is shifted to the far left of the acquisition window enabling maximal visibility of the P-wave and the PQ interval. This allows for the identification of the P-wave boundaries (P beg and P end ) using either the raw ECG signal or its filtered version in step 612 .
[0048] Following identification of the P-wave boundaries, an average or median P-wave may be estimated (for example, being 100 milliseconds long) and each P-wave in the 128-beat sequence is repeatedly cross-correlated (convoluted) and shifted against the average or median P-wave of that sequence of beats in step 614 , and the sample point at which the cross-correlation takes its maximum value is considered the true P-wave peak (fiducial point). In some cases, to make the fiducial point increasingly accurate, an additional interpolation is performed to determine the fiducial point to the nearest sample point.
[0049] Following refinement in identifying the peak of the P-wave, erroneous P-waves may be detected based on one or more of the following criteria: (i) the morphology criterion (as it applies to the P-wave), in which the correlation coefficient between the present beat P-wave and the average or median P-wave of the beat sequence is less than a threshold value of, for example, 0.90, see step 616 , and (ii) the P-to-P interval criterion in which the present beat's P-to-P interval minus the mean P-to-P interval of the previous, for example, 10 beats is less/more than a threshold value of, for example, 50 milliseconds.
[0050] A beat may be classified as good if the morphology indicated “1” in Table 2 criterion alone and/or the P-to-P interval indicated “1” in Table 2 criteria are satisfied, as indicated in a decision matrix that may help classify beats (Table 2). Again, once all of the erroneous beats are detected, then for each erroneous beat the appropriate number of the selected for analysis atrial electrocardiographic waveforms are removed from that sequence of beats, as indicated in Table 2.
[0000]
TABLE 2
Decision matrix for beat classification based on analysis of the P-wave.
Morphology
R a R a
Removed
Case
Criterion
Criterion
Outcome
Beats
Classification
1
0
0
0
3
(previous +
present + next)
2
0
1
0
2
(present + next)
3
1
0
0
2
(previous +
present)
4
1
1
1
0
Normal
[0051] Therefore, in a sequence of beats selected for analysis, after all erroneous beats are detected and for each erroneous beat the appropriate number of the selected atrial electrocardiographic waveforms are removed, the selected atrial electrocardiographic waveform of each removed beat is substituted with a median odd or even selected atrial electrocardiographic waveform template depending on whether the removed beat was an odd or an even one in that sequence in step 618 . After the appropriate beat removal and substitution, a sequence of selected atrial electrocardiographic waveforms may be eligible for further analysis if the number of removed beats is, for example, less than 9%; if the latest condition is not satisfied, the sequence moves forward, is updated with, for example, a new beat, and steps 606 through 610 are repeated.
[0052] If an eligible sequence of beats is identified for further analysis, then for example, if the selected atrial electrocardiographic waveform is a P-wave, an average or median P-wave is obtained and the P-wave boundaries (P beg and P end ) are obtained as previously described. In another implementation an average or median T a -wave (reflecting atrial repolarization) may also be obtained and its boundaries (beginning and end) are again obtained as previously described. The analysis that follows may be applied in either or all selected atrial waveforms reflecting or being part of atrial excitation (for example the P-wave reflecting atrial depolarization and the T a -wave reflecting atrial repolarization).
[0053] In steps 620 and 622 , the power spectrum may be estimated for each time-aligned sequence of sample points within the selected atrial waveform, as previously described. In one case, the selected atrial waveform is split into bins, each bin consisting of at least one sample point. The power spectra for each sample point in a bin may be averaged and the statistical estimates of alternans of atrial electrocardiographic waveforms (for example, the alternans voltage, noise and K-score) are obtained as previously described in step 624 .
[0054] Estimation of alternans of atrial electrocardiographic waveforms can be performed on unipolar signals alone or in combination with bipolar signals in order to more accurately determine susceptibility to atrial-rhythm disturbances. In one example, the use of unipolar and/or bipolar signals may also determine more accurately the site of origin of the atrial-rhythm disturbance. For example, if alternans of atrial electrocardiographic waveforms are present in bipolar signals (e.g. obtained from a pulmonary vein) or unipolar signals (e.g. obtained from the coronary sinus) before treatment, then, if, after treatment of the atrial-rhythm disturbances, alternans of atrial electrocardiographic waveforms persist only in the unipolar signal, treatment at and/or around the site that the bipolar signal was recorded from may be determined to be successful, although there is at least one more site of origin of atrial-rhythm disturbances that should be treated.
[0055] In one example treatment system, the same catheters used to record the fluctuations in the beat-to-beat variability of the selected atrial waveform are used to deliver therapy to the heart via electrical stimulus, ablation, delivery of medication, or other treatment methods. One therapy method involves the delivery of electrical energy to the heart through electrodes in and/or on the heart. This electrical energy may suppress and/or terminate and/or isolate the initiation of atrial-rhythm disturbances at and/or around the site of origin of the abnormal atrial rhythm. The energy of this therapy would be appropriate to interrupt an atrial-rhythm disturbance, such as preventing AF from spreading to the atrial tissue. The therapy may include the delivery of a chemical or biochemical substance. The chemical substance may include a pharmacological agent or gene therapy that reduces the likelihood of an atrial-rhythm disturbance from occurring. The substance may be delivered into the blood stream or directly at and/or around the tissue site of origin of the atrial-rhythm disturbances.
[0056] Therapy may be delivered by an implanted device through electrodes in and/or on the heart and/or tissues and blood vessels that are connected to the heart. The device may be configured to implement the measuring and analysis methods illustrated in FIGS. 2 and 7 and described above. Accordingly, such an implanted device, in addition to performing the measuring steps described above (steps 100 - 102 of FIG. 2 ) may identify time periods and locations within the subject having an increased probability that a heart rhythm disturbance may occur and during which therapy may be delivered. For example the implantable device can incorporate means for generating electrical stimulating pulses of specified energies and apply the pulses to body tissue at specified times, and deliver the impulses used for pacing the heart at the appropriate times and energy levels. The electrical impulses may be delivered at varying inter-impulse intervals so as to increase the level of heart rate variability. For example, the inter-impulse intervals may have a mean of 600 milliseconds and a standard deviation of 120 milliseconds. In general, the mean inter-impulse interval is small enough so that most of the heart beats result from the applied impulses and not from spontaneous cardiac electrical activity. The variable inter-beat intervals will also cause the diastolic intervals associated with cardiac electrical activity in the heart's ventricles to vary. Since the STa and Ta-wave morphology also depend on the duration of the preceding diastolic interval, the variability in the timing of the electrical impulses will also cause increased variability in STa and Ta-wave morphology and thus tend to suppress ατριαλ repolarization alternans.
[0057] The delivered therapeutic electrical stimulus may have a minimum energy level similar to that delivered by pacemakers (pacing pulse), and a maximum energy level similar to that delivered by defibrillators (defibrillation shock). The therapeutic electrical stimulus should be delivered outside the vulnerable window wherein ventricular fibrillation may be induced. When there is alternation in the atrial beat duration (the duration of time from the beginning of depolarization to the end of repolarization), the electrical impulse is delivered at a time interval after the end of repolarization in the beats with the shorter beat duration. This time interval is longer than the diastolic interval that follows the beats with the longer beat duration but shorter than the diastolic interval that follows the beats with the shorter beat duration. Adaptive pacing can be employed in such a way that electrical stimuli will be applied on alternate beats during alternans.
[0058] In another implementation, non-excitatory current will be applied during the absolute refractory period to modulate the local atrial APD and, consequently, the QTa interval. Current pulses may be applied on a beat-to-beat basis during alternans by attempting to prolong (by applying a positive amplitude pulse or anodic stimulus) or shorten (by applying a negative amplitude pulse or cathodic stimulus) the QTa interval, on either the short (in an attempt to prolong it) or the long (in an attempt to shorten it) beats on alternate beats. In one implementation, the following parameters of the current pulses are adjusted to confirm suppression/termination of RA, the: (i) amplitude, (ii) duration, and (iii) delay from the Ra-wave. Monophasic square-wave current pulses with (i) peak amplitudes ranging between 1 and 20 mA in incremental steps of 1 mA (corresponding to an approximate range of 0.5 to 10 V, for ˜500 Ohms impedance), (ii) duration ranging from 10 to 50 milliseconds, in incremental steps of 2 milliseconds, and (iii) delivery of 10 to 50 milliseconds in incremental steps of 2 milliseconds after the Ra-wave, are applied on alternate beats.
[0059] Using the present method, the level of alternans of the selected atrial waveform may be quantified by obtaining the Fast Fourier Transform of the windowed auto-correlation function of a time-aligned sequence of sample points, and then obtaining a measurement of the alternans voltage, noise and the alternans ratio, in one or more electrocardiographic leads. Threshold values of these parameters can be established. For example, the threshold values may include 1.9 microvolts for the alternans voltage and a value of 3.0 for the alternans ratio. Other threshold values may require noise estimates during the alternans estimation to be below a value such as 1.8 microvolts.
[0060] Other threshold values may require that the optimal heart rate for the alternans estimation of the selected atrial waveform be, for example, 105 beats per minute or 5-40% above the patient's intrinsic heart rate. This threshold may be applied by pacing (electrical stimulation of the heart), exercise and/or delivery of a chemical (pharmacologic) substance. If pacing is used, the pacing pulse (artifact) may be eliminated by: (i) high-pass filtering of the ECG signal with a cut-off frequency of, for example, 180 Hz; (ii) application of a threshold algorithm on the filtered signal; or (iii) identification of the pacing pulses as the local maxima.
[0061] When determining estimates of the alternans voltage or the noise from the power spectrum, respiration may affect the amplitude of one or both of them. Accordingly, the respiration frequency may be monitored and the respiration affect on the amplitude of the power spectrum at the alternans frequency (for example, 0.5 cycles/beat) or the noise-band frequencies may be reduced or eliminated, by requiring the subject to breath at a different and specific breathing pattern, by appropriate filtering of the respiration signal, or by appropriately adjusting the estimation of the alternans voltage and noise, and the like.
[0062] The beat-to-beat variability may be manifested as fluctuations of the selected atrial waveform at specific frequencies in the Fast Fourier Transform power spectrum; the amplitude of the Fast Fourier Transform power spectrum at such frequencies is higher (“dominant frequency”) than other frequencies in the spectrum. The Fast Fourier Transform may be obtained on a sequence of time aligned points with respect to fiducial points of the selected atrial waveform (see, for example, FIG. 8 ), such as the peak of the P-wave or the peak of T a -wave. Further analysis of these dominant frequencies may indicate the presence of a site of origin of atrial-rhythm disturbances, or the distance of the site of origin of the atrial-rhythm disturbances from the lead that recorded the specific electrocardiographic waveform. Identification of a dominant frequency may be also used to identify individuals susceptible to abnormal atrial rhythms over the long-term.
[0063] Alternatively, the beat-to-beat variability of the selected atrial electrocardiographic waveform may include a measurement of P-to-P interval variability. Reduced heart rate (R v R v ) variability is a well known predictor of the development of ventricular arrhythmias. A threshold value of P-to-P interval variability may be established, such as the standard deviation of normal-to-normal (SDNN) P-to-P interval variability being, for example, equal to 60 milliseconds. When the P-to-P interval variability (estimated from atrial electrical activity recorded from a specific lead), is less than this threshold value for some period of time (for example one minute), then the site of origin of the atrial abnormal rhythm can be determined to be close and/or around that lead and therapy is delivered to eliminate and/or interrupt the atrial-rhythm disturbances. In that case, successful elimination and/or interruption of the atrial abnormal rhythm may be manifested by adjusting to normal the P-to-P interval variability.
[0064] FIG. 9 illustrates a system 200 for assessing atrial electrical stability. System 200 includes one or more sensors 202 configured to detect atrial activity of the heart of a subject. Sensors 202 may include one or more electrodes and can be connected to a subject to collect electrical data describing the activity of the heart tissue of the subject. The electrodes may include passive electrodes and may be placed in the atria, pulmonary veins, the coronary sinus, or any other tissue or blood vessels attached to the heart. The electrodes may be in a bipolar configuration for recording localized atrial electrical activity, or in a unipolar configuration for recording remote or global atrial electrical activity. Alternatively, atrial activity data may be collected using catheters similar to those used as part of the atrial fibrillation ablation procedure and the detected signals, following amplification, filtering and conditioning, are used for further analysis.
[0065] Sensors 202 may include leads or electrodes of an implanted device such as an implantable cardioverter defibrillator or cardiac pacemaker. The devices may contain micro-processors or other electronic circuitry capable of performing the computations necessary for the measurement. Furthermore, the devices can also serve as a cardioverter defibrillator or pacemaker during the therapy portions of the present method.
[0066] In some implementations, sensors 202 are fabricated within a portable ambulatory electrocardiographic device that also continuously monitors the electrical activity of the heart for 24 hours or more (e.g., a Holter monitor). The extended recording period provided by the ambulatory electrocardiographic device may be used to capture and observe occasional cardiac arrhythmias that would be difficult to identify in a shorter period of time. For patients having more transient symptoms, a cardiac event monitor can be used. Unlike the Holter monitor, however, which records continuously throughout the testing period of 24 to 48 hours, the event monitor does not record until one feels symptoms and triggers the monitor to record ECG tracings at that time.
[0067] The Holter and the event monitor record electrical signals from the heart via a series of electrodes attached to the chest. The number and position of electrodes may vary, but most monitors employ from three to eight. These electrodes are connected to a small piece of equipment that is attached to the patient's belt, and is responsible for keeping a log of the heart's electrical activity throughout the recording period. On the other hand, the event monitor may wirelessly transmit the recording of the event to a physician or to a central monitoring center.
[0068] The electrical signals collected by sensors 202 represent atrial activity data are stored in a computer or other electronic storage medium 204 . In one implementation, the data is stored in a database, or other electronic storage medium on a computer's hard disk. After storage, the data is further processed to determine susceptibility to atrial-rhythm disturbances.
[0069] The data stored in storage system 204 are retrieved by computer 206 for analysis. Computer 206 may include a personal computer, file server, workstation, minicomputer, mainframe, or any other computer capable of communicating and interconnecting with other computers. Input devices such as a mouse and/or a keyboard, a monitor, disk drives, memory, a modem, and a mass storage device such as a hard disk drive may be connected to computer 206 . Computer 206 retrieves data from storage system 204 and is configured to implement one or more steps of the present method. For example, computer 206 may include software for retrieving data from storage system 204 and implemented the method illustrated in FIG. 2 or 7 , for example.
[0070] Computer 206 is connected to output device 208 for outputting data generated by system 200 . In one implementation, output device 208 includes a display system having a two-screen layout and/or a printer. One screen may display raw ECG signals as they are recorded from multiple sites (i.e. coronary sinus, pulmonary veins . . . ), while the second screen may display visual outputs for real-time estimates of atrial alternans magnitude.
[0071] System 200 includes treatment device 210 connected to computer 206 for administrating therapy to a subject. Treatment device 210 may include a mechanism for therapy may include the delivery of a chemical or biochemical substance. The chemical substance may include a pharmacological agent or gene therapy that reduces the likelihood of an atrial-rhythm disturbance from occurring. The substance may be delivered into the blood stream by treatment device 210 or directly at and/or around the tissue site of origin of the atrial-rhythm disturbances.
[0072] Alternatively, treatment device 210 includes an implanted device and is configured to generate electrical stimulating pulses of specified energies and apply the pulses to body tissue at specified times and deliver the impulses used for pacing the heart at the appropriate times and energy levels. The delivered therapeutic electrical stimulus may have a minimum energy level similar to that delivered by pacemakers (pacing pulse), and a maximum energy level similar to that delivered by defibrillators (defibrillation shock). The therapeutic electrical stimulus should be delivered outside the vulnerable window wherein ventricular fibrillation may be induced. When there is alternation in the atrial beat duration (the duration of time from the beginning of depolarization to the end of repolarization), the electrical impulse is delivered at a time interval after the end of repolarization in the beats with the shorter beat duration. This time interval is longer than the diastolic interval that follows the beats with the longer beat duration but shorter than the diastolic interval that follows the beats with the shorter beat duration. Adaptive pacing can be employed in such a way that electrical stimuli will be applied on alternate beats during alternans.
[0073] While several embodiments have been provided in the present disclosure, it should be understood that the disclosed systems and methods may be embodied in many other specific forms without departing from the spirit or scope of the present disclosure. The present examples are to be considered as illustrative and not restrictive, and the intention is not to be limited to the details given herein. For example, the various elements or components may be combined or integrated in another system or certain features may be omitted, or not implemented.
[0074] Also, techniques, systems, subsystems and methods described and illustrated in the various embodiments as discrete or separate may be combined or integrated with other systems, modules, techniques, or methods without departing from the scope of the present disclosure. Other items shown or discussed as coupled or directly coupled or communicating with each other may be indirectly coupled or communicating through some interface, device, or intermediate component, whether electrically, mechanically, or otherwise. Other examples of changes, substitutions, and alterations are ascertainable by one skilled in the art and could be made without departing from the spirit and scope disclosed herein.
|
A method for identifying a susceptibility of a subject to atrial-rhythm disturbances includes a) placing a plurality of sensors on the subject to measure a physiologic signal of the subject, and b) recording the physiologic signal from the sensor. The physiologic signal includes an atrial electrical activity of the subject. The method includes c) determining a beat-to-beat variability in the atrial electrical activity of the subject. The beat-to-beat variability includes alternans of electrocardiographic waveforms of a predetermined number of a sequence of heart beats. The method includes d) determining a susceptibility to atrial-rhythm disturbances of the subject using the beat-to-beat variability in the atrial electrical activity determined in step c), and e) generating a report of the susceptibility to atrial-rhythm disturbances of the subject.
| 0
|
This disclosure was made with Government support under Contract no. DE-FC36-04GO14010, awarded by the Department of Energy. The Government has certain rights in this disclosure.
BACKGROUND
Field
This disclosure relates to high pressure storage devices and processes of manufacture. More particularly, this disclosure relates to improved methods of fabricating composite pressure vessels with internal liners for storage of hydrogen, natural gas, or other gases or liquids, specifically with respect to improvements in high-weight and high-cost efficiency manufacturing methodology.
SUMMARY
According to at least some aspects of some implementations, disclosed is a composite pressure vessel, comprising: a liner assembly having a non-homogenous support profile; and a shell, further comprising: at least one continuous and general layer of a filament wrap disposed around the liner assembly; and at least one non-continuous and local fiber segment.
The location of the at least one fiber segment may correspond to an area of the liner assembly that is more susceptible to rupture than other areas of the liner assembly, according to the non-homogenous support profile. The at least one at least one continuous and general layer of a filament wrap and the at least one non-continuous and local fiber segment may be disposed in alternating layers on the liner assembly.
Complementary pairs of fiber segments may be disposed with respective angles of ±φ relative to a principal axis extending through the composite pressure vessel. The complementary pairs of fiber segments may be configured to address a non-homogenous stress distribution profile of the composite pressure vessel.
The at least one fiber segment may form a hoop disposed axially about a principal axis extending through the composite pressure vessel, wherein each portion of the hoop may be substantially perpendicular to the principal axis. The hoop may be configured to address a non-homogenous stress distribution profile of the composite pressure vessel.
The filament wrap may comprise a filament wound fiber and a resin. The filament wound fiber may comprise at least one inorganic or organic fiber. The inorganic or organic fiber may comprise at least one of carbon, glass, basalt, boron, aramid, Kevlar, high-density polyethylene (HDPE), and nylon.
The fiber segment may comprise a dry fiber impregnated with a resin. The dry fiber comprises at least one inorganic or organic fiber. The inorganic or organic fiber may comprise at least one of carbon, glass, basalt, boron, aramid, Kevlar, high-density polyethylene (HDPE), PP, PE, PET, PEN, zylon, and nylon. The resin may comprise at least one of a thermoset polymer resin and a thermoplastic polymer resin.
Each of the at least one layer of a filament wrap and the at least one fiber segment may be disposed with axial symmetry about a principal axis.
According to at least some aspects of some implementations, disclosed is a composite pressure vessel, comprising: a liner assembly, further comprising: a liner; at least one of a polar boss and a blind boss; and a shell, further comprising: at least one layer of a filament wrap continuously disposed around at least a substantial portion of the liner assembly, wherein the liner assembly and the filament wrap combined have a non-homogenous support profile; and at least one fiber segment locally disposed on an area of the liner assembly and the at least one layer of a filament wrap that is more susceptible to rupture than other areas of the liner assembly, according to the non-homogenous support profile.
The liner may be at least one of a plastic liner and a metal liner configured as a gas barrier. The polar boss may be a metal fitting directly attached to the liner and is configured to provide a connection to a valve system. The composite pressure vessel may be configured for storage of gas or liquid and further configured for any on-board or stationary application.
DRAWINGS
The above-mentioned features and objects of the present disclosure will become more apparent with reference to the following description taken in conjunction with the accompanying drawings wherein like reference numerals denote like elements and in which:
FIG. 1 shows a cross-sectional view of an implementation of a pressure vessel with composite wrapped around the liner assembly;
FIG. 2 shows a cross-sectional view of an implementation of a pressure vessel with liner assembly with polar boss on one dome and blind boss on another dome;
FIG. 3 shows a cross-sectional view of an implementation of a pressure vessel with Tank inside which the liner assembly has polar boss on both domes;
FIG. 4 shows a cross-sectional view of an implementation of a dome region of a pressure vessel having a blind boss;
FIG. 5 shows a cross-sectional view of an implementation of a dome region of a pressure vessel having a polar boss;
FIG. 6 shows a view of an implementation of a cylinder and dome region of a pressure vessel with AFP placed fiber segments only in the dome region;
FIG. 7 shows a view of an implementation of a cylinder and dome region of a pressure vessel with AFP placed fiber segments in both the dome region and cylinder region;
FIG. 8 shows a view of an implementation of a cylinder and dome region of a pressure vessel with AFP placed fiber segments only in the cylinder region;
FIG. 9 shows a view of an implementation of a cylinder and dome region of a pressure vessel with AFP placed fiber segments having the same or different angles relative to the principal axis;
FIG. 10 shows a view of an implementation of a cylinder and dome region of a pressure vessel with AFP placed fiber segments wound in hoop direction in the cylinder region, the dome region, or both; and
FIG. 11 shows a representation of conditions at a dome region of an implementation of a pressure vessel.
DETAILED DESCRIPTION
One of the primary issues associated with implementation of gaseous fueled vehicles and the like is in manufacturing components at cost and weight that can be borne by the consumer and industry. A significant portion of the cost of the vessel is taken by raw material cost.
High-pressure storage vessels may be made by wrapping fiber composites around a liner assembly 20 , which is used as a mandrel. To support high pressure (3,000 to 10,000 or greater PSI service pressure) within the storage vessel, and to maintain safety of operation, greater amounts of material must be used to provide greater support. An increase in the amount of material used results in the penalty of increased weight and material cost.
According to at least some aspects of some implementations, pressure vessel 10 comprises liner assembly 20 configured to enclose a gas or liquid and a shell 40 to provide support to liner assembly 20 . Pressure vessel 10 may have one of a variety of shapes, including cylindrical, spherical, or combinations thereof. Pressure vessel 10 may be axially symmetric about a principal axis 52 extending along a longitudinal length of pressure vessel 10 . According to at least some aspects of some implementations, as shown in FIG. 1 , pressure vessel 10 may comprise cylindrical region 30 and two dome regions 32 . Other shapes are contemplated and considered within the current disclosure.
According to at least some aspects of some implementations, liner assembly 20 comprises liner 22 , and at least one of polar boss 24 and blind boss 26 . Liner 22 may be composed of plastic, metal, or other materials to contain a gas or liquid. According to at least some aspects of some implementations, liner 22 may be impermeable with respect to selected contents of pressure vessel 10 . According to at least some aspects of some implementations, the shape of liner assembly 20 may contribute to the shape of pressure vessel 10 .
At least one of polar boss 24 and blind boss 26 may be disposed near at least one end of liner assembly 20 . For example, as shown in FIG. 1 , polar boss 24 may be disposed at one end and blind boss 26 may be disposed at an opposite end. For example, as shown in FIG. 3 , one polar boss 24 may be disposed at each of two ends. As shown in FIG. 5 , polar boss 24 may provide selective access to the interior portion of liner assembly 20 for providing or discharging the contents of pressure vessel 10 . Polar boss 24 may be configured to provide a connection to a valve system. Polar boss 24 may be made of metal or other durable material. As shown in FIG. 4 , blind boss 26 may provide support to liner 22 . Polar boss 24 and blind boss 26 may allow liner assembly 20 to be supported and rotated about its principal axis 52 as a mandrel.
According to at least some aspects of some implementations, pressure vessel 10 comprises shell 40 . Shell 40 provides support to liner assembly 20 against deformation and rupture due to pressure from within liner assembly 20 . Shell 40 may comprise at least one of filament wrap 42 and fiber segment 44 . According to at least some aspects of some implementations, shell 40 may comprise alternating layers of filament wrap 42 and fiber segments 44 . Either one of filament wrap 42 and fiber segment 44 may provide an innermost layer or an outermost layer.
According to at least some aspects of some implementations, filament wrap 42 may form a continuous wrap around more than one full rotation of liner assembly 20 about its principal axis 52 or along more than one longitudinal length of liner assembly 20 . Filament wrap 42 may form a general layer around liner assembly 20 , such that a substantial portion of liner assembly 20 may be covered by filament wrap 42 .
According to at least some aspects of some implementations, at least one of liner assembly 20 , filament wrap 42 , and fiber segments 44 may have a non-homogenous support profile. A support profile may be defined as an evaluation at every point on the surface of a structure such as a liner assembly 20 (or a wound liner) of the protection against deformation and rupture due to pressure from within the structure. A non-homogenous support profile implies that certain points are more or less susceptible to deformation and rupture than other points on the surface of the structure. Such points are determinable using, at least in part, computational or experimental means discussed herein.
According to at least some aspects of some implementations, liner assembly 20 with at least one layer of filament wrap 42 may have a non-homogenous support profile. While filament wrap 42 may provide generally increased support against rupture, the support profile may nonetheless have absolute or relative deficiencies. According to at least some aspects of some implementations, because some regions on liner assembly 20 with at least one layer of filament wrap 42 have variable radius of curvature, and the stress condition changes as the radius of curvature changes, one layer of filament wrap 42 may not be able to reinforce all of the regions it covers.
According to at least some aspects of some implementations, at least one fiber segment 44 may be included in shell 40 . Fiber segments 44 may be present in shell 40 in non-continuous segments, such that the segments do not wrap around substantially more than one full rotation of liner assembly 20 about its principal axis 52 or along substantially more than one longitudinal length of liner assembly 20 . Fiber segments 44 may be present locally within shell 40 , such that each fiber segment 44 does not cover a substantial portion of liner assembly 20 . Rather, the locality of fiber segment 44 may correspond to an area in which support provided by filament wrap 42 alone is insufficient for a desired purpose or relatively insufficient compared to other areas, according to the general and continuous coverage of filament wrap 42 . Such absolute or relative deficiency is determinable by computational or experimental methods and may correspond to a non-homogenous support profile of liner assembly 20 alone or a non-homogenous support profile of liner assembly 20 with filament wrap 42 .
According to at least some aspects of some implementations, at least one of liner assembly 20 , filament wrap 42 , and fiber segments 44 may have a non-homogenous stress distribution profile. A stress distribution profile may be defined as an evaluation at every point on the surface of a structure such as a liner assembly 20 (or a wound liner) of a direction in which stress is distributed due to pressure from within the structure. The direction in which stress is distributed may be attributable to the geometry of the structure, and may be expressed as having a multiplicity of contributing components. A non-homogenous stress distribution profile implies that at least one point has a distinct direction in which stress is distributed. Such a profile is determinable based on computational or experimental means, as discussed herein.
According to at least some aspects of some implementations, a stress distribution may have multiple contributing components. A representation of certain conditions at dome region 32 of an implementation of pressure vessel 10 is shown in FIG. 11 . For example, at any given point on dome region 32 , a radius of curvature in a meridional direction is defined by R m . The meridional direction corresponds to an arc on the surface of principal axis 52 that intersects principal axis 52 at the tip of dome region 32 , intersects tangent line 50 at two points, and has bilateral symmetry across principal axis 52 . At any given point on dome region 32 , a radius of curvature in a parallel direction and disposed axially about principal axis 52 is defined by R p . The parallel direction corresponds to an arc on the surface of dome region 32 that is perpendicular to principal axis 52 at any given point and is disposed axially about principal axis 52 . Tangent line 50 is an example of an arc of a parallel direction (see FIGS. 6-10 ).
The stress balance, p, of a given point on the vessel inner surface may be expressed as:
N α R m + N β R P = p ,
where N α and N β represent the stress of that point in the meridional and parallel directions, respectively.
R m and R P can be derived and expressed as:
R m = - ( 1 + ( z ′ ) 2 ) 3 / 2 z ″ and R P = - r ( 1 + ( z ′ ) 2 ) 1 / 2 z ′
where r, z′, and z″ are determinable polar coordinates corresponding to the given point.
N α and N β can be derived and expressed as:
N α = - Q 1 + ( z ′ ) 2 rz ′ and N β = - 1 + ( z ′ ) 2 z ′ ( pr - Qz ″ z ′ ( 1 + ( z ′ ) 2 ) ) ,
where Q is axial stress. Mathematical expressions and derivations are further set forth in Appendix A, the entirety of which is incorporated by reference, as if set forth herein in its entirety.
On pressure vessel 10 , near the transition region between cylinder region 30 and dome region 32 , there is a sudden change of R m and R P ; also, along the surface of dome region 32 , R m and R P are constantly varying, therefore the stress condition in these regions is complicated. At each location, for example location A, certain amount and type of reinforcement needs to be placed locally at certain angles; another location, B, even if very close to location A, may require different amount and type of reinforcement placed at different angles to support.
According to at least some aspects of some implementations, WFW is a winding process (i.e. it introduces continuous reinforcement wound into the structure). Therefore if we introduce some material over location A on dome region 32 , in order to support the load there to address a non-homogenous support profile, the reinforcement must also cover other regions, such as cylinder region 30 , simply because of the continuous nature, even though some of these reinforcement materials are parasitic at other locations except location A.
According to at least some aspects of some implementations, at least one non-continuous fiber segment 44 may be locally disposed at or near dome region 32 of pressure vessel 10 . According to at least some aspects of some implementations and as shown in FIG. 6 , tangent line 50 defines the transition between cylinder region 30 and dome region 32 .
According to at least some aspects of some implementations, at least one non-continuous fiber segment 44 is locally disposed at or near dome region 32 of pressure vessel 10 . According to at least some aspects of some implementations, pairs of fiber segments 44 may be disposed with bilateral symmetry across principal axis 52 , as shown in FIGS. 6-9 . As shown in FIG. 6 , at least one pair of fiber segments 44 may be disposed entirely on dome region 32 . As shown in FIG. 7 , a pair of fiber segments 44 may be disposed so as to cross tangent line 50 . As shown in FIG. 8 , a pair of fiber segments 44 may be disposed entirely on cylinder region 30 . As shown in FIG. 9 , fiber segments 44 may form a substantially linear shape from which an angle φ relative to principal axis 52 may be determined. Complementary pairs of fiber segments 44 may be disposed with respective angles of ±φ relative to principal axis 52 . Pairs of fiber segments 44 may intersect or may provide bilateral symmetry across principal axis 52 without intersecting.
According to at least some aspects of some implementations, fiber segment 44 may be configured to address a non-homogenous stress distribution profile. Angles ±φ may be determined to address a non-homogenous stress distribution profile, where pressure, p, at a given point has a meridional stress component N α and a parallel stress component N β . For example, relatively smaller angles for ±φ (approaching φ=0°) may address a relatively larger meridional stress component N α . Relatively larger angles for for ±φ (approaching φ=90°) may address a relatively larger parallel stress component N β . Ideal values for ±φ depend on the geometry of dome region 32 , vary across the surface of dome region 32 , and are determinable.
According to at least some aspects of some implementations, hoops of fiber segments 44 may be disposed around pressure vessel 10 with axial symmetry around principal axis 52 , as shown in FIG. 10 . For example, a hoop may be placed primarily to address a parallel stress component N β .
According to at least some aspects of some implementations, filament wrap 42 , individual fiber segments 44 , pairs of fiber segments 44 having angles ±φ, hoops of fiber segments 44 , or combinations thereof are used to address both a non-homogenous support profile and a non-homogenous stress distribution profile.
Wet filament winding (WFW) processes, may be used to manufacturer gas or liquid storage high pressure vessels. Filament winding processes generally involve winding filaments around a mold or mandrel. Filament materials may include fiber tows impregnated with liquid resin just before it is integrated into the structure or a pre-preg fiber tow, i.e., a filament tow with pre-impregnated resins.
According to at least some aspects of some implementations, at least one filament winding process may be used to form shell 40 onto liner assembly 20 . According to at least some aspects of some implementations, WFW may be performed to contribute filament wrap 42 to shell 40 of pressure vessel 10 . In WFW, liner assembly 20 may act as a mandrel as it rotates about its principal axis 52 while a carriage moves parallel to the principal axis 52 and applies filament wrap 42 . The carriage may travel parallel to the principal axis 52 in one or more directions and subsequently travel in an opposite direction while applying a single continuous filament wrap 42 or multiple continuous filament wraps 42 . This process may be repeated as desired with one continuous filament wrap 42 . The resulting contribution is a filament wrap 42 in helical layers, polar layers, or hoop layers.
According to at least some aspects of some implementations, filament wrap 42 is applied in a desired pattern onto the outer surface of liner assembly 20 . For example, filament wrap 42 may be applied in helical layers, polar layers, or hoop layers around liner assembly 20 and along the length of liner assembly 20 . The pattern may be applied in a regular repeating manner to provide symmetrical distribution of support against high pressures. The pattern may also be varied so that successive layers are plied or oriented differently, to provide diverse and comprehensive coverage. The angle at which material is applied during WFW contributes to the properties of the final product. These properties may be determined from analytical and numerical stress analysis. From stress analysis, it may become clear where the material needs to be placed at given angles in order to reinforce a given region. WFW is well suited to automation.
According to at least some aspects of some implementations, the placement during WFW is general, in that a substantial portion of liner assembly 20 may be covered by WFW. According to at least some aspects of some implementations, the placement during WFW is continuous, in that a single phase of WFW may be used to wrap around more than one full rotation of liner assembly 20 about its principal axis 52 or along more than one longitudinal length of liner assembly 20 .
According to at least some aspects of some implementations, filament wrap 42 comprises a filament wound fiber, such as either inorganic or organic fiber. Examples include carbon, glass, basalt, boron, aramid, Kevlar, high-density polyethylene (HDPE), zylon, PP, PE, PET, PEN, PBT, and nylon. Other inorganic and organic fibers are contemplated by the present disclosure. According to at least some aspects of some implementations, filament wrap 42 further comprises a resin. The resin may be impregnated onto the filament wound fiber before or as the filament wound fiber is wound onto liner assembly 20 .
According to at least some aspects of some implementations, the resin of filament wrap 42 may have a low-viscosity or be in a liquid state as it is impregnated onto the filament wound fiber and applied to liner assembly 20 . The resin may be based on Di-Glycidyl Ether of Bisphenol-A (DGEBA), undiluted and non-toughened epoxy resin cured by a mixture of propyl oxide amine and cyclo-aliphatic amine. The low-viscosity may provide flexibility and ease during application. For example, a continuous and automated WFW process may be operated at a more efficient rate where the resin is in a liquid state. According to at least some aspects of some implementations, once the winding process is finished, the whole assembly is placed in an oven to solidify the resin. According to at least some aspects of some implementations, liner assembly 20 is pressurized as the resin is heated and solidified. For example, a pressure within liner assembly 20 may be relatively higher than the pressure outside liner assembly 20 , such that liner assembly 20 is expanded and filament wrap 42 is compressed, thereby removing air bubbles during the heating process.
According to at least some aspects of some implementations, the repetitive nature of some filament winding processes may result in parasitic fiber tows in places where they are not needed. For example, filament winding may result in a non-homogenous support profile, where some regions having higher support needs may require greater support. Where filament winding processes are continuous and automated, they do not selectively apply additional materials where greater support is needed. If the amount of material is increased generally to support such regions requiring greater support, then the amount of material overall is increased, including in regions not requiring such additional support. These parasitic materials increase the weight and cost significantly.
According to at least some aspects of some implementations, automated fiber placement (AFP) is used in combination with WFW, to locally introduce non-continuous fiber segments 44 to individual locations. Through computational, experimental, or other stress analysis, locations having absolute or relatively insufficient support via filament winding processes may be determined.
According to at least some aspects of some implementations, fiber segments 44 used in AFP may comprise a dry fiber impregnated with a high-viscosity resin in a gel state. The dry fiber may comprise one or more inorganic or organic materials. Examples include carbon, glass, basalt, boron, aramid, Kevlar, high-density polyethylene (HDPE), zylon, PP, PE, PET, PEN, PBT, and nylon. Other inorganic and organic fibers are contemplated by the present disclosure. The resin may be either thermoset or thermoplastic. The range of viscosities for the high-viscosity resin include any viscosity that is conducive to the placement of the fiber segments 44 . For example, the placement during AFP may be made more precise where the resin is in a gel state. According to at least some aspects of some implementations, fiber segment 44 further comprises a toughening agent.
According to at least some aspects of some implementations, fiber segments 44 are heated, applied with pressure, and consolidated on any surface by at least one roller medium. The process causes adhesion of fiber segments 44 to the surface with the resin of fiber segments 44 . According to at least some aspects of some implementations, fiber segments 44 are selectively provided at desired locations. Fiber segments 44 may be in the form of single or multiple narrow, slit tapes or tows to make up a given total prepreg band width. According to at least some aspects of some implementations, a fiber segment 44 forms a hoop disposed axially about principal axis 52 , wherein each portion of fiber segment 44 is substantially perpendicular to the principal axis 52 , as shown in FIG. 10 . According to at least some aspects of some implementations, pairs of fiber segments 44 are placed with respective angles of ±φ relative to principal axis 52 , as shown in FIGS. 6-9 . The pairs provide bilateral symmetry across principal axis 52 , resulting in balanced support.
According to at least some aspects of some implementations, pressure vessel 10 is configured to store a gas or a liquid. Pressure vessel 10 may be configured to store a fuel for a vehicle. Vehicles include, but are not limited to, any means of conveyance across marine, surface, terrestrial, or other medium. Pressure vessel 10 may be configure for stationary application or on-board vehicle application.
While the apparatus and method have been described in terms of what are presently considered to be the most practical and preferred implementations, it is to be understood that the disclosure need not be limited to the disclosed implementations. It is intended to cover various modifications and similar arrangements included within the spirit and scope of the claims, the scope of which should be accorded the broadest interpretation so as to encompass all such modifications and similar structures. The present disclosure includes any and all implementations of the following claims.
|
Disclosed herein is a composite pressure vessel with a liner having a polar boss and a blind boss a shell is formed around the liner via one or more filament wrappings continuously disposed around at least a substantial portion of the liner assembly combined the liner and filament wrapping have a support profile. To reduce susceptible to rupture a locally disposed filament fiber is added.
| 5
|
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent application Ser. No. 13/923,451, filed on Jun. 21, 2013, which is a continuation of U.S. patent application Ser. No. 12/286,317, filed on Sep. 30, 2008, which issued as U.S. Pat. No. 8,477,247 on Jul. 2, 2013.
BACKGROUND
[0002] This relates generally to processing video in a video processing pipeline.
[0003] A video processing pipeline is used to process video streams or still images from a video source, such as a television tuner, a set top box, or a media player such as an optical disk drive. A video processing pipeline may be used to improve received audio and video. The video processing pipeline may also enhance color and contrast of the received video.
BRIEF DESCRIPTION OF THE DRAWINGS
[0004] FIG. 1 is a depiction of a video processing pipeline in accordance with one embodiment;
[0005] FIG. 2 is a schematic depiction of a color and contrast enhancement unit in accordance with one embodiment;
[0006] FIG. 3 is a cumulative distribution function graph for the image shown in FIG. 7 ;
[0007] FIG. 4 is an intensity lookup table for the image shown in FIG. 7 ;
[0008] FIG. 5 is a cumulative distribution function graph for the image shown in FIG. 8 ;
[0009] FIG. 6 is an intensity lookup table for the image shown in FIG. 8 ;
[0010] FIG. 7 is a test image used in connection with FIGS. 3 and 4 ;
[0011] FIG. 8 is a test image used in connection with FIGS. 5 and 6 ;
[0012] FIG. 9 is a flow chart for saturation enhancement according to one embodiment; and
[0013] FIG. 10 is a graph of a saturation lookup table with a saturation boost of −0.15, according to one embodiment.
DETAILED DESCRIPTION
[0014] Referring to FIG. 1 , a video processing pipeline 100 may be used in a variety of applications, including a personal computer, a set top box, a television receiver, or a media player. The video source 102 may, for example, be a tuner, a DVD disk player, or a set top box, to mention a few examples. FIG. 1 shows typical components of a video pipeline, not necessarily proper sequencing, which depends on content, requirements, and the specific algorithms that are used.
[0015] The video source 102 provides interlaced video, in one embodiment, to a noise reduction and filtering unit 104 . The block 104 performs noise reduction filtering on the digital signal provided from the video source 102 . The de-interlacing module 106 converts interlaced video to progressive scan video in one embodiment.
[0016] The color and contrast enhancement 108 is responsible for enhancing both the color and the contrast. In some embodiments, the color and contrast enhancements may be done in “one shot,” meaning that it is not necessary to adjust a first one of color or contrast and then to adjust the second one of color or contrast and then to go back and adjust the first one again to account for the changes in the second one. The position of color/contrast enhancement varies, and is known to interact with sharpness enhancement (perception of sharpness is affected by contrast).
[0017] A sharpness enhancement unit 110 may implement picture sharpness enhancement. A scaling unit 112 may resize the image for display on the display 114 .
[0018] Referring to FIG. 2 , the color and contrast enhancement unit 108 may enhance the color and contrast of received video in one shot. In one embodiment, the unit 108 may first convert to a suitable color space, as indicated in block 12 . For video streams, the input color space is usually YCbCr, and for stills, RGB color space is common.
[0019] The color space to implement the color enhancement algorithm may be uniform in terms of perceived hue so that enhanced colors do not change in hues. In some embodiments, lightness prediction of chromatic colors does not have substantial hue or lightness modulation dependency. The color space may have invertible functional mapping between XYZ (or some other fundamental color description) and the color space dimensions. Also, the color space may be an opponent (has a neutral axis along one dimension) three-dimensional space.
[0020] Transformation to and from a linear color space may not be computationally expensive in some cases. One color space that is suitable is the IPT color space. “I” in IPT is loosely related to intensity, “P” is the red-green dimension, and the yellow-blue dimension is indicated by the letter “T.” The IPT color space linearly models constant perceived hue.
[0021] The input image is unlikely to be in the IPT color space. Therefore, color space conversion may be necessary. Standard RGB (or sRGB) is converted to CIEXYZ for the 1931 2° standard observer with an illuminant of D65. Equation 1 shows the conversion from XYZ to IPT (sRGB is gamma corrected RGB; thus gamma correction is built-into this algorithm).
[0000]
[
X
Y
Z
]
=
[
0.4124
0.3576
0.1805
0.2126
0.7152
0.0722
0.0193
0.1192
0.9505
]
[
R
G
B
]
[
L
M
S
]
=
[
0.4002
0.7075
-
0.0807
-
0.2280
1.1500
0.0612
0
0
0.9184
]
[
X
D
65
Y
D
65
Z
D
65
]
L
′
=
L
0.43
;
L
≥
0
L
′
=
-
(
-
L
)
0.43
;
L
<
0
M
′
=
M
0.43
;
M
≥
0
M
′
=
-
(
-
M
)
0.43
;
M
<
0
S
′
=
S
0.43
;
S
≥
0
S
′
=
-
(
-
S
)
0.43
;
S
<
0
[
I
P
T
]
=
[
0.400
0.4000
0.2000
4.4550
-
4.8510
0.3960
0.8056
0.3572
-
1.1628
]
[
L
′
M
′
S
′
]
(
1
)
[0000] If the input image is in YCbCr space, an additional step to convert to RGB may be used.
[0022] The color data in the IPT space, in accordance with one embodiment, may then be subjected to parallel local contrast enhancement, as indicated in block 16 , global lightness adjustment or contrast enhancement, as indicated in block 14 , and chroma or saturation enhancement, as indicated in block 18 . The results of the parallel, one shot enhancements and adjustments may then be combined in 20 ; the enhanced value for I comes from the ΔI from local contrast enhancement, the new I after lightness correction, and the P and T components come from the chroma enhancement block. The resulting IPT output may then be converted back to its original color space, as indicated in block 22 .
[0023] A color and contrast enhancement unit 108 may be both automatic and independent of image content or color in some embodiments. The unit 108 may also integrate color and contrast enhancement functionalities. The unit 108 may improve the overall saturation while maintaining the original hue in some embodiments. Advantageously, the unit 108 leaves the achromatic colors unaltered. The unit 108 advantageously does not increase the saturation of colors that are already saturated enough, and, thus, reduces perceived loss in sharpness and undesirable color enhancement. Also, the unit 108 may not produce out-of-gamut colors or color artifacts (e.g. blotchiness) in some embodiments. Finally, the unit 108 may be fast enough for the video processing chain operating at a regular frame rate in some embodiments.
[0024] The unit 108 may be implemented in software, hardware, or firmware. A software implementation may include computer executable instructions stored on a computer readable medium. A computer readable medium may be a semiconductor, magnetic, or optical storage.
[0025] In a typical image enhancement operation, increasing the saturation may lead to out-of-gamut or impermissible colors. As the saturation of a color increases, the lightness automatically goes down. Conversely, reducing the lightness gives a perception of increased saturation. Thus, in a typical image with normal exposure, the overall lightness may be reduced before increasing the saturation.
[0026] However, if an image is mostly dark to begin with, either due to under-saturation or due to high dynamic range of the image (which means a part of the image is quite bright at the same time), the lightness may be increased before any perceived color enhancement can be attained. In this case, saturation enhancement may be higher than the normal to counteract the effect of a perceived loss of saturation due to an increase in the lightness. Thus, a determination is made as to whether an image needs to be darkened or lightened, and to what extent. This may be achieved by the global lightness adjustment 14 .
[0027] The global lightness adjustment 14 may be done using a lookup table (LUT). The pixel intensity curve is a straight line with unity slope below a lower threshold (for example, 0.1) and above upper threshold (for example, 0.9). Thus pixel intensities less than the lower threshold and more than the upper threshold are not altered in one embodiment. These thresholds are parameterized, and can be used as user controls.
[0028] Between these thresholds, the intensities are adjusted nonlinearly, for example, according to equation 2:
[0000]
I
OUT-GC
=I
i
, I
i
≦I
LowTH
[0000] I OUT-GC =I i −β sin(π* I i ), I LowTH ≦I i ≦I HighTH
[0000] I OUT-GC =I i , I i ≧I HighTH (2)
[0000] where I i and I OUT-GC are the input and output intensities, and the beta parameter (β) determines the amount of adjustment and depends on the overall image characteristics as described below. A positive beta value darkens the image and a negative beta value lightens the image. The sine function is used to provide a unimodal, symmetric enhancement curve. Other similar mathematical functions can be used, and even sigmoid curves can be applied to implement functions equivalent to histogram equalization which could be built into the block. However, one objective of the lightness adjustment block is to provide the option to increase lightness in a way that synergistically makes saturation enhancement more effective (e.g. lightening a color gives more room for increased saturation, darkening a color improves colorfulness without much saturation enhancement).
[0029] The image intensity corresponding to a cumulative distribution function (CDF) of 0.5 is used to determine whether the image should be darkened or lightened in one embodiment. The 0.5 point of a CDF indicates the lightness below which 50% of the pixels are found. A cumulative distribution function plots the same intensity information normally depicted by histograms. However, the difference between a cumulative distribution function and a histogram is that the intensity values are summed from left to right in the cumulative distribution function. Typically, the cumulative distribution function displays relative frequency in terms of percentiles on the vertical axis and intensity or other units on the horizontal axis.
[0030] If the image intensity for the 0.5 CDF value lies below a pre-defined low CDF threshold (0.1, for example, meaning that 50% of the pixels are at or below 0.1% of the max lightness/intensity), the image may be lightened to the maximum level (β=−0.15, for example). If this intensity lies above a pre-defined high CDF threshold (0.9, for example), the image may be darkened to the maximum level (β=0.15, for example). When the intensity lies in between, β may be computed by linear interpolation. Once β has been calculated, β is used in the calculation of global lightness adjustment formula (2). β is also used in the chroma enhancement block 18 .
[0031] The calculation of β involves computing empirical CDF, finding intensity I at CDF values of 0.2, 0.5, and 0.8 (L20, L50, L80), and applying the following computation method. If 50% of pixel intensity values (L50) lies below a low threshold (paramLowThresCDF50), then the image is lightened to the maximum and beta is set equal to paramBetaMax. Otherwise, if 50% of pixel intensities are greater than a high threshold (paramHighThresCDF50), then the image is darkened to the maximum and beta is set equal paramBetaMax. If % beta lies in between −betaMax and betaMax then beta is computed as a linear interpolation between −betaMax and betaMax {((2*abs(paramBetaMax)*(L50−paramLowThresCDF50))/(paramHighThresCDF50−paramLowThresCDF50))}−paramBetaMax.
[0032] Two additional conditions may be checked to ensure darkening or lightening does not cause some part of the image to be clipped. The first additional condition makes sure that no lightness correction is applied when beta is less than 0 and L80 is greater than or equal paramThresCDF80; i.e. if β<0 &&(L80>=paramLowThresCDF80) then β=0. The second condition makes sure that no lightness corrections is applied when beta is greater than 0 and L20 is less or equal than paramThresCDF20; i.e. if β>0 && (L20<=paramThresCDF20) then β=0.
[0033] Typically, paramLowThresCDF50 is 0.1 with a typical range 0.1 to 0.3, paramBetaMax is 0.15 with a typical range 0.1 to 0.3, and paramHighThresCDF50 is 0.9 with a typical range 0.6 to 0.9. If top 20% pixel intensity in the CDF lies above paramThresCDF80 (which is 0.8), then the image should not be lightened. If beta is greater than 0 and L20 is less than or equal paramThresCDF20 (which is 0.2), i.e. if bottom 20% pixel intensity in the CDF lies below paramThresCDF20, then the image should not be darkened.
[0034] In FIG. 3 , the CDF of an image that needs the maximum amount of lightening is depicted. For this image, the intensity corresponding to a CDF of 0.5 is only 0.107, which means 50% of the image pixels have intensities below 0.107. A plot for the intensity lookup table for β=−0.15 for that image is shown in FIG. 4 .
[0035] In a properly exposed image, shown in FIG. 5 , the intensity corresponding to a CDF of 0.5 is 0.56. By linear interpolation, the value of β was found to be 0.02. This leads to slight darkening of the image, as apparent from the intensity lookup table in FIG. 6 .
[0036] The local contrast enhancement 16 is based on amplification of the difference between each pixel intensity and the local mean calculated on a properly selected region of support (e.g. 5×5 for standard definition images, the size and mean calculation can be made adaptive to size and resolution).
[0037] A 5×5 low-pass averaging filter may be used to get a filtered version of the original intensity image. An exponent is applied to the difference of the original and the filtered intensity data while preserving the sign (sgn) of the difference. The operation is depicted by equation 3, where I i is the input intensity and the parameter φ determines the amount of local enhancement:
[0000]
I
OUT
-
LC
=
sgn
(
I
i
-
I
F
)
*
I
i
-
I
F
(
1
+
φ
100
)
(
3
)
[0000] where I OUT-LC is the output intensity and I F is the low-pass filtered value. The operation preserves the sign of the difference, and φ is the local gain adjustable to ˜15% maximum. Local gain φ can be also a function of the specific lightness or each pixel. One embodiment may use a fixed value and a clipping protection mechanism to avoid generating improper values of I, as was done for lightness adjustment, so values near the end of the range are not modified.
[0038] Finally, the output intensity resulting from global lightness adjustment and local contrast enhancement is obtained from summing the two effects in combiner 20 ( FIG. 2 ), as shown in equation 4:
[0000] I OUT =I OUT-GC +I OUT-LC (4)
[0000] where I OUT-LC is a ΔI value added to the output of I OUT-GC (output of the global lightness adjustment).
[0039] Saturation enhancement 18 may be achieved by multiplying P and T by a saturation enhancement factor (for example, between 1.0 and 1.4). The saturation factor is applied to a range (for example, between 0.1 and 0.9) with a smooth rolloff at the ends so it will not produce banding artifacts (sudden saturation jumps).
[0040] If the chroma (saturation) of a pixel is below the minimum (min) threshold (achromatic) or above the maximum (max) threshold (already saturated), the saturation is left untouched. Otherwise, the saturation values are increased nonlinearly (using a lookup LUT similar to that of lightness adjustment). The saturation increase has a peak value of 20% (a maximum of up to 40% can be used for highly lightened images), with smooth roll-off at 0.1 and 0.9 saturation (so they stay unmodified and no illegal values will be generated)—implemented using a LUT as explained below. The maximum peak saturation of 40% is applied if the lightness gain beta is greater or equal to 0.75 of the max beta value paramBetaMax used in the global lightness adjustment (which is 0.15, as explained before). In IPT space, chroma is square root of P 2 +T 2 .
[0041] The output of the block 34 is the image which is saturation enhanced depending on the value of beta.
[0042] Depending on the value of beta, saturation uses a maximum boost, or moderate boost value: if ((m_Beta<0)&&(abs(m_Beta)>=0.75*m_BetaMax)) then compute LUT with maximum boost. Otherwise, compute LUT with normal boost. The saturation LUT implements a function of the form Boost*sin(π*I i ). A 100 point LUT may be used, in some embodiments, for which the bottom and top portions are linear, and set using two threshold values (e.g. 0.1 and 0.9). The curve for a boost of −0.15 is shown in FIG. 10 .
[0043] In FIG. 9 , P and T planes of the IPT are received, as indicated in block 24 . The chroma value is calculated as √{square root over (P 2 +T 2 )} (block 26 ), and the enhanced value is taken from the LUT. If the chroma is greater than an upper threshold or lower than a lower threshold (diamond 28 ), then the chroma is unchanged (block 30 ). Otherwise, the enhancement factor is the original chroma and the LUT value. Then, the new P and T values are computed using the enhancement factor to save an inverse computation of P and T from the enhanced chroma value, as indicated in block 32 .
[0044] Similar to the global lightness adjustment, saturation enhancement may be achieved through a lookup table. The use of a lookup table avoids hard thresholds and the problems of artifacts associated with them. If the chroma of a pixel is below the low threshold (for example, 0.1), the color is likely to be achromatic and is left unaltered. Also, if the chroma of a pixel is above the high threshold (for example, 0.9), the color is already quite saturated and so is left unchanged. Colors in between these thresholds are increased in a nonlinear fashion, leading to a lookup table very similar to that shown in FIGS. 4 and 6 .
[0045] If an image is significantly lightened, the perceived saturation reduces. Actual saturation enhancement in this case needs to be higher to counteract this effect. In one embodiment, an increase in the saturation was 20%, for significantly lightened images the increase was 40%. If the parameter β in equation 2 is negative, with the absolute value equal to or more than 75% of the maximum permissible β (e.g. 0.15), the image is assumed to be significantly lightened, and thus higher saturation enhancement factor may be used.
[0046] In some embodiments, an integrated approach for color and contrast enhancement can be achieved, in parallel, and in one shot.
[0047] The video processing techniques described herein may be implemented in various hardware architectures. For example, video processing functionality may be integrated within a chipset. Alternatively, a discrete video processor may be used. As still another embodiment, the video processing functions may be implemented by a general purpose processor, including a multicore processor.
[0048] References throughout this specification to “one embodiment” or “an embodiment” mean that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one implementation encompassed within the present invention. Thus, appearances of the phrase “one embodiment” or “in an embodiment” are not necessarily referring to the same embodiment. Furthermore, the particular features, structures, or characteristics may be instituted in other suitable forms other than the particular embodiment illustrated and all such forms may be encompassed within the claims of the present application.
[0049] While the present invention has been described with respect to a limited number of embodiments, those skilled in the art will appreciate numerous modifications and variations therefrom. It is intended that the appended claims cover all such modifications and variations as fall within the true spirit and scope of this present invention.
|
In some embodiments, color and contrast enhancement video processing may be done in one shot instead of adjusting one of color and contrast enhancement, then the other, and then going back to the first one to readjust because of the second adjustment. In some embodiments, global lightness adjustment, local contrast enhancement, and saturation enhancement may be done at the same time and in parallel. Lightness adjustment improves visibility of details for generally dark or generally light images without changing intended lighting conditions in the original shot, and is used to enhance the range of color/saturation enhancement. Local contrast enhancement done in parallel improves visual definition of objects and textures and thus local contrast and perceived sharpness.
| 6
|
BACKGROUND OF THE INVENTION
The present invention relates to a gear pump which is adapted to convey a heated polymeric material without significant leakage. More particularly, the present invention relates to a gear pump of the type which is adapted to be positioned downstream of a plastic extruder so as to serve as a booster or metering pump. Such pumps typically comprise a pair of intermeshing gears, with the gears being rotatably supported by shafts which are mounted in journal bearings, and with one of the shafts extending through the housing and serving as the drive shaft for transmitting torque to the gears.
In the plastic industry, particularly in the man made fiber industry, pumps of the described type are employed as metering pumps which are positioned downstream of an extruder which heats and melts the high polymer plastic and supplies the resulting melt under pressures of up to about 100 bar and higher to the pump. The pump in turn increases the pressure of the high polymer melt to the required spinning or extrusion pressure, which is typically several hundred bars, and then delivers the melt to the spinning or extruding nozzle. When manufactured with adequate precision, the pumps operate reliably and provide a highly accurate flow rate.
It is recognized that a minimum play is unavoidable between the moving parts of gear pumps, and on the high pressure side of the pump, the melt is caused to be forced into the narrow gaps between the sides of the gears and the opposing side wall surfaces of the housing, starting from about the area in which the teeth initially engage. As a result, the melt tends to flow into the bearings, and to flow outwardly through the bearing of the drive shaft. This plastic may pass through the shaft seal and lead to undesirable contamination and deposits, which result in breakdowns.
In the case of gear pumps which serve to deliver lubricating fluids, it has previously been suggested that a secondary flow be established in addition to the main flow for the purpose of maintaining an adequate lubrication of the gear bearings. The secondary flow is guided through the individual bearings, and a steady flow rate of the lubricant is therefore maintained. It has also been proposed to use the change from high pressure to lower pressure which occurs in the fluid cells formed by the intermeshing teeth, so as to produce such a lubricant flow, note for example U.S. Pat. Nos. 3,447,472 and 3,490,382, and EPO Pat. No. 062,405.
EPO Pat. No. 062,405 relates to an improvement of the bearing lubrication of a gear pump. On each pump side, the roller bearings are separated from the supported gears by wearing plates. The journal bores provided in the wearing plates are kept sufficiently large so as to enable a flow of the lubricant through the existing play between the journal shafts and the walls of the journal bores. On its side facing the gears, each wearing plate has a radial recess, which is positioned in the area of the engagement of the teeth on the pump intake side. These recesses are respectively associated with only one gear and are directed to the axis of the same, so that the one recess of the driven gear is associated with the other recess of the follower gear. Both recesses extend respectively from the journal bore for the shaft in the wearing plate and lead up to the area between the root circle and the addendum circle of the respectively associated gear. Another recess is provided on each side of the gears opposite to the first mentioned recesses, but on the outside of the wearing plates, and these further recesses lead from the pump intake up to the associated journal bore for the shaft.
The increasing, enclosed volume of the fluid cells results in that the thereby developed underpressure sucks, via the two recesses located directly adjacent the gear, the lubricant out of the gear bearing and delivers it to the pump intake. A cross connection to the neighboring bearing located on the same side of the pump results in that the underpressure in the first bearing is also operative in the second bearing and generates a suction there as well. This suction is filled on both sides from the pump intake via the recesses respectively located on the same pump side as the first recesses, but provided on the back side of the wearing plate. The described operation is identical on both pump sides.
The measures described in the above prior art reference are not suitable for eliminating the initially described problems in the processing of plastic melts or the like. More particularly, the described generation of secondary flows serving the lubrication would not provide the required accuracy in the case of metering pumps used in the processing of spinning melts and in which the flow of the melt delivered by the pump must be accurately maintained within very narrow limits. Further, the guarantee of an adequate lubrication of bearings is not a problem with which the present invention is concerned.
It is accordingly an object of the present invention to provide a gear pump of the type which is adapted to precisely meter the required flow of a heated plastic melt, and which avoids leakage of the melt from the pump.
It is also an object of the present invention to provide a gear pump of the described type which effectively avoids the deposit of the melt in the bearings, and in particular the bearing of the drive shaft, and which provides a means for removing any such melt which may enter into the shaft bearing.
SUMMARY OF THE PRESENT INVENTION
These and other objects and advantages of the present invention are achieved in the embodiment illustrated herein by the provision of a gear pump which comprises a housing having parallel side walls which define an interior chamber therebetween, and an inlet port and an outlet port. A pair of cooperating gears are rotatably mounted within the interior chamber of the housing, and the gears have intermeshing teeth which define fluid cells therebetween which contract and expand during rotation of the gears, and such that a melted polymeric material or the like may be conveyed from the inlet port at a relatively low pressure (which is above atmospheric pressure) to the discharge port at a relatively high pressure. A journal bore extends through one of the side walls of the housing, and a drive shaft extends through such one side wall and is rotatably received in the journal bore, and the shaft is operatively connected to one of the gears for transmission of rotational torque thereto. In accordance with the present invention, the gear pump further includes an inlet opening communicating with the journal bore, and duct means establishing intermittent communication between the inlet opening and the expanding fluid cells during rotation of the gears. By this arrangement, the expanding fluid cells create a suction which withdraws any plastic material from the journal bore and conveys the same into the expanding fluid cells and thus back into the interior of the housing.
The duct means includes a fluid duct which extends between the inlet opening in the journal bore and to an outlet opening which communicates with the side wall surface of one of the side walls of the housing at a location adjacent but spaced from the intermeshing teeth, and such that the outlet opening is normally closed by the adjacent side of one of the gears. Also, the outlet opening is located on the intake side of the pump and within the root circle on one of the gears. Further, the duct means includes at least one channel extending radially inwardly from the root of the adjacent gear, with the channel communicating with the side of such gear which is adjacent the outlet opening. Thus the channel intermittently overlies and communicates with the outlet opening of the duct means during rotation of the gears, and by this arrangement, intermittent communication is established between the inlet opening and at least one of the expanding fluid cells. While it is preferred that the outlet opening of the duct means be positioned on the intake side of the pump and within the root circle of the follower gear, it may also be located on the intake side of the pump and within the root circle of the driven gear.
Advantageously, the channel connecting the root with the outlet opening may be a groove extending from the associated root of the gear teeth radially inwardly toward the axis of the gear, with the groove being formed in the side of the gear facing the outlet opening. Also, the outlet opening is displaced from a plane extending through the two axes of the gears, and toward the axis of the gear provided with the channel, and it is preferably located at a point where the fluid cell to which it is connected has started to increase in volume, but is still securely closed. The angle by which the outlet opening is displaced from the above defined plane and toward the intake side should be smaller than about one-half the angle covering one tooth pitch, and at least about two degrees. Several flow channels may be evenly distributed over the periphery of the gear, so that each of several fluid cells is intermittently connected to the outlet opening of the duct means. In addition, the channels may each take the form of an enlargement at the associated root, and a relatively narrow groove extending radially inwardly from the enlargement.
In order to avoid having the side of the gear which is located opposite the drive shaft be axially biased from the opposite journal bearing by reason of the removal of the melt from the drive shaft bearing, and by the pressure which is operative on the opposite side, a second by-pass duct means may be advantageously provided which extends from the journal bore of the opposite shaft. The outlet opening of such second duct means is similarly located in the area of tooth engagement on the intake side of the pump, and within the root circle of one of the gears, and so that at least one fluid cell of the respective gear is intermittently connected with the second by-pass duct via a flow channel which communicates with the outlet opening during rotation of the gears. The arrangement of this second outlet opening within the root circle of the gear provides, according to the present invention, that a direct connection between the journal bearing to be relieved, and the pump, is avoided. Advantageously, the edge of the individual outlet opening, which is adjacent the pitch circle, is displaced from the root circle inwardly sufficiently far so that an effective seal against all root spaces which are not provided with a radial channel is insured.
From the above, it will be apparent that the present invention effectively insures that the leakage of the melt through the seal of the shaft bearing will be prevented. Thus, as a result of the effective separation of the flow of the fluid which is delivered by the pump, and the removal by suction of portions of the melt which enter the bearings, the normal operation of the pump is not jeopardized.
BRIEF DESCRIPTION OF THE DRAWINGS
Some of the objects and advantages of the present invention having been stated, others will appear as the description proceeds, when taken in conjunction with the accompanying drawings, in which
FIG. 1 is a sectional side elevation view of a gear pump which embodies the features of the present invention;
FIG. 2 is a front sectional view of the pump shown in FIG. 1, and taken substantially along the line 2--2 of FIG. 1; and
FIG. 3 is a fragmentary and enlarged view of the intermeshing teeth of the gear pump.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring more particularly to the drawings, a gear pump is illustrated which comprises a housing 1 having parallel side walls 21, 21A, which define an interior chamber therebetween. The side walls 21, 21A include wearing plates 22, 22A and 23, 23A which are positioned within the interior chamber, and the wearing plates 22, 23 define one interior side wall surface 41, and the plates 22A, 23A define an opposing interior side wall surface 42. Also, the housing 1 includes an inlet port 4, and an outlet port 5, note FIG. 1.
A pair of cooperating gears 2, 3 are rotatably mounted within the interior chamber of the housing, with the gear 2 being driven in the manner described below, and the gear 3 being a follower. Also, the gear 2 includes opposite parallel sides 32, 35 which are positioned closely adjacent the surfaces 41, 42 respectively, and the gear 3 includes opposite sides 31, 33 which are also positioned closely adjacent the surfaces 41, 42 respectively.
The gear 2 is rotatably supported by a drive shaft 27 on the side 32 thereof, and a coaxial supporting shaft 28 on the opposite side. Similarly, the gear 3 is supported by the shafts 43, 44. The shafts 27, 28 define a rotational axis 36 and are rotatably supported in corresponding journal bores 29, 30, which extend through the wearing plates 22, 22A. The shafts 43, 44 of the gear 3 define a rotational axis 37 and are rotatably supported in the journal bores 39, 40 which extend through the plates 23, 23A. The gear 2 is driven via the shaft 27, which extends outwardly through the side wall 21 of the housing, and the opening in the side wall 21 through which the shaft 27 extends is provided with a seal 25 which surrounds the shaft 27.
The arrows 6 in FIG. 1 illustrate the direction of rotation of the gears 2, 3. Accordingly, the flow of the melt enters through the inlet port 4, passes around the exterior of the gears, and exits through the outlet port 5. When serving as a booster or metering pump, the pump is positioned with its intake port 4 positioned downstream of a melt extruder, which delivers a flow of the melt such as a high polymer spinning melt, and which exits from the exterior at pressures above atmospheric pressure and up to about 100 bar or somewhat higher if necessary. The pump serves to accurately meter the melt to be delivered, and furthermore, it increases the pressure to the spinning or extrusion pressure, which may amount to several hundred bar. This high inside pressure causes the melt to enter into the very narrow spaces between the sides 31, 32, and 33, 35 of the two gears and the wearing plates 22, 22A, 23, 23A, and to flow outwardly along the journal bore 29 of the shaft 27.
In order to avoid having the spinning melt pass through the bore 29 of the shaft 27, there is provided a by-pass duct 6 which includes an inlet opening 45 which communicates with the journal bore, and an outlet opening 8 which communicates with the inner side wall surface 41. The inlet opening 45 is positioned between the seal 25 and the side 32 of the gear 2, and more particularly, it is positioned between the seal 25 and the wearing plate 22 in the illustrated embodiment. The outlet opening 8 is adjacent but radially spaced from the intermeshing teeth, and it is also located at a distance from the axis 37 of the gear 3 which is less than the root circle 16 of this gear. Also, the outlet opening 8 is displaced toward the suction or inlet port 4 of the pump. As can be seen in the drawings, the distance between the gear axis 37 and the outlet opening 8 is dimensioned so that its border adjacent the pitch circle 15 is at a distance 26 from the root circle 16 or the bottom of the roots of the gear 3. This distance 26 is preferably dimensioned so that it provides for an effective seal for the fluid cells 20 which are formed adjacent the root circle 16 by the intermeshing teeth.
To cooperate with the by-pass duct 6, the gear 3 is provided, in the illustrated embodiment, with several flow channels 9, which are evenly distributed over the periphery of the gear and extend radially inwardly from the respective roots at 16. The channels 9 are formed into the side 31 of the gear 3, and extend radially inwardly so as to substantially fully cover the outlet opening 8 of the by-pass duct 6. As an alternative to the radial channels 9, bores may be provided which also extend from the roots at 16 obliquely toward the side 31 of the gear.
It will be understood that portions of the delivered melt also tend to enter into the bearing bore 30 of the shaft 28, and which has a closed inner end at 24. Thus the inside pressure of the pump is also operative at the end 24 of the bore 30. If the side 32 of the gear 2 is relieved via the by-pass duct 6 and the flow channel 9, it will be unavoidable that the gear 2 will be subjected to an axial force which is exerted from the side of the bearing end 24. For this reason, a second by-pass duct 7 may be provided, which extends from the closed inner end 24 of the journal bore 30, and terminates at an outlet opening 38 in the side wall surface 42 of the plate 23A. Similarly, as with the side 31 and outlet duct 8, flow channels 9A are provided in the side 33 of the gear 3, and which extend radially inwardly from the roots at 16 and toward the axis 37, and so that the channels 9A are intermittently connected with the outlet opening 38. In this manner, the axial force exerted on the driven gear 2 at the bore end 24 is relieved.
In the embodiment illustrated in the drawings, the by-pass ducts 6 and 7 lead to the sides 31, 33 of the follower gear 3. Alternatively, it is possible to have the by-pass ducts 6 and 7 terminate within the root circle 16 of the driven gear 2, and in the side wall surfaces adjacent the same. In so doing, the flow channels 9 would proceed from the fluid cells 20A which are formed adjacent the root circle 16A of the gear 2. Similarly, when the need arises, it is possible to intermittently connect the ends of the journal bores 39, 40 of the follower gear 3 with the channels 9 and 9A, in a manner similar to the journal bore end 24, and via corresponding by-pass ducts. This arrangement is indicated in FIG. 2 by dashed lines, with the journal bore 39 being connected with the duct 6 and thus the outlet opening 8, and the journal bore 40 being connected with the duct 7 and thus the outlet opening 38.
The present invention makes use of the sharp pressure drop in the respective fluid cells 20, as they move from the pressure side 5 to the suction side 4, in the area of the intermeshing teeth. This pressure drop results from the fact that the fluid cells defined by the teeth first decrease in size and then increase. The pressure drop starts as the volume begins to increase, and this pressure drop is used for the purpose of relieving the journal bore 29 and possibly also the journal bore 30, as well as the journal bores 39 and 40 when desired. Since in a carefully manufactured pump, the portions of the melt entering into the journal bores is very small, it may suffice to provide for only one or a small number of flow channels 9. Also, it may be advantageous to have the fluid cells 20, 20A, and from which the flow channels proceed, include recesses or enlargements 10. The depth 13 of these enlargements, as measured from the root circle 16, is at most the same as the distance 26 between the outer boundary of the outlet opening 8 or 38 and the root circle 16, but preferably the depth 13 is smaller than the distance 26 by the amount 14.
The outlet opening 8 of the by-pass duct 6, as well as the opening 38 of the by-pass duct 7, are preferably displaced from the plane which includes the two gear axes 36, 37 and toward the suction side, by a distance represented by the angle 11. Thus the openings 8 and 38 are located in the area in which the fluid cells 20 are increasing in size, and the intermittent connection between the channels 9 or 9A and the by-pass ducts 6 or 7 is made when the suction exists in the associated fluid cell 20. Advantageously, the width of the flow channel 9 is, when measured in the circumferential direction, smaller than the corresponding width of the outlet opening 8 or 38.
The magnitude of the angle 11, by which the outlet opening is moved from the plane which includes the two gear axes 36, 37 also depends on whether the teeth of the meshing gears 2, 3 seal each individual fluid cell as they interengage over a certain angle of rotation, i.e. engage without play, or whether a slight play is provided between the meshing teeth, so that each associated closed fluid cell comprises two adjacent fluid cells 20, 20A, with one associated with the gear 2 (20A) and the other with the gear 3 (20). In the first case, an angle 11 as small as about 2° will suffice, since as the fluid cell 20 moves across the plane of the axes 36, 37 toward the intake side 4, the increase of the fluid cell 20 and thus the suction starts. However, in the second case, the angle must be somewhat larger, so that as the coverage of the flow channel 9 and the outlet opening 8 starts, the fluid cell 20 has already reached a somewhat greater volume than the fluid cell 20A, and preferably, the fluid cell 20A of the gear 2 will have moved at least half way through the plane of the axes 36, 37. Accordingly, it will be seen that the angle 11 should not be greater than about one-half the angle 34 covering a complete tooth pitch, but not smaller than about 2°. In gear pumps in which the teeth mesh with a slight play, i.e., in which two fluid cells 20, 20A form a volume together, the angle 11 preferably has a value which corresponds to at least one-fourth of the angle 34. In this instance, it has also been found advantageous that the outlet opening 8 or 38, extends by a small amount 12 further toward the gear axis 37, 36 than does the radial channel 9.
The determination of the number of flow channels 9 or 9A to be provided over the circumference of the gear depends on the leakage which actually occurs, and should, if possible, be designed so that the actual leakage is not exceeded, or only slightly exceeded, by the suction capacity. In an arrangement having by-pass ducts for the two journal bores 29, 30, or all four journal bores, it may be desirable to also provide for a separation of the flow channels 9, 9A, i.e., the flow channels are associated with different fluid cells. In the event flow channels are provided for both gears, it is also preferable that they be sealed from each other so that they proceed from different fluid cells. By this arrangement, it will be possible to associate each journal bore with an individually dimensioned intake path. Also, it will then be advantageous to use gears which mesh without play.
In the drawings and specification, there has been set forth a preferred embodiment of the invention, and although specific terms are employed, they are used in a generic and descriptive sense only, and not for purposes of limitation.
|
A gear pump is disclosed which is adapted to convey a polymeric melt without significant leakage, and which comprises a pair of intermeshing gears. One of the gears is driven by a drive shaft which extends through a journal bore in the pump housing, and a by-pass duct extends between the journal bore and an area in the internal chamber of the pump which is adjacent but spaced from the intermeshing teeth and where the fluid cells defined by the intermeshing teeth are expanding. Also, at least one root of one of the gears includes a channel which leads to the area of the by-pass duct, and so that an intermittent suction resulting from the expanding fluid cells acts to withdraw any melt from the journal bore of the drive shaft and through the by-pass duct, to thereby prevent leakage of the melt outwardly through the journal bore.
| 5
|
BACKGROUND OF THE INVENTION
The invention relates to a device for detachably coupling the orifice of a branchline to a line carrying a pressure medium and having a plurality of discharge valves disposed in spaced relationship with respect to each other on the line, and a discharge opening each closeable by a closing element. The orifice is disposed in a coupling device displaceable longitudinally of the pressure line and is connectable with the line by opening one of the discharge valves.
Coupling devices are known which are fixedly mounted on a branch of a pressure line. In such pressure lines the coupling is carried out by means of a coupling member which is inserted against the pressure and which is removed for decoupling. The disadvantage is that, when changing the operating site the coupling device may be moved only with a high cost of labor.
Furthermore, a device is known (from U.S. Pat. No. 3,195,562), in which a coupling device is movable parallel to a pressure line which may be coupled with discharge valves at the pressure line. For this purpose a double-sided, inclined guide conduit or channel is provided for each coupling, through which a pretensioned plunger for opening the discharge valve is mounted in the coupling device. The structural costs or expenditures in this embodiment are considerable and large displacement forces are required in the area of the discharge valve.
BRIEF SUMMARY OF THE INVENTION
It is an object of the invention to design a device of the aforementioned type in such a manner that the coupling in longitudinal direction of a pressure line is made possible with low structural costs, to achieve a higher degree of operational safety, with a high degree of operating comfort and a high degree of economics.
This object of the invention is obtained by providing the coupling device with a coupling element which is guided on the line and is provided with automatically sealing coupling means in the coupling position, with the discharge valve at the pressure side for an automatic alignment with the orifice, and actuating means which act upon the discharge valve or its pre-control, respectively, in the coupling position of the coupling element.
BRIEF DESCRIPTION OF THE DRAWING
The invention is shown in the accompanying drawing, in which:
FIG. 1 is a schematically shown cross-section of an inventive device in non-coupled operating position;
FIG. 2 is the device in accordance with FIG. 1 in coupled operating position;
FIG. 3 is a cross-section of a discharge valve of the device in accordance with FIG. 1; FIG. 4 is a cross-section through a different embodiment of the discharge valve;
FIG. 5 is a schematic view of the arrangement of the discharge openings in the pressure line;
FIG. 6 is a schematically shown cross-section of a further embodiment of the inventive device;
FIG. 7 is a perpendicular section through a precontrolled discharge valve;
FIG. 8 is a perpendicular view of a coupling means which cooperates with the discharge valve according to FIG. 7;
FIG. 9 is a sectional view along lines III--III in FIG. 2;
FIG. 10 is a cross-section of a line receiving a discharge valve in accordance with FIG. 7.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
FIGS. 1 and 2 show a pressure line or conduit 101 consisting of a square-shaped pipe (FIGS. 3, 4 and 10) on which a coupling device is slideably guided with a coupling element 110 which can be brought into active connection with a discharge valve 100 of line 101.
The discharge valve 100, of which there are usually several present in pressure line 101 (See FIG. 5), is provided with a slot-like discharge opening 102 which penetrates the wall of line 101. Opening 102 expands conically to the outside, so that the inner shoulder forms a valve seat 107 for a movable closing or locking body 103 which consists of a rubber elastic material and a closing or locking member 105 which is supported by a membrane part 104. An edge portion 106 extends upwardly from the membrane portion 104 with which the closing element 103 is supported against the upper wall as well as against the side walls (FIGS. 3 and 4) of line 101, thus defining a chamber 120. The actual closing body 105 in the range of membrane part 104 may be pressed upwardly into chamber 120 (FIG. 2), so as to lift the closing part 105 from valve seat 107. Inner ribs 108 at the closing element 105 form a stroke limit.
Furthermore, the closing element 105 of locking body 103 is centrally penetrated by a pre-control valve 111, which with its free end extends over the closing face of the closing element 105 but is sunk with respect to the lower outer face of line 101. The pre-control valve 111 is tiltably mounted at least along the longitudinal line axis in closing member 105. For this reason, a bore 112 expands conically downwardly in closing element 105. The pre-control valve 111 engages with a shoulder 113 in the locking or closing position in sealing engagement on the inner wall of the closing element 105 and is biased by a spring 114, for example, a spiral or a leaf spring (FIG. 3). Grooves 115 at the shaft of the pre-control valve 111 permit a flow of the pressure medium from the chamber 120. A throttle bore 116 in membrane portion 104 is provided for the flow of the pressure medium into the inside of closing body 103 or into chamber 120, respectively. The flow cross-section of the throttle bore 116 is substantially smaller than the one of the flow grooves 115 so as to achieve an immediate pressure drop in chamber 120 when opening the pre-control valve 111.
When the line 101 is under pressure only a small force is required for opening discharge valve 100, so as to open the pre-control valve 111 by tilting or pressing, whereby the pressure drop which is generated in the chamber 120 causes closing member 105 to open automatically and/or lifts under the influence of a low force from the outside, thus releasing the slot like opening 102 through which the pressure medium may discharge from pressure line 101. When the opening force on the pre-control valve 111 is released and also the retention force on closing member 105, a new pressure builds in chamber 120 through bore 116 after the pre-control valve 111 returns to its closing position, whereby this pressure acts as a locking or closing pressure on the closing element 105 of closing element 103.
The coupling element 110 acts for opening the discharge valve 100 and for coupling to a branchline. This coupling element is provided with a carriage guide 121 which surrounds the line 101 in such a manner (see FIG. 3) that an easy displacement is assured. The coupling element 110 is provided with an orifice 122 which is connectable with a branchline and which can be connected through pressure chamber 123 and a coupling opening 124 with opening 102 of the discharge valve 100, as shown in detail in FIG. 2. The coupling opening 124 is disposed in a membrane 125 mounted in the pressure chamber 123 and adapted to engage the wall of the pressure line 101 at one side. The membrane 125 is positively mounted in a groove 126 in the wall of pressure chamber 123. The coupling 124 in membrane 125 is also in the form of a slot, when the pressure medium flows into the coupling opening 124 it exerts a pressure on the inner face of membrane 125 which presses the membrane 125 against the lower wall of line 101.
Furthermore, the coupling element 110 supports an actuating member 130 which is influenced from the outside for opening the pre-control valve 111 and if need be the closing element 105 of discharge valve 100 when moving over the discharge valve with the coupling device. The actuating member 130 is a pin 131 which extends from below into pressure chamber 123 is guided in a bore 132 ending in an actuating head 133 with a seal shoulder 134 and is also under the influence of a pressure spring 135. At one end pin 131 supports a roller 136 which penetrates the coupling opening 124 but which can roll on the lower jacket face of pressure line 101 when displacing coupling element 110. As can be seen in FIG. 1, the pressure chamber 123 is in connection with the ambient through an open groove 137 in bore 132 of pin 131. In the closed or locked position groove 137 is closed at the head 133 of pin 131 by sealing shoulder 134 (FIG. 2).
For establishing a coupling the coupling element 110 is manually pushed into the position shown in FIG. 2. This can be done by a rapid hand movement without taking into consideration an exact coupling position, since the described device automatically defines the coupling position and fixes it unmovably. When, during this diplacement, roller 136 gets into the range of slot 102 the roller may fall into this slot by the influence of spring 135 and thereby tilt the pre-control valve 111, so that the discharge valve 100 achieves an immediate open position and the pressure medium flows into coupling opening 124. A pressure builds up in pressure chamber 123 which presses the membrane 125 with such a high pressure against the jacket of the pressure line 101 that a manual displacement of the coupling element 110 on the pressure line 101 is made impossible. At the same time, a pressure-tight coupling is assured.
For closing the valve 100 or for displacing the coupling element 110, respectively, the actuating member 130 is pulled downwardly against the effect of spring 135, whereby the precontrol valve 111 returns into its closing position and thereby closes discharge valve 100. Simultaneously, the actuation of pin 131 opens the relief opening 137, whereby the inner face of the membrane 125 is relieved due to the pressure drop in the pressure chamber 123, so that the coupling element can again be easily displaced. In the same manner, the coupling element 110 may be pushed over a discharge valve 100 without triggering and opening the discharge valve.
The actuating member 130 may also be differently constructed, for example, as a pin which is actuated by a pressure key whereby the pin supports an elastic guide. The discharge openings 102 may have different shapes. The coupling element may be constructed for carrying out a simultaneous actuation of a plurality of discharge valves.
FIG. 3 shows the cross-section of line 101 in the form of a flat rectangle with a mounting flange 201'. Since the closing body 103 has a relatively flat cross-sectional shape for stability reasons, a hollow support member 150 may be provided in the area of each closing body 103 or a double pipe with apertures 151 between the individual discharge valves, when a high capacity cross-section is required, as seen in FIG. 4.
The described coupling procedure is carried out in a fraction of the second, whereby the required actuating force must merely correspond to the displacement resistance force of the coupling element before coupling, and amount to about 0.2 kp.
The arrangement shown in FIG. 6 is provided with a line 201, for example, a square-shaped pipe, on which a coupling element 210 is guided and which is coupled to a discharge valve 200 having a slot-like opening 202 the inner shoulder of which forms a valve seat 207 for a closing or locking element 203 with a spring elastic roller membrane 204 and a sealing plate 205 coupled therewith. The edges 206 of roller membrane 204 are connected with line 201 by screws 208.
The coupling element 210 acts for coupling a branchline and is guided on line 201, the coupling element being provided with a pressure chamber 223 with an orifice 222 and a membrane 225 with a discharge opening 224. The membrane is positively mounted in a groove 226 of pressure chamber 223. When opening the discharge valve 200 the flowing medium presses the membrane 225 pressure-tight against the lower wall of line 201.
Furthermore, the coupling element supports an actuating member which is influenced from the outside for engaging the sealing plate 205 when moving over the discharge valve 200 with the coupling element 210.
The actuating member 230 is provided with two adjacent pins 232 supported by a slide 231. The perpendicularly guided slide 231 is under the influence of a spring 233 and presses it against the closing element 203. When missing an outer force P the slide 231 moves into its upper extreme position, in which pins 232 open the closing element 203. In this position, a pressure relief bore 235 which is connected with chamber 223 is closed. The pins 232 support a pressure ring 236 which engages the membrane 225 when lifting the pins 232. When the pin 231 is retracted the coupling element 210 can be easily displaced on line 201 and can be moved into a new coupling position. One does not have to take into consideration an exact coupling position, since the coupling position is automatically defined and fixed. This is already described with respect to the embodiments of FIGS. 1 and 2.
The actuating means may also be differently shaped, as shown in the embodiments of FIGS. 7-10.
The discharge valve in accordance with FIG. 7 is mounted on an insert plate 301 which is inserted between two ribs 302 of a square-shaped pipe 303 and is retained by a snap ring 304 which may be inserted laterally. The insert plate 301 engages the bottom 305 of the square-shaped pipe 303, while the discharge valve 300 extends into the inside of pipe 303 through an opening 306 in bottom 305. The discharge valve 300 is provided with a valve element 307 and a valve lid 308, these parts being coupled with insert plate 301, in a manner not shown. A line or conduit 309 forms the connection to the inside of pipe 303, this line being closed by a membrane 310 disposed between valve element 307 and valve lid 308. The membrane is pressed against a valve seat 313 in valve element 307 by weak springs 311 via a bottom 312. The valve seat surrounds discharge 314 which extends through insert plate 301. The discharge 314 is provided with cams 315 of a bayonet lock in insert plate 301 with the aid of which a conduit is directly coupled to discharge 314.
The opening means for opening the discharge valve are a pre-control valve 317 biased by a spring 316, pre-control lines 318, 319 with a throttle connection 320 and a push rod 324 with a guide 321. When opening the pre-control valve 317 a vacuum is generated at the lid side of membrane 310 due to the throttle connection 320 so that the lifting of the membrane 310 is effected as well as the connection between line 309 and discharge 314.
The pre-control valve 317 is mechanically opened by lifting the push rod 324 which extends through the area of a recess 322. This is carried out by a spring-biased sensor 351 in coupling element 352. The advantage of this discharge valve 300 resides in the fact that its servicing is very simple. After removing the snap ring 304, the insert plate 301 can be removed, the valve can be serviced and reinserted. For sealing pipe 303 to the outside a soft seal 323 is provided. Without any difficulties a filter may be installed into the pre-control line 318. The contamination danger of the pre-control is already low due to the fact that the orifice of the pre-control line 318 is mounted above bottom 305.
FIGS. 8 and 9 show the coupling device 350 which is longitudinally displaceable along line 303. The coupling device is provided with a square-shaped coupling element 352, two side plates 353 with rollers 354 which are mounted at both sides of the coupling element 352, a pivot arm 356 provided with a through-put channel 355 mounted in the coupling element 352, and at the side of line 303 actuating means 357 for opening the pre-control valve 317. At its free end pivot arm 356 is provided with a coupling head 358 in which a pipe coupling 359 with an orifice 360 for receiving a hose 361 is screwed.
The pivot arm 356 is pivotable around a hollow pin 362 through which the pressure medium flows from pipe 303 through pressure chamber 363 and line 355. In the proximity of the bottom of pressure chamber 363 a line orifice 364 is provided through which the pressure medium is supplied from line 303 to hose 361. The connection between the orifice 364 and the hollow pin 362 may be used for installing different line components. As can be seen from FIG. 9, orifice 364 forms the seat of a check ball 366 biased by a spring 365. The pressure medium flows through an opening 367 in the side plate 353 into a hollow flange 368 mounted at the side plate 353, whereby the recess of the hollow flange forms an outer disposed connecting line 369 between orifice 364 and the discharge into hollow pin 362. This connection which is disposed at the outer side of side plate 353 may be used to install line components, for example, a pressure control valve 370 and a lubricator 371, as shown on left side of FIG. 9. The input A constitutes the supply line from orifice 364 and B the discharge into hollow pin 362. It is also possible to install further line components or only one single line component.
The actuating means 357 which are provided in the pressure chamber 363 are provided with an insert element 376 wherein a spring 378 presses against a actuator 351 which is coupled by a pull rod 380 with pivot arm 356. When pulling hose 361 the pivot arm 356 is pivoted away from pipe 303 and the actuating means 357, i.e., sensor 351, is also moved away from pipe 303, so that the opening means of the discharge valve are not actuated and the discharge valve remains closed when the coupling device 350 moves. When the pivot arm 356 is not pulled, the pre-control valve 317 is opened when being flush or in alignment with actuator 351. The pressure medium which flows into pressure chamber 363 acts on the rear side of a membrane 382 which is pushed against the insert plate 301, thus establishing a pressure-tight seal between the insert plate 301 and coupling device 350.
For detaching the coupling, the pressure chamber 363 is vented through a vent valve 383 which is actuated by a buffer rod 384 which is coupled with pivot arm 356.
The individual parts of the discharge valve and the coupling device may consist partly of plastic or metal. The square-shaped pipe 303 is preferably an extruded profile at which the ribs 302 for receiving the insert plate 301 are provided. The ribs 302 from at their upper side a running face 385 for rollers 354 of coupling device 350. A further rib 386 may be provided on line 303 for receiving curtain 387 (FIG. 4).
The operation of the coupling device with the aid of hose 316 is a particularly simple solution. By an inclined pulling of hose 361 the coupling is detached, i.e., a coupling is prevented and the coupling device 350 is displaced on line 303 without opening the discharge valve. When coupling device 350 is moved without pulling hose 361, the coupling of orifice 364 or hose 361 to line 303 is carried out.
In the described embodiments the coupling means, in particular the membranes for the pressure side of the line of the pressure chamber, are mounted in the coupling element. However, it is also possible to arrange these membranes within the pressure line. This means, that one membrane is required for each discharge valve. An eventual wear and tear of the membrane is such distributed to a plurality of membranes.
If a pressure indication for the branchline is required, a manometer may be mounted on pivot arm 356 (FIG. 8), which can be read from below.
It is to be understood that the invention is not limited to the described embodiments, but only by the scope of the appended claims.
|
A device for detachably coupling the orifice of a branchline to a conduit carrying a pressure medium having a plurality of discharge valves disposed spaced apart from each other along said conduit. Each of the valves has a discharge opening, and a closing element for each of said openings. A coupling device has the orifice disposed therein and is longitudinally displaceable along the conduit and connectable with the conduit by opening one of the discharge valves. The coupling device has a coupling element which is guided on the conduit and an automatically sealing coupling in the coupling position with the discharge valve at the pressure side for an automatic alignment with the orifice, and an actuator effective to actuate a respective one of the discharge valves in the coupling position of the coupling element.
| 8
|
This application is a continuation-in-part of U.S. application Ser. No. 10/515,353, filed Nov. 18, 2004 now U.S. Pat. No. 7,507,802, and claims benefit of Korean Application No. 2002/28505, filed May 22, 2002, each of which is incorporated herein by reference.
TECHNICAL FIELD
The present invention relates to immune stimulating composition comprising bacterial chromosomal DNA fragments having methylated CpG sequences and non-toxic lipopolysaccharides.
BACKGROUND ART
Cancer therapy developed from the 1960s has largely involved the use of surgery, radio therapeutics and chemotherapy. These treatments have shown the effect that the upward curve of cancer death rate soared up to 1973 in the U.S. becomes sluggish. However, surgery and radio therapeutics are topical treatment and so they have limitation that patients are convalescing favorably only when cancer is early blocked as local cancer. Chemotherapy is successful only if all cancer cells are completely eliminated and so chemotherapy may damage the host, normal tissue such as immune system of patients and threaten life of the old and the weak. The main purpose of immuno-therapy is to resist the cancerization by reinforcing immune surveillance. There are several trials as follows.
1) Immunological prevention; An animal of the same class was inoculated with cancer tissue to prevent homologous cancer. For example, viral leukemia of animal may be prevented using its cause virus (Morton et al. 1991, proc. am. assoc. cancer res. 2: 492:494). However, this method has never been applied to a person and it is difficult to induce cellular immunity.
2) Immunotherapy;
Active Specific Immunization
This immunization is to prevent cancer cells activating specific immune cancer supervisory cells by inoculating patients with self-cancer cells or homologous cancer cells or inactivated self- or iso-cancer cells regulated by X-ray irradiation or mitomycin-C. However, this method succeeded in animal experiment not in people. Recently, in order to enhance the expression of specific antigens in cancer tissue, various methods have been of attaching with Con-A or exposing hidden antigens by treating with neuramindase or of forming hybridoma with heterologous cells. However, the use of dendritic cells (Sprinzl et al, Cancer Treat Rev . 2001 August; 27 (4): 247-55) or development of other various DNA vaccine treatments (Pantuck et al, Int J Urol. 2001 July; 8 (7):S1-4) still have a limit in their safety and effect.
Non-Specific Immunotherapy
This immunization most spotlighted at present is used solely or with chemotherapeutic agents for treating almost all kinds of tumors. The non-specific immunotherapy means that it will not be restricted by kinds of cancer. Although various theories on its mechanism have been suggested, they are on study only it is suggested that the non-specific immunotherapy stimulate reticuloendothelial system specifically activity of lymphocytes. There is Corynebacterium as the chief material actually used in clinical tests. Picibanil (OK-432), which has been used for patients in Korea already, has been studied and produced mainly in Japanese pharmaceutical company. It has been marketed in Japan, Korea or Southeast Asia. Materials formed of Picibanil has been used in treating cancer long before. In 1968, Bush Fehleison et al., Germans, discovered that the progress of cancer ceased or previously existing cancer decreased. In 1891, Coley, surgeon in Chicago, the U.S., made mixed toxin formed of materials extracted from culture medium of streptococci, which was used for many patients.
BCG (or Tubercle bacillus ) and Associated Material Thereof
Living BCG organism: In the 1960s, Old in the U.S. and Mathe in France reported that animal cancer could be cured by inoculating BCG. In 1970, Morton in the U.S. reported that melanoma could also be cured by inoculating BCG. As a result, BCG and its associated materials were broadly used as non-specific immunotherapy. A great amount of BCG inoculation is required to expect increasing immune response. BCG can be inoculated under the skin, directly in cancer tissue region or orally administrated. However, the oral administration of BCG is not effective for people who were inoculated with BCG in their neonatal days but came into contact with tubercle bacillus thereafter (BCG or tubercle bacillus are not absorbed in people having tuberculin positive). In the treatment using living BCG organism, there are side effects such as requiring the great amount of living BCG organism and ulcer around injection, systemic symptom like chill, fever or liver function disorder. However, in case of using the small amount to decrease the side effects, the efficacy is reduced or weak.
Unmethylated CpG DNA
Mammalian DNA is different from bacterial DNA in that they have many CpG inhibitions and cytosine of CpG dinucleotide is selectively methylated. Recently, it has been recognized that CpG motifs in bacterial DNA rapidly stimulated the polyclonal B-cells and so increased IgM secretion, and stopped the progress of cell cycle by anti-IgM antibody and powerfully inhibited the induction of apoptosis to inhibit c-myc expression and made myn, blc2 and bcl-XL mRNA expression increase to protect cells from apoptosis. In other study, it was reported that CpG motifs activated directly B-cells to increase IL-6 and IL-12 secretion within a short time. Clinical test on immune adjuvants and asthmatic treatments using synthesis oligonucleotides including CpG sequences is going in progress the CPG Company in the America.
As described above, although treatments have been developed using diverse immune regulating materials, BCG and CpG among those treatments are just applied to people. Despite broad effects of BCG, it is difficult to apply a great amount of BCG or by blood injection because of its stability. In case of CpG, synthetic oligonucleotides are too expensive.
DETAILED DESCRIPTION OF THE INVENTION
Accordingly, the object of the present invention is to provide materials for inducing immune response more stable, economic, effective and specific than the conventional ones.
There is provided immune stimulating composition comprising: bacterial chromosomal DNA fragments having methylated CpG; and non-toxic bacterial lipopolysacchrides.
It is preferable that the CpG sequences of bacterial chromosomal DNA fragments are methylated and have size ranging from 2.0 to 0.5 kb and the lipopolysaccharides have dalton ranging from 3,000 to 10,000 dalton.
It is preferable that the least amount of the methylated bacterial chromosomal DNA fragments having methylated CpG and the lipopolysaccharides may be mixed to show the effect of the present invention. Particularly, the present invention shows the increase of dose dependent efficacy in a mass ratio ranging from 500:1 to 1:500. In the above-described mass ratio, the present invention is non-toxic and economic.
It is preferable that the bacterial chromosomal DNA fragments having methylated CpG and the lipopolysaccharides are mixed by shaking.
The composition of the present invention is useful for immune adjuvants or anti-cancer treatments. These effects are shown by inducing immune activation of T-helper 1 type.
It is preferable that the bacteria in the present invention is Escherichia coli or mycobacteria. More preferably, the bacteria is Escherichia coli , particularly, E. coli EG0021 (KCCM-10374).
In the composition of the present invention, synergy effect by mCIA02 (bacterial chromosomal DNA having methylated CpG) may be expected in stability, cell immune induction, synergy effect by CIA05 may be expected in immune reinforcement specifically cancer treatment.
The disclosed immune stimulating and controlling composition comprising bacterial chromosomal DNA fragments having methylated CpG and non-toxic lipopolysaccharides will be described briefly.
The present inventors succeeded in effective production of methylated bacterial oligonucleotides as anticancer adjuvant and development of modified lipopolysaccharides for suitable activation as anti-cancer treatments. A new immune adjuvant, mCIA07, is finally obtained by combining the methylated bacterial DNA fragments having methylated CpG and the lipopolysaccharides.
Generally, the combination of lipopolysaccharide and DNA shows synergy effect. Lipopolysaccharide shows various responses such as serving as independent antigen of T-cells. Here, the synergy effect may cause crucial results such as sepsis.
The present inventors obtained a strain, E. coli EG0021, having short carbohydrate chained lipopolysaccharide from Escherichia coli in healthy human intestines. They deposited the strain with No. KCCM 10374 in Korea culture center of microorganisms, KCCM, located in 361-221 Hongjedong, Seodaemun-gu, Seoul, Korea, in May 2 nd , 2002. They established a method of purifying lipopolysaccharide from this strain.
E. coli DNA, CIA02, representing immune activation was isolated from genomic DNA of E. coli EG0021. mCIA02 is genomic DNA having methylated CpG of E. coli EG0021. The CIA02 and mCIA02 were obtained after fragmentation of the isolated DNA and general treatment.
mCIA07 was finally obtained by combination of the mCIA02 and the CIA05.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a picture illustrating E. coli chromosomal DNA divided into each fraction by using ultrasonicator to detect the size of E. coli DNA representing the optimal effect, wherein Lanes 1, 2, 3 and 4 represent intact (more than 10 kb), 2.0-0.5 kb, 0.5-0.1 kb and less than 0.1 kb of DNA, respectively.
FIG. 2 is a picture showing that CG of E. coli chromosomal DNA is completely methylated. Restriction enzyme HpaII and BstUI digest unmethylated CG and MspI digests both methylated CG and unmethylated CG. In left panel, methylated DNA of the present invention is resistant to HpaII and BstUI thus is fully methylated.
FIG. 3 is graphs illustrating the highest immune increasing effect in E. coli DNA (mCIA02) of about 2-0.5 kb.
FIG. 4 is a picture illustrating lipopolysaccharide product isolated from E. coli outermembrane. The picture illustrates isolated lipopolysaccharide according to 5 times batch.
FIG. 5 is a picture illustrating that the size of isolated E. coli lipopolysaccharide treated with alkali is changed by degrading lipid A and lose toxicity by this treatment, wherein Lane 1 represents isolated lipopolysaccharide product CIA04 and Lane 2 alkali-treated non-toxic lipopolysaccharide CIA05.
FIG. 6 is a graph illustrating the decrease of TNF-α secretion in THP-1 cell line treated with the non-toxic lipopolysaccharide (CIA05).
FIG. 7 is a graph illustrating results of general safety test on the non-toxic lipopolysaccharide (CIA05) in mouse.
FIG. 8 a to 8 b are graphs illustrating the secretion amount of IL-12 p40 and TNF-alpha by methylated E. coli DNA (mCIA02), non-toxic lipopolysaccharide (CIA05) and mCIA07 (mCIA02+CIA05).
FIG. 9 is a graph showing immune response of mCIA07 and CIA07
PREFERRED EMBODIMENTS OF THE PRESENT INVENTION
The disclosed immune stimulating and controlling composition comprising bacterial chromosomal DNA fragments and non-toxic lipopolysaccharides will be described in more details referring to examples below, when are not intended to be limiting.
Example 1
Isolation of Non-Toxic Strain
1-1: Screening and Isolating Mutant E. coli Having Short Carbohydrate Chained Lipopolysaccharide
E. coli EG0021 having short carbohydrate chained lipopolysaccharide was isolated from healthy human intestines, and a method of purifying lipopolysaccharide from the strain was established.
A procedure was 5 times repeated of injecting liquid-cultured single colony of E. coli isolated from healthy adult male intestines, into experimental animal, Balb/C mouse.
50 kinds of strains were selected therein, and one colony in the selected 50 strains was obtained from a plate. After the colony was dissolved in 4 ml of 0.9% physiological saline solution, 1 ml of the solution was moved into an eppendorf tube. The solution was treated with 2 ul of DNase I and reacted at an incubator at 37° C. for 1 hour. After treatment of DNaseI, the solution was treated with 50 ul of Rnase (10 mg/ml) and reacted at an incubator of 37° C. for 1 hour. Then, 100 ul of Proteinase K (20 mg/ml) was put therein and reacted at 37° C. overnight. Human lymphocyte cell line differentiated by GM-CSF was treated with LPS of each strain obtained therefrom. TNF-α secretion was measured and a strain having the least value was selected (see Table 1) and confirmed the molecular weight of lipopolysaccharide by electrophoresis. It was shown that the attenuated strain was not morphologically changed or in its characteristics. Lipopolysaccharides having a molecular weight ranging from 5000 to 10,000 without lipopolysaccharide ladder having a molecular weight ranging from 50,000 to 100,000 were shown in electrophoresis (see FIG. 1 ). This strain was called EG0021.
TABLE 1
TNF-α secretion value of E. coli homogenate
obtained from healthy human intestines
TNF-a
No.
(pg/1 ul)
EG0001
more
(>100)
EG0002
12
EG0003
72
EG0004
85
EG0005
25
EG0006
35
EG0007
71
EG0008
28
EG0009
2
EG0010
13
EG0011
39
EG0012
64
EG0013
8.8
EG0014
9
EG0015
70
EG0016
more
(>100)
EG0017
6
EG0018
11
EG0019
0.3
EG0020
80
EG0021
0.1
EG0022
more
(>100)
EG0023
more
(>100)
EG0024
more
(>100)
EG0025
53
EG0026
12
EG0027
4
EG0028
76
EG0029
92
EG0030
more
(>100)
EG0031
21
EG0032
1.2
EG0033
more
(>100)
EG0034
more
(>100)
EG0035
7
EG0036
87
EG0037
0.7
EG0038
39
EG0039
37
EG0040
91
EG0041
65
EG0042
54
EG0043
More
(>100)
EG0044
More
(>100)
EG0045
17
EG0046
2.1
EG0047
3.5
EG0048
More
(>100)
EG0049
More
(>100)
EG0050
More
(>100)
Example 2
E. coli DNA Having Methylated CpG Perparation Method
2-1: E. coli Chromosomal DNA Purification
E. coli EG0021 was cultured by shaking in TSB (Tryptic soy broth; Difco) culture medium (30 g/L) at 37° C. for 10 hours.
After 10 L cultivation, 150 g of cells obtained by centrifugation at 8,000 G was washed in TE (10 mM Tris, pH 8.0, 25 mM EDTA) buffer solution (300 ml) and centrifuged. The cells (150 g) obtained by centrifugation was dissolved in 750 ml of lysis solution (10 mM Tris (pH 8.0), 25 mM EDTA, 100 ug/mL Lysozyme) and treated at 37° C. for 1 hour.
Thereafter, proteinase K (Sigma) was added in the solution to final concentration 100 ug/ml, and treated at 50° C. for 12 hours.
Mixing the solution with phenol/chloroform/isoamyl alcohol (25:24:1) at a ratio of 1:1 was repeated three times to obtain water layer.
E. coli chromosomal DNA was obtained by ethanol precipitation.
After purified E. coli DNA was diluted using sterile distilled water, the concentration of the E. coli DNA was measured at 260 nm and 280 nms with UV spectrometer.
The concentration was measured according to the following method:
Double stranded DNA concentration (ug/ml)= OD 260 nm×dilution rate×50
Single stranded DNA concentration (ug/ml)= OD 260 nm×dilution rate×40
OD 260 nm/ OD 280 nm=1.7˜1.8
2-2: Methylation on CG Sequence of E. coli DNA
The purified E. coli chromosomal DNA were treated with CpG methylase (M. Sss I; NEB M0226S) at the ratio of 1 unit/10 ug and performed the reaction at 37° C. for 12 hrs. At the reaction 160 uM of S-Adenosylmethionine as methyl donor was used. After methylation reaction, remaining salt and enzyme were removed by using DNA clean kit (CPG DPC60050) and micropure EZ (amicon 42529). The purified methylated DNA were treated with restriction enzyme Hpa II, Msp I or BstU I and confirmed whether the DNA are methylated or not through size change by restriction enzyme on agarose gel (see FIG. 2 ).
2-3: E. coli DNA Fragmentation
The purified E. coli chromosomal DNA having methylated CpG was dissolved in TE buffer solution to 0.5 mg/ml and sonicated in a glass beaker with ultrasonicator.
20 ml of the solution was fragmented at one time using 500 watt sonication VCX500 (Sonics Co.) as ultrasonicator and 630-0220 (tip diameter: ½″ (13 mm)) as tip. Here, in order to identify the size of E. coli DNA representing the optimal effect, the whole E. coli chromosomal DNA was divided in 20,000 J according to time period using ultrasonicator and then separated by size (see FIG. 1 ). Methylated E. coli DNA was divided into the whole DNA (Intact, more than 10 kb), 2.0˜0.5 kb, 0.5˜0.1 kb and less than 0.1 kb according to its size before sonication. In order to identify immune increase effects of E. coli DNA having methylated CpG separated according to size, the effect as immune adjuvant was measured in mouse (see FIG. 3 ). 50 ug of HEL (Sigma) as antigen and 50 ug of each E. coli DNA as adjuvant were injected (i.p) into ICR mouse (a 4-week old male, 20 g) twice at interval of a week. 7 days after final injection, the whole blood was collected and serum was separated. The antibody Ig G2a in serum was measured with HEL as antigen using ELISA method (see FIG. 3 ).
As analysis results, the size of 2.0˜0.5 kb showed the highest antibody value. Thereafter, from repeated experiments, it was shown that about 1 kb represented the optimal effect.
The sonication condition for obtaining 1 kb E. coli DNA determined according to the above result is at 7 minutes in 20,000 J.
Example 3
Removal of Endotoxin from E. coli DNA and Measurement of DNA Purity
Removal of Endotoxin
After sonication, DNA was reacted with chloroform at 4° C. for 12 hours, and three volumes of ethanol was treated therein to obtain a precipitate.
The precipitate was treated with Triton X-114 (Sigma) to 0.5% of final concentration. The resulting precipitate was reacted at 4° C. for 4 hours, warmed at 37° C. for 5 minutes and then mixed with phenol/chloroform/isoamyl alcohol (25:24:1) at a ratio of 1:1 to obtain water layer.
The obtained E. coli DNA was precipitated with ethanol and dissolves in pyrogen free water.
Endotoxin removed DNA was analyzed with Limulus Amebocyte Lysate (LAL) kit (BioWhittaker QCL-1000) to detect the remaining endotoxin.
Table 1 shows the endotoxin value and yield of purified E. coli DNA (CIA02) after removal of endotoxin according to the above method.
TABLE 2
The endotoxin value and yield of purified E. coli DNA(CIA02)
Amount of
DNA
the whole
Endotoxin
Sample
Concentra-
DNA
Pyrogen
(per DNA
Number
tion
(/15 ml)
free DNA
Ratio
1 mg/ml)
Yield
1
3 mg/ml
45 mg
16.2 mg
1.77
<1 ng
36%
2
20.25 mg
1.66
<1 ng
45%
3
18.9 mg
1.71
<1 ng
42%
The amount of remaining organic solvent was measured with GC/MSD (gas chromatography/mass selected detector), HP-5890A/HP-5870B. Ethanol, acetone, chloroform and penol were measured with SIM (Selected Ion Monitoring) having the column of 50 m.ultra-1 (see Table 2).
TABLE 3
Amount of remaining organic solvent
Remaining
organic
solvent
Acetone
Ethanol
Phenol
Chloroform
ng/ul
—
0.813
—
—
More than 99% degree of purity was identified by measuring protein contamination per E. coli DNA mg with Brad-Ford method.
Example 4
Purification of Lipopolysaccharide (CIA04) from Mutant E. coli
Purification of Lipopolysaccharide from Mutant E. coli
E. coli was prepared with the same method as above described DNA isolation method.
The prepared E. coli was mixed with 2 volumes of ethanol thereof, and centrifuged at 4,000 g to obtain a precipitate. 1.5 volumes of acetone of the precipitate was added, mixed and then centrifuged at 4,000 g.
The same amount of ethyl ether was added and mixed in the resulting precipitate, and then centrifuged at 4,000 g. The cell pellet obtained therefrom was covered with aluminum foil and punctured the foil and dried to measure cell mass. Thereafter, 7.5 ml of extraction mixture (90% penol:chloroform:petroleum ether=2:5:8) was added per 1 g of cellular dry weight.
The resulting solution was divided into glass centrifuge tube and centrifuged at 25° C., 3,000 rpm (1,200 g) for 20 minutes to obtain supernatant. The supernatant was left in hood for 12 hours. Then, the solution was divided into glass centrifuge tube and lipopolysaccharides dissolves in ethyl ether by centrifugation at 25° C., 3,000 rpm (1,200 g) for 20 minutes, and then transferred into eppendorf tube. The solution was dried in hood, and dried weight was measured with chemical balance. Then, ethanol was added therein and stored before use.
After ethanol was completely eliminated in purified E. coli lipopolysaccahride stored in ethanol, the amount of KDO (2-Keto-3-deoxyoctonate) in lipopolysacchardie was measured with lipopolysaccharide standard (Lsit Biological Lab.). After the concentration was measured from the standard, the lipopolysaccharides were analyzed with SDS-PAGE according to size and identified by silver staining (see FIG. 4 ). The lipopolysaccharide had molecular weight ranging from about 5,000 to 10,000, and its size was very small compared with general E. coli lipopolysaccharide.
Example 5
Removal of Toxicity in Purified Lipopolysaccharide from Mutant E. coli
5-1: Removal of Toxicity in Lipopolysaccharide by Lipid A Degradation
Purified E. coli lipopolysaccharides diluted to 3 mg/ml of concentration and mixed with 0.2 N NaOH at a ratio of 1:1. The resulting solution was shaken every 10 minutes at 60° C. and deacylated for 140 minutes.
About 1/5 volumes of initial 0.2 N NaOH of 1N acetic acid was added in the resulting solution to titrate pH 7.0. After pH titration, ethanol-precipitated non-toxic lipopolysaccharide was obtained. After the concentration of non-toxic lipopolysaccharide was measured with KDO method, its size change was identified by SDS-PAGE and silver staining in comparison with lipopolysaccharide before treatment. As a result of staining, it was shown that lipid A of lipopolysaccharide was degraded by alkali treatment and the size of lipopolysaccharide became smaller (see FIG. 5 ).
5-2: Confirmation of Toxicity Removal of Non-Toxic Lipopolysaccharide
In order to test stability of non-toxic lipopolysaccharide, experiments on secretion, pyrogenicity and abnormal toxicity of inflammatory proteins were performed.
Experiment on Secretion of Inflammatory Protein
THP-1 (Acute monocytic leukemia) was treated with non-toxic lipopolysaccharide from high to low concentration to measure the amount of secreted TNF-α in comparison with the control group of purified lipopolysaccharide.
While 5 pg TNF-α was secreted in 1 ug of lipopolysaccharide in the control group, 0.1 pg TNF-α was secreted in 1 ug of non-toxic lipopolysaccharide. Here, it was shown that inflammatory reaction induced by toxicity decreased by 50 times. Additionally, it was shown that the amount of TNF-α secreted in E. coli DNA was below 100 fg. As a result, the non-toxic lipopolysaccharide was proved to be very safe material (see FIG. 6 ).
Experiment on General Safety Test
The sample of high dose was injected in more than two kinds of rodents to observe abnormal weight change.
A. Experiment in Guinea Pig
About 350 g of a guinea pig showed no abnormality and gained weight gradually when observed for more than 5 days before use.
The 5 ml of sample was used per one guinea pig.
The sample was one time injected (i.p) into more than two guinea pigs, and they were observed for more than 5 days.
B. Experiment in Mouse
An about 5-week old mouse showed no abnormality and gained weight gradually when observed for more than 5 days before use.
The sample was one time injected (i.p) into more than two mice, and they were observed for more than 7 days.
The sample was proved suitable in this experiment when an animal showed no abnormality during the observation period.
As an experimental result, no abnormal weight change was observed after injection of the sample (see FIG. 7 ).
Pyrogenicity Experiment
After vaccine was injected into three rabbits, change in the rectal temperature was observed. The 0.2 ug/ml of sample per 1 kg of rabbit was injected in ear vein of rabbit. Then, the change in abnormal temperature was measured by inserting a thermometer into the rectum.
Here, the weight of rabbits was over 1.5 kg. The rabbits were reused more than 3 days after they had been used in experiments. The body temperature was measured with an apparatus measuring the temperature up to 0.1° C. An injector and its needle were heat-sterilized at 250° C. for over 30 minutes. Only water was fed from 16 hours before use to completion of the experiment. The animals were fixed not as tight as possible.
The body temperature was measured by inserting the thermometer into the rectum to a constant depth ranging from 60 to 90 mm for constant time. The temperature measured before injection was defined as a control temperature. The sample heated at 37° C. was injected into the ear vein within about 15 minutes after the control was measured. The body temperature was measured every 3 hours, at least 1 hour, after injection. Gap between the control temperature and sample temperature was defined as difference in temperature. The maximum value of the difference in temperature was defined as pyrogen reaction of the experimental animals. Here, the samples of three animals were used.
Pyrogenic material experiment was negative when the total of three animals was below 1.3° C. while positive when over 2.5° C. These experiments were performed three times, and the negative reaction was suitable for these pyrogenic material experiments.
The results are shown in Table 4.
TABLE 4
Before injection
After
(three times)
injection (hrs)
Increased
Sum of increased
The No. of time
Number
1
2
3
0.5
1
1.5
2
2.5
3
body Temp.
body Temp.
Result
standard
1
1
39.1
39.2
39.2
39.4
39.3
39.2
39.2
39.1
39.1
0.2
0.8
pass
<1.3° C.
2
39
39.1
39.3
39
39.2
39.5
39.2
39.1
39.3
0.4
3
39.4
39.2
39.2
39.3
39.5
39.3
39.5
39.3
39.4
0.2
2
1
39
39.3
39.1
39.4
39.2
39.3
39.1
39.2
39
0.4
1.7
pass
<3.0° C.
2
39.4
39.2
39.2
39.1
39.3
39.1
39.2
39.2
0.3
3
39.3
39.3
39.2
39.4
39.4
39.4
39.4
39.3
0.2
3
1
39.2
39.2
39.1
39.2
39.2
39
39.2
39.1
39.1
0.2
2.5
pass
<5.0° C.
2
39.1
39.5
39
39
39.1
39.2
39.1
39.3
39.2
0.4
3
39.2
39.3
39.2
39.3
39.2
39.3
39.2
39.4
39.3
0.2
Example 6
Mixing E. coli DNA Fragment Having Methylated CpG and Non-Toxic Lipopolysaccharide and Identification of Activity
6-1: Mixing E. coli DNA Having Methylated CpG (mCIA02) Fragment and Non-Toxic Lipopolysaccharide and Identification Activity with Whole Blood Analysis
Venous blood from healthy male adult was sterilely obtained in vacuum tube having heparin as anticoagulant. The whole blood obtained therefrom was mixed with RPMI 1640 culture medium (2 mM L-glutamine, 1 mM Sodium pyruvate, gentamycin of 80 ug/ml) at a ratio of 1:1. 20 ul of mCIA07 50 ug of E. coli DNA having methylated CpG (mCIA02)+1 ug or 500 ng, 100 ng of CIA05) or 20 ul of HBSS were added in 1 ml of the whole blood mixed with culture medium and then incubated in 5% CO 2 culture medium at 37° C. for 24 hours. The secretion amount of TNF-alpha (R&D system, DY 210) and IL-12 p40 (R&D system, DY1240) was analyzed in supernatant liquid in the culture medium with ELISA kit. The results were shown in FIG. 8 . The analysis results show that mCIA07 has the synergistic effect on immune response than separatively administrating mCIA02 or CIA05 ( FIG. 8 a ) and mCIA07 has the lower toxicity than separatively administrating mCIA02 or CIA05 ( FIG. 8 b ).
6-2: Comparing Activity Between Methylated CG and Un Methylated CG of E. coli DNA
50 ug of 0.5-2.0 kb E. coli DNA having methylated CpG obtained from example: 2-2 (methylation process) or 50 ug of 0.5-2.0 kb of unmethylated CG of E. coli DNA were mixed with 1 ug of CIA05 to prepare mCIA07 and CIA07 respectively. According to method described in example: 6-1 resulting mCIA07 or CIA07 were carried out whole blood analysis. The amount of IL12 and IFN-gamma were almost same irrespective of methylated DNA or unmethylated DNA (see FIG. 9 ).
Example 7
Measurement of Anti-Cancer Treatment Effect Using Cell Lysis Activity of Composition of the Present Invention
Cancer cell killing activity by the present composition was measured using 51 Cr-release.
Antigen only or with mixture of E. coli DNA fragment+nontoxic LPS was injected under the skin of the bottom of the foot of a 5˜8 week old male C3H/HeN mouse.
RPMI-1640 (10 mM HEPES, 100 units/ml penicillin, 100 μg/ml streptomycin, 300 μg/ml glutamine; Gibco Laboratories, Grand Island, N.Y.) was used for the basal culture medium for culturing cell lines. Inactivated 10% fetal bovine serum (Gibco Laboratories, Grand Island, N.Y.) heated at 56° C. for 30 minutes was added in the basal culture medium. In order to measure activity of LAK cells and cancer cell mediated killing activity, Sarcoma 180 and mouse bladder cancer cell line (MBT-2) were used for target cells.
In order to prepare reaction cell lines, a rat of the experimental group were killed using cervical dislocation. Its spleen was sterilely isolated and minced on stainless steel wire netting using scissors. The fragments were ground and filtered using a glass stick with adding phosphate buffered saline. Then, tissue debris was removed passing through wire netting. After single cell suspension was identified under microscope, cells were washed using the basal culture medium one time. The cells were suspended in 0.84% ammonium chloride solution at 37° C. for 5 minutes to dissolve erythrocyte. The cells were further washed using the basal culture medium two times and suspended in complete culture medium. The cell suspension was divided into culture flasks and cultured in CO 2 constant temperature and humidity chamber at 37° C. for 1 hour. Cells that were not attached to the flasks were obtained therefrom, and survival cell number was measured using trypan blue dye exclusion method. Then, 5×10 6 cells were obtained using the complete culture medium and survival cell number thereof was measured using trypan blue dye exclusion method. Then, 5×10 6 cell/ml of cell suspension were made using the complete culture medium.
Target cell line was cultured and the number of cells was counted. 10 6 cells were obtained and the cells were centrifuged at 300 g, 3 minutes. The supernatant liquid except 0.2˜0.3 ml was removed using Pasteur pipette without damaging precipitated cells. 100 Ci Na 2 51 CrO 4 (1 ml Ci/ml, NEZ 030S, NEN, USA) was added and labeled in shaking thermostat at 37° C. for 1 hour. The cells were washed using the basal culture and survival cell number thereof was measured using trypan blue dye exclusion method. The labeled target cells were re-suspended in the complete culture medium to 5×10 4 cell/ml.
The labeled target cells were divided by 0.1 ml to put 5×10 3 cells per a well on 96 well fine plate having a round bottom. 0.1 ml of reactions cell was added at a ratio of reaction cell:target cell=100:1. The cells were cultured in 5% CO 2 constant temperature and humidity chamber at 37° C. for 4 hours. After more than 3 wells per an experiment were made and the culture for 4 hours was finished, the cells were centrifuged at 500 g for 15 minutes. Radioactivity was measured in the 0.1 ml of supernatant liquid from each well using gamma counter (Packard, USA). Here, in order to induce the maximum emission, 0.1 ml of 5% triton X-100 (Sigma, USA) was added in the control well group. In order to measure natural emission, the labeled cells were cultured in the complete culture medium having the same dose. The cell toxicity was calculated according to the following formula:
Cytotoxicity(%)=( ER−SR/MR−SR )×100
ER: average count (cpm) of experiment group
SR: average count (cpm) target cell cultured in culture medium
MR: average count (cpm) of target cell treated with 5% Triton X-100.
The experimental results were shown in Table 5. LAK cells showed cell lysis increase by 8 times in comparison with non-immune cells, and by 1.5 times in comparison with BCG injection group. MBT-2 cell line showed cell lysis increase by 5 times in comparison with non-immune cells. These results represent possibility of the composition for anti-cancer treatments instead of BCG resulting in various side effects.
TABLE 5
Injection days
0
3
7
15
Sarcoma 180
Control
100
100
100
100
group
BCG
92 ± 4
110 ± 2
632 ± 13
189 ± 4
Composition
94 ± 7
154 ± 3
802 ± 10
109 ± 7
of the
present
invention
MBT-2
Control
100
100
100
100
group
BCG
103 ± 3
96 ± 7
402 ± 11
98 ± 3
Composition
97 ± 4
121 ± 9
513 ± 13
109 ± 6
of the
present
invention
INDUSTRIAL APPLICABILITY
The anti-cancer treatment mCIA07 of mixing two E. coli derived materials mCIA02 and CIA05 according to the present invention has higher safety than the conventional treatment and minimizes production cost due to simplicity of production process. Also, mCIA07 induces more effective and specific immunization due to mixing the two materials. Additionally, the present invention is cheaper than CpG due to physical process of DNA and more effective than BCG.
Accordingly, the E. coli derived anti-cancer treatment mCIA07 according to the present invention is more significant in industrial application for anti-cancer treatment and immune adjuvant.
|
The present invention relates to immune stimulating composition comprising methylated bacterial chromosomal DNA fragments and non-toxic lipopolysaccharides. The composition of the present invention can be industrially applied the effective materials for treating cancers and adjuvant.
| 0
|
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application is the United States National Stage application pursuant to 35 U.S.C. §371 of International Patent Application No. PCT/DE2015/200259, filed on Apr. 16, 2015, and claims priority to German Patent Application No. DE 10 2014 208 697.3 of May 9, 2014, which applications are incorporated by reference in their entireties.
FIELD
[0002] The invention relates to an eddy current brake for a clutch device, more specifically to an eddy current brake including a brake rotor having an electrically conductive brake region which is movable in a magnetic field formed by a coil.
BACKGROUND
[0003] Electromechanical and electrohydraulic clutch actuating systems are known, for example, for clutch by wire (CBW) applications. Actuators of the respective different type (electromechanical/electrohydraulic) are used specifically for this, which have in each case, drive systems adapted to the actuator. This requires appropriate effort for development but also in other areas, such as for example, design, production, parts support, parts management, or warehousing.
[0004] In hybrid vehicles, an internal combustion engine and an electric drive motor are frequently provided to propel the hybrid vehicle. The hybrid vehicle may be propelled either only by the internal combustion engine, only by the electric drive motor, or by both. In order to start the internal combustion engine during purely electric driving operation or to couple it to the drivetrain, a clutch device is provided which includes an electric actuator, for example, an eddy current brake. The eddy current brake includes an electrically conductive brake region, for example a metal disk, which is movable in a controllable magnetic field, which is producible by a coil. As the magnetic disk moves in the magnetic field voltages are produced in it by induction, resulting in eddy currents, which in turn produce magnetic currents of their own contrary to the external magnetic field, which slow down the electrically conductive area. This sets the torque characteristic curve of the clutch.
[0005] Such a clutch with electric actuator is disclosed in DE 10 2012 222 830 A1.
[0006] Such a clutch with eddy current brake is disclosed in German patent application DE 10 2013 223 044.3. The eddy current brake there has a central coil, and the special construction, in which the coil is positioned opposite only one lateral face of the metal brake disk, provides for a very space-saving configuration of the coil arrangement and at the same time a large effective eddy current area.
[0007] The inventors have undertaken the task of increasing the reliability of the clutch device of the prior art.
SUMMARY
[0008] To reduce at least part of this effort, it is proposed to use one and the same electric motor (including electronics) for both electromechanical and electrohydraulic clutch actuation. Accordingly, this electric motor is intended as a module for at least the two enumerated actuator variants.
[0009] The object is fulfilled in particular by a clutch device having an actuating device, wherein the actuating device has an electrical eddy current brake, wherein the eddy current brake has a brake stator with at least one coil and a brake rotor with a brake region, wherein the brake region has a first layer which is electrically conductive and which has a first lateral face and a second lateral face, the first lateral face facing toward the coil and the second lateral face facing away from the coil, and wherein the brake region has a second layer which is magnetic and which is connected to the second lateral face.
[0010] The object is further fulfilled by a method for producing a clutch device having an actuating device, wherein the actuating device has an electrical eddy current brake, wherein a brake stator with at least one coil and a brake rotor with a brake region are built into the eddy current brake, wherein the brake region is designed with a first layer which is electrically conductive and which has a first lateral face and a second lateral face, the first lateral face being positioned facing toward the coil and the second lateral face being positioned facing away from the coil, wherein the brake region is designed with a second layer which is magnetic and which is connected to the second lateral face.
[0011] As a result, it is possible on the one hand to continue to retain a compact construction form. On the other hand, at the same time it is possible to minimize the existing air gaps in comparison to the prior art. Thus, it is now possible to enlarge an air gap that is present between the back or the second layer and the adjacent component, for example, a part of the brake stator, since the magnetic circuit now no longer has to close primarily across this air gap. This prevents malfunctioning due to contact of the brake rotor with the corresponding adjacent component. Because of the second layer located on the second lateral face, the magnetic circuit can now close advantageously already in the brake stator, and the magnetic field does not run across a second air gap between two components that move relative to one another. Thus, the thickness of the path of the magnetic field through air gaps is reduced overall, and the magnetic flux density and with it the braking torque of the eddy current brake is therefore increased. Furthermore, the heat capacity of the brake rotor is increased by the second layer, so that the brake rotor heats up less as a braking torque is generated (for example, to start the engine, or to couple the combustion engine in deceleration mode).
[0012] The clutch device is preferably a clutch device for a drivetrain of a motor vehicle, where the drivetrain has a combustion engine, an electric machine with a stator and a rotor, and a transmission device, wherein the clutch device is positioned in the drivetrain between the combustion engine on the one side and the electric machine and the transmission device on the other side. The clutch device is set up in the drivetrain of a hybrid vehicle, in particular, to start and/or engage the combustion engine. It is, by particular preference, a disconnect clutch (a so-called e-clutch) for a hybrid drivetrain. It is preferably a dry, multi-plate clutch. It is preferably integrated into a rotor of the electric machine of the drivetrain. The disconnect clutch is preferably set up to couple the combustion engine to the drivetrain or to decouple it from the drivetrain. Except for the design of the eddy current brake with two layers according to the invention, the clutch device is preferably identical to the clutch disclosed in German patent application 10 2013 223 044.3, in particular the clutch shown in FIG. 2.
[0013] The eddy current brake is preferably set up to produce a pilot torque from a rotation of the rotor from the electric machine. The pilot torque is preferably transformed by the actuating device into a (partial) engagement of the clutch device. The production of the pilot torque by the eddy current brake makes rapid activation of the internal combustion engine possible, while the eddy current brake works without wear.
[0014] The actuating device is preferably set up to disengage and engage the clutch. The actuating device preferably has two ramps which are rotatable toward one another, by means of which an axial displacement of a contact plate relative to a pressure plate of the clutch device can be performed by rotating. The actuating device preferably has a planetary gear set, on which the eddy current brake acts. This planetary gear set amplifies the pilot torque produced by the eddy current brake, and therefore increases the effect of the eddy current brake.
[0015] For example, when operating under purely electric motor propulsion, the disconnect clutch is disengaged, so that the combustion engine is uncoupled from the drivetrain. If more power is required, or if the electrical energy reserve is running out, the combustion engine is started by partially engaging the disconnect clutch, while the disconnect clutch goes into deceleration mode. The eddy current brake is preferably engaged to this end, so that within the disconnect clutch the eddy current brake slows one of the ramps, so that a speed difference of the rotatable ramps occurs, as a result of which the disconnect clutch at least partially engages. This causes the combustion engine to be started by the electric motor. When the combustion engine is turning faster than the electric motor (that is, it is transitioning to traction mode), a freewheel mechanism closes, which causes the disconnect clutch to become completely engaged. When the freewheel mechanism closes in traction mode, the combustion engine transmits part of its torque through an additional sun gear, which is connected to the freewheel mechanism, as well as the planetary gears and ring gear of a planetary gear set, to the ramp on the ring gear side, so that the disconnect clutch is completely engaged and is then able to transmit the entire torque of the combustion machine in traction mode. When the eddy current brake is opened, the clutch is disengaged, for example, by leaf or coil springs which were pre-tensioned while it was being engaged. The combustion engine is preferably turned off during or after the disengagement process.
[0016] The brake stator is preferably a component which is rotatable relative to the brake rotor. It preferably has a central coil as its only coil. The central coil preferably has a rotationally symmetrical shape, preferably concentric to the axis of rotation of the eddy current brake. The brake stator preferably has a first claw pole with first pole claws and a second claw pole with second pole claws. The central coil is preferably surrounded by the first claw pole with its first pole claws and the second claw pole with its second pole claws.
[0017] The first claw pole preferably has a disk segment. The disk segment preferably has a radially outer rim. The first pole claws are preferably positioned on the radially outer rim of the disk segment. The first pole claws are preferably at least partially angled approximately perpendicular to the disk segment of the first claw pole. The first pole claws are preferably distributed around the disk segment of the first claw pole in the circumferential direction. Gaps are preferably formed between the first pole claws.
[0018] The second claw pole preferably has a disk segment. The disk segment preferably has a radially outer rim. The second pole claws are preferably positioned on the radially outer rim of the disk segment. The second pole claws are preferably at least partially angled approximately perpendicular to the disk segment of the first claw pole. The second pole claws are preferably distributed around the disk segment of the second claw pole in the circumferential direction. Gaps are preferably formed between the second pole claws.
[0019] The first claw pole and the second claw pole are preferably positioned with their disk segments parallel to one another and spaced apart from one another. The first pole claws and/or the second pole claws preferably each have one free end. The first claw pole and the second claw pole are preferably positioned so that the free ends of the first pole claws and the free ends of the second pole claws are directed toward one another. The first pole claws and the second pole claws preferably each mesh alternately with one another. The first pole claws preferably reach into the gaps formed between the second pole claws. The second pole claws preferably reach into the gaps formed between the second pole claws. The free ends of the first pole claws and/or the free ends of the second pole claws are preferably designed so that they taper from wide to narrow.
[0020] The brake stator preferably has an internal stator which has the (central) coil and preferably the claw poles, and the brake rotor is positioned at least partially radially outside of the internal stator.
[0021] The brake stator is preferably a component which is rotatable relative to the brake stator.
[0022] In the brake region of the brake rotor, the eddy currents are producible by a magnetic field coming from the brake stator. The brake region is preferably a cylindrical and/or disk-shaped partial region of the brake rotor.
[0023] The brake rotor is preferably of disk-shaped design, by particular preference cup-like; that is, it has a radially extending, preferably disk-shaped section or floor section and an axially extending, preferably cylindrical section or wall section. It may be a single piece or multiple pieces. The brake region is part of the radially extending section and/or of the axially extending section, or the radially extending section and/or the axially extending section are formed by the brake region. By particular preference, the brake region is located at least partially radially outside of the internal stator. For example, the brake rotor has a cup-like shape with a wall section as the brake region, and the wall section is located radially outside of the internal stator. The internal stator preferably has pole claws which are located directly opposite the brake region and are spaced apart from it by an air gap. The brake rotor preferably also has a floor section, and with this floor section is positioned on the disk segment of the second claw pole with an interval between them, the floor section and disk segment preferably being positioned parallel to one another.
[0024] The first layer (which may also be referred to as the first material layer) preferably has a maximum thickness of 10 mm, preferably 5 mm, by particular preference 1 mm. By particular preference, it has a constant thickness (essentially, for example with a tolerance of ±0.1 mm). From the mechanical and thermal perspectives, the greatest possible material thickness (5-10 mm) should be chosen. In addition, the resistance decreases (larger cross section) at the greatest possible material thickness, which enables the position of the maximum torque to be optimized. However, the real thickness is influenced chiefly by the choice of material. If it is a ferromagnetic material (such as iron), then the increasing thickness has no influence on the air gap in the magnetic circuit (the air gap corresponds merely to the optically recognizable air gap between magnetic pole and electrically conductive material. On the other hand, if a paramagnetic material (such as aluminum or nickel) or a diamagnetic material (such as copper) is used, the air gap increases as the material thickness increases, since the disk material has the same permeability as air (the air gap corresponds to the optically recognizable air gap plus the thickness of the electrically conductive material. An expanding air gap affects the magnetic field negatively, since the magnetic resistance increases and thus the flux density in the air gap decreases while the magnetic geometry otherwise remains the same. This, in turn, results in reduced braking torque of the eddy current brake. For this reason, the material thickness generally falls within the range of 1-3 mm for paramagnetic and diamagnetic materials.
[0025] The first layer preferably consists of a (first) material, which is electrically conductive, so that the eddy currents can form in it advantageously. It is preferably a most highly electrically conductive material. The material preferably has an electrical conductivity of more than 15·10 6 S/m, by particular preference more than 30·10 6 S/m (in each case at a temperature of 300K). For example, the first material is preferably iron, tungsten, or nickel. By particular preference, the first material is brass, copper, or aluminum. The electrically conductive material is generally chosen with regard to the geometric dimensions of the disk and the resulting speed of the “moving conductor,” as well as the desired speed of rotation and effective range of the eddy current brake. As the specific electric resistance increases, the maximum braking torque is reached only at a higher relative speed. Applications having a small effective radius of the electrically conductive material and the position of maximum torque at low speeds of rotation thus require a material with a low specific electric resistance (such as copper or aluminum). On the other hand, if the effective radius is larger and the maximum torque is to be reached only at a greater disk speed, then a material having a greater electric resistance (such as steel) is adequate.
[0026] The first and second lateral faces of the first layer are preferably two boundary surfaces of the first layer which are preferably essentially parallel to one another. In the case of a cylindrical brake region, these are, for example, an inner and an outer circumferential surface, in the case of a disk-shaped brake region, a front axial surface and a back axial surface.
[0027] The first lateral face faces toward the coil and the second lateral face faces away from the coil. For example, it is preferred that the coil, by particular preference, the center point of the coil, is at a smaller minimum distance from the first lateral face than from the second lateral face. As a result, because of a current flowing through the coil, two magnetic poles are formable which are both located on one side of the brake region, i.e., close to that side, so that the magnetic fields of both poles, starting from the respective pole, first penetrate the first lateral face and only then the second lateral face of the first layer of the brake region. This forces a closure of the magnetic circuit from the perspective of the coil beyond the first layer of the brake region, so that as a result a magnetic field line must pass through the first layer of the brake region twice, which results in even more efficient eddy current generation.
[0028] The second layer (which may also be referred to as the second material layer) preferably has a minimum thickness of 10 mm, preferably more than 5 mm, by particular preference more than 1 mm. By particular preference, it has a constant thickness (essentially, for example with a tolerance of ±0.1 mm). By particular preference, material thickness is position-dependent. In principle, it is to be fixed such that in the entire magnetic circuit a constant flux density results—at a maximum electric coil power close to the saturation polarization of the material used. This results in a best possible material utilization and can be achieved very simply, for example by means of sintered components. On the other hand, if the claw poles are formed from sheet metal, then it must be kept in mind that the greatest flux density occurs in the area of the poles. As can be seen from FIG. 2 , the poles are also tapered to a point, so that in the air gap a constant magnetic field develops over the entire breadth.
[0029] The second layer is magnetic, so that the magnetic circuit is able to close in it advantageously. The layer preferably consists of a (second) material having the highest magnetic permeability, by particular preference a ferromagnetic material. It preferably has a relative permeability μr of at least 200, preferably at least 2000. The second layer preferably consists of iron (of the highest possible purity), low-alloy steel or some other alloy such as mu metal or a Fe—Si alloy.
[0030] The second layer is preferably non-rotating in relation to the first layer. The second layer is preferably non-rotatably connected to the second lateral face of the first layer. The second layer is preferably non-rotatably connected to the brake rotor. Preferably, the first layer is positioned between the second layer and the first lateral face of the first layer. Preferably, the second layer is attached to the second lateral face of the first layer, or the first layer is attached to the second layer by means of the second lateral face of the first layer. The one layer is preferably welded, screwed or especially pressed onto the other layer. The second layer is preferably continuously present in the brake region in the circumferential direction of the brake rotor. The second layer is preferably point-symmetric in reference to a point on the axis of rotation of the brake rotor.
[0031] In another clutch device according to the invention, the brake region is at least partially cylindrical and the second layer is made of a ring-shaped material.
[0032] This makes an advantageous arrangement of the brake region possible in an area located radially far outside relative to the total radial extension of the eddy current brake, which increases the braking torque, since on the one hand the area of the brake region is larger and on the other hand the distance from the axis of rotation.
[0033] The brake rotor preferably has a cup-like component of an electrically conductive material, with the wall region of this component being part of the brake region. This wall region is cylindrical, and the ring-type pre-formed second layer is attached to this wall region on the outside (in the case of an internal stator).
[0034] In another clutch device according to the invention, the second layer is attached to the second lateral face by means of a press fit. In another method according to the invention, the second layer is attached to the second lateral face by means of a pressing process.
[0035] This achieves a uniformly adhering, easily realizable attachment of the second layer. Preferably the ring-type pre-shaped second layer is pressed onto the wall region of the cup-like component of the rotor on the outside (in the case of an internal stator).
[0036] In another method according to the invention, the second layer is pre-formed in a ring shape and the pressing procedure includes pressing the ring-type pre-formed second layer onto a cylindrical wall region of the brake rotor.
[0037] In another clutch device according to the invention, the second layer is positioned radially outside of the first layer and the brake stator has an internal stator which contains the coil.
[0038] Thus the coil is located radially inside the first layer. This achieves an especially compact construction, in which the brake region in addition may have a large radius, so that the braking torque is very advantageous.
[0039] In another clutch device according to the invention, there is a minimal air gap present between the internal stator and the first layer, which is smaller than a minimal air gap between the second layer and a stator component adjacent to the second layer.
[0040] This spaces the brake rotor apart from the internal stator with the smallest air gap. This is possible because other air gaps lose influence, as the magnetic circuit can already close in the second layer. Through the provision of larger distances or air gaps relative to the second layer or other stator components, malfunctions resulting from contact of the rotor with external components of the stator can be prevented.
[0041] A stator component is a component which is rotatable relative to the brake rotor. It may be part of an internal stator or an external stator, preferably an external stator.
[0042] A minimal air gap is preferably understood to mean the air gap between two components at the location of the smallest distance between these parts.
[0043] In another clutch device according to the invention, the extension of the second layer is greater in the axial direction than in the radial direction.
[0044] This achieves an especially large-area extension of the second layer perpendicular to the operative magnetic field, and thus greater efficiency.
[0045] In another clutch device according to the invention the second layer is thicker than the first layer.
[0046] Preferably the ratio of the thickness of the second layer to the first layer is in the range from greater than 1:1 up to and including 1.5:1, preferably greater than 1.5:1, especially preferably greater than or equal to 2:1, by particular preference greater than or equal to 4:1. In each case, this yields advantageous relationships of magnetic permeability and electrical conductivity of the brake region. In practical application, layer thickness ratios of 1:1-1.5:1 achieve a sufficiently advantageous effect.
BRIEF DESCRIPTION OF THE DRAWINGS
[0047] Various embodiments are disclosed, by way of example only, with reference to the accompanying schematic drawings in which corresponding reference symbols indicate corresponding parts, in which:
[0048] FIG. 1 is a schematic diagram of a clutch device according to the invention with a current eddy brake;
[0049] FIG. 2 is a perspective sectional view of the eddy current brake according to the prior art;
[0050] FIG. 3 a is a sectional view of an eddy current brake according to the invention; and,
[0051] FIG. 3 b is a sectional view along A-A of the eddy current brake according to the invention from FIG. 3 .
DETAILED DESCRIPTION
[0052] At the outset, it should be appreciated that like drawing numbers on different drawing views identify identical, or functionally similar, structural elements. It is to be understood that the claims are not limited to the disclosed aspects.
[0053] Furthermore, it is understood that this disclosure is not limited to the particular methodology, materials and modifications described and as such may, of course, vary. It is also understood that the terminology used herein is for the purpose of describing particular aspects only, and is not intended to limit the scope of the claims.
[0054] Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood to one of ordinary skill in the art to which this disclosure pertains. It should be understood that any methods, devices or materials similar or equivalent to those described herein can be used in the practice or testing of the example embodiments.
[0055] It should be appreciated that the term “substantially” is synonymous with terms such as “nearly,” “very nearly,” “about,” “approximately,” “around,” “bordering on,” “close to,” “essentially,” “in the neighborhood of,” “in the vicinity of,” etc., and such terms may be used interchangeably as appearing in the specification and claims. It should be appreciated that the term “proximate” is synonymous with terms such as “nearby,” “close,” “adjacent,” “neighboring,” “immediate,” “adjoining,” etc., and such terms may be used interchangeably as appearing in the specification and claims. The term “approximately” is intended to mean values within ten percent of the specified value.
[0056] FIG. 1 shows a clutch device 102 according to the invention with eddy current brake 300 . The clutch device 102 has an actuating device 204 , which in turn has an eddy current brake 300 . The eddy current brake 300 has a brake stator 303 having at least one coil 320 and a brake rotor 302 having a brake region 323 . The brake region 323 has a first layer 324 , which is electrically conductive and which has a first lateral face 324 . 1 and a second lateral face 324 . 2 . The first lateral face 324 . 1 faces toward the coil 320 and the second lateral face 324 . 2 faces away from the coil 320 . The brake region 323 has a second layer 325 , which is magnetic and which is connected to the second lateral face 324 . 2 .
[0057] During operation of the clutch device 102 , by activating the eddy current brake 300 , i.e., by applying current to the coil 320 , a magnetic field is generated which produces eddy currents in the first layer 324 . Through the second layer 325 , the magnetic circuit (dashed line) closes in the second layer 325 and thus already in the brake rotor 302 .
[0058] This avoids, in particular, the magnetic field from having to pass through yet another air gap, for example to an outer stator. Thus, the distance from the external stator or some other component in the vicinity of the brake rotor 302 can be enlarged and therefore the operational reliability increased. Furthermore, the brake rotor 302 gains heat capacity, which guards better against overheating, and efficiency is achieved due to the smaller air gap distance of the magnetic circuit.
[0059] FIG. 2 shows a perspective sectional view of the eddy current brake 300 according to the prior art. It has a brake stator 303 and a brake rotor 302 . The brake stator 303 has an internal stator 304 and an external stator 306 . At this point we refer to FIG. 4 of German patent application 10 2013 223 044.3, whose reference labels continue to be used and which shows the internal stator 304 in greater detail. The internal stator 304 has a first claw pole 308 having a disk segment 310 and pole claws, such as 312 . The internal stator 304 has a second claw pole 314 having a disk segment 316 and pole claws, such as 318 . The internal stator 304 has a central coil 320 . The pole claws 312 of the first claw pole 308 are located on the radially outer side of the disk segment 310 . The pole claws 312 of the first claw pole 308 are each angled at about 90° to the disk segment 310 , and each have a free end tapering from wide to narrow. The pole claws 312 of the first claw pole 308 are distributed around the disk segment 310 in the circumferential direction. There are gaps between the pole claws 312 of the first claw pole 308 . The pole claws 318 of the second claw pole 314 are located on the radially outer side of the disk segment 316 . The pole claws 318 of the second claw pole 314 are each angled at about 90° to the disk segment 316 , and each have a free end tapering from wide to narrow. The pole claws 318 of the second claw pole 314 are distributed around the disk segment 316 in the circumferential direction. There are gaps between the pole claws 318 of the second claw pole 314 . The first claw pole 308 with its disk segment 310 and the second claw pole 314 with its disk segment 316 are positioned on both sides of the central coil 320 . The pole claws 312 of the first claw pole 308 and the pole claws 318 of the second claw pole 314 surround and grip the central coil 320 radially on the outer side. The free ends of the pole claws 312 of the first claw pole 308 and the free ends of the pole claws 318 of the second claw pole 314 face toward one another. The pole claws 312 of the first claw pole 308 and the pole claws 318 of the second claw pole 314 mesh alternately with one another. The first claw pole 308 and the second claw pole 314 surround and grip the central coil 320 radially on the inside. The brake rotor 302 has a cup-like shape with a floor section 322 and a brake region with wall section and first layer 324 . The brake rotor 302 is positioned with its floor section 322 on the second claw pole 314 and with its wall section positioned with the first layer 324 radially on the outer side of the internal stator 304 . The external stator 306 is of coil-free design, and has a thin, flat ring-shaped form. The external stator 306 is magnetically permeable. The external stator 306 is positioned radially on the outer side of the brake rotor 302 . The internal stator 304 and the external stator 306 are firmly connected to a supporting part 326 . The supporting part 326 has a flange section and a hub section. The supporting part 326 and the external stator 306 form a housing-like receptacle for the internal stator 304 and the brake rotor 302 . The first claw pole 308 is located on the flange section of the supporting part 326 . The hub section of the supporting part 326 protrudes through a central cutout in the internal stator 304 . The brake rotor 302 is supported rotatingly on the hub section of the supporting part 326 with the help of a bearing 328 .
[0060] An eddy current brake 300 of this type has an air gap between the external stator 306 and the first layer 324 , and the magnetic circuit must close in addition across this air gap.
[0061] FIG. 3 a shows a sectional view along A-A of an eddy current brake 300 according to the invention, and FIG. 3 b shows a sectional view of the eddy current brake according to the invention from FIG. 3 . This eddy current brake builds on FIG. 1 and FIG. 2 . In contrast to the eddy current brake 300 from FIG. 2 , the brake rotor 302 has a second layer 325 in the brake region 323 , i.e., here in the wall section having the first layer 324 , and an external stator 306 is not absolutely necessary. In other respects it has preferably the same features as the eddy current brake 300 from FIG. 2 and FIG. 1 . Furthermore, the brake region 323 is at least partially cylindrical and the second layer 325 is made of a ring-shaped material. The second layer 325 is attached to the second lateral face 324 . 2 by means of a press fit. The second layer 324 . 2 is located radially outside of the first layer 324 . 1 , and the brake stator 303 has an internal stator 304 which contains the coil 320 . There is a minimal air gap present between the internal stator 304 and the first layer 324 , which is smaller than a minimal air gap between the second layer 325 and a stator component adjacent to the second layer 325 . The extension of the second layer 325 is greater in the axial direction than in the radial direction. The second layer 325 is thicker than the first layer 324 .
[0062] During operation of the clutch device, the magnetic circuit runs along the indicated path from {circle around ( 1 )} through {circle around ( 2 )} to {circle around ( 3 )}. From a pole claw 318 of the second claw pole 314 here it runs across the air gap between the internal stator 304 and the first layer 324 of the brake rotor 302 . It penetrates the first layer 324 (see {circle around ( 1 )}) and passes over into the second layer 325 , where it runs tangentially divided in the direction of the two adjacent pole claws 312 of the first claw pole 308 (see {circle around ( 2 )}) and back again through the first layer 324 , the air gap between internal stator 304 and the first layer 324 (see {circle around ( 3 )}) into the first claw pole 308 .
[0063] Hence, the magnetic circuit now runs only across an air gap, instead of—as in FIG. 2 —also imperatively across the air gap between the external stator 306 and the brake rotor 302 . The reliability is thus increased, and in addition also the efficiency, since it is possible to dispense with keeping the distance between an external stator or similar component small and since the thermal capacity is higher.
[0064] With this invention, a clutch device having an eddy current brake with a reduced air gap has been presented. In this case, the magnetic circuit is not closed via the external stator, as in the past, but via an additional layer (e.g., ring-shaped) which rotates together with the brake rotor (for example a brake disk). This layer is preferably of a material having the highest possible permeability, and is pressed directly onto the eddy current ring. This arrangement makes it possible to prevent a malfunction due to the rotor and the external stator touching. Because of the reduced air gap, the magnetic flux density in the air gap and thus the braking torque of the eddy current brake continue to be increased. In addition, this variant has the advantage that the thermal mass of the disk is increased, and thus the latter heats up less when generating the braking torque for starting the motor (e.g., in deceleration mode to couple the combustion engine).
[0065] It will be appreciated that various aspects of the disclosure above and other features and functions, or alternatives thereof, may be desirably combined into many other different systems or applications. Various presently unforeseen or unanticipated alternatives, modifications, variations, or improvements therein may be subsequently made by those skilled in the art which are also intended to be encompassed by the following claims.
REFERENCE LABELS
[0000]
102 clutch device
204 actuating device
300 eddy current brake
302 brake rotor
303 brake stator
304 internal stator
306 external stator
308 first claw pole
310 disk segment
312 pole claw
314 second claw pole
316 disk segment
318 pole claw
320 central coil
322 floor section
323 brake region
324 first layer
324 . 1 first lateral face
324 . 2 second lateral face
325 second layer
326 supporting part
328 bearing
|
The invention comprises a clutch device having an actuating device, wherein the actuating device has an electrical eddy current brake. The eddy current brake has a brake stator with at least one coil and a brake rotor with a brake region, wherein the brake region has a first layer which is electrically conductive and which has a first lateral face and a second lateral face, the first lateral face facing toward the coil and the second lateral face facing away from the coil. The brake region has a second layer which is magnetic and which is connected to the second lateral face. The invention further comprises a corresponding production method.
| 5
|
BACKGROUND
With heightened security requirements at facilities across the country and overseas, the need has become apparent for a device that can easily upgrade gates and fences to meet necessary crash barrier requirements. A simple device in use at Argonne National Laboratory since the mid-1980s provides an approach that has been improved with this invention. That device is believed to be the “novel gate barrier” determined to be in the public domain according to a letter on Argonne National Laboratory letterhead from E. Gale Pewitt, Chief Operations Officer, to Mr. David Fitzgerald at the Tennessee Innovation Center, dated Sep. 22, 1987. The “novel gate barrier” is simply a straight steel pipe with a wire rope cable through it. The cable ends are connected so that the cable forms a loop, part inside and part outside the pipe. The pipe is attached to the fence and the cable loop hangs below the pipe. A variation at another gate apparently has metal standoffs welded to the pipe and clamped to the cable to hold the cable above the pipe. The pipe is attached to the gate, and two bollards with hooks will catch the cable loop when impacted in such a way that the pipe passes through the bollards. Barrier Concepts, Inc., Crisp & Associates, and Performance Development Corporation have offered this “novel gate barrier” style barrier reinforcement for sale since the late 1980s.
The various versions of this “novel gate barrier” reinforcing system permit the full force of impact to bear as a concentrated load on one thickness of cable at the bollard catch-hook after the pipe has pushed through. Similarly, these systems do not provide protection against cutting action of the pipe ends or the standoffs on the wire rope.
In early 2003, Performance Development Corporation offered a system wherein two straight sections of pipe reinforced with cable and connected to each other were to be attached to a gate. This system was heavier and more complex in that it required additional cable fittings, additional pipe, an additional row of catch hooks on the bollards, and more precise placement of the attachments to the gate.
Although it is not known whether the “novel gate barrier” version used an I-beam to reinforce the bollards, the Barrier Concepts, Inc. and Performance Development Corporation versions did. Installation of reinforcing steel in the bollards can be inconsistent, potentially reducing the benefit of the reinforcement in resisting higher impact crashes.
The “novel gate barrier,” the Barrier Concepts, Inc., and the early 2003 Performance Development Corporation bollards all used catch hooks fabricated from pipe, welded to the surface of the bollard.
Our improved Security Barrier Reinforcing System 1) provides for distribution of the loading on the cable at impact, 2) transfers critical impact loading from the cable to the pipe, 3) eliminates sharp edges that could cut the cable from long term use or impact, 4) uses an improved catch hook design that is welded both at the surface and at the opposite side of the bollard, and 5) includes a modified reinforcement technique for the bollard to facilitate installation.
While numerous gates and barriers have been developed to stop or ensnare vehicles, patented devices to modify or strengthen existing gates and barriers are uncommon. Fischer's Fortified Gate System addressed in U.S. Pat. No. 5,740,629 (issued Apr. 21, 1998) and U.S. Pat. No. 5,987,816 (issued Nov. 23, 1999) is an example of such a reinforced system. The Fischer system, however, requires anchors with a spring-loaded locking mechanism, and does not provide a passive mechanism such as trapping the bollard catch to arrest forward motion. Once installed, our Security Barrier Reinforcing System does not require operation of any active elements to perform its function.
Field of Search:
Classifications 49/9; 256/13.1; 256/73
BRIEF SUMMARY OF THE INVENTION
This invention provides an improved system to upgrade a preexisting swinging or sliding gate or other barrier section to an effective anti-ram vehicle barrier by attaching to the barrier a reinforcing structural member and cable assembly that provides more evenly distributed loading and reduced damage potential to the cable. The invention also improves the bollards to catch the attached assembly by 1) increasing the strength of the catch hook and its attachment to the bollard and 2) providing for reinforcement positioning so that the bollards may be more easily installed properly.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an isometric drawing showing the best mode embodiment of the cable and structural member stopping assembly and bollards as installed to reinforce an existing gate.
FIG. 2 shows the best mode embodiment of the stopping assembly as attached to an existing barrier.
FIG. 3 shows a top view of the best mode embodiment of the stopping assembly and bollard arrangement
FIG. 4 shows a top view of the best mode embodiment, providing a detail of the anchored and reinforced vertical members (bollards) with catch hook.
FIG. 4 a shows a side cutaway view of the best mode embodiment, providing a detail of the anchored and reinforced vertical members (bollards) with catch hook.
FIG. 4 b shows a side view of the best mode embodiment providing a detail of the cable and structural member stopping assembly.
DETAILED DESCRIPTION OF THE INVENTION
An overview of the preferred embodiment (or best mode) of the invention is shown in FIG. 1 . This embodiment is based on a twenty foot wide drive, with an intent to stop a fifteen-thousand pound vehicle traveling at fifty miles per hour. In the preferred embodiment, the cable ( 1 ) is a 1½″ multistrand steel cable, but any cable of sufficient strength to provide the required stopping force would suffice. The invention consists of an assembly of flexible cable ( 1 ) routed through a structural member ( 2 ) that has joints and ends finished so that when impacted, the force of the impact is absorbed by both the structural member and the cable, the force is distributed with regard to the cable and no surface provides a cutting action on the cable. This assembly shall be of sufficient width to span the barrier or gate section to be protected (O) and shall be attachable to an existing barrier or gate in such a way as not to impede the regular operation of said barrier or gate. Additionally, the invention consists of a minimum of two bollards ( 3 ) made of reinforced, anchored structural members on the protected side of the barrier. These bollards shall be spaced to permit passage when the barrier/gate is open, and to catch the structural member/cable assembly when the gate is closed. Said bollards shall have catch hooks ( 4 ) arranged to catch said cable/structural assembly if the barrier or gate is impacted with a force greater than the barrier or gate alone would withstand, as by a vehicle attempting to crash through the barrier or gate.
Cable ( 1 ), structural member ( 2 ), and bollards ( 3 ) shall be sized according to the anticipated threat. In the preferred embodiment, the cable is formed into a loop by joining the ends using a standard means for joining cable sufficient to maintain required strength of the cable, such as a splice or multiplicity of rope clamps. The structural member in the attachable assembly shall be formed in such a manner as to avoid sharp edges that could cut the cable. Similarly, the bollard/catch-hook arrangement shall not present any sharp edges capable of cutting any part of the structural member/cable assembly.
FIG. 2 shows the attachable stopping assembly in greater detail. The structural member ( 2 ) could be any pipe, tube, beam, or channel of sufficient strength that could be configured with smooth bends so that no sharp edge will pull against the cable when impacted. The structural member could be bent so that no interior edges are exposed, or it could be welded, with any rough edges ground smooth. In the preferred embodiment, the structural member is 4″ schedule 40 or heavier steel pipe. The long straight section is a twenty-two foot section of pipe. Two ninety-degree bends with a short section of pipe between them are butt-welded to each end of the straight section of pipe. Small holes ( 5 ) are drilled in the outside low point of the elbow attached to each end of the straight pipe to provide drainage for rainwater or condensation that collects inside the pipe assembly. Once fabricated, the pipe assembly is hot dip galvanized. (The drain holes and coating are provided to reduce corrosion. The drain holes also reduce weight by preventing water build-up in the pipe.)
The cable ( 1 ) is routed through the pipe assembly ( 2 ), pulled tight, and the ends joined with a swaged fitting. (Any joining method that maintains the tensile strength of the cable is suitable. For instance, multiple rope clamps have been used to join the ends on occasion.) Once joined, the loop is pulled around so that the joint is inside the pipe assembly. The assembly provides a smooth interior surface and is arranged so that the cable enters the two open ends of the pipe with no cutting force against it as shown in FIG. 2 .
The cable and pipe assembly are then attached to the gate or barrier ( 0 ). In the preferred mode, this attachment is by clamping the cable with U-bolt brackets ( 6 ) to braces on the gate, but the attachment could be by any means to the bracing, fencing, or other barrier material, so long as it is sufficiently sturdy to support the assembly. If needed, braces could be added to the gate or barrier to support the cable/pipe assembly. Figure three shows a top view of the stopping assembly attached to the gate or barrier adjacent to the bollards.
FIG. 4 provides a detail view of the bollard. In the preferred mode of the invention, the bollards ( 3 ) are made up of a shell of 8′ long schedule 40 or heavier 12″ steel pipe with an 8″×23# reinforcing I-beam ( 7 ) inside along the centerline for approximately the bottom seven feet. The length of the bollard should be adjusted as appropriate for the application. Short pieces of rebar ( 8 ) are welded to the I-beam to center it within the pipe. A hole is cut in one side of the pipe for the cable horn catch, which is made of 3½″ round stock and welded to the pipe both where it penetrates the pipe and where it meets the opposite wall of the pipe at a 15° angle downward and 15° outward from the I-beam ( 7 ) web. The pipe may also have a hole cut in the opposite pipe wall, to facilitate welding the end of the catch hook from the outside. Excess round stock or weld material on the side opposite the hook is cut off and ground smooth as needed prior to galvanizing or painting. A tab ( 9 ) is attached to the pipe, welded in the preferred embodiment, at approximately ground level to indicate the orientation of the bollard. This tab is located to mark the face of the pipe that is to be installed facing the plane of the gate.
A 1″ hole is drilled through each side of the bollard pipe, perpendicular to the desired orientation of the I-beam web, approximately one foot below ground level, and approximately one foot above the bottom. In the preferred mode, the pipe/hook assembly is then hot-dip galvanized or coated to reduce corrosion.
Holes are drilled through the web of the I-beam to match the 1″ holes in the pipe. Short lengths of rebar are tack-welded onto the I-beam web to keep the I-beam centered in the pipe. The I-beam is then inserted into the pipe and suspended in position with 1″ rods (or rebar) ( 10 ) through the holes. The bollards are installed vertically, embedded for 5′ of their length below ground level in a concrete base. The installed bollards are filled with concrete to add to their mass and rigidity. The bollards should be close enough to the assembly attached to the gate or barrier to ensure that the assembly will catch on the hooks when impacted. In the preferred mode arrangement, this distance was set at 2″–3″. The base size should be adjusted for local conditions, to ensure sufficient anchoring to absorb the anticipated impact. In some conditions, rather than embedding the post in a concrete anchor, it might be desirable to attach vanes to the pipe and set the bollard in tamped earth without the concrete or to use some other anchoring technique. It is conceivable that one might want to build the bollard on a baseplate and reinforce the bollard with gussets for a more temporary arrangement.
|
A system for upgrading new and existing gates or barriers to provide improved crash barrier rating. This system comprises a reinforcing attachment to the gate or barrier and improved reinforced bollards with catch hooks to absorb the energy of impact from a vehicle. The reinforcing attachment is an arrangement of cable and structural members that provide for increased reinforcement by ensuring that the load is distributed on the cable to minimize the risk of breakthrough as a result of cable failure. The bollards have been improved by strengthening the catch hook attachments and adding reinforcement positioning elements to facilitate proper assembly.
| 4
|
The National Institutes of Health provided funding used in part for this invention under grant GM 24365. Accordingly, the Federal Government may have certain rights in this invention pursuant to 35 U.S.C. 202.
This application is a continuation of application Ser. No. 07/293,235, filed Jan. 4, 1989 now U.S. Pat. No. 5,030,566.
BACKGROUND OF THE INVENTION
A. Field of the Invention
The present invention describes a method for producing DNA length standards useful in sizing long DNA molecules (40-600+kb) typically encountered when working with chromosomal DNA, for example during chromosomal mapping, or with large viral and plasmid DNA. Specifically, the invention is a method for enzymatically constructing such standards by use of crude cell extracts and with the realization of both a previously unattainable stability of the standards and control of their length.
B. Description of the Related Art
As the study of molecular biology evolved, workers in this field strived to manipulate and fractionate by size larger and larger pieces of DNA using the molecular tools previously successful on smaller fragments of DNA. However, serious difficulties arise when manipulating very large DNA molecules. One set of the problems has given way to recent advances in the field of electrophoresis which utilize rotating gels or pulsing electric fields. Using these new techniques, it is now possible to fractionate by length DNA molecules as long as 10 megabases (Cantor, et al., 1988; Cantor and Schwartz, 1984; Serwer, 1987; U.S. patent application, Ser. No. 212521 incorporated herein by reference).
Not the least of the problems remaining for workers wishing to use the new techniques of rotating gel electrophoresis (RGE) and pulsed-field electrophoresis is the availability of stable, reproducible length standards which provide discrete markers of known length. The most useful primary length standards used in the past have been obtained by annealing single-stranded ends of mature, 49 kb bacteriophage λ to form concatemers (end-to-end multimers of the monomeric DNA).
However, λ standards suffer limitations due to their short terminal repeats (12 bp); damage to these ends either before or during the concatemerization process limits the length of the concatemers. The concatemers of λ phage that do form are not particularly stable to denaturation since the overlapping ends are quite short. Thus, when used under conditions that even mildly denature DNA, such as elevated temperature, bacteriophage λ standards are destabilized and rendered useless as DNA length markers.
Additional problems arise with the λ standards if the standard preparation is allowed to sit for even short periods of time. Since the concatemerization which occurs with the λ DNA is non-enzymatic, these preparations tend to further concatemerize over time giving rise to non-reproducible results from one usage to the next and to a much shorter shelflife. The only successful manner in which to prevent deterioration of λ standards is to maintain them in significantly diluted solutions which requires at least one subsequent concentration step or which renders them too dilute for many applications.
Other viruses with terminally repetitious, double-stranded DNA are the T-odd bacteriophages. During infection, T7-related bacteriophages produce linear, end-to-end concatemers of the unit length viral genome. These concatemers are then incorporated as a single viral genome into preformed coat-protein shells called proheads. Although the exact mechanism for construction and cleavage of the concatemers and the subsequent packaging of this DNA into the bacteriophage coat-protein has been the subject of extensive study, it is not yet completely understood.
The details of some of the physiological events for the T7 bacteriophage began to be known around 1970 when investigators noticed "intermediates" during the intracellular DNA synthesis of several species of bacteriophage (Kelly and Thomas, 1969). By the middle of the 1970's, workers using rate zonal centrifugation and electron microscopy established that the formation of DNA concatemers inside the bacterial host cell did not arise from normal bacteriophage recombination (Miller et al., 1976). Subsequently, it was found that most of this type of concatemer did not contain integral multiples of the monomeric length T7 DNA (Serwer, et al., 1987).
Using restriction endonuclease analysis, it was possible to determine that most of the concatemeric DNA from T7-infected cells consisted of bacteriophage genomes arranged in a linear head-to-tail fashion. (Langman et al., 1978; Serwer, et al., 1987). Adjacent genomes within a concatemer were found to overlap for a length of about 200 base pairs which was far greater than the overlapping 12 base pair tails of λ bacteriophage DNA (Langman et al., 1978). Later, the length of the T7 terminal repeat was found to be 160 base pairs (Dunn & Studier, 1983).
Advances in a similar double-stranded bacteriophage, T3, established that an in vitro system could be used in which mature DNA purified from T3 was packaged into the empty viral head precursors. The concatemers generated by this method were visualized by electron microscopy and by their incorporation into infectious bacteriophage particles (Fujisawa et al., 1980). The emphasis of subsequent research using the T3 bacteriophage has been to refine the in vitro system for the purposes of maximizing the T3 DNA packaging reaction when conducted with unconcatemerized, monomeric DNA (Hamada et al., 1986; Shibata et al., 1987).
Studies of organization and expression of T7 DNA led to the determination of its nucleotide sequence and the localization of some of the genetic elements responsible for the bacteriophage functions in the host cell (Studier and Dunn, 1983; Dunn and Studier, 1983; Lee and Sadowski, 1984; White and Richardson, 1987). It is important to note that all of the studies involving the use of mutants of T7 and of processing of bacteriophage DNAs have focused upon the complete maturation cycle. Though the concatemers formed by these systems were manipulated extensively and fractionated by centrifugation, nothing in the literature suggested that the concatemeric products of the T7 bacteriophage themselves could be viewed as an end-product useful as a DNA length standard for which a maximized system might be derived.
Attempts by one of the inventors of the current invention to fractionate in vivo T7 concatemeric DNA by agarose gel electrophoresis initially met with very limited success (Serwer and Greenhaw, 1981; Serwer, et al. 1987). Only a minority of these in vivo concatemers formed bands at integral (η) length the multiples of the T7 monomer; the longest of these had an 0 of 4. It was not feasible to control the natural viral metabolism in a manner to produce stable, discrete DNA length standards. It was necessary to overcome these problems in order for the T7 concatemers, which possessed several advantages to the concatemers of λ DNA, to be used as DNA length markers.
SUMMARY OF THE INVENTION
Accordingly, the present inventors have now discovered a successful method for enzymatically joining segments of DNA to form concatemers useful as DNA length standards. These concatemers, formed in vitro, are primarily found as discrete-length classes each representing an integer multiple of substrate DNA (Son, et al., 1988). During rotating gel electrophoresis, these discrete-length concatemers form a series of bands referred to as a ladder.
It is the intent of the invention, therefore, to provide the benefits of using these DNA concatemers by disclosing a method for the production of stable, reproducible standards via techniques that allow precise control of length distribution. The invention provides an unexpectedly successful method for producing concatemeric DNA molecules with a distribution of defined and discrete lengths. In a preferred embodiment, it achieves this by adding purified DNA to extracts of bacterial cells which have been infected with selected bacteriophage mutants, buffered in a unique manner to accommodate temperature fluctuations, and then controlling the ensuing concatemerization of DNA in the buffered cell extracts in a precise way using a surprising property of the packaging enzymes of the extract.
Therefore, according to the present invention there is provided a method for producing ranges of DNA length standards. It is, for instance, possible to achieve concatemerization of exonuclease-digested, exogenous DNA added to mere extracts of bacterial cells themselves. However, by infecting the cells with either nonmutated T7 or a related bacteriophage or with bacteriophage mutated in one or more important genes, significant improvements can be realized in production of concatemers.
For example, the inclusion of T7 gene product 6 increases concatemerization without relying on addition of exogenous exonuclease to the extract. Furthermore, by using extracts from bacterial cells infected with bacteriophage having mutations in one or more of the genes responsible for bacteriophage DNA synthesis, unwanted endogenous DNA synthesis by the infecting bacteriophage is virtually eliminated. Generally, in order to provide these gene products in the eventual extract, it is advantageous to produce two separate, complementing extracts each individually incapable of promoting bacteriophage DNA synthesis but, in combination, completely capable of doing so. By mixing the separately prepared extracts, one achieves an extract fully capable of concatemerization but which has no significant background of DNA prior to the addition of substrate DNA.
Additionally, it has been demonstrated that the substantial elimination of packaging in the extracts is an advantageous component of the present invention. This can be achieved by mutating one or more of the genes responsible for packaging T7 DNA. By doing so, it is possible to produce concatemers by incubating the extract with substrate DNA at 30° C., a temperature at which packaging would otherwise occur. However, the maximal production achieved by the present invention limits packaging and the rate of concatemerization by either lowering the temperature to 0°-4° C. or by a combination of low temperature and mutation of one or more packaging genes.
The resulting product of the process described herein is virtually a custom-made-to-order range of standards selected by altering the conditions of the reaction or by altering the substrates themselves in kind or concentration. By varying the mutant combinations, the extract reaction conditions or the substrate DNA, it is possible to produce a variety of standard preparations. For instance, by reducing the concentration of the substrate DNA used, progressively more open circular DNA is produced. In this manner, open circular DNA useful as a DNA standard in its own right can be produced for DNA as long as 4η.
The preparations produced in accordance with the present invention provide a readily usable, highly concentrated and very stable source of DNA length standards. They can be applied in the determination of the lengths of unknown DNA fragments using a wide variety of typically encountered electrophoretic methods including the state-of-the-art rotating gel or pulsed-field techniques.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1--Concatemerization cycle of the invention. Depicted here is the leading theory for the mechanism of concatemerization in T7 bacteriophage as it would occur in the extract produced by the method claimed.
FIG. 2--Formation of concatemers at 0° C. The experiment of FIG. 2a was performed at 0° C. The times (minutes) of quenching used were (1) 0, (2) 3, (3) 6, (4) 9, (5) 12, (6) 15, (7) 18. The arrow indicates the direction of electrophoresis, the arrowheads indicate the origin of electrophoresis, and the asterisk indicates a band of circular DNA deduced from data not included herein.
FIG. 3--Formation and packaging of concatemers in vitro. (a) A T7 4 ,9 +T7 5 ,19 extract. Immediately after adding DNA, these mixtures were incubated at 30° C. for the times indicated below before quenching and analysis by RGE. (b) A second experiment was simultaneously performed, as described above, but with one alteration; the extract-DNA mixture was incubated at 0° C. for 30 minutes before incubation at 30° C. The following were the times (minutes) of incubation at 30° C. (number of lanes indicated): (0) 0, (1) 2.5, (2) 5, (3) 10, (4) 15, (5) 20, (6) 30, (7) 45, (8) 60, (9) 60 but with digestion by DNase I before quenching. The arrow indicates the direction of electrophoresis; the arrowheads indicate the origins of electrophoresis.
FIG. 4--Identification of bands. Subjected to RGE in the same gel were the following linear DNA length markers: lane 2, a mixture of the mature DNAs of bacteriophage T4, T5, and T7; lane 1, a restriction endonuclease HindIII digest of bacteriophage λ DNA. Lane 3 contained concatemers formed by a T7 4 ,9 +T7 5 ,19 extract after 4 minutes at 0° C. The direction of electrophoresis is indicated by the arrow, the arrowheads indicate the origin of electrophoresis, and the asterisk indicates a band of circular DNA deduced from data not included herein. The positions of the fragments of the HindIII digest are indicated by their fraction of the length of mature T7 DNA.
FIG. 5--Ladders formed by either a mixture of two double mutants or one double mutant. Extracts were divided into 10 μl aliquots. Either pooled extracts (A) of T7 5 ,19 +T7 4 ,9 or single extracts (B) of T7 3 ,19 were used. To each aliquot T7 DNA was added to bring the final DNA concentration to 100 μg/ml and these aliquots were incubated at 0°-4° C. (Lanes A1-A8 and lanes B1-B6) or at 30° C. (Lanes A9-A12 and lanes B7-B11). Lanes to the extreme right and left contain mature T4, T5 and T7 as markers. Incubation times (minutes) were as follows; A1=3, A2=6, A3=9, A4=12, A5=15, A6=18, A7=21, A8=30, A9=2, A10=5, A11=7, A12=9; B1=10, B2=20, B3=30, B4=44, B5=56, B6=85, B7=2, B8=4, B9=6, B10=8, B11=11.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Therefore, in accordance with the present invention, there is provided a method for the production of DNA length standards useful in sizing long DNA molecules. In a preferred embodiment, specific mutant combinations are used to produce the necessary bacteriophage gene products and to exclude unwanted DNA and, in some cases, bacteriophage gene products from the extract. While it is possible to use uninfected cells as described further herein, the significant advantage of using bacteriophage extracts allows formation of at least 10-11 higher multimers.
Certain gene products have been found to be advantageous when included in the concatemerization extracts. For instance, one may exploit the exonuclease activity of the bacteriophage gene 6 product either endogenous to the extract or added exogenously to provide the necessary 3' overhangs. Under the conditions existing in the normally infected cell, the 3' overhangs are believed to be produced through incomplete DNA synthesis toward the 5' end of the single-stranded template and not by the functioning of the gene 6 product. It is believed that several other exogenously added exonucleases can substitute in vitro for gene 6 product. Exonuclease III of E. coli, an enzyme that produces 5' overhangs, is an example successfully tried by the inventors.
The use of bacteriophage having amber mutations in certain genes (for example, Dunn and Studier, 1983) allows one to exclude unwanted bacteriophage gene products from the reaction mixtures. Mutations can be made in any of the genes required for bacteriophage DNA metabolism, including gene 3, 4 or 5 or combinations of these genes. Gene 4 and 5 mutations eliminate DNA synthesized in vivo from the extracts. Likewise, the use of mutations in bacteriophage genes required for packaging the concatemers into viral coat proteins can be made; these genes include 8, 9, 10, 18 or 19 or combinations of these genes.
Practice of the invention is facilitated by the surprising discovery that concatemerization and packaging can be uncoupled; concatemerization is slowed and packaging is virtually stopped by lowering the temperature to about 0°-4° C. Substrate-extract mixtures incubated for one hour at 0° C. produce about 1×10 9 fold fewer plaques than similar mixtures incubated at 30° C. Even when the reactions are allowed to proceed overnight, the ratio remains as high as 1×10 4 to 1×10 5 . By exploiting the difference in sensitivity to temperature, one may virtually eliminate packaging of concatemers while simultaneously allowing successive cycles of concatemerization to proceed at a slowed and, therefore, more easily controlled rate. Finally, in order to take advantage of this distinction between the extract activities, the inventors had to design a buffering system which would provide adequate buffering capacity at both the higher and the lower temperatures utilized in the method.
The concatemers produced by the methods disclosed here may be used as discrete standard markers of exactly known lengths for gel electrophoresis. In its most preferred embodiment, precise ranges of the concatemeric standards can be produced in a made-to-specifications process since the methods provide a previously unattainable technique for the precise control of concatemerization. The products of these methods, aside from their uniquely controlled production, provide distinct advantages as DNA length standards over those currently available. The present method is highly reproducible and convenient given the proper techniques and starting materials. With the aid of the present disclosure, the production of the concatemers would be easily accomplished in the working laboratory by one of skill in the art.
A variety of alternatives exist which provide flexibility to the methods described. For example, under certain conditions, one may prefer to eliminate the infection of the host cell altogether. By doing so, the range of possible multimers is significantly reduced but the need and expense required to generate the infecting bacteriophage is eliminated. Alternatively, the skilled worker may choose to use a single infecting bacteriophage to supply the gene product 6. In another embodiment, an exonuclease from an exogenous source, for example, purified gene product 6 or E. coli exonuclease III, may be used to treat the substrate DNA to create the overhangs necessary for concatemerization. Such exonuclease-treated substrate DNA can be produced either by first treating the substrate DNA with the selected exogenous exonuclease and then mixing the substrate DNA with the bacterial cell extract, or alternatively, by simply preparing a mixture of the bacterial cell extract, the substrate DNA, and the exogenous exonuclease. Accordingly, the term "exonuclease-treated" DNA is expressly intended to refer to DNA treated in accordance with either of these procedures.
Finally, in a highly preferred embodiment, one may infect separate bacterial cell cultures with separate bacteriophage. These bacteriophage are selected from a collection of double amber mutants, each of which contains a mutation in a different bacteriophage gene required for DNA synthesis and also each of which contains a mutation in the same bacteriophage gene required for packaging the concatemers. In other words, one may separately infect at least two bacterial cell cultures each with a different T7 bacteriophage where; (1) the infecting bacteriophage are selected so that functional T7 gene 6 is present in either one of the bacteriophage or in the combination of both, and where (2) one bacterial cell culture is infected with a first T7 bacteriophage characterized further in that the first bacteriophage contains mutations in at least one of the T7 genes responsible for viral DNA synthesis and in at least one of the T7 genes responsible for packaging of the viral DNA, and where (3) the other bacterial cell culture is infected with a second T7 bacteriophage characterized further in that the second bacteriophage contains mutations in at least one of the T7 genes responsible for viral DNA synthesis distinct from that selected in the first bacteriophage and which contains mutations in the same T7 gene or genes responsible for packaging of the viral DNA as was mutated in the first bacteriophage.
For example, the first double mutant selected might be T7 4 ,9 where gene product 4 is required for DNA synthesis and gene product 9 is required for packaging. The second double amber mutant could be T7 5 ,9 where gene product 5 is required for DNA synthesis but is different from gene product 4 and where gene product 9 is again mutated as in the first double mutant eliminating it altogether from the mixed extract. Alternatively, it may be preferred to use bacteriophage having mutations in gene 19 instead of in gene 9.
In yet another embodiment, concatemerization is carried out on extracts devoid of functional gene product of T7 gene 3. With this embodiment, substrate DNA may be incubated with either extracts of bacterial cells infected with a single T7 bacteriophage having a mutation in gene 3 or with a mixture of extracts of separately infected bacterial cells, where each of the infecting bacteriophage has a mutation in gene 3.
The general method of the invention can be applied in its most preferred embodiment to strains of E. coli. Even more preferred are non-permissive E. coli host strains such as E. coli BB/1. Alternatively, similar enteric hosts for T7 can be utilized, namely certain strains of Shioella or Yersinia.
The selection of an optimal buffer in which to extract the host cells may markedly enhance the success of the method. Such a buffer should retain the lysis-enhancing characteristics of Tris buffers. Additionally, the buffer should have the capacity to function at temperatures below 30° C. In its most preferred embodiment, the extraction buffer should be composed of a Tris-phosphate buffer at about pH 7.4. Such a buffer combines the attributes of Tris with the temperature capacity of phosphate buffers.
The substrate DNA added exogenously to the concatemerization extract can be any one of a number of DNAs. It will typically be a T7-related bacteriophage DNA (such as T7 or T3) with the characteristic long terminal repeats of this group of bacteriophage. T5 DNA has been tried by the inventors but presents problems as yet unresolved. Alternatively, the substrate DNA may comprise at least some nonviral DNA, for example synthetic DNA. In yet another embodiment, the substrate DNA may be a mutant variety of the selected bacteriophage DNA. In its most preferred embodiment, however, the DNA will be that of non-mutant T7 bacteriophage.
One may run the concatemerization reactions at 30° C. or at a lower temperature, for example, about 0°-4° C. This may be done at the lower temperatures without using bacteriophage mutated in the packaging genes, but in another embodiment may be accomplished at either temperature range in combination with such mutant bacteriophage. In its most preferred embodiment, the method would utilize mutation in at least one of the packaging genes of the infecting bacteriophage in combination with a reaction temperature of about 0°-4° C.
Upon completion of the desired level of concatemerization, one may inactivate the enzymes of the extract by a variety of means including the use of anionic detergents. While the exact mechanism for concatemerization is still unknown for T7, it involves at least some required enzymatic activity. It is the intention of the invention to produce a stable concatemer mixture by inactivating the enzymatic concatemerization activity of the extracts with detergent. These detergents may include lauryl sulfate and N-lauroylsarcosine (sarkosyl). In addition, it will often prove advantageous to treat the concatemer product solution with a non-specific protease. These proteases may include subtilisin or protease K. The T7 concatemers thus produced have been stable for as long as 12 months or greater.
Finally, since large DNAs are quite susceptible to shearing forces, it is advantageous to minimize handling and the resulting shearing force it produces. Therefore, in a preferred embodiment one may trap the product concatemers in agarose blocks conveniently sized to allow ease of use in various electrophoretic procedures (Cantor and Schwartz, 1984).
The methods described above can be depicted as a cyclical concatemerization (FIG. 1). The concatemerization process begins at the center of the diagram with a monomeric (0) DNA substrate molecule and proceeds in a cyclical manner through three stages before advancing to the next turn of the cycle; (1) gene product 6 or an enzyme with similar characteristics (for example E. coli exonuclease III) creates single-stranded overhangs via an exonuclease activity on each of the existing ends of the substrate DNA, (2) two molecules of the exonuclease-digested substrate, each with a different chain digested, are joined by base pairing between the complementary overhangs to produce a duplex molecule, (3) limited DNA repair takes place over the joint between the pair of substrate molecules and some may be covalently joined by ligation producing a 2η substrate DNA for the next turn of the cycle.
Under normal conditions, both in the cell and in the extracts, concatemers formed in this manner undergo maturation back into the monomeric bacteriophage genome and are packaged into the coat-protein of the viral head. The invention teaches the exploitation of an unexpected differential temperature sensitivity between those reactions leading to packaging and maturation and those reactions which extend the concatemer lengths. Since the packaging reaction is eliminated, selection of specific time points at which the concatemerization reaction is inactivated gives rise to a given range of concatemers.
Though it is not shown in this diagram for the sake of simplicity, it can be seen that concatemers with odd-numbered multiplicities can arise by combinations of an η sized fragment base pairing with a 2η, 4η, etc. sized fragment. Additionally, it can be seen that the head-to-tail hybridization between ends of the same molecule could produce circular molecules. Such molecules have been seen in the in vitro concatemers as open circles of DNA for multimers of up to 4η.
Furthermore, it can be seen in FIG. 1 and as described further here that circular DNA molecules can readily be formed by the annealing of the complementary overhangs of a single monomer length molecule or of any of the higher multimers. It has been found by the inventors that by limiting the initial substrate DNA concentration one may generate proportionally more circular standards in comparison to linear molecules. The invention, therefore, encompasses production of circular standards as well as production of the preferred linear standards.
The following examples describe the actual steps necessary to generate a selected range of T7 concatemers and to visualize them after electrophoresis by RGE. These examples are intended to illustrate certain aspects of the present invention and should not be construed as limiting the claims thereof.
EXAMPLE I
The following protocols describe the particular experiments which led to the disclosed invention. These experiments were designed to study both the concatemerization and the packaging reactions. The results conclusively demonstrate that the in vitro reaction of crude extracts of infected cells can selectively concatemerize DNA while limiting packaging.
A. BACTERIOPHAGE AND HOST STRAINS
Bacteriophage T7 amber mutants in gene 4, 5, 9, or 19 were described by Studier (1969). A T7 amber mutant is indicated by T7 with the number of the mutated gene(s) in subscript. The double mutants, T7 4 ,9 and T7 5 ,19, were constructed with a genetic cross and tested by complementation. The permissive host for amber mutants was Escherichia coli 0-11'. The nonpermissive host and the host for wild-type T7 (T7 wt ) was E. coli BB/1.
B. MEDIA, BUFFERS, AND REAGENTS
Bacteriophages were stored in Tris/Mg buffer (0.2 M NaCl, 0.01M Tris-Cl, pH 7.4, 0.001M MgCl 2 ) NET buffer was used for storing DNA (0.1M NaCl, 0.01M Tris-Cl, pH 7.4, 0.001M EDTA). Extract buffer was used for preparing in vitro assembly extracts (0.1M NaCl, 0.02M Tris-phosphate, pH 7.4, 0.006M MgSO 4 , 10 μg/ml gelatin). Stop buffer was used to terminate in vitro assembly (0.1M NaCl, 0.1M EDTA, 0.033M Tris-Cl, pH 7.5, 1% Sarkosyl, 36 μg/ml RNase A). Sample buffer (for electrophoresis) was 55% sucrose, 400 μg/ml bromphenol blue, 0.01M sodium phosphate, pH 7.4, 0.001M EDTA. Electrophoresis buffer, used for RGE, was 0.01M sodium phosphate, pH 7.4, 0.001M EDTA. The protease, subtilisin, and its inhibitor, phenylmethylsulfonyl fluoride (PMSF), were purchased from Sigma Chemical Co.
Bacteria were grown in 2X LB medium: 20 g bacto tryptone, 10 g yeast extract, 5 g NaCl, 1000 ml water. Seakem LE agarose, obtained from the Marine Colloids Division of FMC Corp., was used to form all gels for electrophoresis. Restriction endonuclease XbaI was purchased from New England Biolabs (Beverly, Mass.).
C. MATURE BACTERIOPHAGE DNAs
To obtain mature T7 DNA, bacteriophage T7 wt was grown in 2X LB medium and purified as previously described (Serwer, 1980). DNA was extracted from T7 with phenol as described in Maniatis, et al. (1982). The DNA was stored in NET buffer at 4° C. and used as a substrate for concatemerization within 6 months. The mature DNAs of bacteriophage T4 and T5 were obtained as described in Serwer (1980). These DNAs were used as markers for the length of linear, double-stranded DNA. The length of T7 DNA is known to be 39.936 kb (Dunn and Studier, 1983). The reported lengths of T5 and T4 DNAs vary but a reasonable consensus appears to be 111-116 kb for T5 (McCorquodale, 1975) and 170 kb for T4 (Kutter and Ruger, 1983). The fragments of HindIII digests of bacteriophage λ DNA were used to mark the positions of linear DNA shorter than mature T7 DNA. The HindIII fragments visible here had lengths of 22.1, 8.82, 6.12, and 4.03 kb (Wellauer et al., 1974). The restriction enzyme HindIII digest used was purchased from Bethesda Research Laboratories (Gaithersburg, Md.). Bacteriophage λ DNA, 48.50 kb long (Sanger et al., 1982), was purchased from the same source. To cyclize λ DNA, the procedure described in Serwer and Hayes (1987) was used.
D. PREPARATION OF INFECTED CELLS FOR IN VITRO CONCATEMER FORMATION
A culture of E. coli BB/1 was grown to 4×10 8 /ml in 2X LB medium with aeration at 30° C., and was then infected with T7 4 ,9 (m.o.i.=5). At 19-20 minutes after infection, the cells were chilled to 0° C. and pelleted at 10,000 rpm for 10 minutes in a Beckman J-20 rotor. The pellet was washed once in extract buffer at 0° C. and then resuspended in extract buffer in a volume 1/350X that of the infected culture. The resuspended cells were frozen at -70° C. Frozen cells infected with T7 5 ,19 were also prepared by the procedure described above.
E. IN VITRO CONCATEMER FORMATION
To prepare an extract for in vitro concatemer formation, infected cells frozen as described above were thawed with vortexing at 4° C. after adding a 1/50 vol of 10 mg/ml lysozyme in 0.015M Tris-Cl, pH 8.0, 0.0075M MgCl 2 , 0.01M EDTA. Subsequently, the lysates were incubated at 0° C. for 10 minutes and were clarified by centrifugation in an Eppendorf tabletop centrifuge at 4° C. for 2 minutes (15,000 rpm). After clarification, a portion of a T7 4 ,9 extract was added to an equal volume of a T7 5 ,19 extract. To this mixture was added a 0.25X vol of 50% dextran-10 in extract buffer. Two final additions were made: (a) a 0.111X volume of 0.1M MgSO 4 , 0.02M ATP, 0.025M spermidine, pH 7.4, and (b) a 0.00025X volume of β-mercaptoethanol. This mixed extract will be referred to as T7 4 ,9 +T7 5 ,19 extract After the final additions, this mixture was held on ice for no more than 1 hour before addition of DNA and incubation, as described below. Extracts prepared as described above and analyzed by agarose gel electrophoresis-ethidium bromide staining (without addition of DNA), as described below, had no detectable background of DNA. However, if the clarification was omitted after thawing of infected cells, there was a detectable background of monomeric DNA. This DNA presumably was released from infecting bacteriophage that had absorbed to, but had not injected their DNA into bacteria.
F. INACTIVATION OF IN VITRO REACTIONS AND ANALYSIS OF DNA BY RGE
Reactions in the extract-substrate DNA mixture were inactivated to prepare the samples for analysis by rotating gel electrophoresis using the following procedure. A 10X volume of stop buffer was added to the mixture and it was incubated at room temperature for 30 minutes, followed by an additional incubation at 75° C. for 10 minutes (second incubation is optional). The latter incubation, but not the former, would completely release from its capsid any of the DNA packaged in mature T7. Subsequently, a 0.043X volume of 30 mg/ml subtilisin was added, followed by incubation at 30° C. for 1 hour and at 4° C. overnight. Omission of the subtilisin resulted in DNA that arrested near the origin of electrophoresis, presumably because of aggregation with proteins. The digestion with subtilisin was stopped by adding 1 μl of 0.01M PMSF to 40 μl of digested sample.
Next, 5 μl of sample buffer was added and the entire amount was layered in the sample well of a gel for RGE. To avoid degradation by shear (Davison, 1959), the DNA was pipetted slowly with a pipet that had an inner diameter of 1 mm. The gel used for RGE was a 1.5% agarose gel, poured in electrophoresis buffer as previously described (Serwer, 1987) and submerged beneath electrophoresis buffer. After layering DNA in sample wells, the DNA was electrophoretically driven into the gel for 10 min at 3 V/cm, without rotation of the gel. Reciprocal, periodic rotation of the gel to two positions was then started and electrophoresis was continued at the indicated voltage gradient and temperature, as previously described (Serwer, 1987). The angle between the two positions (Ψin Serwer, 1987) was 144°. The time between rotations (i.e., the time that the gel was stationary) was 20 seconds and the speed of rotation was 100°/second. Temperature was controlled to within±2% by circulating buffer through a temperature-controlled water bath.
After electrophoresis, the gel was stained for 2-3 hours in 1 μg/ml ethidium bromide dissolved in electrophoresis buffer. Gels were photographed on Kodak Tri-X film through a Tiffen 23A (orange) filter during illumination with a 300-nm (peak wavelength) ultraviolet transilluminator.
G. CONCATEMERIZATION AT 0° C.
The following experiment describes results obtained when extracts prepared as described above were incubated and used to selectively inhibit packaging almost completely while allowing progressive concatemerization of substrate DNA to proceed at a controlled rate. The methods used were identical to those above except that incubation was carried out at about 0°-4° C. as opposed to 30° C. After 3 minutes at 0° C., the first band of concatemer had formed (FIG. 2, lane 2; a 0-minute sample was analyzed in lane 1). As the time increased to 6, 9, 12, 15, and 18 minutes, bands of larger concatemers progressively formed (FIG. 2, lanes 3-7, respectively). In comparison with results obtained at 30° C., FIG. 3, (a) the intensity of bands was increased at the expense of the continuous background of DNA, and (b) concatemerization was slowed. There was no detectable packaging of DNA in FIG. 2. In a separate experiment, the titer of infectivity produced after overnight incubation at 4° C. was 8.5×10 7 , significantly above background, but 3-4 orders of magnitude below a titer of 1.8×10 11 achieved at 30° C. after a 60-minute incubation with the same extract. Thus, incubation at 0°-4° C. inhibits packaging significantly more than it inhibits concatemerization.
These results demonstrate the significant advantage afforded by the use of lower temperatures for the formation of distinct concatemer bands. This is particularly evident when comparison is made with the equivalent reactions at 30° C. described in FIG. 3.
H. CONCATEMERIZATION AT 30° C.
For sake of comparison, experiments were carried out at both higher (30° C.) and lower (0°-4° C.) temperature ranges. To observe the conversion products of mature T7 DNA as a function of time at 30° C. in a T7 4 ,9 +T7 5 ,19 extract, the conversion products were observed by RGE at 2.5, 5, 10, 15, 20, 30, 45, and 60 minutes after the start of incubation. By 2.5 minutes, almost all DNA migrated more slowly than monomeric T7 DNA (FIG. 3a, lane 1). Both a continuous background of DNA and DNA that formed bands was observed. As shown below, all but a small fraction of this DNA is linear. The profile did not change at 5 minutes (FIG. 3a, lane 2), and was also not altered by preincubation of the DNA-lysate mixture at 0° C. for 30 minutes (FIG. 3b, lane 1), a procedure that caused extensive concatemerization. By 10 minutes an increase in the amount of monomeric DNA was observed (FIGS. 3a and 3b, lanes 3). This increase in monomeric DNA continued at 15-60 minutes (FIG. 3a, lanes 4-8) and its kinetics were not altered by the preincubation (FIG. 3b, lanes 4-8). To determine whether or not the monomeric DNA present at 60 minutes was packaged, before quenching a duplicate 60-minute sample was digested with DNase I. The result was digestion of all concatemeric, but not most monomeric, DNA (FIG. 3b, lane 9). Thus, most of the monomeric DNA at 60 minutes was packaged. The absence of an effect of preincubation on the rate of packaging suggests that concatemerization is not rate limiting for DNA packaging.
As DNA was packaged in FIGS. 3a and 3b, the bands formed by concatemeric DNA became significantly more intense in relation to the continuous background and the average distance from the origin increased (and, therefore, the average length of a DNA molecule decreased). Both of these observations suggest that the DNA packaged was cut from concatemers. The six bands closest to the band of monomeric DNA were separated by a roughly constant nearest neighbor distance.
I. THE LENGTHS OF CONCATEMERS
To determine the lengths of the concatemers that formed bands in FIGS. 2 and 3, the positions of these bands in relation to the positions of bands formed by T4 and T5 DNA markers of known length were determined (FIG. 4). To increase the resolution of this analysis in the region covered by the markers (2-5X the length of monomeric T7 DNA), the voltage gradient was lowered to 2 V/cm. An additional consequence of this change in voltage gradient was some loss of resolution for longer concatemers. The position of the band of concatemer indicated by 3 at the right in FIG. 4, lane 3, is coincident with the position of the band formed by T5 DNA (lane 2). Because the length of T5 DNA has been found to be 0.93-0.97 times the length expected of a trimeric T7 concatemer, the DNA that forms band 3 is assumed to be a trimeric concatemer. The DNA that forms band 2 is assumed to be a dimeric concatemer. If so, then the data of FIG. 4 suggest that T5 DNA is 118 kb long, 3-7% longer than previously reported. Band 4 in lane 3, FIG. 4 is in the position relative to T4 DNA (lane 2) of a tetrameric concatemer. These data suggest that the bands in the constant spacing series observed in FIGS. 2 and 3 are formed by linear T7 concatemers that consist of n monomeric DNAs; η is the band's number as indicated in FIG. 4. The largest value of 0 thus far observed is 15 (See FIG. 5). There was no obvious selection either for or against any concatemer in the experiments of FIGS. 2, 3 or 4.
EXAMPLE II
The methods of Example I were used here with the exception that both a pooled extract and an extract resulting from a single, mutant bacteriophage was compared. Concatemers were obtained either by using extracts of cells injected with T7 3 ,19 or a mixed extract produced by mixing an extract of cells infected with T7 4 ,9 with an extract of cells infected with T7 5 ,19
Extracts, either pooled T7 4 ,9 +T7 5 ,19 or single T7 3 ,19, were divided into 10 μl aliquots. To each of these aliquots, mature T7 DNA was added to a final DNA concentration of 100 μg/ml. The aliquots were incubated either at 0°-4° C. (Lanes 1A-8A pooled extracts or lanes 1B-6B single extract) or at 30° C. (Lanes 9A-12A pooled extracts or 7B-11B single-extract).
The extracts were incubated at the two temperature ranges for various time periods (See FIG. 5 legend) and the resulting concatemers were electrophoresed using RGE as described in Example 1. As can be seen in FIG. 5, concatemers were formed in both the pooled and single extracts. As incubation time increased, higher ranges of multimers were seen. The level of concatemerization of the single extract is comparable to that of the pooled extract. Additionally, as can be seen most clearly in lane A3, circular forms of the T7 DNA representing monomer (lower) and dimer (upper) are formed using the conditions described above.
EXAMPLE III
As stated above, in an alternative embodiment of the invention, substrate DNA may be treated with an exogenous exonuclease (for example, the exonuclease encoded by gene 6 of T7) by adding the exogenous exonuclease to the extract of infected or uninfected bacterial cells together with the substrate DNA, or by preincubating substrate DNA with the exonuclease and then adding the pretreated DNA to the extract. The following example describes these particular aspects of the invention.
Extracts are prepared essentially as described in the preceding examples except that infection of bacterial cells with selected bacteriophage is optional and substrate DNA (T7 DNA, in this example) is treated with exogenous exonuclease (T7 gene 6 exonuclease) according to either of the general procedures described below.
In the first case 1 microliter of T7 DNA at a concentration of 100 μg/ml in NET buffer together with 3-10 units of protein 6 (United States Biochemical Corporation) in 1 μl of (Protein-6)-assay buffer (50 mM Tris-HCl pH 8.1, 5 mM MgCl 2 , 20 mM KCl, 5 mM 2-mercaptoethanol, 10 μg/ml of bovine serum albumin (Pentex --brand, Miles Laboratories) is added to 10 μl of an extract, which is then incubated at 0°-4° C. for 20 minutes, after which stop buffer is added. In the second case, 1 μl of T7 DNA (100 μg/ml in NET-buffer) is preincubated at +37° C. for 5 minutes with 0.3-1 units of protein 6 in 3 μl of (Protein-6)-assay buffer. The preincubation can be terminated by a heat treatment (by inactivation of protein 6 via heat treatment): the solution is made 0.1M with NaCl, incubated at +75° C. for 10 minutes, cooled slowly, and added to 10 microliters of extract at 0°-4° C. which is then incubated at 0°-4° C. for 20 minutes. The concatemers produced by these procedures may be further processed for electrophoresis as described in Example I.
Therefore, with a collection of concatemers such as described here, one could readily size linear DNA of unknown length in a manner similar to that used by the present inventors to determine the correct length. Since the concentration and stability of these standards remains high, one may conveniently store preparations at refrigerator temperatures until they are required.
More specifically, using appropriately gentle handling techniques, agarose gels or gel matrices of similar pore size can be loaded with the T7 concatemeric standards into wells adjacent to those loaded with unknown linear DNA samples. Upon electrophoresis the concatemeric standard will be resolved into a series of discrete bands (or ladder), where each band contains either monomeric substrate or a multimer thereof. The distance of migration of the unknown sample may then be compared to the distance migrated by the bands of the concatemeric standard to allow one to determine the size of the unknown sample. Rough estimates of size, useful in some situations, may be made by simply visualizing the positions of the band of unknown DNA relative to the position of the known standards. More exact determinations can be made by calculations and methods available to those of skill in the art, for example, by using a plot of length versus distance migrated.
The foregoing description of the invention has been directed to a particular preferred embodiment in accordance with the requirements of the patent statutes and for purposes of explanation and illustration. It will be apparent, however, to those skilled in the art that many modifications and changes in the methods and in the ultimate use of the product in a variety of applications may be made without departing from the scope and spirit of the invention.
For example, though the use of the product in gel electrophoresis is amply indicated herein, equivalent use can be made in any setting where size markers may be required. This may include scanning electron microscopy and gradient centrifugation techniques.
It will be further apparent that the invention may also be utilized with suitable modifications within the state of the art; for example, in combination with other DNA length standards such as λ and yeast chromosomes. It is the Applicant's intention in the following claims to cover all such equivalent modifications and variations which fall within the true spirit and scope of the invention.
REFERENCES
The following references may be useful in assisting understanding or practice of certain aspects of the present invention. Accordingly, each is expressly incorporated herein by reference.
1. Cantor, C. R. and Schwartz, D. C. 1984. U.S. Pat. No. 4,473,452, filed Nov. 18, 1982.
2. Cantor, C. R., et al. 1988. Ann Rev. Biophys. Biophys. Chem. 17:287-304.
3. Davison, P. F. 1959. Proc. Natl. Acad. Sci. USA 45:1560-1568.
4. Dunn, J. J. and Studier, F. W. 1983. J. Mol. Biol. 166:477-535.
5. Fujisawa, H., et al. 1980. Virol. 101:327-334.
6. Hamada, K., et al. 1986. Virol. 151:119-123.
7. Kelly, T. J. and Thomas, C. A. 1969. J. Mol. Biol. 44:459-475.
8. Kutter, E. and Ruger, W. 1983. In "Bacteriophage T7" (C. K. Mathews, E. M. Kutter, G. Mosig, and P. B. Berget, Eds.), pp. 219-245. American Society for Microbiology, Washington, D.C.
9. Langman, L., et al. 1978. Can. J. Biochem. 56:508-516.
10. Lee, D. D. and Sadowski, P. D. 1985. Can. J. Biochem. Cell Biol. 63:237-242.
11. Maniatis, T., Fritsch, E. F., and Sambrook, J. 1982. "Molecular Cloning: A Laboratory Manual," Cold Spring Harbor Laboratory, Cold Spring Harbor, N.Y.
12. McCorquodale, D. J. 1975. Rev. Microbiol. 4:101-159.
13. Miller, R. C., et al. 1976. J. Mol. Biol. 101:223-234.
14. Sanger, F., et al. 1982. Mol. Biol. 162:729-773.
15. Serwer, P. 1980. Biochemistry 19:3001-3004.
16. Serwer, P. and Greenhaw, G. A. 1981. In, Electrophoresis '81 (Eds. Allen and Arnaud), pp. 627-633. Walter de Gruyter & Co., Berlin, FRG.
17. Serwer, P. 1987. Electrophoresis 8:301-304.
18. Serwer, P., et al. 1987. J. Virol. 61:3499-3509.
19. Serwer, P., and Hayes, S. J. 1987. Electrophoresis 224-246.
20. Serwer, P. 1987. U.S. patent application Ser. No. 212 521, filed Jun. 28, 1988, now U.S. Pat. No. 5,041,203.
21. Shibata, H., et al. 1987. J. Mol. Biol. 196:845-851.
22. Son, M., et al. 1988. Virol. 162:38-46.
23. Studier, F. W. 1969. Virol 39:562-574.
24. Studier, F. W. and Dunn, J. J. 1983. Cold Spring Harbor Symp. Quant. Biol. 47:999-1007.
25. Wellauer, P. K , et al. 1974. Proc. Natl. Acad. Sci. USA 71:2823-2827.
26. White, J. H. and Richardson, C. C. 1987. J. Biol. Chem. 262:8845-8850.
27. White, J. H. and Richardson, C. C. 1987. J. Biol. Chem. 262:8851-8860.
|
The use of T7 bacteriophage to produce DNA length standards by enzymatically joining terminally repetitious, blunt-ended DNA has now been demonstrated. It is now possible to precisely control the formation of concatemeric DNAs thereby generating custom-made size-ranges of length standards. Furthermore, the standards thus produced are stable over time providing a highly reproducible and convenient product for the molecular biologist.
| 8
|
CROSS-REFERENCES TO RELATED APPLICATIONS
The present application is a division of U.S. application Ser. No. 10/732,747, filed Dec. 10, 2003, which is a division of U.S. application Ser. No. 09/940,768, filed Aug. 27, 2001, now U.S. Pat. No. 6,688,368, which is a division of U.S. application Ser. No. 09/339,089, filed Jun. 22, 1999, now U.S. Pat. No. 6,299,115, issued on Oct. 9, 2001, which claims priority to U.S. provisional application No. 60/090,269, filed Jun. 22, 1998. Each of the above-referenced applications are hereby incorporated by reference as though fully set forth herein.
BACKGROUND OF THE INVENTION
a. Field of the Invention
The instant invention is directed toward a support structure and remotely controllable operating system for a retractable covering for an architectural opening. More specifically, it relates to the hardware for supporting a retractable covering for an architectural opening, and includes a control system that may be controlled manually or by use of a remote control transmitter.
b. Background Art
It is well known that it is frequently desirable to place retractable coverings for architectural openings in remote locations that are not easily accessible (e.g., coverings over windows that are substantially above ground level). In order to take advantage of the benefits inherent in such retractable coverings, it is necessary to be able to operate the coverings from a distance, and possibly without physically touching the actual hardware that retracts and extends the covering.
Although various attempts have been made to address the problems presented by such a remotely mounted covering, there remains a need for an improved apparatus for permitting remote operations of such remotely mounted retractable coverings for an architectural openings.
Prior attempts to control the retraction and extension of a covering using an electric motor have employed mechanical limit switches to stop the extension or retraction of the covering. It is, however, desirable to eliminate the presence of such mechanical limit switches.
SUMMARY OF THE INVENTION
It is an object of the disclosed invention to provide an improved retractable covering for an architectural opening.
It is a further object of the disclosed invention to improve the retractable covering with an improved mounting bracket. In one form of the mounting bracket, it has a top surface with at least one mounting slot through it, a back surface with at least one mounting slot through it, an upper leg, a lower leg, a lip slot defined between the upper leg and the lower leg, a pressure strip including a distal end and an opposite end, and a retention clip including a downward projecting portion. The retention clip is attached to the distal end of the pressure strip, and the opposite end of the pressure strip is mounted to the upper leg. In another form of the mounting bracket, the lower leg includes a split tongue having a compression slot across its width. In yet another form, the mounting bracket top surface has two adjustable mounting slots through it, and the back surface also has two adjustable mounting slots through it.
It is a further object of the disclosed invention to improve the retractable covering with an improved limit stop to prevent over-retraction and over-extension of the retractable covering. In one form of the limit stop, it has a mounting half and a working half that are pivotally attached to each other. The working half further includes a main body with an outer edge having at least one bottom rail stop arm projecting therefrom. The main body of the working half also includes an underside having at least one curvilinear portion extending therefrom and forming a pocket at it intersection with the main body of the working half. In a preferred form, the working half is pivotally attached to the mounting half by a hinge pin. If a hinge pin is used, the working half includes a main body having a hinge edge with a plurality of alternating hinge portions projecting therefrom, and the mounting half also includes a main body having a hinge edge with a plurality of alternating hinge portions projecting therefrom. The hinge portions from the working half cooperate with the hinge portions from the mounting half. It is yet a further object of the disclosed invention to improve the retractable covering with an improved battery pack mounting bracket for attaching a power supply to a head rail of the retractable covering. In one form of the battery pack mounting bracket, it includes a tongue having a base, and at least one upper leg attached to the base of the tongue so as to define a lip slot. This battery pack mounting bracket may be part of a battery pack mounting apparatus for attaching a battery pack to a head rail. The apparatus includes at least two battery pack mounting brackets and a distancing strip. The distancing strip establishes an appropriate distance between the two battery pack mounting brackets. In a preferred form, the distancing strip includes downward projecting lips that clip over the battery pack mounting brackets. Alternatively, the distancing strip may include one or more holes that server to position the distancing strip relative to the two battery pack mounting brackets. In another form, the battery pack mounting apparatus includes a first battery pack holding means to removably secure the battery pack to one of the battery pack mounting brackets, and a second battery pack holding means to removably secure the battery pack to the other of the battery pack mounting brackets.
It is a further object of the disclosed invention to improve the retractable covering with an improved control system that, if desired, may be operated at a location remote from the actual hardware attached to the retractable covering. In one form of the control system, it includes a means for mounting the retractable covering adjacent to an architectural opening, a power source, means for rotating an element on which the covering is rolled, means for commanding the means for rotating the element, means for preventing over-extension of the covering, and means for preventing over-retraction of the covering.
It is still a further object of the disclosed invention to improve the retractable covering with an improved method of using a wireless remote control or a manually operated switch to activate a motor to control the configuration of the covering, including the extension or retraction of the covering, and the transmissivity of the covering. If a wireless remote control, having an up button and a down button, is used, the method includes monitoring an amount of extension of the covering, monitoring an amount of transmissivity of the covering, monitoring a speed of the covering, and monitoring a signal from the remote control for an indication of a pressing of either the up button or the down button. Then, the method includes commanding the motor to make a predetermined adjustment to the covering upon recognizing a single press and release of either the up button or the down button, wherein the predetermined adjustment is based upon the monitored amount of extension, the monitored amount of transmissivity, the monitored speed, and the monitored signal. If a manual operating switch is used, the method includes monitoring an amount of extension of the covering, monitoring an amount of transmissivity of the covering, monitoring a speed of the covering, and monitoring a signal from the manual operating switch for an indication of a pressing of the manual operating switch. Then, the method includes commanding the motor to make a predetermined adjustment to the covering upon recognizing a single press and release of the manual operating switch, wherein the predetermined adjustment is based upon the monitored amount of extension, the monitored amount of transmissivity, the monitored speed, and the alternating treatment of the press of the manual operating switch as either an up request or a down request.
It is a further object of the disclosed invention that the remote control aspects of the control system be field retrofittable.
A more detailed explanation of the invention is provided in the following description and claims, and is illustrated in the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a fragmentary isometric view of the top and front of a retractable covering according to the present invention;
FIG. 1A is an isometric view of a remote control comprising part of the present invention;
FIG. 2 is a fragmentary end view taken along line 2 - 2 of the apparatus depicted in FIG. 1 ;
FIG. 3 is a fragmentary isometric view taken along line 3 - 3 of FIG. 1 , depicting a section of the apparatus displayed in FIG. 1 ;
FIG. 4 is a cross-sectional view taken along line 4 - 4 of FIG. 3 through one of the main mounting brackets;
FIG. 5 is a fragmentary top view taken along line 5 - 5 of FIG. 4 , depicting a portion of one of the main mounting brackets;
FIG. 6 is a partial cross-sectional view taken along line 6 - 6 of FIG. 5 , depicting engagement of a main mounting bracket with the arcuate cover;
FIG. 7 is a partial cross-sectional view taken along line 7 - 7 of FIG. 5 , depicting a locking tab engaging a pressure strip comprising a portion of a main mounting bracket;
FIG. 8 is an exploded isometric view of two components comprising part of a main mounting bracket;
FIG. 9A is an exploded isometric view of a limit stop;
FIG. 9B is an isometric view of the underside of the working half of the limit stop depicted in FIG. 9A ;
FIG. 10 is a fragmentary cross-sectional view of the power supply taken along line 10 - 10 of FIG. 2 ;
FIG. 11A is an exploded fragmentary isometric view of the power supply depicted in FIG. 10 ;
FIG. 11B is a cross-sectional view of the head rail taken along line 11 B- 11 B of FIG. 3 through the first battery pack mounting bracket;
FIG. 11C is an exploded isometric view of the adjustable conductor-end anchor plate and the battery tube support piece shown in FIGS. 10 and 11A ;
FIG. 11D is an exploded isometric view of the compression spring slider piece and the compression spring anchor piece shown in FIGS. 10 and 11A ;
FIG. 12 is a fragmentary cross-sectional view of the drive end (the right end as depicted in FIG. 1 ) of the apparatus, showing placement of the gear motor;
FIG. 13 is a cross-sectional view taken along line 13 - 13 of FIG. 12 ;
FIG. 14 is an exploded isometric view of the back side of the drive end taken along line 14 - 14 of FIG. 1 ;
FIG. 15 is an exploded isometric view of the gears driven by the gear motor;
FIG. 16 is an exploded isometric view of the circuit board housing and components attached thereto;
FIG. 17 is an isometric view of the top side of the remote control;
FIG. 18 is an exploded isometric view of the back side of the remote control depicted in FIG. 17 ;
FIG. 19 is a top planform view of the remote control depicted in FIG. 17 ;
FIG. 20 is an end view of the remote control depicted in FIG. 19 taken along line 20 - 20 of FIG. 19 ;
FIG. 21 is a partial cross-sectional view taken along line 21 - 21 of FIG. 3 through a limit stop and shows the limit stop capturing the stop rib when the retractable covering attempts to over extend;
FIG. 22 is a view similar to FIG. 21 and shows the relative position of a limit stop with respect to the roll bar when the covering is in a normal, fully extended and fully open configuration;
FIG. 23 is a cross-sectional view of the head rail through a limit stop as the bottom rail is drawn upward toward the head rail as the covering approaches a fully retracted configuration;
FIG. 24 is a cross-sectional view of the head rail similar to FIG. 23 , but wherein the covering is in its fully retracted configuration;
FIG. 25A is a block diagram of the remotely-controllable operating system;
FIGS. 25B and 25C are circuit diagrams of the electronics that control operation of the control system; and
FIGS. 26 , 27 , 28 , 29 , 30 , 31 , and 32 together comprise a flow chart of the logic used by the control system of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In general, the instant invention relates to a remotely controllable retractable covering for architectural openings 10 . As depicted in FIGS. 1 and 1A , the apparatus comprises a control system mounted in a head rail 12 for extending, retracting, and otherwise adjusting a covering 14 attached between the head rail 12 and a bottom rail 16 , wherein the control system mounted in the head rail may be operated using a remote control 18 . In a preferred embodiment, two main mounting brackets 20 attach the head rail 12 to a desired mounting surface (e.g., a wall above the opening), two battery pack mounting brackets 22 attach a power supply 24 to the head rail 12 , and two limit stops 26 prevent over-retraction and over-extension of the covering 14 . A particularly preferred covering 14 for use with the present invention comprises a first flexible sheet or element 28 and a second flexible sheet or element 30 with vanes 32 attached between these first and second flexible sheets 28 , 30 , respectively. The first and second flexible sheets 28 , 30 , respectively, are secured to the bottom rail 16 . Left and right end caps 34 , 34 ′, respectively, support components, aesthetically shield various internal components from view, and include auxiliary support pockets 36 that may be used in select applications to position the head rail 12 above an architectural opening to be covered. As depicted in FIG. 2 , the power supply 24 is hidden from view in the preferred embodiment when the head rail 12 is attached to a mounting surface.
Referring next to FIGS. 3 , 4 , 5 , 6 , 7 , and 8 , details concerning the elements comprising each main mounting bracket 20 are described. FIG. 3 depicts the main mounting bracket 20 supporting the right end of the apparatus as depicted in FIG. 1 . As shown in FIGS. 3 and 4 , each main mounting bracket 20 includes an upper break away tab 38 and a lower break away tab 40 . These upper and lower break away tabs 38 , 40 , respectively, may be used to properly distance the head rail 12 from the mounting surface. If the tabs 38 , 40 are not required, they may be broken away from the remainder of the main mounting brackets 20 . As shown to best advantage in FIG. 3 , each main mounting bracket 20 comprises four adjustable mounting slots 42 , two on a top surface 43 and two on a back surface 45 .
Mounted in the center of each main mounting bracket 20 is a pressure strip 44 , which, in the preferred embodiment, is metallic. The pressure strip 44 is shown to best advantage in FIGS. 5 and 8 . In FIG. 8 , it is clearly shown that the pressure strip 44 includes a pair of holes including a locking tab hole 46 and a second hole 48 . Near a distal end 50 of the pressure strip 44 , a notch 52 is formed on each side of the pressure strip 44 , and the pressure strip 44 is slightly bent downward adjacent the notches 52 on the side of the notches 52 closest to the second hole 48 .
FIG. 8 also includes an isometric view of a retention clip 54 . The retention clip 54 comprises a downward projecting portion 56 , which snaps over the front of a top edge 58 of an arcuate cover 60 ( FIG. 1 ) when the mounting bracket 20 is positioned on the arcuate cover 60 (see FIGS. 3 , 4 , and 6 ). The retention clip 54 also includes a first upper guide 62 , a second upper guide 64 , and a lower guide 66 . When the retention clip 54 is slid onto the distal end 50 of the pressure strip 44 , the portion of the pressure strip 44 between its distal end 50 and the notches 52 is guided into the slot defined between the lower guide 66 , and the first and second upper guides 62 , 64 , respectively, (see FIGS. 5 and 6 ). FIG. 5 shows the first and second upper guides 62 , 64 , respectively, in position over the top surface of the section between the distal end 50 and the notches 52 . FIG. 6 shows the same relationship between the first and second upper guides 62 , 64 , respectively, and the section between the distal end 50 and the notches 52 ; and FIG. 6 also depicts the lower guide 66 of the retention clip 54 riding on the bottom surface, as depicted, of the pressure strip 44 between its distal end 50 and the notches 52 in the pressure strip 44 .
As seen to best advantage in FIGS. 5 and 8 , a pair of detents 68 are formed in the retention clip 54 beneath the first upper guide 62 . When the pressure strip 44 is inserted into the retention clip 54 , these detents 68 snap into the notches 52 in the pressure strip 44 . Once the retention clip 54 is thereby retained on the distal end 50 of the pressure strip 44 , the opposite end of the pressure strip 44 is inserted under a retention bridge 69 and into a slot 70 formed in the top surface 43 of the main mounting bracket 20 . This slot 70 in the top surface 43 of the main mounting bracket 20 may be seen to best advantage in FIGS. 3 and 5 . When the pressure strip 44 is inserted completely into the slot 70 in the top surface 43 , a locking tab 72 snaps through the locking tab hole 46 in the pressure strip 44 (see FIGS. 3 and 7 ), thereby retaining the pressure strip 44 in the slot 70 in the top surface 43 of the main mounting bracket 20 .
Once the main mounting bracket 20 is assembled by slipping the distal end 50 of the pressure strip 44 into the retention clip 54 , and then slipping the opposite end of the pressure strip 44 into the slot 70 in the top surface 43 of the main mounting bracket 20 , the main mounting bracket 20 may be attached to the head rail 12 . As may be seen to best advantage in FIGS. 4 and 6 , the main mounting bracket 20 attaches to a mounting lip 74 of the arcuate cover 60 . Each main mounting bracket 20 includes an upper leg 76 and a lower leg 78 defining a slot 80 therebetween ( FIG. 6 ). As seen to best advantage in FIG. 5 , both the upper leg and the lower leg (shown in phantom) extend laterally from side-to-side of the main mounting bracket 20 . When the main mounting bracket 20 is forced onto the arcuate cover 60 , it snaps into and retains its position thereon. In order to more clearly understand how each main mounting bracket 20 snappingly attaches to the arcuate cover 60 , several features of the arcuate cover 60 must first be described.
Referring to FIGS. 4 , 6 , and 21 , the elements of the arcuate cover 60 (labeled in FIG. 1 ) are described. Each of these figures shows the cross section of the arcuate cover 60 . The arcuate cover 60 includes a top edge 58 that is substantially perpendicularly joined to a front surface 82 that is curved toward the covering 14 at the arcuate cover's 60 bottom edge 84 . Moving toward the rear of the head rail 12 (to the right in FIGS. 4 , 6 , and 21 ) from the intersection of the top edge 58 with the front surface 82 of the arcuate cover 60 along the bottom or inside portion of the top edge 58 , a downward ridge 86 is first encountered. Continuing toward the rear of the head rail 12 , the top edge 58 slopes downward at a shoulder 88 to the mounting lip 74 , which extends along the full longitudinal length of the back side of the top edge 58 of the arcuate covering 60 . The lowest point of the downward ridge 86 and the under side of the mounting lip 74 are substantially coplanar as seen to best advantage in FIG. 6 . Moving downward, as depicted, along the front surface 82 of the arcuate cover 60 from the intersection of the front surface 82 with the top edge 58 , a support ledge 92 is encountered on the inside, as depicted, of the front surface 82 . Continuing substantially horizontally from the support ledge 92 , a support ridge 94 is next encountered. The support ledge 92 and the support ridge 94 are substantially coplanar. A sloped channel 96 is defined between the support ledge 92 and the support ridge 94 . An upper trough 98 is defined below the support ledge 92 between the back side of the front surface 82 and one side of the sloped channel 96 . Near the bottom edge 84 of the front surface 82 of the arcuate cover 60 a lower trough 100 is defined. The left and right end caps 34 , 34 ′, respectively, each has an arcuate portion (not shown) defined on its inside surfaces that engages the upper and lower troughs 98 , 100 , respectively, on the inside of the front surface 82 of the arcuate cover 60 . Thus, the end caps 34 , 34 ′ are frictionally held onto the arcuate cover 60 by the upper and lower troughs 98 , 100 , respectively.
Referring again to FIGS. 4 and 6 , attachment of the main mounting brackets 20 to the arcuate cover 60 is now described. The lower leg 78 of each main mounting bracket 20 includes a split tongue 102 having a compression slot 104 across its entire width. In other words, the compression slot 104 shown in cross section in FIGS. 4 and 6 extends through the lower leg 78 from one lateral edge of the lower leg 78 to the other lateral edge. When the mounting bracket 20 is forced onto the arcuate cover 60 , the split tongue 102 portion of the lower leg 78 is inserted into the “pocket” formed by the underside of the mounting lip 74 , the downward ridge 86 , the support ledge 92 , and the support ridge 94 . Since the top-to-bottom thickness of the split tongue 102 of the lower leg 78 is slightly greater than the vertical distance between the plane defined by the downward ridge 86 and the inside of the mounting lip 74 , and the plane defined by the support ledge 92 and the support ridge 94 , the split tongue 102 is compressed slightly as it is inserted into the previously defined pocket. The compression slot 104 thereby decreases in size as the split tongue 102 is forced into the pocket. Since the upper and lower portions of the split tongue 102 resist this compression, this resistance helps maintain the main mounting bracket 20 in position.
While the split tongue 102 is being inserted into the above-defined pocket, the slot 80 defined between the upper leg 76 and the lower leg 78 of the main mounting bracket 20 slides over the mounting lip 74 on the top edge 58 (see FIG. 6 ). When the mounting lip 90 is completely seated into the slot 80 , the downward projecting portion 56 of the retention clip 54 snaps over the corner of the top edge 58 . The main mounting bracket 20 is thus held securely in position by the split tongue 102 , slot 80 , and retention clip 54 . In particular, the main mounting bracket 20 cannot move further leftward in FIG. 6 because the base of the mounting lip 74 is pressing against the bottom of the slot 80 , and the main mounting bracket 20 will not move rightward in FIG. 6 because of the downward projecting portion 56 of the retention clip 54 . Similarly, up-and-down motion of the main mounting bracket 20 is inhibited by the interaction between the lower leg 78 , the upper leg 76 , the retention clip 54 , and the arcuate cover 60 . If it becomes desirable to remove the main mounting bracket 20 from the arcuate cover 60 , the downward bias generated by the pressure strip 44 that keeps the retention clip 54 clipped over the arcuate cover 60 may be overcome by lifting upward on the retention clip 54 , for example, by pressing a thumb upward against the downward projecting portion 56 of the retention clip 54 to force it onto the top edge 58 of the arcuate cover 60 . When the downward projecting portion 56 of the retention clip 54 is thus disengaged from the arcuate cover 60 , the main mounting bracket 20 may be pulled rightward in FIGS. 4 and 6 with sufficient force to completely remove the main mounting bracket 20 from the arcuate cover 60 .
Referring next to FIGS. 1 , 3 , 9 A, 9 B, 21 , 22 , 23 , and 24 , construction of a limit stop 26 and attachment of the limit stop 26 to the arcuate cover 60 is described next. As clearly depicted in the preferred embodiment of FIGS. 1 and 3 , the present invention includes two limit stops 26 that prevent over-retraction and over-extension of the covering 14 . FIG. 9A is an exploded, isometric view of one limit stop 26 . As shown in this figure, each limit stop 26 comprises four main components: a mounting half 106 , a working half 108 , a biasing spring 110 , and a hinge pin 112 .
Looking first at the working half 108 , one edge comprises a plurality of alternating hinge portions 114 . In the preferred embodiment, these hinge portions 114 each comprise approximately half of a hinge section. Corresponding hinge portions 116 are located on the mounting half 106 . The hinge portions 114 on the working half 108 interlock with the hinge portions 116 on the mounting half 106 , thereby forming a hinge channel to accommodate the hinge pin 112 . When the mounting half 106 and the working half 108 of the limit stop 26 are assembled, the hinge pin 112 is slid through the channel defined by the hinge portions 114 , 116 , and the hinge pin 112 is slid through a loop in the central portion of the biasing spring 110 to maintain the spring's position between the mounting half 106 and the working half 108 . A spring groove 118 is cut in the top portion, as depicted, of the main body 113 of the working half 108 , and a similar spring groove (not shown) may be formed in the middle one of the retention fingers 122 on the mounting half 106 . Two pivot stops 124 are mounted on the working half 108 of the limit stop 26 . These pivot stops 124 comprise plate-like surfaces near the hinge edge of the working half 108 . Two of the hinge portions 116 on the mounting half 106 comprise extensions 126 that impact the pivot stops 124 if the assembled limit stop 26 starts to flex too greatly in one direction about the hinge pin 112 . For example, in FIGS. 9A and 21 , if the mounting half 106 were held stationary and the working half 108 were rotated far enough counter-clockwise, the extensions 126 on the mounting half 106 would impact the pivot stops 124 on the working half 108 of the limit stop 26 , thereby preventing excessive upward or counter-clockwise rotation of the working half 108 of the limit stop 26 .
Referring to FIG. 9A , the mounting half 106 of the limit stop 26 includes three retention fingers 122 in the preferred embodiment. The retention fingers 122 are suspended above the main body 128 , thereby forming a “pocket” between the main body 128 and the retention fingers 122 . On a distal edge of the main body 128 is a substantially vertical projection 130 .
Referring now to FIG. 21 , when the mounting half 106 of the limit stop 26 is slid onto the top edge 58 of the arcuate cover 60 , the substantially vertical projection 130 on the distal edge of the main body 128 snaps into an upper channel 132 (clearly visible in FIGS. 4 and 6 ) defined by the front surface 82 of the arcuate cover 60 and the downward ridge 86 on the underside of the top edge 58 of the arcuate cover 60 , while the retention fingers 122 frictionally engage the top surface of the mounting lip 74 and the main body 128 slides under the mounting lip 74 and the downward ridge 86 . The limit stop 26 is thereby attached to the arcuate cover 60 in close frictional engagement therewith.
As shown in FIGS. 9A , 9 B, and 21 , the working half 108 of the limit stop 26 includes two bottom rail stop arms 134 . The function of the bottom rail stop arms 134 will be described further below with reference to FIG. 24 . The underside of the working half 108 (see FIG. 9B ) includes two curvilinear portions 136 , which ride on the outer surface of the covering 14 as it is rolled onto a roll bar 138 (see FIG. 23 ). Where these curvilinear portions 136 intersect the main body 113 , a pocket 140 is defined (most clearly visible on the right-hand edge of FIG. 9A ). As shown in FIG. 21 , this pocket 140 helps prevent over-rotation of the roll bar 138 and over-extension of the covering 14 . If, for some reason, the apparatus attempts to over extend the covering 14 , a forward extending stop rib 142 of the roll bar 138 gets trapped in the pocket 140 defined behind the curvilinear portions 136 ( FIG. 21 ). When the forward extending stop rib 142 is thus captured by the pocket 140 , a motor 144 ( FIG. 12 ) rotating the roll bar 138 is stalled, preventing over-rotation of the roll bar 138 . From the direction depicted in FIG. 21 , the roll bar 138 rotates clockwise during extension of the covering 14 and counter-clockwise during retraction of the covering 14 .
Starting from the position shown in FIG. 21 , when it is time to retract the covering 14 , the roll bar 138 is caused to rotate counter-clockwise by the gear motor 144 (the gear motor is clearly visible in FIG. 12 , for example). The curvilinear portions 136 of the working half 108 of the limit stop 26 are designed to permit retraction of the covering 14 even after the apparatus has attempted to overly extend the covering 14 . The shape of the forwarding extending stop rib 142 also helps in this regard since it has an arched back surface that impacts the curvilinear portions 136 during retraction of the covering 14 (i.e., during the first counterclockwise rotation of the roll bar 138 as depicted in FIG. 21 ).
Referring now to FIGS. 1 , 3 , 11 A, 11 B, 11 C, and 11 D, attachment of the power supply 24 to the head rail 12 is described next. Referring first to FIGS. 3 , 11 A, and 11 B, the portions of each battery pack mounting bracket 22 that mounts it to the arcuate cover 60 are described next. First and second upper legs 146 , 148 , respectively, extend over a substantially longer tongue 150 having a substantially rectangular port or window 152 in it ( FIG. 11A ). A pair of slots 154 are formed where the first and second upper legs 146 , 148 , respectively, intersect the base of the tongue 150 ( FIG. 11A ). A flexible arm 156 ( FIG. 11B ) extends from the side of the port 152 nearest the base of the tongue 150 and substantially fills the port 152 . Near the free end of the flexible arm 156 , a pair of ridges 158 , 160 on the underside of the flexible arm 156 define a channel 162 . When the battery mounting bracket 22 is in position on the arcuate cover 60 , the tip 151 (see FIG. 11A ) of the tongue 150 extends into the “pocket” defined by the downward ridge 86 , the underside of the mounting lip 74 , the support ledge 92 , and the support ridge 94 (the support ledge 92 and the support ridge 94 are clearly shown in FIG. 6 ). The two slots 154 between the first and second upper legs 146 , 148 , respectively, and the tongue 150 frictionally engage the mounting lip 74 , and the channel 162 in the flexible arm 156 captures the support ridge 94 , with the second ridge 160 of the flexible arm 156 being accommodated by the sloped channel 96 integrally formed in the arcuate cover 60 ( FIG. 11B ).
Referring next to FIGS. 1 , 2 , 10 , 11 A, 11 C, and 11 D, the power supply 24 and hardware for mounting it to the head rail 12 are next described. As shown to best advantage in FIGS. 1 and 2 , the power supply 24 is mounted on the back side of the head rail 12 and is thereby substantially hidden from view. FIG. 11A is an exploded view of the components comprising the power supply 24 . The battery pack mounting brackets 22 are attached to the arcuate cover 60 as previously described. The appropriate distance, which is a function of the length of the battery tube (or battery pack) 206 which itself is a function of the energy requirements of the control system, is established between the mounting brackets 22 using a distancing strip 164 (see FIGS. 10 and 11A ). As shown in FIGS. 10 and 11A , the distancing strip 164 has a lip 166 on each end of it and a hole 168 near each end of it. The lip 166 on one end of the distancing strip 164 clips over one mounting bracket 22 , while the lip 166 on the opposite end of the distancing strip 164 clips over the edge of the other battery pack mounting bracket 22 . The distancing strip 164 in position with the lips 166 so arranged with respect to the battery pack mounting brackets 22 is most clearly shown in FIG. 10 . A strip bed 170 ( FIG. 11A ) is defined in the bottom of each battery pack mounting bracket 22 , and a placement pin 172 projects from the bottom of the strip bed 170 . The strip bed 170 is approximately as deep as the distancing strip 164 is thick. Thereby, when the distancing strip 164 is properly placed, the placement pin 172 in each battery pack mounting bracket 22 is accommodated by the holes 168 in the distancing strip 164 , and the strip bed 170 in each battery pack mounting bracket 22 is substantially filled by the distancing strip 164 .
Once the first and second battery pack mounting brackets 22 are attached to the arcuate cover 60 , and are arranged the appropriate distance apart by the distancing strip 164 , the remainder of the power supply 24 may be assembled. A first conductor terminal plate 174 is attached to a conductor plate bed 176 in an adjustable, conductor-end anchor piece 178 ( FIGS. 11A and 11C ). The first conductor terminal plate 174 is metal, while the adjustable, conductor-end anchor piece 178 is plastic in the preferred embodiment. The first conductor terminal plate 174 may be snapped onto pins extending from the conductor plate bed 176 , or it may be bolted onto the conductor plate bed 176 , or the first conductor terminal plate 174 may be glued directly onto the conductor plate bed 176 . Subsequently, a battery tube support piece 180 is attached to the adjustable, conductor-end anchor piece 178 (best seen in FIG. 11C ). In the preferred embodiment, the battery tube support piece 180 snaps onto the adjustable, conductor-end anchor piece 178 . The battery tube support piece 180 includes a conductor port 182 ( FIG. 11A ). A second conductor terminal plate 184 is riveted to the battery tube support piece 180 in the preferred embodiment (see FIG. 11C ).
Once the adjustable, conductor-end anchor piece 178 and the battery tube support piece 180 are fixed to one another in the manner described further below, a first locking lug 186 is attached to the adjustable, conductor-end anchor piece 178 . The locking lug 186 is inserted into a lug hole 188 in the adjustable, conductor-end anchor piece 178 . The first locking lug 186 includes a screwdriver slot 190 in a cylindrical portion 192 , and an irregular, enlarged portion 194 is adjacent the cylindrical portion 192 . The lug hole 188 includes an expansion slot 196 through the center of it. When the first locking lug 186 is rotated using a screwdriver inserted into the screwdriver slot 190 , the enlarged portion 194 of the first locking lug 186 tends to expand the expansion slot 196 , thereby preventing the adjustable, conductor-end anchor piece 178 from sliding in the first battery pack mounting bracket 22 . The adjustable, conductor-end anchor piece 178 includes a first lip 198 and a second lip 200 near its bottom surface ( FIG. 11C ). Once the first locking lug 186 is inserted into the lug hole 188 in the adjustable, conductor-end anchor piece 178 , and after the first conductor terminal plate 174 has been attached to the adjustable, conductor-end anchor piece 178 , and the battery tube support piece 180 has been attached to the adjustable, conductor-end anchor piece 178 , the first lip 198 may be slid into a first groove 202 of the first battery pack mounting bracket 22 , while the second lip 200 is slid into a second groove 204 of the first battery pack mounting bracket 22 . When the adjustable, conductor-end anchor piece 178 is thus slid into the first battery pack mounting bracket 22 , the anchor piece 178 rides on top of the distancing strip 164 , thereby keeping the distancing strip 164 in its strip bed 170 , and keeping the first locking lug 186 in the lug hole 188 in the anchor piece 178 . Once the anchor piece 178 is positioned at a desired location, the first locking lug 186 may be rotated to expand the expansion slot 196 and thereby nonpermanently fix the anchor piece 178 to the first battery pack mounting bracket 22 .
The power supply 24 on the preferred embodiment also includes a side-by-side battery tube 206 , which, in the preferred embodiment, holds eight AAA batteries 208 . One end of the battery tube 206 includes a fixed end cap 210 having two external conductor strips on it. The second external conductor 212 is visible in FIG. 11A . The opposite end of the battery tube includes a removable end cap 214 having a conductive strip 216 on its inner surface to connect the four batteries 208 in one side of the battery tube 206 in series with the four batteries 208 on the opposite side of the battery tube 206 . The removable end cap 214 also includes a figure eight portion 218 , which fits into an end of the side-by-side battery tube 206 until the conductive strip 216 contacts the batteries 208 in the battery tube 206 . The removable end cap 214 also includes a cylindrical portion 220 that is cradled by a compression spring slider piece 222 (see FIG. 11D ). When the fixed end cap 210 of the battery tube 206 is properly inserted into the battery tube support piece 180 , the external conductors on the fixed end cap 210 make electrical contact with the first and second conductor terminal plates 174 , 184 , respectively (both may be seen in FIG. 11C ). In particular, the second external conductor 212 on the fixed end cap 210 makes electrical contact with the second conductor terminal plate 184 , which is riveted to the conductor port 182 in the battery tube support piece 180 . Similarly, the first external conductor on the fixed end cap 210 makes electrical connection with the first conductor terminal plate 174 mounted in the conductor plate bed 176 of the adjustable, conductor-end anchor plate 178 . As shown in FIG. 11C , a first wire lead 224 is soldered to the first conductor terminal plate 174 , and a second wire lead 222 is soldered to the second conductor terminal plate 184 .
The cylindrical portion 220 of the removable end cap 214 is supported by the compression spring slider piece 222 ( FIGS. 10 and 11D ). The compression spring slider piece 222 includes an arcuate support surface 228 that cradles the cylindrical portion 220 of the removable end cap 214 . An arcuate outer wall 230 also engages the cylindrical portion 220 of the removable end cap 214 . An abutment surface 232 extends between the arcuate support surface 228 and the arcuate outer wall 230 , and this abutment surface 232 presses against the end of the removable end cap 214 , holding it in position.
One side of the compression spring slider piece 222 includes a range-limiting bracket 234 . The range-limiting bracket 234 extends around and behind an upright wall 236 of a compression spring anchor piece 238 . A compression spring 240 maintains pressure between the compression spring anchor piece 238 and the compression spring slider piece 222 . The compression spring slider piece 222 and the compression spring anchor piece 238 each includes a spring-mounting pin 242 having an outside diameter that is substantially the same size as the inside diameter of the compression spring 240 . The compression spring 240 may be thereby slid onto the spring-mounting pins 242 .
To assemble the three primary components that support the removable end cap 214 , a second locking lug 244 (which is the same as the first locking lug 186 in the preferred embodiment) is inserted into a lug hole 246 in the compression spring anchor piece 238 . This lug hole 246 (visible in FIGS. 11A and 11D ) similarly is divided by an expansion slot 248 in the base of the compression spring anchor piece 238 . The compression spring anchor piece 238 includes a first lip 250 and a second lip 252 . The first lip 250 is slidably engaged in a first groove 254 of the second battery pack mounting bracket 22 , while the second lip 252 of the compression spring anchor piece 238 is slidable engaged in a second groove 256 of the second battery pack mounting bracket 22 . Since the first and second battery pack mounting brackets 22 are the same in the preferred embodiment, the first groove 254 of the second battery pack mounting bracket is the same as the first groove 202 of the first battery pack mounting bracket. Similarly, the second groove 256 of the second battery pack mounting bracket is the same as the second groove 204 of the first battery pack mounting bracket. When the anchor piece 238 is thus slid into the second battery pack mounting bracket 22 , the underside (not labeled) of the anchor piece 238 keeps the distancing strip 164 in the strip bed 170 of the second battery pack mounting bracket 22 , and the second locking lug 244 is held in the lug hole 246 . The compression spring slider piece 222 also includes a first lip 258 and a second lip 260 . The compression spring 240 is slid over the mounting pin 242 of the anchor piece 238 , and then the first and second lips 258 , 260 , respectively, of the compression spring slider piece 222 are slid into the first and second grooves 254 , 256 , respectively, of the second battery pack mounting bracket 22 , while ensuring that the range-limiting bracket 234 is placed around the upright wall 236 of the compression spring anchor piece 238 . Once the anchor piece 238 and the slider piece 222 are each inserted into the grooves 254 , 256 of the second battery pack mounting bracket 22 , and the compression spring 240 is properly placed between these two pieces 238 , 222 , they may be placed in a desired position along the first and second grooves 254 , 256 , respectively. Once the anchor piece 238 is properly positioned, a screwdriver blade is inserted into the screwdriver slot of the second locking lug 244 , and the second locking lug 244 is rotated to spread the expansion slot 248 and thereby hold the compression spring anchor piece 238 in the desired position in the first groove 254 and second groove 256 of the second battery pack mounting bracket 22 . The compression spring anchor piece 238 thereby also keeps the compression spring slider piece 222 from falling out of the first groove 254 and second groove 256 of the second battery pack mounting bracket 22 .
If the slider piece 222 slides in a first direction, it eventually compresses the compression spring 240 enough that the slider piece 222 cannot slide any further in the first direction. If, on the other hand, the slider piece 222 slides in the opposite direction, the range-limiting bracket 234 eventually gets caught by the upright wall 236 of the compression spring anchor piece 238 . When the removable end cap 214 is properly mounted to the end of the battery tube 206 , it may be slid into the compression spring slider piece 222 . In order to insert the battery tube 206 into position, it may be necessary to manually force the slider piece 222 toward the anchor piece 238 , thereby compressing the compression spring 240 to provide sufficient space to slip the cylindrical portion 220 of the removable end cap 214 into frictional engagement with the arcuate support surface 228 and the arcuate outer wall 230 of the compression spring slider piece 222 . When the compression spring 240 is permitted to force the compression spring slider piece 222 away from the compression spring anchor piece 238 , the pressure generated by the spring 240 maintains the battery tube 206 in the desired position between the battery tube support piece 180 and the compression spring slider piece 222 .
FIGS. 11C and 11D show details concerning the hardware that support the ends of the battery tube 206 depicted in FIG. 11A . Referring first to FIG. 11C , details concerning the adjustable, conductor-end anchor plate 178 and the battery tube support piece 180 are described next. FIG. 11C shows details of the two pieces that support the fixed end cap 210 of the battery tube 206 , namely the adjustable, conductor-end anchor piece 178 and the battery tube support piece 180 . The conductor-end anchor piece 178 includes a conductor plate bed 176 integrally formed therein (see FIG. 11A for a clear view of the conductor plate bed 176 ). As shown in FIG. 11C , the first conductor terminal plate 174 is mounted in the conductor plate bed 176 , and a first wire lead 224 is soldered to the first conductor terminal plate 174 . Near the mid section of the conductor end anchor piece 178 are two upright support arms 262 , each having a hole in its distal end (see FIG. 11C ). These substantially vertical upright support arms 262 flex outward slightly so that the holes in the support arms 262 will snap over the mounting pins 264 on the battery tube support piece 180 when the battery tube support piece 180 is snapped into position.
On the left end of the conductor-end anchor piece 178 , as depicted in FIG. 11C , is a lug hole 188 and expansion slot 186 , which are both integrally formed in the conductor-end anchor piece 178 . The lug hole 188 rotatably accommodates the cylindrical portion 192 of the first locking lug 186 . The bottom side (not shown) of the conductor-end anchor piece 178 , below the lug hole 188 shown in FIG. 11C , is cut out to accommodate the enlarged portion 194 of the first locking lug 186 . The cylindrical portion 192 has a screwdriver slot 190 formed therein. When the first locking lug 186 is positioned in the lug hole 188 and a screwdriver is used to rotate the locking lug 186 , the enlarged portion 194 of the locking lug 186 expands the expansion slot 196 in a known manner to force the first lip 198 and second lip 200 apart. Thus, when the first lip 198 of the conductor-end anchor piece 178 is in the first groove 202 of the first battery pack mounting bracket 22 and the second lip 200 is in the second groove 204 of the first battery pack mounting bracket 22 , rotation of the locking lug 186 nonpermanently fixes the position of the conductor-end anchor plate 178 relative to the first battery pack mounting bracket 22 .
The battery tube support piece 180 includes a pair of mounting pins 264 that are pivotally accommodated by the substantially vertical upright support arms 262 of the conductor-end anchor piece 178 . The mounting pins 264 are positioned below the conductor port 182 (visible in FIG. 11A ) of the battery tube support piece 180 . The mounting pins 264 , which define the pivot axis of the battery tube support piece 180 are also mounted below the center of the abutment surface 266 of the support piece 180 (the center of the abutment surface 266 roughly corresponds to the position of the conductor port 182 , which has the second conductor terminal plate 184 riveted to it in FIG. 11C ). Thus, when the fixed end cap 210 of the battery tube 206 is positioned against the abutment surface 26 of the battery tube support piece 180 , pressure exerted by the fixed end cap 210 against the abutment surface 266 tends to rotate the battery tube support piece 180 , if at all, counterclockwise about the mounting pins 264 depicted in FIG. 11C . This counterclockwise rotation of the battery tube support piece 180 in the holes in the upright support arms 262 of the conductor-end anchor piece 178 rotates the trailing edge 268 of the support piece 180 against the surface of the conductor-end anchor piece 178 .
As clearly shown in FIG. 11C , the second conductor terminal plate 184 is riveted in the conductor port 182 (visible in FIG. 11A ), and the second wire lead 226 is soldered to the second conductor terminal plate 184 , which is visible in FIG. 11C . When the battery tube 206 is correctly positioned in the battery tube support piece 180 , and the battery tube support piece 180 is snapped into position in the conductor-end anchor piece 178 , the batteries 208 in the battery tube 206 are connected in series with the first wire lead 224 and the second wire lead 226 . The first and second lead wires 224 , 226 , respectively, are then connected to a plug 270 , which may be seen in FIG. 3 . Once the power supply 24 is positioned on the back of the head rail 12 , the plug 270 on the end of the first wire lead 224 and the second wire lead 226 is plugged into a power connection port 272 visible in, for example, FIGS. 3 and 14 .
Focusing now on FIG. 11D , the details concerning the hardware components that support the removable end cap 214 of the battery tube 206 are described next. The compression spring anchor piece 238 includes a lug hole 246 divided by an expansion slot 248 . The lateral edges of the bottom portion of the anchor piece 238 comprises a first lip 250 and a second lip 252 . When the anchor piece 238 is correctly positioned in the second battery pack mounting bracket 22 ( FIG. 11A ), the first lip 250 rides in the first groove 254 and the second lip 252 rides in the second groove 256 . Once the anchor piece 238 is correctly positioned in the second battery pack mounting bracket 22 , the locking lug 244 is rotated in the lug hole 246 to expand the expansion slot 248 and frictionally bind the anchor piece 238 in the second battery pack mounting bracket 22 . The anchor piece 238 also includes a substantially vertical upright wall 236 that has a spring mounting pin 242 integrally formed thereon. Once the anchor piece 238 is properly positioned, the compression spring 240 may be slipped onto the spring mounting pin 242 of the anchor piece 238 . The spring mounting pin 242 is designed to frictionally fit into the inside of the compression spring 240 . The compression spring slider piece 222 is next positioned in the second battery pack mounting bracket 22 by placing the range-limiting bracket 234 around the upright wall 236 of the compression spring anchor piece 238 and slipping the first lip 258 and the second lip 260 on the bottom lateral edges of the slider piece 222 into the first groove 254 and second groove 256 on the second battery pack mounting bracket 22 .
The side of the abutment surface 232 that is not visible in FIG. 11D has a spring mounting pin like the pin 242 integrally formed on the compression spring anchor piece 238 . This spring mounting pin rides inside the opposite end of the compression spring 240 , thereby trapping the compression spring 240 between the compression spring anchor piece 238 and the compression spring slider piece 222 . When thus mounted, the compression spring slider piece 222 is prevented from sliding off the second battery pack mounting bracket 22 by the interaction between the range-limiting bracket 234 and the upright wall 236 , and the interaction between the first lip 258 and second lip 260 of the slider piece 222 in the first groove 254 and second groove 256 , respectively, of the second battery pack mounting bracket 22 .
The slider piece 222 may, however, slide toward and away from the compression spring anchor piece 238 a predetermined amount by applying varying amounts of pressure to the abutment surface 232 and thereby compressing the compression spring 240 or permitting it to expand. The arrangement depicted in FIG. 11D thereby maintains longitudinal pressure on the battery tube end caps 210 , 214 , which enhances the battery tube's ability to maintain a complete electrical circuit.
FIG. 12 shows a cross-sectional view of the gear motor 144 and the circuit board housing 274 , which protects a circuit board 276 (see FIG. 16 ) that controls operation of the gear motor 144 . In the preferred embodiment, the gear motor 144 , which is powered through first and second power terminals, 145 , 147 , respectively, is a reversible, direct current (dc) motor. Also shown in FIG. 12 is a signal receiver 278 and a manual operation switch 280 . As shown in FIG. 13 , the circuit board housing 274 includes ports that accommodate the signal receiver 278 and a plug 282 . Depending upon the particular mounting of the retractable covering 14 , the signal receiver 278 and the plug 282 may be interchanged to facilitate the clearest line of sight from the remote control 18 to the signal receiver 278 .
Referring now to FIGS. 14 and 15 , additional details concerning the drive end of the head rail 12 are visible. A power connection port 272 is visible in FIG. 14 . When the power supply 24 is properly mounted on the head rail 12 as previously described, a plug 270 (visible in FIG. 3 ) connected to the first wire lead 224 and the second wire lead 226 is plugged into the power connection port 272 shown adjacent the circuit board housing 274 in FIG. 14 . The power connection port 272 is connected by a ribbon cable 284 to the circuit board 276 inside of the circuit board housing 274 . The gear motor 144 shown in FIG. 12 has a gear shaft 286 attached to it. The gear shaft 286 is clearly visible in FIG. 15 . The distal end of the gear shaft includes a pair of locking tabs 288 . Surrounding a portion of the gear shaft 286 is a motor gear 290 . In the preferred embodiment, the motor gear 290 comprises fifteen teeth or splines. In the preferred embodiment, three orbiting transfer gears 292 slide onto corresponding dowels or pivot pins 294 mounted at equal intervals around the motor gear 290 so as to meshingly engage the motor gear 290 . In the preferred embodiment, the orbiting transfer gears 292 each comprises twenty-one teeth or splines. Subsequently, an internal gear 296 is slid over the orbiting transfer gears 292 so that the internal gear 296 meshes with the three orbiting transfer gears 292 . In the preferred embodiment, the internal gear 296 comprises fifty-eight teeth or splines. When the internal gear 296 is sufficiently slid onto the orbiting transfer gears 292 , the pair of locking tabs 288 on the distal end of the gear shaft 286 retain the internal gear 296 in position. As shown to good advantage in FIGS. 14 and 15 (see also FIGS. 21 and 22 ), the internal gear 296 has extended ribs 297 on its outer surfaces 299 . These extended ribs 297 ride in an alignment channel 301 comprising part of the roll bar 138 . Thus, when the gear motor 144 drives the internal gear 296 , that in turn drives the roll bar 138 through the interaction between the extended ribs 297 and the alignment channel 301 . A plurality of smaller ribs 303 ride on the inner surface of the roll bar 138 when it is mounted on the internal gear 296 .
FIG. 16 is an exploded isometric view of the circuit board 276 in the circuit board housing 274 . Clearly visible in FIG. 16 is the signal receiver 278 and the signal receiver wiring 298 shown in two selectable positions. The signal receiver 278 may be mounted in either side of a circuit board housing cover 300 , depending upon the intended mounting location for the covering 14 . In the preferred embodiment, the signal receiver wiring 298 has a plug 302 soldered to it that plugs into an appropriate socket 304 on the circuit board 276 . The ribbon cable 284 that joins the circuit board 276 to the power connection port 272 ( FIG. 14 ) may be seen in FIG. 16 . Also, a rotator counter 306 that provides required position information to the electronics may be seen in FIG. 16 .
FIGS. 17 , 18 , 19 , and 20 show the primary features of the remote control 18 . FIG. 17 is an isometric view of the top surface of the remote control 18 . Clearly visible in FIG. 17 is a frequency selection switch 308 . In the preferred embodiment, it is possible to select one of two control frequencies so that more than one retractable covering 14 may be separately controlled by a single remote control 18 . Mounted just below the frequency selection switch 308 , as depicted, is a control rocker switch 310 . Also shown in FIG. 17 is a control signal 312 emanating from the end of the remote control 18 . FIG. 18 is an exploded isometric view of the back side of the remote control 14 showing a battery housing cover 314 and a locking tab 316 that holds the battery housing cover 314 in position over the three AAA batteries 318 used by the remote control 18 in the preferred embodiment. FIG. 19 is a top view of the remote control 18 and shows further details of the control switches. In particular, the control rocker switch 310 includes a raised up arrow 320 and a recessed down arrow 322 . Since the up arrow 320 is slightly raised and the down arrow 322 is slightly recessed, it is possible to use the remote control 18 in low light or no light conditions. Also visible in FIG. 19 is a transmission indicator LED 324 . When the up arrow 320 or down arrow 322 on the rocker switch 310 is pressed, the transmission indicator LED 324 lights so that the user knows that the remote control 18 is attempting to transmit a signal 312 to the receiver 278 mounted in the head rail 12 . Finally, FIG. 20 shows an end view of the remote control 18 along line 20 - 20 of FIG. 19 . Clearly visible in FIG. 20 is the control signal transmitter port 326 (this port is also shown in phantom in FIG. 19 ). The control signal 312 emanates from the transmitter port 326 . Thus, the transmitter port 326 must be aimed at the receiver 278 during transmission.
FIG. 21 depicts the limit stop 26 operating to prevent the roll bar 138 from over-rotating and thereby over-extending the covering 14 . As previously discussed, if the gear motor 144 attempts to over-extend the covering 14 , the forward extending stop rib 142 will engage the pocket 140 defined by the main body 113 and the curvilinear portion 136 of the working half 108 of the limit stop 26 . The locking engagement between the forward extending stop rib 142 and the pocket 140 prevents the roll bar 138 from continuing to rotate. When the roll bar 138 is thus stopped from rotating, the electronics continue to command the drive motor 144 to rotate the roll bar 138 , but no rotation results. After a short duration, the electronics realize that the gear motor 144 is stalled and command the gear motor 144 to stop attempting to extend the covering 14 . FIG. 21 also clearly shows a first sheet-retention channel 305 retaining the first flexible sheet 28 , and a second sheet-retention channel 307 retaining the second flexible sheet 30 .
When the control system is commanded to retract the covering 14 , the forward extending stop rib 142 is easily rotated out of engagement (counterclockwise in FIG. 21 ) with the pocket 140 on the underside of the limit stop 26 and, as the covering 14 is wound around the roll bar 138 , it rolls over the top of the forward extending stop rib 142 , thereby covering it. When the covering 14 is not fully extended, the forward extending stop rib 142 is covered or concealed by the covering 14 . Thus, if the system is commanded to extend the covering 14 , and the covering 14 is not yet fully extended, the curvilinear portions 136 of the stop limit 26 slide over the exterior surface of the covering 14 , and the forward extending stop rib 142 does not and cannot become trapped in the pocket 140 behind the curvilinear portions 136 . When the control system is operating properly, the forward extending rib 142 does not get caught in the pocket 140 since the control system commands extension of the covering 144 to stop before it attempts to over-rotate the roll bar 138 and over-extend the covering 14 . This latter, more typical, operation of the control system is shown in FIG. 22 .
The general operation of the remotely controllable the retractable covering 10 of the present invention is described next. The covering 14 may be in the configuration depicted in FIG. 24 , which is in its most retracted configuration. From this fully retracted configuration, the operation of the remotely controllable retractable covering 10 proceeds as follows. If the down arrow 322 on the remote control 18 is pressed and released one time, the gear motor 144 begins to drive the roll bar 138 to extend the covering 14 (i.e., clockwise as depicted in FIGS. 21-24 ). If no additional buttons are pressed on the remote control 18 , the motor 144 continues to drive the roll bar 138 until the covering 14 is fully extended, but in a minimum transmissivity configuration (i.e., the vanes 32 between the first flexible sheet 28 and the second flexible sheet 30 are closed and blocking the maximum amount of light and air transmission through the covering). This configuration is not shown separately in the figures, but the bottom rail 16 would be in a position similar to that depicted in FIG. 23 , and the covering 14 would be otherwise filly extended. Then, if the down arrow 322 is pressed and released a second time while the covering 14 is in the fully extended configuration, the gear motor 144 again rotates the roll bar 138 (clockwise as depicted in FIG. 21 ) until the bottom rail 16 is horizontal and the transmissivity through the covering 14 is at a maximum (i.e., the vanes 32 between the first flexible sheet 28 and the second flexible sheet 30 are open in a substantially horizontal configuration). This configuration of the covering 14 is shown in FIG. 22 . When the blind is in the resulting “fully opened” configuration, any further pressing of the down arrow 322 on the remote control 18 has no effect on the configuration of the covering 14 .
If, instead, the up arrow 320 on the remote control 18 is pressed and released one time while the covering 14 is in its fully opened configuration (the FIG. 22 configuration), the gear motor 144 rotates the roll bar 138 until the covering 14 is in its “fully closed” configuration (i.e., until the vanes 32 between the first flexible sheet 28 and the second flexible sheet 30 are substantially vertical and block the maximum amount of light or air attempting to pass through the covering 14 ). This latter configuration change involves rotating the roll bar 138 in a counterclockwise direction as depicted in FIG. 21 . The covering 14 then remains in its fully extended but minimally transmissive configuration until another button 320 , 322 is pressed on the remote control 18 . If the up arrow 320 is again pressed and released, the gear motor 144 is commanded to drive the roll bar 138 until the covering 14 is in its fully retracted configuration (shown in FIG. 24 ), which is the configuration from which operation of the retractable covering commenced in this example.
Whenever the covering 14 is in motion, that motion may be interrupted by pressing and releasing either the up arrow 320 or the down arrow 322 on the remote control 18 . The up-and-down operation of the covering 14 and the transmissivity-adjustment of the covering 14 may both be interrupted by pressing either the up arrow 320 or the down arrow 322 on the remote control 18 . For example, if the gear motor 144 has been commanded to extend the covering 14 , and the bottom rail 16 is traveling downward but has not yet reached its lowest point of travel (see FIG. 23 ), if either the up arrow 320 or the down arrow 322 on the remote control 18 is pressed and released, the gear motor 144 is commanded to cease all motion of the covering 14 . If the down arrow 322 is then pressed and released, the gear motor 144 will be commanded to continue extending the covering 14 . If, on the other hand, the up arrow 320 is pressed and released after the covering 14 was stopped, the gear motor 144 will be commanded to reverse the direction of rotation of the roll bar 138 , and will begin to retract the covering 14 onto the roll bar 138 (i.e., the roll bar 138 will be rotated in the counterclockwise direction as depicted in FIGS. 21-24 ). Similarly, if the covering 14 is being retracted and the up arrow 320 or the down arrow 322 is pressed and released, retraction of the covering 14 stops. Then, if the up arrow 320 is pressed and released again, retraction of the covering 14 commences. If, on the other hand, the down arrow 322 is pressed and released after stopping the retraction of the covering 14 , the gear motor 144 will begin to rotate the roll bar 138 so as to extend the covering 14 .
Transmissivity of the extended covering 14 is also fully adjustable using the remote control 18 . When the covering 14 is in its fully extended configuration, the transmissivity of the covering 14 (i.e., the amount of light or air that is permitted to pass through the covering 14 ) may be adjusted by selectively pressing and releasing either the up arrow 320 or the down arrow 322 . When the covering 14 is in its fully extended configuration, the gear motor 144 operates in a second, slower speed. Therefore, the transmissivity adjustments take place at the slower speed. The counter 306 used to determine the position of the covering 14 commands the gear motor 144 to operate at the slower speed for a predetermined number of counts from the fully extended configuration of the covering 14 . The counter 306 is thus able to inform the gear motor 144 via the circuit board 276 when the covering 14 is configured for maximum transmissivity, minimum transmissivity, or any desired level of transmissivity between the maximum and the minimum.
The control system of the present invention uses counting as a primary means of controlling the position and orientation of the bottom rail 16 relative to the head rail 12 . In certain situations, the control system may place the gear motor 144 into a stall as a means of determining what configuration the covering 14 is in. For example, if the gear motor 144 attempts to over-extend the covering 14 , as depicted in FIG. 21 , the forward extending stop rib 142 on the roll bar 138 will engage the pocket 140 behind the curvilinear portion 136 of the working half 108 of the limit stop 26 . If such capture of the forward extending stop rib 142 occurs, the gear motor 144 is thereby placed in a stall, which informs the circuitry that the gear motor 144 is attempting to over-rotate the roll bar 138 and over-extend the covering 144 . After being in a stall for a short period, the gear motor 144 is instructed to stop attempting to rotate the roll bar 138 . A second scenario where the gear motor 144 may be placed into a stall occurs when the covering 14 is fully retracted, as shown in FIG. 24 . As shown, in the fully retracted configuration, an edge of the bottom rail 16 strikes the bottom rail stop arms 134 on the working half 108 of the limit stop 26 . This interaction between the bottom rail 16 and the stop arms 134 accomplishes two goals. First, when the gear motor 144 rotates the roll bar 138 sufficiently to drive an edge of the bottom rail 16 into the stop arms 134 , the curvilinear portions 136 on the underside, as depicted in FIG. 9B , of the working half 108 of the limit stop 26 are thereby raised off the roll bar 138 and the covering material 14 that has collected thereon. Second, when the bottom rail 16 is captured by the bottom rail stop arms 134 , the gear motor 144 ultimately goes into a stall, and the control electronics recognize the stall and shut down the gear motor 144 . Thus, the covering 14 takes on its fully retracted configuration, wherein the bottom rail 16 holds the working half 108 of the limit stop 26 off of the actual covering material 14 , which prevents the curvilinear portions 136 which ride on the covering material 14 as it is retracted or extended from creasing or denting, which may otherwise occur if the covering 14 is kept in a fully retracted configuration over an extended period of time.
It is also possible to control the retractable covering apparatus of the present invention without using the remote control 18 . A manual operation switch 280 is mounted to the circuit board housing 274 and circuit board housing cover 300 (see FIGS. 12 and 13 , for example). Selective pressing of the manual operation switch 280 permits a user to configure the covering 14 in any desired configuration that is obtainable through use of the remote control 18 . In general, with each press of the manual operation switch 280 , the control electronics on the circuit board 276 treat each press of the manual operation switch 280 as first a press of the up arrow 320 on the remote control 18 followed by a press of the down arrow 322 on the remote control 18 , or vice versa. In other words, each time the manual operation switch 280 is pressed, the control electronics interpret that as alternating presses of the up arrow 320 and down arrow 322 on the remote control 18 . An exception to this general rule by which the control electronics interpret the presses of the manual operation switch 280 occurs when the covering 14 is in its fully extended configuration. When the covering 14 is in the fully extended configuration, the control electronics must determine whether the user is attempting to retract the covering 14 or merely adjust the transmissivity of the fully extended covering 14 . For example, if the covering 14 is in its fully extended configuration and its minimally transmissive configuration (i.e., the covering 14 has just reached its fully extended configuration and stopped), a subsequent press of the manual operation switch 280 is interpreted by the control electronics as a command to “open” the extended covering 14 , increasing the transmissivity thereof by rotating the roll bar 138 to move the vanes 32 to a more horizontal configuration. If the manual operation switch 280 is again pressed during adjustment of the transmissivity, the gear motor 144 is signaled to stop movement. If the covering 14 is thus placed in a configuration somewhere between its maximally transmissive configuration and its minimally transmissive configuration, a subsequent press and release of the manual operation switch 280 will either increase the transmissivity or decrease the transmissivity depending upon whether the transmissivity was increasing or decreasing when the manual operation switch 280 was pushed to stop motion of the gear motor 144 . If the transmissivity was being increased when the gear motor 144 was commanded to stop rotating the roll bar 138 , a subsequent press and release of the manual operation switch 280 will instruct the control electronics to command the gear motor 144 to continue increasing the transmissivity as long as the maximum transmissivity configuration had not yet been achieved. If, on the other hand, the transmissivity was being reduced when the manual operation switch 280 was pressed to stop rotation of the roll bar 138 , a subsequent press and release of the manual operation switch 280 will cause the control electronics to instruct the gear motor 144 to rotate the roll bar 138 to continue decreasing the transmissivity until the minimum transmissivity configuration is obtained or the manual operation switch 280 is again pressed, whichever occurs first.
In summary, if the manual operation switch 280 is pressed while the gear motor 144 is rotating the roll bar 138 and the covering 14 has not yet reached a fully extended or fully retracted configuration, the gear motor 144 will be commanded to stop rotating the roll bar 138 . A subsequent press and release of the manual operation switch 280 will reverse the direction of rotation of the roll bar 138 .
For example, if the covering 14 was being extended before the gear motor 144 was instructed to stop rotating the roll bar 138 , a subsequent press and release of the manual operation switch 280 will result in the gear motor 144 rotating the roll bar 138 so as to retract the covering 14 . On the other hand, if the gear motor 144 was driving the roll bar 138 so as to retract the covering 14 when the manual operation switch 280 was pressed to stop retraction of the covering 14 , a subsequent press and release of the manual operation switch 280 will cause the control electronics to command the gear motor 144 to rotate the roll bar 138 so as to extend the covering 14 . When the covering 14 is in the fully extended configuration (see FIGS. 1 and 22 ), pressing and releasing the manual operation switch 280 does not necessarily reverse the direction of rotation of the roll bar 138 . The direction of rotation of the roll bar 138 is only reversed if the transmissivity has reached a maximum before the manual operation switch 280 is pressed and released two times. For example, if the transmissivity is being increased, but has not yet reached the maximum transmissivity configuration, when the manual operation switch 280 is pressed and released, rotation of the roll bar 138 stops. If the manual operation switch 280 is again pressed and released, the roll bar 138 is rotated in the same direction that it was previously rotating until the maximum transmissivity configuration is obtained. Thus, the direction of rotation of the roll bar 138 is not always reversed following an interruption or stopping of the motion of the roll bar 138 while adjusting transmissivity (i.e., while the covering 14 is in its fully extended configuration).
FIG. 25A is a block diagram of the control system electronics. FIGS. 25B and 25C are schematic diagrams of the control system electronics. The electronics are described next using FIGS. 25A , 25 B, and 25 C. Input power for the electronics is supplied by one or more batteries 208 connected in series. Connected between the battery 208 and the microprocessor 328 is circuitry 330 that provides battery reversal protection, a voltage regulator, noise filters, and a fuse to an H bridge. The voltage regulator is always on, and the quiescent current for the regulator is about one micro amp. A resistor R 1 and two capacitors C 2 and C 5 together filter motor noise and prevent it from affecting the voltage regulator. A third capacitor C 3 provides additional power filtering. Finally, the fuse F 1 provides fault protection to the H bridge circuit. The microprocessor 328 has a built in “watch dog” timer that is used to wake up the microprocessor from sleep mode. Resistor R 2 and capacitor C 4 form an oscillator at nominally 2.05 MH (.+−0.25%). Resistor R 0 allows for in-circuit programming.
The receiver 278 in the preferred embodiment is a 40 KHz infrared receiver connected to terminals P 3 and P 4 . Power is supplied to the receiver directly from the microprocessor 328 . The output from the receiver 278 (high when idle, low when a valid signal is being received) is connected to the microprocessor 328 . An external photo-eye may be connected to terminal P 2 (to board via jumper J 1 - 2 ). It is automatically used as soon as it is connected (and the internal photo-eye is then ignored). Switch S 1 is the manual operation switch 280 , which is shown, for example, in FIG. 13 . A slotted optical sensor 306 is mounted for rotation with the roll bar 138 . A light emitter used in conjunction with the slotted optical sensor 306 is on only when the microprocessor 328 needs to check the sensor 306 , and is driven by the microprocessor 328 with current limiting resistor R 3 . The output of the sensor (an open collector transistor) is connected to a microprocessor pin with an internal pull-up resistor.
Three leads from the microprocessor 328 control the H bridge: LEFT (left N MOSFET), RIGHT (right N MOSFET), and RUN (which turns on the appropriate P MOSFET). The N MOSFETs (QIA and B) are turned on by placing five volts on the gate. A P MOSFET (Q 2 A or B) will be turned on when the RUN signal is high and either LEFT or RIGHT is low. When this happens, Q 3 A or B will turn on and pull the gate of Q 2 A or B to ground, which turns it on (R 4 A or B pulls the gate to the same level as the source, and keeps the P MOSFET off). This setup only allows a P MOSFET to be on if the N MOSFET on the same side is off. If both LEFT and RIGHT are low when RUN is active, then both P MOSFETs will turn on and act as a brake.
Diodes internal to the P MOSFETs provide protection from back EMF from the motor. The output of the H bridge connects to the motor via jumper J 3 - 4 , then via connector P 5 or P 6 depending on left versus right-hand operation. Capacitor C 5 filters some of the high frequency noise from the motor.
All times discussed in the present specification are nominal; actual times vary by .+−0.25%. Also when the IR receiver is turned on, during the first millisecond (msec) of the interval the output is ignored to allow the unit to settle.
The following discusses the modes of operation of the microprocessor 328 .
Normal sleep/wake operation: Microprocessor 328 wakes up and checks the override button. If it is not pushed, the IR receiver 278 is turned on for 5.5 msec. Any active IR signal will cause the receiver 278 to be turned on again for 55 msec looking for a valid signal.
In sleep, the N MOSFETs are both on (brake), the P MOSFETs are off, the opto-sensor LED is off, the IR receiver 278 power and signal leads are driven low, and the option and manual switches are driven low. This is the minimal power state. Sleep lasts nominally 300 msec (210 minimum-480 maximum). This time is set by an RC timer inside the microprocessor 328 and is independent of the clock.
If the override button was pushed, then the IR receiver 278 is not turned on yet. The motor will be activated in the opposite direction from the last movement, and then the IR receiver 278 will start cycling (see below).
If any signals are present during the 5.5 msec test interval, then the receiver 278 stays off for 9.5 msec (during this time no other components are on besides the microprocessor 328 ). Then the receiver 278 is turned on for 55 msec. During this time, the receiver 278 is checked every 160.mu.sec. This data is checked by a state machine. At the end of the interval, the receiver 278 is shut off. If a valid sequence (our channel either up or down) was not received, then the microprocessor 328 goes back to a sleep mode.
If a valid up (down) command was received, and the upper (lower) limit has not been reached, then the motor 144 is turned on going up (down). If the command was up (down), and the upper (lower) limit has been reached, then the remote button is checked to determine if it is held for more than 1.7 seconds. If so, then the limit is over-ridden and the motor 144 starts in the appropriate direction. If it later stalls, a new limit will be set. During this check, the microprocessor 328 stays on the entire time, and the receiver 278 is cycled 9.5 msec off, 55 msec on.
Motor running: The receiver 278 is cycled 9.5 msec off, 55 msec on. After the on time, the status is checked: (1) the button is still held from when the motor 144 started (leave motor running); (2) the button has been released (leave motor running); or (3) the button has been re-pushed which means stop (see below). In a similar fashion the manual override button is checked every cycle. If the opto-sensor 306 changes state, then the stall timer is reset and the revolution counter is updated depending on the direction the motor 144 and hence the covering are moving. If the covering is moving up, then it is checked to determine if it reached the upper limit, and if so, then the motor 144 is stopped. If the lower limit is reached and the covering is moving down, then the motor 144 is stopped. Finally, the stall timer is checked. If it expires, then the motor is stopped and a new limit is set.
Stop: The P MOSFETs are turned off, and after 1 msec, the N MOSFETs are both turned on (brake), then the manual pushbutton and the IR remote are checked to determine that they are no longer pushed, then the microprocessor 328 reverts to a sleep mode.
FIGS. 26 , 27 , 28 , 29 , 30 , 31 , and 32 together comprise a flow chart representation of the logic used by the control system of the present invention. The logic may be implemented in software or firmware for execution by the microprocessor 328 . All times shown in the flow chart are nominal. Actual times may vary in the preferred embodiment by .+−0.25%. Items in a box are actions that are performed. Items in a diamond are tests that are made and the possible outcomes are written next to the arrows leaving the diamond. An arrow to a number goes to that number on another figure.
The following ten scenarios provide insight into how the control system electronics follow the logic depicted in FIGS. 26 , 27 , 28 , 29 , 30 , 31 , and 32 .
Scenario 1: Batteries 208 first inserted, no buttons pushed. Execution starts with item 400 in FIG. 26 , then 402 to initialize the system. The system then stays in the idle loop with items 404 , 410 , 416 , and 420 .
Scenario 2: Covering 14 not fully closed, motor 144 is stopped, the down button 322 on the transmitter 18 is pushed and released, and the user lets it go to the transition point. We are somewhere in the idle loop 404 , 410 , 426 , 420 When item 412 completes, the result of the test will be yes, moving to condition 2 (i.e., from element 414 on FIG. 26 to element 432 on FIG. 27 . Item 434 ( FIG. 27 ) will cycle the IR sensor 278 , which will decode the button, and we move to condition 4 (i.e., from element 448 on FIG. 27 to element 458 on FIG. 28 ), which executes items 460 and 462 , which starts the motor 144 going down, full speed, and we move to condition 7 (i.e., from element 464 on FIG. 28 to element 490 on FIG. 30 ). We are now in a loop doing item 492 . As the motor 144 turns, the rotating sensor 306 will change, causing us to go to condition 8 (i.e., from element 496 on FIG. 30 to element 512 on FIG. 31 ), and item 520 where we decrement the rotation counter. Assuming we do not reach the transition point, we move back to condition 7 (i.e., from element 546 on FIG. 31 to element 490 on FIG. 30 ) and the loop doing item with the motor 144 running at full speed. Task number 1 in item 492 will cause the system to check if the button 310 on the transmitter 18 is still pushed. When it is released, this is noted. The motor 144 continues, and we go back to the loop doing item 492 . Finally, the covering 14 reaches the transition point. We go through items 514 , 520 , 524 , 532 , 536 ( FIG. 31 ) and condition 10 (i.e., we move from element 542 of FIG. 31 to element 506 of FIG. 30 ), and item 508 which stops the motor 144 and puts us back in the idle loop 404 , 410 , 416 , 420 ( FIG. 26 ).
Scenario 3: Covering 14 not fully closed, motor 144 is stopped, the down button 322 on the transmitter 18 is pushed then released, and the user lets it go awhile, then pushes the button 322 again to stop the covering 14 partially closed. We got to the loop doing item 492 ( FIG. 30 ) the same as scenario 2 . Task number 1 in item 492 will cause the system to check if the button 322 on the transmitter 18 is still pushed. When it is released, this is noted. The motor 144 continues, and we go back to the loop doing item 492 . When the button 322 is re-pushed, this same task takes us to condition 10 where we go to item 508 , where we stop the motor 144 . We stay in item 508 until the button is released. Then we go back to the idle loop 404 , 410 , 416 , 420 ( FIG. 26 ).
Scenario 4: Covering 14 not fully closed, motor 144 is stopped, the up button 320 on the transmitter 18 is pushed and released, and the user lets it go to the top limit. We are somewhere in the idle loop 404 , 410 , 416 , 420 ( FIG. 26 ). When item 410 completes, the result of the test in item 412 will be “yes,” moving to condition 2 (i.e., we move from element 414 of FIG. 26 to element 432 of FIG. 27 ). Item 434 will cycle the IR sensor 278 , which will decode the button 320 , and we move to condition 3 (i.e., we move from element 452 in FIG. 27 to element 454 of FIG. 28 ), which executes items 456 and 462 , which starts the motor 144 going up, full speed, and we now transfer from element 464 of FIG. 28 to element 490 of FIG. 30 . We are now in a loop doing item 492 . As the motor 144 turns, the rotation sensor will change, causing us to go to condition 8 (i.e., from element 496 of FIG. 30 to element 512 of FIG. 31 ) and item 518 , where we increment the rotation counter 306 . Assuming we do not reach the top, we go back to the loop doing item 492 ( FIG. 30 ) with the motor 144 running at full speed. Task number 1 in item 492 will cause the system to check if the button 320 on the transmitter 18 is still pushed. When it is released, this is noted. The motor 144 continues and we go back to the loop doing item 492 . Finally, the covering 14 reaches the upper limit. We go through items 514 , 518 , 526 ( FIG. 31 ) and condition 10 (i.e., from element 530 of FIG. 31 to element 506 in FIG. 30 ), and item 508 , which stops the motor 144 and puts us back in the idle loop 404 , 410 , 416 , 420 .
Scenario 5: Covering 14 not fully open, motor 144 is stopped, the up button 320 on the transmitter 18 is pushed then released, and the user lets it go awhile, then pushes the button 320 again to stop it partially open. We get to the loop doing item 492 ( FIG. 30 ) the same as scenario 4 . Task number 1 in item 492 will cause the system to check if the button 320 on the transmitter 18 is still pushed. When it is released, this is noted. The motor 144 continues, and we go back to the loop doing item 492 . When the button 320 is re-pushed, this same task takes us to condition 10 where we go to item 510 , where we stop the motor 144 . We stay in item 510 until the button 320 is released. Then we go back to the idle loop 404 , 410 , 416 , 420 ( FIG. 26 ).
Scenario 6: Covering 14 at top limit, motor 144 is stopped, the up button 320 on the transmitter 18 is pushed and held until the limit is over-ridden, and the user lets it go to the top stall (or stalls it partially open to set a new upper limit). We are somewhere in the idle loop 404 , 410 , 416 , 420 ( FIG. 26 ). When item 410 completes, the result of the test in item 412 will be “yes,” moving to condition 2 (i.e., from element 414 in FIG. 26 to element 432 in FIG. 27 ). Item 434 will cycle the IR sensor 278 , which will decode the button 320 , and we move to condition 4 (i.e., from element 448 in FIG. 27 to element 458 in FIG. 28 ), which executes item 460 and 462 , which starts the motor 144 going down, full speed. We are now in a loop doing item 492 ( FIG. 30 ). As the motor 144 turns, the rotation sensor will change, causing us to go to condition 8 (i.e., from element 496 on FIG. 30 to element 512 on FIG. 31 ) and item 520 , where we decrement the rotation counter 306 . Assuming we do not reach the bottom, we go back to the loop doing item 492 with the motor 144 running at full speed. When the motor 144 reaches the top, or for any other reason stops rotating (stalls), the stall timer will time-out, and we go to condition 9 (i.e., from element 500 in FIG. 30 to element 548 in FIG. 32 ). We execute item 552 to set the new upper limit, then go to item 508 ( FIG. 30 ), where we stop the motor 144 . Then we go back to the idle loop 404 , 410 , 416 , 420 ( FIG. 26 ). Task number 1 in item 492 ( FIG. 30 ) will cause the system to check if the button on the transmitter 18 is still pushed. When it is released, this is noted. The motor 144 continues and we go back to the loop doing item 492 .
Scenario 7: Brand new covering 14 not at bottom, motor 144 is stopped, the down button 322 on the transmitter 18 is pushed and released, and the user lets it go to the bottom stall. We are somewhere in the idle loop 404 , 410 , 416 , 420 ( FIG. 26 ). When item 410 completes, the result of the test in item 412 will be “yes,” moving to condition 2 (i.e., from element 414 in FIG. 26 to element 432 of FIG. 27 ). Item 434 will cycle the IR sensor 278 , which will decode the button 322 , and we move to condition 4 (i.e., from element 448 of FIG. 27 to element 458 of FIG. 28 ) which executes item 460 and 462 , which starts the motor 144 going down, full speed. We are now in a loop doing item 492 ( FIG. 30 ). As the motor 144 turns, the rotation sensor will change, causing us to go to condition 8 (i.e., from element 496 of FIG. 30 to element 512 of FIG. 31 ) and item 520 , where we decrement the rotation counter 306 . Assuming we do not reach the bottom, we go back to the loop doing item 492 ( FIG. 30 ) with the motor 144 running at full speed. When the motor 144 reaches the bottom, or for any other reason stops rotating (stalls), the stall timer will time-out, and we go to condition 9 (i.e., from element 500 of FIG. 30 to element 548 of FIG. 32 ). We execute item 554 ( FIG. 32 ) to set the new lower limit and transition point, then go to item 508 ( FIG. 30 ) where we stop the motor 144 . Then we go back to the idle loop 404 , 410 , 416 , 420 ( FIG. 26 ). Task number 1 in item 492 ( FIG. 30 ) will cause the system to check if the button 322 on the transmitter 18 is still pushed. When it is released, this is noted. The motor 144 continues and we go back to the loop doing item 492 .
Scenario 8: Covering 14 fully closed, motor 144 is stopped, the down button 322 on the transmitter 18 is pushed unintentionally and released quickly. We are somewhere in the idle loop 404 , 410 , 416 , 420 ( FIG. 26 ). When item 410 completes, the result of the test in item 412 will be “yes,” moving to condition 2 (i.e., from element 414 of FIG. 26 to element 432 of FIG. 27 ). Item 434 will cycle the IR sensor 278 , which will decode the button 322 , and we move to condition 5 (i.e., from element 446 of FIG. 27 to element 466 of FIG. 29 ), which starts the loop running item 468 . When the user realizes the covering 14 is already down and releases the button 322 , we go to the idle loop 404 , 410 , 426 , 20 ( FIG. 26 ).
Scenario 9: Covering 14 fully open, motor 144 is stopped, the up button 320 on the transmitter 18 is pushed unintentionally and released. We are somewhere in the idle loop 404 , 410 , 416 , 420 ( FIG. 26 ). When item 410 completes, the result of the test in item 412 will be “yes,” moving to condition 2 (i.e., from element 414 of FIG. 26 to element 432 of FIG. 27 ). Item 434 will cycle the IR sensor 278 , which will decode the button 320 , and we move to condition 6 (i.e., from element 450 in FIG. 27 to element 478 in FIG. 29 ), which starts the loop running item 480 . When the user realizes the covering 14 is already down and releases the button 320 , we go to the idle loop 404 , 410 , 416 , 420 ( FIG. 26 ).
Scenario 10: Same as scenarios 2-6 but the manual button 280 is pushed instead of the IR button 310 . Instead of moving to condition 2 we go to condition 1 (i.e., from element 408 in FIG. 26 to element 422 in FIG. 27 ). We then go the opposite way that we moved last time. We then go to condition 3 (i.e., from element 428 in FIG. 27 to element 454 in FIG. 28 ) or 4 (i.e., from element 430 in FIG. 27 to element 458 in FIG. 28 ) just like we pushed the appropriate button on the remote 18 . We get to loop doing item 492 ( FIG. 30 ), and the scenarios are the same except we note the manual button 280 is released instead of the remote button 310 . If the manual button 280 is re-pushed (as in scenario 3 or 5 ), then we execute item 508 , which stops the motor 144 , and then we go to the idle loop 404 , 410 , 416 , 420 ( FIG. 26 ).
Although preferred embodiments of this invention have been described above, those skilled in the art could make numerous alterations to the disclosed embodiments without departing from the spirit or scope of this invention. Further, all directional references (e.g., up, down, leftward, rightward, bottom, top, inner, outer, above, below, clockwise, and counterclockwise) used above are to aid the reader's understanding of the present invention, but should not create limitations, particularly as to the orientation of the apparatus. It is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative only and not limiting.
|
An improved retractable covering for an architectural opening includes an improved mounting bracket, an improved limit stop to prevent over-retraction and over-extension of the retractable covering, an improved battery pack mounting bracket for attaching a power supply to a head rail of the retractable covering, an improved battery pack mounting apparatus for attaching a battery pack to a head rail, an improved control system for the retractable covering, and an improved method of using a wireless remote control or a manually operated switch to activate a motor to control the configuration of the covering, including the extension or retraction of the covering, and the transmissivity of the covering. The disclosed improvements are field retrofittable.
| 8
|
BACKGROUND OF THE INVENTION
This invention relates to a method and apparatus for applying a uniform electrical charge to a structure, and more particularly to a method and apparatus for applying a uniform corona produced charge to an electrophotographic member or imaging surface.
It is well known that in electrostatic printing equipment a corona generating device including a corona discharge electrode is employed to place positive or negative charges onto a photoconductive member or surface. The photoconductive member or surface is then exposed to a pattern of light which corresponds to the image to be printed. The pattern of light will discharge the photoconductive surface selectively in accordance with the presence and intensity of the light creating an electrostatic image of the light pattern on the surface. This electrostatic image may be employed in a number of ways now well known in the art in order to reproduce an image on a sheet of paper, or in some instances, the surface or member may be fixed in order to reproduce the electrostatic image.
The nature of photoconductive members is such that it will retain the charge deposited thereon for a very short time period, and only then if maintained in a darkened environment. If it takes some period of time for the charge to be applied to the member the level or intensity of the charge applied at the beginning of the charging process will have delayed or reduced as compared to the charge level applied at the end of the charging process. If the lighted image is exposed after the entire charging process the electrostatic image produced may be nonuniform as a result of this variation in charge level.
The corona generated in the above noted devices could be positively or negatively biased in order to produce either a positive or negative charge depending upon the nature of the photoconductive surface employed. When a positive corona is generated from a metallic filament electrode, the resultant charge applied to the photoconductive surface is generally relatively uniform due to the uniformity of the positive corona electrode emission. Many of the more currently available devices require a negative corona. When a negative corona is generated from a metallic filament electrode, the photoconductive surface obtains a charge which varies in density from point to point due to the nonuniform negative corona electrode emission. It is believed that this nonuniformity in charge is manifest in the developed image since areas containing a higher charge will attract more electrostatic developer material thereto thereby creating a streaked image appearance.
A number of devices have been developed in order to provide a uniform charge on the desired photoconductive surface. One such device employs specially coated electrodes which suppress the widely spaced emission nodes common to negatively biased corona electrode emissions. Another device moves the metallic corona electrode and the surface being charged substantially in orthogonal directions. Still other devices employ alternating currents plus a high voltage direct current to minimize or reduce the nonuniformity. These devices appear to provide a more uniform charge for the above equipment. It should be noted, however, that the above noted equipment generally is rather limited in its photographic reproduction capabilities to reproducing printed matter, because of the nature of the photoconductive surfaces employed.
Electrophotographic members are being developed which are much more sensitive than the members employed in the above-noted equipment. These electrophotographic members are of a quality capable of reproducing or creating high resolution images; that is, each point on the surface of the member is capable of selectively discharging in accordance with the intensity of incident light so that an almost infinite scale of gray can be reproduced in the resultant image. In order to make full use of this feature, the applied corona charge must be substantially uniform across the entire member or surface of the member. This is necessary in order to produce a resultant image which has varying shades that result from variations in the intensity of incident light and not from variations in the initial corona produced charge.
SUMMARY OF THE INVENTION
In practicing this invention a method for charging an electrophotographic member or imaging surface is provided which includes reciprocating at least one longitudinally disposed corona electrode substantially in the longitudinal direction. A corona voltage is applied to the reciprocating electrode in order to develop a corona about the electrode whereby a substantially uniform corona charge will be applied to the entire electrophotographic member or surface. As an additional step the electrode and the electrophotographic member or imaging surface can be moved relative to one another simultaneously with the electrode reciprocation.
An apparatus is also provided which includes a corona producing device having at least one elongate longitudinally disposed corona electrode. A supporting structure mounts the electrode and is adapted to reciprocate in the longitudinal direction. A driver, which in the preferred embodiment takes the form of a motor, is coupled to the support structure and is operative to provide the drive for reciprocating the support structure whereby a substantially uniform corona charge may be applied to the electrophotographic member or surface. In one embodiment a second drive device is coupled to either the support structure or the electrophotographic imaging surface or member for moving one relative to the other during reciprocation of the electrode.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the corona discharge apparatus of this invention, and a partial block diagram of the associated electronic equipment;
FIG. 2 is another view of the corona discharge apparatus of this invention and a partial block diagram of the associated electronic equipment.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, a corona producing device generally identified by the numeral 10 is shown and includes a baseplate 12. Baseplate 12 can be formed from either a conductive or non-conductive material and must have a thickness sufficient to make the plate relatively rigid. Mounting blocks 14 and 16 are secured to one side 18 of baseplate 12. A support arm 20 formed from a sheet of relatively thin flexible material has one end thereof secured in mounting block 14. A second support arm 22 identical to support arm 20 is secured in mounting block 16. Support arms 20 and 22 extend substantially perpendicular to the plane of baseplate 12. Apertures 24 and 26 are formed through support arm 20 adjacent the distal end thereof and apertures 28 and 30 are formed through support arm 22 at substantially the same points as apertures 24 and 26.
Corona producing electrodes 34 extend from aperture 24 to aperture 28 and from aperture 30 to aperture 26. Corona producing electrodes 34 are of the type commonly known in the art which will develop corona about themselves when a high voltage is applied thereto and when they are a proper distance from a ground plane. They are secured in each of the above noted apertures thus effectively providing two elongate corona producing electrodes extending between supporting arms 20 and 22.
Corona producing electrodes 34 are positioned such that they extend substantially parallel to the plane formed by baseplate 12 in a longitudinal direction. If support arms 20 and 22 are formed from an electrically nonconductive material such as, for example, plastic sheets, electrodes 34 may be secured directly to arms 20 and 22 at the four apertures. If, however, support arms 20 and 22 are formed from an electrically conductive material, such as, for example, spring steel, electrodes 34 must be isolated from support arms 20 and 22. This may be accomplished by fitting plastic insulation inserts into apertures 22, 24, 26, 28 and 30, then securing electrodes 34 in these plastic inserts.
In the preferred embodiment, electrodes 34 are thin and quite flexible. In order to operate effectively they must be rigidly maintained between support arms 20 and 22. That is, they must be held under tension in order to keep them straight. In order to maintain this tension coupling member 44 is secured to and extends between support arms 20 and 22. Member 44 is positioned between surface 18 of baseplate 12 and electrodes 34 and is curved in order to give it rigidity. In addition to providing the noted tension it acts also to couple support arms 20 and 22 together and to insure that both support arms 20 and 22, as well as the corona electrodes 34, move in synchronism.
An insulated conductor 36 is connected at one end to the ends of electrodes 34 at apertures 24 and 26 respectively. The other end of insulated conductor 36 is secured to electrical connection terminal 40. A fractional horsepower motor 46 is shown secured to side 18 of baseplate 12 with the rotating shaft thereof extending substantially perpendicular to the plane of baseplate 12. Motor 46 has a rotational speed of approximately 1800 rpm. An eccentric 50 is secured to the end of rotating shaft 48 and a connection or coupling arm 52 connects eccentric 50 to a pivot pin 51 which is secured to pivot arm 53. Pivot arm 53 is secured to supporting arm 22 at location 54. The rotation of rotating shaft 48 and eccentric 50 will cause connection or coupling arm 52 to move longitudinally while pivoting somewhat at pivot pin 51 so that connection arm 52 reciprocates. Connection arm 52 will reciprocate at 1800 reciprocations per minute the same reciprocation rate as the speed of motor 46. The movement or reciprocation of connection arm 52 puts tension on pivot arm 53 which causes supporting arm 22 to flex or bend following the movement of connection arm 52. The movement of arm 22 is transferred, via the member 44 to support arm 20 so that the entire structure consisting of support arms 20 and 22, member 44 and electrodes 34 reciprocates in a longitudinal direction with the rotation of shaft 48 in motor 46. Conductors for providing an electrical connection to motor 46 are shown connected to electrical connection terminals 56 and 58.
Connection terminal 58 for one side of the motor winding is shown schematically as being connected to ground potential. Electrical connection terminal 40 is coupled via conductor 60 to the output of a corona power supply 62. Corona power supply 62 may be any one of the type well known in the art which will supply a voltage sufficient to cause electrodes 34 to develop a corona. The input control to corona power supply 62 is coupled via conductor 64 to one output of control circuit 66. A second output of control circuit 66 is coupled via conductor 68 to terminal 56, which as noted previously is connected to motor 46. A switch 72 has one terminal thereof coupled to the input of control circuit 66 and the other terminal connected to ground potential. The third output of control circuit 66 is coupled via conductor 70 to an electrophotographic member drive transport 74 shown in block diagram form in FIG. 2 which operates to move electrophotographic member 76.
Referring to FIG. 2 corona producing device 10 is shown positioned above electrophotographic member 76 whose upper or imaging surface 78 is to be charged. Corona producing device 10 and electrodes 34 are positioned with the longitudinal axis or direction of electrodes 34 transverse to the direction of movement of member 76 and at a predetermined distance or height above surface 78 of electrophotographic member 76.
In operation, push button switch 72 is momentarily depressed providing a ground connection to control circuit 66. Control circuit 66 upon actuation will develop three control signals. The first control signal is coupled via conductor 68 and connection terminal 56 to motor 46 causing the motor to begin rotating and reciprocating support arms 20 and 22, member 44 and electrodes 34 at the first reciprocation rate or speed noted previously. The second control signal is developed by control circuit 66 at the same time as the first control signal and is coupled to corona power supply 62 via conductor 64 energizing supply 62 to develop the necessary corona voltage. The corona voltage is coupled to electrodes 34 via conductor 60 so that the desired corona is developed in the area surrounding electrode 34.
It is believed that the electrodes 34 exhibit nonuniformity in the form of nodes at random points on their surfaces which create higher energy corona emissions. The reciprocation of the electrodes 34 causes the corona emission from each node, which moves identically with the electrodes 34, to charge a greater area of the electrophotographic member. The reciprocation amplitude is made large enough such that the areas charged by each seperate node will overlap, resulting in a uniform charge on the electrophotographic member. The corona voltage developed by supply 62 will continue for a period of time determined by the length of the control signal from control circuit 66 which is a period sufficient to totally charge the surface 78 of the portion of the electrophotographic member 76 to be exposed.
The third control signal developed by control circuit 66 is developed simultaneously with the first and second control signals and is coupled by conductor 70 to electrophotographic drive transport 74. Electrophotographic drive transport 74 causes the electrophotographic member 76 to move past the longitudinally reciprocating electrodes 34 at a second rate of speed. The speed of movement of electrophotographic member 76 produced by drive transport 74 and the reciprocation speed of electrodes 34 are selected such that the corona, shown via the dots 80 in FIG. 2 will be substantially uniformly dispersed around and below electrodes 34 thus uniformly charging the entire surface 78 of member 76. When the portion of member 76 to be exposed has been charged all three control signals will terminate.
All of the apparatus shown in FIG. 2 is secured in a closed housing (not shown), particularly member 76 which must be maintained in a dark environment except when exposed to the lighted image to be reproduced. In this embodiment, surface 78 of member 76 is exposed to the lighted image to be reproduced immediately after it has been charged and passed beyond the charging area of corona producing device 10. The exposure preferably occurs as member 76 moves beyond corona producing device 10 with sections of the entire image being continuously, sequentially exposed to corresponding sections of the member 76 during its movement. This can be performed by a shutter like device whose operation must also be synchronized with the operation of control circuit 66. This technique eliminates the possibility of producing a nonuniform electrostatic image as a result of variations in charge levels on the surface 78 of member 76 which can result from delaying exposure until the entire portion of member 76 to be exposed is charged.
It is to be understood that although the preferred embodiment is shown with electrophotographic member 76 being moved relative to corona producing device 10 while electrodes 34 reciprocate, such an arrangement is not the only one feasible. In an alternate embodiment electrophotographic member 76 may be fixed and corona producing device 10 may be mounted to a movable track. Electrophotographic drive transport 74 would be omitted in such an arrangement and a second drive would be provided for moving corona producing device 10 along the track to which it is mounted in a direction transverse to the direction of reciprocation of electrodes 34 at a second rate of speed as noted above. In this arrangement as well as the previously described arrangement the primary requirement is that electrodes 34 and member 76 are moved relative to one another while electrodes 34 are reciprocated in a longitudinal direction.
|
A method for charging an electrophotographic imaging surface includes the steps of reciprocating at least one longitudinally disposed corona electrode along the longitudinal axis and simultaneously applying a corona voltage to the electrode for developing a corona so that a substantially uniform corona charge is applied to the entire electrophotographic imaging surface. An additional step, performed simultaneously with production of the corona and reciprocation of the electrode can be the movement of one of the electrodes or the electrophotographic imaging surface relative to the other. Apparatus employed to perform this method also is disclosed.
| 6
|
FIELD OF THE INVENTION
[0001] The present disclosure relates to a multi-purpose liquid cleaning composition. The cleaner is particularly effective as a degreaser for use on heavy grease, including the type that may accumulate on motor vehicles. The cleaning composition is non-toxic, biodegradable, and will not cause harm to the user, the surface, or the environment.
BACKGROUND OF THE INVENTION
[0002] The present disclosure relates to an environmentally benign, yet powerful, cleaning composition. Commercially available cleaning compositions generally incorporate chemicals that are detrimental to the environment. These chemicals include surfactants, solvents, boosters and chelators. Other common ingredients in cleaning compositions that can harm the environment include phosphates, nitrilotriacetic acid, ethylenediaminetetraacetic acid, nonylphenol ethoxylates, and heavy metals; some of which have been demonstrated to accumulate in ground water.
[0003] Toxic chemicals from cleaning compositions have been found in fresh water such as ponds, lakes, and streams in high levels. Aquatic organisms, including both plants and animals, are at risk from exposure to high levels of these chemicals in water systems. Further, humans exposed to these chemicals through water systems may suffer from health problems. Additionally, many cleaning compositions contain toxic or carcinogenic chemicals, including volatile organic compounds (VOCs) and hazardous air pollutants (HAPs) that can pollute the air. As a result, alternative cleaning compositions which do not contain these and other environmental and bio-hazardous chemicals are desired.
[0004] Typical cleaning compositions require multiple surfactants, solvents, and builder combinations to achieve adequate consumer performance. For cost-effectiveness and out of concern for the environment, focus has shifted to producing cleaning compositions containing naturally occurring chemicals. There has long been a need for a naturally-based cleaning composition that achieves acceptable consumer performance with a limited number of natural components compared to highly developed compositions using synthetic surfactants and solvents.
[0005] A number of representative compositions include high numbers of ingredients and synthetic compounds, leading to higher costs of production and limited usefulness. For example, U.S. Pat. Nos. 6,759,382, 6,686,323 6,117,820 and 6,537,960 disclose cleaning compositions with high complexity and large numbers of ingredients.
[0006] Prior compositions have not successfully minimized ingredients while maintaining quality of cleaning, particularly with environmentally benign compounds. Accordingly, it is an object of the present invention to provide a cleaning composition that overcomes the disadvantages and shortcomings associated with existing cleaning compositions.
SUMMARY OF THE INVENTION
[0007] This composition is multi-purpose cleaner, particularly effective for heavy grease removal. Heavy grease includes the type that may accumulate on the sides or backs of diesel powered public transit buses and locomotives, subway cars, intercity trains and light rail vehicles. This composition may be customized for different purposes by adjusting the pH through dilution. Varying the levels of dilution of this composition results in a different pH targeted for specific applications.
[0008] In accordance with the above objects and those that will be mentioned and will become apparent below, one embodiment of the present invention comprises a natural cleaning composition having a chelating agent, which may be of the aminocarboxylate class of chelating agents. The formulation also contains a surfactant of the ethanolamine class. Additionally, the formulation contains an abrasive, such as sodium silicate. Further, the formulation includes an amphoteric surfactant such as b-Alanine,N-(2-carboxyethyl)-N-[3-(decyloxy)propyl]-, sodium salt (1:1). A thickener amine oxide such as ethanol, 2,2-iminobis-, N-(3-(branched decyloxy)propyl) derivs, N-oxides is also included. Finally, a quaternary amine surfactant such as Tomamine® Q-17-2 is included in this embodiment of the formulation of the present disclosure.
[0009] The formulations of the present disclosure may further comprise a chelating agent. A shine polymer may further be added for those applications requiring a shined surface following cleaning. Optional compositions further contain dyes and/or fragrances.
DETAILED DESCRIPTION
[0010] This disclosure provides formulations for environmentally friendly specialty cleaning chemicals. The present disclosure provides three separate environmentally friendly cleaning formulations.
[0011] Method of Application
[0012] The cleaning composition of the present disclosure may be applied to the target surface by a variety of means, including direct application by means of a spray, pump or aerosol dispensing means, or by other means, including the use of a carrier, or dilution system, as for example, but not limited to a wash, dip or immersion process. Regarding applications by use of a carrier, such suitable carriers include, for example, an impregnated wipe, foam, sponge, cloth, towel, tissue or paper towel or similar releasably absorbent carrier that enables the inventive compositions to be applied by direct physical contact and transferred from the carrier to the target surface, generally during a spreading, padding, rubbing or wiping operation. Combinations of a direct application, followed by a spreading, padding, rubbing or wiping operation performed with the aid of a foam, sponge, cloth, towel, tissue or paper towel, squeegee or similar wiping implement is also suitable for applying the cleaning compositions of the present disclosure.
[0013] The cleaning composition may be also be sprayed directly onto the target surface and therefore are typically packaged in a spray dispenser. The spray dispenser can be any of the manually activated means for producing a spray of liquid droplets as is known in the art, e.g., trigger-type, pump-type, electrical spray, hydraulic nozzle, sonic nebulizer, high pressure fog nozzle, non-aerosol self-pressurized, and aerosol-type spray means. Automatic activated means can also be used herein. These types of automatic means are similar to manually activated means with the exception that the propellant is replaced by a compressor. The spray dispenser can be an aerosol dispenser. Said aerosol dispenser comprises a container which can be constructed of any of the conventional materials employed in fabricating aerosol containers. A more complete description of commercially available aerosol-spray dispensers appears in U.S. Pat. Nos. 3,436,772 and 3,600,325, both of which are fully incorporated herein by reference. Alternatively, the spray dispenser can be a self-pressurized non-aerosol container having a convoluted liner and an elastomeric sleeve. A more complete description of self-pressurized spray dispensers can be found in U.S. Pat. Nos. 4,260,110; 5,111,971 and 5,232,126, both of which are fully incorporated herein by reference. The container and the pump mechanism can be constructed of any conventional material employed in fabricating pump-spray dispensers, including, but not limited to: polyethylene; polypropylene; polyethyleneterephthalate; blends of polyethylene, vinyl acetate, and rubber elastomer. Other materials can include stainless steel. A more complete disclosure of commercially available dispensing devices appears in: U.S. Pat. Nos. 4,082,223; 4,161,288; 4,274,560; 4,434,917; 4,735,347; 4,819,835; 4,895,279; and 5,303,867; all of which are fully incorporated herein by reference.
[0014] One of skill in the art would understand the term “about” is used herein to mean that a concentration of “about” a recited percentage (%) produces the desired degree of effectiveness in the compositions and methods of the present invention. One of skill in the art would further understand that the metes and bounds of “about” with respect to the concentration of any component in an embodiment can be determined by varying the concentration of one or more components (all percentages listed herein are by weight, as would be understood by one of ordinary skill in the art), determining the effectiveness of the mixture for each concentration, and determining the range of concentrations that produce mixtures with the desired degree of effectiveness in accordance with the present disclosure. The term “about” is further used to reflect the possibility that a mixture may contain trace components of other materials that do not alter the effectiveness or safety of the mixture.
[0015] It will be understood that emollients, humectants, fragrances, coloring agents, and other components may be added to or used with the compositions and methods provided herein. One of skill in the art can select additional components and determine suitable amounts and formulations such that the final composition functions with the desired degree of effectiveness to remove lacquer as provided herein.
[0016] The foregoing descriptions illustrate selected embodiments of the present invention and in light thereof various modifications will be suggested to one of skill in the art, all of which are in the spirit and purview of this invention.
Formulation Examples
[0017] A formulation of the present disclosure comprises a mixture of about 75-93% water, about 2.0-5.0% Tetrasodium Iminidisuccinate, about 0.5-4.0% Monoethanolamine, about 1.0-5.0% Sodium Silicate, about 1.5-7.0% Amphoteric surfactant, about 1.5-7.0% Amine Oxide, and about 1.5-7.0% Quaternary Amine. The formulation of the present disclosure is generally applied at a pH of between 6.0 and 8.0; however, depending upon the intended use of the product, the pH can be adjusted. The CAS number of water is 7732-18-5. The CAS number of Tetrasodium Iminidisuccinate is 144538-83-0. The CAS number of Monoethanolamine is 141-43-5. The CAS number of Sodium Silicate is 1344-09-8. The CAS number of amphoteric surfactant 64972-19-6. The CAS number of amine oxide is 68478-65-9. The CAS number of Quaternary amine is 68610-19-5.
[0018] A specific embodiment of the formulation of the present disclosure comprises a mixture of 83.9% water, 3.0% Tetrasodium Iminidisuccinate, 1.5% Monoethanolamine. 3.0% Sodium Silicate, 3.0% Amphoteric surfactant, about 2.8% Amine Oxide, and 2.8% Quaternary Amine. The formulation of the present disclosure is applied at a pH of 12.0.
[0019] A second embodiment of this formulation substitutes CAS 144538-83-0 with CAS 6381-92-6, however, the cleaning performance of the formulation is somewhat reduced. An embodiment of this formulation substitutes CAS 1344-09-8 with CAS 6834-92-0. In a fourth embodiment of this formulation, CAS 61789-39-7 can substitute for CAS 64972-19-6. In a fifth embodiment of this formulation, CAS 71486-82-3 or 223129-76-8 can substitute for CAS 68478-65-9. In a sixth embodiment of this formulation either CAS 61791-10-4 or CAS 68478-94-4 can be substituted for CAS 68610-19-5.
|
Provided is a multi-function liquid cleaning composition. The cleaning composition may be diluted to produce a composition for a variety of different purposes. The cleaning solution is particularly effective as a degreaser for heavy grease removal. Heavy grease includes the type that may accumulate on motor vehicles. The cleaning formulation is environmentally benign and non-toxic.
| 2
|
FIELD AND BACKGROUND OF THE INVENTION
This invention relates in general to a method for the decoloring and refining or purifying of beet juice.
More particularly, this invention is concerned with decoloring and refining processes which include the step of more efficiently discoloring and purifying beet juice containing colorants in sugar-manufacturing processes, by the use of adsorbent of similar type of synthetic hydrotalcite, at the temperature of 40°-100° C. or more preferably at 60°-80° C.
Also, in a first embodiment of the invention, the process includes a step for efficiently regenerating an adsorbent by replacing the adsorbate through ion exchange by contacting an adsorbent containing the adsorbate with various inorganic salts-solutions to cause the ion-exchange.
In the second embodiment of the invention, the process includes a step for efficiently regeneration, an adsorbent by removing the adsorbate through heating of the adsorbent within a temperature range as high as 750°-950° C. or preferably 800°-900° C.
Originally, sugar beet as a raw material for manufacturing the sugar does not contain any pigment, however, it is known that colorants are formed in beet juice during the sugar-manufacturing process.
These colorants are various on those types and are chemically unknown on numerous points, and yet, these are generally said to be caramel-substances, polyphenol-iron complexes, melaidine, and melanine.
Accordingly, in order to inhibit the formation of these pigments, hydrogen sulfide, ascorbic acid, sulfurous acid gas, etc., namely, deoxidizers have been used so far, without sufficient results. In the treatment os sugar cane, decoloring, purification or refinement of colored juice is performed by the combined use of activated carbon with organic ion exchange resins. However, in the treatment of beet juice, it is improper to use the activated carbon, and the decoloration is now typically being made by the combined treatment with SO 2 - gas (saturated or blowing-off of the gas), and organic ion exchange resins but, it is not preferable to use such gas in view of food-hygiene.
SUMMARY OF THE INVENTION
The present inventors have discovered efficient methods for decoloration and purification or refinement of beet juice at rather high temperatures of 60°-80° C. in purifying and refining processes by the use of a known adsorbent of aluminate-type a Japanese laid-open patent Gazette No. 50-153456 showing remarkable adsorbing efficacy for the treatment of sewage containing organic contaminants especially, among the recently suggested novel adsorbents. The aforesaid Japanese laid open patent gazette discloses a method treating sewage containing organic contaminants, featuring that the dehydrated solid co-precipitated substances formed by unsolubilizing the metal-ingredients in those solutions containing at least one type of the metal-ingredients selected from Mg and Ca as well as at least one type of metal-ingredients selected from Al and Fe are contacted with the sewage containing organic contaminants, thereby, making adsorption of the organic contaminants into the said solid substances.
However, the said adsorbent can be obtained by the reaction of various aluminates with more than one compound of silicates, ferrates, zincates, and alkaline-earth metals. The formed structure of the adsorbent is very similar to that of naturally occurring hydrotalcite shown with the chemical formula: MgxAl [(OH) 2x+2 1/2CO 3 ] (x-1) H 2 O (x=2-3, 1CO 3 ≦4H 2 O).
Accordingly, upen using the adsorbent for decoloration and refinement of beet juice, in view of the natures of beet juice (higher viscosity, etc.), the benefits of both granulation into smaller grains and the handling by a column-flowing system, may be applied. The ordinary thermal regeneration-method adopted for adsorbents even with granulation, by the use of any binders cause crystal-granular disintegration accompanied by the release of the structural water, formed within the structure of the crystal, and results in pulverization of the adsorbent itself. Moreover, the adsorbency is markedly reduced by the regeneration. The present inventors have tested the adsorbents of aluminates which have the above natures or features with respect to the methods used for the decoloration and refinement of beet juice containing the colorants in sugar-purifying processes.
Thus, in the first embodiments of the invention, the inventors have discovered that the adsorbents of aluminates having physical adsorbency and those higher ion-exchanging action of inorganic anion of the structural atoms showed higher decoloring and refining functions even at rather higher temperature ranges of 40°-100° C. and, preferably 60°-80° C.
The inventors have also discovered that the regeneration of the said adsorbents can be efficiently performed by contacting the adsorbates and solutions of various inorganic salts to cause ion-exchange, and that the adsorbents, after regeneration, could be used repeatedly without disturbing any adsorbing function. Moreover, the mechanical strength of the adsorbents during the above process is not reduced.
Thus, the present invention is directed to a method for the refining and purifying of beet juice, including the first step of adsorbing colorants on adsorbents by contacting the adsorbents and beet juice containing the colorants at 40°-100° C. and the second step of regenerating the adsorbents by contacting the adsorbents and an aqueous solution of inorganic salts or compounds.
Moreover, in a second embodiment of the invention, the inventors have discovered greater bleaching or decoloring and refining ability even in rather high temperatures in the range of 40°-100° C. or preferably 60°-80° C. through higher activity of physical adsorbing characters, despite a slightly reduced adsorbing effect in the ion-exchanging nature possessed by the adsorbents originally after heat-treatment of adsorbents of aluminates at 750°-950° C. or preferably 800°-900° C. Also, the inventors have further discovered that the regeneration of the adsorbents can be efficiently performed at 750°-950° C. or preferably as higher as 800°-900° C., and that it is possible to repeatedly use the adsorbents after regeneration without losing the adsorbing function and without reducing the mechanical strength of the granular adsorbents during the repeated uses.
Hence, this invention relates to a method of refining or purifying beet juice which includes the first step of adsorbing of the said colorants by contacting the beet juice, containing the colorants at 40°-100° C., and the second step of regenerating the adsorbents by heating the adsorbents at higher temperatures in the range 750°-950° C.
The method of this invention is superior to the conventional sulfur dioxide gas saturating and filling method which has the defects of requiring complicated handling techniques and poor operativity.
Only contact between the adsorbents and beet juice, for its treatment, can make full decoloration and purification. Unlike the forementioned conventional method which should cover the adjustment or control of the "second filtering juice" as named in the sugar-refining process by means of adjustment of blow-gas volume towards the optimum pH 8-9, the method by this invention inevitably brings about pH 8-9 of the treating solution by the buffer-action possessed with the said adsorbents. That is, in the present invention, decoloration and refinement as well as the adjustment to the optimum pH can be performed at the same time.
It is an object of the invention to provide a method of refining beet juice having a colorant comprising the step of contacting the beet juice with an adsorbent in a temperature range of 40° to 100° C. to form an adsorbate thereby decoloring the beet juice. In accordance with a preferred embodiment of the invention the inventive technique further comprises a step of contacting the adsorbate with an aqueous solution of inorganic salt to regenerate the adsorbent. In accordance with still a further embodiment of the invention the technique further comprises heating the adsorbate to a temperature in the range of 750° to 950° C. to regenerate the adsorbent. In accordance with a further preferred embodiment of the invention, the beet juice is contacted with an adsorbent in a temperature range of 60° to 80° C. and the step of heating the adsorbate is conducted preferably in a temperature range of 800° to 900° C.
The method of the invention is preferably carried out utilizing an adsorbent which is a dehydrated solid of a coprecipitated substance formed by insolubilizing metallic ingredients in an aqueous solution containing at least one metallic ingredient selected from the group consisting of calcium and magnesium and at least one metallic ingredient selected from the group consisting of aluminum and iron.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The adsorbents, in the present invention, mean those of synthetic hydrotalcite type which is a dehydrated solid of coprecipitated substance formed by the non-dissolution of metallic ingredients in the aqueous solution containing at least one metallic ingredient selected from the group Ca, Mg, and at least one metallic ingredient selected from the group of aluminium and iron. By syhthesizing this adsorbent, it is possible to add reinforcements of solid materials such as silicic acid or silicates.
In the first step of contacting the adsorbents with beet juice containing colorants, either a batch-process or continuous technique may be utilized for the contact method of ordinary adsorbents with adsorbates at 40°-100° C., preferably 60°-80° C.
For instance, for batch processing adsorbents in powder form may be added and mixed with beet juice. After decoloration, the adsorbent is precipitated and isolated or filtered. In continuous processes granular adsorbent is filled in a column, and beet juice is circulated from the upper or lower portion of the column of the adsorbent-layer.
As for the technique of regenerating the said adsorbents in the second step, in the first embodiment of the invention, adsorbates can be isolated by circulating or contacting various inorganic salt solutions at 40°-100° C. or preferably 60°-80° C., followed by the removal of inorganic compounds attached to adsorbents by the use of cool or warm water, and again, the adsorbents can be used for adsorbing operation.
The aqueous solutions of inorganic compounds applicable for the present invention may be any solutions containing anions for making ion-exchange with adsorbates, for which, remarkable effects can be obtained by using the salts or compounds, containing CO 3 2- , SO 4 2- , or HPO 4 2- ions having valence of two.
Accordingly, aqueous solutions having at least one compound among carbonates such as sodium carbonate or potassium carbonate, sulfates such as sodium sulfate or potassium phosphate, and phosphates such as sodium phosphate or potassium phosphate may be effectively utilized.
By the above operations, the colorants produced by ion-exchange with inorganic anions of adsorbents can be further put to ion-exchange with anions of inorganic salts or compounds. After regeneration of the said adsorbents, by repeating the adsorption and detachment for producing ion-exchange between anions of inorganic salts and colorants, the adsorbents can be regenerated and used again.
Moreover, aqueous solution of inorganic salts by the repeated uses can be saturated and condensed by colorants detached from the adsorbents. This saturated and condensed solution can be treated by burning and the like.
There is no restriction of the concentration and quantity of the aqueous solutions of inorganic salts used under the conditions with full ion-exchange with adsorbates.
Detailed explanation is made hereinafter on the present invention by examples, as follows:
Chromaticity was measured by the adsorbency of the visible ray with its wave-length of 420nm in accordance with the platinum standard solution method with reference to JIS L-101.
REFERENCE EXAMPLE 1
Magnesium chloride (MgCl 2 .6H 2 O) in a quantity of 143 g and sodium aluminate in as quantity of 47 g containing 25 g as Al 2 O 3 were each put into a 1000 ml beaker and dissolved in water to make a solution of 700 ml. Both solutions were put into 600 ml-water in a beaker of 5 liters, being stirred by the use of a magnetic stirrer while the pH of the solution was kept at 8.5 by dropping 10%-NaOH solution under room-temperature, it was poured at the speed of about 24 ml/min by using a quantitative pump for 30 minutes, and the resulting gel was filtered and washed with water.
This substance consisted of Al 2 O 3 8.4%, MgO 8.9% and total water 80.5%, and one-time yield was 270 g.
This gel-like substance was dried at 110° C. for 16 hours, and was pulverized to obtain the powdered adsorbent (hereinafter referred to as Powdered Product 1).
This powder consisted of Al 2 O 3 25.4%, MgO 31.8% and total water-content was 41.8%.
The obtained powdered adsorbent in a quantity of 100 g was kneaded with binder (cement) in an amount of 5 g, and was formed into a cylinder-shape having a 0.5-0.8 mm diameter. After drying at the temperature of 110° C., firing was made at the temperature of 400° C. for preparing a formed adsorbent (hereinafter referred to as Granulated product 1).
REFERENCE EXAMPLE 2
Magnesium chloride in a quantity of 143 g was dissolved in water to make a solution of 700 ml, and also, sodium aluminate in a quantity of 31 g containing 18 g of Al 2 O 3 and sodium silicate in a quantity of 8.6 g containing 6 g of SiO 2 were dissolved in water to make 700 ml. Other operations were the same as those of Reference Example 1, and the formed adsorbent and powder as in Reference Example 1 were obtained (hereinafter referred to as Powder Product 2 and Granulation Product 2).
This product consisted of Al 2 O 3 21.6%, MgO 31.9%, SiO 2 6.7% and total water content 36.6%.
EXAMPLE 1
Powdered products 1 and 2, each in an amount of 10 g, obtained by Reference Examples was put into a beaker with 100 ml of beet juice of chromaticity 6,200 ppm (Pt). The solution was stirred and shaked for 210 minutes under the temperature of 70° C. Thereafter, the suspended adsorbent was centrifuged for isolation with the sedimentation.
The supernatant solution was filtered by C-filter paper, and the chromaticity of the filtered solution was measured. Thus, a decreased value was determined as an indication of decolorizing rate.
Next, the filtered adsorbent was put into a beaker with an aqueous solution with a quantity of 50 ml of 20%-Na 2 CO 3 , and was stirred for 20 minutes under the temperature of 70° C.
After filtration, the adsorbent was further washed with water for removing the aqueous solution of Na 2 CO 3 completely.
The regenerated adsorbent was active again for decoloration of beet juice, and no decrease of adsorption-faculty was observed. This operation was repeated 10 times, and the removing rates are shown in Table 1.
EXAMPLE 2
Granulated products 1 and 2, in an amount of 60 g, were each loaded into a glass-column having a warming jacket. Beet juice with chromaticity 5,800 ppm (Pt) was circulated at the flow rate of SV 0.3 hr - at the temperature of 70° C. The chromaticity of the treated solution obtained at the outlet of the column was continuously measured.
As a result, 4.2-4.6 liters of beet juice could be treated with the concentration-ratio, between the outlet and inlet, up to 0.5 in the column of beet juice.
To this granulated products 1 and 2, 20%-Na 2 CO 3 aqueous solution 250 ml was circulated at the temperature of 70° C., and adsorbates were detached. Moreover, attached Na 2 CO 3 was removed by a little quantity of water, and adsorbent was washed.
The above adsorption and regeneration cycles were repeated 10 times, and it was possible to treat beet juice in the amount shown in Table 1.
Moreover, chromaticity of the Na 2 CO 3 -aqueous solution used for the regeneration 10 times was about 21,000 ppm (Pt), and chromaticity of the original beet juice was condensed up to about 36 times. Furthermore, the mechanical strength of the granulated product 1 used for the regeneration 10 times was shown in Table 3 as a result of measurement with the distribution of granularity. That is, the change was very minor as compared with new products. That is, the change was very minor as compared with new products.
EXAMPLE 3
In Example 2, the aqueous solution of 20%-Na 2 CO 3 was replaced with 170 ml of 30%-Na 2 SO 4 aquous solution, and the similar treatment was performed, thus similar to Example 1, the results shown in Tables 1 and 3 were obtained.
EXAMPLE 4
In the Example 2, 20%-Na 2 CO 3 aqueous solution was replaced with 500 ml of 10%-Na 2 HPO 4 aqueous solution, and the similar treatment was made. Thus results similar to those of the Example 1 were obtained as listed in Tables 1 and 3.
COMPARATIVE EXAMPLE 1
Similar adsorbing treatment to that of Example 1 and 2 was performed under room temperature as to the powdered products 1 and 2 as well as Granulated products 1 and 2. The results of decoloration-rate and the treated or disposed liquid (juice) volume were listed in Table 2.
Comparative Example 2
Powdered products 1 and 2 with similar adsorption-treatment to that of the Example 1 were washed with water, and dried at 110° C. for 16 hours. Then the disposal or treatment for regeneration was performed in a muffle furnace at 600° C. for 1.5 hour.
Each cycle of adsorption and regeneration was repeated 10 times, and the result of decoloration rate was listed in Table 1.
Comparative Example 3
Granulated products 1 and 2 treated with adsorption similar to that of Example 2 were washed with water. After extracting from the column, it was dried at 110° C. for 16 hours, and further, regeneration-treatment was made in a muffle furnace at 600° C. for 1.5 hour.
Each one cycle of the above operation of adsorption and regeneration was repeated 10 times, and the results of treated quantity and mechanical strength were listed in Tables 1 and 3.
TABLE 1__________________________________________________________________________SpecimenDecoloration rate (%)Powdered product Treated quanity (lit.) of beet juice1 2 Granulated productMethod Com- Com- 1 2Regen- Exam- parative Exam- parative Exam- Exam- Exam- Comparative Exam- Exam- Exam- Comparativeerated ple example ple example ple ple ple example ple ple ple exampletimes 1 2 1 2 2 3 4 3 2 3 4 3__________________________________________________________________________0 82.1 82.1 83.5 83.5 4.2 4.2 4.2 4.2 4.4 4.4 4.4 4.41 81.6 76.2 82.6 74.8 4.0 3.9 4.0 4.0 4.1 3.9 3.9 4.12 81.5 66.5 81.9 66.8 4.0 3.9 3.9 3.8 4.0 4.0 3.8 4.03 80.9 61.1 82.0 60.9 4.1 3.9 3.9 3.3 4.1 4.0 4.0 3.74 81.7 55.8 82.1 57.1 4.0 4.1 4.0 3.0 4.1 4.1 3.9 3.55 81.3 58.1 81.9 50.7 3.9 4.0 4.1 2.8 4.2 3.9 3.8 3.26 81.5 45.1 83.1 46.2 4.0 3.9 3.9 3.0 4.1 3.9 3.8 3.07 82.0 38.9 82.8 41.1 4.2 4.0 3.8 2.2 4.0 4.0 4.0 2.68 80.8 34.2 81.6 34.1 4.0 4.0 3.9 2.0 4.2 4.1 4.0 2.39 81.9 29.8 81.9 28.6 3.9 3.9 3.8 1.8 4.2 4.0 4.1 2.010 81.6 24.1 82.3 25.0 4.1 3.9 3.9 1.5 4.2 4.1 4.0 1.7__________________________________________________________________________
TABLE 2______________________________________ Decoloration rate (%) Treatment quantity (lit.)Specimen Powdered product Granulated productMethod: 1 2 1 2______________________________________ Example 1 82.1 83.5 -- -- Example 2 -- -- 4.2 4.4 Compara- tive example 1 21.6 25.2 0.8 0.9______________________________________
TABLE 3______________________________________Specimen:Granulated product 1 Com- parative New Example Example Example exampleMethod product 2 3 4 3______________________________________Granularity(Mesh)20 up 0.4 0.3 0.5 0.2 0.220-24 26.3 20.2 23.7 20.0 1.624-28 27.8 32.5 23.2 30.8 24.128-32 17.0 16.8 15.5 17.5 23.232-42 17.7 19.9 17.7 21.2 26.842-60 8.4 8.7 11.8 7.3 14.360 under 2.4 1.6 7.6 2.8 9.8______________________________________
Moreover, in accordance with the second embodiment of the invention, regeneration of the said adsorbent can be performed by heating the said adsorbent as high as 750°-950° C., preferably 800°-900° C., with the burining removal of adsorbates by burning. By this method, batch-system or continuous system can be optionally selected in accordance with the shape or form (powder or granule) of the said adsorbent.
Under the burning temperatures for regeneration at normal temperatures up to 450° C., the strength of the granular form can be maintained to a certain extent, however, by removal of the adsorbates is incomplete, the regenerating power may be insufficient.
At regenerating temperatures less than 450°-750° C., adsorbates are removed or extracted. However, the crystal-structure of the adsorbent itself becomes; solid-solution substance of MgO of Al or inactive MgO. Hence, regeneration of adsorbing function deteriorates greatly. Moreover, in the granular form, thermal expansion--contraction of the particle is great during the adsorption--regeneration reaction, and thus the mechanical strength is reduced.
At regenerating temperature over 950° C., adsorbates can be completely moved, and it is possible to maintain the mechanical strength of the granular form due to the formation of gamma-Al 2 O 3 and spinel (MgAl 2 O 4 ), whereas the crystalline particle-diameter is increased, and the surface-area is markedly decreased, thereby, the adsorption ability is stabilized at its lower level. While at regenerating temperatures 750°-950° C., preferably 800°-900° C., adsorbates can be fully removed.
Also, at such temperatures, mechanical strength as granular substance can also be maintained by a partial formation of γ-Al 2 O 3 and spinel of MgAl 2 O 4 . Moreover, no increase is observed on the diameter of crystalline diameter, and the decrease of the surface is a little, thus no lowered function for adsorption occurs by the repetition of regeneration--adsorption.
Accordingly, the said adsorbent regenerated for a certain time at the temperature of 750°-950° C., preferably 800°-900° C., is again placed on the adsorbing process, and it becomes possible to make repeated use without damaging the adsorbing function semi-permanently. As noted above, it is a feature of the present invention that, the adsorbing function of the adsorbent can be maintained and elevated with the maintenance of the mechanical strength as granular substance, by making the regeneration at 200°-700° C. applicable for the general adsorbents in the use for the adsorption of organic substances.
A further additional feature of the inventive technique is that the regenerating atmosphere is not restricted to vapor, etc. in spite of the regeneration at rather higher temperatures.
EXAMPLE 1A
Each 5 g of Powdered products 1 and 2 obtained by Reference Examples was put into a beaker with beet juice in amount of 100 ml having a chromaticity 6100 ppm (Pt). It was stirred for 210 minutes at 70° C.
Thereafter, the suspended adsorbent was centrifuged, and its supernatant solution was filtered by C-filter paper. The chromaticity of the thus filtered solution was measured to determine the decoloration-rate as a function of a reduction in the amount of chromaticity.
Next, the filtered adsorbent was washed with a small quantity of water, and was dried at 110° C. for 16 hours, followed by calcination for one hour at 800° C. in a muffle furnace.
The adsorbent after regeneration was active on the occasion of decoloration of beet juice again, and no decrease of adsorbency was observed.
This operation was repeated 10 times, and the removal rate was shown in Table 4.
EXAMPLE 2A
Granulated products 1 and 2 obtained by the Reference Examples each in a quantity of 300 ml was filled in the column provided with a warming jacket, and beet juice having a chromaticity 6100 ppm (Pt) was introduced with flow rate of S.V. 0.3 hr at a temperature of 70° C. The treated solution at the outlet of the column was continuously measured on the chromaticity continuously.
The result showed the fact that concentration-ratio at the inlet was 0.5-0.6, and treatment of beet juice was done on its quantity of 26-37 liters.
Each of the above Granulated products, 1 and 2, was washed with warm water at 70° C., and taken out of the column, given a drying treatment at 110° C. for 16 hours, and calcinated in a muffle furnace at 800° C. for one hour.
The above one cycle of adsorption--regeneration was repeated 10 times.
The result was shown in Table 4, demonstrating the treated quantity of beet juice, and there was no decrease of the adsorption-function.
Moreover, the mechanical strength of Granulated product 1 used for regeneration 10 times was shown in Table 6 as a result of measurement due to the distribution of granularity, that is, the change was very little as compared with a new product.
EXAMPLE 3A
In Example 3A, by changing the firing temperature of 800° C. into 900° C., the similar operation was performed, the results are shown in Tables 4 and 6.
COMPARATIVE EXAMPLE 1A
Similar adsorption-treatment to that of Examples 1A and 2A was performed at room-temperature for the Granulated products 1 and 2 as well as Powdered products 1 and 2. The result was shown in Table 5 on decoloration-rate and the quantity of the treated solution.
Table 2 also shows the decoloration-rate by Powdered products 1A and 2 obtained by Example 1, and the quantity of the treated solution (beet juice) by Granulated Products 1 and 2 obtained by Example 2A.
COMPARATIVE EXAMPLE 2
Powdered product 1 and 2 used for adsorption-treatment similar to that of Example 1A was washed with water, and dried at 110° C. for 16 hours, thereafter, regeneration-treatment was made by heating at 600° C. for 1.5 hour.
The above one cycle of adsorption-regeneration was repeated 10 times, and the results are shown in Table 1 on the decoloration rate.
COMPARATIVE EXAMPLE 3A
Powdered products 1 and 2 used for adsorption-treatment similar to that of Example 1A was each washed with water and dried at 110° C. for 16 hours, and regeneration was performed by heating at 1000° C. for 1.5 hours in a muffle furnace.
The above one cycle of adsorption-regeneration was repeated 10 times, and the result of decoloration was shown in Table 4.
COMPARATIVE EXAMPLE 4A
Granulated product 1 and 2A treated with adsorption similarly to Example 2 was washed with water and taken out of the column, and dried at 110° C. for 16 hours. Further, it was treated with regeneration by heating at 600° C. for 1.5 hour in a muffle furnace.
This one cycle of adsorption-regeneration was repeated 10 times, the results of treated quantity of beet juice and mechanical strength are shown in Tables 4 and 6.
COMPARATIVE EXAMPLE 5A
Granulated product 1 and 2 treated with adsorption similarly to Example 2A was washed with water, and taken out of the column,
It was dried at 110° C. for 16 hours, and was regenerated at 1000° C. in a muffle furnace for 1.5 hour.
The above one cycle of adsorption-regeneration was repeated 10 times, and the results are shown in Tables 1 and 3 as to the treated quantity of beet juice and mechanical strength.
TABLE 4__________________________________________________________________________ Decoloration rate (%) Treated quanity (lit.) of beet juice Powdered product Granulated productMeasurement 1 2 1Specimen Com- Com- Com- Com- Com- Com-Method parative parative parative parative parative parative 2Regen- Exam- exam- exam- Exam- exam- exam- Exam- Exam- exam- exam- Ex- Comparativeerated ple ple ple ple ple ple ple ple ple ple ample exampletimes 1A 2A 3A 1A 2A 3A 2A 3A 4A 5A 2A 3A 4A 5A__________________________________________________________________________0 84.8 84.8 48.2 86.1 86.1 50.3 31 28 31 13 32 30 32 151 85.1 80.2 47.7 85.6 81.8 49.9 34 28 30 12 31 28 30 122 83.9 71.1 48.1 86.4 73.6 48.7 32 29 28 15 35 28 28 113 84.2 62.0 47.2 85.9 64.2 50.1 37 26 24 11 30 29 26 124 84.9 54.1 47.8 85.5 57.0 48.8 35 27 21 14 33 31 23 145 83.6 49.2 49.1 85.5 52.1 50.5 35 29 19 13 31 27 21 136 84.4 40.3 47.7 86.0 44.3 49.8 34 28 16 13 30 27 16 127 84.1 32.8 46.9 86.3 37.5 49.8 35 28 16 11 32 28 17 148 84.6 21.6 48.1 85.4 29.7 50.5 33 29 13 12 30 26 14 129 83.9 19.8 47.6 86.1 23.3 48.9 34 28 11 13 31 27 12 1310 84.7 15.3 47.9 86.1 19.9 50.1 35 29 10 13 33 27 10 14__________________________________________________________________________
TABLE 5______________________________________ TreatedMeasurement Decoloration rate (%) quantity (lit.)Specimen Powdered product Granulated productMethod 1 2 1 2______________________________________Example 1A 84.8 86.1 -- --Example 2A -- -- 31 32Comparativeexample 1A 19.3 21.9 3.8 4.1______________________________________
TABLE 6______________________________________SpecimenGranulated product 1 Com- Com-Method parative parativeGranularity New Example Example example example(mesh) product 2A 3A 4A 5A______________________________________20 up 0.8 0.4 0.4 0.1 0.620-24 8.4 9.2 8.5 1.7 8.224-28 26.2 15.6 20.2 6.3 21.628-32 33.8 32.5 32.3 14.7 33.132-42 29.2 39.0 35.4 60.3 34.242-60 1.2 2.8 3.0 15.4 1.860 under 0.2 0.4 0.2 1.7 0.3______________________________________
|
A method of refining beet juice containing a colorant wherein the beet juice is contacted with an adsorbent composed of a dehydrated solid of a coprecipitated substance formed by insolubilizing metallic compounds in an aqueous solution. The adsorbent contains either a calcium or magnesium compound and also either an aluminum or iron compound. The process is conducted in a temperature range of 40°-100° C.
| 2
|
This is a continuation, of application Ser. No. 671,535, filed Mar. 29, 1976 now abandoned.
BACKGROUND OF THE INVENTION
The present invention relates in general to the art of earth boring and more particularly to a cutting element for an earth boring apparatus.
Earth boring apparatus having hard insert elements mounted in a cutter member body are utilized in the boring of holes in the earth because of the ability of the hard insert cutting elements to penetrate the earth formations. A problem has been encountered with this type of apparatus, and generally with all earth boring apparatus, in maintaining the desired diameter or gage of the hole being bored. This is important in the boring of raise holes and tunnels as well as being critically important in the drilling of oil and gas wells and the like. For example, in the drilling of a deep well wherein more than one bit will be used in the well, the gage cutting inserts must maintain the hole at the full diameter. Otherwise, it would be necessary for the next bit being lowered into the hole to ream the undersized hole out to the desired diameter before the new bit reached drilling depth and could begin drilling its length of assigned hole. Such reaming action would reduce the useful lifetime of the second bit because by the time the second bit reached its assigned drilling depth, a substantial part of the lifetime of the gage cutting elements would be exhausted.
The inserts in the gage row are exposed to the most rigorous drilling. They must drill a larger area of the hole. In addition, the formation outwardly of the gage row of inserts is not being drilled and hence provides some degree of lateral support for the formation being drilled by the gage row. It will be appreciated that an improvement in the ability of an earth boring apparatus to maintain gage will be an improvement of the entire earth boring apparatus and contribute significantly to the performance efficiency, economy, and life of the earth boring apparatus.
BRIEF DESCRIPTION OF PRIOR ART
In the prior art the accepted method of determining the exact bit diameter was to grind the outer or gage surface of the gage compact. This would produce a flat on the surface of the gage insert. The flat would contact with the wall of the hole. It is impractical to grind the outer or gage surface of the existing gage inserts to the extent necessary to contact the wall of the hole with the majority of the length of their extended surfaces. In addition, the grinding of the inserts reduces the overall strength of the insert.
In U.S. Pat. No. 3,442,342 to F. H. McElya and R. A. Cunningham patented May 6, 1969 a specially shaped insert for compact rock bits and rolling cutters and rock bits using such inserts is shown. The original inserts of cemented tungsten carbide had hemispherical cutting tips, and rock bits using such inserts were used to drill the hardest abrasive formations, such as taconite, bromide, and chert. This shape is not particularly effective for the drilling of abrasive formations of medium hardness, e.g., hard shales, dolomite, and some limestones, and the inventors herein have developed inserts with more of a chisel or wedge shape to cut such rock. At the same time, they avoid the pitfalls of the "roof-top" style of cutting tip, one in which there are two flanks with flat surfaces converging to a flat crest.
Two basic shapes of cutting tips are disclosed: (1) a modified chisel with convex flanks converging to a crest which is convex along both its elongated lengths and its uniform narrow width, the flanks being normal to a common plane passing through the axis of the insert so that their projected intersection is a curve normal to such axis: and (2) a wedge shape in which the flanks are twisted or canted away from each other so that there is no single plane through the insert axis which is normal to both flanks and the projected intersection is not normal to the axis, the result being that the crest formed normal to the axis increases in width from one end to the other.
In all forms rounded intersections are provided to avoid the sharp corners and sharp edges which cause high-stress concentration. The inventor's theory is that their rounding and their convex surfaces distribute the operating load over the cutting edge of the insert and direct such load to the center of the insert, thus avoiding the high-stress at the edges which they believe to be responsible for the shipping and breaking of roof-top inserts.
In U.S. Pat. No. 2,990,025 to M. L. Talbert and W. E. Scarborough patented June 27, 1961 an improved arrangement of wear-resistant inserts to maintain the hole being drilled at gage is shown. A first circumferential row of gage cutting wear-resistant inserts is situated at the heel of the cutter. A second circumferential row of wear-resistant inserts is spaced inwardly of the first row toward the longitudinal axis of the head with the spacing between the first and second rows being such that the track of the second row on the bottom of the hole being drilled overlaps the track of the first row. The first row is situated at a substantially zero oversized angle and the second row is situated at a larger oversized angle than is the first row so that the second row effects disintegration of the earthen formations closely adjacent the wall of the hole at a level below the first row, whereby the formation to be disintegrated by the first row is left without substantial inner lateral support thereby facilitating cutting the hole to gage by the first row.
In U.S. Pat. No. 3,800,891 to A. D. White and A. E. Wisler patented Apr. 2, 1974 a hardfacing composition and gage hardfacing on rolling cutter rock bits is shown. This patent relates to a tooth-type bit rather than an insert bit, however, the patent points out the importance of maintaining the proper gage. Beginning at column 1, line 49, the importance of maintaining gage is discussed as follows "the importance of such gage maintaining function in an oil well can scarcely be exaggerated. Since all subsequent operations such as running in casing and cementing it in place depend on having a full gage hole, the customer demands and obtains it in one way or another. If a bit drills an undersized hole, the following bit must be used to ream the hole to full gage, even if in so doing the second bit becomes useless for further drilling. Needless to say, the bit which drilled the undersized hole will not be reordered if a better one is available. Thus, the gage surface of a rolling cutter used in oil field drilling is completely unlike many other bits used in drilling rock, and must even be better than the bottom--cutting structure of the same rolling cutter on which it is employed. Wear of a gage surface cannot be tolerated, whereas it makes little difference if the teeth which cut the inner part of the hole gradually wear away, so long as they continue to penetrate effectively."
In U.S. Pat. No. 2,774,570 to R. A. Cunningham patented Dec. 18, 1956 a roller cutter for earth drills is shown. The rolling cutter includes an annular series of cylindrical inserts of hard wear-resistant material having their axis extending outwardly and substantially normal to the surface of the body and presenting protrusions at the surface thereof to affect disintegrating action and to maintain gage of the well bore being drilled.
SUMMARY OF THE INVENTION
The present invention provides more surface on the gage row inserts for contacting the wall of the bore hole. This decreases wear on the gage inserts and therefore increases the ability of the earth boring apparatus to maintain a full gage hole. The insert of the present invention contacts the wall of the hole with the majority of the length of its extended surface and with the same angle as the gage angle of the earth boring apparatus and maintains maximum hole gage retaining ability. The earth boring apparatus includes at least one cutter member for forming a hole in the earth. The cutter member has an annular gage row of inserts mounted in sockets in the cutter member body for cutting the gage of the hole. The inserts have a shape prior to assembly in the sockets that includes an asymmetric head with an extended gage contacting face. The gage contacting face is planar and is substantially larger than any other planar face on the head. The above and other features and advantages of the present invention will become apparent from a consideration of the following detailed description of the invention when taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cut-away perspective illustration of a three-cone rolling cutter rock bit embodying the present invention.
FIG. 2 is an enlarged side view illustration of a gage row insert of the bit shown in FIG. 1.
FIG. 3 is an end view of the insert shown in FIG. 2 showing the gage cutting surface.
FIG. 4 is a side view of another insert constructed in accordance with the present invention.
FIG. 5 is an end view of the insert shown in FIG. 4.
FIG. 6 is an illustration of yet another insert constructed in accordance with the present invention.
FIG. 7 is an end view of the insert shown in FIG. 6.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to the drawings and to FIG. 1 in particular, a rotary rock bit generally designated by the reference character 10 embodying the present invention is illustrated. The bit 10 includes a bit body adapted to be connected at its pin end to the lower end of a rotary drill string (not shown). The bit body includes a passage providing communication for drilling muds or the like passing downwardly through the drill string to allow the drilling mud to be directed to the bottom of the well bore and pass upward in the annulus between the wall of the well bore and the drill pipe carrying cuttings and drilling debris therewith.
Depending from the body of the bit are three substantially identical arms. Arms 11 and 12 are shown in FIG. 1. The lower end portion of each of the arms is provided with a conventional bearing pin. Each arm rotatably supports a generally conical cutter member. The cutter members being designated 13, 14, and 15 in FIG. 1. The bearing pins carrying the cutting members 13, 14, and 15 define axis of a rotation respectively about which the cutter members rotate. The axis of rotation are tilted downwardly and inwardly at an angle. The direction of rotation of drill bits is in a clockwise direction so that the threads making up the various joints of the drill string are constantly tightened by the forces exerted as the drill string rotates the bit 10.
Each of the cutter members 13, 14, and 15 includes a nose portion that is oriented toward the bit axis of rotation and a base that is positioned at the intersection between the wall of the well bore and the bottom thereof. The cutting action of the base defines the diameter or gage of the well bore.
Each of the cutter members 13, 14, and 15 includes annular rows of inserts 16 for destroying the inner portion of the hole. Each of the cutter members 13, 14, and 15 also include annular rows of inserts 17 that are located adjacent the base of each cutting member. The inserts 17 cut the intersection between the well bore wall and the bottom thereof. The annular rows of inserts 17 are generally referred to as "gage rows" and the inserts 17 are designated "gage inserts." The gage row inserts are subjected to the most rigorous drilling action.
The present invention affords more surface for the gage row inserts to contact the wall of the hole. This decreases wear on the gage inserts, therefore increasing the ability of the bit to maintain a full gage hole. Applicants have provided an insert which contacts a wall of the hole with the majority of the length of its extended surface and with the same angle as the gage angle of the bit. This insert is believed to have the maximum gage retaining ability.
In the prior art the accepted method of determining the exact bit diameter was to grind the outer or gage surface of the gage compact. This would produce a flat on the surface of the gage insert. The flat would contact the wall of the hole. It is impractical to grind the outer or gage surface of the existing gage inserts to the extent necessary to contact the wall of the hole with the majority of the length of their extended surfaces. In addition, the grinding of the inserts reduces the overall strength of the insert.
Referring now to FIG. 2, a side view of one of the gage inserts 17 is shown enlarged and in greater detail. The outer or gage angle α of this compact before gage grind is within 1° 30' of the gage angle of the bit. It is not necessary to grind the outer or gage surface excessively to bring the insert gage angle to the bit gage angle. The inner angle β of this compact is considerably less than the outer or gage angle α. This difference between the inner and outer angles allows the length of the crest 19 to approximate that of conventional gage inserts. The sides or flank surfaces of the gage insert can be flat or convex surfaces, convex surfaces on the flanks result in a larger flat area on the outer angle than do the flat angled flanks.
Referring now to FIG. 3, an end view of the insert 17 shown in FIG. 2 is illustrated. The insert 17 contacts the wall of the hole with the majority of its extended surface 21 and with substantially the same angle as the gage angle of the bit. The surface 21 is the largest plane surface on the cutting head of the insert 17. The plane surface 21 contacts the wall of the hole and performs the gage cutting function. Since the surface 21 is relatively large compared to other surfaces on the insert 17, the lifetime of the insert 17 will be increased.
The insert 17 is formed by pressing granules of a wear-resistant material such as tungsten carbide together with granules of a binder such as cobalt. The wear-resistant material granules and binder granules are pressed together with wax and formed in the desired insert shape. The head of the insert may be formed in a die. For example, the head of the insert may be formed by a punch member which molds the end of the insert into the desired finished shape. The inserts are de-waxed in a furnace and sintered at a higher temperature in a furnace. The insert is then press fit into the body of a cutter member with the asymmetric head oriented so that the extended plane surface of the insert is at gage. Very little, if any, gage grinding is required.
The foregoing should be contrasted with prior art inserts having symmetrical heads. The prior art inserts are pressed into the cutter member and subsequently a gage surface is ground around the gage of a cutter producing ground flats on the gage inserts. The inserts of the present invention are pressed into the cutter with the pre-formed plane gage contacting surface located at substantially the gage angle of the bit.
Referring now to FIG.4, a side view of another embodiment of an insert 22 is shown in some detail. The insert 22 includes a cylindrical body portion 23 adapted to be mounted in a socket in the cutter body. The head of the insert 22 includes an inner surface 24 and an outer or gage surface 26. The outer or gage surface 26 is substantially larger than the inner surface 24. The roof top or crest 25 of the insert has substantially the same length as that of prior art gage inserts.
Referring now to FIG. 5, an end view of the insert 22 shown in FIG. 4 is illustrated. The insert 22 contacts the wall of the hole with the majority of its extended surface 26 and with substantially the same angle as the gage angle of the bit. The surface 26 is the largest plane surface on the cutting head of the insert 22. The plane surface 26 contacts the wall of the hole. Since the surface 26 is relatively large compared to the other surfaces on the insert 22, the lifetime of the insert 22 will be increased.
Referring now to FIG. 6, a side view of another embodiment of a gage insert 27 constructed in accordance with the present invention is illustrated. The insert 27 has a generally spherical formation contacting head 29 and a generally cylindrical body portion 28. The body portion 28 is adapted to fit within sockets in the cutter body. The outer or gage angle of the gage connecting surface 30 of this compact before gage grinding is within 1° 30' of the gage angle of the bit. It is not necessary to grind the outer or gage surface extensively to bring the insert gage angle to the bit gage angle.
Referring now to FIG.7, an end view of the insert 27 shown in FIG. 6 is illustrated. The insert 27 contacts the wall of the hole with the majority of its extended surface 30 and with substantially the same angle as the gage angle of the bit. The surface 30 is the largest plane surface on the cutting head of the insert 27. The plane surface 30 contacts the wall of the hole. Since the surface 30 is relatively large, compared to other surfaces on the insert 27, the lifetime of the insert 27 will be increased.
|
An asymmetric gage row insert provides a larger amount of wall contacting surface thereby decreasing the wear on the gage insert and increasing the ability of the earth boring apparatus to maintain a full gage hole. The insert has a shape prior to assembly onto the earth boring apparatus that includes a base integrally joined to an asymmetric head. The base is mounted in a socket in the earth boring apparatus. The head projects from the earth boring apparatus and includes an extended gage cutting surface. The gage cutting surface is the largest plane surface on the head. The gage cutting surface contacts the wall of the hole with the majority of the length of its extended surface and with the same angle as the gage angle of the bit.
| 4
|
[0001] This continuation-in-part application claims priority from U.S. patent application Ser. No. 12/510,796 filed Jul. 28, 2009, the contents of which are incorporated herein by reference.
BACKGROUND
[0002] Latch mechanisms having a rotatable latch element for engaging/disengaging a striker element are common, as seen, for example, in U.S. Pat. No. 4,438,964 to Peters and U.S. Pat. No. 5,042,853 to Peters, the contents of each are fully incorporated herein by reference. While effective for latching containers and the like, these latch assemblies suffer from security issues where the locking feature can be defeated by thieves. For example, a single hook shaped retaining member such as that found in the Peters latch assembly can be defeated if the lid/latch bar can be pushed in to bypass the locking cam. This results in an unacceptable security risk where important items are to be stored.
SUMMARY OF THE INVENTION
[0003] The present invention overcomes the security issue raised above by providing a guard plate that prevents defeat of the locking cam by retaining the striker element in the locking cam when the latch is in the locked closed or locked position. The guard plate can mount to the back of the housing and comprises a surface that mounts flush to the back of the housing, and a horizontal spacing portion directed away from the housing to a position just before or after the hook portion of the locking cam. A shield plate extends vertically from the horizontal spacing portion, the shield portion having a lateral edge that cooperates with the hook portion of the locking cam to form a window enclosure for the striker element. The cooperation of the shield portion and the locking cam retain the striker element therebetween to prevent a thief, sudden impact, or other trauma from dislodging the striker element and defeating the locking mechanism.
BRIEF DESCRIPTION OF THE DRAWINGS
[0004] FIG. 1 is an enlarged, elevated front perspective view of a first embodiment of the present invention;
[0005] FIG. 2 is an enlarged, elevated rear perspective view of the embodiment of the present invention depicted in FIG. 1 ;
[0006] FIG. 3 is an exploded view of the embodiment of present invention depicted in FIG. 1 ;
[0007] FIG. 4 is a side view of a second embodiment of the present invention;
[0008] FIG. 5 is a rear view of the embodiment of FIG. 4 ;
[0009] FIG. 6 is a rear view of the embodiment of FIG. 4 with the striker rotated; and
[0010] FIG. 7 is a rear view of the embodiment of FIG. 4 with the striker rotated and the.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0011] FIGS. 1-3 show a paddle latch assembly 12 for a tool box or the like, embodying the features of the present invention. The paddle latch 12 includes a housing 20 with a rectangular body 21 defining a cup-shaped recess 22 and having a peripheral mounting flange 24 with an enlarged portion 26 and a plurality of mounting holes 27 through the flange 24 for accepting screws, or the like, to fix the latch assembly 12 to the receptacle of a tool box. A rectangular paddle/release member/lever 28 is mounted for rotation within the recess 22 about a hinge pin 30 extending through opposite walls of the body 21 .
[0012] A pair of rotary cams/latch elements 38 , 40 are pivotably connected at the rear face of the housing 21 by means of a rivet 42 and a spacer washer 43 . The rivet 42 passes successively through the cam/latch element 38 , the cam/latch element 40 , the washer 43 , and opening 45 in the housing 20 and is suitably anchored to the housing 20 . The cam/latch element 38 has a hooked end 44 for engaging a striker bar (not shown) on the tool box lid, and a projecting finger 46 . Rotary cam/latch element 40 includes a depending leg 50 and an upper offset lever arm 54 projecting through an opening 55 in the housing 20 . With the latch mechanism 12 assembled, a shoulder 53 on the leg portion 50 of the rotary cam/latch element 40 abuts a confronting shoulder 56 on the rotary cam/latching element 38 , thereby engaging the cams/latching elements 38 , 40 to cause the cam/latch element 38 to follow the cam/latch element 40 in an unlatching pivoting direction about the rivet 42 indicated by arrow A, i.e. in a counterclockwise direction. The cam/latch element 38 has a depending tab 57 on which the shoulder 56 . A coil spring 48 is connected between the finger 46 on the cam/latch element 38 and a post 49 projecting from the rear face of the rectangular body 21 , and acts to rotationally bias the cam/latch element 38 and interengaged cam 40 in a clockwise direction (opposite Arrow A).
[0013] A key lock 58 is mounted on the housing 20 and passes through an opening 59 on the enlarged flange portion 26 . The key lock 58 and opening 59 have matched, non-circular cross sections to prevent rotation of the key lock 58 within the opening 59 . The key lock 58 has a grooved lock cylinder 60 with a rotatable locking lever/arm 61 keyed to one end thereof by means of a lock washer 62 and keyway 63 in the locking lever/arm 61 .
[0014] The paddle/release member 28 has a front face 66 defining a graspable handle 68 , a pair of spaced sidewalls 70 , 72 for engaging the hinge pin 30 , and a top wall/flange 76 . The pin 30 guides movement of the paddle/release member 28 between a normal position, shown in FIG. 1 , and a release position in which the handle is rotated about the pin 30 . In operation, the flange 76 engages the lever arm 54 of the rotary cam/latch element 40 projecting through the opening 55 in the housing 20 . As a rotative force is applied to the handle 68 , the paddle/release member 28 is rotated about the hinge pin 30 , with the flange 76 forcing the lever arm 54 downwardly and thereby rotating the rotary cam 40 about the pivot 42 . Due to the engagement of the shoulders 56 , 53 on the cams/latch elements 38 , 40 , rotation of the cam/latch element 40 induced by actuation of the paddle 28 results in rotation of the cam 38 from a latched position, shown in FIG. 2 , to a release position in which hook end 44 rotates counterclockwise to thereby disengage the hooked end 44 of the cam/latch element 38 from the striker element (not shown) on the tool box lid. The tool box is thereby unsecured and may be opened.
[0015] A restoring force is continuously applied to the cam/latch element 38 by the spring 48 . As the cam/latch element 38 is rotated out of engagement with the striker 18 , the spring 48 is extended and acts to apply a restoring force to the cam/latch element 38 . Once the handle 68 is released to its normal position, the spring 48 acts to rotate the interengaged cams/latch elements 38 , 40 in a clockwise direction in FIG. 3 .
[0016] The locking lever/arm 61 of the key lock 58 may be rotated by actuation of an external key (not shown) between a locked position wherein the free end 77 of the locking lever/arm 61 confronts the leg 50 of the rotatable cam/latch element 40 and thereby blocks the path of the cam/latch element 40 from its engaged to its disengaged position. When one attempts to actuate the handle 68 of the paddle/release member 20 with the locking lever/arm 61 in its locked position, the flange 76 of the paddle/release member 28 abuts the lever arm 54 of the fixed cam/latch element 40 but cannot displace the lever arm 54 due to the blocking function of the free end 77 of the locking lever/arm 61 , preventing rotation of the paddle/release member 28 about the hinge pin 30 . In order to disengage the hooked end 44 of the cam/latch element 38 from the striker element, it is necessary to rotate the locking lever/arm 61 out of its locked position to thereby allow the paddle/release member 28 to rotate and effectuate rotation of the interengaged cams/latching elements 38 , 40 .
[0017] A guard plate 80 is mounted to the back of the housing for enclosing the striker element with the hook end 44 when the latch is in the locked position. Without the guard plate 80 , the striker element can be displaced from the hook end 44 of the cam 38 by various forces, such as projecting a tool through the opening 55 or by pushing heavily on the housing back and forth. The guard plate 80 has a lower section 85 that attaches to the rear of the housing, such as by welding, adhesive, rivet, fastener, or the like. The lower section 85 may include a projecting arm 90 that extends to the cam 40 and behind the finger 46 of the cam 38 . Extending from the upper edge 92 of the lower section 85 of the guard plate 80 is a spacer section 94 that horizontally offsets the upper portion 96 adjacent the hook end 44 from the lower portion 85 mounted against the housing 20 . The upper portion 96 projects vertically from an end of the spacer section 94 , and includes a vertical edge 98 that extends to the hook end 44 of the cam 38 . The vertical edge 98 cooperates with the hook end 44 to form a window that captures the striker element when the cam 38 is rotated in the position shown in FIG. 2 . With the guard plate in place, a striker element cannot be dislodged or pried away from the hook member as was the case with the prior art systems. In this manner, the latch assembly is more securely locked to prevent theft and accidental dislodgement of the striker element.
[0018] In a second embodiment of the present invention, as shown in FIGS. 4-7 , a rotary spring 200 is wound around the rivet 42 and has two legs, a first leg 202 that projects through the window 55 and a second leg 204 that is positioned under a tab 206 on the rotational element 38 . The rotary spring 200 biases the rotational element 38 in a closed position as shown in FIG. 5 . With the rotatable locking lever/arm 61 in the locked position as shown in FIGS. 5 and 6 , the rotational member 40 a cannot rotate clockwise because the end 210 abuts the locking lever/arm 61 . Thus, the paddle cannot release and the latch remains closed. However, unlike the previous embodiment, the latch member can be closed while the lock is in the locked position. That is, in the previous embodiment the latch must be unlocked before the striker pin could enter the latch between the rotational member 38 and guard plate 80 , because the rotational member 40 would not let the rotational member 38 release when the lock was engaged. However, in FIG. 6 , it can be seen that the rotatable locking lever/arm 61 is engaged, but rotational element 38 may rotate against the bias of the rotary spring 200 to allow a striker pin to enter the window between guard plate 80 a and the rotational element's hook member 44 . When a downward force is applied on the surface 230 , as would be the case if a striker pin were to try and engage the locked latch, the force of the pin would cause the rotational element 38 to rotate against the bias of the coiled spring 200 until the pin entered the window formed between the hook portion 44 and the guard plate 80 a. At this point, the spring would rotate the rotational element back to its home position as shown in FIG. 5 with the latch pin captured between the rotational element 38 and the guard plate 80 a. It can only be released, as shown in FIG. 7 , by disengaging the lock and rotating the rotatable locking lever/arm 61 down so that the lever 210 of the rotational member 40 a can release as described below.
[0019] When the paddle 28 is raised and the lock 60 is disengaged, the arm 54 of the rotational member 40 a is driven down, rotating the rotational member 40 a in the direction shown by the arrow 300 in FIG. 6 . Rotation of the rotational member 40 a drives the leg portion 220 clockwise as shown in FIG. 7 , which in turn pushes the lever 225 of the rotational member 38 in the same clockwise direction. This rotates the hook portion 44 away from the guard plate 80 a and releases the striker pin (now shown) from the latch. Thus, the rotational element 38 can be rotated either by the paddle 28 through the rotational element 40 a, or by the force of the locking pin against the surface 230 (against the bias of the rotary spring 200 ).
|
A latch assembly for releasably securing a closure element with a striker element in a closed position. The latch assembly consists of first and second latch elements mounted to a housing for movement relative to each other and the housing, with the first latch element being movable relative to the housing between a latched position and a release position, and cooperating structure on the release lever for moving the second latch element relative to the housing and, in response thereto, causing the first latch element to move from its latched position to its release position. A guard plate is positioned between the housing and the first latch element to more securely retain the striker element and prevent tampering or theft.
| 4
|
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to an information processing system, an information processing method, and a computer program, which process visible information, such as still images and moving images. More particularly, the invention relates to an information processing system, an information processing method, and a computer program, which add a value to a user image, such as a picture or moving image, and reproduce the value-added user image.
[0003] 2. Description of the Related Art
[0004] Recently, personal information devices, such as personal computers (PCs), personal digital assistants (PDAs), cellular phones, and portable media players, are becoming popular, and are widely used in daily life as well as in industrial activities. Available applications for those kinds of information devices include saving and reproduction of contents mainly intended for personal use, such as user images like still images and moving images captured by a digital camera, or music pieces.
[0005] For example, there have been proposed various kinds of image management software to organize and retrieve still images and moving images stored in a local disk, loaded into a PC, according to a subject and the imaging environment, to easily edit such still images and moving images to create a DVD (Digital Versatile Disc), and to add effects, such as sound effects and comments to such still images and moving images and upload the resultant images a content sharing site. At present there are numerous content sharing sites are present on the Internet, or most of social networking services (SNS) provide content sharing capability.
[0006] Methods of viewing various kinds of contents, such as still images and moving images captured by a user's own digital camera include a method of reading and reproducing contents from a local disk using image management software, and a method of downloading contents from a content sharing server on the Internet, such as a content sharing site. In the latter case, the server which has received a content retrieval request from a PC of an individual user (i.e., client) can process the content retrieval request by further using an external program or a separate server, and return generated information.
[0007] Generally, image management software allows a user to view, or reproduce, contents to which the user has authority to access and which are stored on a local disk in a PC, a remote disk outside a PC, or the like. For example, the image management software displays a list of thumbnails of viewable contents and allows the user to select (click) a desired thumbnail such that the corresponding contents is reproduced on the entire screen. Some ways of displaying a list of thumbnail images include a calendar view to sort images according to image capturing dates and a map view to sort images according to image capturing locations in addition to the general folder view (see, for example, JP-A-2006-107260 (Patent Document 1)). One example of image management software is “PMB (Picture Motion Browser)” provided by Sony Corporation, and one example of music management software is “SONICSTAGE (Registered Trademark by Sony Corporation)”.
[0008] There has been a proposal on a picture processing apparatus which automatically selects a template to paste a picture image in at the time of printing out a picture or displaying a picture (see, for example, JP-A-2006-155181 (Patent Document 2)). The apparatus can enhance the visual effect of a picture, or display additional information to a picture to add a value thereto.
[0009] There also is a proposal on an information processing method which stores news information on politics, economy, sports, etc. corresponding to time scale information on the time a picture image has been captured, as added information, in an extended area in an image file based on the time scale information (see, for example, JP-A-2003-52007 (Patent Document 3)).
SUMMARY OF THE INVENTION
[0010] It is desirable to provide an information processing system, an information processing method, and a computer program, which are excellent in processing visible information, such as still images and moving images.
[0011] It is also desirable to provide an information processing system, an information processing method, and a computer program, which are excellent in adding a value to a user image, such as a picture or moving image, captured by a user with a digital camera, and reproducing the value-added user image.
[0012] According to an embodiment of the present invention, there is provided an information processing system including:
[0013] a user image storage section that stores a plurality of user images;
[0014] an image reproducing section that reproduces an image;
[0015] an image selecting section that selects an image to be reproduced from the plurality of user images stored in the user image storage section;
[0016] an advertisement image acquiring section that acquires an advertisement image matched with the user image selected by the image selecting section and containing link information to related advertisement information; and
[0017] a control section that merges the user image selected by the image selecting section into a user information display region in the advertisement image acquired by the advertisement image acquiring section, causes the image reproducing section to reproduce the merged image, and provides advertisement information corresponding to one piece of link information contained in the advertisement image according to selection of that piece of link information.
[0018] The term “system” used herein means a logical aggregation of a plurality of apparatus (or functional modules which achieve specific functions), regardless of whether the individual apparatuses or functional modules are located in a single casing.
[0019] The information processing system may be configured so that when the advertisement image acquired by the advertisement image acquiring section includes a moving image, the control section makes it possible to change the user image to be merged into the user information display region according to a reproduction progress time for the moving image, and merges the user image into the user information display region to be reproduced.
[0020] The advertisement image including the moving image may have a user information display region defined frame by frame.
[0021] The information processing system may be configured so that when the image selecting section simultaneously selects a plurality of user images, the control section sequentially reproduces the plurality of user images in the user information display region in a slideshow.
[0022] The information processing system may be configured so that when the user image selected by the image selecting section is a moving image, the control section merges the selected user image as a moving image into the user information display region to be reproduced.
[0023] The information processing system may be configured so that the user image storage section stores user information on a user whose user image is to be reproduced, the advertisement image has a target user condition on a user who is to be provided with information, and the advertisement image acquiring section acquires an advertisement image having a target user condition fulfilling the user information of the user image selected by the image selecting section.
[0024] The information processing system may be configured to include a user-side information device having the user image storage section, the image reproducing section, the image selecting section, the advertisement image acquiring section, and the control section, and an advertisement distribution server that distributes a plurality of advertisement images. The advertisement image acquiring section acquires that in the advertisement images distributed by the advertisement distribution server which is matched with the user image selected by the image selecting section.
[0025] The information processing system may be configured to include a user-side information device having the image reproducing section and the control section, and an advertisement distribution server that has the user image storage section for storing a user image uploaded from the user-side information device, the image selecting section, and the control section, and distributes a plurality of advertisement images. The advertisement image acquiring section acquires that in the plurality of advertisement images which is matched with the user image selected by the image selecting section, and the control section causes the image reproducing section in the user-side information device to reproduce an advertisement image merged with the user image.
[0026] The information processing system may be configured to include a user-side information device having the image reproducing section and the control section, and a content sharing server that has the user image storage section for storing a user image uploaded from the user-side information device, and the image selecting section, and an advertisement distribution server that distributes a plurality of advertisement images. The control section causes one of the user-side information device, the content sharing server and the advertisement distribution server to perform a process of merging a user image into a user information display region of an advertisement image.
[0027] According to another embodiment of the invention, there is provided an information processing method including:
[0028] a user image storage step of storing a plurality of user images;
[0029] an image selecting step of selecting an image to be reproduced from the plurality of user images stored in the user image storage step;
[0030] an advertisement image acquiring step of acquiring an advertisement image matched with the user image selected in the image selecting step and containing link information to related advertisement information; and
[0031] an image reproducing of merging the user image selected in the image selecting step into a user information display region in the advertisement image acquired by the advertisement image acquiring step, and reproducing the merged image on a user-side information device; and
[0032] an advertisement information providing step of providing advertisement information corresponding to one piece of link information contained in the advertisement image according to selection of that piece of link information by user.
[0033] According to still another embodiment of the invention, there is provided a computer program which is written in a computer readable manner so as to execute a process of reproducing a user image on a computer, and allows the computer to function as:
[0034] a user image storage section that stores a plurality of user images;
[0035] an image reproducing section that reproduces an image;
[0036] an image selecting section that selects an image to be reproduced from the plurality of user images stored in the user image storage section;
[0037] an advertisement image acquiring section that acquires an advertisement image matched with the user image selected by the image selecting section and containing link information to related advertisement information; and
[0038] a control section that merges the user image selected by the image selecting section into a user information display region in the advertisement image acquired by the advertisement image acquiring section, causes the image reproducing section to reproduce the merged image, and provides advertisement information corresponding to one piece of link information contained in the advertisement image according to selection of that piece of link information by user.
[0039] The computer program according to the embodiment of the invention defines a computer program which is written in a computer readable manner so as to execute a predetermined process on a computer. In other words, this computer program, when installed onto a computer, performs a cooperative operation on the computer to provide functions and effects similar to those of the foregoing information processing system.
[0040] The embodiments of the invention can provide an information processing system, an information processing method, and a computer program, which are excellent in processing visible information, such as still images and moving images.
[0041] The embodiments of the invention can also provide an information processing system, an information processing method, and a computer program, which are excellent in adding a value to a user image, such as a picture or moving image, captured by a user with a digital camera, and reproducing the value-added user image.
[0042] According to the embodiments of the invention, a user image, such as a picture or moving image, captured by a user with a digital camera, can be merged with an advertisement image to reproduce a merged image, making it possible to provide the user image added with a value according to the display contents of the advertisement image. In addition, an advertisement image contains one or more pieces of link information to related advertisement information, so that when any piece of link information contained in the advertisement image is selected by the user, the corresponding advertisement information is provided. This provides the user viewing user images with appealing product information, thereby contributing to sales promotion of commodities.
[0043] According to the embodiment of the invention, it is possible to change a user image to be merged into the user information display region according to a reproduction progress time for an advertisement image including a moving image. It is also possible to merge a user image into the user information display region which is defined frame by frame, and reproduce the merged image.
[0044] Moreover, it is possible to sequentially merge a plurality of user images, simultaneously selected, into the user information display region of an advertisement image, and sequentially reproduce the merged images in a slideshow.
[0045] Further, it is possible to merge a user image including a moving image into the user information display region of an advertisement image as a moving image.
[0046] Furthermore, it is possible to merge user information of a user image into an advertisement image having a target user condition fulfilling the user information, and reproduce the merged image.
[0047] Other objects, features and advantages of the invention may best be understood by reference to the following detailed description of embodiments of the invention along with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0048] FIG. 1 is a diagram showing how to paste a user image to an advertisement image to introduce a commodity, and reproduce the resultant image;
[0049] FIG. 2A is an exemplary diagram illustrating process procedures of merging a user information display region and an advertisement image display region into one display screen;
[0050] FIG. 2B is a diagram showing an advertisement image displayed in the advertisement image display region;
[0051] FIG. 3 is a flowchart illustrating process procedures for distributing an advertisement image from an advertisement distribution server, and executing an image merging process of merging the advertisement image with a user image on a user's information device;
[0052] FIG. 4 is a flowchart illustrating process procedures for merging a user image with an advertisement image on an advertisement distribution server, and distributing the merged image to a user's information device;
[0053] FIG. 5 is a flowchart illustrating process procedures for merging a user image uploaded to a content sharing site with an advertisement image provided from an advertisement distribution server, and distributing the merged image to a user's information device;
[0054] FIG. 6 is a diagram showing an example of the configuration of a user's information device which displays a user image; and
[0055] FIG. 7 is a diagram showing an example of the configuration of an advertisement distribution server or a server provided at a content sharing site.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0056] Embodiments of the present invention will be described below with reference to the accompanying drawings.
[0057] As mentioned above, user images, such as still images and moving images, captured by a digital camera can be reproduced with image management software. According to an embodiment of the invention, an advertisement image is pasted at the time of reproducing user images, such as pictures and moving images, captured by a user with a digital camera.
[0058] FIG. 1 shows how to paste a user image to an advertisement image to introduce a commodity, and reproduce the resultant image.
[0059] The image management software displays a list of thumbnails of contents, which a user can reproduce, in an arbitrary view form like a folder view, calendar view or map view. It is assumed that the user selects (clicks) a desired thumbnail from the list, or that a user image to be reproduced is automatically selected every predetermined time interval not depending on a user action. Although only a single user image is selected in the illustrated example, a plurality of user images may be selected simultaneously.
[0060] A target for reproduction of a user image is, for example, a portable media player or the monitor display of a PC. A user information display region which is used to display a user image, and an advertisement image display region which is used to display an advertisement image are allocated in the display screen of such a device. In the illustrated example, the advertisement image display region is allocated to the peripheral portion of the display screen so as to look like a “frame”, and the user information display region is allocated therewithin. It is to be noted however that the subject matter of the invention is not limited to a specific way of allocating those regions.
[0061] FIG. 2A exemplarily illustrates process procedures of merging the user information display region and the advertisement image display region into one display screen.
[0062] A user image to be displayed in the user information display region is stored in, for example, an information device where the user image is displayed, such as a PC or a portable media player, or is provided at a content sharing site, and can be acquired using image management software. A method of selecting a user image to be displayed from multiple user images is optional; a user image to be displayed may be selected from a list of thumbnails by a user action, or may be selected automatically. A user image to be used may be subjected to enlargement, reduction, cutting or the like, so that the user image fits in the size of the user information display region.
[0063] An advertisement image to be displayed in the advertisement image display region is provided by a manufacturer or seller of a commodity, or by an advertiser who has a business contract with the manufacturer or seller. The description will be given on the assumption that an advertisement image is provided from an advertisement distribution server set on the Internet. Link information to related advertisement information is embedded in an advertisement image. It is to be noted however that the subject matter of the invention is not limited to a specific mode of providing an advertisement image.
[0064] FIG. 2B shows an advertisement image displayed in the advertisement image display region. An advertisement image provided from the advertisement distribution server includes a moving image file or a still image file. In the illustrated example, the advertisement image display region is located at the peripheral portion of the display screen, and a user image is merged into the user information display region located at a center portion. Region coordinate information which specifies a position where a user image is pasted is set in an advertisement image. In other words, the region coordinate information defines the advertisement image display region and the user information display region. When the advertisement image display region is rectangular as shown in FIG. 2B , the coordinates of the vertexes (53, 45), (203, 44), (38, 144) and (191, 155) is the region coordinate information. When an advertisement image includes a moving image, it is assumed that the user information display region is defined frame by frame. An advertisement image is provided with an anchor in which link information to advertisement information, such as detailed information on a commodity to be advertised or related information thereof is embedded. The link information is described in, for example, the URL (Uniform Resource Locator) form (well-known form).
[0065] A user image is merged into the user information display region, designated by the region coordinate information, for a moving image or still image file provided from the advertisement distribution server, and the merged image is displayed on the monitor display. When a plurality of user images are selected simultaneously, the user images may be sequentially displayed in a slideshow, for example. When a user image selected is a moving image, the user image is merged as a moving image into the user information display region of the advertisement image. When the advertisement image includes a moving image, the user information display region is defined frame by frame, so that a user image to be merged is merged into the user information display region in such a way as to be changeable according to the progress time of reproduction of the moving image.
[0066] Designating an anchor in an advertisement image by clicking a mouse or the like jumps to a page of advertisement information, such as detailed information on a commodity or related information thereof which is specified by the link information embedded in the anchor.
[0067] When an advertisement image to be displayed in the advertisement image display region includes a moving image, a user image to be merged has only to be merged into the user information display region in such a way as to be changeable according to the reproduction progress time. For example, the user information display region (i.e., region coordinate information) should be defined and saved for each frame of a moving image.
[0068] When the user selects a plurality of user image (or a plurality of user images are automatically selected by the system), the user images may be displayed in the user information display region in a slideshow.
[0069] There are, for example, three variations available for the image merging process of coupling a user image and an advertisement image, and a distribution location for an advertisement image.
[0000] (1) Method of distributing an advertisement image from an advertisement distribution server, and merging the advertisement image with a user image on a user's information device
[0070] For example, a user image managed by image management software and an advertisement image distributed from the advertisement distribution server are merged with each other on a user's PC.
[0000] (2) Method of merging of a user image and an advertisement image on a single advertisement distribution server, and distributing the merged image to a user's information device
[0071] For example, a user image uploaded to a content sharing site is merged with an advertisement image provided within the content sharing site, and the merged image is distributed to a user's information device. In addition, a reproduction which is distributed in a streaming form at a dynamic-image sharing site is reproduced within the advertisement image.
[0000] (3) Method of merging a user image managed by one server and an advertisement image stored in another server on an arbitrary server, and distributing the merged image to a user's information device
[0072] For example, a user image uploaded to one content sharing site is merged with the an advertisement image at on another content sharing site or a server, and the merged image is distributed to the user's information device.
[0073] The methods (1) to (3) will be described in detail below.
[0000] (1) Method of distributing an advertisement image from an advertisement distribution server, and merging the advertisement image with a user image on a user's information device
[0074] In realizing this method, the advertisement distribution server manages information shown in Table 1 below for individual advertisement images to be provided. Information shown in Table 2 below is managed on a user's information device (client).
[0000]
TABLE 1
Information to be Managed on Advertisement Distribution Server
priority
information
details of information
order
S1: advertisement
type of moving image or still
essential
image
image
S2: merging region
region coordinate information
essential
S3: medium to be
type of moving image or still
essential
merged
image
S4: link
URL
essential
information
S5: target user
user profile, purchased
optional
condition
product, management
application to be displayed,
etc.
[0000]
TABLE 2
Information to be Managed on User's Information Device
priority
information
details of information
order
C1: user image to be
image selected using image
essential
merged with
management software, or image
advertisement image
selected by arbitrary method
C2: user
user profile, purchased
optional
information
product, etc.
[0075] The “target user condition (S 5 )” in Table 1 is an item describing information for designating a user with whom an advertiser wants to provide the advertisement image (i.e., target for the advertisement of a commodity), and whether or not to include the management information is optional. The “user information (C 2 )” in Table 2 is an advertisement for describing user attribute information, such as the profile of the user who reproduces a user image (C 1 ) like a moving image or a picture, or commodity purchase history, and whether or not to include the management information is optional. C 2 is the condition for determining an advertisement image to be merged, and is collated with S 5 at the time of reproducing the user image (to be described later).
[0076] FIG. 3 illustrates process procedures for distributing an advertisement image from an advertisement distribution server, and executing an image merging process of merging the advertisement image with a user image on a user's information device in the form of flowchart.
[0077] First, when a user image is selected on the user's information device (step ST 1 ), a request for an advertisement image is given to the advertisement distribution server. A method of selecting a user image to be displayed from multiple user images is optional; a user image to be displayed may be selected from a list of thumbnails by a user action, or may be selected automatically.
[0078] Meanwhile, in response to the request, the advertisement distribution server retrieves the requested advertisement image (step ST 2 ), and outputs a retrieval result (step ST 3 ). The retrieval result contains the items S 1 to S 5 given in the Table 1 for the advertisement image in question.
[0079] Upon reception of the retrieval result (S 1 -S 5 ) from the advertisement distribution server, the user's information device collates the “target user condition (S 5 )” for the transmitted advertisement image (S 1 ) with the “user information (C 2 )” to determine whether the advertisement image (S 1 ) fits to be merged with the user information selected in step ST 1 (step ST 4 ).
[0080] When the determination is affirmative (Yes in step ST 4 ), the user image (C 1 ) selected in step ST 1 is merged with the advertisement image (S 1 ) retrieved in step ST 2 (step ST 5 ). Region coordinate information (S 2 ) is set as management information in the advertisement image, and the user's information device performs a process of pasting the user image into the user information display region which is specified by the region coordinate information. An anchor in which link information to a page of advertisement information describing detailed information on a commodity to be advertised or related information thereof is embedded is provided at a proper location in the advertisement image, and is displayed on the monitor display (step ST 6 ).
[0081] When the user selects the anchor in the advertisement image on the display screen by, for example, clicking with a mouse cursor (Yes in step ST 7 ), jump is made to the page of the advertisement information, such as detailed information on a commodity or related information thereof specified by the link information embedded in the anchor (step ST 8 ).
[0000] (2) Method of merging of a user image and an advertisement image on a single advertisement distribution server, and distributing the merged image to a user's information device
[0082] In realizing this method, the advertisement distribution server manages information shown in Table 3 below. The management information contains items S 1 to S 5 for each advertisement image, and items C 1 and C 2 for each user who is to be provided with the advertisement image.
[0000]
TABLE 3
Information to be Managed on Advertisement Distribution Server
priority
information
details of information
order
S1: advertisement
type of moving image or still
essential
image
image
S2: merging region
region coordinate information
essential
S3: medium to be
type of moving image or still
essential
merged
image
S4: link
URL
essential
information
S5: target user
user profile, purchased
optional
condition
product, management
application to be displayed,
etc.
C1: user image to be
image selected using image
essential
merged with
management software, or image
advertisement image
selected by arbitrary method
C2: user
user profile, purchased
optional
information
product, etc.
[0083] The “target user condition (S 5 )” in Table 3 is an item describing information for designating a user with whom an advertiser wants to provide the advertisement image (i.e., target for the advertisement of a commodity), and whether or not to include the management information is optional. The “user information (C 2 )” in Table 3 is an advertisement for describing user attribute information, such as the profile of the user who reproduces a user image (C 1 ) like a moving image or a picture, or commodity purchase history, and whether or not to include the management information is optional. C 2 is the condition for determining an advertisement image to be merged, and is collated with S 5 at the time of reproducing the user image (to be described later).
[0084] FIG. 4 illustrates process procedures for merging a user image with an advertisement image on the advertisement distribution server, and distributing the merged image to the user's information device.
[0085] The advertisement distribution server first selects a user image uploaded from the user's information device (step ST 11 ). A method of selecting a user image to be displayed from uploaded multiple user images is optional; a user image to be displayed may be selected from a list of thumbnails by a user action, or may be selected automatically.
[0086] Next, the advertisement distribution server retrieves the requested advertisement image (step ST 12 ), and outputs a retrieval result (step ST 13 ). The retrieval result contains the items S 1 to S 5 given in the Table 3 for the advertisement image in question.
[0087] Next, the advertisement distribution server collates the user image (C 1 ) selected in step ST 11 with the target user condition (S 5 ) for the advertisement image ( 51 ) output in step ST 13 to determine whether the advertisement image (S 1 ) fits to be merged with the user image (C 1 ) (step ST 14 ).
[0088] When the determination is affirmative (Yes in step ST 14 ), the user image (C 1 ) selected in step ST 11 is merged with the advertisement image (S 1 ) retrieved in step ST 12 (step ST 15 ). Region coordinate information (S 2 ) is set as management information in the advertisement image, and the advertisement distribution server performs a process of pasting the user image into the user information display region which is specified by the region coordinate information. An anchor in which link information to detailed information on a commodity to be advertised or related information thereof is embedded is provided at a proper location in the advertisement image. Then, the advertisement distribution server transfers the user image added with the advertisement image to the information device of the associated user (step ST 16 ). Alternatively, after producing the user image added with the advertisement image, the advertisement distribution server does not immediately transfer the user image, but may store the user image, and transfer it at a predetermined timing such as upon reception of a transfer request from the user. In any case, upon reception of the user image with the advertisement image, the user's information device displays the user image on the monitor display.
[0089] When the user selects the anchor in the advertisement image on the display screen by, for example, clicking with a mouse cursor (Yes in step ST 17 ), jump is made to the page of the advertisement information, such as detailed information on a commodity or related information thereof specified by the link information embedded in the anchor (step ST 18 ).
[0000] (3) Method of merging a user image managed by one server and an advertisement image stored in another server on an arbitrary server, and distributing the merged image to a user's information device
[0090] In realizing this method, the advertisement distribution server manages information shown in Table 4 for individual advertisement images provided. A content sharing site manages the information shown in Table 5 for each user image uploaded from the user's information device.
[0000]
TABLE 4
Information to be Managed on Advertisement Distribution Server
priority
information
details of information
order
S1: advertisement
type of moving image or still
essential
image
image
S2: merging region
region coordinate information
essential
S3: medium to be
type of moving image or still
essential
merged
image
S4: link
URL
essential
information
S5: target user
user profile, purchased
optional
condition
product, management
application to be displayed,
etc.
[0000]
TABLE 5
Information to be Managed on Content Sharing Site
priority
information
details of information
order
C1: user image to be
image selected using image
essential
merged with
management software, or image
advertisement image
selected by arbitrary method
C2: user
user profile, purchased
optional
information
product, etc.
[0091] The “target user condition (S 5 )” in Table 4 is an item describing information for designating a user with whom an advertiser wants to provide the advertisement image, and whether or not to include the management information is optional. The “user information (C 2 )” in Table 5 is an advertisement for describing user attribute information, such as the profile of the user who reproduces a user image (C 1 ) like a moving image or a picture, or commodity purchase history, and whether or not to include the management information is optional. C 2 is the condition for determining an advertisement image to be merged, and is collated with S 5 at the time of reproducing the user image (to be described later).
[0092] FIG. 5 illustrates process procedures for merging a user image uploaded to the content sharing site with an advertisement image provided from the advertisement distribution server, and distributing the merged image to the user's information device.
[0093] First, the content sharing site selects a user image uploaded from the user's information device (step ST 21 ), and requests the advertisement distribution server of an advertisement image. A method of selecting a user image to be displayed from uploaded multiple user images is optional; a user image to be displayed may be selected from a list of thumbnails by a user action, or may be selected automatically.
[0094] Meanwhile, in response to the request, the advertisement distribution server retrieves the requested advertisement image (step ST 22 ), and outputs a retrieval result (step ST 23 ). The retrieval result contains the items S 1 to S 5 given in the Table 1 for the advertisement image in question.
[0095] Upon reception of the retrieval result (S 1 -S 5 ) from the advertisement distribution server, the “target user condition (S 5 )” for the transmitted advertisement image (S 1 ) is collated with the “user information (C 2 )” at the content sharing site to determine whether the advertisement image (S 1 ) fits to be merged with the user information selected in step ST 1 (step ST 24 ).
[0096] When the determination is affirmative (Yes in step ST 24 ), the user image (C 1 ) selected in step ST 1 is merged with the advertisement image (S 1 ) retrieved in step ST 2 (step ST 25 ). Region coordinate information (S 2 ) is set as management information in the advertisement image, and the image merging process is realized by pasting the user image into the user information display region which is specified by the region coordinate information (as mentioned above). An anchor in which link information to a page describing advertisement information, such as detailed information on a commodity to be advertised or related information thereof, is embedded is provided at a proper location in the advertisement image.
[0097] According to the embodiment, where the image merging process is performed is optional. For example, the image merging process may be performed at a content sharing site, or may be performed on the user's information device as done for the process procedures illustrated in FIG. 3 , or may be performed on the advertisement distribution server as done for the process procedures illustrated in FIG. 4 .
[0098] In any case, upon reception of the user image with the advertisement image, the user's information device displays the user image on the monitor display (step ST 26 ).
[0099] When the user selects the anchor in the advertisement image on the display screen by, for example, clicking with a mouse cursor (Yes in step S 27 ), jump is made to the page of the advertisement information, such as detailed information on a commodity or related information thereof specified by the link information embedded in the anchor (step S 28 ).
[0100] According to the individual embodiments of the invention, as apparent from the above, a user image, such as a picture or a moving image captured by a user with a digital camera can be added with a value according to the display contents of an advertisement image by pasting the advertisement image at the time of reproducing the user image. Since an anchor having link information embedded therein is contained in an advertisement image superimposed on a user image, the user can jump via the anchor to a home page describing advertisement information such as detailed information on a commodity. An advertiser or a manufacturer or seller of a commodity can provide a user viewing user images with appealing product information, thereby contributing to sales promotion of commodities.
[0101] In steps ST 2 , ST 12 and ST 22 in the flowcharts respectively illustrated in FIGS. 3 to 5 , there are various ways of deciding an advertisement image for a recommended commodity. For example, when a user image is selected according to the intention of a user through image management software in preceding step ST 1 , ST 11 , ST 21 , an advertisement image which matches with the type of a medium for the user image (e.g., either a moving image or a still image) may be a recommendable candidate. Alternatively, when a user image is selected automatically by the system, a user image which is displayed often on a user's information device may be selected, and merged with a predetermined advertisement image to be provided.
[0102] Further, some measures may be taken in merging a user image with an advertisement image in steps ST 5 , ST 15 , ST 25 in the flowcharts respectively illustrated in FIGS. 3 to 5 .
[0103] When a user image and an advertisement image both include a still image, for example, the user image is modified and merged in the position of the user information display region defined by the region coordinate information.
[0104] When a user image including a moving image is merged with an advertisement image including a still image of a commodity, the moving image may be modified and merged in the position of the user information display region defined by the region coordinate information.
[0105] When a user image including a still image is merged with an advertisement image including a moving image of a commodity, the user image including the still image may be modified and merged in the user information display region for each frame of the moving image.
[0106] When a user image including a moving image is merged with an advertisement image including a moving image of a commodity, the moving image of the user image may be modified and merged, for each frame, in the user information display region for each frame of the advertisement image including the moving image of the commodity.
[0107] FIG. 6 is a diagram showing an example of the configuration of a user's information device, such as a cellular phone, which displays a user image.
[0108] A CPU (Central Processing Unit) 151 controls the operations of the individual sections to execute various processes according to a program stored in an ROM (Read Only Memory) 152 or a program loaded from a storage section 154 to an RAM (Random Access Memory) 153 . Data needed for the CPU 151 to execute various processes is stored in the RAM 153 as needed.
[0109] The CPU 151 , the ROM 152 and the RAM 153 are connected to one another by a bus 155 . The bus 155 is connected with a storage section 154 , a wireless LAN communication section 122 , an operation section 156 , a microphone 102 , a GPS detection section 125 , an imaging section 121 , vibrators 124 - 1 and 124 - 2 , a sound output control section 158 , a display 101 , and an LED 159 . The information device can capture a moving image or a still image to be a user image using the imaging section 121 .
[0110] The operation section 156 includes buttons and a jog dial or the like, and accepts an operation performed by a user. The sound output control section 158 outputs an audio sound corresponding to supplied audio information (electric signal) from a speaker 105 . The LED 159 emits light to, for example, draw the attention of the user to the information device at the time of providing the user with information.
[0111] The information device shown in FIG. 6 can work as a user's information device in the process procedures illustrated in FIGS. 3 to 5 as the CPU 151 executes a predetermined application program, for example. At that time, a moving image or a still image captured by the imaging section 121 is stored as a user image in the storage section 154 . A user image can be uploaded or transferred to an external server, such as one in a content sharing site, via the wireless LAN communication section 122 , for example. It is also possible to acquire an advertisement image from an external advertisement distribution server, or download various contents, such as user images merged with advertisement images, via the wireless LAN communication section 122 . Reproduction of a user image can be carried out on the display 101 , so that the user can use the operation section 156 to select a user image to be reproduced.
[0112] FIG. 7 shows an example of the configuration of an advertisement distribution server or a server provided at a content sharing site. Part of a user's information device is configured as shown in FIG. 7 .
[0113] A CPU 201 executes various application programs under the execution environment that is provided by the operating system (OS). The OS is a program which controls the basic operations of a computer, typified by WINDOWS (Registered Trademark by Microsoft Corporation) XP or Mac OS (Registered Trademark by Apple Computer Inc).
[0114] The CPU 201 is connected to a front side bus (FSB) 202 which is further connected to a north bridge 203 . The north bridge 203 has an AGP (Accelerated Graphics Port) 204 and a hub interface 210 .
[0115] The north bridge 203 , which is connected to a cache memory 208 and an RAM 209 or a main memory, controls operations to access those memory devices. The RAM 209 is formed by, for example, a DRAM (Dynamic RAM), and stores a program to be executed by the CPU 201 , and work data needed for the operation of the CPU 201 . The cache memory 208 is formed by a memory device, such as an SRAM (Static RAM), which achieves fast writing or reading, and caches or temporarily stores a program or data used by the CPU 201 .
[0116] The north bridge 203 is connected to a video controller 205 via the AGP 204 . The video controller 205 generates image data corresponding to data received from the CPU 201 , or stores image data received from the CPU 201 into an internal video memory (not shown) directly, and displays an image corresponding to the image data in the video memory on an LCD 206 or a VGA controller 207 . The LCD 206 or the VGA controller 207 displays an image, characters or the like based on the data supplied from the video controller 205 . The VGA controller 207 is a display of the VGA (Video Graphics Array) type.
[0117] The north bridge 203 is connected to a south bridge 211 via the hub interface 210 . The south bridge 211 incorporates an AC link interface 211 A, a USB (Universal Serial Bus) interface 211 B, an IDE (Integrated Drive Electronics) interface 211 C, a PCI (Peripheral Component Interconnect) interface 211 D, an LPC (Low Pin Count) interface 211 E, an LAN interface 211 F, etc. The south bridge 211 controls the input/output operations of various devices connected thereto via devices connected to an AC link bus 212 , a USB bus 217 , and an IDE bus 222 .
[0118] The AC link bus 212 is connected with a modem 213 , a sound controller 214 , and the like. The sound controller 214 acquires a sound from a microphone 215 , generates data corresponding to the sound, and outputs the data to the RAM 209 . The sound controller 214 drives a speaker 216 , and outputs a sound thereto.
[0119] A USB connector 218 is connected to the USB bus 217 so that various USB devices can be connected. A USB interface 221 B transmits data to and receives data from an external device connected via the USB bus 217 .
[0120] The IDE interface 211 C includes two IDE controllers, namely, a primary IDE controller and a secondary IDE controller, and a configuration register (neither shown). The primary IDE controller is connected with an HDD (Hard Disk Drive) 223 via the IDE bus 222 . The secondary IDE controller is electrically connected with an IDE device, such as a CD-ROM drive 224 or HDD (not shown), when the IDE device is connected to another IDE bus.
[0121] A wireless LAN communication section 225 is connected to a network via wireless LAN communication based on, for example, IEEE 802.11a/b or the like. The LAN interface 211 F transmits data to and receives data from a network connected to the wireless LAN communication section 225 .
[0122] An LPC bus 251 is connected with ROM 252 , an I/O (Input/Output) interface 253 and a controller 256 . The BIOS (Basic Input Output System) or the like is stored in an ROM (Read Only Memory) 252 . The BIOS is a collection of basic input/output commands, and controls the input/output of data between the OS or the application program and a peripheral device.
[0123] The I/O interface 253 is connected with a serial terminal 254 and a parallel terminal 255 , and performs serial input/output and parallel input/output with respect to devices respectively connected to those terminals. User input devices, such as a keyboard 258 and a mouse 257 , can be connected to the controller 256 . The controller 256 has capabilities of monitoring the terminal voltage of a battery 260 or the main power supply, and controlling the charge/discharge operation thereof.
[0124] A PCI bus 226 is connected with a card interface 229 , an IEEE 1394 interface 227 , and other unillustrated PCI devices. The card interface 229 supplies data supplied from an expansion card (not shown) connected to a slot 230 to the CPU 201 or the RAM 209 , and outputs data supplied from the CPU 201 to the expansion card connected to the slot 230 . The IEEE 1394 interface 227 transmits and receives data (data stored in a packet) conforming to the IEEE 1394 standards via an IEEE 1394 port 228 .
[0125] The device shown in FIG. 7 can operate, for example, as an advertisement distribution server or a user's information device in the process procedures illustrated in FIGS. 3 to 5 , or as a server in a content sharing site shown in FIG. 5 when the CPU 201 executes a predetermined application program. User images and advertisement images can be stored in the HDD 223 , and uploading of a user image and transfer of an advertisement image can be carried out via the wireless LAN communication section 225 . A desired user image can be selected by operating a GUI (Graphical User Interface), such as the mouse 257 . It is possible to select a user image through the display screen of the VGA controller 207 , and reproduction of a user image merged with an advertisement image can be carried out under control of the video controller 205 .
[0126] The detailed description of the invention has been given referring to particular embodiments. However, it should be apparent to those skilled in the art that the embodiments may be modified and changed departing from the spirit or scope of the invention. That is, the present examples and embodiments are to be considered as illustrative and not restrictive and the present invention is not to be considered by reference to the scope of the appended claims.
[0127] The present application contains subject matter related to that disclosed in Japanese Priority Patent Application JP 2009-212081 filed in the Japan Patent Office on Sep. 14, 2009, the entire contents of which is hereby incorporated by reference.
|
An information processing system includes: a user image storage section that stores a plurality of user images; an image reproducing section that reproduces an image; an image selecting section that selects an image to be reproduced from the plurality of user images stored in the user image storage section; an advertisement image acquiring section that acquires an advertisement image matched with the user image selected by the image selecting section and containing link information to related advertisement information; and a control section that merges the user image selected by the image selecting section into a user information display region in the advertisement image acquired by the advertisement image acquiring section, causes the image reproducing section to reproduce the merged image, and provides advertisement information corresponding to one piece of link information contained in the advertisement image according to selection of that piece of link information.
| 6
|
CROSS-REFERENCE TO RELATED APPLICATIONS
The present patent application claims priority from Great Britain Patent Application No. 0301447.9, filed on Jan. 22, 2003.
BACKGROUND OF THE INVENTION
1). Field of the Invention
The present invention relates to an optical system image sensor operating in structures which may contain media with different spectral transmission characteristics; for example, in vessels containing both crude oil and water, either by rendering all media transparent simultaneously, or, on command, by rendering one or more of the media opaque to allow its detection.
2). Discussion of Related Art
In the oil industry, amongst others, it is necessary to inspect surfaces for cracks, corrosion, scale or other defects or characteristics, to examine welds to establish the integrity of a structure and ascertain the need for repair or replacement. It is desirable to use a single sensor to inspect internal surfaces of structures such as tanks, wells and pipelines containing crude oil and water, and also distinguish between oil and water, without emptying, flushing or cleaning the structure. It is also desirable to inspect surfaces coated with oil or wax in air.
Image sensors operating in structures containing fluids transparent in the visible region of the electromagnetic spectrum such as water are well-known, and disclosed, for example, in EP0846840, EP0264511, and WO0206631.
Operation may be extended to opaque fluids by flushing the vessel with a transparent fluid in the vicinity of the image sensor, and a method for doing this is disclosed in U.S. Pat. No. 4,238,158.
An image sensor operating directly in fluids which are opaque in the visible region of the spectrum but transmit energy at other wavelengths, for example, crude oil, is disclosed in GB2332331B. Transmission in these fluids may be limited, restricting operation of a practical sensor to close range.
The absorption at a given wavelength varies widely for different crude oils, but the general shape of each plot of absorption against wavelength is very similar and transmission “windows” occur at the same wavelengths in the spectrum, as shown in U.S. Pat. No. 5,266,800 which discloses a method for using infrared absorption measurements to discriminate between different crude oils.
As well as discriminating between crude oils, is also possible to distinguish between other fluids by measuring their spectral absorption characteristics, as disclosed in U.S. Pat. No. 4,994,671.
It is an object of the present invention to enable an image sensor to operate within, and also by remote command or autonomous internal control to discriminate between, media such as crude oil and water, which have transmission bands in different regions of the spectrum.
SUMMARY OF THE INVENTION
The invention, in one aspect, provides an in-vessel or down-hole imaging sensor comprising means adapted to selectively emit and/or detect two or more independently controllable wavelengths or wavebands.
The independently controllable wavelengths or wavebands render the media in the field of view opaque or transparent, or reveal the presence of one or more medium or component in the media by some other means such as exciting fluorescence.
In accordance with another aspect, the invention provides a method of obtaining images in a vessel, comprising operating a sensor and illuminating means to selectively emit and/or detect radiation of two or more independently controllable wavelengths or wavebands.
It is also an object of the present invention to provide uniform illumination and maximum illumination power on targets in the surrounding media close to, or in contact with, the image sensor window, to allow imaging at close range (e.g., from 0 to 25 mm) in media with limited transmission. This is provided by a further aspect of the invention, which provides an in-vessel or down-hole imaging sensor comprising a sensor window; illuminating means for emitting radiation; optical means for directing said radiation through an area of said sensor window in a first direction and optical means for receiving radiation reflected from a target illuminated by radiation from said illuminating means through the same area of the said sensor window in a second direction. Thus a target in contact with the image sensor window will be illuminated by the outgoing radiation.
The image sensor preferably comprises an imaging detector and associated electronics and mechanical housing, an illuminator and, optionally, a common-path optic which forms the window for both the outgoing and incoming radiation.
In the preferred embodiment of the invention, the detector comprises a vacuum tube device sensitive to visible and near infrared radiation, but may also comprise other detectors such as charge couple devices, active pixel sensors, thermo-electric sensors, bolometric sensors or InGaAs devices, either as two-dimensional arrays, or linear array sensor or single point detectors with a scanning device.
In a further embodiment of the invention, a thermo-electric cooler may be used to stabilize or lower the temperature of the detector, and the heat pumped from it is conducted through the housing into the surrounding fluid. Other coolers may be used, including, but not limited to, Joule-Thomson or Stirling coolers. Alternatively, energy can be absorbed into a medium within the housing which heats up or changes phase. Cooling or temperature control allows the invention to be used in media at temperatures higher than the desired or maximum operating temperature of the detector, detectors or other components. For example, the cooler or coolers may be used to control, reduce or eliminate the dark signal generated in the detector or detectors, and to control, reduce or stabilise other temperature dependant effects in the detector or electronics.
In the preferred embodiment of the invention, incoming energy is focused onto the detector using optics which can incorporate anti-reflection coatings optimised either for the full spectral range of incoming radiation, or for the discrete wavelengths or wavebands emitted by the illuminators or transmitted by the media in which the image sensor will be operated.
In an alternative embodiment of the invention, optics designed for use in the visible spectrum but still providing adequate performance in the spectral range used by the image sensor may be employed.
In the preferred embodiment of the invention the optics map the scene onto the detector using a tan theta function, but other techniques such as a tele-centric system may be employed.
In a further embodiment of the invention, fiducial marks may be incorporated in the images to assist the use of the images for metrology. The optical system may place the fiducial marks in the scene viewed by the detector, or the marks may be added electronically to the output signal.
In the preferred embodiment of the invention, the illuminator comprises sources selected to match the spectral transmission of the media in which the image sensor will be used, which may be laser diodes, for example, in the 1500–1650 nm waveband for crude oil and in the visible-1350 nm waveband for water. When both types of source are illuminated imaging is possible in both oil and water simultaneously. When only the source in the 1500–1650 nm band is energised imaging in crude oil is possible but water will appear black, as it absorbs strongly in this waveband, and the converse is true when only the source emitting in the visible-1350 nm band is energised. Alternatively, a broadband source such as an incandescent filament lamp, discharge (including flash) lamp, Light Emitting Diode or an electro-luminescent device could be used together with filters to select the appropriate wavebands, or a combination of broad and narrow band sources, with or without filters, could be used. By this means imaging is possible in both crude oil and water, and, by energising only one of the two types of illumination, the presence of either fluid may be detected as globules, layers, or separate slugs, in multiphase flow, in tanks, wells, or pipelines.
In an alternative embodiment of the invention, a broadband source and detector or detectors together with mechanically interchanged filters, or filters whose transmission wavelength or waveband can be altered electrically, may be used.
In an alternative embodiment of the invention, a mosaic of wavelength selecting filters are applied to individual pixels in an array or line detector, and images in each medium obtained by appropriate electronic processing of the output signals. For example, this is done in conventional single-sensor colour cameras operating in the visible region of the spectrum, where a red filter is placed over every third pixel in each line on the sensor, a green filter over each neighbouring pixel, and a blue filter over the remaining pixels. Clearly this technique can be applied to an arbitrary number of wavebands some or all of which can be outside the visible region of the spectrum.
In an alternative embodiment of the invention, some or all of the wavelengths or wavebands required are produced by the illuminator, and radiation returning from the target is focused onto a slit. Radiation passing through the slit is then dispersed using, for example, a prism or prisms or a diffraction grating, operate in either transmission or in reflection. The dispersed spectrum is then imaged onto multiple discrete detectors or a detector array or arrays, and wavelength selection is performed by selecting the appropriate discrete detector or location within a detector array. In this embodiment, spectral information is provided in one axis and spatial information is provided in the other, and two-dimension spatial images may be formed by scanning the incoming radiation over the slit.
In an alternative embodiment of the invention, illumination is provided in all the required wavebands, and a separate detector is provided for the waveband transmitted by each medium, the incoming radiation being separated into the appropriate wavebands by a beam-splitter or beam splitters and directed to each detector by relay optics. A single focusing lens may be used, which does not have to bring all wavelengths to a focus on the same plane as the detectors may be placed at different distances from the target, or separate focusing lenses optimised for each waveband may be used. Detectors optimised for each waveband may also be used, and may provide colour or monochrome outputs. In the oil and water example, a monochrome infrared sensor may be used for the oil transmission band, and a colour detector may be used in the visible region of the spectrum in water. This arrangement provides separate images in each medium simultaneously from one instrument. Each medium can be detected by comparing the images. In a further embodiment of this technique, images are combined electronically or by other means to form composite images, and individual media can be revealed by subtracting images or by adding false colour.
In an alternative embodiment of the invention, more than one assembly comprising relay and focusing optics and detector or detectors is provided to enable stereoscopic images to be obtained.
Optionally, polarizing filters may be included in the optical system.
Oil and water are discussed in the example above, but by incorporating appropriate illumination further embodiments of the invention can be applied to different media and also to more than two media. The media may be, e.g., gases or vapours.
It may not be possible to select illumination wavelengths such that the absorption in the various media in which the image sensor operates is identical. For example, with the preferred embodiment of the invention, the absorption in crude oil in the 1500–1650 nm band is typically much higher than the absorption in water in the visible to 1350 nm band. In order to stay within the dynamic range of the detector, the output power for each emitted waveband is matched to characteristics of the medium it penetrates, allowing the image sensor to operate continuously while passing through different media. In the oil and water example, lower output power is needed in the water band than in the oil band. When the image sensor operates in media with different absorption characteristics, the illumination level at each wavelength or waveband can only be exactly equal at one distance from the image sensor. In the more strongly absorbing medium, objects closer than this distance will appear brighter, and objects further away will appear fainter, than in the more weakly absorbing medium.
In order to mitigate the consequences of this effect, a further aspect of the invention provides a down-hole or in-vessel imaging apparatus comprising illuminating means for emitting radiation of a specified wavelength or waveband through a medium to a target; detector means for detecting radiation deflected by said target; and amplifier means for providing non-linear amplification of the detector means output.
The preferred embodiment of the invention incorporates a video amplifier with a non-linear response to compress the dynamic range in the analogue output signal. Since the non-linear absorption effects described above are generally believed to be exponential, or approximately exponential, this could be counteracted, in one example using a logarithmic or approximately logarithmic response. If the absorption effect is not exponential, then an appropriate amplifier response could be selected to counteract the effect. This enhances the pictures and makes video and still images easier to interpret when using display systems with lower dynamic range than the detector, and reduces the number of bits needed to digitise the output. Non-linear functions may also be applied by digital processing after digitising the analogue output. Optionally, different functions may be selected to suit the medium in which the sensor is operating, for example, a linear response could be selected in water and a logarithmic response in oil. The commands used to select the illumination source could also be also to select the response functions, or separate command could be used.
This apparatus may find application in different types of imaging systems where the medium surrounding the target has a non-linear illumination absorption effect.
Preferably, however, this arrangement is used with a selectable wavelength or waveband system as previously described. Different amplifiers may be provided for the different wavelengths or wavebands for different media, with means for selecting between the amplifiers. Alternatively, a single amplifier may be provided with selectable characteristics.
In the preferred embodiment of the invention, the non-linear function applied to output signal can be varied, as appropriate to the particular application, for example by adjusting the slope of a logarithmic amplifier. This may be adjusted by remote control. A remote control command may be provided by superimposing control signals on the video output signal.
In another embodiment of the invention, the illumination power is controlled automatically using a signal derived from the output from the detector to ensure that energy received from the scene lies within the dynamic range of the detector.
In the preferred embodiment of the invention, illumination is provided by a single laser diode or an array of laser diodes assembled into a module or modules installed within the image sensor housing and incorporating the mechanical mounting and electrical connections to each diode. Separate electrical connections are provided to diodes or groups of diodes emitting at different wavelengths. In an alternative embodiment of the invention, the emitting device or devices are also thermally coupled to a heat sink such as the image sensor housing using a high conductivity link or heat pipe, optionally incorporating a thermo-electric or other cooler such as a Joule-Thomson or Stirling device to control, stabilize or lower the temperature of the emitting devices. Alternatively, energy can be absorbed into a medium within the housing which heats up or changes phase. When cooling or temperature control is provided, the illumination system may be operated when the housing is immersed in media at temperatures above the desired or maximum operating temperature of components used to provide the illumination. For example, the cooler or coolers may be used to control, stabilise or increase the output from the emitting devices and to control, reduce or stabilize other temperature dependant effects. For example, the cooling system may be used to increase the output from laser diodes, the output from which reduces as the temperature increases.
In an alternative embodiment of the invention, illumination is provided by collimated laser beams scanned over the target using known techniques such as rotating mirrors.
In an alternative embodiment of the invention, illumination is provided by a broad-band source or sources such as an incandescent filament lamp or lamps or by a discharge lamp or lamps and, optionally, selectable optical filters are used to provide wavelength switching.
In an alternative embodiment of the invention, illumination is provided by more than one independently-controllable broad-band source, each with its own wavelength restricting filter or filters.
The filters may be moveable or may be fixed with independently moveable shutters to select the desired wavelengths or wavebands.
In the preferred embodiment of the invention, cylindrical spheric or aspheric lenses in front an array of laser diodes or other single or multiple discrete sources direct radiation into the common-path optic. Optionally, lenslet arrays may be used. Optionally, a diffuser may be placed in the optical path of the illumination system. This arrangement provides uniform illumination of the scene viewed by the image sensor. The envelope of the beam projected into the surrounding media may be matched to the field of view of the image sensor at the desired operating distance, or a collimated beam may be used. Optionally, the illumination may be polarized, for example when operating with targets or media sensitive to polarisation.
In the preferred embodiment the common-path optic also forms the image sensor window and must withstand the ambient pressure in media in which the image sensor is immersed. The common-path optic transmits the out-going illumination radiation and the returning radiation from the scene through the same window area in contact with the surrounding media. In the preferred embodiment of the invention, the refractive index of the common path optic is chosen to match that of the media in which the image sensor operates in order to avoid reflections at the window. In an alternative embodiment, reflections are controlled using anti-reflection coatings matched to the wavebands emitted by the illuminator and the refractive indices of the media in which the image sensor will operate.
In an alternative embodiment, the common-path optic may comprise an assembly of more than one component, including, for example, solid components coupled by appropriate means such as optical cement or a fluid or fluids which may be chosen such that the refractive indices match, or which may incorporate anti-reflection coatings.
The common-path optic can also provide optical power, for example to form all or part of the image sensor focussing optics, the illuminator beam shaping optics and to correct distortion in the optical system. The common-path optic can be configured in various ways to do this, for example by shaping external surfaces, incorporating other refracting or reflecting optical components, incorporating diffractive elements or graded index elements, or a combination of some or all of these techniques.
In an alternative embodiment of the invention, the illumination system is external to the image sensor casing. This arrangement may be used when the refractive indices of the surrounding media are significantly different; for example, when viewing in air objects coated in oil or wax. In this situation the invention will show the visible surface, and, on command, render the oil or wax transparent to reveal the underlying surface of the object.
One embodiment of the image sensor is supplied from a single electrical supply, and incorporates power conditioning for the laser diode array and detector, an analogue video output, and control electronics to adjust independently the power output of two or more laser diodes or groups of diodes. The output power control is commanded by signals applied to the video output line, decoded within the image sensor. In a further embodiment of the image sensor, signals applied to the video line are also used to adjust the characteristics of the non-linear amplifier.
A further embodiment of the invention incorporates internal digitisation and compression of the output signal, and a digital output, with separate command lines.
Further embodiments of the invention can incorporate some or all of the following features: power from internal batteries, internal data storage, and pre-programmed, automatic switching between the different wavelengths. If some or all of these features are incorporated, the resulting embodiment of the image sensor can be deployed remotely to acquire images autonomously without the need for external connections, with the internally-stored data being down-loaded on retrieval of the sensor.
In one embodiment of the invention, the image sensor is arranged in a cylindrical geometry with a sideways-looking optical system. This configuration is suited to imaging the inner walls of pipes, and may be deployed horizontally, for example on a pig or crawler, or vertically, for example on a wireline. In a further embodiment, the side view window is curved to match the cylindrical profile of the sensor housing, and, when operating in media which do not match the refractive index of the window, compensating optics can be included to counteract the cylindrical-lens effect of the curved outer face.
A similar arrangement, but with a rectangular rather than a cylindrical housing, is suited to inspecting the inner walls of tanks.
In another embodiment the image sensor is arranged with the window at the end of the housing. This geometry is suited to inspecting the bottom surface of tanks or obstructions in pipes.
Other geometries may be employed in embodiments of the invention tailored to other applications, including, but not limited to, examples such as welds joining right-angle plates.
All the embodiments described above may be deployed in various ways, examples of which include wirelines, arms, crawlers, or remotely operated vehicles.
BRIEF DESCRIPTION OF THE DRAWINGS
Preferred embodiments will now be described, by way of example only, with reference to the drawings.
FIG. 1 shows a schematic view of one embodiment of a sensor according to the present invention;
FIG. 2 shows a schematic view of a further embodiment of a sensor according to the present invention;
FIG. 3 shows a schematic view of a yet further embodiment of a sensor according to the present invention.
FIG. 4 shows a block diagram showing the common-path optic principle of an embodiment of the invention;
FIG. 5 shows a schematic view of an optical system used in a sensor according to the invention;
FIG. 6 shows another embodiment of an optical system used in a sensor according to the invention;
FIG. 7 shows another embodiment of an optical system used in a sensor according to the invention;
FIG. 8 shows an electrical block diagram of an image sensor processing stage; and
FIG. 9 shows a sensor without a common path optic operating in a single medium opaque to visible radiation, as disclosed in GB2332331B, in which the present invention may find application.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows a schematic diagram of a structure 1 in which a sideways-looking embodiment of the image sensor 2 is immersed in medium 3 and medium 5 . The target 4 is viewed by the image sensor while straddling the boundary between the two media. The figure shows the image sensor deployed in the vertical axis, but, with an appropriate delivery mechanism, it may be deployed in any orientation.
To view and image the target 4 , the image sensor 2 emits radiation at wavelengths which are transmitted by each media 3 and 5 . For example, if medium 5 is crude oil, and medium 3 is water, the sensor will emit radiation in the 1500–1650 nm waveband, and also in the visible-1350 nm waveband. This may be achieved in various ways. For example, sensor 2 may comprise light emitting or laser diodes, or groups of diodes, which operate in the respective wavebands and, for simultaneous imaging in both media, both diodes or groups of diodes will be operated as illumination sources. Alternatively, sensor 2 could emit radiation covering the visible-1650 nm waveband which would then be split, by a beam-splitter (not shown). Of course, for different media, different wavelengths or wavebands would be used.
The illumination radiation is preferably directed through a sensor window, as described in more detail in relation to FIGS. 4 to 6 .
The radiation is, because of its selected wavelengths, transmitted through both media 3 and 5 and strikes the target 4 . The reflected radiation is focused onto the detector by optics 8 , and an image of the target can then be derived using any of various known imaging techniques including the use of two dimensional photo-sensitive arrays such as charge coupled devices, or vacuum tube devices, or line or single point sensors together with scanning mechanisms, and appropriate electronic readouts.
Preferably the radiation reflected by the target is directed through the same sensor window as the emitted radiation (as discussed further below) and processed by the imaging sensor to form an image of the target.
FIG. 2 shows a schematic diagram of a structure 1 containing an end-viewing embodiment of the image sensor 6 . As with the sideways-looking embodiment, this configuration can be deployed in any orientation.
The image sensor is immersed in medium 3 , while the target 4 is immersed in medium 5 . The sensor 6 can be arranged to emit radiation which is transmitted by medium 3 . If medium 5 is also transparent to some or all of this radiation, the target can be illuminated. If the spectral transmission “windows” in medium 3 and medium 5 partly overlap, medium 5 can be made either transparent or opaque while the sensor is in medium 3 by selecting the wavelength of the emitted radiation. If there is no overlap between the spectral transmission “windows” in media 3 and 5 , medium 5 will be detected as a dark region in front of the sensor but the target cannot be illuminated. Medium 5 will remain opaque until the sensor passes through medium 3 and into medium 5 . Once in medium 5 , illumination with an appropriate wavelength or waveband can be emitted and the target 4 will be visible.
Switching between the different wavebands or wavelengths could be done automatically by switches operating according to a pre-programmed sequence.
FIG. 3 shows a schematic diagram of a structure 1 containing an end-viewing embodiment of the image sensor 6 . The image sensor and the target 4 are immersed in medium 3 , and the target is coated in medium 5 . As with the sideways-looking embodiment, this configuration can be deployed in any orientation.
Here, the sensor 2 could be arranged to emit radiation in a waveband which is transmitted by medium 3 , but not by medium 5 , to give an image of the coated object target 4 . Further, on command, the sensor could emit radiation which is transmitted by medium 5 , to reveal the underlying surface of the coated object. The types of illumination source and image processing are as described above in relation to FIG. 1 . Switching between the different wavebands or wavelengths could be done automatically by switches operating according to a pre-programmed sequence.
FIG. 4 shows a block diagram illustrating the principle of the common-path optic. Radiation, at the selected wavelength(s), is emitted by the illumination source(s) 11 of the imaging sensor. This radiation is directed by a so-called common-path optic 7 (described in more detail in relation to FIGS. 4 , 5 and 6 ) to exit through a sensor window. The emitted radiation strikes the target 4 in the vicinity of the window and radiation reflected by the target is directed through the same area 17 on the same window through which the illumination radiation passes. The common-path optic 7 then transmits the reflected radiation to focusing optics 8 which form an image of the target on the detector(s) 9 of the imaging sensor.
As discussed above, this common-path optic allows imaging at close range in media with limited transmission. The target is still illuminated even when in contact with the window, an improvement on the arrangement illustrated in FIG. 3 , where the sensor window and illuminators are separated by a finite distance. FIGS. 5 to 7 below show examples of practical implementations of the common-path optic.
FIG. 5 shows a schematic diagram of the optical system for an example embodiment of the invention, in this case an end-viewing image sensor. The common-path optic 7 is sealed into the image sensor housing 10 and forms the window for the illumination system and the detector. The output from illuminators 11 , which may incorporate beam shaping or collimating optics, is directed into the common-path optic. Radiation reflected back from the target 4 passes through the common-path optic to the lens 8 which focuses the scene onto the detector 9 . In this example two illuminators are shown, but any number from one to a continuous ring of units, or a single ring-shaped unit, around the detector lens 8 may be used.
FIG. 6 shows a schematic diagram of the common-path optic in an alternative embodiment of an end-viewing geometry. The common-path optic 7 is sealed into housing 10 , which contains the detector 9 , detector focusing optics 8 and the illuminator 11 and illuminator beam shaping optics 12 . Target 4 is illuminated by, and viewed by, the image sensor.
FIG. 7 shows a schematic diagram of the common-path optic for the sideways-looking embodiment of the image sensor. The common-path optic 7 is also sealed into the housing 10 , and forms the window for the illuminator 11 and the detector. Radiation from the illuminator passes through the common-path optic to the target 4 . Returning radiation passes back into the common-path optic 7 and is reflected by the coating 13 into the lens 8 and focused onto the detector 9 . In a further embodiment of this configuration the external surface of the common-optic may be curved in one direction to match a cylindrical housing, to facilitate operation in a cylindrical vessel.
FIG. 8 shows an electrical block diagram for an example embodiment of the image processing components of the sensor. Since, where objects are viewed in different media, different rates of absorption exist, the illuminatioh levels at each wavelength or waveband are different. So as to mitigate the effects of this, a video amplifier 14 and other amplifiers 14 ′ and 14 ″ with a non-linear response may be connected to the detector 9 to compress the dynamic range in the output signal. For example, a logarithmic response may be applied. The response characteristics of the amplifier are preferably adjustable; for example, the slope would be adjustable if a logarithmic response were applied. The resulting processed image can then be further transmitted, recorded and/or displayed. The non-linear amplifier may be integral with the image sensor, or may be located in a separate unit outside the image sensor housing.
One application for the present invention is in a system such as that described in GB-B-2332331, an embodiment of which is shown schematically in FIG. 9 , the system being adapted for detecting targets in different media, as described above.
FIG. 9 shows a schematic diagram of a sensor 6 without a common path optic operating in a medium 3 (for example crude oil) contained in a tubular structure 1 . In this example the radial position of the sensor is controlled by the spider assembly 17 . The illuminators 11 which, using the present invention, are as described above, are mounted on the spider assembly, in this case to illuminate the internal walls of the structure, and returning radiation is collected at the sensor window 16 .
This system could also be adapted to incorporate the common path optic and/or amplifier features described above.
|
The present invention relates to an in-vessel or down-hole optical imaging sensor or system for operating in structures which may contain media with different spectral transmission characteristics. The imaging sensor of the present invention selectively emits and/or detects two or more independently controllable wavelengths or wavebands. The imaging sensor comprises an illuminator for emitting radiation of a specified wavelength or waveband through a medium to a target, at least one detector for detecting the radiation deflected by said target and at least one amplifier for providing non-linear amplification of the detector output.
| 4
|
This is a continuation of application Ser. No. 846,642, filed Oct. 28, 1977 now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates in general to earth boring drill bits and in particular to improved bearings and means for retaining the rotatable cutters on such bits.
2. Prior Art
The success of rotary drilling enabled the discovery of deep oil and gas reservoirs. The rotary rock bit was an important invention which made that success possible. Only the soft formations could be commercially penetrated with the earlier drag bit, but the two cone rock bit invented by H. R. Hughes, U.S. Pat. No. 930,759, drilled the hard cap rock at the Spindletop Field near Beaumont, Tex. with relative ease.
That distant invention, within the first decade of this century, could drill a scant fraction of the depth and speed of the modern rotary rock bit. If the original Hughes bit drilled for hours, the modern bit drills for days. Bits today sometimes drill for miles instead of feet. Many improvements contributed to the impressive improvement in the performance of rock bits.
The original bit of Hughes had rotatable cutters, frictional bearing surfaces and ring-type retainers generally threaded for retention in the cutter. Because of the difficulty in providing seals with long life, relatively large lubricant reservoirs were required. By the decade of the thirties, drill bits with anti-friction bearing that were unsealed became commercially successful and replaced the sealed and lubricated drill bits. This type drill bit may be seen in the U.S. patent to Lewis E. Garfield et al. U.S. Pat. No. 2,030,442.
G. O. Atkinson et al obtained U.S. Pat. No. 3,075,781 on a seal that minimized leakage and required only a small reservoir of lubricant. The pressure compensator is an improvement that minimizes the pressure differential across the seal and increases its reliability. A recent version of the pressure compensator and pressure relief system is shown in the U.S. Pat. of Stuart C. Millsapps, Jr., No. 3,942,596. E. M. Galle patented an O-ring type seal, U.S. Pat. No. 3,397,928, that ultimately made friction bearings once again feasible in drill bits. An illustration of a recent bearing configuration is shown in the U.S. Pat. No. 3,922,038 issued to S. R. Scales. This bit has a cylindrical, friction bearing and a cutter retained by a ball bearing similar to that shown in the above patent to Lewis E. Garfield et al.
A ball bearing in a lubricated rock bit bearing has inherent disadvantages. A failure in any one of the numerous balls or the raceway in which they are positioned may permit metallic fragments to enter the friction bearing, with near certain damaging results. Metallic particles will often damage the seal ring, causing lubricant loss and rapid bearing failure. The necessity for a hole drilled into the ball race for introduction of the balls, retained by a welded plug, adds complexity to the bit that provides additional room for manufacturing error. The rock bit is the focal point of an expensive drilling process that has a low tolerance for failure.
There is shown in the prior art rock bit bearing and retainer means that are totally frictional; that is, without anti-friction ball or roller bearings. The original Hughes bit had friction bearings exclusively. A few of the many bits with only frictional bearings will be mentioned briefly.
F. L. Scott in U.S. Pat. No. 1,803,679 discloses a lubricated, tapered frictional rock bit bearing that retains its cutter by means of a resilient snap ring. J. C. Wright et al in U.S. Pat. No. 2,049,581 discloses a cutter rotatably secured with a snap ring to a bearing shaft releasably connected to the legs or head sections of a bit. The U.S. Pat. No. 2,814,465 to W. G. Green discloses a lubricated frictional bearing having tapered and cylindrical portions joined by suitable means and secured to a cutter by a retainer ring. A lock ring is shown in Edward B. Williams, Jr.'s U.S. Pat. No. 3,844,363 for retaining a cutter and shaft with frictional bearings to a rock bit. A frictional bearing with tapered and cylindrical portions is disclosed by E. M. Galle in his U.S. Pat. No. 3,361,494, along with frictional plug lock and pin lock retaining systems. A recent revival of the earlier seen threaded ring retainer is seen in U.S. Pat. No. 3,971,600 of Murdoch et al. Notwithstanding this array of ideas, the only significantly successful rock bit in commerce today uses a ball bearing retainer.
The threaded retainer ring has some disadvantage that may have limited its success. The threads act as stress raisers and the ring must be secured against rotation while the cone is mated with it. This generally requires a drilled hole in the head section.
Snap rings may have stress raising groove configurations and exhibit a tendency to retract during drilling into the assembly groove and permit accidental cutter loss. When a cutter is thrust inward, as when reaming for example, the loading of the ring causes stresses that tend to urge the ring into the assembly groove, with the possibility of cutter loss.
SUMMARY OF THE INVENTION
The invention may be summarized as an improved friction bearing and snap ring retainer means for a rock bit of the type having rotatable cutters, with sealed and lubricated bearings and a pressure compensation system. The preferred snap ring is circulated in cross section for assembly within two registering snap ring grooves, one in the cutter and the other in the bearing shaft that supports the cutter. The grooves in the preferred form have circular or semicircular bottoms, one being an assembly groove of a depth at least as great as the cross-sectional thickness of the ring. The other groove, the retainer groove, has a depth less than the cross-sectional thickness of the ring. When the cutter is thrust outward (toward the wall of the bore hole), there is clearance between the ring and assembly groove, but when the cutter is thrust inward, the ring is confined between the assembly groove and the retainer groove. The ring is forced outward into the retainer groove by either the offset edge of the assembly groove or an inclined wall formed on the edge of the assembly groove, either of which produces a conical force distribution. This urges the ring into the retainer groove and prevents accidental displacement of the ring into the assembly groove and loss of the associated cutter. Further assurance of cutter retention is provided because the distance from the edge of the assembly groove to the opposing edge of the retainer groove is less than the thickness of the ring when the cone experiences thrust loading.
Additional objects, features and advantages of the invention will become apparent in the following description.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a fragmentary view, partially in section, of a rock bit which embodies the features of the invention.
FIG. 2 is a full view of a snap ring used to rotatably retain the cutter on the bearing shaft or pin of the rock bit of FIG. 1.
FIG. 3 is an enlarged, fragmentary view in longitudinal section of a portion of the cutter and the bearing pin of FIG. 1.
FIG. 4 is a fragmentary view, in longitudinal section, of a region of the cutter and bearing pin around the cross-sectioned snap ring, of FIG. 1, the cutter being thrust outwardly on the bearing shaft.
FIG. 5 is, like FIG. 4, a fragmentary view, in longitudinal section but with the cutter thrust inwardly on the bearing shaft.
FIG. 6 is a fragmentary view, in longitudinal section, of a second construction with the cutter thrust inward.
FIG. 7 is a fragmentary view, in longitudinal section, of a third construction, with the cutter thrust inward.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Portions of an earth boring drill bit 11 are shown in FIG. 1, including a body 13 formed of three head sections 15 that are typically joined by a welding process. Threads 17 are formed on the top of body 13 for connection to a conventional drill string (not shown). Each head section 15 has a cantilevered shaft or bearing pin 19 having its unsupported end oriented inward and downward. A generally conically shaped cutter 21 is rotatably mounted on each bearing pin 19. Cutter 21 has earth disintegrating teeth 23 on its exterior and a central opening or bearing recess 25 in its interior for mounting on the bearing pin 19. Friction bearing means formed on the bearing pin 19 and cutter bearing recess 25 are connected with lubricant passages 27. (See U.S. Pat. Nos. 3,397,928 and 4,012,238 for bearing surface treatments.) A pressure compensator 29 and associated passages constitute a lubricant reservoir that limits the pressure differential between the lubricant and the ambient fluid which surrounds the bit after flowing through the nozzle means 32. (See the copending application of Stuart C. Millsapps, Jr., Lubricant Pressure Compensator For an Earth Boring Drill Bit, Ser. No. 687,131, filed May 17, 1976 now U.S. Pat. No. 4,055,225.) An O-ring seal 31 located between each bearing pin 19 and cutter 21 at the base of the bearing pin prevents egress of lubricant and ingress of borehole fluid. (See U.S. Pat. No. 3,397,928 for O-ring seal disclosure and U.S. Pat. No. 3,935,114 for lubricant.)
Referring to FIGS. 3, 4 and 5, an annular assembly groove 33 is formed on the cylindrical surface 34 of the bearing pin 19. Groove 33 has a circular bottom portion 35 formed about a radius located on centerline 41. An outer and an inner sidewall designated respectively sidewall 37 or 39 extend from the semi-circular bottom portion 35 to the surface of the bearing pin 19, outer sidewall 37 being the one farther from the inner end or nose 43 of the bearing pin 19. Outer sidewall 37 is planar and perpendicular to the coaxis (not shown) of the bearing pin 19 and cutter 21.
Inner sidewall 39 is a conical thrust surface or inclined wall nonperpendicular to the axis of the bearing pin, oriented at an angle α of preferably 15° with respect to a plane perpendicular to axis of the bearing pin. This produces an entrance to groove 33 larger than the diameter of its circular bottom portion 35 and is a beneficial thrust surface as will be explained subsequently.
A registering retainer groove 45 is formed in the bearing recess 25 of cutter 21. Groove 45 has sidewalls 46 and 50, with outer sidewall 46 located farthest from nose 43 of bearing pin 19. As seen in section, sidewall 46 has the form of a circular arc equal to one quarter of a circle, with a radius substantially equal to the radius of the bottom portion 35 of the previously described groove 33. The depth of groove 45 is greater than the radius of the circular arc. As seen in section in FIG. 4, inner sidewall 50 consists of a straight line connected at one end by means of a small radius with the quarter-circular arc of sidewall 46 and its other end extends to form one surface of a tapered or conical frictional nose bearing 52.
Grooves 33 and 45 are located so that they register to define an irregularly shaped annular cavity with curved bottoms. A snap ring 47 with a curved boundary and preferably circular cross-section is located in this cavity. It is formed of resilient metal, preferably piano wire, and contains a gap 49 (see FIG. 2) so that its annular diameter may be compressed or expanded. The annular diameter of ring 47 is selected so that it will expand tightly into groove 45 when relaxed. The cross-sectional diameter of 47 is substantially equal to the diameter of the circular portion 35 of groove 33.
The depth of assembly groove 33 is at least as large as the cross-sectional diameter of ring 47. This enables ring 47 to be stressed and retract fully into groove 33 for assembling cutter 21 over bearing pin 19. The depth of retainer groove 45 is greater than one-half the cross-sectional diameter of ring 47 but less than its cross-sectional full diameter. This depth is greater than the thickness of one-half the diameter of the cross section of ring 47 by an amount, conveniently called the "offset", which in the preferred form is in the range from 0.005 inch to 0.020 inch. This places the cross-sectional centerline 51 of ring 47 outside the cylindrical surface 34 of the bearing pin and also outside the edge of the retainer groove by the same quantity.
To assemble the cutter 21 over bearing pin 19, a tool (not shown) is used to compress ring 47 into groove 33. The cutter 21 is then inserted partially over the bearing pin 19 and the tool removed. Cutter 21 is then forced outwardly and against the bearing pin until engagement of the opposing surfaces of the tapered nose bearing 52, as shown in FIG. 4. Groove 45 will be sufficiently aligned with groove 33 for ring 47 to snap into it. Ring 47 is shown in FIG. 4 against sidewall 46 of groove 45, and is not touching sidewall 50. Sidewall 39 of groove 33 also is separated from the ring by a clearance space C 1 to assure movement into retainer groove 45. The centerline 51 of ring 47 is offset to a position outside the surface 34 of the bearing pin 19 by the preferred distances of 0.005 to 0.020 inch.
Centerlines 41 and 51 do not lie on a common plane perpendicular to the bearing pin axis. Rather, centerline 51 is spaced closer to the nose 43 than centerline 41. Because of clearance C 1 the cutter 21 may move inward on bearing pin 19 to the position shown in FIG. 5. Here, ring 47 is confined between sidewall 46 of groove 45 and the corner of sidewall 39 of groove 33. A clearance C 2 appears between the opposing surfaces of conical or tapered thrust bearing 52.
The distance from the offset annular edge of wall 39 of the assembly groove 33 to the opposite corner or outer wall 46 in retainer groove 45 is less than the thickness or diameter of snap ring 47 when the cutter is thrust inward to the position shown in FIG. 5. That is, the diameter of the snap ring in FIG. 5 is represented by the letter x+y. The distance from the edge of wall 39 to the opposite corner of groove 46 is a lesser distance x. Hence, when the cone is thrust inward, the ring cannot be retracted into the assembly groove 33 but must remain in the retainer groove 45 to prevent accidental cutter loss.
In operation, the most normal drilling condition produces outward thrust of cutter 21 on bearing pin 19 as seen in FIG. 4. No external forces are exerted on ring 47 due to engagement of the surfaces of tapered bearing 52 and the resulting clearance C 3 between the ring 47 and wall 37 of groove 33. If thrust on the cutter is inward, as sometimes occurs when reaming an undersized hole, the tendency will be for the cutter 21 to be pushed inwardly and from the bearing pin 19. This tendency will be resisted by ring 47, which transmits the thrust between sidewall 46 and sidewall 39 as shown in FIG. 5. Inner sidewall 39 serves as a thrust surface, providing a compressive reacting force.
The forming of inner sidewall 39 at an angle α generates a force component F (see FIG. 6) at the same angle α and in a direction oblique to the axis of rotation of the cutter 21. Thus, the configuration of the groove 33 produces a three dimensional conical force distribution F that expands the ring 47 outward into groove 45 in cutter 21. This prevents compression of ring 47 into the groove 33 of bearing pin 19 and the consequent loss of cutter 21.
FIG. 6 is a second construction from that shown in FIGS. 4 and 5 in that the walls 37', 39' of assembly groove 33' are parallel and formed at the angle α'. The "offset" is smaller in FIG. 6 and is not necessarily utilized since here the tapered wall 39' exerts a force component F normal to the surface of ring 47' to urge the ring into retainer groove 45'.
In FIG. 7 is shown a third construction in which the walls 37", 39" of assembly groove 33" are parallel and perpendicular the centerline of the bearing pin. Here the edge or outer wall 39" of groove 33" engages the ring 47" at a distance from the centerline 51" of the ring 47" equal to the "offset" from cylindrical bearing surface 34". A force component F is exerted obliquely against the ring, at an angle normal to the surface of ring 47", to urge the ring into the retainer groove 45" when the cone is thrust inward.
The preferred construction of FIGS. 4 and 5 is a combination of the features of FIGS. 6 and 7 in that wall 39 (but not wall 37) of groove 33 is tapered and the "offset" feature is also used. The quantity of offset in the specified preferred range is such that angle α of preferably 15° results in surface 39 contact with the ring rather than sharp edge contact. This provides a superior wear condition since a sharp edge will wear the ring more rapidly.
Each of the three constructions of FIGS. 4 through 7 have a feature that further minimizes loss of a cutter, as previously explained in connection with FIG. 5. That is, the cross-sectional thickness x+y of the ring 47 is greater than the distance x from the edge of wall 39 to the opposite corner of groove 46 when the cutters are thrust inwardly on their bearing shafts.
It should be apparent from the foregoing that improvements having significant advantages have been made. The utilization of a bearing structure which consists of lubricated frictional bearing surfaces, including a frictional retainer means, simplifies construction and increases reliability. The utilization of the disclosed snap ring and groove configuration minimizes the danger of loss of the cutter. The previously described offset position between the centerline of the ring and the surface of the bearing near the assembly groove results in an oblique force component that urges the ring into its retainer groove. The smooth angular thrust surface in the assembly groove to engage the ring when the cone is thrust inward provides an advantageous wear environment. Further, the inclined orientation of this surface, which acts as a thrust surface, also urges the retainer ring into its retaining groove when the cone is thrust inward. The ring configuration and thickness being lesser than the distance across the groove assures cutter retention.
While the invention has been shown in only one of its forms, it should be apparent to those skilled in the art that it is not thus limited but is susceptible to various changes and modifications without departing from the spirit thereof.
|
Disclosed herein is an earth boring bit of otherwise conventional construction except for the bearing and cutter retention. A snap fit ring is used to retain the cutter, the grooves that receive the ring and the ring construction being such that the ring is forced into the retainer groove when the cone is thrust inward. The ring cannot therefore accidentally return to its assembly position to permit cutter loss. This enables the use of exclusively frictional bearings and retainer means of exceptional strength and reliability.
| 5
|
[0001] This is a Continuation of U.S. patent application Ser. No. 14/859,397 filed Sep. 21, 2015.
BACKGROUND
[0002] Generating broadband quadrature-modulated signals presents a number of challenges in achieving wide bandwidth and spectral purity, in shaping the waveform, in eliminating spurious components and non-linearities from the delivered signal, and in calibrating the quadrature modulation. Receiving and demodulating the signals presents similar challenges, particularly in cases of frequency conversion relating to image rejection and local oscillator (LO) leakage at the intermediate frequency (IF). Another issue involves quadrature imbalance at the local oscillator, where imbalances occurring at different points in the transmit/receive path are typically inseparable and are therefore not readily correctible. Thus, it would be desirable to have apparatus and methods for generating and receiving quadrature-modulated signals having not only wide bandwidth and spectral purity, but also featuring ease of calibration and rejection of undesirable artifacts in the signal. This goal is met by embodiments of the present invention.
SUMMARY
[0003] An embodiment of the present invention provides extremely wide-band signal-generating apparatus featuring multiple signal synthesizers and multiple quadrature modulators having independently-selectable configurations for flexible interconnections. Apparatus according to this embodiment allows convenient combination and isolation of different sections to enable convenient characterization of spectral components and filters for optimizing performance and rejection of spurious signal artifacts.
[0004] Another embodiment of the present invention provides quadrature modulators having internal digital filters to compensate for the frequency-dependencies of low-pass anti-aliasing filters.
[0005] A further embodiment of the present invention provides digital pre-processing apparatus for conditioning an input waveform to signal generation apparatus as disclosed herein.
[0006] Other embodiments of the present invention provide methods for self-calibration of analog and digital components of signal generating and receiving apparatus as disclosed herein.
[0007] Embodiments of the present invention are particularly well-suited to being incorporated within integrated circuits.
[0008] Further advantages offered by embodiments of the present invention include the ability for configurations to be adapted on the fly, and to be adaptively optimized according to the specific environment and operational settings. Embodiments of the present invention can thus be optimized in the various degrees of freedom (e.g. per frequency) for performance, spur rejection, interference resiliency, signal-to-noise ratio, bit error rate, and so forth.
[0009] It is understood that the present invention is not limited to the particular area of Radar and that embodiments of the invention are also applicable to other areas of the microwave signal field; including but not limited to: communications; radio frequency (RF) imaging; multiple input—multiple output (MIMO) communications and phased arrays; sensor-based applications (e.g. material analysis/monitoring); and test equipment implementation, such as vector network analyzers (VNA).
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The subject matter disclosed may best be understood by reference to the following detailed description when read with the accompanying drawings in which:
[0011] FIG. 1A illustrates a signal generator with pre-corrected digital inputs according to an embodiment of the present invention.
[0012] FIG. 1B illustrates a sideband selector switch for the signal generator of FIG. 1A , according to a related embodiment of the present invention.
[0013] FIG. 2 illustrates a signal generator according to an embodiment of the present invention.
[0014] FIG. 3 illustrates a multiple signal generator according to an embodiment of the present invention.
[0015] FIG. 4 illustrates a transceiver according to an embodiment of the present invention.
[0016] FIG. 5 illustrates a quadrature receiver according to an embodiment of the present invention.
[0017] FIG. 6 illustrates a multistatic radar apparatus according to an embodiment of the present invention.
[0018] FIG. 7 illustrates a 3-channel MIMO transceiver according to an embodiment of the present invention.
[0019] FIG. 8 illustrates a spectral component measurement arrangement at the output of the signal generation block according to an embodiment of the present invention.
[0020] FIG. 9 illustrates a receiver-assisted spectral component measurement arrangement according to an embodiment of the present invention.
[0021] FIG. 10A illustrates a symmetrized receiver-assisted spectral component measurement arrangement for characterization of a first quadrature modulation block according to the present invention.
[0022] FIG. 10B illustrates a symmetrized receiver-assisted spectral component measurement arrangement for characterization of a second quadrature modulation block according to the present invention.
[0023] FIG. 11 illustrates a multi-module referenced based scaling arrangement according to an embodiment of the present invention.
[0024] FIG. 12 is a flowchart of a method of calibrating a signal generator according to an embodiment of the present invention.
[0025] For simplicity and clarity of illustration, elements shown in the figures are not necessarily drawn to scale, and the dimensions of some elements may be exaggerated relative to other elements. In addition, reference numerals may be repeated among the figures to indicate corresponding or analogous elements.
DETAILED DESCRIPTION
[0026] FIG. 1A illustrates a signal generator 100 with pre-corrected digital inputs 181 and 183 according to an embodiment of the present invention.
[0027] In a quadrature modulation block 101 , digital-to-analog converters (DAC) 103 and 107 , respectively, receive digital inputs 181 and 183 and send analog signals corresponding thereto to anti-aliasing low-pass filters (LPF) 105 and 109 , respectively. Digital input 181 is a pre-corrected in-phase input I C , whereas digital input 183 is a pre-corrected quadrature input Q C . Anti-aliasing low-pass filters 105 and 109 in turn output signals to multiplicative mixers (“mixers”) 111 and 113 , respectively. A 90° splitter 115 receives a synthesized frequency from a synthesizer 121 and outputs two signals which are 90° out of phase, with the signal to mixer 113 lagging 90° behind the signal to mixer 111 . The mixed outputs from mixer 111 and mixer 113 are input to a summing unit 117 .
[0028] The output from quadrature modulation block 101 is input to a switch 133 A, which can be selectably switched to pass the direct output of quadrature modulation block 101 or the output of quadrature modulation block 101 mixed by a mixer 131 with a synthesized frequency from a synthesizer 123 .
[0029] Various embodiments of the invention feature switches configured in a manner similar to that of switch 133 A. Certain embodiments of the invention provide that these switches be independently selectably switchable. Independent switchability according to these embodiments of the invention not only provides versatility in configuring apparatus, but also provides benefits in calibration of the apparatus, as detailed below.
[0030] Quadrature modulation typically suffers from spurious image-frequency signal and from local oscillator feed-through. These imperfections can be significantly reduced by signal pre-compensation in the digital domain The setting of the pre-compensation or pre-correction coefficients requires a feedback mechanism allowing the measurement of the above spurious signals.
[0031] Therefore, an embodiment of the present invention provides for pre-correction as follows. A numerically-controlled oscillator (NCO) 141 receives a frequency signal 143 to set the frequency f of the oscillator, and an initial phase signal 143 to set the initial phase φ 0 . Numerically-controlled oscillator 141 outputs two signals, a sine wave 147 sin (f, φ 0 ) and a cosine wave 149 cos (f, φ 0 ), which are input to a complex multiplier 151 , whose other inputs are an in-phase data stream 153 I data (k) and a quadrature data stream 155 Q data (k). The complex product outputs of complex multiplier 151 are a desired in-phase data wave 157 I and a desired quadrature data wave 159 Q. However, in order to compensate for effects such as amplitude imbalance of quadrature modulation to be performed by quadrature modulation block 101 , a pre-correction is needed, which is furnished by a matrix multiplier 161 , containing filters 163 , 165 , 167 and 169 for single sideband (SSB) rejection. In addition, matrix multiplier 161 also corrects for local oscillator leakage with direct current offsets I DC and Q DC into summing mixers 177 and 175 , respectively.
[0032] Furthermore, in accordance with an embodiment of the present invention, digital filters 163 , 165 , 167 , and 169 feeding into summing mixers 171 and 173 , respectively, are incorporated into matrix multiplier 161 to compensate for the frequency-dependencies of anti-aliasing low pass filters 105 and 109 . The result, as previously noted, are pre-corrected in-phase input 181 I C . and pre-corrected quadrature input 183 Q C .
[0033] FIG. 1B illustrates a sideband selector configuration switch 133 B according to a related embodiment of the present invention. Sideband selector configuration switch 133 B selectively switches between the direct output of quadrature modulation block 101 and either the upper sideband of the output of quadrature modulation block 101 mixed via mixer 131 with the output of synthesizer 123 , or the lower sideband thereof, as passed by an upper sideband filter 135 or a lower sideband filter 137 , respectively.
[0034] In the above descriptions, transmission signal generation is a hybrid configurable one/two conversion process as illustrated in FIG. 1A . The different states reached under the topology depend on the setting of switch 133 A and are as follows:
[0035] Direct conversion based on a frequency synthesizer 121 , which is directly modulated by wide-band quadrature modulator block 101 ;
[0036] Double conversion operation based on mixing between the output of quadrature modulator block 101 with synthesizer 123 .
[0037] This architecture inherently features an extremely wide frequency coverage (DC to 10 s GHz) while maintaining low spurious signal content. In certain cases the synthesizer frequency range is increased by digital dividers. In these cases, for noise minimization and stability, it may be of interest to have the synthesizers operate at different frequencies. Digitally divided signals, however, typically have high spurious harmonic content.
[0038] Operation over a multi-octave frequency range normally requires complicated re-configurable filters and filter banks to suppress these spurious signals. By heterodyne down-conversion of the direct modulated signal, wide frequency coverage can be achieved with the spurious signals lying out-of-band.
[0039] As the frequency coverage requirement widens, so does the coverage requirement from the synthesizers and direct modulators. Employing both direct and double conversions may relax the above requirement. For example, a quadrature modulator covering the range 4-8 GHz may be mixed with an additional 8-12 GHz synthesizer in order to cover the DC −4 GHz range, and with a 12-16 GHz synthesizer in order to cover the 8-12 GHz frequency range. Higher frequencies may be covered by using up-conversion rather than down-conversion.
[0040] Another benefit provided by embodiments of the present invention is the capability of arbitrarily modulating a wide-band waveform (as wide as the baseband) at any frequency within the frequency coverage. This permits the use of modulation schemes such as chirp/pseudo-random bit sequence (PRBS) for pulse compression in radar applications, communication constellations, and so forth.
[0041] Further use of the arbitrary digital modulation provided by embodiments of the present invention allows a fine-frequency offset in the digital domain. This permits coarser frequency steps in the synthesizers, improving their phase noise performance for the same frequency resolution requirement.
[0042] Another benefit provided by embodiments of the present invention is the ability to reach a certain output frequency via several different configurations. In a non-limiting example, by stepping the synthesizer to a higher frequency and correspondingly stepping the baseband frequency to a lower frequency the output frequency is unchanged. This is instrumental in producing a coherent frequency coverage across all synthesizer frequencies, even though it does not retain a specific phase over frequency change.
[0043] FIG. 2 illustrates a signal generator according to another embodiment of the present invention, where a second quadrature modulation block 203 is utilized to directly modulate synthesizer 123 to create the local oscillator for the second conversion. This enables a tradeoff of quadrature modulation imbalance versus phase noise to attain arbitrary frequency in generating the local oscillator for the conversion node.
[0044] FIG. 3 illustrates a multiple signal generator according to an embodiment of the present invention. Frequency synthesizer 301 feeds quadrature modulation blocks 303 and 305 , and frequency synthesizer 351 feeds quadrature modulation blocks 353 and 355 . Selector switches 311 , 331 , 361 , and 381 operate as previously described for selector switch 133 A ( FIG. 1A ), and selectably switch between the direct output of quadrature modulation blocks 303 , 305 , 353 , and 355 respectively, and outputs of mixers 313 , 333 , 363 , and 383 , respectively, all of which receive input from frequency synthesizer 391 .
[0045] As previously noted, various embodiments of the present invention provide selector switches 311 , 331 , 361 , and 381 to be independently switchable.
[0046] The arrangement illustrated in FIG. 3 is useful in Radar communication systems where there is a need for multiple microwave signals in parallel. Non-limiting examples of such needs include:
[0047] Simultaneous generation of transmit signal and of a receive local oscillator signal;
[0048] Generation of multiple transmit signals in multiple input—multiple output (MIMO) and phased/true delay array systems; and
[0049] Generation of sine and cosine local oscillator signals of quadrature down conversion.
[0050] For example, by digitally modulating the transmit signal and the receive local oscillator signal in a short range frequency-modulated continuous wave (FM-CW) radar system one can introduce an intentional frequency offset so as to avoid handling near-DC signals (see FIG. 4 ). An inherent trait of this architecture is that several direct conversion blocks and heterodyne converters may be fed from the same synthesizers, thereby naturally meeting the aforementioned need. This allows phase tracking between different microwave signals, as well as tracking of the phase noise.
[0051] Another advantage of this architecture is the distribution of a generated signal among many nodes, such as transmission antennas/receivers etc. This enables applications such as “Multistatic Radar” (see below).
[0052] Further embodiments of the present invention provide multiple synthesizers (as in FIG. 3 ), some of which are modulated and some are not, so as to simultaneously generate multiple signals at arbitrarily spaced frequencies.
[0053] FIG. 4 illustrates a transceiver according to an embodiment of the present invention. A frequency synthesizer 401 feeds quadrature modulator blocks 403 and 405 having selector switches 411 and 431 respectively, which select between direct output from the quadrature modulator blocks and the outputs of mixers 413 and 433 , respectively, both of which receive input from a frequency synthesizer 407 . The output of selector switch 411 feeds into an amplifier 451 , which in turn feeds an antenna switch/circulator 453 to an antenna 455 for transmission. Signals received from antenna 455 (such as by reflections of the transmitted signal) are fed to a mixer 457 , which receives input from switch 431 . Output of mixer 457 feeds to an anti-aliasing low-pass filter 459 and thence to an analog-to-digital converter 461 (ADC).
[0054] By modulating quadrature modulation blocks 403 and 405 , fed by the same synthesizer 407 with a frequency shift, both the transmit signal and local oscillator drive for an arbitrary intermediate frequency (IF) receiver are produced. The received signal is down-converted to an intermediate frequency corresponding to the offset of the modulation frequency between quadrature modulation blocks 403 and 405 .
[0055] Another example of arbitrary waveform modulation-based receiver local oscillator generation is a modulation with a pseudo-random binary sequence (PRBS) modulation, for a spread-spectrum radar.
[0056] A further example of an arbitrarily-configurable demodulation is multi-tone demodulating. Such a configuration is useful in the simultaneous measurement of several spectral components, e.g. by down-converting them to distinct intermediate frequencies. Both the amplitudes and phases of the spectral components may be measured.
[0057] The above capability of the signal generator for attaining an output frequency in several configurations, enables relating measurements across the entire frequency range, i.e. including local oscillator and measured path phase. According to a related embodiment, this is achieved by overlapping measurements between different local oscillator frequencies, where the baseband frequencies are adjusted to account for the local oscillator frequency offset between the measurements. This phase-related measurement differs from the common practice in the art, where, as the local oscillator is tuned over the coverage range, unaccounted-for phase changes occur. Retaining the relative phase according to this embodiment is instrumental in characterizing non-linear parameters in a vector network analyzer (VNA) embodiment of the present invention.
[0058] FIG. 5 illustrates a quadrature receiver according to an embodiment of the present invention. A switch 511 and a switch 531 are ganged together by a common selector 533 , to generate a 0° local oscillator 541 and a 90° local oscillator 543 , which feed mixers 561 and 563 , respectively, to convert a signal received by an antenna 555 , which is amplified by an amplifier 551 . The two intermediate frequency signals are fed into anti-aliasing low-pass filters 571 and 575 , respectively, to be demodulated by analog-to-digital converters 573 and 577 , respectively.
[0059] The configuration illustrated in FIG. 5 allows the generation of a 90° split over a wide frequency range, as opposed to conventional analog techniques, and without introducing substantial spurious harmonic content, which occurs when using digital dividers.
[0060] According to related embodiments of the invention, calibration techniques can be used to adjust the relative phase and amplitude between the quadrature channels. In non-limiting examples: measuring the phase and amplitude between the in-phase (I) and quadrature (Q) components of the down-converted continuous wave signal; simultaneously measuring the phase and amplitude on several signals; and cross-correlation measurements between the I and Q arms.
[0061] FIG. 6 illustrates a multistatic radar apparatus according to an embodiment of the present invention. In many cases it is desirable for a generated signal to be distributed among many nodes, such as transmission antennas/receivers, and so forth.
[0062] FIG. 7 illustrates a 3-channel multiple input—multiple output (MIMO) transceiver according to an embodiment of the present invention. In this embodiment, the above-described coherent arbitrary modulation topology is used in conjunction with parallelism (i.e. all quadrature modulation blocks are fed by the same synthesizer and are coherent to each other). This configuration enables active beamforming such as in the context of phased-array antennas. Current implementations are usable principally in narrow-band arrays, where carrier frequencies reach the microwave regime and analog delay-induced phase shifts are used. This embodiment of the present invention provides true beam-forming by digital relative delay means. Beam-forming is achieved by baseband modulation of coherent channels relative to each other, and does not hinder the broad band nature of the transceiver array. In addition, this embodiment provides ease of implementation with digital accuracy. Steering resolution and phase coherence are very precise since the relative phase attainable at any baseband frequency is practically arbitrary, as it is limited principally by digital-to-analog converter resolution.
Calibration
[0063] Calibration plays a significant role, where quadrature modulation imbalance, local oscillator leakage and the response of the receiver and transmitter paths comprise fundamental factors in attaining the required performance of a transceiver.
[0064] Quadrature modulation imbalance and local oscillator leakage calibrations are typically performed by a minimization of mixing products after passage through a broadband envelope detector. The quadrature modulator is subjected to modulation by complex sine wave at frequency f BB . At the output of the envelope detector, the detected power fluctuates at frequencies associated with the frequency offset between the desired signal and the spurious signals (either 2 f BB for the quadrature modulation image or f BB for the local oscillator leakage). The power fluctuations are typically measured by an analog-to-digital converter (ADC). It is important to note that if a high f BB is used then a high speed ADC is needed in order to capture and quantify the power fluctuations (the ADC bandwidth needs to be at least twice the baseband bandwidth in order to capture both spectral components).
[0065] Current techniques suffer from inherent difficulties associated with spurious signals and mixing products which fall on the to-be-measured quantities. As an example, mixing products from 2 f signal −2 f LO fall on the to-be-measured frequency associated with the quadrature modulated image: f signal −f image . Thus, the measurements are not independent. Embodiments of the invention facilitate the calibration for quadrature modulation imbalance and local oscillator leakage, without increase in architectural complexity.
[0066] The corrective action for compensation of quadrature modulation imbalance and local oscillator leakage are well known in the art. The quadrature modulation imbalance compensation involves pre-multiplying the I and Q components by a matrix of correction coefficients. The compensation of local oscillator leakage typically involves adding DC coefficients to the I and Q components. The difficult part of this procedure is determining which coefficients' values to use. This involves a feedback measurement of the strength of the image and spectral components of the local oscillator leakage.
[0067] FIG. 8 illustrates a spectral component measurement arrangement at the output of the signal generation block according to an embodiment of the present invention. Here, two quadrature modulation blocks are fed by a single, common, synthesizer. A method of measuring the image or local oscillator leakage is by placing the second synthesizer—used to convert the signal to the baseband—at a frequency offset relative to the spectral component of interest.
[0068] To measure the image, situated at f image =f Sa −f IQa1 , placing the second synthesizer at f Sb =f image −f IF which will be, after f IF conversion, linear in the original image magnitude. In order to reach the desired frequency at the output of the second synthesizer—driving the conversion of the output of the quadrature modulation block—fine frequency selection may be facilitated by either/or both the utilization of a fractional N synthesizer and an quadrature modulation of the synthesizer output. Only a single channel (one quadrature modulator, two synthesizers) is needed for the above scheme.
[0069] FIG. 9 illustrates a receiver-assisted spectral component measurement arrangement according to an embodiment of the present invention.
[0070] FIG. 10A illustrates a symmetrized receiver-assisted spectral component measurement arrangement for characterization of a first quadrature modulation block according to the present invention.
[0071] FIG. 10B illustrates a symmetrized receiver-assisted spectral component measurement arrangement for characterization of a second quadrature modulation block according to the present invention.
Baseband Filter Characterization
[0072] Baseband filter characteristics may vary at production. In the case of integrated circuit implementation, the filter bandwidth and shape may depend on process, temperature and voltage. The characteristics of baseband filters in the transmit and receive chains may affect system performance regarding signal-to-noise ratio, inter-symbol interference, power flatness, mask conformity, and so forth. It is thus desirable to characterize the filters and compensate for their deviation from desired characteristics. Examples of compensation include directly adjusting the filter and performing digital compensation.
[0073] The hardware architecture of embodiments of the present invention facilitates measurement of filter characteristics without further increasing complexity.
[0074] To characterize the transmit filter, the f BB is scanned throughout the range of interest. For each f BB the synthesizer's frequencies (f sa , f sb ) are adjusted such that the resulting intermediate frequency is constant; thus avoiding the receive filter response variation (when measuring at different intermediate frequencies per f BB ).
[0075] The receiver can be tuned to a frequency corresponding to an aliased frequency ±f BB +N·f sample (where f sample is the digital-to-analog converter sampling frequency). By doing so, the low pass filter in the transmit path can be characterized beyond the Nyquist frequency of the digital-to-analog converter.
[0076] Embodiments of the invention as described above and depicted in FIG. 8 and FIGS. 10A and 10B illustrate two similar schemes for scanning the baseband frequency as described above, by digitizing the output of the signal generation block.
[0077] Measuring the receiver filter is conceptually similar to the above schemes, but benefits from prior knowledge of the transmitter filter response: by knowing the response of the transmission filter, the quadrature modulation frequency can be tuned to scan the frequencies of the receiver filter. Alternatively, it is possible to measure the receiver filter separately without first characterizing the transmission filter. To do so, the quadrature modulation is held at a constant frequency (so as to not incur response variation) and the receiver frequencies are scanned by tuning the synthesizer's frequencies.
[0078] The intermediate frequency can be tuned beyond the Nyquist frequency of the analog-to-digital converter so that the receive anti-alias low-pass filter reacts to the input intermediate frequency, while the digitized output is at an aliased frequency ±f BB +N·f sample (where f sample is the analog-to-digital converter sampling frequency. By doing so, the low pass filter in the receive path can be characterized beyond the Nyquist frequency of the analog-to-digital converter.
Self-Characterization of Phase Noise
[0079] Digitization of the first synthesizer, down converted by the second synthesizer, allows characterizing the relative phase noise between the two synthesizers. This measurement can be used for either self-test purposes or for performance optimizations, such as setting the phase-locked loop parameters so as to optimize the phase noise. An example of such parameter is the setting of the charge pump current in the phase detector.
[0080] FIG. 11 illustrates a multi-module referenced based scaling arrangement according to an embodiment of the present invention.
[0081] FIG. 12 is a flowchart 1200 of a method of calibrating a two-synthesizer signal generator according to an embodiment of the present invention. In a step 1201 the first frequency synthesizer is set to the desired test frequency. In a step 1203 an outer loop begins, in which the first numerically-controlled oscillator is set to the desired test frequency offset. In a step 1205 , the second frequency synthesizer and the second numerically-controlled oscillator are set to obtain the desired receiving intermediate frequency.
[0082] In a step 1207 an inner loop begins for configuring a set of quadrature modulation imbalance correction coefficient values, and in a step 1209 an imbalance-related magnitude is measured. At a decision point 1211 , if the coefficient set is not exhausted, the method returns to step 1207 . Otherwise, if the set is exhausted, the loop beginning in step 1207 exits and the method proceeds to a step 1213 , in which optimal correction coefficients are calculated.
[0083] At a decision point 1215 , if the first numerically controlled oscillator frequencies are not exhausted, the method returns to step 1203 . Otherwise, if the frequencies are exhausted, the loop beginning in step 1203 exits, and the method concludes with a step 1217 , in which the optimal frequency-dependent correction coefficients are calculated.
|
Apparatus and methods for signal generation, reception, and calibration involving quadrature modulation and frequency conversion. Embodiments of the present invention provide extremely wide bandwidth, high spectral purity, versatility and adaptability in configuration, and ease of calibration, and are particularly well-adapted for use in integrated circuitry.
| 7
|
FIELD OF THE INVENTION
The present invention relates generally to support of rock and specifically to support of rock with yielding rock bolts.
DESCRIPTION OF THE RELATED ART
In many rocks, in order to achieve effective rock support over a desired length of time, the means of support must accommodate rock expansion by yielding. Particularly in the mines prone t rock bursts, large displacements are encountered during the rock burst events, which can cause failure of rock support such as rock bolts.
In rock bolts, extension is achieved by utilizing one or more of the following methods.
In the expansion type mechanical rock bolt shells, a steel wedge gradually slips between two or more segments of a cylindrical steel sleeve, forcing them into surrounding rock. This provides more or less constant friction force between the sleeve segments and the wedge, allowing a moderate rock bolt extension while providing continuous support to the rock. While this method of yielding rock support is relatively reliable, it can accommodate only a moderate rock bolt extension before the wedge slips through the shell and the rock bolt fails.
The split set type rock bolt is a pipe with a slot. During installation it is forced into a drill hole which is slightly smaller than the split set, forcing it to deform. This deformation provides a friction force between the split set and the hole in the rock. The rock expansion is accommodated by slippage of the split set within the hole when the supported load exceeds the friction force. While this method can accommodate larger expansions of rocks, it is less reliable than expansion shells and not suitable in many applications.
Another method of yielding rock support involves placing an oversized steel plug within a steel pipe in series with a standard rock bolt anchor. When an unusually large rock expansion occurs, the plug slips within the pipe while expanding it. Although this method provides a larger rock bolt extension than a mechanical expansion shell, it is less reliable and it's rock support performance is less predictable.
It would be therefore desirable to obtain a method and apparatus for a yielding rock support, which would allow a relatively large rock bolt extensions, while reliably maintaining a relatively constant force of rock support.
SUMMARY OF THE INVENTION
An object of the present invention is to proved a method of rock support, which allows relatively large rock displacements while reliably maintaining rock support force within a predetermined range.
Another object of the present invention is to provide a reliable rock support force at two or three levels of loading, in order to accommodate both, the smaller rock displacements due to rock excavations and large rock displacements due to rock bursts.
Yet another object of the present invention is to provide means of rock support capable of maintaining rock support force within predetermined ranges while accommodating relatively large rock displacements.
These and other objects of the present invention are met by a method and apparatus according to which means of rock support expands at two or more predetermined levels of loading at two or more rates of extension, while maintaining reliable rock support within a relatively large range of extension.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1 and 2 are schematic diagrams of displacements at three levels of loading according to the present invention;
FIG. 3 is a side view cross section of the preferred embodiment of a yielding rock bolt according to the present invention;
FIG. 4 is a side view cross section showing the yielding means of the preferred embodiment of a yielding rock bolt according to the present invention, in the initial position;
FIG. 5 is a side view cross section showing the yielding means of the preferred embodiment of a yielding rock bolt according to the present invention with the first yielding means partially yielded;
FIG. 6 is a side view cross section showing the yielding means of the preferred embodiment of a yielding rock bolt according to the present invention, with the first yielding means completely yielded and second yielding means partially yielded;
FIG. 7 is a detailed side view cross section of the yielding means used in the embodiment of FIG. 5, before yielding;
FIG. 8 is a detailed side view cross section of the yielding means used in the embodiment of FIG. 5, after yielding;
FIG. 9 is a side view cross section showing the yielding means of another embodiment of a yielding rock bolt according to the present invention, in the initial position;
FIG. 10 is a side view cross section showing the yielding means of another embodiment of a yielding rock bolt according to the present invention, after yielding; and
FIG. 11 is a plan view of a yielding rock bolt according to FIGS. 9 and 10.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 schematically illustrates the preferred method of rock support according to the present invention. The rock support is accomplished in three stages. After the initial tensioning of the means of support to the level of normal operating load, the level of load is maintained at this level during the stage 1 within the range of displacement C. If at any time during the stage 1 the load level increases beyond the normal load, such as during a rock burst, displacement rate increases but the normal level of load is maintained. If the higher than normal level of load continues, the displacement reaches the final value C and the stage 2 begins. During the stage 2 the high level of load is maintained within the range of displacement D. The rock continues to be supported safely as long as the displacement does not exceed the combined length of C. and D. Once the final value of displacement D is reached, the stage 3 begins. If during stage 3 the level of load continues to increases, the means of support reaches the breaking point.
FIG. 2 schematically illustrates another method of rock support according to the present invention. After the initial tensioning of the means of support to the level of normal operating load, the normal level of load is maintained within the range of displacement E. If at any time the load level increases beyond the normal load to a high load level, displacement rate increases and the high level of load is maintained until the load decreases again to a normal level. The rock continues to be supported safely as long as the displacement does not exceed the length of E. Once the final value of displacement E is reached, the final stage begins. If during the final stage the level of load continues to increase, the means of support reaches the breaking point.
The side view cross section of a preferred embodiment of a yielding rock support according to the present invention is illustrated in FIG. 3. Rock bolt assembly 1 installed in the hole 2 within rock 3 consist of a steel rod 4, standard rock bolt anchor 5 such as resin grout, roof plate 6 and yielding element 7.
The side view cross section of a preferred embodiment of the yielding element 7 is illustrated in FIG. 4. The yielding element 7 consists of a cylinder 8 with a bottom plate 9 on one end and open collar 10 on the other end. Yielding elements 11 and 13, placed within the cylinder 7, have different yielding properties. The low yield strength corrugated sleeve 11, whose length is C 1 , is located between the bottom plate 9 and the spacer 12. The high yield strength corrugated sleeve 13, whose length is D 1 , is located between the spacer 12 and the spacer 14. The yielding element 7 is held on the threaded part 15 of the rock bolt rod 4 by nuts 16 and 17. The nut 17 is used to rotate the rock bolt assembly 1 with the yielding element 7 during the installation in the hole 2 against the roof plate 6. The yielding elements 11 and 13 are designed to deform at two predetermined levels of load on the roof plate 6.
The side view cross section of the yielding element 7 with low yield strength corrugated sleeve 11 deformed to the length C 2 is illustrated in FIG. 5.
The side view cross section of the yielding element 7 with low yield strength corrugated sleeve 11 deformed to the final length C 3 and the high yield strength corrugated sleeve 13 deformed to the length D 3 is illustrated in FIG. 6.
The side view cross section of the preferred embodiment of the corrugated sleeve 13 within the cylinder 8, before any deformation, is illustrated in FIG. 7. Such corrugated sleeve can be manufactured from a suitable ductile material such as ductile iron, steel, metal ally, plastic or other materials.
The side view cross section of the corrugated sleeve 13 within the cylinder 8, deformed to about 50% of it's original length, is illustrated in FIG. 8.
Another embodiment of the yielding element 7 is illustrated in FIG. 9. The yielding element 7A consists of a cylinder 18 with a bottom plate 19 on one end and an open collar 20 on the other end. Rock bolt rod 21 is inserted through the bottom plate 19 containing seal 22 to prevent leakage of hydraulic fluid 30 from the cylinder 18. Piston 23 is attached to the threaded end 24 of the rod 21. Two or more ports 25 and 26 are drilled within the piston 23. The ends of ports 26 are threaded to accommodate pressure relief valves 27 and 28. Piston 23 contains seal 29 to prevent leakage of hydraulic fluid 30 from the cylinder 18. When the piston 23 is located near the collar 20, at the distance E 1 from the bottom plate 19 of the cylinder 18, the key 32 is inserted into the key slot 31. The key 32 is a part of installation plate 33 welded to the collar 20. Installation plates 33 are used to rotate the rock bolt 4 with the yielding element 7A during the installation in the hole 2 against the roof plate 6. The pressure relief valves 27 and 28 are designed to release hydraulic fluid 30 at two predetermined levels of load on the roof plate 6, thus allowing reduction of the distance E 1 and extension of the rock bolt assembly 1.
The side view cross section of the yielding element 7A with the distance between the bottom plate 19 and the piston 23 reduced to the length E 2 is illustrated in FIG. 10.
The plan view of the yielding element 7A is illustrated in FIG. 11. Installation plates 33, welded to the open collar 20, contain keys 32 which are inserted into the key slots 31 in the piston 23 with pressure relief valves 28.
Numerous modifications and adaptations of the present invention will be apparent to those skilled in the art and it is intended to cover by the following claims all such modifications and adaptations which fall within the true spirit and scope of the invention.
|
An apparatus for yielding rock support in a rock bolt where yielding is achieved by one or more yielding elements at one or more levels of loading.
| 4
|
FIELD OF THE INVENTION
The present invention relates to an electronic device having a power supply control function for a device connected to the electronic device through a communication means, such as a USB, which simultaneously performs data communication and supplies power, a control method for the electronic device, and a storage medium.
BACKGROUND OF THE INVENTION
As a method of connecting a peripheral device to a PC (Personal Computer), a method using a USB (Universal Serial Bus) has been proposed and has become popular. In this method, a plurality of peripheral devices are connected to a personal computer by serial communication, and allows plug-and-play (the function of automatically recognizing a connection when a peripheral device is newly connected or disconnected), hot insertion (the function of allowing connection/disconnection while there is power to the system), and the function of supplying power. This method is designed to save the user the trouble of setting addresses and the like in establishing connection.
Connection using a USB requires attachment/detachment of a combination of a total of four wires, called a VBUS, i.e., a 5-V power line, GND line, and two signal lines D+ and D−, by using a dedicated connector. The current value that can be supplied by this power supply is limited. More specifically, this current value is limited to 100 mA to 500 mA according to the USB standards. In addition, with the USB a peripheral device must be set in a suspend state in accordance with an instruction from the host. In this state, current consumption by the VBUS must be as small as 500 μA. A resume instruction is used to restore from a suspend state.
In this case, a connection like the one shown in FIG. 3 is established between the USB and the peripheral devices. With the USB, a plurality of devices can be connected to one host. For them, a tree-like connection is defined, with the host always being at the top of the tree. That is, one host serves as a controller for all the devices, and branches are formed through devices called HUBs, thereby connecting peripheral devices to the host.
The following problems arise in this connection scheme. The following two types of devices are connected to the end portions of the tree: a self-powered device having a power supply unit by itself; and a bus-powered device that has no power supply unit and receives power through a power line included in a communication cable such as a USB.
According to the prior art described above, when a device having a small power capacity, such as a digital camera, serves as a host, and a bus-powered device whose power consumption exceeds the allowable power supply capacity of the host is connected to the host, the host instantaneously fails because power exceeding the allowable capacity is used by the connected device through the host.
The user therefore must connect a bus-powered device to a host upon checking how much power can be supplied from the host to the bus-powered device, and how much power is required for the bus-powered device to be connected.
SUMMARY OF THE INVENTION
The present invention has been made in consideration of the above problems, and has as its object to provide an electronic device which can establish connection between a host and a device to be connected thereto without any problem, a control method for the electronic device, and a storage medium.
In order to solve the above objects and achieve the above object, an electronic device according to the present invention is an electronic device capable of supplying power to a connected device through a connection terminal, comprising: acquisition means for acquiring information about power for the device through the connection terminal upon connection of the device; and restriction means for restricting supply of power to the device when it is determined on the basis of the information acquired by said acquisition means that power consumption of the connected device exceeds power supplied by said electronic device.
The electronic device according to the present invention is characterized by further comprising, switching means for switching between a first mode of allowing power to be supplied to the device with a first current value and a second mode of allowing power to be supplied to the device with a second current value smaller than the first current value, wherein said switching means switches to the second mode when it is determined on the basis of the information acquired by said acquisition means that power consumption of the connected device exceeds power supplied by said electronic device.
The electronic device according to the present invention is characterized by further comprising display means for displaying information indicating that supply of power to the device is restricted, when said restriction means restricts supply of power to the device.
The electronic device according to the present invention is characterized in that, wherein the restriction means does not restrict supply of power to the device when the electronic device is driven by an external power supply.
The electronic device according to the present invention is characterized by further comprising, monitoring means for monitoring a residual capacity of said electronic device, wherein said restriction means restricts supply of power to the device when said monitoring means determines that a power capacity of said electronic device is smaller than a predetermined amount while power is supplied to the device.
The electronic device according to the present invention is characterized in that, wherein the restriction means restricts supply of power to the device in accordance with an operation state of the electronic device while power is supplied to the device.
The electronic device according to the present invention is characterized in that wherein the electronic device is a portable electronic device having a limited power capacity.
The electronic device according to the present invention is characterized in that wherein said electronic device is an image sensing device.
A control method for an electronic device according to the present invention a control method for an electronic device capable of supplying power to a connected device through a connection terminal, comprising: the acquisition step of acquiring information about power for the device through the connection terminal upon connection of the device; and the restriction step of restricting supply of power to the device when it is determined on the basis of the information acquired in the acquisition step that power consumption of the connected device exceeds power supplied by the electronic device.
The control method for the electronic device according to the present invention is characterized by further comprising, the switching step of switching between a first mode of allowing power to be supplied to the device with a first current value and a second mode of allowing power to be supplied to the device with a second current value smaller than the first current value, wherein the switching step comprises switching to the second mode when it is determined on the basis of the information acquired in the acquisition step that power consumption of the connected device exceeds power supplied by the electronic device.
The control method for the electronic device according to the present invention is characterized by further comprising, the display step of displaying information indicating that supply of power to the device is restricted, when supply of power to the device is restricted in the restriction step.
The control method for the electronic device according to the present invention is characterized by further comprising, wherein the restriction step comprises imposing no restriction on supply of power to the device when the electronic device is driven by an external power supply.
The control method for the electronic device according to the present invention is characterized by further comprising, the monitoring step of monitoring a residual capacity of the electronic device, wherein the restriction step comprises restricting supply of power to the device when it is determined in the monitoring step that a power capacity of the electronic device is smaller than a predetermined amount while power is supplied to the device.
The control method for the electronic device according to the present invention is characterized in that, wherein the restriction step comprises restricting supply of power to the device in accordance with an operation state of the electronic device while power is supplied to the device.
A storage medium according to the present invention is a storage medium storing a control program for an electronic device capable of supplying power to a connected device through a connection terminal, the control program comprising: a code for the acquisition step of acquiring information about power for the device through the connection terminal upon connection of the device; and a code for the restriction step of restricting supply of power to the device when it is determined on the basis of the information acquired in the acquisition step that power consumption of the connected device exceeds power supplied by the electronic device.
The storage medium according to the present invention is characterized by further comprising a code for the switching step of switching between a first mode of allowing power to be supplied to the device with a first current value and a second mode of allowing power to be supplied to the device with a second current value smaller than the first current value, wherein the switching step comprises switching to the second mode when it is determined on the basis of the information acquired in the acquisition step that power consumption of the connected device exceeds power supplied by the electronic device.
The storage medium according to the present invention is characterized by further comprising a code for the display step of displaying information indicating that supply of power to the device is restricted, when supply of power to the device is restricted in the restriction step.
The storage medium according to the present invention is characterized in that wherein the restriction step comprises imposing no restriction on supply of power to the device when the electronic device is driven by an external power supply.
The storage medium according to the present invention is characterized by further comprising, a code for the monitoring step of monitoring a residual capacity of the electronic device, wherein the restriction step comprises restricting supply of power to the device when it is determined in the monitoring step that a power capacity of the electronic device is smaller than a predetermined amount while power is supplied to the device.
The storage medium according to the present invention is characterized in that wherein the restriction step comprises restricting supply of power to the device in accordance with an operation state of the electronic device while power is supplied to the device.
Other objects and advantages besides those discussed above shall be apparent to those skilled in the art from the description of a preferred embodiment of the invention which follows. In the description, reference is made to accompanying drawings, which form a part hereof, and which illustrate an example of the invention. Such example, however, is not exhaustive of the various embodiments of the invention, and therefore reference is made to the claims which follow the description for determining the scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a flow chart showing the basic operation of an image sensing device according to an embodiment;
FIG. 2 is a block diagram showing part of the image sensing device according to the embodiment; and
FIG. 3 is a view showing an example of a USB connection tree.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The preferred embodiments of the present invention will be described in detail below with reference to the accompanying drawings.
(First Embodiment)
FIG. 2 is a block diagram showing part of the arrangement of a digital camera which is common to the embodiments of the present invention.
Referring to FIG. 2, reference numerals 21 and 22 respectively denote a USB and a communication/power supply connector, both of which are incorporated in the digital camera and used to communicate with an externally connected device.
In this embodiment, a USB (Universal Serial Bus) scheme is exemplified as a communication scheme. However, the communication scheme is not limited to the USB scheme as long as it is a communication method using a power line for supplying power to a device connected to the communication connector 22 , in addition to data signal lines, in communication with the connected device. For example, a communication scheme like IEEE 1394 can be used without posing any problem. In addition, since a USB communication method is exemplified as a communication method, the communication connector 22 in this case indicates a USB connector. However, this connector is not specifically limited as long as it corresponds to the communication scheme.
Reference numeral 23 denotes a device connection detection unit for detecting that a device is externally connected to the USB connector 22 .
Reference numeral 24 denotes a display unit incorporated in the digital camera. This display unit is not specifically limited as long as the user can recognize its output, e.g., liquid crystal display, blink of an LED, or beeps.
Reference numeral 25 denotes a power supply unit for connecting/disconnecting the digital camera to/from the device externally connected to the USB connector 22 .
Reference numeral 26 denotes a power supply capacity monitoring unit for monitoring power supplied to the device externally connected to the USB connector 22 .
Reference numeral 27 denotes a power monitoring unit for monitoring the power capacity of the power supply incorporated in the digital camera.
Reference numeral 28 denotes a power supply incorporated in the digital camera. This power supply comprises a rechargeable battery pack incorporated in the digital camera and an electrical power intake for taking in an AC power supplied through a wall outlet.
The operation of the first embodiment will be described with reference to FIGS. 1 and 2.
In step S 101 , the digital camera is activated and ready to shoot, or a communication mode with a connected device is selected from several operation modes. In this case, the device connection detection unit 23 always (or at predetermined intervals) detects whether a device is externally connected to the USB connector 22 (step S 102 )
Upon detecting that a device is connected to the USB connector 22 , the device connection detection unit 23 shifts to the operation mode of allowing a maximum current of 100 mA complying with the USB with respect to the connected device in accordance with an instruction from the power supply capacity monitoring unit 26 (step S 103 ).
After the shift to the maximum current (100 mA) operation mode, the device connection detection unit 23 generates a USB device request (step S 104 ). With the USB device request, various basic settings required for USB communication are made with the device connected to the USB connector 22 , e.g., data transfer direction, address settings for the connected device, the configuration of the connected device, and descriptor settings for the device.
With the device descriptors set by the device connection detection unit 23 (step S 105 ), general information about the connected device is loaded from the connected device through the USB connector 22 . For example, this information includes a protocol, USB vendor ID, and the index of a string descriptor representing the manufacturer, product name, and product number of the connected device.
With the configuration descriptors set by the device connection detection unit 23 (step S 106 ), information about power for the connected device is loaded from the connected device through the USB connector 22 . For example, this information includes information indicating whether it is necessary to supply power to the connected device, and the power consumption of the connected device.
If the information about the connected device, obtained by a configuration descriptor, indicates that the connected device is a bus-powered device to which power needs to be supplied from the digital camera through the USB, electric energies are compared as follows.
The power consumption information about the connected device, obtained with a configuration descriptor (step S 106 ) is compared with the allowable power supply amount from the power supply incorporated in the digital camera which is monitored by the power supply capacity monitoring unit 26 to check whether
(1) power consumption of connected device<allowable power supply amount from power supply, or
(2) power consumption of connected device>allowable power supply amount from power supply.
In case (1), power large enough to drive the connected device can be supplied. Therefore, more detailed communication settings are made (step S 108 ) first, and then connection to the connected device is completed (step S 109 ) Thereafter, power is supplied to the connected device (step S 110 ). The digital camera and connected device then start to operate normally (step S 111 ).
If a constant amount of power is always supplied from an AC power supply to the digital camera (USB host), condition (1) is satisfied. If, therefore, the digital camera (USB host) is driven by the AC power supply, connection to the device can be permitted.
In case (2), power large enough to drive the connected device cannot be supplied. In this case, therefore, the power supply unit 25 restricts the supply of power to the device in accordance with an instruction from the power supply capacity monitoring unit 26 . More specifically, the power supply unit 25 stops the supply of power which is started in the previously selected operation mode “maximum current (100 mA) operation mode (step S 103 )” (step S 113 ), and then shifts to a suspend operation mode complying with the USB (step S 114 ). In this suspend operation mode, the current supplied to the connected device is set to a small current value with a maximum current of 500 μA, thereby minimizing the influences on the power supply on the digital camera (USB host) side. Note that in the suspend mode, no power may be supplied to the connected device.
When the operation mode shifts to the suspend operation mode (step S 114 ), an error is displayed on the display unit 24 of the digital camera (step S 115 ), notifying the user that the digital camera cannot be driven by its power supply.
(Second Embodiment)
The operation of the second embodiment will be described with reference to FIGS. 1 and 2.
If condition (1) power consumption of connected device<allowable power supply amount from power supply is satisfied in power comparing operation in the first embodiment, the supply of power to the connected device is permitted, and the flow shifts to normal operation (step S 111 ). This operation has been described in the first embodiment.
In the second embodiment, even after the flow shifts to normal operation (step S 111 ), the digital camera itself keeps monitoring the residual capacity of a power supply 28 through a power monitoring unit 27 .
The digital camera then uses a power supply capacity monitoring unit 26 to check, on the basis of the data of the residual capacity of this power supply, whether sufficient power supplied to the connected device remains.
In this case, if condition (1):
power consumption of connected device<allowable power supply amount from power supply
is satisfied, power is kept supplied to the connected device.
If power is consumed after normal operation (step S 111 ), and condition (2):
power consumption of connected device>allowable power supply amount from power supply
is satisfied, the power supply capacity monitoring unit 26 notifies a device connection detection unit 23 and power supply unit 25 that power cannot be continuously supplied from the power supply of the digital camera to the device. In response to this notification, the device connection detection unit 23 notifies the connected device that the supply of power will be restricted, thus stopping the operation of the connected device. Thereafter, the power supply unit 25 restricts the supply of power to the connected device (step S 113 ). When the supply of power to the device is restricted, the operation shifts to suspend operation (step S 114 ). Error display is then performed on the display unit attached to the digital camera body (step S 115 ) to notify the user that the connected device is disconnected.
(Third Embodiment)
The operation of the third embodiment of the present invention will be described with reference to FIGS. 1 and 2.
When power is supplied to the bus-powered device shown in FIG. 1 to make it operate normally (step S 111 ), the digital camera may perform operation which demands large power, e.g., shooting. In this case, the digital camera system may temporarily become unstable due to a drop in power. In order to prevent such a problem, in this embodiment, when a power supply capacity monitoring unit 26 determines that the digital camera requires large power, a power supply unit 25 temporarily restricts the supply of power to the bus-powered device, as needed.
In addition, if, for example, it is known in advance that large power is required, the supply of power to the bus-powered device is prohibited in accordance with the operation mode of the digital camera.
Obviously, the objects of the embodiments can also be achieved by providing a storage medium (or recording medium) storing program codes for implementing the functions of the above embodiments to a system or apparatus, reading the program codes, by a computer (CPU or MPU) of the system or apparatus, from the storage medium, then executing the program. In this case, the program codes read from the storage medium realize the functions according to the embodiments, and a storage medium storing the program codes constitutes the invention. Furthermore, besides above functions according to the above embodiments are realized by executing the program codes which are read by a computer, the present invention includes a case where an OS (operating system) or the like running on the computer performs a part or entire process in accordance with designations of the program codes and realizes functions according to the above embodiments.
Furthermore, the present invention also includes a case where, after the program codes read from the storage medium are written in a function expansion card which is inserted into the computer or in a memory provided in a function expansion unit which is connected to the computer, CPU or the like contained in the function expansion card or unit performs a part or entire process in accordance with designations of the program codes and realizes functions of the above embodiments.
When each embodiment is to be applied to the above storage medium, program codes corresponding to the flow chart described above (FIG. 1) are stored in the storage medium.
In the above embodiments described above, the image sensing device has been exemplified. However, the embodiments are not limited to the image sensing device and can be widely applied to other various electronic devices that can supply power to other devices. In this case, the embodiments can be suitably applied to devices having limited power capacities such as portable electronic devices, in particular.
As has been described above, according to the embodiments, when a device having a small power capacity, e.g., an image sensing device, is a USB host, and a bus-powered device whose power consumption exceeds the allowable power supply amount of the host is connected to it, the supply of power to the connected device is rejected. This makes it possible to prevent both the device that supplies power and the device that receives power from failing. In addition, a warning about the rejection of connection to the device can be given to the user by using the display unit.
While power is supplied to a connected device by using the internal power supply of a device having a small power capacity, e.g., an image sensing device, power large enough to drive the connected device may not be ensured because of a drop in power level of the internal power supply. In such a case, the display unit or the like is used to warn the user that power large enough to drive the connected device cannot be ensured. The user can respond to such a situation by, for example, switching the power supply to an AC power supply before operation failures occur.
Necessary power can always be ensured by stopping the supply of power to a bus-powered device, as needed, in accordance with the operation mode of the image sensing device or the necessity to use large power as in shooting.
This makes it possible to stabilize a system in operation in which a bus-powered device is connected to a device having a small power capacity, e.g., an image sensing device.
The present invention is not limited to the above embodiments and various changes and modifications can be made within the spirit and scope of the present invention. Therefore, to apprise the public of the scope of the present invention the following claims are made.
|
An object of this invention is to provide an electronic device which can establish connection between a host and a device to be connected thereto without any problem. In order to achieve this object, when a device whose power consumption exceeds the allowable power supply capacity of an electronic device which can supply power to the connected device through a connection terminal is connected to the electronic device, the supply of power to the device is restricted.
| 7
|
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation of U.S. patent application Ser. No. 09/486,901, filed on May 19, 2001, now U.S. Pat. No. 6,591,471, which is the National Stage of International Application No. PCT/GB98/02582, filed on Sep. 2, 1998, and published under PCT Article 21(2) in English. The aforementioned related patent applications are herein incorporated by reference in their entirety.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a method and apparatus for aligning tubulars.
2. Description of the Related Art
During the construction, repair and maintenance of oil and gas wells it is necessary to connect a plurality of tubulars. Conventionally this is achieved via screwed connections.
In order to screw the tubulars together it is usual to hold a lower tubular having an upwardly facing socket in slips in the rig floor. The downwardly extending pin of the next tubular is then aligned with the socket. The tubular is then lowered into position and the upper tubular rotated to the desired torque to make the connection.
It is important that the pin should be correctly aligned with the socket prior to lowering the upper tubular since, if this is not the case, the tubular being lowered can damage the thread of the socket which can prevent satisfactory connection.
One known apparatus for aligning tubulars comprises a positioning head which is mounted on a telescopic arm which can be hydraulically extended and retracted and pivoted in a horizontal plane to position the tubular.
This apparatus is actuated remotely by a skilled operator who has a control panel with a joystick. This apparatus is very satisfactory. However, time is critical in the oil and gas industry and even a few seconds saved in each connecting operation can amount to a very significant overall cost saving.
SUMMARY OF THE INVENTION
With this in mind the present invention provides a method for aligning tubulars, which method comprises the steps of:
a) securing a lower tubular in slips; b) aligning an upper tubular with said lower tubular with a remotely actuable apparatus; c) memorising the position of said stabbing guide when said upper tubular is aligned with said lower tubular; d) connecting said upper tubular and said lower tubular; e) releasing said slips; f) lowering said upper tubular and said lower tubular; g) securing said upper tubular in said slips; h) gripping a tubular to be connected to said upper tubular in said apparatus; i) causing said apparatus to move said tubular to said memorized position; j) adjusting the position of said tubular, if necessary; and k) connecting said tubular to said upper tubular.
The ability to automatically bring a tubular to its previous optimum position can save seconds on making each connection. Furthermore, it is not unknown for a tired operator to lower a tubular inappropriately with damage resulting to both the pin of the tubular being lowered and the socket of the tubular in the slips. The present invention reduces the probability of this happening with true tubulars where the alignment positions of each tubular will be approximately the same.
Whilst new tubulars are relatively straight this is often not the case for old and rental tubulars which may have been used on multiple occasions and rethreaded and/or shortened due to previous damage. It will be appreciated that although the position of the socket of the tubular in the slips may be reasonably constant the position of the apparatus may have to be varied significantly to ensure alignment of the pin and socket. In these cases the method of the invention is less advantageous although it does provide a first approximation to moving the tubular to the desired position.
Step (c) may be carried out before step (d) or after step (d). Furthermore, the threads of the upper tubular and the lower tubular may be partially made up before step (c) and then fully made up after step (c), i.e. step (c) may be carried out part way through step (d).
Preferably, the memorized position can be adjusted where desired. This may be appropriate if the initial position was memorized using a tubular which was not true.
The present invention also provides an apparatus for aligning tubulars, which apparatus comprises a remotely controllable head adapted to guide a tubular, characterised in that said apparatus is provided with sensing means responsive to the position of said head, means to memorise a position of said head, and means operative to return said head to said operative position.
Preferably, said apparatus comprises a telescopic arm which supports said head.
Advantageously, said sensing means comprises a linear transducer which is associated with said telescopic arm.
Preferably, said linear transducer forms part of a piston-and-cylinder which is used to extend and retract said telescopic arm.
Advantageously, said telescopic arm is mounted on a rotor which is pivotally mounted on a base.
Preferably, said rotor is pivotable by expansion and retraction of a piston-and-cylinder assembly mounted on said base.
Advantageously, said sensing means comprises a linear transducer which is a associated with said piston-and-cylinder assembly.
Preferably, said linear transducer forms part of said piston-and-cylinder assembly.
Advantageously, said telescopic arm is movable between an operative position in which it is generally horizontal and an inoperative position in which it extends upwardly, preferably vertically.
Preferably, said apparatus further comprises a remote control console having a “memory” button which, when actuated, will memorise the position of said head and a “recall” button which, when actuated, will return said head to its memorized position.
BRIEF DESCRIPTION OF THE DRAWINGS
For a better understanding of the present invention reference will now be made, by way of example, to the accompanying drawings, in which:
FIG. 1 is a side elevation, with part cut-away, of one embodiment of an apparatus in accordance with the present invention, and
FIG. 2 is a plan view of the apparatus shown in FIG. 1 .
DETAILED DESCRIPTION
Referring to the drawings, there is shown a apparatus for aligning tubulars which is generally identified by reference numeral 101 . The apparatus 101 comprises a base 103 which can be conveniently be bolted to a derrick where required.
A rotor 104 is rotatably mounted on said base 103 and can be pivoted with respect to the base 103 by extension and retraction of the piston 105 of a piston-and-cylinder assembly 106 which is mounted fast on the base 103 .
Two ears 107 extend upwardly from the rotor 104 and support a pivot pin 108 on which is mounted a telescopic arm 109 . The telescopic arm 109 comprises a first box section 110 and a second box section 111 which is slidably mounted in the first box section 110 . A head 112 is mounted on the end of the second box section 111 and can be opened to allow the entry of a tubular into opening 113 . The head 112 comprises two arms 114 , 115 each of which is provided with two centering devices 116 , 117 , 118 , 119 which can be moved radially inwardly and outwardly according to the diameter of the tubular to be accommodated. As can be better seen in FIG. 2 , each arm 114 , 115 is pivoted on a respective pin 120 , 121 and is provided with a respective pin 122 , 123 which can travel within respective arcuate slots 124 , 125 in a transverse member 126 .
The arms 114 , 115 can be opened and closed by a small hydraulic actuator 134 disposed beneath the transverse member 126 .
The transverse member 126 is connected to a crossmember 127 which is connected to the piston 128 of a hydraulic piston-and-cylinder assembly 129 , the other end of which is connected to the first box section 110 over the rotational axis of the rotor 104 .
A valve assembly 130 is mounted on the base 103 and is operable from a remote console to direct hydraulic fluid to and from the piston-and-cylinder assembly 106 , the piston-and-cylinder assembly 129 , the hydraulic actuator 134 for opening and closing the arms 114 , 115 , and a piston-and-cylinder assembly 131 which acts between a fitting 132 on the first box section 110 and a fitting 133 on the rotor 104 . Extension of the piston-and-cylinder assembly 131 displaces the telescopic arm 109 into an inoperative, upwardly extending position, whilst contraction of the piston-and-cylinder assembly 131 moves the telescopic arm 109 to its operative, horizontal, position.
In use, the valve assembly 130 is controlled from a remote console which is provided with a joystick which is spring biased to a central (neutral) position. When the operator displaces the joystick the valve assembly 130 controls the flow of hydraulic fluid to the appropriate piston-and-cylinder assemblies. As soon as the joystick is released the head 112 stops in the position which it has obtained.
The description thus far relates to Applicants existing apparatus.
The present invention differs from the aforedescribed apparatus in that the apparatus 101 includes sensing devices for sensing the position of the head 112 . In particular, a linear transducer, for example as sold by Rota Engineering Limited of Bury, Manchester, England, is incorporated in both the piston-and-cylinder assembly 129 and the piston-and-cylinder assembly 106 . The linear transducers provide a signal indicative of the extension of both the respective piston-and-cylinder assemblies 106 , 129 which is transmitted to the operator's console.
At the commencement of a running operation the telescopic arm 109 is lowered into a horizontal position by contracting piston-and-cylinder assembly 131 . The arms 114 and 115 are then opened and the head 112 maneuvered so that the arms 114 and 115 lie around the tubular to be positioned. The arms 114 and 115 are then closed.
The tubular is then maneuvered into position above and in alignment with a lower tubular held in slips. The tubular is then lowered so that the pin enters the socket and the joint is then made up in the usual manner. When the tubular is in this position the operator presses a button marked “memorise” on his console.
After the slips have been released the tubulars are lowered down the borehole and the slips re-set. The next tubular is then in the proximity of the well centre, either being suspended from an elevator or ready for collection from a magazine mounted on the rig floor.
In either event the apparatus 101 is actuated so that the head 112 encircles and grips the new tubular. However, at this time the operator simply presses a button on his console marked “recall”. The telescopic arm 109 then immediately moves to the memorized position, this being achieved by a control system (not shown) which displaces the piston-and-cylinder assembly 129 and the piston-and-cylinder assembly 106 until the signals from their respective linear transducers equal the signals memorized. The operator then checks the alignment of the tubulars. If they are correctly aligned the upper tubular can be lowered and the tubulars secured together. If they are not correctly aligned the operator can make the necessary correction by moving the joystick on his console. When the tubulars are correctly aligned the operator can, if he chooses, update the memorized position. However, he may omit this if he believes that the deviation is due to the tubular not being straight.
Various modifications to the embodiment described are envisaged. For example if the tubulars are to be collected from a fixed point the operator's console may have a button for memorising the collection area. This may be particularly appropriate if the tubulars are stored on a rotating magazine alongside the slips. In this case, the collection of the tubular and its positioning ready for stabbing can be very highly automated with only minimal visual verification.
Whereas the position of the head is preferably memorized electronically it could also be memorized mechanically or optically.
The apparatus 101 described is designed so that head 112 merely guides the tubular being stabbed with the weight of the tubular being supported by an elevator or similar device. However, it would be possible to construct the apparatus 101 to take the entire weight of the tubular. In this case it would be desirable to include a device for raising and lowering the tubular to facilitate the stabbing operation and, optionally, modifying the head 112 to allow rotation of the tubular whilst inhibiting vertical movement. Vertical adjustment could conveniently be provided by hydraulic cylinders between the base 103 and the rig floor or the derrick on which the apparatus 101 is mounted.
If desired the centering devices 116 , 117 , 118 and 119 could be remotely adjustable to accommodate tubulars of different sizes. Such an arrangement might also include sensors to report the positions of the centering devices.
In practice it is known that certain operators appear to have a gift for making successful connections quickly and efficiently. On observing these operators it can be seen that they apply extremely personal complex motions to the upper tubular as it is being inserted into the socket. A second aspect of the present invention contemplates recording these motions via the sensing means and reproducing these motions during a subsequent connecting operation. This procedure may be applied in conjunction with or completely separate and distinct from the method of aligning tubulars herein before described.
While the foregoing is directed to embodiments of the present invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof, and the scope thereof is determined by the claims that follow.
|
An apparatus is provided with position sensors. When the apparatus has moved one tubular into alignment with another tubular a button on a remote control console is pressed to memorize the position. After the next tubular has been gripped by the apparatus a “recall” button is pressed and the apparatus automatically moves the next tubular to the memorized position. This saves vital seconds in joining tubulars and also reduces the likelihood of threads being damaged due to misalignment of the tubulars.
| 4
|
BACKGROUND OF THE INVENTION
The present invention relates to latch assemblies and more particularly to an adjustable retention latch assembly used to provide temporary retention and alignment of a heavy object, such as an aircraft door, that is to be secured with fasteners.
Many aircraft doors have relatively severe curvatures and are hinged at one end so that the door may be opened and closed with a swinging motion away from or toward the end that is not hinged. The door is secured using threaded panel fasteners inserted through holes in the door panel which threadably engage nuts mounted on the frame to which the door is attached. It is highly desirable to align the holes in the door with their respective nuts before attempting to secure the panel fasteners to avoid damaging the threads of the fasteners. Likewise, maintaining alignment of the door panel is preferred when unfastening it to minimize damaging or even breaking the panel fasteners. The possibility of damage is enhanced if the door panels are heavy. Typically, workman attempts to align the holes in the door panel with their respective nuts by holding the door in position with one hand while securing the panel fasteners with the other. When such a door is quite heavy or if there is a seal between the door and the frame, as is often the case, alignment is extremely difficult and quite often impossible. The difficulty encountered is even greater if the door is positioned in such a manner as to be swung open toward the ground. In order to secure or remove the fasteners, the door must be held in an upward position against the force of gravity. This is often the case with aircraft doors placed on the underside of aircraft.
The adjustable retention latch assembly of the present invention solves the foregoing problems by providing a means for aligning the holes in the door panel with their respective receptacles or nuts, and retaining the door in such aligned position, thereby freeing the hands of a workman to install or remove the threaded panel fasteners without damaging the fasteners or harming himself due to the weight of the swinging door.
SUMMARY OF THE INVENTION
The adjustable retention latch assembly of the present invention includes a striker and a hook mechanism. The striker, comprising a crosspin positioned in an adjustable mounting, is attached to the frame of an aircraft near the opening to be closed by a door. The mounting preferably has slotted holes to provide flexibility in positioning the striker relative to the hook mechanism for gross door adjustment.
The hook mechanism comprises a hook for engagement with the striker mounted on a bracket to provide pivotal movement of the hook toward or away from the striker. The hook mechanism also includes a spring biasing the hook toward the striker. There is also provided a slide for urging the hook mechanism toward or away from the striker mounted on the bracket and connected to the hook. An adjustment means is connected to the bracket and engages the slide to move the slide in response to its operation.
The adjustment means disclosed herein, includes a camming means comprising a rotatable cylinder on the underside of the slide with an eccentric portion extending through a slot in the slide. The slide and the hook can be moved toward or away from the striker by rotating the cylinder with a tool inserted in a receptacle in the cylinder from the underside of the hook mechanism accessible from the exterior of the door onto which the bracket is mounted.
The adjustable retention latch assembly also preferably includes a locking means for restricting movement of the cylinder to prevent unintentional slipping of the hook mechanism. The locking means shown comprises two spherical balls positioned in a transverse bore in the cylinder. The balls are urged outwardly by a spring positioned between the balls to frictionally engage the bracket thereby preventing unintentional movement of the cylinder.
It will be noted that gross alignment and retention of the door panel is accomplished by engagement of the hook with the striker and final alignment of the holes in the door with their respective nuts attached to the frame is accomplished by appropriately adjusting the camming means to urge the hook mechanism away from the striker after the hook has been engaged to draw the door and frame together.
In the accompanying drawings:
FIG. 1 is a side elevational view of the hook mechanism of the present invention attached to a door panel.
FIG. 2 is a plan view of the hook mechanism of FIG. 1.
FIG. 3 is a rear view of the hook mechanism of FIG. 1.
FIG. 4 is a view showing the underside of the hook mechanism of the present invention as seen from the exterior of the door panel on which it is mounted.
FIG. 5 is a side elevational view of the adjustable retention latch assembly of the present invention including the striker.
FIG. 6 is a side elevational view of the adjustable retention latch assembly of FIG. 5 with the hook engaging the striker prior to final alignment with a camming tool.
FIG. 7 is a side elevational view of the adjustable retention latch assembly of the present invention after final alignment has been made and the camming tool is removed.
FIG. 8 is a side elevational view of the adjustable retention latch assembly constructed according to the principles of the present invention showing the camming tool used to disengage the hook mechanism to open the door panel.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIGS. 1-4, there is shown a hook mechanism 10 constructed in accordance with the principles of the present invention. The hook mechanism 10 is shown attached to an aircraft door panel 12 although, as previously stated, it is to be understood that the present invention may be utilized with other types of panels.
The hook mechanism 10 comprises a bracket 14 with mounting holes 15 in its base through which rivets 16 or other means may be inserted to attach the bracket 14 to the panel 12. Typically the hook mechanism 10 is located on the panel 12 near the edge to be secured, i.e. the edge which is farthest from the panel door hinges. The bracket 14 has first and second crosspin 17, 18 positioned at the forward and rear portions of the bracket 14. The holes 19, 20 in the bracket 14 through which the crosspins 17, 18 pass are elongated to allow movement of the slide 21 relative to the bracket 14 as will be further discussed.
A hook 23 is loosely connected to the forward edge of the bracket 14 by attaching it to the first crosspin 17 to provide relative ease of motion of the hook 23 on the crosspin 17. There is also a spring 24 located on the bracket 14 which biases the hook 23 away from the bracket 14 and toward a striker. One tail 25 of the coil spring 24 shown rests on the hook 23 while the other tail 26 is supported by the slide 21 that is also connected to the crosspins 17, 18 mounted on the bracket 14 and capable of moving relative to the bracket 14.
As is best seen in FIG. 3, the slide 21 comprises an inverted generally U-shaped member located on the upper portion of the bracket 14. In the upper surface of the slide there is an elongated slot 22 through which passes the protruding portion 28 of a cylindrical member 27 also connected to the bracket 14.
The cylindrical member 27 is part of the camming means employed to move the slide 21 relative to the bracket 14. The cylindrical member 27 is generally centrally located in the bracket 14 extending beneath the bracket 14 a sufficient amount to also fit into an appropriately located hole 52 in the door panel 12 so that access to the drive slot 32 in the cylindrical member 27 may be achieved from outside the panel 12 with an appropriate tool.
The cylindrical member 27 has a transverse bore 29 in which are located two spherical members 30 separated and urged outwardly by a spring 31 to provide a means for maintaining the position of the cylindrical member 27 thereby restricting unintentional rotation of it. As shown in FIG. 3 portions of the spherical members 30 are in frictional engagement with the bracket 14 to provide the restriction of rotation.
The hook mechanism 10 is adapted to engage a striker 33 mounted on the frame 38 to which the panel 12 is secured. The striker 33 shown in FIGS. 5-8 includes a crosspin 34 for engagement by the hook 23 which is connected to a bracket 14 with cotter pins 36 in a conventional manner. The mounting holes 37 in the striker bracket 35 are preferably elongated to form slots 37 that allow displacement of the striker 33 relative to the hook 23 for facilitating installation of the latch assembly 10 by providing a means for gross adjustment of the assembly 10. The striker bracket 35 may be attached to the frame 38 in any conventional manner such as the bolt 39 and nut 40 shown.
Also mounted on the frame 38 is a nut 41 to which the fastener 42 is secured. It is often desirable to provide a retainer ring 43 on the fastener 42 to prevent total removal of the fastener 42 from the panel 12. In the embodiment shown there is also a seal 44 attached to the panel 12 which is sometimes used to provide a tighter fit between the panel 12 and frame 38.
In order to secure the fastener 42, the panel 12 is typically pushed by hand toward the frame 38. As shown in FIG. 5, when this occurs, the hook 23 contacts the striker 33 and slides along it, as represented by the phantom line 50, until the hook 23 rides over the striker 33 to retain the panel 12 in the position as shown in FIG. 6. It is to be noted that the hook 23 provides retention of the panel 12 to allow further alignment of the fastener 42 in the panel 12 and the nut 41 in the frame 38. At this point, both of a workman's hands are available to align and then secure the fastener 42.
Once the hook 23 engages the striker 33, alignment of the fastener 42 and its associated nut 41 is accomplished by operation of the camming means. In the embodiment shown, the cylindrical member 27 has a conventional hex hole 32 into which a standard tool, such as an allen wrench 53, can be positioned to operate the camming means. It should be noted, however, that other forms of slots could be used in conjunction with other tools without departing from the principles of the present invention. Final alignment is provided by rotating the cylindrical member 27 thereby moving the slide 21 along the bracket 14 in an attempt to move the hook 23 away from the striker 33. Since the hook 23 is in engagement with the striker 33, the frame 38 and panel 12 will be drawn together to properly align the fastener 42 and nut 41. When alignment is achieved, it is maintained by frictional engagement of the outwardly disposed spherical members 30 with the bracket 14 preventing rotation of the cylindrical member 27 and therefore movement of the hook mechanism 10, so the fastener 42 can be secured without damaging it or the nut 41.
Similarly, the panel door 12 may be opened by first loosening the fasteners 42 while the hook mechanism 10 holds the panel 12 in place allowing all fasteners 42 to be loosened without damaging them and without requiring a workman to hold the panel 12 in place. After all fasteners 42 are loosened and retracted, door panel 12 is moved away from frame 38 by rotating cylindrical member 27 with tool 53. The workman, while supporting the panel 12, can then disengage the hooks 23 by inserting the tool 53 in the panel hole 51 under the hook 23 as shown in FIG. 8 and then open the door panel 12.
While the adjustable retention latch assembly of the present invention has been described with reference to the particular embodiment disclosed herein, changes and variations may be made by those skilled in the art without departing from the scope of the invention as defined by the following claims:
|
A latch assembly for aligning the holes in a panel and a frame such as those used in aircraft doors. The assembly includes a hook for engagement with a striker to retain the panel and a sliding hook mechanism to align the holes. The sliding hook mechanism is operated by a camming means to urge the hook toward or away from the striker to bring the holes into alignment thereby preventing damage to the fastener and freeing both hands of a workman to secure or release the fasteners.
| 4
|
CROSS-REFERENCE TO RELATED APPLICATIONS
The present application is a continuation of U.S. patent application Ser. No. 12/796,165, filed Jun. 8, 2010, which is a divisional of U.S. patent application Ser. No. 11/560,187, filed Nov. 15, 2006, which is a continuation-in part of U.S. patent application Ser. No. 10/772,964 filed Feb. 4, 2004, which claims priority to European Patent Application No. 03025769.5, filed Nov. 11, 2003. The contents of each of the foregoing applications are hereby incorporated by reference in their entirety.
FIELD OF THE INVENTION
The invention relates generally to a formulation for the controlled release of hormones to the systemic circulation and/or to the brain (by bypassing the blood-brain barrier) after nasal application and for the modulation of brain functioning. More specifically, the invention relates to the treatment of neuroendocrinologic disorders, such as Female Sexual Disorder (FSD) by nasally administering a formulation comprising a hormone drug.
BACKGROUND
A growing body of evidence suggests a modulatory role of brain-acting compounds, such as neurosteroids (e.g., androgens, progestins) or neurotransmitters in the regulation of disorders influenced by receptors in the brain, such as depression, Parkinson's disease, Alzheimer's, or even loss of libido.
Considerable importance has been placed on the measurement of receptor concentrations in the brain. However, the underlying mechanisms of action are still poorly understood. Much of the confusion about the wide range of effects and side effects is due to various non-genomic actions. Tissues traditionally considered non-targets for clinical action are today found to be vividly regulated by non-genomic mechanisms.
Generally, genomic actions are typically due to compounds binding to intracellular receptors, traveling to the nucleus of the cell, and binding to DNA to initiate expression of various proteins. These various proteins exert a wide range of effects. The compounds may also induce transcription-independent signaling, thus modulating non-genomic responses. These second messenger pathways involve kinase pathways, including ion flux as well as cAMP or lipase. In contrast to the genomic effects, most of the non-genomic effects are immediate.
Thus, the mechanisms mediating the effects of a molecule can be both genomic and non-genomic. The clinical relevance of the genomic effects often is understood. However, there is very little knowledge of the possible differential relevance of a molecule's non-genomic actions in different cell types. It is hypothesized that non-genomic signaling mechanisms might be more of a pharmacological phenomenon. At the very best, these can be influenced by the way a molecule is administered.
Nasal drug delivery offers many advantages that include rapid adsorption due to the abundant presence of capillary vessels in the nose, fast onset of action, avoidance of hepatic first-pass metabolism, utility for chronic medication, and ease of administration. It is also known that, in contrast to large and/or ionized molecules, lipophilic pharmaceutical compounds having a sufficiently low molecular weight generally are readily absorbed by the mucous membrane of the nose. For such drugs, it is possible to obtain pharmacokinetic profiles similar to those obtained after intravenous injection.
However, maintaining constant in vivo therapeutic drug concentrations for an extended period of time has been problematic. The rapid mucociliary clearance of a therapeutic agent from the site of deposition and the presence of enzymes in the nasal cavity (that may cause degradation of the therapeutic agent) result in a short time span available for absorption.
Many efforts have been made in the art in attempt to overcome these limitations. GB 1987000012176 describes the use of bioadhesive microspheres to increase residence time in the nasal cavity. It has also been found that the use of enhancers improves permeability of the nasal membrane and stabilizers prevent drug degradation. PCT/GB98/01147 (U.S. Pat. No. 6,432,440) describes the use of in situ gelling pectin formulations.
Investigations on the nasal absorption of sexual steroids, which are rather small and lipophilic compounds, have shown that sexual steroids are readily absorbed by the mucous membrane of the nose and are found very quickly in serum. Due to this fact, the short half-life of sexual steroids, and the limited possibilities for formulating nasal application forms with sustained release, the use of sexual steroids in clinical practice has been limited because hormone replacement therapy, in general, is a long-term application.
Several formulations have been proposed for sexual steroid drugs. Testosterone is nearly water-insoluble and somewhat more soluble in vegetable oil. Hussain et al., J. Pharm. Sci. 91(3): 785-789 (2002), concluded that testosterone would be an ideal candidate for nasal administration if its solubility in water could be increased. Hussain et al. proposed using a water-soluble pro-drug, testosterone 17β-N,N-dimethylglycinate, and found serum levels equal to intravenous administration with peak plasma concentrations within twelve minutes (25 mg dose) and twenty minutes (50 mg dose) and elimination half-lives of about fifty-five minutes. It should be noted, however, that this speed is not necessary or desirable because sex hormone replacement is not an emergency therapy.
Ko et al., J. Microencaps., 15(2): 197-205 (1998), proposed the use of charged testosterone submicron O/W emulsion formulations (water/Tween80, soybean oil/Span80) based on the hypothesis that increased absorption is possible upon solubilization of the drug and/or prolongation of the formulation residence time in the nose. Ko et al. found higher relative bioavailability for the positively (55%) and negatively (51%) charged emulsions compared to the neutral one (37%). T max was observed in every case at about twenty minutes after administration. However, because Ko et al. did not take blood samples before application, it is not possible to evaluate the differences in the decrease of serum levels, although from a graph it seems that after intravenous application (hydroalcoholic solution) the level shows the longest elimination half time. In practice, however, such an emulsion is not suitable for nasal application because of the droplet size (approximately 430 nm).
The solubility of progesterone in water and oil is somewhat comparable to that of testosterone but investigators have taken different approaches. It has been that progesterone dissolved in almond oil (20 mg/ml) and administered by nasal spray lead to higher bioavailability than that provided by progesterone dissolved in dimethicone or a PEG-based ointment (Fertil Steril 56(1): 139-141 (1991); Maturitas 13(4): 313-317 (1991); Gynecol Endocrinol 6(4): 247-251 (1992); Fertil Steril, 60(6): 1020-1024 (1993); and Maturitas 19(1): 43-52 (1994)).
After nasal application of progesterone in almond oil, C max levels were observed after thirty to sixty minutes, decreasing significantly six to eight hours after a single administration. Steege et al., Fertil Steril, 46(4): 727-729 (1986), dissolved progesterone in polyethylene glycol (200 mg/ml) and found T max at thirty minutes. The duration of serum levels was at least eight hours but with high variations. When progesterone was formulated in ethanol/propylene glycol/water, however, T max was at only 5.5 minutes (Kumar et al, Proc. Natl. Acad. Sci. U.S.A., 79: 4185-9 (1982)). Provasi et al., Boll. Chim. Farm. 132(10): 402-404 (1993), investigated powder mixtures (co-ground and co-lyophilized progesterone/cyclodextrin) containing progesterone. Provasi et al. found T max at within two to five minutes with serum levels decreasing after only twenty minutes.
The results for progesterone described above are quite similar to that found for testosterone and for an already marketed aqueous nasal spray containing estradiol, formulated in cyclodextrin (commercially available as AERODIOL® from Servier Laboratories, France). Maximum plasma levels are reached within ten to thirty minutes and decrease to 10% of the peak value after two hours. Again, this speed is not necessary for sex hormone replacement therapy and is not desirable in view of the short elimination half-life of hormones.
Apart from the “liberation/adsorption” problem shown above in connection with sexual hormones and bioavailability, the focus of research has centered on the crucial liver metabolism and the short half-life of the compounds. However, high protein-binding also presents a problem because only the unbound fraction is biologically active. Approximately 40% of circulating plasma testosterone binds to sex hormone binding globulin (SHBG)—2% in men and up to 3% in women remains unbound (free)—and the remainder binds to albumin and other proteins. The fraction bound to albumin dissociates easily and is presumed to be biologically active, whereas the SHBG fraction is not. It should be noted that the amount of SHBG in plasma determines the distribution of testosterone in free and bound forms, whereas free testosterone concentrations determine (limit) the drug's half-life.
Additional research has shown that pharmacokinetics (and the resulting efficacy) may be determined by the route of testosterone administration. Previous research has shown that sublingual application of testosterone undecanoate results in a very fast and high testosterone peak that triggers sexual arousal. Apperloo et al., J Sex Med, 3:541-549 (2006), recently found that a single dose of a vaginally-applied testosterone propionate results in a slower rising and lower testosterone peak that does not trigger sexual arousal. Apperloo et al. found an acute and prolonged rise in testosterone and free testosterone above physiological levels with a peak at 5.5 hours is not sufficient to influence the female sexual response. Recently, it was hypothesized that some effects of hormones are typically mediated by their neurobiological activity. Thus, these application forms probably lack a sufficient CNS effect. In order to achieve a corresponding efficacy, the therapeutic agent has to cross the blood-brain barrier. The therapeutic agent, however, not only has to cross the blood-brain barrier in a certain concentration, it additionally has to stay in the brain long enough to exert its desired action.
Accordingly, there has remained a need for a sexual hormone drug formulation system that is therapeutically effective when administered to the nose of a patient and is safe, stable and easily manufactured.
SUMMARY OF THE INVENTION
The inventor has surprisingly found that the incorporation of various hormone drugs, such as sexual hormones, into a special lipophilic or partly lipophilic system not only leads to a higher bioavailability in general caused by sustained serum levels in plasma but also to a more favorable serum level profile. In an especially important aspect, the lipophilic or partly lipohilic system of the invention allows hormones to cross the blood-brain-barrier in such a way as to achieve efficacy in medicines for disorders of the central nervous system (CNS).
The invention comprises a formulation for nasal application comprising: (a) at least one active ingredient; (b) at least one lipophilic or partly lipophilic carrier; and (c) a compound or a mixture of compounds having surface tension decreasing activity in an amount effective for in situ generation of an emulsion upon contact of the formulation with water.
While not wishing to be bound by theory, it is believed that nasal administration of the formulation of the invention may be able to recruit selective actions of a molecule which, in turn, may provide new clinical applications. Of particular interest is the use of formulations to modulate brain functioning. Application of the formulation of the invention to the nose results in surprising and different action of compounds to the brain as compared to what is seen with conventional formulations. While not wishing to be bound by theory, it is believed that this effect is due to new, possibly also non-genomic, mechanisms that are made available by the gel formulation of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a comparison of DHT levels after application of different doses of testosterone as a dermal or nasal gel to hypogonadal men.
FIG. 2 shows the serum levels of free testosterone at baseline and after nasal application of testosterone.
FIG. 3 shows the effect of a single nasal dose of 0.9 mg testosterone in women.
FIG. 4 shows the fMRI data indicating the brain response to emotional faces after nasal administration of testosterone.
FIG. 5 shows the fMRI data indicating the brain response to emotional faces after nasal administration of placebo.
FIG. 6 shows the serum concentration of testosterone in women over time during fMRI.
FIG. 7 Percentage (±SEM) of frequency of Eyebrow Raising (A), Chest Rubbing (B), Masturbation (C), Head Cocking (D) and Mutual Gaze (E), measured by instantaneous sampling in the different phases (Baseline, Treatment 1, Wash Out, Treatment 2) for the Group 1 (G1: Placebo-Noseafix) and Group 2 (G2: Noseafix-Placebo). *p<0.05 vs. baseline.
FIG. 8 Percentage (±SEM) of frequency in the Baseline (A), Treatment 1 (B), Wash Out (C) and Treatment 2 (D), of behaviors measured by instantaneous sampling (Eyebrow Raising, Chest Rubbing, Masturbation, Head Cocking and Mutual Gaze). For Group 1 (G1: Placebo-Noseafix) and Group 2 (G2: Noseafix-Placebo). *p<0.05 vs. Placebo.
FIG. 9 Percentage (±SEM) of observation time of grooming (A), courtship (B) and agonistic behavior (C), measured by continuous recording in different phase (Baseline, Treatment 1, Wash Out, Treatment 2) for the Group 1 (G1: Placebo-Noseafix) and Group 2 (G2: Noseafix-Placebo). *p<0.05 vs. Baseline, Treatment 1 and Wash Out. The total Observation Time was: 224 minutes for Baseline and 140 minutes for each Treatment and Wash Out phase.
FIG. 10 Percentage (±SEM) of observation time in Baseline (A), Treatment 1 (B), Wash Out (C) and Treatment 2(D), of grooming, courtship and agonistic behavior, measured by continuous recording for Group 1 (G1: Placebo-Noseafix) and Group 2 (G2: Noseafix-Placebo). *p.<0.05 vs. Placebo. The total Observation Time was: 224 minutes for Baseline and 140 minutes for each Treatment and Wash Out phase.
FIG. 11 shows the plasma testosterone levels in different phases of the study for the animals treated with placebo and the product Noseafix.
DETAILED DESCRIPTION OF THE INVENTION
The formulation of the invention is chemically and physically stable and can be in the form of a suspension or a solution of the pharmacologically active substance. The formulation of the invention may be filled into a preservative-free device able to accurately deliver doses of the above formulation, even at higher viscosities.
After nasal application of the formulation of the invention, the active ingredient or active ingredient particles are efficiently trapped at the deposition site and are absorbed at a predictable rate across the mucous membrane of the patient, thereby limiting possible deactivation by metabolizing enzymes and/or protein-binding.
It will also be understood that the terms and expressions used herein have the ordinary meaning as is accorded to such terms and expressions with respect to their corresponding respective areas of inquiry and study except where specific meanings have otherwise been set forth herein.
The term “higher availability” shall mean that after a single application a serum level of hormone significantly higher than baseline is maintained for six hours, more preferably for eight hours and most preferably for at least ten hours. The term “higher availability” shall also mean that, after a single application, a cerebral spinal fluid (CSF) level significantly higher than baseline can be achieved and maintained long enough to exert the desired action.
The term “hormone” shall mean polypeptide hormones, oligopeptide hormones, amine hormones, steroid hormones (such as sexual hormones, including testosterone), and lipid and phospholipids-derived hormones.
The term “sexual hormone drug” shall mean a sexual hormone (such as testosterone), a biologic pro-drug of a sexual hormone (such as androstenedione, progesterone, 17-α-hydroxyprogesterone), a derivative of a sexual hormone (such as mestanolone and 4-chloro-1-dehydromethyltestosterone), or a combination thereof.
The inventive formulation for nasal application comprises (a) at least one active ingredient; (b) at least one lipophilic or partly lipophilic carrier; and (c) a compound or mixture of compounds having surface tension decreasing activity in an amount effective for in situ generation of an emulsion upon contact of the formulation with water.
The active ingredient is generally a hormone drug. Preferably, the hormone drug is comprised within the formulation in an amount up to about 0.2 to about 6% by weight, preferably 0.2 to 4% by weight. In one aspect of the invention, the hormone drug is a sexual hormone drug. Preferably, the sexual hormone drug is testosterone.
In one aspect, the active ingredient may be introduced into the formulation in a processed form, such as nano- or microparticles, liposomes, bilayer vesicles, and micelles, among others.
The formulation of the invention also comprises at least one lipophilic or partly lipophilic carrier. The formulation of the invention comprises oil in a range of about 30% to about 98% by weight, preferably about 60 to about 98% by weight, more preferably about 75% to about 95% by weight, even more preferably about 85% to about 95% by weight, and most preferably about 90% by weight. In a preferable aspect, the lipophilic carrier comprises an oil or a mixture of oils, such as a vegetable oil, such as castor oil, soybean oil, sesame oil, or peanut oil, fatty acid esters such as ethyl- and oleyloleat, isopropylmyristate, medium chain triglycerides, glycerol esters of fatty acids, or polyethylene glycol, phospholipids, white soft paraffin, hydrogenated castor oil, or a mixture thereof. More preferably, the oil is a vegetable oil. Most preferably, the oil is castor oil. In one aspect, the lipophilic carrier may comprise a mixture of oils. In a preferable aspect, the vegetable oil is castor oil.
The formulation of the invention also comprises a compound or mixture of compounds having surface tension decreasing activity in an amount effective for in situ generation of an emulsion upon contact of the formulation with water in an amount of about 1 to about 20% by weight, preferably about 1 to about 10% by weight, more preferably about 1 to about 5% by weight, and most preferably at about 4% by weight. The surface tension decreasing component generally comprises at least one surfactant selected from the group consisting of anionic, cationic, amphoteric, and non-ionic surfactants, including, but not limited to, lecithin, fatty acid ester of polyvalent alcohols, fatty acid ester of sorbitanes, fatty acid ester of polyoxyethylensorbitans, fatty acid ester of polyoxyethylene, fatty acid ester of sucrose, fatty acid ester of polyglycerol, oleoyl macrogolglycerides, and/or at least one humectant such as sorbitol, glycerine, polyethylene glycol, macrogol glycerol fatty acid ester, or mixture thereof. Preferably, the surface tension decreasing component is an oleoyl macrogolglyceride (such as LABRAFIL® M 1944 CS, as available from Gattefossé (Saint-Priest, France)). In another aspect, the surface tension decreasing component may comprise a surfactant mixture. In a preferable aspect, the surface tension decreasing component comprises an oleoyl macrogolglyceride or a mixture of oleoyl macrogolglycerides.
The particular amount of surface tension decreasing component that constitutes an effective amount is dependent on the particular oil or oil mixture used in the formulation. Generally, depending on the carrier component selected for the formulation, particularly where the carrier component is an oil or oil mixture, it is necessary to select surfactants with compatible hydrophilic/lipophilic balance (HLBF) values to form the most stable emulsions.
While it is not practical to enumerate specific amounts of surface tension decreasing components for use with a variety of different carrier components, Table 1 below provides a general guide for providing the formulation of the invention.
TABLE 1
Typical composition of lipid formulation.
Content of formulation (% w/w)
Excipient
Type 1
Type 2
Type 3
Type 4
Type 5
Oil
100
40-100
40-100
<20
—
Surfactant
—
0-60
—
—
0-20
HLB ≦ 12
Surfactant
—
—
20-40
20-50
30-80
HLB ≧ 12
Hydrophilic
—
—
0-40
20-50
0-50
co-solvent
The formulation may optionally further comprise a viscosity regulating agent, such as a thickener or gelling agent. While the amount of the viscosity regulating agent used in the formulation is dependent on the carrier used in the formulation, the formulation generally comprises the viscosity regulating agent in an amount of from about 0.5 to about 10% by weight, preferably about 0.5 to about 7% by weight, more preferably about 1 to about 4% by weight, and most preferably about 4% by weight. Examples of viscosity regulating agents include, but are not limited to, cellulose and derivatives thereof, polysaccharides, carbomers, polyvinyl alcohol, povidone, colloidal silicon dioxide, cetyl alcohols, stearic acid, beeswax, petrolatum, triglycerides, lanolin, the like, or mixture thereof. A preferred viscosity regulating agent is colloidal silicon dioxide (such as ACROSIL 200®, as available from Degussa).
Optional Components
In another aspect of the invention, the formulation may optionally comprise a viscosity regulating agent in an amount of from about 0.5 to about 10% by weight, preferably about 0.5 to about 7% by weight, more preferably about 1 to about 4% by weight, and most preferably about 4% by weight. Preferably, the viscosity regulating agent comprises a thickener or gelling agent, such as cellulose and cellulose derivatives, polysaccharides, carbomers, polyvinyl alcohol, povidone, colloidal silicon dioxide, cetyl alcohols, stearic acid, beeswax, petrolatum, triglycerides and lanolin, or a mixture thereof. More preferably, the viscosity regulating agent is colloidal silicon dioxide.
In another aspect, the viscosity regulating agent may comprise a mixture of viscosity regulating agents. In a preferred aspect, the mixture of viscosity regulating agents together with an ointment base such as oleo gel or PEG-, lanolin alcohol-, or petrolatum-ointment and about 0.5 to about 40% (w/w) of lanolin, hydroxypropyl methylcellulose, petrolatum, PEG 300-6000, glyceryl monostearate, beeswax, or CARBOPOL® (Noveon, Inc).
Constituents
% - wt
Useful
Preferably
Preferred
Active
—
0.2-0.6
0.2-4
Carrier
60-98
75-95
85-95
Surfactant
1-20
1-10
1-5
Viscosity Builder
0.5-10
0.5-7
1-4
Processing.
Generally, the formulation of the invention can be prepared very easily. The lipophilic carrier and surface tension decreasing component are filled into a stirrer vessel and about 75% of the viscosity regulating agent is mixed in. The active ingredient is added under stirring to obtain a homogenous dispersion of the active ingredient. Next, the formulation is adjusted to the necessary viscosity with the remainder of the viscosity regulating agent. The formulation is preferably filled into a preservative-free unit-dose container.
Because some hormones have lower levels of solubility in water, liberation from the formulation is the speed-limiting step for adsorption. It has been surprisingly found that the incorporation of a hormone drug such as testosterone in the oily formulation of the invention containing a suitable surfactant leads to physiologic serum levels and to a steady, sustained action of the hormone over time, as well as to increased levels in the CSF.
It is believed that the special release of the hormone is due to the oily carrier and because the formulation remains on the mucous membrane for a prolonged period of time due to its viscosity. Upon contact of the formulation with the humidity of the mucous membrane, precipitation of the active ingredient is hindered by the ability of the surface tension decreasing component to form oil drops containing the active ingredient. Thus, by adding a surface tension decreasing component to the formulation, the dissolution pattern of the active ingredient becomes more favorable and effective because there is no big variability in dissolution, which ensures bioequivalence.
Treatment.
The steroid hormone testosterone exerts its effects in tissues before or after testosterone is reduced by 5-alpha reductase to dihydrotestosterone (DHT). Since DHT has stronger binding properties than testosterone, DHT produces different actions in the body. As shown in FIG. 1 , although the testosterone level in serum of hypogonadal men is comparable, application of the nasal gel of the invention results in a much lower level of DHT as compared to application of a dermal gel on the market. Formulations resulting in low levels of DHT are particularly desired because there is some evidence that DHT promotes cell growth in the prostate gland and is linked to promoting the spread and growth of prostate cancer cells.
The formulation described below in Table 2 was selected for treatment of hypogonadism because of the serum/CSF level achieved for the active ingredient but also because of skin care properties, such as moistening of the nasal membrane, which are important for long term applications.
TABLE 2
Representative Formulation
Compound
Concentration
Delivery per nostril
Testosterone
4%
≈4 mg
Colloidal silicon dioxide
4%
≈4 mg
Oleoyl macrogol-glycerides
4%
≈4 mg
Castor oil
88%
≈88 mg
In another aspect of the invention, the formulation according to the invention may also be processed into powder form, such as by lyophilization or spray-drying.
Referring now to FIG. 2 and the preferred formulation containing testosterone described above in Table 2, C max is clearly decreased in the special formulation of the invention, which is desirable in view of toxicological considerations. Further the level of unbound testosterone is very constant over at least ten hours, which mimics the physiologic daily rhythm of testosterone release. The dotted line shows the serum level after application of one spray per nostril of the preferred formulation.
It can be concluded that the inventive formulation for nasal application is different from conventional formulations, especially those designed for sustained release, because the inventive formulation mimics the physiologic daily rhythm of testosterone release. The invention also avoids supra- and sub-normal testosterone levels, which is easier for the patient to tolerate and, importantly, is suitable for hormone replacement therapy. As shown in FIG. 2 (upper line), a simple nasal spray containing testosterone is unsatisfactory in this sense.
As shown in FIG. 3 , application of testosterone in the inventive nasal gel formulation to women results in peak level (C max ) after about fifteen and before at least seventy-five minutes. Previous data regarding other forms of testosterone administration indicate: (1) a testosterone patch provides peak levels of testosterone at 24-36 hours (Advisory Committee Briefing Document, 2 Dec. 2004, P&G, p. 128); (2) a transdermal spray administered to the abdomen or forearm results in a peak level at 14-18 hours (Humberstone, A. J., et al., Poster No. P2-218; (3) a vaginal gel results in peak level at 5.5 hours (Apperloo et al.); and (4) an oral capsule of testosterone results in peak level at 5-7 hours (Houwing, N. S., et al., Pharmacotherapy 23(10): 1257-65 (2003)).
WORKING EXAMPLES
The following examples are intended to further illustrate, and not limit, embodiments in accordance with the invention.
Example 1
Nasal Administration of Testosterone to Women
The rapid and relatively high peak concentration of testosterone after application of testosterone was shown to correspond to a signal in the brain. Fourteen healthy, premenopausal women, between thirty-five and forty-five years of age during early follicular phase and who were not taking hormonal contraceptives, received the inventive nasal gel containing 0.9 mg testosterone or a placebo forty minutes before scanning. Scanning was done with functional magnetic resonance imaging (fMRI) using a 1.5 T Siemens Sonata MR scanner (TR 2.29 s, TE 30 ms, 3.5×3.5×3.5 mm voxels) to investigate the regional cerebral blood flow. During scanning, the subjects had to match the emotional expression with faces of different individuals expressing either anger or fear. As shown in FIG. 4 , the fMRI data shows that application of the nasal testosterone gel formulation produces rapid effects on the neural emotion circuitry. Although not wishing to be bound by theory, it is believed that the rapid effects on the neural emotion circuitry are mediated by non-genomic mechanisms.
Previous data has shown that the amygdala response is important to sexual arousal. Karama et al., Hum. Brain. Mapp. 16:1-13 (2002), has shown that female sexual arousal is associated with increased amygdala activation and Baird et al., Ann. Neurol. 55: 87-96 (2004), has shown that increased sexual drive is associated with larger amygdala volume. As shown in FIG. 4 , the nasally applied testosterone gel formulation leads to an amygdala response after not more than forty minutes. The fMRI results show that a single dose of nasal administration of the inventive formulation is able to restore the activation of amygdala region. The nasally applied testosterone gel formulation therefore is useful for the treatment of Female Sexual Dysfunction (FSD) or female sexual arousal disorder.
As shown in FIG. 5 , young women between nineteen to thirty years of age have a higher amygdala response than that seen in middle-aged women between thirty-five to forty-five years of age when both groups are given placebos. A comparison of FIG. 4 with FIG. 5 demonstrates that treatment with the testosterone nasal gel of the invention increases the emotional reactivity of the middle-aged women to a level similar to that seen with the young women in the placebo group.
In addition to the fast response seen in the brain, the nasal gel formulation also triggers a long lasting effect. Further fMRI data and serum concentration levels, as shown in FIG. 6 , show that the response lasts for 2.5 hours. Therefore, both genomic and non-genomic signaling mechanisms can be assumed. Because it is not sufficient for a neurotherapeutic agent to cross the blood-brain barrier (the neurotherapeutic agent must also stay in the brain long enough to exert its action), a prolonged serum level is desirable for the action in the periphery.
It was also found that an intermittent nasal application of the inventive gel promotes female sexual proceptivity, which, for safety reasons, is extremely favorable in women.
Example 2
Effects of Nasal Administered Testosterone on the Sexual Behavior of Female Capuchin Monkeys ( Cebus apella )
The objective of the study was to investigate the effects of nasal administered testosterone on the sexual behavior of female capuchin monkeys ( Cebus apella ).
Ten brown tufted capuchins ( Cebus apella ) were used as subjects as focal animals in this study. Animals were all adult females (>5 years old). All animals were weighted prior to and following the experimental procedures as described in Table 1.
TABLE 1
Weight of Female Capuchins Monkeys in the Noseafix Experiment.
Female
Baseline
Treat. 1
Treat. 1
Washout
Treat. 2
Treat. 2
Number
Sept. 23
Sept. 30
Oct. 03
Oct. 08
Oct. 10
Oct. 13
1
2.120
2.070
2.205
2.140
2.175
2.115
2
2.265
2.330
2.545
2.520
2.370
2.390
3
2.390
2.360
2.355
2.390
2.350
2.340
4
2.390
2.330
2.385
2.395
2.320
2.345
5
2.500
2.195
2.225
2.315
2.310
2.245
6
2.510
2.490
2.640
2.315
2.480
2.615
7
2.500
2.445
2.610
2.600
2.450
2.465
8
1.740
1.725
1.795
1.765
1.755
1.760
9
2.610
2.595
2.695
2.740
2.700
2.745
10
2.520
2.370
2.325
2.430
2.410
2.325
Females were housed in heterosexual pairs, see Table 2:
TABLE 2
N°
Housing Condition
Females' Number
Females' Name
n = 4
Family Groups
2
Rosa
(reproductive pair and
4
Drica
offspring)
7
Salomé
9
Chiquinha
n = 2
Adult Male
1
Maneca
6
Cida
n = 2
Adult male and young
3
Mila
female
8
Salete
n = 2
Adult male and one
5
Delia
adult female
10
Aurora
The ten subjects were assigned to the two groups based on age and on the housing condition. They never had experienced exogenous testosterone before. Females were randomly assigned to the treatment and placebo group, comprising five animals, see Table 3.
TABLE 3
Design of the Female Capuchin Groups
in the Noseafix Experiment.
Treatment 1 (A)
Treatment 2 (B)
Animal Number
Animal Name
(Sept. 09-Oct. 03)
(Oct. 09-Oct. 13)
(1)
Maneca
Placebo
Noseafix
(2)
Rosa
Placebo
Noseafix
(3)
Mila
Noseafix
Placebo
(4)
Drica
Placebo
Noseafix
(5)
Delia
Placebo
Noseafix
(6)
Cida
Noseafix
Placebo
(7)
Salomé
Noseafix
Placebo
(8)
Salete
Placebo
Noseafix
(9)
Chiquinha
Noseafix
Placebo
(10)
Aurora
Noseafix
Placebo
The monkeys were housed and tested at the Primate Center of the University of Brasilia, Brazil, under natural light, temperature and humidity conditions. The Primate Center is located within the grounds of an ecological reserve, such that home cages are surrounded by nearby native tropical semideciduos gallery forest. Subjects were housed in the Cebus Colony room of the Primate Center, which contains two species of cebids: Brown tufted capuchins— Cebus apella and Squirrel monkeys— Saimiri ustus . The colony room consists of two rows of 6 cages (4 m length, 2, 9 width, ×2 m height, each cage respectively) consist of two concrete walls, separating adjacent cages, and a wire mesh front, back and ceiling forming an outdoor/semi-indoor housing system. Each cage consist of two concrete walls, separating adjacent cages, and a wire mesh front, back and ceiling forming an outdoor/semi-indoor housing system.
Each home cage contains a suspended wood nest-box, several wood perches at different heights, a food tray (where food bowl is placed) and a thick layer of natural dry leaves and twigs on the floor. Olfactory and acoustic contact is possible between all members of the colony, but not visual contact.
Food is provided once a day at 7:30 am., remaining in the home cages until 5:30 pm. The provisions include a variety of fresh fruits and vegetables. Dry pellets and fresh water are available ad libitum. Animals are weighted and clinically evaluated by a veterinary once a month.
The study was a randomized, double-blinded, cross-over with a non-treatment run-in. The experimental procedure was divided into 23 days in 4 consecutive phases:
Baseline=8 days (−7, −6, −5, −4, −3, −2, −1, 0)
Treatment 1 (A)=5 days (1 to 5)
Wash out=5 days (6 to 10)
Treatment 2 (B)=5 days (11 to 15)
The study started with a no-treatment run-in. In this study phase, the non-influenced (sexual) behavior of the female capuchin monkeys was observed and recorded as baseline. Behavioral observations were carried out daily during 23 experimental days (between 8 am and 5 pm). During all the phases, the behavior of the females' capuchin monkeys was individually observed throughout the day by four experienced observers. The behaviors were scored using a combination of continuous recording and instantaneous sampling (point samples every 7 minutes), (Martin and Bateson, 1986). The description of sexual behaviors is based on studies on capuchins sexual behavior, (Carosi et al., 1999; Carosi and Visalberghi, 2002). All behaviors were scored manually on spreadsheets and chronometers.
Each animal was observed four times a day (two sessions in the morning and two sessions in the afternoon). Each observation session lasted 14 min (7 min for instantaneous sampling and 7 min for continuous recording). The total amount of hours observed throughout the four phases of the experiment were 214.6.
Reliability for behavior identifications was assessed using data from three observations' days previous to the beginning of the study. Interaobserver (between the four observers) and intraobserver reliability were calculated as the sum of agreements between observers divided by the sum of disagreements. The concordance' index was up to 85%.
The behaviors observed were classified in sexual: eyebrow raising, mutual gaze, head cocking, chest rubbing, masturbation, extended arm(s), body touching mounting attempt, mounting, courtship, and non-sexual behaviors: resting, repetitive behavior, grooming, activity, and agonistic. Their operational definitions are presented in Table 4.
TABLE 4
Behavioral Definitions and Recording Techniques Used
Behavior (recording
technique)
Definition
Eyebrow raising (I)
F's eyebrows are raised up and backwards and
the fur over the crown is flattened.
Mutual gaze
F and M maintain mutual eye contact for at
least 2-3 s. It involves eyebrow raising.
Head cocking (I)
F's head is tilted to one side (approx. 45°). The
head may gently change side every few
seconds.
Chest rubbing (I)
F's hand(s) are slowly rubbed back and forth
on the fur of its own chest. The movements
are usually upward and/or downward and
repeated several times in a row.
Masturbation (I)
F rubs its own genital with hands.
Extended arm(s) (CR)
F slowly moves/stretches one or both arms
toward M, without contacting M. Individuals
are in proximity usually seated, facing and
looking at each other.
Body touching (CR)
F's hand gently reaches out and touches M's
body for at least a few seconds.
Mounting attempt (CR)
M tries to mount F, but F moves away.
Mounting (CR)
M mounts F in a position which allows for
copulation. Thrusting usually occurs. A
mounting bout starts when M gains a mounting
position and ends when it dismounts. Bouts
can be isolated or form a mounting sequence. F
may also mount M.
Courtship (CR)
F seeks the M attention or the observer
attention. The courtship includes all the
behaviors described for instantaneous
sampling: eyebrow raising, mutual gaze, head
cocking, chest rubbing and masturbation.
Resting (CR)
F is still on a substrate without doing anything
else.
Stereotypy behavior (CR)
F goes, moves repeatedly to one place to
another without any other behavior associated.
Grooming (CR)
F cleans its hair, another animal hair or it is
cleaned by another animal.
Activity (CR)
It includes all the non-sexual female behaviors
that were not described before such as
foraging, playing, drinking, eating and moving.
Agonistic (CR)
Aggressive behavior including threat, chase
way, grab with or without vocalization.
* Abbreviations: I, instantaneous sampling (-s intervals); CR, continuous recording; F, female; M, male.
Measurements.
The following measurements were done during the study:
Baseline phase: Body weight
Testosterone morning concentration Behavior
Wash-out phase: Body weight
Testosterone morning concentration Behavior
Treatment phases: Body weight
Testosterone morning concentration Behavior
The daily dose of the respective study drug was administered in the morning by study staff using the original recipient for a single dose. The test drug and the placebo were administered at the same interval time in the morning by the same experimenter in all days during the treatment 1 and 2. The drug was administered after the blood has been collected by the same experimenter in both nostrils of each animal.
The study staff filled out a treatment protocol for each animal and confirmed the administration with date and signature.
In order to obtain the blood samples during all the phases of experience, the animals were captured by a caretaker with the aid of a net, removed with leather gloves, anesthetized with isoflurano nasal and then transported to a table where the procedure was done. The order of capture of the females was maintained for all the days of the experiment. Time between the capture, blood collection and recovery of the females varies from 5 to 30 minutes depending on the animal.
Blood samples were drawn between 08:15 to 10:40 a.m. six times throughout the total time of experiment during the baseline, wash-out and treatment phases (Days=−5, 2, 5, 10, 12 and 15, respectively). The isoflurano 1 ml was administered nasally in a cotton ball placed at the nose of the animals until that sedation effect was observed. Once the animal is anesthetized, 1.5 ml of the venous blood was drawn from each female. On day 10 th we could not get a blood sample of the female number 4, Drica.
The transport of the analytical samples (plasma samples) from the Primate Center to the analytical laboratory at the Pharmacology Department at the University of Brasilia, was performed in thermo-isolated boxes contained dry ice. The temperature during the transport was not warmer than −20° C. Each blood sample containing heparin was immediately centrifuged at 2000 rpm for 10 minutes. The plasma was separated and put in duplicate test tubes labeled with the protocol number, study period, animal number, animal name, date and time of sampling. The test tubes with the blood were safely closed. The plasma samples were safely racked and immediately frozen for storage at −80° C.
Samples were stored in labeled tubes containing heparin as anticoagulant. The label of the blood collecting tubes contained information about protocol number, study period, animal number, animal name, date and time of sampling.
Phase 1: Baseline.
This first phase consisted of 8 consecutive days (from −7 to 0 day) where the baseline values of sexual and non-sexual female behaviors were recorded for 10 animals. During this phase, the non-influenced (sexual) behavior of the females' capuchin monkeys was individually observed through the day by 04 independent observers. The behaviors were scored using focal animal's continuous recording and focal instantaneous sampling methods. On the day −5, the first blood sample was collected for each female. After the blood has been collected, the animal was placed back into their home cage and released.
Phase 2: Treatment 1(A).
This phase consisted of 5 consecutive days (day 1 to day 5) with the nasal administration as single doses of 0.48 mg of testosterone (Noseafix®) 0.48 mg of testosterone (0.24 mg per nostril), once daily for 5 female capuchin monkeys (animal numbers 3, 6, 7, 9 and 10) as presented in Table 3. The 5 other females received gel for nasal administration with content identical to Noseafix. On day 2 and 5, blood samples were collected for the animals. Sexual and non-sexual behavior were recorded by the same observers of the previous phase for all days and according to the behavior categories described before. The blood samples were obtained using the same procedure described in the general description of protocol.
Phase 3: Wash Out.
During five consecutive days (day 6 to day 10), sexual and non-sexual behavior were recorded by the same observers of the previous phases using the same behavioral categories already described. On day 10 th for nine females we draw 1, 5 ml of venous blood. It was not possible to get a blood sample of the animal 4 on this day.
Phase 4: Treatment 2(B).
This phase was equal to the Treatment 1 except by the fact that the animals that got drug received placebo and vice-versus. All the procedures to capture the animals, collect blood, administer the drug or placebo and recording the behavior were the same as described previously. On the days 12 th and 15 th , new sample blood were taken from all the capuchin females.
Noseafix®.
Name of the drug: Noseafix® (0.48 mg of testosterone/vial)
Pharmaceutical form: gel for nasal administration Content: active ingredient: testosterone Excipients: according to the analytical certificate Mode of administration: nasal, as single doses of 0.48 mg of testoterone (0.24 mg per nostril), once daily for 5 days Manufacturer: HOLOPACK GmbH—Abtsgmünd/Germany for Mattern Research AG-Stans/Switzerland
Noseafix® Placebo.
Name of the drug: Placebo
Pharmaceutical form: gel for nasal administration Content: identical to the gel base of Noseafix® Mode of administration: nasal, single dose (same volume as measured for Noseafix®), once daily for 5 days Manufacturer: HOLOPACK GmbH—Abtsgmünd/Germany for Mattern Research AG-Stans/Switzerland
Behavioral Analysis.
Behavioral raw data were transformed for the analysis as a function of the length of time of the observational sessions. Individually daily frequencies or durations were divided by the duration (in seconds) of each observational session. Thus, rates and percentages of time spent in each behavior were obtained. Daily scores of the behaviors sampled with the instantaneous technique were expressed as a proportion of the total number of point samples of the sessions.
Statistical Analysis
Data are expressed as the mean±SEM Results are based in two-tailed statistical tests Significance level was set at p≦0.05
Comparisons were done within each group to evaluate if the variables measured for each behavior were significantly modified by the treatment. With this purpose, we carried out one-way Analysis of Variance (ANOVA), taking each behavior as dependent variable, and the experiment's phase as independent variable, followed by post hoc analysis with Tukey's all-pair wise comparisons when applicable.
The results are presented separately for data collected using the Scan and the Continuous Recording methods.
Eyebrow Raising.
In female tufted capuchins “eyebrow raising”, “touching and running”, “nuzzling”, and, to a lesser extent, “headcocking” are displays strongly correlated to the periovulatory phase and represent female proceptivity (Carossi, et al., 1999).
Statistical comparisons within Group 1 (Placebo in the treatment 1 phase—Noseafix in the treatment 2 phase) indicated significant differences between treatments [F 3, 366 =3.692, p=0.012] (see FIG. 7 ). Post hoc tests demonstrated differences between Treatment 1 and Treatment 2 [p=0.029], and between Wash-Out phase and Treatment 2 [p=0.022]. These results indicate that animals treated with Noseafix at treatment phase 2 showed increased frequency of “eyebrow raising” when compared to treatment phase 1 (placebo).
Also, comparisons within Group 2 (Noseafix-Placebo) treatments showed significant difference between phases [F 3, 454 =2.786, p=0.040]. Post hoc analysis indicated an increase of the frequency of this behavior during the treatment phase 1 (Noseafix), although not significant, the Wash-Out phase when compared with Baseline [p=0.022] ( FIG. 7A ), and during the treatment phase 2 (Noseafix). It is interesting to note that these increases reach significance during the Wash-Out phase which could be interpreted as a long lasting effect of Noseafix.
The frequency of eyebrow raising behavior was not different between groups during Baseline [t=1.691, p=0.093] ( FIG. 8A ), Treatment 1 [t=1.916, p=0.057] ( FIG. 8B ) and Treatment 2 [t=−1.140, p=0.256] ( FIG. 8D ). During the Wash-Out phase ( FIG. 8C ) the groups differed significantly [t=2.972, p=0.004], where Group 2 shown more frequently this behavior than the Group 1. These results suggest a long lasting effect of Noseafix treatment.
Chest Rubbing.
This behavior in Capuchin monkeys has been reported as one of the most prominent indication of female courtship (Carosi and Visalberghi, 2002). When multiple comparison within Group 2 (Noseafix-Placebo) were done, differences between phases were observed [F 3, 454 =3.439, p=0.017] (see FIG. 7B ). Post hoc tests showed a significant increase during Treatment 1 phase when compared to both Baseline [p=0.049] and Treatment 2 [p=0.02]. Multiple comparisons within Group 1 did not show any significant difference due to the experimental phase [F 3, 366 =0.652] ( FIG. 7B ). These results indicate an effect of Noseafix treatment increasing the “chest rubbing” behavior. The placebo treatment had no effect at all. During Baseline [t=0.505, p=0.614] and Treatment 2 [t=−1.186, p=0.239], the frequency of the Chest Rubbing behavior ( FIGS. 8A and 8D ) did not differ between the groups. Group 2 had a greater frequency for this behavior compared to Group 1 in both Treatment 1 [t=−2.046, p=0.043] and Wash-Out [t=−2.811, p=0.006] phases ( FIGS. 8B and 8C ). These results again indicate an increase of “chest rubbing” by Noseafix. Moreover, the incidence of this behavior during the Wash-Out phase suggests a long lasting effect of the compound.
Masturbation.
Female capuchin monkeys perform mounting on adult males lasting from a few seconds up to 1-2 min. They usually stay on the male back in a position resembling that of an infant on its mother. However, the female can also take up a more proper mounting position, perform pelvic thrusts, and rub her genitals on the male's fur, as if masturbating. She can also perform a masturbation-like behavior by rubbing her genitals with the hands. This type of behavior typically occurs when the female is proceptive and she persistently solicits the male (Carosi and Visalberghi, 2002).
Multiple comparisons within each group did not find differences in Group 1 [F3, 366=0.822, p=0.482]. However, comparisons within Group 2 revealed differences due to phase [F3, 454=3.329, p=0.020]. Post hoc analysis indicated differences between Baseline and Treatment 1 [p=0.049], where during Treatment 1 an increase of the frequency of this behavior was found ( FIG. 7C ). This result suggests an effect of Noseafix treatment on the frequency of this behavior. No significant increase of masturbation was observed during treatment with placebo.
Comparisons for this behavior within phases between groups did not show significant differences [Baseline: t=1.467, p=0.145; Treatment 1: t=0.721, p=0.472; Wash-Out: t=0.925, p=0.358; Treatment 2: t=0.894, p=0.373] ( FIG. 8A to 8D ).
Head Cocking.
This behavior is characterized by the head tilted to one side (approximately 45°). The head may gently switch side every few seconds. The actor is constantly gazing at the recipient while cocking the head. This is performed by both sexes. Head cocking is performed by several prosimian and platyrrhine species during explorative activities, such as visual inspection of objects and unfamiliar persons (possibly to improve visual and auditory perception). The head cocking observed during capuchins' sexual interactions is unlikely to be related to the functions reported in other species (Carosi and Visalberghi, 2002).
Multiple comparisons within each group for the different phases, neither comparisons between the two groups within each phase showed any significant difference in the frequency of this behavior [Group 1: F 3, 366 =0.508, p=0.677; Group 2: F 3, 454 =0.891, p=0.446] ( FIG. 7D ), [Baseline: t=0.011, p=991; Treatment 1: t=−0.894, p=0.373; W-O: the behavior was not observed; Treatment 2: t=0.791, p=0.430] ( FIG. 8A to 8D ).
Mutual Gaze.
The monkeys may move repeatedly closer and farther apart while mutual gazing. Regardless of the distance between them, they try to regain mutual gaze. The mutual gaze usually lasts for several minutes, with occasional interruptions of a few seconds.
It is usually accompanied by one or all of the following behavioral patterns: eyebrow raising with grin and vocalizations, head cocking, and chest rubbing (Carosi and Visalberghi, 2002).
Comparisons for Mutual Gaze behavior between phases within each group did not show any significant difference [Group 1: F 3, 366 =0.837, p=0.474; Group 2: F 3, 454 =1.264, p=0.268] ( FIG. 7E ). Comparisons between groups within each phase also did not show significant differences for this behavior [Baseline: t=1.779, p=0.078; Treatment 1: t=−1.388, p=0.168; Wash-Out: t=−0.652, p=0.515; Treatment 2: t=−0.459, p=0.647] ( FIG. 8A to 8D ).
Grooming.
Differences between treatment phases were observed within Group 1 [F 3, 366 =3.246, p=0.022]. Post hoc analysis demonstrated significant difference between Baseline and Treatment 2 [p=0.017], due to an increase of this behavior during Treatment 2 (when the subjects were under Noseafix treatment, see FIG. 9A ). No such differences were observed within Group 2 [F 3, 454 =2.153, p=0.093].
Comparisons within each phase did not show any difference in the time spent in Grooming between groups [Baseline: t=0, 7, p=0.485; Treatment 1: t=0.674, p=0.501; Wash-Out: t=0.138, p=0.89; Treatment 2: t=1.131, p=0.259] ( FIG. 10A to 10D ).
Courtship.
This category includes the following behaviors: extended arm(s), sexual display, body touching, courtship and mounting.
Multiple comparisons within each group between phases revealed significant differences for Group 1 [F3, 366=5.71, p=0.001] during Treatment 2 due to an increase of this category when compared to Baseline [p=0.03], Treatment 1 [p=0.005] and Wash-Out [0.001]; and for Group 2 [F3, 454=2.455, p=0.063] between Baseline and Wash-Out [p=0.043] ( FIG. 9B ). These results indicate that treatment with Noseafix increase courtship in female capuchin monkeys.
Comparisons of the time spent in courtship behaviors within each phase between groups shown significant differences during Treatment 1 [t=−2.007, p=0.047] and during Wash-Out [t=−3.08, p=0.003]. In both situations Group 2 spent more time than Group 1 ( FIGS. 10B and 10C ). During Baseline [t=0.975, p=0.33] and Treatment 2 [t=−1.654, p=0.101] no differences were observed between groups ( FIGS. 10A and 10C ).
Stereotypy.
Differences in the time spent in stereotyped behavior between phases within each group were not found [Group 1: F3, 366=1.878, p=0.133; Group 2: F3, 454=0.549, p=0.649] (Data not shown in figures).
Comparisons between groups within each phase demonstrated that Group 1 shown significantly higher percentage of time in this behavior than Group 2 in all the phases [Baseline: t=3.138, p=0.002; Treatment 1: t=3.538, p=0.001; Wash-Out: t=4.379, p<0.001; Treatment 2: t=−3.188, p=0.002] (Data not shown in figures).
Agonistic Behavior. (Chase Away).
Multiple comparisons between phases within each group did not show significant differences in the observation time [Group 1: F3, 366=0.079, p=0.971; Group 2: F3, 454=1.703, p=0.166] ( FIG. 9C ).
Comparisons of Agonistic Behavior within each phase between groups shown significant difference between them during the Wash-Out phase [t=−2.356, p=0.02], where the Group 2 shown more agonistic behavior than Group 1 ( FIG. 10C ). For the remaining phases significant differences were not observed [Baseline: t=−1.719, p=0.087; Treatment 1: t=−0.859, p=0.391; Treatment 2: t=0.265, p=0.792] ( FIGS. 10A , 10 B and 10 D). It is worth to mention that this Chase Away behavior was observed only in one animal, although during a long time. It is not possible to be sure that this behavior observed during the Wash-Out period was elicited by the effect of testosterone (Noseafix) administered during treatment 1 phase (long lasting effect). However, it seems not likely since in capuchin monkeys, high levels of testosterone were not associated with aggressive behavior (Lynch, et al., 2002).
FIG. 11 shows the plasma testosterone levels in different phases of the study for the animals treated with placebo (blue squares) and Noseafix (red squares). As can be observed, the administration of Noseafix induced an increase in plasma testosterone level. It is interesting to observe that the high magnitude effect was observed when the animals were at the Wash-Out phase. This effect fits perfectly with the higher frequency of sexual arousal behaviors observed during the Wash-Out phase. Therefore, behavioral and plasma testosterone level shows a close relationship.
The two yellow squares in the Figure—Treatment 2 phase, illustrates the “possible” residual effect of Noseafix treatment during Treatment 1 phase. It would be interesting in other study to introduce a second Wash-Out phase (after treatment 2) in order to confirm this residual (long lasting) effects of Noseafix treatment on plasma testosterone levels and the proceptivity of female capuchin monkeys.
In summary, the results obtained indicate that administration of Noseafix seem to promote female sexual proceptivity in the tufted capuchin monkey ( Cebus apella ), which characterizes this species mating system. These effects are in close relationship to the plasma testosterone levels measured during this study. The following aspects summarize the major findings and the results that corroborate this conclusion:
The frequency of Eyebrow Raising, Chest Rubbing and Masturbation were enhanced by the administration of Noseafix. These behaviors are an indicative of female's sexual solicitation and are frequent displayed during the preiovulatory period ( FIG. 1 ). It is important to mention that none of these behaviors were significantly observed in animals under placebo administration. Therefore, the females' proceptivity can not be related to the natural ovulatory cycle, although we can not rule out a possible interaction between Noseafix and ovulatory cycle in some animals. In order to exclude this possibility would be necessary to conduct another experiment in females where the natural cycle is blocked by the administration of a contraconceptive drug. The female sexual appetitive activities such as invitational patterns and active initiative in approaching, investigating, and sexually soliciting the male were only observed in animals under Noseafix treatment ( FIGS. 7 to 10 ). It is worth to mention that some of these behaviors were also observed during the Wash-Out phase, but only for the animals that have received Noseafix before. Therefore, it is possible that Noseafix has a long lasting effect. Since we did not do a PK study, it is not possible to know how long are the Noseafix effects in capuchin monkeys. Moreover, a second Wash-Out phase, after Treatment 2, would be interesting to observe possible occurrence of sexual display behaviors in animals treated with Noseafix during Treatment 2 phase. The compound tested did not exert a significant effect upon the frequency of exploratory activity or stereotyped behaviors in the monkeys tested. Therefore, the effects of Noseafix were not due to changes in the subject's level of activity.
The features disclosed in the foregoing description, in the claims and/or in the drawings may, both separately and in any combination thereof, be material for realizing the invention in diverse forms thereof.
|
This invention relates to a gel formulation for nasal administration of a controlled release formulation of hormones to the systemic circulation and/or to the brain. The special lipophilic or partly lipophilic system of the invention leads to higher bioavailability of the active ingredient caused by sustained serum levels in plasma but also leads to a more favorable serum level profile. The special lipophilic or partly lipophilic system also allows for the modulation of brain functioning. The invention also relates to the nasal administration of steroid hormones for treatment of female sexual dysfunction (FSD) or female arousal disorder.
| 0
|
CROSS REFERENCE TO RELATED APPLICATION
This application is based upon and claims benefit of copending and co-owned U.S. Provisional Patent Application Ser. No. 61/339,463 entitled “Collapsible Waste and Recycling Container”, filed with the U.S. Patent and Trademark Office on Mar. 3, 2010 by the inventor herein, the specification of which is incorporated herein by reference.
BACKGROUND
1. Field of the Invention
This invention relates to supports or bag holders. More particularly, this invention relates to a collapsible garbage bag holder or, in some instances, a collapsible waste and recycling receptacle, container, or can.
2. Description of Related Art
Disposable plastic bags are used ubiquitously in various applications. Their durable, lightweight, and disposable features have contributed to their popularity. However, when used for tasks such as collection of trash or other material, a disposable plastic bag alone is impractical. Typically, the mouth of the plastic bag tends to close.
This problem is pronounced when one person must hold the mouth of the bag open while attempting to insert trash or the like. Windy conditions exacerbate the problem by blowing the mouth closed, especially when the bag is empty or nearly empty. If the mouth is held open, one may efficiently insert trash and other material. Generally, such tasks require two people, or a very dexterous person. However, even a single talented person may be unable to fully hold the bag open and also insert trash.
One solution is to use a sturdy support container for the bag, such as a trash can lined with the plastic bag. However, trashcans, particularly those designed to hold large yard bags, are large, heavy, and cumbersome. Furthermore, once filled, typically the plastic bag must be lifted from the trashcan for disposal.
Support devices for holding collapsible bags in open position are not new to this art. Some of the prior art devices incorporate a circular loop having a series of hooks mounted thereon for hooking a bag in various positions about the periphery of the mouth. These hooks have tended to initiate rips and tears at stress points in the collapsible bag, thereby essentially destructing the bag when it is attempted to use the bag as intended, not to mention the time consuming task of attaching this series of hooks to the bag itself. Other devices incorporating a ring to hold the bag utilize clamps positioned about the periphery of the ring and bag to hold the bag in position. Although the clamps themselves did not rip or tear the collapsible bag, the problem of non-uniform support around the bag mouth periphery remained, resulting in potential tears at the stress points of connection of the bag to the ring.
Other solutions offer a framework to support the plastic bag. However, these devices are often complicated, thin, and cumbersome. Often such devices must be stored in an assembled condition, thereby wasting valuable storage space.
Other bag holding devices incorporated a support pole with a ring mounted thereto that was formed from two essentially flat pieces of flexible material attached to each other to form the circular ring. Due to the required flexibility and inherent low torsional resistance, this type of bag support device lacked sufficient support to maintain a collapsible bag attached thereto upright under moderate loading conditions.
Additionally, conventional bag supports such as garbage cans are generally bulky items that require considerable space for storage as well as for display in retail stores, and are awkward to handle due to their bulkiness. It would thus be desirable if such items could be collapsed so as to require less space and be more convenient to handle.
Public events that draw large crowds to sites that do not often accommodate such events usually encounter the need to place a large number of trashcans or receptacles temporarily at various locations throughout the sites. This can often prove to be an expensive and time-consuming task depending on how many receptacles must be used to collect the quantities of garbage that can be estimated to be produced because of the public event. For example, many truckloads of comparatively large, heavy receptacles may have to be rented and transported to and from the site, then situated at various locations on the site from which the garbage must be collected.
Improved, lower cost, and less-manpower intensive techniques and methods are needed to provide for the garbage and trash handling needs of such public events.
SUMMARY
Recognizing the need for improvements in the equipment, techniques, and methods for meeting the garbage and trash collection requirement that are created by holding large public events at sites that aren't often used for such events, the present invention is generally directed to satisfying this need and overcoming the limitations seen in the prior art devices and methods.
It is, therefore, an object of the present invention to provide a collapsible bag holder that avoids the disadvantages of the prior art.
It is another object of the present invention to provide improved equipment, techniques, and methods for meeting the garbage and trash collection requirements that are created by holding large public events at sites that are not often used for such events.
It is another object of the present invention to provide lower cost and less worker intensive techniques and methods for meeting garbage and trash collection needs.
In accordance with the present invention, a collapsible garbage or trash bag holder for primary use with a throw-away, trash collection bag, of the type that has a large opening through which trash can be inserted into the bag, and where the holder can fold into a flat shape for storage and is especially well suited for use in locations that temporarily require garbage or trash collection, includes: (a) rectangular front and rear panels, each having a top, bottom and side edges, (b) two side panels, each having two rectangular, foldable parts with top, bottom and side edges, (c) side hinges which connect the adjoining side edges of said side panel folding parts so as to allow them to fold together along said hinges, (d) primary hinges which connect the side edges of said front and rear panels to the outer side edges of said side panel folding parts so as to allow the side panels to be folded so that the front and rear panels can be brought into close and overlapping proximity to one another, and (e) a top ring that is adapted to fit over the top edges of said panels so as to locate and hold open the opening of a throw-away, trash collection bag.
When the holder is deployed, the sides are folded out into a rectangular shaped cylinder having an open top and bottom. The shape is then maintained by placing a top ring over the holder. This ring prevents the holder from collapsing and holds a throwaway, trash collection bag in place. Once the ring is removed, the holder can collapse into a flat position equaling the approximate thickness of its four sides.
To empty the holder, its top ring is removed, then the throwaway, trash collection bag is tied at its top and the holder is lifted up off the collection bag. The bag of trash can then be thrown into a proper disposal unit. The holder can also be used without a collection bag or liner to create organized piles of waste when the holder is removed. In such instances, the present invention might more appropriately be referred to merely as a receptacle, rather than as a holder.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other features, aspects, and advantages of the present invention are considered in more detail, in relation to the following description of embodiments thereof shown in the accompanying drawings, in which:
FIG. 1 shows an embodiment of the present invention in various stages of going from being fully collapsed, with a ring attached to the outside of one if its wide panels, to being fully opened and with a collection bag inserted into the holder.
FIG. 2 is a perspective view of a partially collapsed bag holder according to an embodiment of the present invention.
FIG. 3 is a front elevational view of the holder of FIG. 2 .
FIG. 4 is a rear elevational view of the holder of FIG. 2 .
FIG. 5 is a side elevational view of the holder of FIG. 2 .
FIG. 6 is a bottom plan view of the holder of FIG. 2 .
FIG. 7 is a top plan view of the holder of FIG. 2 .
FIG. 8 is an enlarged view of a portion of FIG. 7 .
FIG. 9 is a series of views of a front and back panel for a holder according to the present invention.
FIG. 10 is a series of views of one side panel for a holder according to the present invention.
FIG. 11 is an enlarged view of a portion of the panel in FIG. 10 .
FIG. 12 is a series of views of another side panel for a holder according to the present invention.
FIG. 13 is an enlarged view of a portion of the panel in FIG. 12 .
FIG. 14 is a top plan view of top ring according to an embodiment of the present invention.
FIG. 15 is a bottom plan view of the top ring of FIG. 14 .
FIG. 16 is an enlarged view of a portion of FIG. 15 .
FIG. 17 is a side elevational view of the top ring of FIG. 14 .
FIG. 18 is an enlarged view of a portion of FIG. 17 .
FIG. 19 is a top plan view of an alternate top lid according to an embodiment of the present invention.
FIG. 20 is a bottom plan view of the alternate top lid of FIG. 19 .
FIG. 21 is a side elevational view of the alternate top lid of FIG. 19 .
FIG. 22 is an isometric view of the holder with each type of top lid.
FIG. 23 is a top view of fully open holder according to an embodiment of the present invention.
FIG. 24 is a top view of fully closed holder according to an embodiment of the present invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
The invention summarized above and defined by the enumerated claims may be better understood by referring to the following description, which should be read in conjunction with the accompanying drawings in which like reference numbers are used for like parts. This description of an embodiment, set out below to enable one to practice an implementation of the invention, is not intended to limit the preferred embodiment, but to serve as a particular example thereof. In addition, 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. The invention is capable of other embodiments and of being practiced and carried out in various ways. Those skilled in the art should appreciate that they may readily use the conception and specific embodiments disclosed as a basis for modifying or designing other methods and systems for carrying out the same purposes of the present invention. Those skilled in the art should also realize that such equivalent assemblies do not depart from the spirit and scope of the invention in its broadest form.
The present invention is seen to be a collapsible garbage or trash bag holder for primary use with a throw-away, trash collection bag, of the type that has a large opening through which trash can be inserted into the bag, and where the holder can fold into a flat shape for storage, and is especially well suited for use in locations that temporarily require garbage or trash collection. When the present invention is used without a collection bag or liner to create organized piles of waste, the present invention might more appropriately be referred to as a receptacle, rather than as a holder.
The present invention is intended to be used in, but is not limited to, locations that temporarily require a trash can. The receptacle can be quickly deployed and then, once it is no longer needed, it can be folded for storage. Since the holder can be folded, the holder will not waste space during storage. This allows the holder to be transported and stored efficiently.
The bag holder is designed to hold a bag for collection of a large volume of waste. The problem with large volumes of waste is that the weight of the waste may be very heavy. In a preferred embodiment of the present invention, the holder does not have a bottom so that the waste can be removed from the holder without lifting the waste out of the holder. In a preferred embodiment, the holder will be lined with a liner bag so that the waste is contained within the liner bag. The top ring will retain the bag in place. To take out the bag, the ring is removed, then the bag is tied at the top and the holder is lifted up off the contained trash, folded, and stored. The bag of trash can then be thrown into a proper disposal unit. The holder can be used without a bag or liner to create organized piles of waste when the holder is removed.
In general, the holder's profile is a rectangle constructed out of six panels. Two symmetric large panels comprise two of the opposite sides. The other two opposite sides are each comprised of two smaller panels that together are sized so that when the holder is folded the vertices of the smaller two sides, also known as the hinge points, clear each other for the holder to fold flat. The smaller panels are attached to each other and to the large panels by interlocking hinges. The smaller panel sides fold inwardly when the holder is collapsed. In a preferred embodiment, each smaller panel is slightly less than half as wide as each larger panel. Therefore, the holder can be folded into itself much like the way a paper bag flattens out.
A preferred embodiment of the invention is made of commercial grade injection molded plastic. Other versions of the invention could be made of various materials such as metal or wood. The invention must be made of a rigid material.
Referring to the drawings, FIG. 1 shows a holder 10 according to the present invention. When the holder 10 is deployed, the sides are folded out into a rectangular shape. The shape is then maintained by placing a top ring 13 over the holder 10 . FIG. 1 show the present invention in various stages of going from being fully collapsed, with its top ring 13 attached to the outside of one if its panels, to being fully opened and with a collection bag inserted into the holder 10 . The top ring 13 (see FIGS. 14-18 ) prevents the holder 10 from collapsing and holds the bag or other liner in place. When the top ring 13 is removed, the holder can collapse into a flat position having a thickness approximately equal to the thickness of the four sides. In a preferred embodiment, the holder 10 folds to a thickness of approximately 2 inches. Other embodiments could fold to other thicknesses. In some embodiments, the top ring 13 has a large opening for all waste. In other embodiments, an alternate lid 16 can replace the top ring 13 , such as shown in FIGS. 19-21 . Such alternate lid 16 has at least one shaped opening 19 for a specific kind of waste; an aluminum can is an example of such a kind of specific waste. Some versions of the holder 10 may have a weight constructed into the bottom of one or more of the sides to prevent the holder 10 from falling over when empty and/or under wind loads. Some embodiments of the holder 10 will have a foothold that can be used to seize the holder 10 when removing the top ring 13 and may further include finger holes for opening the holder 10 from its collapsed position. Preferably, all holders 10 of the same size can be nested onto each other by alternating their orientation for efficient storage.
FIG. 2 shows a perspective view of a partially collapsed bag holder 10 according to an embodiment of the present invention. The holder 10 has two wide panels 21 and four narrow panels, two each of panels 23 and 25 . The wide panels 21 are hingedly attached at one long edge to panel 23 and at the opposite long edge to panel 25 . Narrow panels 23 and 25 are hingedly attached to each other at their remaining long edge. In FIGS. 2-7 , the holder 10 is partly folded at the attachment points of wide panel 21 and narrow panels 23 , 25 . Wide panel 21 may also include a handle opening 28 that can be used to aid in removing the holder 10 over the top of a filled trash collection bag. FIGS. 6 and 7 are bottom and top views, respectively, of the partially open holder 10 . FIG. 8 is an enlarged portion of FIG. 7 , labeled A.
FIG. 9 shows front, back, side, and top views of a wide panel 21 for a holder 10 according to the present invention. Panel 21 is substantially rectangular in shape having two short sides 30 , 31 and two long sides 33 , 34 . The long sides 33 , 34 have tabs 37 configured for attachment to narrow panels 23 and 25 to form a hinged joint. One panel 21 forms the front of holder 10 and a second panel 21 forms the back of holder 10 .
In a preferred embodiment, the holder 10 includes a means for attaching the top ring 13 or alternate lid 16 to the side of the collapsed holder during storage. A plurality of flat hooks 40 can be integrated with the tabs 37 . The flat hooks 40 are sized and configured to enable a ledge 43 of the top ring 13 to slide under the flat hook 40 , as shown in FIG. 8 .
In some embodiments of the invention, the flat hooks 40 can be used to allow for inserting a panel 42 ( FIG. 1 ) with advertising, sponsorships, and or useful information pertaining to the event or location in which the holder 10 is used. As shown in FIG. 1 , an advertising panel 42 can be inserted into the flat hook pieces 40 . This is particularly useful for community and government fund raising events, construction site advertising, and any event where a display of any kind maybe of use.
FIGS. 10 and 11 show front, side, and top views of one narrow panel 23 for a holder 10 according to the present invention. Panel 23 is substantially rectangular in shape having two short sides 45 , 46 and two long sides 48 , 49 . The long side 48 has tabs 52 configured for attachment to wide panel 21 . The long side 49 has tabs 53 configured for attachment to narrow panel 25 to form a hinged joint that translates inwardly of the holder 10 when in a collapsed position. One panel 23 forms half of each side of the holder 10 .
FIGS. 12 and 13 show front, side, and top views of a second narrow panel 25 for a holder 10 according to the present invention. Panel 25 is substantially rectangular in shape having two short sides 55 , 56 and two long sides 58 , 59 . The long side 58 has tabs 62 configured for attachment to wide panel 21 . The long side 59 has tabs 63 configured for attachment to narrow panel 23 to form a hinged joint that translates inwardly of the holder 10 when in a collapsed position. One panel 25 forms half of each side of the holder 10 .
The hinges formed by the long sides of panels 21 , 23 , and 25 can be any kind of hinge. A preferred embodiment envisions a traditional knuckle and pin hinge illustrated in FIGS. 11 and 13 . Other hinges could be made of a fold or crease in the material that the wide panel 21 and narrow panels 23 , 25 are made of. Alternatively, the hinge could be a piece of flexible material that links the wide panel 21 and narrow panels 23 , 25 together.
FIG. 14 is a top view of a top ring 13 according to the present invention. Top ring 13 is sized and configured to cover the top edges 30 , 45 , and 55 of the wide panel 21 and narrow panels 23 , 25 , respectively, when in the holder 10 is in a fully open position. FIG. 15 shows a bottom view of top ring 13 , and FIG. 17 shows a side view of top ring 13 . FIG. 16 is an enlarged portion of FIG. 15 , labeled B and FIG. 18 is an enlarged portion of FIG. 17 , labeled C. The top ring 13 includes a ledge 43 around the perimeter of the top ring 13 . The top ring 13 further includes a flange 65 around the inner portion of the top ring 13 , adjacent to and substantially perpendicular to the ledge 43 . The flange 65 is sized and configured to fit inside the top edges 30 , 45 , and 55 of the wide panel 21 and narrow panels 23 , 25 , respectively, when the holder 10 is in the fully open position. As shown in FIG. 16 , the flange 65 may be beveled at its corner to allow for fit with the hinge formed at the intersection of the wide panel 21 and narrow panels 23 , 25 .
FIG. 19 shows an alternative version to maintain the holder 10 in an open condition. The lid 16 does not have the typical large opening through which trash is passed in order to deposit it in a collection bag that is kept by the holder 10 . In this embodiment, the lid 16 has one or more shaped openings 19 for a specific kind of waste. An aluminum can is an example of such a kind of specific waste. FIG. 20 shows a bottom view of lid 16 , and FIG. 21 shows a side view of lid 16 . As with the top ring 13 described above, lid 16 includes a ledge 67 around the perimeter of the lid 16 . The lid 16 further includes a flange 69 around the inner portion of the ledge 67 , adjacent to and substantially perpendicular to ledge 67 . The flange 69 is sized and configured to fit inside the top edges 30 , 45 , and 55 of the wide panel 21 and narrow panels 23 , 25 , respectively, when the holder 10 is in the fully open position.
The holder 10 can be made of any rigid material. A preferred embodiment of the invention envisions a holder 10 made of plastic. Other versions of the holder 10 can be made of metal or wood. Still other versions of the holder 10 can be made of cardboard or rigid paper. In some versions, different parts of the holder 10 can be made of different materials. As an example, and not meant as a limitation, the wide panels 21 could be made of one material, while the narrow panels 23 , 25 could be made of another. Alternatively, the top ring 13 could be made of a different material than the rest of holder 10 .
The invention has been described with references to preferred embodiments. While specific values, relationships, materials and steps have been set forth for purposes of describing concepts of the invention, it will be appreciated by persons skilled in the art that numerous variations and/or modifications can be made to the invention as shown in the specific embodiments without departing from the spirit or scope of the basic concepts and operating principles of the invention as broadly described. It should be recognized that, in the light of the above teachings, those skilled in the art could modify those specifics without departing from the invention taught herein. Having now fully set forth the preferred embodiments and certain modifications of the concept underlying the present invention, various other embodiments as well as certain variations and modifications of the embodiments herein shown and described will obviously occur to those skilled in the art upon becoming familiar with the underlying concept. It is intended to include all such modifications, alternatives, and other embodiments insofar as they come within the scope of the appended claims or equivalents thereof. It should be understood, therefore, that the invention might be practiced otherwise than as specifically set forth herein. Consequently, the present embodiments are to be considered in all respects as illustrative and not restrictive.
|
A portable trash container for holding a removable plastic bag for storing paper, bottles, cans, and like trash. The holder includes rectangular front and rear panels, each having a top, bottom and side edges, (b) two side panels, each having two rectangular, foldable parts with top, bottom and side edges, (c) side hinges which connect the adjoining side edges of said side panel folding parts so as to allow them to fold together along said hinges, (d) primary hinges which connect the side edges of said front and rear panels to the outer side edges of said side panel folding parts so as to allow the side panels to be folded so that the front and rear panels can be brought into close and overlapping proximity to one another, and (e) a top ring that is adapted to fit over the top edges of said panels so as to locate and hold open the opening of a throw-away, trash collection bag.
| 8
|
CROSS-REFERENCE TO RELATED APPLICATION
This U.S. application claims priority under 35 U.S.C 371 to, and is a U.S. National Phase application of, the International Patent Application No. PCT/CN2014/072278, filed 19 Feb. 2014, which claims the benefit of prior Chinese Application No. 201210571692.6 filed 19 Dec. 2012. The entire contents of the above-mentioned patent applications are incorporated by reference as part of the disclosure of this U.S. application.
FIELD OF INVENTION
The present invention relates to a vibration isolator with zero stiffness whose angle degree of freedom is decoupled with a spherical air bearing, which can be used for low frequency and high performance vibration isolation in precision measurement instruments and manufacturing equipments.
DESCRIPTION OF PRIOR ART
With quick development of precision measurement and manufacturing, environmental vibration has become a main factor that limits the precision and performance of precision measuring instruments and manufacturing equipments. For example, step-scan lithography machines are most precise among all kinds of manufacturing equipments, their line width of lithography is up to 22 nm, and their wafer positioning precision and overlay precision are up to several nanometers. Meanwhile, movement speed of their wafer stages is up to 1 m/s, and acceleration is up to dozens of times of gravitational acceleration. For such ultra-precision equipments, precision vibration isolation is a key technology. A very quiet environment should be provided for measuring systems and objective lens, while wafer stages should be moved with high speed and acceleration. 3D nature frequencies of vibration isolation systems should be smaller than 1 Hz. On the other hand, relative position between key parts in a lithography machine, such as the distance between objective lens and wafers should be precisely controlled, control precision of relative position between upper mounting plates and lower mounting plates of vibration isolators should reach 10 μm.
The natural frequency of a passive vibration isolator is proportional to its stiffness, and inversely proportional to its mass. Therefore it is a very efficient way to lower natural frequency of a vibration isolator and improve its performance through reducing its stiffness. However, for a traditional vibration isolator based on air spring, it's very difficult to further reduce its stiffness, especially horizontal stiffness. To solve this problem, researchers introduce a “pendulum” structure in a vibration isolator based on air spring to reduce their lateral stiffness (1. Nikon Corporation. Vibration Isolator with Low Lateral Stiffness. U.S. Patent No.: US20040065517A1; 2. U.S. Philips Corporation. Positioning Device with a Force Actuator System for Compensating Center-of-gravity Displacements, and Lithographic Device Provided with Such A Positioning Device. U.S. Patent No.: US005844664A). With this method, lateral stiffness of a vibration isolator based on air spring can be reduced and its performance can be improved to a certain extent. However, there are following shortcomings: 1) the extent of reducing of horizontal and vertical stiffness is limited by material property and structural stiffness; 2) horizontal and vertical positioning precision of a vibration isolator based on air spring is too low to meet requirement of lithography; 3) a large length of “pendulum” is needed to achieve low horizontal stiffness, being apt to result large height of the vibration isolator, chord-membrane-resonance and poor stability.
It's difficult to meet requirements of low stiffness and high positioning precision in a lithography machine with existing vibration isolators based on air spring. German company IDE presents a new vibration isolator (1. Integrated Dynamics Engineering GmbH. Isolatorgeometrie Eines Schwingungsisolationssystem. European Patent No.: EP1803965A2; 2. Integrated Dynamics Engineering GmbH. Schwingungsisolationssystem Mit Pneumatischem Tiefpassfilter. European Patent No.: EP1803970A2; 3. Integrated Dynamics Engineering GmbH. Air Bearing with Consideration of High-Frequency Resonances. US Patent No.: US20080193061A1). Air bearing surface is introduced to decouple and isolate vertical and horizontal vibration, and very low stiffness and natural frequency can be achieved. However, there are still following shortcomings: 1) high positioning precision can't be achieved with presented design; 2) in patent EP1803965A2, there are no rotary degrees of freedom around horizontal axes between upper and lower mounting plates, so stiffness and natural frequency in that direction are both high, a rubber block is used to provide rotary degrees of freedom around horizontal axes in patents EP1803970A2 and US20080193061A1, however, the angle degree of freedom can't be effectively decoupled due to large angular stiffness of the rubber block.
Netherlandish company ASML has proposed a similar design (1. U.S. Philips Corp, ASM Lithography B.V. Pneumatic Support Device with A Controlled Gas Supply, and Lithographic Device Provided with Such A Support Device. US Patent No.: US006144442A; 2. Koninklijke Philips Electronics N.V., ASM Lithography B.V. Lithographic Pneumatic Support Device with Controlled Gas Supply. International patent publication No.: WO99/22272; 3. ASML Netherlands B.V. Support Device, Lithographic Apparatus, and Device Manufacturing Method Employing A Supporting Device, and A Position Control System Arranged for Use in A Supporting Device. US Patent No.: US007084956B2; 4. ASML Netherlands B.V. Support Device, Lithographic Apparatus, and Device Manufacturing Method Employing A Supporting Device and A Position Control System Arranged for Use in A Supporting Device. European Patent No.: EP1486825A1). The air pressure is close-loop controlled to increase the stability and performance of the vibration isolator in patents US006144442A and WO99/22272. A vibration sensor is mounted on the upper mounting plate and a reference system is introduced as well to improve performance of vibration isolation in patents US007084956B2 and EP1486825A1. However, problems of precision positioning and decoupling of angle degree of freedom between the upper and lower mounting plates are not solved.
SUMMARY OF INVENTION
In order to solve the problem of precision positioning and decoupling of angle degree of freedom between the upper and lower mounting plates, the prevent invention provides a vibration isolator with 3D zero stiffness whose angle degree of freedom is decoupled with a spherical air bearing. And it can be used for high performance vibration isolation in precision measuring instruments and manufacturing equipments, such as step-scan lithography machines.
The present invention provides a vibration isolator with zero stiffness whose angle degree of freedom is decoupled with a spherical air bearing, which comprises a upper mounting plate ( 1 ), a lower mounting plate ( 2 ), a clean air compressor ( 3 ), air pipe ( 26 ) and a main body ( 4 ), the main body ( 4 ) is fitted between the upper mounting plate ( 1 ) and the lower mounting plate ( 2 ), the clean air compressor ( 3 ) is connected to the main body ( 4 ) with the air pipe ( 26 ); in the main body ( 4 ), the lower surface of a downside-down sleeve ( 6 ) and the lower mounting plate ( 2 ) are lubricated and supported against each other with a planar air bearing surface ( 21 ), a upside-down piston cylinder ( 5 ) is fitted inside the sleeve ( 6 ) and they are lubricated and supported against each other with a cylindrical air bearing surface ( 22 ), a spherical air bearing ( 7 ) is fitted between the piston cylinder ( 5 ) and the upper mounting plate ( 1 ), a voice coil motor in Z direction ( 10 ), a displacement sensor in Z direction ( 13 ) and a limit switch in Z direction ( 16 ) are fitted between the piston cylinder ( 5 ) and the sleeve ( 6 ), a voice coil motor in X direction ( 8 ), a displacement sensor in X direction ( 11 ) and a limit switch in X direction ( 14 ) as well as a voice coil motor in Y direction ( 9 ), a displacement sensor in Y direction ( 12 ) and a limit switch in Y direction ( 15 ) are fitted between the sleeve ( 6 ) and the lower mounting plate ( 2 ), the direction of driving force of the voice coil motor in Z direction ( 10 ) is vertical, while the direction of driving force of the voice coil motor in X direction ( 8 ) and voice coil motor in Y direction ( 9 ) is horizontal and perpendicular to each other, the sensitive direction of the displacement sensor in X direction ( 11 ), the displacement sensor in Y direction ( 12 ) and the displacement sensor in Z direction ( 13 ) as well as the limit switch in X direction ( 14 ), the limit switch in Y direction ( 15 ) and the limit switch in Z direction ( 16 ) are the same as the direction of driving force of the voice coil motor in X direction ( 8 ), the voice coil motor in Y direction ( 9 ) and the voice coil motor in Z direction ( 10 ) respectively; the displacement sensor in X direction ( 11 ), the displacement sensor in Y direction ( 12 ) and the displacement sensor in Z direction ( 13 ) as well as the limit switch in X direction ( 14 ), the limit switch in Y direction ( 15 ) and the limit switch in Z direction ( 16 ) are connected to signal input terminals of a controller ( 19 ), signal output terminals of the controller ( 19 ) are connected to signal input terminals of a driver ( 20 ), and signal output terminals of the driver ( 20 ) are connected to the voice coil motor in X direction ( 8 ), the voice coil motor in Y direction ( 9 ) and the voice coil motor in Z direction ( 10 ) respectively.
Preferably an air pressure sensor ( 17 ) is fitted inside the piston cylinder ( 5 ), there is an air inlet ( 23 ) and an electromagnetic valve ( 18 ) in the piston cylinder ( 5 ), the air pressure sensor ( 17 ) is connected to a signal input terminal of the controller ( 19 ), a signal output terminal of the controller ( 19 ) is connected to a signal input terminal of the driver ( 20 ), a signal output terminal of the driver ( 20 ) is connected to the electromagnetic valve ( 18 ).
The voice coil motor in X direction ( 8 ), the voice coil motor in Y direction ( 9 ) and the voice coil motor in Z direction ( 10 ) are cylindrical voice coil motors or flat voice coil motors.
The displacement sensor in X direction ( 11 ), displacement sensor in Y direction ( 12 ) and displacement sensor in Z direction ( 13 ) are grating rulers, magnetic grid rulers, capacitive grid rulers or linear potentiometers.
The limit switch in X direction ( 14 ), limit switch in Y direction ( 15 ) and limit switch in Z direction ( 16 ) are mechanical limit switches, hall limit switches or photoelectric limit switches.
Preferably the air pressure inside said piston cylinder ( 5 ) is 0.1 MPa˜0.8 MPa.
Preferably the thickness of compressed air film of the planar air bearing surface ( 21 ) and the cylindrical air bearing surface ( 22 ) is 10 μm˜20 μm.
The diameter of throttle holes in cylindrical air bearing surface ( 25 ) of the piston cylinder ( 5 ) and planar air bearing surface ( 24 ) of the sleeve ( 6 ) is φ0.1 mm˜φ1 mm.
The present invention has following advantages:
(1) No fiction, wear and additional stiffness introduced into vibration isolators during decoupling of angle degree of freedom. The present invention introduces a spherical air bearing to decouple the angle degree of freedom between the upper and lower mounting plates, and the problem of friction, wear and introduction of additional stiffness in existing designs and patents during decoupling with elastic body can be successfully solved.
(2) Approximate zero stiffness so that outstanding low frequency vibration isolation performance can be achieved. The present invention employs a planar air bearing surface and a cylindrical air bearing surface to decouple and isolation vibration in horizontal and vertical directions, the difficulty of very low stiffness and contradiction between stiffness and stability in existing designs and patents can be solved.
(3) High positioning precision for control of relative position between upper and lower mounting plates. The present invention employs voice coil motors, displacement sensors, limit switches, a controller and a driver to form position close-loop control systems in vertical and horizontal directions, so that the relative position between upper and lower mounting plates can be precisely controlled to 10 μm. The problem of low positioning precision and contradiction between positioning precision and stiffness in existing design and patents can be solved.
(4) Ideal gravity balance for excellent vertical vibration isolation with zero stiffness. The present invention employs an air pressure sensor, an electromagnetic valve, a controller and a driver to form an air pressure close-loop control system, so that the air pressure inside the sleeve is precisely controlled, and the gravity of vertical load of the vibration isolator can be balanced with high precision.
BRIEF DESCRIPTION OF ACCOMPANYING DRAWINGS
FIG. 1 is a structure diagram of the vibration isolator with zero stiffness whose angle degree of freedom is decoupled with a spherical air bearing.
FIG. 2 is a cross-sectional view of the vibration isolator with zero stiffness whose angle degree of freedom is decoupled with a spherical air bearing.
FIG. 3 is a 3D cross-sectional view of the vibration isolator with zero stiffness whose angle degree of freedom is decoupled with a spherical air bearing.
FIG. 4 is a block diagram of control of the vibration isolator with zero stiffness whose angle degree of freedom is decoupled with a spherical air bearing.
FIG. 5 is one embodiment of throttle holes in the planar air bearing surface of the sleeve.
FIG. 6 is one embodiment of throttle holes in the cylindrical air bearing surface and the spherical air bearing surface of the piston cylinder.
DESCRIPTION OF PREFERRED EMBODIMENTS
Preferred embodiments of the present invention will be described in detail with reference to accompanying drawings.
As shown in FIG. 1 , FIG. 2 and FIG. 3 , a vibration isolator with zero stiffness whose angle degree of freedom is decoupled with a spherical air bearing comprises a upper mounting plate 1 , a lower mounting plate 2 , a clean air compressor 3 , an air pipe 26 and a main body 4 , the main body 4 is fitted between the upper mounting plate 1 and the lower mounting plate 2 , and the clean air compressor 3 is connected to the main body 4 with the air pipe 26 ; in the main body 4 , the lower surface of a downside-down sleeve 6 and the lower mounting plate 2 are lubricated and supported against each other with a planar air bearing surface 21 , a upside-down piston cylinder 5 is fitted inside the sleeve 6 and they are lubricated against each other with a cylindrical air bearing surface 22 , a spherical air bearing 7 is fitted between the piston cylinder 5 and the upper mounting plate 1 , a voice coil motor in Z direction 10 , a displacement sensor in Z direction 13 and a limit switch in Z direction 16 are fitted between the piston cylinder 5 and the sleeve 6 , a voice coil motor in X direction 8 , a displacement sensor in X direction 11 and a limit switch in X direction 14 as well as a voice coil motor in Y direction 9 , a displacement sensor in Y direction 12 and a limit switch in Y direction 15 are fitted between the sleeve 6 and the lower mounting plate 2 , the direction of driving force of the voice coil motor in Z direction 10 is vertical, while the direction of driving force of the voice coil motor in X direction 8 and voice coil motor in Y direction 9 is horizontal and perpendicular to each other, the sensitive direction of the displacement sensor in X direction 11 , the displacement sensor in Y direction 12 and the displacement sensor in Z direction 13 as well as the limit switch in X direction 14 , the limit switch in Y direction 15 and the limit switch in Z direction 16 are the same as the direction of driving force of the voice coil motor in X direction 8 , the voice coil motor in Y direction 9 and the voice coil motor in Z direction 10 respectively; the displacement sensor in X direction 11 , the displacement sensor in Y direction 12 and the displacement sensor in Z direction 13 as well as the limit switch in X direction 14 , the limit switch in Y direction 15 and the limit switch in Z direction 16 are connected to signal input terminals of a controller 19 , signal output terminals of the controller 19 are connected to signal input terminals of a driver 20 , and signal output terminals of the driver 20 are connected to the voice coil motor in X direction 8 , the voice coil motor in Y direction 9 and the voice coil motor in Z direction 10 respectively.
Preferably an air pressure sensor 17 is fitted inside the piston cylinder 5 , there is an air inlet 23 and an electromagnetic valve 18 in the piston cylinder 5 , the air pressure sensor 17 is connected to a signal input terminal of the controller 19 , a signal output terminal of the controller 19 is connected to a signal input terminal of the driver 20 , a signal output terminal of the driver 20 is connected to the electromagnetic valve 18 .
The voice coil motor in X direction 8 , the voice coil motor in Y direction 9 and the voice coil motor in Z direction 10 are cylindrical voice coil motors or flat voice coil motors.
The displacement sensor in X direction 11 , displacement sensor in Y direction 12 and displacement sensor in Z direction 13 are grating rulers, magnetic grid rulers, capacitive grid rulers or linear potentiometers.
The limit switch in X direction 14 , limit switch in Y direction 15 and limit switch in Z direction 16 are mechanical limit switches, Hall limit switches or photoelectric limit switches.
Preferably the air pressure inside said piston cylinder 5 is 0.1 MPa˜0.8 MPa.
Preferably the thickness of compressed air film of the planar air bearing surface 21 and the cylindrical air bearing surface 22 is 10 μm˜20 μm.
The diameter of throttle holes in cylindrical air bearing surface 25 of the piston cylinder 5 and planar air bearing surface 24 of the sleeve 6 is φ0.1 mm˜φ1 mm.
One embodiment of the prevent invention is provided with reference to FIG. 1 , FIG. 2 and FIG. 3 . In this embodiment, the lower mounting plate 2 is fitted onto the base of measurement instruments or manufacturing equipments, and the upper mounting plate 1 is fitted onto the load to be vibration isolated. The voice coil motor in X direction 8 , the voice coil motor in Y direction 9 and the voice coil motor in Z direction 10 are cylindrical voice coil motors. Take the voice coil motor in Y direction 9 for example, it comprises an iron yoke of motor Y 9 a , a magnetic block of motor Y 9 b , a coil skeleton of motor Y 9 c , a coil of motor Y 9 d and a mounting piece of motor Y 9 e . The iron yoke of motor Y 9 a , the magnetic block of motor Y 9 b , and the coil skeleton of motor Y 9 c are cylindrical, the coil of motor Y 9 d is wound around the coil skeleton of motor Y 9 c , the mounting piece of motor Y 9 e provide a mounting structure for the coil skeleton of motor Y 9 c . According to electromagnetic theory, magnitude and direction of driving force which the motor outputs can be precisely controlled by adjusting magnitude and direction of current in the coil.
The spherical air bearing 7 in this embodiment is fitted in such a way: its lower surface is mounted onto the piston cylinder 5 , and is lubricated and supported against the piston cylinder 5 with the spherical air bearing surface 27 , the upper surface of spherical air bearing 7 is rigidly fitted onto the upper mounting plate 1 .
In this embodiment, the displacement sensor in X direction 11 , the displacement sensor in Y direction 12 and the displacement sensor in Z direction 13 are grating rulers. Take the displacement sensor in Z direction 13 for example, it comprises a mounting piece of grating Y 13 a , a reading head of grating Z 13 b and a glass ruler of grating Z 13 c . The mounting piece of grating Y 13 a provides a mounting structure for the reading head of grating Z 13 b . The reading head of grating Z 13 b can detect the relative displacement between itself and the glass ruler of grating Z 13 c , and then deliver the displacement signal to the controller 19 .
In this embodiment, the limit switch in X direction 14 , the limit switch in Y direction 15 and the limit switch in Z direction 16 are Hall limit switches. Take the limit switch in Z direction 16 for example, it comprises two limit blocks of switch Z 16 a , two Hall switches of switch Z 16 b and a mounting piece of switch Z 16 c . Two Hall switches of switch Z 16 b are fitted back to back against each other. The mounting piece of switch Z 16 c provides a mounting structure for two Hall switches of switch Z 16 b . When two Hall switches of switch Z 16 b are moved close to two limit blocks of switch Z 16 a , a limit signal will be generated and delivered to the controller 19 .
In this embodiment, the voice coil motor in Z direction 10 , the displacement sensor in Z direction 13 and the limit switch in Z direction 16 are all fitted between the piston cylinder 5 and the sleeve 6 and inside the piston cylinder 5 .
The load of the presented vibration isolator is supported in such a way: the clean air compressor 3 feeds clean compressed air into the piston cylinder 5 via the air pipe 26 , the electromagnetic valve 18 and the air inlet 23 . The controller 19 adjusts the open degree of the electromagnetic valve 18 according the feedback signal of the air pressure sensor 17 . As a result, the air pressure in the piston cylinder 5 is precisely adjusted so that the upward force applied on the piston cylinder 5 is balanced with load, gravity of the piston cylinder 5 and other parts fitted together with it.
In this embodiment, the pressure of clean compressed air in the piston cylinder 5 is 0.4 Mpa, the effective radius of the lower surface of the piston cylinder 5 is 100 mm, so the mass that a single vibration isolator can support is: m=p×πr 2 /g≈1282 kg, where p is the air pressure, p=0.4 Mpa, r is the effective radius of the lower surface of the piston cylinder 5 , r=100 mm, and g is the gravity acceleration, g=9.8 m/m 2 .
A preferred embodiment of throttle holes in planar air bearing surface of sleeve 6 is provided with reference to FIG. 5 . In this embodiment, 8 throttle holes in planar air bearing surface 24 with diameter of φ0.2 mm are uniformly distributed in a circle direction around the center of the lower surface of the sleeve 6 .
A preferred embodiment of throttle holes in cylindrical air bearing surface and spherical air bearing surface of the piston cylinder 5 is provided with reference to FIG. 6 . In this embodiment, two rows of throttle holes in cylindrical air bearing surface 25 of piston cylinder 5 are uniformly distributed in a circle direction in the side wall of the piston cylinder 5 . There are 8 throttle holes with diameter of φ0.2 mm in each row. Throttle holes in spherical air bearing surface 28 with diameter of φ0.2 mm are uniformly distributed in a circle direction around the center of the upper surface of the piston cylinder 5 .
In the accompanying drawings:
upper mounting plate
1
lower mounting plate
2
clean air compressor
3
main body
4
piston cylinder
5
sleeve
6
spherical air bearing
7
voice coil motor in X direction
8
voice coil motor in Y direction
9
iron yoke of motor Y
9a
magnetic block of motor Y
9b
coil skeleton of motor Y
9c
coil of motor Y
9d
mounting piece of motor Y
9e
voice coil motor in Z direction
10
iron yoke of motor Z
10a
magnetic block of motor Z
10b
coil skeleton of motor Z
10c
coil of motor Z
10d
mounting piece of motor Z
10e
displacement sensor in X direction
11
displacement sensor in Y direction
12
mounting piece of grating Y
12a
reading head of grating Y
12b
glass ruler of grating Y
12c
displacement sensor in Z direction
13
mounting piece of grating Y
13a
reading head of grating Z
13b
glass ruler of grating Z
13c
limit switch in X direction
14
limit switch in Y direction
15
limit block of switch Y
15a
Hall switch of switch Y
15b
mounting piece of switch Y
15c
mounting piece of limit Y
15d
limit switch in Z direction
16
limit block of switch Z
16a
Hall switch of switch Z
16b
mounting piece of switch Z
16c
air pressure sensor
17
electromagnetic valve
18
controller
19
driver
20
planar air bearing surface
21
cylindrical air bearing surface
22
air inlet
23
throttle hole in planar air bearing surface
24
throttle hole in cylindrical air bearing surface
25
air pipe
26
spherical air bearing surface
27
throttle hole in spherical air bearing surface
28
|
A vibration isolator with zero stiffness whose angle degree of freedom is decoupled with a spherical air bearing has a main body, in which a sleeve and a lower mounting plate, a piston cylinder and the sleeve are both lubricated and supported with air bearing surfaces respectively, and the angle degree of freedom between a upper mounting plate and the lower mounting plate is decoupled with a spherical air bearing; a position close-loop control system comprising voice coil motors, displacement sensors, limit switches, a controller and a driver is introduced, and the relative position between the upper mounting plate and the lower mounting plate is precisely controlled.
| 6
|
CROSS REFERENCE TO RELATED APPLICATION(S)
[0001] This application claims priority from U.S. Provisional Application having Ser. No. 60/577,982 and a filing date of 8 Jun. 2004.
BACKGROUND
[0002] 1. Field of Invention
[0003] The present invention is directed to the design and manufacturing of a lightweight, stiff, and curved reflector, particularly, for the incorporation with a thin rear projection display system, front projection display system, or fiber optic light source.
[0004] 2. Description of Background
[0005] Generally, the consumer market has desired, inter alia, increasingly larger displays capable of displaying brighter and higher resolution image displays. In one particular market segment, the display screens on televisions (hereafter display units) have increased considerably over the last few decades. Moreover, while the viewing area of the display screens has increased, there has been a current trend to reduce the depth of the unit, (e.g., low profile flat screens wherein the depth of the unit approaches zero clearance; W×H×D where D is increasingly smaller).
[0006] However, as the image displays of the units have become larger, pragmatic issues, particularly manufacturing costs, have surfaced therefrom. For example, the increase in weight of a unit has also increased costs; inter alia, increased material, handling/shipping costs per unit, which in turn may incur safety issues, e.g., injuring ones back installing or moving such a conventionally large unit, or should the unit fall over onto an individual. Currently, the greater depth of the unit based on the current technology, the greater the handling/shipping costs, not to mention a greater allocation of floor space. Hence, these characteristics of contemporary large displays become a significant limitation to their usability, are undesirable, and hence should be minimized.
[0007] To reduce the depth of a rear projection display design beyond what is achievable with a flat folding mirror, a range of new projection display systems designs have been conceived that utilize curved reflectors to further reduce the depth of the rear projection display device. For example, U.S. Pat. No. 6,457,834 issued to C. T. Cotton et al. describes the use of a thin projection display system that uses a rectangular curved reflector to fold the light imaging path between a projection light engine and a special projection display screen with a light redirecting optical element.
[0008] In U.S. Pat. No. 6,631,994 issued to Suzuki et al. (hereafter Suzuki '994), the first stated objective thereof, is to provide an image display device that provides an enlarged display of distortion-free images and permits further reduction of its depth dimension than in the prior art. Although it is preferable to minimize the depth dimension of the image display device if the image size displayable is the same, Suzuki '994 appears to attempts to accomplish the depth minimization by incorporating alignment and distortion corrective techniques, but neither references nor addresses the characteristics of weight and rigidity of a mirror, nor methods of manufacturing such a mirror.
[0009] Moreover, others have disclosed that incorporating additional components, e.g., additional mirrors, is one approach to minimizing the depth of the overall unit. For example, in U.S. Pat. No. 6,561,656 B1 issued to Kojima et al, a small-sized, lightweight projector may be achieved by bending the optical path of the illumination optical system through the use of an additional reflecting mirror, or the like provided in the illumination optical system, thereby to make the arrangement of the components compact. However, this piece of art too fails to reference or address the advantages of a lightweight and rigid characteristic of a mirror.
[0010] However, while the use of such a curved mirror has been described in the literature no reference has been given as to how to design and/or manufacture such mirrors to make them economical, light weight, stiff, and of sufficient quality suitable for mass production.
[0011] Existing systems utilize a diamond turned reflector machined from a solid block of Aluminum, thereby making it expensive, heavy, and impractical for the consumer market. Alternatively, slumping of glass over a curved surface has been discussed prior to this application; however, the quality and production yields of the resulting surface shape have rendered this option of being implemented, impractical. Molding the surface with a plastic material into a conventional shape also poses significant quality problems due to the inherent material shrinkage and stress build up of the various moldable materials presently available. Moreover, the amount of materials needed to make this reflector structurally stable makes the resulting reflector heavy and too expensive for a mass production consumer application. This is particularly the case when the longest dimension of the curved reflectors is on the order of one meter (I m) and the widest dimension is approximately one-seventh ( 1/7th) of the longest dimension (here approximately 0.142 m), or when the optical surface has both concave and convex surface portions.
[0012] Alternatively, U.S. Pat. No. 6,527,396 issued to Shinji et. al. (hereafter Shinji '396) describes the use of a curved coupling reflector in order to optimize the coupling optic of a front projection display system. However, while this patent sets forth the benefit of such a design, it fails to shed light on the issue of how to design and/or manufacture said curved coupling reflector, so as incorporate the characteristics of being lightweight and stiff into such a reflector.
[0013] In other art, the output of a fiber optic light source is often coupled to an illumination target with a series of lenses and/or combination of lenses and/or homogenizers. This coupling focuses the beam, which is an optional characteristic. Moreover, the coupling further complicates the issue, by rendering the beam steering device mechanically heavy, and thus undesirable for fine surgical or for extended surgical light treatment applications.
[0014] Thus, the need exists for an improved curved reflector for an optical display system, particularly, a lightweight, stiff, curved mirror with a substantially rectangular form factor for use in combination with a projection display screen, whether rear or frontal, or fiber optic light source; in addition to as the existence of the need of methods of mass manufacturing the same.
[0015] It is an objective of the present invention to teach how to design a curved reflector with a mechanical stiff structure that has an optical surface and at the same time is both lightweight and has a high resistance to compression, tensile and tensional forces.
[0016] It is second objective of the present invention to present methods of manufacturing said mechanical structure in a mass producible manner.
[0017] It is a third objective of the present invention to utilize said curved reflector to manufacture thin, large rear projection display systems.
[0018] It is fourth objective of the present invention to utilize said stiffening mechanical design to improve the stiffness/mass ratio of other curved reflectors utilized within front and rear projection display systems, as well as within other optical imaging and illumination systems. It is further another objective of the present invention to utilize said stiffening mechanical design to improve the manufacturability of curved coupling reflectors for use with projection and fiber optic light sources.
[0019] Those and other advantages and benefits of the present invention will become apparent from the detailed description set forth herein below.
SUMMARY OF THE INVENTION
[0020] The present invention is directed to an improved design and manufacturing methods of a curved reflector and its utilization in a front or rear projection display system, in particular, a thin projection display system with a high width to depth ratio (W/D>5) and as a coupling and beam steering optic in the light engine design of a projection display system and/or fiber optic light sources. In particular, it relates to curved reflectors comprising a curved optical surface and at least one flange surface with at least two portions of said flange surface mechanically rigid connected at the edge of said optical surface at a high tilt angle thereby providing a compression and stretching resistance in at least one direction.
[0021] The curved reflector of the present invention has substantially a rectangular or trapezoidal body, comprising an optical surface and preferentially two pairs of flange surfaces oriented substantially perpendicular to the optical surface, all said surfaces mechanically rigidly connected together along at least some portions near the edges of said optical surface and near the edges of the neighboring flange surface, and where said optical surface is curved at least in two dimensions and where all said optical and flange surfaces have substantially a similar uniform material thickness. The edges of all said oriented flange surfaces above or below to the optical surface together form a reference surface. The mechanical orientation and interconnection of all these surfaces provides a high stiffness to weight ratio and a high resistance to compressive and tensile deformation of the optical surface but low resistance to torsion deformation of said optical surface. The combination of said reference surface with a mating mounting surface provide a very high torsion resistance and a high torsion stiffness to weight ratio, thus providing a shape that is inherently light weight and stiff while simultaneously utilizing a minimum of material to provide these characteristics.
[0022] A preferred method of manufacturing such a shaped curved reflector is to manufacture said structure as a continuous shape with substantially homogeneous material thickness and with practically no mechanical interruptions between said optical and flange surface elements with either a Ni or an NiCo alloy electroforming copy process from a suitably shaped tool and/or molding, and stamping such a structure in a suitable press from a metal foil or moldable material source.
[0023] Another preferred method of the present invention is to manufacture said shape first by cutting, stamping, and/or machining, etc. metal foils into a suitable surface section, and then assembling said curved reflector from a plurality of surface sections, and to rigidly connecting them into the final curved reflector, while a suitable shaping tool stabilizes the optical surface section so that the correct curved surface shape is maintained, thus resulting in a substantially uniform thickness, light weight and stiff structure.
[0024] Preferred methods for said rigid connections of said shaped surface sections include, inter alia, gluing, spot welding, laser welding, arc welding, tack welding, crimping with connection guides, riveting, etc., thereby substantially mating surfaces together. Optionally each such surface can have bendable flanges and/or mounting slots that together can facilitate the mechanical rigid connection of the various surfaces sections while the optical section of the tool is being shaped (e.g., pressed) into the curved surface shape.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] For the present invention to be clearly understood and readily practiced, the present invention shall be described in conjunction with the drawings set forth below:
[0026] FIG. 1 shows an isometric view depicting a LSCR on a mounting surface;
[0027] FIG. 2 shows an isometric view depicting a LSCR on a mounting surface with mounting post;
[0028] FIG. 3 shows the set of shapes cut from thin sheets of material;
[0029] FIG. 4 shows the set of shapes cut from thin sheets of material with mounting holes and slots;
[0030] FIG. 5 shows a schematic representation of the shaping for the optical surface from a foil;
[0031] FIG. 6 shows an isometric view depicting a LSCR assembled from multiple surface sections;
[0032] FIG. 7 shows an isometric view depicting a LSCR assembled from multiple surface sections with two mounting surfaces;
[0033] FIG. 8 shows a rear projection display system incorporating a LSCR;
[0034] FIG. 9 shows a front projection display systems incorporating a LSCR; and
[0035] FIG. 10 shows a preferred fiber optic coupling system.
DETAILED DESCRIPTION OF THE INVENTION
[0036] The present invention is directed to an improved curved reflector for use within an optical display system, particularly, a projection display system and fiber optic light sources. It can be utilized either as part of the projection optic and/or as part of the beam steering and focusing coupling optic. Both applications can benefit from a lightweight, stiff curved reflector.
[0037] FIG. 1 exhibits a first embodiment of the present invention, a light weight, stiff, curved reflector system (LSCR) comprising a thin concave or convex optical curved surface 1 , wherein the optical curved surface 1 further comprises an optical and non-optical side (non-optical side shown in FIG. 1 ); and at least one thin flange surface 2 . The flange surface 2 is in mechanical contact to an optional mounting surface 3 . The flange surface(s) 2 are cooperatively connected, preferably mechanically rigidly connected, to the optical surface 1 along the proximal edge 4 and to the optional mounting surface 3 along the distal edge 5 and to each other along the intermediate edge 6 (only some shown). The flange surfaces 2 are oriented substantially perpendicular to the proximal edge 4 of the optical surface 1 . In this manner, the LSCR by itself is very resistant to compression and tensile forces along the major dimension of the flange surface 2 . When the lamp reflector module (hereafter LRM) is laid to rest on a mounting surface 3 , wherein the distal edges 5 are in contact therewith, the assembly thereof is also very resistant against torsion forces even when the LRM structure is very thin compared to its length, width, or height.
[0038] FIG. 2 exhibits a second embodiment of the present invention for a LSCR having a both concave and convex shaped optical surface 1 , as compared to FIG. 1 illustrating a concave/convex optical surface 1 (depending on perspective) wherein the non-optical side of the optical surface 1 is shown, as is similarly illustrated in FIG. 2 . However, FIG. 2 illustrates a mounting post 7 mounted onto the optional mounting surface 3 , wherein said post 7 supports the LSCR at the distal edge 5 . Alternatively, the flange surface 2 can have a flange mounting support feature 8 supporting the optical surface 1 while in contact to the mounting surface 3 . It is preferred that the thickness of the LSCR is substantially uniform for the whole object or preferentially chosen so as to minimize the material (weight) requirement to fulfill a minimum stiffness requirement specifications.
[0039] For example, if the LSCR is made with a first preferred manufacturing method, i.e. electroforming with a pure Ni electroforming copy process operated close to a zero stress level over a suitable stainless steel mandrel, the thickness can be typically on the order of 1/500- 1/2000 of the longest dimension of the optical surface thus forming a seamless structure and quasi stress free shape. In a second preferred manufacturing process, the material used in the electroforming process is a Ni alloy, for example NiCo, or other combination chosen in such a manner that they make a stiffer part than the pure Ni material itself Optionally, such a preferred manufacturing process enables the overall material thickness to be further minimized so as to achieve equivalent flexure resistance performance.
[0040] Optionally, the optical surface 1 is coated with a reflectivity enhancing thin film, for example enhanced Aluminum or multi layer metal and/or dielectric material comprising high and low index materials deposited with an e-beam and/or sputtering physical vapor deposition process or other equivalent processes.
[0041] In another preferred manufacturing process the optical surface 1 is overcoated with a surface roughness reducing thin film, for example UV curing epoxy or higher temperature capable polyimide film prior to the application of a reflectivity enhancing and/or modifying coating.
[0042] In another preferred embodiment of the present invention, the side flange surface has a portion 9 of its surface not present, e.g., the height of the flange surface varies, so as to further reduce the material cost, while still providing sufficient stiffness against compressive, tensile, and tensional forces trying to distort the shape of the optical surface 1 . More particularly, the total surface area (and thus material cost) of the flange is minimized by varying the height of the flange between the proximal 4 and distal 5 edges.
[0043] In a further preferred embodiment of the present invention the back side or non-optical side of the LSCR (i.e. opposite to the optical active side of the optical surface 1 ), is further stiffened by the coating application of fiberglass resin, carbon fiber matrix embedded into epoxy, structural foam, etc. As such, the material thickness may be further reduced providing that the combination with the back stiffening coating application provides sufficient stiffening resistance for the application at hand. For example, the thickness of the LSCR can be so thin that it might otherwise be subjective to sound vibration, thus enabling the building of an accurate built-in support structure thereby reducing material consumption of the basic LSCR material, for example Ni. Preferentially, such a stiffening-enhancing layer is applied after the vacuum deposition of a reflectivity altering/enhancing film.
[0044] As illustrated in FIG. 2 for an inside optical surface 1 , the optional cutouts 10 of the mounting surface 3 , allows the optical surface to interact with incident light, and perform an imaging and beam steering function.
[0045] Another preferred embodiment of the present invention uses a molding process to make the LSCR shape shown in FIGS. 1 and 2 , which allows a significant minimization of material consumption while maintaining the desired functional performance. Optional glass fiber filled resins are being used to increase the stiffening of the thin material mold. Draft angles, edge feature, and material delivery gates need to be chosen in such a manner so as to minimize any surface shape distortions of the optical surface 1 . It is preferred that low shrinkage thermal setting resins are used for such a molding process, for example BMC 304 or 300 or an equivalent manufactured by Bulk Molding Corporation. A UV curing surface roughness reduction layer (for example UVB553B or equivalent) can be applied to increase the surface reflectivity performance prior to vacuum metallization of the thus achieved LSCR.
[0046] The starting point of a further preferred embodiment of the present invention is shown in FIGS. 3 and 4 . FIG. 4 exhibits mostly rectangular shapes with mounting flange tabs 23 and mounting flange slots 25 . The thin sheets are cut into the required shapes. Stamping, laser cutting, jet cutting, machining are some of the optional shaping processes suitable to create the basic shape. The optical surface 11 and 21 is preferentially made from an optically smooth (polished) thin sheet that optionally is protected one side by a thin plastic film. The flange surfaces 12 and 22 can be made from the same or different material. Optionally, the optical surfaces 11 and 21 , and 12 and 23 can also be molded or slumped sheets of plastic and/or glass.
[0047] FIG. 5 exhibits a thin sheet 31 that is to be shaped by an optically polished shaping tool 33 with a matching counter tool 34 inside a press and/or heated oven.
[0048] FIG. 6 exhibits an assembled and connected LSCR made from individual segments 11 / 21 and 12 / 22 or combinations thereof. The intermediate edge 6 is formed between two side flanges 2 . Several methods are shown to connect the individual surfaces together at their respective proximal edges 4 and intermediate edges 6 . For example, an auxiliary structural support bracket 40 can be used to stiffen the corners. Alternatively, welding, (e.g., spot-, laser- or tack-welding), or gluing of spots 43 may be utilized to stiffen said corners, providing that the spacing frequency is sufficiently dense over the respective edges 4 and 6 .
[0049] FIG. 7 exhibits an assembled LSCR shape wherein only rectangular sheets 21 and 22 are being used to create the stiffened curved reflector. Two mounting reference surfaces 3 A and 3 B are being shown below and above the optical surface 1 . Optionally, the reference surface formed by the respective edges 5 A and 5 B are not parallel to the optical surface 1 . The mounting flange tabs 23 are inserted in to the mounting flange slots 25 , bent around, and connected with a local connection spot 43 .
[0050] FIG. 8 depicts still another preferred embodiment of the present invention: a LSCR reflector is being used in combination with an illumination light engine 100 that is projected with a projection lens 101 , the LSCR with optical surface 1 and side flanges 2 , and the beam steering optic 102 onto the projection screen 103 . The housing 104 contains all the components thus forming a rear projection display system (PDS) of the present invention.
[0051] FIG. 9 depicts yet another preferred embodiment of the present invention where a lamp reflector module (LRM) (for example, an étendue efficient LRM as discussed in U.S. Pat. No. 6,356,700 issued to K. Strobl (hereafter Strobl '700), or an elliptical or parabolic LRM) illuminates a color wheel 200 , is homogenized by an integrator 201 (for example hollow or solid rectangular integrator or EP102 by K. Strobl), and coupled by an coupling lens 202 and an LSCR onto a display device 203 (for example a reflective DMD or LCOS or a transmissive LCD light valve), whose light output is then projected by a projection lens 204 onto a projection screen 205 , thus forming a front projection display system.
[0052] U.S. Pat. No. 6,527,396 issued to Shinji et. al. (hereafter Shinji '396) describes such a front projection display system, however, Shinji '396 fails to teach how to build such a reflector or how to maximize the stiffness/weight ratio of such a reflective focusing and beam steering mirror. Optionally, one or more such LSCR coupling reflectors can be used in a rear projection display system both in the illumination and in the projection optical path.
[0053] Similarly, such a folding mirror can also be used to beam steer, magnify, and optionally, color filter the output of a fiber optic light guide, and to focus the beam back down to the same or different spot size, depending on the application requirements. Color filtration occurs due to the color reflectivity dependent coating applied to the LSCR shape on the respective optical surface 1 side. The benefit from the utilization of such a LSCR reflector is the light weight and rugged device becomes buildable, and well suitable for fine mechanical work, like surgical and light curing and treatment applications, wherein accurate beam steering is accomplished by visual and manual feedback.
[0054] Another preferred manufacturing process of the present invention for such LSCR is to bond, hold, or wedge them at the distal edge 5 onto a mounting surface (preferably a stiff, lightweight plane). The individual shapes 11 / 21 and 12 / 22 can be cut first from a foil or thin sheet, and shaped either first individually, and then assembled, or while the optical surface 1 is inside a press-like forming tool 33 and 34 .
[0055] The benefit of using an electroforming or molding manufacturing process is that one continuous shape can be made that has as many edges, corner and folds as needed to provide the overall structure with sufficient stiffening resistance against normal torque, tensile, and compressive handling forces.
[0056] Optionally, the side flanges 2 have additional auxiliary flanges at their respective distal edges 5 so as to further increase the stiffening resistance of the overall structure, thus allowing further material savings.
[0057] For example, a 100×10×5 mm rectangular optical surface can be made very stiff and lightweight (<10 g) with suitable optimized Ni electroforming processes with thickness of the LSCR as little as 50 μm and even thinner with NiCo processes.
[0058] FIG. 10 shows another embodiment of the preferred invention, wherein a LSCR is used to both redirect and refocus the light emitted from an output surface 300 of a light guide 301 onto an illumination target 304 . Optionally, an auxiliary lens 306 is used to change the magnification of the illumination spot 308 at the illumination target 304 . Said fiber optic light guide 301 is being illuminated by a Fiber Optic Light source FO. The shape of the curved LSCR can optionally be chosen in such a manner that it also magnifies or minifies the image of the output surface 300 of the light guide 301 . Optionally, suitable apertures 310 can be inserted into the light path to shape the profile and/or intensity distribution of the illumination spot 308 . A plurality of apertures 310 can be combined on a wheel 312 or slider to facilitate the exchange of one aperture shape to another.
[0059] All of the above referenced patents; patent applications and publications are hereby incorporated by reference. Many variations of the present invention will suggest themselves to those of ordinary skill in the art in light of the above detailed description. All such obvious modifications are within the full-intended spirit and scope of the claims of the present application both literally and in equivalents recognized at law, as set forth and claimed hereinbelow.
|
A reflector for improving front and rear projection systems and fiber optic light sources, comprising a curved optical surface and at least one flange surface having at least two portions of said flange surface rigidly connected at the edge of said optical surface at a high tilt angle, thereby providing a compression and stretching resistance in at least one direction and method for manufacturing the same.
| 6
|
CONTRACTUAL ORIGIN OF THE INVENTION
This invention was made with Government support under Prime Contract #NAS-9-98100 awarded by the National Aeronautics and Space Administration. The United States Government has certain rights in the invention.
FIELD OF THE INVENTION
This invention relates generally to electronic networking equipment, and is particularly directed to an enhanced method and apparatus for the translation of different data protocols in a high throughput communication link employing both wired and wireless network platforms. More specifically, this invention is directed to the connection of a high speed, variable data rate satellite network to a conventional ground-based, fixed data rate commercial communications network in a manner which increases systems throughput without impacting satellite or ground-based network design and operation.
BACKGROUND OF THE INVENTION
With the advent of personal computers, the need for interconnectivity between computational platforms has grown exponentially. In the business environment, connectivity is necessary for transmittal of email and numerous other types of data including audio and video. In the residential area, many homes are now connected via the Internet. All of this interconnectivity requires increasingly higher throughput across both wired and wireless networks.
The transmission of high data rates, such as for video signals, requires expensive connections when performed over wired networks. For temporary applications, the installation cost becomes prohibitive. The most economical solution is to transmit data via satellites. This method eliminates the high cost of connecting any location with coaxial wire or fiber optics to the nearest telephone switching office.
Existing satellites are equipped with several transponders that relay information. Each transponder typically has a pass-band of 36 megahertz. Using present modulation and coding systems, these transponders can handle a data rate of nearly 70 megabits/second. Satellites operating in the Ka band are expected to be available to the marketplace in the next 2–3 years. These Ka band transponders will support pass-bands of 100 to 500 megahertz.
On the ground, existing networking equipment runs at established fixed speeds. These speeds include (in megabits/second): 1.5, 45, 155, and 622. To connect a satellite communications network with ground-based network, the satellite modem must operate at lower speeds that are identical to ground-based speeds. This severely limits the efficiency of the satellite's available bandwidth.
The satellite connection is handled through a satellite modem. Current satellite modems use a serial input/output such as RS-449. A translation device is required to connect the standards based ground network to the satellite modem. If the satellite is operating at a similar speed, it can be effectively connected using a commercial router. To operate efficiently at any other speed, the connection must be made through a different interface device.
The prior art includes three types of interface devices. All of these devices convert the satellite modem serial data to/from the standards based protocols of Asynchronous Transmission Mode (ATM) or Ethernet. These devices, two of which are commercial and one of which is a governmental (NASA) design, include:
1) The COMSAT Link Accelerator (CLA-2000) converts RS-449 serial interface at up to 8 megabits/second to an ATM interface at a fixed 45 megabits/second. The CLA-2000 was recently upgraded to support 10 megabits/second Ethernet in addition to ATM.
2) The Metrodata LA-1000 converts, an Asynchronous Serial Interface (ASI) to ATM. The LA-1000 interfaces between satellite modems with DVB-ASI interfaces and ATM networks at speeds up to about 100 megabits/second. The LA-1000 does not support satellite modems with Emitter Coupled Logic (ECL) interfaces.
3) The NASA Goddard Space Flight Center's Ground Router Interface Device (GRID) includes the features of the CLA-2000 and the capability to support multiple RS-449 interfaces. This device is also limited to 8 megabits/second on the terrestrial serial interface. Details of GRID are proprietary and not publicly available. Current systems in the ECL domain are thus limited to 8 megabits/second.
Referring to FIG. 1 , there is shown a simplified block diagram of a current satellite communication system 10 for communicating with the International Space Station (ISS) 12 . The ISS 12 communicates with a ground station 16 , which in the present case is NASA's White Sands Complex (WSC), via a Tracking & Data Relay Satellite (TDRS) 14 . The uplink from the ground station 16 to TDRS 14 is at a data rate of 3 megabits per second (Mb/s), while the downlink to the ground station is at the rate of 50 Mb/s. The Ku-SA channel forward link from TDRS 14 to ISS 12 is 50 MHz wide, while the Ku-SA channel return link from ISS to TDRS is 225 MHz wide. The TDRS ground system 16 does not afford a Forward Error Correction (FEC) capability, which limits the capability of this link. The downlink signal received from TDRS 14 undergoes frequency translation in the ground station 16 and is provided to a TDRS modem 18 which demodulates the 50 Mb/s signal down to a baseband signal which includes an ECL clock signal and the received data. The ECL clock signal and the data are provided to a high rate switch 20 , which is adapted for interfacing with the combination of a domestic satellite (DOMSAT) 26 and DOMSAT modem 24 within the ground station 16 . An “Air Gap” is illustrated in the ground station 16 between the high rate switch 20 and a SONET mux 22 to illustrate that there is currently no available means for linking a 50 Mb/s signal to a conventional ground communication network such as SONET. The ECL clock signal and data are provided from the high rate switch 20 to the domestic satellite 26 via the DOMSAT modem 24 . Domestic satellite 26 is a commercial spacecraft operating in the Ku band, which receives signals and retransmits the signals at a data rate of 50 Mb/s. The domestic satellite 26 retransmits the data in a downlink to an earth facility such as NASA's Marshall Space Flight Center (MSFC) 28 and NASA's Johnson Space Center (JSC) 30 in the form of synchronous serial data. This satellite communications network is government proprietary and thus not available to the general public, is expensive to operate, and suffers from an extensive signal delay in the link between ground station 16 and the NASA space centers 28 and 30 via the domestic satellite 26 , e.g., an average delay of 270 ms.
Another disadvantage of this and other prior approaches is that satellites are forced to operate at data rates dependent on the terrestrial network components at either end of the link. Often, the ideal data rates of the wireless satellite network segment lie in between the supported terrestrial data rates. To guarantee error-free connections via satellite, sufficient signal power must be provided to account for atmospheric disturbances such as clouds and rain. Reducing the data rates effectively eliminates the need to increase RF power levels to compensate. However, prior approaches do not allow for agile data rates.
Another disadvantage of prior approaches involves Forward Error Correction (FEC), which is a well-known tool for increasing communications link reliability. The high rate satellite modems 18 for Tracking & Data Relay Satellites (TDRS) do not employ Reed-Solomon FEC. To maximize the capability of these high rate connections, Reed-Solomon FED must be employed on the ISS 12 and at the high rate modem 18 .
The present invention addresses the aforementioned limitations of the prior art by providing continuously adjustable input/output serial data rates via ECL-based satellite modems and converting the data rate to standards-based terrestrial network data rates with Reed-Solomon FEC capability at speeds up to 622 megabits/second.
OBJECTS AND SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to link an Emitter Coupled Logic satellite communications network to a conventional ground-based Asynchronous Transfer Mode Network with minimum impact on the operations and configuration of the network.
It is another object of the present invention to connect a high speed, variable data rate communications network to a fixed data rate communications network in a synchronous manner.
Yet another object of the present invention is to provide a data rate independent, synchronous RF network connecting a standards-based satellite network and a standards-based ground communications network, which allows for interactive communications between the two networks.
A further object of the present invention is to provide adaptive error correction coding in a satellite and ground-based communications network operating at the high data rates available in conventional ground-based communications networks.
A still further object of the present invention is to provide a communications interface between synchronous serial data circuits and a fiber optic or wide area network.
Another object of the present invention is to provide an agile satellite serial data rate that allows a satellite transponder/modem to operate at its most efficient data rate.
A still further object of the present invention is to provide a satellite modem interface to any protocol above ATM such as Internet Protocol (IP), User Datagram Protocol (UDP), and Transmission Control Protocol (TCP).
The present invention contemplates conversion of Emitter Coupled Logic (ECL)-based synchronous serial data having a variable data rate such as used in satellite-based space communications to a high speed, fixed data rate such as employed in ground-based communications networks such as of the ATM type with minimal impact on the operation and configuration of the communications network. The inventive approach employs a network protocol translation device, which permits synchronous serial data from the satellite network to be converted to the protocol of any one of various ground-based conventional communications networks such as of the ATM type at virtually any serial data rate up to the available effective bandwidth of the ATM connection. Adaptive forward error correction is provided in the protocol translation, with operation possible at data rates intermediate the fixed, stratified rates of conventional ground communications networks. The ECL-ATM protocol interface device includes both ECL-ATM and ATM-ECL processors for bi-directional communications and includes ATM interfaces for SONET and other terrestrial connections such as Ethernet.
BRIEF DESCRIPTION OF THE DRAWINGS
The appended claims set forth those novel features, which characterize the invention. However, the invention itself, as well as further objects and advantages thereof, will best be understood by reference to the following detailed description of a preferred embodiment taken in conjunction with the accompanying drawings, where like reference characters identify like elements throughout the various figures, in which:
FIG. 1 is a simplified block diagram of a current satellite communications system for the International Space Station (ISS);
FIG. 2 is a simplified block diagram of a communications system in accordance with the present invention for use with the ISS;
FIG. 3 is a simplified block diagram of an ECL-ATM protocol interface device in accordance with the principles of the present invention;
FIG. 4 is a simplified block diagram of an ECL-ATM processor used in the protocol interface device of FIG. 3 ;
FIG. 5 is a simplified block diagram of an ATM-ECL processor used in the protocol interface device of FIG. 3 ;
FIG. 6 is a flow chart illustrating the series of steps carried out in data frame acquisition by the ECL-ATM processor of FIG. 4 ;
FIG. 7 is a simplified flow chart illustrating the series of steps to ensure correct synchronization of the adaptive forward error correction (FEC) code values carried out by the ECL-ATM processor shown in FIG. 4 ;
FIG. 8 is a simplified flow chart illustrating the series of steps carried out to ensure correct synchronization of the adaptive FEC coding process by the ATM-ECL processor shown in FIG. 5 ;
FIG. 9 is a simplified block diagram of a pair of ECL-ATM protocol interface devices illustrating the overall synchronization scheme shown in FIG. 7 and FIG. 8 , the configuration of and signal flow in each device as well as the interfacing between a pair of devices within a communication network in accordance with the present invention; and
FIG. 10 is a simplified timing diagram showing how differing timing rates of the ATM and ECL data streams are reconciled by showing the cell or frame composition of data streams in various portions of an ECL-ATM protocol interface arrangement in accordance with the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 2 , there is shown a simplified block diagram of a satellite communications system 40 in accordance with the present invention. The satellite communications system 40 provides a networkprotocol translation for allowing a variable data rate satellite communications network to interface directly with a conventional ground-based, fixed rate commercial communications network such as of the ATM type. The specific example in terms of which the present invention is disclosed provides a link between the International Space Station (ISS) 42 via a Tracking & Data Relay Satellite (TDRS) 44 to a ground station 46 . In a specific example of the invention, the White Sands Complex (WSC) is contemplated as the ground station 46 , which interfaces by means of the present invention with the Marshall Space Flight Center (MSFC) 54 and Johnson Space Center (JSC) 56 . As in the previously described prior art system, ground station 46 communicates with TDRS 44 by means of a TDRS modem 48 , which is coupled to a high rate switch 50 . The MSFC 54 and JSC 56 are connected by means of a commercial fiber optic ground network 58 to a SONET mux 52 within the ground station 46 . In accordance with the present invention, an ECL-ATM protocol interface device 70 connects the high rate switch 50 and the SONET mux 52 in ground station 46 . The term “gateway” as used herein means a translation or protocol interface device for permitting two communications networks having different protocols to communicate without restriction. The ECL-ATM protocol interface device 70 of the present invention allows a high speed standard communications network to operate at its most efficient data rate with a commercial ground-based communications network using industry standard interface criteria. A comparison of FIGS. 1 and 2 shows that the satellite communication system 40 of the present invention eliminates the domestic satellite link of prior art satellite-ground communications networks to provide a more cost effective approach which allows for conversion of Emitter Coupled Logic (ECL)-based serial data from a satellite modem to a conventional ground-based communications network data protocol such as Asynchronous Transfer Mode (ATM).
Referring to FIG. 3 , there is shown a simplified block diagram of an ECL-ATM protocol interface device 70 for use in the present invention. The protocol interface device 70 includes a line receiver 72 at the ECL interface for receiving signals transmitted from a satellite or satellite-compatible modem utilizing ECL format such as a TDRS modem 48 as shown in FIG. 2 . The output of the line receiver 72 is provided to a bit sync/clock recovery circuit 74 , which separates the data and clock signal in the received signal. The bit sync/clock recovery circuit 74 includes a jitter buffer for smoothing out any changes in the data rate which is accomplished by an ECL-ATM processor 76 . The data and clock signals are provided to the ECL-ATM processor 76 , which is shown in block diagram form in FIG. 4 and is described in detail below. Other inputs to the ECL-ATM processor 76 are a “mode” signal from a user operated mode switch 78 and a “control” signal from a control input 80 . Control input 80 and a display output 82 from a human operator interface allow an operator to exercise control over ECL-ATM protocol interface device 70 . Control input 80 is preferably in the form of a computer keyboard or plural switches, while display output is preferably in the form of a cathode ray tube or LED readout. A display interface 84 provides an appropriate input to the display output 82 from the ECL-ATM processor 76 and an ATM-ECL processor 88 for the display of information for use by the operator. The ECL-ATM processor 76 converts the serial data stream received from the bit sync/clock recovery circuit 74 from a frame format to a cell format, as described in detail below, which cell formatted signal is provided to a line driver 86 for providing an ATM or SONET interface. The ECL-ATM processor 76 also links together the variable data rate satellite clock and the terrestrial network clock having a fixed data rate so that no valid data is lost.
ECL-ATM protocol interface device 70 further includes an ATM-ECL processor 88 , which is shown in block diagram form in FIG. 5 and is described in detail below. The ATM-ECL processor 88 is coupled to the ECL-ATM processor 77 for the exchange of data and control signals. The ATM-ECL processor 88 receives input data from a line receiver 90 , which serves as an ATM interface with the ATM network. The output of the ATM-ECL processor 88 is an ECL-based signal having a data component and a clock component, which are provided to a bit encoding circuit 92 where they are combined. The output of the bit encoding circuit 92 is provided to a line driver 94 at the ECL interface for providing a frame-compatible signal to the satellite communications network.
Referring to FIG. 4 , there is shown a simplified block diagram of the ECL-ATM processor 76 used in the ECL-ATM protocol interface device 70 of FIG. 3 . The ECL-ATM processor 76 receives data and clock signals from the ECL interface, which are provided to a deinterleaver 102 in the ECL-ATM processor. Deinterleaver 102 unscrambles the received ECL-based signal and provides the unscrambled signal to a Forward Error Correction (FEC) circuit 104 , which detects bit errors in the received signal arising from noise and corrects these errors. The control and status circuit 112 indicates to the deinterleaver 102 the “distance” of interleaving used by the transmitter of this data, so that the same value is used by both transmitter and receiver. The control and status circuit 112 also initially forces the deinterleaver 102 to shift incoming data until the correct synchronization of data on frame boundaries occurs. Deinterleaver 102 provides this frame sync indication to the forward error correction circuit 104 as well as to a frame disassembly circuit 106 . Frame disassembly circuit 106 receives the output from the FEC circuit 104 for removing idle cells from the frames in the received ECL-based signal. The idle cells removed from the signals by the frame disassembly circuit 106 are provided to an add header error correction circuit 108 which computes the error correction code so the data receiver can correct for errors in the header portion of the cell signals. The cell signals are then provided to a form cell stream circuit 110 which forms the cell into a bit stream which is output in the form of data and a clock signal to an ATM interface. The control and status circuit 112 receives various control and status inputs and provides various control and status outputs. For example, a mode control input is provided from the ECL interface to the control and status circuit 112 . A control input is provided from the control input 80 in the operator interface to the control and status circuit 112 as previously described. An error signal indicating the number of errors in the received data is provided by the forward error correction circuit 104 to the control and status circuit 112 . Other control inputs are provided to the control and status circuit 112 from the ATM-ECL processor and the control and status circuit provides various outputs to the display interface as previously described. The status output provided by the control and status circuit 112 to the display interface allows an operator to be informed of the numbers of bit errors in the data as well as to determine if the system is operating correctly with a statistical summary of system operation provided visually such as on a video display. The mode and control inputs to the control and status circuit 112 are initiated by an operator to allow the operator to override automatic control signals. Timing signals are provided between the control and status circuit 112 and a timing control circuit 114 and a frame number input is provided from the frame disassembly circuit 106 to the control and status circuit 112 . A frame sync signal output by the deinterleaver circuit 102 is also provided to the control and status circuit 112 which, in turn, provides “shift” and “distance” signals to the deinterleaver circuit 102 . Timing control circuit 114 also provides timing control signals to the add header error correction circuit 108 , the form cell stream circuit 110 , and a form idle cells circuit 116 for syncing the cells. The number of idle cells inserted in the data stream by the form idle cells circuit 116 is determined by the timing difference between the timing control input from the ECL clock and the input from the control and status circuit 112 for providing an output to the form cells stream circuit 110 which outputs data and a clock signal to the ATM interface.
This insertion of idle cells makes up any difference in data rate between the ECL data stream and the ATM data stream while maintaining the constant data rate and standardized format of the ATM interface.
Referring to FIG. 5 , there is shown a simplified block diagram of the ATM-ECL processor 88 used in the ECL-ATM protocol interface device 70 of FIG. 3 . The left hand portion of FIG. 5 represents the ATM interface for interfacing with the ground-based communications network, while the right hand portion of the figure represents the ECL interface for interfacing with the satellite communications network. The ATM-ECL processor 88 includes a cell delineation circuit 122 , which receives data and a clock signal from the ATM interface. The cell delineation circuit 122 synchronizes the cells received from the ATM interface and provides an “aligned” signal to a control and status circuit 140 once cell synchronization is achieved. The cell delineation circuit 122 determines where one cell ends and the next cell starts. A clock signal is provided to the cell delineation circuit 122 as well as to a cell timing control circuit 130 which provides timing signal inputs to the cell delineation circuit 122 , a discard header error correction circuit 124 , a discard idle cells circuit 126 , and a cell buffer circuit 128 . This portion of the ATM-ECL processor 88 processes the incoming cells from the ATM communications network. The discard header error correction circuit 124 removes the header error correction from the received cell, while the discard idle cell circuit 126 removes idle cells from the received data and provides the data to the cell buffer circuit 128 for storage therein until there are enough cells to form a frame. The discarded idle cells are provided by the discard idle cell circuit 126 to a control and status circuit 140 for determining how many idle cells are included in the frame in synchronizing the timing of the received cells and the outgoing frames. The received cells are temporarily stored in the cell buffer circuit 128 for compensating for cells being received at various data rates. The output of the cell buffer circuit 128 is provided to the serial combination of a frame generator circuit 132 , a forward error control circuit 134 , an interleaver circuit 136 , and a form frame stream circuit 138 , all of which are used in the generation of frames comprised of the received cells. The control and status circuit 140 is connected to each of these latter circuits and provides control signals to each of these circuits for controlling the data and clock signal output to the ECL interface by the form frame stream circuit 138 .
Various inputs are provided to the control and status circuit 140 for controlling its operation. For example, a “mode” signal is provided from the operator control mode switch 78 within the ECL-ATM protocol interface device 70 as shown in FIG. 3 . Control signals are also provided to the control and status circuit 140 from the operator interface. Other inputs to the control and status circuit 140 of the ATM-ECL processor 88 are received from the ECL-ATM processor 70 shown in FIG. 4 . The control and status circuit 140 provides a “frame count” input to the frame generator circuit 132 for keeping track of the number of frames generated and for generation of each frame following receipt and detection of the required number of cells. The control and status circuit 140 also provides a “block size” input to the forward error control circuit 134 and provides a “distance” input to the interleaver circuit 136 . The interleaver circuit 136 scrambles the order of data bytes within the frame units for purposes of distributing the effects of a large noise burst into smaller perturbations among multiple frames. The forward error control circuit 134 provides the encoding portion of Reed-Solomon Forward Error Correction (FEC). A frame timing control circuit 142 receives timing inputs from the control and status circuit 140 and provides timing signals to each of the frame generator circuit 132 , forward error control circuit 134 , interleaver circuit 136 , and form frame stream circuit 138 . The form frame stream circuit 138 takes the information in the frames and outputs a clock signal as well as a serial data stream in the form of 1's and 0's to the bit encoding circuit 192 as shown in FIG. 3 for providing frame information to the ECL interface.
Referring to FIG. 6 , there is shown a simplified flow chart of the series of steps carried out in data frame acquisition by the ECL-ATM processor 76 of FIG. 4 . The ECL-ATM processor initiates frame acquisition at step 130 followed by monitoring of each group of received bits to determine if an IN — SYNC flag representing successful synchronization of a frame is present at step 132 . The detection of an IN — SYNC signal at step 132 indicates that the system has detected the beginning of a frame in the normal operating mode, and the program then proceeds to step 134 for incrementing the expected frame number by 1. The program then reads the incremented frame number at step 136 and determines at step 138 if the detected frame number is the same as the expected frame number. If the detected frame number matches the expected frame number as determined at step 138 , the program proceeds to step 142 and verifies that the IN — SYNC signal is true, confirming the acquisition of a frame and proceeds to step 146 for exiting the program. If at step 138 it is determined that the detected frame number does not match the expected frame number, the program proceeds to step 140 and determines if there is a Forward Error Correction (FEC) error present. If it is determined that a FEC error is present, the program proceeds to step 142 for confirming the IN — SYNC signal indicating that a frame has been acquired. The program then proceeds to step 146 for exiting the frame acquisition program. If at step 140 it is determined that there is no FEC error, the program sets the IN — SYNC flag FALSE to indicate that frame acquisition has not occurred the next time this cycle is executed. The program then proceeds to step 146 for exiting the frame acquisition program. If at step 132 , it is determined that the IN — SYNC signal is not present, the program proceeds to step 148 for determining if an output shift has occurred and then proceeds to step 146 for exiting the frame acquisition program.
Referring to FIG. 7 , there is shown a series of steps carried out by the ECL-ATM processor 76 of FIG. 4 for synchronizing the adaptive FEC code values received from the satellite. In this program, information provided by the receiver tells the transmitter that the number of errors in the received data has changed and that the transmitter must change its correction code value. The adaptive coding program in ECL-ATM processor 76 is initiated at step 150 followed by a reading of the transmit frame number at step 152 . The transmitted frame number is received in the ECL format from a satellite. The program then at step 154 determines if the transmit frame number is 0. Frame number 0 is used to communicate between the transmitter and receiver. If at step 154 it is determined that the transmit frame number is not 0, the program proceeds to step 162 to determine if the received frame number is greater than 3. If at step 154 , it is determined that the transmit frame number is 0, the program proceeds to step 156 and calculates the bit error rate which is calculated once every 256 bits, or counts. The adaptive coding routine shown in FIG. 7 increases the number of bits used for error correction as the bit error rate increases. The bit error rate is calculated on an ongoing basis from the number of corrected errors per frame. After calculating the bit error rate, the program proceeds to step 158 to determine the current Forward Error Correction (FEC) code value from a lookup table. The FEC code value changes with the bit error rate detected by the system, increasing in value with an increase in the detected bit error rate to provide the desired level of forward error correction. The FEC code value obtained from the lookup table is then divided by 2 at step 160 and is stored as the new FEC code value in memory. The program then at step 162 determines whether the received frame number is greater than 3, which is the frame in which an updated code value is sent to the transmitter. If it is determined at step 162 that the received frame number is not greater than 3 the program proceeds to step 174 and ends while continuing to use the FEC code value originally stored in the lookup table as determined at step 158 .
If at step 162 , it is determined that the received frame number is greater than 3, the program updates the transmitter value by proceeding to step 164 and setting the FEC code value equal to the received header value times 2. The program then at step 166 determines whether the received code value is 0. If the received code value is 0, the program branches to step 174 and exits the program. If at step 166 , it is determined that the received FEC code value is not equal to 0, the program proceeds to step 168 and determines if the received code value is equal to the FEC value. If these two values are the same, the program proceeds to step 174 for exiting the program. If at step 168 , it is determined that the received FEC code value is not equal to the FEC value, the program proceeds to step 170 to determine if the received frame number is 7. If the received frame number is not 7, the program proceeds to 174 and exits the program. If at step 170 it is determined that the received frame number is 7, the program proceeds to step 172 and sets the receiver FEC value to the new correction code value. The program then proceeds to step 174 and exits the program.
Referring to FIG. 8 , there is shown a simplified flow chart illustrating the series of steps carried out in the same adaptive FEC coding synchronization process shown in FIG. 7 but carried out by the ATM-ECL processor 88 of FIG. 5 in proceeding from the ATM protocol to the ECL protocol. The adaptive FEC coding program stored in the ATM-ECL processor 88 is initiated at step 180 followed by a reading of the received frame number from the ATM interface at step 182 . The program then at step 184 determines if the received frame number is 0, and if so, proceeds to step 186 and sets the correction code value equal to the received correction code value times 2. The program at step 188 then compares the just reset code value to the FEC value currently being used. If the new code value is equal to the current FEC value, the program proceeds to step 192 and determines if the received frame is frame number 4. If at step 188 it is determined that the reset code value is not equal to the current FEC value, the program proceeds to step 190 and updates the code value with the new FEC code value and proceeds to step 192 for determining if the received frame is frame number 4. Thus, the program updates the FEC code value at frame 0 if the code value has changed.
If at step 184 , the program determines that the received frame number is not 0, the program proceeds to step 192 to determine if the received frame number is 4. If it is determined at step 192 that the received frame number is 4, the program proceeds to step 194 and sets the transmitted code value to the new code value. The program then proceeds to step 196 to determine if the transmitted frame number is 0. If at step 192 it is determined that the received frame number is not 4, the program proceeds to step 196 to determine if the transmitted frame number is 0. If the transmitted frame number is 0, the program proceeds to step 198 and updates the transmitter FEC value with the new code value. The program then proceeds to step 200 and exits the transmit adaptive error correction coding program. If at step 196 it is determined that the transmitted frame number is not 0, the program proceeds to step 200 for exiting the transmit adaptive error correction coding program.
Referring to FIG. 9 , there is shown a simplified combined block diagram and flow chart illustrating the various components of and operations carried out by a pair of common ATM satellite interfaces (CASI) 90 and 130 communicating with one another via a satellite link in accordance with the present invention. The boxes in solid lines in FIG. 9 represent hardware components of the CASI's 90 and 130 , while the blocks in dotted lines represent operations carried out by each of the CASl's. All the processing elements shown in the portions of this diagram labeled “ECL-ATM” are shown in FIG. 8 and all the processing elements shown labeled “ATM-ECL” are shown in FIG. 7 . In the first CASI 90 , ATM data is received from the ground-communications network by an ATM conversion circuit 92 which provides the data to a frame buffer 94 which provides the received frame number 98 to a save until frame equal 0 algorithm 116 . This algorithm provides the transmitted FEC value to the frame buffer 94 which, in turn, provides the FEC value to a FEC transmitter 100 for providing the FEC value via a satellite link to a receiver FEC 142 , which in turn, provides the received code value 148 to a frame buffer 144 in the second CASI 130 . The received code value 148 , as well the frame number 146, are read from the frame buffer 148 when the frame number is greater than 3 at step 156 . An ATM conversion circuit 150 provides the data in ATM format from the second CASI 130 to an ATM ground communications network. The new FEC value is compared with the current FEC value at step 152 . If the FEC value has changed, the new FEC value is transmitted in frame number 4 for updating the current FEC value on the next frame number 0 at step 152 . This comparison is made by providing the current FEC value 154 for the aforementioned comparison at step 152 . Also in the ATM-ECL portion of the second CASI 130 , the ATM data is converted by an ATM conversion circuit 132 and is provided to a frame buffer 134 , which provides the received frame number 136 at step 152 for comparing the current FEC value with the received FEC value at step 152 . The transmitted code value 138 is provided by the frame buffer 134 to an FEC transmitter 142 , which provides the data via a satellite link to the first CASI 90 .
The first CASI 90 includes an FEC receiver 102 . The FEC receiver 102 provides this data to a frame buffer 110 in the first CASI 90 , which provides the frame number 104 as well as the received code value 106 at step 114 for comparing the received code value with the current code value in frame number 0. If at step 114 it is determined that the code value has changed, the current FEC value 118 is provided to the FEC receiver 102 , which provides the updated FEC value to frame buffer 110 . The FEC receiver 102 also provides an indication of the errors in the received data at step 112 for determination of the transmitted code value based on the received bit error rate. At step 112 , the new code value is determined and provided to step 116 for saving until frame 0, whereupon the new code value is provided to frame buffer 94 for determining the transmitted code value. The output of frame buffer 110 is provided to an ATM conversion circuit 108 at the output of the first CASI 90 for providing ATM data to an ATM ground communication network.
Referring to FIG. 10 , there is shown timing diagrams of signals in various portions of the ECL-to-ATM protocol network gateway of the present invention. The top line represents the ATM input cells stream to the first CASI 90 shown in FIG. 9 . The cell stream shows 10 cells consecutively numbered to show their flow through the system in the embodiment shown with several of these bits of the idle bit type for implementing the FEC coding arrangement of the present invention. The second line from the top represents the ECL frame stream transmitted by the satellite in the form of a header followed by plural cells each comprised of 53 bytes per the ATM standard. The ECL transmitted frame stream further includes a FEC coding stream. The ECL frame stream shown in line 2 is transmitted via the satellite link to the second CASI 130 of FIG. 9 also in the form of plural cells in a synchronous data stream. The cells in the received frame stream shown in the third line of FIG. 10 are converted to an ATM output cell stream as shown in the bottom line of FIG. 10 comprised of plural cells, including several of which are idle cells.
While particular embodiments of the present invention have been shown and described, it will be obvious to those skilled in the art that changes and modifications may be made without departing from the invention in its broader aspects. Therefore, the aim in the appended claims is to cover all such changes and modifications as fall within the true spirit and scope of the invention. The matter set forth in the foregoing description and accompanying drawing is offered by way of illustration only and not as a limitation. The actual scope of the invention is intended to be defined in the following claims when viewed in their proper perspective based on the prior art.
|
A network protocol translation device that allows serial data sent using the standard Asynchronous Transfer Mode (ATM) protocol to be used between two locations, using a satellite link or a terrestrial wireless link between the two locations. This is done by translating the standard ATM data to a standard satellite modem interface at one location, and translating the data back to the ATM format at the second (remote) location. The translation can occur at any data rate up to the available effective bandwidth of the ATM connection. The device is also capable of providing Forward Error Correction in the protocol translation. The device is functionally transparent to protocols above ATM, i.e., IP, UDP and TCP. It also interfaces with standard physical layers below ATM such as Synchronous Optical Network (SONET). At the satellite interface, the device is compatible with (but not limited to) Emitter Coupled Logic (ECL).
| 7
|
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to subscriber telephone instuments of the electronic-microprocessor type, and more particularly to telephone instruments which require fast connect and disconnect functions to the speech network, as a part of such operations as dialing, hold or flash signaling.
2. Background Art
Many previous designs of network disconnect circuitry involve the use of series pass elements such as a PNP type transistor. A prior art example of such a design is found in the "Linear II" telephone manufactured by GTE Communication Systems Corporation. In this particular implementation a Darlington PNP transistor arrangement was used to achieve the required saturation level of the switch. A third NPN type transistor was required to switch the two PNP transitors of the Darlington configuration "on" or "off". Each of the transistors used in this circuit implementation were high voltage types in order to withstand lightning surges which may appear on the telephone subscriber line. The described circuitry however does not protect the speech network from voltage surges. Instead it uses an external metalic oxide varistor for protection. For bias purposes in this arrangement, a pulldown resistor having a value on the order of 24,000 ohms was employed. The resulting low level of DC bias current combined with a high level of AC impedence, permits the electronic switch to become virtually transparent in regard to the receive, sidetone and transmit characteristics of a conventional hybrid voice network circuit. However, the circuit advantages are achieved at the cost of an extra PNP high voltage transistor and an increase in the switches "on" state voltage from approximately 0.3 volts DC to 0.7 volts DC.
An earlier example of the prior art is represented by the "Duofone 160" repretory dial telephone marketed by Radio Shack Incorporated. This circuit uses a single PNP type transistor for a series pass element where the "on" and the "off" state is controlled by a common emitter NPN transistor connected to the PNP transistor's base. AC isolation for these two high voltage transistors is provided by a series connected inductor and resistor coupled between the two transistors. In addition to cost and space factors, this circuit exhibits poor AC isolation at the low end of the voiceband frequencies. It also requires significant DC bias current to maintain the required level of saturation for the PNP transistor switch. Both of these factors can have a significantly degrade the accoustic characteristics of a telephone's voice network.
Accordingly, it is the object of the present invention to provide a low cost circuit which includes a electronic switch for telepone voice network applications which is transparent to the accoustic characteristics of the voice network, exhibits a low "on" state voltage drop and includes a means of surge voltage protection.
SUMMARY OF THE INVENTION
The present invention describes an electronic switch which is used to couple a voiceband circuit-speech network to the telephone subscriber's line employing a hookswitch and polarity correcting means. In the proposed circuitry, a first NPN type transistor receives positive bias from the telephone subscriber line through a high resistance voltage divider to circuit ground, forming an input voltage dependent bias source for this transistor. AC signals are significantly attenuated by the first high value resistor in the voltage divider and then shunted to circuit ground through a high value capacitor to achieve, in effect, a low pass filter. The output current is limited by a voltage dropping resistor in series with the NPN type transistor's base. This first NPN type transistor is operated as an emitter follower in the active region. The resistor in the emitter circuit allows the transistor to act as a DC input voltage controlled constant current source. The time constant of the low pass filter combined with the emitter resistor's effect, acts to minimize any response of the resulting current source to transient input voltages due to either lightning surges or ringing signals. The collector of this first NPN type transistor provides the current sink for the PNP type transistor forming the electronic switch element. The emitter of this PNP transistor is coupled to the positive side of the telephone subscriber line following the hookswitch. The collector, in turn, is connected to the voice network. Sufficient base current is sourced to the PNP transistor switch by the first NPN bias transistor to provide a highly saturated condition for the switching transistor when in the "on" state regardless of input loop voltage. Also due to the constant current source nature of this NPN bias transistor stage, a high AC impedence occurs in relation to the PNP tranistors input and output circuits thereby minimizing any audio losses due either to DTMF address signaling or voice signals.
During a voltage surge both the PNP switch and the attached voiceband circuitry are protected by an output voltage limiter. The present circuitry employs the current versus voltage characteristics of the attached voiceband circuitry to limit the conduction of current through the PNP transistor switch. This is accomplished by connecting a zener diode from the PNP transistor's collector to both a threshold sensing bias resistor connected to circuit ground and a first diode which is used to couple this output to the base of a second, common emitter connected NPN type transistor. The NPN transistor's collector is coupled to the aforementioned voltage dropping resistance and or the base of the first NPN type transistor in such a manner that it acts as a negative source of bias current.
When sufficient voltage appears at the PNP transistor switch's output to cause the output voltage limiting zener diode to conduct, positive bias is applied through the aforementitoned first diode to the base of the second NPN transistor. This transistor works with the first NPN transistor to effect a reduction in the bias current to the PNP switching transistor. Therefore, under surge conditions, the output voltage limiter acts to restrict the flow of current to the voiceband circuit. The second NPN type transistor also functions as a logic signal interface element that allows a microprocessor to signal a "network disconnect" command to disconnect a voiceband circuit such as the speech network by means of a cutoff of bias to the PNP transistor switch. This is accomplished by injecting a positive voltage due to a logic "high" input signal to the base of the second NPN transistor betweens its base connection and first diode. In this instance, total network disconnect occurs because the second NPN transistor switches on and drains virtually all the available bias current from the first NPN type transistor. As a result, the first NPN transistor's collector no longer conducts any bias current from the base of the PNP transistor switch such that the PNP transistor is turned off. In addition, the filter capacitor is discharged by the collector of the second NPN type transistor. When the "network disconnect signal" is switched back to a logic "zero" state approaching zero volts, the capacitor within the lowpass filter must be charged back up sufficiently to turn on the first NPN type transistor which then turns on the PNP switching transistor. This turn on delay can require several milliseconds. Electronic Industries Association (EIA) specification RS-470 prohibits serious opens which cause the subscriber line current to drop below 17 milliamperes for longer than one millisecond if the UDK (Universal Dial Keying) or DTMF (Dual Tone Multi frequency) dial out-address signaling sequence has not been completed. As a result, a speedup circuit is added to solve the problem of (UDK) pulse address signaling circuits which experience protracted periods between manually dialed digits. In this instance, the speech network is initially disconnected in order that loop current can only flow through the shunt dialer circuit preceding the electronic switch disconnecting the speech network. A seperate logic signal input is then utilized to provide a means of minimizing the spurious open circuit effect when the logic circuitry reconnects the speech network following an interdigital interval timeout. This logic signal's voltage is used to precharge the low pass filter capacitor such that the requirements of EIA specification RS-470 are satisfied. The series charging circuit consists of a second forward biased silicon diode and a current limiting resistor which is connected to this capacitor.
A third silicon diode is connected between the filter capacitor and the emitter input of the PNP switch which is also coupled to the telephone subscriber line. Under normal conditions, this diode is reversebiased so that the input voltage to the PNP transistor's emitter is larger than the voltage across the capacitor. When this situation is reversed, the diode becomes forward biased and acts as a discharge path for the low pass filter's capacitor. As such, the bias voltage available to the first NPN transistor is reduced and the base current used to bias the PNP transistor switch is also reduced. This process, then, is used to protect the PNP switching transistor and the connecting voiceband circuitry when the telephone is taken off hook and subjected to the high AC voltage sources (typically 86 volts AC+50 volts DC) used to ring the subscriber. This diode allows to the capacitor to discharge during the zero voltage crossing of the telephone subscriber line.
The circuitry of the present invention is particularly useful on those lines where lightning surge protection is required wherein the circuitry controlling the flow of surge current must protect both itself and the speech network. This circuitry is also efficient in controlling audio losses due to the high switch saturation level achieved and the high AC impedance of the biasing portion of the circuit.
BRIEF DESCRIPTION OF THE DRAWING
The single sheet of accompanying drawings shows a simplified schematic of a network connect-disconnect switch as part of a typical telephone instrument application in accordance with the present invention. It should be noted that detailed functions of the circuitry of the telephone other than the tip and ring inputs, polarity guard, hookswitch and varistor are not shown in as much as they do not form a portion of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the accompanying drawing PNP transistor Q1 is the main switching element operating in saturation during the "on" state. Bias to transistor Q1 is provided by a constant current source comprising NPN transistor Q2 operating as an emitter follower in the active region. The operation of both transistors Q1 and Q2 are controlled by NPN transistor Q3. In conjunction with voltage limiting zener diode CR4 and diode CR3, transistor Q3 acts as a surge protection circuit for both the electronic switch and the attached voiceband circuitry connected at that terminal designated "to speech network". Alternately, the network disconnect (ND) logic signal input to transistor Q3 via resistors R8 and R9 provides an electronic means of selectively disconnecting the voiceband circuits from the telephone subscriber's line. A low pass filter, consisting of resistors R2, R3 and R6 and capacitor C1, provides an input voltage dependent DC bias supply for transistor Q2 in order that transistor Q1 can be maintained in a saturated "on" state and the electronic switch exhibits a high AC impedence. Diode CR1 provides a ringing signal surge protection means by discharging capacitor C1 during the AC waveform's zero voltage crossing. Resistor R1 and diode CR2 coupled between the "Fast Network Enable" (FNE) logic signal input and capacitor C1 provide a fast means to turn on the electronic switch.
The input voltage dependent, DC voltage controlled, current source is defined by the input voltage on the base of NPN transistor Q2 and the value of emitter resistor R7. The base of transistor Q2 is coupled to the output of a low pass filter by resistor R4. The input for this filter is connected to the emitter of the PNP transistor Q1, a surge voltage protection metalic oxide varistor MOV and the hookswitch S1 which is coupled to the positive side of the telephone subscriber line via diode bridge rectifier BR-1. The low pass filter consists of a voltage; divider includes resistor R2, R3 and R6 and capacitor C1, connected in parallel with the output resistor R6. The frequency response of this filter is such that the emitter-follower current source transistor Q2 is not significantly controlled by the 180 Hertz to 5,000 Hertz voice-band signals used in accordance with EIA specification RS-470, for the receive, transmit and sidetoned requirements for a telephone subscriber unit. As a result, the circuit shown in the accompanying drawing exhibits a very high value for the equivalent AC impedance at both its input and output terminals. A minimum time constant for the low pass filter appears to be indirectly defined by this same EIA specification which calls for a desired maximum of 5% for the receive signal's harmonic distortion. Assuming a fundamental frequency of 90 Hertz, then a time constant of greater than 35 milliseconds appears to be required. By comparison, the minimum frequency used for ringing signals has a half period of 32 milliseconds. This information was used to add additional surge protection to the circuit for those cases where the telephone goes "off-hook" in the presence of an applied AC ringing signal. First, diode CR1 was added to significantly discharge filter capacitors C1 via PNP transistor Q1 during the zero voltage crossing points of the AC voltage waveform appearing across the tip and ring inputs to the telephone subscriber line. Next the charging time constant of the low-pass filter was increased to be more than 65 milliseconds so that the output voltage across filter capacitor C1 is minimally increased during the subsequent charge interval. As a result the voltage applied to the current source transistor Q2 is decreased so that the collector-base current supplied to PNP transistor Q1 is greatly reduced. This PNP transistor subsequently can be current limited during the short interval required by the central office to terminate the ringing signal.
The circuitry of the present invention includes an "ND" logic signal input in order to effect a "Network Disconnect" via the non-conducting state of transistor Q1 when a logic "1" signal is applied to the "ND" input,. This logic 1 represents a voltage signal of approximately 2.5 volts. When the logic "1" signal is applied to the "ND" input, transistor Q1 is turned on forcing the voltage applied to the base of transistor Q2 to approach zero volts. The turn-off of transistor Q2 also causes transistor Q1 to cease conducting current. At some later time the "ND" input signal changes to a logic "zero" (less than 0.5 volts) causing transistor Q3 to turn "off" and transistor Q1 again behaves as a saturated switch connecting the speech network-voiceband circuitry to the subscriber line. This provision permits the circuit to be used in a UDK (Dial Pulse Address Signaling) application involving a shunt dialer circuit (not shown) connected between the hookswitch S1 and circuit ground. Unfortunately such an arrangement may generate a spurious open during the transistion from the dialer's conduction of loop current during an interdigital interval to the conduction of to loop current by the electronic switch circuit of this invention. This may be a problem during manual dial out since EIA specification RS470 forbids the generation of a spurious open, such that the subscriber's loop current drops to be less than 17 milliampures for longer than one millisecond, until the dialout is completed. The problem is resolved using the "FNE" logic signal input circuitry. Filter capacitor C1 is precharged via resistor R1 and diode CR2 before the shunt dialer ceases to conduct loop current. Furthermore, the electronic switch is then turned on by logic zero signal at the "ND" input, so that transistor Q3 no longer discharges capacitor C1 during this precharge period. As a result, the redirection of loop current from the shunt dialer circuit to the electronic switch is not characterized by the defined spurious open condition.
The electronic switch's output circuit to the speech network voice-band circuitry is protected from damaging surge voltages, especially lightning surge conditions, by a voltage limiter. The present circuitry uses NPN transistor Q3 to discharge filter capacitor C1 when transistor Q1's collector voltage exceeds the zener breakdown voltage of diode CR4 and conducts enough current through bias resistor R5 to forward bias both diode CR3 and the base emitter diode of transistor Q3. As a result, the voltage applied to the base of transistor Q2 is reduced so that the electronic switching transistor Q1 becomes current limited by the threshold voltage needed to operate the voltage limiter. Surge voltage inputs to transistor Q1 are limited to some maximum value by the varistor MOV.
It will be seen from the foregoing that the present invention discloses an electronic switch exhibiting a high degree of "on" state saturation regardless of the subscriber line's loop current and which exhibits a high value of AC impedance with regard to both its input and output terminals. Additional features include means for controlling the electronic switch's state using an externally supplied logic signal, the inclusion of a voltage limiter which both limits the maximum output voltage to the speech network voice-band circuitry and also current limits the electronic switch and the inclusion of current limiting means used to help protect the electronic switch and speech network voice-band circuitry from short-term, AC voltage surges due to applied ringing signals. It will also be obvious to those skilled in the art that numerous modifications may be made without departing from the spirit of the present invention which shall be limited only by the scope of the claims appended here to.
|
A fast response electronic switch used for control of connect and disconnect functions, primarily related to speech network applications for electronic-microprocessor based telephones utilizing dual tone multifrequency and/or universal pulse dial address signaling. Disclosed circuitry includes an active surge protector, a saturated transistor switch and bias circuit which exhibits a high AC impedance with respect to the telephone subscriber line.
| 7
|
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority under 35 U.S.C. §119 to U.S. Provisional Application Ser. No. 61/705,968, filed Sep. 26, 2012, the entirety of which is incorporated herein by reference.
FIELD
[0002] The disclosure generally pertains to percutaneous and intravascular devices for nerve modulation and/or ablation.
[0003] BACKGROUND
[0004] Certain treatments require the temporary or permanent interruption or modification of select nerve function. One example treatment is renal nerve ablation which is sometimes used to treat conditions related to congestive heart failure. The kidneys produce a sympathetic response to congestive heart failure, which, among other effects, increases the undesired retention of water and/or sodium. Ablating some of the nerves running to the kidneys may reduce or eliminate this sympathetic function, which may provide a corresponding reduction in the associated undesired symptoms.
[0005] Many body tissues such as nerves, including renal nerves, brain tissue, cardiac tissue and the tissue of other body organs are in close proximity to blood vessels or other body cavities and thus can be accessed percutaneously or intravascularly through the walls of the blood vessels. In some instances, it may be desirable to ablate perivascular nerves using a radio frequency (RF) electrode. In other instances, the perivascular nerves may be ablated by other means including application of thermal, ultrasonic, laser, microwave, and other related energy sources to the vessel wall.
[0006] In treatments involving perivascular nerves such as renal nerves, treatment methods employing such energy sources have tended to apply the energy as a generally circumferential ring to ensure that the nerves are modulated. However, such a treatment may result in thermal injury to the vessel wall near the electrode and other undesirable side effects such as, but not limited to, blood damage, clotting, weakened vessel wall, vessel thrombus, and/or protein fouling of the electrode.
SUMMARY
[0007] It is therefore desirable to provide for alternative systems and methods for tissue treatment such as intravascular nerve modulation which distributes ablation or modulation sites along and around the vessel or other body cavity.
[0008] Some embodiments of the disclosure are directed to a balloon catheter configured for tissue modulation such as nerve modulation and/or ablation. The balloon catheter includes an inflatable balloon at or proximate a distal end of the device. The wall of the balloon is constructed so as to include areas for transmitting therapeutic energy from the balloon into body tissue. These areas may be, for example, RF electrodes located on the surface of the balloon or ionically permeable windows for permitting the transmission of ionic energy from within the balloon lumen. Fluid may be supplied to the balloon through a plurality of fluid inlet ports and may be evacuated from the balloon through one (or more) fluid outlet ports. The plurality of fluid inlet ports direct the inflation fluid against the interior of the balloon wall. The plurality of fluid inlet ports may be configured to direct the fluid directly against the areas for transmitting therapeutic energy or may be configured to direct the fluid against areas of the interior of the balloon wall other than those areas for transmitting therapeutic energy.
[0009] The above summary of some example embodiments is not intended to describe each disclosed embodiment or every implementation of the disclosure.
BRIEF DESCRIPTION OF DRAWINGS
[0010] The disclosure may be more completely understood in consideration of the following detailed description of various embodiments in connection with the accompanying drawings, in which:
[0011] FIG. 1 is a schematic view illustrating a renal nerve modulation system in situ.
[0012] FIG. 2 is a schematic view illustrating the distal end of a renal nerve modulation system.
[0013] FIG. 3 is a cross-sectional view of the renal nerve modulation system of FIG. 2 .
[0014] FIG. 4 is a cross-sectional view of the renal nerve modulation system of FIG. 2 .
[0015] FIG. 5 is a schematic view illustrating the distal end of a renal nerve modulation system.
[0016] While the disclosure is amenable to various modifications and alternative forms, specifics thereof have been shown by way of example in the drawings and will be described in detail. It should be understood, however, that the intention is not to limit aspects of the disclosure to the particular embodiments described. On the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the disclosure.
DETAILED DESCRIPTION
[0017] The following description should be read with reference to the drawings wherein like reference numerals indicate like elements throughout the several views. The drawings, which are not necessarily to scale, are not intended to limit the scope of the claimed invention. The detailed description and drawings illustrate example embodiments of the claimed invention.
[0018] All numbers are herein assumed to be modified by the term “about.” The recitation of numerical ranges by endpoints includes all numbers subsumed within that range (e.g., 1 to 5 includes 1, 1.5, 2, 2.75, 3, 3.80, 4, and 5).
[0019] As used in this specification and the appended claims, the singular forms “a”, “an”, and “the” include the plural referents unless the content clearly dictates otherwise. As used in this specification and the appended claims, the term “or” is generally employed in its sense including “and/or” unless the content clearly dictates otherwise.
[0020] It is noted that references in the specification to “an embodiment”, “some embodiments”, “other embodiments”, etc., indicate that the embodiment described may include a particular feature, structure, or characteristic, but every embodiment may not necessarily include the particular feature, structure, or characteristic. Moreover, such phrases are not necessarily referring to the same embodiment. Further, when a particular feature, structure, or characteristic is described in connection with an embodiment, it would be within the knowledge of one skilled in the art to effect such feature, structure, or characteristic in connection with other embodiments whether or not explicitly described unless clearly stated to the contrary.
[0021] While the devices and methods described herein are discussed relative to renal nerve modulation through a blood vessel wall, it is contemplated that the devices and methods may be used in other applications where nerve modulation and/or ablation are desired. The term modulation refers to ablation and other techniques that may permanently alter the function of affected nerves and other tissue such as brain tissue or cardiac tissue. When multiple ablations are desirable, they may be performed sequentially by a single ablation device. In some embodiments, one ablation catheter can perform multiple treatments.
[0022] FIG. 1 is a schematic view of an illustrative renal nerve modulation system in situ. System 10 may include one or more conductive element(s) 16 for providing power to a renal ablation system including a renal nerve modulation device 12 disposed within a delivery sheath 14 , which may be adapted to slidably contain the renal nerve modulation device 12 when the radially expanding region (not shown) of the elongate member is in a non-expanded configuration, the details of which can be better seen in subsequent figures. A proximal end of conductive element(s) 16 may be connected to a control and power element 18 , which supplies necessary electrical energy to activate one or more electrodes to which the distal end of wire(s) 16 are attached at or near a distal end of the renal nerve modulation device 12 . When suitably activated, the electrodes are capable of ablating tissue as described below. The terms electrode and electrodes may be considered to be equivalent to elements capable of ablating adjacent tissue in the disclosure which follows. Suitable materials for the delivery sheath 14 , renal nerve modulation device 12 and elements capable of ablating adjacent tissue are known in the art and in some embodiments may include internal and/or external layers of lubricious material(s). In some instances, return electrode patches 20 may be supplied on the legs, the back near the kidneys or at another conventional location on the patient's body to complete the circuit. A proximal hub (not illustrated) having ports for a guidewire, an inflation lumen and a return lumen may also be included.
[0023] The control and power element 18 may include monitoring elements to monitor and control parameters such as power, temperature, time, voltage, pulse size, impedance and/or shape and other suitable parameters, with sensors mounted along renal nerve modulation device 12 , as well as suitable controls for performing the desired procedure. In some embodiments, the power element 18 may control a radio frequency (RF) electrode. The electrode may be configured to operate at a frequency of approximately 460 kHz. It is contemplated that any desired frequency in the RF range may be used, for example, from 450-500 kHz. It is further contemplated that other ablation devices may be used as desired, for example, but not limited to resistance heating, ultrasound, microwave, and laser devices and these devices may require that power be supplied by the power element 18 in a different form.
[0024] FIG. 2 illustrates the distal portion of a renal nerve modulation device 12 . Renal nerve modulation device 12 includes a balloon 22 and an electrode (or transmitter) 24 . When in use, the balloon is preferably filled with a conductive fluid 26 such as saline to allow the ablation energy to be transmitted from the electrode 24 through windows 28 that are permeable to ionic energy. The windows 28 are arranged to achieve complete circumferential coverage of the blood vessel while being spaced apart longitudinally. Other appropriate conductive fluids include hypertonic solutions, contrast solution and mixtures of saline or hypertonic saline solutions with contrast solutions. The conductive fluid may be introduced through fluid inlets 32 a - 32 d in a central shaft 35 and evacuated through a fluid outlet between central shaft 35 and an outer shaft 34 . One or more sensors 40 , such as a thermocouple, may be included and may be disposed on the shaft 34 , on the balloon 22 or at another suitable location. Further details may be had with reference to U.S. Patent Provisional Application No. 61/605,615, filed Mar. 1, 2012 and titled “DEVICES AND METHODS FOR NERVE MODULATION USING A NOVEL CATHETER WITH POLYMERIC ABLATION ELEMENTS,” incorporated herein by reference.
[0025] A cross-sectional view of the central shaft 35 and outer shaft 34 at section line 3 in FIG. 2 is illustrated in FIG. 3 . The central shaft 35 may include a guidewire tube 37 defining a guidewire lumen 36 . The central shaft 35 includes a fluid inlet lumen 42 that fluidly connects to the fluid inlets 32 a - 32 d. A fluid outlet lumen 30 is defined by the outer shaft 34 and the inner shaft 35 . The electrode 24 , or a conductive element to supply power to the electrode may extend along the outer surface of the shaft 35 or may be embedded within the shaft 35 . The electrode 24 proximal to the balloon is preferably electrically insulated and is used to transmit power to the portion of the electrode disposed in the balloon. The sensor 40 may also extend along the shaft 35 . The shafts may be generally concentrically arranged as illustrated or some other suitable arrangement may be used. For example, the lumens 42 , 30 of central shaft 35 may have a side-by-side arrangement or an embodiment may include a single multi-lumen shaft where the fluid inlet lumen, fluid outlet lumen and guidewire lumens are incorporated into a single shaft. Some embodiments may omit the guidewire lumen or include other elements such as steering wires and the like. The lumens 30 , 42 may extend proximally to a hub where they may be connected to an evacuation reservoir or vacuum, and a fluid supply or pump, respectively.
[0026] A cross-sectional view of the shaft 34 of the renal nerve modulation device 12 at section line 4 in FIG. 2 is illustrated in FIG. 4 . Shaft 35 may include a guidewire lumen 36 and a lumen 42 connected to the fluid inlet port 32 . In some embodiments, the guidewire lumen extends from the distal end of the device to a proximal hub. In other embodiments, the guidewire lumen can have a proximal opening that is distal to the proximal portion of the system.
[0027] Balloon 22 is shown in cross-section as having a first layer 25 and a second layer 23 . A window 28 is formed in balloon 22 by the absence of second layer 23 . First layer 25 is preferably made from an ionically permeable material. One suitable material is, for example, a hydrophilic polyurethane. The second layer 23 is preferably made from an electrically non-ionically permeable polymer such as a non-hydrophilic polyurethane, Pebax, nylon, polyester or block-copolymer.
[0028] In the embodiment illustrated in FIGS. 2 and 5 , the ionic energy from the electrode 24 may become concentrated (higher current density) at the edges of the conductive windows where there is a large delta in impedance of the two adjacent materials (window material and insulation coating material) of the balloon 22 and in particular in the portions of the balloon wall that lack the non-conductive second layer 23 . Thus ports 32 are located and configured to direct the fluid against those regions of the balloon wall. For example, it can be seen in both FIGS. 2 and 3 that the ports 32 are directed at the balloon windows 28 under standard flow conditions. These ports may be configured to direct the fluid directly out of the port or may be configured to direct the fluid at an angle. “At an angle” herein means at a non-zero angle to a radius of the balloon. For examples, the ports 32 may direct the fluid at an angle such that the fluid is given a clockwise or counterclockwise motion in the balloon lumen. The ports 32 may, alternatively or in addition, be directed to angle the fluid in a proximal direction. The ports 32 may all be at the same angle or may be at different angles relative to each other. The ports 32 may be the same size or different sizes.
[0029] FIG. 5 illustrates the distal portion of a renal nerve modulation device 12 that includes a balloon 22 on which are disposed RF electrodes 38 . Electrodes 38 , disposed on the balloon 22 , are arranged to achieve complete circumferential coverage of the blood vessel while spaced apart longitudinally and may be powered by leads (not illustrated) extending along the surface of the balloon or extending up from the central shaft 35 . The electrodes 38 are depicted as circular but may be any desired shape. They may, for example, be oval or oblong. The balloon 22 is filled through a fluid supply lumen through ports 32 a - 32 f. The fluid is evacuated through a fluid evacuation lumen connected to fluid outlet lumen 30 . One port 32 is provided under, or adjacent to, each electrode 38 . Each one of the ports 32 may be configured to direct the fluid directly out of the port towards the respective electrode 38 or may be configured to direct the fluid at an angle towards the respective electrode 38 . Ports 32 are illustrated as having different sizes with the proximal-most port, port 32 a, being the smallest and the distal-most port, port 32 f, being the largest. The size of the ports may vary to maintain a uniform output of fluid from each port or may be varied to provided more or less fluid flow against particular areas of the balloon and/or or particular electrodes. Other variations of the ports such as discussed above may be included as well.
[0030] In use, a renal ablation system such as system 10 is provided. The system may be used with a standard guide catheter such as a 6 French guide catheter. The balloon and in particular the hydrophilic or tecophilic material may be hydrated as part of the preparatory steps. Hydration may be effected by soaking the balloon in a saline solution. A one minute, five minute, or other suitable soak may be beneficial. Then the renal nerve modulation device 12 may then be introduced percutaneously as is conventional in the intravascular medical device arts by using a guide catheter and/or a guide wire. For example, a guide wire such as a 0.014″ diameter guidewire may be introduced percutaneously through a femoral artery and navigated to a renal artery using standard radiographic techniques. In some embodiments, a delivery sheath 14 may be introduced over the guide wire and the guide wire may be withdrawn, and the renal nerve modulation device 12 may be then introduced through the delivery sheath. In other embodiments, the renal nerve modulation device 12 may be introduced over the guidewire, or the system 10 , including a delivery sheath 14 may be introduced over a guidewire. In embodiments involving a delivery sheath 14 , the renal nerve modulation device 12 may be delivered distally from the distal end of the delivery sheath 14 into position, or the delivery sheath may be withdrawn proximally to expose the distal portion of renal nerve modulation device 12 . A conductive fluid 26 is introduced into the balloon through fluid inlet ports 32 and may expand the balloon to the desired size. The balloon expansion may be monitored indirectly by monitoring the volume, or flow rate, of conductive fluid introduced into the system or may be monitored through radiographic or other conventional means. Once the balloon is expanded to the desired size, the conductive fluid 26 may be circulated within the balloon by continuing to introduce the fluid through the fluid inlet ports 32 while withdrawing fluid from the balloon through the fluid outlet 30 . The rate of circulation of the fluid may be between 2 and 20 ml/min, between 3 and 15 ml/min, between 5 and 75 ml/min or other desired rate of circulation.
[0031] The balloon may be kept at or near a desired pressure such as a pressure of between 0.25 and 6 atmospheres, between 1.5 and 4 atmospheres, between 2.5 and 3.5 atmospheres, or other desired pressure. The electrode(s) is then activated by supplying energy. The energy may be supplied at 400-500 Hz and at between 0.05 and 1 amp. The energy is transmitted to the blood vessel wall to modulate or ablate the surrounding tissue. The progress of the treatment may be monitored by monitoring changes in impedance through the electrode. Other measurements such as pressure and/or temperature measurements may be conducted during the procedure as desired. The circulation of the conductive fluid 26 may mitigate the temperature rise of the tissue or the blood vessel 48 in contact with the windows 28 . The electrode 24 is preferably activated for an effective length of time, such as 1 minute or 2 minutes. Once the procedure is finished at a particular location, the balloon 22 may be partially or wholly deflated and moved to a different location such as the other renal artery, and the procedure may be repeated at another location as desired using conventional delivery and repositioning techniques. Various modifications and alterations of this disclosure will become apparent to those skilled in the art without departing from the scope and principles of this disclosure, and it should be understood that this disclosure is not to be unduly limited to the illustrative embodiments set forth hereinabove. All publications and patents are herein incorporated by reference to the same extent as if each individual publication or patent was specifically and individually indicated to be incorporated by reference.
|
An intravascular catheter for tissue modulation, comprising an elongate member having a proximal end and a distal end, a balloon disposed on the elongate member and having an interior surface, an exterior surface, a lumen defined by the interior surface and at least a first region for transmitting therapeutic energy from the exterior surface of the balloon, wherein the elongate member has a fluid supply lumen having a plurality of ports fluidly connected to the balloon lumen and a fluid evacuation lumen having a port fluidly connected to the balloon lumen.
| 0
|
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is continuation application of U.S. application Ser. No. 12/801,952, filed Jul. 2, 2010, which was a continuation of U.S. application Ser. No. 12/659,980, filed Mar. 26, 2010, which issued as U.S. Pat. No. 7,797,970, which was a divisional of U.S. application Ser. No. 11/806,245, filed May 30, 2007, which issued as U.S. Pat. No. 7,743,633, which in turn claims the benefit of Korean Patent Application Nos. 2006-49501 and 2006-49482, both filed on Jun. 1, 2006, in the Korean Intellectual Property Office, the disclosures of which are incorporated herein by reference.
BACKGROUND
[0002] 1. Field
[0003] The present invention relates generally to a washing machine having at least one balancer, and more particularly to a washing machine having at least one balancer that increases durability by reinforcing strength and that is installed on a rotating tub in a convenient way.
[0004] 2. Description of the Related Art
[0005] In general, washing machines do the laundry by spinning a spin tub containing the laundry by driving the spin tub with a driving motor. In a washing process, the spin tub is spun forward and backward at a low speed. In a dehydrating process, the spin tub is spun in one direction at a high speed.
[0006] When the spin tub is spun at a high speed in the dehydrating process, if the laundry leans to one side without uniform distribution in the spin tub or if the laundry leans to one side by an abrupt acceleration of the spin tub in the early stage of the dehydrating process, the spin tub undergoes a misalignment between the center of gravity and the center of rotation, which thus causes noise and vibration. The repetition of this phenomenon causes parts, such as a spin tub and its rotating shaft, a driving motor, etc., to break or to undergo a reduced life span.
[0007] Particularly, a drum type washing machine has a structure in which the spin tub containing laundry is horizontally disposed, and when the spin tub is spun at a high speed when the laundry is collected on the bottom of the spin tub by gravity in the dehydrating process, the spin tub undergoes a misalignment between the center of gravity and the center of rotation, thus resulting in a high possibility of causing excess noise and vibration.
[0008] Thus, the drum type washing machine is typically provided with at least one balancer for maintaining a dynamic balance of the spin tub. A balancer may also be applied to an upright type washing machine in which the spin tub is vertically installed.
[0009] An example of a washing machine having ball balancers is disclosed in Korean Patent Publication No. 1999-0038279. The ball balancers of a conventional washing machine include racers installed on the top and the bottom of a spin tub in order to maintain a dynamic balance when the spin tub is spun at a high speed, and steel balls and viscous oil are disposed within the racers to freely move in the racers.
[0010] Thus, when the spin tub is spun without maintaining a dynamic balance due to an unbalanced eccentric structure of the spin tub itself and lopsided distribution of the laundry in the spin tub, the steel balls compensate for this imbalance, and thus the spin tub can maintain the dynamic balance.
[0011] However, the ball balancers of the conventional washing machine have a structure in which upper and lower plates formed of plastic by injection molding are fused to each other, and a plurality of steel balls are disposed between the fused plates to make a circular motion, so that the ball balancers are continuously supplied with centrifugal force that is generated when the steel balls make a circular motion, and thus are deformed at walls thereof, which reduces the life span of the balancer.
[0012] Further, the ball balancers of the conventional washing machine do not have a means for guiding the ball balancers to be installed on the spin tub in place, so that it takes time to assemble the balancers to the spin tub.
[0013] In addition, the ball balancers of the conventional washing machine have a structure in which a racer includes upper and lower plates fused to each other, so that fusion scraps generated during fusion fall down both inwardly and outwardly of the racer. The fusion scraps that fall down inwardly of the racer prevent motion of the balls in the racer, and simultaneously result in generating vibration and noise.
SUMMARY
[0014] Accordingly, the present invention has been made to solve the above-mentioned problems occurring in the prior art, and an object of the present invention is to provide a washing machine having at least one balancer that increases durability by reinforcing the strength of the balancer, which is installed on a rotating tub in a rapid and convenient way.
[0015] Another object of the present invention is to provide a washing machine having at least one balancer, in which fusion scraps generated by fusion of the balancer are prevented from falling down inward and outward of the balancer.
[0016] Additional aspects and/or advantages of the invention will be set forth in part in the description which follows and, in part, will be apparent from the description, or may be learned by practice of the invention.
[0017] In order to accomplish these objects, according to an aspect of the present invention, there is provided a washing machine having a spin tub to hold laundry to be washed and at least one balancer. The balancer includes first and second housings, the first housing having at least one support for reinforcing a strength of the balancer. The first and second housings have an annular shape and are fused together to form a closed internal space.
[0018] Here, the first housing may have the cross section of an approximately “C” shape, and the support protrudes outwardly from at least one of opposite walls of the first housing.
[0019] Further, the spin tub may include at least one annular recess corresponding to the balancer such that the balancer is able to be coupled to the spin tub by being fitted within the recess.
[0020] Further, the support may protrude from the first housing and comes into contact with a wall of the recess, and guides the balancer to be maintained in the recess in place.
[0021] Also, the supports may be continuously formed along and perpendicular to the opposite walls of the first housing.
[0022] Further, the supports may be disposed parallel to the opposite walls of the first housing at regular intervals.
[0023] Meanwhile, the washing machine may be a drum type washing machine. A front member may be attached to a front end of the spin tub and a rear member may be attached to a rear end of the spin tub. The recesses may be provided at the front and rear members of the spin tub, and the balancers may be coupled to opposite ends of the spin tub at the recesses of the front and rear members.
[0024] The foregoing and/or other aspects of the present invention can be achieved by providing a washing machine having at least one balancer. The balancer includes a first housing and a second housing fused to the first housing, and the first and second housings are fused together to form at least one pocket between the first housing and the second housing, the pocket capable of collecting fusion scraps generated during fusion.
[0025] Here, the first housing may include protruding fusion ridges protruding from ends of the first housing, and the second housing may include fusion grooves receiving the fusion ridges of the first housing when the first housing and the second housing are fused together.
[0026] Further, the first housing may further include inner pocket ridges protruding from the first housing and spaced inwardly apart with respect to the fusion ridges of the first housing.
[0027] Further, the second housing may further include outer pocket flanges protruding from the second housing and being situated on outer sides of the fusion grooves when the first housing is fused together with the second housing so the outer pocket flanges are spaced apart from the fusion ridges of the first housing by a predetermined distance, causing an outer pocket to be formed between the fusion ridges and the outer pocket flanges.
[0028] Further, the second housing may include guide ridges protruding from the second housing and protruding toward the first housing to closely contact the inner pocket ridges of the first housing when the first and second housings are fused together.
[0029] Also, the balancer may further include a plurality of balls disposed within an internal space formed by fusing the first and second housings together, the balls performing a balancing function.
[0030] In addition, the washing machine may further include a spin tub disposed horizontally, and the balancers may be installed at front and rear ends of the spin tub.
BRIEF DESCRIPTION OF THE DRAWINGS
[0031] The above and other aspects, features and advantages of the present invention will be more apparent from the following detailed description of the embodiments, taken in conjunction with the accompanying drawings, in which
[0032] FIG. 1 is a sectional view illustrating a schematic structure of a washing machine according to the present invention;
[0033] FIG. 2 is a perspective view illustrating balancers according to the present invention, in which the balancers are disassembled from a spin tub;
[0034] FIG. 3 is a perspective view illustrating a balancer according to a first embodiment of the present invention;
[0035] FIG. 4 is an enlarged view illustrating section A of FIG. 1 in order to show the sectional structure of a balancer according to a first embodiment of the present invention;
[0036] FIG. 5 is a perspective view illustrating a balancer according to a second embodiment of the present invention;
[0037] FIG. 6 is an enlarged view illustrating the sectional structure of a balancer according to the second embodiment of the present invention;
[0038] FIG. 7 is a perspective view illustrating a disassembled balancer according to a third embodiment of the present invention;
[0039] FIG. 8 is a perspective view illustrating an assembled balancer according to the third embodiment of the present invention;
[0040] FIG. 9 is a partially enlarged view of FIG. 7 ; and
[0041] FIG. 10 is a sectional view taken line A-A of FIG. 8 .
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0042] Reference will now be made in detail to the embodiments of the present invention, examples of which are illustrated in the accompanying drawings, wherein like reference numerals refer to the like elements throughout. The embodiments are described below to explain the present invention by referring to the figures.
[0043] Hereinafter, exemplary embodiments of the present invention will be described with reference to the attached drawings.
[0044] FIG. 1 is a sectional view illustrating the schematic structure of a washing machine according to the present invention.
[0045] As illustrated in FIG. 1 , a washing machine according to the present invention includes a housing 1 forming an external structure of the washing machine, a water reservoir 2 installed in the housing 1 and containing washing water, a spin tub 10 disposed rotatably in the water reservoir 2 which allows laundry to be placed in and washed therein, and a door 4 hinged to an open front of the housing 1 .
[0046] The water reservoir 2 has a feed pipe 5 and a detergent feeder 6 both disposed above the water reservoir 2 in order to supply washing water and detergent to the water reservoir 2 , and a drain pipe 7 installed therebelow in order to drain the washing water contained in the water reservoir 2 to the outside of the housing 1 when the laundry is completely done.
[0047] The spin tub 10 has a rotating shaft 8 disposed at the rear thereof so as to extend through the rear of the water reservoir 2 , and a driving motor 9 , with which the rotating shaft 8 is coupled, installed on a rear outer side thereof. Therefore, when the driving motor 9 is driven, the rotating shaft 8 is rotated together with the spin tub 10 .
[0048] The spin tub 10 is provided with a plurality of dehydrating holes 10 a at a periphery thereof so as to allow the water contained in the water reservoir 2 to flow into the spin tub 10 together with the detergent to wash the laundry in a washing cycle, and to allow the water to be drained to the outside of the housing 1 through a drain pipe 7 in a dehydrating cycle.
[0049] The spin tub 10 has a plurality of lifters 10 b disposed longitudinally therein. Thereby, as the spin tub 10 rotates at a low speed in the washing cycle, the laundry submerged in the water is raised up from the bottom of the spin tub 10 and then is lowered to the bottom of the spin tub 10 , so that the laundry can be effectively washed.
[0050] Thus, in the washing cycle, the rotating shaft 8 alternately rotates forward and backward by of the driving of the driving motor 9 to spin the spin tub 10 at a low speed, so that the laundry is washed. In the dehydrating cycle, the rotating shaft 8 rotates in one direction to spin the spin tub 10 at a high speed, so that the laundry is dehydrated.
[0051] When spun at a high speed in the dehydrating process, the spin tub 10 itself may undergo misalignment between the center of gravity and the center of rotation, or the laundry may lean to one side without uniform distribution in the spin tub 10 . In this case, the spin tub 10 does not maintain a dynamic balance.
[0052] In order to prevent this dynamic imbalance to allow the spin tub 10 to be spun at a high speed with the center of gravity and the center of rotation thereof matched with each other, the spin tub 10 is provided with balancers 20 or 30 according to a first or a second embodiment of the present invention (wherein only the balancer 20 according to a first embodiment is shown in FIGS. 1-4 ) at front and rear ends thereof. The structure of the balancers 20 and 30 according to the first and second embodiments of the present invention will be described with reference to FIGS. 2 through 6 .
[0053] FIG. 2 is a perspective view illustrating balancers according to the present invention, in which the balancers are disassembled from a spin tub.
[0054] As illustrated in FIG. 2 , the spin tub 10 includes a cylindrical body 11 that has open front and rear parts and is provided with the dehydrating holes 10 a and lifters 10 b , a front member 12 that is coupled to the open front part of the body 11 and is provided with an opening 14 permitting the laundry to be placed within or removed from the body 11 , and a rear member 13 that is coupled to the open rear part of the body 11 and with the rotating shaft 8 (see FIG. 1 ) for spinning the spin tub 10 .
[0055] The front member 12 is provided, at an edge thereof, with an annular recess 15 that has the cross section of an approximately “C” shape and is open to the front of the front member 12 in order to hold any one of the balancers 20 . Similarly, the rear member 13 is provided, at an edge thereof, with an annular recess 15 (not shown) that is open to the rear of the front member 12 in order to hold the other of the balancers 20 .
[0056] The front and rear members 12 and 13 are fitted into and coupled to the front or rear edges of the body 11 in a screwed fashion or in any other fashion that allows the front and rear members 12 and 13 to be maintained to the body 11 of the spin tub 10 .
[0057] The balancers 20 , which are installed in the recesses 15 of the front and rear members 12 and 13 , have an annular shape and are filled therein with a plurality of metal balls 21 performing a balancing function and a viscous fluid (not shown) capable of adjusting a speed of motion of the balls 21 .
[0058] Now, the structure of the balancers 20 and 30 according to the first and second embodiments of the present invention will be described with reference to FIGS. 3 through 6 .
[0059] FIG. 3 is a perspective view illustrating a balancer according to a first embodiment of the present invention, and FIG. 4 is an enlarged view illustrating part A of FIG. 1 in order to show the sectional structure of a balancer according to a first embodiment of the present invention.
[0060] As illustrated in FIGS. 3 and 4 , a balancer 20 according to a first embodiment of the present invention has an annular shape and includes first and second housings 22 and 23 that are fused to define a closed internal space 20 a.
[0061] The first housing 22 has first and second walls 22 a and 22 b facing each other, and a third wall 22 c connecting ends of the first and second walls 22 a and 22 b , and thus has a cross section of an approximately “C” shape. The second housing 23 has opposite edges that protrude toward the first housing 22 and that are coupled to corresponding opposite ends 22 d of the first housing 22 by heat fusion.
[0062] The opposite ends 22 d of the first housing 22 protrude outward from the first and second walls 22 a and 22 b of the first housing 22 , and the edges of the second housing 23 are sized to cover the ends 22 d of the first housing 22 .
[0063] Thus, when the balancer 20 is fitted into the recess 15 of the front member 12 of the spin tub 10 , the first and second walls 22 a and 22 b are spaced apart from a wall of the recess 15 because of the ends and edges of the first and second housings 22 and 23 which protrude outward from the first and second walls 22 a and 22 b . Further, because the first and second walls 22 a and 22 b are relatively thin, the first and second walls 22 a and 22 b are raised outward when centrifugal force is applied thereto by the plurality of balls 21 that move in the internal space 20 a of the balancer 20 in order to perform the balancing function.
[0064] In this manner, the plurality of balls 21 make a circular motion in the balancer 20 , so that the first and second walls 22 a and 22 b are deformed by the centrifugal force applied to the first and second walls 22 a and 22 b of the first housing 22 . In order to prevent this deformation, the second housing 22 is provided with supports 24 according to a first embodiment of the present invention.
[0065] The supports 24 protrude from and perpendicular to the first and second walls 22 a and 22 b of the first housing 22 which are opposite each other, and may be continued along an outer surface of the first housing 22 , thereby having an overall annular shape.
[0066] The supports 24 have a length such that they extend from the first housing 22 to contact the wall of the recess 15 . Hence, the first and second walls 22 a and 22 b are further increased in strength, and additionally function to guide the balancer 20 so as to be maintained in the recess 15 in place.
[0067] Here, when the plurality of balls 21 make a circular motion in the first housing 22 , the centrifugal force acts in the direction moving away from the center of rotation of the spin tub 10 . Hence, the centrifugal force acts on the first wall 22 a to a stronger level when viewed in FIG. 4 . Thus, the supports 24 may be formed only on the first wall 22 a.
[0068] In the balancer 20 according to the first embodiment of the present invention, when the first and second housings 22 and 23 are fused together and fitted into the recess 15 of the spin tub 10 , the supports 24 are maintained in place while positioned along the wall of the recess 15 . Finally, the balancer 20 is coupled and fixed to the front member 12 of the spin tub 10 by screws (not shown) or in any other fashion that allows the balancer 20 to be coupled to the front member 12 .
[0069] Although not illustrated in detail, the balancer 20 is similarly installed on the rear member 13 of the spin tub 10 .
[0070] The ends 22 d of the first housing 22 include fusion ridges 42 a that protrude toward the second housing 23 . The fusion ridges 42 a are inserted within fusion grooves 43 a of the second housing 23 .
[0071] FIGS. 5 and 6 correspond to FIGS. 3 and 4 , and illustrate a balancer 30 according to a second embodiment of the present invention.
[0072] The balancer 30 according to the second embodiment of the present invention has an annular shape and includes first and second housings 32 and 33 that are fused together forming an internal space 30 a therebetween in which a plurality of balls 31 are disposed. The balancer 30 according to the second embodiment of the present invention is similar to that of balancer 20 according to the first embodiment of the present invention, except the structure of supports 34 of balancer 30 is different from that of the structure of the supports 24 of balancer 20 .
[0073] As illustrated in FIGS. 5 and 6 , the supports 34 according to the second embodiment of the present invention protrude parallel to first and second walls 32 a and 32 b of a first housing 32 which are opposite each other, and the supports 34 are disposed at regular intervals along the first and second walls 32 a and 32 b . The first housing 32 further includes a third wall 32 c . Ends 22 d of the first housing 32 extend from an end of the first and second walls 32 a and 32 b.
[0074] Similar to the supports 24 according to the first embodiment, the supports 34 of the second embodiment have a length such that the supports 34 extend from the first housing 32 to contact the wall of the recess 15 . The surfaces of the supports 34 thereby abut portions of the front member 12 . Hence, the first and second walls 32 a and 32 b are further increased in strength, and additionally function to guide the balancer 30 so as to be maintained in the recess 15 in place.
[0075] Next, the construction of a balancer 40 according to a third embodiment of the present invention will be described with reference to FIGS. 7 through 10 .
[0076] FIGS. 7 and 8 are perspective views illustrating disassembled and assembled balancers according to the third embodiment of the present invention, FIG. 9 is a partially enlarged view of FIG. 7 , and FIG. 10 is a sectional view taken along line A-A of FIG. 8 .
[0077] As illustrated in FIGS. 7 and 8 , a balancer 40 includes a first housing 42 having an annular shape and a second housing 43 having an annular shape that is fused to the first housing 42 , thereby forming an annular housing corresponding to the recess 15 (see FIG. 2 ) of the spin tub 10 . The first and second housings 42 and 43 may be, for example, formed of synthetic resin, such as plastic by injection molding.
[0078] As illustrated in FIG. 9 , the first housing 42 has a cross section of an approximately “C” shape, includes fusion ridges 42 a protruding to the second housing 43 at opposite ends thereof which are coupled with the second housing 43 , and inner pocket ridges 42 b protruding to the second housing 43 spaced inwardly apart from the fusion ridges 42 a.
[0079] The second housing 43 , which is coupled to opposite ends of the first housing 42 in order to form a closed internal space 40 a for holding a plurality of balls 41 and a viscous fluid, includes fusion grooves 43 a recessed along edges thereof so as to correspond to the fusion ridges 42 a , outer pocket flanges 43 b and guide ridges 43 c . The outer pocket flanges protrude to the first housing 42 on outer sides of the fusion grooves 43 a so as to be spaced apart from the fusion ridges 42 a of the first housing 42 by a predetermined distance. The guide ridges 43 c protrude to the first housing 42 on inner sides of the fusion grooves 43 a and closely contact the inner pocket ridges 42 b of the first housing 42 .
[0080] The guide ridges 43 c of the second housing 43 move in contact with the inner pocket ridges 42 b of the first housing 42 when the second housing 43 is fitted into the first housing 42 , to thereby guide the fusion ridges 42 a of the first housing 42 to be fitted into the fusion grooves 43 a of the second housing 43 rapidly and precisely.
[0081] Thus, when the fusion ridges 42 a of the first housing 42 are fitted into the fusion grooves 43 a of the second housing 43 in order to fuse the first housing 42 with the second housing 43 , as shown in FIG. 10 , an inner pocket 40 b having a predetermined spacing is formed between the fusion ridges 42 a and inner pocket ridges 42 b , and an outer pocket 40 c having a predetermined spacing is formed between the fusion ridges 42 a and the outer pocket flanges 43 b.
[0082] In this state, when heat is generated between the fusion ridges 42 a of the first housing 42 and the fusion grooves 43 a of the second housing 43 , the fusion ridges 42 a and the fusion grooves 43 a are firmly fused with each other. At fusion, fusion scraps that are generated by heat and fall down inward of the first housing 42 are collected in the inner pocket 40 b , so that the scraps are not introduced into the internal space 40 a of the balancer 40 in which the balls 41 move. Fusion scraps falling down outward of the first housing 42 are collected in the outer pocket 40 c , and thus are prevented from falling down outward of the balancer 40 .
[0083] In the embodiments, the balancers 20 , 30 and 40 have been described to be installed on a drum type washing machine by way of example, but it is apparent that the balancers can be applied to an upright type washing machine having a structure in which a spin tub is vertically installed.
[0084] As described above in detail, the washing machine according to the embodiments of the present invention has a high-strength structure in which at least one balancer is provided with at least one support protruding outward from the wall thereof, so that, although the strong centrifugal force acts on the wall of the balancer due to a plurality of balls making a circular motion in the balancer, the wall of the balancer is not deformed. Thus, the plurality of balls can make a smooth circular motion without causing excess vibration and noise, and thus increasing the durability and life span of the balancer.
[0085] Further, the washing machine according to the embodiments of the present invention has a structure in which the balancer can be rapidly and exactly positioned in the recess of the spin tub by the supports, so that an assembly time of the balance can be reduced.
[0086] In addition, the washing machine according to the present invention has a structure in which fusion scraps generated when the balancer is fused are collected in a plurality of pockets, and thus are prevented from'falling down inward and outward of the balancer, so that the internal space of the balancer, in which a plurality of balls are filled and move in a circular motion, has a smooth surface without the addition of fusion scraps. As a result, the balls are able to move more smoothly, and excess noise and vibration are minimized. The balancer may have a clear outer surface to provide a fine appearance without the fusion scraps, so that it can be exactly coupled to the spin tub without obstruction caused by the fusion scraps.
[0087] Although a few embodiments of the present invention have been described for illustrative purposes, those skilled in the art will appreciate that various modifications, additions and substitutions are possible, without departing from the scope and spirit of the invention as disclosed in the accompanying claims and their equivalents.
|
A front loading washing machine including a housing; a water reservoir installed in the housing for containing washing water; a spin tub provided in the water reservoir to hold laundry to be washed, the spin tub having an annular recess and rotating with respect to a horizontal axis of the washing machine; and at least one balancer installed in the annular recess of the spin tub, the balancer comprising an annular shaped race formed of a plastic material.
| 3
|
BACKGROUND OF THE PRESENT INVENTION
[0001] 1. Field of Invention
[0002] The present invention relates to the preparation of IgY (egg yolk immunoglobulin) for the prevention and treatment of oral diseases, wherein further relates to the production of immuno-safe-toothpaste against oral diseases by using the IgY as a major ingredient
[0003] 2. Description of Related Arts
[0004] Recently, there are various kinds of toothpaste, but they usually contain chemicals that is harmful to human beings, such as Sodium Dodecyl Sulfonate (SDS), Sodium Dodecyl Sarcosinate, Dodecyl Ethylene amide, Polyacrylic acid with Sodium polyacrylate, etc. Therefore, ingestion or swallowing of such toothpastes should be prevented while brushing teeth. Unfortunately, research had shown that adults could accidentally ingest 15-20% of the toothpaste used in terms of percentage volume while they are brushing teeth; a result of 40% had be shown for children in the same research. The pro-long use of such toothpaste is chronologically harmful to the body, and which is more serious to children and teenagers. The influence should not be neglected.
[0005] Furthermore, toothpastes recently on the market that are relatively effective contains fluoride, this chemical treatment cannot overcome the problem from the root and raised other problems:
[0006] (1) the occurrence mottled enamel: fluoride was added to tape water in Hong Kong and Guangzhou in 1961 and 1965 respectively to prevent dental caries, as a result, mottled enamel bloom;
[0007] (2) a research was carried out with observing children using fluorinated toothpaste for two months, results indicated that over-fluoride-absorption occurred in the children as the amount of toothpaste used varies and swallowing of toothpaste is serious. It is harmful to the health of children, especially those living in high-fluorine area;
[0008] (3) the pro-long use of fluoride will bring the dental caries Streptococcus to mutate, fluorine-resistant mutant strain can tolerate high fluorine concentration and even having higher caries ability, thus, worsen caries.
[0009] Moreover, most of the toothpastes designed for periodontitis and halitosis recently in the market contains wide-spectrum chemical germicides. These chemical germicides kill probiotic bacteria together with the pathogens in the oral cavity, which is seriously altering the oral micro-ecosystem. The effective period of these germicides only last for a few hours after teeth brushing, and pathogens bloom again after the hours. In addition, the pro-long use of chemical germicide leads pathogens to build tolerance, which finally worsen the fact.
[0010] To prepare IgY, organic solvents such as octanoic acid, alcohol, acetone, chloroform should be used during the extraction process in the classical methods recently. These solvents affect the activity of IgY and chemical residues generated are harmful to health. Besides organic solvents, precipitation is another preparation method. Polyethylene glycol, Dextran sulfate are common precipitation inducers, but the yield from is low and there is chemical residue also. The most recent method is water dilution extraction. The advantage of this method is having simple processes, high yield, low cost, no chemical hazards and safe, on the other hand, this method cannot remove excessive fat.
SUMMARY OF THE PRESENT INVENTION
[0011] Targeted on the inadequate of the recent technologies, this invention is to provide a new IgY preparation method, and make this IgY to be an ingredient of a toothpaste that could control and treat oral diseases.
[0012] To achieve the recited objective, this invention include the methods to prepare IgY to control and treat oral diseases, wherein comprises:
[0013] (1) the incubation of pathogenic bacteria: using conventional practice to incubate major pathogenic bacteria regarding to dental caries, periodontitis and halitosis;
[0014] (2) the production of antigen complex: produce antigen complex from the pathogenic bacteria incubated;
[0015] (3) the injection: inject the antigen complex to egg-laying avian (e.g. hens, ducks, turkeys, etc.);
[0016] (4) the obtainment of immunized egg: analyze and pick immunized eggs laid by immunized avian;
[0017] (5) the production of egg yolk immunoglobulin: prepare egg yolk immunoglobulin from the egg yolk of the immunized eggs collected.
[0018] The method (1) of this invention, type C, D and G of Streptococcus mutans are incubated and obtained based on the pathogens arising dental caries; Fusobacterium nucleatum, Porphyromonas gingivalis, Actinomyces viscosus, Actinobacillus actinomycetemcomitans, Capnocytophaga ochracea, Treponemas denricola and Bacteroides forsythus are incubated and obtained based on the pathogens arising periodontitis and halitosis.
[0019] The method (5) in this invention, the preparation of IgY comprises:
[0020] (1) the extraction of egg yolk from the immunized eggs using “egg yolk sieve”, and mixing the extraction thoroughly;
[0021] (2) the addition of distilled water 4-6 times to the volume of the extraction;
[0022] (3) the adjustment of the pH of the mixture within 4.5-6.5;
[0023] (4) the addition of 2% Sodium alginate and make its concentration in the mixture within 1.0%-2.0%, and stir to precipitation;
[0024] (5) the addition of 2% CaCl 2 and make its concentration in the mixture within 0.5%-1.0%, and stirring thoroughly;
[0025] (6) the positioning of the mixture in 2-6° C. for 8-12 hours, an the siphoning of the supernatant;
[0026] (7) the centrifugation of the supernatant in (6) for 20 minutes at 8,000-12,000 rpm, and the taking of the supernatant;
[0027] (8) the ultra filtration for the supernatant in (7), and the sterilization with 0.22 μmembrane filter; and
[0028] (9) the freeze drying and the obtainment of the IgY extract.
[0029] The product in this invention, using the recited IgY to produce toothpaste, wherein contains 0.01-10.0% of the recited immunoglobulin, and:
[0030] (1) 0.3-5.0% foaming agent,
[0031] (2) 0.2-2.0% Sodium alginate,
[0032] (3) 0.5-5.0% Carboxymethylcellulose sodium,
[0033] (4) 0.12-20.0% Glycerol,
[0034] (5) 1.0-20.0% Sorbitol,
[0035] (6) 0.12-0.5% Aspartame, and
[0036] (7) appropriate ratio of flavorings.
[0037] The method (5) in this invention, the preparation of IgY comprises the followings.
[0038] In order to minimize the altering of foaming agent to the activity of IgY, foaming agent that does not denature protein could be used, the foaming agent could be Hydrogenated Castor Oil Polyoxyethylene Ether, Sodium N-lauroylamide ethanoate, or sodium N-lauroyl sarcosinate or the combination of either of the recited foaming agent. Appropriate ratio of oral mucosa adsorbent could also be added, such as 0.5-5.0% Caborpl.
[0039] To enhance the life of IgY within the paste, the IgY could be coated by water insoluble inert membrane, which does not affect the activity of the immunoglobulin, as micro-capsule, and make IgY distributed thoroughly throughout the paste.
[0040] The IgY prepared with the methods in this invention has high activity, high specificity, high effectiveness and safe, the processes are simple, low-cost and environmental friendly, and furthermore, the integrated use of side products such as egg shells, egg white and the other parts of egg yolk is another advantage. The brand new safe-toothpaste using the IgY as the major ingredient is having effective result on the control and treatment of caries, periodontitis and halitosis, and accidental ingestion is safe as there is no harmful chemicals within the toothpaste.
[0041] These and other objectives, features, and advantages of the present invention will become apparent from the following detailed description, the accompanying drawings, and the appended claims.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0042] 1. The Preparation Procedures of IgY Complex:
[0043] This invention is applied with the principle of passive-immunity, IgY against specific pathogens could be obtained from the egg laid by egg-laying avian that immunized with appropriate amount of the specific antigen. The content of this sample comprises the incubation of the major pathogens with conventional practice with reference to the pathogens arising caries, periodontitis and halitosis, which is to make the IgY prepare is specific on the recited pathogens.
[0044] For the pathogens arising caries, serotype C, D and G of Streptococcus mutans could be selected. Mix the incubated S.mutans of different serotypes and add Freund adjuvant at the ratio 1:1; after the shattering and mixing of the mixture with a liquid mixer up to 10,000-30,000 rpm, antigen complex of S.mutans is prepared.
[0045] Besides caries, the following bacteria arising periodontitis and halitosis could be selected:
[0046] (1) Actinobacillus actinomycetemcomitans,
[0047] (2) Fusobacterium nucleatum,
[0048] (3) Porphyromonas gingivalis,
[0049] (4) Actinomyces viscosus,
[0050] (5) Capnocytophaga ochracea,
[0051] (6) Treponemas denricola, and
[0052] (7) Bacteroides forsythus, etc.
[0053] Mix the 7 representative pathogens that arising periodontitis and halitosis in appropriate ratio and add Freund adjuvant at the ratio 1:1; after the shattering and mixing of the mixture with a liquid mixer up to 10,000-30,000 rpm, antigen complex with whole bacterium and bacterial contents of multiple pathogens arising periodontitis and halitosis is prepared. Antigen complex arising halitosis only could also be prepared with several bacteria related to halitosis such as Fusobacterium nucleatum, Porphyromonas gingivalis, and Actinomyces viscosus by using the same recited procedures.
[0054] Perform hypodermic injections or wings-intravenous injections with one or several antigen complexes prepared from the above methods separately into well-breed and egg-laying hens, ducks or turkey that is having high sensitivity immune respond and selected by experiments. Second injection should be performed two weeks after the first injection, and three injections per avian in total. The eggs lay by the hens, ducks or turkeys 20 days after the first injection could be collected, the immunized eggs should be labeled differently according to the antigen injected.
[0055] The immunized eggs will be treated with the following processes:
[0056] (1) Extract the egg yolk from the immunized eggs using “egg yolk sieve”, and mix the extraction thoroughly;
[0057] (2) add distilled water 4-6 times to the volume of the extraction;
[0058] (3) adjust the pH of the mixture within 4.5-6.5;
[0059] (4) add 2% Sodium alginate (Food graded) and make its concentration in the mixture within 1.0%-2.0%, and stir to precipitation;
[0060] (5) add 2% CaCl2 (Food Graded) and make its concentration in the mixture within 0.5%-1.0%, and stir thoroughly;
[0061] (6) place the mixture in 2-6° C. for 8-12 hours, siphon the supernatant;
[0062] (7) centrifuge the supernatant in (6) for 20 minutes at 8,000-12,000 rpm, and take the supernatant;
[0063] (8) perform ultra filtration for the supernatant in (7), and sterile with 0.22 μmembrane filter; and
[0064] (9) freeze dry and obtain the IgY extract.
[0065] 2. Experimental Researches Regarding the IgY Prepared Above
[0066] (1) Chronic toxicity test: Feed selected, health Sprague-Dawlye (SD) rats with the above IgY with 80 mg IgY/kg body weight/day for 30 days. Results had shown that rats did not carry any clinical symptoms, blood and urine tests resulted normal, liver and kidney test resulted normal, pathological surgery and tests on brain, heart, liver, kidney and testes did not find any abnormality.
[0067] (2) Activity test: Valence of Indirect Hemagglutination Inhibition Test was 1:512, and which of Enzyme-linked Immunosorbent Assay was 204,800 units.
[0068] (3) Adhesion inhibition test: Even the dilution factor of IgY reaches 1:8, the IgY still perform effective adhesion and inhibition to oral pathogens such as S.mutans, Actinomyces viscosus and Actinobacillus actinomycetemcomitans.
[0069] (4) Animal caries-prevention test: The above IgY was given to 10 rats in experimental group and placebo was given to 10 rats in control group. Results indicate that using the IgY of this invention to treat S.mutans infected rats could prevent the rats from dental caries. See table 1.
TABLE 1 Test Control Experimental Caries on Enamel only 47 19 Caries deep to ¼ of dentin 25 0.57 Caries deep to the whole dentin 8 0
[0070] By, statistical analysis, P<0.01, difference between two groups is significant.
[0071] From results of the above experiments, the IgY prepared using methods from this invention is having high activity, high specificity, high effectiveness and safe, the processes are simple, low-cost and environmental friendly, and furthermore, the integrated use of side products such as egg shells, egg white and the other parts of egg yolk is another advantage.
[0072] 3. IgY Safe-Toothpaste
[0073] The product, IgY Safe-toothpaste, of this invention is a brand new toothpaste that invented by targeting on the inadequateness of the classic toothpastes (most of the toothpastes recently in the market), which the IgY safe-toothpaste:
[0074] (1) is having IgY, which prepared with targeting on pathogens, as its major ingredient, which is harmless and do not come with toxic or side effects;
[0075] (2) is an edible toothpaste that has no harmful chemical, and having completely different ingredient with the classic toothpaste;
[0076] (3) is significantly effective as it is specific on the pathogens;
[0077] (4) is safe, edible, mouth-rinsing is not required after brushing teeth, thus, its convenient from in-house to travel and especially suitable for children.
[0078] Toothpastes now in the market contain various chemicals, especially foaming agents, such as Sodium Lauryl Sulfate, Sodium Dodecyl Sarcosinate, Lauroyl Diethanolamide, and Sodium Polyacrylate are strongly destructive to the activity of IgY. Result of an experiment that adding IgY to toothpaste without foaming agent in the concentration of 0.15% had shown that the IgY activity in the toothpaste can keep for a very long period of time. But, the activity of IgY had dropped from 1:64 to 1:8 in 1 minute, and decreased to 1:2 in 3 minutes, and finally approach zero in 10 minutes in the same experiment with the toothpaste replaced to classic toothpaste that contains foaming agent. It is significant that if the destruction effect on the activity of IgY from the chemicals, especially foaming agents, in toothpastes cannot be eliminated, IgY toothpaste will becomes valueless and meaningless.
[0079] With plenty of experiments, this invention uses a series of methods and measures to overcome the problems, makes the activity of IgY within the toothpaste become stable and lasting, and prepared an IgY safe-toothpaste which is highly active, highly stable and highly effective.
[0080] (1) Adjusting the Structure of the Toothpaste Tube
[0081] Make the classic, single-lumen tube a sandwich tube. This sandwich tube is composed with a set of two plastic tubes in different size and designated to fill with pastes with different contents. For example, the inner tube filled with the paste with IgY but do not come with foaming agent, and which the paste in the outer lumen contains foaming agent without IgY; and vise versa. When pressure is applied to the tube, paste in the inner lumen will be squeezed out from the center of the tube-neck, and the paste in the outer lumen will be squeezed out from the surrounding of the center of the tube-neck, making the pastes to combine. The design of the tube-neck could also be changed, for example, divide the circle exit into two semicircle, paste from the inner lumen will be coming out through one of the semicircle, and paste from the outer lumen through the other.
[0082] Besides the above designs, the tube could also being designed by using a thin layer plastic membrane as a partition to separate the paste with foaming agent (without IgY) and which with IgY (without foaming agent).
[0083] The designs above could separate IgY from the foaming agent until the pastes are squeezed out, thus, the activity of IgY inside the paste could be maintained.
[0084] (2) Using Mild Foaming Agent
[0085] Choose materials with foaming ability, and add into toothpaste with different ratio to test if the foaming effect reaches the standard requirement of toothpaste. Afterwards, the passed foaming materials will then mixed with IgY in different ratio, the best foaming material that most harmless to IgY was chosen to be the foaming agent based on the activity recorded at 1 min, 3 mins, 10 mins and 24 hrs.
[0086] After hundreds of experiments and tests, the best foaming agents are:
[0087] (i) Polyoxyethylene ether hydrogenated castor oil,
[0088] (ii) Sodium N-lauroylamide ethanoate, and
[0089] (iii) Sodium N-lauroyl sarcosinate
[0090] These foaming agents are having the least destructive effect on the activity of IgY and can generate sufficient foam when used in toothpaste. In tests that mixing the foaming agent with IgY and toothpaste, after 10 mins, 30 mins, 24 hrs, 30 days and 60 days, all of the above 3 foaming agents can keep the activity of IgY above 1:16 throughout the tests.
[0091] Another test was performed by placing the toothpastes (which the same as the previous test) in the temperature of 40° C., activity of the toothpaste was checked on day 15, 30, and 60, activity do only decrease insignificantly and keep high activity (≧1:16). All of the 3 selected foaming agents are mild, edible and none of toxic or side effects, accidental ingestion is harmless while brushing teeth with the toothpaste composed with either one of these foaming agents.
[0092] Experimental results shown that the selected foaming agents can fulfill the requirement of preparing IgY toothpaste.
[0093] (3) Coat with Micro-Capsule
[0094] To further stabilize the activity of IgY complex, a special micro-capsule coating technique, which comprise the coating of IgY by using a water insoluble inert material that do not affect the activity of IgY, could also be applied. This invention had discovered that, using a complex of Polybenzylamide and Polyethylene amide as the coating agent could do, or other materials that is inert, water insoluble and do not denature protein could also do. The coating agent selected is edible and haven't any toxic or side effects. The function of this coating agent is to wrap IgY with a thin layer as a capsule, make the IgY become suspended in the toothpaste and insulated to the reactions between IgY and the other chemicals in the toothpaste. When paste is squeezed out, the micro-capsule will break easily with the action of teeth brushing, thus IgY releases and functions.
[0095] One of the advantages of using the thin layer capsule to wrap IgY is further rising the stability of IgY in the toothpaste and thus increase the shelf-life; another advantage is the thin layer is easy to break, which means mild friction or pressure can release the wrapped IgY. These advantages give this brand new toothpaste practical effectiveness. On the other hand, if classic micro-capsule technique is used, IgY could also be protected, but its difficult to break and not all the IgY is released during teeth brush, resulting negative effects.
[0096] (4) Addition of Oral Mucosa Adsorbent
[0097] In this invention, oral mucosa adsorbent (slow-release formulation), such as Caborpl, is added to toothpaste for prolonging the time of pathogen inhibition and the effectiveness by keeping the IgY to stay on the oral mucosa longer.
[0098] (5) The Formulation of IgY Safe-Toothpaste
[0099] The following ingredients are measured in (w/w):
[0100] i. IgY preparation: 0.01-10.0%;
[0101] ii. Caborpl: 0.5-1.0%;
[0102] iii. Sodium N-lauroylamide ethanoate: 0.3-5.0%;
[0103] iv. Sodium alginate: 0.2-2.0%;
[0104] v. Sodium carboxy methylcellulose: 0.5-5.0%;
[0105] vi. Glycerol: 0.12-20.0%;
[0106] vii. Sorbitol: 1.0-20.0%;
[0107] viii. Aspartame: 0.12-0.50%;
[0108] ix. Menthol essence: 0.1-0.5%;
[0109] x. Orange essence: 0.1-0.5%;
[0110] xi. Peach essence: 0.1-0.5%;
[0111] xii. Vanilla essence: 0.1-0.5%.
[0112] All the ingredients must be food-graded. Food preservative could be added according to the designated shelf-life. This formula was tested to be harmless to the activity of IgY.
[0113] In the following preferred embodiment, ingredients could be: (in (w/w))
[0114] i. IgY preparation: 5.0%;
[0115] ii. Caborpl: 0.5%;
[0116] iii. Sodium N-lauroylamide ethanoate: 2.5%;
[0117] iv. Sodium alginate: 3.0%;
[0118] v. Sodium carboxy methylcellulose: 2.5%;
[0119] vi. Glycerol: 10.0%;
[0120] vii. Sorbitol: 5.0%;
[0121] viii. Aspartame: 0.20%;
[0122] ix. Menthol essence: 0.25%;
[0123] x. Orange essence: 0.15%;
[0124] xi. Peach essence: 0.15%;
[0125] xii. Vanilla essence: 0.25%.
[0126] (6) Production Arts:
[0127] Melt iv and v in 60 mL of distilled water; add other ingredients one by one and mix thoroughly; add IgY as the final ingredient and mix; add distilled water to 100 mL and mix to cool paste formation; infuse the paste into tubes.
[0128] 4. The Effectiveness Test of IgY Safe-Toothpaste
[0129] (1) Effectiveness Observation on Dental Caries Prevention:
[0130] To ensure the practical effectiveness of the above IgY Safe-toothpaste on caries prevention, clinical tests was done on population by the inventor. The mouth (oral cavity) of 60 non-caries volunteers were cleaned and volunteers are randomly divided into two groups with 30 volunteers each, which all the volunteers brush their teeth twice a day (in the morning and prior to bed) for 3 minutes each time, the experimental group uses the IgY toothpaste of this invention, and the volunteers of control group brush their teeth with classic toothpaste. Bacterial samples were picked from plaque and tongue surface and inoculated on TS medium (as the total anaerobic bacteria medium) and TSB medium (as a selective medium for S.mutans ), CFU and the percentage S.mutans in total anaerobic bacteria was calculated after 36 hrs anaerobic incubation. Samples were taken once a week for 9 weeks, and the results are indicated in table 2.
Percentage S. mutans in total anaerobic bacteria Experimental Group Control Group Week Saliva (%) Plaque (%) Saliva (%) Plaque (%) 0 56.23 56.43 52.56 50.10 1 45.60 42.28 49.10 48.10 2 41.80 38.39 49.20 47.08 3 32.83 30.15 48.10 46.15 4 28.15 19.10 47.70 43.60 5 25.29 18.32 43.19 45.55 6 23.19 17.92 49.20 46.35 7 21.08 15.10 50.05 50.26 8 20.05 13.96 51.16 49.18
[0131] For weeks after the starting day, the experimental group uses the IgY toothpaste in this invention got a deep drop of percentage S. mutans in total anaerobic bacteria for both saliva and plaque; with statistical analysis, result=P<0.01, reflect that there is significant change before and after experiment. On the other hand, the control group which uses classic toothpaste remains unchanged, statistical analysis results P>0.05, reflect no significant change. The results indicate that the IgY toothpaste of this invention can significantly inhibit S. mutans in saliva and plaque, thus having specific effectiveness on preventing caries.
[0132] (2) Specific Inhibition Effectiveness Observation on Pathogen Arising Periodontitis:
[0133] 100 periodontitis mid-age volunteers with mid-phase periodontitis and similar symptoms were selected and the mouth (oral cavity) of all volunteers are cleaned. Volunteers are randomly divided into two groups of 50 volunteers, which all the volunteers brush their teeth conscientiously twice a day (in the morning and prior to bed) for 3 minutes each time, the experimental group uses the IgY toothpaste of this invention, and the volunteers of control group brush their teeth with classic toothpaste. Bacterial samples were picked from periodontal area, and CFU was calculated after 36 hrs anaerobic incubation. CFU of week 0 was set to be 100%, the result of every sampling was compare with which of week 0 (relative CFU), and tabulated below:
TABLE 3 Relative CFU variation of major periodontitis pathogens (%) Experimental Group Control Group Week Relative CFU Relative CFU 0 1 1 1 0.90 0.98 2 0.70 0.90 3 0.65 0.92 4 0.60 0.86 5 0.52 0.88 6 0.50 0.85 7 0.45 0.86 8 0.38 0.90
[0134] Relative CFU is the comparative result between CFU of sample taken at every week and which of week 0 (illustrated in percentage).
[0135] From the analysis above, major pathogens arising periodontitis found in the periodontal area dropped deeply in experimental group, which uses the IgY toothpaste of this invention, after 4 weeks, it drop from 100% to 60%, and further decreased to 38% at week 8 in terms of relative CFU. With statistical analysis, P<0.01, represent significant difference. On the other hand, the relative CFU of control group, which uses classic toothpaste, remains unchanged, statistical analysis reflect no significant change as P>0.05. The results indicate that the IgY toothpaste of this invention can perform specific inhibition on the pathogens causing periodontitis significantly.
[0136] One skilled in the art will understand that the embodiment of the present invention as shown in the drawings and described above is exemplary only and not intended to be limiting.
[0137] It will thus be seen that the objects of the present invention have been fully and effectively accomplished. It embodiments have been shown and described for the purposes of illustrating the functional and structural principles of the present invention and is subject to change without departure from such principles. Therefore, this invention includes all modifications encompassed within the spirit and scope of the following claims.
|
The present invention relates to a preparation method of IgY for preventing and cure mouth disease, and a safe toothpaste containing the IgY.
| 2
|
PRIORITY
[0001] This application is a continuation of U.S. patent application Ser. No. 13/510,202, filed Nov. 21, 2012, which claims priority from U.S. Provisional Patent Application 61/262,365 filed Nov. 18, 2009, the entire contents of which are incorporated herein by reference.
FIELD
[0002] The present specification relates generally to signal processing and more specifically relates to a method, apparatus and system for sensing a signal with automatic adjustments for changing signal levels.
BACKGROUND
[0003] Various methods have been used to track the rotational speed of anything from car wheels to turbine engines. There are various approaches for capturing these rotational speeds. One approach is to attach a small generator, to a shaft or other rotating device which puts out a voltage proportional to the speed the generator is turning. This approach is often not desirable as it involves an additional mechanical connection.
[0004] Another approach is a magnetic tachometer having a Hall-Effect sensor, which changes voltage when a magnetic field passing through the sensor changes. The voltage output is used to trigger an electronic circuit. These devices depend on the pulse being of a certain size to trigger the circuit and any attendant noise on the signal wire to be small enough not to trigger the circuit.
[0005] Another approach is optical. In this case a photo transistor or photo diode senses reflected light and when the light increases or decreases, a change in current occurs in the attached circuit. This current is translated into a voltage, which is captured as noted above.
[0006] In these approaches there are three common factors: a. A rotating or oscillating machine; b. Coupling method (mechanical, magnetic, optical); c. A Circuit for detecting a voltage, voltage change, or current.
[0007] The electronics related to these approaches are tasked with ignoring electronic noise and detecting a true signal. Various methods have been used to achieve these tasks, but common methods comprise filtering noise electronically, while ensuring the signal level would be great enough or of sufficiently different frequency not to be filtered or ignored.
[0008] Of these approaches, optical systems are often selected. Optical systems include a light source and a photo sensor and a detector. The photo sensor can be, for example, a phototransistor or a photodiode or a charge coupled device (CCD). Light is emitted from the light source onto the moving part. (“Moving” captures all types of movement, including rotations and oscillations). The photo sensor captures reflections. The detector detects a difference contrast (lightness or darkness) on the moving.
[0009] In general, optical approaches face the problem of having enough light illuminating something of sufficient contrast to provide a signal big enough above the ‘noise floor’ to be considered valid. More specifically, problems involved in the optical approach include sufficient light; a paint spot, marked tape, color patch, (or some other optically differentiating part of the surface that add a different reflectance to the illuminating light source, and as detected by the photo sensor) which didn't fall off, fade, become tarnished, dirty, or discolored; and an electronic circuit that was tolerant of possible changes over time, optical path changes/variations, and rotating speeds. General electronics filtering and technology can be used for these purposes.
[0010] One method of handling these signals, since they do not change markedly, is to run them through a Phase-Lock-Loop. This is an electronic circuit that ‘seeks’ to oscillate in phase and at the same frequency as an incoming signal; but if there are some skips or small variations in the incoming signals, it will keep the output frequency steady. Thus, it is noise tolerant. This can be used since the signal does not change frequency suddenly. A car, for instance, will not come to a halt without braking, nor instantly go to sixty miles per hour without accelerating to that speed. (The only times things stop suddenly is because they hit something and the output of the tachometer is not likely to be instance under such circumstances.)
[0011] Another signal processing method is to take the AC signal (i.e., the changing part of the signal as opposed to the average or DC signal) and compare its crests to another voltage and when the crest exceeded the comparing voltage, an output pulse would be generated by the electronics to the system monitoring the speed. However this works when the signal does not change amplitude appreciably. As the moving mechanical part increases in speed, there is a tendency for the signal to get small, since the reflected light or magnetic field is passing more quickly. By the same token, as the moving mechanical part decreases in speed, there is a tendency for the signal to get large. However, this requires that an operator turn a knob (variable resistor) to adjust the comparison voltage to the right level to get valid output pulses.
SUMMARY
[0012] The present specification provides a signal conditioner circuit comprising:
[0013] a filter for receiving an electrical signal generated by a sensor; said sensor configured to detect periodic movement and generate said electrical signal based on said periodic movement; said filter for generating a filtered signal having a peak where said electrical signal is greatest; a peak detector configured to receive said filtered signal and to detect said peak and generate a detected-peak signal that holds said peak; a peak-divider configured to receive said detected-peak signal and to divide said detected-peak signal by a predetermined amount and thereby generate a divided-peak signal; a comparator configured to receive said divided-peak signal and said filtered signal; said comparator configured to generate and output a pulse when a comparison between said divided-peak signal and said filtered signal results in a determination that said filtered signal exceeds said divided-peak signal.
[0014] The circuit can further comprise a pulse generator configured to generate a further pulse, based on said pulse; said further pulse conditioned for monitoring equipment.
[0015] The sensor can be an optical sensor.
[0016] The sensor can be a magnetic sensor.
[0017] The periodic movement can be rotational. Each peak can represent a single rotation, or a plurality of said peaks can represent a single rotation. The periodic movement may correspond to rotation of a turbine in a jet engine.
[0018] The periodic movement can be oscillatory. The periodic movement can correspond to reciprocating movement of a piston.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] FIG. 1 shows a signal sensing system in accordance with a first embodiment.
[0020] FIG. 2 shows a signal sensing system in accordance with another embodiment.
[0021] FIG. 3 shows a block diagram of an exemplary implementation of the signal conditioner circuit of FIG. 1 and FIG. 2 .
[0022] FIG. 4 shows a specific circuit diagram giving an example of how the block diagram of FIG. 3 can be implemented.
[0023] FIG. 5 shows another specific circuit diagram giving an example of how the block diagram of FIG. 3 can be implemented.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0024] Referring to FIG. 1 , a signal sensing system is indicated generally at 50 . System 50 comprises a light source 54 , a light sensor 58 and a signal conditioner circuit 62 connected to the light sensor via a link 66 . A moving element 70 is provided having an optical marker 74 disposed thereon. In a present example, moving element 70 is rotating in the direction “A”.
[0025] Light source 54 emits light 78 which is reflected off the surface of element 70 . Different amounts of light are reflected each time marker 74 passes in front of light 78 . Light source can be from a fibre optic cable, or ambient light, or other source. Light sensor 58 captures reflected light 79 as it is reflected from element 70 . Link 66 may be a signal wire or even a radio channel. In general link 66 is configured to introduce as little error as possible to any signal 80 captured by light sensor 58 .
[0026] System 50 is a simplified illustrative example. It is to be understood however that the term “move” and its variants (e.g. “moving”) can refer to any type of movement, including rotation and oscillation. A piston is an example of an oscillating element. In a practical application, moving element 70 can be, for example, an engine turbine used on an aircraft. On review of this specification, other practical applications will occur to those skilled in the art.
[0027] Notable characteristics of a periodic signal from a rotating or oscillating object, such as element 70 , are that a periodic signal does change markedly in amplitude or frequency and that most noise is at most about sixty percent of the real signal amplitude. (If such characteristics are not met, the desired functionality from the rotating element will be nearly unworkable in any case.) Based on this characteristic, circuit 62 can be configured to capture the present peak signal, and then a fixed fraction of that signal can be used to validate a rotational signal. Such a circuit 62 can be configured to adapt to the time, speed, and optical/magnetic variations that can occur in tachometer systems.
[0028] Optical marker 74 is any type of contrasting mark such as a reflective tape, or paint, which changes the level of reflected light 79 .
[0029] Light sensor 58 can be implemented as a phototransistor, photodiode, or charge couple device (CCD) or the like. Light sensor 58 captures reflected light 79 and generates an electrical signal 80 (e.g. voltage or current) that is substantially proportional to the amount of reflected light 79 captured by light sensor 58 .
[0030] Signal conditioner circuit 62 receives the electrical signal from sensor 58 . Signal conditioner circuit 62 , which may be referred to as a fractional peak discriminator circuit, processes the electrical signal from sensor 58 and outputs an output signal to monitoring equipment (not shown).
[0031] Signal conditioner circuit 62 will be discussed in greater detail below. However, before proceeding further it is to be understood that other types of sensing modalities may be used to obtain the electrical signal that is processed by signal conditioner circuit 62 . Referring now to FIG. 2 , another signal sensing system is indicated generally at 50 a . System 50 a is a variant on system 50 , and so like elements bear like references except followed by the suffix “a”.
[0032] Of note is that in system 50 a , light source 54 and marker 74 are eliminated. In their place, a magnetic element 75 a is provided on the surface of moving element 70 a . Magnetic element 75 a emits a magnetic field 81 a , which is periodically detected by a magnetic sensor 58 a , used in place of optical sensor 58 . Magnetic sensor 58 a is thus configured to generate an electrical signal 80 a . Magnetic sensor 58 a can be based on a hall-effect detector, in which case a voltage signal is generated that is proportional to the detected magnetic field 81 a . Magnetic sensor 58 a thus generates an electrical signal 80 a that is received by signal conditioner circuit 62 a.
[0033] FIG. 3 shows a block diagram representing a possible implementation for signal conditioner circuit 62 (or signal conditioner circuit 62 a ). Signal conditioner circuit 62 comprises a filter 100 which receives signal 80 a via link 66 . Filter 100 input sends filtered signal 102 to a peak detector 104 and a comparator 108 . The detected-peak signal 106 from peak detector 104 provides input to peak divider 112 . The divided-peak signal 114 provides a second input to comparator 108 , which is configured to make a comparison between filtered signal 102 and divided-peak signal 114 . As will be discussed further below, comparator 108 will generate a pulse when a comparison 109 results in a determination that filtered signal 102 exceeds divided-peak signal 114 . The compared-signal 110 outputted from comparator 108 provides input to pulse generator 116 . Generated-pulse signals 118 are outputted from pulse generator 116 and provide input to monitoring equipment (not shown).
[0034] The operation of signal conditioner circuit 62 will now be discussed in greater detail, which will also provide further understanding as to how signal conditioner circuit 62 may be constructed. As noted above, signal 80 comes from a photo-sensor 58 or magnetic sensor 58 a or other type of voltage or current-generating device.
[0035] It is contemplated that system 50 may be located within a noisy environment and so noise may be introduced on link 66 or elsewhere, resulting in the acquisition of noise on link 66 (or elsewhere) which will be outside the frequency of interest for the purposes of the tachometer. Accordingly, signal 80 is filtered at filter 100 as a precautionary design practice to reduce or eliminate frequencies outside those of interest. “AC bypassing” techniques and “RC Filtering” techniques can be usual for these purposes. To add dynamic range, it can be desired to amplify the filtered version of signal 100 before doing any peak detection.
[0036] Filter 100 is thus configured to generate filtered signal 102 , which is “well behaved”, in that it signal 102 shows a crest or peak where the optical or magnetic return is greatest. N system 50 or system 50 a , this crest or peak may be a once per revolution. However, multiple peaks may occur where a plurality of markers 74 (or magnetic elements 75 a ) are employed. It will now be apparent that the number of markers 74 (or magnetic elements 75 a ) can be selected according to the different design specifications for system 50 or system 50 a.
[0037] Peak detector 104 comprises a peak-and-hold circuit, which can be implemented through the use of an operational amplifier to impress a voltage on a capacitor as the filtered signal 102 rises to a peak. A diode can also be provided to prevent (or at least reduce the likelihood of) the capacitor from discharging as the voltage declines from the peak, thus storing a voltage charge on the capacitor substantially equal to the peak of the input and filtered signal. This voltage level is transmitted to a voltage buffering circuit (also known as a voltage follower) which isolates the capacitor from discharging.
[0038] Peak divider 112 then buffers and divides the detected peak signal 106 (i.e. the peak voltage) using a voltage divider circuit, which can be implemented using two resistors in series. This can be an adjustable point on the circuit so that any percentage of the peak can be utilized as a comparison voltage to the signal peaks that follow.
[0039] Divided-peak signal 114 is the transmitted to comparator 108 to be compared with filtered signal 102 . Comparator 108 is thus provided with the incoming signal train of pulses representing the optical pulses (or magnetic pulses) of element 70 , and a percentage of the peak of the previous signal. Since the signal peaks are fairly constant from cycle-to-cycle, this is a substantially reliable method of detecting the next peak of the signal.
[0040] Comparator 108 thus determines when signal 102 is greater than the divided-peak signal 114 . Compared-signal 110 will thus be a ‘high’ voltage (such as 2.4 volts to 5 volts) during the period when the incoming signal is of a greater voltage than the chosen percentage of the peak signal. Compared-signal 110 is transmitted to pulse generator 116 .
[0041] Compared-signal 110 may or may not be sufficient to meet the requirements of the equipment monitoring the rotation speed of the mechanical system, therefore a pulse generator 116 is provided which meets the voltage and amplitude needs of the monitoring equipment. It will now be apparent though that depending on the monitoring equipment, pulse generator 116 may be obviated.
[0042] Generated pulse signals 118 are then sent to the monitoring equipment, which lets the monitoring equipment know when the optical marker 74 (or magnetic element 75 a ) has been detected moving past on the moving element 70 .
[0043] Referring now to FIG. 4 and Table I, a specific but non-limiting example of how circuit 62 can be implemented is provided, which is indicated generally as circuit 62 b .
[0000]
TABLE I
Block Element
Part Reference
Part Description
Filter 100
R1
Resistor, 10 kohms,
5%, 0.1 Watt
U1B
Filter 100
R2
Resistor, 100 ohms,
5%, 0.1 Watt
Filter 100
C1
Capacitor 0.1 uF, 25 V,
10%
Filter 100
O1
Integrated Circuit
Operational Amplifier;
Prec JFET
Peak-detector 104
D1
Schottky Diode,
100 mA, VR = 45 V
Peak-detector 104
C4
Capacitor 1 uF, 16 V,
10%, C1206
Peak-detector 104
O2
Integrated Circuit
Operational Amplifier
Prec JFET
Peak Divider 112
R10
Resistor, 5 Kohms
Peak Divider 112
O3
Integrated Circuit
Operational Amplifier
Prec JFET
Comparator 108
R11
Resistor 15 Kohms,
5%, 0.1 W
Comparator 108
C9
Capacitor 0.01 uF
Comparator 108
O4
Operational Amplifier
LT3941S8
[0044] Referring now to FIG. 5 and Table II, a further specific, but non-limiting example of how circuit 62 c can be implemented is provided.
[0000]
TABLE II
Block Element
Part Reference
Part Description
Filter 100
R1
Resistor, 10 kohms,
5%, 0.1 Watt
U1B
Filter 100
R2
Resistor, 100 ohms,
5%, 0.1 Watt
Filter 100
C1
Capacitor 0.1 uF, 25 V,
10%
Filter 100
O1
Integrated Circuit
Operational Amplifier;
Prec JFET
Peak-detector 104
D1
Schottky Diode,
100 mA, VR = 45 V
Peak-detector 104
C4
Capacitor 1 uF, 16 V,
10%, C1206
Peak-detector 104
O2
Integrated Circuit
Operational Amplifier
Prec JFET
Peak Divider 112
R10
Resistor, 5 Kohms
Peak Divider 112
O3
Integrated Circuit
Operational Amplifier
Prec JFET
Peak Divider 112
C51
Capacitor, 1.0 uF, 25 V,
5%
Peak Divider 112
R32
Resistor, 25.5 Kohms,
1%, 0.1 W
Peak Divider 112
R33
Resistor, 25.5 Kohms,
1%, 0.1 W
Peak Divider 112
O5
Integrated Circuit
Operational Amplifier
Prec JFET
Comparator 108
R11
Resistor 15 Kohms,
5%, 0.1 W
Comparator 108
C9
Capacitor 0.01 uF
Comparator 108
O4
Operational Amplifier
LT3941S8
[0045] In circuit 62 c of FIG. 5 , modifications were made to the peak divider 112 to reduce (and, as much as possible, minimize) jitter in the divided-peak signal 114 .
[0046] This was achieved by operational amplifier 05 and the associated components as shown in FIG. 5 . The added amplifier's output is summed with (connected to) the output of the voltage buffering amplifier to create a Buffered Peak Signal.
[0047] It will now be apparent that one of the advantages of provided by this specification is a means to sense of an optical or magnetic signal that automatically adjusts for a changing signal level, but not incorrectly trigger on random electronic noise.
[0048] Combinations, subsets and variations of the foregoing are contemplated.
|
The present specification provides a method, apparatus and system for sensing a signal with automatic adjustments for changing signal levels. A novel fractional peak discriminator circuit is provided which can be incorporated into a system for measuring periodic signals from moving elements. The circuit can be used regardless of whether the periodic signals are detected using optics, magnetic detector or other methods.
| 7
|
This invention relates to an improved building construction tool or implement, and more particularly, to an improved device for lifting prefabricated wall sections of a building into final vertical position during construction.
BACKGROUND OF THE INVENTION
The construction of buildings with prefabricated wall sections is a common practice. Such prefabricated wall sections, which may vary in length, generally are placed horizontally on the floor of the building structure, with the ultimate lower edge of the horizontal wall section placed immediately adjacent the floor location on which it will rest in vertical, upright position. The wall section is lifted and tilted into its desired vertical position, and the section is then secured to the floor.
It has been suggested to provide lifting devices, such as wall jacks, to raise prefabricated wall sections from horizontal to final vertical position in construction of buildings. U.S. Pat. Nos. 2,812,077 and 3,485,386 each disclose a wall jack construction comprising a mechanical hoist having an elongated boom, the lower end of which is pivotally attached by a hinge to the floor of the building construction. Attached to a lower end portion of the boom is a winch with cable. The cable passes about a sheave on the upper end of the boom, and the outer end of the cable is suitably connected to the prefabricated wall adjacent its eventual upper end. The winch is manually operated to pivotally raise the wall section to a vertical position as the boom pivots from vertical to a generally 45 degree angular position during the lifting operation.
BRIEF OBJECTS OF THE PRESENT INVENTION
It is an object of the present invention to provide an improved lifting device for raising prefabricated wall sections of a building from a horizontal to a vertical, upright position during building construction.
It is a further object to provide an improved, economical, light-weight trolley lifting device for use in building construction which can be transported, employed, and operated by a single workman to lift prefabricated wall sections into vertical position during construction of a building.
BRIEF DESCRIPTION OF THE DRAWINGS
The above, as well as other objects of the invention, will become more apparent and the invention will be better understood from a following detailed description of the invention, when taken together with the accompanying drawings, in which:
FIG. 1 is a side elevation view of a floor of a building under construction, utilizing the lifting device of the present invention, and illustrating the overall arrangement and use of beam and trolley components to lift a prefabricated wall section from horizontal to vertical position during construction operations;
FIG. 2 is an enlarged side elevation view of the lower end portion of the beam, with surrounding trolley as seen in FIG. 1, showing the beam in vertical position and in operative engagement with the floor of a building at the beginning of a lifting operation;
FIG. 3 is a top plan view of the lower end portion of the beam and trolley, as seen in FIG. 2;
FIG. 4 is an enlarged side elevation view of the upper end portion of the wall section and beam with surrounding trolley which moves along the beam, the trolley being shown located at its uppermost position on the beam at the end of the lifting operation;
FIG. 5 is an enlarged side elevation view of only the right end portion of the building floor and bottom of a horizontally disposed wall section as shown in FIG. 1, before the wall is lifted;
FIG. 6 is an enlarged side elevation view of the bottom portion of the beam, only, in a vertical position;
FIG. 7 is a side elevation view of one of the driven rollers of the trolley; and
FIG. 8 is a right end view of the roller of FIG. 7; and
FIG. 9 is a side elevation view of a floor of a building under construction, as in FIG. 1, but illustrating flexible connection means for use with the beam and trolley for retention of the wall section in vertical position until its positive securement to the building floor.
SUMMARY OF THE INVENTION
The present invention is an improved lightweight, economical, motorized device for lifting prefabricated building wall sections from a horizontal position to their intended upright, vertical position during construction of a building. The device comprises a motorized trolley which is designed to move along a lifting beam, such as an existing 4"×4" soft wood post typically available as a building material at the construction site.
The trolley includes a generally open, rectangular support frame having a pivotal hinge portion designed to be suitably attached to the eventual top edge of a prefabricated wall section, and a pair of spaced, motor-driven rollers which frictionally grip and engage an elongated rigid member, such as a 4"×4" rectangular pine post. The post serves as a beam, the bottom of which is supported by a building floor and is suitably blocked against sliding movement, and for pivotal movement, by a board fixed to the floor of the building. Motor means carried on the frame of the trolley drive the rollers to move the trolley along the beam as it pivots downwardly from vertical position to lift the prefabricated wall section from horizontal to vertical position. The eventual lower end of the prefabricated wall is suitably fixed to the building construction floor for pivotal movement, and against sliding movement, during the lifting operation.
The lifting device may be easily transported, erected, and operated by a single workman to elevate prefabricated wall sections to upright positions during building construction. Depending upon the weight and/or length of the prefabricated wall section to be lifted, one or more such lifting devices may be employed and operated simultaneously from floor level by an operator to raise the wall section.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
As best seen in the drawings, FIG. 1 is a side elevation view of a building under construction, showing the overall arrangement, operation, of the device of the present invention and use to lift a prefabricated wall section from a resting, horizontal position to a final vertical position of use. The overall lifting mechanism 10, as shown in solid lines in FIG. 1, is supported on the floor 11 of a building, and is attached to a horizontally disposed wall section 12 at the beginning of the lifting operation. The device, its component parts, and the vertical prefabricated wall section are identified by prime numbers and are represented in broken lines as they would be seen in their final position in lifting the wall.
As shown, the overall lifting mechanism 10 includes an elongated beam 14, which preferably is a soft pine wood 4"×4" post typically available as an on-site building material, and a motor-driven trolley 16 which surrounds the beam and moves therealong during the wall-lifting operation. For lifting 8 foot high wall section, the beam may be typically about 14 feet long.
FIGS. 2 and 3 are respective enlarged side elevation and top plan views of the trolley 16 and lower portion of the beam 14. The beam is shown in vertical position and the trolley is located at the bottom end of the beam at the beginning of the lifting operation, as seen in solid lines in FIG. 1. Trolley 16 comprises a generally rectangular open frame of opposing pairs of walls 18, 20, which supportably carry for rotation therein a pair of spaced, substantially identical motor-driven rollers 22, 24. FIGS. 7 and 8 show in more detail one roller 24 of the pair. Each of the rollers have toothed, or roughened, drive surface 25 to frictionally grip and engage opposite sides of the 4"×4" soft pine beam 14. A pair of electrically driven, reversible gear motors 26, 28 are mounted on outwardly extending walls 30, 32, respectively, of the frame and are operatively connected through right-angle reduction gear to independently drive the two rollers 22, 24. The walls 30, 32 of the frame are reinforced by triangular web reinforcements 34. The walls 18, 20, 30, 32 and reinforcements 34 may be formed of suitable high strength material, such as cast aluminum or molded plastic.
The gear motors 26, 28 may be of a suitable type, e.g., an electric motor with right-angle gear motor shaft output, such as an AC/DC motor manufactured by Dayton, Model No. 2Z797. The output gear ratio may typically be approximately 1800/1, such that the gear motors slowly rotate the rollers 22, 24 to move the trolley along the beam 14 during the lifting operation. The frame of trolley 16 carries a hinge 36 consisting of a rectangular plate 37 with flange portion 37', and a pair of generally triangular hinge arms 38 pivotally attached by a pivot pin 39 to opposing side walls 18 of the rectangular frame at point below and outside of the rotational axis of the nearest adjacent roller 24. The lower right edge of each of the side walls 18 of the frame, as seen at 40 in FIGS. 2 and 4, is disposed at a 45 degree angle to permit free pivotal movement and clearance of hinge 36 as it pivots on the frame of the trolley as the trolley moves up the beam 14 during lifting operations. As seen in FIGS. 2, 3, and 4, plate 37 of the hinge is secured to the upper end of the prefabricated wall to be lifted, as by nails, bolts, or the like.
The pair of spaced, motor-driven rollers 22, 24 (FIG. 3) which contact opposite sides of rectangular beam 14 in gripping, frictional engagement are supportably mounted at each of their end portions 43 (FIG. 7) for rotation in the trolley frame by suitable bearing means, such as ball-bearing rings 42 (one of which is seen in FIGS. 2 and 4), which are press fit into openings in the frame walls 18. Each of the rollers 22, 24 has one extending stub shaft portion 44 having a central passageway with keyway 46 adapted to receive in driving engagement therewith a suitably keyed output drive shaft 48 of one of the gear motors. Each gear motor is connected to a suitable source of electrical power, such as AC or DC energy, by electrical wiring (not shown), and may be operated in forward or reverse directions from suitable control means, or devices, located at floor level for use by a single workman operator.
As best seen in FIG. 6, a portion of the bottom end surface of the 4"×4" beam is cut away, at a 45 degree angle, as at 14", to form a base portion 14"' which rests upon a suitable stop member, such as a suitable length, e.g., 30 inches, 2"×4" board 50, which is nailed to the floor 11 of the building construction. The beam of the lifting device is thus fixed against sliding movement, and for pivotal movement, about an edge of the 2"×4" board as it pivots from a vertical position to a 45 degree diagonal position during the lifting of the prefabricated wall section, as shown in broken lines in FIG. 1.
FIG. 5 is an enlarged side elevation view of a portion of the ultimate lower end of the prefabricated wall section 12 and the supporting floor section 11. As seen, the ultimate lower end of wall section 12 is fixed against sliding movement, but for pivotal movement about its lower end, during the lifting operation by suitable fastening means, such as flexible metal bands, one of which, 52, is shown. The bands are attached to the floor and wall section at spaced locations therealong by suitable means, such as nails.
FIG. 4 is an enlarged side elevation view of the upper portion of the beam with trolley attached to the upper end of the prefabricated wall section 12. FIG. 4 shows in full line presentation the position of the trolley 16 and upper end of the beam 14 at the completion of the lifting operation. As is evident from FIGS. 1 and 4, trolley hinge 36 attached to the upper end of the wall section 12 pivots about pivot point 39 as the trolley moves up the beam and the beam 14 pivots downwardly to a final approximate 45 degree angle when the wall section 12 is in vertical position.
To facilitate retention of the preformed wall section 12 in vertical position and resist its movement past the vertical, in the direction of its pivot, until it can be firmly secured to the floor 11, one or more flexible elements, or cables 56, may be employed and attached by eye plates 58, 59 to the floor 11 and upper end of the wall 12 at spaced locations along the length of the wall. One of the cables 56 is illustrated in FIG. 9. The retaining cables 56 may be spaced along the length of wall 12 near or between adjacent lifting devices and resist displacement of the lower end of the beam and further pivotal movement of the wall past a vertical position. The effective lengths of the wall-retaining cables 56 employed are determined by the height of the wall to be lifted and thin attachment points to the floor and wall. Typically, the cables may have an effective length equal to the length of the hypotenuse of the right angle formed by the wall in horizontal and vertical positions, plus about six inches, to compensate for the positions of the eye plates on the floor and wall section.
Certain motor-driven devices have been disclosed for trimming tree trunks and for climbing tree and pole-like objects. U.S. Pat. Nos. 2,477,922; 2,727,335; 2,174,525; and 3,520,383 disclose such devices. However, it is not known that motorized trolley-type lifting devices of the type disclosed herein have ever been employed in the building industry to effect pivotal vertical erection of prefabricated walls from a horizontal position. In this regard, it has been found that pressures and moments of force on the lifting trolley 16 as it moves along the pivoting beam vary greatly, and the design of the trolley and location of hinge 36 of the present invention are such that the driven rollers 22, 24 at all times positively engage the beam during the lifting operation. As seen in FIGS. 3 and 4, the pivot point of the hinge of the trolley is located relative to the rotational axes of the driven rollers and the central longitudinal axis of the beam moving therebetween to accommodate attachment to the wall and provide optimum driving engagement of the rollers with the beam during lifting operations. It is also desirable that the motors be positively driven in forward and reverse directions to ensure positive retention and positioning of the heavy prefabricated wall sections during their upward travel to vertical position.
From the foregoing, it can be appreciated that the lifting device of the present invention may be economically constructed, operated, and transported between sites of operation. The motorized trolleys may be assembled with existing on-site wood beam materials and operated by a single individual worker to lift preformed wall sections of a building during construction. Depending upon the length and weight of the wall section to be lifted, the wall section may be reinforced to prevent excessive bending and/or one or more lifting devices may be employed along the length of the wall and operated simultaneously from a floor location by a single operator to raise the wall to vertical position.
|
A lifting device for pivotally raising a prefabricated wall section from a substantially horizontal position to a vertical position on the floor of a building under construction comprising a trolley having a frame, a pair of spaced rollers mounted for rotation thereon and defining an opening for receipt and passage therethrough of an elongated beam with the rollers in frictional, gripping engagement with the beam, motors mounted on the frames in operative driving engagement with the rollers, and a hinge pivotally mounted on the frame for attachment to the ultimate upper end portion of a prefabricated wall section to permit pivotal movement of the hinge about its point of attachment to the frame during wall-lifting operations. The trolley travels along the beam as the beam pivots on the floor of the building from vertical to diagonal position during corresponding pivotal movement of the prefabricated wall from horizontal to vertical position.
| 4
|
TECHNICAL FIELD
[0001] The present invention relates to a light flux controlling member configured to control the distribution of light emitted from a light emitting element. Further, the present invention relates to a light emitting device including the light flux controlling member, a surface light source device including the light emitting device, and a display apparatus including the surface light source device.
BACKGROUND ART
[0002] Some transmission type image display apparatuses such as liquid crystal display apparatuses employ a direct-type surface light source device as a backlight. In recent years, a direct-type surface light source device including a plurality of light emitting elements has been increasingly used as a light source.
[0003] A direct-type surface light source device has, for example, a substrate, a plurality of light emitting elements, a plurality of light flux controlling members (lenses) and a light diffusion member. The plurality of light emitting elements are disposed in a matrix on the substrate. Over each light emitting element, the light flux controlling member is disposed for expanding light emitted from each light emitting element in the surface directions of the substrate. The light output from the light flux controlling member is diffused by the light diffusion member, and planarly illuminates a member to be irradiated (e.g. a liquid crystal panel).
[0004] FIGS. 1A to 1C illustrate a configuration of a conventional light flux controlling member. FIG. 1A is a perspective view from the rear side, FIG. 1B is a cross-sectional perspective view from the rear side, and FIG. 1C is a cross-sectional view. In FIGS. 1A and 1B , legs formed on the rear side are not illustrated. As illustrated in FIGS. 1A to 1C , conventional light flux controlling member 20 includes incidence surface 22 on which light emitted from a light emitting element is incident and emission surface 24 for outputting the light entered from incidence surface 22 toward the outside. Incidence surface 22 is a surface with a recessed shape relative to the light emitting element and formed so as to face the light emitting surface of the light emitting element.
[0005] FIGS. 2A to 2C are illustrations of optical paths in light flux controlling member 20 . FIG. 2A is an illustration of an optical path of a beam with emission angle 30°, FIG. 2B is an illustration of an optical path of a beam with emission angle 40°, and FIG. 2C is an illustration of an optical path of a beam with emission angle 50°. As used herein, “emission angle” ( 0 in FIG. 2A ) means an angle of a beam relative to optical axis LA of light emitting element 10 . Also in FIGS. 2A to 2C , legs formed on the rear side are not illustrated.
[0006] As illustrated in FIGS. 2A to 2C , the light emitted from light emitting element 10 enters the inside of light flux controlling member 20 from incidence surface 22 . The light entered light flux controlling member 20 reaches emission surface 24 , and is output toward the outside from emission surface 24 (solid arrow). At this time, the light is refracted according to the shape of emission surface 24 , so that the traveling direction of the light can be controlled. On the other hand, part of the light reached emission surface 24 is reflected by emission surface 24 (Fresnel reflection) and reaches rear surface 26 facing the substrate on which light emitting element 10 is mounted (dashed arrow). When the light reached rear surface 26 is reflected by rear surface 26 , excessive light travels in the direction directly above light flux controlling member 20 and therefore, luminance unevenness occurs. When the light reached rear surface 26 is output from rear surface 26 , the light is absorbed into the substrate and therefore, the loss of light is large.
[0007] It is undesirable that the light reflected by emission surface 24 travel in the direction directly above light flux controlling member 20 or be absorbed into the substrate. PTL 1 proposes a light flux controlling member that can solve the above problems.
[0008] FIGS. 3A to 3C illustrate a configuration of a light flux controlling member disclosed in PTL 1. FIG. 3A is a perspective view from the rear side, FIG. 3B is a cross-sectional perspective view from the rear side, and FIG. 3C is a cross-sectional view. In FIGS. 3A and 3B , legs formed on the rear side are not illustrated. As illustrated in FIGS. 3A to 3C , in light flux controlling member 30 disclosed in PTL 1, annular inclining surface 32 is formed in rear surface 26 . Inclining surface 32 is rotationally symmetric (circularly symmetric) about central axis CA of light flux controlling member 30 , and inclined at a predetermined angle (e.g. 45°) relative to central axis CA.
[0009] FIGS. 4A to 4C are illustrations of optical paths in light flux controlling member 30 . FIG. 4A is an illustration of an optical path of a beam with emission angle 30°, FIG. 4B is an illustration of an optical path of a beam with emission angle 40°, and FIG. 4C is an illustration of an optical path of a beam with emission angle 50°. Also in FIGS. 4A to 4C , legs formed on the rear side are not illustrated. As illustrated in FIGS. 4A to 4C , light reflected by emission surface 24 reaches inclining surface 32 in light flux controlling member 30 . Then, part of the light reached inclining surface 32 is reflected by inclining surface 32 and travels in a lateral direction (see FIGS. 4A and 4B ).
[0010] In this way, in light flux controlling member 30 disclosed in PTL 1, the light reflected by emission surface 24 does not easily travel in the direction directly above light flux controlling member 30 or is not easily absorbed into the substrate. Therefore, a light emitting device including light flux controlling member 30 disclosed in PTL 1 can radiate light more efficiently and uniformly than a light emitting device including conventional light flux controlling member 20 .
CITATION LIST
Patent Literature
[0011] PTL 1: Japanese Patent Application Laid-Open No. 2009-43628
SUMMARY OF INVENTION
Technical Problem
[0012] As illustrated in FIG. 4C , even in light flux controlling member 30 disclosed in PTL 1, when a beam has a large emission angle, part of light reflected by emission surface 24 may reach the substrate under light flux controlling member 30 after passing through inclining surface 32 according to the angle of inclining surface 32 . The light reached the substrate under light flux controlling member 30 in this way may be reflected by the surface of the substrate to travel in the direction directly above light flux controlling member 30 , or may be absorbed into the substrate. From the perspective of energy saving, it is preferable to reduce the amount of light passing through inclining surface 32 as much as possible.
[0013] An object of the present invention is to provide a light flux controlling member configured to control the distribution of light emitted from a light emitting element, the light flux controlling member being capable of using light reflected by an emission surface more efficiently while preventing the occurrence of luminance unevenness.
[0014] Another object of the present invention is to provide a light emitting device including the light flux controlling member, a surface light source device including the light emitting device, and a display apparatus including the surface light source device.
Solution to Problem
[0015] A light flux controlling member configured to control the distribution of light emitted from a light emitting element, the light flux controlling member includes: an incidence surface formed on a rear side of the light flux controlling member so as to intersect a central axis of the light flux controlling member, the incidence surface being configured such that light emitted from the light emitting element is incident on the incidence surface; an emission surface formed on a front side of the light flux controlling member so as to intersect the central axis, the emission surface being configured to output light entered from the incidence surface toward outside; and a plurality of linear protrusions each having a cross-section that is substantially triangle-shaped, the linear protrusions being formed to surround the central axis; wherein each of the plurality of linear protrusions includes a first reflection surface, a second reflection surface, and a ridge line that is an intersection line of the first reflection surface and the second reflection surface, the plurality of linear protrusions are disposed rotationally symmetric about the central axis, and a virtual line including the ridge line intersects the central axis at a position which is farther into a front side area of the light flux controlling member than the ridge line.
[0016] A light emitting device of the present invention includes a light emitting element and the light flux controlling member of the present invention, wherein the light flux controlling member is disposed such that the central axis thereof coincides with the optical axis of the light emitting element.
[0017] A surface light source device of the present invention includes the light emitting device of the present invention and a light diffusion member which is configured to diffuse and transmit the light emitted from the light emitting device at the same time.
[0018] A display apparatus of the present invention includes the surface light source device of the present invention and a display member to which light emitted from the surface light source devices is radiated.
Advantageous Effects of Invention
[0019] A light emitting device including a light flux controlling member of the present invention can radiate light more efficiently and uniformly than a light emitting device including a conventional light flux controlling member. Therefore, a surface light source device and display apparatus of the present invention have higher light use efficiency and less luminance unevenness occurrence than conventional ones.
BRIEF DESCRIPTION OF DRAWINGS
[0020] FIGS. 1A to 1C illustrate a configuration of a conventional light flux controlling member;
[0021] FIGS. 2A to 2C are illustrations of optical paths in the light flux controlling member illustrated in FIGS. 1A to 1C ;
[0022] FIGS. 3A to 3C illustrate a configuration of a light flux controlling member disclosed in PTL 1;
[0023] FIGS. 4A to 4C are illustrations of optical paths in the light flux controlling member illustrated in FIGS. 3A to 3C ;
[0024] FIGS. 5A and 5B illustrate a configuration of a surface light source device according to Embodiment 1;
[0025] FIGS. 6A and 6B are cross-sectional illustrations illustrating the configuration of the surface light source device according to Embodiment 1;
[0026] FIG. 7 is a partially enlarged cross-sectional view of an enlarged part of FIG. 6B ;
[0027] FIGS. 8A and 8B illustrate a configuration of a light flux controlling member according to Embodiment 1;
[0028] FIGS. 9A to 9D illustrate the configuration of the light flux controlling member according to Embodiment 1;
[0029] FIG. 10 is a cross-sectional view of the light flux controlling member according to Embodiment 1 to explain the directions of ridge lines;
[0030] FIGS. 11A to 11C are illustrations of optical paths in the light flux controlling member according to Embodiment 1;
[0031] FIG. 12 is a graph illustrating illuminance distributions on the surfaces of substrates under the light flux controlling members;
[0032] FIG. 13 is a graph illustrating average illuminances in regions under the light flux controlling members;
[0033] FIG. 14 is a graph illustrating incident light fluxes in the regions under the light flux controlling members;
[0034] FIGS. 15A and 15B are bottom illustrations of modifications of the light flux controlling member according to Embodiment 1;
[0035] FIGS. 16A and 16B illustrate a configuration of a light flux controlling member according to Embodiment 2;
[0036] FIGS. 17A to 17D illustrate the configuration of the light flux controlling member according to Embodiment 2;
[0037] FIGS. 18A and 18B illustrate a modification of the light flux controlling member according to Embodiment 2;
[0038] FIGS. 19A and 19B illustrate another modification of the light flux controlling member according to Embodiment 2; and
[0039] FIG. 20 is a cross-sectional view of a light flux controlling member according to Embodiment 3.
DESCRIPTION OF EMBODIMENTS
[0040] Hereinafter, embodiments of the present invention will be described in detail with reference to the accompanying drawings. In the following description, as representative examples of surface light source devices of the present invention, surface light source devices suitable for backlights of liquid crystal display apparatuses or the like will be described. These surface light source devices may be used as display apparatuses in combination with members to be irradiated (e.g. liquid crystal panels) to which light from the surface light source devices is radiated.
Embodiment 1
Configurations of Surface Light Source Device and Light Emitting Device
[0041] FIGS. 5A to 7 illustrate a configuration of a surface light source device according to Embodiment 1. FIG. 5A is a plan view, and FIG. 5B is a front view. FIG. 6A is a cross-sectional view taken along line A-A shown in FIG. 5B , and FIG. 6B is a cross-sectional view taken along line B-B shown in FIG. 5A . FIG. 7 is a partially enlarged cross-sectional view of an enlarged part of FIG. 6B .
[0042] As illustrated in FIGS. 5A to 6B , surface light source device 100 according to Embodiment 1 includes casing 110 , a plurality of light emitting devices 200 , and light diffusion member 120 . Light emitting devices 200 are disposed in a matrix on bottom plate 112 of casing 110 . The inner surface of bottom plate 112 functions as a diffusion and reflection surface. Top plate 114 of casing 110 has an opening. Light diffusion member 120 is disposed so as to fill the opening, and functions as a light emitting surface. The size of the light emitting surface is, for example but not limited to, about 700 mm in length and about 400 mm in width.
[0043] As illustrated in FIG. 7 , each of light emitting devices 200 is fixed to each of substrates 210 . Each of substrates 210 is fixed on bottom plate 112 of casing 110 at each predetermined position. Each of light emitting devices 200 includes light emitting element 220 and light flux controlling member 300 .
[0044] Light emitting element 220 is a light source of surface light source device 100 , and mounted on substrate 210 . Light emitting element 220 is a light-emitting diode (LED) such as a white light emitting diode.
[0045] Light flux controlling member 300 is a diffusion lens configured to control the distribution of light emitted from light emitting element 220 , and fixed on substrate 210 . Light flux controlling member 300 is disposed over light emitting element 220 such that central axis CA thereof coincides with optical axis LA of light emitting element 220 (see FIG. 10 ). Later-described incidence surface 320 and emission surface 330 of light flux controlling member 300 are both rotationally symmetric (circularly symmetric), and rotation axes thereof coincide with each other. The axes of incidence surface 320 and emission surface 330 are hereinafter referred to as “central axis CA of the light flux controlling member.” Further, “optical axis LA of the light emitting element” means a center beam of a three-dimensional light flux from light emitting element 220 . A gap to release generated heat from light emitting element 220 to the outside is formed between substrate 210 on which light emitting element 220 is mounted and rear surface 340 of light flux controlling member 300 .
[0046] Light flux controlling member 300 is formed by integral molding. The material of light flux controlling member 300 is not particularly limited as long as light with desired wavelength can pass through. For example, the material of light flux controlling member 300 is a light-transmissive resin such as polymethylmethacrylate (PMMA), polycarbonate (PC) or epoxy resin (EP), or glass.
[0047] A main feature of surface light source device 100 according to the present embodiment lies in a configuration of light flux controlling member 300 . Therefore, light flux controlling member 300 will be described in detail later.
[0048] Light diffusion member 120 is a plate-shaped member having light diffusivity, and configured to diffuse and transmit the light emitted from light emitting device 200 at the same time. Normally, the size of light diffusion member 120 is substantially the same as the size of a member to be irradiated such as a liquid crystal panel. For example, light diffusion member 120 is formed of a light-transmissive resin such as polymethylmethacrylate (PMMA), polycarbonate (PC), polystyrene (PS) or styrene-methylmethacrylate copolymer resin (MS). To confer light diffusivity, fine irregularities are formed on the surface of light diffusion member 120 , or light diffusion elements such as beads are dispersed in light diffusion member 120 .
[0049] In surface light source device 100 according to the present embodiment, light emitted from each light emitting element 220 is expanded by light flux controlling member 300 to illuminate a broad region of light diffusion member 120 . Further, the light output from each light flux controlling member 300 is diffused by light diffusion member 120 . As a result, surface light source device 100 according to the present embodiment can uniformly illuminate a planar member to be irradiated (e.g. liquid crystal panel).
(Configuration of Light Flux Controlling Member)
[0050] FIGS. 8A to 9D illustrate a configuration of light flux controlling member 300 according to Embodiment 1. FIG. 8A is a perspective view from the rear side, and FIG. 8B is a cross-sectional perspective view from the rear side. FIG. 9A is a plan view, FIG. 9B is a front view, FIG. 9C is a bottom view and FIG. 9D is a cross-sectional view taken along line C-C shown in FIG. 9A . In FIGS. 8A and 8B , legs 370 formed on the rear side are not illustrated.
[0051] As illustrated in FIGS. 8A to 9D , light flux controlling member 300 includes recess 310 , incidence surface 320 , emission surface 330 , rear surface 340 , reflection portion 350 , flange 360 and a plurality of legs 370 .
[0052] Recess 310 is formed in a central portion of the rear side (light emitting element 220 side) of light flux controlling member 300 . The inner surface of recess 310 functions as incidence surface 320 . Incidence surface 320 allows most of the light emitted from light emitting element 220 to enter the inside of light flux controlling member 300 while controlling the traveling direction of the light. Incidence surface 320 intersects central axis CA of light flux controlling member 300 and is rotationally symmetric (circularly symmetric) about central axis CA.
[0053] Emission surface 330 is formed on the front side (light diffusion member 120 side) of light flux controlling member 300 so as to protrude from flange 360 . Emission surface 330 is configured to output the light entered light flux controlling member 300 while controlling the traveling direction of the light. Emission surface 330 intersects central axis CA and is rotationally symmetric (circularly symmetric) about central axis CA.
[0054] Emission surface 330 includes first emission surface 330 a located in a predetermined area about central axis CA, second emission surface 330 b formed around and continued from first emission surface 330 a , and third emission surface 330 c connecting second emission surface 330 b with flange 360 (see FIG. 9D ). First emission surface 330 a is a smoothly curved surface protruding to the rear side (light emitting element 220 side). The shape of first emission surface 330 a is a concave shape such that a part of spherical surface is cut off. Second emission surface 330 b is a smoothly curved surface protruding to the front side (light diffusion member 120 side) located around first emission surface 330 a . The shape of second emission surface 330 b is a toric convex shape. Third emission surface 330 c is a curved surface located around second emission surface 330 b . In the cross-section illustrated in FIG. 9D , the cross-sectional shape of third emission surface 330 c may be linear or curved.
[0055] Rear surface 340 is a plane located on the rear side and extending radially from the opening edge of recess 310 . Rear surface 340 allows light emitted from light emitting element 220 but not entered from incidence surface 320 to enter light flux controlling member 300 .
[0056] Reflection portion 350 is disposed in a ring form on the rear side (light emitting element 220 side) of light flux controlling member 300 so as to surround the opening of recess 310 . A plurality of linear protrusions 352 are formed in reflection portion 350 . Linear protrusions 352 are formed such that a cross-section of each linear protrusion vertical to later-described ridge line 352 c is substantially triangle-shaped, and that the linear protrusions are formed rotationally symmetric about central axis CA (when the number of the linear protrusions is n, they are n-fold symmetrical). Each linear protrusion 352 includes planar first reflection surface 352 a , planar second reflection surface 352 b , and ridge line 352 c that is an intersection line of first reflection surface 352 a and second reflection surface 352 b . Linear protrusion 352 functions like a total reflection prism. As illustrated in FIG. 10 , a virtual line including ridge line 352 c intersects central axis CA at a position which is farther into the front side area (light diffusion member 120 side) of the light flux controlling member than ridge line 352 c . That is, each linear protrusion 352 is inclined at a predetermined angle (e.g. 45°) relative to central axis CA such that the front end (light diffusion member 120 side) of linear protrusion 352 is closer to central axis CA than the rear end (light emitting element 220 side) of linear protrusion 352 is.
[0057] Reflection portion 350 will be described from a different perspective. A ring formed groove about central axis CA is formed in rear surface 340 . The cross-sectional shape of the ring formed groove in a cross-section including central axis CA is substantially V-shaped. Of the two surfaces forming the V-shape, the inner surface is substantially parallel to optical axis LA of light emitting element 220 , and the outer surface is inclined at a predetermined angle (e.g. 45°) relative to optical axis LA of light emitting element 220 . On the outer inclining surface, linear protrusions 352 (total reflection prisms) are formed.
[0058] Reflection portion 350 reflects light, which is reflected by emission surface 330 and travels to rear surface 340 , in a lateral direction (radially outside relative to central axis CA). The light reached reflection portion 350 is reflected sequentially by two surfaces (first reflection surface 352 a and second reflection surface 352 b ) of any one of linear protrusions 352 and travels in a lateral direction. The light reflected by reflection portion 350 is output from flange 360 , for example.
[0059] Reflection portion 350 is preferably located such that linear protrusions 352 are formed in a region where a large amount of light reflected by emission surface 330 reaches, but the location is not limited to thereto. Although the arrival position of the light reflected by emission surface 330 varies according to various factors such as the shape of emission surface 330 , in light flux controlling member 300 according to the present embodiment illustrated in FIG. 9D , most of the light Fresnel-reflected by emission surface 330 after entered from incidence surface 320 reaches a predetermined annular region on rear surface 340 (see FIGS. 11A to 11C ). In the case of light flux controlling member 20 (with the outer diameter of rear surface of 15.5 mm) used in a later-described simulation of illuminance distribution in a region facing rear surface 340 on substrate 210 , the highest illuminance value is obtained in a region 5 to 6 mm apart from central axis CA (see FIG. 12 ). It can be deduced that the region is where a substantial amount of light Fresnel-reflected by emission surface 24 after entered from incidence surface 22 is likely to reach. Therefore, it is preferable to form a plurality of linear protrusions 352 at least in the region 5 to 6 mm apart from central axis CA in light flux controlling member 20 .
[0060] Flange 360 is located between the outer peripheral portion of emission surface 330 and the outer peripheral portion of rear surface 340 , and protruding radially outside. The shape of flange 360 is a substantially ring form. Although flange 360 is not an essential component, handling and alignment are easier with flange 360 formed. The thickness of flange 360 is not limited, and can be determined in view of the required area of emission surface 330 , formability of flange 360 , or the like.
[0061] A plurality of legs 370 are substantially cylindrical members protruding from rear surface 340 . Legs 370 hold light flux controlling member 300 at an appropriate position relative to light emitting element 220 .
[0062] FIGS. 11A to 11C are illustrations of optical paths in light flux controlling member 300 . FIG. 11A is an illustration of an optical path of a beam with emission angle 30°, FIG. 11 is an illustration of an optical path of a beam with emission angle 40°, and FIG. 11C is an illustration of an optical path of a beam with emission angle 50°. In FIGS. 11A to 11C , legs 370 are not illustrated. As illustrated in FIGS. 11A to 11C , light reflected by emission surface 330 reaches reflection portion 350 in light flux controlling member 300 . The light reached reflection portion 350 is reflected sequentially by first reflection surface 352 a and second reflection surface 352 b of linear protrusion 352 and travels in a lateral direction.
[0063] As can be seen from light flux controlling member 30 disclosed in PTL 1, when inclining surface 32 is formed in rear surface 26 , the direction of light Fresnel-reflected by emission surface 24 can be changed in a lateral direction, so that light use efficiency can be increased. However, when a beam has a large emission angle, part of light reflected by emission surface 24 may reach the substrate under light flux controlling member 30 after passing through inclining surface 32 (see FIG. 4C ), and further improvement may be needed. In light flux controlling member 300 according to the present embodiment, linear protrusions 352 (total reflection prisms) are formed on the inclining surface, so that a beam having a large emission angle which is Fresnel-reflected by emission surface 330 can be reflected in a lateral direction (see FIG. 11C ). Therefore, in light flux controlling member 300 according to the present embodiment, more light reflected by emission surface 330 travels in lateral directions, so that the loss of light caused by light reflected by emission surface 330 being reflected by or absorbed into substrate 210 can be limited.
[0000] (Simulation of Illuminance Distribution in Region under Light Flux Controlling Member)
[0064] For light flux controlling member 300 according to Embodiment 1 illustrated in FIGS. 8A to 9D , the illuminance distribution in a region under the light flux controlling member was simulated. For comparison, the illuminance distribution was simulated also for conventional light flux controlling member 20 illustrated in FIGS. 1A to 1C and light flux controlling member 30 disclosed in PTL 1 illustrated in FIGS. 3A to 3C .
[0065] In the simulation, the illuminance distribution on the surface of substrate 210 when light emitting element 220 and light flux controlling member 300 (or 20 or 30 ) are disposed on substrate 210 illustrated in FIG. 7 was measured. Light reached the surface of substrate 210 was set to be not reflected but absorbed. Three light flux controlling members 300 , 20 and 30 used for simulations are different from each other only in that whether or not they have inclining surface 32 or reflection portion 350 on the rear sides. Parameters for light flux controlling members 300 , 20 and 30 were set as follows:
(Common Parameters)
[0066] Outer diameter of emission surface: 14.778 mm
[0067] Outer diameter of rear surface: 15.5 mm
[0068] Opening diameter of recess: 3.53 mm
[0069] Height from surface of substrate to rear surface: 1.1 mm
[0070] Height from surface of substrate to highest point of emission surface: 5.867 mm
[0071] (Parameters Only for Light Flux Controlling Member 30 )
[0072] Outer diameter of inclining surface: 6.057 mm
[0073] Angle of inclining surface: 45° relative to optical axis
[0074] (Parameters Only for Light Flux Controlling Member 300 )
[0075] Outer diameter of reflection portion: 6.057 mm
[0076] Angle of ridge line: 45° relative to optical axis
[0077] FIG. 12 is a graph illustrating the illuminance distribution on the surface of substrates under the light flux controlling member. The abscissa represents the distance (mm) from the central axis of the light flux controlling member on the line intersecting the central axis of the light flux controlling member. The ordinate represents the illuminance (lx) at different points. The result of light flux controlling member 20 having no inclining surface is shown by thin dashed line, the result of light flux controlling member 30 not having a plurality of linear protrusions but having an inclining surface is shown by thin solid line, and the result of light flux controlling member 300 having a plurality of linear protrusions is shown by thick solid line. As shown in the graph, the illuminance in the region 4.5 to 6.5 mm apart from the central axis is different among the light flux controlling members. That is, the illuminance in the region under light flux controlling member 30 having the inclining surface (see FIGS. 3A to 3C ) is lower than the illuminance in the region under light flux controlling member 20 having no inclining surface (see FIGS. 1A to 1C ). Further, the illuminance in the region under light flux controlling member 300 having the linear protrusions (see FIGS. 8A to 9D ) is lower than the illuminance in the region under light flux controlling member 30 having the inclining surface (but not having a plurality of linear protrusions) (see FIGS. 3A to 3C ).
[0078] FIG. 13 is a graph illustrating average illuminance (lx) in the region under light flux controlling member (circular region with a diameter of 19 mm) On the abscissa, “A” represents light flux controlling member 20 having no inclining surface, “B” represents light flux controlling member 30 not having a plurality of linear protrusions but having the inclining surface, and “C” represents light flux controlling member 300 having the linear protrusions. This graph also shows that light flux controlling member 300 having the linear protrusions (see FIGS. 8A to 9D ) exhibits low illuminance in the region under the flux controlling member compared to flux controlling member 20 having no inclining surface (see FIGS. 1A to 1C ) and flux controlling member 30 having the inclining surface (but not having a plurality of linear protrusions) (see FIGS. 3A to 3C ).
[0079] FIG. 14 is a graph illustrating incident light flux (lm) in the region under the light flux controlling member (circular region with diameter 19 mm) Also on the abscissa of this graph, “A” represents light flux controlling member 20 having no inclining surface, “B” represents light flux controlling member 30 not having a plurality of linear protrusions but having the inclining surface, and “C” represents light flux controlling member 300 having the linear protrusions. The amount of light flux from a light emitting element is 1 lm. This graph also shows that light flux controlling member 300 having the linear protrusions (see FIGS. 8A to 9D ) exhibits a small amount of light flux reached the region under the flux controlling member compared to flux controlling member 20 having no inclining surface (see FIGS. 1A to 1C ) and flux controlling member 30 having the inclining surface (but not having a plurality of linear protrusions) (see FIGS. 3A to 3C ).
[0080] As described above, in light flux controlling member 300 according to the present embodiment, the light reflected by emission surface 330 does not easily travel in the direction directly above light flux controlling member 300 or is not easily absorbed into substrate 210 . Therefore, light emitting device 200 according to the present invention can radiate light more efficiently and uniformly than light emitting devices including the conventional light flux controlling member.
[0081] In the present embodiment, light flux controlling member 300 in which rear surface 340 is a flat surface is described, but a part or all of rear surface 340 may be a light scattering surface. For example, as illustrated in FIGS. 15A and 15B , a part of rear surface 340 may be light scattering surface 342 (the region indicated by hatching). In FIG. 15A , the region inside legs 370 is roughened. In FIG. 15B , the region inside reflection portion 350 is roughened. When a part or all of rear surface 340 is a light scattering surface, luminance unevenness caused by light entered from rear surfaces 340 being gathered in an unintended direction can be prevented.
[0082] To obtain such an effect, it is preferable that a region of rear surface 340 where light from light emitting element 220 may directly reach be a light scattering surface. The size of the region varies according to the distance between light emitting element 220 and rear surface 340 , the size of light emitting element 220 , the size of the opening of recess 310 , or the like. Therefore, the region to be a light scattering surface may be appropriately set according to these parameters.
Embodiment 2
Configurations of Surface Light Source Device and Light Emitting Device
[0083] A surface light source device and light emitting device according to Embodiment 2 differ from surface light source device 100 and light emitting device 200 according to Embodiment 1 illustrated in FIGS. 5A to 7 in that the former include light flux controlling member 400 according to Embodiment 2 instead of light flux controlling member 300 according to Embodiment 1. Accordingly, only light flux controlling member 400 according to Embodiment 2 will be described in the present embodiment.
(Configuration of Light Flux Controlling Member)
[0084] FIGS. 16A to 17D illustrate a configuration of light flux controlling member 400 according to Embodiment 2. FIG. 16A is a perspective view from the rear side, and FIG. 16B is a cross-sectional perspective view from the rear side. FIG. 17A is a plan view, FIG. 17B is a front view, FIG. 17C is a bottom view and FIG. 17D is a cross-sectional view taken along line D-D shown in FIG. 17A . In FIGS. 16A and 16B , legs 370 formed on the rear side are not illustrated.
[0085] As illustrated in FIGS. 16A to 17D , light flux controlling member 400 includes recess 310 , incidence surface 320 , emission surface 330 , first rear surface 440 a , second rear surface 440 b , reflection portion 450 , flange 360 and a plurality of legs 370 . Elements that overlap with those of light flux controlling member 300 illustrated in FIGS. 8A to 9D are provided with symbols that are the same as those in FIGS. 8A to 9D , and a description thereof will be omitted.
[0086] In light flux controlling member 400 according to Embodiment 2, reflection portion 450 is formed lower (substrate 210 side) than the opening of recess 310 . Hence, on the rear side of light flux controlling member 400 , first rear surface 440 a that is a plane extending from the opening edge of recess 310 to the upper end of reflection portion 450 , and second rear surface 440 b that is a plane extending radially from the lower end of reflection portion 450 are formed. First rear surface 440 a allows light emitted from light emitting element 220 but not entered from incidence surface 320 to enter light flux controlling member 400 .
[0087] (Effect)
[0088] Light flux controlling member 400 according to Embodiment 2 has the same effect as light flux controlling member 300 according to Embodiment 1. In light flux controlling member 300 according to Embodiment 1, light entered from incidence surface 320 at a large angle relative to optical axis LA may be reflected by reflection portion 350 in an unintended direction after reaching reflection portion 350 . On the other hand, in light flux controlling member 400 according to Embodiment 2, reflection portion 450 is formed lower than the opening of recess 310 , so that such unintended reflections do not occur.
[0089] In light flux controlling member 400 according to the present embodiment, the size of the region accepting reflected light from emission surface 330 can be controlled by adjusting the parameters of reflection portion 450 (e.g. the size and inclination of first reflection surface 352 a and second reflection surface 352 b , and the length and inclination of ridge line 352 c ). For example, as illustrated in FIGS. 18A and 18B , the area of second rear surface 440 b may be smaller, or the intervals between ridge lines 352 c in reflection portion 450 may be longer. Further, as illustrated in FIGS. 19A and 19B , the area of reflection portion may be larger by not forming second rear surface 440 b . In FIGS. 18A to 19B , legs 370 formed on the rear side are not illustrated.
[0090] In light flux controlling member 300 and 400 according to the present embodiment, each ridge line 352 c may be formed by chamfering the ridge formed by two reflection surfaces 352 a and 352 b intersecting each other.
[0091] Further, in the mode such as light flux controlling member 400 according to Embodiment 2 in which reflection portion 450 is formed lower (substrate 210 side) than the opening of recess 310 , light flux can be controlled more efficiently by expanding the area of emission surface 330 by forming thinner flange 360 with due considerations of handling and formability.
Embodiment 3
Configurations of Surface Light Source Device and Light Emitting Device
[0092] A surface light source device and light emitting device according to Embodiment 3 differ from surface light source device 100 and light emitting device 200 according to Embodiment 1 illustrated in FIGS. 5A to 7 in that the former include light flux controlling member 500 according to Embodiment 3 instead of light flux controlling member 300 according to Embodiment 1. Accordingly, only light flux controlling member 500 according to Embodiment 3 will be described in the present embodiment.
(Configuration of Light Flux Controlling Member)
[0093] FIG. 20 is a cross-sectional view of light flux controlling member 500 according to Embodiment 3.
[0094] As illustrated in FIG. 20 , light flux controlling member 500 includes recess 310 , incidence surface 320 , emission surface 330 , rear surface 340 , reflection portion 350 , flange 560 and a plurality of legs 370 . Elements that overlap with those of light flux controlling member 300 illustrated in FIGS. 8A to 9D are provided with symbols that are the same as those in FIGS. 8A to 9D , and a description thereof will be omitted.
[0095] In light flux controlling member 500 according to Embodiment 3, the thickness of flange 560 in the central axis CA direction is small. As described above, the thickness of flange 560 is not limited, and can be determined in view of the required area of emission surface 330 , formability of flange 560 , and the like. In light flux controlling members 300 and 400 according to Embodiments 1 and 2, part of light entered light flux controlling members 300 and 400 from the vicinity of the openings of recesses 310 directly reaches flange 360 . Since flange 360 is not intended for controlling the distribution of light, it is not desirable that light directly reach flange 360 . In light flux controlling member 500 according to the present embodiment, more light entered from the vicinity of the opening of recess 310 can directly reach emission surface 330 . In the present embodiment, flange 560 is formed lower (rear surface 340 side) than a line (dashed line in FIG. 20 ) passing through opening edge P 1 of recess 310 and the innermost point P 2 of reflection portion 350 (ring formed groove) in a cross-section including central axis CA. In this way, emission surface 330 of light flux controlling member 500 according to Embodiment 3 is formed larger than emission surface 330 of light flux controlling member 300 according to Embodiment 1, and can output more controlled light.
[0000] (Simulation of Illuminance Distribution in Region under Light Flux Controlling Member)
[0096] For light flux controlling member 500 according to Embodiment 3 illustrated in FIG. 20 (hereinafter also referred to as light flux controlling member (f)), the illuminance distribution in a region under the light flux controlling member was simulated. For comparison, the illuminance distribution in a region under the light flux controlling member was also simulated for: conventional light flux controlling member 20 (hereinafter also referred to as light flux controlling member (a)) illustrated in FIGS. 1A to 1C ; light flux controlling member 30 (hereinafter also referred to as light flux controlling member (b)) disclosed in PTL 1 illustrated in FIGS. 3A to 3C ; light flux controlling member 300 (hereinafter also referred to as light flux controlling member (c)) according to Embodiment 1 illustrated in FIGS. 8A to 9D ; light flux controlling member (d) whose flange is made thinner in conventional light flux controlling member 20 (light flux controlling member (a)) so that light entered from the vicinity of the opening of the recess can directly reach the emission surface; and light flux controlling member (e) whose flange is made thinner in light flux controlling member 30 (light flux controlling member (b)) disclosed in PTL 1 so that light entered from the vicinity of the opening of the recess can directly reach the emission surface. The amounts of light fluxes in the regions under light flux controlling members (b) to (f) were calculated relative to the amount of light flux in the region under conventional light flux controlling member 20 (light flux controlling member (a)) as 100%.
[0097] In the simulation, the amount of light flux to the surface of substrate 210 when light emitting element 220 and each of light flux controlling members (a) to (f) are disposed on substrate 210 illustrated in FIG. 7 was measured. Parameters for each of light flux controlling members (a) to (f) are the same as in the simulation carried out in Embodiment 1 except for the thickness of the flange. The thicknesses of the flanges of light flux controlling members (a), (b) and (c) in the central axis CA direction are 2.35 mm, and the thicknesses of the flanges of light flux controlling members (d), (e) and (f) in the central axis CA direction are 1.7 mm. The light flux controlling members used in the simulation, the thicknesses of flanges, the relative values of the amounts of light fluxes to substrate 210 are shown in Table 1.
[0000]
TABLE 1
Light flux controlling
member
a
b
c
d
e
f
Feature of rear surface
Flat surface
Inclining surface
Inclining surface
Flat surface
Inclining surface
Inclining surface
linear protrusions
linear protrusions
Thickness of flange (mm)
2.35
2.35
2.35
1.7
1.7
1.7
Relative value of amount
100
81
71
97
78
64
of light flux (%)
[0098] As shown in Table 1, the amount of light flux is low in the region under the light flux controlling members (d) to (f) having thin flange (1.7 mm), in which even light entered from the vicinity of the opening of the recess can directly reach the emission surface, compare to light flux controlling members (a) to (c) having thick flange (2.35 mm), in which part of light entered from the vicinity of the opening of the recess directly reaches the flange. Further, the amount of light flux is low in the region under light flux controlling member (f) according to the present embodiment, which has an inclining surface, a plurality of linear protrusions and the thin flange, compare to light flux controlling members (a) and (d) having no inclining surface, light flux controlling members (b) and (e) having inclining surfaces (but not having a plurality of linear protrusions), and light flux controlling member (c) having an inclining surface, a plurality of linear protrusions and the thick flange. It can be understood that light flux controlling member (f) according to the present embodiment can control the distribution of more light.
(Effect)
[0099] Light flux controlling member 500 according to Embodiment 3 has the same effect as light flux controlling member 300 according to Embodiment 1. Further in light flux controlling member 500 according to Embodiment 3, flexibility of design of emission surface 330 can be enhanced by forming thin flange 560 . Further, light flux controlling member 500 according to Embodiment 3 can control the distribution of more light due to large emission surface 330 .
[0100] When trying to form emission surface 330 without flange 560 , which can control traveling directions of light to required light emitting directions, the diameter of the light flux controlling member may increase. In that case, the light flux controlling member may be appropriately designed with due considerations of the balance between the form of the light flux controlling member and emitted light.
[0101] This application claims priority based on Japanese Patent Application No. 2012-186459, filed on Aug. 27, 2012, and Japanese Patent Application No. 2013-064009 filed on Mar. 26, 2013, the entire contents of which including the specifications and the drawings are incorporated herein by reference.
INDUSTRIAL APPLICABILITY
[0102] The light flux controlling member, light emitting device and surface light source device of the present invention may be employed in a backlight of a liquid crystal display apparatus or a general lighting.
REFERENCE SIGNS LIST
[0000]
10 light emitting element
20 , 30 light flux controlling member
22 incidence surface
24 emission surface
26 rear surface
32 inclining surface
100 surface light source device
110 casing
112 bottom plate
114 top plate
120 light diffusion member
200 light emitting device
210 substrate
220 light emitting element
300 , 400 , 500 light flux controlling member
310 recess
320 incidence surface
330 emission surface
340 rear surface
342 light scattering surface
350 , 450 reflection portion
352 linear protrusion
352 a first reflection surface
352 b second reflection surface
352 c ridge line
360 , 560 flange
370 leg
440 a first rear surface
440 b second rear surface
P 1 opening edge of recess
P 2 innermost point of reflection portion
|
This luminous flux control member has: an incidence surface through which light emitted from a light-emitting element enters; an emission surface through which the light entering from the incidence surface is emitted to the outside; and multiple ridges that are formed on the back side so as to surround the central axis (CA) and that have a substantially triangular cross-sectional shape. Each of the multiple ridges has a first reflecting surface, a second reflecting surface, and a ridge line which is the line of intersection of the first reflecting surface and the second reflecting surface. An imaginary line containing the ridge lines intersects the central axis (CA) at a position closer to the front side than the ridge lines.
| 6
|
FIELD OF THE INVENTION
[0001] The invention relates to aprocess and in particular to a process for stripping volatile constituents from polymers melts.
BACKGROUND OF THE INVENTION
[0002] The removal of volatile constituents from polymer melts is generally one of the last process steps in the production of polymers. The volatile constituents to be removed may be solvents which were used for the production of the polymers or residues of unreacted monomers after concluded transesterification or esterification or polymerisation reactions and elimination products from transesterification or esterification reactions.
[0003] For the purposes of the present invention, volatile constituents are taken to mean any volatile impurities such as monomers, i.e. any starting materials, and volatile components of all kinds such as for example solvents, low molecular weight reaction products, elimination products from the reaction, and decomposition and breakdown products which arise during the reaction, together with any secondary compounds introduced via the feedstocks. In relation to the residual monomers, low molecular weight reaction products are hereinafter taken to mean those with a degree of polycondensation of up to 3.
[0004] The removal of such constituents is necessary because such accompanying substances generally give rise to deficiencies in material properties such as thermal stability, processability, flow behavior etc. Such volatile constituents may also give rise to unwanted odor nuisances and/or be harmful to health.
[0005] Various apparatuses or processes are known depending on the viscosity of the polymer melts from which the volatile constituents are to be removed. Known apparatuses for this task in polymer melts are, for example, film evaporators or filmtruders, screw machines, strand evaporators or tubular evaporators.
[0006] Removal of volatile constituents by chemical means is described, for example, in EP 0 768 337 A1. Removal is effected by addition of CH-acidic organic compounds. The chemical conversion of residual monomers may possibly give rise to products with unwanted environmental impact, which distinctly complicates the use of the products in practical applications. Said process also cannot be used for removing residual solvents.
[0007] The process for reducing residual monomers with unsaturated fatty acids according to U.S. Pat. No. 4,215,024 suffers from the same shortcomings.
[0008] Another known process describes the reduction of residual monomers by treating the moulding compositions with electron beam radiation, as described in DE 2 843 292 A1. The process is, however, much too costly on a full industrial scale. A process for the removal of residual volatiles by injection of supercritical solvents or gases into the polymer melt with subsequent depressurisation described in EP 0 798 314 A1 has also proved equally costly.
[0009] Conventional and usual processes are also based on the removal of volatile constituents by means of mechanically assisted systems. Accordingly, extruders, such as for example in U.S. Pat. No. 4,423,960, DE 2 721 848 C2, EP 0 411 510 B1 or in “Entgasen von Kunststoffen in mehrwelligen Schneckenmaschinen” [Degassing of plastics in multiscrew machines], Kunststoffe 71 (1981), pages 18-26, devolatilising centrifuges (U.S. Pat. No. 4,940,472), friction compaction (EP 0 460 450 A2) or film evaporators (DE 1 925 063 A1 or EP 0 267 025 A1) are used. These processes conventionally have a short residence time of the order of a few minutes.
[0010] All the above-stated mechanically assisted processes exhibit the disadvantage that heavy moving parts which move at high rotational speed and rotational frequencies are required in the apparatus. This results in costly apparatus or machinery which is susceptible to malfunctioning and wear. If adequate degassing efficiency is to be achieved, frequent circulation of the product is necessary. At the short residence times, elevated temperatures are, on the one hand, necessary in order to shift the diffusion coefficients and physical equilibria of the volatile components towards favourable values. On the other hand, such elevated temperatures are unavoidable because the frequent circulation of the product results in elevated input of energy. The person skilled in the art is aware that elevated temperatures strongly promote and accelerate unwanted reactions in polymers. Such reactions result in unwanted reductions in quality, such as for example discoloration and/or formation of gel particles, particles or specks and branched structures or even dissociation into monomers. The mechanical energy is usually produced from electrical energy, resulting in higher costs relative to the use of primary energy. Typical energy inputs of such processes are in the order of 0.05 to 0.2 kWh/kg of product.
[0011] “Static” degassing processes, which introduce mechanical energy only via pumps, usually gear pumps, are furthermore known to the person skilled in the art. These static processes operate in such a manner that a polymer melt, optionally with additives, is introduced into a degassing vessel, in which the volatile constituents evaporate and are drawn off in gaseous form. Such processes often have multiple stages.
[0012] One example of a static process is DE 10 031 766 A1, which describes a two-stage, continuous process for degassing styrene copolymers, in which, in a first stage, the concentration of polymer is adjusted to above 99.8 wt. % in a shell-and-tube heat exchanger with evaporation of volatile constituents and simultaneous input of energy and, in a second stage, the final concentration is obtained in a strand evaporator without intermediate superheating.
[0013] A strand evaporator operates by forming free-falling strands of melt in a cabinet, i.e. without supply of mechanical energy. In the cabinet, the strands are generally exposed to a vacuum at elevated temperatures. The heights of such apparatus are limited and thus so too is the residence time during which evaporation may occur. Another disadvantage of the process resides in the very large number of holes which are required for a good degassing result in the strand evaporator. The diameters of the holes are in the lower, single digit millimetre range, while, at throughput of a few tonnes per hour, the holes range in number from some thousands to a hundred thousand. This is disadvantageous. Given the large number of holes, it is to be feared that specks and swollen solids may give rise to blockages and disruption to flow on exit from the hole. Finally, the efficiency of a strand evaporator depends on the stability of the strands, which in turn depends in complex manner on product rheology, flow conditions in the gas space of the strand evaporator, the geometry and quality of the holes and temperature. It is accordingly difficult to establish and control constant processing conditions.
[0014] Another example of a static process is U.S. Pat. No. 4,699,976, which describes a two-stage, continuous process for degassing rubber-containing styrene polymers. This process uses two degassing stages which are equipped with shell-and-tube heat exchangers. In the first stage, the polymer solution is concentrated to a residual content of volatile constituents of between 3% and 15%. In the second stage, evaporation is then performed to obtain the desired final concentration. During this process, foaming occurs inside the tubes. This process cannot, however, be used if the concentration of volatile constituents is so low that the polymer melt does not foam because the volume of gas which arises is insufficient.
[0015] “Neue Mischverfahren mit geringem Energiebedarf für Polymerherstellung und-aufbereitung” [Novel low-energy mixing processes for polymer production and processing], Chemische Industrie (1985) 37 (7), pages 473 to 476, describes a static process in which, prior to the final stage, an entraining agent is mixed with the polymer before the product is introduced in the final stage into a degassing vessel. As is familiar to the person skilled in the art, the entraining agents used are primarily inert gases, such as for example nitrogen or carbon dioxide or alternatively also water. In EP 0 027 700 A2, an inert entraining agent from the group comprising water, nitrogen, carbon dioxide or hydrocarbons with one to four carbon atoms is mixed with a polymer solution and flashed in a chamber. Both the above-stated processes have disadvantages. Inert gases reduce the performance of the condensers in which the volatile constituents are to be condensed and increase the volume to be conveyed by the vacuum system, so increasing the cost of the process. The use of water is disadvantageous because it entails restricting the temperature of the condensers to above 0° C. in order to prevent freezing and this limits the performance of the condensing system, which must in turn be compensated by a larger and more costly vacuum installation. Water may also react with various polymers, resulting in degradation of molecular weight and impairment of properties.
[0016] The concentration of residual volatiles is at thermodynamic equilibrium, when, with ideal mass transfer and after an adequate residence time, the product is at equilibrium with the gas in the stripping apparatus at the selected temperature and the selected pressure, i.e. the concentration undergoes no further change. Changes of a chemical nature due to thermal processes, such as dissociation, decomposition and the like, may severely restrict this statement and are not taken into account in the definition. This definition is familiar to the person skilled in the art. If degassing is to be possible at all in an apparatus, the concentration of residual volatiles in the product must always be higher than corresponds to the thermodynamic equilibrium. A degassing apparatus is particularly advantageous if the concentrations of the constituents to be stripped at the outlet thereof are as close as possible to the thermodynamic equilibrium, it being physically impossible for the concentrations to fall below this level.
[0017] Static processes of the above-stated kind have the disadvantage that, for each stage, they permit and enable only one single desgassing step in order to move towards the thermodynamic equilibrium before the product is again discharged from the stage. If, for reasons of degassing efficiency, it is possible in the individual stage to reduce the concentration of a volatile component only by, for example, a factor of 3 relative to the input value, but the degassing task requires a reduction by a factor of 20 relative to the input value, a three-stage installation is required. Obviously, this is costly, highly complex and thus to be avoided if at all possible.
[0018] Without exception, the stated apparatuses have short residence times. It is endeavoured to achieve short residence times in order to reduce the products' exposure to elevated temperatures because, as is familiar to the person skilled in the art, exposure to elevated temperatures results in quality impairment, such as for example discoloration and/or in the formation of particles or specks due to secondary and decomposition reactions. The short residence times relate only to those states in which the product has a large surface area per unit mass in the stripping apparatus, i.e. not in “sumps” in which the product is collected prior to discharge from the evaporation apparatus, where the surface area per unit mass is low.
[0019] In order to achieve the aim of low content of residual solvents or monomers, in known, mechanically assisted processes and apparatuses temperatures are raised, vigorous surface renewal is achieved, usually by elevated energy input, and it is endeavoured to achieve the best vacuums so that stripping may be performed efficiently, if possible within short residence times. In order to be able to operate with short residence times, the fullest possible use must be made of the effective parameters such as temperature, elevated mechanical energy input for rapid surface renewal and vacuum. The parameters diffusion and mass transfer, which are also highly significant, are product-specific, temperature-dependent physical variables and can only be influenced within this framework.
[0020] However, as a consequence of elevated product temperatures, the processes known from the prior art frequently result in partial modification of the products. These modifications may, for example be manifested by discoloration and particle formation due to secondary and decomposition reactions. The formation of particles or also specks entails increased filtration efforts. Filtration units for viscous products are complex and, due to steep pressure gradients, difficult to operate. Temperatures are often increased in order to lower the melt viscosities of the products and so reduce the pressure gradient. However, the increase in temperature in turn has a disadvantageous impact on product quality.
SUMMARY OF THE INVENTION
[0021] A process for stripping volatile constituents from polymer melts is disclosed. The process entails introducing the polymer melt into a horizontally oriented cylindrical device that contains a plurality of perforated disks rotating about a common horizontally oriented shaft bringing the melt and disks into contact in a manner calculated to constantly renew the surface of the melt to be stripped. Also disclosed is an apparatus suitable for the process.
BRIEF DESCRIPTION OF THE DRAWING
[0022] FIG. 1 is a schematic drawing of the preferred embodiment of the inventive apparatus.
DETAILED DESCRIPTION OF THE INVENTION
[0023] The object accordingly arose of providing, on the basis of the prior art, a process for stripping volatile constituents from polymer melts using an apparatus which avoids the disadvantages stated in the prior art and gives rise to good results in terms of stripping volatile constituents and of product quality.
[0024] It has now surprisingly been found that an apparatus of rotating perforated annular disks in horizontal cylinders used in a process for stripping volatile constituents from polymer melts does not require a further increase in product temperature and stripping of the volatile constituents may proceed at a comparatively moderate temperature level. Surprisingly, despite the longer residence times, the products produced in this apparatus exhibit good quality. It has also been found that it is advantageous and efficient for stripping if the polymer melt is exposed to the stripping conditions (temperature and vacuum) for a relatively extended period and the melt is continuously taken up from the bottoms in the apparatus, so constantly forming new surfaces, and exposed to the vacuum and remixing of stripped polymer melt with as yet unstripped polymer melt is avoided. The longer residence times permit lower temperatures, which are very gentle on the product. It has also been found to be particularly advantageous that, even at different throughputs, the movement of the melt may be determined and controlled externally by the rotational speed of the rotor, i.e. of the perforated annular disks. In many other apparatuses, the flow profiles and residence times and thus the preconditions for uniform results change as throughput varies. In the apparatus according to the invention, a change in residence time due to a variation in throughput, which always has an impact on the stripping result, may readily be corrected by adjusting filling level and rotational speed.
[0025] Particular advantages of the stripping apparatus used according to the invention are its cascading action, the extended residence times, which then also enable lower temperatures, the constantly renewed surfaces due to rotation and consequent continuous film formation and stretching of the films as they run off the disks, the elevated throughputs per unit time which are possible in the stripping apparatus according to the invention and the independence from flow profiles, as occur in other stripping installations. A cascading action is taken to mean that, as a result of the flow through the apparatus from the inlet to the outlet, the product running off the disks is conveyed with this flow towards the outlet and is not mixed with freshly inflowing product. Instead, the melt, which has already in part moved towards thermodynamic equilibrium, is picked up again by the disks and degassed again. This results in the “cascading action”, which may also be viewed as a division of the apparatus into several stages in a similar manner as in a column or in a series of stirred-tank reactors. Due to the cascading, surface formation rates are vastly higher than in other stripping installations. It is furthermore advantageous to introduce the melts into the stripping apparatus at low delivery pressures; these pressures are incomparably higher for example in strand evaporator installations due to the very large number of nozzles and the need to achieve a uniform distribution among all the nozzles. Another advantage is the low input of mechanical energy due to low rotational speeds, which rules out product stress due to elevated temperatures and a severe shear field. Further processing of the monomer-reduced melts may be performed without further temperature correction, i.e. under mild conditions, without the melts having to be cooled for further processing operations due to excessively high temperatures, for example downstream from extruders or film evaporators.
[0026] The extended residence time and good surface renewal of the apparatus makes it possible in general to achieve the stripping performance of the apparatus without raising the temperature.
[0027] In particular, this apparatus does not have the disadvantage of the static apparatuses that only one single stage is possible in order to approach thermodynamic equilibrium. Accordingly, at identical processing pressure, this apparatus is capable of achieving distinctly lower contents of residual volatiles than are static apparatuses. The person skilled in the art would not have expected that excellent product quality may be obtained under conditions of extended residence time.
[0028] The object was surprisingly achieved by a process for stripping volatile constituents from polymer melts using an apparatus which, under the action of gravity, constantly forms free films and has an elevated film formation rate. This is achieved with a horizontally arranged stripping apparatus comprising a cylindrical housing which accommodates an externally driven rotor. The rotor comprises perforated disks in the form of circular rings which are connected together. This connection may consist of a central shaft, of external connecting elements, e.g. in form of straight or angled plates or tubes, or of a hollow shaft (herein also referred to as hollow cylinder), which may be perforated. The embodiment with a perforated hollow shaft is preferred.
[0029] The perforated disks are circular rings are perforated in such a manner that the ratio of the total area of the circular ring to the area occupied by the webs between the holes is from 2.2-6.5, preferably from 2.5-5. It is particularly preferred to select the equivalent hole diameter in accordance with the formula
A=x (η 2 /(kg 2 m −5 s −2 )) 1/3
[0030] The equivalent hole diameter A is here defined as the diameter of a circle of identical area. The dimensionless numerical factor x may vary between 0.002 and 0.030, preferably between 0.004 and 0.016. η is the kinematic melt viscosity in Pas.
[0031] The holes may assume various geometric shapes. The holes are preferably in the form of equilateral, rotationally symmetrical polygons which permit constant web widths of the surrounding metal surface, and rectangles.
[0032] It is possible to deviate from these shapes at the inner and outer edges of the annular disks so that the edge may be made circular. At elevated viscosities, the equivalent hole diameter is so large that spokes must be provided between the inner and outer edges, optionally with a further division by a central ring. The boundaries of these holes are then the spokes and spoke sections and circular ring sections.
[0033] It is preferred that the holes of one disk are of the same size and same geometry. Likewise it is preferred that all disks used in the apparatus are of the same type regarding size and geometry of the holes.
[0034] All the metal surfaces or webs surrounding the holes are advantageously of a square or rectangular cross-section. Selection of the web widths makes it possible optimally to adapt the ratio of the melt-bearing area as the circular ring disk emerges from the melt relative to the surrounding hole as a function of melt viscosity and other properties of the melt. In the case of a circular ring disk, it has proved favourable to select all the metal surfaces or webs surrounding the holes to be cross-sectionally constant and identical in size.
[0035] The power input into such an apparatus may be very low, of the order of 0.01 kWh/kg. The increase in temperature to which the product is exposed in this apparatus is accordingly slight. Since the internal surface of the apparatus which is available for heat transfer is very large relative to throughput, it is, however, also possible to heat or optionally cool the product by means of the wall temperature.
[0036] The rotational speed of the rotors is favourably between 0.3 and 10 revolutions per minute, preferably between 0.5 and 5 revolutions per minute, particularly preferably between 0.8 and 3 revolutions per minute. The film formation rate is here greater than 5 and preferably greater than 10. It is defined as the ratio of the quantity of that material which is drawn up by the rotating disk and runs back down in the form of a free film to the total quantity of the throughput of the reactor.
[0037] According to the invention, the described apparatuses corresponding to the above-stated requirements may take various forms.
[0038] A preferred apparatus is described in “Polymerisieren im Ringscheibenreaktor” [Polymerising in an annular disk reactor], Kunststoffe 82 (1992) 1, pages 17-20 under the name VSR. The rotor here consists of various wheels which are connected with a central shaft via two ( FIG. 2 ) to four ( FIGS. 3 and 4 ) spokes.
[0039] It has been found that a particularly preferred apparatus for stripping volatile constituents from polymer melts is a horizontally arranged cylindrical vessel with an agitator, as is described in DE 44 47 422 C2 (Karl Fischer Industrieanlagen GmbH) column 1, line 63 to column 7, line 39.
[0040] The external diameter of the rotor is selected such that it fits into the heatable cylindrical housing (herein also referred to as outer cylinder), the length-to-diameter ratio of the outer cylinder preferably being between 0.6 and 2.5, particularly preferably between 0.8 and 2.
[0041] It is also advantageous to arrange the rotor eccentrically in the outer cylinder, such that the vapours formed may be discharged via an enlarged slot in the upper part of the apparatus. This measure brings about a major reduction in entrainment of polymer particles into the vapour line and vacuum installation.
[0042] A particular advantage of the particularly preferred embodiment is the extremely rigid construction and form of the hollow shaft bearing the perforated disks. The hollow shaft is likewise provided with orifices or holes, such that the resultant vapours may flow away unimpeded. The manner in which the rotor is mounted makes it possible to operate the reactor with different temperatures in the bottoms zone and in the vapour zone. The design furthermore makes it possible to limit the entrainment of relatively high viscosity melts as the rotor rotates by the incorporation of stators which project between the disks. Especially in the case of relatively high viscosity melts, this measure optimises the ratio of melt surface area to melt volume on the disk.
[0043] However, for optimum and thus very particularly preferred use of the apparatus presented in DE 4 447 422 C2 for stripping polymer melts, it is convenient to make still further modifications to the designs presented in the stated application.
[0044] If melt viscosities are too low, typically below 20 Pa s, it may thus happen that wetting of the rotating circular disk is inadequate. It has proved advantageous in this connection to arrange lifting elements on the outer periphery of the annular disks in such a manner that, as the lifting elements rise, the circular disk is continuously rinsed with melt.
[0045] When stripping relatively high viscosity polymer melts, typically above 200 Pa s, lifting of excessive quantities of product by the rotating circular disk may result in unwanted conditions, such as for example disruption of film formation. A method for preventing this phenomenon, which is improved relative to DE 4 447 422 C2, is to provide horizontal doctor bars on the stators at the bottoms filling level. Any coalescence of melt behind this bar in the direction of rotation of the rotor is thus avoided. These bars may be mounted directly on the housing or be supported by optional additional bars which are likewise fastened to the evaporator wall. The doctor bars and/or supporting bars may here be designed, as described in DE 44 47 422 C2, in such a manner as to promote material conveyance. This is particularly significant and advantageous to assist conveyance of the melt to the evaporator outlet.
[0046] It may be advantageous to heat the vapour or gas zone differently from the underlying melt or bottoms zone. It is accordingly advantageous to heat the upper gas zone to a lower level, e.g. lower by 5 to 20° C., than the melt zone therebelow. Any polymer films on the walls in the gas zone have a long residence time and suffer less damage due to lower temperatures.
[0047] This measure ensures longer evaporator service periods, reduced formation of specks due to cracked products and better colours of the final products.
[0048] Different degassing process temperatures must be selected for different polymers. They are substantially dependent on the thermal stability of the polymer to be processed. Another vital factor is also the desired residual content of constituents to be stripped. Pressures are adjusted between 0.01 and 15 mbar, preferably 0.05 to 10 mbar and the average residence times amount to 10 to 240 minutes, preferably 15 to 180 minutes and particularly preferably between 20 and 60 minutes.
[0049] If the temperatures of the polymer melts introduced into the evaporator apparatus are appreciably below, e.g. by 20 to 50° C., the desired operating temperatures of the evaporator apparatus (200 to 350 K), it may be advantageous to heat the melt before introduction with heat exchangers suitable for polymer melts. In this manner, it is possible to reduce the temperature differences between the heating medium and the product in the evaporator in order to avoid product damage on the walls.
[0050] Preferably, the product is introduced into the evaporator via a valve with automatic pressure control in such a manner that direct depressurisation into the product space occurs at the input end of the evaporator. Due to the elevated thermal potential of the immediate surroundings, cooling effects are avoided, which may be disadvantageous with regard to particle contents, for example of a crystalline nature. To this end, the product inlet valve is for example arranged in the front face of the reactor.
[0051] It is advantageous to offset the vapour outlets arranged on the top of the evaporator by 15° to 60° relative to the perpendicular in the direction of rotation of the rotor, in order to reduce melt reflux.
[0052] The object of the invention is further achieved with a stripping apparatus comprising a horizontally arranged, cylindrical housing, a rotor comprising circular perforated disks which are mounted on a central shaft and connected together with a horizontally arranged, perforated hollow cylinder, wherein the length-to-diameter ratio of the first cylinder is between 0.6 and 2.5.
[0053] Any conventional materials which do not cause direct damage to the product may be used for the production and manufacture of the evaporator apparatus according to the invention. Particularly suitable materials for the treatment of polycarbonates are non-rusting steels of type CrNi(Mo) 18/10, such as for example 1.4571 or 1.4541 (steel classification 2001, publisher: Stahlschlüssel Wegst GmbH, Th-Heuss-Straβe 36, D-71672 Marbach) and Ni-based alloys of type C, such as for example 2.4605 or 2.4610 (steel classification 2001, publisher: Stahlschlüssel Wegst GmbH, Th-Heuss-Straβe 36, D-71672 Marbach). The non-rusting steels are used at process temperatures of up to approx. 290° C. and the Ni-based alloys at process temperatures of above approx. 290° C. When treating styrene polymers and styrene copolymers, for example comprising acrylonitrile, a stainless steel typical for chemical applications, for example 1.4571 to DIN or 316 SS to ASME, is advantageous for product quality.
[0054] The principle of the apparatus according to the invention is shown in FIG. 1 . The polymer melt is introduced via the product inlet 1 of the housing 10 using a pipe with control valve into the front face of the evaporator. The product discharge 2 of the polymer melt takes place at the opposite end on the underside of the housing 10 by means of a gear pump. The evaporated volatile constituents are drawn off at the top via the vapour port 3 . The rotor with the annular disks 5 mounted thereon is set in rotation with a shaft 4 . The annular disks 5 are connected together via a hollow shaft (hollow cylinder) 9 . The stators 6 fastened to the inner wall 8 of the housing 10 spread the polymer melt on the annular disks 5 and, at elevated viscosities, prevent bridging between the annular disks 5 . The level of the bottoms is adjusted with an overflow weir, which may be a metal sheet 7 without or also with openings. In the embodiment shown in FIG. 1 , the central shaft is arranged centrally in the housing (outer cylinder) 10 .
[0055] The necessary vacuum is preferably generated using jet or vapour pumps which are ideally operated with substances inherent to the system and process. It is, however, also possible to use conventional liquid ring pumps in combination with lobe pumps to generate the vacuum. It is advantageous to operate the liquid ring pumps with a substance from the process.
[0056] The present invention provides the use of such apparatus for the removal of volatile components from polymer melts, in particular from melts of engineering thermoplastics such as polycarbonate, polyester, polyester carbonates, polyamides, polymethyl methacrylate, and blends of these polymers etc., particularly preferably polycarbonate, polyester, polyester carbonates, and blends of these polymers, very particularly preferably polycarbonate.
[0057] The present invention also provides the use of the process according to the invention in processes for the production of polymers, in particular of engineering thermoplastics such as polycarbonate, polyester, polyester carbonates, polyamides, polymethyl methacrylate, polystyrene, copolymers of styrene and acrylic monomers such as acrylonitrile and/or methyl methacrylate, and blends of these polymers etc., particularly preferably polycarbonate, polyester, polyester carbonates and copolymers of styrene and acrylonitrile, and blends of these polymers, very particularly preferably polycarbonate.
[0058] The polymer melts to be stripped may originate from various processes such as two-phase interfacial condensation reactions, melt transesterification reactions, solid phase condensation reactions, emulsion polymerisation reactions, bulk polymerisation reactions and the like or be produced by melting existing polymeric material. There are no limitations or restrictions with regard to the manner of polymer production, the installation used or the production process which is performed.
[0059] The polymer melts to be stripped may be combined with inhibitors before the apparatus according to the invention is used. Inhibitors are taken to mean any compounds which have a decisive inhibitory effect on chemical reaction kinetics, such that quality-impairing modification of the polymer is avoided. Addition thereof is, for example, necessary after the production of polymers which still contain monomers and reaction products after completion of the reaction in order to reduce the contents of low molecular weight compounds by thermal processes.
[0060] Suitable inhibitors for polycarbonate which has been produced by the transesterification process are acid components such as Lewis or Brøonsted acids or esters of strong acids. The pKa value of the acid should be no greater than 5, preferably less than 3. The acid components or the esters thereof are added in order to deactivate the reaction mixture, i.e. ideally to bring the reaction to a complete standstill.
[0061] Examples of suitable acid components are: orthophosphoric acid, phosphorous acid, pyrophosphoric acid, hypophosphoric acid, polyphosphoric acid, benzenephosphonic acid, sodium dihydrogenphosphate, boric acid, arylboronic acids, hydrochloric acid (hydrogen chloride), sulfuric acid, ascorbic acid, oxalic acid, benzoic acid, salicylic acid, formic acid, acetic acid, adipic acid, citric acid, benzenesulfonic acid, toluenesulfonic acid, dodecylbenzenesulfonic acid and any other phenyl-substituted benzenesulfonic acids, nitric acid, terephthalic acid, isophthalic acid, stearic acid and other fatty acids, acid chlorides such as phenyl chloroformate, stearic acid chloride, acetoxy-BP-A, benzoyl chloride and esters, semi-esters and bridged esters of the above-stated acids such as for example toluenesulfonic acid esters, phosphoric acid esters, phosphorous acid esters, phosphonic acid esters, dimethyl sulfate, boric acid esters, arylboronic acid esters and other components which regenerate acid on exposure to water such as tri-iso-octylphosphine, Ultranox 640 and BDP (bisphenol diphosphate oligomer).
[0062] Compounds which may preferably be considered here are orthophosphoric acid, phosphorous acid, pyrophosphoric acid, hypophosphoric acid, polyphosphoric acid, benzenephosphonic acid, sodium dihydrogenphosphate, boric acid, arylboronic acid, benzoic acid, salicylic acid, benzenesulfonic acid, toluenesulfonic acid, dodecylbenzenesulfonic acid and any other phenyl-substituted benzenesulfonic acids, acid chlorides such as phenyl chloroformate, stearic acid chloride, acetoxy-BP-A, benzoyl chloride and esters, semi-esters and bridged esters of the above-stated acids such as for example toluenesulfonic acid esters, phosphoric acid esters, phosphorous acid esters, phosphonic acid esters, boric acid esters, arylboronic acid esters and other components which regenerate acid on exposure to water such as tri-iso-octylphosphine, Ultranox 640 and BDP.
[0063] Compounds which may particularly preferably be considered are orthophosphoric acid, pyrophosphoric acid, polyphosphoric acid, benzenephosphonic acid, benzoic acid, benzenesulfonic acid, toluenesulfonic acid, dodecylbenzenesulfonic acid and any other phenyl-substituted benzenesulfonic acids and esters, semi-esters and bridged esters of the above-stated acids such as for example toluenesulfonic acid esters, phosphoric acid esters, phosphorous acid esters, phosphonic acid esters and other components which regenerate acid on exposure to water such as tri-iso-octylphosphine, Ultranox 640 and BDP.
[0064] Compounds which may very particularly preferably be used are orthophosphoric acid, pyrophosphoric acid, benzenesulfonic acid, toluenesulfonic acid, dodecylbenzenesulfonic acid and any other phenyl-substituted benzenesulfonic acids and esters, semi-esters and bridged esters of the above-stated acids such as for example toluenesulfonic acid esters and phosphoric acid esters.
[0065] The acidic components may be apportioned in solid, liquid or gaseous form. In a preferred method, the acidic component is continuously homogeneously incorporated into the product stream from which monomers are, for example, to be removed directly once the desired final molecular weight has been achieved in order to begin evaporating the residual monomers immediately thereafter. In a particularly preferred method, incorporation of additives to improve individual product properties is performed downstream from apportionment of the acid and stripping and not together with the stripping step because additives are often used which are volatile under a vacuum, which is essential to stripping, and the necessary concentrations in the polymer are then difficult to establish.
[0066] The acidic components are preferably added in liquid form. Since the quantities to be apportioned are very small, solutions of the acidic components are preferably used.
[0067] Suitable solvents are those which do not disrupt the process, are chemically inert and evaporate rapidly.
[0068] Properties of the resultant polymers may be modified with conventional additives and additional substances (e.g. auxiliaries and reinforcing materials). The purpose of adding additives and added substances is to extend service life (for example hydrolysis or degradation stabilisers), to improve colour stability (for example heat and UV stabilisers), to simplify processing (for example mould release agents, flow auxiliaries), to improve service characteristics (for example antistatic agents), to improve flame retardancy, to influence visual appearance (for example organic colorants, pigments) or to adapt polymer properties to specific stresses (impact modifiers, finely divided minerals, fibrous materials, silica flour, glass fibres and carbon fibres). These may all be combined at will in order to establish and obtain desired properties. Such added substances and additives are described, for example, in “Plastics Additives”, R. Gächter and H. Müller, Hanser Publishers 1983, in Additives for Plastics Handbook, John Murphy, Elsevier, Oxford 1999 or in Plastics Additives Handbook Hans Zweifel, Hanser, Munich 2001.
[0069] These additives and added substances may be added to the polymer melt individually or in any desired mixtures or in two or more different mixtures and in particular directly on isolation of the polymer or alternatively after melting pelletised material in a “compounding” step.
[0070] The additives and added substances or mixtures thereof may here be added to the polymer melt as a solid, i.e. as a powder, or as a melt and also in the form of solutions in suitable solvents. Another apportionment method is to use masterbatches or mixtures of masterbatches of the additives or mixtures of additives.
[0071] These substances are preferably added to the finished polymer using known apportioning units, but, if required, they may also be added at another stage of the polymer production process. Mixing with the polymer proceeds in apparatus known for this purpose, such as for example screw machines or static mixers.
EXAMPLES
[0000] Determination of Stated Analytical Characteristics:
[0000] Rel. Viscosity:
[0072] Relative viscosity is determined as the quotient of the viscosity of the solvent and the viscosity of the polymer dissolved in this solvent. It is measured in dichloromethane at 25° C. at a concentration of 5 g/l of solution.
[0000] Residual Monomer Content:
[0073] Residual monomer content is determined by dissolving the sample in dichloromethane and then precipitating it with acetone/methanol. Once the precipitated polymer has been separated, the filtrate is evaporated. The residual monomers are quantified by reverse-phase chromatography in a 0.04% phosphoric acid/acetonitrile mobile solvent gradient. Detection is by UV means.
[0000] YI:
[0074] The YI value is determined to ASTM E 313 on injection moulded samples 4 mm in thickness. The injection moulding temperature is 300° C.
[0075] The following Examples are intended to illustrate the invention, but without restricting its scope:
[0076] The same polycarbonate, produced by the transesterification process, is used for all the Examples. The data are stated in Table 1. In order to be able to achieve and compare the stripping effect, the polycarbonate pellets are sprayed prior to use with such a quantity of 1% phosphoric acid and homogenised at room temperature in a tumble dryer that the concentration of 100% phosphoric acid relative to the polycarbonate is 5 ppm.
[0077] Likewise in all the Examples, the pellets were melted at 290° C. at a rate of 50 kg/h in a melting extruder (model ZSK 32 MC, Coperion Werner & Pfleiderer) in order to be introduced directly thereafter into the stripping apparatus.
Example 1
[0078] The melt produced in the melting extruder is [conveyed] into a device according to DE 4 447 422 C2 with a rotor diameter of 620 mm and a ratio of rotor diameter-to-length of 0.8, which is operated at a rotational speed of 1.3 revolutions per minute at 290° C. and 1 mbar absolute. The filling level is adjusted such that an average residence time of 20 minutes is obtained. The melt is discharged with a gear pump via a nozzle, shaped into bristles, cooled and pelletised. The data obtained are shown in Table 1.
Comparative Example 1
[0079] As Example 1, but using an apparatus according to DE 4 447 422 C2 with a rotor diameter of 620 mm and rotor diameter-to-length ratio of 3. The rotational speed, pressure and temperature are as in Example 1, but the average residence time is 90 minutes.
Comparative Example 2
[0080] The melt produced in the melting extruder is conveyed into a model ZSK 40 degassing screw machine from Werner & Pfleiderer with a screw diameter of 40 mm and a ratio of external to root diameter of the screws of 1.55. The degassing screw machine, which is operated at a wall temperature of 300° C., has two degassing zones. The first degassing zone is operated at atmospheric pressure. 0.25% by mass of nitrogen, relative to the quantity of melt, is apportioned before the second degassing zone. The pressure in the second degassing zone is 2 mbar absolute. The melt is discharged via a nozzle, shaped into a plurality of strands, cooled and pelletised. The data obtained are shown in Table 1.
Comparative Example 3
[0081] The melt produced in the melting extruder is passed into a strand evaporator, which is heated to 290° C. and is at a vacuum of 1 mbar absolute. The melt is here subdivided into strands by means of a spinneret plate with 150 bores, each of a diameter of 3 mm, the strands free-falling for 3 m in the cabinet. The melt coalesces on the base and is discharged with a gear pump via a nozzle, shaped into a plurality of strands, cooled and pelletised. The data obtained are shown in Table 1.
TABLE 1 Relative DPC BPA Phenol viscosity [ppm] [ppm] [ppm] YI Initial product 1.204 520 11 76 1.9 Example 1 1.208 50 5 49 2.3 Comparative 1.211 45 6 55 3.4 Example 1 Comparative 1.205 175 8 67 2.5 Example 2 Comparative 1.205 220 8 70 2.4 Example 3
[0082] Although the invention has been described in detail in the foregoing for the purpose of illustration, it is to be understood that such detail is solely for that purpose and that variations can be made therein by those skilled in the art without departing from the spirit and scope of the invention except as it may be limited by the claims.
|
A process for stripping volatile constituents from polymer melts is disclosed. The process entails introducing the polymer melt into a horizontally oriented cylindrical device that contains a plurality of perforated disks rotating about a common horizontally oriented, externally driven shaft bringing the melt and disks into contact in a manner calculated to constantly renew the surface of the melt to be stripped. Also disclosed is an apparatus suitable for the process.
| 2
|
CROSS-REFERENCE TO RELATED APPLICATION
[0001] Not applicable.
STATEMENT OF FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not applicable.
BACKGROUND OF THE INVENTION
[0003] This invention relates to sinks. In particular, this invention relates to utility sinks such as laundry sinks.
[0004] Although many clothes are laundered using modern washing machines and dryers, some types of fabrics still require hand washing. Although washtubs for hand washing fabrics were once commonplace, it is now rather rare for individuals to have a dedicated washtub. Thus, most hand washing, if not performed by a professional cleaner, is done using an available sink.
[0005] Typically, hand washing of clothes and other fabrics is performed by plugging the available sink, filling the sink with water of an appropriate temperature, adding cleaner, and allowing the fabrics to soak. After scrubbing the clothes, the sink is drained and the clothes are rinsed. The clothes may then be wrung out and hang dried.
[0006] However, it can be inconvenient to commit a sink to washing clothes and fabrics since this renders the sink temporarily inaccessible for other uses such as, for example, the washing of hands or other items. As many utility sinks are used for a variety of purposes, surface of the sink can become soiled. Particularly when these substances are oily or could stain the clothes, it may be undesirable to use an all-purpose sink for hand washing.
[0007] Hence, a need exists for improved means of hand washing fabrics. In particular, there is a need for a better way to hand wash fabrics that does not require the use of antiquated devices, such as washtubs.
SUMMARY OF THE INVENTION
[0008] The present invention provides a utility sink comprising a sink and a bucket. The sink has a basin extending from an upper edge to a drain. The bucket has walls extending to a lip and has at least one opening formed in a side portion of the walls. The lip is configured to selectively contact the upper edge of the basin such that the bucket is suspended in the basin. The at least one opening of the bucket, in addition to facilitating handling, provides a form of overflow when the bucket is suspended in the basin of the sink, such that the at least one opening places an interior volume of the bucket and the basin of the sink in communication with one another.
[0009] Additionally, the bucket may have a structure conducive to the openings performing as pour spouts. The side portion of the walls may extend from a base portion of the walls at a non-right angle. The at least one opening may be located on the walls proximate a radiused transition between the side portion of the walls and the lip. Thus, the at least one opening may located on a non-vertical plane that promotes pouring out of the handles at relatively low angle of tilt for the bucket.
[0010] Further, a portion of the lip may raises around the at least one opening in the bucket such that the at least one opening is accessible from between the sink and the bucket. In this way, the bucket may be removed or lifted from the sink in an ergonomic manner.
[0011] According to one aspect of the invention, when the bucket is suspended from the upper edge of the sink, the lip covers at least half of the upper edge. Additionally, a rack can be placed on a floor of the basin to cover the drain and may further support the bucket.
[0012] The present invention can further include a shallow tray having an outer rim that selectively mates with the lip of the bucket. The shallow tray can have at least one opening formed therein. When the shallow tray mates with the lip of the bucket, the at least one opening of the shallow tray can nest over the at least one openings of the bucket. The shallow tray may include a plurality of holes formed therein. The shallow tray may also include a central larger hole that facilitates the hanging of the shallow tray between uses.
[0013] According to another aspect of the invention a utility sink is provided comprising a sink, a rack, a bucket, and a shallow tray. The sink has a basin extending from an upper edge to a drain. The rack is placed on a floor of the basin such that the rack covers the drain. The bucket has walls extending to a lip and having at least one opening. A side portion of the walls is angled away from a base portion of the bucket. The at least one opening is located on the walls proximate a radiused transition between the side portion of the walls and the lip. Accordingly, the at least one opening is not located on a vertical plane. Further, a portion of the lip is raised around the at least one opening in the bucket. The shallow tray has an outer rim that selectively mates with the lip of the bucket. The at least one opening of the bucket, in addition to facilitating handling, provides a form of overflow when the bucket is positioned in the basin of the sink and filled with water. This overflow is possible because the at least one opening places an interior volume of the bucket and the basin of the sink in communication with one another
[0014] Thus, the present invention provides a utility sink for the hand washing of fabrics that has a removable bucket. When the bucket is suspended above the basin of the sink, the bucket can be filled with water for the hand washing of clothes. The bucket openings place the interior volume of the bucket with the basin such that when the water level in the bucket exceeds the height of the openings, the water in the bucket overflows into the basin and can flow down the drain.
[0015] Moreover, once the bucket is filled with water, the bucket can be temporarily removed from the basin of the sink to make the sink available for other uses while hand washing, soaking, and the like of clothes is performed in the bucket. Then, the bucket may either be returned to the sink, or one of the openings may be used as a pour spout to empty the water contained in the bucket back into the sink to drain.
[0016] When the bucket is suspended above the basin, this configuration also provides a form of overflow rinsing. The clothes to be rinsed are placed in the bucket which is suspended in the basin. Water from a faucet fills the bucket until the water begins to overflow from the openings of the bucket into the basin. The continual flow of water into and out of the bucket rinses the clothes contained the bucket. Because the clothes do not cover the drain, the chance that the drain will be blocked during rinsing is minimalized. Thus, clothes can be rinsed without close observation by the cleaner.
[0017] These and still other advantages of the invention will be apparent from the detailed description and drawings. What follows is merely a description of a preferred embodiment of the present invention. To assess the full scope of the invention the claims should be looked to as the preferred embodiment is not intended to be the only embodiment within the scope of the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] FIG. 1 is a perspective view of a utility sink with a bucket, a shallow tray, and a base tray shown removed from the sink;
[0019] FIG. 2 is a perspective view of the utility sink with the bucket positioned in the basin of the sink;
[0020] FIG. 3 is a perspective view of the utility sink with the bucket positioned in the basin of the sink and the shallow tray placed over the bucket;
[0021] FIG. 4 is a perspective view of the sink;
[0022] FIG. 5 is a cross-sectional side view of the sink taken along line 5 - 5 of FIG. 4 ;
[0023] FIG. 6 is a cross-sectional side view of the sink along line 6 - 6 of FIG. 4 ;
[0024] FIG. 7 is a perspective view of the bucket;
[0025] FIG. 8 is a top plan view of the bucket;
[0026] FIG. 9 is a cross-sectional side view of the bucket along line 9 - 9 of FIG. 8 ;
[0027] FIG. 10 is another cross-sectional side view of the bucket along line 10 - 10 of FIG. 8 ;
[0028] FIG. 11 is a perspective view of the shallow tray;
[0029] FIG. 12 is a top plan view of the shallow tray; and
[0030] FIG. 13 is a cross-sectional side view of the shallow tray along line 13 - 13 of FIG. 12 ;
[0031] FIG. 14 is another cross-sectional side view of the shallow tray along line 14 - 14 of FIG. 12 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0032] Referring now to FIG. 1 , the utility sink 10 is shown which includes a sink 12 with a basin 14 , a rack 16 (shown hung on a wall in FIG. 1 ), a bucket 18 (shown on a countertop 20 in FIG. 1 ), and a shallow tray 22 (shown hung on the wall in FIG. 1 ). A faucet 24 that provides water extends over the sink 12 .
[0033] Referring now to FIGS. 4-6 , the sink 12 has a flanged portion 26 that extends from the basin 14 . As shown, the flanged portion 26 of the sink 12 is rectangular with rounded corners. The flanged portion 26 may assist in supporting the sink 12 in the countertop 20 . The flanged portion 26 and the basin 14 meet an upper edge 28 of the basin 14 . The upper edge 28 provides a radiused transition between the flanged portion 26 and the basin 14 . The basin 14 then extends down along side walls 30 to a base 32 of the sink 12 . The base 32 of the sink 12 has a drain 34 which can be connected to a waste water pipe (not shown).
[0034] As the side walls 30 basin 14 extend from the upper edge 28 down towards the base 32 and the drain 34 , they angle slightly inward (i.e., towards the drain). Likewise, the base 32 angles slightly downward to the drain 34 . This geometry encourages any water filling the basin 14 to be directed towards the drain 34 .
[0035] Referring now to FIGS. 7-10 , further details of the bucket 18 are shown. The bucket 18 has walls including a base portion 36 and side portion 38 extending to a lip 40 . The side portion 38 angle outward from the base portion 36 . The side portion 38 have a transition 43 into the lip 40 . The walls have at least one opening 42 formed therein. As shown, the bucket 18 has two such openings formed proximate the transition 43 spanning the side portion 38 of the walls and the lip 40 .
[0036] Referring now to FIGS. 11-14 , the shallow tray 22 is shown in further detail. The shallow tray 22 has a flat portion 44 having a plurality of holes 46 . The flat portion 44 can also include a large hole 48 that may be suitable for hanging the shallow tray 22 from a hook 49 , such as is shown in FIGS. 1 and 2 , so that the shallow tray 22 can be dried. The flat portion 44 has short side walls 50 that extend to an outer rim 52 . At least one opening 54 is formed in the shallow tray 22 . As shown, the shallow tray 22 has two openings 54 formed in the short side walls 50 and outer rim 52 .
[0037] Referring back to FIG. 2 , the utility sink 10 is shown with the rack 16 inserted into the bottom of the sink 12 and the bucket 18 received in the basin 14 . In this arrangement, the lip 40 of the bucket 18 contacts the upper edge 28 of the basin 14 of the sink 12 to suspend the bucket 18 in the basin 14 . It is contemplated that in some configurations, the lip 40 may cover at least half of the upper edge 28 of the basin 14 .
[0038] The rack 16 may provide additional support for the bucket 18 , particularly if the bucket 18 is filled with water. Further, the rack 16 covers the drain 34 . The rack 16 has a structure that permits water to flow past the rack 16 and down the drain 34 , but will prevent items such as clothing from clogging the drain 34 . For example, the rack 16 may have a mesh surface similar to the shallow tray 22 or be a wire tray.
[0039] It is also contemplated that the bucket 18 may not be suspended in the basin 14 , but rather solely supported by the rack 16 . Such a configuration would require constructing the rack 16 and bucket 18 such that for a given sink depth, the lip 40 of the bucket does not engage the upper edge 28 of the sink 12 . In such an arrangement, it is contemplated that as the openings 42 would still be in the basin 14 , that the openings 42 could still perform an overflow function and, as the bucket 18 sits on the rack 16 so that the bucket does not block the drain 34 , the overflow water would be permitted to flow down the drain 34 .
[0040] Importantly, when the bucket 18 is suspended in the basin 14 (or placed on a rack 16 in the basin 14 ), the openings 42 of the bucket 18 place the inner volume of the bucket 18 and the basin 14 in fluid communication with one another. Thus, when the bucket 18 is filled with water by the faucet 24 and the water level in the bucket 18 reaches the openings 42 , the excess water overflows through the openings 42 and into the basin 14 of the sink 12 .
[0041] It should be appreciated that in addition to providing overflow capabilities, the openings 42 of the bucket 18 may serve as a pouring spout. This may be beneficial when the bucket 18 is filled with water, the clothes and cleaner are placed in the bucket 18 , and left to soak outside of the basin 14 . When the water in the bucket 18 needs to be emptied, the bucket 18 may be tilted such that the water runs out of one of the openings 42 . The openings 42 may be formed on a non-vertical surface for surface to easy pouring. For example, if the openings 42 are formed on the angled side portion 38 of the walls as shown, it reduces the angle at which the bucket 18 must be tilted before pouring action begins (i.e., the water level will more quickly approach the openings 42 when the side portion 38 of the walls are angled).
[0042] Further the openings 42 of the bucket 18 can serve as handles for lifting the bucket 18 . In one form, the lip 40 is raised around the openings 42 such that, when the lip 40 contacts the upper edge 28 of the basin 14 , the openings 42 can be accessed from between the bucket 18 and the sink 12 . This provides an ergonomic structure for lifting as the fingers of the individual lifting the bucket 18 from the sink 12 can go into the openings 42 from the outside, rather than the inside, of the bucket 18 .
[0043] Referring now to FIG. 3 , the utility sink 10 of FIG. 2 is shown with the shallow tray 22 further placed on top of the bucket 18 . The outer rim 52 of the shallow tray 22 may mate with the lip 40 of the bucket 18 . In this arrangement, the openings 54 of the shallow tray 22 may nest or partially nest in the openings 42 of the bucket 18 . This arrangement makes it easy to lift both the bucket 18 and the shallow tray 22 at the same time. When using the openings 42 as a pouring spout, it is also contemplated that the outer rim 52 of the shallow tray 22 may be held against the lip 40 of the bucket 18 , such that pouring can occur out of unobstructed openings 42 while retaining any solid items, such as clothing, in the bucket.
[0044] The shallow tray 22 may also be used as a scrubbing surface during the hand washing of fabrics. In particular, the plurality of holes 46 located in the flat portion 44 provides a surface with sufficient abrasion for scrubbing while also permitting the water to pass through it. It is contemplated that scrubbing may occur when the shallow tray 22 is mated to the lip 40 of the bucket 18 or when the shallow tray is separated from the bucket 18 .
[0045] Thus, the present invention provides a utility sink that can be used to hand wash clothes or other fabric items. As the bucket 18 can be suspended in the basin 14 , hand washed clothes are less likely to come into contact with contaminants found on the inner surface of a basin 14 of the sink 12 . Moreover, since the bucket 18 can be removed from the sink 12 during soaking, the utility sink 10 can be used for other operations while the clothes are being soaked.
[0046] Although the present invention has been described with reference to washing clothes, it is contemplated that the utility sink may be useful any application in which it is desirable to have a bucket that can be suspended by, but is also removable from, a basin.
[0047] Many modifications and variations to this preferred embodiment will be apparent to those skilled in the art, which will be within the spirit and scope of the invention. Therefore, the invention should not be limited to the described embodiment. To ascertain the full scope of the invention, the following claims should be referenced.
INDUSTRIAL APPLICABILITY
[0048] The invention provides a utility sink for the hand washing of clothing.
|
A utility sink system is disclosed comprising a sink and a bucket. The sink has a basin extending from an upper edge to a drain. The bucket has walls extending to a lip and has at least one opening formed therein. The lip is configured to contact the upper edge of the basin such that the bucket is suspended in the basin. The at least one opening of the bucket, in addition to facilitating handling, may provide a form of overflow when the bucket is suspended in the basin of the sink, such that the at least one opening places an interior volume of the bucket and the basin of the sink in communication with one another. Further, the at least one opening of the bucket may provide a pouring spout.
| 3
|
RELATED APPLICATIONS
This application claims priority from provisional 60/166,649 filed Nov. 19, 1999, entitled “Special NiFe Deposition Process To Reduce Surface Roughness And Fly Height Of Multilayer Media,” the entire disclosure of which is hereby incorporated herein by reference.
CROSS REFERENCE TO RELATED APPLICATIONS
This application discloses subject matter related to subject matter disclosed in co-pending U.S. patent applications: Ser. No. 09/496,341, filed on Feb. 2, 2000; Ser. No. 09/634,253, filed Aug. 7, 2000; Ser. No. 09/612,319, filed on Jul. 7, 2000; Ser. No. 09/433,377, filed on Nov. 3, 1999 now U.S. Pat. No. 6,268,075; Ser. No. 09/433,375, filed on Nov. 3, 1999 now U.S. Pat. No. 6,381,200; Ser. No. 60/109,230, filed on Nov. 18, 1998; Ser. No. 09/433,378, filed on Nov. 3, 1999 now U.S. Pat. No. 6,324,181; and Ser. No. 09/421,393, filed on Oct. 20, 1999, now U.S. Pat. No. 6,335,063, incorporated herein by reference.
TECHNICAL FIELD
The present invention relates to the recording, storage and reading of magnetic data, particularly rotatable recording media, such as thin film magnetic disks having smooth surfaces for data zone. The invention has particular applicability to high density recording media exhibiting low noise and having improved flying stability, glide performance and head-media interface reliability for providing zero glide hits.
BACKGROUND ART
The requirements for high areal density impose increasingly greater requirements on magnetic recording media in terms of coercivity, remanent squareness, low medium noise and narrow track recording performance. Data are written onto and read from a rapidly rotating recording disk by means of a magnetic head transducer assembly that flies closely over the surface of the disk.
It is considered desirable during reading and recording operations to maintain each transducer head as close to its associated recording surface as possible, i.e., to minimize the flying height of the head. This objective becomes particularly significant as the areal recording density increases. The areal density (Mbits/in 2 ) is the recording density per unit area and is equal to the track density (TPI) in terms of tracks per inch times the linear density (BPI) in terms of bits per inch.
The increasing demands for higher areal recording density impose increasingly greater demands on flying the head lower because the output voltage of a disk drive (or the readback signal of a reader head in disk drive) is proportional to 1/exp(HMS), where HMS is the space between the head and the media. Therefore, a smooth recording surface is preferred, as well as a smooth opposing surface of the associated transducer head, thereby permitting the head and the disk to be positioned in closer proximity with an attendant increase in predictability and consistent behavior of the air bearing supporting the head.
In recent years, considerable effort has been expended to achieve high areal recording density. Among the recognized significant factors affecting recording density are magnetic remanance (Mr), coercivity, coercivity squareness (S*), signal/noise ratio, and flying height, which is the distance at which a read/write head floats above the spinning disk. Prior approaches to achieve increased areal recording density for longitudinal recording involve the use of dual magnetic layers separated by a non-magnetic layer as in Teng et al., U.S. Pat. No. 5,462,796, and the use of a gradient magnetic layer interposed between two magnetic layers as in Lal et al., U.S. Pat. No. 5,432,012.
However, the goal of achieving a rigid disk recording medium having an areal recording density of about 100 Gb/in 2 has remained elusive. In particular, the requirement to further reduce the flying height of the head imposed by increasingly higher recording density and capacity renders the disk drive particularly vulnerable to head crash due to accidental glide hits of the head and media. To avoid glide hits, an accurately controlled movement of the head and a smooth surface of data zone are desired.
It is extremely difficult to produce a magnetic recording medium satisfying such demanding requirements, particularly a high-density magnetic rigid disk medium for longitudinal and perpendicular recording. The magnetic anisotropy of longitudinal and perpendicular recording media makes the easily magnetized direction of the media located in the film plane and perpendicular to the film plane, respectively. The remanent magnetic moment of the magnetic media after magnetic recording or writing of longitudinal and perpendicular media is located in the film plane and perpendicular to the film plane, respectively.
In theory, perpendicular media is capable of considerably higher linear data density. Generally, this possibility stems from the fact that information is stored in perpendicular media in discrete domains having opposite magnetization to the magnetization found in the surrounding areas. Such domains can potentially reside in crystals in the media. Typically the information is read from the media through use of a magnetic head that converts local discontinuities present in the discrete domains of perpendicular magnetization into electrical fields which can then be processed as information.
However, between the discrete domains of magnetization, magnetization parallel to the surface of the media, or subdomains or opposite magnetization, are usually present. This is particularly true in situations where remanent magnetization of a layer is significantly smaller than the saturation magnetization of the media. In such situations, the transitions between the domains can cause undesirable electronic signals stemming from, essentially, magnetic noise.
Several terms that are important in describing magnetic recording media are explained below. Coercivity essentially refers to how firmly the media holds a particular orientation of magnetization. For example, how much energy is required to cause a crystal in the media to change orientation. On a magnetization hysteresis (M-H) curve, the required applied magnetic field to reduce the magnetization of the material to zero is called coercivity Hc. Permeability (μ) is equal to B/H, where B is the flux density and H is the applied magnetic field.
The easy axis of magnetization of a crystal is the direction of spontaneous domain magnetization in the demagnetized state. The direction of the easy axis of magnetization can be detected on M-H curves. Along the easy axis of magnetization, the M-H curve is forms a square. Along the hard axis direction, the M-H curve is skewed.
Anisotropy refers to the energy stored in a crystal by virtue of the work done in rotating the magnetization of a domain of the crystal away from the easy axis of magnetization. Output basically refers to the strength of the flux created by the media to read the media. Media noise comes from the recording medium. When a magnetic pulse and a transition is written during recording, there is a noise when the signal is being readback.
Some materials change dimension when exposed to a magnetic field. This effect is called magnetostriction. Most NiFe compositions exhibit magnetostriction, except the composition of Ni 81 Fe 19 .
A multilayer superlattice has a structure with many interfaces of magnetic/non-magnetic layers. A bilayer superlattice [A/B]n has n bilayers stacked together to form a superlattice, e.g., [Co/Pt]n, [Co/Pd]n, [CoX/Pt]n, [CoX/Pd]n, where X=Cr, B, etc. The thickness of layers A and B can vary from about 3 Å to about 10 Å and from about 5 Å to about 20 Å, respectively.
A soft magnetic layer (also referred as “keeper layer”) is a layer on the substrate of a magnetic recording medium that gives better writing efficiency by pulling the magnetic flux down from the writing pole of a head of the magnetic recording medium. Soft magnetic layers are made of soft magnetic materials. Soft magnetic material is one of the two kinds of commonly available magnetic materials. One kind has a high coercivity and is called hard magnetic material, e.g., CoCr, CoCrTa and CoCrPt. Because it has high coercivity, it is “hard” to change the magnetization direction unless a strong reverse magnetic field is applied. Another kind is has a very low coercivity in the range of 0.1 Oe to 500 Oe and is called a soft magnetic material, e.g., NiFe, CoZrNb, FeAlNx. Because it has a low coercivity, it is easy (“soft”) to change the magnetization direction with a very small reverse magnetic field. “Hard” and “soft” magnetic materials in the context of this invention are not related to mechanical softness or hardness of the material.
In order to undertake perpendicular recording, it is necessary to utilize a magnetic recording media having perpendicular anisotropy. Perpendicular anisotropy is essentially due to a crystal structure of the magnetic material that creates a magnetic moment perpendicular to the surface of the media. One typical perpendicular magnetic material is the alloy cobalt-chromium (CoCr).
A substrate material conventionally employed in producing magnetic recording rigid disks comprises an aluminum-magnesium (Al—Mg) alloy. Such Al—Mg alloys are typically electrolessly plated with a layer of NiP at a thickness of about 15 microns to increase the hardness of the substrates, thereby providing a suitable surface for polishing to provide the requisite surface roughness or texture.
Other substrate materials have been employed, such as glass, e.g., an amorphous glass, glass-ceramic material which comprise a mixture of amorphous and crystalline materials, and ceramic materials. Glass-ceramic materials do not normally exhibit a crystalline surface. Glasses and glass-ceramics generally exhibit high resistance to shocks.
A conventional longitudinal recording disk medium is depicted in FIG. 1 and typically comprises a non-magnetic substrate 10 having sequentially deposited on each side thereof an underlayer 11 , 11 ′, such as chromium (Cr) or Cr-alloy, a magnetic layer 12 , 12 ′, typically comprising a cobalt (Co)-base alloy, and a protective overcoat 13 , 13 ′, typically containing carbon. Conventional practices also comprise bonding a lubricant topcoat (not shown) to the protective overcoat. Underlayer 11 , 11 ′, magnetic layer 12 , 12 ′, and protective overcoat 13 , 13 ′, are typically deposited by sputtering techniques. The Co-base alloy magnetic layer deposited by conventional techniques normally comprises polycrystallites epitaxially grown on the polycrystal Cr or Cr-alloy underlayer. A conventional perpendicular recording disk medium is similar to the longitudinal recording medium depicted in FIG. 1, but does not comprise Cr-containing underlayers.
Conventional methods for manufacturing longitudinal magnetic recording medium with a glass or glass-ceramic substrate comprise applying a seed layer between the substrate and underlayer. A conventional seed layer seeds the nucleation of a particular crystallographic texture of the underlayer.
Conventional Cr-alloy underlayers comprise vanadium (V), titanium (Ti), tungsten (W) or molybdenum (Mo). Other conventional magnetic layers are CoCrTa, CoCrPtB, CoCrPt, CoCrPtTaNb and CoNiCr.
The seed layer, underlayer, and magnetic layer are conventionally sequentially sputter deposited on the substrate in an inert gas atmosphere, such as an atmosphere of pure argon. A conventional carbon overcoat is typically deposited in argon with nitrogen, hydrogen or ethylene. Conventional lubricant topcoats are typically about 20 Å thick.
Tang et al., U.S. Pat. No. 5,750,270, discloses multi-layer magnetic recording media incorporating a soft magnetic layer for better writing efficiency. Tang et al. discloses that NiFe with very low magnetostriction, low coercivity, and high permeability is one of the preferred materials as the soft magnetic layer for perpendicular recording. The thickness of the soft magnetic layer may require to be as thick as 5000 Å. However, this inventor found that with the conventional sputtering process using Argon sputter gas, the surface roughness increases as the thickness of NiFe increases. In particular, when the thickness of the Argon sputtered NiFe layer is about 5000 Å, the surface roughness of the NiFe layer is high, which causes the top surface of media to also have a high roughness. This in turn could cause head crash due to accidental glide hits of the head and media.
Therefore, there exists a need for technology enabling the use of a structure that could increase the medium coercivity by increasing the interfacial anisotropy and provide a smooth topography of the soft magnetic layer of a recording medium.
SUMMARY OF THE INVENTION
During the course of the present invention, it was found that a multilayer magnetic recording medium comprising a multilayer superlattice could have a smooth topography of the soft magnetic layer of a recording medium by using a special process for thick NiFe deposition. This process can reduce surface roughness of thin films remarkably, as well improve the soft magnetic properties of NiFe keeper layer. Therefore, the glide height performance could be improved.
This inventor unexpectedly discovered that the presence of interstitial nitrogen in a soft magnetic layer greatly reduces the surface roughness of the soft magnetic layer as compared to another soft magnetic layer without interstitial nitrogen. “Interstitial nitrogen” refers to nitrogen within the interstices of the soft magnetic layer. Interstitial nitrogen is different from nitrogen in the material forming the soft magnetic layer. For example, FeAlNx is a soft magnetic material but nitrogen of FeAlNx is not interstitial nitrogen. Interstitial nitrogen could be nitrogen by itself or nitrogen of a nitrogen-containing material that is not a soft magnetic material.
In particular, with the sputtering gas ratio Ar/Nitrogen at 90:10 (i.e. 10% of nitrogen concentration), the coercivity on the NiFe could be improved from a few hundred oersted (which sputtered with pure argon gas) to only a few oersted in the direction of easy axis of magnetization. The process with Ar/nitrogen mixture gas could also reduce the surface roughness of NiFe film by half.
The present invention is a magnetic recording medium comprising a substrate, a multilayer superlattice comprising a magnetic layer and a non-magnetic layer and a soft magnetic layer comprising interstitial nitrogen interposed between the substrate and the multilayer superlattice.
An embodiment of the present invention is a method of manufacturing a magnetic recording medium, the method comprising sputter depositing a soft magnetic layer comprising interstitial nitrogen on a substrate; and sputter depositing a multi layer superlattice comprising a magnetic layer and a non-magnetic layer on the soft magnetic layer.
Another embodiment of this invention is a magnetic recording medium comprising a substrate; a multilayer superlattice comprising a magnetic layer and a non-magnetic layer and a soft magnetic layer interposed between the substrate and the multilayer superlattice, wherein the soft magnetic layer comprises a means for reducing the surface roughness of the soft magnetic layer. Embodiments of the means for reducing the surface roughness of the soft magnetic layer include, but are not limited to, interstitial nitrogen or any other material in the soft magnetic layer, wherein the other material is capable of causing the soft magnetic layer to have a smooth surface. For example, the other material could be a lubricant or an additive in the soft magnetic layer.
Additional advantages and other features of the present invention will be set forth in part in the description which follows and in part will become apparent to those having ordinary skill in the art upon examination of the following or may be learned from the practice of the present invention. The advantages of the present invention may be realized and obtained as particularly pointed out in the appended claims. As will be realized, the present invention is capable of other and different embodiments, and its several details are capable of modifications in various obvious respects, all without departing from the present invention. The drawings and description are to be regarded as illustrative in nature, and not as restrictive.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 schematically shows a conventional magnetic recording medium structure (Prior Art).
FIG. 2 schematically shows a magnetic recording medium structure comprising a superlattice multilayer in accordance with an embodiment of the present invention.
DESCRIPTION OF THE INVENTION
The present invention enables the manufacture of magnetic recording media comprising a multilayer superlattice and exhibiting high coercivity and low surface roughness of the soft magnetic layer. This media is suitable for high density longitudinal and perpendicular magnetic recording. The anisotropy of the media could be increased by multilayer interfacial anisotropy while the surface roughness of the soft magnetic layer could be reduced by the presence of interstitial nitrogen in the soft magnetic layer.
These objects of this invention are achieved in accordance with the embodiments by strategically forming a soft magnetic layer comprising interstitial nitrogen on a substrate of media comprising the multilayer superlattice. The soft magnetic layer could be sputter deposited directly on the substrate or on a soft underlayer located on the substrate. In another embodiment, the soft magnetic layer could be coated.
Embodiments of the substrate include any substrate made of a glass or glass-ceramic, NiP/Al, metal alloys, plastic/polymer material, ceramic, glass-polymer, composite materials or other non-magnetic materials.
In one embodiment, the soft magnetic layer has a coercivity of about 0.1 Oe to about 50 Oe, preferably 0.15 Oe to 10 Oe, along an easy axis of magnetization.
In one embodiment, the magnetic medium could have a coercivity of more than 2000 Oe, more preferably more than 3000 Oe, and most preferably more than 4000 Oe. The media could have a coercivity of 5000 Oe or more. The multilayer superlattice could comprise 5 to 100 bilayers of the magnetic layer and the non-magnetic layer, more preferably 10 to 80 bilayers, and most preferably 20 to 50 bilayers. The bilayers could be Co/Pd bilayers or Co/Pt bilayers or CoCr/Pd bilayers, or CoCrB/Pd bilayers. The magnetic layer could have a thickness of about 2 Å to about 10 Å, more preferably about 3 Å to about 8 Å, most preferably about 4 Å to about 6 Å. The non-magnetic layer could have a thickness of about 3 Å to about 20 Å, more preferably about 5 Å to about 15 Å, most preferably about 8 Å to about 12 Å. The soft magnetic layer could advantageously be deposited at a total thickness of about 100 Å to about 10,000 Å, preferably about 500 Å to about 5,000 Å, most preferably about 1,000 Å to about 3,000 Å. The soft magnetic layer could be sputter deposited employing a target containing Ni and Fe, of which the target preferably contains more Ni than Fe. Optionally, one or more elements such as B, W, Ta, Zr, P, Pd, Co, Cr, and Nb could be included in target. The magnetic recording medium could further comprise an underlayer and/or a seedlayer above or below the soft magnetic layer. The underlayer and/or seedlayer could be NiFe, FeAl x N y , FeAlSi, CrZrNb, CoNiFe and any combination of the above. In a preferred embodiment of the magnetic recording medium, the substrate could be a glass substrate or an aluminum substrate, the magnetic layer could be a Co-containing layer and the non-magnetic layer could be a Pd-containing layer.
In one embodiment, the soft magnetic layer is a sputtered NiFe film comprising the interstitial nitrogen and the sputtered NiFe film has a decreasing surface roughness with an increasing power density of a NiFe target for sputtering said NiFe film.
Embodiments of the present invention also comprises surface oxidizing a layer of the recording medium. A surface-oxidized layer is one having more than 0.5 at. % oxygen in a top 50 Å region after in-situ sputter removal of a 40 Å surface layer. In a preferred embodiment, the surface-oxidized layer has more than 10 at. % oxygen in the top 50 Å region after in-situ sputter removal of a 40 Å surface layer. The surface of the soft magnetic layer itself could be oxidized.
Embodiments of the present invention also comprise forming an adhesion enhancement layer, such as Cr or Cr alloy or Ti or Ti alloy, between the soft magnetic layer and the substrate. An adhesion enhancement layer is a sputter-deposited thin film layer in the thickness range of 15 Å to 100 Å that creates a better adhesion between underlayer and substrate. In a preferred embodiment, the adhesion enhancement layer is a sputter-deposited thin film layer in the thickness range of 25 Å to 75 Å.
Embodiments of the present invention comprise sputter-depositing an adhesion enhancement layer that is substantially Cr or a Cr alloy. Suitable Cr alloys include Cr and up to about 30 at. %, e.g., up to about 20 at. % of an alloying element, such as titanium and vanadium. Advantageously, the present invention could be easily integrated into existing production facilities in a cost effective manner, in that the adhesion enhancement could be sputter deposited.
Embodiments of the present invention also comprise a carbon-containing overcoat thereon, such as hydrogenated carbon. As in conventional practices, a lubricant topcoat could be applied on the carbon-containing overcoat.
An embodiment of the present invention is schematically illustrated in FIG. 2 and comprises a substrate 20 . Sequentially deposited on each side of substrate 20 is soft magnetic layer 21 , 21 ′, seedlayer 22 , 22 ′, multilayer superlattice 23 , 23 ′ comprising multiple bilayers of magnetic material 23 a, 23 a′ and non-magnetic material 23 b, 23 b ′, and protective overcoat 24 , 24 ′. Embodiments of the present invention also include a lubricant topcoat (not shown) deposited on protective overcoat 24 , 24 ′.
In particular, FIG. 2 shows the cross section of an embodiment of a multilayer film structure for this invention, which include a soft magnetic layer, a seedlayer, a CoX/Pd (or CoX/Pt) multilayer, an overcoat layer, and a lubrication layer. The substrate material can be glass, ceramics (oxide, nitride, carbide), glass-ceramics, NiP/Al, metals, plastics, metal alloys or composite materials. The soft magnetic layer can be NiFe (81-19), NiFe (50-50), NiFe (45-55), CoNiFe, FeAl-Nitride, (e.g. 2 to 3 atomic percent Al) or any other high magnetic moment material. When the composition of NiFe is Ni 45 Fe 55 , the soft magnetic layer has a high saturation moment (Bsat) while the composition of Ni 81 Fe 19 has zero magnetostriction and is good for the mechanical properties.
The Ar/Nitrogen and high power density processes can be applied on the listed material and other soft layer deposition. The thin seedlayer material can be Pd, Pt, Pd/Pt, Pt/Pd, or other metal, semi-metal, non-metal, oxide, nitride material. The multilayer media can produce perpendicular coercivity higher than 5000 Oe, if the seedlayer thickness higher than 20 Å. The bilayer superlattice has a structure from 5 to 100 bilayers of Co/Pd or Co/Pt or CoX/Pd, or CoX/Pt. Each Co (or CoX) layer has thickness ranged from 2 to 10 Å, preferably, 3 to 4 Å. Each Pd or Pt layer has thickness ranged from 3 to 20 Å, preferably, 7 to 13 Å. The overcoat can be a-C:H, a-C:HxNy, a-C:N, ion beam carbon, cathodic-arc-deposited carbon, or other SiNx, AINx, SiC, and dual layer overcoat material, e.g. SiN/C, AlN/C, and SiC/C. The thickness of overcoat is in the range of 20 Å to 100 Å. The lubricant material can be HMW-Z-Dol, MMW-Z-Dol, Z-Tetraol, AM2001, PFPE, and the other mobile/solid lube mixture or solid lube coating to improve the head-disk interface. With the load/unload mechanism design, solid lube could be one of the candidates for the design of multilayer recording media of this invention.
Advantageously, the present invention could be conducted by sputter depositing the soft magnetic layer, the underlayer, the multilayer superlattice and protective overcoat in an apparatus comprising a plurality of sequentially spaced sputtering chambers. In particular, the multilayer superlattice could be formed by sequentially depositing a magnetic layer and a non-magnetic layer to form multiple bilayers of the magnetic/non-magnetic layers.
EXAMPLES
All samples were fabricated with direct current (DC) magnetron sputtering. Carbon films, if deposited, would be deposited by alternative current (AC) magnetron sputtering. A soft magnetic layer of NiFe is sputter deposited on a NiP/Al substrate using a gas ratio Ar/Nitrogen at 90:10 (i.e. 10% of nitrogen concentration). Since it was desired to measure the effect of NiFe layer on surface roughness, the disk samples of the Examples whose results are shown in Tables 1-3 did not have a Cr/carbon underlayer, a magnetic layer of [Co/Pd]n or [CoCr/Pd]n multilayer, and a carbon overcoat layer.
Optionally, however, as disclosed in co-pending U.S. application Ser. No. 09/634,253, filed Aug. 7, 2000, incorporated herein by reference, all samples could have [Co/Pd]n or [CoCr/Pd]n multilayer, wherein the bilayer number is n=20 and films sputtered at 20 mtorr, to prepare multilayer media. The cobalt thickness could be 3 Å and Pd thickness could be 10 Å.
It was found that the surface roughness of sputtered NiFe films improved as the power density of NiFe targets increases from 3.09 Watts/cm 2 (power at 1 kwatts) to 12.34 Watts/cm 2 (sputtering power at 4 kWatts). Here, the diameter of NiFe target is 8 inches. The area of target is 50.24 in 2 or 324 cm 2 . The sputtering gas pressure is at 10 mtorr and the Ar/N 2 ratio at 90 to 10. Table 1 is the summary of the relationship between the surface average roughness and sputtering power density.
The surface parameters could be measured by atomic force microscope (AFM). The AFM used for this invention has the tradename NanoScope.® The statistics used by the AFM are mostly derived from ASME B46.1 (“Surface Texture: Surface Roughness, Waviness and Law”) available from the American Society of Mechanical Engineers, which is incorporated herein by reference.
In particular, the surface parameters are defined as follows:
(1) Average surface roughness (R a ): Arithmetic average of the absolute values of the surface height deviations measured from a mean plane. The value of the mean plane is measured as the average of all the Z values within an enclosed area. The mean can have a negative value because the Z values are measured relative to the Z value when the microscope is engaged. This value is not corrected for tilt in the plane of the data; therefore, plane fitting or flattening the data will change this value.
R
a
=[|Z
1
|+|Z
2
|+ . . . +|Z
n
|]/N
(2) RMS: This is the standard deviation of the Z values within the enclosed area and is calculated as
RMS =[{Σ( Z i −Z avg ) 2 }/N] 1/2
where Z avg is the average of the Z values within the enclosed area, Z i is the current Z value, and N is the number of points within the enclosed area. The RMS value is not corrected for tilt in the plane of the data; therefore, plane fitting or flattening the data will change this value.
(3) Maximum height (R max ): This the difference in height between the highest and lowest points on the surface relative to the mean plane.
(4) R z : This is the average difference in height between five highest peaks and five lowest valleys relative to the mean plane.
TABLE 1
The relationship between the Surface Roughness Parameters Ra, Rmax,
and Rz and Sputtering Power and Power Density of NiFe Films.
Power
1 kW
2 kW
3 kW
4 kW
Power Density
3.09 w/cm 2
6.17 w/cm 2
9.26 w/cm 2
12.34 cm 2
Ra, Rmax, and
Ra: 1.6 nm
Ra: 0.75 nm
Ra: 0.5 nm
Ra: 0.8 nm
Rz for NiFe
Rmax: 12
Rmax: 5
Rmax: 3.6
Rmax: 5 nm
Film Thickness
nm
nm
nm
at 1000 Å
Rz: 10 nm
Rz: 4.5 nm
Rz: 3.1 nm
Rz: 4.5 nm
Ra, Rmax, and
Ra: 5.2 nm
Ra: 2.1 nm
Ra: 1.6 nm
Ra: 0.76 nm
Rz for NiFe
Rmax: 33
Rmax: 15
Rmax: 12
Rmax: 5.5
Film Thickness
nm
nm
nm
nm
at 3000 Å
Rz: 30 nm
Rz: 13 nm
Rz: 10 nm
Rz: 4.1 nm
Ra, Rmax, and
Ra: 3.7 nm
Ra: 2.2 nm
Ra: 1.6 nm
Ra: 1.0 nm*
Rz for NiFe
Rmax: 27
Rmax: 20
Rmax: 10
Rmax: 7.8
Film Thickness
nm
nm
nm
nm
At 5000 Å
Rz: 22 nm
Rz: 15 nm
Rz: 9.6 nm
Rz: 6.6 nm
If NiFe films were sputtered five times with 1000 Å each time, the Ra was 0.7 nm. In order to show the material effect of process conditions on the surface roughness of the soft magnetic layer, the Ra values of soft magnetic layers, which were sputtered deposited under conditions shown in Table 2, were measured by AFM. The measured values of Ra are shown in Table 3.
TABLE 2
BPS Sputter power vs NiFe Surface Roughness AFM (Ra)
Target
Sputter Power setting
NiFe Thickness
1.0 kw
2.0 kw
3.0 kw
4.0 kw
1000 Å
N1-1K
N1-2K
N1-3K
N1-4K
Sputter Time (sec)
30
15
11
7
AFM Ra (Å)
16
8
5
8
3000 Å
N3-1K
N3-2K
N3-3K
N3-4K
Sputter Time (sec)
90
45
33
21
AFM Ra (Å)
52
21
16
8
5000 Å
N5-1K
N5-2K
N5-3K
N5-4K
N5-4K5X
Sputter Time (sec)
150
75
55
38
8 sec × 5
AFM Ra (Å)
37
22
16
11
7
TABLE 3
Disk conditions
AFM
Disk ID
Sub
Cr/Carbon
NiFe(Å)
CO/Pd(N#)
Carbon(Å)
Ra (Å)
Comment
N1-1K
NiP/Al
no
1000
no
no
16
BPS Sputter 30 sec, 1.0 KW, 10 mtorr Ar/N2 90/10
N1-2K
NiP/Al
no
1000
no
no
8
BPS Sputter 15 sec, 2.0 KW, 10 mtorr Ar/N2 90/10
N1-3K
NiP/Al
no
1000
no
no
5
BPS Sputter 11 sec, 3.0 KW, 10 mtorr Ar/N2 90/10
N1-4K
NiP/Al
no
1000
no
no
8
BPS Sputter 7 sec, 4.0 KW, 10 mtorr Ar/N2 90/10
N3-1K
NiP/Al
no
3000
no
no
52
BPS Sputter 90 sec, 1.0 KW, 10 mtorr Ar/N2 90/10
N3-2K
NiP/Al
no
3000
no
no
21
BPS Sputter 45 sec, 2.0 KW, 10 mtorr Ar/N2 90/10
N3-3K
NiP/Al
no
3000
no
no
16
BPS Sputter 33 sec, 3.0 KW, 10 mtorr Ar/N2 90/10
N3-4K
NiP/Al
no
3000
no
no
6
BPS Sputter 21 sec, 4.0 KW, 10 mtorr Ar/N2 90/10
N5-1K
NiP/Al
no
5000
no
no
37
BPS Sputter 150 sec, 1.0 KW, 10 mtorr Ar/N2 90/10
N5-2K
NiP/Al
no
5000
no
no
26
BPS Sputter 75 sec, 2.0 KW, 10 mtorr Ar/N2 90/10
N5-3K
NiP/Al
no
5000
no
no
16
BPS Sputter 55 sec, 3.0 KW, 10 mtorr Ar/N2 90/10
N5-4K
NiP/Al
no
5000
no
no
10
BPS Sputter 38 sec, 4.0 KW, 10 mtorr Ar/N2 90/10
N5-4K5X
NiP/Al
no
5 × 1000Å(5000Å)
no
no
7
BPS Sputter 4.0 KW, 8 sec × 5, 10 mt Ar/N2 90/10
In Table 2, “BPS sputter” refers to a BPS sputtering machine, where “BPS” stands for Balzers Process Systems, Germany. In Table 3, “N1-1K,” “N1-2K,” “N1-3K” and “N1-4K,” etc. refer to NiFe samples sputtered at 1 KW, 2 KW, 3 KW and 4 KW, respectively. Also, in Table 3, “Sub” refers to the substrate. The term “no” under column “Cr/Carbon” means that the disk samples of Table 3 did not contain a Cr/carbon-containing underlayer, which could optionally have been used. In the term “Co/Pd(N=)” the term “(N=)” refers to the number of layers of Co/Pd sublayers in a multi-layer medium. Since the effect of NiFe on surface roughness was desired to be measured independent of the effect of Co/Pd multilayers, the term “no” under column “Co/Pd(N=)” means that there were no layers of Co or Pd on the NiFe layer of the disks of Table 3. Similarly, since the effect of NiFe on surface roughness was desired to be measured independent of the effect of carbon overcoat layer, the term “no” under column “Carbon(Å)” means that there were no layers of carbon on the NiFe layer of the disks of Table 3.
The results in Tables 2 and 3 show process parameters and AFM roughness Ra data for various NiFe deposition conditions. The surface roughness of sputtered NiFe films could be reduced from 16 Å to 8 Å and 5 Å as the sputter power of NiFe increased from 1 KW to 2 and 3 KW, respectively. The high power sputtering NiFe sample has shown better surface roughness and low glide height performance.
|
A multilayer superlattice having a structure with many interfaces of magnetic/non-magnetic layers could increase the coercivity of a magnetic recording medium by increasing the interfacial anisotropy. A soft magnetic layer comprising interstitial nitrogen between the substrate and the multilayer superlattice reduces the surface roughness between the substrate magnetic layer. This in turn reduces the fly height and boosts the coercivity of the magnetic recording medium.
| 8
|
TECHNICAL FIELD
[0001] The present invention pertains generally to e-commerce and, in particular, to a web-based system and method for conducting and facilitating the sale and purchase of items.
BACKGROUND ART
[0002] Numerous internet websites are available for people to post items for sale. Prospective buyers may review postings and, if they find an item that they want to purchase, purchase the item either directly from the seller (using Craig's List, for example) or through the website (eBay, for example).
SUMMARY OF THE INVENTION
[0003] In one embodiment, the present invention provides a computer implemented method for facilitating the online selling and purchasing of items, comprising: receiving in a facilitator a post from a seller having an item to sell, the post including information about the item, a purchase price, and an amount of any sales commission; providing the seller's post to a broker who is accessing the facilitator; receiving in the facilitator a first purchase request from a first buyer who learned about the item from the broker, the first purchase request including a code provided by the broker, the code including an identification of the broker, the item, and an amount of any discount offered by the broker to the first buyer; receiving in the facilitator payment information, less the discount, from the first buyer; upon receipt in the facilitator of an indication that the first buyer has received the item from the seller, providing the seller with the purchase price, less the commission and discount; and providing the broker with the commission, less the discount.
[0004] In another embodiment, the present invention provides a networked online marketplace facilitator, comprising: a processor; a plurality of network portals coupled to the processor and configured to interconnect sellers of items, prospective buyers of items, and brokers through the facilitator; and memory coupled to the processor. The memory is configured to store instructions for: receiving in the facilitator a post from a seller having an item to sell, the post including information about the item, a purchase price, and an amount of any sales commission; providing the seller's post to a broker who is accessing the facilitator; receiving in the facilitator a first purchase request from a first buyer who learned about the item from the broker, the first purchase request including a code provided by the broker, the code including an identification of the broker, the item, and an amount of any discount offered by the broker to the first buyer; receiving in the facilitator payment information, less the discount, from the first buyer; upon receipt in the facilitator of an indication that the first buyer has received the item from the seller, providing the seller with the purchase price, less the commission and discount; and providing the broker with the commission, less the discount.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] FIG. 1 is a block diagram of an embodiment of a networked on-line marketplace facilitator of the present invention;
[0006] FIG. 2 is a block diagram of an embodiment of a facilitator of the facilitator of FIG. 1 ;
[0007] FIG. 3 is a block diagram illustrating a relationship of a seller, buyer and the facilitator of FIG. 2 ;
[0008] FIG. 4 is a block diagram illustrating a relationship of a seller, broker, and the facilitator of FIG. 2 ;
[0009] FIG. 5 is a block diagram illustrating a relationship of a seller, a broker, buyer, and the facilitator of FIG. 2 ;
[0010] FIG. 6 is a flow chart of one process implemented on the facilitator of FIG. 2 ; and
[0011] FIGS. 7A and 7B are a flow chart of another process implemented on the facilitator of FIG. 2 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0012] The described features, structures, or characteristics of the invention may be combined in any suitable manner in one or more embodiments. In the following description, numerous specific details are provided to provide a thorough understanding of embodiments of the invention. One skilled in the relevant art will recognize, however, that the invention can be practiced without one or more of the specific details, or with other methods, components and so forth. In other instances, well-known structures, materials, or operations are not shown or described in detail to avoid obscuring aspects of the invention.
[0013] Current e-commerce web-based marketplace services are designed to allow buyers and sellers to negotiate and transact the sale of items directly with each other, although payment of the purchase price of an item sold on eBay and other similar services is routed through eBay instead of directly to the seller. The present invention provides an online marketplace that facilitates the sale and purchase of items by accommodating individuals who may not wish to purchase an item but who are able to find those who do outside the sphere of the marketplace itself. These individuals, who are referred to herein as “brokers,” may be anyone and do not actually take possession of the item being sold (except when acting only as buyers) but, rather, provide an avenue to allow the buyer to obtain the item directly from the seller, with payment being routed through the facilitator. Moreover, the facilitator gives a seller the option to offer a commission to brokers as an incentive.
[0014] FIG. 1 is a block diagram of an embodiment of a networked on-line marketplace facilitator 10 of the present invention having a connection with the internet 1 or other network to allow sellers 102 , 104 , 106 , and 108 of items, buyers and prospective buyers 110 , 112 , 114 of items, and brokers 120 , 124 , 124 , 126 to have two-way communication access the facilitator 10 . As illustrated in FIG. 2 , sellers, buyers, and brokers, represented by the seller 104 , the buyer 110 , and the broker 122 , use the internet 1 to interconnect with the facilitator 10 through seller, buyer, and broker network portals 12 A, 12 B, 12 C, respectively. The facilitator 10 may include a memory 14 and a processor 16 coupled to the portals 12 A, 12 B, 12 C. The memory 14 is configured to store instructions to be executed by the processor 16 . The memory 14 is also configured to store a database containing seller, buyer, broker, and item information. It will be appreciated that the single memory 14 block illustrated in FIG. 2 and described herein is merely representative; the instructions and database may be stored on separate physical memory devices. The facilitator 10 may also be configured to provide a website with a display 18 to users over the network 1 to permit sellers, buyers, and brokers, represented again by the seller 104 , the buyer 110 , and the broker 122 , to access the database and view items posted for sale, and log in to view commissions associated with items for sale, and sell, buyer, or broker items. Such access may be provided by selection options that are displayed, such as a seller log-in option 20 , a view-items option 22 , a buyer log-in option 24 , and a broker log-in option 26 .
[0015] In a first scenario, referring to FIG. 3 and the flowchart of FIG. 5 , a seller, such as the seller 104 , wishing to offer an item 200 for sale may access the facilitator 10 using the internet 1 and select the seller log-in option 20 . The seller 104 posts a description of the item 200 (step 300 ), perhaps with a photo, indicates the price (step 302 ), and states the amount of any commission that he or she is will to give (step 304 ). Such information is stored in the database. If a commission is to be offered, the facilitator may require a minimum amount, such as 1% of the sale price. A typical commission may be up to 5%, or even higher.
[0016] A buyer, such as the buyer 110 , may also access the facilitator 10 using the internet 1 and select the view-items option 22 to view information about items for sale, including the item 200 being sold by the seller 104 (step 306 ). If the buyer 110 decides (step 308 ) not to purchase the item 200 , he or she can view other items or exit (step 310 ). If, instead, the buyer 110 decides (step 308 ) to purchase the item 200 , the buyer 110 may select the buyer log-in option 24 and go through the process of paying for the item 200 (step 312 ) using any means offered by the facilitator, such as a credit card, PayPal, Braintree, the service's own payment system (“mobile wallet”), or the like. Before forwarding any money to the seller 104 , the facilitator retains the full commission (step 314 ) and waits until it receives confirmation that the buyer 110 has received the item 200 (step 316 ). The purchase price, less the commission, is then sent to the seller 104 (step 318 ) and the process ends (step 320 ). Alternatively, the facilitator may credit an account of the seller 104 with the purchase price, less the commission.
[0017] In another scenario, referring to FIG. 4 and the flowchart of FIG. 7A , another seller, such as the seller 106 , wishing to offer an item 202 for sale may access the facilitator 10 using the internet 1 and select the seller log-in option 20 . As before, the seller 106 posts a description of the item 202 (step 402 ), perhaps with a photo, indicates the price (step 404 ), and states the amount of any commission that he or she is willing to give (step 406 ).
[0018] A broker, such as the broker 120 , may also access the facilitator 10 using the internet 1 and select the view-items option 22 to view information about items for sale, including the item 202 being sold by the seller 106 (step 408 ). If the broker 120 decides (step 304 ) to purchase the item 202 for him/herself, he or she may select the broker log-in option 26 , view the commission offered with the item 202 , and go through the process of paying for the item 202 , paying the purchase price less a predetermined percentage of the commission, such as 50% (step 412 ). The seller 106 may then send the item 202 to the broker 120 (step 414 ). Before forwarding any money to the seller 106 , the facilitator retains the balance of the commission, such as the remaining 50%, (step 416 ) and waits until it receives confirmation that the broker 120 has received the item 202 . The purchase price, less the commission, is then sent to the seller 106 (step 418 ). Under a different arrangement, the broker 120 may pay the full purchase price to the facilitator which retains the predetermined percentage of the commission and credits an account of the broker with the balance of the commission.
[0019] Referring now to FIG. 5 and the flowcharts of FIG. 7A , continuing onto FIG. 7B , a broker 122 may decide (step 410 ) that he or she can find a buyer for an item 204 offered by a seller 102 instead of purchasing the item 204 for him/herself. Thus, the broker 122 may seek a buyer (step 420 ) through channels outside of the sphere of the facilitator. In doing so, the broker 122 may be in contact with a number of prospective buyers, such as the representative prospective buyers 130 , 132 , 134 in FIG. 5 . This may be word of mouth, special-interest clubs, conventional advertising, Craig's List, eBay, Facebook, Twitter, Instagram, other social networks, among others, or by any other means. As an incentive for a buyer to purchase the item 204 through the broker 122 , the broker 122 may offer a discount off the listed sale price (step 422 ), thereby sharing the commission with the buyer. A prospective buyer, such as the prospective buyer 130 , may view information about the item 204 through the facilitator or through other channels (step 424 ). The prospective buyer 130 may decide (step 426 , FIG. 6B ) not to purchase the item 204 and the process ends (step 428 ). Alternatively, the prospective buyer 130 may decide (step 426 ) to purchase the item 204 .
[0020] The broker 122 may then provide to the formerly prospective buyer 130 , now an actual buyer, (or may already have provided) a link (step 430 ) that enables the buyer 130 to directly access the facilitator server 10 and purchase the item 204 (step 432 ). The link may have a unique code embedded in it that was provided by the facilitator 10 and which identifies the broker 122 and the item 204 , and may also identify any discount offered by the broker 122 . Alternatively, the broker 122 may provide the broker's unique broker/item/discount code to the buyer 130 (step 434 ) which the buyer can enter during checkout (step 436 ) in order to take advantage of the discount offered by the broker 122 .
[0021] In either event, as part of the check-out process, the buyer 130 pays the purchase price, less the discount, to the facilitator using whatever methods the facilitator makes available (step 438 ). As before, the facilitator withholds the commission, less the discount, from the purchase price (step 440 ). After the seller sends the item 204 to the buyer 130 (step 442 ) and the buyer 130 confirms receipt of the item 204 , the facilitator sends the commission, less the discount, to the broker 122 or credits his/her account (step 444 ) and sends the balance to the seller (step 446 ). The transaction is then complete (step 448 ).
[0022] In contrast to conventional e-commerce websites, the facilitator of the present invention encourages more widespread dissemination of information about items for sale. By offering a commission, a seller can provide an incentive for brokers to find buyers for an item using avenues, such as personal contact, the broker's special interest clubs, and the broker's social networks, among others, that are unavailable to the seller. For example, an individual wanting to sell a box of old comic books could use the facilitator of the present invention to post information about the comics. Although any prospective buyer could view the information and purchase, a broker having expertise with comic books could also view the information. Such a broker may have contacts within a group of avid comic book collectors and thus may be able to find more knowledgeable prospective buyers who would better appreciate the value of the comics that the seller is selling. Prospective buyers thus have access to items that they might not otherwise know about. The broker can make money by serving as a middle-man in the transaction. And, by offering a discount to prospective buyers that a broker finds, the broker can provide his or her own incentive for a buyer to enter the broker's code during checkout rather than bypassing the broker as in FIGS. 3 and 5 , thereby ensuring that the broker receives compensation for his/her efforts.
[0023] The description of the present invention has been presented for purposes of illustration and description, but is not intended to be exhaustive or limited to the invention in the form disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art. The embodiments were chosen and described in order to best explain the principles of the invention, the practical application, and to enable others of ordinary skill in the art to understand the invention for various embodiments with various modifications as are suited to the particular use contemplated.
|
A computer implemented method is provided for facilitating the online selling and purchasing of items, comprising: receiving in a facilitator a post from a seller having an item to sell; providing the seller's post to a broker who is accessing the facilitator; receiving in the facilitator a first purchase request from a first buyer who learned about the item from the broker, the first purchase request including an identification code provided by the broker; receiving in the facilitator payment information, less any discount offered by the broker, from the first buyer; upon receipt in the facilitator of an indication that the first buyer has received the item from the seller, providing the seller with the purchase price, less any commission offered by the seller and less the discount; and providing the broker with the commission, less the discount.
| 6
|
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to location finding and tracking of a satellite by an antenna system. Specifically, this invention relates to satellite antenna acquisition via accurate signal identification for reducing the time for acquisition of a correct satellite.
2. Description of Related Art
Fixed satellite and vehicle-mounted in-motion satellite tracking antennas provide users a means to achieve one-way or two-way communication via satellites. In both fixed and in-motion use, satellite antennas need to be positioned correctly in space in order to receive a signal from a desired satellite. In a fixed satellite application, the set up procedure is performed upon installation and generally does not require satellite re-acquisition unless more than one satellite is desired or natural or environmental effects, such as storms or wildlife, disturb the satellite antenna position. In the in-motion use, the satellite antennas need to be positioned correctly each time they are activated, while they are in-motion and each time they lose the satellite signal due to blockage by objects that naturally appear between the satellite antenna and the satellite as the vehicle moves.
The time it takes to reacquire the satellite signal can range from an annoyance to a technology acceptance-limiting event. In a fixed application, although the occurrence of an incorrectly positioned satellite antenna is infrequent, a trained technician is generally required to position the satellite antenna correctly. Satellite service in this case could be down for hours or days. In in-motion use, satellite reacquisition occurs very frequently with significant, but shorter time intervals to correct positioning.
In conventional satellite antenna acquisition steps, whether manual or automatic, the sky is searched by scanning 360 degrees in azimuth and 20 to 70 degrees in elevation angle. Signal detection during scanning is a two-step process:
1. First, the total received in-band signal power is monitored. As soon as the in-band signal power exceeds a certain threshold level, the antenna is held pointed toward that position in space waiting for a set top box to lock on to the signal and confirm the signal lock.
2. Second, the set top box locks and confirms the signal lock.
The antenna scanning speed and the antenna acquisition time are closely related to how fast the power monitoring in Step 1 can be performed and how fast the confirmation from the set top box in Step 2 can be accomplished. Typically, power monitoring can be performed within a few milliseconds. This means that the speed at which the antenna can scan its beam width through the target can never be faster than a few milliseconds.
Beyond the time and effort required to correctly position the satellite antenna and achieving set top box signal lock (typically about 2-3 seconds), the signal acquisition process is problematic because there are many ways a satellite antenna can experience a false lock. Typical examples of false lock include: locking on a wrong satellite with the same frequency; signal power fluctuation due to noise, inaccuracy in power monitoring and detection circuitry; locking onto the sidelobe of other terrestrial radiators at a closer distance; locking on to noise and locking onto a reflected signal from a nearby structure. Each false lock increases the antenna acquisition time by a few seconds.
The design of the antenna acquisition steps is significantly impacted by the false lock and missed detection effects. If the power-monitoring threshold in Step 1 is set high, false lock probability is reduced. However, there is a higher possibility of missed detection. Each time the missed detection occurs, the antenna must scan through the entire cycle then change the threshold again, then scan again, keep on repeating the process, before returning to the correct position for antenna acquisition. This increases the acquisition time significantly. Lowering the power monitoring threshold in Step 1 leads to frequent false lock, each costing a 2 to 3 second penalty (for Step 2) in antenna acquisition time. Thus, false locks can significantly increase the overall antenna acquisition time.
U.S. Pat. No. 5,585,804 describes the use of electronic compasses to decrease the scanning range, thereby speeding up the satellite signal acquisition. However, electronic compasses can be negatively affected by metal structures or magnetic field from conductors carry current of electrical components in the vehicle. And it is almost impossible to have the resolution of less than 10 degree for automobile application. Which make them unreliable in use with most vehicles and tend to be overly costly for large volume cost sensitive applications.
U.S. Pat. No. 5,828,957 describes an antenna acquisition means by searching for and acquiring a strongest pilot channel, searching for signaling channels on the acquired strongest pilot channel and monitoring the acquired signaling channel instead of beam acquisition of a modulated channel. This system has the limitation that the satellite must transmit pilot tone.
U.S. Pat. No. 6,127,967 describes an antenna acquisition means by searching for and acquiring a beacon signal. This system has the limitation that the desired satellite must transmit a beacon signal.
It is desirable to provide an improved approach to significantly reduce false lock error and the time it takes to acquire the desired satellite at a reasonable cost.
SUMMARY OF THE INVENTION
It has been found that in satellite signal acquisition, many factors affect the system performance including:
1. the position in azimuth of the satellite to the original pointing position of the satellite antenna since, the further the original pointing position is away from the satellite antenna, the longer it will take to acquire the satellite under event the best of situations;
2. the position in elevation of the satellite to the original pointing position of the satellite antenna since, the further the original pointing position is away from the satellite antenna, the longer it will take to acquire the satellite under even the best of situations;
3. the number of satellites with nearby frequencies, the more nearby satellite signal frequency congestion, the higher the probability that a false lock will occur;
4. the number of terrestrial or low altitude radiators at a close distance since, the more high-powered sources of signal frequency, the higher the probability that a false lock will occur;
5. the signal reflection since, the more facsimiles of the same signal frequency from the desired satellite, the higher the probability that a false lock will occur; and
6. the noise and interference since too many powerful and errant unwanted signal frequencies increase the probability that a missed detection or false lock will occur.
Each individual factor increases satellite antenna acquisition time and the possibility of false locks.
The present invention positions a satellite antenna using signal identification to accurately determine antenna signal lock and speed the acquisition of the correct satellite. The present invention improves system performance by looking at characteristics of the satellite signal in order to reduce false lock error. The present invention can operate at a comparable or faster speed of conventional power detection schemes.
The advantages of the invention include improved in-motion satellite reception and a faster fixed satellite antenna installation and installation tuning process. The invention will be more fully described by the reference to the following drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a flow diagram of a method for satellite acquisition via signal identification.
FIG. 2 is a schematic diagram of a total DBS downlink signal spectrum.
FIG. 3 is a flow diagram of an alternate embodiment of a method for satellite acquisition via signal identification.
FIG. 4A is a schematic diagram of a satellite acquisition system including a satellite antenna receiver power monitoring circuit.
FIG. 4B is a schematic diagram of an alternate embodiment of a satellite acquisition system including a satellite antenna receiver power monitoring circuit.
FIG. 5 is a schematic diagram of a downconverter.
DETAILED DESCRIPTION
Reference will now be made in greater detail to a preferred embodiment of the invention, an example of which is illustrated in the accompanying drawings. Wherever possible, the same reference numerals will be used throughout the drawings and the description to refer to the same or like parts.
FIG. 1 is a flow diagram of a method for satellite acquisition via signal identification 10 in accordance with the teachings of the present invention. In block 12 , a first signal power of a satellite antenna at a desired first signal frequency is measured at a first position of the satellite antenna. For example, the desired first signal frequency can correspond to a peak of a transponder signal. In one embodiment, the signal is a direct broadcast signal.
FIG. 2 illustrates the characteristics of the direct broadcast satellite (DBS) signal. It carries 32 transponder signals with two circular polarizations. The DBS signal has a total bandwidth of 500 MHz, including thirty-two 24 MHz transponder signals with a 5 MHz spacing between the transponder signals. Sixteen of the transponder signals use right-hand circular polarization and the other sixteen transponder signals use left-hand circular polarization. The transponder signal on the right-handed circular polarization are at 12.224 GHz, 12.253 GHz, and up through 12.661 GHz, and the transponder signal on the left-handed circular polarization are at 12.238 GHz, 12.267 GHz, and up through 12.675 GHz. Accordingly, in this embodiment, power is monitored at a predetermined frequency of a peak of one or more of the DBS transponder signals in block 12 . In alternate embodiments, the satellite signals can be fixed satellite service (FSS) and very small aperture satellite (VAST) signals and predetermined frequencies of the satellite signals can be measured.
Referring to FIG. 1 , a second signal power of a satellite antenna at a desired second signal frequency is measured at the first position of the satellite antenna, in block 14 . In one embodiment, the second signal frequency can be at a spacing between the transponder signal measured in block 12 and an adjacent transponder signal. It is appreciated that the power at the spacing between two adjacent transponder signals should have a lowest value. This typically corresponds to noise level between the adjacent transponders or spectral sidelobe of the two adjacent transponders.
In block 16 , a difference of the first signal power and the second signal power is determined. In block 18 , it is determined if the difference corresponds to a predetermined value. If the difference corresponds to a predetermined value, the satellite antenna is determined to be correctly positioned to receive a signal from the desired satellite and the satellite antenna can be locked at the first position, in block 19 . It has been found that the difference can differ by more than 10 dB. If the difference does not correspond to the predetermined value, the antenna is beam steered or moved to a different satellite position rather than the first position of satellite, in block 20 , and blocks 12 - 18 can be repeated. If the difference exceeds the predetermined value, blocks 12 - 18 can be repeated with a peak frequency of one or more of the transponder signals of the DBS signal for confirmation that satellite is locked. Each of the blocks of method 10 and method 20 can be performed in sequence or in parallel and all the blocks do not have to be performed. Alternatively, the first signal frequency and the second signal frequency can be outside of DBS signal bandwidth as an additional check to confirm signal lock. In this embodiment, the measurements at the two frequencies separated by the same amount do not have a peak and valley of signal power as the first signal frequency and the second signal frequency within the DBS signal bandwidth. The present invention can also be used during antenna tracking to monitor if the antenna stays locked on to the satellite. The satellite antenna can be steered in the azimuth and elevation positions and method 10 and method 20 can be performed at their various positions.
FIG. 3 is a flow diagram of an alternate embodiment of a method for fast satellite acquisition via signal identification 20 . In block 22 , a first signal power of a satellite antenna at a desired first signal frequency is measured at a first position of the satellite antenna at a first polarization. In block 24 , a second signal power of a satellite antenna at a desired second signal frequency is measured at the first position of the satellite antenna at the first polarization. In block 25 , a first difference of the first signal power and the second signal power is determined. In block 26 , a switch to a second polarization is performed and a third signal power is measured at the first signal frequency at the second polarization and a fourth signal power is measured at the second signal frequency at the second polarization. Both the first signal frequency and the second signal frequency can be measured at the first position. In block 28 , a second difference of the third signal power and the fourth signal power is determined. The second polarization is opposite to the first polarization. It has been found that a peak in signal power at a certain frequency at one polarization corresponds to the valley in signal power at the same frequency but with the opposite polarization. In block 29 , it is determined if the first difference and/or the second difference corresponds to a predetermined value. If the first difference and/or the second difference corresponds to a predetermined value, the satellite antenna is determined to be correctly positioned to receive, a signal from the desired satellite and the satellite antenna can be locked at the first position. If the difference does not correspond to the predetermined value, blocks 22 - 28 can be repeated by using a different first signal frequency in blocks 22 and 26 and different second signal frequency in blocks 24 and 26 . For example, blocks 22 - 28 can be repeated with a frequency of a peak of one or more of the transponder signals of the DBS signal. Alternatively, blocks 22 - 28 can be repeated with the first signal frequency in blocks 22 and 26 and the second signal frequency in blocks 24 and 26 measured at a different position of the satellite antenna.
FIG. 4A is a schematic diagram of a satellite acquisition system 40 including a satellite antenna receiver power monitoring circuit. Signal 41 from satellite antenna 42 is amplified with low noise amplifier 44 . Signal 41 is filtered with bandpass filter 45 . Bandpass filter can be a wide bandpass filter having a bandwidth of the entire signal. For example, for a DBS signal bandpass filter 45 can have a 500 MHz bandwidth. The signal goes through a down-converter to a lower intermediate frequency (IF) frequency. In one embodiment, the, signal goes through two stages of down-conversion, initially through the first IF frequency and subsequently through the second IF frequency. Two stages of down-conversions are used to provide good image frequency rejection and also be able to implement a narrower bandpass filter at a low frequency (second IF). In the case of DBS, the first IF is typically at 950 MHz to 1.45 GHz (spanning 500 MHz) and the second IF can be in the sub-100 Mhz range. The selection of the second IF frequency allows the 5 MHz bandpass filter to be reliably implemented with roughly 5% to 10% bandwidth (i.e., 5 MHz divided by the 2 nd IF). Local oscillator of down-converter 46 is adjusted to select a desired signal frequency to measure the signal power. For example, if the desired signal frequency of the received signal to be sampled is at F SIG and a center frequency of the 5 MHz bandpass filter is at f 1 , the local frequency F LO1 can be set adjusted to F SIG −F 1 . Accordingly, this allows the signal spectrum at F SIG to pass through the center of the filter bandpass while the signal away from the F SIG is rejected by the filter.
One or more narrow band bandpass filters 47 a can be used to monitor power at specific frequencies. For example, narrow band bandpass filters 47 a can have a bandwidth of approximately 5 MHz for a DBS signal, which corresponds to the peak of each transponder signal, at one polarization. The polarizations of narrow band bandpass filters 47 a , 47 b can be switched. The bandwidth of narrow band bandpass filters 47 a , 47 b can be adjusted for evaluating various satellite signals, such as FSS and VAST signals.
One or more narrow band bandpass filters 47 b can be used to measure power at an adjacent 5 MHz spacing between two transponders at the same polarization. At the 5 MHz spacing the signal power should be the lowest. Power detector 48 a detects the power 50 a of signal 49 a from narrow band bandpass filter 47 a . Power detector 48 b detects the power 50 b of signal 49 b from narrow band bandpass filter 47 b . Additional power detectors 48 can be used if additional narrow band bandpass filters 47 are used. Processing means 52 determines a difference of between power 50 a and power 50 b . For example, processing means 52 can be a microprocessor. Processing means 52 activates satellite antenna adjustment means 54 for locking satellite antenna 52 or scanning satellite antenna in the azimuth and elevation positions with conventional methods.
FIG. 4 b illustrates an alternate embodiment in which signal power from narrow band bandpass filter 47 a and narrow band bandpass filter 47 b is sampled using a signal power detector 60 by alternating switch 62 . Power detector 60 determines power of signal 49 a and power of signal 49 b . Processing means 52 determines a difference of between power 50 a and power 50 b.
FIG. 5 is the block diagram for down-converter 46 . The F SIG 70 is the signal from LNA, which will multiply in the multiplier 75 with the output of local oscillator 72 F LO . The frequency of the F LO is generated by synthesizer 73 and controlled by frequency controller 71 , which adjust the F LO so that the output of down converter will have two frequency components (F SIG +F LO ) and (F SIG −F LO ). After low pass filter 77 , the high frequency components will be filtered and only the low frequency components left which should have the center frequency of F 1 and F 2 as defined in narrow band bandpass filters 47 a and 47 b . The setting for the local oscillator should be: F LO =F SIG −F 1 or F LO =F SIG −F 2 .
In general, the method and system of the present invention has the following advantages: the monitoring of signal power can be accomplished expeditiously, typically within about a few milliseconds, thereby providing fast signal scanning and fast signal acquisition. For example, if the antenna azimuth beam width is about 2 degrees, the satellite antenna can scan through every two degrees within about 5 milliseconds, thereby providing scanning of 360 degrees within about 1 second. The only limited factor is the speed of the motor to turn the antenna for azimuth tracking. The present invention provides significant reduction in the false lock probability by using individual detectors of signal characteristics, thereby a typical antenna acquisition can be accomplished within a single scan through a possible region. The present invention provides in one embodiment, lessened sensitivity to the accuracy of the signal power monitor because the relative signal levels at two different frequencies rather than an absolute signal power level monitored. The differential power can also reduce the fluctuations of outputs from power detectors due to environmental influence such as temperature or drift of parameters.
It is to be understood that the above-described embodiments are illustrative of only a few of the many possible specific embodiments, which can represent applications of the principles of the invention. Numerous and varied other arrangements can be readily devised in accordance with these principles by those skilled in the art without departing from the spirit and scope of the invention.
|
The invention relates to a method and apparatus for fast satellite antenna acquisition via signal identification. The method and apparatus operate by positioning a satellite antenna using signal identification in order to reduce false satellite signal locks and missed detections and speed the acquisition of the correct satellite.
| 7
|
RELATED APPLICATIONS
[0001] This Application is a Continuation application of copending prior application Ser. No. 11/462,358, filed on Aug. 3, 2006 which is a Division of application Ser. No. 09/881,133 filed on Jun. 14, 2001, now abandoned, which claims the priority of Provisional Application Ser. No. 60/211,912, filed Jun. 16, 2000.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a method of doing business providing litigation services and in particular to a method of doing business preparing multimedia presentations scripts by providing a virtual scripting room allowing a plurality of remotely located participants to contribute concurrently to the presentation script.
[0004] 2. Description of the Prior Art
[0005] To prepare a multimedia presentation, the sources (individuals or documents) must be in the same physical location as the scripting technician (the “Scripting Room”). Within the context of a lawsuit, for example (and as shown in FIG. 1 ), a trial consultant or technician (“Operator” or controller), meets with one or more attorneys, witnesses and/or experts (“Clients” or contributors) in the Scripting Room and together they utilize multimedia software to create a scripted presentation (a “Script”) of evidence relating to a specific witness or the opening/closing of a trial. Software for creating such a scripted presentation is disclosed in U.S. Pat. No. 5,473,744, which is incorporated herein in its entirety by reference. As an alternative, the Clients may provide the Operator an outline of an examination, opening statement, or closing statement.
[0006] In the Scripting Room, the Operator creates a script corresponding to the outline. A physical scripting room as currently utilized in the art may include Clients 11 and 12 working with an Operator 10 (trial consultant or technician) to script a multimedia presentation. The Operator utilizes multimedia software and data source material on a CPU 14 and associated display monitor 15 , which the Clients (and the Operator) view on a large screen display 16 linked to the Operator's CPU.
[0007] Regardless of how the Script is initiated, the Clients and the Operator still must physically meet to review the Script and work together in the Scripting Room to make final revisions to the Script. This entails synchronizing the schedules of potentially a large number of persons, and will typically involve the additional expense and effort of travel.
SUMMARY OF THE INVENTION
[0008] The present invention offers a solution to this problem by providing, in one aspect, a method and system for preparing a presentation, comprising connecting a plurality of geographically dispersed contributors to a controller through a network to collaborate to prepare the presentation; allowing the contributors to propose contributions to the presentation, the proposed contributions residing on storage devices under the control of the contributors; making the proposed contributions available for viewing and comment by all contributors; allowing the controller to select one or more of the proposed contributions; and providing the controller access through the network to the storage devices to retrieve the selected contributions for inclusion into the presentation.
[0009] In a further aspect, the present invention provides a method and system for making a presentation wherein selected contributions are retrieved from respective storage devices immediately prior to displaying the selected contribution. In a yet further aspect, the invention provides a method and system for making a presentation that includes providing access through a network to view the presentation while the presentation is being made.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 is a view of a typical Scripting Room as known in the art;
[0011] FIG. 2 is a view of a typical court room in which the presentation prepared in the Scripting Room is displayed, as known in the art;
[0012] FIG. 3 is a diagram illustrating distributed scripting according to the invention;
[0013] FIG. 4 is another diagram illustrating distributed scripting according to the invention;
[0014] FIG. 5 represents various system functionality components;
[0015] FIG. 6 is a diagram of functions that may be performed by a Presentation Creator in accordance with the invention;
[0016] FIG. 7 is a diagram of functions that may be performed by a Presenter in accordance with the invention; and
[0017] FIG. 8 is a diagram of functions that may be performed by an Application Administrator in accordance with the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0018] With reference to the previous example of a presentation prepared within the context of a lawsuit, FIG. 2 depicts a typical courtroom in which the presentation Script would be displayed to enhance the effective presentation of visual evidence (documents, video taped depositions, photographs, etc.) and ultimately to assist the presenting attorney to control juror focus. The Operator 17 is utilizing multimedia software to display the Script and associated data source material from her CPU and associated hard drives at the direction of the speaking attorney 24 . The Script is displayed on a conveniently positioned large screen display 18 to both the judge 19 and the jury 20 . In addition, there are display devices on counsel table 21 , in front of the judge 22 , in front of the witness (not shown), and in front of the Operator 23 .
[0019] Common terms used throughout the specification are defined as follows. A Script is a series of presentation segments that will be used during a trial. A Segment is a logically grouped set of graphical components that make up a single element of a script. Using a variety of windows on the screen's real estate, a Segment may integrate animation, video deposition segments, live action video, graphics, document images, text, and any other type of information that may be visually displayed. An Exhibit is a collection of files that will be used for display as a single entity. For example, several TIFF files may be placed in an exhibit. A Case is a unit used to identify a group of scripts. The main office refers to the physical facility where the Operator is located as well as the entity (e.g. the business entity) that control this facility and the Operator.
[0020] With reference to the drawings, and as further described in detail elsewhere in the specification, in one aspect of the present invention a Distributed Scripting method is provided whereby the physical Scripting Room is replaced by a virtual one (“Virtual Scripting Room”). As shown in FIG. 3 , in the Distributed Scripting method of the invention the Operator and the scripting computer are located in the Scripting Room, while the Clients may be situated in their offices wherever located. The Operator and the Clients are in effect together in the Virtual Scripting Room connected by the Internet (or directly connected via Intranet, fiber optic cable, satellite, ISDN or other high-speed transmission line). The connection may either be in real time or the Clients may time shift.
[0021] The scripting computer executes software that enables communication between the Operator and the various clients, as well as the development of the Script itself. The interactive nature of the software facilitates time shifting and collaboration in general. Elements of the Script (video, documents, graphics and text) are streamed between the Operator and the Clients. Each Client has the ability to utilize the software's tools to modify existing script segments, to create new script segments, and to append comments to any scripted segment. The revisions are stored with a Script as temporary script segments identified by creator and revision number (example: Client Able working on script segment 6 first revision: Segment 6 A- 1 ; second revision: 6 A- 2 ; etc.). However, only the changes made or accepted by the Operator become final in a Script. The Operator may view a single script segment, all of its renditions, and its modifications and comments simultaneously as thumbnails sized proportionally to fill the screen, and may open and activate each by a left mouse click. The Virtual Scripting Room may be equipped with video teleconferencing running on each Client's monitor and on a second monitor for the Operator.
[0022] With further reference to FIG. 3 , Clients 25 and 26 are shown working with an Operator 27 (trial consultant or technician) to script a multimedia presentation in the Virtual Scripting Room. For this example of Distributed Scripting, Client 25 is located in his office in the State of Washington, while Client 26 is located in the City of New York. The Operator is located in the Los Angeles Scripting Room. Each of the CPUs of the Clients and the Operator are connected over the Internet (or directly connected via Intranet, fiber optic cable, satellite, ISDN or other high-speed transmission line). The Operator is utilizing two display devices: a monitor 28 to show script segments, suggested revisions, suggested new segments and notes from the Clients, and another monitor 29 to provide the visual image of the Clients to the Operator via video teleconferencing. The Operators CPU includes a storage device (not shown) as is known in the art (e.g. hard drive, cd-rom, zip drive, tape drive) for storing the presentation and any segments contributed by the Clients. The Clients are able to view the scripted segments and the work in progress on their respective display devices 30 and 31 . They may also able to view the real time image of the Operator on their display devices, when each Client and the Operator have digital video cameras for video teleconferencing 32 , 33 and 34 .
[0023] All Clients may make changes to the Script, but only the Operator has the ability to save the Script and thus the final authority on the form and components of the final Script. The Operator, and/or an Application Administrator, can confer such privileges upon some of the Clients. A Client may also choose to work independently on a working copy of the Script, and may save this working copy independently of the final copy, and may further provide this working copy for review by the other Clients and the Operator for possible incorporation into the final Script. As the Clients make changes to the Script, each Client's actions are saved in a log for later recall and accountability.
[0024] To further facilitate Distributed Scripting, the method of the invention includes the ability to utilize data source material (Image, Video, Audio, Text, CAD and Graphic Files) located outside of the Scripting Room. The software may enable this feature by tracking and storing in a Script the complete path, including access codes, to each data source element. Each Client in the Virtual Scripting Room may contribute data source material either by scripting such material or providing the Operator access to such Client's hard drives or other media storage devices (cd-rom drives, zip drives, optical drives, tape drives, magneto-optical drives, etc.). This feature is particularly suited to utilizing data stored in Internet based repositories, such as FTP servers or on “Internet hard drives” such as those provided by Xdrive, i-drive, and others. Of course, any storage device connected to the same network as the Clients and Operator may be used to supply data for inclusion into the Script.
[0025] Each individual component of any one segment may thus be remotely located on a different storage device. In this embodiment, the Script contains a path for each component of each segment, so that the Script is completely portable and does not rely on default paths or storage devices that must be connected to the computer upon which the Script is being executed (such as a computer in the court room). Thus, data supplied by the Clients for inclusion into the Script may be transferred to the scripting computer for local storage together with the Script, and upon displaying the presentation, the data is available locally on the same computer as the Script. Alternatively, the data may be transferred ‘on-the-fly’ from the original source when displaying the presentation, without the need of first saving the data on the computer on which the presentation Script is being executed. This features offers additional flexibility in incorporating last-minute changes in the presentation while actually displaying the presentation, and eliminates the need for downloading and locally storing all data that may possibly be required during the presentation.
[0026] The Distributed Scripting methodology provided by the present invention enables delivery of trial presentation services from a single main office to clients nationwide and worldwide. The delivery of worldwide services may be further facilitated by the use of regional service providers (each a “Local Provider”) as depicted in FIG. 4 . Each Local Provider may not only provide local support, but may also source regional litigation clients. Typically, Local Providers would be litigation photocopy companies with the ability to scan and create document images, but could be any type of litigation support entity, including court reporters. Digital video and other graphics may be created regionally or in the main office. The Local Provider would gather the source data and provide it to the main office either physically or electronically. The Local Provider may also provide Clients with a remote scripting facility linked over the Internet to the Virtual Scripting Room in the main office. In an alternative embodiment, regional attorney Clients would work with a Trial Consultant/Technician Operator in the main office from their own computers, connecting via the Internet to the Virtual Scripting Room.
[0027] Because the software will have communication capability, remote users could monitor the preparation of the Script via Web browsers such as Internet Explorer or Netscape by logging on to a web site, optionally entering a password, and viewing the Script as the Operator and Clients build it and edit it.
[0028] Once Scripting has been completed, a Trial Consultant could provide in-court presentation services. The role of the Trial Consultant can be a function of the ability of the software to: (i) create software rather than graphic based “slides” prior to trial containing segments of video, documents and/or graphics; (ii) order the “slides” into a Script paralleling the attorney's examination outline; and (iii) as a result of the “slides” being maintained as a software matrix rather than as a single graphic file, modify existing “slides”, randomly access and display any slide within a Script, and incorporate new or revised animations, video deposition segments, live action video, graphics, and document images during trial. The Trial Consultant may also assist in the analysis of evidentiary issues arising in connection with the multimedia presentation of evidence both as a sword (how far to go) and as a shield (when to object to the other side's use of evidence).
[0029] In some cases, the regional attorney Client or personnel provided by the Local Provider could do the in-court presentation of scripts. In this scenario, the main office could provide daily supplemental Scripting and support either through a Virtual Scripting Room, or by the now on-site Trial Consultant.
[0030] FIG. 4 depicts the use of Distributed Scripting with the assistance of a Local Provider 35 to provide multimedia support services to a trial team in a remote location. The Clients 36 and 37 are working with an Operator 38 (trial consultant or technician) to script a multimedia presentation in the Virtual Scripting Room. Once again, Client 36 , perhaps an expert, is located in his office in the State of Washington, while Client 37 is located in the City of New York. The Operator is located in the Los Angeles Scripting Room. Each of the CPUs of the Clients, perhaps the Local Provider, and the Operator are connected over the Internet (or directly connected via Intranet, fiber optic cable, satellite, ISDN or other high-speed transmission line).
[0031] As in FIG. 3 , the Operator 38 is utilizing two display devices: a monitor to show script segments, suggested revisions, suggested new segments and notes from the Clients, and another monitor to provide the visual image of the Clients to the Operator via video Tele-conferencing. The Clients are able to view the scripted segments and the work in progress on associated display devices. The Local Provider may act to gather the source data and provide it to the main office either physically or electronically. The Operator is utilizing multimedia software to display a Script and associated data source material from not only her CPU and associated hard drives, but may also utilize remote storage devices 39 such as Internet hard drives. The Scripts and other visual evidence will be displayed to the trier of fact located in a remote courtroom 40 , by an in-court Operator 37 , by the speaking attorney 35 , by the Local Provider (not shown), or even by an Operator 38 located in the main office. Most typically, the main office Operator 38 will electronically transfer a compressed Script and underlying data source material to the in-court Operator 37 . For a remote Operator to present evidence in the courtroom, or an Operator located in a courtroom to pull scripted source data from remote hard drives, the courtroom must have telecommunication facilities such as access to the Internet. Alternatively, remote telecommunication devices such as cellular telephones may be used to access the Internet or other communication network.
[0032] The communications capability of the software may also permit the broadcast of the presentation over the network (e.g. the Internet) as the presentation is made in court. Thus, attorneys located remotely may track the presentation; the presentation may also be provided to a news service such as CNN for live TV broadcast. The software may also be compatible with Web browsers such as Microsoft Internet Explorer and Netscape, and allow the presentation to be viewed by remote users accessing the Internet through such browsers.
Software
[0033] The following subsection presents in greater detail a model of the system functionality as may be implemented in a software package embodying the method and system of the invention. The graphical depictions in this subsection are Use Case diagrams. Use Case diagrams map each user role to the tasks associated with that role and the key software components that service those tasks. They are composed using the following symbols:
[0034] Actor—an Actor represents anyone or anything that interacts with the system. An actor is a stick figure; see FIG. 5 a.
[0035] Use Case—a Use Case represents a task or task grouping that the system performs. A Use Case is represented by an oval with text inside describing the task (Edit List) or a group of tasks (List Manager); see FIG. 5 b.
[0036] Relationship—A Relationship provides information about how Actors and Use Cases interact with each other. They are depicted as lines with arrowheads. A line with an arrowhead on each end indicates a 2-way communication. A line with an arrowhead on one end indicates that one diagram object is using the one that is pointed to by the arrow; see FIG. 5 c.
[0037] A common misunderstanding is not differentiating a person's responsibilities from the roles they play in the business. In some businesses, for example, the database administrator, system administrator, and application administrator are different individuals, each of whom has only one role. However, other businesses have a single individual who is responsible for more than one role. Combining the database administrator and application administrator is common, for instance. For a system to be flexible enough to accommodate these differences in operating styles, it should be designed with the assumption that a single individual can perform one or more roles in the system.
[0038] The Presentation Creator typically builds the multimedia presentation from components like documents, audio recording, video recording, animations, and pictures, as shown in FIG. 6 . The Presenter manages the presentation for the lawyer. Usually the Presentation Creator and the Presenter are the same person, as depicted in FIG. 7 . The Application Administrator handles all technical tasks required to install, operate, and fix the application. In order to perform these tasks, in particular the problem resolution tasks, they can temporarily assume any role in the system, as shown in FIG. 8 .
Functional Requirements
[0039] This subsection describes the functions that may offered in a preferred software implementation of the system.
[0040] The text in a document may be extracted into separate (child) windows (“child” refers to client nomenclature, not object-oriented nomenclature).
[0041] The text in a window can be enlarged or diminished in 2-point increments using one button.
[0042] The text in a window can be highlighted in color.
[0043] The text in a window can be highlighted and underlined in separate colors.
[0044] The text in a window can be selected and circled or boxed using precise drawing elements like circles and rectangles.
[0045] The text in a window can be selected and marked in the following ways:
strikethrough highlight underline
[0049] The text in a window can be marked by graphical elements like checkmarks and bullets.
[0050] The text in a window can be obscured from view.
[0051] Freehand drawing can be performed on a text window.
[0052] Text can be selected and highlighted while all other text is changed to a different color, for instance, grayed out.
[0053] Individual text highlighting can be “undone” or removed without affecting other highlighted text.
[0054] Individual text formats like strikethrough, etc. can be “undone” or removed without affecting other text formats.
[0055] Individual text edits that obscure text can be “undone” or removed without affecting other obscured (or redacted) text.
[0056] Each text edit can be individually removed or undone.
[0057] All text highlighting on a segment can be removed with one action.
[0058] Individual documents in a segment containing multiple documents can be brought to front with a single keystroke and/or mouse action (mouse roller wheel selection). Repeating the keystroke and/or mouse action cycles through each document, raising to the front in turn.
[0059] Documents in a segment can be expanded to full screen.
[0060] The system allows the user to page forward and backwards through the document a page at a time. In addition, there must be a way to jump to the beginning and end of the document. Finally, will be a method to jump to a specific page number.
[0061] Documents can be rotated by 90 degree angles.
[0062] Subsections of pictures can be selected (either with a oval or rectangle) and highlighted.
[0063] Subsections of pictures can be selected (either with a oval, or rectangle) and turned opaque.
[0064] Subsections of pictures can be selected (either with a oval, or rectangle), extracted into a separate window and blown up.
[0065] A picture subsection window can be incrementally magnified or diminished with a single button, one for magnifying and one for decreasing the size of the subsection.
[0066] Freehand drawing can be performed on a graphic window.
[0067] Pictures in a segment can be expanded to full screen.
[0068] Subsections of video can be selected (either with a circle, or rectangle) and highlighted.
[0069] Subsections of video can be selected (either with a circle, or rectangle) and extracted and enlarged as a still picture into a separate window.
[0070] A video recording can be slowed and sped up incrementally using single user actions for each.
[0071] A video recording can be slowed to a stop and then advanced one frame at a time.
[0072] When a video recording is being advanced one frame at a time, the full still picture can be captured and extracted to a separate window.
[0073] The volume can be controlled on a per video basis. The volume can be set during segment building and controlled during presentation.
[0074] The volume can be modulated for a minimum and maximum volume. For instance, a sound below the minimum is increased to the minimum and a sound above the maximum is reduced the maximum.
[0075] Multiple marks can be created in a video recording.
[0076] A repeating loop can be run between video recording marks.
[0077] The video can be set to run to a mark and pause until some action is taken that runs it to the next mark.
[0078] The video recording can rewind or fast forward and automatically stop on the first encountered mark.
[0079] A video recording(s) can be synchronized with positions in a document(s). That is, when the user clicks a particular section of the document (transcript), the video jumps to the synchronized position in the video recording and vice versa.
[0080] A video recording can be synchronized with other video recordings. That is, when the user re-positions in one video, it causes the synchronized video to automatically re-position and stay in sync.
[0081] Freehand drawing can be performed on a video window.
[0082] Video in a segment can be expanded to full screen.
[0083] Full video controls are provided, similar to those found on a VCR.
[0084] A segment or set of segments can be cut and pasted into a different script.
[0085] Annotations can be created and attached to any segment component.
[0086] Segment can be saved using a single action like a keystroke, button, or mouse click.
[0087] A script can be merged with another script.
[0088] A script can be copied to another script.
[0089] A set of segments can be re-ordered in a script.
[0090] A set of segments can be extracted and saved as a script.
[0091] Each segment has an id reflecting its order in the script.
[0092] A “hot save” function for saving a segment along with or without its association. For example, it would be named “HS3_filename”.
[0093] The “hot save” function will put the saved segment at the end of the segment list in script.
[0094] Need to pull and work with, in presentation mode, elements that not part of the script or segment. File select needs to be unobtrusive.
[0095] Saving process in script mode needs to be simplified. Needs a hot key to save all segments and the script.
[0096] Need to have full segment edit capabilities in presentation mode.
[0097] Be able to show segments in script order or select and display on the fly.
[0098] Need small segment id on screen for the current segment.
[0099] While playing video, The system may provide the ability to have scripted documents show up at specific, timed points in the video.
[0100] The system may allow the user to create document scrolling in synchronization with video.
[0101] The system may print scripts.
[0102] The system may print individual or selected or all segments.
[0103] The system may print a slide show format of the segments in a script (proof sheet).
[0104] The system may print a slide show w/barcodes (proof sheet w/barcodes).
[0105] The system may print segment components.
[0106] The system may print a segment description-barcode cross-reference.
[0107] The system may print a barcode-file name cross-reference within a specified directory.
[0108] The user can select which files will be included in the cross-reference.
[0109] Saving a segment containing multiple elements retains the dominance (i.e. which document is in front) seen on the screen.
[0110] An element's size can be set individually within a segment.
[0111] The software will preferably be able to interface with a wide variety of other software, e.g. word processors (MS Word, WordPerfect, etc.), presentation software (Power Point, etc.), databases (Oracle, Dbase, etc.), case management software (Summation, etc.), video preparation and editing software (e.g. QuickTime), image preparation and editing software (e.g. Photoshop), and others. The software may convert certain files into a preferred format (e.g. convert all Word files into RTF format) and save the min this preferred format. However, the software will ideally also be able to read and display any format on-the-fly.
[0112] This function will enable the Presenter to incorporate new components into segment at a moment's notice even if the new components are located remotely and are not available on the CPU running the Script in court. In this manner, the invention allows the Presenter to access new information located anywhere in the world, provided that the information is accessible remotely (e.g. stored on servers connected to the Internet), and incorporate the information into the presentation Script as may be required by new and unanticipated developments.
Potential Uses and Markets
[0113] Other services may be provided in addition to the in-court presentation of evidence via the method and system of the invention. Such additional services may be further aided by the addition of two supplemental software features, as described below.
1) Interactive Text Objects
[0114] This feature may take the form of an utility that permits a form or other text document to be treated as a scripting object in a fashion similar to other data source material, with the exception that the Operator may at any time add text to the form and save both the form and the new text in a script segment together with other objects (graphics, photographs, etc). This utility may be used in the medical and insurance fields, for instance, where a physician in a medical testing facility could in the course of evaluating an Ultra Sound or NMR image complete an electronic medical evaluation/diagnosis form and script the image and completed form together in a single script segment. In this situation, the Script represents a patient's medical file rather than a witness examination. The patient Script could be maintained by the main office in the role of the Operator, while the testing facility physician, the treating physician, the specialist (surgeon) and the hospital would each have the role of a Client. The resulting Script may be transmitted to other facilities for viewing, diagnosis, patient treatment, or for billing and insurance reimbursement.
2) Distributed Presentation
[0115] Ultimately a Script, whether created in a physical or virtual scripting room, may be presented either: (a) to an audience physically in the presence of the Operator, as in the case of a jury in a courtroom where a lawyer is presenting evidence with assistance of an Operator; or (b) to an audience connected to the Operator over the Internet (or directly connected via Intranet, fiber optic cable, satellite, ISDN or other transmission line; “Distributed Presentation”), as in the case of Internet based marketing—e.g. the Victoria's Secret fashion shows, General Motors introduction of new car models, or the latest Microsoft software introduction. The audience may be a single individual, a group of individuals sitting together or a geographically distributed group located throughout the world.
[0116] Each of the following examples may utilize Distributed Scripting and/or Distributed Presentation.
[0117] Insurance Claim Processing and Reimbursement—The Script is the claim file; the Clients are the claim adjuster, the investigators, repair or replacement sources, the claims manager and the payer; the Operator is either the Insurance Company or the main office.
[0118] Medical Diagnostic and Payment—The Script is the patient file; the Clients are the testing facility physician, the treating physician, the specialist (surgeon), the hospital and ultimately the insurer; the Operator is the main office.
[0119] Corporate Presentations and Marketing—The Script is the presentation topic; the Clients are the internal team members responsible for the project, external consultants and in some cases the audience; the Operator is the corporation.
[0120] Development of Corporate Collateral and Marketing—The Script is the assemblage of the corporate collateral being created; the Clients are the in-house marketing personnel, the in-house executive in charge of the project, the senior executive who ultimately approves the project, the external marketing/advertising executive in charge of the project, the graphic designers; the Operator is either the corporation or the marketing entity.
[0121] Advertising Graphic Development and Delivery—The Script is the advertising campaign being created; the Clients are the in-house marketing personnel, the in-house executive in charge of the project, the senior executive who ultimately approves the project, the external advertising executive in charge of the project, the graphic designers and other team members; the Operator is the advertising company.
[0122] Corporate Road Shows—The Script is the offering materials, Company history and prospects; the Clients are the senior management of the corporation, the auditors, the investment bankers and attorneys; the Operator is either the lead investment bank or the main office.
[0123] Internet Conferencing—The Script is the presentation topic; the Clients are the internal team members responsible for the project, external consultants and in some cases the audience; the Operator is either the Web hosting corporation, or the main office.
[0124] Project Development and Oversight: Architecture, Construction and Finance—The Script is the project, including the development contract, the finance contract, and the plans, progress reports and testing; the Clients are the financing entity, the architects, subcontractors, the general contractor and inspectors; the Operator is the owner/buyer.
[0125] Banking: Finance Packages and Loan Processing—The Script is the borrower and the loan package; the Clients are the borrower, the loan officer, the approval committee; the Operator is the Bank or lending institution.
[0126] Aircraft, Satellite and Space Craft Construction Management and Reporting—The Script is the individual aircraft, satellite or space craft, including the development contract, the finance contract, and the plans, progress reports and testing; the Clients are the financing entity, the architects, subcontractors, the manufacturer, the construction managers, safety inspectors and regulatory agencies; the Operator is the owner/buyer.
[0127] Shipbuilding—The Script is the vessel, including the construction contract, the finance contract, and the plans, progress reports and testing; the Clients are the financing entity, the architects, subcontractors, the builder, the project manager, safety inspectors and certification societies; the Operator is the owner/buyer.
[0128] Focus Group Results—The Script is the research results, statistical charts and conclusions; the Clients are the researcher and/or the facilitator, the entity paying for the study; the audience are the financial backers of the study, the studio executives, in the case of a movie, the product line executives, in the case of a new product release; the Operator is either the entity putting on the research or the main office.
[0129] Focus Group Results: Litigation—The Script is the research results, statistical charts, case themes and conclusions; the Clients are the Jury consultant, the facilitator, the attorneys on the trial team involved in the litigation; the audience are the trial team members, the client party to the litigation and/or the client representative; the Operator is either the jury consulting firm or the main office.
[0130] Having now described the invention in accordance with the requirements of the patent statutes, those skilled in this art will understand how to make changes and modifications in the present invention to meet their specific requirements or conditions. Such changes and modifications may be made without departing from the scope and spirit of the invention as set forth in the following claims.
|
A method for preparing a presentation connects a plurality of geographically dispersed contributors to a controller through a network to collaborate to prepare the presentation, allows the contributors to propose contributions to the presentation residing on storage devices under the control of the contributors, makes the proposed contributions available for viewing and comment by all contributors, allows the controller to select one or more of the proposed contributions, and provides the controller access through the network to the storage devices to retrieve the selected contributions for inclusion into the presentation.
| 7
|
BACKGROUND OF THE INVENTION
Staples and brads for manual, pneumatic and electrical tools are all made by drawing wires and forming two flat sides on each wire. The force that flattens the wire is applied to opposite sides of the wire simultaneously to form two flat surfaces and two round surfaces opposite each other.
Each round side is used to attach each wire to the next wire to form a package by adhesively bonding the round sides. The flat sides are not used as the bonding surfaces. The bonding is performed by adhesives well known in the art.
As a result of this manufactured process, the bonding strength between each wire in a package is weak. The line of contact between each round side of each wire is at the apex point on the curve created by each round side. The inherent failure causes a weak glue line and eventually causes the package of brads or staples to fall apart in the hands of the consumer during installation, Moreover, the user must then force the separated staples or wires into a feeder eventually leading to jamming or misfeed. Sometimes these jams result in destruction of the feeding unit.
A further problem inherent in producing round wires for brads or staples is width control. Width control is critical in producing wires because any discrepancies in width will produce unusable wire to form staples or brads. The tolerances are critical for size or width of a wire which fits in a fastener gun and the drawing process now required to meet these limitations is expensive and time consuming.
SUMMARY OF THE INVENTION
A method for making a wire package for use as staples or brads is recited as forming a plurality of round wires, forming a plurality of flattened sides in each wire to prepare even bonding surfaces on each wire and bonding each wire to an adjacent wire by mating the surfaces of each wire.
It is an object of the present invention to form a package of brads having flattened bonding surfaces.
It is an object of the present invention to form a package of divergent staples having flattened bonding surfaces.
Another object of the present invention is to form a plurality of wires with a controlled width.
Yet another object of the present invention is to form wires having three or more sides which are bonded at each side to produce a wire package.
Still another object of the present invention is to control the width of each wire used in making a wire package by deforming each and making a plurality of flat sides.
A method of making a novel brad or staple packaging is disclosed and presented to illustrate wire having 3 or more flat sides and preferably 6 or more. The method controls the width of each wire and to make the package.
DETAILED DESCRIPTION OF THE DRAWINGS
FIG. 1 is a wire package of the prior art.
FIG. 2 is an illustrated block diagram of a process of making a wire package of the present invention.
FIG. 3 is an exploded view of the circled portion of FIG. 4 .
FIG. 4 is a plain view of a wire package of the present invention.
FIG. 5 is a wire package of the prior art.
FIG. 6 is an exploded view of the circled portion of FIG. 4 . of the prior art.
FIG. 7 is an exploded view of the circled portion of FIG. 4 .
FIG. 8 is a plain view of a wire package of the present invention.
FIG. 9 is a plain view of a brad package of the present invention.
FIG. 10 is a plain view of an alternative embodiment wire package of the present invention.
FIG. 11 is a plain view of an alternative embodiment wire package of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
A novel method of making a package of wire brads or divergent staples is disclosed and illustrated in FIGS. 2-10 and described in the present application. FIG. 1 illustrates a prior art wire package 1 drawn and formed into a brad or a staple package. A round wire is drawn and deformed to produce two flat sides 2 , 3 and two round sides 4 , 5 . The round sides 6 and 7 are bonded to round sides 8 , 9 of adjacent wires 10 , 11 to form the package 1 . The bonding at the center of the curve of the wire fails to provide adequate contact area.
A method of making a wire package is schematically shown in FIG. 2. A plurality of round wires 12 are drawn from a well known drawing apparatus 13 for producing round wires 14 . Each wire 20 is formed of metal such as copper, steel, stainless steel, or titanium. As many as 2-200 wires at a time could be drawn from the wire drawing apparatus. In order to form the size of the wire 20 to the selected width, the techniques used in the drawing process must be precise to control the tolerances allowed in making the wire an exact width. The wires 12 as a group are drawn from the drawing apparatus 13 by conventional means where the wires 12 next enter a station 22 used to form a plurality of flat sides on each individual wire.
In order for the drawing apparatus 21 and the forming station 22 to handle anywhere from 5-200 or more wires simultaneously during the process, each station is made up of multiple modular substations. The number of substations used depends on the size of the package in production. Each substation may be added or subtracted depending on the need of the production line. Likewise, the drawing apparatus may include more substations depending on production requirements.
As shown in FIG. 2 , the production of a wire package requires an in line wire handling conveyor 23 , for handling a plurality of undetermined length wires 12 as they move along the line to each station. Draw station 21 produces and conveys the wires 12 to the flat side forming station 22 . The flat side forming station 22 receives each wire 20 in a flat side modular substation 24 where multiple sides are formed on each wire by a deforming press 25 . The deforming press 25 includes 3 or more flat side forming presses 26 - 31 . Each flat sided forming station is modular in design and in use in that the substations and or the presses may be interchanged or added or eliminated through a quick disconnect attachment system. Since all of the stations, substations, deforming presses and flat side forming presses are identical only one will be described in order to simplify the explanation.
After the wires are bonded to form a unit, each unit is cut to a predetermined length by a severing and forming station 39 to form a wire piercing projections on one or both ends of each wire in the package. The wire package is then transferred to a deforming station 40 to make a staple package or wire package.
As shown in FIGS. 3 and 4 , each flat side 32 - 35 of each wire provides a bonding surface and the process controls the width of each wire. The wires as a group 36 , are then conveyed through a bonding station 37 where the wires 36 are bonded together to form a wire unit or package 38 . The wires are bonded by conventional means side by side and side by side to form the package as shown in FIG. 4 . The flat surfaces formed on each wire provide a large smooth bonding surface. The bonding technique prevents the unit from coming apart during the installation process.
FIGS. 5 and 6 illustrates examples of prior art packages made of wires having rounded sides for bonding having a different number of sides. FIGS. 7-9 illustrate a brad wire packages of the present invention having wires with flat bonding sides and formed into packages.
The present method of forming a package of staples permits the formation of 4-12 flat bonding sides on each round wire.
In order to form a brad wire package, the wire unit is passed to a brad forming unit where heads are formed on one end of each wire. On the opposite the end, a piecing point is formed using the process previously process. The package of brads is now complete and moved to a station for packing.
In order to form a divergent staple, the wire unit is conveyed to a staple forming station where each wire unit is deformed into a u-shaped configuration. An end of the wire unit opposite of the piercing point is then cut to form a second piercing point on each wire. The bond areas created by the flat sides further prevent breaking of the bond during the deforming process.
FIGS. 5 and 6 disclose prior art brads 50 having round sides 51 which are bonded at each side. FIGS. 7 , 6 and 9 disclose brads 60 having flat sides 61 which form the bonding surfaces to assemble a package 62 of brads.
FIG. 10 illustrates a wire package 70 having wires 71 , each wire having at least 5 sides. Each side is flat to provide a flat bonding surface 72 . FIG. 11 illustrates a wire package 80 having wires 81 , each wire having a flat bonding surface 82 .
|
A method for making a wire package for use as staples or brads is recited as forming a plurality of round wires, forming a plurality of flattened bonding sides on each wire to prepare even bonding surfaces on each wire and bonding each wire to an adjacent wire by adhering the surfaces of each wire. Each staple includes two or more flat surfaces to improve the bonding strength of each staple. A package of diverging staples or brads are formed using the flat bonding surfaces
| 1
|
FIELD OF THE INVENTION
This invention relates to novel curable resin compositions and to cured products produced therefrom. More particularly, the invention relates to compositions comprising an organic dicyanate, a bismaleimide and an ether derived from an arylcyclobutenealkyl compound and a di(hydroxyphenyl) oligomer.
BACKGROUND OF THE INVENTION
The curing of monomeric materials to produce polymeric thermoset resins is well known in the art. In general, the polymerizable monomers have one and customarily more than one reactive group which serves as an active site for a curing or crosslinking polymerization to produce the cured or thermoset resins. Crosslinking of many if not most of the polymerizable monomers requires the use of a second polymerizable monomer, e.g., a stoichiometric curing agent, to cause the curing to occur at an acceptable rate. The stoichiometric curing agent is employed in substantial quantities and will greatly influence the properties of the cured product.
Other polymerizable monomers will cure without the presence of a curing agent and are termed "self-curing." These monomers are also frequently cured with other polymerizable monomers in order to obtain more desirable properties. One class of self-curing monomers contain arylcyclobutene moieties, most frequently benzocyclobutene moieties. It appears likely that such materials undergo, on application of heat, ring opening of the four-membered ring to form very reactive intermediates which crosslink through reaction with adjacent molecules. The arylcyclobutene monomers also undergo reaction with a wide variety of unsaturated species such as maleic anhydride, maleimides, organic cyanates and allyl ethers. The products are thermoset resins having good properties of shelf-life and high use temperatures.
One class of such benzocyclobutene materials is disclosed by a series of U.S. patents to Kirchhoff of which U.S. Pat. No. 4,540,763 is illustrative. The disclosed compounds are characterized by direct linkages from the six-membered ring of the benzocyclobutene through a functional group to the remainder of the molecule. Reaction of such benzocyclobutene derivatives with bismaleimides is shown by Hahn et al, U.S. Pat. No. 4,730,030. A somewhat different class of benzocyclobutene derivatives is shown by copending U.S. patent application Ser. No. 349,546, filed May 9, 1989, wherein the six-membered ring is connected through an alkylene group to the remainder of the molecule. Specifically disclosed and claimed are benzocyclobutenealkyl ethers of bisphenols.
The class of organic dicyanates is a class of reactive polymerizable monomers which typically crosslink to form trimerized cyanurate resins which are highly crosslinked. The thermally cured products have high glass transition temperatures but also exhibit brittleness which renders the cured products unsuitable for some applications. For structural applications the cyanate resins are toughened by blending with up to 50% by weight of thermoplastic engineering thermoplastics as tougheners. However, conventional thermoset processing becomes difficult if not impossible at concentrations of thermoplastic greater than about 20% by weight because of viscosity problems. It would be of advantage to provide an alternate method of toughening cyanate resins.
SUMMARY OF THE INVENTION
The present invention provides improved resin compositions which cure upon application of heat to produce toughened cyanate resins. More particularly, the present invention provides a class of curable resin compositions comprising an organic dicyanate, a bismaleimide and an arylcyclobutenealkyl ether of a di(hydroxyphenyl) oligomer.
DESCRIPTION OF THE INVENTION
The compositions of the invention comprise a cyanate resin of at least two cyanate groups, i.e., --OCN groups, and a toughener system for the cyanate resin formed from an arylcyclobutene ether of a di(hydroxyphenyl) oligomer and a bis(maleimide). The resulting compositions exhibit high glass transition temperatures characteristic of cyanate resins but also demonstrate improved toughness.
The arylcyclobutene-containing component is an ether of a di(hydroxyphenyl) oligomer. As employed herein, the term "oligomer" applies to a low molecular weight material of from 1 unit (a monomer) to a relatively few monomeric units. Although a variety of oligomers having hydroxyphenyl end groups are useful in the compositions of the invention, the preferred di(hydroxyphenyl) oligomers are represented by the formula ##STR1## wherein X independently is a direct valence bond, alkylene of up to 8 carbon atoms inclusive, oxy, thio, sulfonyl, carbonyl or carbonato and n is an average number from 0 to about 20, preferably from 0 to about 10. Within the compounds of the above formula I it is preferred that at least one X group is alkylene such as methylene or 2,2-propylene and the group of alkylene, oxy or sulfonyl linking moieties comprises a preferred group of X moieties. One of the simplest members of the class of compounds of formula I is 2,2-di(4-hydroxyphenyl)propane also known as bisphenol A or BPA. Also preferred are the oligomers wherein at least one monomeric unit is derived from 2,2-di(4-hydroxyphenyl)propane and at least one unit is derived from 2,2-di(4-hydroxyphenyl) sulfone. These oligomers are known compounds or are produced by known methods.
The ether component of the compositions of the invention are arylcyclobutenealkyl ethers of the di(hydroxyphenyl) oligomer of formula I. The ethers are produced by reaction of a metal salt, particularly an alkali metal salt, of the oligomer and an arylcyclobutene alkyl compound of the formula
Ar--R--W (II)
wherein Ar is an arylcyclobutene moiety connected to --RW from a carbon atom of a six-membered ring and R is alkylene of up to 4 carbon atoms inclusive. Suitable W groups in the above formula II are those which, when attached to an aromatic ring are thought to be meta-directing or ring-activating or, expressed differently, are those groups commonly referred to as good "leaving groups" in nucleophilic substitution reactions. Preferred W groups are upper halo, i.e., those halogens other than fluoro (chloro, bromo or iodo), or sulfonic ester groups such as arylsulfonate, e.g., tosylate, brosylate, or nosylate, alkyl sulfonate groups, e.g., mesylate, and fluoroalkyl sulfonate, e.g., triflate or nonaflate. The term "R" of formula II is alkylene of up to 4 carbon atoms inclusive, e.g., methylene, 1,2-ethylene or 1,4-butylene, but preferably is methylene.
The arylcyclobutene group "Ar" is an aromatic ring system of up to 4 aromatic rings and up to 30 carbon atoms inclusive which contains at least one cyclobutene ring fused to a six-membered aromatic ring. Suitable aromatic ring systems are illustrated by a single aromatic ring system compound benzene, the fused aromatic ring system compounds naphthalene, anthracene and phenanthrene, the directly joined aromatic ring system compounds biphenyl and triphenyl and the indirectly joined aromatic ring system compounds of two or more aromatic rings joined by alkylene of up to 8 carbon atoms inclusive such as diphenylalkanes, e.g., diphenylmethane and 2,2-diphenylpropane. The preferred aromatic ring system is the single aromatic ring system compound benzene and the preferred arylcyclobutene moiety is a benzocyclobutene moiety. The Ar moiety is hydrocarbyl containing only atoms of carbon and hydrogen or is substituted hydrocarbyl containing additional atoms as inert carbon atom substituents such as cyano or middle halo. The preferred Ar group is a benzocyclobutene group.
In a preferred embodiment of the ethers of the invention the arylcyclobutenealkyl compound is a halomethylcyclobutene of the formula ##STR2## wherein W' is upper halo, i.e., chloro, bromo or iodo, but preferably is chloro or bromo, particularly chloro. The halomethylbenzocyclobutenes are produced by one of several reaction schemes depending upon the desired spatial arrangement of the halomethyl substituent and the cyclobutene ring. A 4-halomethylbenzocyclobutene is prepared from p-methylbenzyl halide, preferably p-methylbenzyl chloride, in two steps by the procedure of Ewing et al, J. Chem. Soc., Chem. Comm., 207 (1979). Preparation of 3-chloromethylbenzocyclobutene is accomplished in a similar manner starting from o-methylbenzyl chloride. In the latter case, however, the procedure yields an about 1:2 molar mixture of 3-chloromethylbenzocyclobutene and 4-chloromethylbenzocyclobutene. This mixture is separated into its individual components by conventional methods such as distillation or chromatographic separation or alternatively is used as such without separation of the isomers. Other arylcyclobutenealkyl compounds are also known compounds or are produced by known methods.
The arylcyclobutenealkyl compound of formula II is reacted with the metal salt of the di(hydroxyphenyl) oligomer. Although other metal salts are useful in the production of the ethers of the compositions of the invention, the preferred metal salts are alkali metal salts and lithium, sodium, potassium, rubidium and cesium salts are satisfactory. Sodium or potassium salts are preferred. In one modification, the alkali metal salt is formed and isolated prior to reaction with the arylcyclobutenealkyl compound. The di(hydroxyphenyl) oligomer is contacted with strong alkali metal base, e.g., alkali metal hydroxide, in aqueous solution at moderate temperatures such as from about 15° C. to about 30° C. Subsequent to reaction the alkali metal salt is isolated by conventional methods such as solvent removal or selective extraction. In a preferred process the alkali metal salt is formed as described above and reacted with the arylcyclobutenealkyl compound in situ. Because of the difficulty of providing a solvent in which both the alkali metal salt and the arylcyclobutenealkyl compound are soluble, the reaction is frequently conducted in a two-phase system employing a first solvent in which the alkali metal salt is soluble, e.g., water, and a second solvent in which the arylcyclobutenealkyl compound is soluble, e.g., toluene or ethylbenzene. Reactant contact is at the interface of the two phases and is facilitated by vigorous stirring or shaking. It is also useful to employ a phase transfer agent such as a tetroalkylammonium salt or a member of the class of macrocyclic polyethers known as "crown ethers". The contacting of the reactants takes place at an elevated temperature, e.g., from about 25° C. to about 150° C. and at a reaction pressure sufficient to maintain the mixture in a non-gaseous state. Subsequent to reaction the arylcyclobutenealkyl ether of the di(hydroxyphenyl) oligomer is recovered by well known methods such as precipitation or solvent removal. By way of specific illustration, the above procedure produces the di(4-benzocyclobutenemethyl) ether of 2,2-bis(4-hydroxyphenyl)propane by interfacial reaction of 4-chloromethylbenzocyclobutene and the sodium salt of 2,2-bis(4-hydroxyphenyl)propane.
The ethers, broadly, are conveniently depicted by removal of the hydroxylic hydrogens of the di(hydroxyphenyl) oligomer and the replacement thereof by arylcyclobutenealkyl groups. In terms of the preferred ether precursors (formulas I and IIa) the ether components are represented by the formula ##STR3## wherein X and n have the previously stated meanings.
In the compositions of the invention the arylcyclobutenealkyl ether of the di(hydroxyphenyl) oligomer is mixed with a bismaleimide and a dicyanate compound. A wide variety of bismaleimides is useful in the compositions including those described in U.S. Pat. No. 4,730,030, incorporated herein by reference. A preferred class of bismaleimides, however, is represented by the formula ##STR4## wherein X has the previously stated meaning and m is zero or 1. Such bismaleimides are illustrated by 1,3-di(maleimido)benzene, bis(4-maleimidophenyl)methane, 2,2-bis(maleimido)propane, bis(4-maleimidophenyl) sulfone, bis(4-maleimidophenyl) ether and bis(4-maleimidophenyl) ketone. The preferred bismaleimides are bis(maleimidophenyl)alkanes and particularly preferred are bis(4-maleimidophenyl)methane and 2,2-bis(4-maleimidophenyl)propane.
A wide variety of dicyanate compounds is also suitable as components of the compositions of the invention. The preferred dicyanate compounds are oligomers represented by the formula ##STR5## wherein X and n have the previously stated meanings. The nomenclature of such dicyanates is difficult to determine because of the complexity thereof but the simplest member of the series in which X is 2,2-propylene is 2,2-di(4-cyanatophenyl)propane. Other dicyanate compounds will be apparent from the above formula V. The dicyanate compounds are known materials or are produced by known methods. A number of the dicyanato materials are commercially available and some are available mixed with a bismaleimide, e.g., the mixed resin BT-2100 available from Mitsubishi Gas.
The resin compositions are prepared by mixing together the components of the resin composition at moderate to elevated temperatures preferably no higher than about 170° C. The proportions of the components is variable within some limits. The arylcyclobutenealkyl ether of the di(hydroxyphenyl) oligomer is present in an amount from about 20% by weight to about 60% by weight, based on total resin composition, but amounts from about 30% by weight to about 50% by weight on the same basis are preferred. The bismaleimide is suitably present in an amount of from about 5% by weight to about 35% by weight based on total resin composition, preferably from about 5% by weight to about 25% by weight on the same basis. The dicyanato compound is suitably present in an amount of from about 20% by weight to about 80% by weight based on total resin composition with quantities from about 45% by weight to about 55% by weight on the same basis being preferred. The method of mixing the components is not material so long as a homogenous mixture of the components is obtained. A preferred method of mixing comprises melting the components together at an elevated temperature, e.g., at about 150°-160° C.
The resin compositions suitably contain conventional additives for thermosetting resin compositions such as fillers, reinforcements, stabilizers, antioxidants, colorants or dyes designed to improve the processability of the resin composition or modify the properties of the cured product.
The curing of the resin compositions of the invention is accomplished by application of heat. Curing temperatures above about 180° C. are satisfactory although curing temperatures from about 200° C. to about 300° C. are preferred. It is useful on occasion to cure the resin composition in stages as by heating the resin composition to a relatively low curing temperature, e.g., 200°-210° C., and after curing has been initiated raise the curing temperature to a somewhat higher temperature, for example from about 220° C. to about 240° C.
The cured products are characterized by relatively high glass transition temperatures which are phase separated and by improved toughness over cured compositions which do not include the arylcyclobutenealkyl ether component. The compositions are thermosetting resin compositions and are processed by methods conventional for such materials such as extrusion and molding. The cured compositions have good high temperature properties and toughness and are particularly useful where elevated temperature applications are contemplated, for example, in electrical and electronic parts and baseboards.
The invention is illustrated by the following Illustrative Embodiment describing compositions of the invention as well as compositions included for comparative purposes. The data presented should not be regarded as limiting the invention.
ILLUSTRATIVE EMBODIMENT
Compositions containing various resin materials were produced by mixing the indicated components at 150° C. and curing the compositions between glass plates set 1/8-inch apart. Curing was accomplished by heating the compositions at 200° C. for 2 hours and at 220° C. for 6 hours. The properties of the various cured compositions are shown in the Table in terms of the components initially mixed. The components employed are the following.
Component A: Resin BT-2100 marketed by Mitsubishi Gas consisting of 90% 2,2-di(4-cyanatophenyl)propane and 10% bis(4-maleimidophenyl)methane.
Component B: Bis(4-maleimidophenyl)methane.
Component C: The di(4-benzocyclobutenemethyl) ether of 2,2-di(4-hydroxyphenylpropane.
Component D: The di(4-benzocyclobutenemethyl) ether of ##STR6## the ether having a number average molecular weight of about 3100.
Component E: A dicyanato compound of the formula ##STR7##
Component E1 has a number average molecular weight of 5000 and Component E2 has a number average molecular weight of 10,000.
TABLE______________________________________ Tensile Elon-Components Modulus Strength gation Kq Tg(phr) (KSI) (PSI) (%) (PSI in.sup.1/2) (°C.)______________________________________A(100) 503 5660 1.2 531 266A(53) 492 9710 2.3 717 220, 253B(17)C(32)A(50) 672 13,800 4.2 1577 197, 279D(50)A(50) -- -- --E1(50) 1196 237A(50) -- -- -- 1384 --E2(50)______________________________________
|
Improved toughness is demonstrated by cured resin compositions produced by heating a curable resin composition comprising (1) an arylcyclobutenealkyl ether of a di(hydroxyphenyl) oligomer, (2) a bismalemide and (3) a di(cyanatophenyl) oligomer.
| 2
|
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to assemblable and disassemblable frame structures such as used for tents, awnings, canopies and the like, and more particularly relates to such structures which utilize conventional junction elements and compound tube beam and rafter components enabling relatively greater spans and relatively simpler construction than is possible with conventional single tube beam and rafter components.
2. Description of the Prior Art
Conventional tent, awning and canopy frame structures of a readily assemblable and disassemblable nature such as utilized in the rental trade are commonly made up of cylindrical tubing and various types of junction elements or connectors, or so-called slip fit or slip-on fittings, commonly termed corner, ridge intermediate, intermediate, three-way crown, four-way crown, six-way crown and eight-way crown fittings, fabricated of 1.66" OD aluminum or steel tubing. To assemble a given desired structure, it is conventional to use 2" OD cylindrical tubing with 1/8" inch wall thickness in appropriate lengths to make up the uprights (suitably in 7'8" lengths), eave beams (suitably in 9'4", 14'4" and 19'4" lengths) and hip rafters (suitably in 6'10", 10'6", 14'4", 21'10" and 29'4" lengths) and, where used, intermediate rafters (suitably 5', 10'6", 16'1" and 21'8" lengths) with the various rafters being interconnected by a crown fitting at the ridge or peak or peaks or by corner or intermediate fittings at the eave beams. Conventionally, also, the tubes and fittings are joined together in a telescoping manner with the tubes telescoped over associated arms of the fittings and the tubes and fittings are interlocked together by so-called locking quick pins. With such conventional single tube constructions, it is common to limit the span between uprights to ten feet, i.e. limit the length of the eave beams to 9'4" so that the structure had adequate strength to withstand unusual loads, windstorms or the like with an adequate safety margin. It is also known to use single tube eave beams of 14'4" length in certain light duty applications. However, when sturdy tent, awning or canopy structures are desired of relatively larger area coverage, the assemblage becomes quite complicated with need oftentimes for additional internally placed supporting components.
Crow U.S. Pat. No. 1,958,296 discloses tent frames providing an increased span between corner posts by use of arched braces, also called trusses, which in general are made up of laterly spaced top and bottom chords interconnected by spaced struts.
In general it is also known as in Dithridge U.S. Pat. No. 426,558 to construct "beams or sills for railway-cars" with tubular edges and with one or more connecting plates therebetween and with the one or more connecting plates arranged essentially coplanar with the axial centers of the tubular edges, but without any suggestion of utilization of any similar compound tubular configuration in readily assemblable and disassemblable structures such as the structures to which the present invention applies.
SUMMARY OF THE INVENTION
The principal feature and advantage of the present invention is the provision, in readily assembleable and disassemblable tent, awning and canopy structures, of double tubular rafters of unique cross section to double the span between upright posts and quadruple the area which the structure overlies, and to do so in a manner so that the double tube rafter components are usable with conventional interconnectors and are interchangeable with single cylindrical tubing components conventionally used, to the extent desired in any given structural configuration.
It is a further object and feature of the present invention to provide a double tube tent, awning or canopy frame beam and rafter configuration with a maximized strength-to-weight ratio and a like cross section end for end so as to be readily fabricated as by extrusion from high strength aluminum alloy or the like.
It is a further object and feature of the present invention to provide what has been heretofore a gap in the design of readilly assemblable and disassemblable tent frame structures, i.e. to provide what has been the missing structural component between typical small tent, awning or canopy frame components and the large building frame components using massive aluminum tubing of rectangular cross-section. Critical to the beam and rafter structure concept of the present invention is the feature of upward compatibility with all slip fit fittings for standard event tents. With the double tube beam and rafter constructions of the present invention it is possible to build a 40' frame tent structure using exactly the same fittings as are now used to build a 20' or a 30' frame. In addition, the assembly and disassembly times are markedly reduced, in some cases as much as 50%. With the double tube beam and rafter components provided by the present invention, it is possible to build a sturdy tent frame with 20', spacings between the legs or uprights. For example, one can build a 20' by 20' frame using only four corner fittings, four legs, four hip rafters, four eave beams, and one four-way crown fitting. Double tubing and conventional single tubing can be mixed and matched according to special event needs. For example, one can span one side of a 20' by 20' frame with only one twin tube beam, while using standard fittings and tubing on the other sides. When compared with standard 2" single tubing, the double tubing of the present invention provides up to six times the resistance to deflection.
These and other objects, features, advantages and applications of tent, awning and canopy structure and components thereof will be evident from the following description and accompanying illustrations.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an isometric view of a conventional tent frame constructed of single 2" tubing and associated connectors to provide a 20' by 20' (20×20) structure;
FIG. 2 is an isometric view on an enlarged scale of a 20' by 20' (20×20) tent frame utilizing double tube beams and rafters according to the present invention and standard connectors;
FIG. 3 is an enlarged detail view of one of the corner connectors and associated beams and rafter of the tent structure shown in FIG. 2;
FIG. 4 is a further enlarged detail view of one of the double tube beams or rafter of the tent structure shown in FIGS. 2 and 3, showing a lateral cross section thereof;
FIG. 5 is a view similar to that of FIG. 4 showing the lateral cross section of a modified form of double tubing beam or rafter according to the present invention wherein the cylindrical portions thereof are spaced laterally a distance approximately equal to a diameter of the tubular portions;
FIG. 6 is an isometric view on a reduced scale, as compared with FIG. 2, of a more complex tent structure assembly according to the present invention utilizing the double tubes of the present invention for the rafters, eaves and uprights along with conventional connectors, the configuration of the structure providing a coverage of substantially 40' by 80' (40×80).
FIGS. 7A, 7B, 7C, 7D, 7E, 7F and 7G are diagrammatic showings of typical other structural arrangements of tent frames with double tube rafters according to the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring specifically to the drawings, FIG. 1 illustrates in somewhat schematic form a conventional assembly for a 20' by 20' tent frame (20×20), comprising single tube uprights or posts 10, single tube eave beams 12, four hip rafters 14, and four intermediate rafters 16. In conventional style, corner fittings 18 interconnect the corner uprights 10, the adjacent eave beams 12 and hip rafters 14, intermediate connectors 20 interconnect adjacent uprights 10, eave beams 12 and intermediate rafters 16, and the various hip and intermediate rafters 14, 16 are interconnected at the peak by an eight-way crown fitting 22. Such construction provides a substantially 10' span between uprights around the periphery of the structure. As is also conventional, the single tube uprights and rafters are commonly 2" OD aluminum tubing with a 1/8th inch wall thickness and the various slip fit or slip-on fittings have arms with a 1.66" OD and are fabricated of steel or aluminum alloy.
FIG. 2 illustrates on an enlarged scale a 20' by 20' (20×20) tent frame assembly according to the present invention. In this instance, corner fittings 18 are of the same conventional form as utilized in the structure of FIG. 1, as are the single tube uprights or posts 10. According to the invention, double tube eave beams 30 extend between adjacent corner fittings 18 over substantially a 20' span (with 19'4" eave beams) and the corner fittings 18 interconnect the corner uprights 10 and the eave beams 30 and associated hip rafters 32, also of double tube configuration, with the hip rafters 32 in turn being interconnected by being telescoped over four of the arms of an eight-way crown fitting 22, it being apparent with respect to this latter fitting that a four-way crown fitting would serve as well in that four of the arms of the eight-way crown fitting are not used in the assembly of FIG. 2.
FIG. 3 shows on a further enlarged scale one of the corner fittings 18 and portions of the associated double tube eave beams 30 and hip rafter 32 of the tent frame assembly shown in FIG. 2. In a manner conventional per se, the beams and rafter 30, 32 are assembled with one of the tubular portions at the respective ends 34, 36 thereof telescoped over respective arms 38, 40 of the fitting 18. In a manner also conventional per se, each of the arms 38, 40 and each of the beams and rafter 30, 32 is provided with a diametrically extending hole 31, 33, respectively, through which a conventional locking quick pin 42 is installed and is frictionally held in place by contact with the external surface of the beam or rafter. As will be understood, each beam and rafter 30, 32 is similarly interconnected with each corner fitting 18 in the tent frame assembly shown in FIG. 2, and a similar locked interconnection is provided between each of the hip rafters 32 and the associated arms of crown fitting 22 in the assembly of FIG. 2, although not there shown because of the smallness of this detail.
The detail showing in FIG. 3 also illustrates an optional aspect of the configuration of the eave beams 30, which are cut away at about a 45° angle in the end portion 44 thereof to accommodate closer assembly of the double tube form with respect to the associated hip rafter 32. Evident also in FIG. 3 is the arrangement of the downwardly depending arm 46 of the corner fitting 18 onto which the uprights or posts 10 are telescoped (as shown in FIG. 2).
In any tent frame structure such as shown in FIGS. 1 and 2, it is also conventional to stabilize the structure by cables or the like (not shown) extending outwardly from the corner fittings 18 to ground stakes or other anchors.
FIG. 4 shows further detail in lateral cross-section of the double tube beams and rafters 30, 32. In this form of double tube beam or rafter the strength-to-weight ratio is optimized with a cross-sectional configuration including two circular walls 50, 52 interjoined by two planar walls 54, 56 interconnecting the circular wall substantially at diametrically opposed circumferential locations in the circular walls. In this form of rafter wherein the circular walls are 2" in outside diameter (OD) and the wall thickness throughout is 1/8", the two circular walls are joined at the circumferential location 58 therebetween and the form overall can be simply categorized as being of 2" by 4" (2×4) size (actually 2"×37/8" by reason of the shared common circumferential wall portions).
FIG. 5 illustrates an alternative form of beam or rafter 60 wherein the configuration cross-sectionally comprises two circular walls 62, 64 interjoined by two planar walls 66, 68 with the innerfacing portions 70, 72 of the circular walls spaced apart a distance about equal to the diameter of the circular walls. This beam or rafter configuration, wherein the circular walls 62, 64 have an outside diameter of 2", and the wall thicknesses throughout are 1/8", can be categorized as being substantially 2" thick and 6" wide, i.e. 2×6 in form. This form is actually 2"×53/4" in an optimal design so that there is a clearance dimension of 13/4" along both the x-x axis and the y-y axis of the tubing. This configuration allows use of the 2×6 type tubing as uprights with corner fittings like that shown in FIG. 3 which are modified to have a double depending arm in place of the single depending arm 46 to fit within the double tubes of the 2×4 form (FIG. 4) and also the 2×6 form dimensioned as described.
FIG. 6 is a further illustration in isometric and somewhat schematic view of a more complex tent frame structure characteristic of the invention, utilizing double tube beams and rafters and, in this instance, double tube uprights or posts, the structure being designed to cover a ground or floor space approximately 40' by 80' (40×80). In this structure, conventional corner fittings 110 interjoin double tube corner posts 112, corner eave beams 114 and hip rafters 116. Intermediate six-way fittings 118 interjoin double tube posts 120, intermediate eave beams 122, center rafters 124 and diagonal 126. Like intermediate six-way fittings 128 (utilizing only four arms thereof) interjoin double tube posts 130, corner and intermediate eave beams 114, 122, and laterally intermediate rafters 132. Similarly, also, intermediate end end fittings 134 interjoin double tube posts 136, end eave beams 114 and longitudinal roof rafters 138. The various roof rafters 116, 126, 132, and 138 are joined along with double tube ridge beams 140 by eight-way crown fittings 142 and a center eight-way crown fitting 144, four arms of which are used, interconnects roof rafters 124 and ridge beams 140.
As an optional component, in some structures it may be considered desirable to increase the lateral support centrally of the frame, which can be done simply by cable interconnection between the center intermediate fittings 118, with such a cable connection being schematically indicated in FIG. 6 at 146. Comparable cable interconnections (not shown) may also interconnect intermediate fittings 128, if desired.
FIGS. 7A through 7G diagrammatically illustrate other typical tent frame structural arrangements possible with double tube rafters according to the present invention with 20' spans between uprights along the sides thereof.
FIG. 7A is a concept diagram of a 20×20 frame structure, which is the structure illustrated and discussed with respect to FIG. 2. FIG. 7B shows the rafter arrangement for a typical 20' by 40 ' (20×40) tent structure according to the present invention, the FIG. 7C shows a 20' by 60' (20×60) version thereof.
FIG. 7D, 7E and 7F respectively show diagrammatically the rafter plan for 40×40, 40×60 and 40×100 tent structures according the invention, all of which are similar in many respects to the 40×80 frame structure shown and discussed with respect to FIG. 6.
FIG. 7G is a further form of tent structure diagram according to the present invention, in this instance of hexagonal form with six sides (40x HEX) each approximately 20' in length with a single peak.
As an example of practice of the invention in the rental trade, it is common to color code various upright beams and rafters by color to denote application and length. Thus, an inventory of various styles, sizes and lengths can include, for both 2" single tubing and 2×4 double tubing, legs or uprights black in color and 7'8" in length, eave beams white in color and 9'4" in length, intermediate rafters green in color and 10'6" in length, hip rafters red in color and 14'4" in length, intermediate rafters brown in color and 16'1" in length (for 30' wide configurations), eave beams blue in color and 19'4" in length, hip rafters orange in color and either 21'81/2" in length in the 2×4 form or 21'10" in length for the 2" tubing form, and 2×6 double tube eave beams 29'4" in length and color coded yellow which are used for example to bridge over a substantially 30' span at the front of an open stage type tent frame.
As earlier indicated, the double tube forms of beams and rafters typifying and contemplated by the present invention are characterized by a substantially increased strength-to-weight ratio as compared with the conventional single tube rafter construction. This can be demonstrated by a comparison of the moment of inertia of the respective tubular configurations. Addressing first the conventional single tube rafter which had an outside diameter of 2" and a 1/8" wall thickness, and which is fabricated of a suitable aluminum alloy such as alloy 6005T5, and utilizing standard formulations such as found in, "Machinery's Handbook", 12 Ed., published by The Industrial Press, NY, N.Y. (1944), at pages 298, 346 and 347, the moment of inertia of a conventional single tube is 0.324 in 4 along both its X axis and Y axis, and the weight thereof is 0.884 pounds per foot. The 2×4 (actually 2" by 37/8") form of double tube as shown and discussed with respect to FIG. 4 has a moment of inertia of 1.92 in 4 along the X axis and 0.82 in 4 along the Y axis (with such axes being schematically shown in FIG. 4) and a weight per foot of 2.076 pounds. The 2×6 (actually 2" by 53/4") form of double tube as shown and discussed with respect to FIG. 5 demonstrates a moment of inertia of 7.1325 in 4 along the X axis and 1.31 in 4 along the Y axis (with such axes being shown schematically in FIG. 5) and a weight of 2.67 pounds per foot.
Correspondingly, consideration is to be accorded a form of double tube of the same alloy with two 2" OD cylinders of circular form in cross section and with 1/8" wall thicknesses, joined by a panel 1/4" thick in planar form along the Y axis and coplanar with the centers of the tubular components, which double tube form is essentially the same as that illustrated in FIG. 1 of Dithridge U.S. Pat. No. 426,558. Such component tube configuration demonstrates a moment of inertia of 6.708 in 4 along the X axis, a moment of inertia of 0.65 in 4 along the Y axis, and a weight of 2.37 pounds per foot.
From these comparative figures, it is to be observed that the 2×4 tubing is stronger along its X axis than is the single tube by a factor of 5.93:1 while being heavier by a factor of 2.35:1. Comparing the 2×6 double tube with the 2" single tube, the 2×6 tube is stronger by a factor of 22.01:1 while exhibiting an increased weight by a factor of 3.25:1 along its X axis and an increased strength by a factor of 2.53:1 along its Y axis. Comparing the 2×6 form with the form of double tube referred to in the Dithridge patent, the 2×6 form exhibits a strength factor of 1.06:1 along its X axis and a strength factor of 2.02:1 along its Y axis while being slightly heavier by a factor of 1.13:1. It is notable with respect to the strength factor along the Y axis that such strength factor is significant in relatively long span beam applications so that any tendency of the beam to buckle is minimized.
As will be evident, further forms of double tubes characteristic of the present invention with planar walls joining circular sides at substantially diametrically opposed circumferential locations on the circular walls can be fabricated to provide rafters for use in tent frame construction according to the invention, such as forms similar to that shown in FIG. 5 with a lesser or greater lateral spacing between the cylindrical portions such as 2×5 and 2×8 forms, for example. Other assembly configurations than those shown in FIGS. 6 and 7A-7G will also readily occur to those skilled in the art to which the invention is addressed.
|
Readily assemblable and disassemblable tent, awning and canopy frame structures incorporating conventional slip fit junction elements and beams and rafters of double tube form which enable greater spans between uprights and simplified structures for larger area tent or like frames, the configuration of the double tube beams and rafters being such that the double tube beam, rafter and upright components can be interchanged with single tube beams, rafters and uprights. The unique double tube forms are characterized by a cross-sectional configuration including two circular walls interjoined by two planar walls interconnected with the circular walls substantially at diametrically opposed circumferential locations in the circular walls and by increased strength-to-weight ratios.
| 4
|
RELATED APPLICATIONS
[0001] This application claims priority to U.S. provisional application Ser. No. 62/257,571, filed on Nov. 19 th , 2015, the entire contents of which are incorporated herein by reference.
BACKGROUND
[0002] Metal organic framework (MOF) crystals have been extensively studied for many applications such as sensing, catalysis, separations, and gas storage in part due to their high surface area and tunability. Some MOF materials have low stabilities, and their nanometer to micrometer powder size is sometimes not ideal for specific applications. Zirconium based MOFs (ZrMOF) are becoming more popular due in part to their superior stability relative to MOFs based on other metals. In this regard, ZrMOF, UiO-66 (also called Zr-BDC) is considered the archetypal MOF.
[0003] In order to increase the suitability of MOFs to other applications, work has been done to grow MOF crystals on various substrates such as porous stainless steel, metal alloys, and polymeric hollow-tube membranes. Recently, nanofibers have been introduced as a MOF growth platform. In particular, plastic nanofibers are a promising material due to their established use in many fields such as sensing, protective clothing, and separations. Some work has included electrospun MOF impregnated nanofibers, with secondary growth of MOFs on the fibers. However, to synthesize nano-composite MOF/ nanofiber materials with secondary growth of MOF, the nano-composite MOF/ nanofiber materials must be placed in a solvent, and heated above 100° C. for extended periods of time in order to effectively grow the MOF crystals. These conditions are generally too extreme for the nanofibers, and can lead to dissolution or contraction of the nanofibers. Hence, there is a need for a method of producing nano-composite MOF/ nanofiber materials that is less reliant on polymers that require a high thermal stability, high chemical stability, with solubility in specific solvents.
SUMMARY
[0004] Some embodiments include a method of preparing polymer nanofiber composites comprising providing at least one cross-linkable polymer precursor, and at least partially solvating the at least one cross-linkable polymer precursor with at least one solvent. Further, the method can include forming a nanofiber precursor by mixing at least one first metal-organic-framework (MOF) crystal material with the solvated polymer precursor, where the at least one first MOF crystal material comprises at least one metal ion coupled to at least one multidentate ligand. Further, the method can include forming a plurality of nanofibers by electro-spinning at least some portion of the nanofiber precursor, where at least a portion of the nanofibers include a dispersion of the at least one first MOF crystal material. The method can include crosslinking at least a portion of the plurality of nanofibers by irradiating at least a portion of the plurality of nanofibers with UV light, IR light, visible light, gamma radiation, and/or electro-beam radiation. Further, the method can include applying a second MOF crystal material between at least a portion of the cross-linked nanofibers and the at least one first MOF material.
[0005] In some embodiments, the second MOF crystal material comprises a composition different from the first MOF crystal material. In further embodiments, the compositions of the first and second MOF crystal materials are substantially the same. In some embodiments, the first MOF crystal material is a product of reaction between ZrCl 4 and terephthalic acid in the presence of dimethylformamide.
[0006] In some embodiments, the at least one metal ion comprises Zirconium. In some further embodiments, the at least one cross-linkable polymer precursor comprises poly(vinyl cinnamate). In some embodiments, the specific period of time is between 30 minutes and 3 hours. In some embodiments, the least one second MOF crystal material is formed in-situ.
[0007] In some embodiments, the least one second MOF crystal material is formed in-situ using a process comprising exposing at least a portion of the cross-linked nanofibers with the least one first MOF material to a mixture of ZrCl 4 and terephthalic acid in dimethylformamide, and heating in an autoclave to a specific temperature for a specific secondary reaction time.
[0008] In some embodiments, the mixture comprises 0.115 g of ZrCl 4 and about 0.083 grams of terephthalic acid in about 35 mL of DMF. In some further embodiments, the specific temperature is between 80° C. and 100° C. In some embodiments, the process further comprises removing the cross-linked nanofibers from the autoclave after heating and allowing the cross-linked nanofibers to cool.
[0009] In some embodiments, the process is repeated at least once. In some further embodiments, the polymer precursor includes a secondary photoreactive polymer, prepolymer, blend, or mixtures thereof. In some embodiments, the photoreactive polymer includes at least one of a polyurethane or polyester acrylate.
[0010] In some embodiments, the nanofiber composites preparation method comprises forming a nanofiber precursor by mixing at least one metal-organic-framework (MOF) crystal material with at least one polymer precursor and at least one solvent, and forming a plurality of nanofibers by electro-spinning at least some portion of the nanofiber precursor, where the plurality of nanofibers include a dispersion of the at least one first MOF crystal material. Further, the method can include crosslinking at least a portion of the plurality of nanofibers, and forming a second MOF crystal material in-situ on or between at least a portion of the cross-linked nanofibers.
DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 shows a summary of a metal-organic framework—polymer composites synthesis process in accordance with some embodiments of the invention.
[0012] FIG. 2 shows a PVCi crosslinking mechanism in accordance with some embodiments of the invention.
[0013] FIG. 3 shows FTIR absorbance for pure PVCi nanofiber irradiation times of 0, 30, 60, and 120 minutes stacked and normalized to each spectra's maximum intensity in accordance with some embodiments of the invention.
[0014] FIG. 4 shows normalized and stacked FTIR absorbance spectra of the UiO-66 seeds and UiO-66 impregnated PVCi membranes after crosslinking and at each reported stage of secondary growth at 80° C. in accordance with some embodiments of the invention.
[0015] FIG. 5 shows normalized and stacked FTIR absorbance spectra of the UiO-66 seeds and UiO-66 impregnated PVCi membranes after crosslinking and at each reported stage of secondary growth at 100° C. in accordance with some embodiments of the invention.
[0016] FIG. 6 shows PXRD patterns comparing the final membranes after each 12 hour growth period at 80° C. and 100° C. compared to a simulated pattern for pure UiO-66 powder in accordance with some embodiments of the invention.
[0017] FIG. 7 shows PXRD patterns of membranes after each 12 hour growth period for 80° C. synthesis temperatures normalized to the maximum intensity found from the 3rd growth at 100° C. in accordance with some embodiments of the invention.
[0018] FIG. 8 shows PXRD patterns of membranes after each 12 hour growth period for 100° C. in accordance with some embodiments of the invention.
DETAILED DESCRIPTION
[0019] Before any embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. The use of “including,” “comprising,” or “having” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. Unless specified or limited otherwise, the terms “mounted,” “connected,” “supported,” and “coupled” and variations thereof are used broadly and encompass both direct and indirect mountings, connections, supports, and couplings. Further, “connected” and “coupled” are not restricted to physical or mechanical connections or couplings.
[0020] The following discussion is presented to enable a person skilled in the art to make and use embodiments of the invention. Various modifications to the illustrated embodiments will be readily apparent to those skilled in the art, and the generic principles herein can be applied to other embodiments and applications without departing from embodiments of the invention. Thus, embodiments of the invention are not intended to be limited to embodiments shown, but are to be accorded the widest scope consistent with the principles and features disclosed herein. The following detailed description is to be read with reference to the figures, in which like elements in different figures have like reference numerals. The figures, which are not necessarily to scale, depict selected embodiments and are not intended to limit the scope of embodiments of the invention. Skilled artisans will recognize the examples provided herein have many useful alternatives that fall within the scope of embodiments of the invention.
[0021] Some embodiments include polymers that comprise a homopolymer comprising cross-linkable functional groups. In some further embodiments, the polymer can comprise a copolymer including at least one type of cross-linkable group. In some further embodiments, the polymer can comprise a polymer blend including at least one polymer that includes a cross-linkable group. Some embodiments of the invention include the use of a commercially available polymer, Poly(vinyl cinnamate) (hereinafter PVCi) to produce polymer composites including a metal-organic-framework (hereinafter “MOF”). In some embodiments, a Zirconium-based MOF (hereinafter “ZrMOF”) is used. In some embodiments, the ZrMOF can comprise the group of materials UiO (University of Oslo), including, but not limited to, UiO-66. In some embodiments, the polymer can be cross-linked by exposure to UV light. In some other embodiments, the polymer can be cross-linked by exposure to infra-red light. In some further embodiments, the polymer can be cross-linked by exposure to visible light. In some embodiments, the polymer can be cross-linked by exposure to multiple wavelengths of light including, but not limited to, UV light, IR light, and visible light.
[0022] In some embodiments, the PVCi is electrospun. In some embodiments, changes in structure, chemical stability, and thermal stability are induced by ultraviolet light crosslinking of the PVCi. In some embodiments, ZrMOF is grown via solvothermal secondary growth on electrospun mats to form various topologies. Using these methods, in some embodiments, continuous UiO-66 membranes with PVCi scaffolding for structural support can be prepared. In some other embodiments, other MOFs requiring strong solvents and temperatures, as well as any other polymers that can be electrospun and cross-linked can be used.
[0023] FIG. 1 shows a summary of the metal-organic framework—polymer composites synthesis process described above. In some embodiments of the invention, the process can include providing a cross-linkable polymer (shown as step 10 ). In some embodiments, the cross-linkable polymer can comprise a photoreactive cross-linkable polymer such as PVCi. PVCi comprises a polyvinyl alcohol backbone that includes cinnamoyl side chains that can be photo-cross-linked using UV irradiation through cycloaddition reactions (see FIG. 2 showing PVCi monomers 100 crosslinking to crosslinked PVCi 200 ). In some other embodiments, the polymer precursor can comprise a further or secondary photoreactive polymer, prepolymer, blend, or mixtures thereof. For example, in some embodiments, the photoreactive polymer, prepolymer, blend, or mixtures thereof can include at least one photoreactive monomer or oligomer. As one non-limiting example, some embodiments include a photoreactive acrylate such as a polyurethane or polyester acrylate. Further, in some embodiments, the polymer precursor can include a photoinitiator. For example, in some embodiments, a UV sensitive or reactive photoinitiator can be used that is soluble in the polymer precursor or polymer precursor solution.
[0024] In some embodiments, the cross-linkable polymer can be solvated using a solvent for the polymer to produce a polymer solution (shown as step 20 ). For example, in some embodiments, dichloromethane can be used to form a PVCi solution. Following polymer solvation, one or more MOF materials can be added as a MOF seed material (step 30 ) to form a polymer solution with dispersed MOF seed (hereinafter referred to as “nanofiber precursor”). For example, solvothermal reactions can be carried out in a Teflon® lined autoclave by mixing about 0.357 grams of ZrCl 4 and about 0.254 grams of terephthalic acid in about 21 mL of dimethylformamide (DMF) and about 8.6 mL of acetic acid. The mixture solution can be heated to about 120° C. for about 24 hours, and then cooled to room temperature yielding white colored crystals. The synthesized sample (comprising UiO-66 crystals) can be obtained by filtration, and dried in air for about 24 h before use. In some embodiments, solutions of about 10 wt % PVCi/DCM with about 100 mg of UiO-66 crystals can be prepared and stored in darkness at room temperature until use.
[0025] In some embodiments, the nanofiber precursor can be electrospun to produce a plurality of nanofibers (step 40 ). In some embodiments, PVCi and PVCi with UiO-66 samples can be fed through a metallic needle by a syringe pump (such as one produced by New Era Pump Systems, Inc.) at the rate of about 3 and about 4.2 ml h − 1, respectively. A voltage of about 22 kV (Gamma High Voltage Research) can be applied between the spinneret and the collector with a distance of about 6 cm at room temperature. The spun-nanofibers mats can be collected and dried at room temperature for about 24 hours. In some embodiments, the nanofiber precursor can be electrospun into a plurality of fibers. In some further embodiments, the nanofiber precursor can be electrospun into a mat. In some other embodiments, the nanofiber precursor can be electrospun into a membrane or any other physical structure.
[0026] In some embodiments, the nanofibers can comprise nanofibers with a dispersion or distribution of the MOF materials that can be originally found in the nanofiber precursor. In some embodiments, at least a portion of the MOF materials can be dispersed substantially homogenously through at least a portion of the nanofiber. In some other embodiments, at least a portion of the MOF materials can be substantially unevenly distributed through at least a portion of the nanofiber. In some embodiments, at least some portion of the MOF materials can exist as discrete particles. In other embodiments, at least a portion of the MOF materials can comprise an association or cluster of a plurality of MOF particles within or on the nanofibers. In some embodiments, the MOF materials can comprise a particle or cluster size of between about 1 and about 10 microns. In some other embodiments, at least some portion of the MOF materials can be sub-micron sized. In some other embodiments, at least a portion of the MOF materials can comprise nano-sized particles.
[0027] In some embodiments, the nanofibers (either as a plurality of nanofibers, a mat, or a membrane) can be cross-linked (step 50 ). For example, in some embodiments, the nanofibers can be cross-linked by exposing the electrospun nanofibers to UV irradiation. In some embodiments, the electrospun PVCi mats can be irradiated with ultraviolet (UV) light for about 30, or about 60, and/or about 120 minutes. FIG. 3 shows a graph 300 of FTIR absorbance for pure PVCi nanofiber irradiation times of 0 minutes (spectra 305 ), 30 minutes (spectra 310 ), 60 minutes (spectra 315 ), and 120 minutes (spectra 320 ) stacked and normalized to each spectra's maximum intensity in accordance with some embodiments of the invention.
[0028] In some further embodiments, the PVCi with UiO-66 solution can be UV irradiated for about 3 h. The irradiation of nanofibers can be carried out by a UVM-28 EL Series UV Lamp (UVP, LLC, CA, USA) emitting a light intensity of about 2000 μW/cm 2 at a wavelength of about 302 nm at room temperature. The mats can be placed under the UV light with a distance of about 4 cm from the lamp head. An initial about 15 minute time period was allotted for the lamp to warm up before exposing to nanofibers. In other embodiments, other wavelengths of UV light, IR light, visible light, gamma radiation, electro-beam radiation, and/or an initiator can be used to cross-link the nanofibers.
[0029] Some embodiments include alternatives to solution electrospinning as described. For example, in some embodiments, coaxial electrospinning can be used where multiple solutions and be prepared and co-injected through a tip of a spinneret. In some further embodiments, emulsion electrospinning can be used. For example, in some embodiments, an emulsion of polymer, solvent and MOF can be prepared and electrospun through a tip of a spinneret. In other embodiments. In some other embodiments, melt electrospinning can be used with a polymer including dispersed MOF. For example, in some embodiments, the seed MOF can be introduced into the polymer using solution casting, in-situ reaction, extrusion, blending, or other conventional composite fabrication method, and then subsequently melt-spun to produce polymer nanofiber with dispersed seed MOF.
[0030] In some embodiments, the cross-linked nanofibers can be exposed to additional MOF materials to initiate and encourage a secondary growth of MOF within and/or on the nanofibers (step 60 ). For example, in some embodiments, UiO-66 seeds were synthesized and suspended in solutions of PVCi in DCM. In some embodiments, the seeds can be about 500 nm in diameter. Through the process of electrospinning, MOF and PVCi were passed through the needle resulting in seeds mechanically anchored into the fibers to provide nucleation points for secondary growth. Further, for example, in some embodiments, photo-cross-linked PVCi with UiO-66 mats can be cut to fit inside a 100 mL Teflon lined autoclaves and filled with a solution of about 0.115 g of ZrCl4 and about 0.083 grams of terephthalic acid in about 35 mL of DMF. Samples can be heated at 100° and 80° C. for about 12 hours. The membranes can be collected from the autoclave and allowed to cool. The procedure was repeated three or four times at about 100° C. and about 80° C., respectively. Final membranes can be washed multiple times with DMF to remove any excess UiO-66. In some embodiments, the MOF used in the secondary growth can be the same as the seeded MOF. In other embodiments, the seed MOF and the secondary growth MOF can comprise a different composition.
[0031] In some embodiments, to achieve the nearly complete crosslinking desired for the secondary growth of UiO-66, a 3 hour UV irradiation time was carried out to achieve a similar degree of crosslinking as the 2 hour time for pure PVCi nanofibers according to FTIR. It is hypothesized that the longer times required to crosslink MOF impregnated nanofibers relative to pure nanofibers is because of the increased average distance between PVCi functional groups caused by the presence of MOFs impregnated in the fibers, and a smaller amount of available crosslinking sites available because of this spacing.
[0032] In some embodiments of the invention, after crosslinking, UiO-66 secondary growths were performed at 100° C. and 80° C., and every 12 hours the samples were dried and placed into a fresh growth solution until the final membranes were produced. Samples were analysed at each time step to study the effects of each temperature and each growth. FTIR spectra patterns of each growth were recorded. For example, FIG. 4 shows normalized and stacked FTIR absorbance spectra of the UiO-66 seeds and UiO-66 impregnated PVCi membranes after crosslinking and at each reported stage of secondary growth at 80° C. in accordance with some embodiments of the invention. Further, FIG. 5 shows normalized and stacked FTIR absorbance spectra of the UiO-66 seeds and UiO-66 impregnated PVCi membranes after crosslinking and at each reported stage of secondary growth at 100° C. in accordance with some embodiments of the invention. From the FTIR spectra it can be seen that the peaks representative of the UiO-66 crystal pattern increase with increasing growths. In reference to the FIG. 4 , graph 400 shows UiO-66/PVCi with no secondary growth (spectra 405 ), UiO-66/PVCi with one secondary growth (spectra 407 ), UiO-66/PVCi with two secondary growths (spectra 409 ), UiO-66/PVCi with three secondary growths (spectra 411 ), UiO-66/PVCi with four secondary growth (spectra 413 ), and UiO-66 seeds (spectra 415 ). In reference to the FIG. 5 , graph 500 shows UiO-66/PVCi with no secondary growth (spectra 505 ), UiO-66/PVCi with one secondary growth (spectra 507 ), UiO-66/PVCi with two secondary growths (spectra 509 ), UiO-66/PVCi with three secondary growths (spectra 511 ), UiO-66/PVCi with four secondary growth (spectra 513 ), and UiO-66 seeds (spectra 515 ). The stability of the PVCi fibers at increased temperature, and prolonged chemical exposure times is reaffirmed by the absence of a doublet or peak shift at 1737 cm −1 , which would indicate the breaking of crosslinking bonds. Systematic decreases in representative PVCi peaks across the FTIR spectra occur as well at 1737 cm −1 , 1498 cm −1 , 754 cm −1 , and 608 cm −1 , while peaks provided by the UiO-66 seeds steadily become more prominent with growths at 1675 cm −1 , 1507 cm −1 , 1157 cm −1 , 1094 cm −1 , 1020 cm −1 , and 750 cm −1 .
[0033] FIGS. 6-8 shows PXRD patterns performed on membranes of each time step to monitor the synthesis of UiO-66 at each interval. For example, FIG. 6 shows PXRD patterns comparing the final membranes after each 12 hour growth period at 80° C. (spectra 605 ) and 100° C. (spectra 610 ) compared to a simulated pattern 615 for pure UiO-66 powder in accordance with some embodiments of the invention. Further, FIG. 7 shows a plot 700 of PXRD patterns of membranes after each 12 hour growth period for 80° C. synthesis temperatures normalized to the maximum intensity found from the 3rd growth at 100° C. in accordance with some embodiments of the invention. For example, the plot 700 shows 1 st growth spectra 705 , 2 nd growth spectra 710 , third growth spectra 715 , and 4 th growth spectra 720 . Further, FIG. 8 shows a plot 800 of PXRD patterns of membranes after each 12 hour growth period for 100° C. in accordance with some embodiments of the invention. Plot 800 shows 1 st growth spectra 805 , 2 nd growth spectra 810 , third growth spectra 815 . The intervals each show an increase in crystallinity as the UiO-66 crystals emerge and engulf the PVCi fibers, and the final pattern for each temperature are compared to a simulated PXRD pattern from single crystal XRD data. The peaks from the membranes match the peaks of the simulated pattern with the addition of a peak near 12 2θ, which was also present in the UiO-66 seed crystals.
[0034] It will be appreciated by those skilled in the art that while the invention has been described above in connection with particular embodiments and examples, the invention is not necessarily so limited, and that numerous other embodiments, examples, uses, modifications and departures from the embodiments, examples and uses are intended to be encompassed by the claims attached hereto. The entire disclosure of each patent and publication cited herein is incorporated by reference, as if each such patent or publication were individually incorporated by reference herein. Various features and advantages of the invention are set forth in the following claims.
|
Some embodiments include a method of preparing polymer nanofiber composites using a cross-linkable polymer precursor solvated with a solvent, and forming a nanofiber precursor by mixing with a metal-organic-framework (MOF) crystal material that includes a metal ion coupled to at least one multidentate ligand. Further, the method can include forming a plurality of nanofibers by electro-spinning the nanofiber precursor, where at least a portion of the nanofibers includes a dispersion of the first MOF crystal material. The method can include crosslinking the plurality of nanofibers by irradiating the plurality of nanofibers with UV light, IR light, visible light, gamma radiation, and/or electro-beam radiation. Further, the method can include applying a second MOF crystal material between the cross-linked nanofibers and the first MOF material.
| 3
|
BACKGROUND OF THE INVENTION
In the electromechanical arts, a switch is a device used for effecting the completion and interruption of a circuit. See "The Way Things Work: an Illustrated Encyclopedia of Technology", volume 1 published by Simon and Schuster, 1967, pages 96-97. There are various types of switches and switch configurations for various applications.
One type of switch is a pressure switch. In general, a pressure switch has an upper electrode and a lower electrode spaced from each other. Under a predetermined (threshold) load, the two electrodes are brought together and make contact. The switch has two positions (states), open and closed. Typically the switch is open when an applied load is less than the threshold pressure such that the two electrodes are spaced apart from each other. The switch is in its closed state when a load greater than the threshold pressure is applied to the switch causing the two electrodes to make contact with each other.
SUMMARY OF THE INVENTION
The present invention provides a threshold pressure switch that is formed by silicon micromachining and wafer to wafer bonding techniques. In particular, the present invention switch fabrication method takes advantage of (i) the residual pressure from gases trapped in a cavity during a wafer to wafer bonding, and (ii) the plastic deformation of silicon.
In a preferred embodiment the pressure switch is of the type having a first electrode spaced from a second electrode. The first electrode moves toward and contacts the second electrode upon application of a threshold pressure to the switch. Formation of the first electrode spaced from the second electrode is by (a) trapping gas in an enclosed cavity formed between two working layers, and (b) expanding the gas to generate pressure sufficient to bloat (radially outward from the cavity) at least one of the working layers. The bloated working layer serves as the first electrode and the other working layer across the cavity from the bloated working layer serves as the second electrode.
The device in its preferred embodiment has a permanently hemispherically-shaped top electrode separated from the bottom electrode. The geometry of the top electrode allows the designer to predict the threshold pressure of the switch, that is, the pressure at which the top electrode collapses making contact with the bottom electrode thereby closing the switch. Additionally, the geometry of the top electrode allows the exploitation of an inherent mechanical characteristic of hemispherical domes under pressure loading, namely mechanical hysteresis.
The top electrode collapses under the action of a uniform pressure loading of sufficient magnitude. The hemispherical mode shape of the top electrode is stable for uniform pressure loading below the threshold level. However, as the loading increases this hemispherical mode shape is no longer stable and the structure changes its mode shape to a more stable configuration under the increased load. The stable mode shape adopted by the structure will be termed a collapsed mode shape because the center of the hemispherical dome will have gone from a position of maximum height to a position of minimum height. This mechanical action results in the top electrode contacting the bottom electrode, thereby closing the switch. It should be noted that the collapsing of the top electrode is not destructive to that mechanical element. The collapsing of the top electrode is a non-linear process, but the local deformations are within the linear elastic region of the material.
Mechanical hysteresis as it applies to the operation of the present invention switch means that the pressure at which the switch closes is higher than the pressure at which the switch subsequently opens. Therefore, as a pressure is applied to the top electrode, the switch remains open until the threshold pressure is reached. At this point, the top electrode collapses and the switch closes and remains closed for higher pressures. As the applied pressure is reduced, the top electrode remains collapsed and the switch closed until at some significantly reduced pressure the top electrode pops back to its original hemispherical shape. The mechanical hysteresis is due to the reduced mechanical restoring force of a collapsed hemispherical dome compared to the uncollapsed structure.
Preferably, the bloated working layer is single crystal silicon.
In accordance with one aspect of the present invention the step of trapping gas in the cavity is accomplished as follows. A cavity is formed in a first silicon layer through the upper surface of the silicon layer such that the cavity has an opening at the upper surface. A second silicon layer is attached to the upper surface of the first silicon layer such that a portion of the second silicon layer covers the cavity opening and in turn traps gas in the cavity. Preferably the second silicon layer is attached to the first silicon layer by silicon wafer bonding techniques. Other techniques for securing the two layers together are suitable as long as the strength of said structure prevents the layers from separating during fabrication of the device, particularly during the plastic deformation of one of the layers.
According to another aspect of the present invention, the step of expanding the gas trapped in the cavity includes heating the gas above a temperature at which the bloated working layer plastically deforms.
Accordingly, one of the preferred embodiments of the present invention provides an upper electrode by plastically deforming a portion of a first working layer covering a cavity formed in another working layer which serves as the lower electrode. The pressure switch changes from an open state to a closed state when a pressure sufficient to collapse the upper electrode to the lower electrode spaced across the cavity is applied to the switch.
In another embodiment, the bloated working layer that forms the top electrode is not necessarily plastically deformed. Instead, the trapped gas within the sealed cavity is heated causing the top electrode working layer to expand upward and then some layer of material is deposited onto the surface of the now bloated working layer locking in the shape of the bloated working layer. The shape is retained upon the cooling of the structure. Generally, the deposited layer covers the bloated working layer and provides the mechanical force necessary to maintain the shape of the working layer.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing and other objects, features and advantages of the invention will be apparent from the following more particular description of preferred embodiments of the invention, as illustrated in the accompanying drawings in which like reference characters refer to the same parts throughout the different views. The drawings are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the invention.
FIGS. 1a and 1b are a cross section and plan view respectively of a pressure switch embodying the present invention, the cross section being taken along the line I--I in FIG. 1b.
FIG. 2 is the cross section of the pressure switch of FIG 1a in a closed position.
FIGS. 3a-3q illustrate the fabrication process of the present invention pressure switch.
FIG. 4 is a graphic illustration of the mechanical hysteresis behavior of the present invention pressure switch.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
A schematic diagram of a threshold pressure switch 11 embodying the present invention is shown in FIGS. 1a and 1b, both in cross-section and plan view respectively. A hemispherically-shaped, preferably silicon, membrane 13 forms the top electrode of switch 11. The dimensions of this membrane 13 are designed such that the membrane will collapse under a pre-determined loading (threshold) pressure. If the thickness of the membrane 13 is sufficiently small, the threshold pressure can be quite small, e.g., less than about 1 atm as made clearer later.
The top electrode (membrane 13) is spaced from the bottom electrode 15 across a cavity 19. Separation of the electrodes 13, 15 is maintained by the mechanical restoring force due to the mechanical rigidity of the hemispherically shaped top electrode 13 and the internal pressure of inert gases trapped within the sealed cavity between the electrodes. The separation is maintained until the applied pressure force on the top surface of the top electrode 13 is sufficient to cause the top electrode 13 to collapse.
The bottom electrode 15 is also preferably made of a layer of silicon, but is much thicker, about 0.5 mm. The layers of silicon for both top and bottom electrodes 13, 15 are doped heavily to ensure minimal resistive losses in the layers. Outside the switch contact area, the two silicon layers are separated from each other by a layer of insulating material 17, for example silicon dioxide.
Pressure switch 11 is a two terminal switch which is normally in an open state without pressure loading. As shown in FIG. 1, terminal 21 is connected to top electrode 13, and terminal 23 is connected to bottom electrode 15, electrically isolated from top electrode 13. As pressure loading increases, a threshold is reached where the hemispherical membrane 13 collapses (i.e., deflects so as to make contact with bottom electrode 15) as shown in FIG. 2. In turn, with the membrane (top electrode) 13 making contact with the bottom electrode 15, switch 11 closes (i.e., is in its closed state). The output signal through terminals 21, 23 is a significant change in resistance, from infinite impedance when loaded below the threshold pressure, to near zero impedance when loaded at or above the threshold pressure.
The method of fabrication of the pressure switch of the present invention provides features and advantages heretofore unattained. As mentioned above, both the top and bottom electrodes 13, 15 are preferably made of respective layers of silicon. The two layers of silicon are joined using a technique called silicon wafer to wafer bonding which results in a bonded composite structure having near single crystal strength. Generally, such a bond is strong enough to allow plastic deformation without the two layers coming apart.
The fabrication of the switch relies on two fundamental properties in silicon wafer to wafer bonding. The first is that if two wafers are bonded together wherein one of the wafers has a cavity etched into it prior to bonding, a residual pressure exists inside this cavity and is equal to 0.8 atm if the bonding is done in air. Presumably, as two wafers are bonded, the air in the cavity is trapped. During the high temperature phase of the bonding, the air can not escape before the cavity is permanently sealed. Additionally, during a subsequent high temperature anneal, the oxygen content of air, about 20%, reacts with the exposed silicon sidewalls forming a thin layer of silicon dioxide. The inert gases in air, notably nitrogen and argon, remain in the cavity leading to the residual gas pressure measured at about 0.8 atm.
The second property relates to the deformation of silicon. By exposing two bonded wafers that have a cavity within the composite structure to a suitably high temperature (i.e., yield temperature of silicon) environment, one can deform the silicon. This is due to (i) the expansion of the residual gases within the cavity as a result of heating from the high temperature environment, and (ii) the reduced yield and flow stress of silicon at such elevated temperatures. The effect is most noticeable when one of the wafers is etched back to a relatively thin layer, less than 10 μm for a 5 mm radius cavity, prior to high temperature exposure. Further the expanding residual gases provide the loading to deform (i.e., bloat radially outward from the cavity) the silicon layer, and this layer has a yield and flow stress less than the stress caused by the expanding gases at the appropriately selected elevated temperature. The threshold temperature for the onset of plastic deformation of silicon is above about 600° C. depending on surrounding conditions.
The method of fabrication of the present invention pressure switch exploits the residual pressure inside the sealed cavities and the deformation (and in particular, plastic deformation) of silicon in order to realize the structure shown in FIG. 1. These two features are considerations in another patent application, entitled "Method of Making a Microvalve", U.S. patent application Ser. No. 07/566,997, filed Aug. 13, 1990 and assigned to the assignee of the present invention and Bosch of the Federal Republic of Germany. A detailed fabrication sequence of the present invention follows, preceded by a discussion of the mechanical behavior of the pressure switch Il.
The mechanical behavior of the pressure switch 11 is generally characterized by (i) its nominally spherically-shaped structure, and (ii) its collapsing and hysteresis operation by design. In particular top electrode 13 is approximately hemispherically shaped (or at least a portion of a hemisphere). Thus the theory of elastic stability of spherical shells can be applied in determining the threshold pressure for collapsing.
As to the fabrication and design of the present invention switch, two complications must be addressed as follows.
First, the structure must be designed so as to withstand the pressure loading from the expansion of gases in cavity 19 during heating. That is, the structure must be able to survive the forces placed on it due to the expanding gas within the cavity 19 before the silicon begins to plastically deform. Second, for a pressure switch sensing pressure above 1 atm, the resultantly deformed structure must be able to withstand atmospheric or greater pressure static loading, ensuring that the top electrode 13 is not initially collapsed and contacting bottom electrode 15. For alternative switches of the present invention, such as a vacuum pressure switch, the top electrode 13 will be collapsed under atmospheric pressure but will pop back out to a bloated shape at some reduced pressure in a vacuum chamber.
Applicants have found that circular cavities with a radius of 1.8 mm, and a top electrode 13 layer of silicon 8 μm thick, will fracture at 600° C. if the cavity is much deeper than 10 μm. In such cases, the expanding gases inside the sealed cavity load the top electrode 13 layer of silicon beyond its yield point resulting in failure. Thus to determine the dimensions of the cavity such that the switch structure is likely to withstand the pressure forces, the ideal gas law in conjunction with simple mechanics are applied as follows.
From the ideal gas law, the pressure inside a cavity as a result of heating is: ##EQU1## where
T 1 and T 2 are the initial (room temperature) and final (maximum process temperature) temperatures, respectively;
P 1 and P 2 are the initial and final pressures, respectively; and
V 1 and V 2 are the initial and final volumes, respectively.
The change in volume, ΔV is given by: ##EQU2## where h 1 is the height of the top electrode 13 with respect to the plane in which top and bottom electrode 13, 15 layers are bonded together, and a is the radius or top electrode 13 assumed to be spherically shaped. Also, the equation for large deflection of the uniformly loaded circular top electrode is given by: ##EQU3## where
h 1 is deflection of the top electrode 13;
a is the plate radius;
E is Young's modulus;
t is the thickness of the top electrode 13; and
q is the differential pressure loading across the top electrode causing the deflection and is given by: ##EQU4## where
P 1 =P atm (atmospheric pressure).
The maximum allowable deflection of the top electrode layer is then estimated by calculating the maximum stress in a uniformly-loaded circular plate and comparing this result to the known yield point for silicon at the appropriate temperature. The maximum stress in a uniformly loaded circular plate undergoing large deflections is given by: ##EQU5## where
E is Young's modulus;
a is the radius of the plate;
t is the thickness; and
q is the differential pressure loading across the plate.
Combining Equation 3 and 5 and simplifying, the following expression for strain, ε, can be written: ##EQU6## where σ is the maximum stress, E is Young's modulus, h 1 is the deflection, and a is the plate radius. Assuming a maximum strain of 0.1% before fracture and setting Equation 6 equal to 0.001, it is found that:
h.sub.1 ≦0.03a; Equation 7
to prevent fracture.
Another design problem for present invention pressure switches desired to operate above 1 atm is the static collapsing (i.e. closure) of the top electrode 13 due to atmospheric loading. Since the effective volume of the cavity has swelled due to the plastically deformed top electrode layer 13, the residual pressure inside the cavity has been reduced. In turn, with the cavity pressure much reduced, the top electrode 13 layer may collapse under atmospheric loading alone. For example, a 0.5 mm radius circular membrane having a thickness of 3 μm and a cavity depth of about 3 μm, has been found to collapse under atmospheric loading.
Estimating worst case, Applicants assume that the pressure inside the cavity is allowed to equal the pressure outside the cavity during heating, that is, the stress produced by the expanding trapped gases is allowed to be relieved by a permanent strain in the top electrode layer. Therefore, using the ideal gas law, ##EQU7## at T 2 =1000° C., V 2 is equal to 3.47V 1 . Further the final volume v 2 is then given by:
V.sub.2 =V.sub.1 +ΔV, Equation 9
where ΔV is the change in the volume given by Equation 2 above, and V 1 is the initial volume given by πa 2 h 2 , with h 2 equal to the cavity depth. Simultaneously solving these two equations we find a relation between h 1 , the top electrode 13 layer height, and h 2 , the cavity depth, which is h 1 =4.94h 2 , assuming h 2 <<a.
If the cavity is now cooled to room temperature and assuming that the volume remains constant, the pressure inside the cavity becomes 0.23 Atm. Consequently, the static loading of the membrane is 0.77 Atm directed downward. This calculation assumes that the plastically deforming membrane (i.e., top electrode) layer can not resist the stress placed on it by the expanding gases. In reality the flow stress of silicon will not be zero and therefore this calculation gives a worst case scenario
If the critical load for the top electrode to collapse is less than 0.77 Atm, the switch will be closed under atmospheric pressure.
Having disclosed design considerations of top electrode height h 1 , cavity depth h 2 and top electrode radius a, the mechanical hysteresis operation of the present invention switch 11 is discussed next. Generally switch 11 exhibits mechanical hysteresis by closing upon advocation of a threshold load (critical pressure P B ) and subsequently opening at a lesser load (release pressure P r ) as shown in FIG. 4. At applied loads less than the release pressure P r , the switch 11 exhibits deflection as a monotonic function of applied load P.
The FIG. 4 graph of top electrode deflection with respect to pressure is illustrative, where one axis labeled P indicates applied pressure, and the orthogonal axis labeled d indicates deflection of top electrode 13 under the applied pressure. At an initial pressure, say for example atmospheric pressure P atm , top electrode 13 is undeflected and hence switch 11 is open. With increasing applied pressure from P atm through P B , deflection of top electrode 13 increases monotonically as shown by dashed line 57.
At the threshold pressure for collapsing P B , top electrode 13 maximally deflects, (i.e., collapses to contact bottom electrode 15), such that switch 11 is closed. This collapsing at P B is a nonlinear change in deflection, or a discontinuity (singularity) in the pressure-deflection behavior as shown by line 59 in FIG. 4. As the applied load is subsequently decreased from P B to release pressure P r , top electrode 13 remains collapsed (i.e., at maximal deflection d max as shown by line 61 in FIG. 4), and hence switch 11 remains closed.
At P r there is a second discontinuity in the pressure-deflection behavior of switch 11; namely, top electrode 13 changes from maximally deflected to an intermediate level of deflection as shown by line 63. Thereafter as applied pressure decreases, deflection of top electrode 13 also decreases as shown by dashed line 65.
For comparison, a pressure switch device exhibiting non-mechanical hysteresis behavior is illustrated by solid line 60 in FIG. 4. Such a device exhibits deflection-pressure behavior to a maximal deflection for applied loads up to a threshold pressure P t . At P t and greater applied pressure, that device remains at maximal deflection. At
subsequent applied pressures decreasing below P t the device exhibits the deflection-pressure behavior previously exhibited at those pressures. Thus there are no discontinuities in deflection-pressure behavior as in the present invention switch 11.
FABRICATION PROCESS
The present invention process for fabricating threshold pressure switch 11 is now described with reference to FIGS. 3a-3q. The fabrication sequence of the preferred embodiment of switch 11 begins with a n-type <100>0.5-2.0 ohm-cm 4-inch silicon wafer 25 illustrated in FIG. 3a. This wafer ultimately serves as the bottom electrode 15 and hence is referred to as the bottom electrode wafer 25. The wafer is placed in a phosphorus diffusion furnace at 925° C. for 1.5 hours in order to highly dope the surfaces of the wafer. A phosphorous doped SiO 2 glass layer is formed in order to highly dope surfaces of the wafer. This doping step is done to ensure that the bottom electrode 15 is a good conductor.
After a one hour drive-in diffusion at 950° C., the wafer is placed in a hydrofluoric acid based etchant to remove the phosphorous-doped SiO 2 glass, and a 1000 Å thick silicon oxide layer 27 is thermally grown on wafer 25 as shown in FIG. 3b. Oxide layer 27 serves as a mask and as such is patterned using photolithographic techniques illustrated in FIG. 3c. After the masking oxide layer 27 is patterned, the wafer 25 is placed in 20% KOH at 56° C. to etch circular recessed electrodes 29 about 1 to 8 μm deep and about 0.1 to 0.5 mm in radius, in wafer 25 as shown in FIG. 3d. The etch rate of KOH at 56° C., 20% concentration is approximately 0.3 μm/min. Other wet anisotropic etchants of the dimensioned electrodes may be used in addition to or in preference over KOH. Further, a dry etchant such as plasma may be used to form the cavity.
During the patterning and etching steps of FIGS. 3c and 3d, the oxide layer 27 becomes damaged. Thus, the masking oxide layer 27 is removed by a wet hydrofluoric acid etch shown in FIG. 3e. A new thermal oxide layer 31 is grown on wafer 25 to replace masking oxide layer 27 as shown in FIG. 3f. This thick layer 31 of silicon dioxide is sufficiently thick (about 1.0 μm to about 2.0 μm) to act as an insulator between the field regions of the switch electrodes 13, 15. The thermal oxide layer 31 is then patterned by photolithographic techniques to remove the oxide from the recessed electrode areas 29 and thereby expose silicon wafer 25 as shown in FIG. 3g. It is important that the insulating oxide layer 31 is patterned using a mask having a slightly larger radius than the electrode area 29. This is because the oxide grown over a cavity has a slightly enhanced oxidation right at the cavity corner causing an elevated ridge around the cavity edge. This ridge prevents good bonding at the cavity edge and is therefore undesirable.
Next, a wafer 33 which ultimately serves as the membrane or top electrode 13 layer is prepared. This includes heavily boron doping a 4 inch <100> p-type 10-20 ohm-cm wafer 33 so as to create a p++ layer 35 on the front side of wafer 33 as shown in FIG. 3h. This p++ layer 35 serves as an anisotropic etch stop in a later described wafer thinning step. A second n-type layer 37 is deposited on top of the p++ layer 35. This second layer 37 is a deposited epitaxial film and preferably about 5 microns thick for the cavity radii and cavity depths desired.
The two wafers 25, 33 are cleaned using a standard pre-oxidation clean, and then hydrated by immersion into a 3:1, sulfuric acid:hydrogen peroxide solution. After a spin rinse and dry, the polished surfaces (oxide layer 31 and second layer 37) of the wafers 25, 33 are physically placed into intimate contact. Such intimate contact and bonding is made possible by the mirror smoothness of the polished sides of the wafers 25, 33, and by the high concentration of OH groups on the wafer surfaces from the hydration step. That is, the mirror smoothness of the wafer surfaces allows good (a uniform) contact to be made between the two wafer surfaces. And the OH groups on the two wafer surfaces have an attraction for each other, such that upon contact of the two surfaces a hydrophilic reaction takes place between the two wafers 25, 33.
The composite two-wafer structure 39 is placed into a dry oxidation furnace at 600° C. in pure nitrogen. The furnace temperature is ramped to 1000° C., at this point the nitrogen is turned off and oxygen is turned on. The wafer structure 39 is kept in the furnace for one hour at 1000° C. in dry O 2 to complete the bond. Preferably at the end of the oxidation in the furnace, the temperature is gradually decreased from 1,000° C. to about 600° C. before removing the two-wafer structure 39. This is to ensure that no large temperature gradient exists between the oxide and the furnace ambient that may result in large thermal stresses in the wafers 25, 33. After the oxidation step, the two-wafer structure 39 is completely bonded. Upon removal from the furnace, the bonded wafers are as illustrated in FIG. 3i.
The foregoing step creates the cavity 43 between the bottom electrode wafer 25 and second wafer 33. Also at this time, residual gases are trapped in cavity 43.
The bonded wafers 39 are then placed in a 20% KOH anisotropic etchant solution at 56° C. for approximately 24 hours. This results in the second wafer 33 being etched back or prethinned to a thickness of about 30 μm as shown in FIG. 3j. The bonded wafers 39 are then placed into a solution of CsOH, also a silicon anisotropic etchant but having better etchstop characteristics on p++ silicon than KOH. Thus, prethinning of wafer 33 from the backside is accomplished in KOH as described above in FIG. 3j, while removal up to the etch stop (p++ layer 35) is accomplished in CsOH. Preferably, etching to the p++ layer 35 is carried out in 60° C., 60% CsOH which has an etch rate of 8 microns per hour. When the p++ layer 35 is exposed to the solution, etching is significantly reduced and able to be observed visually by the absence of bubbles. Once bubbling has ceased, indicating that the p++ layer 35 is exposed and the etch with CsOH is affectively ended, the bonded wafers 39 are removed as shown in FIG. 3k.
Next a suitable chemical formula is employed to selectively remove the p++ layer 35. Specifically, the bonded wafers 39 are immersed in a mixture 8:3:1 acetic acid: nitric acid: hydrofluoric acid which has a calculatable etching time. After the bonded wafers 39 are immersed into this solution, the solution turns brown indicating the presence of HNO 2 . At the end of the calculated etching time, the bonded wafers 39 are removed from the etchant and typically bear brown stains. The brown stains indicate the presence of porous silicon in the lightly doped regions. To remove the brown stains, (i.e, porous silicon), the bonded wafers 39 are immersed in a mixture of 97:3 nitric acid: hydrofluoric acid for approximately 15 seconds. Upon removal from this mixture, what remains is the second layer 37 on the oxide layer 31 supported by wafer 25 as shown in FIG. 31. The resultant thickness of the second layer 37 is dependent on the thickness of the epitaxial n-type silicon layer and is preferably about 5 μm. It is this silicon layer 37 which serves as top electrode 13 as made clear by the following.
Following an RCA cleaning, a 5000 Å thick low-temperature masking oxide (LTO) 40, is deposited onto the just etched surface as shown in FIG. 3m. The LTO layer 40 is then patterned using a resist mask, and the layer 40 is etched using either a wet etchant, such as buffered oxide etch, or a dry etchant, such as plasma, to expose the thin silicon second layer 37. The thin silicon layer 37 is then etched using a dry etchant, such as plasma, or using a wet chemical etch, such as KOH, to form the shape of the top electrode 13 as shown in FIG. 3n. Masking oxide layer 40 is then removed by a hydrofluoric acid etchant or a buffered oxide etchant.
The foregoing is carried out in temperatures well below the onset of plastic deformation of silicon and preferably at about 400° C. Such low temperature processing is enabled by the use of the low temperature oxide masking layer 40. In addition, this layer 40 is deposited at a thickness much less than the thickness of the thin silicon layer 37 to expedite the patterning and etching of the masking oxide layer 40.
Next a masking and wet oxide step selectively removes oxide 31 from the surface of bottom electrode wafer 15 so as to form contact vias 41 shown in FIG. 3o. Common photolithographic techniques are used. The photoresist is removed in the asher. The wafer structure 39 is then placed into a high temperature furnace (above about 600° C.) to plastically deform the top electrode layer 37 as shown in FIG. 3o. The extent of the deformation is strongly dependent on the cavity depth etched into bottom electrode wafer 15, the thickness of the capping thin silicon layer 37 and temperature.
In the preferred embodiment, the wafer structure 39 is left in a furnace at a temperature above about 850° C. for about one hour. Temperatures between about 850° C. and 1100° C. are preferred. During this time, the trapped residual gas in cavity 43 expands causing swelling of the cavity walls, (i.e., thin silicon layer 37). In turn, the swelling generates a pressure directed radially outward from the cavity 43 and which is greater than 1 atm at the high furnace temperature. As a result, the thin silicon layer 37 yields and plastically deforms. The thin silicon layer 37 being less than 5 microns thick ensures that the generated internal pressure exceeds the yield stress of silicon.
Alternatively, the wafer structure 39 is placed in a high temperature environment (e.g., a furnace) to bloat but not plastically deform the top electrode layer 37 as shown in FIG. 3q. Since silicon plastically deforms above about 600° C., this operation is preferably carried out at a lower temperature. The heat causes the trapped gases to expand as described before, and this induces the top electrode layer 37, which is a capping layer over the cavity, to deflect outward, i.e., bloat. Some suitable layer 51, such as LTO is then deposited onto this bloated layer 37 to lock the shape into place, i.e., cause a permanent set. Upon removal of the bloated wafer structure 39 from the furnace, the cavity capping top electrode layer 37 retains its permanent set. The shape setting (LTO) layer 51 is deposited and patterned by common techniques, such that the contact vias 41 remain accessible. Shape setting layer 51 has physical characteristics (i.e., dimensions and mechanical properties) which allow top electrode layer 37 to respond to applied loads as described in FIGS. 1a-2 and 4.
Subsequent to high temperature exposure in either case of FIG. 3o and 3q, a thin layer of aluminum is e-beam evaporated, sputtered or otherwise deposited onto the upper surface of the wafer structure 39. The deposited aluminum layer 45 is then patterned in contact vias 41 formed on the wafer structure surface in FIG. 3o. Following this step, the aluminum layer 45 is wet etched to form the contacts 47, 48 of the pressure switch as shown in FIG. 3p. Preferably the patterning and etching are accomplished by photolithoghraphy techniques and etchants comprising phosphoric acid, acetic acid, nitric acid, and water preferably with relative concentrations of 16:2:2:1. The aluminum layer 45 is then sintered in nitrogen at about 375° C. for 30 minutes to form Al-Si alloy for the contacts. The individual pressure switches formed many to one wafer are separated by common techniques and packaged.
POTENTIAL APPLICATIONS
Potential applications for a threshold pressure switch of the present invention are now described. Much of the attractiveness of the invention switch stems from its low per-unit cost of manufacturing which is due to the switch being batch fabricated, similar to the low per-unit cost of integrated circuits. Additionally, the threshold pressure at which the switch closes is easily tailorable to specific applications and can be tightly controlled. This is du to the switch design and to the preciseness of integrated circuit fabrication techniques. The critical dimensions for the switch are cavity depth, the radius of the cavity and the thickness of the top electrode layer. Each of these dimensions can be very accurately controlled either by the use of etchstop techniques or standard photolithography technology.
A first application relates to an active sensor for indicating tire pressure of an automobile and the like. By mounting a chip with an appropriately dimensioned threshold pressure sensor on it inside the tire of a vehicle, the tire pressure can be continuously monitored. Ideally the invention switch would be connected to a light on the dashboard. If the tire pressure is adequate, say above 34 psi, the switch is closed and the light goes off, however if the tire pressure falls below a certain level, the switch opens and the dashboard light illuminates indicating to the driver that air is required for proper inflation. Due to the mechanical hysteresis inherent in the invention switch structure, the pressure at which the switch would open will be below the 34 psi required to close the switch electrodes. In this way, the light on the dashboard would not illuminate until the tire pressure fell significantly and therefore would not be an annoyance to the vehicle operator. The cost of manufacture and installment would be low and reliability very good for this switch, making it well suited to this application.
Another potential application for the threshold pressure switch of the present invention is in air and gas compressors. Currently, air and gas electromechanical compressors utilize a pressure sensing switch inside the storage tank to monitor the tank pressure. The compressor motor continues to operate, compressing the air or gas and storing it in the tank until the threshold pressure of the switch is reached. At this point the switch changes state and the compressor motor is turned off thereby saving energy and motor wear. As the tank pressure drops due to use and leaks, the pressure switch will change states once again after the tank pressure drops to some set point. The changing of the switch signals the compressor motor to start thereby bringing the tank pressure back up.
Another application relates to using the invention threshold pressure switch in a keyboard i.e., as pressure switches for each key of the keyboard. As a person types and applies pressure to the keys, the switches are closed and opened after removal of pressure. Again the threshold pressure can be tailored to this application and the resulting cost quite low.
Another application is to use the invention threshold pressure switch as a scale (weight detection mechanism) whereby if a sufficiently heavy object is placed onto the switch it will close, otherwise it stays open. Since the size of the switches is small, a number of switches may be used in order to distribute them properly under the test object. This type of scale could prove useful where sorting of objects is done depending on their weight. For example, if a postal service wished to sort boxes depending on their weight, then a conveyer belt would move each box over an array of threshold pressure switches of the present invention. If the box was sufficiently heavy, as indicated by the switches, it would be moved (via conveyer belt) in a certain direction. However, if the box was not heavy enough to close the switches, then it would be moved in another direction. The attractiveness of such a set up is the simplicity and low cost of the threshold pressure switches configured for this application.
By fabricating an array of these pressure switches over a surface of a wafer, a tactile sensor array for robotic applications can be made. Ideally, the compliance of the wafer should be increased to aid in conforming the tactile sensor array to various structures. This is easily achieved by etching away the appropriate amount of silicon to thin the wafer and increase its flexibility.
By venting the sealed cavity of the invention switch, to atmospheric pressure, a mechanical memory element can be realized and would determine the proximity of various rigid bodies. Such venting is easily accomplished by etching channels through the backside of the bottom electrode wafer to the cavity. An array of such vented switches would then be assembled together, each switch having a different top electrode radius and hence different threshold buckling pressure. Further each switch would be open until it was placed in an environment of interest which caused the switch to close. Once closed, a switch remains closed until application of a negative pressure. Thus, after removing the array of switches from a subject environment, closed switches would be inspected to determine the closeness of various objects in the subject environment. To reset the closed switches for further application of the mechanical memory element (i.e., array of switches), a negative pressure is applied accordingly.
It is understood that other applications (e.g., a vacuum switch) are suitable and within the purview of one skilled in the art.
EQUIVALENTS
While the invention has been particularly shown and described with reference to a preferred embodiment thereof, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the spirit and scope of the invention as defined by the appended claims. For example, it is understood that other materials beside silicon are suitable. The foregoing description and discussion involving silicon are for purposes of illustration and not limitation.
|
A pressure activated threshold switch has two electrodes separated by a small distance across a cavity. One of the electrodes is made of a mechanically compliant material. As a uniform pressure is applied to the mechanically compliant electrode, a threshold is reached at which the electrode buckles under the applied load and makes contact with the second electrode thereby closing the switch. The switch exhibits mechanical hysteresis by subsequently opening under a lower applied load. The pressure threshold switch is fabricated using wafer to wafer silicon bonding along with conventional integrated fabrication steps. The techniques of integrated circuit technologies enable dimensional control to be very good and hence activation pressures are tightly controlled. The fabrication method exploits properties of wafer to wafer silicon bonding, such as residual pressure inside sealed cavities and plastic deformation of silicon. The buckling load or threshold pressure at which the switch closes is easily tailored to specific applications. Potential applications include threshold pressure sensors for indicating when automotive tires need inflation, tank pressure monitors in air and gas compressors, switches for keyboard pads, weight detectors and robotic tactile sensor arrays.
| 8
|
BACKGROUND OF THE INVENTION
This invention relates to reflector lamps and more particularly reflector lamps in which the light source is a tungsten-halogen lamp.
Incandescent reflector lamps are well known. This type of lamp comprises an outer lamp envelope, part of which is a reflector surface for reflecting light incident thereon, and an incandescent filament within the outer envelope. The incandescent filament is positioned relative to the reflector surface for illuminating it during lamp operation. The light from the incandescent filament that is incident on the reflector surface is reflected out of the lamp.
A comparatively recent development is the use of a small tungsten-halogen electric lamp as the light source within a reflector lamp. This allows the lamp to have the higher efficacy, higher color temperature and improved maintenance of tungsten-halogen lamps and at the same time have the directional characteristics and light concentrating properties of reflector lamps.
The incorporation of tungsten-halogen lamps into reflector outer envelopes presents size problems, particularly in smaller lamps. Small reflector lamps do not have sufficient depth to easily accommodate the tungsten-halogen lamp, and mechanical interference between the tungsten-halogen lamp and the outer envelope can be a limitation on the size of the reflector lamp.
One solution to the size problem in small reflector lamps has been to make the lens end of the lamp envelope protrude further forward in order to increase the depth of the lamp interior. This permits the tungsten-halogen lamp to be mounted inside the reflector lamp outer envelope, together with associated parts such as a light shield, without any interference with the lamp outer envelope.
It is known to use a diffusing lens in a reflector lamp in order to broaden the light distribution pattern. A lens having stippling or other surface features will cause the light passing through it to become more diffuse. The beam of light from a reflector lamp will be broader the greater the degree of diffusion that is caused by the lamp lens. By using lamp lenses of different degrees of diffusivity, in lamps that are otherwise identical, lamps having different beam widths can be realized.
The lens surface features which define its diffusing properties are permanently molded in the lens in the course of manufacture. Therefore, lenses having different diffusing properties require different molds, even if they are identical in shape and nominal dimensions. The molds are expensive.
Accordingly, it is an object of the invention to provide a reflector lamp design in which the beam width can be increased without any change to the lens design.
It is another object of the invention to provide a narrow spot reflector lamp made of stock components and which uses a tungsten-halogen incandescent lamp as a light source.
SUMMARY OF THE INVENTION
According to the invention a narrow spot reflector lamp is comprised of an outer envelope having a concave reflector surface and a lens covering the reflector surface and joining the reflector surface at its outer edge. The lens has a protruding wall extending forward from the edge of the reflector surface and a stippled dome surface through which light passes out of the lamp.
A light source is positioned within the outer envelope on the lamp axis of symmetry. A light shield within the outer envelope between the light source and the lens dome is positioned and dimensioned to obstruct light from the light source and prevent direct transmission of light from the light source out through the lens. The reflector surface has stippling which is effective for smoothing the spatial distribution of the reflected light to impart to it a narrow spot beam pattern.
In a preferred embodiment the light source is a tungsten-halogen lamp comprised of an envelope and a filament mounted within the halogen lamp. The focal point of the reflector surface is forward of the outer edge of the reflector, and the halogen lamp is mounted with the filament positioned at the focal point of the reflector surface, and the halogen lamp extends into the region bounded by the protruding wall of the lens.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a vertical section of a narrow spot reflector lamp according to the invention;
FIG. 2 is a partial cross-section of the narrow spot reflector lamp shown in FIG. 1; and
FIG. 3 is a graph of the beam pattern of the narrow spot reflector lamp shown in FIG. 1 and a prior art reflector lamp, which illustrates the increased beam spread of the invention.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 is a vertical section of a narrow spot reflector lamp 1 according to the invention. The lamp has a glass outer envelope comprised of a back section 2 having a concave reflector surface 3. A very thin reflecting layer, commonly metallic aluminum, is disposed on the reflector surface 3. The thin reflecting layer has the same shape as the reflector surface 3 and is not identified by a separate reference numeral.
For most applications the concave reflector surface 3 is a paraboloid of revolution, although it may have a different shape, such as that of an ellipsoid, if desired. The reflector surface 3 ends at an outer edge 6. An axis of symmetry of the reflector surface is chosen as the axis of symmetry of the lamp. The rear section 2 of the outer envelope is symmetrical about its geometric center.
The lamp outer envelope further comprises a front lens covering the reflector surface 3. The lens has a protruding wall 4 adjacent the outer edge 6 of the reflector surface which protrudes in the forward direction of the lamp, and a dome 5 closing the front of the lamp and covering the reflector surface 3. At least the lens dome 5 is translucent to allow light to exit the lamp through it. Typically, the entire lens is a single piece of glass so that the protruding wall 4 will also be translucent. The lens dome 5 will usually have a fine texture or stippling in order to diffuse light which passes through it. The lens stippling smooths and broadens the beam pattern of the light emitted from the lamp.
A tungsten-halogen incandescent lamp 10 is symmetrically mounted inside the lamp outer envelope on the lamp axis of symmetry. The tungsten-halogen lamp 10 has a horizontal filament 11 positioned at the reflector surface focal point. The focal point of the reflector surface 3 is forward of the outer edge 6 of the reflector surface, and the halogen lamp 10 protrudes into the space defined by the lens protruding wall 4.
A pair of metal ferrules 12 are pressed into the back of the rear section 2 of the reflector lamp envelope. The ferrules 12 are connected to heavy wire lead supports which provide conductive paths to the halogen lamp 10 and mechanically support it within the reflector lamp envelope.
A cup-shaped light shield 15 is positioned between the halogen lamp 10 and the lens domes 5. The shield 15 intercepts all of the direct light from the halogen lamp 10 that would otherwise pass through the reflector lamp lens. The only light that escapes from the reflector lamp is that which is incident on the reflector layer 3 and reflected from it through the lens. As a consequence, the beam spread of the light emitted from the lamp is very narrow.
The lamp structure described up to now was known at the time of the discovery of the present invention. It has been applied to very narrow spot parabolic aluminized reflector (PAR) lamps having a diameter of about 4.5 inches. Lamp size is specified in units of one-eighth inch, and a 4.5 inch PAR lamp is designated PAR 36. A PAR 36 lamp like that described has a beam spread of about 4° to 5° measured between half candlepower points.
It was desired to make PAR 36 lamps of the type just described with a halogen lamp light source, but with an appreciably larger beam spread of at least 8° to 10° to classify them as narrow spot reflector lamps. In order to expand the lamp beam spread a new lens design that is not commercially available would be required. This would involve the manufacture of new molds and considerable expense.
The present invention achieved the desired result, without any modification of the lens, by changing the reflector surface 3 to impart light diffusing properties to it. Because the reflector lamp envelope rear section 2 having such a reflector surface was already commercially available it was possible to realize a narrow spot reflector lamp of the type described without resorting to the manufacture of new molds.
The reflector surface 3 has a surface stippling which is imparted to it by sandblasting the mold surface that form the reflector surface 3. When an aluminum layer is deposited on the reflector surface 3 it acquires a mottled appearance as if covered with a multitude of miniature dune-like irregularities. This appearance is a consequence of minutes surface variations which are a departure from an idealized focussing surface and are effective of the reflected light.
The diffusing properties are caused by the surface geometry of the reflective surface 3 on which the aluminum reflecting layer is disposed, and not by any stippling or other treatment of the reflecting side of the aluminum layer itself. Consequently, its reflectivity is not diminished. The result is a narrow spot reflector lamp having a beam spread of the order of 10° that is achieved without the necessity of the new lens design.
FIG. 2 is a partial cross-section of the lamp according to the invention illustrated in FIG. 1. It shows the effect of the stippling on the underlying reflector surface 3. The light shield 15 obstructs light from the halogen lamp filament 11. Only reflected light leaves the lamp and all of the light reflected forward by the reflecting layer undergoes diffusion as it is reflected. Further diffusion occurs as the light passes through the reflector lamp lens and the desired beam spread is achieved.
EXAMPLE
A PAR 36 lamp was made having the structure illustrated in FIG. 1. The reflector layer 3 has a focal length of one inch and is a paraboloid of revolution. A 50 watt tungsten-halogen lamp with a horizontal filament is mounted with the filament at the focal point. The cup-shaped light shield 15 is approximately hemispherical with a diameter of approximately 1.2 inches and is mounted with its lower edge slightly below the lamp filament. The reflector surface 3 is stippled so that the reflecting layer will diffuse reflected light. The rear section 2 of the reflector lamp outer envelope is available from Corning Glass Works, Part No. 154042-3.
The lamp according to the invention was compared with a lamp identical in every respect, except that the reflector layer 3 was without stippling so that the reflecting coating was non-diffusing. The light intensity distribution for the two lamps, expressed in arbitrary units of candlepower, is shown in FIG. 3. The curves are normalized so that their maxima coincide. The lamp according to the invention has a beam spread of approximately 10°, compared with the approximate 4° beam spread of the prior art lamp. This data establishes the effectiveness of a light diffusing reflector in the lamp according to the invention and its ability to realize a narrow spot reflector lamp using commercially available components.
|
A narrow spot reflector lamp having a halogen lamp light source. The reflector surface and lens are both stippled and the halogen lamp is shielded so that all of the transmitted light undergoes two diffusions to achieve the desired beam spread.
| 5
|
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a control system for controlling operation of an automatic door.
2. Description of the Prior Art
Heretofore, as a control system for an automatic door, there have been known various systems such as a control system including limit switches for detecting the position of a door, a control system in which a rotation detector is provided on a rotary shaft of a drive motor or another rotary shaft and numerical control of the drive motor is effected on the basis of the detected rotational data, a control system in which teeth on a timing belt for coupling a drive motor to a door are detected and counted and numerical control of the drive motor is effected on the basis of the counted data, or the like.
However, in these known control systems in the prior art, it was necessitated to provide any type of door position detector means separately from drive means for a door. Hence, the number of component parts of the system could not be reduced, and so, it was difficult to achieve simplification of the construction and reduction of manufacturing costs.
SUMMARY OF THE INVENTION
It is a principal object of the present invention to provide a control system for an automatic door that is free from the above-described shortcoming in the prior art.
A more specific object of the present invention is to provide a control system for an automatic door in which there is no need to provide door position detector means separately from drive means for the door and hence reduction of manufacturing costs can be achieved.
The improvements in the control system for an automatic door according to the present invention exist in that a brushless D.C. Motor, referred to herein as a D.C. brushless motor, is employed as a drive motor for a door, and magnetic pole position detection signals generated by a magnetic pole position detector inherently provided within a D.C. brushless motor circuit are utilized for detecting the door position in a position control circuit and for detecting the speed of movement of the door in a speed control circuit.
According to one feature of the present invention, there is provided a control system for an automatic door which comprises a D.C. brushless motor coupled to a door member via speed reduction means to transmit driving power to the door member and adapted to deliver magnetic pole position detection pulses. A position control circuit is included responsive to the magnetic pole position detection pulses delivered from the D.C. brushless motor for determining the position of the door member and thereby generating a speed command signal indicating the direction and magnitude of the speed of the door member. Also included is a speed control circuit responsive to the magnetic pole position detection pulses and the speed command signal which applies a drive control signal to the D.C. brushless motor so that the motor is driven at such rotational speed that the door member is moved at the speed indicated by the speed command signal.
The above-mentioned and other features and objects of the present invention will become more apparent by reference to the following description of a preferred embodiment of the invention taken in conjunction with accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a general system diagram showing one preferred embodiment of the present invention; and
FIG. 2 is a more detailed partial circuit diagram showing the construction of a D.C. brushless motor contained in the control system shown in FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENT
In the following, the present invention will be described in greater detail in connection to one preferred embodiment of the invention.
Referring now to FIG. 1, a D.C. brushless motor M is coupled to a driving pulley 2 via a reduction gear 1, a door drive belt 4 is wrapped around the driving pulley 2 and a driven pulley 3, and a door 5 is connected to the belt 4 via a connecting member 6 so that the door 5 can be moved in the opening or closing direction by rotating the D.C. brushless motor M in the normal or reverse direction, respectively.
In this D.C. brushless motor M, as shown in FIG. 2, generally armature windings 11 form a stator and a field magnet 12 forms a rotor. In addition, three magnetic pole position detectors 13 each constructed of a Hall effect element, a magnetic reluctance element or a photoelectric element are disposed on the stator at an angular interval of 120° (only one magnetic pole position detector 13 is illustrated in FIG. 2), so that three pulse trains having their phases shifted by 120° from one another are delivered from these magnetic pole position detectors 13 in response to rotation of the field magnet 12 forming the rotor. In a control circuit section enclosed by a chain line frame C, the angular position and rotational speed of the field magnet 12 forming a rotor are determined on the basis of the magnetic pole position detection pulses P consisting of these three pulse trains, and a drive control signal is applied to the D.C. brushless motor M on the basis of the position and speed data. In the D.C. brushless motor M, a power switch circuit 10 associated therewith (See FIG. 2) switches D.C. drive currents fed to the respective armature windings 11 in accordance with the drive control signal to generate the necessary drive torque.
The control circuit section C comprises a position control circuit 7, a speed control circuit 8 and a D.C. power supply circuit 9 which can be switched on and off externally of the control circuit section C. The magnetic pole position detection pulses P delivered from the magnetic pole position detectors 13 in the D.C. brushless motor M are input to the position control circuit 7 and the speed control circuit 8.
The position control circuit 7 has its power supplied from the D.C. power supply circuit 9, and is connected to an access sensor switch SW such as a door mat switch, an infrared sensor, a capacitive sensor, etc. which senses the presence of a human body or other object at an automatic door and issues an actuation signal for the position control circuit 7. This position control circuit 7 determines the direction of rotation of the motor M on the basis of the phase relations among the three pulse trains delivered from the respective magnetic pole position detectors 13, and also determines the position of the door 5 by counting up or counting down the pulses depending upon the direction of rotation (starting from a reference position of the door 5). It is to be noted that the pulses forming the three pulse trains are generated for every 1/3 revolutions or 1/6 revolutions of the rotor depending upon whether pulses of one polarity or pulses of both polarities are taken into consideration.
Within the position control circuit 7 is stored a program consisting of a predetermined sequence of operations for opening and closing the door 5 in response to the actuation signal sent from the access sensor switch SW. Hence, after the access sensor switch SW has sensed presence of an object at the automatic door, the position control circuit 7 issues a speed command signal indicating the direction and magnitude of the desired speed of the door 5 on the basis of the stored sequence program and the determined current position of the door 5, and this speed command signal is applied to the speed control circuit 8.
The speed control circuit 8 calculates and determines the speed of the door 5 on the basis of the magnetic pole position detection pulses P issued from the magnetic pole position detectors 13 in the D.C. brushless motor M, and as a result of comparison between the desired direction and magnitude of the speed of the door 5 indicated by the speed command signal applied from the position control circuit 7 and the current direction and magnitude of the speed of the door 5, it determines the necessary acceleration of the D.C. brushless motor M and issues a drive control signal having a polarity and a magnitude corresponding to the direction and magnitude of the necessary acceleration, which is applied to the D.C. brushless motor M so that the motor may be driven at such rotational speed that the door 5 can be moved at the desired speed indicated by the speed command signal.
In the control system for an automatic door having the above-described construction, when an object such as a human body comes close to the automatic door, the access sensor switch SW is operated and an actuation signal is applied to the position control circuit 7 in the control circuit section C. In response to the actuation signal, the position control circuit 7 generates a speed command signal on the basis of a stored program of the predetermined sequence of operations and the current position of the door 5 on the basis of the magnetic pole detection pulses P, and applies the speed command signal to the speed control circuit 8, which in turn applies a drive control signal to the D.C. brushless motor M to open and close the door 5 according to the predetermined sequence of operations.
During the movement of the door 5, the pulses delivered from the magnetic pole position detectors 13 in the D.C. brushless motor M are applied to the position control circuit 7 as well as to the speed control circuit 8 for use in determining the current position and the current speed of the door 5.
In addition, owing to the employment of the D.C. brushless motor, the buzz noise generated by an A.C. motor in the automatic door in the prior art can be eliminated, and thereby noises generated upon opening and closing the automatic door can be reduced. Moreover, since control of rotational speed and torque of a D.C. brushless motor is easily achieved, controllability of the opening/closing speed of the automatic door is excellent. In the case of employing an AC/DC converter as the D.C. power supply circuit 9, even in an area of a foreign country where the A.C. voltage of the commercial power line is different from that in Japan, the control system according to the present invention can be adapted to the different A.C. voltage in a relatively simple manner only by modifying the circuit of the AC/DC converter.
The principal advantage of the present invention resides in that owing to the use of a D.C. brushless motor as a drive source, the detection pulses issued from the magnetic pole position detectors which is inherently associated with the motor for controlling rotation of the motor, can be utilized for determining the position of the door, hence there is no need to provide a position detector for the door separately from the drive motor, thus the number of component parts are reduced, and thereby reduction of manufacturing costs are realized.
While the principle of the present invention has been described above in connection to one preferred embodiemnt of the invention, it is intended that all matter contained in the above description and illustrated in the accompanying drawing shall be interpreted to be illustrative and not as a limitation to the scope of the invention.
|
As a driving power source for an automatic door, a brushless D.C. motor is employed, and the position and the speed of a door member are determined by making use of detection pulses issued from magnetic pole position detectors which are associated with the brushless D.C. motor without providing any additional detector means separately. On the basis of the current position and the current speed of the door as determined from the detection pulses and of a programmed sequence of opening and closing operations for the door as stored in a control system, the opening and closing movements of the door member are controlled.
| 4
|
CROSS REFERENCE TO RELATED APPLICATION
[0001] The following application claims priority to provisional patent application 60/526,375 filed on Dec. 2, 2003.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The following invention relates to sub-diffraction limit resolution in microscopy. The invention has particular utility in the use of microscopy in the testing of fracture toughness of thin ceramic substrates and will be described in connection with such utility, although other utilities such as measuring sub-micron size particles including biological particles.
[0004] 2. Description of the Prior Art
[0005] Indentation techniques are well developed for hardness study. The American Society of Testing and Materials (ASTM) developed a standard test method for Vickers indentation hardness of advanced ceramics (ASTM C 1327-96a, 1996) incorporated herein by reference. Vickers indentation techniques have also been widely used for studying fracture toughness of brittle materials such as glass and ceramics since surface crack traces were first recognized as indicative of fracture toughness by Palmqvist in 1957. These crack traces are referred to as indention traces or Palmqvist cracks.
[0006] In general, the procedure of the Vickers indentation toughness test includes producing an indentation on a plane surface of the material under investigation by a standard hardness tester and subsequently studying the induced cracks by a microscope. It is important to note that indentation is considered micro when the applied indenter load is less than 5N, otherwise, indentation is called macro indentation.
[0007] With the measured data of the indenter, load, and the dimensions of the induced cracks, it is possible to evaluate the toughness of the material. For example, a Vickers hardness tester usually makes a diamond indentation with cracks emanating from the diamond corners as shown in FIG. 1 . For most mathematical models based on the Vickers hardness tester and published in the literature, the c/a or l/a ratio depicted in FIG. 1 was limited to a certain range. For example, Niihara et al (1982) proposed an equation that requires the l/a ratio to be between 0.25 and 2.5.
[0008] The advantages of the Vickers indentation toughness technique are the simplicity and cost effectiveness of the measurement procedure. The specimen preparation is also relatively simple, requiring only a flat surface. And, at least 10 tests can be performed on a surface of only 100 mm 2 . The disadvantage of this technique is that an accurate measurement of the crack length c or l, usually measured under an optical microscope, is difficult. The indentation induced cracks are often hard, if not impossible, to observe because the width of indentation-induced cracks is very narrow, especially near the crack tips that the indention-induced cracks are beyond the resolution of common optical microscopes. Although measurements of the indention induced cracks can be conducted under a scanning electronic microscope (SEM), the usage of a SEM will significantly slow down the experimental procedure and greatly increase experiment costs.
[0009] Also, ordinary optical microscopes are limited in resolving power, and therefore cannot observe smaller indention cracks using light diffraction. Even assuming an optical system is perfect, because of the wave property of the light, the smallest spot resolvable by an optical microscope is ultimately defined by the diffraction of the illuminating light. At a small enough scale, physical optics principles take effect, i.e., the wave-like motion of light will deflect around comers of an object under observation to a tiny but finite degree. This phenomenon is known as the “diffraction limit” of an optical microscope. For example, suppose two point sources of light are to be imaged by a microscope. Because of light diffraction the two point sources of light will be imaged by a microscope as two discs of light distribution. These discs are each referred to as an Airy Disc, i.e., a high irradiance circular spot. FIG. 2 shows graphically a light distribution pattern of an Airy Disc of a point source due to light diffracting from an object under observation.
[0010] As shown in FIG. 2 , the Airy Disc consists of a central bright peak surrounded by a set of concentric dark and light rings. The resolution limit of a microscope is defined as the distance of the two point sources at which their images has a separation so that the peak of one Airy Disc coincides with the first dark ring of the other. This is referred to as the Rayleigh's Criterion for resolution. The numerical expression of Rayleigh's Criterion is as follows:
d = 1.22 λ f D = 0.61 λ N . A . ( 1 )
where d is the smallest distance between two objects resolvable by a microscope, λ is the wavelength of light, f is the focal length of the microscope's objective lens, D is the diameter of the aperture of the microscope, and N.A. is the numerical aperture of the microscope (Smith, 1966).
[0011] Using Eq. (1), a numerical value of the resolution imposed by the diffraction limit can be calculated. For example, for a modem microscope objective lens having a N.A. of 1.3, assuming that the illumination light has a wavelength of 400 nm, the smallest object the microscope can resolve is 200 nm. However, it is desirable to be able to optically observe objects smaller than that scale.
[0012] Several designs have been invented to overcome the aforementioned problem with microscopes available in the art. Among them are confocal microscopes with a spatial resolution of 200 nm (Pawley, 1995), and near-field scanning microscopes with a spatial resolution of 60 nm (Dunn, R. C., 1999). There is also an older technique in optical microscopy called dark-field microscope, which is capable of observing particles of the size as small as 5 nm (Monk, 1963).
[0013] Outside the field of microscopy, there also exist several ways to observe structures with dimensions smaller than the diffraction limited scale. In optical testing, a Foucault knife-edge method is commonly used to find defects as small as one tenth of the wavelength λ/10 (e.g. 40 nm, using blue light illumination at 400 nm) in an optical component, such as a mirror surface. In this technique, an illuminated pinhole and a sharp knife-edge are located in the same plane away from the mirror (e.g. a spherical concave mirror) being tested. If the mirror surface is perfectly spherical and free of any defect, then an image of the pinhole will be formed with a uniform light distribution. When the knife-edge is moved across the line of light at the image point, a uniform shadow can be observed to cross the surface of the mirror. However, if very small surface defects exist on the mirror, these defects will cause the light impinged upon them to diffract and subsequently deform the spherical wave of the incident light. Now an observer behind the knife-edge will see light spots (diffraction patterns from the defects) on the dark shadow when the knife-edge is moved across the field (Longhurst, 1973). This technique resembles the method used in dark-field microscope, in which the direct illuminating light beam is obstructed and only half of the diffraction orders from the small particles are observed. Furthermore, an extension of the Foucault knife-edge, or the Schlieren method, is used to detect small variation of refractive index in a medium. The Schlieren method has been applied to fluid dynamics to study the behavior of a moving fluid (Longhurst. 1973).
[0014] In addition, to solve some of the above problems with microscopy, some researchers focused on the observability of indention cracks. Ponton and Rawlings (Ponton and Rawlings, 1989b) proposed a method where a minimum indenter load of about 50 N produces visible cracks so that accurate measurement of the indention cracks under common optical microscope. These macro-hardness testers have dominated the art because they ensure cracks produced by the Vickers hardness tester could be measured, and micro indentation was believed to produce no indentation cracking (Anton and Subhash, 2000). Other researchers have focused on improving the observability of indentation cracks produced using Vickers hardness testers by polishing the surface of the test specimens. The specimen surfaces were usually polished to at least 1 μm diamond finish (Ponton and Rawlings, 1989b). Although Ponton and Rawlings pointed out that processes such as polishing, could produce residual stresses on the surface to prevent correct test results (Ponton and Rawlings, 1989b), polishing seemed to be a necessary process for specimen preparation reported in the literature.
[0015] However, most of the prior art mathematical models are based on the assumption that there are no pre-existing surface stresses on test specimens. Although proper heat treatment could remove the stresses created by polishing; it may change the physical properties of the test specimen. Other prior art methods proposed to deal with the problems associated with these pre-existing stresses on specimens by highlighting the pre-existing surface cracks using a fluorescent dye penetrant (Ponton and Rawlings, 1989). However, these methods produce side effects, such as extra post-indentation slow crack growth in many ceramics, thereby preventing an accurate evaluation of the specimen's toughness.
[0016] There are other problems with the above mentioned methods of indention testing. Thin ceramic substrates are widely used as electrolytes in solid oxide electrolyzers, and are typically made by a tape-cast process. After sintering, the products are usually in the form of thin sheets with a typical thickness 0.5 mm or less in engineering applications. As a result, indenter load of 50 N tends to break the specimen substrates. In practice, the majority of the ceramic substrates with this thickness can only be indented by micro-indentation.
[0017] Other researchers in the art, Cook and Pharr (1990), found that a radial crack forms extremely early (possibly almost instantly) in the loading process (typically 0.8 N). Small cracks caused by such loads can not possibly be detected by the conventional optical methods described above. In addition, many thin ceramic substrates are used with an as-fired surface finish. Polishing of such surfaces would alter the actual fracture toughness of the substrates. However, leaving the surface of the substrate unpolished introduces even more difficulties in the observation and measurement of small cracks.
[0018] Thus, a better technique for measuring indentation cracks in thin substrates is needed.
SUMMARY OF THE INVENTION
[0019] The present invention provides a system, i.e., method and apparatus for sub-diffraction limit resolution by modification of a conventional polarizing microscope by obstructing a portion of the illuminating beam upstream of the condenser lens whereby to produce a shadow or dark background or region upon which diffracted light from the target may be projected.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] Further features and advantages of the present invention will be seen from the following detailed description taken in conjunction with the accompanying drawings wherever like numerals depict like parts, and wherein:
[0021] FIG. 1 shows a diamond pattern produced from a Vickers hardness tester with measured cracks;
[0022] FIG. 2 shows graphically a light distribution pattern of an Airy Disc of a point source due to light diffracting from an object under observation;
[0023] FIGS. 3 ( a ) and 3 ( b ) illustrate the optical path of a light beam when a conventional polarizing microscope and method are used to evaluate a sample and the optical path of a light beam ( FIG. 3 ( a )), and when an exemplary microscope and method of the invention are used for the observation of the sub micron cracks ( FIG. 3 ( b )), respectively;
[0024] FIG. 4 shows in detail the optical path of a light beam for an unobstructed part of the beam and a diffracted part of the beam in a microscope employing the exemplary method of the invention;
[0025] FIG. 5 is an SEM micrograph of pure 8YSZ for use in an experiment employing the exemplary method of the invention; and
[0026] FIGS. 6 ( a ) and 6 ( b ) show a Vickers indentation on an 8YSZ specimen at about 300× magnification without a shadow ( FIG. 6 ( a )) and with a shadow ( FIG. 6 ( b )), respectively.
DETAILED DESCRIPTION OF THE INVENTION
[0027] The instant invention provides a system for achieving sub-diffraction limit resolution in microscopy by a modification of a conventional polarizing microscope. More particularly, in accordance with the present invention a portion of the illuminating beam to a polarizing microscope is obscured upstream of the condenser lens as to produce a shadow or dark background upon which diffracted light from the target is projected.
[0028] FIG. 3 ( a ) illustrates the optical paths of a conventional polarizing microscope and FIG. 3 ( b ) a modification permitting the observation of the micro-indentation cracks consistent with an embodiment of the instant invention respectively. Both the conventional polarizing microscope and the polarizing microscope of the instant invention include a polarizer 100 , a condenser lens 102 , a specimen stage 104 , an objective lens 106 , and analyzer 108 and an eyepiece 110 . In the conventional polarizing microscope, a light beam (depicted by arrows) passes through the polarizer 100 , where the light beam is plane polarized, to condenser lens 102 . The condenser lens 102 focuses the light beam onto the specimen stage 104 . At the specimen stage 104 , the light beam is separated into individual wave components that are each polarized in separate, but perpendicular planes i.e., “extraordinary rays”. The extraordinary rays then pass through the objective lens 106 , where magnification occurs, to the analyzer 108 . The analyzer 108 polarizes light at a 90 degree angle from the polarizer, and if no specimen is present, the field will become black. However, if a specimen is placed on the specimen stage 104 , the extraordinary rays will be polarized by the analyzer, where the recombined light beam will be passed to the eyepiece. Light rays will then emerge from the eyepiece parallel from each other, and the specimen will appear bright or colored.
[0029] In the polarizing microscope of the instant invention the polarizer 100 includes a frame edge 10 positioned at the middle of the field of view for the microscope, and a rotating specimen stage 104 a . The frame edge 10 obstructs half of the illuminating light beam. This obstruction produces two effects. First, it generates an oblique, incident beam on the specimen under observation e.g., a crack line, and part of this oblique light beam is diffracted by the crack line. Second, the shadow of the frame edge provides a dark background to see the diffracted light from the crack line (if no crack is seen, the specimen stage may be rotated and/or moved). The combination of these two effects makes it possible to observe features with sub diffraction-limit resolution.
[0030] FIG. 4 shows in detail the optical ray trace of the unobstructed part of illuminating beam 200 , i.e., the solid lines, and the diffracted beam 202 , i.e., the dashed lines, from a sub-micron object or target 204 , e.g., an indention crack in accordance with the present invention. As is shown in FIG. 4 , half of the light beam passes through the polarizer 100 , where the light is polarized, to the condenser lens 102 . From the condenser lens 102 , the light beam then passes to the sub-micron sized object or target 204 , where part of the illuminating beam is diffracted off the sub-micron sized object or target and into the darkened region. Thus, an image of the sub-micron sized object or target against a dark background is produced when the sub-micron sized object or target is viewed from an eyepiece.
[0031] As can be seen from FIG. 4 , generally, two geometrical conditions are met for this system to work optimally: (1) the object needs to be located in the vicinity of the shadow line made by the frame edge; and (2) the object needs to be able to cause diffraction into the dark region. This entails it having structural components parallel to the edge of the frame edge. The first condition specifies the size of the observation range. The second requirement presents a limitation on the observable structural feature of the object. However, this limitation can be overcome by making two orthogonal images of the same object and superimposing them to form a complete picture.
[0000] Experiments and Test Results
[0032] Thin (0.76 mm in thickness) specimens of 8-mol % yttria stabilized zirconia (8YSZ) were made from TZ-8YSZ powder (from Tosoh, Japan). The powder was then processed into a slurry with dispersant, binder, and plasticizer, and the slurry was tape-cast. The specimens were laser-cut out of green sheets and sintered at 1450° C. for 3 hours (Cheng, Chen and Sridhar, 2002). The surface flatness of as-fired specimens was between 20 and 30 μm as measured by a microscope. FIG. 5 is a SEM picture showing the microstructure of this material. An intersection method was used to estimate the average grain size, i.e., lines were drawn on the SEM pictures, with the distance between two grain-boundaries being measured along the lines. The average grain size of pure 8YSZ is found from FIG. 5 to be 2.1 μm.
[0033] A micro Vickers indentation was made with a MICROMET®3 micro hardness tester, which is a product of BUEHLER LTD. The indenter load applied was 4.91 N—which was determined by trial and error to ensure a c/a ratio within the required range. The half-diagonal length (a) of the indentation was measured directly by the light microscope attached to the hardness tester.
[0034] To determine the crack length, a polarizing metallurgical microscope (Zeiss Model IM 35) was used to measure the total length ( 2 c ) of the induced crack on the ceramic sheet specimen. The characteristics of the crack are as follows: length of the crack typical 80 μm and width of the crack 40 nm, as measured by a scanning electron microscope (Hitachi, Model S-2460N). These cracks were not visible under the normal working condition of the Zeiss microscope at 300× magnification ( FIG. 6 ( a )). When the magnification was switched to 1000×, the image could no longer be properly focused due to the surface roughness. Therefore, it was impossible to observe any cracks by this microscope in normal operation mode. However, using the method of this invention, the expected cracks could be observed. The crack line became clearly visible when the opaque frame of the polarizer of the polarizing microscope was moved to near the center of the observing field with the shadow of the polarizer frame being near the location of the crack line, as shown in FIG. 6 ( b ).
[0035] The above method was repeated using a BUEHLER® metallurgical microscope (BUEHLER® VERSAMET 3 METALLOGRAPH) and the same effect was observed. The only visible crack line was the one parallel to the shadow cast by the frame. Crack lines perpendicular to the frame edge were not visible because the incident light was only being diffracted in the bright region, producing a small signal in a very noisy background. Thus, the diffracted beam could not reach the dark region to be observed.
[0036] Two thin 8YSZ ceramic substrates were tested using the above method and apparatus, and over 30 tests were performed on each substrate. With the indenter loads and the dimensions of indentation and the resultant cracks, the test results were processed to obtain fracture toughness values using the following equations (Selçuk and Atkinson, 2000).
K IC = 0.035 H V a ϕ ( E ϕ H V ) 2 5 ( l a ) - 1 2 for 0.25 ≤ l a ≤ 2.5 ( 2 ) K IC = 0.0143 ( E H V ) 2 3 ( p c 3 2 ) ( l a ) - 1 2 for 1 ≤ l a ≤ 2.5 ( 3 ) K IC = 0.055 H V a 1 2 ϕ ( E ϕ H V ) 0.4 log 10 ( 8.4 a c )
and ( 4 ) K IC = H V a 1 2 ( E H V ) 2 5 ( 10 F ) ( 5 )
where E is the Young's modulus, Hv is the Vickers hardness, Φ is a dimensionless constant taken to be 2.7, P is the applied load, a is the half length of the indenter diagonal, c is the crack length from the center of the indent, and l is the crack length from the corner of the indent. In Eq. (5),
F=− 1.59−0.34 x− 2.02 x 2 +11.23 x 3 −24.97 x 4 +16.32 x 5 (6)
where x=log 10 (c/a).
[0037] The reason for selecting these four equations is not only because they have been reported to be valid for the Palmqvist-type cracks and more accurate in determining toughness than others, but also that these equations have been used by Selçuk and Atkinson (2000) to evaluate the toughness of the same material using macro indentation toughness evaluation methods. Thus, it is possible to compare the test results from different sources using different methods.
[0038] The Young's modulus used in Equations (2)-(5) to evaluate toughness values was 216 GPa. This is in concurrence with the Young's modulus of 8YSZ ceramic material as reported by Selçuk and Atkinson (2000). The fracture toughness results reduced from the experiments using the method of this invention are shown in Table 1. The results by Selçuk and Atkinson (2000) are also listed in Table 1 for comparison. The test results are statistically stable as evidenced by the small standard deviations. The specimens A and B can be considered identical in properties since they were made from one green tape with the same processing parameters. The tests on specimens A and B were conducted at different times intentionally for the purpose of avoiding perspective errors. Tests on specimen A were about one week later than those on specimen B. it is shown from Table 1 that the differences of the measurements of the average toughness between specimen A and specimen B are 0.53% by Eq. (2), 6.09% by Eq. (3), 1.61% by Eq. (4) and 2.27% by Eq. (5). The number of tests on specimen A and B were more than 30 each. Equation (2) shows the minimum standard deviation among these four equations whereas Eq. (3) shows the maximum standard deviation. In comparison with the toughness measurement results from Selçuk and Atkinson (2000) as shown in Table 1, the micro indentation toughness evaluation results obtained using the system of this invention are comparable with the results obtained by macro indentation evaluation methods. It should be noted that the system of this invention is more versatile and can be applied on thin or small specimens where macro indentation is not applicable.
TABLE 1 Fracture toughness (KIC, MPa · m1/2) measured by micro Vikers indentation at ambient temperature for 8YSZ Selçuk and Atkinson Specimen A Specimen B Equation KIC std KIC Std KIC Std Equation (2) 1.85 0.11 1.89 0.06 1.90 0.10 Equation (3) 1.50 0.18 1.15 0.12 1.22 0.21 Equation (4) 1.85 0.09 1.86 0.09 1.89 0.13 Equation (5) 1.80 0.08 1.76 0.10 1.80 0.16
[0039] To investigate the effects of surface polishing on the toughness values, another group of micro Vickers indentation toughness evaluation tests were performed on a surface-polished but otherwise the same specimen. The test results, which are listed in Table 2, confirmed that the surface polishing could significantly change the test results. The tests were conducted on a specimen with the same surface condition as that in practical service; otherwise, the specimen must be rigorously heat treated to recover the surface condition.
TABLE 2 Fracture toughness values (K IC , MPa · m 1/2 ) of 8YSZ with different surface machining finish measured by micro Vickers indentation technique oat ambient temperature Equation Equation Equation Equation (2) (3) (4) (5) State K IC std. K IC std. K IC std. K IC std. As-fired 1.90 0.10 1.22 0.21 1.89 0.13 1.80 0.16 Polished 2.22 0.20 1.99 0.58 2.25 0.17 2.21 0.16
[0040] Thus, if the SEM measurements are assumed to be an accurate determination of crack length, the experimental results using the system of the present invention show that the error of measurement was within 5%. Thus, it is possible to use the system of this invention with a conventional microscope to evaluate the toughness of thin ceramic substrates, even substrates with as-fired surface conditions.
[0041] Further, specimens of 8YSZ material were tested using the system of the present invention. The experimental results are comparable to the results from literature, corroborating the validity of the present invention. Experiments with surface-polishing specimens indicated that the polishing procedure increased the toughness measurement results significantly. Thus, the present invention provides an efficient method and apparatus and economical method and apparatus to measure small crack dimensions on thin ceramic substrate surfaces, either polished or as-fired.
[0042] While the invention has been described in connection with measuring of small crack, i.e., sub-micron size dimensions on thin ceramic substrate surfaces the invention also advantageously may be used for detecting and for measuring sub-micron sized particles such as mold, dust, and various biological particles including weaponized bio-agents. A particular feature and advantage of the present invention is that the invention permits resolution to 40 nm (equivalent to λ/10 in visible wavelength), using a conventional polarizing microscope with minimal, low-cost modification.
|
A method and apparatus for visualizing sub-micron size particles employs a polarizing microscope wherein a focused beam of polarized light is projected onto a target, and a portion of the illuminating light is blocked from reaching the specimen, whereby to produce a shadow region, and projecting diffracted light from the target onto the shadow region.
| 6
|
RELATED APPLICATION
[0001] This application claims the benefit of Provisional Patent Application Ser. No. 60/854,327 filed 25 Oct. 2006.
BACKGROUND OF THE INVENTION
[0002] Guns are often equipped with a front sight and a rear sight to provide a two-point visual reference for locating an intended target.
[0003] A user views the target through the rear sight, closest to the user's eye, and then aligns the front sight, typically a pin, on the target.
[0004] The rear sight is sometimes equipped as a “peep sight,” or a circular structure with a void space in the middle for referencing and framing the front site. With the increasing use and popularity of long-range firearms such as rifles, the use and popularity of scope sights have likewise increased.
SUMMARY OF THE INVENTION
[0005] This invention relates to a rotatable and retractable rear gun sight for attachment to a gun. The rear gun sight member is rotatable to expose one of two or more apertures provided on the rotatable rear sight member. The different apertures can be used for different estimated target distances, from nearer to farther. Because the plurality of apertures are spaced further apart from their axis of rotation, a longer distance from the axis of rotation will result in a farther target distance, because aligning the aperture and the front sight will result in raising the tip of the gun barrel.
[0006] A retractable frame member is provided, which is rotatable about a second axis of rotation. The frame member retracts from a first, generally vertical shooting position to a second, generally horizontal non-shooting position. This member is coupled to the body of a gun.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] FIG. 1 is a prior art rear sight, attached to a body of a gun, and a front sight;
[0008] FIG. 2 is a front view of a rotatable and retractable rear gun sight of the present invention;
[0009] FIG. 3 is a perspective view of a gun sight aperture of the present invention;
[0010] FIG. 4 is a front view of the gun sight aperture of the present invention;
[0011] FIG. 5 is a back view of the gun sight aperture of the present invention;
[0012] FIG. 6 is a side view, with portions broken away, of the rotatable and retractable rear gun sight of the present invention;
[0013] FIG. 7 is a top view of a sight coupling for carrying the rotatable and retractable rear gun sight of the present invention on a gun;
[0014] FIG. 8 is a front view of a gun sight frame of the rotatable and retractable rear gun sight of the present invention;
[0015] FIG. 9 is a front view of a sight base component of the rotatable and retractable rear gun sight;
[0016] FIG. 10 is a side view of a sight base component of the rotatable and retractable rear gun sight;
[0017] FIG. 11 is a front view of a sight frame member component of the rotatable and retractable rear gun sight;
[0018] FIG. 12 is a side view of a sight frame member component of the rotatable and retractable rear gun sight.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0019] Although the disclosure hereof is detailed and exact to enable those skilled in the art to practice the invention, the physical embodiments herein disclosed merely exemplify the invention which may be embodied in other specific structures. While the preferred embodiment has been described, the details may be changed without departing from the invention, which is defined by the claims.
[0020] Referring now to FIG. 1 , a prior art rear sight is shown attached to a body of a gun. A front sight is shown to provide a two-point, and considering the target, a three-point frame of reference so that the shooter can align the gun with the intended target. In use, a user looks through the rear sight and locates the front sight on the target. This creates a two-point alignment system, and when the target is located, both horizontal and vertical alignment is intended. The frame serves to hold the vertical and horizontal alignment bars, as well as to provide a field of view reference, so that the user can visually acquire the target easier.
[0021] As is shown in FIG. 1 , the prior art often uses a crosshairs type stadia alignment system, with vertical and horizontal reference bars framing the peep hole. A frame further defines the field of view and holds the vertical and horizontal reference bars.
[0022] Referring now to FIG. 2 , a front view of a rotatable and retractable rear gun sight 10 of the present invention is shown. A frame 30 carries a rotating gun sight aperture 20 , and bar 31 , and defines a field of view through the void space or window of the frame. A rotating gun sight aperture 20 with peep hole 24 further defines the field of view on the intended target, along with horizontal reference bar 28 carried by the aperture 20 . The front sight 22 is not attached to the rotatable and retractable rear gun sight 10 but is instead carried closer to the gun barrel as shown in the prior art of FIG. 1 .
[0023] A dial 50 is carried by frame member 40 , the dial in operative association to rotate the aperture 20 to one of a predetermined number of, preferably three, aperture members 20 a, 20 b, and 20 c as will be described later.
[0024] A windage dial 60 is provided for adjusting the rear gun sight 10 left and right due to wind. Windage refers to the side-to-side adjustment of a rifle's sight, used to change the horizontal component of the aiming point. The up-down adjustment for the vertical component is the elevation.
[0025] Spring loading ball detents 70 are provided for retracting the rotatable and retractable rear gun sight 10 into a horizontal position, and vice-versa into the shooting position.
[0026] A sight base 80 is providing for holding the rotatable and retractable rear gun sight 10 coupled to the gun, as will be described later.
[0027] Referring now to FIGS. 3-5 , the rotating gun sight aperture 20 of the present invention is shown. As can be seen, a predetermined number of, preferably three, aperture members 20 a, 20 b, and 20 c are provided. In this manner, a user can rotate the rotating gun sight aperture 20 to correspond with three different distances. In the embodiment shown, distance indicia 26 can be provided on the rotating gun sight aperture 20 for ease of reference. Additional sets of apertures 20 can be interchanged with the single set 20 shown, for greater or lesser distances.
[0028] It will be appreciated that the shorter the distance from the peep 24 to the center of the rotating gun sight aperture 20 , the shorter the target distance represented, as the selected peep 24 of aperture members 20 a, 20 b, and 20 c will be at the 12 o′ clock position during shooting.
[0029] Referring now specifically to FIGS. 5 and 6 , a back view of the gun sight aperture 20 of the present invention is shown. Slots 32 are provided for engagement with spring loaded ball detents 36 as will be described with reference to FIG. 6 , a side view of the rotatable and retractable rear gun sight 10 .
[0030] Referring now to FIG. 6 , it will be seen that the slots 32 on the rotating gun sight aperture 20 are engaged by spring loaded ball detents 36 . When a user engages the dial 50 , the user can exert enough pressure on the springs of the spring loaded ball detents 36 to allow rotation of the gun sight aperture 20 through to the selected aperture 20 a, 20 b, or 20 c. Once the appropriate selected channel 32 is engaged by the spring loaded ball detents 36 , the spring loaded ball detents 36 click into the channel 32 .
[0031] Still referring to FIG. 6 , the rotatable and retractable rear gun sight 10 similarly can be retracted by tilting downward on frame 30 , dislodging ball detents 70 from their associated void spaces on the sight base 80 . This engagement is also shown on FIG. 9 .
[0032] Referring now to FIG. 7 , a top view of a sight coupling 110 for carrying the rotatable and retractable rear gun sight 10 is shown. Site base 80 is coupled to the sight coupling 110 (not shown), and sight coupling 110 is in turn coupled to the gun (not shown), such as is shown with reference to the prior art of FIG. 1 .
[0033] Referring now to FIG. 8 , a front view of the gun sight frame 30 is shown.
[0034] Referring now to FIGS. 9-10 , front and side views of the sight base 80 of the rotatable and retractable rear gun sight 10 are shown, with portions broken away.
[0035] Referring now to FIGS. 11-12 , front and side views of the sight frame member 30 component of the rotatable and retractable rear gun sight 10 are shown. If the user wishes to remove the apertures 20 either for placing different apertures into the sight 10 , or for using the apertures 20 on a different gun, the user can remove sight frame member 40 and remove apertures 20 .
[0036] The foregoing is considered as illustrative only of the principles of the invention. Furthermore, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described. While the preferred embodiment has been described, the details may be changed without departing from the invention, which is defined by the claims.
|
A rotatable and retractable rear gun sight is disclosed. The rear gun sight is coupled to a body of a gun. Three different apertures are provided for rear sight viewing of targets of three different distances. The apertures can be rotated out of view or into use depending on the estimated target distance. The rear gun sight can also be flipped down.
| 5
|
BACKGROUND OF THE INVENTION
This invention relates to mounting hardware for a self-leveling laser instrument. These instruments are used extensively in the construction industry to project lines and planes of light for building references. The invention allows the user to quickly and efficiently mount the laser instrument in a wide variety of conditions.
On a construction site a worker normally must carry his layout tools around the building site for each job. It is, therefore, advantageous and beneficial to have a small, compact measurement tool to do measurement jobs normally done using a tripod, transit, and a grade rod. In the prior art, the laser instrument has often been mounted on a tripod with an elevating column. The disadvantage of this method is that the tripod is large and clumsy to carry as well as being expensive. The elevating column is required to adjust the height of the laser instrument to position the laser beam at the needed elevation. Using the present invention, the number, weight and volume of accessories required to use a laser instrument is minimized saving the user cost and storage space. The invention makes the best use of available materials at the building site. The invention allows a self-leveling laser instrument to be mounted on virtually any structure already on the building site through the use of a flexible clamp and attached rotating turntable. Such structures include half-built walls, batter boards, ladders and many other items, whether permanently fixed or temporarily in a stable position.
SUMMARY OF THE INVENTION
The first component of the layout tool mounting device of the invention is a clamp with a pistol grip. This clamp may be that manufactured by the American Tool Company, described in U.S. Pat. Nos. 5,022,137 and 4,926,722. A clamp jaw is modified by adding a second component, a rotatable turntable, to which a self-leveling laser instrument is mounted, such as the instrument described in my copending application Ser. No. 248,517, now U.S. Pat. No. 5,459,932. The turntable provision allows the projected laser beam to be pointed anywhere in the level plane without changing its elevation. The attachment to the turntable is via a threaded rod or a magnet on a rod. The use of a magnet facilitates the quick fastening and unfastening as is required in setting up the laser instrument for one job and another in quick succession without having to take time to screw the parts together. Using a pistol grip of the clamp device, the operator is able to mount the laser instrument on walls, window frames, building studs, batter boards, or numerous other objects on the construction site.
As is known with the referenced clamps, the pistol grip of the clamp allows the operator to clamp onto objects with one hand. Tension in the clamp is controlled by the applied squeeze in the grip. The operator's second hand can be used to finely position the clamp to the elevation as required. When the position has been reached, the clamp is tightened to secure the mount assembly in place. The typical laser instrument used with the invention is provided with a threaded hole for convenient mounting. A 1/4-20 thread is often used for this purpose to accommodate conventional tripods. A threaded rod on a manually rotatable turntable is screwed into the laser instrument to provide attachment.
The laser instrument for primary use with the subject invention typically has a self-leveling range of plus or minus three to five degrees or more in any direction. When clamped on a vertical member, the adjustment for rough level in one axis is automatic, since the clamping jaws are vertical at their engaging faces. Rough leveling in the direction perpendicular to the jaws of the clamping member can be done by slightly loosening the clamp and moving the pistol grip up or down to rotate the clamp about a horizontal axis. When the laser instrument appears to be vertical, it is certain to be within a few degrees of level; the operator then tightens the pistol grip locking the instrument in place. Because the rotatable turntable is on an approximately vertical axis, the self-leveling laser instrument may now be rotated about its axis creating a horizontal reference plane.
The turntable assembly allows mounting on either of two opposed sides which gives the clamp greater flexibility in positioning the laser instrument relative to the vertical clamping surface. For example, when a room door frame is clamped, one clamp jaw is in the room and one is outside the room. Since only one jaw of the clamp has the turntable assembly, the clamp must be turned around to place the turntable in the needed position. This flexibility in mounting is possible since the laser instrument can be mounted on either side of the turntable, and either side of the turntable can be used as a knob to rotate the turntable to the desired direction.
To achieve the objectives of smooth wobble-free rotation as well as cost-effective manufacture, the threaded rod which fastens to the laser instrument is used as an adjustment mechanism. The spacing between the two turntable platforms, or turntables, needs to be adjusted so as to provide sufficient friction to sustain the laser instrument in the direction pointed. On the other hand, the friction must not be so great that the operator has difficulty in directing the laser instrument. The same threaded rod which fastens to the laser instrument securely connects to the two turntables. The spacing is controlled by screwing the two turntables toward or away from each other. Their final position is maintained by a thread locking compound.
In an alternate method of fastening the laser instrument to the turntable, only the center section of the rod is threaded. A small magnet is fastened at each end of the rod to hold the instrument in place. The steel threaded insert within the laser instrument is attracted by the magnet with sufficient strength to secure the laser instrument to the turntable.
In an alternate embodiment of the invention, a fixed mounting platform is included instead of the rotating turntable. In this case a self-leveling rotating laser or a self-leveling plane generating laser instrument can mounted on a jaw of the clamp, without the need for a rotating mount. Such laser instruments must be leveled to within the self-leveling range of the instrument. The benefits of easy height adjustment and rough leveling provided by the clamp make this application attractive.
It is among the important objects of the invention to provide a simple and efficiently used clamping tool and method for use of a self-leveling laser instrument for layout work, such as at a construction site. The clamp device and method enable an operator to very quickly set up a laser mounting platform tool within the self-leveling range of the instrument, as well as providing an easy means and procedure of height adjustment. The invention eliminates the need for a tripod and provides a far more versatile mounting procedure than available with a tripod. 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 perspective view showing a quick-action mounting clamp of the invention.
FIG. 2 is a somewhat schematic top view showing the clamp device engaged on a structure and indicating a laser instrument outlined in two different positions of rotation, projecting a beam in two directions.
FIG. 3 is a section drawing through one jaw of the clamp device, showing detailed construction of the turntable assembly, with two opposed turntables, one of which holds a laser instrument.
FIG. 4 is a sectional view showing a magnetic attachment to the turntable for retaining a laser instrument.
FIG. 5 is a schematic elevation view showing the slide bar of a mounting clamp which is engaged on a horizontal surface and a magnetic attachment held to the clamp's slide bar and providing a platform for the laser instrument.
DESCRIPTION OF PREFERRED EMBODIMENTS
The clamp device of the invention is generally indicated at 2 in FIG. 1. In its most common application, the jaws 4 and 5 of the device clamp a vertical surface such as a column or door frame, generally in the orientation shown in FIG. 1. A pistol grip 7 which is fixed to the jaw 4, including the known one way drive with a release lever 9, advances with the jaw 4 on a steel slide bar 10. The fixed jaw 5 and movable jaw 4 of the clamp have rubber pad covers 6 and 8 to grip rough surfaces. Plastic rotating turntables 12 and 16 of a turntable assembly 13 each have a smooth flat surface 15 to form the interface between a laser instrument 17 (FIGS. 2 and 3) and the turntable. A threaded rod 14 extends on a vertical axis in this clamp position, passing through the jaws and both turntables. The two plastic turntables rotate together (as explained below) so that the operator can easily screw the threaded rod into the laser instrument by rotating the turntable.
A top view of the invention is shown in FIG. 2. Dotted lines indicate two positions of the self-leveling laser instrument 17. The smaller dotted lines at 18 represent the projected laser beams from the two positions. As can be envisioned from this view, the laser beams can scan approximately 270 degrees in a preferred embodiment. Modifications can be made to the jaw 5 and turntable assembly to extend out the axis of the rod 14 so as to provide full 360° rotation, if desired. A portion of an object to which the invention is clamped is indicated at 19. The jaw 5 supports the turntable 12 as well as the rubber cover pad 8 (the other clamp jaw 4 and the pistol grip 7 are not seen in FIG. 2). The threaded mounting rod is seen at 14 and the steel bar is at 10. If the structure 19 were a door frame to a room, the laser beam could not scan the portion of the room obstructed by the door frame 19. Because of the symmetry of the turntable 12, the clamp device can be turned upside down and remounted at the other side of the door frame to allow scanning of the rest of the room. This ability to mount the laser instrument on the inside or the outside of the door frame is an important feature of the invention.
FIG. 3 shows the clamp device in a section view taken at the turntable assembly 13, with a cutaway drawing of the laser instrument to show the fastening detail. Part numbers correspond to those in the previous figures. 22 represents the frame of the clamp jaw 5 which has a hole through it to allow the threaded rod 14 to connect the two turntables 12 and 16. These turntables have threaded brass inserts 29 and 33 respectively. Washers 30 and 32 provide a smooth bearing surface for mating to the plastic of the turntable. To further ensure the smooth motion of the turntables, the distance between the turntables is adjusted using the thread adjustment via the threaded liners 29 and 33. The final position of the threaded rod in the liners 29 and 33 is locked in place using a thread-locking adhesive such as that manufactured by the Loctite Corporation. The adhesive takes several minutes to harden. This time allows the fit to be adjusted at the time the turntables are fastened to the frame.
A portion of a laser instrument 17 is also shown in FIG. 3. The housing is indicated cut away to show a threaded steel nut 34 which is captured within the instrument.
A quick-disconnect feature is shown in FIG. 4 as an alternative laser tool engagement. A threaded rod 40 (or a non-threaded rod) replaces the threaded rod 14 of FIG. 3. A magnet 42 is held in place by a small screw 41. The threaded steel insert 34 of the laser tool is fastened in the housing 21 of the laser tool 17 and holds the laser instrument to the turntable 16 via magnetic attraction rather than threads. To improve the holding strength of the magnet, it is poled in the direction of a diameter instead of along the axis of the cylindrical magnet.
FIG. 5 shows an alternative arrangement for mounting a laser instrument 17 using a quick grip clamp whose slide bar 10 is seen in FIG. 5. The clamp may be identical to what is shown in FIGS. 1 through 3, but it can be simply an off-the-shelf quick grip clamp such as shown in the above referenced U.S. Pat. Nos. 5,022,137 and 4,926,722, including the steel bar 10 which is used for the mounting arrangement in FIG. 5. In this laser mounting procedure, the quick grip clamp is secured to a horizontal surface such as a table top (not shown). The steel bar 10 of the clamp extends either downwardly or upwardly (as shown), providing a flat surface, facing to the right in FIG. 5, onto which a magnet 48 may conveniently be placed. The magnet 48 forms a part of an L-shaped mounting bracket 50 of the invention, and permits very convenient attachment of the mounting bracket, with easy adjustment of the height of the bracket, by movement on the slide bar 10.
As shown, the bracket 50 provides a platform 52 for the laser instrument 17. The platform preferably, but not necessarily, includes a machine screw mount with a tightening knob 54 for engagement of the laser tool via a threaded opening such as through the steel insert 34 as shown in FIG. 3. Other arrangements, such as magnetic retention, can be used in lieu of the screw thread; alternatively, a simple flat and wider platform can be provided at 52 for resting the tool 17 on the platform without positive securement.
FIG. 5 shows that the laser instrument 17, preferably a self-leveling laser instrument as described in copending application Ser. No. 248,517 (incorporated herein by reference), can project a plumb laser beam 18a as well as the horizontal beam 18. The apparatus of the invention described herein can be useful for operators desiring to utilize the plumb beam 18a, alone or in conjunction with the level beam 18. For purpose of lateral adjustment, the tightening knob 54 and screw thread arrangement therewith can be fitted through a slotted hole in the platform 52. Also, the quick action clamp (not shown in FIG. 5) can be moved laterally to the position desired. As also noted in FIG. 5, the laser instrument 17 can be one which also projects a third essentially intersecting beam, comprising a second horizontal beam 18b. This is useful for layout tasks wherein the laser instrument is located at one point and two lines at right angles are to be located by use of the horizontal beams 18a and 18b.
A further use of the quick action bar clamp of the invention, used alone or in conjunction with the L-shaped mounting bracket 50 of FIG. 5, is in providing stable mounting for a distance measuring laser instrument. Many such instruments require precise pointing, and a stable platform can be provided using the apparatus of the invention.
It should be understood that mounting platforms and retention devices can be located at other positions on either of the jaws of the clamp tool. For example, threaded rods and platforms or turntables could be at right angles to the threaded rod 14 in FIG. 1 and secured to the fixed jaw 5, oriented toward the left in FIG. 1 or at right angles to that position. These can be useful if the clamp tool cannot be oriented as in FIG. 1 or 2.
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 this preferred embodiment 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.
|
A quick action bar clamp has provision for mounting an alignment laser instrument on one jaw of the clamp. The mounting provision allows manual pointing of the laser to facilitate projecting a level line or plane of light with a self-leveling laser instrument. By engagement of the clamp on a fixed structure such as a column, wall stud or door frame, the operator can quickly bring the laser instrument into its self-leveling range and easily adjust the beam height. The attachment of the laser instrument to the clamp is via a threaded rod or a magnetic attachment retention. An L-shaped magnetic attachment can be used in another procedure, to connect the laser to the steel slide bar of the clamp.
| 5
|
This patent is a continuation in part of U.S. patent applications 09/389,916, 09/390,047 and 09/390,044, each filed Sep. 3, 1999, each of which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
It is known in the art to annotate or “mark” objects in a video stream with an interactive link. For example, suppose one was watching a video program of an automobile race, and there were several racing cars shown driving around a track. Also suppose that these cars were marked with interactive links. This means that one can position a cursor over the image of one of the cars and click on the image (or alternatively, click on special icons associated with the car). This causes the system controlling the video screen to take a predetermined action (e.g. execute a software program, or initiate some other event such as a telephone call) or display information that is linked to that image. This link can be in the form of a pop-up window for note annotation. (A pop-up window for note annotation is a small window that appears on the screen so that a user can write a small note. It is like an electronic “post-it” note.) Alternatively, the link can be in the form of a URL. If the link is invoked, the system will display a web page depicting information concerning the car or driver that has been clicked on. For example, the system can display details concerning the driver. As mentioned above, by clicking on the icon or image, one could also initiate an action, e.g. a telephone call to a merchandise company to buy a memorabilia product related to what has been clicked on.
During annotation, an area or region within the video frames surrounding the image of an object of interest (in the above-mentioned example, the racing car) is established as an “active area.” If one moves the cursor into the active area and clicks, one will initiate an action or invoke the link corresponding to the object within that active area. Typically, an object associated with the active area moves about the video screen during a video clip. For example, a video clip of an automobile race shows a group of cars moving about a racetrack, and these cars typically move about a television screen during the clip as the race proceeds. In such a video clip, a car might move from the right side of the video screen to the left side of the video screen. Thus, the active area must also move across the television screen to keep up with the object of interest. The above-incorporated patent applications pertain to methods for annotating video clips, i.e. defining the active area for each object of interest, and for each frame, in the video clip. These methods permit annotation with a reduced amount of human involvement in the process. It would, however, be desirable to further simplify the process of defining active areas in a video clip.
SUMMARY
A method in accordance with the invention comprises the step of providing a template or a set of templates to be associated with a video screen. The template defines a set of active regions of the video screen. The active regions typically do not overlap one another. Each active region corresponds to a process or link that can be invoked. In one embodiment, the link is to an internet web page. When that link is invoked, the contents of the web page are displayed on the screen.
In another embodiment, the link is to a source of information other than an internet web page. For example, the link can cause a video system to display information from a memory to be displayed on the screen. The memory can either be local or non-local.
In yet another embodiment, invoking the link causes a software routine or application program to be executed.
Alternatively, invoking the link initiates an event, e.g. a telephone call.
In one embodiment, the active areas of the template are visible to the user. For example, the active areas of the template can be a particular color, or bear a particular icon, or can be shaded. Thus, the user knows the location of the active areas, and can move a cursor to the active areas to invoke links associated therewith. In another embodiment, the active areas are not visible. However, when the cursor is moved to the active areas, the appearance of the cursor changes, so the user knows that the cursor is positioned over an active area. In yet another embodiment, the active areas are not visible, and the cursor does not change appearance when positioned over the active areas.
The video screen can display any type of video information, e.g. a still image, a video image, a web page, a Windows-type desk top output, or other computer output. For example, a user can watch a television program on the video screen and manipulate a cursor to invoke the links associated with the template. Alternatively, the user can read a web page on the video screen and can manipulate a cursor to invoke the links associated with the template.
One advantage of this invention is that the use a set of templates is a simple way of providing robust dynamic linking. A person using the template does not have to chase a small moving object on a screen with a cursor in order to invoke a link.
A set of templates in accordance with one embodiment of the invention allows a content provider to choose the most appropriate template without complicated content-oriented linking (i.e. without the complication of having the active areas move in sync with associated objects on the video screen). In some cases this solution can be preferable to fixed static icon (one fixed template) solutions and completely dynamic (moving active area) solutions.
In accordance with another aspect of the invention, templates can be used for secure communication of data associated with a video stream. For example, in one embodiment, each active area of a template can be considered as a symbol (or letter) that is part of an arbitrary complicated password, which allows a user to be re-directed to selected internet pages, to call a secret telephone number or start a special application.
These and other aspects of the invention are described in greater detail below.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates a video screen including an overlay template comprising a set of active areas.
FIG. 2 illustrates a second template overlaying a first template on a video screen.
FIG. 3 is a block diagram illustrating a video system in accordance with the invention.
DETAILED DESCRIPTION
Referring to FIG. 1, video system 1 comprises a substantially rectangular video screen 2 having active regions 4 a to 4 d and a region 6 . Regions 4 a to 4 d correspond to a “template.” Video screen 2 can display any type of visual information. For example, in one embodiment, screen 2 displays a still image, e.g. a picture. In another embodiment, screen 2 displays a movie or television program. In another embodiment, screen 2 displays a web page. In yet another embodiment, screen 2 displays a computer output, e.g. an image of a Windows-type desk top. Screen 2 can be a CRT screen, an LCD screen, a video projection screen, or other type of screen capable of displaying a visual image. The image displayed on screen 2 can originate from a conventional television receiver that receives radio waves or a receiver that receives signals from a cable or optical fiber. Alternatively, the image on screen 2 can originate from the internet, from a personal computer, a VCR, or other source of visual information, either in digital or analog form.
In a first embodiment, regions 4 a to 4 d are not visually distinguishable from the remainder of screen 2 . In other words, if screen 2 is displaying a television program, one cannot tell, merely by looking at screen 2 , where regions 4 a to 4 d are located.
Also shown on screen 2 is a cursor 8 . Cursor 8 can be any shape, or have any appearance. A user manipulates cursor 8 with a control device, e.g. a remote controller 10 comprising a joystick, trackball, mouse, touch pad (e.g. touch pad 11 a ) or appropriate control buttons 11 b . If a user moves cursor 8 to region 4 a , a link is invoked corresponding to region 4 a . If the user moves cursor 8 to region 4 b , a link is invoked corresponding to region 4 b , and so forth. In one embodiment, the link is to a web page. Moving the cursor to region 4 a invokes the link, and information corresponding to the web page is displayed on screen 2 . (In an alternative embodiment, one must move cursor 8 to region 4 a and click on region 4 a to invoke the link, rather than merely moving cursor 8 to region 4 a .)
In another embodiment, the link is to a data source other than a web page. This data source could be another source of visual information, e.g. another movie or television program. Alternatively, the link could execute application software. Alternatively, the link could result in the display of data from a local data source, e.g. a disk drive, or a non-local data source. In one embodiment, the link is to a pop-up window for note annotation.
As mentioned above, in a first embodiment, regions 4 a to 4 d are not visible per se. In a second embodiment, when cursor 8 is moved to one of regions 4 a to 4 d , cursor 8 changes appearance (e.g. cursor 8 changes shape, color, light intensity, or otherwise manifests a changed appearance). Thus, a user can determine whether cursor 8 is located in an active region by observing the appearance of cursor 8 .
In a second embodiment, regions 4 a to 4 d can be detected visually. For example, regions 4 a to 4 b can be shaded differently from other portion 6 of screen 2 . Thus, a user can still use the entire video screen to watch a video image, but the user will know where the active regions are located. In lieu of shading the active regions differently, a set of lines such as lines 4 a ′ to 4 d ′ are visible so that a user can see where the active regions are located.
In a third embodiment, an image is displayed in region 6 of screen 2 , but that image is not displayed in active regions 4 a to 4 d . Thus, regions 4 a to 4 d can be used to display something other than that image, e.g. other visual information such as icons, alphanumeric information, thumbnail still or video images, and so forth. The images displayed in regions 4 a to 4 d can come from any appropriate source, e.g. a cable or optical fiber, a conventional television receiver, a computer memory (either local or remote), a VCR or other source of visional information.
In this embodiment, regions 4 a to 4 d can be thought of as containing images interposed over and eclipsing the main image on screen 2 . In one embodiment, the images in regions 4 a to 4 d can be generated using a 3D graphics chip within the video display system. Circuitry for providing the images in regions 4 a to 4 d can be as described in U.S. patent application Ser. No. 09/344,442, filed Jun. 25, 1999. (The '442 application discloses means for binding 2D images to a planar surface using a 3D graphics pipeline. The '442 application is incorporated herein by reference.)
In a version of the third embodiment, one can adjust the images in regions 4 a to 4 d from being completely opaque to completely transparent, or somewhere in between. In other words, when the images in regions 4 a to 4 d are completely opaque, any underlying image is completely eclipsed. By rendering regions 4 a to 4 d more transparent, one can perceive a “ghost image” of the information displayed in regions 4 a to 4 d along with the underlying image. By rendering regions 4 a to 4 d completely transparent, one simply sees the underlying image in regions 4 a to 4 d of screen 2 .
In a fourth embodiment, regions 4 a to 4 d display images that periodically change. For example, for thirty seconds, a first thumbnail still or video image appears in region 4 a , and thereafter, a second image appears in region 4 a . After another thirty seconds elapses, a third image appears in region 4 a . The link associated with region 4 a can change at the same time the image changes. Alternatively, in other embodiments, the link remains unchanged. In one embodiment, invoking the link associated with region 4 a alters the image shown in regions 4 b to 4 d . In another embodiment, invoking the link associated with one region does not affect the images shown in the other active regions.
In a fifth embodiment, the size and/or appearance of regions 4 a to 4 d can be changed, e.g. by actuating appropriate buttons on controller 10 . Thus, regions 4 a to 4 d can be made smaller or larger.
In one embodiment, the links associated with regions 4 a to 4 d are related to the content displayed in region 6 . (In this embodiment, the template comprising regions 4 a to 4 d is typically provided by the content provider of the image shown in region 6 .) For example, if region 6 displays a sporting event, regions 4 a to 4 d might correspond to links for displaying information about that or related sporting events. Thus, if the sporting event is a baseball game, regions 4 a to 4 d might correspond to links concerning statistics pertaining to the teams or players. In addition, the images depicted in regiosn 4 a to 4 d are related to the content displayed in region 6 . However, in another embodiment, the images shown at regions 4 a to 4 d are unrelated to the content displayed in region 6 .
As mentioned above, regions 4 a to 4 d form a template. Suppose the image on screen 2 is annotated with links corresponding to active regions 12 and 14 . Region 12 is located within region 6 and outside regions 4 a to 4 d , and is activated e.g. by using cursor 8 to click on active region 12 . Thus, a user can invoke the link associated with region 12 by using cursor 8 to click on region 12 , even though the template is active. However, region 14 is located within region 4 c . The template covers active area 14 , and the link associated with area 14 cannot be invoked unless one removes the template (e.g. in a manner discussed below). Thus, if one moves cursor 8 to area 14 in an effort to invoke the link associated with area 14 , one will only succeed in invoking the link associated with region 4 c.
As mentioned above, in one embodiment, the image on screen 2 is a video image. This image can be annotated with links in the manner described in the above-incorporated patent applications. In other words, portions of a video image are associated with interactive links. By placing the template over the video image, any links underneath regions 4 a to 4 d are effectively masked.
In another embodiment, the image on screen 2 is a web page. Web pages typically include active areas for invoking links to other web pages. If screen 2 displays a web page, those links appearing within region 6 can be accessed by a user, and invoked in the normal manner. However, those links within regions 4 a to 4 d are effectively masked, and cannot be invoked by a user unless the template is removed.
The template itself is typically stored in a memory device associated with the video system of which screen 2 is part. This memory device can be a semiconductor memory such as a RAM, a ROM, an EPROM, a disk drive, tape drive, or other memory device. This memory stores the location of the active regions 4 a to 4 d , and the links (e.g. URLs) with which regions 4 a to 4 d are associated. In one embodiment, the template (e.g. the links associated with active regions 4 a to 4 d ) is determined by the user. In other words, a person viewing screen 2 can determine the links that are associated with regions 4 a to 4 d , e.g. by inputting appropriate link address information into a memory, e.g. with an alphanumeric keypad coupled to video system 1 . (The keypad can be part of controller 10 or some other structure coupled to system 1 .) The user can activate or deactivate the template.
In another embodiment, the template can originate from the same source as the video information displayed on screen 2 . For example, if the program displayed on screen 2 originates from a cable TV source, the links associated with active regions 4 a to 4 d also originate from that source. (Optionally, the locations of active regions 4 a to 4 d within screen 2 can also originate from that source.)
In another embodiment, the links can originate from a source that is different from the origin of the image displayed on screen 2 . For example, the image on screen 2 can be a conventional television program received from a radio antenna, whereas the links can be obtained via the internet. Optionally, the location of regions 4 a to 4 d can also be received from the internet.
In one embodiment, a user can activate or deactivate the template, e.g. by pressing an appropriate control button on remote control device 10 . If deactivated, regions 4 a to 4 d no longer serve as active regions, and any active regions previously masked by regions 4 a to 4 d become unmasked. Thus, active region 14 , previously masked by region 4 b , can then be clicked on, and the link associated with active region 14 can be invoked. When deactivated, any visual indication of the location of regions 4 a to 4 d is removed. Thus, if regions 4 a to 4 d previously had a different appearance, when the template is deactivated, regions 4 a to 4 d of screen 2 no longer have a different appearance. If, prior to deactivation, cursor 8 had a different appearance when positioned in regions 4 a to 4 d , when deactivated, cursor 8 no longer takes on a different appearance when positioned in regions 4 a to 4 d . Regions 4 a to 4 d are typically activated or deactivated together as a group, e.g. by actuating the above-mentioned control buttons. In another embodiment, regions 4 a to 4 d can be individually activated or deactivated.
A user can also reactivate the template, e.g. by actuating an appropriate control button on remote control device 10 . Alternatively, a user can activate a different template, e.g. by actuating an appropriate control button on remote control device 10 . This different template can have active regions having shapes and locations that are different from regions 4 a to 4 d . Also, the links associated with this different template can be to data sources other than the links associated with regions 4 a to 4 d.
A user can also place one template over one or more other templates. For example, referring to FIG. 2, by actuating an appropriate button on controller 10 , a user can activate a template having regions 16 a to 16 d . As can be seen, region 16 a entirely covers and masks region 4 a . Region 16 b is elliptical, and only masks a portion of region 4 b . Thus, portions of region 4 b are still accessible. Region 16 c is trapezoidal, but still covers and masks all of region 4 c . A user can deactivate the template corresponding to regions 16 a to 16 d if so desired by actuating an appropriate button on controller 10 .
In one embodiment, the various templates can be activated, deactivated, and placed over one another by an external source, e.g. the source providing the image in region 6 of screen 2 . As indicated above, this image can come from any of a number of places, e.g. a video broadcast using radio waves, optical cable or electrical cable. This image can originate from other sources as well, e.g. the internet. Thus, the provider of this image can determine which templates should be associated with the image at any given time.
In one embodiment, a template can be activated for only a predetermined time and then deactivated. Thus, if the image is a quiz show, the active regions can correspond to the answers to a question being asked on the quiz show. The active template might remain active for only so long as the question was pending.
In one embodiment, each region 4 a to 4 d represents an independent link. In another embodiment, one can actuate regions 4 a to 4 d in different orders to obtain different results. For example, if one clicked on regions 4 a , 4 b , 4 a , 4 d , that might constitute a “code” for causing a certain event to occur, or for invoking a certain link. Alternatively, if one clicked on a different sequence of regions, that might cause a different event to occur, or invoke a different link. Templates could be added or removed, depending upon this order. Alternatively, templates could be locked in place or locked out, depending upon this order. (This capability of requiring active areas 4 a to 4 d to be actuated in a certain order could be used for security purposes, e.g. for permitting or forbidding a user to access certain information, video images or web pages. Alternatively, this capability might also be part of a game, e.g. a user would have to figure out certain clues in order to figure out the correct order in which to actuate regions.)
One embodiment of our invention can be practiced using a PC having the following:
1. A CPU such as a Celeron or Pentium, e.g. as manufactured by Intel, or a K6/K7 processor, e.g. as manufactured by Advanced Micro Devices.
2. 24 MB of memory or greater.
3. The operating system can be Windows 95, Windows 98, WinCE, Win2000, or any other operating system that supports Direct X, Direct 3D and/or Direct Draw.
These packages can be used to apply images to regions 4 a to 4 d . The Windows operating system includes a standardized platform called Direct X for Windows.
FIG. 3 is a block diagram of a computer system 50 for performing a method in accordance with our invention. Referring to FIG. 3, system 50 comprises a CPU 52 , e.g. a Pentium II class CPU, comprising a cache memory 52 a , a core 52 b and an internal bus 52 c for facilitating communication between core 52 b and cache 52 a . Core 52 b communicates via a CPU bus 54 to a system controller 56 . System controller 56 communicates with the system memory 58 via a memory bus 60 . System memory 58 includes system memory.
Also included in system 50 is a PCI bus 62 for facilitating communication between system controller 56 and I/O devices 64 , 66 and disk drive 68 . I/O device 64 can be any type of I/O device, e.g. a modem or telephone for communicating with a telephone line. In one embodiment, I/O device 66 is a video capture card with a driver. The video capture card can be coupled to receive a video program from an antenna, a cable or optical fiber, a VCR, a video disk, or other video signal source. Data from the video capture card is either loaded by DMA (direct memory access) or CPU 52 into a frame buffer, typically within main memory 58 . However, the frame buffer may be in other memories within system 50 .
Graphics controller 70 uses its own local memory 74 to generate and store pixel arrays to be displayed on a video display unit 76 .
It is emphasized that system 50 is only one example of a system that performs a method in accordance with our invention. Other hardware can be used as well.
Stored within a memory within video display system 1 are the locations on screen 2 of regions 4 a to 4 d . CPU 52 (or other logic hardware within system 1 ) determines whether cursor 8 has been moved to one of regions 4 a to 4 d , i.e. by comparing the position of cursor 8 to the values stored in memory corresponding to the location of regions 4 . (This memory can be memory 58 or another memory within the system.)
As mentioned above, the image displayed on screen 2 can be annotated with active areas. The locations of these active areas (and the links associated with the active areas) are also stored in the above-mentioned memory (e.g. memory 58 ). Microprocessor 52 (or the above-mentioned other hardware) also compares the position of cursor 8 with the locations of these other active areas. However, microprocessor 52 (or the other hardware within the system) also ascertains whether these other active areas are masked by the template (e.g. regions 4 a to 4 d ). If the cursor is moved over an active area which is masked by region 4 a , for example, microprocessor 52 ascertains that the link associated with region 4 a is to be invoked.
Memory 58 can store numerous templates, each of which can be activated or deactivated, e.g. by controller 10 . These templates can also be placed over one another.
While the invention has been described with respect to specific embodiments, those skilled in the art will appreciate that changes can be made in form and detail without departing from the spirit and scope of the invention. For example, any type of display screen can be used in conjunction with the invention. For example, projection video display screens, LCDs, CRTs or other types of display devices can be used. Similarly, although the drawings display a screen depicting four active regions, different numbers of active regions can be used.
Although the template of FIG. 1 permits active areas within region 6 to be activated, in other embodiments, only the active areas of the active template itself can be activated.
As mentioned above, in one embodiment video system 1 displays various images in regions 4 a to 4 d . In one embodiment, these images can be applied to regions 4 a to 4 d using a method discussed in U.S. patent application Ser. No. 09/344,442. Accordingly, all such changes come within the invention.
|
A video system comprises a screen. Interactive linking is provided based on a representative set of region-based templates. Each template can be associated with said screen. The template comprises a set of active areas (usually non-intersecting), that can be actuated by moving a cursor to those areas, to thereby invoke a process or link. The link can be to a web page or other information source. In addition to template usage for surfing of active screen areas, templates can be used for secure link (process) activation. Each region can be considered as a symbol (“letter”) in the password. By using mouse or similar device user can click (“type) a sequence of symbols to follow an existing password.
| 7
|
TECHNICAL FIELD OF THE INVENTION
[0001] The present invention relates to a relay processing technique between a Web site and a client terminal.
BACKGROUND OF THE INVENTION
[0002] When a Web page containing a table which is provided on the assumption that it is displayed on a display screen of a personal computer is displayed on a cellular phone or PDA (Personal Digital Assistant) having a display screen smaller than the display screen of the personal computer, there is a problem in not only perspicuity, but also operability because the table runs off the edge of the display screen.
[0003] Thereupon, for example, EP-0949571-A discloses such a technique that a Web document which is designed so as to be displayed on a display screen of a desk top computer is displayed on a smaller display of PDA, a cellular phone or the like. According to this technique, a Web document obtained from a distributed network is analyzed to generate an abstract syntax tree, and various modifications are applied to the elements of the document to divide the Web document into smaller subpages, which can be displayed on a display device having a limited display area so that each subpage is legible and can be navigated. Moreover, this technique has a document filtering subsystem, and a user can select information to be displayed on the display device having the limited display area. However, it is not designed so that the user can define the hierarchical structure of the Web page when the table is divisionally displayed.
[0004] According to the above technique, if truly necessary data are located at a lower hierarchical layer of the Web page when the table is divisionally displayed, much labor and much time are needed to browse the data concerned.
SUMMARY OF THE INVENTION
[0005] Therefore, an object of the present invention is to provide a technique of enabling any user to browse data of a table in a desired hierarchical structure.
[0006] In order to attain the above object, an HTML (Hyper Text Markup Language) file processing method according to the present invention comprises: if an HTML file containing a table definition is received from another server in response to a request from a terminal of a user, referring to a hierarchical display definition data storage for storing hierarchical display definition data of a table preset by the user for a specific HTML file containing a table definition, and specifying a hierarchical display definition data for the received HTML file; and by extracting display elements to be displayed at a first hierarchical layer of the received HTML file according to the specified hierarchical display definition data, generating and transmitting to the terminal of the user, an HTML file for the first hierarchical layer.
[0007] Accordingly, the HTML file containing the table definition is reconstructed by using the hierarchical display definition data set by the user, and thus the user can efficiently browse desired data in the table.
[0008] Incidentally, the aforementioned HTML file for the first hierarchical layer may contain data for enabling an instruction of generating (including reconstructing) the hierarchical display definition data for the received HTML file. That is, it becomes possible for the user to instruct the generation of the hierarchical display definition data corresponding to the HTML file relating to a Web page, which is firstly browsed, or the hierarchical display definition data corresponding to the HTML file relating to a Web page, which is browsed again, by instructing only browsing of the Web page. Therefore, the convenience for the user is enhanced.
[0009] Furthermore, the aforementioned HTML file for the first hierarchical layer may include data for enabling selection of any one of display elements to be displayed at the first hierarchical layer. In the case of the table, even when data of only one or plural columns are displayed, it is difficult to say that the data is easily viewable for users. For example, because it is not rare to pay attention only to a specific line, a line to which attention should be paid is specified at the first hierarchical layer, and the data of the line concerned is displayed at a lower hierarchical layer.
[0010] Furthermore, the HTML file processing method of the present invention may further comprise: if an instruction of generating hierarchical display definition data is received from the terminal of the user, generating and transmitting to the terminal of the user, an HTML file containing headings contained in the aforementioned table and data for enabling to designate a display hierarchical layer for each of the headings, by referring to the received HTML file; and if designation data of the display hierarchical layer of the heading is received from the terminal of the user, generating and storing into the hierarchical display definition data storage, hierarchical display definition data from the designation data. Accordingly, the user can easily define a way for hierarchical display of the table.
[0011] A program for making a computer execute the HTML file processing method of the present invention can be created, and the program is stored in a storage medium or a storage device, such as a flexile disk, CD-ROM, an magneto-optical disk, a semiconductor memory, a hard disk or the like. Moreover, the program may be distributed as digital signals through a network or the like. An intermediate processing result is temporarily stored in a storage device such as a main memory or the like.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 is a diagram showing a system according to one embodiment of the present invention;
[0013] FIG. 2 is a diagram showing a first processing flow of the embodiment of the present invention;
[0014] FIG. 3 is a diagram showing a second processing flow of the embodiment of the present invention;
[0015] FIG. 4 is a diagram showing an example of table definition;
[0016] FIG. 5 is a diagram showing an example of an HTML file;
[0017] FIG. 6 is a diagram showing an example of displaying a table on a large-sized display screen;
[0018] FIGS. 7A to 7 D are diagrams showing examples of a divisional table page and examples of a definition input page;
[0019] FIG. 8 is a diagram showing a third processing flow of the embodiment of the present invention;
[0020] FIG. 9 is a diagram showing a fourth processing flow of the embodiment of the present invention; and
[0021] FIG. 10 is a functional diagram of a normal computer.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0022] FIG. 1 shows a diagram showing a system according to one embodiment of the present invention. For example, one or plural Web serves 9 and a Web contents control system 3 for executing the main processing in this embodiment are connected to a network 1 such as the Internet, LAN (Local Area Network) or the like. The Web contents control system 3 is connected to a radio base station 7 through a network 6 such as the Internet or the like. A cellular phone 5 a or PDA 5 b , which has a Web browser, is wirelessly connected to the radio base station 7 . The numbers of cellular phones, PDAs and radio base stations are not limited to specific values, and they are not main portions of the present invention. Therefore, they are singly illustrated in FIG. 1 . Moreover, the networks 1 and 6 may be any type of networks.
[0023] The Web contents control system 3 is set up between the Web server 9 and the cellular hone 5 a or PDA 5 b , is a system for relaying Web page data and is composed of one or plural servers. The Web contents control system 3 comprises: a user DB 32 for storing IDs and passwords of the users and the like; an authentication processor 31 for carrying out authentication processing for users by referring to the user DB 32 and outputting the user ID of an access source user to a table reconfiguration processor 35 ; an proxy access unit 33 for accessing the Web server 9 or the like on behalf of the cellular phone 5 a or the like and storing obtained Web page data into a Web page data storage 34 ; the Web page data storage 34 for storing Web page data (containing an HTML file) obtained by the proxy access unit 33 ; a table definition data storage 36 for storing table definition, which is data representing a hierarchical structure when a table in a Web page is divisionally displayed; the table reconfiguration processor 35 for referring to the table definition data storage 36 to specify table definition to be applied, generating divided table page data from the Web page data stored in the Web page data storage 34 according to the table definition concerned, and storing the divided table page data thus generated into a divided table page data storage 37 ; the divided table page data storage 37 for storing the divided table page data, an access allocation processor 40 for carrying out the processing of allocating accesses from the cellular phone 5 a or the like to the proxy access unit 33 , a table definition setting processor 38 and the table reconfiguration processor 35 ; the table definition setting processor 38 for referring to the table definition data storage 36 and the Web page data storage 34 to generate definition input page data to prompt a user to input data used as an origin for the table definition, storing the generated definition input page data into a definition input page data storage 41 , generating table definition on the basis of a response from the user, and storing the generated table definition into the table definition data storage 36 ; the definition input page data storage 41 for storing the definition input page data; and a transmitter 39 for transmitting the page data stored in the definition input page data storage 41 or the divided table page data storage 37 to the cellular phone 5 a or the like. Incidentally, it is assumed that the corresponding relationship between received URL (Uniform Resource Locator) and URL of a transfer destination Web server has been registered in the Web contents control system 3 in advance. In addition, after authentication processing is once completed by the authentication processor 31 , the session between the user terminal such as the cellular phone 5 a or the like and the Web contents control system 3 is assumed to be maintained and managed by a cookie or a session ID in URL during an appropriate period. The maintenance and management of the session are well known, and thus the description thereof is omitted. In this embodiment, it is assumed that an HTML file (i.e. URL) and user ID can be specified from a session ID.
[0024] Next, the processing flow of the system shown in FIG. 1 will be described with reference to FIGS. 2 to 8 . First, in response to an instruction of a user, a user terminal (cellular phone 5 a or PDA 5 b , the same is applied to the following description) transmits a request for an access to a specific Web site to the Web contents control system 3 (step S 1 ). When the authentication processor 31 of the Web contents control system 3 receives an access from a user terminal for which the session management is not carried out (when it receives a request for an access to a specific Web site) (step S 2 ), it temporarily stores the request into a storage device such as a main memory or the like, and transmits authentication page data to the user terminal (step S 3 ). The user terminal receives the authentication page data from the Web contents control system 3 , and displays it on the display device (step S 5 ). The user inputs his or her user ID and password into the authentication page. The user terminal accepts the input of the user ID and the password, and transmits them to the Web contents control system 3 (step S 7 ). The authentication processor 31 of the Web contents control system 3 receives the user ID and the password from the user terminal (step S 9 ) , and refers to the user DB 32 to carry out the authentication processing (step S 11 ). Because the user ID and the password are registered in the user DB 32 , and it searches the user DB 32 on the basis of the received user ID to extract the corresponding password, and compares the extracted password with the received password. If it is judged that both the passwords are not coincident with each other or the password cannot be extracted from the user DB 32 , the authentication fails and thus the processing returns to the step S 3 .
[0025] In a case where it is judged that the passwords are coincident with each other, that is, authentication succeeds, a processing request for the received access request is output from the authentication processing unit 31 to the proxy access unit 33 of the Web contents control system 3 , and the proxy access unit 33 accesses a specific Web site on behalf of the user terminal (step S 13 ). That is, the access request to the specific Web site, which was received in the step S 2 , is transmitted to the specific Web site (in this case, the Web server 9 ). In response to the access request, the Web server 9 returns specific Web page data (in this case, HTML file, the same is applied to the following description). The proxy access unit 33 of the Web contents control system 3 receives the specific Web page data and stores the data into the Web page data storage 34 (step S 15 ).
[0026] The table reconfiguration processor 35 analyzes the Web page data stored in the Web page data storage 34 , and judges whether the page contains a table or not (step S 17 ). If the table is contained, a <table> tag is contained in the HTML file, and thus the judgment is made on the basis of the presence or absence of the <table> tag. If a <table> tag is contained in the HTML file, the processing shifts to the processing of FIG. 3 through a terminal A.
[0027] On the other hand, if no <table> tag is contained in the HTML file, the table reconfiguration processor 35 stores into the divided table page data storage 37 , the specific Web page data itself, which was stored in the Web page data storage 34 . The transmitter 39 transmits the specific Web page data to the user terminal (step S 19 ). The user terminal receives the specific Web page data from the Web contents control system 3 , and displays the data on the display device (step S 21 ). The subsequent processing is the same as the prior art, and when the user terminal transmits a request for the access to the specific Web site to the Web contents control system 3 (step S 23 ), the access allocation processor 40 receives the access request (step S 25 ), and judges that the access is a normal access, and thus requests the proxy access unit 33 to carry out the processing with respect to the access request. That is, the processing is shifted from a terminal B to the step S 13 .
[0028] Next, the processing subsequent to the terminal A will be described with reference to FIG. 3 . The table reconfiguration processor 35 refers to the table definition data storage 36 to judge whether the table definition corresponding to the received Web page data (HTML file) is stored or not (step S 31 ). At this time, by using user ID specified by the authentication processor 31 , it specifies the file of the table definition corresponding to the specified user ID in the table definition data storage 36 , and checks whether the table definition corresponding to the received HTML file is contained in the file of the table definition of the user concerned. If it is judged that the corresponding table definition is not stored in the table definition data storage 36 (containing a case where the file of the table definition corresponding to the user ID does not exist), it acquires default table definition from the table definition data storage 36 (step S 33 ). On the other hand, if it is judged that the corresponding table definition is stored in the table definition data storage 36 , it acquires the corresponding table definition from the table definition data storage 36 (step S 35 ).
[0029] FIG. 4 shows an example of the table definition, and FIG. 5 shows an example of the corresponding HTML file (a part of the HTML file). In this embodiment, one file for the table definition is provided every user. In the example of FIG. 4 , the file contains a record for specifying a target HTML file (URL: [/bsc.fujitsu.co.jp/ikisaki.html]), a target table name (Name=schedule), data for specifying a first heading of the table (Hedder1.name=name) and data for specifying the hierarchical layer number thereof (Hedder1.order=1), data for specifying a second heading of the table (Hedder2.name=destination) and data for specifying the hierarchical number thereof (Hedder2.order=2), data for specifying a third heading of the table (Hedder3.name=return time to office) and data for specifying the hierarchical number thereof (Hedder3.order=2), and data for specifying a fourth heading of the table (Hedder4.name =memo) and data for specifying the hierarchical number thereof (Hedder4.order=3).
[0030] FIG. 5 shows the contents of [/bsc.fujitsu.co.jp/ikisaki.html]. A <form> tag is a tag for defining a table, and it defines the table name with an attribute name. Here, the table name is “schedule”. Moreover, a heading name of the table is provided between a <th> tag and a </th> tag.
[0031] Accordingly, as shown in FIG. 4 , the target table name “schedule” and the heading names of the table “name”, “destination”, “return time to office”, “memo” are contained in the table definition. According to the table definition of FIG. 4 , “name” is set to the first hierarchical layer, “destination” and “return time to office” are set to the second hierarchical layer, and “memo” is set to the third hierarchical layer.
[0032] With respect to the table definition set by a specific user, all the table definitions are stored in one file in the form as shown in FIG. 4 . On the other hand, the default table definition is applied to all the HTML files containing tables, and for example, it contains data for instructing to successively construct hierarchical layers from the left side of the heading names contained in the table. Accordingly, with respect to the table of the HTML file as shown in FIG. 5 , the hierarchical structure is specified like “name” is set to the first hierarchical layer, “destination” is set to the second hierarchical layer, “return time to office” is set to the third hierarchical layer and “memo” is set to the fourth hierarchical layer.
[0033] Returning to the explanation of FIG. 3 , the table reconfiguration processor 35 generates divided table page data containing data at columns of elements (heading columns) defined for the first hierarchical layer, according to the obtained table definition, and stores the generated data into the divided table page data storage 37 (step S 37 ). The table reconfiguration processor 35 sets n, which is a counter, to 1 (step S 39 ).
[0034] Thereafter, the transmitter 39 refers to the divided table page data storage 37 and transmits the divided table page data stored therein to the user terminal (step S 41 ). The user terminal receives the divided table page data from the Web contents control system 3 and displays the data on the display device (step S 43 ).
[0035] Here, there will be described such a case that a URL of an HTML file for making a table display as shown in FIG. 6 on a large-size screen such as a display screen of a personal computer or the like is accessed. In the table shown in FIG. 6 , a name column, a destination column, a column of “return time to office” and a memo column are contained, and each record (line) of “sato”, “tanaka”, “itou”, “Suzuki”, and “nakamura” is contained.
[0036] FIG. 7A shows an example of the divided table page for the first hierarchical layer generated at the step S 37 . FIG. 7A shows a case where the heading name for the first hierarchical layer is “name”. A message “which information would you refer to?” is added, and display elements “sato”, “tanaka”, “itou”, “Suzuki”, “nakamura” for the heading name “name” contained in the table are set as choices in the combo box. In addition, a “next” button to shift to the next hierarchical layer and a “select display manner” button to generate a table definition are also added. That is, the divided table page data contains data (a combo box, a group of radio buttons) for enabling selection of display elements relating to the heading for the first hierarchical layer, data (link, button or the like) for enabling an instruction of transition to the divided table page for the second hierarchical layer, and data (link, button or the like) for enabling an instruction of generating the table definition.
[0037] As described above, by making the user select the display elements relating to the headings for the first hierarchical layer, an effect is obtained in which the amount of data displayed in the second and subsequent hierarchical layers can be reduced and also the user can easily recognize the display contents.
[0038] Moreover, because the “select display manner” button for the transition to the page of generating the table definition is provided, the user can easily designate the hierarchical display configuration for a specific table.
[0039] The user looks at a display screen displayed on the display device of the user terminal as shown in FIG. 7A , and inputs data. The user terminal accepts an instruction input from the user, and transmits the instruction input data to the Web contents control system 3 (step S 45 ). The access allocation processor 40 of the Web contents control system 3 receives the instruction input data from the user terminal (step S 47 ), and judges on the basis of, for example, URL contained in the instruction input data whether an access to a specific page is instructed (step S 49 ). In the example of FIG. 7A , it judges whether a “return” button is clicked. This is a case where an upper hierarchical layer page, which is just above the Web page shown in FIG. 6 , is accessed, for example. In this case, the proxy access unit 33 is requested to access a specific page (in this example, the page at the just above-hierarchical layer). Therefore, the processing shifts to the step S 13 of FIG. 2 via the terminal B.
[0040] On the other hand, if it is judged that it is not the access instruction to the specific page, the access allocation processor 40 judges whether “select display manner”, that is, generation of the table definition is instructed or not (step S 51 ). In the example of FIG. 7A , it judges whether the “select display manner” button is clicked or not. If the generation of the table definition corresponding to the table shown in FIG. 6 is instructed, the access allocation processor 40 requests the table definition setting processor 38 to carry out the processing, and the processing shifts to the processing flow of FIG. 9 through a terminal D. On the other hand, if it is judged that the “select display manner”, that is, the generation of the table definition is not instructed, it judges that shift to the next hierarchical layer or to the preceding hierarchical layer is instructed, and thus the processing shifts to the processing flow of FIG. 8 through a terminal C.
[0041] The processing flow subsequent to the terminal C will be described with reference to FIG. 8 . The access allocation processor 40 requests the table reconfiguration processor 35 to carry out the table reconfiguration processing so that “shift to next hierarchical layer” or “shift to preceding hierarchical layer” is carried out. The table reconfiguration processor 35 judges on the basis of the received instruction input data or the like whether the instruction is “shift instruction to next hierarchical layer” or “shift instruction to preceding hierarchical layer” (step S 55 ). If the instruction is judged as the “shift instruction to next hierarchical layer”, the table reconfiguration processor 35 first increments the counter n by 1 (step S 57 ). However, it judges whether n is equal to the number of hierarchical layers before the increment. If it is judged that n is equal to the number of hierarchical layers, n is set to 1. On the other hand, if it is judged that the instruction is the “shift instruction to the preceding hierarchical layer”, the table reconfiguration processor 35 decrements the counter n by 1 (step S 59 ). In the divided table page shown in FIG. 7A , which has only the “next” button, the “shift instruction to preceding layer” is not made.
[0042] Subsequently, the table reconfiguration processor 35 specifies the HTML file and the user ID on the basis of the received instruction input data and the session ID or the like to read out the corresponding table definition from the table definition data storage 36 , and also reads out the data of the HTML file stored in the Web page data storage 34 . Then, by using the read data, it generates divided table page data containing the data at columns of elements (heading columns) defined for the n-th hierarchical layer, and stores it in the divided table page data storage 37 (step S 61 ). The transmitter 39 reads out the divided table page data stored in the divided table page data storage 37 , and transmits the data concerned to the user terminal (step S 63 ). The user terminal receives the divided table page data from the Web contents control system 3 , and displays the data on the display device (step S 65 ). In the case of n=2, a display screen as shown in FIG. 7B is displayed. FIG. 7B shows the display screen when the name “sato” is selected on the preceding page, and it contains display elements “second convention room” and “16:00” for the headings “destination” and “return time to office” which are contained in the record of the name “sato” and designated for the second hierarchical layer. Moreover, a “next” button for instructing shift to the next hierarchical layer and a “preceding” button for instructing shift to the preceding hierarchical layer are provided. Incidentally, as in the case of FIG. 7A , a “return” button for returning to the page at the hierarchical layer higher than the page of FIG. 6 is also provided.
[0043] The user looks at the display screen of the user terminal, and inputs some data. The user terminal accepts an instruction input from the user, and transmits the instruction input data to the Web contents control system 3 (step S 67 ). The access allocation processor 40 of the Web contents control system 3 receives the instruction input data from the user terminal (step S 69 ). The processing returns to the step S 49 of FIG. 3 through a terminal E.
[0044] In a case where the “preceding” is clicked on the display screen shown in FIG. 7B , the display screen is shifted to the display screen shown in FIG. 7A . On the other hand, if the “next” is clicked, the display screen shown in FIG. 7C is displayed. In the example of FIG. 7C , n=3, and because the name “sato” is selected, it contains a display element “ 2233 ” for the heading name “memo” which is contained in the record of the name “sato” and designated for the third hierarchical layer. Moreover, a “next” button for instructing shift to the next hierarchical layer and a “preceding” button for instructing shift to the preceding hierarchical layer are provided. When the “next” button is clicked, the counter n is returned to 1 because n=the number of hierarchical layers (= 3 ) in the step S 57 , and the display screen shown in FIG. 7A is displayed. Moreover, as in the case of FIG. 7A , a “return” button for returning to the page at the hierarchical layer higher than the page of FIG. 6 is provided.
[0045] Next, the processing subsequent to the terminal D will be described with reference to FIG. 9 . The table definition setting processor 38 reads out the user instructing the generation of the table definition and the table definition corresponding to the HTML file to be processed from the table definition data storage 36 by using the instruction input data and the session ID, generates the definition input page data from the heading names and the current setting values (hierarchical structure) and then stores the data into the definition input page data storage 41 (step S 71 ). Incidentally, there is a case where the user ID of the user instructing the generation of the table definition and the table definition corresponding to the HTML file to be processed do not exist. In this case, it reads out the HTML file stored in the Web page data storage 34 , and generates the definition input page data from the data of the read HTML file. The transmitter 39 transmits to the user terminal, the definition input page data stored in the definition input page data storage 41 (step S 73 ). The user terminal receives the definition input data from the Web contents control system 3 , and displays the data on the display device (step S 75 ) For example, a display screen as shown in FIG. 7D is displayed. In the example of FIG. 7D , a message of “how to divide?”, a list of heading names “name”, “destination”, “return time to office” and “memo”, a comb box for designating the hierarchical number corresponding to each heading name, a “register” button and a “return” button are provided. The initial values of the combo box are hierarchical numbers contained in the existing table definition corresponding to the user ID and the HTML file. If no existing definition exists, the hierarchical numbers are successively allocated to the headings from the left side in the table, for example.
[0046] The user looks at the display screen as shown in FIG. 7D to designate the hierarchical layer number for each heading, and clicks the “register” button. Incidentally, in a case where the user judges that no problem occurs in the table definition, which has already been registered, the user clicks the “return” button. Moreover, in this embodiment, only one heading can be designated for the first hierarchical layer, and plural headings can be designated for the subsequent hierarchical layers. The user terminal accepts the setting input (or the instruction for returning to the preceding display) from the user, and transmits the setting input data (or the instruction input data to return to the preceding display) to the Web contents control system 3 (step S 77 ). The access allocation processor 40 of the Web contents control system 3 receives the setting input data (or the instruction input data to return to the preceding display) from the user terminal (step S 79 ), and in the case of the setting input data, the access allocation processor 40 outputs the data to the table definition setting processor 38 . The table definition setting processor 38 generates table definition from the received setting input data, and registers in the table definition data storage 36 , the table definition corresponding to the user ID and the HTML file on the basis of the HTML file specified by the session ID or the like and the user ID (step S 81 ). After the step S 81 or when the instruction input data to return to the preceding display is received, the access allocation processor 40 requests the table reconfiguration processor 35 to carry out the processing. Then, the processing returns to the step S 31 of FIG. 3 through the terminal A.
[0047] By carrying out the processing as described above, the user can designate the display style of a hierarchical structure, which is easily usable, for the table. Moreover, a necessary record can be narrowed down from the heading in the first hierarchical layer, and thus the display can be more easily viewable than a simple table dividing manner. Furthermore, the display screen can be shifted from the divided table page for the first hierarchical layer, which is displayed in response to an instruction of displaying a specific page containing a table, to the setting of the table definition, so that the table definition can be immediately reset to an easily viewable style, resulting in enhancement of usability.
[0048] The embodiment of the present invention has been described above, however, the present invention is not limited to the aforementioned embodiment. For example, the functional block diagram of FIG. 1 is an example, and each functional block does not necessarily correspond to an actual program module. Furthermore, the processing flow described above is an example, and thus any processing flow may be used insofar as the display screens shown in FIGS. 7A to 7 D can be realized.
[0049] In addition, the Web contents control system 3 is a computer, and the computer has a configuration as shown in FIG. 10 . That is, a memory 2501 , a CPU 2503 , a hard disk drive (HDD) 2505 , a display controller 2507 connected to a display device 2509 , a drive device 2513 for a removal disk 2511 , an input device 2515 , and a communication controller 2517 for connection with a network are connected through a bus 2519 . An operating system (OS) and an application program for carrying out the foregoing processing stored in the HDD 2505 , and when executed by the CPU 2503 , they are read out from the HDD 2505 to the memory 2501 . As the need arises, the CPU 2503 controls the display controller 2507 , the communication controller 2517 , and the drive device 2513 , and causes them to perform necessary operation. Besides, intermediate processing data is stored in the memory 2501 , and if necessary, it is stored in the HDD 2505 . In this embodiment of this invention, the application program to realize the aforementioned functions is stored in the removal disk 2511 and distributed, and then it is installed into the HDD 2505 from the drive device 2513 . It may be installed into the HDD 2505 via the network such as the Internet and the communication controller 2517 . In the computer as stated above, the hardware such as the CPU 2503 and the memory 2501 , the OS and the necessary application program are systematically cooperated with each other, so that various functions as described above in details are realized.
[0050] Furthermore, the cellular phone 5 a and PDA 5 b has a flash memory in place of the HDD 2505 , the drive device 2513 and the like, and there is no large difference with the aforementioned configuration shown in FIG. 10 .
[0051] Although the present invention has been described with respect to a specific preferred embodiment thereof, various change and modifications may be suggested to one skilled in the art, and it is intended that the present invention encompass such changes and modifications as fall within the scope of the appended claims.
|
In order to provide a technique of enabling any user to browse data of a table in a desired hierarchical structure, an HTML (Hyper Text Markup Language) file processing method comprises: if an HTML file containing a table definition is received from another server in response to a request from a terminal of a user, referring to a hierarchical display definition data storage for storing hierarchical display definition data of a table preset by the user for a specific HTML file containing a table definition, and specifying a hierarchical display definition data for the received HTML file; and by extracting display elements to be displayed at a first hierarchical layer of the received HTML file according to the specified hierarchical display definition data, generating and transmitting to the terminal of the user, an HTML file for the first hierarchical layer. Accordingly, the HTML file containing the table definition is reconstructed by using the hierarchical display definition data set by the user, and thus the user can efficiently browse desired data in the table.
| 6
|
CROSS-REFERENCE TO RELATED APPLICATION
This application is the U.S. national phase of PCT Appln. No. PCT/EP2006/004449 filed May 11, 2006 which claims priority to German Application DE 10 2005 022 856.9 filed May 18, 2005.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to a process for preparing diorganopolysiloxanes which have an Si-bonded hydroxyl group only at one end of the molecule's chain.
2. Description of the Related Art
U.S. Pat. No. 3,445,426 A discloses the polymerization of hexaorganocyclotrisiloxane in the presence of catalytic amounts of a pentacoordinated silicon catalyst, an alkali metal, ammonium or phosphonium siliconate. The catalysts, however, have the disadvantage that they are costly and inconvenient to prepare and are very sensitive to moisture. Described as an initiator for the ring-opening polymerization is alcohol in combination with water, which always leads to polymer mixtures, i.e., to OH-terminated polymers and monoalkoxy-terminated polymers.
EP 0 331 753 A1 describes the polymerization of hexaorganocyclotrisiloxanes in the presence of sil(ox)anols and with the aid of alkali metal sil(ox)anolates as polymerization initiators. Alkali metal sil(ox)anolates likewise exhibit a sensitivity to moisture. In this case the catalysts used are organometallic compounds, which, as mentioned, possess an extreme sensitivity to moisture.
EP 0 338 577 A2 discloses the polymerization of hexamethylcyclotrisiloxane in the presence of trialkylsilanol and a lithium catalyst such as butyllithium. The use of organometallic compounds, however, is problematic from a safety standpoint.
L. M. Tartakovskaya et al., Vysokomol. Soedin. Ser. B 26 234, 1984 (Chemical Abstracts vol. 101, 73186d, 1984) describe the ring opening and polymerization of cyclic siloxanes in the presence of fluoride ions. On account of their toxicity, these catalysts are adjudged disadvantageous in industrial use.
DE 41 16 014 A1 describes the polymerization of cyclic siloxanes with catalysts comprising fluoride ions. These fluoride catalysts, however, have the disadvantage of side reactions with siloxanes, forming Si—F units. Moreover, the disclosed catalysts also exhibit toxicity, which makes industrial use more difficult.
EP 1 369 449 A1 discloses the polymerization of cyclic siloxanes with alcohols as initiator, with carbonate salts used as catalysts. The compounds obtained in this way, however, have the disadvantage of the formation of an alkoxy-silyl end group, which is not stable on storage. For example it may react with the silanol compound that is likewise present, with elimination of alcohol, and so may lead to chain extension.
The current processes therefore all have the disadvantage either of leading to unstable products or else of using reactants and/or catalysts that are problematic from a safety standpoint.
SUMMARY OF THE INVENTION
It is an object of the present invention, therefore, to provide a process for preparing diorgano(poly)siloxanes which have an Si-bonded hydroxyl group only at one end of the molecule's chain, this process leading to storage-stable products which, if desired, may be further functionalized. The reactants used in this preparation ought to be stable, readily accessible, and relatively unproblematic from a safety standpoint. These and other objects have surprisingly been discovered by the process of the invention, wherein cyclic trisiloxanes are reacted with sil(ox)anols having a water content of less than 1% by weight.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The invention accordingly provides a process for preparing diorgano(poly)siloxanes of the general formula (I)
R 1 R 2 Si(OSiR 2 ) m (OSiR 2 2 ) n OH (I),
by reacting hexaorganocyclotrisiloxane of the general formula (II)
(R 2 2 SiO) 3 (II)
with sil(ox)anol of the general formula (III)
R 1 R 2 Si(OSiR 2 ) m OH (III)
in the presence of a catalyst and,
if desired, of further additives selected from the group containing driers, solvents, phase transfer catalysts, lithium compounds or mixtures thereof,
where
R independently at each occurrence is a monovalent, unsubstituted or substituted C 1 -C 13 hydrocarbon radical, R 1 is a hydrogen atom or an unsubstituted or substituted C 1 -C 13 hydrocarbon radical, R 2 independently at each occurrence is a monovalent, unsubstituted or substituted C 1 -C 13 hydrocarbon radical, m is 0 or an integer of at least 1 to 3 and n is an integer of at least 3 to 1000,
characterized in that the sil(ox)anols of the general formula (III) employed possess a water content of below 1% by weight.
Preferably m is a 0, 1, 2 or 3, and preferably n is an integer from 3 to 999, with particular preference from 9 to 150.
Examples of hydrocarbon radicals R are alkyl radicals such as the methyl, ethyl, n-propyl, isopropyl, n-butyl, isobutyl, tert-butyl, n-pentyl, isopentyl, and neopentyl tert-pentyl radicals, hexyl radicals such as the n-hexyl radical, heptyl radicals such as the n-heptyl radical, octyl radicals such as the n-octyl radical and isooctyl radicals such as the 2,2,4-trimethylpentyl radical, nonyl radicals such as the n-nonyl radical, decyl radicals such as the n-decyl radical, dodecyl radicals such as the n-dodecyl radical; alkenyl radicals, such as the vinyl and the allyl radical; cycloalkyl radicals, such as cyclopentyl, cyclohexyl, cycloheptyl and methylcyclohexyl radicals; aryl radicals such as the phenyl and the naphthyl radicals; alkaryl radicals such as the o-, m-, p-tolyl radicals, xylyl radicals, and ethylphenyl radicals; and aralkyl radicals, such as the benzyl radical and the alpha- and the beta-phenylethyl radicals.
Examples of substituted hydrocarbon radicals R are haloalkyl radicals such as the 3,3,3-trifluoro-n-propyl radical, 2,2,2,2′,2′,2′hexafluoroisopropyl radical, the heptafluoroisopropyl radical; haloaryl radicals such as the o-, m- and p-chlorophenyl radicals; and acyloxyalkyl radicals, such as the acetoxyethyl radical and (meth)acryloyloxypropyl radical.
The examples given above of hydrocarbon radicals R and substituted hydrocarbon radicals R also fully apply to hydrocarbon radicals R 1 and also R 2 and to substituted hydrocarbon radicals R 1 and also R 2 . Preferably R is an alkyl radical, with particular preference, a methyl radical. Preferably R 1 is a hydrogen atom, alkyl radical, alkenyl radical or substituted hydrocarbon radical, with particular preference a methyl, vinyl, allyl or (meth)acryloyloxypropyl radical. Preferably R 2 is an alkyl radical, with particular preference a methyl radical.
Examples of the preferred, inventive diorgano(poly)siloxanes of the general formula (I) are those of the following formulae:
Me 3 Si(OSiMe 2 ) m (OSiMe 2 ) n OH,
HMe 2 Si(OSiMe 2 )m(OSiMe 2 ) n OH,
(H 2 C═CH)Me 2 Si(OSiMe 2 ) m (OSiMe 2 ) n OH,
(H 2 C═CH—CH 2 )Me 2 Si(OSiMe 2 ) m (OSiMe 2 ) n OH,
(CF 3 CH 2 CH 2 )Me 2 Si(OSiMe 2 )m(OSiMe 2 ) n OH,
H 2 C═CHC(O)O(CH 2 ) 3 Me 2 Si(OSiMe 2 ) m (OSiMe 2 ) n OH, and
H 2 C═C(Me)C(O)O(CH 2 ) 3 Me 2 Si(OSiMe 2 ) m (OSiMe 2 ) n OH,
where Me is a methyl radical and m and n are as defined above.
The inventive diorgano(poly)siloxanes of the general formula (I) preferably display a viscosity of 4 to 9L150\f“Wingdings2”\s1210 5 mPa·s at 25° C.
Examples of the hexaorganocyclotrisiloxanes used in the process of the invention, of the general formula (II), are hexamethylcyclotrisiloxane, hexaethylcyclotrisiloxane, 1,3,5-trimethyl-1,3,5-triethylcyclo-2,4,6-trisiloxane, 1,3,5-trimethyl-1,3,5-triphenylcyclo-2,4,6-trisiloxane, and 1,3,5,-trimethyl-1,3,5-tris(3,3,3-trifluoropropyl)cyclo-2,4,6-trisiloxane. In the process of the invention hexamethylcyclotrisiloxane is used with preference as hexaorganocyclotrisiloxane of the general formula (II).
The ratio of hexaorganocyclotrisiloxane of the general formula (II) to silanol of the general formula (III) that is employed in the process of the invention determines the average chain length of the product. Hexaorganocyclotrisiloxane of the general formula (II) is employed preferably in amounts of 1 to 333 mol, more preferably in amounts of 1 to 70 mol, based in each case on 1 mol of silanol (III).
The triorganosiloxy group at the end of the molecule's chain in the diorgano(poly)siloxane of the general formula (I) that is prepared in the process of the invention is introduced via the sil(ox)anol of the general formula (III) that is employed.
As siloxanol of the general formula (III) it is preferred to employ triorganosilanol, with particular preference trimethylsilanol or vinyldimethylsilanol. The introduction, for example, of the vinyldimethylsiloxy or perfluoroalkyldimethylsiloxy group may take place via oligomeric or polymeric sil(ox)anols, owing to the instability of the corresponding sil(ox)anols. Tetrasiloxanols are readily accessible via the reaction of hexaorganocyclotrisiloxane with the corresponding chlorosilane. This is described, for example, in DE 29 18 312 A1, whose disclosure in this context is also incorporated herein by reference. An example of one such siloxanol is alpha-hydroxy-omega-vinyldimethylsiloxyhexamethyltrisiloxane.
Disiloxanes or polysiloxanes formed in the course of storage or during the reaction as a result of condensation of the sil(ox)anol of the general formula (III) that is employed do not disrupt the course of the reaction.
The sil(ox)anols of the general formula (III) that are employed should preferably possess a water content of below 1% by weight. Very particular preference is given to a water content of below 0.5% by weight. For this purpose the sil(ox)anol of the general formula (III) must, where appropriate, be dried or purified by distillation in order to remove traces of water, which in the case of the polymerization lead to unwanted difunctional byproducts.
In the process of the invention a basic inorganic salt is used as catalyst. In other words, the process takes place under heterogeneous catalysis. The catalyst used is preferably an alkaline earth and/or alkali metal carbonate, alkaline earth and/or alkali metal oxide, an alkaline earth or alkali metal carbonate attached to a support material, an alkaline earth or alkali metal oxide attached to a support material, or a mixture of two or more of the aforementioned compounds.
Examples of alkaline earth metal carbonates and alkali metal carbonates are lithium carbonate, sodium carbonate, magnesium carbonate, calcium carbonate, potassium carbonate, and cesium carbonate, preference being given to potassium carbonate.
Alkaline earth metal oxides and alkali metal oxides are, for example, lithium oxide, sodium oxide or potassium oxide.
Examples of support material are aluminas, titanium dioxides, zirconium oxides, zeolites, silica gels, diatomaceous earths, and ion exchange resins, preference being given to aluminas. Particular preference is given in the process of the invention to employing potassium carbonate, more particularly potassium carbonate supported on alumina.
Potassium carbonate on a support material may be prepared, for example, by evaporating a mixture of alumina and potassium carbonate in water, by drying a mixture of alumina and potassium carbonate that have been triturated with one another under drying conditions, or by hydrolysis of aluminum triisopropoxide, zirconium tetraisopropoxide or titanium tetraisopropoxide in the presence of potassium carbonate. The catalyst is preferably employed in dried form.
In the process of the invention the catalyst is preferably employed in amounts of 0.01%-5% by weight, more preferably 0.1% to 0.5% by weight, based in each case on the total weight of the hexaorganocyclotrisiloxane employed. Preferably the catalyst is removed by filtration for the termination of the reaction.
In order to increase the catalytic selectivity and the conversion it is possible as cocatalyst, if desired, to use a lithium compound as well, preferably a lithium salt, with particular preference an inorganic lithium salt. Examples of such salts are lithium carbonate, lithium chloride, lithium bromide, and lithium sulfate.
The catalyst or catalyst mixture is in powdered form in order to maximize the surface/volume ratio. Preference is given in this context to particle sizes of less than 1 millimeter, with very particular preference of less than 500 micrometers.
Likewise for the purpose of increasing the selectivity of the reaction it is possible to carry out the process of the invention in the presence of polar, aprotic organic solvent(s), where appropriate in a mixture with an apolar solvent. Examples of polar, aprotic organic solvents are acetone, methyl isobutyl ketone (MIBK), methyl ethyl ketone (MEK), dimethylformamide, dimethyl sulfoxide, acetonitrile, tetrahydrofuran, diethyl ether, dibutyl ether, methyl tbutyl ether, diethylene glycol dimethyl ether, polyethylene glycol dimethyl ether, n-butyl acetate, and ethyl acetate. Examples of apolar solvents are toluene, xylene, cyclohexane, methylcyclohexane, heptane, and siloxanes such as octamethylcyclotetrasiloxane, decamethylcyclopentasiloxane, hexamethyldisiloxane or octamethyltrisiloxane.
Depending on the nature of the catalyst containing carbonate ions that is employed, polar, aprotic organic solvent preferably is employed in amounts of 0% to 50% by weight, more preferably 5% to 30% by weight, and with particular preference 5% to 20% by weight, based in each case on the total weight of silanol and hexaorganocyclotrisiloxane.
For improved homogenization of the reaction mixture, apolar organic solvent can be employed in amounts of 0% to 80% by weight, preferably 50% to 70% by weight, based in each case on the total weight of silanol and hexaorganocyclotrisiloxane.
To increase the selectivity and/or rate of the reaction it is possible in the process of the invention to employ mixtures of different solvents.
The solvent is generally removed by distillation after the end of reaction. If the polysiloxane of the invention is to be processed further in solution, however, the removal of the solvent can be dispensed with. In this case, depending on the intended use, it is also possible for high-boiling liquids which can no longer be separated off by distillation, such as polydimethylsiloxanes, to be employed as solvents.
In order to increase the selectivity and/or rate of the reaction it is possible in the process of the invention to use phase transfer catalysts from among quaternary ammonium salts such as benzyltriethylammonium chloride, crown ethers such as 18-crown-6, 1,4,7,10,13-hexaoxacyclooctadecane, polyethylene glycol dimethyl ether, or tertiary amines such as 4-dimethylaminopyridine, N,N-dimethylcyclohexylamine or 1,4-diazabicyclo[2.2.2]octane.
In order to exclude traces of moisture it can be judicious to use driers such as zeolites, anhydrous sodium sulfate or anhydrous magnesium sulfate, in the process of the invention.
The process of the invention is preferably carried out at a temperature which lies above the melting temperature of the reactants that are employed, more preferably at a temperature of 40° C. to 120° C. When using solvents, the reaction is preferably carried out at 60° C. to 110° C. The reaction can be carried out through to full conversion of the hexaorganocyclotrisiloxane, but is preferably discontinued before 100% conversion is reached.
The process of the invention is carried out at atmospheric pressure, subatmospheric pressure or superatmospheric pressure, preferably under the pressure of the surrounding atmosphere, i.e., approximately at 1020 hPa absolute.
The reaction time in the process of the invention, depending on reaction temperature and on identity and quantity of the reactants and solvents employed, is preferably 0.25 to 48 hours. The reaction can be discontinued at less than full conversion by cooling to room temperature and/or removal of the catalyst by filtration. The reaction can also be discontinued by addition of an acid, such as acetic acid, formic acid, 2-ethylhexanoic acid or phosphoric acid.
The process of the invention displays advantages over the prior art as follows. On the one hand, the catalyst employed is simple and easy to prepare and is available commercially, and is unproblematic in its handling, in air for example. The preparation of the inventive diorgano(poly)siloxanes of the general formula (I) with the catalyst of the invention has the further advantage that the catalyst, which is employed in solid form, can easily be removed from the reaction mixture, by means of simple filtration, for example. Moreover, the inventively prepared diorgano(poly)siloxanes of the general formula (I) display high stability on storage.
The inventively prepared diorgano(poly)siloxanes of the general formula (I) can subsequently be functionalized further with suitable organosilanes, in the manner described, for example, in DE 100 51 886 C1, DE 103 03 693 A1, DE 102 19 734 A1 or DE 101 09 842 A1, which are incorporated herein by reference. The diorgano(poly)sioxanes of the general formula (I) prepared by the process of the invention, following functionalization with suitable organic groups, preferably with further organic polymers, butyl acrylates for example, are reacted to form copolymers, and are used, for example, as coatings auxiliaries.
EXAMPLES
The examples below describe certain embodiments in performing the present invention, but without confining it to the content disclosed therein.
Example 1
Preparation of the Supported Catalyst
10.1 g (0.1 mol) of alumina (obtained from Merck KGaA, Darmstadt, Germany) are mixed with 6.9 g (0.1 mol) of anhydrous potassium carbonate (obtained from Merck KGaA, Darmstadt, Germany) and the mixture is ground and heated at 200° C. for 24 hours. The powder is stored in a sealed glass bottle.
Example 2
A mixture of 222 g (1 mol) of hexamethylcyclotrisiloxane is heated at 60° C. in 80 g of methyl ethyl ketone p.a. (obtained from Merck KGaA, Darmstadt, Germany), and 1 g of catalyst from Example 1 is added. Subsequently 30 g (0.33 mol) of trimethylsilanol (water content 0.45%) are added. The mixture is stirred at 60° C. for four hours and filtered over silica gel 60 (obtained from Merck KGaA, Darmstadt, Germany), and the filtrate is concentrated on a rotary evaporator at 40° C. and 5 mbar. This gives 241.6 g of a clear, colorless oil which according to the results of the 29 Si NMR spectrum and of the MALDI-TOF mass spectrum corresponds to a silicone of the following formula: (CH 3 ) 3 Si—[OSi(CH 3 ) 2 ] 9 —OH. The ratio of the Si—OH and Me 3 Si end groups according to NMR is 1:1.
The end group ratio remained constant over the observation period of 4 months. The octamethylcyclotetrasiloxane content was 4.2% by weight.
Example 3
Procedure in Analogy to Example 2
A mixture of 666 g (3 mol) of hexamethylcyclotrisiloxane is heated at 60° C. in 200 g of methyl ethyl ketone p.a. (obtained from Merck KGaA, Darmstadt, Germany), and 1 g of potassium carbonate dried at 200° C. is added. Subsequently 30 g (0.33 mol) of trimethylsilanol (water content 0.45%) are added. The mixture is stirred at 60° C. for four hours and filtered over silica gel 60 (obtained from Merck KGaA, Darmstadt, Germany), and the filtrate is concentrated on a rotary evaporator at 40° C. and 5 mbar. This gives 648 g of a clear, colorless oil which according to the results of the 29 Si NMR spectrum and of the MALDI-TOF mass spectrum corresponds to a silicone of the following formula: (CH 3 ) 3 Si—[OSi(CH 3 ) 2 ] 27 —OH. The ratio of the Si—OH and Me 3 Si end groups according to NMR is 1:1.
The end group ratio remained constant over the observation period of 4 months.
Example 4
A mixture of 666 g (3 mol) of hexamethylcyclotrisiloxane is heated at 60° C. in 200 g of methyl ethyl ketone p.a. (obtained from Merck KGaA, Darmstadt, Germany), and 1 g of potassium carbonate dried at 200° C. is added. Subsequently 30 g (0.33 mol) of trimethylsilanol (water content 1.35%) are added. The mixture is stirred at 60° C. for four hours and filtered over silica gel 60 (obtained from Merck KGaA, Darmstadt, Germany), and the filtrate is concentrated on a rotary evaporator at 40° C. and 5 mbar. This gives 648 g of a clear, colorless oil which according to the results of the 29 Si NMR spectrum corresponds to a silicone mixture of the following formula: (CH 3 ) 3 Si—[OSi(CH 3 ) 2 ] n —OH/H—[OSi(CH 3 ) 2 ] m —OH. The ratio of the Si—OH and Me 3 Si end groups according to NMR is 1.1:1. The increased water content of the trimethylsilanol leads to an increased amount of difunctional products.
The end group ratio remained constant over the observation period of 4 months.
Example 5
A mixture of 222 g (1 mol) of hexamethylcyclotrisiloxane is heated at 60° C. in 80 g of methyl ethyl ketone p.a. (obtained from Merck KGaA, Darmstadt, Germany), and 1 g of catalyst from Example 1 is added. Additionally 0.6 g of dried lithium chloride is added as well. Subsequently 30 g (0.33 mol) of trimethylsilanol (water content 0.45%) are added. The mixture is stirred at 60° C. for four hours and filtered over silica gel 60 (obtained from Merck KGaA, Darmstadt, Germany), and the filtrate is concentrated on a rotary evaporator at 40° C. and 5 mbar. This gives 241.6 g of a clear, colorless oil which according to the results of the 29 Si NMR spectrum and of the MALDI-TOF mass spectrum corresponds to a silicone of the following formula: (CH 3 ) 3 Si—[OSi(CH 3 ) 2 ] 9 —OH. The ratio of the Si—OH and Me 3 Si end groups according to NMR is 1:1.
The end group ratio remained constant over the observation period of 4 months. The octamethylcyclotetrasiloxane content was 1.2% by weight.
Example 6
Comparative Example, not Inventive, in Analogy to EP 1 369 449 A1
A mixture of 222 g (1 mol) of hexamethylcyclotrisiloxane, 96.2 g (1.6 mol) of 2-propanol p.a. (obtained from Merck KGaA, Darmstadt, Germany), and 20 g of 0.4 nm molecular sieve (obtained from Merck KGaA, Darmstadt, Germany) is heated to 60° C. and admixed with a suspension of 1 g of catalyst (from Example 1) in 46.4 g (0.8 mol) of acetone p.a. (obtained from Merck KGaA, Darmstadt, Germany). The mixture is stirred at 60° C. for four hours and filtered over silica gel 60 (obtained from Merck KGaA, Darmstadt, Germany), and the filtrate is concentrated on a rotary evaporator at 40° C. and 5 mbar. This gives 237.3 g of a clear, colorless oil which according to the results of the 29 Si NMR spectrum and the MALDI-TOF mass spectrum corresponds to a silicone of the following formula: (CH 3 ) 2 CH—[OSi(CH 3 ) 2 ] 44 —OH. The end group ratio was 1.0:1.01, and rose in the course of the next 2 weeks to 1:1.08 (Si—OH:Si—OR). There was a slight increase likewise in the average molecular weight.
The examples according to the invention show unambiguously that in contrast to the prior art, using particularly simple processes and safe reactants, it is possible to prepare monofunctional silicone oils which, furthermore, are still stable on storage.
|
Mono-hydroxyl-functional organopolysiloxanes are prepared with minimal byproducts and increased storage stability by reaction of cyclotrisiloxanes with sil(ox)anols containing less than 1 weight percent water in the presence of heterogenous alkali metal or alkaline earth metal oxide or carbonate catalysts.
| 2
|
CROSS REFERENCE TO RELATED PATENT APPLICATION
This application claims the benefit of U.S. Provisional Patent Application No. 61/697,058, filed Sep. 5, 2012, which is hereby incorporated by reference herein in its entirety.
TECHNICAL FIELD
The disclosed subject matter relates to systems, methods and devices for washing or drying items, including personal care and delicate items. More particularly, the disclosed subject matter relates to systems, methods and devices for washing items that are susceptible to damage when placed in washing machines or dryers, for example, personal care items, prosthetic devices and delicate items such as lingerie, brassieres, and other intimate apparel.
BACKGROUND
Given that intimate apparel is often not subject to the same wear and tear that regular garments are, it is often very delicately constructed. Adding to the delicate construction of such apparel is the proximity it shares with the wearer as well as the desired aesthetics it is expected to exude. Even in instances where intimate apparel is not nearly as delicate in construction, it is, nevertheless, constructed keeping in mind certain enhancements or features that appeal to its wearer. For example, a brassier may be constructed such that it enhances and/or supports the wearer's breasts. Similarly, speciality thongs and underwear are often constructed to enhance the buttocks of the wearer. Such a construction typically requires special care in handling, washing, drying, etc., than afforded regular garments to maintain the integrity of the offered enhancements and other features. Indeed, washing machines and dryers try to address such concerns by offering, for example, a delicate spin cycle and variations in drying temperatures. The foregoing concern is not limited to intimate apparel, but also extends to other items, for example, prosthetic devices that, too, require delicate handling when being cleaned and/or dried.
Despite efforts to address issues relating to the cleaning and drying of items requiring special care by, for example, offering a delicate spin cycle or variations in drying temperatures, such items, nevertheless, suffer damage. For example, traditional washing of bras in a standard washing machine generally results in the bra straps of two or more bras becoming entangled, forming a “Gordian Knot” that is difficult and frustrating to unravel.
In addition to offering a delicate spin cycle and variations in drying temperatures, numerous attempts have been made to eliminate this frustration by providing holders/containers for brassieres and similar garments for use during washing and/or drying. However, such efforts have predominantly suffered from various limitations in addressing the problem, and some have even introduced further complications.
Related patents and published patent applications known in the background art include the following, which are incorporated herein in their entirety.
U.S. Pat. No. 2,473,408, issued to Alkin on Jun. 14, 1949, discloses clothes hanger providing an improved form and disposition of clips which are adapted to suspend items and permit a tension to be applied to the clipped part of the item.
U.S. Pat. No. 5,320,429, issued to Toyosawa on Jun. 14, 1994, discloses a laundry net for holding a brassiere while the brassiere is being laundered, has a dome-shaped bag having a substantially circular bottom member and a substantially conical upper member joined thereto for covering cups of the brassiere.
U.S. Pat. No. 5,556,013, issued to Mayer on Sep. 17, 1996, discloses an intimate garment protector for protecting a garment or multiple garments, namely bras, during laundering. The device comprises first and second basket members that are designed and configured to receive the cup portions of at least one bra. Preferably, the basket members have a generally dome-like or conical-like shape.
U.S. Pat. No. 5,829,083, issued to Sutton on Nov. 3, 1998, discloses a device used during washing of a brassiere to protect the brassiere and maintain the shape of the cups of the brassiere. It includes an inner spherical framework contained within a larger outer spherical framework. Each framework is formed by a pair of hemispherical sections that upon being coupled together form the individual frameworks. With the inner framework open, the brassiere is fitted over the hemispherical sections, with one section being placed inside each cup of the brassiere. The sections of the inner framework with the brassiere thereon are then closed and placed inside an open outer framework. The outer framework is then closed to enclose the inner framework, and the assembly of frameworks is placed into a washing machine.
U.S. Pat. No. 5,971,236, issued to DesForges et al. on Oct. 26, 1999, discloses a device for protecting a brassiere in a washing machine that includes a pair of hemispherically shaped shells (preferably injection molded polypropylene material) adapted to assemble together over a cup of the brassiere as a protective covering for the cup. The outer shell has a circularly shaped first rim portion and a hemispherically shaped first dome portion larger than the cup of the brassiere that extends to the first rim portion. The inner shell has a circularly shaped second rim portion and a hemispherically shaped second dome portion that extends to the second rim portion, said second dome portion having a size adapted to fit within the first dome portion of the outer shell with the first and second rim portions in concentric relationship and the cup of the brassiere disposed intermediate the first and second dome portions.
U.S. Pat. No. 6,234,368, issued to DesForges et al. on May 22, 2001, discloses a device for protecting a brassiere and other delicate undergarments during laundering and includes a pair of domed or hemispherically shaped shells adapted to assemble together over a cup of the brassiere as a protective covering for the cup. The outer shell has a circularly shaped first rim portion and a hemispherically shaped first dome portion larger than the cup of the brassiere that extends to the first rim portion. The inner shell has a circularly shaped second rim portion and a hemispherically shaped second dome portion that extends to the second rim portion, said second dome portion having a size adapted to fit within the first dome portion of the outer shell with the first and second rim portions in concentric relationship and the cup of the brassiere disposed intermediate the first and second dome portions.
U.S. Pat. No. 6,742,683, issued to Phan on Jun. 1, 2004, discloses a device for washing, drying, and storing brassieres and bikini tops and the like comprises an outer shell having two halves that have a plurality of holes. A foraminous inner form, which also contains a plurality of holes, has an exterior surface shaped like the contours of a padded bra cup breast side. The bra cups' breast side rests against the inner form's exterior surfaces to prevent it and the bra's underwires from losing their natural curvature. The inner form is hollow and provides space for the containment of a bra's shoulder and back straps. The inner form is secured to the outer shell's two halves by a first hinge, which allows the inner form to swing from first half to second half and vice-versa, and also allows first half and second half to open and close like a clamshell. A second hinge is located between the first hinge and the inner form to allow the inner form to swing away from the outer shell's two halves and back to its original position for easy placement and removal of bra(s) inside in the device. A latching mechanism secures the device in a closed and locked or latched position and is located between the exterior and interior surfaces of the outer shell's two halves. The protruding rim on one half of the outer shell nestles within the receiving rim on the other half to prevent lateral movement of the two halves.
U.S. Pat. No. 6,973,808, issued to Peska on Dec. 13, 2005, discloses an apparatus for washing at least one item, comprising a frame having a dome shape when viewed from its end, and a generally semicircular shape when viewed from its side; and a flow through mesh on the frame which allows washing fluid (generally water) to freely flow to and from the item being washed; the apparatus having an opening through which the at least one item to be washed can be placed into and removed from the apparatus. The frame may have an endless pocket; and a stiffener disposed within the pocket, the stiffener having a length exceeding that of the endless pocket, so that ends of the stiffener overlap each other within the pocket.
U.S. Pat. No. 7,350,679, issued to Radtke et al. on Apr. 1, 2008, discloses a container for supporting a brassiere or a similar garment for cleaning and storage includes opposed flat plate members connected by a hinge, and opposed container cup members connected to the respective plate members at hinge connections for folding the container cup members over the plate members and for folding the plate members with respect to each other to form a closed container for supporting a brassiere. The plate members include hinged support members, each having an arcuate cross shape, for supporting brassiere cups between the plate members and the container cup members. Spaced apart clips secure the brassiere straps to the plate members. Spaced apart latches releasably secure the cup members to the plate members and the plate members to each other for placing the container in a compact folded position.
U.S. Pat. No. 7,743,953, issued to Okazaki et al. on Jun. 29, 2010, discloses a brassiere holder that includes two cup receiving portions, a connecting portion and a hook portion. When the cup receiving portions are pressed from the side, the connecting portion is elastically deformed to allow the two cup receiving portions to be folded back on each other such that a part of a flange portion of the two cup receiving portions is brought into contact with the other part of the flange portion and a gap gradually increasing toward the upper side is formed between the two cup receiving portions.
Traditional approaches to cleaning and drying delicate items rely on confining such items in a structure moulded to conform to the shape of the item. Other approaches have included confining such items to a bag. In addition to structural and implementation limitations these approaches present with respect to, for example, front and top loaded washers and dryers, and washers with a centrally located agitator, some approaches also tend to limit the surface area of the item being exposed to the cleaning agent, soap, detergent, water, etc. Indeed, some approaches even seem to work against the washer and dryer by hindering and limiting the cleaning and drying potential offered by such appliances. Yet other approaches tend to only accomplish separating the delicate items from the remainder, but leave unaddressed how such delicate items interact with each other within the confines of a bag.
There is therefore a need in the art for approaches that minimize the wear and tear of delicate items without any significant reduction in the cleansing or drying of said items. Accordingly, it is desirable to provide methods, systems, and media that overcome these and other deficiencies of the prior art.
BRIEF SUMMARY
In accordance with various embodiments, systems, methods and devices for washing delicate items are provided.
In certain embodiments, the assembly comprises a clothes line assembly comprising an elongated line made from a stretchable material, e.g., a bungee cord, the elongated line terminating on both the distal and proximal ends in a connector. Each connector is configured and dimensioned for releasable attachment to, for example, a water spin drain hole in the wall of the tub of a standard washing machine. Each connector may either be affixed or attached to an end of the elongated line. The assembly described herein is further comprised of clips or brackets configured for releasable securing, for example, a bra to the elongated line.
In certain embodiments, the product may be secured within a plastic container which is then secured to the elongated line, either by securing means of the plastic container or by separate clips/brackets.
In accordance with some embodiments, the assembly need not be run diametrically across the cylinder, particularly when, for example, an agitator blocks the path. In such instances, or when desired by the user, the assembly described herein is capable of being secured to the interior of the appliance in a cord like fashion that does not pass through the centre.
In accordance with some embodiments, mechanisms are provided to address the problem of tangled bra straps during washing using a washing machine.
It should be noted that the described assembly is reusable and provides a cleaning and drying system that is economical to manufacture. In addition, the described assembly also secures the product without unduly limiting the surface area exposed to the cleansing liquid, soap, detergent, fabric softener, etc.
There has thus been outlined, rather broadly, the features of the present invention in order that the detailed description that follows may be better understood, and in order that the present contribution to the art may be better appreciated. There are additional features of the invention that will be described and which will form the subject matter of the claims. Additional aspects and advantages of the present invention will be apparent from the following detailed description of an exemplary embodiment which is illustrated in the accompanying 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 are for the purpose of description and should not be regarded as limiting.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an illustration of an assembly for reducing wear and tear of products within an appliance, showing an exemplary use of the assembly according to certain embodiments of the disclosed subject matter.
FIG. 2 is an illustration of an assembly for reducing wear and tear of products within an appliance, showing the elements of assembly 100 , according to certain embodiments of the disclosed subject matter.
FIGS. 3-5 illustrate three connectors suitable for use with an assembly for reducing wear and tear of products within an appliance, according to certain embodiments of the disclosed subject matter.
FIG. 6 is an illustration of a holding element suitable for use with an assembly for reducing wear and tear of products within an appliance, according to certain embodiments of the disclosed subject matter.
FIG. 7 is an illustration of another holding element suitable for use with an assembly for reducing wear and tear of products within an appliance, according to certain embodiments of the disclosed subject matter.
FIG. 8 is an illustration of yet another holding element suitable for use with an assembly for reducing wear and tear of products within an appliance, according to certain embodiments of the disclosed subject matter.
DETAILED DESCRIPTION
It will be understood by one of ordinary skill in the art that the embodiments described herein may be adapted and modified as is appropriate for the application being addressed and that the embodiments described in more detail below may be employed in other suitable applications, and that such other additions and modifications will not depart from the scope hereof.
FIG. 1 is an illustration of an assembly for reducing wear and tear of products within an appliance, showing an exemplary use of the assembly according to certain embodiments of the disclosed subject matter. FIG. 1 shows an appliance 200 , which is a front-loading clothes washer and dryer. Appliance 200 performs a wash cycle for washing clothes and a dry cycle for drying clothes. Appliance 200 includes a tub 210 , which holds the clothes for washing and drying. Tub 210 includes a plurality of holes 220 along its surface for allowing circulation and drainage of water when appliance 200 is performing the wash cycle. Holes 220 further allow drainage of water and circulation of air and water vapour during the period when appliance 200 is performing the dry cycle. While various embodiments of the disclosed subject matter have been illustrated with the example of a clothes washer and dryer, it would be apparent to one skilled in the art that the principles and teachings of the disclosed subject matter may be applied to various other appliances, such as but not limited to front-loading or top-loading washing machines, clothes dryers, dishwashers, etc.
FIG. 1 further shows assembly 100 for reducing wear and tear of a product 300 within appliance 200 . In various embodiments, product 300 may be a delicate item susceptible to wear and tear within appliance 200 . Product 300 shown in FIG. 1 is a brassiere, which includes delicate parts such as cups, underwires, padding, etc., and is therefore particularly prone to damage and/or deformation during washing and drying. The brassiere also includes straps 310 , which are prone to entanglement during washing and drying in appliance 200 , thereby forming knots that are typically untangled manually after the washing and drying cycle. Such manual disentanglement is often tedious and time consuming. Further, the entanglement and subsequent disentanglement may also cause damage to the delicate parts of the brassiere and reduce its lifespan. While various embodiments of the disclosed subject matter have been illustrated in the context of a brassiere, it would be apparent to one skilled in the art that the principles and teachings of the disclosed subject matter may be applied to various other products or delicate items, such as but not limited to other lingerie items, prosthetic devices, and etc.
Assembly 100 includes an elongated member 110 , first and second connectors 120 (not shown), and at least one holding element 130 . First and second connectors 120 are attached to a proximal and distal end of elongated member 110 respectively. Connectors 120 connect elongated member 110 to parts of appliance 200 . In various embodiments, connectors 120 are inserted into first and second holes 220 of tub 210 to connect elongated member 110 to appliance 200 . While various embodiments have been described with the example of connectors 120 that affix to holes 220 of tub 210 , it will be apparent to one skilled in the art that other mechanisms for connecting elongated member 110 to appliance 200 , such as vacuum cups/grippers, adhesives, hooks, screws, etc. may be used without deviating from the spirit and scope of the disclosed subject matter. Holding elements 130 are removably mounted on elongated member 110 and releasably hold product 300 . Assembly 100 holds product 300 within appliance 200 in a manner that significantly mitigates the damage caused to product 300 during the operation of appliance 200 . In various embodiments, assembly 100 serves to distance product 300 from moving parts of appliance 200 , or areas within appliance 200 experiencing extreme temperatures that may damage product 300 , or from other objects within appliance 200 that may damage product 300 during operation.
FIG. 2 is an illustration of an assembly for reducing wear and tear of products within an appliance, showing the elements of assembly 100 , according to certain embodiments of the disclosed subject matter. FIG. 2 shows elongated member 110 , connectors 120 , and holding elements 130 . In various embodiments, elongated member 110 is made of an extensible material, such as extensible cord or a bungee cord. In another embodiment, elongated member is an extensible telescopic rod. The extensibility of elongated member 110 allows a user to easily adapt it for use with a variety of appliances 200 with different geometries, as well as for different use configurations within appliance 200 . Connectors 120 may be, without limitation, hooks, clamps, vacuum cups, adhesive pads, or other suitable fastening mechanisms. In various embodiments, connectors 120 removably connect elongated member 110 to appliance 200 .
Holding elements 130 hold product 300 to reduce wear and tear suffered by it during operation of appliance 200 . Holding element 130 includes a mechanism for holding product 300 , and a mechanism for mounting itself on elongated member 110 . In various embodiments, holding element 130 has a jaw-like structure for gripping product 300 securely. In addition, in various embodiments, holding element 130 has smooth and rounded edges to further ameliorate the wear and tear of product 300 .
FIGS. 3-5 illustrate three connectors suitable for use with an assembly for reducing wear and tear of products within an appliance, according to certain embodiments of the disclosed subject matter. FIG. 3 shows a hook connector 310 , an embodiment of connector 120 . Hook connector 310 is attached to an end of elongated member 110 and inserted through hole 220 to connect elongated member 110 to tub 210 as shown. FIG. 4 shows a screw connector 410 , another embodiment of connector 120 . Screw connector 410 is attached to an end of elongated member 110 and inserted and screwed into hole 220 to connect elongated member 110 to tub 210 as shown. Screw connector 410 has a substantially helical shape, with increasing radius as shown. Such a shape allows ease of insertion into hole 220 , while still providing a snug and secure fit between screw connector 410 and tub 210 . FIG. 5 shows a snap-on connector 510 , another embodiment of connector 120 . Snap-on connector 510 is attached to an end of elongated member 110 and inserted and snapped into position in hole 220 to connect elongated member 110 to tub 210 as shown.
FIG. 6 is an illustration of a holding element suitable for use with an assembly for reducing wear and tear of products within an appliance, according to certain embodiments of the disclosed subject matter. FIG. 6 shows a structure of holding element 130 that will secure a product 300 while allowing adequate water and air flow to product 300 to facilitate washing and drying. Holding element 130 shown in the figure has a jaw-like structure, and includes an upper lip 602 and a lower lip 604 . Upper lip 602 and lower lip 604 are connected by hinge 606 . Lips 602 and 604 are shaped to form an elongated member channel 608 , which houses elongated member 110 during use of holding element 130 . Further, lips 602 and 604 have interlocks 610 that lock into each other when lips 602 and 604 are pressed shut, and keep them shut during use. Upper lip 602 has a convex surface 612 , and lower lip 604 has a concave surface 614 . Surfaces 612 and 614 are shaped to fit substantially snugly with each other when lips 602 and 604 are pressed shut. In various embodiments, at least one of surfaces 612 and 614 is made of compressible material, such as rubber. Lower lip 604 further includes one or more transverse bands 616 , which may be used to weave with a part of product 300 to secure product 300 with holding element 130 . In certain embodiments, transverse bands 616 may be strong rubber bands. Lips 602 and 604 further have recesses 618 that provide space for housing the portion of product 300 that connects the parts retained within holding element 130 and the remainder of product 300 . In certain embodiments, recesses 618 have a smooth and rounded surface, and are composed of soft material, to minimize wear and tear to product 300 .
For washing and drying of product 300 , for example a brassiere, a part of product 300 , for example the straps 310 of the brassiere, may be weaved into transverse bands 616 before snapping upper lip 602 and lower lip 604 shut to firmly hold the brassiere. The shape of surfaces 612 and 614 , in conjunction with the compressible material used therein, provides a firm grip over straps 310 to withstand the strains of washing and drying, while minimizing the risk of wear and tear. Recesses 618 house the remaining portion of straps 310 and/or the connection between the brassiere and straps 310 . As a result, only a small part of product 300 is covered by holding element 130 , and a majority of the surface area of product 300 is directly accessible to the washing liquid/water and air for effective washing and drying.
Holding element 130 further includes circulation holes 620 , which allow washing fluids and air to circulate within holding element 130 , thereby providing for washing and drying of portions of product 300 retained within holding element 130 as well. In various embodiments, finger tabs 622 are provided in at least one of lips 602 and 604 to facilitate easy opening of holding element 130 .
In certain embodiments, hinge 606 includes a locking mechanism. The locking mechanism, when in an unlocked position, allows lips 602 and 604 to rotate along hinge 606 relative to each other. Once the locking mechanism is turned to a locked position, upper lip 602 and lower lip 604 are securely abutted against each other, and hold product 300 as well as elongated member 110 firmly.
FIG. 7 is an illustration of another holding element suitable for use with an assembly for reducing wear and tear of products within an appliance, according to certain embodiments of the disclosed subject matter. The figure shows a holding element 130 that includes a hanging hook 702 . Hanging hook 702 is pivotally connected with a hinge 704 , and can rotate along the axis of the hinge, as shown by rotating positions 702 a and 702 b of hanging hook 702 . Hanging hook 702 may be used to hang product 300 in order to, for example, air dry or store product 300 . During use within appliance 200 , hanging hook may be rotated to recede into a hook cavity 706 in a lip 708 , to prevent damage during operation of appliance 200 .
FIG. 8 is an illustration of yet another holding element suitable for use with an assembly for reducing wear and tear of products within an appliance, according to certain embodiments of the disclosed subject matter. Holding element 130 shown in the figure includes an upper lip 802 and a lower lip 804 joined together at joint 806 . Lips 802 and 804 have circulation holes 808 , which allow washing fluids and air to circulate within holding element 130 , thereby providing for washing and drying of portions of product 300 retained within holding element 130 as well. In various embodiments, lips 802 and 804 are made of soft, strong, and flexible material such as polymers. Lips 802 and 804 may be closed shut by the use of closing elements 810 provided substantially along the peripheries of lips 802 and 804 . In various embodiments, closing elements 810 are, without limitation, patches of Velcro® hooks and loops, interlocking Ziploc® type members, or other mechanisms for reversible and reusable fastening.
Holding element 130 also includes a perforation 812 to facilitate better circulation of washing fluids and air within the holding element 130 . In certain embodiments, perforation 812 may also be used to removably attach holding element 130 with elongated member 110 . Further, in certain embodiments, elongated member 110 may be encircled by upper lip 802 and lower lip 804 once they have been closed using closing elements 810 .
Recesses 814 are provided along the periphery of holding element 130 to provide space to accommodate the connecting portion of product 300 . Holding element 130 further includes one or more binders 816 attached to lower lip 804 . Binders 816 are wound around a loop 818 as shown, and include fastening elements 820 for securing binders 816 .
In an exemplary use case in accordance with certain embodiments, binders 816 are tightened over brassiere straps 310 woven through them, and secured using fastening elements 820 . The remaining portion of straps 310 exits holding element 130 through recesses 814 . Elongated member 110 is attached to holding element 130 by encircling it within lips 802 and 804 . Alternatively, a portion of elongated member 110 may be received in holding element 130 through perforation 812 to achieve the desired attachment. The brassiere is thus suspended from elongated member 110 using holding element 130 inside tub 210 for the washing and drying cycle for the brassiere. Circulation holes 808 and perforation 812 provide for circulation of washing fluids and air within holding element 130 to enable cleaning and drying of straps 310 retained inside holding element 130 .
Although the invention has been described and illustrated in the foregoing illustrative embodiments, it is understood that the present disclosure has been made only by way of example, and that numerous changes in the details of implementation of the invention can be made without departing from the spirit and scope of the invention, which is only limited by the claims which follow. Features of the disclosed embodiments can be combined and rearranged in various ways.
|
Systems, methods and devices for washing delicate items are provided. In accordance with some embodiments, an assembly for reducing wear and tear of products within an appliance is provided. The assembly comprising an elongated member having distal and proximal connectors that are secured to receiving parts of the appliance, and having least one holding element that is removably mounted along the length of the elongated member and is configured to releasably hold at least one product.
| 3
|
TECHNICAL FIELD
[0001] The present disclosure concerns a robotic packaging apparatus and method, including an end effector for picking a work product, bending the oppositely extending lateral sides of the work product to form a U-shape, and placing the U-shaped product in a container.
BACKGROUND OF THE DISCLOSURE
[0002] In the packing of goods in multiple levels in a box or other shipping container, it may be desirable to have a packing insert placed in the shipping container that extends between levels of the goods in the container to avoid the weight of the goods in an upper level from bearing against the goods below. This also tends to strengthen the container when several of the containers are stacked one upon another. For example, packing inserts may be used in containers for protecting food products, products that comprise fragile goods or soft goods like bread, or other products that might become damaged by the weight of an upper layer of goods bearing down on a lower layer of goods.
[0003] One form of a packing insert might be an inverted U-shaped cardboard sheet having an intermediate portion that is to be placed over the goods and facing the opening of the shipping container and opposed lateral sides bent downwardly to form the inverted U-shape. The lower layer of goods will be placed in the shipping container before the packing insert is placed in the container. The downwardly extending lateral sides of the packing insert will be telescopically tucked into the container adjacent the opposite side walls of the container, between the side walls and the goods in the container, until the lateral sides of the packing insert extend down into engagement with the bottom of the container and the intermediate portion of the packing insert extends across the top of the goods in the shipping container. The lateral sides of the packing insert provide support for the intermediate portion of the packing insert that extends over the lower layer of the goods. The intermediate portion of the packing insert functions to support the upper layer of goods.
[0004] The U-shaped packing insert may also rigidify the shipping container so that several shipping containers may be stacked upon one another without damage to the containers and the goods in the containers. This also helps to protect the container from penetration by sharp objects, thereby assuring safer delivery to the customer.
[0005] Generally, the panel that forms the U-shaped packing insert, which in this instance is considered to be the “work product”, may include score lines that assist in folding the panel into the correct proportions that correspond to the proportions of the container and the goods in the container. While the use of score lines on the panels assist in forming the panel into a U-shape, it is still burdensome for the panels to be properly bent and inserted into the containers by hand in a large volume continuous packing operation.
SUMMARY OF THE DESCRIPTION
[0006] Accordingly, this disclosure concerns an end of arm tool for a robot that includes a dual function of placement of goods in a shipping container, followed by picking, forming and placing the protective packing insert that extends about and over the goods in the shipping container.
[0007] The packing insert may be a generally flat work product, such as that described above, comprising a cardboard sheet that includes an intermediate portion of the work product, and the oppositely extending lateral sides of the work product that are bent to form the inverted U-shape with respect to the intermediate portion of the work product. The end of arm tool picks the work product from a supply, forms the work product into a U-shape and then places the U-shaped work product in the shipping container over the goods packed in the container. The opposite parallel ends of the work product are tucked internally of the shipping container adjacent the opposite side walls of the shipping container so that the work product extends about the goods in the shipping container.
[0008] The method and apparatus disclosed herein provide for continual repetitive operation of an end of arm tool. This may comprise a first step of picking and placing a pattern of goods in the shipping container that form a lower layer of goods. A second step may comprise a sequence of picking the work product, folding the work product into an inverted U-shape, introducing the work product into the shipping container with the lateral sides of the work product aligned with the outer boundaries of the first layer of goods in the shipping container, and withdrawing the tool from the work product and shipping container while maintaining the work product in its position during the withdrawal movements.
[0009] The process may further include a third step of picking and placing a second pattern of goods in the shipping container on the intermediate portion of the work product, to form an upper layer of goods in the shipping container. The weight of the upper level of goods tends to urge the work product downwardly in the shipping container until the lateral sides of the work product engage and become supported by the bottom wall of the container.
[0010] All of these steps are to be done in rapid and accurate movements, automatically and efficiently in a minimum amount of time.
[0011] The tool that is placed at the end of an arm of a robot may include a vacuum plenum housing with at least one vacuum retriever extending down from the vacuum plenum housing for engaging and picking the work products. The vacuum retriever may be suction cups or suction bellows that contact and adhere to the goods that are to be packed in the shipping container. The same vacuum retrievers may be used for engaging and picking the intermediate portion of the work product so that it may lift the work product away from a supply of the work products, and move the work product from the supply toward the shipping containers.
[0012] The tool may include a pair of forming arms that are used to engage and fold the oppositely extending lateral sides of the work product into an inverted U-shape with respect to the intermediate portion of the work product. The forming arms may also be used in the procedure of picking and packing the goods into the container by urging the goods in a compact configuration that best fits in the shipping container.
[0013] The forming arms may include proximal ends that are pivotally supported adjacent the vacuum plenum housing and distal ends that are pivoted from the level above the vacuum retrievers to a downwardly, substantially parallel arrangement during which time the forming arms engage the oppositely extending lateral sides of the work product and bend them into a U-shape with respect to the intermediate portion of the work product.
[0014] The forming arms may include an obtuse angle adjacent their distal ends for the purpose of tucking the distal ends of the lateral sides of the work product into the shipping container.
[0015] The tool may also include a discharge means that is moveable between the packing positions out of the way of the vacuum retriever and then to distended positions in which they engage the intermediate portion of the work product after the folded lateral sides of the work product have been at least partially tucked into the sides of the shipping container. This pushes the work product on into the container as the vacuum is released from the vacuum retriever. This allows separation between the vacuum retriever and the intermediate portion of the work product, leaving the work product behind and positioned inside the shipping container as the tool withdraws from the shipping container to begin a repeat cycle of its operations.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] FIGS. 1-3 illustrate the sequence of placing a pattern of goods in a shipping container.
[0017] FIGS. 4-10 illustrate the sequence of picking and forming the work product, inserting the product divider over the pattern of goods in the shipping container, and then withdrawing from the shipping container.
[0018] FIGS. 11-14 illustrate the sequence of placing another layer of goods in the container that are separated by the product divider from the original layer of products.
DETAILED DESCRIPTION
[0019] Referring now in more detail to the drawings, in which like numerals indicate like parts throughout the several views, FIGS. 1-3 illustrate the sequence of placing goods A in a shipping container 8 , in which the end of arm tool 10 has picked the goods, such as loaves of bread that are soft and are likely to be damaged by applying the weight of other loaves stacked on them and has moved the goods over the shipping container 8 ( FIG. 1 ). The tool 10 is lowered ( FIG. 2 ) to place the goods A on the bottom of the container, and then raised to leave the goods in the shipping container ( FIG. 3 ). This is conventional in the art.
[0020] FIGS. 4-10 illustrate the sequence of picking and forming the work product, inserting the work product in the shipping container, and then withdrawing from the shipping container.
[0021] FIG. 4 illustrates the side view of an end of arm tool 10 that is connected to the arm of a robot 12 . The robot arm 12 is shown in FIG. 4 as holding the end of arm tool 10 in engagement with the work product 1 that may be a single layer of the work product or the top work product on a vertical stack 2 of such products. The tool 10 is to pick a work product 1 and form the work product into an inverted U-shape ( FIGS. 6 and 7 ). The work product is then inserted into a shipping container 8 ( FIGS. 8 and 9 ) containing the goods A. The work product may have score lines 6 and 7 ( FIGS. 4-6 ) that divide the work product into the intermediate portion 3 and side portions 4 and 5 . The work product may be folded at its score lines as shown in FIGS. 6 and 7 so that its side portions 4 and 5 may be tucked into the shipping container between the vertical side walls of the shipping container 8 . At this stage of the process, the work product does not have to be fully inserted about the goods A but should be aligned with the space below that is between the goods A and side walls of the shipping container.
[0022] The tool 10 includes a mast 14 connected to the robot arm 12 and a tool support 16 connected to the mast 14 . Housing 18 is supported by tool support 16 and defines a vacuum plenum housing 20 , and a source of vacuum such as the inlet of as a compressor (not shown) is connected to housing 18 to draw reduced air pressure within the vacuum plenum housing in a conventional manner. The tool support 16 may be formed as part of the housing 18 , if desired.
[0023] Housing 18 includes a bottom wall 22 and a plurality of openings 24 are formed in the bottom wall. Vacuum retrievers 26 extend downwardly from the downwardly facing surface of the bottom wall 22 in communication with the openings 24 . In this manner, the reduced air pressure of vacuum plenum housing 20 is applied to each vacuum retriever 26 . Valves (not shown) are used to regulate the vacuum applied to each vacuum retriever 26 . Vacuum retrievers and valves suitable for this use are disclosed in more detail in U.S. Pat. No. 7,000,964 and in my patent application Ser. No. 12/763,242, the disclosures of which are fully incorporated herein by reference.
[0024] Forming arms 30 and 31 are pivotally mounted to opposite sides of the upper portion of the housing 18 , above the vacuum retrievers 26 , by hinge pins 34 and 35 , respectively. The forming arms may be identical in construction and each includes a proximal end portion 36 on the upper side of its hinge pin and a distal end portion 38 on the other side of its hinge pin. The distal end or tip 40 of each forming arm 30 , 31 extends at an obtuse angle 41 , forming a slight bend in the length of the distal end portion 38 of the forming arms 30 , 31 .
[0025] With this arrangement, the forming arms are moveable in arcs indicated by the double-headed arrows 44 of FIG. 6 for folding the side portions 4 and 5 with respect to the intermediate portion 3 of the work product 1 at the score lines 6 and 7 .
[0026] Fluid actuated cylinders 46 and 48 are supported over the vacuum plenum housing 20 , with a support bracket 50 extending from the tool support 16 on opposite sides of the housing 18 . Pistons 52 and 53 extend from the cylinders and are connected to the distal end portions 36 of the forming arms 30 and 31 . When the pistons 52 , 53 are distended, the forming arms 30 and 31 are tilted in a downward direction as indicated by the arrows 44 of FIGS. 1 and 3 , to substantially parallel positions as shown in FIGS. 4 and 5 . Likewise, when the pistons are retracted into their respective fluid actuated cylinders 46 and 48 , the vacuum retrievers 26 move back from the position shown in FIG. 7 to the position shown in FIG. 4 .
[0027] While FIG. 4 shows the end of arm tool 10 suspended over the work product 1 , FIG. 5 shows the tool in engagement with the generally flat work product 1 , with the vacuum retrievers 26 in full engagement with the work product 1 and with the low air pressure in the vacuum plenum housing 20 in direct communication with the work product 1 . This connects the vacuum retrievers to the intermediate portion of the work product so that the work product will be picked by the tool 10 . The work product 1 may be a single work product or the top work product in a vertical stack 2 of the products. The vacuum is applied by the tool only to the top work product so that when the tool is lifted from the stack of work products, only the top work product will be lifted, as shown in FIG. 6 .
[0028] FIG. 6 shows the end of arm tool 10 after it has engaged the work product 1 , has lifted the work product away from the stack of work products, and is beginning the movement toward a shipping container 8 shown in FIG. 8 .
[0029] Shipping container 8 typically is a rectangular box formed of corrugated cardboard having lids 60 and 61 extending upwardly from side walls 64 and 65 . The lid flaps are open so as to expose the upper opening of the shipping container. The shipping container will have been previously filled with the products B that are to be stored and/or shipped, typically with the products substantially filling the bottom half of the container 8 .
[0030] As shown in FIG. 6 , as the end of arm tool 10 moves from the stack of work products 1 toward the shipping container 8 , fluid actuated cylinders such as pneumatic cylinders 46 and 48 begin to tilt the forming arms 30 and 31 as shown by arrows 44 of FIG. 6 . When the forming arms are tilted to the extent shown in FIG. 6 , they become engaged with the lateral sides 4 and 5 of the work product 1 , bending the lateral sides 4 and 5 in the directions as indicated by arrows 62 and 63 , from a horizontal attitude toward a vertical attitude shown in FIG. 7 . The work products may have score lines such as score lines 6 and 7 to create accurate folding of the lateral side portions of the work products. When the forming arms 30 and 31 reach their downwardly extending substantially parallel attitudes, they will have moved from a level above the vacuum retrievers 26 to a level below the vacuum retrievers 26 , reaching the lateral side portions 4 and 5 of the work product 1 and folding the side portions 4 and 5 inwardly to their vertical positions as shown in FIG. 7 .
[0031] As shown in FIG. 7 , the tip ends 40 of the forming arms 30 and 31 are formed at an obtuse angle 41 so that when the forming arms reach their approximately vertical positions, the tip ends 40 are angled toward each other. This allows the forming arms 30 and 31 to have the ability to push against the oppositely extending lateral sides 4 and 5 of the work product when the upper portions of the forming arms straddle the intermediate portion 3 of the work product 1 at the obtuse angle 41 .
[0032] FIG. 7 shows the end of arm tool 10 after it has formed the work product in its desired position, ready for insertion in the shipping container. The tool and its work product will be in this configuration when the end of arm tool is positioned over the shipping container, ready to insert the work product into the shipping container.
[0033] The end of arm tool 10 and its work product 1 will be positioned directly over the shipping container 8 , and the tool will be lowered as shown in FIG. 8 so that the lateral sides 4 and 5 of the work product will be accurately aligned just inside the container side walls 64 and 65 , respectively. The forming arms 30 and 31 will guide the lateral side portions 4 and 5 into a tucked relationship just inside the side walls 64 and 65 of the shipping container, aligned between the goods A and the adjacent side walls 64 and 65 of the shipping container 8 , as shown in FIGS. 8 and 9 . The intermediate portion 3 of the work product is oriented horizontally and will come to rest at the entrance opening of the product container 8 .
[0034] As shown in FIG. 5 , once the work product 1 has been aligned with the shipping container 8 , the vacuum retrievers will release their vacuum that is applied to the work product and the vacuum retrievers are no longer attached to the work product and the end of arm tool 10 is ready to begin to move upwardly to withdraw from the product container 8 .
[0035] The end of arm tool 10 may leave the work product at a level in the shipping container with the lateral sides fully inserted about the sides of the goods A or only partially inserted as shown in FIGS. 9-11 where they are aligned with the space between the goods A and the sidewalls of the shipping container 8 .
[0036] As shown in FIGS. 7 and 9 , evacuation cylinders 66 and 67 include piston rods 68 and 69 that distend downwardly for urging against the upwardly facing horizontal surface of the intermediate portion 3 of the work product 1 . The evacuation cylinders and/or their piston rods may extend through the housing 18 so that the piston rods are positioned in the array of vacuum retrievers 26 in the vicinity of the intermediate portion 3 of the work product 1 .
[0037] In order to make sure that the work product 1 is inserted into the container 8 to the proper depth, the piston rods 68 and 69 of evacuation cylinders 66 and 67 ( FIG. 9 ) are distended and engage the upwardly facing horizontal surface of the intermediate portion 3 of the work product 1 , tending to push the work product further into the product container 8 as the forming arms 30 and 31 begin to withdraw from adjacent the side walls 64 and 65 of the product container 8 . This assures that the action of withdrawing the forming arms 30 and 31 does not inadvertently lift the work product 1 out of the product container 8 during withdrawal. Also, this function applies a downward force to the work product and assures that the work product is properly inserted into the product container.
[0038] After the work product has been properly placed within the product container 8 over goods A as shown in FIGS. 9 and 10 , the end of arm tool 10 will move away from the product container, back to retrieve another group of goods B. In the meantime, the piston rods 68 and 69 may be retracted back up into their respective evacuation cylinders 66 and 67 , and the forming arms 30 and 31 may be pivoted upwardly from their positions shown in FIGS. 4 and 5 back to their original positions such as shown in FIGS. 1 and 2 .
[0039] While only two evacuation cylinders 66 and 67 and their respective piston rods 68 and 69 are illustrated, other evacuation means, such as four cylinders and their respective piston rods may be used in a rectangular array for urging the work product into the shipping container 8 . Thus, the evacuation cylinders and their respective piston rods function as discharge means that may be supported by the tool support for urging the U-shaped work product away from the vacuum retrievers and for urging the side portions of the work product into the container.
[0040] By using the same procedures, another level of goods B may be placed on the top of the work product that extends over the first level of goods A, as shown in FIGS. 11-14 . The weight of the on coming second level of goods will push the work product down toward the upper surfaces of the goods A, but the lateral sides of the work product are dimensioned to engage the bottom of the shipping container as the intermediate portion of the work product approaches the lower level of the goods A, as shown in FIG. 14 . This avoids the weight of the goods in the upper level of goods B from bearing on the goods A in the lower level.
[0041] Although a preferred embodiment of the invention has been disclosed in detail herein, it will be obvious to those skilled in the art that variations and modifications of the disclosed embodiment can be made without departing from the spirit and scope of the invention as set forth in the following claims.
|
End of arm tool ( 10 ) is used to load goods A and B in two layers in a packing container ( 8 ), with a packing insert positioned between the layers. The tool ( 10 ) also grasps a packing insert in the form of a flat sheet, bends the ends of the packing sheet downwardly to form an inverted U shape, and then inserts the packing insert in a straddling relationship about the lower layer of goods A, to protect the lower layer of goods from the weight applied by the upper layer of goods.
| 1
|
CROSS REFERENCE TO RELATED PATENT APPLICATIONS
This patent application is a continuation of U.S. patent application Ser. No. 08/608,794 which was filed on Feb. 29, 1996 now U.S. Pat. No. 5,741,810 in the name of Burk.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention provides cyclopentane heptanoic acid, 2 heteroaryl alkyl or alkenyl derivatives which may be substituted in the 1-position with hydroxyl, alkyloxy, amino and amido groups, e.g. 1-OH cyclopentane heptanoic acid, 2 heteroarylalkenyl derivatives. In particular, these derivatives are 7-[5-hydroxy-2-(heteroatom-substituted hydroxyhydrocarbyl)-3-hydroxycyclopentyl] heptanoic or heptenoic acids and amine, amide, ether, ester and alcohol derivatives of said acids wherein one or more of said hydroxy groups are replaced with an ether group. These compounds are potent ocular hypotensives and are particularly suited for the management of glaucoma. Moreover, the compounds of this invention are smooth muscle relaxants with broad application in systemic hypertensive and pulmonary diseases; with additional application in gastrointestinal disease, reproduction, fertility, incontinence, shock, inflammation, immune regulation, disorder of bone metabolism, renal dysfunction, cancer and other hyperproliferative diseases.
2. Description of Related Art
Ocular hypotensive agents are useful in the treatment of a number of various ocular hypertensive conditions, such as post-surgical and post-laser trabeculectomy ocular hypertensive episodes, glaucoma, and as presurgical adjuncts.
Glaucoma is a disease of the eye characterized by increased intraocular pressure. On the basis of its etiology, glaucoma has been classified as primary or secondary. For example, primary glaucoma in adults (congenital glaucoma) may be either open-angle or acute or chronic angle-closure. Secondary glaucoma results from pre-existing ocular diseases such as uveitis, intraocular tumor or an enlarged cataract.
The underlying causes of primary glaucoma are not yet known. The increased intraocular tension is due to the obstruction of aqueous humor outflow. In chronic open-angle glaucoma, the anterior chamber and its anatomic structures appear normal, but drainage of the aqueous humor is impeded. In acute or chronic angle-closure angle-closure glaucoma, the anterior chamber is shallow, the filtration angle is narrowed, and the iris may obstruct the trabecular meshwork at the entrance of the canal of Schlemm. Dilation of the pupil may push the root of the iris forward against the angle, and may produce pupilary block and thus precipitate an acute attack. Eyes with narrow anterior chamber angles are predisposed to acute angle-closure glaucoma attacks of various degrees of severity.
Secondary glaucoma is caused by any interference with the flow of aqueous humor from the posterior chamber into the anterior chamber and subsequently, into the canal of Schlemm. Inflammatory disease of the anterior segment may prevent aqueous escape by causing complete posterior synechia in iris bombe, and may plug the drainage channel with exudates. Other common causes are intraocular tumors, enlarged cataracts, central retinal vein occlusion, trauma to the eye, operative procedures and intraocular hemorrhage.
Considering all types together, glaucoma occurs in about 2% of all persons over the age of 40 and may be asymptotic for years before progressing to rapid loss of vision. In cases where surgery is not indicated, topical b-adrenoreceptor antagonists have traditionally been the drugs of choice for treating glaucoma.
Certain eicosanoids and their derivatives have been reported to possess ocular hypotensive activity, and have been recommended for use in glaucoma management. Eicosanoids and derivatives include numerous biologically important compounds such as prostaglandins and their derivatives. Prostaglandins can be described as derivatives of prostanoic acid which have the following structural formula: ##STR1##
Various types of prostaglandins are known, depending on the structure and substituents carried on the alicyclic ring of the prostanoic acid skeleton. Further classification is based on the number of unsaturated bonds in the side chain indicated by numerical subscripts after the generic type of prostaglandin [e.g. prostaglandin E 1 (PGE 1 ), prostaglandin E 2 (PGE 2 )], and on the configuration of the substituents on the alicyclic ring indicated by α or β [[e.g. prostaglandin F 2 α (PGF 2 α)].
Prostaglandins were earlier regarded as potent ocular hypertensives, however, evidence accumulated in the last decade shows that some prostaglandins are highly effective ocular hypotensive agents, and are ideally suited for the long-term medical management of glaucoma (see, for example, Bito, L. Z. Biological Protection with Prostaglandins Cohen, M. M., ed., Boca Raton, Fla., CRC Press Inc., 1985, pp. 231-252; and Bito, L. Z., Applied Pharmacology in the Medical Treatment of Glaucomas Drance, S. M. and Neufeld, A. H. eds., New York, Grune & Stratton, 1984, pp. 477-505. Such prostaglandins include PGF 2 α, PGF 1 α, PGE 2 , and certain lipid-soluble esters, such as C 1 to C 2 alkyl esters, e.g. 1-isopropyl ester, of such compounds.
Although the precise mechanism is not yet known experimental results indicate that the prostaglandin-induced reduction in intraocular pressure results from increased uveoscleral outflow [Nilsson et.al., Invest. Ophthalmol. Vis. Sci. (suppl), 284 (1987)].
The isopropyl ester of PGF 2 α has been shown to have significantly greater hypotensive potency than the parent compound, presumably as a result of its more effective penetration through the cornea. In 1987, this compound was described as "the most potent ocular hypotensive agent ever reported" [see, for example, Bito, L. Z., Arch. Ophthalmol. 105, 1036 (1987), and Siebold et.al., Prodrug 5 3 (1989)].
Whereas prostaglandins appear to be devoid of significant intraocular side effects, ocular surface (conjunctival) hyperemia and foreign-body sensation have been consistently associated with the topical ocular use of such compounds, in particular PGF 2 α and its prodrugs, e.g., its 1-isopropyl ester, in humans. The clinical potentials of prostaglandins in the management of conditions associated with increased ocular pressure, e.g. glaucoma are greatly limited by these side effects.
In a series of co-pending United States patent applications assigned to Allergan, Inc. prostaglandin esters with increased ocular hypotensive activity accompanied with no or substantially reduced side-effects are disclosed. The co-pending U.S. Ser. No. 596,430 (filed Oct. 10, 1990), relates to certain 11-acyl-prostaglandins, such as 11-pivaloyl, 11-acetyl, 11-isobutyryl, 11-valeryl, and 11-isovaleryl PGF 2 α. Intraocular pressure reducing 15-acyl prostaglandins are disclosed in the co-pending application U.S. Ser. No. 175,476 (filed Dec. 29, 1993). Similarly, 11,15-9,15 and 9,11-diesters of prostaglandins, for example 11,15-dipivaloyl PGF 2 α are known to have ocular hypotensive activity. See the co-pending patent applications U.S. Ser. Nos. 385,645 (filed Jul. 7, 1989, now U.S. Patent 4,994,274), 584,370 (filed Sep. 18, 1990, now U.S. Patent 5,028,624) and 585,284 (filed Sep. 18, 1990, now U.S. Patent 5,034,413).
Other patents and patent applications assigned to Allergan, Inc. disclose and claim other compounds which are useful in treating increased intraocular pressure and thus are useful in the treatment of glaucoma. Said patents and patent applications include U.S. Pat. application Ser. No. 08/174,535, which is entitled Cyclopentane (ene) Heptenoic or Heptanoic Acids and Derivatives Thereof Useful as Therapeutic Agents and was filed on Dec. 28, 1993 and U.S. patent application Ser. No. 08/443,992, which is entitled Cyclopentane Heptan(ene) oic Acid, 2-Heteroarylalkenyl Derivatives as Therapeutic Agents and was filed on May 18, 1995.
The disclosures of all of these patent applications are hereby expressly incorporated by reference.
SUMMARY OF THE INVENTION
The present invention concerns a method of treating ocular hypertension which comprises administering to a mammal having ocular hypertension a therapeutically effective amount of a compound of formula I ##STR2## wherein the wavy segments represent an α or β bond, dashed lines represent a double bond or a single bond, R is a heteroaryl radical or a substituted heteroaryl radical, R 1 is hydroxyl or a hydrocarbyloxy or heteroatom sustituted hydrocarbyloxy comprising up to 20, e.g. up to 10 carbon atoms, and preferably a lower alkyloxy radical having up to six carbon atoms, X is selected from the group consisting of --OR 6 and --N(R 6 ) 2 , wherein R 6 is hydrogen or a lower alkyl radical having from 1 to 6 carbon atoms and Y is ═O or represents 2 hydrogen radicals and further provided that at least one of R 1 is a hydrocarbyloxy or heteroatom substituted hydrocarbyloxy.
In particular, the substituents on the heteroaryl radical may be selected from the group consisting of lower alkyl, e.g. C 1 to C 6 alkyl; halogen, e.g. fluoro, chloro, iodo and bromo; trifluoromethyl (CF 3 ); COR 7 , e.g. COCH 3 ; COCF 3 ; SO 2 NR 7 , SO 2 NH 2 ; NO 2 ; CN; etc., wherein R 7 is a lower alkyl radical having from 1 to 6 carbon atoms.
In a further aspect, the present invention relates to an ophthalmic solution comprising a therapeutically effective amount of a compound of formula (I), wherein the symbols have the above meanings, or a pharmaceutically acceptable salt thereof, in admixture with a non-toxic, ophthalmically acceptable liquid vehicle, packaged in a container suitable for metered application.
In a still further aspect, the present invention relates to a pharmaceutical product, comprising
a container adapted to dispense its contents in a metered form; and
an ophthalmic solution therein, as hereinabove defined.
A further aspect of the present invention provides methods of treating cardiovascular, pulmonary-respiratory, gastrointestinal, productive, allergic disease, shock and ocular hypertension which comprises administering an effective amount of a compound represented by the formula I.
Finally, certain of the compounds represented by the above formula, disclosed below and utilized in the methods of the present invention are novel and unobvious.
BRIEF DESCRIPTION OF THE DRAWING FIGURES
FIG. 1 is a schematic of the chemical synthesis of certain 1-carboxylic acid compounds and ester derivatives thereof specifically disclosed as Example 4(a)-(e) and 5(a)-(e) below.
FIG. 2 is a schematic of the chemical synthesis of certain 1-amido compounds specifically disclosed as Examples 6(b)-(g) below.
FIG. 3 is a schematic of the chemical synthesis of certain 1-isopropyl ester compounds specifically disclosed as Examples 7(f)-(i), below.
FIG. 4 is a schematic of the chemical synthesis of certain 15-methoxy-substituted carboxylic acid compounds and isopropyl derivatives thereof.
DETAILED DESCRIPTION OF THE INVENTION
The present invention relates to the use of cyclopentane heptan(ene)oic acid, 2-heteroaryl alkyl or alkenyl derivatives as therapeutic agents, e.g. as ocular hypotensives. The compounds used in accordance with the present invention are encompassed by the following structural formula I: ##STR3## wherein the substituents and symbols are as hereinabove defined.
Preferably, the compounds used in accordance with the present invention have the following structural formula II: ##STR4## wherein the hatched segments represent α bonds, the solid triangle represents a β bond and the substituents and symbols are as hereinabove defined. The dotted lines on bonds between carbons 5 and 6 (C-5) and carbons 13 and 14 (C-13) indicate a single or double bond. If two solid lines are used at C-5, or C-13, it indicates a specific configuration for that double bond. Hatched lines used at position C-8, C-9 and C-11 indicate the α configuration. A triangle at position C-12 represents β orientation. A more preferred group of the compounds of the present invention includes compounds that have the following structural formula III: ##STR5## wherein Z is selected from the group consisting of O and S, A is selected from the group consisting of N, --CH, and C, R 2 is selected from the group consisting of hydrogen, halogen, and lower alkyl having from 1 to 6 carbon atoms, R 3 and R 4 are selected from the group consisting of hydrogen, halogen, lower alkyl having from 1 to 6 carbon atoms, or, together with ##STR6## , R 3 and R 4 forms a condensed aryl ring and R 5 is a lower alkyl having from 1 to 6 carbon atoms. Preferably, when X is --N(R 6 ) 2 , Y is ═O.
More preferably, R 5 is methyl and at least one of R 2 , R 3 or R 4 are independently selected from the group consisting of chloro, bromo and lower alkyl. In one aspect of the invention, at least one of R 2 , R 3 or R 4 is chloro or bromo, and more preferably at least one of R 2 , R 3 or R 4 is bromo or at least two of R 2 , R 3 or R 4 are chloro or bromo. In another aspect of this invention, at least one of R 2 , R 3 or R 4 is ethyl, propyl, or butyl.
Another preferred group includes compounds having the formula IV: ##STR7##
The above compounds of the present invention may be prepared by methods that are known in the art or according to the working examples below. The compounds, below, are especially preferred representative of the compounds of the present invention.
7-[3α,5α-Dihydroxy-2-(3α-methoxy-5-(3-(2-methyl)-thienyl-1E-pentenyl)cyclopentyl]-5Z-heptenoic acid
7-[3α,5α-Dihydroxy-2-(3α-methoxy-5-(2-furanyl)-1E-pentenyl)cyclopentyl]-5Z-heptenoic acid.
Isopropyl 7-[3α,5α-Dihydroxy-2-(3α-methoxy-5-(2-furanyl)-1E-pentenyl)cyclopentyl]-5Z-heptenoate.
A pharmaceutically acceptable salt is any salt which retains the activity of the parent compound and does not impart any deleterious or undesirable effect on the subject to whom it is administered and in the context in which it is administered. Of particular interest are salts formed with inorganic ions, such as sodium, potassium, calcium, magnesium and zinc.
Pharmaceutical compositions may be prepared by combining a therapeutically effective amount of at least one compound according to the present invention, or a pharmaceutically acceptable acid addition salt thereof, as an active ingredient, with conventional ophthalmically acceptable pharmaceutical excipients, and by preparation of unit dosage forms suitable for topical ocular use. The therapeutically efficient amount typically is between about 0.0001 and about 5% (w/v), preferably about 0.001 to about 1.0% (w/v) in liquid formulations.
For ophthalmic application, preferably solutions are prepared using a physiological saline solution as a major vehicle. The pH of such ophthalmic solutions should preferably be maintained between 6.5 and 7.2 with an appropriate buffer system. The formulations may also contain conventional, pharmaceutically acceptable preservatives, stabilizers and surfactants.
Preferred preservatives that may be used in the pharmaceutical compositions of the present invention include, but are not limited to, benzalkonium chloride, chlorobutanol, thimerosal, phenylmercuric acetate and phenylmercuric nitrate. A preferred surfactant is, for example, Tween 80. Likewise, various preferred vehicles may be used in the ophthalmic preparations of the present invention. These vehicles include, but are not limited to, polyvinyl alcohol, povidone, hydroxypropyl methyl cellulose, poloxamers, carboxymethyl cellulose, hydroxyethyl cellulose and purified water.
Tonicity adjustors may be added as needed or convenient. They include, but are not limited to, salts, particularly sodium chloride, potassium chloride, mannitol and glycerin, or any other suitable ophthalmically acceptable tonicity adjustor.
Various buffers and means for adjusting pH may be used so long as the resulting preparation is ophthalmically acceptable. Accordingly, buffers include acetate buffers, citrate buffers, phosphate buffers and borate buffers. Acids or bases may be used to adjust the pH of these formulations as needed.
In a similar vein, an ophthalmically acceptable antioxidant for use in the present invention includes, but is not limited to, sodium metabisulfite, sodium thiosulfate, acetylcysteine, butylated hydroxyanisole and butylated hydroxytoluene.
Other excipient components which may be included in the ophthalmic preparations are chelating agents. The preferred chelating agent is edentate disodium, although other chelating agents may also be used in place or in conjunction with it.
The ingredients are usually used in the following amounts:
______________________________________Ingredient Amount (% w/v)______________________________________active ingredient about 0.001-5 preservative 0-0.10 vehicle 0-40 tonicity adjustor 1-10 buffer 0.01-10 pH adjustor q.s. pH 4.5-7.5 antioxidant as needed surfactant as needed purified water as needed to make 100%______________________________________
The actual dose of the active compounds of the present invention depends on the specific compound, and on the condition to be treated; the selection of the appropriate dose is well within the knowledge of the skilled artisan.
The ophthalmic formulations of the present invention are conveniently packaged in forms suitable for metered application, such as in containers equipped with a dropper, to facilitate the application to the eye. Containers suitable for dropwise application are usually made of suitable inert, non-toxic plastic material, and generally contain between about 0.5 and about 15 ml solution.
The invention is further illustrated by the following non-limiting Examples, which are summarized in the reaction schemes of FIGS. 1 through 4, wherein the compounds are identified by the same designator in both the Examples and the Figures.
Compound 5a
7-[3α,5α-Dihydroxy-2-(3α-hydroxy-5-(2-(3-chloro)benzothienyl-1E-pentenyl)cyclopentyl]-5Z-heptenoic acid
Step 1: Preparation of Enone 2a
To a suspension of sodium hydride (27 mg, 1.15 mmol) in tetrahydrofuran (THF) (2.0 mL) cooled to 0° C. was added dimethyl 4-(2-(3-chloro) benzothienyl)-2-oxo-butylphosphonate(363 mg, 1.15 mmol) in THF (2.2 mL). (In this Example, benzothienyl is an example of the hetero aryl radicals represented by R in the disclosure and claims and Ar in the Figures.) After 0.25 h a solution of the aldehyde 1 (507 mg, 1.04 mmol) in THF (2.0 mL) was added and the reaction was allowed to slowly warm to 23° C. over a period of 8 h. (In FIG. 1 TFP represents tetrahydropyranyl.) The reaction solution was quenched with saturated aqueous NH 4 Cl and extracted with ethyl acetate (EtOAc.) The aqueous phase was made slightly acidic and extracted again with EtOAc. The combined organics were washed with brine, dried over MgSO 4 , filtered and concentrated in vacuo. Flash column chromatography (silica gel, 2:1 hexane/EtOAc) gave 729 mg of enone 2a.
Step 2: Preparation of Alcohol 3a
Sodium tetrahydridoborate (40 mg, 1.05 mmol) was added to a solution of the enone (729 mg, 1.05 mmol) in methanol (MeOH)(2.1 mL) at 0° C. After 2 h the solvent was removed in vacuo and the residue was stirred with 1N NaOH and EtOAc for 0.5 h. The organic portion was separated, dried over MgSO 4 , filtered and concentrated in vacuo. The α-alcohol 3a was separated by flash column chromatography or HPLC (silica gel, 3:1 hexane/EtOAc).
Step 3: Preparation of Triol 4a:
A solution of the alcohol 3a and pyridinium p-toluene sulfonate (PPTs) (53 mg, 0.212 mmol) in MeOH(0.4 mL) was heated at 40° C. for 4 h. The solvent was removed in vacuo and the residue was diluted with EtOAc and then washed with 1N HCl, saturated aqueous NaHCO 3 and brine. The organic portion was dried over MgSO 4 , filtered and concentrated in vacuo the triol 4a.
Step 4: Preparation of Carboxylic Acid 5a
The triol 4a was diluted with THF (0.8 mL) and lithium hydroxide (0.4 mL of a 0.5 N solution in H 2 O, 0.186 mmol) was added. After 16 h the reaction was acidified with 1N HCl and extracted with EtOAc. The organic portion was washed with brine, dried over MgSO 4 , and concentrated in vacuo. The residue was purified by flash column chromatography (silica gel, 9:1 EtOAc/MeOH) to give 14.0 mg of free acid 5a.
By methods described for compound 5a, steps 1 through 4, the following compounds were prepared as illustrated in Scheme 1:
Compound 5b
7-[3α,5α-Dihydroxy-2-(3α-hydroxy-5-(5-(2,3-dibromo)thienyl)-1E-pentenyl)cyclopentyl]-5-Z-heptenoic acid
Prepared according to the procedures described above for 5a except the use of dimethyl 4-(5-(2,3-dibromo)thienyl)-2-oxo-butylphosphonate afforded 45 mg of free acid 5b.
Compound 5c
7-[3α,5α-Dihydroxy-2-(3α-hydroxy-5-(2-methyl)furanyl-1E-pentenyl)cyclopentyl]-5-Z-heptenoic acid
Prepared according to the procedures described above for 5a except the use of dimethyl 4-(5-(2-methyl)furanyl)-2-oxo-butylphosphonate afforded 63.6 mg of free acid 5c.
Compound 5d
7-[3α,5α-Dihydroxy-2-(3α-hydroxy-5-(3-(2,5dibromo)thienyl)-1E-pentenyl)cyclopentyl]-5-Z-heptenoic acid
Prepared according to the procedures described above for 5a except the use of dimethyl 4-(3-(2,5-dibromo)thienyl)-2-oxo-butylphosphonate afforded 74 mg of free acid 5d.
Compound 5e
7-[3α,5α-Dihydroxy-2-(3α-hydroxy-5-(5-(2-bromo-3-methyl)thienyl)-1E-pentenyl)cyclopentyl]-5-Z-heptenoic acid
Prepared according to the procedures described above for 5a except the use of dimethyl 4-(5-(2-bromo-3-methyl)thienyl)-2-oxobutylphosphonate afforded 40.6 mg of free acid 5e
Synthesis of amides 6b-g (Scheme 2)
Compound 6b
7-[3α,5α-Dihydroxy-2-(3α-hydroxy-5-(S-(2,3-dibromo)thienyl)-1E-pentenyl)cyclopentyl]-5-Z-heptenamide
The 3α-triol 4b (27 mg, 0.048 mmol) isolated from step 3 during synthesis of 5b, was placed in a tube with ammonium chloride (76 mg, 1.42 mmol). Ammonia gas ˜4.5 mL was condensed into the tube at -70° C. The tube was sealed and heated to 65° C. for 16 h. The tube was cooled to -70° C., vented and the ammonia allowed to evaporate on its own accord. The residue was dissolved in 1:1 EtOAc/H 2 O. The organic portion was separated, dried over MgSO 4 , filtered and concentrated in vacuo. Flash column chromatography (silica gel, 9:1 CH 2 Cl 2 /MeOH) gave 16.8 mg of the title compound 6b.
Compound 6c
7-[3α,5α-Dihydroxy-2-(3α-hydroxy-5-(5-(2-methyl)furanyl)-1E-pentenyl)cyclopentyl]-5-Z-heptenamide
According to the procedures described above for preparation of 6b the 3α-triol 4c (51 mg, 0.126 mmol) was converted to 25.1 mg of the title compound 6c.
Compound 6d
7-[3α,5α-Dihydroxy2-(3α-hydroxy-5-(3-(2,5-dibromo)thienyl)-1E-pentenyl)cyclopentyl]-5-Z-heptenamide
According to the procedures described above for the preparation of 6b the 3α-triol 4d (24 mg, 0.42 mmol) was converted to 12 mg of the title compound 6d.
Compound 6e
7-[3α,5α-Dihydroxy-2-(3α-hydroxy-5-(5-(2-bromo-3-methyl)thienyl)-1E-pentenyl)cyclopentyl]-5-Z-heptenamide
According to the procedures described above for the preparation of 6b the 3α-triol 4e (63 mg, 0.126 mmol) was converted to 33 mg of the title compound 6e.
Compound 6f
7-[3α,5α-Dihydroxy-2-(3α-hydroxy-5-(2-furanyl)-1E-pentenyl)cyclopentyl]-5-Z-heptenamide
According to the procedures described above for the preparation of 6b Methyl 7-[3α,5α-Dihydroxy-2-(3α-hydroxy-5-(2-furanyl)-1E-pentenyl) cyclopentyl]-5Z-heptenoate 4f (50 mg, 0.127 mmol) was converted to 12 mg of the title compound 6f.
Compound 6g
7-[3α,5α-Dihydroxy-2-(3α-hydroxy-5-(4-(2-methyl)thienyl)-1E-pentenyl)cyclopentyl]-5Z-heptenamide
According to the procedures described above for preparation of 6b Methyl 7-[3α,5α-Dihydroxy-2-(3α-hydroxy-5-(4-(2-methyl)thienyl)-1E-pentenyl)cyclopentyl]-5Z-heptenoate 4 g (65 mg, 0.154 mmol) was converted to 35.8 mg of the title compound 6g.
The isopropyl esters 7f-i were prepared as illustrated in Scheme 3 from the corresponding carboxylic acids 5f-i, which were prepared in an analogous manner to carboxylic acids 5a-e:
Compound 7f
Isopropyl 7-[3α,5α-Dihydroxy-2-(3α-hydroxy-5-(2-furanyl)-1E-pentenyl) cyclopentyl]-5Z-heptenoate
A solution of the previously prepared carboxylic acid 5f (11.0 mg, 0.029 mmol) and O-isopropyl-N, N'-diisopropylisourea (270 mg. 1.45 mmol) in benzene (1.5 mL) was heated to 75° C. for 4 h. The reaction mixture was concentrated in vacuo and the residue was purified by flash column chromatography (silica gel, 100% EtOAc) to afford 3.7 mg of the title compound 7f.
Compound 7g
Isopropyl 7-[3α,5α-Dihydroxy-2-(3α-hydroxy-5-(4-(2-methyl)thienyl-1E-pentenyl) cyclopentyl]-5Z-heptenoate
According to the procedures described above for the preparation of 7f the previously prepared carboxylic acid 5g (10 mg, 0.025 mmol) was converted to 7.3 mg of the title compound 7g.
Compound 7h
Isopropyl 7-[3α,5α-Dihydroxy-2-(3α-hydroxy-5-(5-(2-methyl)thienyl)-1E-pentenyl)-cyclopentyl]-5Z-heptenoate
According to the procedures described above for the preparation of 7f the previously prepared carboxylic acid 5h (10 mg, 0.025 mmol) was converted to 7.8 mg of the title compound 7h.
Compound 7i
Isopropyl 7-[3α,5α-Dihydroxy-2-(3α-hydroxy-5-(3-(2-methyl)thienyl)-1E-pentenyl)-cyclopentyl]-5Z-heptenoate
According to the procedures described above for the preparation of 7f the 7-[3α,5α-Dihydroxy-2-(3α-hydroxy-5-(3-(2-methyl)thienyl)-1E-pentenyl)-cyclopentyl]-5Z-heptenoic acid 5i (10 mg, 0.025 mmol) was converted to 7.0 mg of the title compound 7i.
Compound 11f
7-[3α,5α-Dihydroxy-2-(3α-methoxy-5-(2-furanyl)-1E-pentenyl) cyclopentyl]-5Z-heptenoic acid
Step 1: Methylation of C-15 Hydroxyl Group
Methyl triflate (MeOTF) (97 mL, 0.86 mmol) was added to a solution of the mixture of alcohols 8f (160 mg, 0.28 mmol) and 2,6di-t-butyl-pyridine (0.22 mL, 1.00 mmol) in CH 2 Cl 2 (1.5 mL) at 0° C. The reaction was then allowed to warm to room tempeature and stirring was continued for 16 h. After quenching with saturated aqueous NaHCO 3 the reaction was extracted with EtOAc. The organic portion was washed with 1N HCl, brine, dried over MgSO 4 , filtered and concentrated in vacuo. Flash column chromatography (silica gel, 4:1 hexane/EtOAc) provided 123 mg of the mixture of 15α, β-methyl ethers 9f.
Step 2: Removal of the Bis-Tetrahydropyranyl Protecting Groups
A solution of alcohols 9f (123 mg, 0.214 mmol) and pyridinium p-toluenesulfonate (40 mg, 0.16 mmol) in MeOH (3.0 mL) was heated at 40° C. for 4 h. The solvent was removed in vacuo. The residue was diluted with EtOAc and then washed with 1N HCl, saturated aqueous NaHCO 3 and brine. The organic portion was dried over MgSO 4 filtered and concentrated in vacuo. Purification of the residue by flash column chromatography (silica gel, 1:1 hexane/EtOAc followed by 100% EtOAc) gave 20.6 mg of 15α-methyl ether 10f.
Step 4: Preparation Carboxylic Acid 11f
The ester of 10f (10 mg, 0.025 mmol) was diluted with THF (0.4 mL) and lithium hydroxide (0.2 mL of a 0.5 N solution in H 2 O, 0.05 mmol) was added. After 16 h the reaction was acidified with 1N HCl and extracted with EtOAc. The organic portion was washed with brine, dried over MgSO 4 , and concentrated in vacuo. The residue was purified by flash column chromatography (silica gel, 9:1 MeOH/EtoAc) to furnish 5.0 mg of the carboxylic acid 11f.
Compound 11i
7-[3α,5α-Dihydroxy-2-(3α-methoxy-5-(3-(2-methyl)thienyl)-1E-pentenyl) cyclopentyl]-5Z-heptenoic acid
According to the procedures described above for the preparation of 11f the mixture of alcohols 8i (295 mg, 0.50 mmol) were converted to 9.4 mg of title compound 11i.
Compound 12f
Isopropyl 7-[3α,5α-Dihydroxy-2-(3α-methoxy-5-(2-furanyl)-1E-pentenyl) cyclopentyl]-5Z-heptenote 12f.
A mixture of ester 10f (20 mg, 0.05 mmol) and potassium carbonate (20.4 mg, 0.15 mmol) in anhydrous isopropanol (3.0 mL) was heated at 100° C. for 16 h. The reaction was concentrated in vacuo and the residue as stirred with 1:1 EtOAc/H 2 O (˜20 mL) for 0.5 h. The organic portion was separated, dried over MgSO 4 , filtered and concentrated in vacuo. Purification of the residue by flash column chromatography (silica gel, 2:1 hexane/EtOAc) provided 20.2 mg of the title compound 12f.
Certain of the above compounds were tested for activity in the various in vitro assays described below and the results are reported in Tables 1 and 2, below.
TABLE 1__________________________________________________________________________ EC.sub.50 (nM) FP/ Dog DP/ IC.sub.25 EP.sub.4 Platelets IOP Hyp/ AGN-# FP EP.sub.1 EP.sub.3 EP.sub.2 EP.sub.4 Ratio TP aggreg inhib (1 day) Miosis__________________________________________________________________________ 568 21190 0.03 - 0.8 23 0.03 692 - 24 23 1.0 >10.sup.4 0.1%/ -2.7 1.13/ pinpoint - 0.25 1## - 1.4 12## - 2.2 165 0.01 NA - 291 3760 0.08 0.1%/ -2.1 0.75/ pinpoint - 0.44 5## - 50 R16## - 35 620 0.06 NA 0.1%/ -4.4 0.01%/ -3.2 1.0/ pinpoint 1.5/ pinpoint__________________________________________________________________________
TABLE 2__________________________________________________________________________ EC.sub.50 (nM) FP/ Dog DP/ IC.sub.25 EP.sub.4 Platelets IOP Hyp/ AGN-# FP EP.sub.1 EP.sub.3 EP.sub.2 EP.sub.4 Ratio TP aggreg inhib (1 day) Miosis__________________________________________________________________________ 33 1630 0.02 NA 0.1%/ -3.6 0.6/ pinpoint - #STR19## - #STR20## - #STR21## - #STR22## - 4 57 0.07 - 5 100 0.05 - #STR25## Activity at different prostanoid receptors was measured in vitro in isolated smooth muscle preparations. FP-activity was measured as contraction of the isolated feline iris sphincter. EP.sub.4 -activity was measured as relaxation of smooth muscle of isolated rabbit jugular vein. TP-vasoco nstrictor activity was measured as contraction of rings of the isolated rat thoracic aorta. Effects on platelets from healthy human donors were measured by incubating platelet-rich plasma with the compounds described herein. Inhibition of aggregation was determined by the ability of the compounds described herein to inhibit platelet aggregation in platelet-rich plasma induced by 20 μM adenosine diphosphate
Potential therapeutic applications of the compounds described above are in osteoporosis, constipation, renal disorders, sexual dysfunction, baldness, diabetes, cancer and in disorder of immune regulation.
Many examples also have pronounced activity at the FP receptor, provisionally termed FP VASC associated with the vascular endothelium in the rabbit jugular vein preparation. Since such agents would be vasodilators they have potential in hypertension and any disease where tissue blood perfusion is compromised. Such indications include, but are not limited to, systemic hypertension, angina, stroke, retinal vascular diseases, claudication, Raynauds disease, diabetes, and pulmonary hypertension.
The effects of certain of the compounds of the working examples on intraocular pressure are also provided in the following tables. The compounds were prepared at the said concentrations in a vehicle comprising 0.1% polysorbate 80 and 10 mM tris (hydroxy methyl) aminomethane hydrochloride (TRIS) base. Dogs were treated by administering 25 μl to the ocular surface, the contralateral eye received vehicle as a control. Intraocular pressure was measured by applanation pneumatonometry. Dog intraocular pressure was measured immediately before drug administration and at 6 hours thereafter.
The compounds of the invention may also be useful in the treatment of various pathophysiological diseases including acute myocardial infarction, vascular thrombosis, hypertension, pulmonary hypertension, ischemic heart disease, congestive heart failure, and angina pectoris, in which case the compounds may be administered by any means that effect vasodilation and thereby relieve the symptoms of the disease. For example, administration may be by oral, transdermal, parenterial, subcutaneous, intravenous, intramuscular, intraperitoneal, transdermal, or buccal routes.
The compounds of the invention may be used alone, or in combination with other of the known vasodilator drugs.
The compounds of the invention may be formulated into an ointment containing about 0.10 to 10% of the active ingredient in a suitable base of, for example, white petrolatum, mineral oil and petrolatum and lanolin alcohol. Other suitable bases will be readily apparent to those skilled in the art.
The pharmaceutical preparations of the present invention are manufactured in a manner which is itself known, for example, by means of conventional dissolving or suspending the compounds, which are all either water soluble or suspendable. For administration in the treatment of the other mentioned pathophysiological disorders. The pharmaceutical preparations which can be used orally include push-fit capsules made of gelatin, as well as soft, sealed capsules made of gelatin and a plasticizer such as glycerol or sorbitol. The push-fit capsules can contain the active compounds in liquid form that may be mixed with fillers such as lactose, binders such as starches, and/or lubricants such as talc or magnesium stearate and, optionally, stabilizers. In soft capsules, the active compounds are preferably dissolved or suspended in suitable liquids, such as in buffered salt solution. In addition, stabilizers may be added.
In addition to being provided in a liquid form, for example in gelatin capsule or other suitable vehicle, the pharmaceutical preparations may contain suitable excipients to facilitate the processing of the active compounds into preparations that can be used pharmaceutically. Thus, pharmaceutical preparations for oral use can be obtained by adhering the solution of the active compounds to a solid support, optionally grinding the resulting mixture and processing the mixture of granules, after adding suitable auxiliaries, if desired or necessary, to obtain tablets or dragee cores.
Suitable excipients are, in particular, fillers such as sugars, for example lactose or sucrose, mannitol or sorbitol, cellulose preparations and/or calcium phosphates, for example tricalcium phosphate or calcium hydrogen phosphate, as well as inders such as starch, paste using for example, maize starch, wheat starch, rich starch, potato starch, gelatin, tragacanth, methyl cellulose, hydroxypropylmethylcellulose, sodium carboxymethylcellulose, and/or polyvinyl pyrrolidone. If desired, disintegrating agents may be added such as the above-mentioned starches and also carboxymethyl-starch, crosslinked polyvinyl pyrrolidone, agar, or algenic acid or a salt thereof, such as sodium alginate. Auxiliaries are, above all, flow-regulating agents and lubricants, for example, silica, talc, stearic acid or salts thereof, such as magnesium stearate or calcium stearate, and/or polyethylene glycol. Dragee cores are provided with suitable coatings which if desired, are resistant to gastric juices. For this purpose, concentrated sugar solutions may be used, which may optionally contain gum arabic, talc, polyvinyl pyrrolidone, polyethylene glycol and/or titanium dioxide, lacquer solutions and suitable organic solvents or solvent mixtures. In order to produce coatings resistant to gastric juices, solutions of suitable cellulose preparations such as acetylcellulose phthalate or hydroxypropylmethyl-cellulose phthalate, are used. Dye stuffs or pigments may be added to the tablets or dragee coatings, for example, for identification or in order to characterize combinations of active compound doses.
Suitable formulations for intravenous or parenteral administration include aqueous solutions of the active compounds. In addition, suspensions of the active compounds as oily injection suspensions may be administered. Aqueous injection suspensions may contain substances which increase the viscosity of the suspension include, for example, sodium carboxymethyl cellulose, soribitol, and/or dextran. Optionally, the suspension may also contain stabilizers.
The foregoing description details specific methods and compositions that can be employed to practice the present invention, and represents the best mode contemplated. However, it is apparent for one of ordinary skill in the art that further compounds with the desired pharmacological properties can be prepared in an analogous manner, and that the disclosed compounds can also be obtained from different starting compounds via different chemical reactions. For example, the present invention contemplates certain prodrugs and derivatives of the above disclosed compounds, wherein R 6 is ##STR26## These compounds may be made by methods known in the art, i.e. the acetylation of the 1-hydroxy or 1-amino or 1-amido derivatives, etc., disclosed above, with the appropriate acid chloride or acid anhydride.
R 6 may be ##STR27## as well, when said 1-hydroxy, or 1-amino or 1-amido derivatives are reacted with the appropriate ortho ester. Similarly, different pharmaceutical compositions may be prepared and used with substantially the same result. Thus, however detailed the foregoing may appear in text, it should not be construed as limiting the overall scope hereof; rather, the ambit of the present invention is to be governed only by the lawful construction of the appended claims.
|
The present invention provides cyclopentane heptanoic acid, 2 heteroaryl alkyl or alkenyl derivatives which may be substituted in the 1-position with hydroxyl, alkyloxy, amino and amido groups, e.g. 1-OH cyclopentane heptanoic acid, 2 heteroarylalkenyl derivatives. In particular, these derivatives are 7-[5-hydroxy-2-(heteroatom-substituted hydroxyhydrocarbyl)-3-hydroxycyclopentyl] heptanoic or heptenoic acids and amine, amide, ether, ester and alchohol derivatives of said acids wherein one or more of said hydroxy groups are replaced with an ether group. These compounds are potent ocular hypotensive and are particularly suited for the management of glaucoma. Moreover, the compounds of this invention are smooth muscle relaxants with broad application in systemic hypertensive and pulmonary diseases; with additional application in gastrointestinal disease, reproduction, fertility, incontinence, shock, inflammation, immune regulation, disorder of bone metabolism, renal dysfunction, cancer and other hypoproliferative diseases.
| 0
|
CROSS-REFERENCE TO RELATED APPLICATIONS
The present application is a Continuation of U.S. application Ser. No. 14/752,165, filed Jun. 26, 2015, which is a Continuation of U.S. application Ser. No. 12/846,545, filed Jul. 29, 2010, which claims priority from Korean Patent Application No. 10-2009-0070994, filed Jul. 31, 2009. The disclosure of each of these applications is incorporated herein by reference in its entirety.
TECHNICAL FIELD
The present invention generally relates to ultrasound systems, and more particularly to an ultrasound system and method for performing sensor coordinate calibration through image-based registration between a three-dimensional ultrasound image and a computed tomography (CT) image.
BACKGROUND
The ultrasound system has become an important and popular diagnostic tool due to its non-invasive and non-destructive nature. Modern high-performance ultrasound imaging diagnostic systems and techniques are commonly used to produce two- or three-dimensional images of internal features of patients (target objects).
However, the ultrasound system suffers from inherent shortcomings of an ultrasound image such as a low signal-to-noise ratio and a limited field of view. Thus, the image registration of a CT (or MR) image onto the ultrasound image has been introduced in order to compensate for deficiencies of the ultrasound image. A sensor has been used to perform the image registration of a CT (or MR) image onto the ultrasound image. Researches have been introduced to calibrate the sensor to match coordinates of the CT image and coordinates of the sensor.
Conventionally, after outer markers are attached on a surface of a target object, a CT image and an ultrasound image for the target object with the markers are acquired. Thereafter, the calibration is carried out by using a relationship between coordinates of the markers in the CT and ultrasound image. That is, the outer markers should be attached to the surface of the target objects before obtaining the CT image and the ultrasound image and be maintained in the same position until completing the acquisition of the ultrasound image. Moreover, a sensor must sense the positions of the respective outer markers.
Further, the registration between the coordinate of the CT image and the coordinate of the sensor has been performed by manually inputting inner markers on the CT image. Thus, a user of the ultrasound system had to input the inner markers, which causes the registration between the coordinate of the CT image and the coordinate of the sensor to be wrong.
SUMMARY
An embodiment for forming a plurality of three-dimensional ultrasound images is disclosed herein. In one embodiment, by way of non-limiting example, an ultrasound system, includes: an ultrasound image forming unit including a ultrasound probe and being configured to form a three-dimensional ultrasound image of a target object; a sensor coupled to the ultrasound probe; a memory configured to store a three-dimensional computed tomography (CT) image of the target object and position information on a position between the three-dimensional ultrasound image and the sensor; and a processor configured to perform image registration between the three-dimensional CT image and the three-dimensional ultrasound image to thereby form a first transformation function for transforming a position of the sensor to a corresponding position on the three-dimensional CT image and perform calibration of the sensor by applying the position information to the first transformation function.
In another embodiment, a method of performing a calibration of a sensor, includes: a) obtaining a three-dimensional ultrasound image of a target object obtained by the ultrasound system and a three-dimensional CT image; b) calculating a position information on a position between the three-dimensional ultrasound image and the sensor; c) performing registration between the three-dimensional ultrasound image and the three-dimensional CT image to obtain a first transformation function for transforming a position of the sensor to a corresponding position on the three-dimensional CT image; and d) performing calibration of the sensor by applying the position information to the first transformation function.
The Summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This Summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used in determining the scope of the claimed subject matter.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram showing an illustrative embodiment of an ultrasound system.
FIG. 2 is a block diagram showing an illustrative embodiment of an ultrasound image forming unit.
FIG. 3 is an illustrative embodiment of an ultrasound probe.
FIG. 4 is a block diagram showing an illustrative embodiment of a processor.
FIG. 5 is a schematic diagram showing an example of eigenvalues in the Hessian matrix.
DETAILED DESCRIPTION
A detailed description may be provided with reference to the accompanying drawings. One of ordinary skill in the art may realize that the following description is illustrative only and is not in any way limiting. Other embodiments of the present invention may readily suggest themselves to such skilled persons having the benefit of this disclosure.
FIG. 1 is a block diagram showing an illustrative embodiment of an ultrasound system. The ultrasound system 100 may include an ultrasound image forming unit 110 , a sensor 120 , a memory 130 , a processor 140 and a display unit 150 .
The ultrasound image forming unit 110 may be configured to transmit ultrasound signals to a target object (not shown) and receive ultrasound echo signals reflected from the target object. The ultrasound image forming unit 110 may be further configured to form a three-dimensional ultrasound image of the target object based on the received ultrasound echo signals.
FIG. 2 is a block diagram showing an illustrative embodiment of an ultrasound image forming unit 110 . The ultrasound image forming unit 110 may include a transmit (Tx) signal generating section 111 , an ultrasound probe 112 including a plurality of transducer elements (not shown), a beam former 113 , an ultrasound data forming section 114 and an image forming section 115 .
The Tx signal generating section 111 may generate Tx signals according to an image mode set in the ultrasound system 100 . The image mode may include a brightness (B) mode, a Doppler (D) mode, a color flow mode, etc. In one exemplary embodiment, the B mode may be set in the ultrasound system 100 to obtain a B mode ultrasound image.
The ultrasound probe 112 may receive the Tx signals from the Tx signal generating section 111 and generate ultrasound signals, which may travel into the target object. The ultrasound probe 112 may further receive ultrasound echo signals reflected from the target object and convert them into electrical receive signals. In such a case, the electrical receive signals may be analog signals. The ultrasound probe 112 may be a three-dimensional probe, a two-dimensional probe, a one-dimensional probe or the like.
FIG. 3 is an illustrative embodiment of an ultrasound probe 112 . At least one transducer element (not shown) of the ultrasound probe 112 generates an image plane IP, which is used to scan a region of interest ROI. The image plane IP may be one of slice planes of the three-dimensional ultrasound image. The sensor 120 is attached to the housing of the ultrasound probe 112 to determine the position and orientation of the image plane IP. The ultrasound system 100 coupled with the ultrasound probe 112 via the probe cable 105 can use the data generated by the sensor 120 to determine the position and orientation of the sensor 120 and/or the image plane IP, as described below.
In this preferred embodiment, the sensor 120 is a magnetic sensor that monitors the free-hand movement of the ultrasound probe 112 in six degrees of freedom with respect to a transducer element 170 . As shown in FIG. 3 , the sensor 120 and the transducer element 170 each define an origin ( 122 , 172 , respectively) defined by three orthogonal axes (X′, Y′, Z′ and X″, Y″, Z″, respectively). The sensor 120 monitors the translation of the origin 122 with respect to the origin 172 of the transducer element 170 to determine position and monitor the rotation of the X′, Y′, Z′ axes with respect to the X″, Y″, Z″ axes of the transducer element 170 to determine orientation.
The position and orientation of the sensor 120 can be used to determine the position and orientation of the image plane IP. As shown in FIG. 3 , the image plane IP defines an origin OR defined by three orthogonal axes X, Y, Z, which are preferably aligned with the origin of a center acoustic line generated by the ultrasound probe 112 . The position of the origin 122 and the orientation of axes X′, Y′, Z′ of the sensor 120 may not precisely coincide with the position of the origin OR and the orientation of the axes X, Y, Z of the image plane IP. For example, in FIG. 3 , the origin OR of the image plane IP is offset from the origin 122 of the sensor 120 by a distance z 0 along the Z-direction and a distance of y 0 along the Y-direction. In FIG. 3 , there is no offset along the X-direction nor is there a rotational offset in the orientation of the axes. Accordingly, the position and orientation of the sensor 120 do not directly describe the position and orientation of the image plane IP.
To determine the position an orientation of the image plane IP from the position and orientation of the sensor 120 , sensor calibration data is used to transform the position and orientation of the sensor 120 to the position and orientation of the image plane IP. For simplicity, the term “position and orientation” is used to broadly refer to position and/or orientation. Accordingly, if the sensor 120 has the same orientation as the image plane IP, then the position and orientation calibration data may not contain any orientation calibration data. Similarly, as shown in FIG. 3 , the sensor 120 may not have a positional offset with respect to one or more axes of the image plane IP.
There are a number of ways of defining the image plane/sensor offset. One method of calibrating at least some types of sensors use three orthogonal linear dimension offsets in X, Y, Z and three rotation angles about each of these axes. Other methods include using a position transformation matrix or quaternions, which are described in the user manual for the mini Bird™ and the Flock of Bird™ systems by Ascension Technology Corp.
As described above, the ultrasound probes with position and orientation sensors are typically used only with ultrasound systems that contain the calibration data for the probe/sensor pair. Conventionally, the probe/sensor pair is calibrated, and the calibration data is stored in the ultrasound system 100 , which will be used in conjunction with the probe/sensor pair. If the probe/sensor pair is to be used with a different ultrasound system, then the probe/sensor pair typically needs to be re-calibrated on that different ultrasound system. Since sonographers are often unable or unwilling to perform probe/sensor pair calibration, probe/sensor pairs are often used only with the ultrasound system for which the probe/sensor pair was initially calibrated.
Referring back to FIG. 2 , the beam former 113 may convert the electrical receive signals outputted from the ultrasound probe 112 into digital signals. The beam former 113 may further apply delays to the digital signals in consideration of the distances between the transducer elements and focal points to thereby output receive-focused signals.
The ultrasound data forming section 114 may form a plurality of ultrasound data by using the receive-focused signals. In one embodiment, the plurality of ultrasound data may be radio frequency (RF) data or IQ data. The image forming section 115 may form the three-dimensional ultrasound image of the target object based on the ultrasound data.
Referring back to FIG. 1 , the sensor 120 may be mounted on one side of the ultrasound probe 112 . In one embodiment, by way of non-limiting examples, the sensor 120 may be built in the ultrasound probe 112 to be away from the plurality of transducer elements (not shown) by a predetermined distance. Alternatively, the sensor 120 may be externally mounted on the ultrasound probe 112 to be away from the plurality of transducer elements. The sensor 120 may include three-dimensional sensor, which can detect a three-dimensional position and an angle of the ultrasound probe 112 .
The memory 130 may store a three-dimensional CT image of the target object. In one embodiment, by way of non-limiting examples, the three-dimensional CT image may be a three-dimensional CT image of a liver in which a diaphragm and a blood vessel are extracted. The memory 130 may store information on a position between the three-dimensional ultrasound image and the sensor 120 (hereinafter, referred to as “position information”). The position information may include information on a distance between the transducer elements (not shown) and the sensor 120 . In one embodiment, by way of non-limiting examples, the memory 120 may include at least one of a random access memory (RAM), a hard disk drive or the like.
The processor 140 may be configured to perform registration between the three-dimensional CT image and the three-dimensional ultrasound image, thereby forming a transformation function (T probe ) for representing the ultrasound probe 112 on the three-dimensional CT image. Furthermore, the processor 140 may perform calibration of the sensor 120 to match coordinates of the three-dimensional CT image (not shown) and coordinates of the sensor 120 based on the position information and the transformation function.
FIG. 4 is a block diagram showing an illustrative embodiment of the processor 140 . The processor 140 may include a diaphragm extracting section 141 , a vessel extracting section 142 , a diaphragm refining section 143 , a registration section 144 , a calibration section 145 and an image processing section 146 .
The diaphragm extracting section 141 may be configured to extract a diaphragm from the three-dimensional ultrasound image formed in the ultrasound image forming unit 110 . In one embodiment, the diaphragm extracting section 141 may perform a Hessian matrix based flatness test upon the three-dimensional ultrasound image to extract the diaphragm. The diaphragm may be considered as a curved surface in the three-dimensional ultrasound image. Thus, regions in which a voxel intensity change in a normal direction at a surface is greater than a voxel intensity change in a horizontal direction at the surface may be extracted as the diaphragm. FIG. 5 is a schematic diagram showing an example of eigenvalues λ1, λ2 and λ3 in the Hessian matrix.
Hereinafter, an operation of the diaphragm extracting section 141 will be described in detail. The diaphragm extracting section 141 may be configured to select voxels having a relatively high flatness value. The flatness μ(ν) may be defined as the following equation (1).
μ(ν)=φ 1 (ν)φ 2 (ν)φ 3 (ν)/φ 3 max (ν) (1)
wherein φ 1 (ν), φ 2 (ν) and φ 3 (ν) in the equation (1) may be represented as the following equation (2).
ϕ 1 ( v ) = ( 1 - λ 1 ( v ) λ 3 ( v ) ) 2 , ϕ 2 ( v ) = ( 1 - λ 2 ( v ) λ 3 ( v ) ) 2 , ϕ 3 ( v ) = ∑ i λ i ( v ) 2 ( 2 )
wherein λ 1 , λ 2 and λ 3 denote eigenvalues of the Hessian matrix at voxel ν. The flatness μ(ν) may be normalized to have values of ranging 0-1. A flatness map may be formed based on the flatness values obtained from all of the voxels according to the equations (1) and (2). Thereafter, the voxels having a relatively high flatness value are selected. In one embodiment, the voxels having the flatness over 0.1 may be selected.
The diaphragm extracting section 141 may be further configured to perform the morphological opening upon the selected voxels to remove small clutters therefrom. The morphological opening may be carried out by sequentially performing erosion and dilation. That is, a predetermined number of the voxels are removed in the edges of the area in which the voxels exist, and thus, the area becomes contracted (erosion). In this manner, it becomes possible to remove small clutters. Thereafter, the edges of the area are expanded by the predetermined number of the voxels (dilation). These erosion and dilation may be performed by one or more voxels.
The diaphragm is the largest surface in the three-dimensional ultrasound image. The largest surface may be selected among candidate surfaces obtained by the intensity-based connected component analysis (CCA) for the voxles and the selected surface may be regarded as the diaphragm in the three-dimensional ultrasound image. The voxel-based CCA is one of the methods of grouping regions in which voxel values exist. For example, the number of voxels connected to each of the voxels through a connectivity test by referring to values of voxels neighboring the corresponding voxel (e.g., 26 voxels) may be computed. The voxels, of which connected voxels are greater than the predetermined number, are selected as candidate groups. Since the diaphragm is the widest curved surface in the ROI, the candidate group having the most connected voxels may be selected as the diaphragm. The surface of the diaphragm may be smoothened.
The vessel extracting section 142 may be configured to perform vessel extraction upon the three-dimensional ultrasound image. The vessel extracting section 142 may be configured to perform the vessel extraction through ROI masking, vessel segmentation and classification.
To avoid mis-extraction of the vessels due to mirroring artifacts, the ROI masking may be applied to the three-dimensional ultrasound image by modeling the diaphragm as a polynomial curved surface. For example, the ROI masking may be used to model the diaphragm as the polynomial curved surface by using the least means square. However, if all of the lower portions of the modeled polynomial curved surface are eliminated, then meaningful vessel information may be lost at a portion of regions due to an error of the polynomial curved surface. To avoid losing the vessel information, the lower portion of the modeled polynomial curved surface may be eliminated with a marginal distance. For example, the marginal distance may be set to about 10 voxels at a lower portion of the ROI mask.
Subsequently, the vessel extracting section 142 may be further configured to segment a vessel region and a non-vessel region. To exclude non-vessel high intensity regions such as the diaphragm and vessel walls, a low intensity bound value having a less reference bound value in the ROI masked three-dimensional ultrasound image may be set as a reference bound value. Thereafter, voxels with a higher intensity value than the reference bound value may be removed. The remaining regions may be binarized by using an adaptive threshold value. Then, the binarized segments may be labeled as vessel candidates.
Next, the vessel extracting section 142 may be further configured to remove non-vessel-type clutters from the binarization image to form real vessel regions from the vessel candidates. In one embodiment, the vessel classification may include a size test, which evaluates the goodness of fit to a cylindrical tube, for filtering out tiny background clutters, a structure-based vessel test for removing non-vessel type clutters, i.e., an initial vessel test, a gradient magnitude analysis, and a final vessel test for precisely removing the clutters. Although some clutters are not removed through the structure-based vessel test, an initial threshold may be marginally set so that all vessels may be included. For example, a threshold value of the initial vessel test may be set to 0.6. At the final vessel test, clutters, which may be formed by small shading artifacts having low gradient magnitudes, may be precisely removed by considering variation of voxel values, i.e., gradient magnitudes, to thereby extract vessel data. In one embodiment, a threshold of the final vessel test may be set to 0.4.
The diaphragm refining section 143 may be configured to refine the diaphragm region by removing the clutters with the extracted vessel regions. The clutters are mainly placed near the vessel walls. Especially, the vessel walls of inferior vena cava (IVC) are more likely to be connected to the diaphragm and cause clutters. These clutters may degrade the accuracy of the feature based registration, and thus, it may be necessary to refine the diaphragm region. To refine the diaphragm, the vessel regions are extracted according to the vessel extraction mentioned above, the extracted vessel regions may be dilated, and then the dilated vessel regions may be subtracted from the initially extracted diaphragm region to estimate vessel walls. The estimated vessel walls may be removed from the diaphragm region. Finally, the diaphragm region may be extracted by applying CCA and the size test.
The registration section 144 may be configured to perform the image registration between the three-dimensional ultrasound and CT image. The registration section 144 may extract sample points from the vessel regions and the diaphragm region, respectively, among the features extracted from the three-dimensional ultrasound image. Also, after the vessel regions and the diaphragm region are extracted from the CT image, the registration section 144 may extract sample points from the vessel and the diaphragm region, respectively. The image registration between the three-dimensional ultrasound and CT image may be performed based on the extracted sample points to thereby form the transformation function (T probe ) between the three-dimensional CT image and the three-dimensional ultrasound image. The transformation function (T probe ) may be given by a matrix and used to transform a position of the ultrasound probe 112 to a corresponding position on the three-dimensional CT image.
The calibration section 145 may perform the calibration of the sensor 120 based on the transformation matrix (T probe ) from the registration section 144 and the position information stored in the memory 130 . More particularly, the calibration section 145 may form a transformation matrix (T sensor ) between the sensor 120 and the three-dimensional ultrasound image, i.e., a transformation matrix representing a position of the sensor 120 with respect to the three-dimensional ultrasound image. The transformation matrix (T sensor ) may be given by a matrix. The transformation matrix (T sensor ) may be defined as the following equation (3).
T sensor = r 11 r 12 r 13 x r 21 r 22 r 23 y r 31 r 32 r 33 z 0 0 0 1 ( 3 ) r 11=cos θ y *cos θ z +sin θ x *sin θ y *sin θ z
r 12=sin θ z *cos θ y −sin θ x *sin θ y *cos θ z
r 13=cos θ x *sin θ y,r 21=sin θ z *cos θ x
r 22=cos θ z *sin θ x,r 23=sin θ x
r 31=sin θ z *sin θ x *cos θ y −cos θ z *sin θ y
r 32=−cos θ z *sin θ x *cos θ y −sin θ z *sin θ y
r 33=cos θ x *cos θ y
wherein, x denotes coordinate of a lateral direction of the sensor 120 , y denotes coordinate of an elevation direction of the sensor 120 , z denotes an axial direction of the sensor 120 , θ x denotes an angle of the sensor 120 from the x-axis, θ y denotes an angle of the sensor 120 from the y-axis, and θ z denotes an angle of the sensor 120 from the z-axis. The elevation direction may be a swing direction of the transducer elements, the axial direction may be a scan line direction from the transducer elements and the lateral direction may be a longitudinal direction of the transducer elements.
The calibration section 145 may perform the calibration based on the transformation matrix (T probe ) and the transformation matrix (T sensor ). The calibration section 145 may form a transformation matrix (T) representing the position of the sensor 120 on the three-dimensional CT image. In one embodiment, the calibration section 145 may form the transformation matrix (T) through matrix multiplication of the transformation matrix (T probe ) and the transformation matrix (T sensor ).
The image processing section 146 may apply the transformation matrix (T) to the three-dimensional CT image to thereby form a two-dimensional CT image according to a two-dimensional ultrasound image.
Referring back to FIG. 1 , the display unit 150 may display the two-dimensional CT image, which is provided from the processor 140 . Furthermore, the display unit 150 may display the three-dimensional ultrasound image and the three-dimensional CT image.
Any reference in this specification to “one embodiment,” “an embodiment,” “example embodiment,” “illustrative embodiment,” etc. means that a particular feature, structure or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. The appearances of such phrases in various places in the specification are not necessarily all referring to the same embodiment. Further, when a particular feature, structure or characteristic is described in connection with any embodiment, it is submitted that it is within the purview of one skilled in the art to affect such feature, structure or characteristic in connection with other ones of the embodiments.
Although embodiments have been described with reference to a number of illustrative embodiments thereof, it should be understood that numerous other modifications and embodiments can be devised by those skilled in the art that will fall within the spirit and scope of the principles of this disclosure. More particularly, numerous variations and modifications are possible in the component parts and/or arrangements of the subject combination arrangement within the scope of the disclosure, the drawings and the appended claims. In addition to variations and modifications in the component parts and/or arrangements, alternative uses will also be apparent to those skilled in the art.
|
Sensor coupled to the ultrasound probe provides position information related to an ultrasound imaging position in the object. A processor performs first registration between the medical image and the ultrasound image based on the anatomical feature in the ultrasound image and a medical image of the object acquired by imaging modality different from the ultrasound apparatus, obtains first registration information which provides a relationship between a coordinate system of the medical image and a coordinate system of the ultrasound image based on the first registration, performs second registration between the sensor and the medical image based on the position information and the first registration information, and obtains second registration information based on the second registration. A display may display a portion of the medical image corresponding to the ultrasound imaging position based on the second registration information.
| 6
|
BACKGROUND OF THE INVENTION
[0001] Kayak hull design has progressed to target specific handling characteristics that are desirable for the conditions in which it will be used. Prior to this invention there was not an easily adaptable accessory that could change the handling characteristics of a kayak hull that was designed to be very maneuverable.
[0002] Kayaks can have a variety of hull configurations that represent the keel of a traditional boat. A keel that is proud of the hull surface will have better linear tracking, than that of a boat with a smooth bottom. The vessel shown in the preferred embodiment does not have a defined keel, which is a generally longitudinal plane down the midline of the vessel, and is referred to in this writing as the virtual keel.
[0003] A vessel without a defined keel is typically very maneuverable, which also means it doesn't track in a linear manner very well. For a man powered aquatic vessel to track properly, the same amount of propelling force needs to be applied to the left side as the right side. If one side is favored, there is an amount of latent energy that will need to be released. This manifestation of energy can show itself by having the vessel turning in a direction other than its intended vector. This is wasted energy that could have been channeled in a positive direction. Technical skill and experience are required to make a smooth bottom vessel track in a linear fashion, and to minimize the loss of energy. Furthermore forces that can cause the deviation of a vessel heading include, but are not limited to wind, waves, current, primary propulsion and auxiliary propulsion.
[0004] Prior to this invention a method for changing the handling and tracking characteristics, on a vessel that tracked poorly, was to add an inboard skeg. To install a previously designed retractable skeg into an existing hull takes a fair amount of tools, special materials, and expertise. This can be accomplished by cutting an opening in the stern hull of the kayak, mounting a skeg box that has the pivot mechanism inside, then sealing the box to the raw opening. Keep in mind that once this is mounted in place, it is very difficult to re-align the rigid skeg blade with the virtual keel line. Another inherent problem is that the pivot point is below the surface of the water, which makes the hull vulnerable to leaks. The control linkage then needs to exit through the surface of the deck, and becomes a possible leak as well. A typical kayak with a retractable inboard skeg consumes some of the dry storage available, is very difficult to service while the kayak is in deep water and can be jammed by any small amount of debris, like a pebble from the beach. It can be difficult to resolve a jamming problem, since the mechanism is enclosed inside the hull, and the skeg blade is submersed.
PRIOR ART
[0005] The following list is a compilation of searches in the technical field of the invention, which are noted to assist the Patent Examiner.
Reference: Des.315,772 Date of Patent: Mar. 26, 1991 Patentee: St. John Reference: Des.343,437 Date of Patent: Jan. 18, 1994 Patentee: De Paoli Reference: 3,352,272 Date of Patent: Nov. 14, 1967 Patentee: J. H. Brazier Reference: 3,516,100 Date of Patent: Jun. 23, 1970 Patentee: R. Ellis Reference: 3,575,124 Date of Patent: Apr. 13, 1971 Patentee: Alter Reference: 3,707,935 Date of Patent: Jan. 2, 1973 Patentee: Rachie Reference: 3,728,983 Date of Patent: Apr. 24, 1973 Patentee: Ingham Reference: 3,752,105 Date of Patent: Aug. 14, 1973 Patentee: Hackett Reference: 3,902,441 Date of Patent: Sep. 2, 1975 Patentee: Reference: 3,921,561 Date of Patent: Nov. 25, 1975 Patentee: Reference: 3,946,693 Date of Patent: Mar. 30, 1976 Patentee: Brown Reference: 4,008,677 Date of Patent: Feb. 22, 1977 Patentee: Wordell, Sr. Reference: 4,211,180 Date of Patent: Jul. 8, 1980 Patentee: Brooks, Jr. Reference: 4,320,546 Date of Patent: Mar. 23, 1982 Patentee: Knox Reference: 4,326,479 Date of Patent: Apr. 27, 1982 Patentee: Kawasaki Reference: 4,789,368 Date of Patent: Dec. 8, 1988 Patentee: Reference: 4,805,546 Date of Patent: Feb. 21, 1989 Patentee: Geller et al. Reference: 4,807,553 Date of Patent: Feb. 28, 1989 Patentee: Reference: 4,883,436 Date of Patent: Nov. 28, 1989 Patentee: Reference: 5,235,926 Date of Patent: Aug. 17, 1993 Patentee: Jones
SUMMARY OF THE INVENTION
[0006] This invention can greatly improve linear tracking, general stability and overall versatility on aquatic vessels.
[0007] The preferred embodiment of the invention also resolves many of the disadvantages associated with previous versions of submerged retractable skeg designs. It does not use any space inside the hull, does not leave any holes in the deck or hull, the skeg blades are easily accessible and replaceable, safety features are designed into it, minimal effort is required to install, assemble and use this invention.
[0008] Safety features include:
[0009] Flexible skeg blades, that pivot to reduce the chance of creating a rigid fulcrum hazard when the skeg blade strikes an obstacle;
[0010] The control line has a safety release knot designed into it, so an operators recovery would not be hindered by the control lines strength, if it were caught on a obstacle;
[0011] The control line anchor locations are away from the normal sweeping path of a paddle stroke, this reduces the chance of an injury due to a person's hand coming in contact with the hardware during a paddle stroke;
[0012] The shape of said anchors is such that it avoids entanglement with an obstacle;
[0013] An interference with the mount bracket is designed into the hinge bracket to prevent the skeg blades from pivoting too far above the stern deck, which could hinder a recovery effort of an overturned kayak.
[0014] Other aquatic applications could include, but not be limited to, using it on the motor mount of a fisherman's float tube, an inflatable raft, personal fishing pontoon, boat or on a canoe.
BRIEF DESCRIPTION OF THE DRAWING VIEWS
[0015] Referring to the accompanying drawings which are for illustrative purposes:
[0016] FIG. 1 is a port side perspective view of a kayak having the preferred embodiment of the invention mounted on the stern, and in the deployed position.
[0017] FIG. 2 is a rear elevational view of FIG. 1 , showing the generally horizontal waterline.
[0018] FIG. 3 is the top plan view of the kayak in FIG. 1 , showing the relationships between the operator's reach and the inventions control line, while in the retracted position.
[0019] FIG. 4 is the port side view of FIG. 3 .
[0020] FIG. 5 is the top plan view of FIG. 1 , showing the relationships between the operator's reach and the inventions control line, and the clearance of the invention at the tip of the stern.
[0021] FIG. 6 is an enlarged view of FIG. 5 , showing motion about a generally horizontal axis.
[0022] FIG. 7 is a front elevational view of the actuator linkage.
[0023] FIG. 8 is a side view of FIG. 7 , showing the coaxial ends.
[0024] FIG. 9 is a top plan view of the hinged bracket.
[0025] FIG. 10 is the port side view of FIG. 9 .
[0026] FIG. 11 is the front elevational view FIG. 9 .
[0027] FIG. 12 is an exploded view of the hinged bracket assembly, showing multiple skeg blades.
[0028] FIG. 13 is an enlarged detail view of FIG. 12 , showing two blades stacked together.
[0029] FIG. 14 is a detail view of the safety knot at the end of the control line.
[0030] FIG. 15 is the front elevational view of the control line anchor.
[0031] FIG. 16 is the mounting base of FIG. 15 .
[0032] FIG. 17 is a perspective view of the starboard side of the mounting bracket.
[0033] FIG. 18 is a top plan view FIG. 17 .
[0034] FIG. 19 is a perspective view of the starboard side of FIG. 17 , in an alternate embodiment that can be mounted on a generally vertical surface.
[0035] FIG. 20 is a top plan view of the hinged bracket assembly with two accessories, and ready to be stored separately from the complete assembly shown in FIG. 1 .
[0036] FIG. 21 is the port side view of FIG. 20 .
[0037] FIG. 22 is a port side perspective view of FIG. 20 .
[0038] FIG. 23 is a top plan view of the hinged bracket assembly, with one accessory.
[0039] FIG. 24 is the port side view of FIG. 23 .
[0040] FIG. 25 is a port side perspective view of FIG. 23 .
[0041] FIG. 26 is a port side perspective view of the accessory in FIG. 23 .
[0042] FIG. 27 is a perspective view of the starboard side of the shipping card for the hinged bracket assembly, ready to be stored separately from the complete assembly shown in FIG. 1 .
[0043] FIG. 28 is a top plan view with the hinged assembly and the control mechanism removed.
[0044] FIG. 29 is a port side perspective view of FIG. 28 .
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0045] In the drawings, all figures have a number preceded by the word ‘FIG. ’, all components have their own number, and any feature associated with the component has the component number which is then appended with an alphabetical character.
[0046] Referring now to the drawings, FIG. 1 shows a linear tracking device working assembly 12 mounted onto the stern 10 b of a kayak 10 , which will be referred to as the vessel from this point on.
[0047] Mount Bracket 1 , direction attention FIG. 18 , is formed from a man made material rated for outdoor use. Said bracket has a control line guide 1 g , a flange 1 b with pivot feature 1 d , another flange 1 c with pivot feature 1 e . Said flanges 1 b and 1 c are parallel and pivot features 1 e are 1 d coaxial. Other features of Mount Bracket 1 may include hardware mounting features 1 j , 1 k and 1 m , a flow relief hole 1 a , and an existing vessel accessory 10 j clearance hole 1 n . Further details of mount bracket 1 include guide detail 1 h that avoids having to thread the end of the control line loop 6 d through the guide 1 g . The actuator seating detail 1 f is for capturing the actuator leg 2 f while the invention 12 is in the retracted position, this relationship is best shown in FIG. 5 . Direction attention to FIG. 4 , while the hinged bracket 3 is in the retracted position, surface 3 k rests on an adjustable surface 1 r , which allows the angular relationship between 1 p and 3 h to be adjusted for differing vessel stern deck 10 b configurations. The mount bracket 1 , direction attention FIG. 17 , can be mounted with the pivot features 1 d and 1 e ahead of, or behind, the stern tip 10 e , direction attention FIG. 6 . Direction attention FIG. 17 , mount bracket hinge axis features 1 d and 1 e , are concentric with actuator features 2 a and 2 b , and are also concentric with, direction attention FIG. 10 , the hinged accessory bracket pivot feature 3 d to maintain parallel alignment between the virtual keel 10 g and the skeg mechanism 4 , while the invention is in the preferred embodiment. Direction attention to FIG. 19 , said mount bracket has surfaces 1 p and 1 q at an angular relationship, which will allow the mount bracket 1 to be mounted on a generally vertical surface, in relation to the generally horizontal waters surface.
[0048] Actuator linkage 2 , direction attention FIG. 7 , is formed from an outdoor rated material that has a different dimension 2 h when it is removed from the invention assembly 12 . Direction attention to FIG. 5 , said linkage 2 is formed in a shape 2 c that will avoid interference with the tip of a vessel stern 10 e . Direction attention to FIG. 8 , actuator linkage 2 has two pivot surfaces 2 a and 2 b that are coaxial with each other when installed into the inventions assembly 12 , surfaces 2 a and 2 b are used as the coaxial link between the mount bracket 1 and the hinged bracket 3 . Surfaces 2 a and 2 b remain above the generally horizontal water surface 10 d best shown in FIG. 2 . The actuator linkage 2 has a location 2 d designated for connection of a control line 6 , and more specifically loop 6 d . Direction attention to FIG. 12 , either pivot surface end 2 e or 2 g , can be used as a tool to release the grasp of the reusable fastener 8 , by pushing 8 a which exposes its core stem surface 8 b.
[0049] Hinged bracket 3 is formed from a man made material rated for outdoor use, has a flange 3 b with pivot feature 3 d , at least one accessory 4 fastening detail 3 p , and can have a flow relief feature 3 a . Direction attention to FIG. 10 , the hinged bracket 3 flanges 3 b and 3 c are offset and parallel to the virtual keel line 10 g , best shown within the preferred embodiment 12 in FIG. 3 . Said flanges have their pivot feature 3 d and mounting features 3 p aligning in a coaxial arrangement, best shown in FIG. 10 . The skeg blade fastening detail 3 p is capable of holding multiple skeg blades 4 parallel to each other. Hinged bracket 3 has actuator engagement details 3 e and 3 f , which bind against the actuator 2 near location 2 f . Said hinged bracket 3 has material removed 3 g to avoid contact with the vessel stern tip 10 e throughout its range of motion about the generally horizontal pivot feature 3 d . Hinged bracket 3 also has a relatively small surface area 3 h to minimize drag while in the deployed position FIG. 6 of the invention assembly 12 . Hinged bracket 3 may have one or more auxiliary fastener holes 3 m . A mechanical interference between the hinged bracket 3 at surface 3 k and mount bracket 1 at surface 1 r will prevent the invention assembly 12 from having a high angle relative to surfaces 3 h and 1 p , when in the retracted position. Direction attention to FIG. 4 , this mechanical interference is a safety feature intended to prevent the skeg mechanism 4 surface area 4 j from hindering the corrective efforts of an over turned vessel 10 .
[0050] The skeg mechanism 4 , direction attention FIG. 12 , is made from a man made material rated for outdoor use, is durable, flexible and has a uniform thickness. The skeg blade 4 in the invention assembly 12 is shown as a transparent material, but is not limited to having any translucent qualities. The leading edge 4 a and trailing edge 4 c of the blade 4 will not hold onto an undesirable obstacle. Upon either said edge coming in contact with an obstacle while in the deployed position FIG. 6 the skeg blade 4 will cause the rotation of the hinge bracket 3 about the pivot axis 2 b in directions 4 g or 4 h . Features of the blade include at least one mechanical fastener location 4 f , an open-ended slot 4 e connected with pivot alignment hole 4 d . Said blade has a surface 4 b which is intended as a friction reducer between the mount bracket flange 1 b and hinged bracket flange 3 b . Said skeg blades 4 can be stacked next to each other FIG. 13 and allows the vessels handling characteristics to be fine tuned. Said stacking of the skeg blades 4 can not be modified by the operator when they are seated in the vessel 10 cockpit 10 a.
[0051] The control line anchor 5 , direction attention FIG. 15 , is an optional item to be used with the invention assembly 12 . The anchor 5 and the control line 6 are only required, if the skeg blade 4 needs to be retracted FIG. 4 while the operator is using the invention 12 . Direction attention to FIG. 16 , the control line anchor 5 is made from a man made material rated for outdoor use, has a large perimeter dimension 5 b , and at least one smaller dimension 5 c along its core, to create a feature 5 e to hold the control line 6 . Said anchor 5 has a feature 5 d to mechanically fasten it to a surface 10 h and has no sharp edges 5 a when installed. Said control line anchor 5 is mounted to the deck of the vessel in the area between the general range of motion limits 10 c and the general reach limits 10 f of the operator. If the option of retracting the hinged bracket 3 is chosen, control line anchor 5 is used to accomplish two separate tasks. The first is shown in FIG. 5 and notes the location for the control line end anchor 5 that receives the control line end loop 6 d which is tightened around surface 5 e . The second purpose is best shown in FIG. 4 and details the location of the retracting anchor 5 that sets the retracted position of the control line 6 , to have a tangency relation to surface 5 e , which brings the hinged bracket 3 into the retracted position. More control line anchor 5 locations may be desired to manipulate the control line 6 around an obstacle such as gear strapped to the stern deck 10 b.
[0052] The control line 6 , direction attention FIG. 14 , is a standard high strength man made cord and is rated for outdoor use. Said control line 6 is a basic reach extender for the operator, intended to manipulate the hinged bracket assembly 3 . Said control line 6 has a safety release loop 6 d located near each tag end 6 a and inline knot 6 b . The safety release loop is created by folding the control line 6 forming a 180 degree turn at 6 c , then slide the tight fitting resilient collar 7 over 6 c . This creates a noose that will deform and fail well below the control lines 6 capacity. This is another safety feature to avoid hindering a recovery effort if the control line 6 were to get caught on an undesirable obstacle. This invention is not limited to a soft type of linkage shown, it can have a rigid, or semi rigid linkage system to control the assembly 12 . The soft linkage shown consists of components that are inexpensive, lightweight, and simple to operate and install.
[0053] The fasteners 8 are not original to this invention and are of a reusable type rated for outdoor use.
[0054] The storage block 9 , direction attention FIG. 21 , is made of a lightweight, buoyant man made material that is rated for outdoor use. Direction attention to FIG. 11 , said storage block when fitted between the flanges 3 c and 3 b of the hinge bracket 3 , holds the skeg blade surface 4 j parallel to the flange. Direction attention to FIG. 22 , storage block 9 can hold the actuator 2 in place when this subassembly is stored separate from the invention assembly 12 .
[0055] The vessel 10 , direction attention FIG. 1 , is not original to this invention, but is shown as a vessel on which the invention assembly 12 is mounted. Features noted are the cockpit 10 a , stern 10 b , the operators general range of motion 10 c , generally horizontal waterline 10 d , the tip of the stern 10 e , the operators general reach 10 f , virtual keel line 10 g , the area 10 h within reach of the operator while seated in the cockpit 10 a . Said vessel may have an existing accessory 10 j , which is shown to emphasize the mounting brackets 1 versatility. Attention direction to FIG. 28 , heading deviation forces are generalized by 10 x and 10 y . In this set of illustrations any aquatic vessel could be substituted for the one shown in the drawing views including, but not limited to, a raft, an inflatable boat, a fisherman's float tube, a fisherman's personal pontoon or a boat. In the case of a vessel having a generally vertical surface, perpendicular to the longitudinal keel, the embodiment shown in FIG. 19 would be used. Also note this device will work as a kite tail, if it is made of lighter weight materials. For a kite tail embodiment the operators' location would be interpreted as the operator being located at the end of a controlling device, and the cockpit will be interpreted as the location for which control is distributed once control is translated to said kite.
[0056] The flexible hinged bracket extension 11 , direction attention FIG. 23 , is made from a man made material rated for outdoor use, is very flexible, durable and has a uniform thickness. Features of this accessory are that it flexes above the skeg blade trailing edge 4 c when the invention is in motion in a forward direction. It also utilizes the skeg blade trailing edge 4 c as a reinforcing rib when a force is applied 11 e and the outward edge 11 a and the stiffening detail 11 b has interference with the skeg blade trailing edge 4 c . Said bracket extension 11 has at least one mechanical fastener location at 11 c and again at 11 d , and can be assembled with the same reusable fastener 8 shown in FIG. 12 . The intent of this accessory is to make use of kinetic energy in the surrounding environment such as a river current or a wave, which can translate the force 11 e , into forward motion for the vessel 10 .
[0057] The retractable working assembly of the invention 12 , direction attention FIG. 1 , is comprised of all of the parts previously mentioned in the preferred embodiment description, and the mounting hardware noted hereafter.
[0058] The adjustable compression fastener 13 , direction attention to FIG. 5 , is made from a man made material rated for outdoor use. Said fastener is to be used to hold the mount bracket 1 , to the stern of the vessel 10 . Mount bracket 1 , direction attention to FIG. 18 , has fastener details 1 j and 1 k to allow for the adjustment of the linear tracking device 12 to have a parallel relation to the virtual keel line 10 g . Said fastener 13 is also used to mount the control line anchor 5 at feature 5 d to the vessel.
[0059] The fixed hardware fasteners 14 , direction attention to FIG. 5 , are made from a man made material rated for outdoor use. Said fastener is to be used to secure the mount bracket 1 into a true position, as to avoid the assembly 12 from getting bumped out of alignment. All of the fastener 13 and 14 mounting holes can be completely weatherproofed.
[0060] The shipping card 15 , direction attention to FIG. 27 , is made from a man made material rated for outdoor use. Said shipping card, is an alternate embodiment of the storage block 9 , and is intended to hold the skeg blades rigidly, in their desired posture, during storage or during transport. Said shipping card 15 has at least one bend 15 a , and multiple vertical slots 15 b to capture skeg blade surfaces 4 j.
[0061] The initial installation of this invention is accomplished with common tools and does not require expertise in a given trade. Direction attention FIG. 5 , the mount bracket 1 must be installed with four fasteners 13 , then it is then adjusted parallel to the keel line 10 g , and finally can be secured in place with fasteners 14 . The hinge bracket 3 and the actuator 2 need to be assembled to the mount bracket 1 aligning coaxial features 1 d , 2 b and 3 d . Direction attention FIG. 5 , the control line end anchor 5 can be located within the seated operators reach 10 f . Direction attention FIG. 4 , one end of control line 6 at loop 6 d needs to be connected to the actuator 2 at location 2 d in order to locate the placement of the control line retracting anchor 5 to be mounted on the vessel 10 within area 10 h . This is also necessary to establish the overall length of the control line 6 , to allow full deployment and retraction.
[0062] Once the initial installation has been completed, the invention 12 can be assembled FIG. 1 or disassembled FIG. 29 at any time, in a matter of seconds. The control line anchors 5 and the mount bracket 1 stay attached to the vessel 10 . To accommodate transportation of the vessel, the hinged bracket 3 along with any attached parts, the actuator 2 and the control line 6 can remain assembled as shown in FIG. 4 , or can be removed and stowed separate, direction attention to FIG. 22 and FIG. 27 , from the vessel 10 .
[0063] To separate the hinged bracket 3 and its attached parts, from the preferred embodiment 12 shown in FIG. 1 , a person must compress the actuator 2 at areas 2 c best shown in FIG. 7 . This process reduces the dimension 2 h and releases the actuator leg 2 f through features 3 e and 3 f of the hinged bracket 3 , best shown in FIG. 9 . This also releases the actuator 2 from the mount bracket 1 by compressing 2 h to allow 2 e and 2 g through mount bracket 1 features 1 d and 1 e . All loose parts can then be gathered and handled independent of the vessel 10 .
[0064] Direction attention to FIG. 28 , heading deviation forces 10 x or 10 y can be partially or completely neutralized by the invention 12 shown in FIG. 1 , and are not limited to wind, waves, current, primary propulsion or secondary propulsion method.
[0065] Direction attention to FIG. 29 , shows the ability of the mount bracket 1 to avoid any existing hand hold devices 10 j that may be part of the vessel 10 .
[0066] Direction attention to FIG. 1 , to use the invention 12 an operator seated in the cockpit 10 a would propel forward at their leisure until a change in direction is desired. Direction attention to FIG. 5 , the operator would then reach to the area 10 h and swipe with their thumb to catch the control line 6 and loop it to the retracting anchor 5 location, best noted in FIG. 3 . With the hinged bracket 3 in the retracted position FIG. 4 , the operator can make an aggressive course change. When the operator requires a more linear course, they would then release the control line 6 from the retracting anchor 5 location, which uses gravity to deploy the hinged bracket 3 and any attached skeg blade 4 . The actuator 2 feature 2 d is visible by the operator seated in the cockpit 10 a , to allow confirmation of the true position of the hinged bracket 3 assembly in regard to it being fully retracted or deployed.
|
This invention can be fitted to a variety of vessels and accommodate a variety of accessories that may require deployment or retraction such as electronic equipment, downrigger or an outboard skeg mechanism as detailed in the preferred embodiment. This invention in it's preferred embodiment is shown on, but not limited to, the stern of a kayak. It increases the efficiency of linear tracking, allows the handling characteristics of an aquatic vessel to be tuned, and reduces the amount of technical skill required to control the vessel. It can have control linkage to deploy or retract it, can be stowed separate from the vessel, is lightweight, and is easy to assemble and operate.
| 1
|
[0001] This application claims the benefit of U.S. Provisional Application No. 61/475,461, filed on Apr. 14, 2011.
FIELD OF THE INVENTION
[0002] This invention relates to wafers and substrates such as are used in micromechanical electrical system (MEMS) devices or semiconductor devices.
[0003] Background
[0004] Electrostatic MEMS resonators have been a promising technological candidate to replace conventional quartz crystal resonators due to the potential for smaller size, lower power consumption and low-cost silicon manufacturing. Such devices typically suffer, however, from unacceptably large motional-impedance (R x ). MEMS devices operating in the out-of-plane direction, i.e., a direction perpendicular to the plane defined by the substrate on which the device is formed, have the advantage of large transduction areas on the top and bottom surfaces, resulting in a reduction in motional-impedances. Consequently, out-of plane devices have received an increasing amount of attention resulting in significant advances in areas such as digital micro-mirror devices and interference modulators.
[0005] The potential benefit of out-of-plane electrodes is apparent upon consideration of the factors which influence the R x . The equation which describes R x is as follows:
[0000]
R
x
=
c
r
η
2
;
with
η
=
V
∂
C
∂
g
=
ɛ
0
AV
g
2
[0000] wherein “c r ” is the effective damping constant of the resonator,
[0006] “η” is the transduction efficiency,
[0007] “g” is the gap between electrodes,
[0008] “A” is the transduction area, and
[0009] “V” is the bias voltage.
[0010] For in-plane devices, “A” is defined as H×L, with “H” being the height of the in-plane component and “L” being the length of the in-plane component. Thus, η is a function of H/g and H/g is constrained by the etching aspect ratio which is typically limited to about 20:1. For out-of-plane devices, however, “A” is defined as L×W, with “W” being the width of the device. Accordingly, η is not a function of the height of the out-of-plane device. Rather, η is a function of (L×W)/g. Accordingly, the desired footprint of the device is the major factor in transduction efficiency. Out-of-plane devices thus have the capability of achieving significantly greater transduction efficiency compared to in-plane devices.
[0011] Traditionally, out-of-plane electrodes are not fully utilized because of the difficulty in reliably fabricating such devices. For example, packaging is difficult for out-of-plane devices because out-of-plane electrodes are easily damaged during packaging processes. MEMS resonators incorporating an out-of-plane electrode are particularly challenging because such devices require a vacuum encapsulation process.
[0012] What is needed therefore is a simple and reliable device with an out-of-plane electrode and method for producing the device. A device incorporating an out-of-plane electrode that is easily fabricated with an encapsulated vacuum would be further beneficial.
SUMMARY
[0013] In one embodiment, a method of forming an out-of-plane electrode includes providing an oxide layer above an upper surface of a device layer, providing a first cap layer portion above an upper surface of the oxide layer, etching a first electrode perimeter defining trench extending through the first cap layer portion and stopping at the oxide layer, depositing a first material portion within the first electrode perimeter defining trench, depositing a second cap layer portion above the deposited first material portion, vapor releasing a portion of the oxide layer, depositing a third cap layer portion above the second cap layer portion, etching a second electrode perimeter defining trench extending through the second cap layer portion and the third cap layer portion, and depositing a second material portion within the second electrode perimeter defining trench, such that a spacer including the first material portion and the second material portion define a perimeter of an out-of-plane electrode.
[0014] In a further embodiment, a device with an out-of-plane electrode includes a device layer positioned above a handle layer, a cap layer having a first cap layer portion spaced apart from an upper surface of the device layer, and an out-of-plane electrode defined within the first cap layer portion by a spacer.
[0015] In yet another embodiment a method of forming an out-of-plane electrode includes providing an oxide layer above an upper surface of a device layer, epitaxially depositing a first cap layer portion above an upper surface of the oxide layer, etching a first electrode perimeter defining trench extending through the first cap layer portion and stopping at the oxide layer, depositing a first insulating material portion within the first electrode perimeter defining trench, epitaxially depositing a second cap layer portion above the deposited first material portion, performing an HF vapor etch release on a portion of the oxide layer, epitaxially depositing a third cap layer portion above the second cap layer portion, etching a second electrode perimeter defining trench extending through the second cap layer portion and the third cap layer portion, and depositing a second insulating material portion within the second electrode perimeter defining trench, such that a spacer including the first material portion and the second material portion define a perimeter of an out-of-plane electrode.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] FIG. 1 depicts a side cross-sectional view of a sensor device incorporating a spacer defining an out-of-plane electrode, the spacer including two trench portions and a gasket portion in accordance with principles of the invention;
[0017] FIG. 2 depicts a side cross-sectional view of a wafer with a device layer etched to define an in-plane-electrode;
[0018] FIG. 3 depicts a top plan view of the wafer of FIG. 2 ;
[0019] FIG. 4 depicts the wafer of FIG. 2 with the trenches filled with an oxide material and an oxide layer formed above the device layer;
[0020] FIG. 5 depicts a top plan view of the wafer of FIG. 4 ;
[0021] FIG. 6 depicts the wafer of FIG. 4 with an opening etched in the oxide layer above a contact portion of the device layer;
[0022] FIG. 7 depicts a top plan view of the wafer of FIG. 6 ;
[0023] FIG. 8 depicts the wafer of FIG. 6 with a first cap layer portion formed above the oxide layer and trenches formed in the oxide layer;
[0024] FIG. 9 depicts a top plan view of the wafer of FIG. 8 ;
[0025] FIG. 10 depicts the wafer of FIG. 8 with the trenches filled with an insulating material, the insulating material also forming a layer above the first cap layer portion, and an etch stop layer formed above the insulating layer;
[0026] FIG. 11 depicts a top plan view of the wafer of FIG. 10 ;
[0027] FIG. 12 depicts the wafer of FIG. 10 after the insulating layer and etch stop layer have been etched to define gaskets for an out-of-plane electrode and a device layer contact;
[0028] FIG. 13 depicts a top plan view of the wafer of FIG. 12 ;
[0029] FIG. 14 depicts the wafer of FIG. 12 after a second cap layer portion has been deposited above the first cap layer portion and the gaskets, and the second cap layer portion has been planarized;
[0030] FIG. 15 depicts a top plan view of the wafer of FIG. 14 ;
[0031] FIG. 16 depicts the wafer of FIG. 14 after vapor etch vent holes have been etched through the first cap layer portion and the second cap layer portion, and a portion of the oxide layer, the oxide material in the device layer, and a portion of a buried oxide layer have been etched, thereby electrically isolating an in-plane electrode and releasing the first cap layer portion above the in-plane electrode;
[0032] FIG. 17 depicts a top plan view of the wafer of FIG. 16 ;
[0033] FIG. 18 depicts the wafer of FIG. 16 after the vapor etch vent holes have been sealed by a third cap layer portion;
[0034] FIG. 19 depicts a top plan view of the wafer of FIG. 18 ;
[0035] FIG. 20 depicts the wafer of FIG. 18 with trenches formed through the third cap layer portion and the second cap layer portion to upper surfaces of the gaskets;
[0036] FIG. 21 depicts a top plan view of the wafer of FIG. 20 ;
[0037] FIG. 22 depicts the wafer of FIG. 20 with an insulating material deposited within the trenches and along the upper surface of the third cap layer portion, and a contact opening etched through the insulating material to expose a contact portion of the cap layer;
[0038] FIG. 23 depicts a top plan view of the wafer of FIG. 22 ;
[0039] FIG. 24 depicts a side cross-sectional view of a wafer including electrode defining trenches extending through a cap layer portion to an oxide layer and etch stop trenches extending through the cap layer portion and the oxide layer to an upper surface of a device layer;
[0040] FIG. 25 depicts a side cross-sectional view of the wafer of FIG. 24 with nitride trench portions filling the electrode defining trenches, nitride etch stop portions filling the etch stop trenches, gaskets formed above the nitride trench portions and the nitride etch stop portions, and etch vent holes extending through a cap layer, wherein etching of the oxide layer has been constrained by the nitride etch stop portions;
[0041] FIGS. 26-38 depict side cross-sectional views of a wafer as it is processed to provide an electrical contact on the upper surface of the device which extends to the handle layer of the device, while being isolated from the device layer and the cap layer, wherein etching of an oxide layer between the device layer and the cap layer has been constrained by nitride etch stop portions;
[0042] FIG. 39 depicts a side cross-sectional view of a MEMS device with a proof mass which may be fabricated using substantially the same process described with respect to FIGS. 26-38 , the device including two electrically isolated contacts in the device layer on opposite sides of the proof mass and optionally including an out-of-plane electrode;
[0043] FIG. 40 depicts a side cross-sectional view of a MEMS device with a proof mass which may be fabricated using substantially the same process described with respect to FIGS. 26-38 , with an optional out-of-plane electrode and two electrically isolated contacts in the device layer on opposite sides of the proof mass, wherein etching of a buried oxide layer between the device layer and the handle layer has been constrained by nitride etch stop portions; and
[0044] FIGS. 41-62 depict side cross-sectional views of a wafer as it is processed to form the device of FIG. 40 .
DESCRIPTION
[0045] For the purposes of promoting an understanding of the principles of the invention, reference will now be made to the embodiments illustrated in the drawings and described in the following written specification. It is understood that no limitation to the scope of the invention is thereby intended. It is further understood that the present invention includes any alterations and modifications to the illustrated embodiments and includes further applications of the principles of the invention as would normally occur to one skilled in the art to which this invention pertains.
[0046] FIG. 1 depicts a pressure sensor 100 including a handle layer 102 , a buried oxide layer 104 , and a device layer 106 . An oxide layer 108 separates the device layer 106 from a cap layer 110 . A passive layer 112 is located above the cap layer 110 .
[0047] Within the device layer 106 , an in-plane electrode 114 is defined by two etch portions 116 and 118 . The in-plane electrode 114 is isolated from the cap layer 110 by an etched portion 120 of the oxide layer 108 . The etched portions 116 , 118 , and 120 are etched through vent holes 122 which are closed by the cap layer 110 .
[0048] An out-of plane electrode 124 is located above the in-plane electrode 114 and electrically isolated from the in-plane electrode 114 by the etched portion 120 . The out-of-plane electrode 124 is isolated from the rest of the cap layer 110 by two spacers 126 and 128 . The spacers 126 and 128 include a lower nitride portion 130 which extends upwardly from the etched portion 120 , and an upper oxide portion 132 which extends from the nitride portion 130 to the upper surface of the cap layer 110 .
[0049] Spacers 134 and 136 , which are formed like the spacers 126 and 128 , electrically isolate a connector 138 in the cap layer 110 from the rest of the cap layer 110 . The connector 138 is in electrical communication with a connector 140 in the device layer 106 . The connector 140 is in electrical communication with the in-plane electrode 114 , as described more fully below, and isolated from the remainder of the device layer 106 by isolation posts 142 and 144 . The isolation posts 142 and 144 extend from the buried oxide layer 104 to the oxide layer 108 . A bond pad or trace 146 is located above the passive layer 112 and in electrical communication with the connector 138 .
[0050] A process for forming a sensor such as the pressure sensor 100 is discussed with reference to FIGS. 2-23 . Referring initially to FIGS. 2 and 3 , an SOI wafer 200 including a handle layer 202 , a buried oxide layer 204 , and a device layer 206 is initially etched to define an in-plane electrode 208 and a lower contact portion 210 for the in-plane-electrode 208 . A connector 212 is etched between the in-plane electrode 208 and the lower contact portion 210 . The in-plane electrode 208 is defined by a trench portion 214 , while the lower contact portion 210 is defined by a trench portion 216 and the connector 212 is defined by a trench portion 218 . If desired, the structural or handle layer 202 may be a pressure chemical vapor deposition (LPCVD) or epi-polysilicon layer.
[0051] The trench portions 214 , 216 , and 218 are then filled with a trench oxide portion 220 as shown in FIGS. 4 and 5 using a conformal oxide deposition. Oxide deposition further results in an oxide layer 222 on the upper surface of the device layer 206 . The thickness of the oxide layer 222 sets the gap between two electrodes as discussed more fully below. The oxide layer 222 may be planarized by any desired technique such as chemical mechanical polishing (CMP).
[0052] Referring to FIGS. 6 and 7 , a contact opening 224 is then etched through the oxide layer 222 to expose the upper surface of the lower contact portion 210 . An epi-poly deposition fills the contact opening 224 with a lower middle contact portion 226 of epi-poly while depositing a lower cap layer portion 228 above the oxide layer 222 as shown in FIGS. 8 and 9 . The lower middle contact portion 226 thus extends from the upper surface of the lower contact portion 210 to the upper surface of the lower cap layer portion 228 . In an alternative embodiment, the lower cap layer portion 228 may be a single crystal silicon formed using a fusion bonding process followed by grinding/polishing or SmartCut technology to remove the bulk of the bonded wafer. In this alternative embodiment, electrical contacts must be formed after fusion. In a further embodiment, a polished polysilicon device layer may be used.
[0053] FIGS. 8 and 9 further show trenches 230 and 232 which may be etched after CMP of the lower cap layer portion 228 . The trench 230 extends from the upper surface of the lower cap layer portion 228 to the upper surface of the oxide layer 222 to define the lower middle contact portion 226 . The trench 232 includes a trench portion 234 that defines a lower out-of-plane electrode portion 236 , a trench portion 238 that defines a connector 240 , and a trench portion 242 that defines a lower contact portion 244 for the lower out-of-plane electrode portion 236 .
[0054] A low stress nitride is then used to fill the trenches 230 and 232 with trench nitride portions 250 and 252 while a low stress nitride layer 254 is deposited on the upper surface of the lower cap layer portion 228 as shown in FIGS. 10 and 11 . A thin oxide layer 256 is provided on the upper surface of the low stress nitride layer 254 . The thin oxide layer 256 and the nitride layer 254 are then patterned and etched resulting in the configuration of FIGS. 12 and 13 . In FIGS. 12 and 13 , a remainder 258 of the oxide layer 256 and a remainder 260 of the nitride layer 254 form a gasket 262 for an out-of plane electrode described more fully below. A remainder 264 of the oxide layer 256 and a remainder 266 of the nitride layer 254 form a gasket 268 for a contact the in-plane-electrode 208 . The lateral extent of the gaskets 262 and 268 when viewed in cross-section may be selected to provide the desired isolation characteristics for the components defined thereby.
[0055] A thin epi-poly deposition layer 270 is then formed on the upper surface of the lower cap portion 228 and the upper surface of the gaskets 262 and 268 to form a middle cap layer portion 272 (see FIGS. 14 and 15 ). The epi-poly deposition layer may be deposited in the manner described by Candler et al., “Long-Term and Accelerated Life Testing of a Novel Single-Wafer Vacuum Encapsulation for MEMS Resonators”, Journal of Microelectricalmechanical Systems, vol. 15, no. 6, December 2006. The middle cap layer portion 272 may be planarized if desired.
[0056] Referring to FIGS. 16 and 17 , after vent holes 274 are formed, an HF vapor etch release is performed which releases the middle cap layer portion 272 from the in-plane-electrode 208 . The etched portion of the oxide layer 222 between the upper surface of the in-plane-electrode 208 and the lower surface of the middle cap layer portion 272 thus sets the gap between the in-plane-electrode 208 and the lower surface of what will be the out-of-plane electrode. A clean high temperature seal is then performed in an epi reactor to seal the vent holes 274 . Alternatively, the vent holes 274 may be sealed using oxide, nitride, silicon migration, etc. The resulting configuration is shown in FIGS. 18 and 19 wherein a layer portion 276 is formed above the middle cap layer portion 272 .
[0057] A trench 280 and a trench 282 are then etched as depicted in FIGS. 20 and 21 . The trench 280 extends from the upper surface of the layer portion 276 to the upper surface of the gasket 262 which acts as an etch stop. The trench 282 extends from the upper surface of the layer portion 276 to the upper surface of the gasket 268 which acts as an etch stop. A passivation layer 284 , which may be oxide, nitride, etc., is then deposited on the upper surface of the layer portion 276 as depicted in FIGS. 22-23 . The deposited passivation material also fills the trenches 280 and 282 with passivation portions 286 and 288 . The passivation portion 286 , the gasket 262 , and the trench nitride portion 250 thus form a spacer defining an out-of-plane electrode 290 .
[0058] The passivation layer 284 is then etched to create openings 292 and 294 . A metal layer may then be deposited on the passivation layer 284 , and etched to create bond pads or traces, resulting in a configuration such as the configuration of the pressure sensor 100 of FIG. 1 . If desired, piezoresistors may also be deposited on the passivation layer 284 .
[0059] The above described process may be modified in a number of ways to provide additional features. By way of example, FIG. 24 depicts a wafer 300 at about the same process step as the wafer 200 in FIG. 8 . The wafer 300 includes a handle layer 302 , a buried oxide layer 304 , a device layer 306 , an oxide layer 308 , and a lower middle cap layer portion 310 . FIG. 24 further depicts electrode isolation trenches 312 and 314 which are used to isolate an out-of plane electrode portion 316 from the remainder of the lower middle cap layer portion 310 . The wafer 300 further includes release stop trenches 318 and 320 . The trenches 318 and 320 are formed by etching through the oxide layer 308 after the trenches 312 and 314 are formed. The trenches 318 and 320 are used to provide a time-independent cap footprint.
[0060] By way of example, FIG. 25 depicts the wafer 300 after release of the lower middle cap layer portion 310 . In FIG. 25 , a silicon rich nitride has been deposited and etched to form release stop nitride portions 322 and 324 and electrode isolation nitride portions 326 and 328 . Additionally, vent holes 330 have been etched through the lower middle cap layer portion 310 and a portion of the oxide layer 308 has been etched. The foregoing steps are accomplished substantially in the same manner as similar steps described above with respect to FIGS. 10-17 .
[0061] The primary difference between the wafer 200 and the wafer 300 , however, is that the release stop nitride portions 322 and 324 formed in the oxide layer 308 function as an etch stop. Accordingly, once the etch of the oxide layer 308 reaches the release stop nitride portions 322 and 324 , no further etching of the oxide layer 308 occurs, even as the buried oxide layer 304 continues to be etched. Thus, while in the wafer 200 the area of the oxide layer 222 which is etched to release the lower cap layer portion 228 from the device layer 206 is a function of the positioning of the vent holes 274 (see FIGS. 16-17 ) and a relatively uncontrolled etching process, the wafer 300 includes release stop nitride portions 322 and 324 which provide a precise footprint for the released portion of the lower middle cap layer portion 310 .
[0062] A further modification of the process described with reference to FIGS. 2-23 is depicted in FIGS. 26-37 . FIG. 26 depicts a wafer 350 at about the same process step as the wafer 200 in FIG. 6 . The wafer 350 includes a handle layer 352 , a buried oxide layer 354 , a device layer 356 , and an oxide layer 358 . The wafer 300 is modified to provide a substrate electrical contact, however, by etching a trench 360 completely through the oxide layer 358 , the device layer 356 , and the buried oxide layer 354 . Then, formation of a lower cap layer portion 362 (see FIG. 27 ) further forms an epi-poly contact portion 364 which extends to the handle layer 352 . CMP may be performed on the lower cap layer portion 362 .
[0063] As depicted in FIG. 28 , release stop trenches 366 and 368 are then etched through the lower cap layer portion 362 and the oxide layer 358 followed by etching of electrode isolation trenches 370 and 372 and contact isolation trenches 374 and 376 (see FIG. 29 ). The isolation trenches 370 , 372 , 374 , and 376 extend only through the lower cap layer portion 362 .
[0064] A low stress nitride is then used to fill the trenches 366 , 368 , 370 , 372 , 374 , and 376 with release stop nitride portions 378 and 380 , electrode isolation nitride portions 382 and 384 , and contact isolation portions 386 and 388 while a low stress nitride layer 390 is deposited on the upper surface of the lower cap layer portion 362 as shown in FIG. 30 . A thin oxide layer 392 is provided on the upper surface of the low stress nitride layer 390 ( FIG. 31 ). The thin oxide layer 392 and the nitride layer 390 are then patterned and etched resulting in the configuration of FIG. 32 . FIG. 32 shows an electrode gasket 394 , a contact gasket 396 , and an etch stop gasket 398 .
[0065] A thin epi-poly deposition layer 410 is then formed on the upper surface of the lower cap portion 362 and the upper surface of the gaskets 394 , 396 , and 398 to form a middle cap layer portion 412 . The middle cap layer portion 412 may be planarized if desired.
[0066] Referring to FIG. 34 , after vent holes 414 are formed, an HF vapor etch release is performed which releases the middle cap layer portion 412 from the in-plane-electrode 416 . The etched portion of the oxide layer 358 between the upper surface of the in-plane-electrode 416 and the lower surface of the middle cap layer portion 412 is constrained by the release stop nitride portions 378 and 380 . A clean high temperature seal is then performed in an epi reactor to seal the vent holes 414 . The resulting configuration is shown in FIG. 35 wherein a layer portion 418 is formed above the middle cap layer portion 412 .
[0067] A trench 420 and a trench 422 are then etched as depicted in FIG. 36 . The trench 420 extends from the upper surface of the layer portion 418 to the upper surface of the gasket 394 which acts as an etch stop. The trench 422 extends from the upper surface of the layer portion 418 to the upper surface of the gasket 396 which acts as an etch stop. A passivation layer 424 , which may be oxide, nitride, etc., is then deposited on the upper surface of the layer portion 418 as depicted in FIG. 37 . The passivation layer 418 is etched to create an out-of-plane electrode opening (not shown) and an opening 426 . A metal layer may then be deposited on the passivation layer 424 , and etched to create a bond pad or trace 428 , as shown in FIG. 38 . In FIG. 38 , the bond pad 428 is in electrical communication with the handle layer 352 through an epi column 430 .
[0068] The various processes described above allow for a variety of devices to be made simultaneously on the same substrate. By way of example, FIG. 39 depicts a sensor device 450 that includes a handle layer 452 , a buried oxide layer 454 , a device layer 456 , an oxide layer 458 , a cap layer 460 , and a passivation layer 462 . The sensor device 450 further includes an electrode isolation portion 464 , contact isolation portions 466 , and release or etch stop nitride portions 468 . Thus, the same sequence described above may be used to form the sensor device 450
[0069] The sensor device 450 , although made using the same process as, for example, the pressure sensor 100 of FIG. 1 , is different from the embodiments described above. For example, the device 450 includes two pads 470 and 472 which provide for electrical communication with the device layer 456 . Thus, in-plane movement of a proof mass 474 may be detected. An optional third pad 476 may be provided if an out-of-plane electrode 478 is desired. Another difference in the sensor device 450 is that the electrode isolation nitride portions 464 include an extended apron 480 .
[0070] By adding an interim step to the foregoing process, the accelerometer 490 of FIG. 40 may be simultaneously fabricated along with the above described devices. The accelerometer 490 differs from the sensor device 450 of FIG. 39 in that a release or etch stop nitride portion 492 is included to more precisely control the amount of etching within a buried oxide layer 494 .
[0071] A process for forming a sensor such as the accelerometer 490 is discussed with reference to FIGS. 41-62 . Referring initially to FIG. 41 , an SOI wafer 500 including a handle layer 502 , a buried oxide layer 504 , and a device layer 506 is initially covered with an oxide layer 508 . Next, a photoresist layer 510 is provided on the upper surface of the oxide layer 508 ( FIG. 42 ). The wafer 500 is then etched to form etch stop trenches 512 through the photoresist layer 510 , the oxide layer 508 , and the device layer 506 . As shown in FIG. 43 , the trenches 512 are then extended through the buried oxide layer 504 to the upper surface of the handle layer 502 . A plasma containing oxygen may be used to oxidize (“ash”) the photoresist layer 510 .
[0072] As shown in FIG. 44 , a nitride layer 514 is then deposited on the upper surface of the oxide layer 508 . Nitride deposition further results in filling the trenches 512 with nitride etch stop columns 516 . The nitride layer 514 is then etched using the oxide layer 508 as an etch stop resulting in the configuration of FIG. 45 , followed by etching of the oxide layer 508 using the silicon device layer 506 as an etch stop resulting in the configuration of FIG. 46 .
[0073] Next, as shown in FIG. 47 , structure defining trenches 518 are etched through the device layer 506 . The trenches 518 define device layer contact portions 520 and 522 along with a proof mass 524 . Sacrificial etch holes 526 are etched into the proof mass 524 as shown in FIG. 48 . Referring to FIG. 49 , a conformal oxide layer 530 is then deposited on the upper surface of the device layer 506 . The deposition of conformal oxide also fills the trenches 518 and the etch holes 526 . Openings 532 and 534 (see FIG. 50 ) are then etched through the oxide layer 530 to expose the device layer contact portions 520 and 522 .
[0074] An epi-poly deposition fills the contact openings 532 and 534 with lower middle contact portions 536 and 538 of epi-poly while depositing a lower cap layer portion 540 above the oxide layer 530 as shown in FIG. 51 . CMP may be performed on the lower cap layer portion 540 . Next, as shown in FIG. 52 , etch stop trenches 542 are formed through the lower cap layer portion 540 and the oxide layer 530 . If desired, out-of-plane electrode trenches 544 may be formed through the lower cap layer portion 540 (see FIG. 53 ).
[0075] A low stress nitride is then used to fill the trenches 542 and 544 with trench nitride portions 546 and 548 while a low stress nitride layer 550 is deposited on the upper surface of the lower cap layer portion 540 as shown in FIG. 54 . The nitride portions 546 form an etch stop for a later etch. A thin oxide layer 552 is provided on the upper surface of the low stress nitride layer 550 . The thin oxide layer 552 , which will be used as an etch stop, and the nitride layer 550 are then patterned and etched resulting in the gasket 554 of FIG. 56 .
[0076] A thin epi-poly deposition layer 560 is then formed on the upper surface of the lower cap portion 540 and the upper surface of the gasket 554 to form a middle cap layer portion 562 (see FIG. 57 ). The middle cap layer portion 562 may be planarized if desired.
[0077] Referring to FIGS. 58 and 59 , after vent holes 564 are formed, an HF vapor etch release is performed which releases the middle cap layer portion 562 from the proof mass 524 . Horizontal etching of the oxide layer 530 is limited by the etch stop nitride portions 546 . The sacrificial etch holes 526 allow the etch to release the proof mass 524 from the handle layer 502 by etching the buried oxide layer 504 . Horizontal etching of the buried oxide layer 534 is limited by the etch stop nitride columns 516 .
[0078] A clean high temperature seal is then performed in an epi reactor to seal the vent holes 564 . The resulting configuration is shown in FIG. 60 wherein a layer portion 566 is formed above the middle cap layer portion 562 .
[0079] Trenches 568 and trenches 570 are then etched as depicted in FIG. 61 . The trenches 570 extend from the upper surface of the layer portion 566 to the upper surface of the gasket 554 , the oxide layer portion of which acts as an etch stop. The trenches 568 extend from the upper surface of the layer portion 566 to the upper surface of the oxide layer 530 which acts as an etch stop. A passivation layer 572 , which may be oxide, nitride, etc., is then deposited on the upper surface of the layer portion 566 as depicted in FIG. 62 . The passivation layer 572 is etched to create openings 574 and 576 , and optionally 578 . A metal layer may then be deposited on the passivation layer 572 , and etched to create bond pads or traces, resulting in a configuration such as the configuration of the accelerometer 490 of FIG. 40 .
[0080] The above described procedure and variations thereof allow for resonators, inertial sensors, and other such devices to be packaged at the wafer level while incorporating an electrically isolated, out-of-plane electrode into a thin-film cap. Other sensors which may be fabricated in accordance with principles discussed above include silicon cap pressure sensors.
[0081] While the invention has been illustrated and described in detail in the drawings and foregoing description, the same should be considered as illustrative and not restrictive in character. It is understood that only the preferred embodiments have been presented and that all changes, modifications and further applications that come within the spirit of the invention are desired to be protected.
|
In one embodiment, a method of forming an out-of-plane electrode includes providing an oxide layer above an upper surface of a device layer, providing a first cap layer portion above an upper surface of the oxide layer, etching a first electrode perimeter defining trench extending through the first cap layer portion and stopping at the oxide layer, depositing a first material portion within the first electrode perimeter defining trench, depositing a second cap layer portion above the first material portion, vapor releasing a portion of the oxide layer, depositing a third cap layer portion above the second cap layer portion, etching a second electrode perimeter defining trench extending through the second cap layer portion and the third cap layer portion, and depositing a second material portion within the second electrode perimeter defining trench, such that a spacer including the first material portion and the second material portion define out-of-plane electrode.
| 1
|
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] The present application claims priority to U.S. Provisional Patent No. 60/657,678, filed Mar. 1, 2005, the entire contents of which are specifically incorporated herein by reference.
BACKGROUND
[0002] There are a variety of thermoplastic articles that benefit from fire-resisting properties. One method of imparting fire-resisting properties to a plastic is inclusion within the plastic of a fire-retardant component. However, inclusion of such fire retardants, even in minimally effective amounts, often carries adverse side effects. More specifically, such fire retardants can decrease mechanical properties and moldability, increase weight and cost, and be environmentally undesirable.
[0003] Fire resistant coatings may also be used, however such coatings are subject to wear and degradation. Once the coating layer is penetrated, particularly with objects having large relative mass, there is little effect.
[0004] Plastic pallets are an example of plastic articles, which might incorporate fire-retardant components therein. An important criterion for all pallet uses is that the pallet has adequate fire resisting properties. Indeed, all pallets must pass tests that determine how fast and with what heat evolution pallets burn in a simulated warehouse fire. These same pallets must also pass durability and impact tests.
[0005] Plastic pallets have not gained wide acceptance due in large measure to the failure to satisfactorily meet fire resistance criteria, while additionally meeting the structural and durability standards of Grocery Manufacturers of America (GMA). Pallets should have fire resistance sufficient to not exceed the heat release set by Underwriters Lab Standard 3435. In a test under the standard, pallets are subjected to a fire in a test facility, to simulate a warehouse fire. Any fire resisting pallet also must be strong enough to carry specified loads, must not be too heavy, and must be durable in resisting damage during use, as measured by certain tests and field use.
[0006] Because the heat and rate of combustion of the typical polyethylene or polypropylene pallet material are inherently high compared to wood and many other materials, it is, in one sense, desirable to include fire retardant components within the plastics of the pallet. However, while inclusion of fire retardants in plastic pallets may increase the chances of passing fire resistance tests, such inclusion at the same time generally decreases the chances of passing durability and impact tests.
[0007] One partial solution is to construct the deck of a pallet can from metal, while constructing the rest of the pallet as plastic. That has the effect of reducing the amount of plastic in the pallet and the favorably improving the burn test characteristics, and reducing the gross amount of fire retardant in the pallet. However, it may not always be desirable to have a metal deck on a pallet.
[0008] What is needed is a thermoplastic article that is satisfactorily fire resistant, and that is also satisfactorily impact resistant or durable.
SUMMARY
[0009] The above described and other disadvantages of the prior art are overcome or alleviated by the presently disclosed thermoplastic article, comprising plastic parts that having differing fire resistances. In one embodiment, with regard to the rate of heat evolution is concerned compared to the total heat evolution, those portions of a plastic pallet having a higher surface area or those portions of the pallet that are more exposed have higher heat resistances relative to those portions having lower surface areas or those portions that are less exposed.
[0010] In another exemplary embodiment, a pallet's thermoplastic material has different fire retardant content (composition) is tailored according to the portion of the pallet that the material forms. In one such embodiment, thinner and higher surface area to volume ratio sections have higher fire retardant content than do other sections. In another such embodiment, the edges of the top deck of the pallet, or like areas of some other article that are prone to impact damage, have lower fraction of retardant than those portions not prone to impact damage. In another embodiment, the deck of a pallet has higher fire retardant content than the columns upon which the deck is mounted. In another embodiment, part of, or all of, the periphery of the deck has less retardant or no retardant, compared to the interior of the deck which has fire retardant.
[0011] In another exemplary embodiment, a pallet's differing components include a fire resistant coating or layer on portions having a higher surface area or on portions that are more exposed. In one such embodiment, the deck is formed of two or more layers of material that are joined together, wherein the deck comprises a top layer having less fire retardant than a bottom layer.
[0012] The above-described and other features will be appreciated and understood by those skilled in the art from the following detailed description, drawings and appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] Referring now to the accompanying FIGURES, which are meant to be exemplary and not limiting:
[0014] FIG. 1 is a cross sectional view of an exemplary pallet;
[0015] FIG. 2 is a cross sectional view of an exemplary pallet column;
[0016] FIG. 3 is a cross sectional view of an exemplary pallet column and deck;
[0017] FIG. 4 is a cross sectional view of an exemplary pallet corner;
[0018] FIG. 5 is a cross sectional view of an exemplary pallet deck; and
[0019] FIG. 6 is a cross sectional view of an exemplary pallet component mold.
DETAILED DESCRIPTION
[0020] The present disclosure relates to articles comprising thermoplastics, such as high density polyethylene (HDPE) or polypropylene, among others. Components of such articles, e.g., pallets, may be constructed according to any convenient method, for example by injection molding.
[0021] Solid particulate fire retardants may also be included in the thermoplastic compositions, for example Grafguard graphite intumescent material, aluminum trihydrate, magnesium hydroxide or antimony trioxide (often used with bromine compounds), among others. The solid fire retardants may be used in combination with other types of fire retardants, for instance, brominated hydrocarbons. It will be appreciated that the invention may be applied to the inclusion of other ingredients, solid particulate or not, in a pallet and to other articles.
[0022] The present invention recognizes that addition of fire retardants in quantities sufficient to impart minimal to good fire resistance, which in one embodiment, and depending on the material, ranges from 10 to 30 weight percent retardant, correspondingly decreases the fracture toughness of that article. In the example of plastic pallets, the pallet becomes too prone to breakage, particularly around the edges of the pallet where the shanks of the tines of a forklift truck may impact the pallet. Accordingly, an improved article is described, wherein fire resistance of the article is selectively tailored with regard to the geometry and/or position of a component of the article.
[0023] Referring now to FIGS. 1-4 , partial vertical cross sections of portions of exemplary thermoplastic pallets are illustrated. Referring to FIG. 1 , exemplary pallet 20 comprises a deck 22 , which is welded to the columns 26 of base 24 . In this exemplary embodiment, the deck includes a plurality of holes (the deck may take other configurations, e.g., solid or grid-like, among others). The columns 26 , which have hollows at their top ends, are interconnected by rails 30 . Hollow square cross section metal beams 28 are within the rails. In one exemplary embodiment, deck 22 of pallet 20 has a higher concentration of retardant relative to the frame 24 . As an example, HDPE deck has 10% intumescent composition, and the frame has 5%. (All concentrations are by weight unless otherwise indicated.)
[0024] Referring now to FIG. 2 , a portion of exemplary pallet 22 A is illustrated, wherein beam 28 is covered by a floor plate 29 . In an exemplary embodiment, the plate 29 is configured to incorporate of the beam 28 within the base and comprises no or low fire retardant relative to other portions of the pallet. In such embodiment, the beam 28 is strategically engineered to fail in the event of a fire. This is due to the lack of significant fire retardant in the plate 29 . At an early stage in a fire, the beam 28 will be subjected to heat and will fail according to engineered design.
[0025] Referring now to FIG. 3 , an exemplary pallet 20 B is illustrated, wherein such pallet lacks base rails. An exemplary deck is a two-layer composite structure, which may be made for example by co-extrusion, by joining one sheet to another, or by injection molding, among other methods. In one embodiment, the underside layer 27 comprises a first composition with a large amount of fire retardant relative to the top layer 25 . Such exemplary configuration provides durability for the top of the deck, but at the same time provides fire protection to the pallet (oftentimes flames will rise up from below, and the lower deck layer provides a lower barrier relative to heat sources from above as well). Other layers may also be interposed between the top and bottom layers, for other properties or fire resistance. The layers may also be contoured to create cavities therebetween, and the cavities may be filled with foam, such as urethane.
[0026] Referring now to FIG. 4 , opposing edges of an exemplary pallet 20 D is illustrated, wherein deck 22 D has an inner portion comprising a first material having fire retardant (and thus diminished impact or other properties) and an integral edge portion 42 with less fire retardant and better impact properties. In another exemplary embodiment, the edge portion that has minimal or no fire retardant at least spans the openings that are between columns 26 D, through which forks enter the space under the pallet for transport.
[0027] Referring not to FIG. 5 , a top view of exemplary pallet 20 C is illustrated, wherein deck 22 C has a central area 34 with higher retardant content than a periphery portion 32 . The dashed boundary line 33 is one exemplary indication of where the composition changes. Depending on the manufacturing technique that is used, and the objective, the demarcation of composition change may be definite or gradual. While the periphery of the deck may be thin and thus should have fire retardant in accord with another teaching herein, the volume of plastic, which has the inferior fire retardant, is a small fraction of the total pallet. Thus, while burn test performance might be somewhat reduced the performance can still be acceptable, and the “give up” is well traded against durability and strength, in considering the total pallet design.
[0028] Referring now to FIG. 6 , a simplified cross section view of an exemplary mold for a pallet other dual property object is illustrated. The exemplary cavity parts 26 CC, 32 CC and 34 CC are illustrated as corresponding to numeral parts of exemplary pallet 20 C. The mold comprises two mating parts 36 , 38 . When installed in a molding machine, injection mold nozzles feed molten plastic through ports 54 , 56 . Two different material compositions, one with high retardant content, the other with low or no retardant content are provided by two different sets of nozzles, fed by appropriate injection extruders and supplies. The low content material is injected in the ports 54 while the high content material is injected in the ports 56 . In another exemplary manufacturing alternative, with reference to FIG. 5 , the deck parts 34 , 32 may be separately fabricated and then joined together, as by welding.
[0029] While exemplary embodiments have been shown and described, various modifications and substitutions may be made thereto without departing from the spirit and scope of the invention. It is to be understood that the present invention has been described by way of illustration and not limitation.
|
The parts of a pallet or other article have different tailored thermoplastic composition to provide fire resistance according to the shape, location and function of the part in the pallet. In one embodiment, the high surface area to volume deck has high fire retardant content, whereas the heavier portions of the pallet, such as the base and columns have lower content. In another embodiment, the periphery of the deck that is prone to impact damage has low retardant content, compared to the rest of the deck and or the rest of the pallet.
| 1
|
FIELD OF THE INVENTION
The present invention is directed to a cylinder for a folding apparatus. The cylinder uses rollers which run on at least one base cam disk. The cam disk is fixed in place and has troughs. The rollers are supported by levers and are used to switch cylinder fittings.
BACKGROUND OF THE INVENTION
A collecting cylinder is disclosed in EP 0 436 102 A1. This cylinder has a basic cam, fixed in place on the lateral frame, for use in the control of the cylinder fittings. In place of pivotable cover disks, the cylinder has electro-magnetically actuable blocking bolts.
SUMMARY OF THE INVENTION
The object of the present invention is directed to providing a cylinder for a folding apparatus.
In accordance with the present invention, this object is attained by the provision of a cylinder that uses rollers which run on at least one base cam disk, which is fixed in place. The cam disk has troughs which the rollers, that are carried on levers, follow to switch cylinder fittings. An auxiliary cam path for the rollers, and which covers the troughs in the base cam disk, can be formed by the use of a switching element. This switching element selectively blocks or unblocks each roller lever. The switching element is arranged on the rotating cylinder. The roller lever can be blocked or unblocked by a rotary movement of the switching element. The switching element can be driven by a drive motor.
The advantages to be gained by the present invention rest, in particular, in that the switching element now employed in accordance with the present invention, allows short switching times, for example of approximately {fraction (1/300)} seconds. Because of this, the exact and accurate switching of the cylinder fittings can take place, even at large circumferential speeds of the cylinder. The arrangement of a step motor in particular, together with very short switching paths generated by rotation, and the movement of small masses, is advantageous. Limitations of the switching times, of switching delays, which are difficult to calculate, as well as of inexact switching paths, which can occur, for example, because of hysteresis properties of magnetic switching devices, or the compressibility of pressure media, are prevented.
For example, it is possible, by the use of a collecting cylinder which is equipped with the switching element of the present invention, to accomplish single or up to triple collections, and to set, or change, these different collecting rhythms very rapidly and without elaborate technical outlay.
The cylinder for a folder unit, in accordance with the present invention, can be applied in connection with all fittings switchable on cylinders, such as grippers, point spurs, as well as with folding jaws.
BRIEF DESCRIPTION OF THE DRAWINGS
A preferred embodiment of the present invention is represented in the drawings and will be explained in greater detail in what follows. Shown are in:
FIG. 1 , a longitudinal cross-sectional through a cylinder in accordance with the present invention and taken along section line I—I in FIG. 2 , in
FIG. 2 , a cross section through the cylinder of FIG. 1 and taken along section line II—II in FIG. 1 , in
FIG. 3 , a schematic representation of a drive motor with a switching element and a switching lever, and in
FIG. 4 , a schematic representation of a variation of a drive motor with a switching element and a switching lever.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring initially to FIG. 1 , there may be seen generally at 01 a cylinder for a folder unit in accordance with the present invention. Cylinder 01 , which may be, for example, a five-part collecting cylinder 01 of a web-fed rotary printing press consists, for example, of two, or possibly more, spaced lateral disks 02 , 03 arranged on a shaft 04 and separated from each other by cross pieces 06 , if required. The cylinder 01 has a plurality of diverse cylinder fittings 07 , 08 , 09 , 10 , 11 , 13 , 14 , 15 , 16 , 17 on its circumference. These can include, for example, five gripper systems 07 , 08 , 09 , 10 , 11 , which are spaced apart from each other and between each of which is located a folding blade system 13 , 14 , 15 , 16 , 17 , respectively. These cylinder fittings are only suggested or symbolically represented, and are arranged as depicted in FIG. 2 .
Each one of the gripper systems 07 to 11 has a support spindle 19 , which is rotatably seated between the lateral disks 02 , 03 , with grippers 21 arranged, and fixed against relative rotation, on the support spindle 19 and spaced apart over the cylinder width, which grippers 21 can be moved against a gripper rest, which is not specifically represented in FIGS. 1 and 2 .
On one end, the support spindle 19 has secured thereto a first end of a roller lever 22 . The roller lever 22 receives a roller 23 on its second end, as seen in FIGS. 1 and 2 .
The collecting cylinder 01 is seated in lateral frames 28 , 29 of a folder unit, which is not specifically shown by use of shaft journals 24 , 26 of shaft 04 and by the provision of various bearings 27 , for example rolling bearings 27 . The left shaft journal 24 , as seen in FIG. 1 , is connected with a gear wheel 31 , for example a drive gear wheel 31 .
A bushing 32 , which is fixed in place in the lateral frame 28 , and which receives the left rolling bearing 27 , as well as the shaft journal 24 located within the left rolling bearing 27 , is arranged on the driven side of the cylinder 01 , i.e. in the left lateral frame 28 . This bushing 22 supports at least one base cam disk 33 , which is arranged parallel with respect to the lateral frame and between the lateral frame 28 and the lateral disk 02 , and on whose cam disk periphery 34 the cam rollers 23 of the gripper systems 07 to 11 roll off.
On its periphery 34 , the base cam disk 33 has various troughs 36 , 37 , for example a receiving trough 36 , as well as a delivery trough 37 . These troughs 36 , 37 are seen most clearly in FIG. 2 .
Adjacent the end of its respective support spindle 19 , and inboard of the left lateral disk 02 , each one of the cylinder fittings 07 to 11 , i.e. each one of the gripper systems 07 to 11 , has a switching lever 38 , which is fixed on the support spindle and which extends approximately in the radial direction with respect to the shaft 04 . The switching lever 38 is located in, and can extend in the interior of the cylinder in the vicinity of the lateral disk 02 , as seen in FIG. 1. A free end of the switching lever 38 can enter into a connection with a cam-like or propeller-shaped switching element 39 , which is rotatable around an axis of rotation A by operation of a drive motor 41 which is fixed in place on the left disk 02 , all as seen in FIGS. 1 , 2 and 3 . In an advantageous embodiment, the switching element 39 is connected, fixed against relative rotation, with a motor shaft of the drive motor 41 . The drive motor 41 is preferably configured as a step motor 41 . The switching element 39 is configured as either a one-armed lever or as a double-armed lever 39 , for example, wherein a free end of the lever 39 can be used as a stop for the free end of the switching lever 38 and can block it as depicted in FIGS. 3 and 4 .
Each one of the drive motors 41 assigned to the individual gripper systems 07 to 11 is connected by lines 42 , 43 with an electrical control unit 44 which is located, for example, on the exterior of the right lateral disk 03 , as seen in FIG. 1 . This control unit 44 is connected by a line 46 extending over, or through the right shaft journal 26 , with a collector ring body 47 , which is located on the shaft journal 47 and which is enclosed in a housing 30 . The output lines 48 of the collector rings lead to a central control device, which is not specifically represented.
It is, of course, also possible to arrange a rotatable transmitter unit, that is also not represented, in place of the collector ring body 47 , and to transmit the control signals in a contactless manner via a stator, also not represented, to the central control device, and to receive fresh control signals from the latter.
It is furthermore possible to arrange a second base cam disk 49 , for use with the folding blade systems 13 to 17 on the bushing 32 , and thus fixed in place on the lateral frame. Parts of these folding blade systems 13 to 17 are rollers and roller levers, which are similar to the ones discussed in connection with the gripper systems 07 to 11 , and which are not represented. As in connection with the gripper systems 07 to 11 , switching levers, switching elements, as well as step motors, not specifically represented, are also provided for the folding blade systems 13 to 17 . The embodiment of the lateral disks 02 , 03 as multi-piece lateral disks 02 , 03 is advantageous, wherein the folding blade systems 13 to 17 and the gripper systems 07 to 11 are each supported by separate pairs of lateral disks and thus can be rotated in respect to each other.
In this multiple disk pair embodiment, which is not specifically shown, the shaft journal 24 is advantageously embodied as a hollow shaft and is connected, for example, with the lateral disk 02 for the support spindle 19 of the gripper systems 07 to 11 . For example, a second shaft journal, which is not represented, of the lateral disk, also not represented, of the folding blade systems 13 to 17 is arranged inside the shaft journal 24 which is embodied as a hollow shaft.
The systems of the cylinder 01 for a folder unit in accordance with the present invention operate as follows:
In response to the control signals received via the control unit 44 , the drive motors 41 are each actuated by the rotation of their motor shafts in such a way that the free end of the propeller-shaped switching element 39 is brought into a tangential position with respect to the cylinder cross section, as depicted with the gripper system 07 , or into a radial position with respect to the cylinder cross section, as depicted with the gripper system 09 . The gripper system 08 shows the switching element 39 within a switching angle α of rotation of the cylinder 01 , while the gripper system 09 shows the switching element 39 in a resting phase within an angle β of rotation of the cylinder 01 . At high numbers of revolutions of the collecting cylinder 01 , along with high circumferential speeds, the switching element 39 must arrive in its new position within the switching angle α of rotation of the cylinder 01 very quickly, in particular within a time of less than {fraction (1/300)} second, and dependably.
In the tangential position of the switching element 39 , the switching lever 38 of the support spindle 19 is blocked. In this configuration the rollers 23 cannot dip into the trough 36 . An auxiliary cam track 51 is thereby created, which auxiliary cam track 51 prevents the opening of the gripper systems 07 to 11 when the rollers 23 pass through.
In the radial position of the switching element 39 , as seen in the gripper system 09 , the roller 23 passes through the delivery trough 37 and the grippers 21 will now open. In the tangential position of this switching element 39 , an auxiliary cam track 52 would be created for the rollers 23 , and the delivery of imprinted products would be prevented. The axis of rotation A of the switching element 39 which, in the embodiment depicted in FIG. 3 , is congruent with the motor shaft of the drive motor 41 , extends axis-parallel with respect to the support spindle 19 .
The same operating sequence is also applicable in connection with the folding blade systems 13 to 17 , which are not represented in detail.
In accordance with a second preferred embodiment, as depicted in FIG. 4 , it is also possible for a free end of the rotatable lever 39 of the switching element to have a cam 53 , which cam extends almost at right angles to the switching element 39 and axis-parallel with the axis of rotation A of the switching element 39 , or the motor shaft, and which cam 53 , in a blocking position, is rotated underneath the free end of the switching lever 38 and blocks it, so that the support spindle 19 is also not rotatable.
In this second embodiment, the motor shaft of the drive motor 41 extends in a secant-like direction with respect to the cylinder cross section in accordance with FIG. 2 .
It is moreover also possible to employ lifting magnets, which are not specifically represented, for switching the systems, for example for opening and closing the gripper systems 07 to 11 , in place of the previously mentioned drive motors 41 .
The switching lever 38 can also be brought into two different positions by the different placement of the lifting drive.
The generation of the auxiliary cam tracks 51 , 52 can be employed in the same or in a similar manner use with cylinders intended for cutting or folding.
While preferred embodiments of a cylinder for a folder unit, in accordance with the present invention have been set forth fully and completely hereinabove, it will be apparent to one of skill in the art that various changes in, for example the overall size of the cylinder, the number of cylinder fittings on the cylinder, and the like could be made without departing from the true spirit and scope of the present invention which is accordingly to be limited only by the following claims.
|
A collecting cylinder for a folder unit is provided with at least one disk cam that has peripheral switching depressions. These switching depressions can be covered by using an auxiliary curved trajectory which is created by a pivoting drive. Switching levers are selectively blocked or unblocked by motor-driven rotatable switching parts.
| 1
|
BACKGROUND OF THE INVENTION
The field of the present invention is wrenches, especially adjustable and locking wrenches.
The field of wrenches is old, and very crowded with a myriad of types suited for various tasks. A few of these are discussed here in relation to the current invention.
In U.S. Pat. No. 7,275,464, which issued on Oct. 2, 2007, inventors Chervenak et al describe a ratchetable wrench comprising a pliable handle, wherein the handle is rotated to lock the jaws of the wrench.
Inventor William O'Brien reveals a parallel, slidable and lockable jaw wrench in U.S. Pat. No. 5,644,960, which issued on Jul. 8, 1997. This wrench includes ball bearings disposed within a channel.
On Jul. 30, 1996, U.S. Pat. No. 5,540,125 issued to inventor Arthur Haskell. This patent illustrates an adjustable wrench having selectable locking positions. This wrench also comprises ball bearings.
U.S. Pat. No. 5,154,103 issued to inventor Barney Lewis, jr., on Oct. 13, 1992. This patent has a subject a lock, slidably mounted on a crescent wrench.
In U.S. Pat. No. 4,380,941, which issued on Apr. 26, 1983, inventor Hyrum Petersen reveals a detachable and adjustable pipe wrench.
Finally, inventor John Penner describes a lockable crescent wrench in U.S. Pat. No. 4,344,339, which issued on Aug. 17, 1982.
SUMMARY OF THE INVENTION
The invention is drawn to a locking crescent wrench that is capable of free range motion and incremental, staged motion of the jaws. It is also capable of locking in place at any desired position within its range of motion.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective representation of the head of a wrench in a cutaway view and elements there of in accordance with a preferred embodiment of the present invention.
FIG. 2 is an exploded view of the indexing components, in accordance with a preferred embodiment of the present invention.
FIG. 3 is another exploded view of the indexing components, showing the adjusting screw in a cutaway view in accordance with a preferred embodiment of the present invention.
FIG. 4 is a perspective representation of a preferred embodiment of the wrench of the current invention, in the assembled position and cutaway view showing the components of the assembly.
FIG. 5 is an enlarged representation of the position of the shaft, in the free mode in accordance with a preferred embodiment of the present invention.
FIG. 6 is an enlarged representation of the position of the shaft in the indexing mode in accordance with a preferred embodiment of the present invention.
FIG. 7 is an enlarged representation of the position of the shaft, in the locking mode in accordance with a preferred embodiment of the present invention.
The drawings constitute a part of this specification and include exemplary embodiments to the invention, which may be embodied in various forms. It is to be understood that in some instances various aspects of the invention may be shown exaggerated or enlarged to facilitate an understanding of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Detailed descriptions of the preferred embodiment are provided herein. It is to be understood, however, that the present invention may be embodied in various forms. Therefore, specific details disclosed herein are not to be interpreted as limiting, but rather as a basis for the claims and as representative basis for teaching one skilled in the art to employ the present invention in virtually any appropriately detailed system, structure or manner.
A Wrench 100 in accordance with a preferred embodiment of the present invention is portrayed in FIG. 1 . Wrench frame 200 including a solid fixed jaw 210 , the adjusting screw 300 which controls the movement of a moveable jaw 220 to open and close the jaws, a track and recessed area 230 , and a shifting track or slot 240 for adjustment of a slide button 400 to select the position desired for the moveable jaw. Recessed area 230 forms a housing area for shifting track 240 . A centerline CL 1 runs through an elongated handle 110 of the wrench 100 .
Slide button 400 in FIG. 1 is a round or elongated button, recessed into the main body via recessed area 230 for accuracy in shifting, protection from damage, and exclusion of foreign material from entering the shifting slot 240 in the main body 200 .
As portrayed in FIG. 2 , slide button 400 has a horizontal shaft 410 for extending thru the wrench frame 200 , and thru the hole 540 in the vertical shaft 500 , thereby restricting the vertical shaft 500 from turning in the wrench frame 200 . The shaft 410 is secured on the opposite side of the wrench frame 200 by a removable button 430 . In a preferred embodiment, adjustments can be made to the assembled main body 200 making both slide button 400 and removable button 430 either left or right handed. An indexing ring 330 is pressed downward by spring 600 engaging indexing upper teeth 360 on the indexing ring 330 with lower indexing teeth 640 on the adjusting screw 300 , and a centerline CL 2 runs though the center of the adjusting screw 500 .
Slide button 400 is utilized to shift the position of the shaft 500 to any of 3 available positions: free, indexing, and locking. The slide button 400 is attached to, on center, and perpendicular to the shaft 500 .
A C Ring 650 found in FIG. 2 works in relationship to the shaft area 520 , an element of shaft 500 , at the opposite end of the adjustment screw 300 . The adjusting screw 300 is pulled forward compressing the spring 600 , and locating the adjusting screw 300 against the main body 200 . The C ring 650 is pushed on the shaft diameter 520 and the adjusting screw 300 is then allowed to return to its original position, locating the C ring into the recessed area 625 . Ring grooves 530 , 531 and 532 locate and secure the shaft 500 in the desired position, as noted in FIG. 3 , and later Figures.
The spring 600 shown in FIG. 3 resides over the hexagonal shaft 500 applying pressure to the indexing ring 330 maintaining contact between the angular indexing configuration of the face of the indexing ring 330 and the angular indexing configuration on the face of the adjusting screw 300 , as shown in FIG. 1 and FIG. 2 . The spring pressure on the indexing ring 330 biases the adjusting screw 300 into angular alignment with the indexing ring 330 . The spring clip 650 works in relationship to the shaft area 520 located in the recessed area 625 as seen in FIG. 3 , at the opposite end of the adjustment screw 300 .
Shaft 500 in FIG. 2 is displayed in hexagonal shape, as may be found in a preferred embodiment of the current invention. The shaft can also be square, octagonal, star, or of Spline configuration. The locating hole for the hexagonal shaft 500 in the main wrench body 200 can be round in shape, hexagonal, or identical to the configuration of the shaft. The points on the hexagonal (outside edges at the longer diameter angles of hexagonal shaft 500 ) will coordinate and have the same configuration with the center hole of the adjusting screw 300 and the indexing ring 330 . When the shaft 500 passes thru the adjusting screw 300 and indexing ring 330 , the ring restricts rotation. Thus, shaft 500 will not rotate about its long axis. A thru hole 540 perpendicular to the shaft will accept the shaft 410 of the slide button 400 to move the shaft 500 in a lateral direction.
As further demonstrated in FIG. 2 , in a preferred embodiment, the shaft 500 has a smooth, rounded area 520 (on the lower portion of hexagonal shaft 500 ). This diameter will also coordinate with the inside diameter of the adjusting screw 300 and indexing ring 330 . When the adjusting screw 300 and indexing ring 330 are in this position over the diameter area of the shaft 520 they will rotate freely. The transition 505 in FIG. 3 , from the hexagonal shaft 510 ( FIG. 1 ) to the round shaft 520 ( FIG. 1 ) is tapered to enhance engagement of the hexagonal shaft to the indexing ring 330 in FIG. 6 . This round area of the Shaft 520 has Grooves 530 , 531 , and 532 for locating and securing the Shaft 520 into the desired positions utilizing a C Ring 650 .
Indexing ring 330 is preferably located between the compression spring 600 and adjusting screw 300 , as shown in FIG. 3 . The ring has the same center hole configuration as the hexagonal shaft 500 and thus is able to slide over the corresponding hexagonal shaft.
This center hole configuration in a preferred embodiment, may have points in multiples of six. By way of example, if the hexagonal shaft 500 has six points, the center hole may have six, twelve, eighteen, or higher multiple points, and still accept the hexagonal shaft 500 . This will facilitate engagement of the hexagonal shaft 500 . It will also have an indexing face 340 , per FIG. 2 .
The indexing face 340 is utilized on both the indexing ring 330 and the indexing face 320 on the adjustment screw 300 may take on a variety of different forms or types. As displayed for clarity in FIG. 2 , teeth 340 will be utilized in a radial position. When assembled, the indexing face of the indexing ring 330 and the adjusting screw 300 will be mated together and their axial movements will be synchronized to those of the shaft 500 .
Adjustment screw 300 is depicted in FIG. 3 . When rotated, the outside thread of the adjustment screw 300 meshes with the rack gear on the moveable jaw, moving the moveable jaw 220 in either direction. The center hole 310 ( FIG. 2 ) in the adjusting screw 300 , having the configuration of the hexagonal shaft is able to slide over the corresponding hexagonal shaft 500 . The center hole configuration may have 6 points, or multiples of six points. For example: If the hexagonal shaft 500 has six points, the center hole may have six, twelve, eighteen, or higher multiples of 6. This will facilitate engagement of the hexagonal shaft 500 . The recessed area 630 ( FIG. 4 ) in the end of the adjustment screw 300 ( FIG. 2 ) has an indexing face mating to the indexing ring 330 .
FIG. 4 is a perspective representation of the head of a wrench, showing the adjusting screw 300 thereof, in accordance with a preferred embodiment of the present invention. Adjustment screw 300 is shown in cutaway side view. Shaft 500 is shown in the locked position, as will be further described below.
The wrench of the current invention preferably has three stages, as described in the following section and as depicted in FIGS. 5 , 6 , and 7 . FIGS. 5 , 6 , and 7 are enlarged images of the three stages of operation described above. FIG. 5 shows the free stage, with the shaft 500 at the first stop within adjusting screw 300 . FIG. 6 shows the free stage, with the shaft 500 at the second stop within adjusting screw 300 . FIG. 7 shows the locked stage, with the shaft 500 at the final stop within adjusting screw 300 .
Free Position
In the Free Position shown in FIG. 5 , the wrench 100 works like any other adjustable wrench utilizing the Adjustment Screw 300 to move the Movable Jaw 220 ( FIG. 1 ). The slide button 400 is in the top position and the vertical Shaft 500 is moved up to disengage the hexagonal portion 510 from both the indexing ring 330 and the adjusting screw 300 , and the vertical shaft 500 is secured in this position by the C Ring 650 in Groove 530 .
Indexed Adjusting Position
The Indexed Adjusting Position is shown in FIG. 6 . This stage permits the adjusting screw 300 to rotate in increments of 0 to 360 degrees, determined by the number of teeth and the like on the face of the indexing ring 330 ( FIG. 4 ) corresponding to the mating face located on the face of the adjusting screw 300 ( FIG. 4 ). Moving the slide button 400 to the middle position simultaneously moves the shaft 500 to the middle position engaging the indexing ring 330 and secures it from turning by the configuration of the shaft 500 corresponding to the center hole in the indexing ring 330 . The C Ring 650 will slide on the round diameter 520 ( FIG. 7 ), and will be secured in this middle position by the groove 531 on the Shaft 500 with the Indexing Ring 330 secured on the hexagonal shaft 510 . C Ring 650 will not turn, as the Compression Spring 600 holds it in place. This allows the adjusting screw 300 to be rotated over 360 degrees and indexes, by pushing the spring loaded indexing ring 330 away from the adjusting screw, to the desired degrees set by the geometric configuration of the indexing ring face 340 ( FIG. 4 ) and the mating configuration in the adjusting screw 300 ( FIG. 4 ). This will determine the amount of movement of the Movable Jaw 220 per FIG. 1 .
Example
Utilizing a Ten Inch Adjustable Wrench
TABLE I Angular Indexing Table No. of Teeth Rotation Movement of Moveable Jaw 1 360 Degrees .090 Thousands 3 120 Degrees .030 Thousands 6 60 Degrees .015 Thousands
Locked Position
When the desired position of the moveable jaw 220 is achieved by rotating the adjustment screw 300 , locking of the adjusting screw 300 (see FIG. 7 ) is accomplished by moving the slide button 400 down. This movement simultaneously moves the shaft 500 to the locking position, closest to the adjusting screw 300 . This in turn will move the shaft 500 thru the indexing ring 330 , and into the adjusting screw 300 . The alignment is synchronized by the geometry of the indexing ring 330 to the shaft 500 . As shown in FIG. 7 , the shaft will be secured in this position by the spring clip 650 sliding on the round diameter 520 , and being secured in this position by groove 532 in the shaft 500 .
FIG. 5 is a view of the adjusting screw 300 and its components, in accordance with a preferred embodiment of the present invention. The elements of the control mechanism are shown to the left. In enlarged view, the adjusting screw 300 and the upper and lower gears are shown to the right. The beveled teeth of the gears are designed to mate, such that the face of lower gear 640 fits snugly into the face of upper gear 360 . Advancement of the lower jaw toward or away from the upper jaw is achieved by turning the adjusting screw 300 .
The position of shaft 500 governs the choice of degree of movement of the lower jaw. This effect is shown in FIG. 2 . At the bottom, shaft 500 is viewed in expanded format. At the top of shaft 500 are three grooves (in descending order from the top) 532 , 531 , and 530 . The shaft position is governed by the actuator button 400 .
When the wrench user moves the actuator button 400 to the first stop, the shaft 500 rests at the free stage, with groove 532 even with the edge of adjusting screw 300 as depicted in the free stage in FIG. 6 C. In this position, the adjusting screw 300 can be turned freely, and the lower jaw 220 correspondingly moved freely within its limits of travel.
When the wrench user moves the actuator button 400 further to the to the second stop, the shaft 500 comes to rest at the index stage, with groove 531 even with the edge of adjusting screw 300 as depicted in the index stage in FIG. 6 B. In this position, the adjusting screw 300 can be turned incrementally, and the lower jaw 220 correspondingly moved incrementally, step by step, within its limits of travel. The increment depends on the overall size of wrench 100 and particularly upon the size and number of gear teeth in gears 640 and 360 . The greater the number of teeth, the smaller the incremental travel of jaw 220 with each turn of the adjusting screw 300 .
Finally, when the wrench user moves the actuator button 400 to the last stop, the shaft 500 rests at the locking stage, with groove 530 even with the edge of adjusting screw 300 as depicted in the locking stage in FIG. 6 C. In this position, the adjusting screw 300 cannot be turned, and the lower jaw 220 correspondingly locks at its current position.
Thus, if a user wants to adapt to a given range of travel—let us say, to drive nuts in the metric range of 10 to 20 millimeters in diameter—he will select a wrench having the appropriate size and number of teeth in gears 640 and 360 , as displayed in FIG. 2 . Using the index stage of FIG. 6 , the user will adjust the wrench via turning the adjusting screw 300 until the separation between the jaws reaches a given nut size, for example 15 millimeters. This can be done by observation, although use of a gauge or other measuring device is appropriate as needed. Moving the actuator button 400 to the last stop will then lock the wrench jaws. This locks the wrench in position to operate on the given nut size. If the operator needs to adjust the wrench size, the operator simply repeats the process by moving the actuator button 400 to the second stop, adjusting the adjusting screw 300 to change the jaw width incrementally, then moving actuator button 400 to the last stop to lock the jaws into the desired separation. This is a preferred mode of operation of the invention when the sizes of the objects to be operated upon are known and fairly standardized in diameter.
If the sizes of said objects are not known, or vary in unknown ways, the free stage operation mode is a preferred mode. In that case, the wrench operator will again select a wrench having the appropriate size and number of teeth in gears 640 and 360 . Using the free stage of FIG. 5 , the user will adjust the wrench via turning the adjusting screw 300 until the separation between the jaws reaches a given separation width, as appropriate. This again can be done by observation, although use of a gauge or other measuring device is appropriate as needed. Moving the actuator button 400 to the last stop will then lock the wrench jaws. This locks the wrench in position to operate on the given nut size. If the operator needs to adjust the wrench size, the operator simply repeats the process by moving the actuator button 400 to the first stop, adjusting the adjusting screw 300 to change the jaw width incrementally, then moving actuator button 400 to the last stop to lock the jaws into the desired separation.
The advantage of the incremental or indexed stage operation is that is reaches a desired jaw width more quickly and repeatably than the free stage. Jobs can often be performed more quickly with the incremental stage mode. However, the free stage allows for closer tailoring of the jaw width, especially in cases of non-standard widths of workpieces, where the optimum jaw width may lie in between increments.
While the invention has been described in connection with a preferred embodiment or embodiments, it is not intended to limit the scope of the invention to the particular form set forth, but on the contrary, it is intended to cover such alternatives, modifications, and equivalents as may be included within the spirit and scope of the invention as defined by the appended claims.
|
An adjustable wrench is capable of locking and of free and indexed opening and closing of jaws. The wrench operates by means of a multipurpose shaft. The shaft controls an adjustment screw to allow free movement of the wrench jaws, increment adjusting of the jaws, or locking of the jaws in place.
| 1
|
This application is a continuation-in-part of U.S. application Ser. No. 11/421,976, filed Jun. 2, 2006, which is a continuation-in-part of U.S. application Ser. No. 11/188,469, filed Jul. 25, 2005, which is a continuation-in-part of U.S. application Ser. No. 10/810,876, filed Mar. 26, 2004 now U.S. Pat. No. 6,942,625, issued Sep. 13, 2005 and also claims the benefit of and priority to U.S. Patent Application Nos. 60/458,176, filed Apr. 11, 2003 and 60/379,908, filed Mar. 27, 2003. All of the above applications are incorporated by reference in their entireties.
BACKGROUND OF THE INVENTION
The present invention relates to enhancement of the Incentive Spirometer Medical Apparatus, a plastic disposable device, through electronic technology within the medical apparatus itself which is normally used to help in the rehabilitation of the lungs after an operation or similar type situations. The Incentive Spirometer consists of a plastic bell jar with a float inside the bell that rises, due to air being inhaled through a tube that is attached to the bell jar. By inhaling in the tube, the patient attempts to reach different volumes that are represented on the bell jar, where the float is used as a measuring device, but the float in the bell jar moves slowly and does not remain at it's apogee for very long, making visual accuracy for reading it's measurements on the scale, (on the bell jar), difficult especially since it is a repetitive inhalation process. The purpose of this prior art, is to bring air into the patient's lungs. The more air and use of the device, the better the patient's lungs become and thus the lungs are strengthened, however as recent studies have shown, complications such as pneumonia occur, are due to the lack of compliance, by the patient. Normally, the patient must utilize this medical apparatus without ancillary medical assistance and is expected to basically read written information on how to use the device, which is often performed improperly. Prior art required the patient to do the therapy unsupervised. The present invention overcomes the problems with the prior art and provides audible, verbal commands, encouraging phrases, responses, promptings and guidance electronically, allowing not only the sighted but the blind to benefit as well, providing a new method of technology in the medical industry.
Thus, in the past, lack of usage of this simple plastic, antiquated, disposable unit, by the patient, has contributed to severe problems, such as pneumonia. Without prompting, the patient finds it hard to inhale into a tube repetitively, to improve their lungs. Previous applications of prior equipment has been poor, thus adding intelligence in the form of electronic technology, which prompts without assistance, is a tremendous advantage in helping not only the sighted, but also the blind as well, since normally only written information accompanies the incentive spirometer, thus, changing the use of this medical device as we know it today.
SUMMARY OF THE INVENTION
The present invention relates to improving upon a disposable apparatus used in the medical industry, in order to increase transpulmonary pressure and respiratory volumes, improve inspiratory muscle performance, and re-establish the normal pulmonary hyperinflation, utilizing the employment of an audible, verbal, simulated vocalization of a humanlike voice through the use of modern technology, or any process available to accomplish this employment. Since, repeated usage of said medical apparatus on a regular basis allows airway passages to be maintained and lung atelectasis to be prevented or reversed. This new invention will prompt and encourage the patient, through the employment of an audible, verbal, simulated, generated, synthesized, or any similar process that can provide the function to produce humanlike voice, voices, word, words, or phrases, in order to help motivate the patient to use said apparatus and fulfill the recommended therapeutic sessions.
To achieve the function provided by the present invention, as described herein, and being that there are many different components presently available that can be used to facilitate the completion, operation, or function of the present invention, some examples of possible components are: micro chips, micro controllers, intregated circuit controllers, coin cells, power sources, batteries of a variety of sizes, (rechargeable or non-rechargeable), power adapters for direct current power supply for whatever requirements in relationship to any existing country, multiplexor circuits, electrodes, mylar speakers, sound modules, inductors, electro chromium, PC boards, inductive sensory systems, electrolyte layers, voltage regulators, oscillators, or indicators, just to name a few, however, not limited to and the exact components or combination of components will not be described specifically, except when applicable to context in order to simplify the specifications necessary to accomplish, or achieve the concept of the function of the present invention.
The present invention encompasses the entirety of the necessary components for the conception, as herein specified, of the above said medical apparatus, subject to patent allowance, in relationship to the utilization of present, future, new or impending technology, to create the same effect, as described herein as applies to the function of said apparatus, in order to produce audible, verbal, simulated, generated, or prerecorded humanlike voices phrases, or any similar method of providing the same effect, that will supply verbal commands, or responses to the patient, as specified herein.
The present invention encompasses the use of humanlike voices, in which a single word, words, or phrases, are produced through the components required for function, as herein stated, whether simulated, generated, prerecorded, synthesized, artificially produced, or any similar-process, or combination of components imperative in order to supply the necessary function to facilitate the appropriate use of the present invention, as specified herein, in order to supply a verbal vocalization of a humanlike voice. The function of the present invention, to provide a humanlike voice or sound of an audible, verbal, humanlike word, words, or phrases, or any similar function.
The word humanlike does encompass the use of audible, verbal words, or phrases, or a single word that may sound different in a variety of tones, such as a talking or speaking animal, simulated or generated voices, or similar voice animation's, to produce a humanlike sound, as described herein, as animals do not normally speak. So, the variation of sound as specified in the present invention, when relating to the definition of humanlike, as herein pertains, is confined to the characteristic of an audible, verbal, simulated, generated, or synthesized words or a single word, as aforementioned, that sound like human words, encompassing any language in relationship to the function of the above said medical apparatus, as pertains to the present invention.
The word apparatus refers to the use of Incentive Spirometry devices as aforementioned in correlation with the concept of the function of the present invention and more specifically to the incentive spirometer, however not limited to, as with the function of the present invention other applications of the incentive spirometry may apply as deemed.
The word medical, as herein specified, relates to apparatus, or therapy in which the present invention is being employed, in order to benefit those conditions, or any specialized condition, in which the patient, person, or persons, using the prescribed therapy pertaining to the apparatus, through said use of said apparatus, can hopefully benefit.
The word patient, as herein specified, relates to any, person or persons, utilizing the above said medical apparatus, according to the system of therapy in which the medical apparatus applies in relationship to the present invention in regards to the specification to function as herein described, but not limited to.
The accepted name for the above mentioned medical apparatus, which usually only gives incentive to the patient through visual confirmation, is Incentive Spirometry device, also referred to as sustained maximal inspiration (SMI), which is a component of bronchial hygiene therapy. However, to simplify the conception and the specification of the field of the invention, the name of the present invention, which is the incentive spirometer, shall be known herein and referred to as, Lung Enhancer, which is the combination of any or all parts of whatever equipment or components are needed to provide the function of the present invention as herein mentioned and can also be used separately, utilizing it's own housing, supplying an audible, verbal, response without visual affirmation, as it does not require the housing of the above mentioned medical apparatus, should one desire to eliminate it. The Lung Enhancer can utilize voice chips or modules, as applicable, or any similar device, which in combination, can produce, generate, or synthesize, however, not limited to these exact components in order to provide a humanlike voice, word, words or phrases which will give an audible, verbal response or command to the patient, so the patient may obtain the particular goal, predetermined flow rate, or volume of air needed to be inhaled.
When the Lung Enhancer is combined with the above said medical apparatus, or used separately, through the combination of the necessary components, as described herein, the operation of the said medical apparatus can be adjusted, according to the patient's goals, to provide verbal responses, or commands, to the patient, in order to encourage usage. Since, utilizing the combination of those components necessary to facilitate the function of the Lung Enhancer, with the above said medical apparatus provides visual and audible incentive, it is obvious that the combination of the Lung Enhancer with the Incentive Spirometry Device, or said medical apparatus is more applicable for fulfilling the maximum functional purpose of the Lung Enhancer, and will be described herein pertaining to such, however, not limited to.
Thus, the main purpose of the above said, audible, verbal humanlike voice commands or responses as provided by the Lung Enhancer, is to give incentive to the patient in order to encourage the usage of the apparatus, to improve lung function, and correct the possible problems that may occur without proper therapy, as described herein. In order to provide the Lung Enhancer with the appropriate functions for the apparatus, a microcontroller, but not limited to, can be used to facilitate the different settings that the Lung Enhancer can supply in conjunction with the adequate components to provide an audible, verbal, simulated, generated, synthesized, or any similar process that can provide humanlike, words, or phrases, or a single word to the patient in order to encourage use of the apparatus. The target amount of inhaled volume can be set in the Lung Enhancer so that the patient must reach his or her initial volume prior to the next level of increasement needed, per the therapeutic requirements and the Lung Enhancer will automatically increase the increments of volume required for the patient's exercise, thus, the patient will be required to improve their performance and thus, improve their lungs and medical health.
With the above mentioned additional benefit, when the patient reaches his or her particular respiratory inhaled volume, an audible verbal response from the Lung Enhancer will give an immediate indication of whether the volume, volumes, points, ratios, or performances accomplished by the patient, or any similar goal, have been reached through the sound of an audible, verbal, humanlike, simulated, generated, synthesized, or any similar process that will produce a voice, or voices originating from the apparatus itself, by giving the exact measurement and helpful incentive, to encourage the patient to continue to use the apparatus, according to the aforementioned programmable functions. Should the attempted aforementioned programmable, therapeutic goals or volumes fail to be accomplished by the patient, the Lung Enhancer will provide an audible, verbal, simulated, or otherwise produced, as above mentioned, humanlike voice, or phrases which will confirm that the patient has not achieved their goals accordingly, and a corresponding audible, verbal vocalization, as described herein, such as, “try harder” but not limited to, will inform the patient of their particular progress, output, or momentum through a humanlike voice originating from the apparatus itself, as herein described. However, this is not a required addition to the apparatus, but it is covered as part of the invention, in relationship to exploiting the fullness of the complete functional operation of the apparatus, so as to provide the most advantageous benefit to the patient through providing a gauge or similar device, in order to allow the patient to achieve adequate audible, verbal, verification of the patients pre-set goals or achievements.
On the other hand, the constructor of the apparatus may desire to avoid the additional cost of components necessary to produce the additional adjustable function and can be avoided if so desired, as the Lung Enhancer can be constructed to only coincide with the visual readings that normally exists on the above said medical apparatus and will solely provide only those exact readings being performed by the patient and the Lung Enhancer shall provide verification of those inhaled volumes, or readings through the audible, verbal, humanlike phrases, as described herein, without setting any goals, according to the construction of the apparatus. So, the constructor may choose to eliminate the use of allowing the patient to set his or her own settings accordingly. Whether constructing the apparatus with self gauging devices as aforementioned or simply allowing the Lung Enhancer to only audible or verbally speak the ratios or volumes or other readings inhaled by the patient without attempting to reach goals, as aforementioned, both functions allow the blind to benefit as well as the patient with sight, as the blind will be able to hear their inhaled volumes.
So, the construction of the above said apparatus is at the discretion of the constructor, and will be based on the function that one desires to fulfill utilizing the Lung Enhancer, A voice chip, or similar unit, constructed within the above mentioned Lung Enhancer can provide humanlike voice phrases that will allow the patient using it to inhale, while at the same time, an audible and verbal response will verify whether the person using the Lung Enhancer has reached their particular goals. This will be achieved through the use of a simulated, generated, synthesized, prerecorded human voice, or anything similar in order to facilitate function, as herein described, (male or female), which can be applied in combination with said apparatus, as aforementioned and the Lung Enhancer will prompt the patient through audible, verbal simulated words or a single word or phrase, to either, “try again”, or “good job, you hit your mark”, or “great”, or any phrase similar, but not limited to, that applies accordingly, in relationship to the particular use that the Lung Enhancer requires at that time, in relationship to function, as described herein. Since, one must inhale to help facilitate the improvement of ones lung capacity and health, as described herein, an air pressure sensor, or similar device, can be installed at the appropriate location on the Lung Enhancer itself, to measure the exact amount of volume being inhaled and relay those accurate readings in synthesis to the appropriate components, in order to supply audible, verbal verification of said readings as mentioned herein, corresponding to the visual measurements being performed on the apparatus, in order to complete this function of the Lung Enhancer, encouraging or correcting the patient accordingly, with an audible, verbal, simulated humanlike voice, as aforementioned, to give verification of the amount of volume being produced.
The above said sensor can be placed at whatever location facilitates the function of the Lung Enhancer as mentioned herein, and should be connected directly to the area in which one is inhaling. Normally, a tube is used to inhale the amount of air the patient is bringing into the lungs, however, the new Lung Enhancer invention is not limited to the physical structure of any apparatus, that is providing the medical function as described herein. Should cost be a consideration, the Lung Enhancer invention can utilize electronic sensors (but not limited to), attached directly to the above said apparatus at each point, in which the air volume is normally visualized by a float which will relay electronic signals, but not limited to, allowing the constructor of the apparatus to eliminate the above said sensor while still allowing the concept of the facilitation of the function of the lung Enhancer, as herein described. This alternative appropriation of components to achieve the same function by eliminating the pressure sensor, as above stated, will still give the completeness of the necessary function as previously described in relationship to the medical apparatus, prompting the patient using the Lung Enhancer to accomplish the goals or requirements of that therapy, in compliance to the apparatus by employing audible, verbal, incentive utilizing simulated, generated, synthesized or any similar process in order to produce humanlike words, or phrases or a single word which encompasses the concept of the embodiment of the present invention, as herein described. A speaker can be attached to whatever housing, on the aforementioned apparatus, as needed to produce the requirement audible, verbal sound, as herein described and the Lung Enhancer can have as many audible verbal commands and responses, supplying simulated human voice as desired, according to the output potential employed by the construction of the above said apparatus. Said construction is not contained to any degree herein, as specific ratios and outputs will depend on the application and construction designed to promote the usage of the device and obviously some apparatus may require particular specialization's to provide the audible, verbal simulated human voices as aforementioned and the provider of the apparatus shall maintain the specifications or structure of each unit produced in which the new Lung Enhancer invention is utilized, under the SMI therapeutic requirements as aforementioned.
Another important benefit of the Lung Enhancer, is the ability to install a programmable timer for letting the person manipulating the device to know what time he or she should begin using the apparatus. The aforementioned programmable timer is not necessarily required to fulfill the concept of the Lung Enhancer, however, it is encompassed within the concept of the present invention, so as to achieve the fullness of the complete available functional operation of the apparatus according to the patient's particular need, or therapeutic program, which shall virtually be provided without the use of any assistance, as the normal therapeutic requirement, will be replaced by the use of an audible, verbal, simulated, generate, synthesized human voice, word, words, or phrases, or any similar process as described herein, and this function will be provided by the Lung Enhancer, which will automatically vocalize that it is time for the person or patient to use the apparatus as needed. This will assure the patient is diligent to continue the necessary procedure to increase respiratory rate as prescribed, as the Lung Enhancer can be adjusted to continue to provoke the patient, through audible, verbal, simulated human voices, phrases, and reminders that will continue to say audible, verbal, simulated human phrases giving incentive to help encourage the patient, until the patient uses the apparatus, to achieve the patients up-most potential. With a device as important as the aforementioned apparatus, the therapeutic recommended interval for usage of respiratory spirometry devices is normally 1 hour, under the SMI therapeutic requirements as aforementioned, the Lung Enhancer can provide the doctor or therapist with the ability to set the exact amount of time in correlation with the constructor in order to provide the appropriate functions, between each use so that the patient can be reminded accordingly at that time, through an audible, verbal humanlike reminder, as described herein, using a word or phrase to accomplish this recommended therapeutic utilization of the apparatus though the operation of an audible, verbal incentive emanating from within the apparatus itself. However, preferably the construction of the apparatus would be more advantageous by pre-setting the therapeutic time intervals prior to making the unit available to the patient, so that the patient cannot change the intervals on their own, thus, preventing any interruption of the therapeutic session required by the Lung Enhancer. This adjustment of therapeutic time intervals can be pre-set in the unit, so as to make the operation of the present invention as simple as possible and also prevent any tampering with the unit by unauthorized personnel.
Since the Lung Enhancer, will have a “nag” ability, which means a series of continuous verbal command which prompts the patient until the Lung Enhancer is used appropriately and will be programmed within the housing of the Lung Enhancer itself. The aforementioned “nag” program function of the present invention will give incentive for the patient to use it; such as an audible, verbal command saying, “pick the unit up”, or verbal incentive coming directly from the Lung Enhancer itself, saying a phrase such as: “it is now time for the exercise program”, but not limited to these exact commands. A sleep mode can be programmed in the Lung Enhancer, which will allow the Lung Enhancer to basically stop working, or take a break, or turn back on, to perform the appropriate function, such as when to begin the SMI therapeutic sessions again like, “time for your therapy”, but not limited to, in order to save battery life and/or the power source and can be programmed within the housing of the Lung Enhancer. Another way of programming the Lung Enhance, to shut off or on, at any time and/or during the sleeping period of the patient, is by utilizing a card or key, but not limited to this exact principle, made of whatever material facilitates the function, on the apparatus itself, but not limited to, according to the construction per the constructor's design, at whatever location deemed necessary, to achieve said function and can be slid or slid out, to turn the unit on or off, but not limited to, by providing conductivity at the point of origin when inserted, and this shall be known herein as “slip chip”. Removing the slip chip permanently, never allowing the conductivity to be resumed, would avoid any tampering of this most advantageous aspect of the slip chip which is the continuation of the therapeutic performance of the Lung Enhancer.
Another way of facilitating the turn off, turn on ability of the Lung Enhancer would be through the use of light photosensors installed in the unit itself, such as; 1PC81X (Daylight sensor), but not limited to this particular component, which shall perform the duties of turning off the Lung Enhancer during the night, by sensing the absence of light, (darkness), or lack of light and thus, turning the Lung Enhancer back on when light is present. With this in mind, the Lung Enhancer will continue to perform its operation and function throughout the day, or as constructed according to the requirements of the therapist and will allow the patient to sleep during the period when light is not sensed by the sensor in the Lung Enhancer. The embodiment and descriptions to follow, will use gauging of the Lung Enhancer, through the utilization of the float mechanism within the bell jar of the apparatus, in order to provide the most cost effective and advantageous method to perform the function of the present invention, with conductivity. With this in mind, one must have knowledge of the basic construction of the Incentive Spirometer to understand the electronic improvements and enhancements described herein.
With this understanding the Incentive Spirometer comprises of a plastic bell jar with a mechanical float, that rises due to air being inhaled by the person or patient through an attached tube. At the same time, the air (patient's breath), flowing out of the bell jar, when the apparatus is being used, causes the mechanical float in the bell jar to rise, such that the position of the float is relative to the volumetric pressure printed on the bell jar, which accurately reflects the amount of air inhaled. The float in the bell jar moves slowly but does not remain at it's apogee for very long and makes visual accuracy for reading its position measurements on the scale (on the bell jar), difficult. One application for allowing the float mechanism in the Lung Enhancer, is to relay the measurement of the float positioning in correlation, with the numerical positions on the bell jar cylinder, (which encompasses the float).
It is obvious that both the bell jar and the float must have conductive material on them, of whatever conductive material is appropriate to facilitate the function of the present invention, by whatever means is deemed by the constructor of the apparatus. A cylinder sensor strip within the housing of the unit, in correlation with the numerical measurements on the bell jar of the Lung Enhancer's housing, but not limited to, would allow the float and said conductive sensor strip, to adjacently touch, to relay correspondence to the appropriate components. To supply conductivity for said movable float, with the understanding that the preferred method of providing conductivity, for either of the above mentioned float, or conductive sensor strip, could be plating, but not limited to this exact way of supplying conductivity, each above said units with conductive materials such as aluminum, nickel, copper, or gold, or any conductive material that would facilitate the function of the present invention, can be used to relay the electric conducted signal, to the appropriate source, to provide the function of the Lung Enhancer accordingly, as herein specified, for a more accurate reading, through the above said conductive ability.
Another medical application, of the Lung Enhancer, utilizing existing technology as needed, but not limited to, is the ability to insert a data chip or any similar data retaining device or system, to provide information on the usage being performed by the patient. This unit that will transmit or receive data, located in the Lung Enhancer, allowing the therapist or doctor to examine the stored information, whether wireless or by other means, at such time that is deemed necessary. This said data can be retrieved, by removing the data retained on a chip, but not limited to, within the housing of the Lung Enhancer and by inserting a chip or similar unit that applies to data storage, into a PC board, (Computer), that is programmed to provide patient data that is being retrieved at that time.
An alternative answer to retrieving patient data usage, from the Lung Enhancer would be via, infra red, radio waves or similar systems, without the use of any data chips or systems, which will allow transmittal or receiving of data accordingly, from the medical apparatus which will provide the same aforementioned function and shall directly be sent to the PC, or any similar devices such as a hand held unit, similar to a palm pilot, for example an IR 1 FAIRCHILD QED233-ND Transmitter/Receiver, but not limited to these particular components, in order to retrieve or transmit data, from whatever location which is in appropriate range, in order to receive the aforementioned transmitted retrievable signal, that the doctor or therapist is located at any given time. This non-attached unit, would give the therapist or doctor the ability to retain and retrieve the particular patient's data as needed and have a complete breakdown of information of the amount of sessions, measurements, and information on stored data, necessary to properly treat the patient from another location, as deemed by the doctor or therapist, at any time desired.
A code, but not limited to, or similar way of specifying the particular patient, in which data is being retrieved, could simply be entered into the CP, or similar unit, but not limited to, allowing the doctor or therapist to designate which patient he or she is desiring medical information on at that time. This will reduce the valuable time spent, reading charts, or writing information for the doctor to view at a later time. The PC, or similar unit as described as herein, but not limited to, can be at any location deemed accordingly, making the retrieval of data simple and easily obtained. Through the use of the Lung Enhancer, not only will the Medical Industry benefit with this new improved incentive spirometry device, supplying an audible, verbal simulated human voice, which will inform the patient, that it is time for their therapy, what is their progress or volumes reached, when to try again or when to stop, but also the patient as well, for it is well known in the medical industry, “the more one uses the prescribed treatment, the faster one recuperates”.
With the conception of the Lung Enhancer, a new step in medical progress will be made through a cost effective electronically enhanced new device, that guides the patient, under the SMI therapy as aforementioned, from start to finish, as well as prompts, nags, goes into “sleep mode,” and wakes up to encourage usage. The use of an audible apparatus that gives information, or the ability to retrieve stored information data, is invaluable and will allow the patient to recover quicker, as well as, save money by providing a way to prescribe the proper treatment to those patients more effectively and comprehensively. Thus, by using the Lung Enhancer, quicker patient recovery will be achieved, through compliance, with fewer complications. Through the utilization of the present invention employing audible, verbal incentive, prompting the usage by the patient, through encouraging words and phrases, produced by the medical apparatus itself will not only benefit the sighted, but the blind as well, providing a more useful method to assure adequate recovery.
In lieu of the a resistive/conductive sensing circuit for determining movement of the float and obtaining performance measurements, the present invention alternatively can use a capacitive sensing circuit which is also within the scope of the invention and discussed in more detail below.
Through the improvement of using electronically simulated, audible, verbal, human sounding word, words, or phrases that emanate from within the Incentive Spirometer itself, the ability of this programmed new invention, has the intelligence to detect the patient's measurements, as well as prompting the exact time, that the patient should begin therapy again accordingly. This new improved apparatus, will also give the measurement of the volume that the patient has performed during their therapy, along with encouraging phrases that continue to lead and guide the patient until the full therapy is completed.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a Preferred Embodiment of the Present Invention;
FIG. 2 shows the Preferred Embodiment of the Audible Response Unit;
FIG. 3 shows the details of the Gauge;
FIG. 4 shows the Present invention within the housing of a Medical Apparatus;
FIG. 5 shows the details of the Deactivation Key 17 ;
FIG. 6 illustrates several views of one Incentive Spirometer embodiment for the present invention showing the Incentive Spirometer having a float stop member;
FIG. 7 illustrates a screen shot for the PC software interface for communicating with the Incentive Spirometer of the present invention;
FIG. 8 illustrates a schematic view of the resistive method for sensing movement of the float; and
FIG. 9 illustrates a general configuration of the capacitive method for sensing movement of the float as an alternative sensing method.
DETAILED DESCRIPTION OF THE INVENTION
Now referring to the drawings the present invention will be further described. FIG. 1 shows a preferred embodiment of present invention. A Gauge 2 connects to Audible Response Unit 1 through one or more electrical connections labeled 400 . Audible Response Unit 1 connects to Speaker 3 through an electrical connection labeled 401 . Power is supplied from Power Supply 4 to Gauge 2 through an electrical connection labeled 402 . Power is supplied from Power Supply 4 to Audible Response Unit 1 through an electrical connection labeled 403 .
FIG. 2 Shows the Preferred Embodiment of Audible Response Unit 1 . Gauge 2 of FIG. 1 connects to Gauge Connector 5 through one or more electrical connections labeled 400 . Gauge Connector 5 connects to Signal Input Unit 100 which is a subunit of the Microcontroller Unit 7 through one or more electrical connections labeled 202 . Microcontroller Unit 7 contains subunits Signal Input Unit 100 , Program Storage Unit 101 , Data Storage Unit 102 , Central Processor Unit 103 , Signal Output Unit 104 and Timer Unit 105 . Signal Input Unit 100 provides information to Central Processor Unit 103 through a set of signals labeled 302 .
Central Processor Unit 103 receives a set of program instructions that provide the function of the Audible Response Unit 1 from Program Storage Unit 101 by providing control information through signals labeled 300 a and receiving instructions through signals labeled 300 . Information used by the program instructions are kept in Data Storage Unit 102 by providing control information and data to be stored through a set of signals labeled 301 a and by receiving data through a set of signals labeled 301 . Central Processor Unit 103 controls a set of timers in Timer Unit 105 through a set of signals labeled 304 a and receives information from the timers in Timer Unit 105 through a set of signals labeled 304 . The Central Processor Unit 103 uses information from Timer Unit 105 to determine accurate time intervals. Central Processor Unit 103 receives audio data from Audio Storage Unit 6 by providing control information through a set of signals labeled 205 a and by receiving audio data through a set of signals labeled 205 . Central Processor Unit 103 relays the audio data received from Audio Storage Unit 6 to Signal Output Unit 104 by transferring the audio data through a set of signals labeled 303 . Signal Output Unit 104 transfers audio data to Audio Amplifier Unit 8 through a set of signals labeled 204 .
Audio Amplifier Unit 8 transfers amplified audio data to Speaker Connector 9 through a set of signals labeled 203 . Speaker Connector 9 connects to Speaker 3 of FIG. 2 through a set of signals labeled 401 .
FIG. 4 shows the present invention within the housing of a Medical Apparatus 10 , that implements a Gauged Spirometer whose housing is identified as 16 and which encloses the Medical Apparatus 10 , which is comprised of the Speaker 3 , Audible Response Unit 1 , Battery Power Supply 4 , Daylight Sensor 18 , and Deactivation Key. Daylight Sensor 18 is used by the Audible Response Unit 1 , that detects that it is nighttime by measuring the signal on 402 and comparing it to a value within the Data Storage Unit 102 . Deactivation Key 17 , deactivates the Audible Response Unit 1 , that closes a switch that relays a signal over electric conductor 403 , comparing it to a value within the Data Storage Unit 102 , it enters an operational mode called “silent mode”.
FIG. 3 shows details of Gauge 2 , where a Film Strip 24 is attached to the inside wall of the Incentive Spirometer Cylinder 21 , covered with a Conductive Pattern 25 . Float 20 , which is covered with Conductive Skirt 26 , moves freely up and down within the Incentive Spirometer Cylinder 21 , making contact with Conductive Pattern 25 of Film Strip 24 , to create an electric path from contact with Film Strip 24 and the Return Conductor 405 . Current from electric conductor 400 , through Film Strip 21 , through Conductive Pattern 25 , through Float Skirt 26 , through Return Conductor 405 , is proportional to the position of electrical contact, called “float signal”. “Float Signal” is relayed to Audible Response Unit 1 , by electric conductor 400 , interpreted in Audible Response Unit 1 and is able to measure and record performance.
FIG. 5 Detail of Deactivation Key 17 , which causes switch 23 to close, thus connecting Battery Power Supply 4 , to electrical conductor 403 , causing a signal on electric conductor 403 , relayed to Audible Response Unit 1 , interpreting the signal on electrical conductor 403 .
When apparatus 10 in FIG. 1 is used by the operator, a gauge 2 within the apparatus produces an electrical signal on electrical conductor 400 proportional to the physical parameter that is measured by the gauge 2 . The electrical signal on 400 is variable over time and represents an electrical representation of the parameter measured by the Gauge 2 during the duration of time that the Apparatus 10 is used. The electrical signal on 400 is input to the Audible Response Unit 1 where the electrical signal on 400 is evaluated.
The Gauge Connector 5 on FIG. 2 relays the electrical signal on 400 to the Signal Input Unit 100 within Microcontroller Unit 7 where the electrical signal on 400 is converted repeatedly at a fixed rate of once every unit of time called the “sampling interval” for the duration of time when the electrical signal on 400 is being evaluated. The Signal Input Unit 100 converts the electrical signal on 400 into a digital numerical format and relays it through a set of digital electrical signals 302 to the Central Processor Unit 302 . This process is repeated after the transpiring of time equal to the sampling interval for the duration of time over which the electrical signal on 400 is being evaluated.
The parameter being measured by Gauge 2 is thereby converted to a sequence of numerical digital values that represent the magnitude of the parameter over the time duration when the parameter is being evaluated, and each successive numerical digital value represents the magnitude of the parameter measured by Gauge 2 at the time that is one “sampling time” interval later than the preceding numerical digital value.
The Central Processor Unit 103 executes a sequence of instructions that are retrieved from the Program Storage Unit 101 . This sequence of instructions is called the “functional program” and defines the series of steps and decisions that are made to constitute the function of the present invention. The Central Processor Unit 103 retrieves the instructions from the Program Storage Unit 101 by presenting an index called a “program address” to the Program Storage Unit 101 through the set of digital electrical signals 300 a . The “program address” is calculated by the Central Processor Unit 103 as directed by the instructions of the “functional program” that it is executing. The Program Storage Unit 101 responds to the “program address” on 300 a by retrieving and relaying the instruction corresponding to the “program address” to the Central Processor Unit 103 .
The instructions representing the “functional program” relayed to the Central Processor Unit 103 by the Program Storage Unit 101 over digital electrical signals 300 a are executed by the hardware within the Central Processor Unit 103 to perform mathematical calculations, “program address” generation, and decision logic which together constitute the “functional program” of the present invention which in turn defines the behavior and function as defined for the Apparatus 10 .
Intermediate mathematical and logical calculations that are preformed by the Central Processor Unit 103 as it executes the “functional program” result in information collectively called “data” that are stored in the Data Storage Unit 102 . The Central Processor Unit 103 identifies storage locations in the Data Storage Unit 102 for storing or retrieving “data” by presenting an index called the “data address” to the Data Storage Unit 102 through a set of digital electrical signals 301 a . The Central Processor Unit 103 generates the “data address” by performing calculations that it is directed to perform by the instruction of the “functional program” that is being executed. The Central Processor Unit 103 also presents “data” to be stored through the set of digital electrical signals 301 a to the Data Storage Unit 102 . If the Central Processor Unit is retrieving data from the Data Storage Unit 102 , the Data Storage Unit 102 presents the retrieved data associated with the “data address” on 301 a to the Central Processor Unit 103 through a set of digital electrical signals 301 .
The Central Processor Unit 103 directs the Timer Unit 105 by presenting commands that are calculated during the execution of the “functional program” to the Timer Unit 105 through a set of digital electrical signals 304 a . The commands instruction Timer Unit 105 on the time intervals that are to be generated. The Timer Unit 105 relays time interval information to the Central Processor Unit 103 through a set of digital electrical signals 304 . The Central Processor Unit 103 uses the timer interval information for purposes of indicating when one or a set of instructions of the “functional program” should execute. The Central Processor Unit 103 has the ability to synchronize the execution of one or a set of instructions of the “functional program” to a precise point in time or an interval of time.
When the Central Processor Unit 103 determines that an audible response is needed and which audible response is to be generated as determined by the definition of the behavior of the Apparatus 10 and the definition of the “functional program”, it is directed by the instructions within the “functional program” to calculate an index called the “audio address” that is used to retrieve the audible response data called “audio data” from the Audio Storage Unit 6 . The Central Processor Unit 103 presents the “audio address” to the Audio Storage Unit 6 through a set of digital electrical signals 205 a . The Audio Storage Unit 6 responds by relaying the “audio data” associated with the “audio address” to the Central Processor Unit 103 through a set of digital electrical signals 205 .
The Central Processor Unit 103 retrieves time interval information from Timer Unit 105 to determine the appropriate time when retrieved “audio data” can be relayed to the Signal Output Unit 104 . In this way, the “audio data” is successively relayed to the Signal Output Unit at a rate appropriate for the regeneration of the audible response from the “audio data”. The Central Processor Unit 103 relays the “audio data” to the Signal Output Unit 104 through a set of digital electrical signals 303 .
The Signal Output Unit 104 receives “audio data” from the Central Processor Unit 103 at a rate that is indicated by time interval from the Timer Unit 105 . The time interval is calculated by the Timer Unit 105 as it is commanded to do by the Central Processor Unit 103 when it executes the instructions in the “functional program” that controls setting up of the Timer Unit 105 . The time interval is made to be the value required in order to regenerate the audible response correctly when “audio data” is repetitively output at a rate equal to the time interval.
The Signal Output Unit 104 receives “audio data” in a digital numerical form from the Central Processor Unit 103 repetitively starting from the first unit of “audio data” to the last unit of “audio data”. The Signal Output Unit 104 converts the “audio data” to an electrical signal whose magnitude is proportional to the “audio data” repetitively for each “audio data” received. It relays the electrical signal to the Audio Amplifier Unit 8 through an electrical signal 204 . The Audio Amplifier Unit 8 multiplies the magnitude of the electrical signal relayed on the electrical signal 204 such that the amount of power represented by the electrical signal 204 is increased and output to the Speaker Connector 203 . The Speaker Connector 9 relays the amplified electrical signal on 203 to electrical signal 401 which corresponds to electrical signal 401 on FIG. 2 . The amplified electrical signal 401 is presented to the Speaker 3 in FIG. 2 .
The Speaker 3 converts the amplified electrical signal 401 to sound energy that represents the audible response that the Audible Response Unit 1 has calculated in response to the measurement of a parameter that is determined by the Gauge 2 of the Apparatus 10 in accordance to the defined behavior of the Apparatus 10 and of the defined function of the “functional program.”
The present invention describes a method of producing audible response to the measurement of a parameter by an Apparatus 10 so that the audible response is done according to a defined behavior determined by the constructor of the Apparatus 10 . Implementation of the defined behavior of the audible response to measurement of a parameter within the Apparatus 10 is realized by the defined function of the “functional program” that is coupled to the Audible Response Unit 1 by storing the “functional program” in the Program Storage Unit 101 within the Audible Response Unit 1 and by providing a means for the Central Processor Unit 103 within the Audible Response Unit 1 to execute the instructions in the “functional program” and to perform the actions as they direct the Central Processor Unit 103 and the other subunits within the Audible Response Unit 1 .
FIG. 4 shows the Present Invention within the housing of a Medical Apparatus 10 that implements a Gauged Incentive Spirometer whose housing is identified as 16 and which encloses the Medical Apparatus 10 as well as the present invention which is comprised of the Speaker 3 , Audible Response Unit 1 , Battery Power Supply 4 , Daylight Sensor 18 , Deactivation Key 17 . The Medical Apparatus in this embodiment is constructed to perform Incentive Spirometry measurements of the medical patient referred herein as the “operator”. In this embodiment of the present invention, the Power Supply 4 is implemented as a Battery in order to provide a means of operating the Medical Apparatus without the need to connect to an auxiliary power source through means of wire cords. This means is referred to as using a “cordless” power supply.
The present invention also includes a Daylight Sensor 18 that is used by the Audible Response Unit 1 to distinguish between daylight and nighttime. The Daylight Sensor 18 is constructed as but not limited to a photocell that relays a signal to the Audible Response Unit 1 over electrical conductor 402 . When the Audible Response Unit 1 detects that it is nighttime by measuring the signal on 402 and comparing it to a value within the Data Storage Unit 102 , it enters an operational mode called “silent mode”. In “silent mode”, the Audible Response Unit 1 activates itself at the same time intervals as it does in daytime, but does so in order to measure the daylight by means of sensing the Daylight Sensor 18 . If sufficient daylight is not detected, the Audible Response Unit 1 does not emit any audible instructions to the operator but instead sets an internal timer to reactivate itself after a prescribed time interval that is defined in the “functional program” of the Audible Response Unit 1 and then deactivates itself. With this method of daytime detection, it is possible for the Audible Response Unit 1 to permit the “operator” to rest during the nighttime and to maintain a regular programmed interval for reactivation. When the Audible Response Unit 1 is reactivated at the transpiring of the programmed time interval as defined in its “functional program” and detects sufficient daylight, the Audible Response Unit 1 enters an operational mode called “standard mode” and begins emitting audible commands to the “operator” as defined by the “functional program” within the Audible Response Unit 1 .
The present invention also includes a Deactivation Key 17 that provides to the means to deactivate the Audible Response Unit 1 for any period of time in the event that such deactivation is determined to be necessary by qualified personnel responsible for the medical care of the “operator”. The Deactivation Key 17 is a mechanically unique shape that matches the same mechanically unique cavity within the Housing of the Gauged Spirometer 16 . The Deactivation Key 17 when inserted into the housing of the Gauged Spirometer 16 closes a switch that relays a signal over electrical conductor 403 to the Audible Response Unit 1 to indicate the presence of the Deactivation Key 17 . When the Audible Response Unit 1 detects that the Deactivation Key 17 is present by measuring the signal on 403 and comparing it to a value within the Data Storage Unit 102 , it enters an operational mode called “silent mode”. In “silent mode”, the Audible Response Unit 1 activates itself at the same time intervals as it does in “standard mode”, but does so in order to measure the presence of the Deactivation Key 17 by sensing the signal on 403 . If the Deactivation Key 17 is determined to be present, the Audible Response Unit 1 does not emit any audible instructions to the operator but instead sets an interval timer to reactivate itself after a prescribed time interval that is defined in the “functional program” of the Audible Response Unit 1 and then deactivates itself. With this method of detection of Deactivation Key 17 , it is possible for the Audible Response Unit 1 to permit the qualified personnel to deactivate the Audible Response Unit 1 for any period of time and to maintain a regular programmed interval for reactivation. When the Audible Response Unit 1 is reactivated at the transpiring of the programmed time interval as defined in its “functional program” and detects the absence of the Deactivation Key 17 , the Audible Response Unit 1 enters an operational mode called “standard mode” and begins emitting audible commands to the “operator” as defined by the “functional program” within the Audible Response Unit 1 .
FIG. 3 shows details of Gauge 2 as constructed for the Incentive Spirometry application shown in FIG. 4 . The Gauge 2 is constructed of a thin Film Strip 24 of resistive material typically consisting of but not limited to carbon or graphite. The Film Strip 24 is attached to the inside wall of the Incentive Spirometer Cylinder 21 with adhesive. The surface of the Film Strip 24 that faces the interior of the Spirometer Cylinder 21 is covered with a Conductive Pattern 25 . The Float 20 is free to move up and down within the Incentive Spirometer Cylinder 21 and makes contact with the interior facing surface's Conductive Pattern 25 of Film Strip 24 at a point that corresponds to the height position of the Float 20 . The outer edge of the Float 20 that contacts the interior facing surface of the Film Strip 24 is covered with a Conductive Skirt 26 . The Conductive Skirt 26 creates an electrical path from the position of contact with the Film Strip 24 and the Return Conductor 405 . The Float 20 rises as the “operator” inhales through the Air Tube 19 of FIG. 6 so that the gas pressure above the float is lower than the gas pressure beneath the float which is at standard 1 atmosphere. The Float 20 ceases rising when the difference between the gas pressure above and beneath the Float 20 multiplied by the cross sectional surface area (in the direction of the axis of the Spirometer Cylinder 21 ) of the Float 20 is equal than the weight of the Float 20 . The Float 20 falls when the difference between the gas pressure above and beneath the Float 20 multiplied by the cross sectional surface area (in the direction of the axis of the Spirometer Cylinder 21 ) of the Float 20 is less than the weight of the Float 20 .
The amount of electrical current flowing from the electrical conductor 400 through the Film Strip 21 through Conductive Pattern 25 through the Float Skirt 26 through the Return Conductor 405 referred to as the “float signal” is proportional to the position of the electrical contact between the Conductive Pattern 25 and the Float Skirt 26 referred to as the “contact point”. The higher the “contact point” is, the more distance there is between the electrical conductor 400 and the “contact point” and hence the more resistive material that comprises the Film Strip 21 there is, and the higher the electrical resistance there is to current flow from electrical conductor 400 to the Return Conductor 405 . The position of the contact point corresponds to the height position of the Float 20 . Therefore, the amount of electrical current of the “float signal” through electrical conductor 400 is proportional to the height position of the Float 20 . The higher the position of the Float 20 , the less electrical current there is flowing through the electrical conductor 400 at the “float signal”. The lower the position of the Float 20 , the higher the electrical current there is flowing through the electrical conductor 400 at the “float signal”.
The “float signal” is relayed to the Audible Response Unit 1 by electrical conductor 400 and is interpreted by the “functional program” in the Audible Response Unit 1 . The Audible Response Unit 1 takes measurements of the “float signal” and determines the level of the signal that corresponds to when the Float 20 reaches it's apogee and when it settles back down to the bottom of the Spirometer Cylinder. By making this determination, the Audible Response Unit is able to measure and record the performance of the “operator” as measured by the Incentive Spirometer.
FIG. 5 shows a detail of an example of embodiment of the Deactivation Key 17 . It is comprised of a uniquely mechanically shaped device that fits precisely into a cavity within the Housing of the Gauged Incentive Spirometer 16 . When successfully inserted into this cavity, the Deactivation Key 17 causes switch 23 to close thereby connecting the Battery Power Supply 4 to the electrical conductor 403 . The connection of the Battery Power Supply 4 through switch 23 causes a signal on electrical conductor 403 that is relayed to the Audible Response Unit 1 . Audible Response Unit 1 interprets the signal on 403 as described in the previous description of FIG. 3
Some of the advantages and features of my invention include:
I. Electronic technology which has been especially developed to work within the incentive spirometer, that will help the patient by providing simulated audible, verbal, human sounding voices, thus providing instructions, prompting appropriate usage according to therapeutic time schedules, correcting and encouraging patient performance, as well as, giving the appropriate measurement, that the person or patient has performed with the apparatus, eliminating human visual error, help assist the blind and the visually impaired, through the use of today's state of the art equipment, that can produce electronic intelligence within the apparatus at a low cost, thus reducing patients recovery time and complications,
1) a method of providing audibly and verbally, instruction and guidance, to help perform the therapeutic sessions by the patient to improve lung performance, which through medical studies has shown that very few patients perform the required therapy as suggested through the accompanied literature, but through the usage of the present invention, the percentage in regards to lung problems occurring due to failure of patient usage of the Incentive Spirometer, will decease dramatically as the present invention will nag or prompt the patient without stopping, until the patient uses the apparatus and will not stop until the time interval necessary to fulfill the patient's therapeutic need has been accomplished. Through electronic intelligence, the present invention, will prompt the patient to use the medical apparatus, as well as, guide the patient through the proper steps of using said medical apparatus, thus quicker patient recovery will be achieved, through compliance without complication,
2) replacing the normal human visual readings or measurements, eliminating human error of inaccurate readings, due to the prior required float recognition which is imperative to provide visual measurement, since the float doesn't stay always in position long enough to read properly and has to be constantly viewed during therapeutic sessions to observe the exact reading of measurement, with a human sounding electronically programmed voice or voices giving the same readings or measurements as deemed necessary to provide the sighted, as well as the visually impaired patient, with adequate information, to fulfill the patient's therapeutic regiment for recovery and allowing the blind to hear and respond, to the full operation of the therapeutic regiment, of the present invention;
3) a medical apparatus that because of the inexpensive construction, is comparable to the same concept, in relationship to therapeutic use, as the expensive apparatus, due to today's advanced technology. This breakthrough in modern technology allows the patient to afford the new improved apparatus of the present invention, which basically supplies all of the same healthcare purposes in relationship to the therapy of the apparatus, however, it also gives the patient the advantage of hearing the therapeutic guidance and measurements as an added benefit and cost is virtually the same as most disposable incentive spirometry units;
II. A new method to provide the above function of the present invention through the following electronic technology:
1) a number of the following electronic components in order to provide the function as above mentioned:
(a) one or more electronic sensors producing an output signal, (b) one or more electronic modules that convert said sensor output signal (s) into digital format, (c) one or more electronic modules that includes but is not limited to a central processing unit, (d) one or more electronic modules for digital storage of program instructions and data, (e) one or more electronic modules for digital storage of digital audio sound data, (f) one or more electronic modules for generation of audible sound, (g) one or more electronic modules for managing and conserving electrical power, (h) one or more electronic modules for determining accurate intervals of time, (i) one or more electronic modules for communicating remotely with separate agent, (j) one or more electronic sensor for detecting light or the absence of light to turn off or on unit
2) said method of new apparatus capable of measuring output signal of the sensors, converting said output signals into digital format to be stored and processed by the central processing unit, resulting in actions taken by the central processing unit under direction of it's digital program instructions in accordance to it's pre-determined set of actions,
3) said pre-determined actions of the digital program instructions include but not limited to the generation of audible audio sound sequences that provide information relating to said output signals,
4) said electronic sensors capable of measuring but not limited to parameters of performance of the human body in various settings relating to medical therapeutic performance, or physical training,
4a) said electronic sensors being comprised of, but not limited to, a resistor that forms a variable resistance to electric current flow, such as a film of carbon, but not limited to, that forms a resistance to electric current flow, in contact with said resistor,
5) said central processing unit capable of performing tasks as specified in the order defined in digital program, including, but not limited to processing of sensor output signals, execution of control functions defined by the digital program, providing actions in accordance to accurate time intervals, generation of audible sound,
6) said digital program defines control functions that implement therapy or physical rehabilitation regimes,
7) said digital program defining control functions that implement tasks for managing and conserving electrical power,
8) said digital program defining control functions that implement tasks for determining accurate intervals of time,
9) said digital program defining control functions that implement tasks for determining time of day, (for those medical apparatus that need to be turned on or off to begin or end therapeutic sessions),
10) said digital program defining control functions that implement tasks for communicating with a separate agent,
11) said digital program being stored in memory within the electronic module that contains the central processing unit, and or being stored in memory that is not within the electronic module that contains the central processing unit but that is accessible by the central processing unit,
12) said digital audio sound data being stored in memory within the electronic module that contains the central processing unit, and or being stored in memory that is not within the electronic module that contains the central processing unit but that is accessible by the central processing unit,
13) directory table containing descriptive information about those commands, responses, measurements, or words as aforementioned about said digital audio sound data that is stored in memory within the electronic module that contains the central processing unit, or being stored in memory that is not within the same electronic module that contains the central processing unit but that is accessible by the central processing unit,
13a) said digital audio sound data being arranged into multiple units, each unit representing an audible verbal message comprised of a series of words as programmed per the requirements in synthesis with the medical apparatus's therapeutic use,
13b) a method for retrieving and generating the audible sound representing the digital audio data from the start of the message to the end of the message as corresponds to the therapeutic dialogue needed,
13c) a method for retrieving and generating the audible sound representing the digital audio data from an intermediate pint in the message to a subsequent intermediate point in the same message, to allow the medical apparatus to respond to the measurements being produced by the patient accordingly and guide the patient according to the measurement amount,
14) said electronic module for generation of audible sound being the same electronic module that contains the central processing unit, and or a being separate electronic module for the module that contains the processing unit,
15) said electronic module for generation of audible sound including a module that converts digital audio data into continuous analog signal that is amplified to increase the signal power as needed to create audible sound from sound generating modules such as, but not limited to, speakers,
15a) said electronic modules for generation of audible sound providing a sound generating a continuous analog signal that is one half the value of the maximum signal level, such level representing zero sound to be generated,
15b) said electronic module for generation of audible sound providing a sound generating module such, but not limited to, speaker(s) that is capable of receiving a level that is one half the maximum signal level in a way that produces no sound and consumes little or no power,
15c) said sound generating module such as, but not limited to, a speaker(s) whose reference signal level is set at one half the maximum signal level such that it produces no sound when it receives such a signal level,
15d) said sound generating module being provided a reference signal level set at on half the maximum signal level by connecting it between a series of batteries in a way that provides a reference signal that is exactly on half the signal level that is produced by the above said batteries connected in this way,
16) said digital program defining a method for determining the value of a sensor output signal, generating an audible verbal response according to a pre-determined set of controls and functions as described herein, in order to provide instructional information to the operator of whatever medical apparatus is being used for instructional information or guidance,
17) said digital program defining a set of pre-determined set of controls and functions relating sensor output signals to audible verbal commands, responses and measurements, comprises of improving medical conditions of the patient through the use of the said medical apparatus accordingly, along with the present invention.
Furthermore the present invention can include a deactivation chip, which is different from slip chip that can also be used with the present invention. The slip chip can be a component of the invention that can be removed to start the Incentive Spirometer when the nurse or other person removes the slip chip from the unit. The slip chip can also be replaced back to stop the unit from automatically sending voice messages (as programmed for the patient) should there be a need that requires the apparatus or unit to be turn off.
The deactivation chip can be comprised of basic components, such as, but not limited to, the microcontroller, chip(semiconductor) and circuit boards and can be configured or assembled as one removable unit. These components can be reused (even with a disposable Incentive Spirometer) by removing the unit consisting of the components prior to disposing with the rest of the Incentive Spirometer. This, feature helps to save cost for a hospital, patient, etc., as these components can be reused with another Incentive Spirometer for another patient. Thus, when the patient has completed the therapeutic sessions and does not need the Incentive Spirometer, the unit consisting of the components can be removed and used again in the next Incentive Spirometer that is brought in. Several deactivation chips can also be used as needed for more than one patient. The removable unit can be referred to as a deactivation chip since when the unit is removed the components of the unit turn off (i.e. deactivate). The removable unit can be preferably incapsulized so that it is noncontaminated from the patient using the Incentive Spirometer, which thus allows the unit to be removed and reused.
FIG. 6 illustrates stop member for the Incentive Spirometer which prevents the float from significantly moving within the cylinder (housing) in the horizontal plane such that the conductive area of the skirt remains properly aligned with the conductive area (i.e. conductive strip on cylinder wall) on the cylinder for making appropriate contact needed for accurate measurement readings. The measurement readings can then be sent through an output signal to the proper components for further processing. In one embodiment the stop member can be a guiding rod or protrusion or an indention in the molding of the housing itself that could run the extent of the cylinder containing the float (with a means within or on the float that would follow the guide, in order to keep the float aligned). In another embodiment a ridge or protrusion can stick out enough within the cylinder and fit within an indention or cutout on the float itself.
FIG. 7 illustrates a screen shot for one configuration or embodiment of a PC or computer software interface for a base station. The base station provides an alternative mechanism for customizing the Incentive Spirometer by allowing the doctor or whoever to set the time between sessions, turn off times (i.e. without using a photosensor), etc. However, it should be recognized that the Incentive Spirometer can be programmed or customized without the use of a base station and the present invention does not require a base station to fulfill the functions as described above. The base station provides an optional mechanism for the user. The base station also has the ability to allow the operator or person programming or retrieving data to place the Incentive Spirometer in a molded like area for both customizing and retrieving the data stored within the Incentive Spirometer regarding the patient's performance(s) from using the Incentive Spirometer (i.e. measurement readings). The platform for the base station can be provided with one or more pins that insert in the bottom of the chip on the Incentive Spirometer to allow conductivity to perform these said functions. This feature allows the Incentive Spirometer, or any other medical device, to communicate with a computer for working with medical data, and any adjustments can be made on the screen, such as, but not limited to the adjustment capabilities shown on the screen of FIG. 7 . Any adjustment(s) made can then be sent to the electronic components of the Incentive Spirometer through the base station. The Incentive Spirometer can be adjusted or transmit or its medical date through physical connection, such as, but not limited to, through a docking or base station or it can receive and/or transmit information (i.e. adjustment, medical date, etc.) through wireless technology.
The computer will be able, such as by using a curser controlled by a keyboard, mouse, and/or similar devices, (thus avoiding the need for a large apparatus), to make the programming of the Incentive Spirometer simple. In one embodiment, in addition to the computer, a means for holding the Incentive Spirometer (i.e. docking or base station, etc.) is provided to retain the Spirometer, while one uses their mouse and/or keyboard on the computer to adjust or customize the program stored on the Incentive Spirometer. Similarly, the user can also obtain any data stored by the Incentive Spirometer.
In one embodiment, the base station can form a mold in the shape of part of the Incentive Spirometer where the programming area is connected, such as, but not limited to the bottom of the Spirometer where the electronic components to facilitate the functions of the present invention can be preferably located. The actual shape is not considered limiting. It is preferred that there is some correspondence in shapes between the relevant portions of the spirometer and base station, so that the physical mating of the two components is accomplished easier. Alternatively, the base station can be sized and/or shaped to encompass or accommodate more than one size of Spirometer or medical apparatus, and can be manually adjusted to fit or correspond to the size and shape of the apparatus that is connected thereto.
The base station can be a device which facilitates interface to a PC or computer via a USB cable for customization and data download of the Incentive Spirometer, back and forth wireless transmissions can also be communicated through or controlled by the base station. In one embodiment, the Incentive Spirometer can be pressed down onto the base station and the base station can be plugged into the PC or computer, such as through a cable, cord, USB port, etc. The screen shot illustrated in FIG. 7 shows one non-limiting version of the software interface on the PC or computer which can be used to communicate with the Incentive Spirometer. The following represents a summary of the functionality of the base station/PC(computer)/Software combination.
Time Selector: The upper bar on the screenshot can change the “Active Time” of the unit. Any session times outside of the window will not activate the Spirometer so that the patient can sleep or otherwise not be disturbed.
Frequency: Standard Frequency of testing can be every 1 Hour, though such is not considered limiting. This can be adjusted in 15 minute intervals or any other desired interval and all are considered within the scope of the invention.
Number of Exercises: The patient can be required to do several exercises (i.e. 4, etc.) exercises every session by default. The number of exercises per session can be adjusted.
Target Volume: This can be an optional parameter. The Hospital or other user can set this target volume to a value appropriate for each patient.
Load Configuration: This can be a convenience button. One can load up the configuration for “Standard Patient” or “Senior Male” or “Female Child”. There may be some standard set of parameters that the hospital wants to use for different classes of patients.
Save Configuration: Where values to a group of settings that may be used commonly are set, one can save it off to a file for easy retrieval.
Update Configuration: Write the configuration data to the Serial FLASH.
Download Data: The Incentive Spirometer stores exercise result data in the Serial FLASH. This data can be downloaded and saved to a file on the PC or computer by using the Download Data button to confirm patient compliance.
Thus an interface for configuring the Spirometer via the base station can be provided. The top bar can provide times that the Spirometer is “Awake”. i.e., it won't prompt the patient at any time outside of this time band so they can sleep. Thus, the Spirometer can be programmed, customized and adjusted, using the base station, according to the current therapeutic requirements of the patient. In summary, the base station provides a means for programming a particular apparatus (i.e. Incentive Spirometer, etc.). The base station can comprise a means through a connective source that combines measurements, instructions, specific target goals, predetermined values and intervals for rest periods, that may be needed between particular exercises, in order that those therapeutic guidelines are combined in synthesis with whatever apparatus is being programmed. This is not only limited to solely therapeutic needs, as a “timer” may be used for various medical requirements, such as, but not limited to, washing a valve, etc. The base station provides a means for programming the Incentive Spirometer with the therapeutic guidelines, per the particular requirements needed, for the patient and physician's specifications and provides a way for adjusting or customizing each Incentive Spirometer to the specific needs of the patient.
Thus, the Incentive Spirometer, with or without the base station, can be programmed or customized for any adjustments that relate to the exact therapeutic requirements desired by the one who is setting the Incentive Spirometer, within the guidelines of the apparatus, including, but not limited to, period of time in which the unit turns off as well as turns back on to allow for a sleep period for the patient.
The base stations can be programmable and/or operate in one or more languages. In one embodiment, the user can select the language of choice.
It should be recognized the present invention is not considered limited to any specific type of Incentive Spirometer or Incentive Spirometry device. The present invention improvements can be incorporated into any and all Incentive Spirometry devices including, but not limited to, flowrate and volumetric, and all are considered within the scope of the invention. Furthermore, the present invention improved Incentive Spirometry devices can be provided in a disposable or non-disposable construction or configuration and both are considered within the scope of the invention.
It is also within the scope of the invention to use any means for providing flowrate measurements using said verbal employment, including, but not limited to millions of microelectronic hairlike components situated on the area of breathing, measuring the float within the cylinder of the apparatus by conductive strips or by infra red light placed beneath the float or similar unit for determining the volumetric measurements, but not limited to this particular exact means, etc. All capable measuring embodiments are considered within the scope of the invention for achieving the function of the device.
Though the preferred embodiment for the present invention does not use beeps or other audible noises for prompting, it is within the scope of the present invention to also use beeps or audible noises for prompting purposes. As the present invention uses audible messages, such as verbal voice messages, the benefits of the improved Incentive Spirometry devices of the present invention can also be experienced by a “blind” person, who is unable to see visual images.
Thus, in the preferred embodiment the present invention discloses an Incentive Spirometer that audibly, verbally prompts, encourages usage, commands, responds, and/or gives measurements, using humanlike voices to increase compliance by a person utilizing the Incentive Spirometer.
FIG. 8 illustrates a general schematic for the resistive method used for the sensing/measurement component. As discussed above, the current float height measurement method makes use of a resistive strip. This strip is in physical contact with a brass or other conductive material wiper mounted, coated or incorporated on the float. This contact completes the circuit and sends a voltage reading proportionate to the height of the float.
FIG. 9 illustrates an alternative means for determining movement or use of the Incentive Spirometer or other medical or non-medical device and for reading measurements obtained from use of the Incentive Spirometer. In this alternative method, the sensing component is a capacitive sensing component which can be used for determining use of the device, and where desired the measurements obtained by the user from such use. As mentioned above, many medical devices and medical apparatuses require patient usage or performance compliance information, which use or performance needs to be sensed for purposes of ensuring compliance by the patient and to determine the result or measurement obtained from the patient's use or performance.
Though discussed with being used with an Incentive Spirometer, it should be recognized that the capacitive sensing component can be used with various types of devices and apparatuses and all are considered within the scope of the invention.
In this alternative sensing embodiment or configuration a capacitive method is employed where all materials have capacitance (i.e. material's ability to hold electrons). A higher capacitance component in a circuit will cause the voltage to rise more slowly when switched onto that circuit node. Therefore, a change in capacitance can be measured by switching a voltage to the node and detecting a change in voltage rise time. Since the capacitance of an element in the circuit is increased when a conductive object gets near to it, the present invention can detect the proximity of a metalized float as it rises up and down the tube by placing metallic pads, pins or other metallic objects along the length of the Incentive Spirometer tube and monitoring a change in capacitance at each pad/object. A non-limiting example of the circuit is illustrated in FIG. 9 . In this embodiment, there is no physical contact and therefore no friction to overcome. Also, the complete circuit board can be embedded into the side wall of the Incentive Spirometer tube, which can greatly facilitate manufacturability and reliability. Information obtained from the capacitive method is stored within the embedded processor, similar to how described above for the resistive/conductive method. The Incentive Spirometer with the capacitive method performs the same functions and purposes and communicates with same processor, audio response unit, audio storage unit, etc. as described above for the resistive/conductive embodiments.
As seen in FIG. 9 , the float can be coated or otherwise provided with a material that conducts a continuous electrical current across the sensor, which permits the sensor to achieve capacitance. The capacitive sensor works based on proximity and does not have to be directly touched by the float to be triggered.
With the preferred capacitive proximity sensing embodiment, the need for the conductive material in the inside of the tube of the Incentive Spirometer can be eliminated. Some additional advantages over the resistive method discussed above, include, but are not limited to, (a) twice as much programming space; (b) more reliable operation in view of the elimination of parts sticking due to friction; (c) easier manufacturing, and (d) no need to calibrate each unit based on the resistance of the tape. One non-limiting example of a capacitive microchip that could be used with the capacitive proximity sensing embodiment of the present invention is microcontroller part number: Cy8C20434-12LKX.1 made by Cypress. However, other microcontrollers and/or microchips can be used and all are considered within the scope of the invention.
In use, the capacitive sensor functions by detecting the presence of electrically conductive objects. The float can be coated or otherwise provided with a conductive material for detection by the capacitive sensor, which can provide the ability to measure the level of the float. Given that the capacitive sensors detect the presence of conductive material, the proximity of other conductive objects to the capacitive sensors can affect the readings by the sensor. Thus, the conductive presence within the body of the user of the Incentive Spirometer and other conductive objects that are within the sensing vicinity of the sensors should be isolated and prevented from being detected by the capacitive sensors. In one embodiment, a physical guard or cover can be disposed around the sensor region. A keep out distance or spacing of approximately ½ inches is considered sufficient to avoid interference. However, other dimensions can be used and are considered within the scope of the invention. In one non-limiting embodiment, the cover can be disposed around the tubular area of the housing of the incentive spirometer. The spacing distance ultimately selected for the cover from the sensors should be sufficient to block the sensors from detecting conductivity, except for the conductive material associated with the float. With the cover in place, the sensors are permitted to accurately read or detect the exact volumes on the side of the tube (i.e. 500, 1000, 1500, etc.). Any material that can block the non-desired conductivity from being detected by the sensors, can be selected as the material for the covering.
Additionally, in all of the above-described embodiments, the present invention can be turned on and turned off, through programming the microcontroller to perform such functions, and without relying or a light or photo sensor, or any other mechanism to perform such function.
It will be seen that the objects set forth above, and those made apparent from the foregoing description, are efficiently attained and since certain changes may be made in the above construction without departing from the scope of the invention, it is intended that all matters contained in the foregoing description shall be interpreted as illustrative and not in a limiting sense. The instant invention has been shown and described herein in what is considered to be the most practical and preferred embodiment.
|
An apparatus used in the medical industry, in order to increase transpulmonary pressure and respiratory volumes, to improve inspiratory muscle performance and re-establish the normal pulmonary hyperinflation, through the employment of electronic technology, providing audible, simulated, verbal, human sounding words, that assist, guide and prompt, increasing patient usage. In one embodiment, the Incentive Spirometer uses a capacitive sensing circuit for sensing movement of the float within the tube wall and for obtaining a measurement or reading of the patient's performance with the Incentive Spirometer.
| 6
|
CROSS REFERENCE TO RELATED APPLICATIONS
This document claims priority to French Application Number 03 01480, filed Feb. 7, 2003 and U.S. Provisional Application No. 60/449,877, filed Feb. 27, 2003, the entire contents of which are hereby incorporated by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a packaging unit for an article such as an article containing a cosmetic product, and in particular a case or a small box.
2. Discussion of Background
There are known types of packaging which include viewing windows allowing the product located inside the packaging to be viewed. Such a window, however, reduces the surface area of the packaging on which a decorative motif or an inscription can be printed. However, if the packaging does not include a window, in order to exploit the entire surface for decoration, it is not possible to view the article without opening the packaging.
EP 0 403 134 likewise describes a packaging unit which includes a window to enable an article inside the packaging to be seen. The window is formed by a hologram. Depending on the angle at which it is viewed, this arrangement allows for the image carried by the hologram, or the article which is present inside the packaging, to be seen. Holograms, however, require certain lighting conditions in order for the image which they carry to be correctly visualized. In addition, because holograms are generally colored, it will only be possible to see the article located inside the packaging through the colored window, in such a way that the true aesthetic qualities of the article cannot be seen.
U.S. Pat. No. 6,023,866 on the other hand describes an item in the form of a card having a support element on which are located strips bearing portions of an image in such a way as to form several images. The card is not configured in such as way as to be used to package an article.
SUMMARY OF THE INVENTION
It is an object of the invention to provide a packaging unit for an article which will allow the purchaser to see the article while still allowing for a surface to be obtained which can accommodate a relatively large decorative motif.
It is another object of the invention to provide a packaging unit with a new decorative effect.
According to the invention these objects can be achieved by a packaging unit which delimits a space in which an article is located containing a cosmetic product. In accordance with a preferred arrangement, at least one portion is configured to allow at least a part of the article to be seen when viewed in a first direction. When viewed in a second direction different from the first, a first decorative motif can be seen. The arrangement includes at least a first transparent element enabling the article to be viewed and at least a second element covered by the first motif, with the two elements extending in different planes. The arrangement can also be configured such that, in a third direction of observation distinct from the first and the second, a second decorative motif can be seen which is identical to or different than the first.
A packaging unit of this kind allows for the article which it contains to be observed from the outside without opening the packaging, while still providing an external surface of considerable size for decoration.
According to another advantageous aspect, the packaging offers several different views according to the position in which it is being observed. Accordingly, depending on how one moves in relation to the packaging, it is possible to perceive different types of decoration and/or the article. In addition, depending upon the vantage point, one can view, separately or simultaneously, part of the decoration and part of the article itself. With this arrangement, it is possible to adorn points of sale, and in particular shop display windows, at a low cost.
According to an example of the invention, the first transparent element can include a transparent material or even be formed by an opening. This allows the real aesthetic appeal of the article to be visualized. A second packaging element can take the form of a strip, and preferably can include several strips arranged in parallel with one another.
The viewing arrangement can include an insert formed of a sheet folded into a plurality of strips. Alternatively, the viewing portion can include an insert formed by the extrusion of a thermoplastic material or by molding of a single piece of thermoplastic material, in particular by injection molding or thermoforming.
The packaging can take the form of a box or case. In a particularly preferred form, the arrangement is used to pack an article containing a cosmetic product.
According to one of the advantageous aspects of the invention, a packaging unit is provided which delimits a space suitable for containing an article, and which includes at least one portion which, viewed from a first direction, is configured to allow viewing of at least a part of the article and which, viewed from a second direction different from the first, allows a first decorative motif to be seen. This portion includes at least one first element, made of transparent material, allowing for the viewing of the article, and at least one second element covered by the first motif, with the two elements extending in different planes.
The above and other advantageous aspects of the invention will become apparent from the examples disclosed herein. It is to be understood that implementations of the invention need not include every feature of the illustrated examples, but instead could include only some or portions of the illustrated embodiments, or could include variations of the examples described. In addition, implementations need not achieve all of the above described objectives, but might only partially achieve the above objectives as desired.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will become further apparent from the following detailed description, particularly when considered in conjunction with the drawings in which:
FIG. 1 represents an exploded view of a package according to a first embodiment of the invention;
FIGS. 1A to 1C show perspective views from three different directions of the package according to the first embodiment;
FIGS. 2A to 2C represent the different stages of a method of producing an insert arranged in the package illustrated in FIGS. 1 and 1A to 1 C;
FIGS. 3A to 3C show perspective views from three different directions of a package according to a second embodiment;
FIGS. 4A to 4C represent the different stages of a method of producing an insert arranged in the package illustrated in FIGS. 3A to 3C ; and
FIG. 5 represents a variant of the second embodiment.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The packaging unit 10 represented in FIGS. 1 and 1A to 1 C, is in the form of a case. It delimits a space 11 intended to accommodate a bottle of perfume 30 , for example. The case 10 is a parallelepiped in shape and made of thermoplastic material. Alternatively, the case can be made of any other material, such as cardboard, wood, metal, etc. The illustrated example includes six faces, of which one face 12 is traversed by a window 13 , rectangular in shape, for example. The window 13 may, as an alternative, be square, circular, oval, or any other shape. In addition, the case or package can have various other shapes. An insert 20 is fixed in the window 13 .
The insert 20 includes a transparent sheet 21 extending in a plane P. Several identical small strips 22 , each having two opposed faces 22 a and 22 b , preferably extend in a plane perpendicular to the plane P of the sheet 21 , with the small strips preferably arranged parallel to one another. A portion 23 of the sheet 21 preferably surrounds the small strips 22 in such a way as to form a peripheral frame which is intended to be fixed onto the inside surface of the face 12 of the case, all around the window 13 . Preferably, the sheet is recessed such that the small strips do not impinge on the face 12 . For example, the arrangement can be adhesively bonded to the inside surface of a recess 14 surrounding the window. The sheet 21 and the small strips 22 can be formed from a single piece, for example, by extrusion of a thermoplastic material.
A protective film, not shown, could also be provided to protect the small strips from the outside. The film may, for example, be fixed to the opposite side of the sheet 21 in relation to the strips, on the outer surface of the face 12 .
A first decorative motif A, for example of trees, is drawn on a first face 22 a of the strips. In the illustrated arrangement, the entire motif is distributed over the faces 22 a , with each face having a portion of the motif or design. The motif could also be formed by or take the form of an inscription or printing relating to the article. A second decorative motif B, such as a geometric form substantially oval in shape in the illustrated example, is drawn on the second face 22 b of the strips, opposite the first. As with the design or motif on the first faces, the motif on the second faces can be distributed over all of the faces 22 b or over a plurality of the faces.
When the case is viewed in a direction perpendicular to the plane P of the sheet 21 , the perfume bottle 30 (or other cosmetic container) is seen across the sheet 21 which is transparent, as well as the segment 22 c of the strips 22 (see FIG. 1B ). When the case is viewed in a direction forming an angle of, for example, 45° in relation to the sheet 21 , from the left, the first motif A, namely the trees, is seen, which motif is represented on the faces 22 a of the strips, without seeing the bottle (see FIG. 1A ). When viewed in a direction forming an angle of, for example, 45° in relation to the sheet 21 , from the right, the second motif B can be seen, namely the oval geometric shape, which is represented on the faces 22 b of the strips. Between these viewing positions it is possible, from intermediate directions, to see in part the perfume bottle and in part one of the motifs A or B.
In order to form the insert 20 , a thermoplastic material can be extruded such as, for example, polypropylene, polyethylene or polyethylene terephthalate, in such a way as to form the sheet 21 and the strips 22 arranged in a perpendicular manner to the sheet, as can be seen in FIG. 2A . A printing roller is then passed over the insert 20 , displacing it in a manner perpendicular to the strips 22 , as represented in FIG. 2B . The first decorative motif A is thus printed on the faces 22 a . A printing roller is then passed in the other direction in such a way as to print the second decorative motif B on the second faces 22 b opposite the first faces (see FIG. 2C ). When the roller is passed, the small strips 22 are flattened out in such a way that they protect against any printing on the sheet 21 of the insert, which remains transparent.
The insert which is thus obtained is inserted in the case which can be formed in a conventional manner. The insert 20 is, for example, adhesively bonded over its entire periphery 23 to the inside surface of the face 12 surrounding the window, in particular on the inside surface of the recess 14 . Alternately, the insert could be coupled or fixed by other expedients and/or could be coupled at selected locations rather than the entire periphery.
According to a variant which is not shown, the wall in which the window is formed can be curved. This can be, for example, a packaging unit that is cylindrical in shape. The strips are then no longer arranged in a parallel manner to one another, and are each arranged perpendicular to the curved wall. According to this embodiment, each motif or portions of one or more motifs appear in a progressive manner as the viewer moves along this curve.
The packaging unit 110 represented in FIGS. 3A to 3C is in the form of a case or box identical to that which has just been described, but having an insert 120 which differs from that which has just been described. A perfume bottle 130 is likewise located in the interior of the packaging unit.
The insert 120 is formed by a sheet 121 folded in such a way as to form first strips 122 , arranged on the same plane, separated by ridges 123 formed by second and third strips 123 a and 123 b . In order to form the insert, a sheet 121 is taken as the starting point, which sheet is initially transparent, and on which is printed a decorative motif A, such as a rectangle ( FIG. 4A ). The motif A can be spread or distributed over the second strips 123 a , while the rest of the sheet 121 , namely the strips 122 and 123 b , remain transparent. The second strips 123 a are folded in such a way as to form an angle of preferably 45°, by way of example, in relation to the plane of the strips 122 and the third strips 123 b are folded in such a way as to form an angle of 90° in relation to the plane of the strips 122 (see FIG. 4B ). A transparent support film 124 can also be adhesively bonded to the faces of the first strips 122 , opposite the ridges 123 , in such a way as to support the sheet 121 folded in this manner (see FIG. 4C ).
The insert 120 obtained in this way can be fixed in the case 130 by adhesively bonding, for example, the periphery of the film 124 to the inside surface of the face 112 , around the window 130 , with the ridges 123 oriented towards the interior of the case.
Alternatively, the insert 120 can be fixed in the other direction, namely by arranging the ridges 123 toward the outside of the case and the film 124 toward the inside. The insert can then be adhesively bonded at its periphery to the case, for example, on a recess provided around the window 113 , preferably in such a way that the ridges do not impinge on or protrude from the window. Provision can then be made for a protective film which protects the insert from the outside, which can be fixed to the opposite side of the film 124 and adhesively bonded to the outer surface of the face 112 .
According to this embodiment, when the case is viewed in a direction or from a vantage point perpendicular to the plane of the strips 122 , the first motif A on the strips 123 a is seen in part, and in part the perfume bottle (or other cosmetic container) is seen across the first transparent strips 122 and the film 124 ( FIG. 3B ). When viewed in a direction forming an angle of 45° in relation to the plane of the strips 122 , from the left, the perfume bottle 130 is seen across the strips 122 and 123 b and the film 124 ( FIG. 3A ). Finally, when seen in a direction forming an angle of 45° in relation to the plane of the strips 122 , from the right, only the motif is seen, namely the rectangle which is represented on the second strips 123 a , without the perfume bottle being seen.
According to a variant of this second embodiment represented in FIG. 5 , the three strips can have a substantially identical width. The first strips 222 are transparent, while a first motif A is printed on the second strips 223 a and a second motif B is printed on the third strips 223 b . The second and third strips with this arrangement can be adhesively bonded to one another, and can be arranged in a substantially perpendicular manner to the first strips 222 which extend in the same plane. A transparent support film 224 can further be adhesively bonded to the faces of the first strips 222 in such a way as to support the whole of the sheet folded in this manner. Accordingly, the same visual effect is achieved as with the insert described in the first embodiment. As with the earlier embodiments having plural motifs, the motif viewable at one angle can be the same or different from the motif viewable at another angle.
According to another embodiment, not shown, the insert can be formed by a peripheral frame which extends in one plane and delimits a rectangular opening, and by the associated strips. The strips can be arranged parallel to each other, and each extend, for example, in a plane perpendicular to the plane of the frame or in other words the plane along which the opening defined by the frame extends. The two ends of the strips are, for example, inserted into slots provided in the frame in such a way as to be maintained in the frame at an angle with respect to the plane of the frame. According to this embodiment, the strips can be printed on one face only, or on both their faces, before being inserted into the frame. They can, for example, be printed before being cut into strips, or after being cut. In this case, the same visual effect is again obtained as with the insert described in the first embodiment, with the perfume bottle being visible when the case is viewed in a direction perpendicular to the plane of the frame, looking across the opening.
It is of course possible to provide a box or case comprising several windows, each provided with an insert such as that which has just been described.
Obviously, numerous modifications and variations of the present invention are possible in light of the above teachings. It is therefore to be understood that, within the scope of the appended claims, the invention may be practiced otherwise than as specifically described herein.
|
A packaging unit delimiting a space in which an article can be located such as an article containing a cosmetic product. The packaging includes at least one portion configured so that, when seen in a first direction, at least a part of the article can be seen and, when seen in a second direction different from the first, a first decorative motif can be seen. The portion includes at least one first transparent element allowing the article to be viewed, and at least one second element having the first motif associated, with the two elements extending in different planes.
| 1
|
CROSS-REFERENCE TO RELATED APPLICATION(S)
This application is related and claims priority to Provisional Application No. 61/302,972, filed Feb. 10, 2010 and Provisional Application No. 61/303,671, filed Feb. 11, 2010, each of which are hereby incorporated by reference.
BACKGROUND
Universal Mobile Telecommunications System (UMTS) is one of the third generation (3G) mobile telecommunications technologies and is also being developed into a 4G technology. UMTS terrestrial radio access network (UTRAN) is a collective term for a core network including base stations, known as Node Bs, and base station controllers, known as radio network controllers (RNCs), which make up a UMTS radio access network. A UTRAN can carry many traffic types, from real-time circuit-switched traffic to IP-based packet-switched traffic. A UTRAN allows connectivity between user equipment (UE) and the core network. The RNC provides control functionalities for one or more Node Bs. A Node B and an RNC may be combined in a single device, although typical implementations have a separate RNC located in a central office serving multiple Node Bs.
Recently the evolution of mobile access points within the mobile telecommunication industry has introduced femtocells into wireless communication systems. A femtocell is a small cellular base station, typically designed for use in a home or small business. Femtocells generally connect to the service provider's network via a customer's broadband connection, such as a Digital Subscriber Line (DSL) or cable broadband connection. A femtocell allows service providers to extend service coverage indoors, especially where access would otherwise be limited or unavailable. In 3G terms, femtocells are called Home Node Bs (HNBs).
HNBs are often arranged in uncoordinated large-scale deployments of several HNBs, and therefore the connection to the operator's core network needs to be realized efficiently. A closed subscriber group (CSG) is a specific group of UEs permitted access to a HNB. A CSG identifier (CSG-ID) is broadcast from the HNB in a system information block message (SIB), and only those UEs that are members of this group, as defined by a CSG whitelist of CSG IDs (generally stored on the UE), will attempt to select the cell.
Before deciding to hand over a UE to a HNB, a UTRAN generally needs to acquire UE measurement information related to the target HNB cell. The UTRAN can control what measurements the UE performs. In order to allow the UE to make those measurements efficiently, proximity detection can be configured within the UE via a radio resource control (RRC) measurement control message issued by the UTRAN. One type of measurement sent to a UE contains “CSG proximity detection” information, which is used by the UE to enable a proximity detection function to enter or leave one or more HNB cells within the UE's CSG whitelist. HNBs detected by the UE can be reported by the UE to the UTRAN via a proximity report in a measurement report message.
The 3rd Generation Partnership Project (3GPP) specifications define four RRC states in the connected mode: CELL_DCH, CELL_FACH, CELL_PCH, and URA_PCH. These states reflect the level of UE connection and the transport channels that can be used by the UE. For example, the CELL_FACH state, CELL_PCH state and URA_PCH state are characterized by the fact that there is no dedicated transport channel. In contrast, a UE in the CELL_DCH state has an assigned dedicated transport channel. A dedicated transport channel is not allocated in CELL_FACH, where a default common or shared transport channel is assigned. The descriptions for RRC layers are detailed in specification “3GPP TS 25.331 Radio Resource Control (RRC)” and hence are not repeated in detail.
SUMMARY
Current 3GPP specifications indicate that the UTRAN configures proximity detection in a UE by using the CELL_DCH state. While in the CELL_DCH state, the UE receives messages from the UTRAN instructing the UE as to what to measure, when to measure it, and how to report the measurement results. However, when the UE moves from CELL_DCH to CELL_FACH, CELL_PCH, or URA_PCH, there is no standard within current 3GPP specifications to instruct the UE when, where, and how to perform proximity detection and/or report proximity indication to the UTRAN. This creates inefficiencies resulting in decreased battery life of the UE, potential loss of transmitted data, degraded radio resource utilization, and erroneous configurations stored by the UTRAN and/or UE.
Introduced herein are methods and a system for configuring a UE for handling proximity indication and proximity detection in a wireless communication system.
In one embodiment, a UE configured with proximity detection stops reporting proximity indication to the UTRAN when the UE transitions from the CELL_DCH state to one of the CELL_FACH, CELL_PCH or URA_PCH states. Upon stopping the proximity indication reports, the UE stops performing proximity detection.
In some embodiments, a UE configured with proximity detection invalidates or deletes proximity detection configuration stored at a memory of the UE when the UE transitions from the CELL_DCH state to one of the CELL_FACH, CELL_PCH, or URA_PCH states. Upon invalidating or deleting the proximity detection configuration, the UE stops performing proximity detection. Additionally, the UTRAN can invalidate or delete proximity detection information stored by the UTRAN.
In a further embodiment, a UE configured for proximity detection retains proximity detection configuration information stored at a memory of the UE when the UE transitions from the CELL_DCH state to one of the CELL_FACH, CELL_PCH, or URA_PCH states. Upon retaining the proximity detection configuration information, the UE continues to perform proximity detection and to send proximity indication reports, based on the retained proximity detection configuration information. Additionally, the UTRAN retains proximity detection information used to configure the proximity detection at the UE.
In yet another embodiment, a UE configured for proximity detection retains proximity detection configuration information stored at a memory of the UE when the UE transitions from one of the CELL_FACH, CELL_PCH, or URA_PCH states to CELL_DCH. Upon retaining proximity detection, the UE continues to perform proximity detection and to send proximity indication reports, based on the retained proximity detection configuration information.
The solutions presented herein overcome the limitations of prior art, which defines configuring proximity indication in a UE by using CELL_DCH to establish procedural control to configure the UE to detect and to report proximity indication.
BRIEF DESCRIPTION OF THE DRAWINGS
One or more embodiments of the disclosed method/apparatus are illustrated by way of example and not limitation in the figures of the accompanying drawings, in which like references indicate similar elements.
FIG. 1 illustrates a wireless communications system having a UTRAN, UE, and HNB.
FIG. 2 is a high-level block diagram showing an example of the hardware architecture of a UE.
FIG. 3A is a timing diagram of an example communication between a UTRAN and a UE where proximity indication reporting is stopped when the UE transitions from using CELL_DCH to CELL_FACH, CELL_PCH, or URA_PCH.
FIG. 3B is a timing diagram of an example communication between a UTRAN and a UE where proximity indication reporting is retained when the UE transitions from using CELL_DCH to CELL_FACH, CELL_PCH, or URA_PCH.
FIG. 3C is a timing diagram of an example of communication between a UTRAN and a UE where proximity indication reporting is invalidated or deleted when the UE transitions from using CELL_DCH to CELL_FACH, CELL_PCH, and URA_PCH.
FIG. 3D is a timing diagram of an example communication between a UTRAN and a UE where proximity indication reporting is retained when the UE transitions from using CELL_FACH, CELL_PCH, or URA_PCH to CELL_DCH.
DETAILED DESCRIPTION
References in this specification to “an embodiment,” “one embodiment,” or the like mean that the particular feature, structure, or characteristic being described is included in at least one embodiment of the disclosed system. Occurrences of such phrases in this specification do not necessarily all refer to the same embodiment.
Current implementations of 3G wireless communication systems configure proximity detection in a UE using only one of the four connected mode RRC cell states, CELL_DCH. A UE operating in, or transitioned to, CELL_FACH, CELL_PCH, or URA_PCH has no procedure within current 3GPP specifications to enable, disable, or otherwise configure proximity detection. Similarly, the UTRAN used to configure, via CELL_DCH, proximity indication at the UE lacks a standard operating procedure when the UE transitions to CELL_FACH, CELL_PCH, or URA_PCH.
FIG. 1 shows a wireless communications system having a UTRAN 110 , a UE 100 , and an HNB 116 in which the techniques introduced here can be implemented. It is noted that the UE described here is an illustration of one type of a wireless device in which the techniques can be implemented and that other wireless devices can be used for implementing the techniques. For example, UEs may include a cell phone, a personal digital assistant (PDA), a portable email device (e.g., a Blackberry® device), a portable media player (e.g., an Apple iPod Touch®), a tablet or slate computer (e.g., an Apple iPad®), a netbook computer, a notebook computer, an e-reader, or any other device having wireless communication capability.
The UE 100 includes a display 104 used to make and to receive telephone calls and to display data services. In some embodiments, the display 104 is a touch screen that allows for the direct manipulation of displayed data. The UE 100 has a multifunction input module 106 to operate the UE 100 , navigate the display, and perform selections on data. The input module 106 can be, for example, a keyboard, mouse, trackball, touch screen, or any other input module capable of communicating a user selection. Additionally, the UE 100 operates an antenna system 102 to send and receive information via wireless networks.
The UTRAN 110 is a wireless communication network used to communicate to the UE 100 . The UTRAN 110 contains one or more base transceiver stations (or “Node Bs” in 3G networks) 112 to communicate to other base transceivers (not shown) and other network core components within the UTRAN 110 , such as a base station controller or RNC 114 . The core components 112 and 114 of the UTRAN 110 can communicate to the UE 100 via an air interface 108 , such as the wideband code division multiple access (WCDMA) air interface defined within the 3GPP specifications. The air interface 108 is used to handle control plane signaling between the UE 100 and the UTRAN 110 by using RRC messages to control various functions in the UE 100 , such as connection establishment, measurements, radio bearer services, security, and handover decisions.
The Home Node B (HNB) 116 is a femtocell. HNBs 116 may broadcast IDs via a radio frequency 118 that are discoverable by a UE 100 that is configured for proximity detection. The UE 100 detects proximity using an autonomous search function. Network-controlled handover functionality is typically required for a UE 100 in an RRC connected state within the UTRAN 110 . Before making a decision to handover to a HNB 116 , the RNC 114 needs to acquire UE measurement information related to the HNB 116 . A UE 100 that is able to determine that it is proximate to a HNB 116 can inform the RNC 114 by sending a measurement report message containing proximity indication. The RNC 114 and the UE 100 use RRC configuration protocols to communicate the proximity indication.
FIG. 2 is a block diagram of one embodiment of the internal structure of the UE 100 that can implement one or more features of the disclosed system. In the illustrated embodiment, the UE architecture 200 is a computer system that includes a processor subsystem 202 , which further includes one or more processors. The UE architecture 200 further includes a memory 204 containing an operating system 208 , a storage module 210 containing data 218 , an input module 211 , a display module 214 , and a communication module 216 , each interconnected by an interconnect 206 and powered by a power supply 209 .
The UE architecture 200 can be embodied as a single- or multi-processor system that preferably implements a high-level module to receive the data 218 from the UTRAN 110 . The received data 218 is communicated via the communication module 216 , which includes a single or multiple antenna system capable of receiving and transmitting the data 218 using one or more frequencies. The data 218 can be stored in the storage module 210 for retrieval by the processor subsystem 202 and memory 204 . The processor subsystem 202 is configured by the data 218 to perform the features of the system, such as configuring proximity detection and transmitting indication reports.
For example, and as further explained below, upon the receipt of an RRC message containing proximity detection configuration information from the RNC 114 , the communication module 216 , in conjunction with the processor subsystem 202 , relays the message to the storage module 210 via the interconnect 206 . Based on the proximity detection configuration information contained in the message, the processor subsystem 202 is configured based on the data 218 of the message to enable/disable proximity detection of CSG cells, such as the HNB 116 , and/or report the proximity indication to the UTRAN 110 .
The display module 214 is configured to connect to the display 104 ( FIG. 1 ) for illustrating information to view on the display 104 . Information for display can consist of textual, graphical, and/or multimedia information and is presentable in a graphical user interface. In some embodiments, the display 104 includes a touch-sensitive component that allows for the direct manipulation of displayed information. The displayed information is additionally manipulable by the input module 106 .
The input module 211 is configured to receive the data 218 from a signal originating from the input module 106 . The signal may include a user selection transmitted to the input module 211 , which conveys via the interconnect 206 the signal to the processor subsystem 202 and the operating system 208 .
The memory 204 illustratively comprises storage locations that are addressable by the processor subsystem 202 and components 209 , 210 , 211 , 214 , and 216 for storing software program code and data structures associated with the present system. The processor subsystem 202 and components may, in turn, comprise processing elements and/or logic circuitry configured to execute the software code and manipulate the data structures. The operating system 208 , portions of which are typically resident in the memory 204 and executed by the processor subsystem 202 , functionally organizes the UE architecture 200 by (among other things) configuring the processor subsystem 202 to invoke cell state selection and proximity indication related operations in support of the disclosed method/apparatus. It will be apparent to those skilled in the art that other processing and memory implementations, including various computer readable storage media, may be used for storing and executing program instructions pertaining to the technique introduced here.
One skilled in the art will appreciate that a similar structure may be used to operate the HNB 116 and Node B 112 . For example, the internal architecture of Node B 112 includes a communication module 216 , processor subsystem 202 , memory 204 , and storage module 210 , each configured to communicate via an interconnect 206 .
One skilled in the art will also appreciate that some or all of the disclosed method can be implemented using software stored on a computer-readable medium 204 and executed by a processor 202 .
FIG. 3A is a timing diagram of an example communication between a UTRAN and a UE where proximity indication reporting is stopped when the UE transitions from using CELL_DCH to CELL_FACH, CELL_PCH, or URA_PCH. Initially, the UE 100 is configured to use the RRC CELL_DCH state at step 305 . At step 306 , the UTRAN 110 sends proximity indication configuration information via a measurement control message to enable the UE 100 to detect proximity of CSG cells, such as a HNB 304 . The purpose of the measurement control message at step 306 is to set up, modify, or release a measurement in the UE 100 . Upon reception of the measurement control message at step 306 , the UE 100 performs actions based on the contents of the message. If the message directed the UE 100 to enable proximity detection, it performs detection at step 308 on the HNB 304 . For example, the UE 100 may perform CSG proximity detection to detect the proximity of the UE 100 to one or more HNBs 304 broadcasting a CSG identity within the UE's CSG whitelist. The UE 100 then sends the results of the detection at step 308 to the UTRAN 110 as a measurement report at step 310 . In addition to the results of the detection, the measurement report at step 310 may include results of other measurements, such as intra-frequency measurement or traffic volume measurement, configured by the UTRAN.
In step 312 , the UTRAN 110 makes the decision to transition the UE from the CELL_DCH state to a different RRC connected state, such as CELL_PCH, CELL_FACH, or URA_PCH. The decision 312 may be based on a list of events including activity of data transmission from/to the UE monitored by the UTRAN, or the receipt of the measurement report at step 310 . The UTRAN 110 initiates the radio reconfiguration procedure to transition the UE from CELL_DCH by sending a radio bearer reconfiguration message at step 314 . The UE 100 responds with a radio bearer reconfiguration complete message at step 316 . After receiving an acknowledgement message from the UTRAN 110 , the UE 100 enters a new RRC connected state (CELL_PCH, CELL_FACH, or URA_PCH) at step 318 depending on the state specified in the radio bearer reconfiguration message at step 314 . Upon transitioning from CELL_DCH to the new state at step 318 , the UE 100 may also stop sending proximity indication reports at step 320 and the UE 100 may stop performing proximity detection at step 322 . The UE 100 and UTRAN 110 may retain the proximity indication configuration information 324 previously used to configure the UE 100 at step 306 . The UE 100 can optionally (not shown) resume performing proximity detection after the transition from CELL_DCH. The UTRAN 110 may initiate (not shown) a similar radio reconfiguration procedure to transition the UE from the new state to CELL_DCH by sending a radio bearer reconfiguration message. The UE 100 responds with a radio bearer reconfiguration complete message. The UE 100 enters a new RRC connected state (CELL_DCH). Upon transitioning from the new state to CELL_DCH, the UE 100 may also resume sending proximity indication reporting. Additionally the UE may enable the proximity detection if the UE disables the proximity detection from CELL_DCH to the new state at step 338 of FIG. 3A .
In another embodiment (not shown), when the UE 100 transitions from CELL_FACH to CELL_PCH or URA_PCH, the UE 100 may stop sending proximity indication reports and the UE 100 may disable proximity detection. The UTRAN 110 may retain the proximity indication configuration information 324 previously used to configure the UE 100 .
FIG. 3B is a timing diagram of an example communication between a UTRAN and a UE where proximity indication reporting is retained when the UE transitions from using CELL_DCH to CELL_FACH, CELL_PCH, or URA_PCH. Steps 305 - 316 are similar to steps 305 - 316 of FIG. 3A . However, the UTRAN 110 decides to transition the UE 100 to CELL_FACH at step 311 . Upon transitioning from CELL_DCH to CELL_FACH, the UE 100 can determine whether it is configured for CELL_FACH measurement occasion information or high speed downlink shared channel (HS-DSCH) discontinuous (DRX) reception, at step 326 .
CELL_FACH measurement occasion information and HS-DSCH DRX reception in a CELL_FACH state define the times when the UTRAN 110 halts downlink transmissions to the UE 100 in the CELL_FACH state to allow the UE 100 to make measurements on other cells, such as the HNB 304 . Both CELL_FACH measurement occasion information and HS-DSCH DRX reception are configured by the UTRAN 110 using system information broadcasts sent to the UE 100 .
Upon transitioning the UE 100 from CELL_DCH to CELL_FACH and determining that the UE 100 is configured for CELL_FACH measurement occasion information or HS-DSCH DRX reception at step 326 , the UE 100 may continue to report proximity indication at step 328 by performing detection at step 330 and sending measurement reports at step 332 to the UTRAN 110 . The UTRAN 110 may retain the proximity indication configuration information previously used to configure the UE 100 at step 306 .
FIG. 3C is a timing diagram of an example of communication between a UTRAN and a UE where proximity indication reporting is invalidated or deleted when the UE transitions from using CELL_DCH to CELL_FACH, CELL_PCH, and URA_PCH. Steps 305 - 318 are similar to steps 305 - 318 of FIG. 3A . However, upon transitioning from CELL_DCH to the new state at step 318 , the UE may invalidate or delete proximity indication configuration information at step 336 and stop performing proximity detection at step 338 . The UTRAN 110 may also invalidate or delete at step 340 the proximity indication configuration information previously used to configure the UE 100 at step 306 . If the UTRAN 110 needs the UE to perform proximity reporting, the UTRAN 110 needs to send a second measurement control to configure the UE CSG proximity detection again.
An invalidation or deletion may be performed in any manner known in the art. For example, an invalidation may consist of an indication, such as a pointer, reference, or data flag, signaling that a current configuration of the UE 100 and/or the UTRAN 110 not be used. A deletion may be a removal of all or a portion of stored proximity indication configuration information stored at the UE 100 and/or the UTRAN 110 .
In another embodiment (not shown), when the UE 100 transitions from CELL_FACH to CELL_PCH or URA_PCH, the UE may invalidate or delete proximity indication configuration information and disable proximity detection. The UTRAN 110 may also invalidate or delete the proximity indication configuration information previously used to configure the UE.
FIG. 3D is a timing diagram of an example communication between a UTRAN and a UE where proximity indication reporting is retained when the UE transitions from CELL_DCH to CELL_FACH, CELL_PCH, or URA_PCH. Steps 305 - 318 are similar to steps 305 - 318 of FIG. 3A . However, upon transitioning from CELL_DCH to the new state at step 318 , the UE 100 retains the proximity indication configuration information at step 342 that was configured in step 306 . Additionally, the UE may maintain its ability to detect proximity indication at step 344 by performing detection at step 346 on one or more HNBs 304 and reporting the measurements to the UTRAN 110 at step 348 . The UTRAN 110 may also retain the proximity indication configuration information 350 previously used to configure the UE 100 at step 306 .
In some cases, the UE 100 may respond to the radio bearer reconfiguration message received at step 314 of FIGS. 3A-3D by transitioning to a state different from the state indicated by the message at step 314 . In these cases, the UE may invalidate or delete the proximity detection configuration information delivered in step 306 . For example, if the radio bearer reconfiguration message at step 314 contains information to configure the UE 100 to use cell state CELL_FACH, but the UE 100 selects cell state CELL_PCH, CELL_DCH, or URA_PCH, the UE 100 may delete or invalidate the proximity detection configuration information at the UE 100 .
Similarly, in another implementation of the embodiments described in FIGS. 3A-3D , if the UE 100 transitions to a new state at step 318 due to the radio bearer reconfiguration message at step 314 , and the message does not indicate a cell state to which to transition, the UE 100 may invalidate or delete its proximity configuration information.
In another embodiment (not shown), when the UE 100 transitions from CELL_FACH to CELL_PCH or URA_PCH, the UE 100 retains the proximity indication configuration information. Additionally, the UE may maintain its ability to detect proximity indication by performing measurements on one or more HNBs 304 and reporting the measurements to the UTRAN 110 . The UTRAN 110 may also retain the proximity indication configuration information 350 previously used to configure the UE 100 . If the UE 100 transitions to CELL_PCH or URA_PCH due to the radio bearer reconfiguration message and the message does not indicate a cell state to which to transition, the UE 100 may invalidate or delete its proximity configuration information.
In yet another implementation of the embodiments described in FIGS. 3A-3D , if the UE 100 transitions to a new state at step 318 not due to the radio bearer reconfiguration message at step 314 , the UE 100 may invalidate or delete the proximity configuration information at the UE 100 . For example, if the UE 100 cannot detect the UTRAN 110 due to a radio link failure, the UE 100 may perform a transition from one cell state to another. In this case, the UE may invalidate or delete its previously configured proximity indication.
The techniques introduced above can be implemented by programmable circuitry programmed or configured by software and/or firmware, or entirely by special-purpose circuitry, or in a combination of such forms. Such special-purpose circuitry (if any) can be in the form of, for example, one or more application-specific integrated circuits (ASICs), programmable logic devices (PLDs), field-programmable gate arrays (FPGAs), etc.
Software or firmware for implementing the techniques introduced here may be stored on a machine-readable storage medium and may be executed by one or more general-purpose or special-purpose programmable microprocessors. A “machine-readable medium,” as the term is used herein, includes any mechanism that can store information in a form accessible by a machine (a machine may be, for example, a computer, network device, cellular phone, personal digital assistant (PDA), manufacturing tool, any module with one or more processors, etc.). For example, a machine-accessible medium includes recordable/nonrecordable media (e.g., read-only memory (ROM), random access memory (RAM), magnetic disk storage media, optical storage media, flash memory devices, etc.).
The term “logic,” as used herein, can include, for example, special-purpose hardwired circuitry, software, and/or firmware in conjunction with programmable circuitry, or a combination thereof.
Although the present invention has been described with reference to specific exemplary embodiments, it will be recognized that the invention is not limited to the embodiments described, but can be practiced with modification and alteration within the spirit and scope of the appended claims. Accordingly, the specification and drawings are to be regarded in an illustrative sense rather than a restrictive sense.
|
A method and system to configure proximity detection and reporting in a wireless device during a transition of the wireless device from one cell state to another cell state in a third generation (3G) wireless communication system. In a first cell state, the wireless device is configured for proximity indication. The wireless device is transitioned from using the first cell state to using a second cell state. Upon the transition from the first cell state, the wireless device receives information from a base transceiver to reconfigure the proximity indication configuration based on the second cell state. The reconfiguration allows the mobile device to retain the existing proximity indication configuration, remove the proximity indication configuration, or stop reporting proximity indication. Additionally, the base transceiver also adjusts proximity configuration stored at the base station based on the second cell state.
| 7
|
[0001] This application is a continuation-in-part of U.S. patent application Ser. No. 09/277,467 filed Mar. 26, 1999, the disclosure of which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates generally to trench digging and pipe laying equipment, and more particularly to an adjustable coupling connector for use in attaching equipment to an excavator, wherein the equipment includes a pipe laying tool and a compaction wheel.
[0004] 2. Brief Description of the Prior Art
[0005] The process of laying sections of pipe for an underground pipe line involves first digging a trench to the required depth with a shovel attached to an excavator. The shovel is then removed from the excavator and a pipe laying tool is attached to the excavator for lowering the pipe into the trench. The pipe laying tool is then removed from the excavator and replaced with a shovel for use in depositing the required filler over the pipe. The shovel is then removed and a compaction wheel is attached for compacting the filler. Various methods of attaching the shovel, compaction wheel and pipe laying tool to the excavator are used. At the present time there is no standard connector for attaching tools to an excavator. If the excavator can accommodate the compaction wheel but not the pipe laying tool, the pipe may be secured to an end of an arm or boom of the excavator with chains and chokers. A disadvantage of this method is that it is necessary to place a worker in the trench to guide the newly lowered section of pipe into contact with a previously installed section. The worker must also disengage the chains, etc. from the pipe. The task of manipulating the pipe in the trench is not without some hazard, due in part to the weight of the pipe and excavator arm. In deep trenches, the additional hazard of possible collapse of the trench walls must be carefully guarded against for the safety of the trench worker. In cases where there is danger of wall collapse, shoring is often put up in place to support the soil. The shoring must then be removed and reinstalled for the process of laying the next section or sections of pipe, etc.
[0006] U.S. Pat. No. 5,323,502 by Recker describes an apparatus designed to lay pipe with an excavator without the need for a worker in the trench. A horizontally positioned arm 78 is suspended from the working end of an excavator boom assembly, attached with a rotary coupler 76 (FIG. 2 and col. 3, lines 3-32). In order to avoid the need for a worker in the trench to apply pipe sealant, a sealant is forced through the rotary coupler and sprayed from the end of the horizontal arm. The apparatus as described has some disadvantages and is not in common use. The rotary couple with conduit is not a standard quick coupler, and requires special modification of the excavator. Connecting the horizontal arm 78 and conduit requires a second worker, or alternatively the excavator operator has to leave the cab to manually perform the operation. Positioning the arm 78 and support beam 80 in the process of connecting the tool to the excavator arm assembly is also a problem due to the weight of the tool, and the fact that without other support, the tool could only lay on the ground, 90 degrees disoriented, requiring an operator, probably with additional equipment to lift it into position for connecting to the excavator coupling device 70. In addition, the rotary connection 76 is not durable enough to withstand repeated use, or rigid enough to allow undesired rotation of a pipe placed on the arm 78. For example, a typical eight foot section of 54 inch diameter concrete pipe weighs about 1,370 pounds per foot, or a total of 10,960 pounds. A much more rigid and strong connection is required for practical use.
[0007] It is apparent that an improved tool and method of laying pipe is needed that keeps workers out of the pipe trench, and that is robust and can be used with a standard excavator arm quick coupling device. It is also apparent that a coupling device is needed that can accommodate a range of different excavator coupling apparatus.
SUMMARY
[0008] It is therefore an object of the present invention to provide a connector that can be adjusted for a range of sizes of excavator coupling apparatus.
[0009] It is an object of the present invention to provide a tool for use in lowering a section of pipe into a trench that avoids the use of chains and chokers that must be removed by a trench worker.
[0010] It is another object of the present invention to provide a tool for laying pipe that is rugged in construction and that can be attached to the working end of an excavator boom assembly by an excavator operator without leaving the excavator cab.
[0011] It is a further object of the present invention to provide a tool that facilitates the joining of pipe sections without the need for a trench worker.
[0012] Briefly, a preferred embodiment of the present invention includes an adjustable connector for accommodating a range of mating excavator couplers. The adjustable connector includes two parallel bars to which the excavator coupler clamps. One of the bars is fixed in position to risers extending from a connector base. Each end of the other bar is attached to a point off center of a circular plate so that as the plate is rotated, the bar moves laterally relative to the bar axis. The plates are rotatably positioned in holes in the risers, and captivating side plates are welded to the risers for covering a portion of each plate, securing the plates from movement parallel to its axis but allowing the plate to rotate. Holes in the circular plates and side plates are provided, and a bolt is placed through each of the side plates and circular plates for securing each circular plate in a fixed position.
[0013] An advantage of the adjustable connector apparatus of the present invention is that it can accommodate a range of excavator coupler sizes.
[0014] An advantage of the tool of the present invention is that it allows a pipe to be positioned in a trench with improved accuracy.
[0015] A further advantage of the tool of the present invention is that it allows a pipe supported by the tool to be joined to another pipe in a trench without the need for a trench worker.
[0016] A still further advantage of the present invention is that it reduces worker injury by avoiding the need for a worker in the trench during the pipe laying operation.
[0017] Another advantage of the present invention is that it provides a pipe laying tool that is self supporting, and does not require an excavator operator to leave the excavator cab to connect the tool.
IN THE DRAWING
[0018] [0018]FIG. 1 is a perspective view of the pipe laying tool of the present invention;
[0019] [0019]FIG. 2 shows an absorptive buffer mounted to a riser;
[0020] [0020]FIG. 3 illustrates the use of the tool to place a pipe in the trench;
[0021] [0021]FIG. 4 illustrates the use of the tool in combination with an excavator and positioning device for laying a section of pipe in a trench;
[0022] [0022]FIG. 5 is a perspective view of a preferred construction of the coupling connector of FIG. 1 indicating enhanced side support for the connector loops;
[0023] [0023]FIG. 6 is a perspective view of an adjustable quick coupling connector;
[0024] [0024]FIG. 7 is a top planar view of the adjustable connector of FIG. 6;
[0025] [0025]FIG. 8 a is a planar view of the riser plates of the adjustable connector of FIG. 6;
[0026] [0026]FIG. 8 b is a planar view of the circular end plates of FIG. 6;
[0027] [0027]FIG. 8 c is a planar view of the side plates of FIG. 6; and
[0028] [0028]FIG. 9 shows a connector in use with a compaction wheel attached to an excavator.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0029] The preferred embodiment of the pipe laying tool 10 of the present invention is shown in the perspective views of FIGS. 1 and 2. Referring to FIG. 1, the tool 10 has a proximal end 12 , to which is attached a horizontal tool arm 14 extending horizontally in operation to a distal end 16 . The arm 14 is connected at the proximal end of the tool to a vertical riser 18 , in turn attached to a coupling assembly 20 . A lateral support 22 allows the tool 10 to stand unsupported, facilitating the process of connecting the tool to a working end of an excavator arm.
[0030] As shown in FIG. 1, the arm 14 includes a length 24 of 4×4 inch×0.5 inch rectangular tubing about 6 feet long. The length can be longer or shorter depending on the length of pipe to be installed. Optionally, as an alternative embodiment, a pipe extension 26 is included in the tool 10 . The extension has a reduced size section 28 for insertion in the hollow center 30 of tube 24 for use in accommodating somewhat longer pipe. A 1.25×2.0 inch bar 342 is welded to the bottom of the tube 24 for increased strength, and extends over the majority of the arm 14 length to the lateral support 22 including a stabilization bar 34 , constructed from a 30 inch length of 2.0×2.0×0.25 inch wall tubing. The riser 18 is similarly constructed from a 28 inch length of 4×4×0.5 inch tubing 36 , braced with a 34 inch long piece of 0.75×5.0 inch flat bar 38 .
[0031] A support bar 40 of 4×4×0.5 inch tubing by 51.5 inches long is welded to the top end of tube 36 , and provides strength to the coupling assembly 20 . A 1.5 inch thick support plate 42 , measuring about 24 inches wide by 27 inches long is welded to the tube 40 . The assembly 20 includes a coupling connector 44 with a connector plate 46 secured to support plate 42 with bolts 48 or by welding, and supports 50 for positioning coupling bars 52 and 54 .
[0032] The various elements 24 , 34 , 36 , 40 , and 42 described above are welded together along with triangular support members 56 , 58 , 60 , 62 for strength. Similarly, triangular support members 64 , 66 , 68 and 70 , shown in FIG. 3, and corresponding supports on the opposite side of tube 40 are welded between plate 42 and tube 40 , and between tube 40 and tube 36 as show in FIGS. 1, 2 and 3 . A laser receiver 124 and pole 126 are shown mounted to plate 42 . The function of this apparatus will be fully explained in the following description in reference to FIG. 4.
[0033] In order to minimize the probability of damaging the pipe while applying horizontally directed force to engage one section of pipe with another, an absorptive bumper 72 is attached to the riser tube 36 facing the distal end 16 . The bumper apparatus is illustrated in section A of FIG. 2. The bumper 72 preferably includes a 2×4 inch board 74 attached to riser tube 36 with bolts 76 , countersunk into the board 74 as shown in FIG. 2. In order to further cushion the end of the pipe, a rubber sheet 78 is placed over the board 74 as shown in FIG. 2. The sheet 78 is bolted to two plates 80 , 82 welded with one on each side of riser tube 36 . The bumper assembly, including plates 80 and 82 are part of the tool of FIG. 1, but now shown in that figure for the purpose of clarity of illustration.
[0034] Alternative construction methods and materials will be apparent to those skilled in the art, and these are included in the spirit of the present invention. For example, the rectangular tubes shown in FIGS. 1 and 2 could be constructed from round tubing or I-beam shaped material. The supports to be described could alternatively be tubular lengths of material, or even omitted if enough strength is otherwise designed into the structure. The coupling assembly 20 could include a single piece platform welded to the riser 18 .
[0035] Referring now to FIG. 3, the tool 10 is shown with the connector 44 engaged with a corresponding mating connector 84 attached to the working end 86 of excavator 88 arm assembly 90 . In operation, the tool 10 is attached to the working end 86 of excavator 88 . Any time prior to moving a section of pipe such as 92 (dashed lines) into the trench 94 as shown in FIG. 3, a gasket 96 is placed on the pipe spigot end 112 . The excavator 88 is then operated to insert the tool arm 14 inside the length of pipe 92 as it lays outside the trench 94 . FIG. 3 then shows the pipe 92 at position 104 , being lowered down into the trench 94 . Lowering and positioning of the pipe 92 continues until the pipe 92 is in alignment with a previously laid section of pipe, such as 106 on the bottom 108 of the trench 94 . The positioning then includes joining the pipe section 92 to the previously laid section of pipe 106 . The bumper 72 provides a cushioned contact against the end 98 of pipe 92 as the end 112 of pipe 923 is inserted into the adjoining end 114 of pipe 106 .
[0036] Referring to FIG. 4, according to the preferred embodiment of the method and apparatus of the present invention, the tool 10 is accompanied by a laser positioning apparatus 116 . An example of such an apparatus is a device called a Depth Master, manufactured by a company known as Laser Alignment. The apparatus includes a laser transmitter 118 positioned a distance D 1 above surface 120 and adjusted to transmit a reference laser beam 122 at the required slope B. A laser receiver 124 is slideably attached to a pole 126 shown attached to the tool 10 plate 42 .
[0037] The transmitter 118 has a light 128 that turns on when the beam 122 is intercepted by the receiver 124 detector 130 . If the detector 130 is below the line 122 , a light 134 turns on, and if the detector is above the beam 122 , light 136 turns on. In operation, the transmitter 118 is adjusted so that the beam 122 is at an angle B equal to the desired slope of the pipe and trench bottom 108 . FIG. 4 shows a preferred method of adjusting the receiver 124 position on the pole 126 so that when pipe 92 arrives at the proper depth, the light 128 goes on. This is done by lowering a section of pipe 100 into the trench 94 until the pipe 100 just contacts the bottom 108 . The receiver 124 is then positioned on the pole 126 so that beam 122 is intercepted by the receiver detector 130 . The excavator and tool are then used to lay pipe as follows: Assume pipe 100 is laid in position as shown and a second pipe section is picked up by the tool 10 . The excavator is backed up with the second pipe so that when it is lowered it will clear pipe 100 . It is then lowered into the trench until the light 128 goes on. The excavator then moves forward with the second pipe, adjusting as required to keep the light 128 on, assuring that the second pipe is in alignment with pipe 100 , and allowing the second pipe to join properly with pipe 100 . In other words, the distance from the beam to the bottom of the trench is a constant, and the depth measurement equipment assures that the pipe is at that depth when the excavator operator attempts to join the two pipe sections together. The transmitter 118 has a second set of lights 140 that gives the operator a visual indication of the vertical alignment of the receiver 124 and therefore pole 126 . As used in the present invention, this vertical alignment indicator 140 indicates to an excavator operator whether or not a pipe being held by the tool 100 is in a horizontal, or near horizontal position since the slope B is generally very small, as required for proper mating with a previously laid section of pipe.
[0038] Other depth measuring apparatus are also included in the spirit of the present invention. For example, an apparatus using encoders is available. The position of the tool arm 12 relative to a reference such as ground level 108 is determined by the position detection apparatus which includes a processor and monitor for calculating and displaying the position. The calculation is based on signals received from encoders located on the excavator boom assembly to detect the assembly position. The encoders and position monitoring equipment are currently known in the art and applied for positioning shovels mounted on the working end of an excavator arm assembly. The technology of depth detection can be applied to the positioning of a section of pipe as explained above. It is apparent then, that those skilled in the art will know how to apply the technology to measure the depth of the pipe according to the present invention after reading the present disclosure, and a detailed description of the prior art apparatus and how it is used is therefore not included.
[0039] [0039]FIG. 5 is a perspective view of a coupling connector 140 with two rods 142 and 144 forming loops 146 and 148 with the base 150 and side supports 152 and 154 , similar to the structure shown in FIG. 1, etc. except that the supports 50 of FIG. 1 are interconnected with added support material 156 and 158 in FIG. 5.
[0040] [0040]FIG. 6 is a perspective view of an adjustable coupling connector 160 . Parallel side supports 162 and 164 are attached to a base 166 , preferably by welding, and at one end 169 support the ends 163 and 165 of a first rod 168 above the base 166 . The ends 163 and 165 are preferably welded to the corresponding supports 164 and 162 . The rod 168 with supports 162 and 164 and base 166 form a loop 170 , allowing engagement with a corresponding coupling member of an excavator. An adjustable assembly 172 is positioned near a second end 174 of the supports 162 and 164 , allowing a second rod 176 to be adjustable in position relative to the first rod 168 and thereby allowing accommodation of various excavator coupling apparatus. The second rod 176 is suspended over the base 166 by supports 162 and 164 forming a second loop 178 , and together with rod 168 provide engagement with the coupling apparatus of an excavator. The adjustable assembly 172 includes the rod 176 mounted (preferably welded) at each rod end 184 and 186 to circular plates 180 and 182 . The rod ends 184 and 186 are attached to corresponding plates 180 and 182 at a point that is off of the center of each plate so as to provide lateral movement i.e., movement relative to rod 168 as the circular plates 180 and 182 are rotated.
[0041] Circular plates 180 and 182 are mounted in corresponding circular holes 188 and 190 respectively that are formed in the support plates 164 and 162 . The sub-assembly including rod 176 and circular plates 180 and 182 is held in position along the direction of the rod axis 192 by side plates 194 , 196 , 198 and 200 , attached (preferably welded) to the supports 162 and 164 . Side plates 194 and 198 are not visible in the perspective view of FIG. 6, but are shown in the planar top view of FIG. 7. The circular plates 180 and 182 , and the side plates 194 - 200 all have holes. Holes 202 in side plates 196 and 200 are visible in the view of FIG. 6. The holes in the circular plates are shown in FIG. 8 b . Because the rod 176 is mounted off of the center of circular plates 180 and 182 , as the plates are rotated the rod 176 moves in an arc, toward or away from rod 168 as well as moving in a vertical direction. In order to adjust the distance between rods 168 and 176 , the circular plates 180 and 182 are rotated. The holes in the circular plates 180 and 182 and the holes in the side plates 194 - 200 are configured/positioned so that the rod 168 to rod 176 spacing can be selected by aligning specific selected holes in plates 180 and 182 with specific holes in side plates 194 - 200 . A bolt is then inserted through the aligned holes in order to secure the position of rod 176 . This operation will be described in reference to FIGS. 8 a - 8 c for a specific set of parameters as an example. The present invention includes any set of parameters/dimensions, and also includes other constructions for varying the spacing between rods 168 and 176 that will be apparent to those skilled in the art from reading the present disclosure. The bolts for securing the position are not shown in FIG. 6, but are shown in FIG. 7.
[0042] [0042]FIG. 7 is a planar top view of the adjustable connector 160 of FIG. 6. FIG. 7 shows the side plates 194 , 196 , 198 and 200 filly captivating the circular plates 180 and 182 from movement in the direction of the axis 192 of the rod 176 . Rotational movement of the circular plates 180 and 182 is prevented when they are in a desired position with at least one hole in each of the circular plates 180 and 182 lining up with a corresponding hole in each of the plates 194 , 196 , 198 and 200 , by insertion of bolts 202 and 204 through the lined-up holes in the circular plates 180 and 182 with the selected holes in side plates 194 , 196 , 198 and 200 . The bolts 202 and 204 are secured by nuts 206 and 208 . Other methods and apparatus for securing the circular plates 180 and 182 will be apparent to those skilled in the art, and these are also included in the spirit of the present invention. Also, other methods and apparatus for adjustably positioning two rods relative to each other will be apparent to those skilled in the art upon reading the present disclosure, and these are also to be included in the spirit of the present invention.
[0043] Detailed dimensions of a preferred embodiment of a support plate 162 and 164 , circular plates 180 and 182 , and side plates 194 - 200 are shown in the planar view of FIGS. 8 a , 8 b and 8 c . In FIG. 8 a , hole 210 is machined to accept a dimension of the rod 168 . Hole 212 is dimensioned to slideably receive the circular plate such as plates 180 and 182 , and as illustrated plate 214 of FIG. 8 b .
[0044] In FIG. 8 b , the plate 214 has a hole 215 for acceptance of one end of rod 176 to which it is preferably welded. Holes 216 , 218 and 220 are dimensioned for passage of a bolt such as bolt 202 or 204 . The locations of holes 216 , 218 and 220 are designed to place the rod 176 a desired distance from rod 168 when aligned with a corresponding location of a specific one of holes 222 , 224 , 226 or 228 in the side plate 230 of FIG. 8 c . The use of a plurality of holes such as 216 - 220 in the circular plate 214 and a plurality of holes in the side plate 230 allows the holes in the side plate, for example, to be spaced further apart than what would be required if only one hole was used in the circular plate 214 in order to achieve the range of adjustability required. The larger spacing of holes results in a connector with superior strength, which is an important factor in a connector which must handle very heavy loads. With hole 216 of circular plate 214 in alignment with hole 222 of plate 230 , the spacing between rods 168 and 176 is 18 inches. With hole 218 in alignment with hole 224 the spacing is 19 inches. With hole 218 in alignment with hole 226 the spacing is 17½ inches, and with hole 220 aligned with hold 228 , the spacing is 18¾ inches.
[0045] The connector of FIGS. 6 and 7 can be used with any of various heavy equipment requiring coupling to a tool. In particular, the connector of FIGS. 6 - 8 can be used as illustrated in FIG. 1 for coupling to a pipe laying tool. FIG. 9 shows the connector 160 providing coupling between an excavator 232 and a compaction wheel 234 . The connector 160 can also connect to a pipe laying tool such as to the support plate 42 of the tool shown in FIG. 1 instead of the compaction wheel 234 .
[0046] Although the present invention has been described above in terms of a specific embodiment, it is anticipated that alterations and modifications thereof will no doubt become apparent to those skilled in the art. It is therefore intended that the following claims be interpreted as covering all such alterations and modifications as fall within the true spirit and scope of the invention.
|
An adjustable coupling connector apparatus for accommodating a range of mating excavator couplers. The connector apparatus includes two parallel bars upon which an excavator coupler clamps. One of the bars is fixed in position to risers extending from a connector base. Each end of the other bar is attached to a point off center of a circular plate so that as the plate is rotated, the bar moves laterally relative to the bar axis. The plates are rotatably positioned in holes in the risers, and captivating side plates are welded to the risers for covering a portion of each plate, securing the plates from movement parallel to its axis but allowing the plate to rotate. Holes in the circular plates and side plates are provided, and a bolt is placed through each of the side plates and circular plates for securing each circular plate in a fixed position.
| 5
|
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of U.S. Provisional Patent Application No. 61/970,335, filed on Mar. 25, 2014, and incorporated herein by reference.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH AND DEVELOPMENT
Not Applicable.
FIELD OF THE INVENTION
This invention relates generally to wireless communication with a contact lens, and more particularly, to a system and method for transferring data from a contact lens using radio frequencies.
DISCUSSION OF RELATED ART
Wireless transmission of data varies greatly, from one-way broadcast systems such as radio and television signals to two way systems such as Wi-Fi and cellular signals. One type of wireless transmission, radio-frequency identification, or RFID, utilizes electromagnetic or electrostatic fields to transfer data. An RFID device utilizes an antenna and a transceiver to read the radio frequency and transfer information to an external device, and a transponder, or tag, which contains the circuitry of the RFID and the data to be transmitted.
RFID is advantageous over other types of wireless transmission in that it does not require a power source to transmit data. Consequently, RFID transmission is limited to a short range and limited data transfer. As such, RFID is most commonly used for automatically identifying and tracking tags attached to objects, such as clothing, livestock, pets, assembly lines, pharmaceuticals, etc. Powered RFID systems can solve many of the unpowered RFID shortcomings by increasing range and reduced interference.
The human eye, in very simplistic terms, is adapted to provide vision by detecting and converting light into electrical impulses for the brain. While the human eye is extremely intricate and precise, the image produced often needs correction. The most common type of vision correction includes glasses and/or contact lenses, which are used to improve vision by correcting refractive error. This is done by directly focusing the light so that it enters the eye with the proper intensity.
While radio frequency technology has made its way into several industries, size and interference constrains have prevented them from entering into fields such as contact lenses, where size limitations are paramount. Therefore, there is a continued need for a vision correction device which makes use of wireless transmissions and/or wireless charging to transfer data between the vision correction device and an external device.
SUMMARY OF THE INVENTION
The present invention will provide a vision correction device which makes use of wireless transmissions and/or wireless charging to transfer data between the vision correction device and an external device. More specifically, the present invention will incorporate radio frequency technology onto a contact lens, including passive and active embodiments, and may further include wireless charging capability. This is accomplished by positioning an extremely small RF device onto a contact lens, along with an antenna and/or battery, and using a fluid medium to enhance the signal to and from an external device.
When in use, the RF device is adapted to provide identifying information, such as which batch a lens is from and when it was manufactured. Furthermore, the RF device is adapted to notify the user when it is time to dispose of the contact lens, either from time or usage statistics. The RFID device will transmit this information either passively or actively to an external device, providing the user with invaluable information relating to their vision. The RF device can further communicate charging information such as charging states, charging rate, and other relevant information when wireless charging is used.
These and other objectives of the present invention will become obvious to those of ordinary skill in the art after reading the following detailed description of the preferred embodiments. It is to be understood that the foregoing general description and the following detailed description are exemplary, and are intended to provide further explanation of the invention as claimed.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagram illustrating the wireless communication device and contact lens within an external device;
FIG. 2 is a diagram illustrating the antenna, microprocessor, and power source of the contact lens within an external device;
FIG. 3 is a diagram illustrating the method of using the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Illustrative embodiments of the invention are described below. The following explanation provides specific details for a thorough understanding of and enabling description for these embodiments. One skilled in the art will understand that the invention may be practiced without such details. In other instances, well-known structures and functions have not been shown or described in detail to avoid unnecessarily obscuring the description of the embodiments.
Unless the context clearly requires otherwise, throughout the description and the claims, the words “comprise,” “comprising,” and the like are to be construed in an inclusive sense as opposed to an exclusive or exhaustive sense; that is to say, in the sense of “including, but not limited to.” Words using the singular or plural number also include the plural or singular number respectively. Additionally, the words “herein,” “above,” “below” and words of similar import, when used in this application, shall refer to this application as a whole and not to any particular portions of this application. When the claims use the word “or” in reference to a list of two or more items, that word covers all of the following interpretations of the word: any of the items in the list, all of the items in the list and any combination of the items in the list.
The present invention comprises one or a plurality of contact lenses 20 , a wireless communication device 30 , an antenna assembly 40 , 41 , a fluid medium 50 , and an external device 60 . More specifically, the wireless communication device 30 and the antenna assembly 40 , 41 are positioned on the external device 60 , while the external device 60 is not in in physical contact with the contact lens 20 , but is in fluid contact with the contact lens 20 through the fluid medium 50 . When in use, the wireless communication device 30 is adapted to interact with the antenna assembly 40 , 41 to communicate with the external device 60 through the fluid medium 50 . The wireless communication device 30 may be read-only, having a unique key or data sequence, or may be read/write, where data can be written into the wireless communication device 30 .
The wireless communication device 30 is positioned on the outer edge of the contact lens 20 and is adapted to send and/or receive wireless data to/from the external device 60 through the fluid medium 50 . In the preferred embodiment, the wireless communication device 30 is a passive tag RFID device. More specifically, the wireless communication device 30 is a passive tag RFID device adapted to operate without a power source 31 . The wireless communication device 30 is activated when a signal is received from the external device 60 . The signal will power the passive RFID device, which will then begin transmitting data. Advantages of a passive tag RFID device include a smaller size and no power requirements, which are paramount with dealing with contact lenses.
In an alternative embodiment, an active tag RFID (powered) device is used. Here, a small battery or capacitor 31 is positioned on the outer edge of the contact lens 20 in electrical communication with the wireless communication device 30 and operates to provide power for transmitting data through the wireless communication device 30 . Advantages of an active tag RFID device include longer ranges, improved response time, less interference, and lower radiation. In yet a further alternative embodiment, the wireless communication device 30 is adapted to charge a battery or capacitor 31 used for powering a microprocessor chip 32 . Here, the wireless communication device 30 will receive radio frequencies from the external device 60 , convert these radio frequencies into electrical energy, and store this electrical energy in the capacitor or battery 31 . The energy requirements are low, however, and said battery or capacitor 31 may be easily charged wirelessly in this manner.
The antenna assembly 40 , 41 operates to receive data and other radio frequencies, as well as facilitate the transfer of data between the wireless communication device 30 and the external device 60 . A first, or top, antenna 40 is positioned in the cap 61 , while a second, or bottom, antenna 41 is positioned in the external device 60 adjacent to the fluid chamber 62 . In an alternative embodiment, a lens antenna 33 is positioned on the perimeter of the contact lens 20 in electrical communication with the wireless communication device 30 , outside of the view of the user. In all embodiment, the lens antenna 33 , as well as the wireless communication device 30 and/or battery 31 , will not be visible by the user. The antennas is adapted to amplify signals send and received greatly, as these signals are used to activate the wireless communication device 30 .
The fluid medium 50 between the contact lens 20 and the external device 60 operates to amplify the RF signals from 1-10 times. The fluid medium 50 also acts as a disinfectant and improves surface wetablility and comfort of the contact lenses 20 during storage in the external device 60 . In the preferred embodiment, the fluid medium 50 may be saline water. By utilizing the fluid medium 50 , short distance communication between the contact lens 20 and the external case 60 can range from 0.1 mm to 1 cm.
The fluid medium 21 is a sterile, isotonic solution further comprising hyaluronan, sulfobetaine, poloxamine, boric acid, sodium borate, edetate disodium and sodium chloride and preserved with a dual disinfection system comprising polyaminopropyl biguanide and polyquaternium. In the preferred embodiment, the fluid medium comprises an electrical conductivity between 1.6 to 22.2 siemens per meter, a saline concentration between 1% to 25% of the overall solution, and will have a volume between 2.5 mm 2 to 10 mm 2 .
The external device 60 is used to transmit data and/or power to the contact lens 20 . In the preferred embodiment, the external device 60 is a contact lens case further comprising a cap 61 and fluid chamber 62 , where the contact lens 20 may be stored for 1-8 hours daily. Due to the long storage periods, the external device 60 and contact lens 20 may transmit data and energy even at low transfer speeds or energy levels. For example, data collected during use can be transferred from a microprocessor 32 in the contact lens 20 to the external device 60 at extremely low speeds. Also, energy can be transferred from the external device 60 to the battery or capacitor 32 for wireless charging, thus enabling the external device 60 to operate as a power outlet. Lastly, miscellaneous information such as identification numbers (RFID), logged usage data, and user data (blinking, light exposure) can be transmitted from the contact lens 20 to the external device 60 during this time. For example, the present invention may monitor time used and count usage cycles to notify the user when the contact lens 20 needs replacement or care. As mentioned above, the external device 60 will further comprise an antenna assembly 40 , 41 to communicate with the contact lens 20 with less interference, both for data and wireless charging, and the external device 60 will enclose the contact lens 20 in a fluid chamber 62 , further reducing interference and increasing the reliability of the transmission.
When in use, the wireless communication device 30 will receive a message from the external device 60 , or an interrogation message, once it is in range. In the passive embodiment, the signal strength of the interrogation message will activate the wireless communication device 30 . The wireless communication device 30 will authenticate this interrogation message and will respond with identification or other data once authenticated. Alternatively, with an active Tag RFID, the wireless communication device 30 will broadcast an interrogation message, where the external device 60 will receive the message for authentication. In a further alternative embodiment, the interrogation message will operate to wake the wireless communication device 30 from a sleeping state, which will then begin to transmit data with the external device 60 once authenticated.
In the preferred embodiment, the wireless communication device 30 is adapted to fit on the perimeter of a contact lens 20 . As such, the size of the wireless communication device 30 will be within the range of 0.05 mm×0.05 mm. The wireless communication will operate in a frequency range of 10 kHz-100 MHz. The wireless communication device 30 is adapted to communicate at a range of 1 cm-1 m. In the alternative embodiment, where an active tag RFID is used with a battery source 31 , the frequency range increases to 10 kHz-5 GHz, with a range of 1 cm-100 m.
In a further alternative embodiment, a piezoelectric sensor is used to receive a frequency within a specific range for data transmission or wireless charging. The piezoelectric sensor is sensitive enough to distinguish frequencies, and is adapted to receive only frequencies which can communicate with the wireless communication device 30 . The piezoelectric sensor may comprise synthetic piezoelectric ceramics including, but not limited to, barium titanate, lead titanate, lead zirconate titanate, potassium niobate, lithium niobate, lithium tantalite, sodium tungstate, and zinc oxide. Alternatively, the piezoelectric sensor may comprise a polymer piezoelectric such as polyvinylidene fluoride. Lastly, biological piezoelectrics can be used including bone, tendon, silk, wood, enamel, dentin, DNA, and viral protein such as bacteriophage.
In yet a further alternative embodiment, a vibration sensor may be implemented to activate the wireless communication device 30 . Here, either a battery 31 or a piezoelectric sensor is adapted to produce an electrical charge when the vibrational sensor is triggered. The vibration sensor can be triggered when the contact lens 20 is removed from the eye or removed from the external device 60 . Once a vibration, or lack thereof, is sensed, the vibrational sensor will activate the wireless communication device 30 .
In still a further alternative embodiment, the present invention may be paired with a piezoelectric energy harvesting device for powering the wireless communication device 30 and/or vibration sensor. Energy can be harvested from the movement of the eye, blinking, body movement, or other source. A battery or capacitor 31 may be provided to receive and store this energy.
When in use, the user will place a contact lens 20 within an external storage device 60 . An interrogation message will be received from the external device 60 , which is then authenticated within the contact lens 20 . After authentication, wireless data transmission and/or wireless charging may begin between the contact lens 20 and external device 60 . This communication and/or charging may last between 2-8 hours, providing ample time for charging and information transfer.
The present invention is manufactured such that the components work in conjunction to provide data transmission and/or wireless charging with an external storage device 60 . The method of manufacturing the present invention comprises first electrically connecting the wireless communication device 30 with any microprocessors 32 , antennas 33 , and/or power sources 31 , creating a wireless communication circuit. In the preferred embodiment, any transparent materials may be used to reduce obstructing the vision of the user.
Once the wireless communication circuit is created, it is placed directly into a contact lens mold member, preferably the female mold member, or first (anterior) contact lens mold member. The placement would occur preferably robotically and be coupled with a means of centering the assembly and a means of controlling the depth of the assembly during the filling of the mold with a lens precursor material, which can be understood to be a polymerizable silicone hydrogel lens precursor composition. The polymerizable silicone hydrogel lens precursor composition may be understood to be a pre-polymerized or pre-cured composition suitable for polymerization. In alternative embodiments, the lens precursor material may be comprised of silicone, hydrogel, polyimide, kapton, parylene, or SU-8. Non-stretchable lens precursor materials comprise metals, ceramics, and crystals.
The first contact lens mold member is placed in contact with a second contact lens mold member to form a contact lens mold having a contact lens shaped cavity. Next, the two contact lens mold members are placed in contact with one another to form a contact lens shaped cavity, with the polymerizable silicone hydrogel lens precursor composition and wireless communication circuit positioned within the contact lens shaped cavity. The polymerizable silicone hydrogel lens precursor composition is then cured to form a pre-extracted polymerized silicone hydrogel contact lens product. The contact lens mold is then demolded, where the two mold members are separated. The pre-extracted polymerized silicone hydrogel contact lens product is then separated from the contact lens mold members, or delensed. After delensing, the pre-extracted silicone hydrogel contact lens product is extracted. After extraction, the extracted polymerized silicone hydrogel contact lens product is hydrated with water or an aqueous solution to form a hydrated silicone hydrogel contact lens.
While the above description contains specific details regarding certain elements, sizes, and other teachings, it is understood that embodiments of the invention or any combination of them may be practiced without these specific details. Specifically, although certain materials and shapes are designated in the above embodiments, any suitable materials or shape may be used. These details should not be construed as limitations on the scope of any embodiment, but merely as exemplifications of the presently preferred embodiments. In other instances, well known structures, elements, and techniques have not been shown to clearly explain the details of the invention.
The above detailed description of the embodiments of the invention is not intended to be exhaustive or to limit the invention to the precise form disclosed above or to the particular field of usage mentioned in this disclosure. While specific embodiments of, and examples for, the invention are described above for illustrative purposes, various equivalent modifications are possible within the scope of the invention, as those skilled in the relevant art will recognize. Also, the teachings of the invention provided herein can be applied to other systems, not necessarily the system described above. The elements and acts of the various embodiments described above can be combined to provide further embodiments.
Changes can be made to the invention in light of the above “Detailed Description.” While the above description details certain embodiments of the invention and describes the best mode contemplated, no matter how detailed the above appears in text, the invention can be practiced in many ways. Therefore, implementation details may vary considerably while still being encompassed by the invention disclosed herein. As noted above, particular terminology used when describing certain features or aspects of the invention should not be taken to imply that the terminology is being redefined herein to be restricted to any specific characteristics, features, or aspects of the invention with which that terminology is associated.
While certain aspects of the invention are presented below in certain claim forms, the inventor contemplates the various aspects of the invention in any number of claim forms. Accordingly, the inventor reserves the right to add additional claims after filing the application to pursue such additional claim forms for other aspects of the invention.
|
The present invention will provide a vision correction device which makes use of wireless transmissions and/or wireless charging to transfer data between the vision correction device and an external device. More specifically, the present invention will incorporate radio frequency technology onto a contact lens, including passive and active embodiments, and may further include wireless charging capability. This is accomplished by positioning an extremely small RF device onto a contact lens, along with an antenna and/or battery, and using a fluid medium to enhance the signal to and from an external device.
| 0
|
BACKGROUND
[0001] 1. Field of the Invention
[0002] This invention generally relates to methods and apparatuses for image identification, and more specifically to methods and apparatuses for identifying images containing an Embedded Media Marker (EMM).
[0003] 2. Description of the Related Art
[0004] The techniques of linking dynamic media with a static paper document through devices such as camera phones can be applied to many interesting applications, such as multimedia enhanced books and multimedia advertisement on paper. For example, two dimensional barcodes can be utilized on such static paper documents and can therefore be easily recognized by modern camera phones. However, barcodes tend to be visually obtrusive and interfere with the document layout when being associated with specific document content.
[0005] Other systems rely on the document content for identification. For example, visual features within the document can be utilized to identify the document. Linking media to text on the static paper document by utilizing features based on the word bounding boxes of the document (boxes that surround one or more words of a static paper document) is also possible. However, these methods fail to achieve good accuracy and scalability without providing guidance as to which of the content within the static paper document can potentially link to media information. Specifically, if such guidance is not provided adequately to users, an aimlessly captured query image that is submitted for identification may contain various distortions that lead to low identification accuracy. Similarly, without such proper indications, previous systems have needed to characterize and index entire document pages for proper identification; thereby incurring high time and memory costs for large datasets.
[0006] To address these problems, index indicators such as Embedded Media Markers (EMM) have been utilized for identification purposes. EMMs are nearly transparent markers printed on paper documents at certain locations which are linked with additional media information. Analogous to hyperlinks, EMMs indicate the existence of links. An EMM-signified patch overlaid on the document can be captured by the user with a camera phone in order to view associated digital media. Once the EMM signified patch is captured by the camera phone, the captured image can be compared to a database of EMM or index indicators for identification, which can be utilized to retrieve the appropriate digital media.
[0007] FIG. 1 displays a sequence of a conventional process using an EMM, with an example document 100 with an EMM overlaid at the top right corner 101 as shown in FIG. 1( a ). The user takes a close-up of an EMM-signified patch 102 on the example document, as shown in FIG. 1( b ). By using the EMMs, only the EMM-signified patches need to be characterized and indexed. This can greatly reduce feature extraction time and memory usage and further enhance accuracy by excluding noisy features of contents outside the EMM.
[0008] Subsequently, at the identifying stage, the EMMs can guide users to capture an EMM-signified region, yielding a query image with much fewer distortions 103 , as shown in FIG. 1( c ). After a sufficient query image is obtained, the next task of EMM identification is then to recognize the camera-phone-captured query image as an original EMM-signified patch indexed in the dataset so that to retrieve and play relevant media on cell phones 104 as shown in FIG. 1( d ).
[0009] EMMs can be represented as meaningful-awareness markers overlaid on the original paper document to guide image capture and limit processing cost. However, current EMM identification systems still rely strictly on general local-feature-based matching approaches, such as strict comparison of geographical features, without considering any particular matching constraints. Such strict comparison of geographical features suffers from low accuracy and high memory/time complexity in practice.
[0010] Therefore, there is a need for an identification scheme which provides for high accuracy with low memory and time complexity.
SUMMARY
[0011] Aspects of the present invention include a method of image identification, which may involve receiving an image containing an Embedded Media Marker (EMM); conducting a first comparison of the image with database images, the conducting the first comparison comprising representing the received image as a first grid; ranking the database images based on the comparison; conducting a second comparison of the image with images selected based on the ranking the database images, the conducting the second comparison representing the received image as a second grid; ranking the selected images based on the comparison; and returning at least one of the ranked selected images based on the ranking of the selected images. The second grid may have a higher resolution than the first grid.
[0012] Aspects of the present invention further include an apparatus that may include a camera receiving an image containing an Embedded Media Marker (EMM); a first comparison unit conducting a first comparison of the image with database images, ranking the database images based on the comparison, and retrieving images from the database based on the ranking, the first comparison unit representing the received image as a first grid; and a second comparison unit conducting a second comparison of the image with each of the retrieved images, ranking the selected images based on the comparison; and returning at least one of the ranked selected image based on the ranking, the second comparison unit representing the received image as a second grid. The second grid may have a higher resolution than the first grid.
[0013] Aspects of the present invention further include a non-transitory computer readable medium storing instructions for executing a method for image identification. The method stored in the computer readable medium may include receiving an image containing an Embedded Media Marker (EMM); conducting a first comparison of the image with database images, the conducting the first comparison comprising representing the received image as a first grid; ranking the database images based on the comparison; conducting a second comparison of the image with images selected based on the ranking the database images, the conducting the second comparison representing the received image as a second grid; ranking the selected images based on the comparison; and returning at least one of the ranked selected images based on the ranking of the selected images. The second grid may have a higher resolution than the first grid.
[0014] Additional aspects related to the invention will be set forth in part in the description which follows, and in part will be apparent from the description, or may be learned by practice of the invention. Aspects of the invention may be realized and attained by means of the elements and combinations of various elements and aspects particularly pointed out in the following detailed description and the appended claims.
[0015] It is to be understood that both the foregoing and the following descriptions are exemplary and explanatory only and are not intended to limit the claimed invention or application thereof in any manner whatsoever.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] The accompanying drawings, which are incorporated in and constitute a part of this specification exemplify the embodiments of the present invention and, together with the description, serve to explain and illustrate principles of the inventive technique. Specifically:
[0017] FIGS. 1( a ) to 1 ( d ) illustrate a conventional Embedded Media Marker (EMM) identification process.
[0018] FIGS. 2( a ) to 2 ( c ) illustrate image identification based on features of an image according to an embodiment of the invention.
[0019] FIG. 3 is a flowchart illustrating a method according to an embodiment of the invention.
[0020] FIG. 4 illustrates a gridding process according to an embodiment of the invention.
[0021] FIG. 5 illustrates an index file and representation of an image according to an embodiment of the invention.
[0022] FIG. 6 illustrates a flowchart of a comparison method according to an embodiment of the invention.
[0023] FIG. 7 illustrates a translation of a received image based on the dominant orientation of the Embedded Media Marker (EMM) according to an embodiments of the invention.
[0024] FIG. 8 illustrates a functional diagram of an apparatus according to an embodiment of the invention.
[0025] FIG. 9 illustrates an embodiment of a computer platform upon which the inventive system may be implemented.
DETAILED DESCRIPTION
[0026] In the following detailed description, reference will be made to the accompanying drawing(s), in which identical functional elements are designated with like numerals. The aforementioned accompanying drawings show by way of illustration, and not by way of limitation, specific embodiments and implementations consistent with principles of the present invention. These implementations are described in sufficient detail to enable those skilled in the art to practice the invention and it is to be understood that other implementations may be utilized and that structural changes and/or substitutions of various elements may be made without departing from the scope and spirit of present invention. The following detailed description is, therefore, not to be construed in a limited sense. Additionally, the various embodiments of the invention as described may be implemented in the form of a software running on a general purpose computer, in the form of a specialized hardware, or combination of software and hardware.
[0027] Previous approaches fail to consider matching constraints unique to EMM identification. Therefore, such previous approaches have unnecessarily cost more memory and time in order to achieve satisfactory accuracy for EMM identification. To increase both the efficiency and accuracy of EMM identification, exemplary embodiments of the present invention utilize two matching constraints in a hierarchical manner. Of particular interest are the “injection” and “approximate global geometric consistency” (AGGC for short), which are unique for the EMM identification and are further explained below.
The Injection Constraint
[0028] The injection constraint is enforced by the way of generating query images in EMM identification, where the query image is a camera-captured version 201 of an original EMM-signified patch 202 , as shown in FIG. 2( a ). This property implies that each detected “salient” region of a query image can be mapped to by at most one common region of the target image, i.e. “injective mapping”. However, such a constraint may not hold in near-/partial-duplicate image detection, where a query image is generated by extensive digital editing of an original image 204 . FIG. 2( b ) illustrates an exemplary case that violates this constraint, which needs to be targeted by partial-duplicate detection 204 . In order for the appropriate original image 204 to be adequately retrieved, partial sections of the query image 203 therefore may need to be analyzed against images in the database in order to ensure that the appropriate image is obtained.
The AGGC Constraint
[0029] The AGGC constraint is enforced by EMMs, which confines the geometric changes between a query image and its target within a small predictable range, so that the spatial layout of a query image should be globally consistent with that of its target image with high fidelity. Such constraint does not always hold in other similar applications. FIG. 2( c ) illustrates an example of two images 205 and 206 containing the same object of very different scale. Matching them is required for object recognition applications, but it is not expected for EMM identification to match them. Limiting the scope of the search by taking into account the injection and AGGC constraints can help further increase accuracy and reduce memory and time complexity. In this example, by taking into account the scaling issues between the two images 205 and 206 , the appropriate image can thereby be obtained should one of the images be used as a query.
[0030] To fully utilize these matching constraints while achieving high identification accuracy and addressing the issues with each individual constraint, two constraining functions are designed based on multi-resolution gridding information to detect “injective” and “AGGC” correspondences and use them to detect image similarity accurately. A spatial neighborhood search approach is further proposed to address challenging cases with a large translational shift. To achieve scalability, a hierarchical strategy is utilized to compact the memory and limit the processing time.
Workflow of Exemplary Matching Scheme
[0031] FIG. 3 illustrates the workflow of an exemplary matching scheme that incorporates the AGGC and injection matching constraints in accordance to a hierarchical strategy according to exemplary embodiments of the invention. This approach can be called a “Geometric Constrained Correspondences Voting” (GCCV for short). Upon receiving an image containing an EMM 300 , the strategy utilizes the AGGC and injection matching constraints with the following hierarchy:
[0032] (1) Conducting a first coarse comparison and ranking 301 . During this stage, exemplary embodiments of the invention utilize the AGGC constraint to conduct a coarse level ranking of images in a database. Initial “AGGC” correspondences construction works by placing coarse-level grids over each image and only matching visual words residing in the same coarse-level grids to one another. All the indexed images are then ranked based on the aforementioned “AGGC” correspondences.
[0033] (2) Conducting a second refining comparison and ranking 302 based on the ranking from the first coarse comparison. During this stage, exemplary embodiments of the invention utilize correspondence refinement which works by partitioning the top-ranked images into finer resolution grids, and verifying their initial correspondences using the “injection” constraint at fine granularity. To further reduce errors caused by large translational shifts, a “translation compensation” algorithm can also be optionally utilized. The translation compensation algorithm estimates the translation changes and roughly aligns images before finding the qualified correspondences. This is conducted by determining the dominant orientation of the image containing the EMM based on the present orientation of the EMM, and creating a grid or other representation according to the dominant orientation.
[0034] (3) Returning a top image or images to the user 303 . Finally, the qualified correspondences are used for ranking database images and a top image or images may be returned to users for a final confirmation. Alternatively, the process may forgo the final confirmation altogether and utilize the top indexed image for digital media retrieval.
[0035] (4) Retrieve appropriate digital media 304 based on the previous step 303 .
[0036] In addition, a hierarchical encoding/decoding strategy is incorporated for efficiently storing and utilizing the multi-resolution grid information. The grid can be represented in the form of tables, as further described in the technical description of the comparisons below.
[0037] Description of the First Coarse Comparison Ranking Based on the AGGC Matching Constraint
[0038] The “AGGC” constraint implies that the spatial layout of a query image should be globally consistent with that of its target image with high fidelity. Therefore, the corresponding features should be located at similar locations between the two respective images. Based on this assumption, a matching scheme such as Grid-Bag-of-Words (G-BOW) matching can be used for finding initial correspondents which satisfy the “AGGC” constraint. G-BOW matching works by partitioning an image into n equal-sized grids and then matching a local feature f q of a query image to a local feature f idx of an indexed image if f q and f idx are quantized into the same visual word by the quantizer q(.) and have the same grid-id; that is,
[0000]
F
G
-
BOW
(
f
q
,
f
idx
)
=
{
1
if
q
(
f
q
)
=
q
(
f
idx
)
&
grid
-
id
(
f
q
)
=
grid
-
id
(
f
idx
)
0
otherwise
(
1
)
[0039] Summing up the normalized G-BoW matching value of query features within grid i, the matching score of the grid i is thereby obtained:
[0000]
sim
(
I
qi
,
I
idxi
)
=
∑
f
q
∈
I
qi
F
G
-
BOW
(
f
q
,
f
idx
)
I
qi
×
I
idxi
(
2
)
[0040] where |I qi | and |I idxi | are the total number of visual words within grid i of a query image and an indexed image, respectively. The matching score of all the separate grids can be summed up, which yields the final image similarity between query image I q and index image I idx ,
[0000]
sim
(
I
q
,
I
idx
)
=
∑
i
=
0
n
sim
(
I
qi
,
I
idxi
)
(
3
)
[0041] FIG. 4 illustrates an exemplary implementation of the G-BOW method with a 2×2 grid. The image 400 is represented in a 2×2 grid 401 , from which correspondences can be extracted from each grid and a homography matrix can be constructed 402 . The homography matrix represents the correspondences of each grid as a bit string or a word id for easier comparison.
[0042] By utilizing the proposed G-BOW method with appropriate grids (e.g. 2×2, 4×4, etc.), the method ensures that most of the matches satisfies the “AGGC” constraint, whereas a naïve application of the algorithm without gridding would violate the AGGC constraint. Additionally, if the homography is estimated correctly by the aforementioned translation compensation algorithm or by other means, correspondences can be further verified for homography consistency, which will produce significantly less false positives than a naive application without gridding.
[0043] Memory Complexity.
[0044] In practice, to implement G-BoW matching efficiently, the grid id of indexed local features and record them in a table for an indexing file. This solution only costs slightly more memory space for an indexing file than the image file without gridding. For example, to record a grid id of 4×4 grids, only an extra 4 bits are needed for each local feature.
[0045] FIG. 5 is an example of a possible indexing file representing the image of FIG. 4 . The index file may be sorted by word id, which is a representation of a local feature in the image, the grid id corresponding to the local feature representation for indexing, and an appropriate file name.
[0046] Time Complexity.
[0047] Extra time cost for the matching includes: 1) online grid id computing for features of a query image; and 2) fetching the grid id of indexed features from memory and comparing them with that of query image. Normally, such matching would thereby be expected to increase the time cost. However, involving grid matching does not actually increase the time cost. Instead, it slightly decreases the time due to eliminating the need for matching many unqualified features and updating the matching scores.
[0048] Description of the Second Refining Ranking Based on the Injection Matching Constraint
[0049] The first coarse comparison and ranking provides initial correspondences satisfying the “AGGC” constraint. However, such a scheme can not guarantee the “injective mapping” condition when M features, which are quantized into the same grid, match to N (M≠N) features quantized into a common grid. Therefore, by increasing the resolution (i.e. increasing the number of grids, or enforcing a stricter spatial constraint), unqualified correspondences may thereby be excluded. However, this may also decrease the robustness to geometric changes, resulting in absences of qualified correspondences. To solve this problem, homography verification (for example, determining the dominant orientation of the image and conducting the comparison accordingly) can be employed to preserve the “injection” property when the perspective changes between two images are small (such conditions can be satisfied in EMM identification). In an exemplary procedure, a hypothesized homography is first estimated based on candidate correspondences at pixel level, and each correspondence is then verified by checking the homography consistency. Finally, the matching score is updated according to the number of the homography consistent correspondences.
[0050] However, the traditional homography estimation and verification is not ideal due to the following reasons: 1) loading the pixel-level coordinates from hard disk takes too much time; 2) homography estimation and verification using pixel-level spatial information is sensitive to small keypoint location changes; 3) tentative matches obtained from BoW matching are very noisy, which may significantly increase the time for computing a matrix and also decrease the accuracy of the estimated matrix.
[0051] Addressing these limitations, a more efficient verification procedure at grid level, such as Approximate Geometric Verification (AGV), can be utilized. Fine-level grid information of the initial correspondences is used for estimating the homography matrix. Subsequently, all the tentative matches are verified based on the homography consistency.
[0052] FIG. 6 illustrates an exemplary process for approximate geometric verification. Given top candidate images, G-BOW matching is first conducted from the initial correspondences 600 . Homography estimation is then conducted from the initial correspondences and an appropriate homography matrix may be created 601. The query image may be spatially aligned with the candidate image based on the homography matrix 602 . Tentative matches are then verified from bag of words overlapping, and finalized qualified matches may thereby be obtained 603 . The matching score can thereby be updated (for example, according to formulas (2) and (3)), and the top candidate images are re-ranked accordingly 604 .
[0053] Hard quantization for finding the “AGGC” correspondences may cause the loss of some qualified matches, therefore, all the tentative matches are verified to partially make up the loss. When selecting the number of grids for AGV, there is a tradeoff between distinguishing ability and space complexity: the more grids that are used, the more precise the coordinates of correspondences become, but more bits are thereby needed to store the gridding information. Several parameters: 16×16, 32×32 and 64×64 can be utilized, with 32×32 tending to produce the best results.
[0054] AGV Vs. Traditional Geometric Verification.
[0055] Approximate geometric verification outperforms the traditional geometric verification from speed perspective due to two reasons. First, quantized location information is compact enough (e.g. a 32×32 grid id only takes 10 bits per feature) to be stored in memory, which helps eliminating the time for accessing hard disks during refinement step. Second, correspondences obtained by G-BoW matching are much less noisy than those from BoW matching, thus using them can greatly reduce the estimation time. Experiments also show that, using correspondences from G-BoW matching achieves much higher identification accuracy than using those from BoW.
[0056] Translation Compensation
[0057] For challenging cases with large geometric changes, a hard quantization may inevitably discard many qualified “AGGC” correspondences and consequently degenerate the homography estimation accuracy or even completely miss the target image if the target image fails to be placed in the top-ranked candidate list. For example, a translational shift that is larger than image_size/n 1/2 (n is the number of grids in the “AGGC” correspondence construction step) will make all the grids completely misaligned so that none “AGGC” correspondences can be detected for the target image. Therefore, compensating for the errors caused by misalignment is crucial for achieving good identification accuracy.
[0058] A straightforward solution to solve the translation problem is by using soft spatial assignment. In other words, instead of comparing the point of the image with the EMM with the corresponding point in the database image, one solution is to assign a point to the eight neighboring grids beyond the grid where the point falls in. However, such a simple strategy may introduce too much noise and consequently decrease the accuracy and increase the time cost. In most cases, out of nine quantized directions, there is only one direction which can best approximate the real translation changes. Thus, most points assigned to the wrong directions simply become noise.
[0059] To overcome the limitation of soft assignment and reducing the translation-caused errors, the better solution is to determine the dominant orientation of the EMM before conducting the comparison. Once the dominant orientation is determined, the best translation direction can be estimated between the two images and then all the points can be assigned to this direction, and therefore the correct adjacent point or translated point can be determined. To implement this idea, it can be assumed that: the majority of grids should obtain the maximum similarity (as shown in equation (2)) when shifting towards the best translation direction. In other words, the direction which has the most maximum matching scores over all the grids is the best translation direction. The following algorithm describes an exemplary procedure for estimating translation direction.
[0000]
for {each indexed image}
for {each grid i=1:16}
for {each neighbors j=1:9}
compute a matching score S[j]
end
maxScoreCount[i] += find_max(S[j])
end
direction = find_max(maxScoreCount[i])
end
[0060] After obtaining the best translation direction, each point is then assigned to this direction for finding the “AGGC” correspondences. Therefore, a set M best can be obtained, which contains correspondences between words of the current grid and words of the best neighboring grid. To compensate the errors caused by translation changes, the matching score is computed and the homography is estimated using the set M best .
[0061] FIG. 7 provides an example of homography estimation based on the dominant orientation of the received image. From the received image 700 , the translation is conducted based determining the dominant orientation of the EMM (i.e. determining the correct shape, size, orientation, up-scale, down-scale, etc.), and a translation is estimated accordingly 701 . The estimation can take the form of an image or can be a simple matrix or a grid representing the features of the image, or in the same format as the index file.
Hierarchical Encoding/Decoding
[0062] An efficient strategy for storing and decoding the multi-resolution spatial information should meet the following three requirements: 1) it should take as little memory space as possible; 2) it should fast compute the desired information, including coarse-level grid id, neighboring grid id and fine-level coordinates; 3) it should be easy to adjust the parameters, such as the number of coarse-level grids. Therefore, embodiments of the invention can optionally utilize a hierarchical encoding and decoding strategy which best satisfies these requirements. Each image is hierarchically quantized into 2 k ×2 k grids: an image is firstly partitioned into 2×2 grids and then each grid is iteratively subdivided into 2×2 grids, yielding 2 k ×2 k grids at level k. FIG. 4 illustrates an example when k=1. Then each grid at level k is given a unique grid ID (such as sequential numbering or encoded by coordinates (x i , y i ), (1≦i≦k), uniquely denoting one of the 4 positions in the upper level grid (x i−1 , y i−1 )). Finally the coordinates at all levels are concatenated together to form a bit string, and can be indexed accordingly as shown in FIG. 5 .
[0063] Memory Complexity:
[0064] Given the number of finest-level grids, the proposed scheme takes the least memory space by embedding all the coarser-level information into the corresponding finest-level grid id. In addition, such information can be bundled with the image id of each local feature and stored in the inverted file for fast accessing. FIG. 5 shows an exemplary structure of the index. Each visual word has an entry in the index that contains the list of images in which the visual word appears and the corresponding grid ID.
[0065] Time Complexity:
[0066] A hierarchal strategy can parse all the desired information using a few bit/add/subtract operations, which is very fast in practical use.
[0067] FIG. 8 illustrates an example functional diagram of an apparatus 800 according to an exemplary embodiment of the invention. An image containing an EMM 801 is received by a camera 802 , which forwards the image to the first comparison unit 804 to conduct the first comparison with a database 805 . The apparatus may optionally forward the image to a translation unit 803 for translating the image and an encoding unit to encode the image as needed. The results of the first comparison unit is forwarded to a second comparison unit 806 . Results from the second comparison unit may be forwarded to the display 808 , or appropriate digital media may be loaded and displayed. An encoding unit 807 may also be used to represent the received image in the format of an index file or files used to represent the images in the database.
[0068] FIG. 9 is a block diagram that illustrates an embodiment of a computer/server system 900 upon which an embodiment of the inventive methodology may be implemented. The system 900 includes a computer/server platform 901 including a processor 902 and memory 903 which operate to execute instructions, as known to one of skill in the art. The term “computer-readable medium” as used herein refers to any medium that participates in providing instructions to processor 902 for execution. Additionally, the computer platform 901 receives input from a plurality of input devices 904 , such as a keyboard, mouse, touch device or verbal command. The computer platform 901 may additionally be connected to a removable storage device 905 , such as a portable hard drive, optical media (CD or DVD), disk media or any other medium from which a computer can read executable code. The computer platform may further be connected to network resources 906 which connect to the Internet or other components of a local public or private network. The network resources 906 may provide instructions and data to the computer platform from a remote location on a network 907 . The connections to the network resources 906 may be via wireless protocols, such as the 802.11 standards, Bluetooth® or cellular protocols, or via physical transmission media, such as cables or fiber optics. The network resources may include storage devices for storing data and executable instructions at a location separate from the computer platform 901 . The computer interacts with a display 908 to output data and other information to a user, as well as to request additional instructions and input from the user. The display 908 may therefore further act as an input device 904 for interacting with a user.
[0069] Moreover, other implementations of the invention will be apparent to those skilled in the art from consideration of the specification and practice of the invention disclosed herein. Various aspects and/or components of the described embodiments may be used singly or in any combination in the image identification system. It is intended that the specification and examples be considered as exemplary only, with a true scope and spirit of the invention being indicated by the following claims.
|
Methods and apparatuses for identifying an image based on Embedded Media Marker (EMM) identification. A hierarchal comparison including a first coarse comparison and a second refining comparison is used. The first coarse comparison compares an image with an EMM to images in a database at a low resolution. The results are fed to the second refining comparison, which conducts a comparison at a higher resolution than the first coarse comparison. By utilizing this hierarchical comparison approach, it is possible to identify the image with fewer false positives.
| 6
|
BACKGROUND OF THE INVENTION
This invention relates to a sealed motor-compressor unit for refrigeration systems, or more particularly, to a refrigerating machine oil to be supplied for the compressor composing the sealed motor-compressor unit mentioned above.
Conventionally, as far as a refrigerating machine oil to be supplied for the compressor composing the sealed motor-compressor unit constituting a refrigerating cycle is concerned, refrigerating machine oil of ISO-VG 32 grade (more specifically, International Organization for Standardization VG 32 grade), the kinetic viscosity of which is defined to be 27 to 35 centistokes, has been employed for use in common.
However, in the case of the sealed motor-compressor provided with the power rating less than one horse power, the power rating of the motor included in the sealed motor-compressor is not sufficient to fully cope with variations in loads to be often effected in connection, for example, with the unsteady operation. Therefore, under these circumstances as described above, as long as such the refrigerating machine oil of ISO-VG 32 grade having a relatively high kinetic viscosity and thus, providing a rather high oil film or shearing resistance at an ordinary lubricating process, is to be employed, the faulty actuation concerning the sealed motor-compressor will not be avoidable. As a matter of fact, the disadvantages as described above may be especially frequently encountered under a rather low temperature condition, subject to the fact that the initial working load caused by the oil film shearing resistance will be increased in association with the decrease of the environmental temperature. Furthermore, if the machine oil mentioned above has a much higher viscosity due to the reasons as described above, the amount of machine oil to be fed tends to be decreased and thus, the occurrence of undesirable friction loss to be involved in respective sliding portions of the compressor composing the sealed motor-compressor unit has not been avoided.
Accordingly, a refrigerating machine oil especially suitable for use in a sealed motor-compressor unit, particularly constituting a refrigerating cycle and is provided with a motor not having a sufficient reverse capacity in the electric rating against variations in loads, has been strongly demanded.
SUMMARY OF THE INVENTION
Accordingly, an essential object of the present invention is to provide a refrigerating machine oil, which is capable of reducing initial actuating torque required during starting of a sealed motor-compressor unit, and also power consumption during the steady operation of the sealed motor-compressor unit.
Another important object of the present invention is to provide a refrigerating machine oil of above-described type, which ensures a positive starting and steady operation of the sealed motor-compressor unit, irrespective of environmental temperature changes and/or variations of electric voltage impressed to the sealed motor-compressor unit.
A further object of the present invention is to provide a refrigerating machine oil of the above-described type, which is capable of preventing the occurrence of wear or abrasion of respective sliding portions constituting the sealed motor-compressor unit, thereby to keep the sealed motor-compressor in an ordinary operating condition.
A still further object of the present invention is to provide a refrigerating machine oil of the above-described type, which is arranged to include an appropriate amount of phosphate extreme pressure additive, so that the lubricating characteristics are to be enhanced and, thus resulting in a lower electric power consumption.
In accomplishing these and other objects according to one preferred embodiment of the present invention, there is provided a refrigerating machine oil comprising low volatile distillates of naphthenic type oil. The napthenic type oil mentioned above consists of aromatic carbon C A having a range of 5 to 15 wt%, paraffinic carbon C P having a range of 35 to 45 wt%, and naphthenic carbon C N having a range of 45 to 55 wt%. The refrigerating machine oil mentioned above is arranged to have a specific physical property of a comparatively low kinetic viscosity, which is specified by respective kinetic viscosity ranges of 7.0 to 13.0 cst. at 100° F. and 2.0 to 2.5 cst. at 210° F., respectively, with seizure load of more than 450 lbs in respect to the falex test being also confirmed. According to one example of the present invention, the above-mentioned low volatile distillates or more specifically, the refrigerating machine oil was specified to that having an initial boiling point of 281° C. and an end point of 387° C. under an atomospheric pressure condition, which was confirmed by experiments with a method as indicated by ASTM D-1160. Furthermore, a pour point of the refrigerating machine oil mentioned above is below a temperature of -45 ° C., while its flock point is confirmed to be below a temperature of -35° C. Due to the specific properties as mentioned above, according to the present invention, besides the fact a shearing resistance relating to the respective sliding portions of the compressor is much decreased, it becomes clear that the present refrigerating machine oil itself is characterized in its enhanced fluidity.
Furthermore, in order to further enhance the lubricating property, the above-mentioned refrigerating machine oil is further added with phosphate extreme pressure additive including tricyresyl phosphate and triphenyl phospate of 0.1 to 2.0 by weight precent. Consequently, the resultant refrigerating machine oil substantially makes it possible not only to allow the present refrigerating machine oil to be effectively untilized under any undersirable electric supply conditions, but also to appreciably reduce the electric consumption required for driving the sealed motor-compressor unit.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other object and features of the present invention will become apparent from the following description taken in conjunction with the preferred embodiment thereof with reference to the accompanying drawings in which;
FIG. 1 is a graph, particularly showing a correlation plotting a relative ratio (%) of electric power supply required for a compressor in the course of steady operation of an ordinary electric refrigerating system against a kinetic viscosity (cst.) of the sampled refrigerating machine oil at a temperature of 210° F.,
FIG. 2 is a graph, particularly showing a correlation plotting a relative ratio (%) of initial actuating torque required for driving the compressor constituting the ordinary electric refrigerating system against a kinetic viscosity (cst.) of the sampled refrigerating machine oil at a temperature of 100° F., and
FIG. 3 is a graph, particularly showing a correlation plotting a falex index against a kinetic viscosity (cst.) of the sampled refrigerating machine oil at a temperature of 100° F.
DETAILED DESCRIPTION OF THE INVENTION
In the following, one of the preferred embodiments of refrigerating machine oils, which is suitable for use in a motor constituting a sealed motor-compressor unit, according to the present invention, is to be disclosed. According to the present invention, there is provided a refrigerating machine oil, which is mainly constituted by a low volatile distillates of naphthenic type oil. The naphthenic type oil mentioned above consists of aromatic carbon C A having a range of 5 to 15 wt%, paraffinic carbon C P having a range of 35 to 45 wt%, and naphthenic carbon C N having a range of 45 to 55 wt%. The refrigerating machine oil mentioned above is arranged to have a specific physical property of a comparatively low kinetic viscosity, which is specified by respective kinetic viscosity ranges of 7.0 to 13.0 cst. at 100° F. and 2.0 to 2.5 cst. at 210° F. According to one example of the present invention, the above-mentioned low volatile distillates or more specifically, the refrigerating machine oil was specified to that having an initial boiling point of 281° C. and an end point of 387° C. under an atmospheric pressure condition, which was confirmed by experiments with a method as indicated by ASTM D-1160. Owing to the low viscosity arrangement as described above, a shearing resistance to be involved is to be much decreased accordingly, whereby the power input necessary for the refrigerating compressor filled by the refrigerating machine oil according to the present invention is in turn decreased and thus, substantially resulting in an economical reduction in an electrical power consumption accordingly. Moreover, since the occurrence of the undesirable frictional loss and its consequent production of frictional heat are maintained as low as possible due to the specifically low kinetic viscosity of the oil according to the present invention, the refrigerating compressor is not subjected to overheating and thus, a sufficiently long life span of the compressor is expected.
Referring now to FIG. 1, there is shown a correlation, wherein the electric power supply required for the compressor in the course of steady operation of an ordinary electric refrigerating apparatus is plotted against the sampled specific kinetic viscosity (cst.) of the refrigerating machine oil employed for lublication of the compressor. In FIG. 1, the electric power supply mentioned above taken as the ordinate is represented by the relative ratio (%) with respect to that required when the conventional refrigerating machine oil is employed. However, the abscissa of the correlation mentioned above is respective kinetic viscosities of several refrigerating machine oils to be given at a temperature of 210° F. More specifically, the respective kinetic viscosities of the refrigerating machine oils employed for the above-mentioned correlation, i.e., Sample No. 1 to Sample No. 4 are listed in Table 1, with the respective kinetic viscosities to be given at a temperature of 100° F. being also listed. In Table 1, one embodiment of the refrigerating machine oil according to the present invention is denoted by No. 1, while the typical, conventional refrigerating machine oil is denoted by No. 3. The respective refrigerating machine oils denoted by No. 2 and No. 4 are both specifically composed for reference, when two refrigerating machine oils mentioned above are compared with respect to each other. As described hereinabove, in FIG. 1, the respective ratio mentioned above is, therefore, the relative value with respect to that required and referenced by the value of 100 for the employment of the conventional refrigerating machine oil denoted in No. 1.
As is clear from FIG. 1, the correlation of relative electric power supply for the compressor shows a decreasing tendency in accordance with the decrease of the specific value of kinetic viscosity of the refrigerating machine oil employed, whereby the electric power to be consumed by the sealed motor-compressor unit is capable of being effectively decreased, subject to an employment of the appropriate refrigerating machine oil accordingly.
TABLE 1______________________________________Sample Viscosity of refrigerating machine oil (cst.)number 100° F. 210° F.______________________________________No. 1 9.60 2.35No. 2 14.51 2.94No. 3 33.40 4.43No. 4 62.00 5.90______________________________________
Referring now to FIG. 2, there is shown a correlation, wherein a relative ratio (%) of initial actuating torque required for driving the compressor constituting the sealed motor-compressor unit is plotted against the sampled specific kinetic viscosity (cst.) of the refrigerating machine oil employed for lubrication of the compressor at a temperature of 100° F. Respective kinetic viscosities of sampled refrigerating machine oils, which are respectively denoted by No. 1 to No. 3 in FIG. 2, are listed in Table 2. The sample denoted by No. 1 is the refrigerating machine oil according to the present invention, while the sample denoted by No. 3 is the conventional one. The sample denoted by No. 2 is specifically composed one for reference, when two refrigerating machine oils mentioned above are compared with respect to each other. More specifically, FIG. 2 showns the correlation, wherein the relative, initial actuating torque (%) for driving the compressor, with that to be effected with the sample denoted by No. 3 being chosen as a reference value of 100, is plotted against the specific kinetic viscosity of the sampled refrigerating oil at a temperature of 100° F., respectively. As is clear from FIG. 2, the initial actuating torque driving the compressor is capable of being effectively decreased, subject to the employment of the refrigating machine oil specifically having a relative, low kinetic viscosity according to the present invention, whereby a comparatively easy actuation of the compressor is to be effected by impressing the relative low electric voltage thereonto in comparison with the case of the employment of the conventional refrigerating machine oil.
TABLE 2______________________________________Sample Viscosity of refrigerating machine oil (cst.)number 100° F. 210° F.______________________________________No. 1 9.60 2.35No. 2 14.51 2.93No. 3 33.40 4.43______________________________________
The refrigerating machine oil specifically having a relative, low kinetic viscosity according to the present invention has the specific properties as follows. That is to say, a pour point of the refrigerating machine oil mentioned above is below a temperature of -45° C., while its flock point is below a temperature of -35° C. Due to the characteristic properties as described above, since the present oil will not be left in a stagnant state within the explorator consisting the electric refrigerating system, such as the electric refrigerator, electric cold-storage box or electric refrigerating- or electric cold-storage-show case, the occurrence of oil-choking phenomemon is to be prevented, which often affects the refrigerating capacity in an undesirable manner. Accordingly, the refrigerating machine oil according to the present invention is quite suitable for the refrigerating machine oil to be employed for the sealed motor-compressor unit. Furthermore, according to the falex test, which was conducted as one step of the present invention for confirming the lubricating characteristics of the present refrigerating machie oil, it is confirmed that seizure affecting the lubricating portion of the compressor was, in general effeced at the seizure load less tha 450 in and ordinary expermental condition, However, according to the falex test with the refrigerating machine oil of the present invention, the occurance of seizure mentioned above was not confirmed below the seizure load of 480 lbs. Accordingly, it is clear that the refregerating machine oil according to the present invention does not involve any substantial defects related to mechanical friction and seizure. Referring now to FIG. 3, there is shown a correlation, wherein the seizure load or, more specifically, the falex index is plotted against the kinetic viscosity given by the sampled refrigerating machine oil of mineral nature at the temperature of 100° F. The respective kinetic viscosities given by the respective sampled refrigerating machine oil at respective temperatures of 100° F. and 210° F. are listed in Table 3. In Table 3, the sample denoted by No. 2 is the refrigerating machine oil according to the present invention, while the sample denoted by No. 3 is the conventional one. The respective samples denoted by No. 1 and No. 4 are both specifically composed with reference, when two refrigerating machine oils mentioned above are compared with respect to each other. The falex tests were made in the temperature conditions of a room temperature. Accordingly, the respective temperatures of the refrigerating machine oils employed for experiments were first at the temperature of 25° C., whereas these were increased by more or less ten degrees in the course of the seizuring test.
TABLE 3______________________________________Sample Viscosity of refrigerating machine oil (cst.)number 100° F. 210° F.______________________________________No. 1 4.10 1.40No. 2 9.60 2.35No. 3 33.40 4.43No. 4 62.00 5.90______________________________________
In the case wherein the improved lubrication of the large-scaled compressor provided with the lower rating more than one horse power is desired, the lubricating property inherent in the above-mentioned refrigerating machine oil according to the present invention is to be enhanced by adding prosphate extreme pressure additive of 0.1 to 2.0 by weight percent, such as tricyresyl phosphate or triphenyl phosphite.
Consequently, as the refrigerating machine oil according to the present invention is further added with phosphate extreme pressure additive of 0.l to 2.0 by weight percent, such as tricyresyl phosphate or triphenyl phosphite, the resultant refrigerating machine oil substantially makes it possible not only to allow the present refrigerating machine oil to be effectively utilized for the compressor having a power rating more than one horse power, but also to reduce the electric consumption required for driving the sealed motor-compressor unit.
Although the present invention has been fully described by way of example with reference to the accompanying drawings, it is to be noted that various changes and modifications are apparent to those skilled in the art. Therefore, unless otherwise such changes and modifications depart from the scope of the present invention, they should be construed as included therein.
|
Refrigerating machine oil to be filled in a sealed motor-compressor unit constituting a refrigerating cycle system including an electric refrigerator, an electric cold-storage box, a small-scaled electric refrigerating show-case, a small-scaled electric cold-storage show-case and the like, is arranged to have a specifically enhanced property, in which smaller initial driving power consumption of the sealed motor-compressor and easier supply of the predetermined amount of the refrigerating machine oil to the refrigerating system are both guaranteed even in a rather low environmental temperature condition.
| 2
|
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention is in the field of agents that inhibit human ADAM-10 (also known as human Kuzbanian) and their use in the treatment of cancer, arthritis, and diseases related to angiogenesis, such as renal diseases, heart diseases such as heart failure, atherosclerosis, and stroke, inflammation, ulcer, infertility, scleroderma, endometriosis, mesothelioma, and diabetes.
[0003] 2. Summary of the Related Art
[0004] Cell-cell interactions play an important role in regulating cell fate decisions and pattern formation during the development of multicellular organisms. One of the evolutionarily conserved pathways that plays a central role in local cell interactions is mediated by the transmembrane receptors encoded by the Notch (N) gene of Drosophila , the lin-12 and glp-1 genes of C. elegans , and their vertebrate homologs (reviewed in Artavanis-Tsakonas, S., et al. (1995) Notch Signaling. Science 268, 225-232), collectively hereinafter referred to as NOTCH receptors. Several lines of evidence suggest that the proteolytic processing of NOTCH receptors is important for their function. For example, in addition to the full-length proteins, antibodies against the intracellular domains of NOTCH receptors have detected C-terminal fragments of 100-120 kd; see, e.g., Fehon, R. G., et al. (1990). Cell 61, 523-534; Crittenden, S. L., et al. (1994). Development 120, 2901-2911; Aster, J., et al. (1994) Cold Spring Harbor Symp. Quant. Biol. 59, 125-136; Zagouras, P., et al. (1995). Proc. Natl. Acad. Sci. U.S.A. 92, 6414-6418; and Kopan, R., et al. (1996). Proc. Natl. Acad. Sci. U.S.A. 93, 1683-1688. However, the mechanism(s) of NOTCH activation have been hitherto largely unknown.
[0005] During neurogenesis, a single neural precursor is singled out from a group of equivalent cells through a lateral inhibition process in which the emerging neural precursor cell prevents its neighbors from taking on the same fate (reviewed in Simpson, P. (1990). Development 109, 509-519). Genetic studies in Drosophila have implicated a group of “neurogenic genes” including N in lateral inhibition. Loss-of-function mutations in any of the neurogenic genes result in hypertrophy of neural cells at the expense of epidermis (reviewed in Campos-Ortega, J. A. (1993) In: The Development of Drosophila melanogaster M. Bate and A. Martinez-Arias, eds. pp. 1091-1129. Cold Spring Harbor Press).
[0006] Rooke, J., Pan, D. J., Xu, T. and Rubin, G. M. (1996). Science 273, 1227-1231, discloses neurogenic gene family, kuzbanian (kuz). Members of the KUZ family of proteins are shown to belong to the recently defined ADAM family of transmembrane proteins, members of which contain both a disintegrin and metalloprotease domain (reviewed in Wolfsberg, T. G., et al. (1995). J. Cell Biol. 131, 275-278, see also Blobel, C. P., et al. (1992). Nature 356, 248-252, 1992; Yagami-Hiromasa, T., et al. (1995). Nature 377, 652-656; Black, R. A., et al. (1997). Nature 385, 729-733, 1997; and Moss, M. L., et al. (1997). Nature 385, 733-736; see also U.S. Pat. No. 5,922,546 and U.S. Pat. No. 5,935,792).
[0007] Genes of the ADAM family encode transmembrane proteins containing both metalloprotease and disintegrin domains (reviewed in Black and White, 1998 Curr. Opin. Cell Biol. 10, 654-659; Wolfsberg and White, 1996 Dev. Biol. 180, 389-401), and are involved in diverse biological processes in mammals such as fertilization (Cho et al., 1998 Science 281, 1857-1859), myoblast fusion (Yagami-Hiromasa et al., 1995 Nature 377, 652-656) and ectodomain shedding (Moss et al., 1997 Nature 385, 733-736; Black et al., 1997 Nature 385, 729-733; Peschon et al., 1998 Science 282, 1281-1284). The Drosophila kuzbanian (kuz) gene represents the first ADAM family member identified in invertebrates (Rooke et al., 1996 Science 273, 1227-1231). Previous genetic studies showed that kuz is required for lateral inhibition and axonal outgrowth during Drosophila neural development (Rooke et al., 1996; Fambrough et al., 1996 PNAS.USA 93, 13233-13238; Pan and Rubin, 1997 Cell 90, 271-280; Sotillos et al., 1997 Development 124, 4769-4779). Specifically, during the lateral inhibition process, kuz acts upstream of Notch (Pan and Rubin, 1997; Sotillos et al., 1997), which encodes the transmembrane receptor for the lateral inhibition signal encoded by the Delta gene. More recently, a homolog of kuz was identified in C. elegans (SUP-17) that modulates the activity of a C. elegans homolog of Notch in a similar manner (Wen et al., 1997 Development 124, 4759-4767).
[0008] Vertebrate homologs of kuz have been isolated in Xenopus , bovine, mouse, rat and human. The bovine homolog of KUZ (also called MADM or ADAM 10) was initially isolated serendipitously based on its in vitro proteolytic activity on myelin basic protein, a cytoplasmic protein that is unlikely the physiological substrate for the bovine KUZ protease (Howard et al., 1996 Biochem. J. 317, 45-50). Expression of a dominant negative form of the murine kuz homolog (mkuz) in Xenopus leads to the generation of extra neurons, suggesting an evolutionarily conserved role for mkuz in regulating Notch signaling in vertebrate neurogenesis (Pan and Rubin, 1997). U.S. patent application. No. 09/697,854, to Pan et al., filed Oct. 27, 2000, discloses that mkuz mutant mice die around embryonic day (E) 9.5, with severe defects in the nervous system, the paraxial mesoderm and the yolk sac vasculature. In the nervous system, mkuz mutant embryos show ectopic neuronal differentiation. In the paraxial mesoderm, mkuz mutant embryos show delayed and uncoordinated segmentation of the somites. These phenotypes are similar to those of mice lacking Notch-1 or components of the Notch pathway such as RBP-Jk (Conlon et al, 1995, Development 121, 1533-1545; Oka et al., 1995), indicating a conserved role for mkuz in modulating Notch signaling in mouse development. Furthermore, no visible defect was detected in Notch processing in the kuz knockout animals. In addition to the neurogenesis and somitogenesis defect, mkuz mutant mice also show severe defects in the yolk sac vasculature, with an enlarged and disordered capillary plexus and the absence of large vitelline vessels. Since such phenotype has not been observed in mice lacking Notch-1 or RBP-Jk (Swiatek et al., 1994 Genes Dev 15, 707-719; Conlon et al, 1995; Oka et al., 1995 Development 121, 3291-3301), Pan et al. determined that this phenotype reveals a novel function of mkuz that is distinct from its role in modulating Notch signaling, specifically, that kuz plays an essential role for an ADAM family disintegrin metalloprotease in mammalian angiogenesis.
[0009] In view of the important role of KUZ (ADAM-10) in biological processes and disease states, inhibitors of this protein are desirable, particularly small molecule inhibitors.
[0010] Studies have suggested that selective inhibition of matrix metalloproteases is important. A number of small molecule MMPI's have progressed into the clinic for cancer and rheumatoid arthritis, for example. Inhibition of MMP-1 has been implicated as the cause of side effects such as joint pain and tendonitis when unselective TACE inhibitors were employed (see Barlaam, B. et. Al. J. Med. Chem. 1999, 42, 4890). As well, clinical trials of broad spectrum inhibitors, such as “Marimastat,” have been hampered due to musculoskeletal syndrome (MSS) which manifests as musculoskeletal pain after a few weeks treatment. Inhibition of MMP-1 has been suggested as having a role in the appearance of MSS. Recent efforts in the field have been directed toward design of “MMP-1 sparing” inhibitors; for example, BA-129566 emerged as a selective inhibitor which reportedly showed no signs of MSS in phase 2 clinical trials (see Natchus, M. G. et. Al. J. Med. Chem. 2000, 43, 4948).
[0011] Thus, what is needed are selective matrix metalloprotease inhibitors. Of particular use are selective ADAM-10 inhibitors, those that are “MMP-1 sparing.”
[0012] All patents, applications, and publications recited herein are hereby incorporated by reference in their entirety.
SUMMARY OF THE INVENTION
[0013] The present invention provides compounds useful for inhibiting the ADAM-10 protein. Such compounds are useful in the in vitro study of the role of ADAM-10 (and its inhibition) in biological processes. The present invention also comprises pharmaceutical compositions comprising one or more ADAM-10 inhibitors according to the invention in combination with a pharmaceutically acceptable carrier. Such compositions are useful for the treatment of cancer, arthritis, and diseases related to angiogenesis, such as renal diseases, heart diseases such as heart failure, atherosclerosis, and stroke, inflammation, ulcer, infertility, scleroderma, endometriosis, mesothelioma, and diabetes. Correspondingly, the invention also comprises methods of treating forms of cancer, arthritis, and diseases related to angiogenesis in which ADAM-10 plays a critical role. In particular, the invention comprises inhibitors selective for ADAM-10, relative to MMP-1.
[0014] The foregoing merely summarizes certain aspects of the invention and is not intended to be limiting.
DETAILED DESCRIPTION OF THE INVENTION
[0015] The present invention comprises inhibitors of ADAM-10. In one embodiment, the invention comprises a compound of structural formula I:
[0000]
[0016] and pharmaceutically acceptable salts, esters, amides, and prodrugs thereof wherein
[0000] L 1 is —C(O)—, —S(O) 2 —, or —(CH 2 ) n —;
R 1 is —H, —OR 11 , —(CH 2 ) n R 11 , —C(O)R 11 , or —NR 12 R 13 ;
[0017] R 11 , R 12 , and R 13 independently are
a) R 50 ; b) saturated or mono- or poly-unsaturated C 5 -C 14 -mono- or fused poly-cyclic hydrocarbyl, optionally containing one or two annular heteroatoms per ring and optionally substituted with one or two R 50 substituents; c) C 1 -C 6 -alkyl, C 2 -C 6 -alkenyl, C 2 -C 6 -alkynyl, or —C(O)H, each of which is optionally substituted with one, two or three substituents independently selected from R 50 and saturated or mono- or poly-unsaturated C 5 -C 14 -mono- or fused poly-cyclic hydrocarbyl, optionally containing one or two annular heteroatoms per ring and optionally substituted with one, two or three R 50 substituents;
[0021] or R 12 and R 13 together with the N to which they are covalently bound, a C 5 -C 6 heterocycle optionally containing a second annular heteroatom and optionally substituted with one or two R 50 substituents;
R 2 is —R 21 -L 2 -R 22 ;
[0000]
R 21 is saturated or mono- or poly-unsaturated C 5 -C 14 -mono- or fused poly-cyclic hydrocarbyl, optionally containing one or two annular heteroatoms per ring and optionally substituted with one, two, or three R 50 substituents;
L 2 is —O—, —C(O)—, —CH 2 —, —NH—, —S(O 2 )— or a direct bond;
R 22 is saturated or mono- or poly-unsaturated C 5 -C 14 -mono- or fused poly-cyclic hydrocarbyl, optionally containing one or two annular heteroatoms per ring and optionally substituted with one, two, or three R 50 substituents; and
R 50 is R 51 -L 3 -(CH 2 ) n —;
L 3 is —O—, —NH—, —S(O) 0-2 —, —C(O)—, —C(O)O—, —C(O)NH—, —OC(O)—, —NHC(O)—, —C 6 H 4 —, or a direct bond;
R 51 is —H, C 1 -C 6 -alkyl, C 2 -C 6 -alkenyl, C 2 -C 6 -alkynyl, halo, —CF 3 , —OCF 3 , —OH, —NH 2 , mono-C 1 -C 6 alkyl amino, di-C 1 -C 6 alkyl amino, —SH, —CO 2 H, —CN, —NO 2 , —SO 3 H, or a saturated or mono- or poly-unsaturated C 5 -C 14 -mono- or fused poly-cyclic hydrocarbyl, optionally containing one or two annular heteroatoms per ring and optionally substituted with one, two, or three substituents;
wherein n is 0, 1, 2, or 3;
provided that an O or S is not singly bonded to another O or S in a chain of atoms.
[0028] In one example, according to paragraph [0013], L 1 is —C(O)— or —S(O) 2 —.
[0029] In another example, according to paragraph [0014], L 1 is —C(O)— and R 1 is —OR 11 or —(CH 2 ) n R 11 , —OC 1 -C 6 alkyl-mono-C 1 -C 6 alkyl amino, amino, —OC 1 -C 6 alkyl-N-heterocyclyl, —C 1 -C 6 alkyl-mono-C 1 -C 6 alkyl amino, —C 1 -C 6 alkyl-di-C 1 -C 6 alkyl amino, or —C 1 -C 6 alkyl-N-heterocyclyl. In a more specific example, R 1 is C 1 -C 6 -alkoxy-C 1 -C 6 -alkoxy; and in a still more specific example R 1 is methoxyethoxy.
[0030] In another example, according to paragraph [0015], L 1 is —S(O) 2 —, and R 1 is —NR 12 R 13 , —(CH 2 ) n R 11 , —C 1 -C 6 alkyl-mono-C 1 -C 6 alkyl amino, amino, or —C 1 -C 6 alkyl-N-heterocyclyl.
[0031] In another example, according to paragraph [0015] or [0016], L 2 is —O—.
[0032] In another example, according to paragraph [0017], R 2 is phenoxyphenyl wherein each phenyl is optionally substituted with one or two R 50 substituents. In a more specific example, the R 50 substituents are halo.
[0033] In another example, according to paragraph [0018], the saturated or mono- or poly-unsaturated C 5 -C 14 -mono- or fused poly-cyclic hydrocarbyl containing one or two annular heteroatoms per ring is selected from the group consisting of morpholinyl, piperazinyl, homopiperazinyl, pyrrolidinyl, piperidinyl, homopiperidinyl, furyl, thienyl, pyranyl, isobenzofuranyl, chromenyl, pyrrolyl, imidazplyl, isoxazolyl, pyridyl, pyrazinyl, pyrimidinyl, oxadiazolyl, indolyl, quinolinyl, carbazolyl, acrydinyl, and furazanyl, optionally substituted with one or two R 50 substituents.
[0034] In another example, according to paragraph [0018], R 12 and R 13 , together with the N to which they are covalently bound, form a heterocycle selected from the group consisting of morpholinyl, piperazinyl, homopiperazinyl, pyrrolidinyl, piperidinyl, homopiperidinyl, pyrrolyl, imidazolyl, isoxazolyl, pyridyl, pyrazinyl, pyrimidinyl, oxadiazolyl, indolyl, quinolinyl, carbazolyl, acrydinyl, and furazanyl, optionally substituted with one or two R 50 substituents.
[0035] In another example, the compound is according to paragraph [0013], having the absolute stereochemistry of structural formula II:
[0000]
[0036] In another example, the compound is according to paragraph [0013], having the absolute stereochemistry of structural formula III:
[0000]
[0037] In another example, the compound of the invention is according to paragraph [0013], wherein -L 1 -R 1 is selected from Table 1;
[0000] TABLE 1 —R 14
wherein each R 14 is independently selected from —H, —(CH 2 ) 1-3 CO 2 H, alkyl, alkoxy, alkenyl, aryl, heteroaryl, arylalkyl, and heteroarylalkyl;
and R 2 is selected from Table 2;
[0000]
TABLE 2
[0038] In another example the compound is according to paragraph [ 0013 ], selected from Table 3:
[0000]
TABLE 3
[0039] In another aspect, the invention comprises compounds according to formula IV,
[0000]
[0000] and pharmaceutically acceptable salts, esters, amides, and pro-drugs thereof wherein,
[0040] Z is —C(R 15 )=, —C(H)═, or —N═;
[0041] Ar is aryl or heteroaryl, each optionally substituted;
[0042] R 15 is fluoro;
[0043] p is 0, 1, 2, or 3;
[0044] L 1 is —C(O)—, —S(O) 2 —, or —(CH 2 ) n —;
[0045] L 4 is nothing or —O—;
[0046] R 1 is —H, —OR 11 , —(CH 2 ) n R 11 , —C(O)R 11 , or —NR 12 R 13 ;
R 11 , R 12 , and R 13 independently are
d) R 50 ; e) saturated or mono- or poly-unsaturated C 5 -C 14 -mono- or fused poly-cyclic hydrocarbyl, optionally containing one or two annular heteroatoms per ring and optionally substituted with one or two R 50 substituents; f) C 1 -C 6 -alkyl, C 2 -C 6 -alkenyl, C 2 -C 6 -alkynyl, or —C(O)H, each of which is optionally substituted with one, two or three substituents independently selected from R 50 and saturated or mono- or poly-unsaturated C 5 -C 14 — mono- or fused poly-cyclic hydrocarbyl, optionally containing one or two annular heteroatoms per ring and optionally substituted with one, two or three R 50 substituents; or R 12 and R 13 together with the N to which they are covalently bound, a C 5 -C 6 heterocycle optionally containing a second annular heteroatom and optionally substituted with one or two R 50 substituents; and
[0052] R 50 is R 51 -L 3 -(CH 2 ) n —;
L 3 is —O—, —NH—, —S(O) 0-2 —, —C(O)—, —C(O)O—, —C(O)NH—, OC(O)—, —NHC(O)—, —C 6 H 4 —, or a direct bond; R 51 is —H, C 1 -C 6 -alkyl, C 2 -C 6 -alkenyl, C 2 -C 6 -alkynyl, halo, —CF 3 , —OCF 3 , —OH, —NH 2 , mono-C 1 -C 6 alkyl amino, di-C 1 -C 6 alkyl amino, —SH, —CO 2 H, —CN, —NO 2 , —SO 3 H, or a saturated or mono- or poly-unsaturated C 5 -C 14 -mono- or fused poly-cyclic hydrocarbyl, optionally containing one or two annular heteroatoms per ring and optionally substituted with one, two, or three substituents;
[0055] wherein n is 0, 1, 2, or 3;
[0056] provided that an O or S is not singly bonded to another O or S in a chain of atoms.
[0057] In one example the compound is according to paragraph [0025], wherein -L 1 -R 1 is selected from Table 4,
[0000] TABLE 4 —R 14
wherein each R 14 is independently selected from —H, —(CH 2 ) 1-3 CO 2 H, alkyl, alkoxy, alkenyl, aryl, heteroaryl, arylalkyl, and heteroarylalkyl.
[0058] In another example the compound is according to paragraph [0026], wherein Z is —C(R 15 )═ or —C(H)═; L 4 is —O—; and p is at least one.
[0059] In another example the compound is according to paragraph [0027], wherein Ar is selected from the group consisting of phenyl, biphenyl, napthyl, tetrahydronaphthalene, chromen-2-one, dibenzofuran, pyryl, furyl, pyridyl, 1,2,4-thiadiazolyl, pyrimidyl, thienyl, isothiazolyl, imidazolyl, tetrazolyl, pyrazinyl, pyrimidyl, quinolyl, isoquinolyl, benzothienyl, isobenzofuryl, pyrazolyl, indolyl, purinyl, carbazolyl, benzimidazolyl, and isoxazolyl, each optionally substituted.
[0060] In another example the compound is according to paragraph [0028], wherein Ar is phenyl, optionally substituted, with at least one halogen.
[0061] In another example the compound is according to paragraph [0029], wherein p is at least two.
[0062] In another example the compound is according to paragraph [0030], wherein -L 1 -R 1 is —C(═O)OR 14 or —(CH 2 ) 2 OR 14 .
[0063] In another example the compound is according to paragraph [0031], having the structure:
[0000]
[0064] In another example the compound is according to paragraph [0026], wherein Z is —N═; and L 4 is —O—.
[0065] In another example the compound is according to paragraph [0033], wherein Ar is selected from the group consisting of phenyl, biphenyl, napthyl, tetrahydronaphthalene, chromen-2-one, dibenzofuran, pyryl, furyl, pyridyl, 1,2,4-thiadiazolyl, pyrimidyl, thienyl, isothiazolyl, imidazolyl, tetrazolyl, pyrazinyl, pyrimidyl, quinolyl, isoquinolyl, benzothienyl, isobenzofuryl, pyrazolyl, indolyl, purinyl, carbazolyl, benzimidazolyl, and isoxazolyl, each optionally substituted.
[0066] In another example the compound is according to paragraph [0034], wherein Ar is optionally substituted tetrahydronaphthalene.
[0067] In another example the compound is according to paragraph [0035], wherein is —C(═O)OR 14 or —(CH 2 ) 2-3 OR 14 .
[0068] In another example the compound is according to paragraph [0036], wherein p is zero.
[0069] In another example the compound is according to paragraph [0037], having the structure:
[0000]
[0070] In another example the compound is according to paragraph [0026], wherein Z is —N═; and L 4 is nothing.
[0071] In another example the compound is according to paragraph [0039], wherein Ar is selected from the group consisting of phenyl, biphenyl, napthyl, tetrahydronaphthalene, chromen-2-one, dibenzofuran, pyryl, furyl, pyridyl, 1,2,4-thiadiazolyl, pyrimidyl, thienyl, isothiazolyl, imidazolyl, tetrazolyl, pyrazinyl, pyrimidyl, quinolyl, isoquinolyl, benzothienyl, isobenzofuryl, pyrazolyl, indolyl, purinyl, carbazolyl, benzimidazolyl, and isoxazolyl, each optionally substituted.
[0072] In another example the compound is according to paragraph [0040], wherein p is zero.
[0073] In another example the compound is according to paragraph [0041], wherein Ar is optionally substituted phenyl.
[0074] In another example the compound is according to paragraph [0042], wherein -L 1 -R 1 is —C(═O)OR 14 or —(CH 2 ) 2-3 OR 14 .
[0075] In another example the compound is according to paragraph [0043], having the structure:
[0000]
[0076] In another example the compound is according to paragraph [0026], of formula V,
[0000]
[0077] In another example the compound is according to paragraph [0045], wherein Ar is selected from the group consisting of phenyl, biphenyl, napthyl, tetrahydronaphthalene, chromen-2-one, dibenzofuran, pyryl, furyl, pyridyl, 1,2,4-thiadiazolyl, pyrimidyl, thienyl, isothiazolyl, imidazolyl, tetrazolyl, pyrazinyl, pyrimidyl, quinolyl, isoquinolyl, benzothienyl, isobenzofuryl, pyrazolyl, indolyl, purinyl, carbazolyl, benzimidazolyl, and isoxazolyl, each optionally substituted.
[0078] In another example the compound is according to paragraph [0046], wherein Ar is phenyl, optionally substituted, with at least one halogen.
[0079] In another example the compound is according to paragraph [0046], wherein Ar is selected from,
[0000]
[0080] In another example the compound is according to paragraph [0047], wherein the absolute stereochemistry is according to formula VI,
[0000]
[0081] In another example the compound is according to paragraph [0049], wherein -L 1 -R 1 is —C(═O)OR 14 or —(CH 2 ) 2-3 OR 14 .
[0082] In another example the compound is according to paragraph [ 0050 ], having the structure:
[0000]
[0083] In another example, the invention comprises a pharmaceutical composition comprising a compound as described in any of paragraphs [0013]-[0051] and a pharmaceutically acceptable carrier.
[0084] In another example, the invention comprises a method of making a bis-aryl ether sulfonyl halide according to formula VII:
[0000]
[0000] wherein X is a halide; and W 1 and W 2 are each independently an optionally substituted aryl, the method comprising: (a) combining a metal-aryloxide salt of a corresponding hydroxide-substituted aryl compound with a fluoro-substituted nitro aryl compound to make a bis-aryl ether nitro-aromatic compound; (b) reducing a nitro group of the bis-aryl ether nitro-aromatic compound to produce a corresponding aniline derivative; and (c) converting the corresponding aniline derivative to the bis-aryl ether sulfonyl halide.
[0085] In one example, the method is according to paragraph [0053], wherein the metal-aryloxide salt is combined with the fluoro-substituted nitro aryl in an organic solvent.
[0086] In another example, the method is according to paragraph [0054], wherein the organic solvent comprises at least one of DMF and acetonitrile.
[0087] In another example, the method is according to paragraph [0055], wherein the metal-aryloxide salt comprises at least one of a cesium salt and a potassium salt.
[0088] In another example, the method is according to paragraph [0056], wherein the corresponding aniline derivative is converted to the bis-aryl ether sulfonyl halide via a diazonium intermediate of said corresponding aniline derivative.
[0089] In another example, the method is according to paragraph [0057], wherein the fluoro-substituted nitro aryl compound is 3,4,5-trifluornitrobenzene.
[0090] In another example, the method is according to paragraph [0058], wherein the metal-aryloxide salt is a cesium salt.
[0091] In another example, the method is according to paragraph [0059], wherein the corresponding hydroxide-substituted aryl compound is 4-chlorophenol.
[0092] In another example, the method is according to paragraph [0060], wherein the bis-aryl ether sulfonyl halide is 4-(4-chlorophenoxy)-3,5-difluorophenylsulfonyl chloride.
[0093] In another aspect, the invention comprises a sulfonyl halide according to formula VIII:
[0000]
[0000] wherein X is halogen; R 16 , R 17 , R 18 , and R 19 , are each independently either —H or —F; and Ar is aryl or heteroaryl, each optionally substituted.
[0094] In another example, the sulfonyl halide is according to paragraph [0062], wherein R 16 and R 18 are each —H; and R 17 and R 19 are each —F.
[0095] In another example the sulfonyl halide is according to paragraph [0063], wherein Ar is selected from the group consisting of phenyl, biphenyl, napthyl, tetrahydronaphthalene, chromen-2-one, dibenzofuran, pyryl, furyl, pyridyl, 1,2,4-thiadiazolyl, pyrimidyl, thienyl, isothiazolyl, imidazolyl, tetrazolyl, pyrazinyl, pyrimidyl, quinolyl, isoquinolyl, benzothienyl, isobenzofuryl, pyrazolyl, indolyl, purinyl, carbazolyl, benzimidazolyl, and isoxazolyl, each optionally substituted.
[0096] In another example the sulfonyl halide is according to paragraph [0064], wherein Ar is phenyl, optionally substituted, with at least one halogen.
[0097] In another example the sulfonyl halide is according to paragraph [0065], of formula IX:
[0000]
[0098] In another example, the sulfonyl halide is according to paragraph [0066], wherein X is —Cl.
[0099] Yet another example of the invention is a method of treating cancer, arthritis, and diseases related to angiogenesis comprising administering to a mammal in need of such treatment a therapeutically effective amount of a pharmaceutical composition according to paragraph [0052].
[0100] Still yet another example of the invention is a method of modulating the activity of Adam-10 comprising administering to a mammal in need of such treatment a therapeutically effective amount of a pharmaceutical composition according to paragraph [0052].
DEFINITIONS
[0101] The following paragraphs provide definitions of the various chemical moieties that make up the compounds of the invention and are intended to apply uniformly throughout the specification and claims unless expressly stated otherwise.
[0102] The term alkyl refers inclusively to a univalent C 1 to C 20 (unless explicitly stated otherwise) saturated straight, branched, cyclic, and combinations thereof alkane moiety and specifically includes methyl, ethyl, propyl, isopropyl, butyl, isobutyl, t-butyl, pentyl, cyclopentyl, isopentyl, neopentyl, hexyl, isohexyl, cyclohexyl, 3-methylpentyl, 2,2-dimethylbutyl, and 2,3-dimethylbutyl. In certain instances, specific cycloalkyls are defined (e.g. C 3 -C 8 cycloalkyl) to differentiate them from generically described alkyls (that, again, are intended to construe inclusion of cycloalkyls). Thus “alkyl” includes, e.g., C 3 -C 8 cycloalkyl. The term “alkyl” also includes, e.g., C 3 -C 8 cycloalkyl C 1 -C 6 alkyl, which is a C 1 -C 6 alkyl having a C 3 -C 8 cycloalkyl terminus. Alkyl's can be optionally substituted with any appropriate group, including but not limited to one or more moieties selected from halo, hydroxyl, amino, arylalkyl, heteroarylalkyl, alkylamino, arylamino, alkoxy, aryloxy, nitro, cyano, sulfonic acid, sulfate, phosphonic acid, phosphate, or phosphonate, either unprotected, or protected as necessary, as known to those skilled in the art or as taught, for example, in Greene, et al., “Protective Groups in Organic Synthesis,” John Wiley and Sons, Second Edition, 1991.
[0103] The term alkoxy refers to the group —O-(substituted alkyl), the substitution on the alkyl group generally containing more than only carbon (as defined by alkoxy). One exemplary substituted alkoxy group is “polyalkoxy” or —O— (optionally substituted alkylene)-(optionally substituted alkoxy), and includes groups such as —OCH 2 CH 2 OCH 3 , and glycol ethers such as polyethyleneglycol and —O(CH 2 CH 2 O) x CH 3 , where x is an integer of between about 2 and about 20, in another example, between about 2 and about 10, and in a further example between about 2 and about 5. Another exemplary substituted alkoxy group is hydroxyalkoxy or —OCH 2 (CH 2 ) y OH, where y is for example an integer of between about 1 and about 10, in another example y is an integer of between about 1 and about 4.
[0104] The term alkenyl refers to a univalent C 2 -C 6 straight, branched, or in the case of C 5-8 , cyclic hydrocarbon with at least one double bond.
[0105] The term aryl refers to a univalent phenyl, biphenyl, napthyl, and the like. The aryl group can be optionally substituted with any suitable group, including but not limited to one or more moieties selected from halo, hydroxyl, amino, alkylamino, arylamino, alkoxy, aryloxy, nitro, cyano, sulfonic acid, sulfate, phosphonic acid, phosphate, or phosphonate, either unprotected, or protected as necessary, as known to those skilled in the art, for example, as taught in Greene, et al., “Protective Groups in Organic Synthesis,” John Wiley and Sons, Second Edition, 1991). As well, substitution on an aryl can include fused rings such as in tetrahydronaphthalene, chromen-2-one, dibenzofuran, and the like. In such cases, e.g. tetrahydronaphthalene, the aryl portion of the tetrahydronaphthalene is attached to the portion of a molecule described as having an aryl group.
[0106] The term heteroatom means O, S, P, or N.
[0107] The term heterocycle refers to a cyclic alkyl, alkenyl, or aryl moiety as defined above wherein one or more ring carbon atoms is replaced with a heteroatom.
[0108] The term heteroaryl specifically refers to an aryl that includes at least one of sulfur, oxygen, and nitrogen in the aromatic ring. Non-limiting examples are pyryl, furyl, pyridyl, 1,2,4-thiadiazolyl, pyrimidyl, thienyl, isothiazolyl, imidazolyl, tetrazolyl, pyrazinyl, pyrimidyl, quinolyl, isoquinolyl, benzothienyl, isobenzofuryl, pyrazolyl, indolyl, purinyl, carbazolyl, benzimidazolyl, and isoxazolyl.
[0109] The term halo refers to chloro, fluoro, iodo, or bromo.
[0110] As used herein, the term pharmaceutically acceptable salts or complexes refers to salts or complexes that retain the desired biological activity of the above-identified compounds and exhibit minimal or no undesired toxicological effects. Examples of such salts include, but are not limited to acid addition salts formed with inorganic acids (for example, hydrochloric acid, hydrobromic acid, sulfuric acid, phosphoric acid, nitric acid, and the like), and salts formed with organic acids such as acetic acid, oxalic acid, tartaric acid, succinic acid, malic acid, ascorbic acid, benzoic acid, tannic acid, pamoic acid, alginic acid, polyglutamic acid, naphthalenesulfonic acid, naphthalenedisulfonic acid, and polygalacturonic acid. The compounds can also be administered as pharmaceutically acceptable quaternary salts known by those skilled in the art, which specifically include the quaternary ammonium salt of the formula —NR+Z—, wherein R is hydrogen, alkyl, or benzyl, and Z is a counterion, including chloride, bromide, iodide, —O-alkyl, toluenesulfonate, methylsulfonate, sulfonate, phosphate, or carboxylate (such as benzoate, succinate, acetate, glycolate, maleate, malate, citrate, tartrate, ascorbate, benzoate, cinnamoate, mandeloate, benzyloate, and diphenyl-acetate).
[0111] The term pharmaceutically active derivative refers to any compound that upon administration to the recipient, is capable of providing directly or indirectly, the compounds disclosed herein.
[0112] In some examples, as will be appreciated by those skilled in the art, two adjacent carbon containing groups on an aromatic system may be fused together to form a ring structure. The fused ring structure may contain heteroatoms and may be substituted with one or more substitution groups “R”. It should additionally be noted that for cycloalkyl (i.e. saturated ring structures), each positional carbon may contain two substitution groups, e.g. R and R′.
[0113] Some of the compounds of the invention may have imino, amino, oxo or hydroxy substituents off aromatic heterocyclic ring systems. For purposes of this disclosure, it is understood that such imino, amino, oxo or hydroxy substituents may exist in their corresponding tautomeric form, i.e., amino, imino, hydroxy or oxo, respectively.
[0114] Compounds of the invention are generally named using ACD/Name (available from Advanced Chemistry Development, Inc. of Toronto, Canada). This software derives names from chemical structures according to systematic application of the nomenclature rules agreed upon by the International Union of Pure and Applied Chemistry (IUPAC), International Union of Biochemistry and Molecular Biology (IUBMB), and the Chemical Abstracts Service (CAS).
[0115] The compounds of the invention, or their pharmaceutically acceptable salts, may have asymmetric carbon atoms, oxidized sulfur atoms or quaternized nitrogen atoms in their structure.
[0116] The compounds of the invention and their pharmaceutically acceptable salts may exist as single stereoisomers, racemates, and as mixtures of enantiomers and diastereomers. The compounds may also exist as geometric isomers. All such single stereoisomers, racemates and mixtures thereof, and geometric isomers are intended to be within the scope of this invention.
[0117] Methods for the preparation and/or separation and isolation of single stereoisomers from racemic mixtures or non-racemic mixtures of stereoisomers are well known in the art. For example, optically active (R)— and (S)— isomers may be prepared using chiral synthons or chiral reagents, or resolved using conventional techniques. When desired, the R- and S-isomers may be resolved by methods known to one skilled in the art, for example by: formation of diastereoisomeric salts or complexes which may be separated, for example, by crystallization; via formation of diastereoisomeric derivatives which may be separated, for example, by crystallization, gas-liquid or liquid chromatography; selective reaction of one enantiomer with an enantiomer-specific reagent, for example enzymatic oxidation or reduction, followed by separation of the modified and unmodified enantiomers; or gas-liquid or liquid chromatography in a chiral environment, for example on a chiral support, such as silica with a bound chiral ligand or in the presence of a chiral solvent. It will be appreciated that where a desired enantiomer is converted into another chemical entity by one of the separation procedures described above, a further step may be required to liberate the desired enantiomeric form. Alternatively, specific enantiomer may be synthesized by asymmetric synthesis using optically active reagents, substrates, catalysts or solvents, or by converting on enantiomer to the other by asymmetric transformation. For a mixture of enantiomers, enriched in a particular enantiomer, the major component enantiomer may be further enriched (with concomitant loss in yield) by recrystallization.
[0118] “Optional” or “optionally” means that the subsequently described event or circumstance may or may not occur, and that the description includes instances where said event or circumstance occurs and instances in which it does not. It will be understood by one skilled in the art with respect to any group containing one or more substituents that such groups are not intended to introduce any substitution or substitution patterns that are sterically impractical and/or synthetically nonfeasible. “Optionally substituted” refers to all subsequent modifiers in a term, for example in the term “optionally substituted C 1-8 alkylaryl,” optional substitution may occur on both the “C 1-8 alkyl” portion and the “aryl” portion of the molecule; and for example, optionally substituted alkyl includes optionally substituted cycloalkyl groups, which in turn are defined as including optionally substituted alkyl groups, potentially ad infinitum.
[0119] “Substituted” alkyl, aryl, and heterocyclyl, for example, refer respectively to alkyl, aryl, and heterocyclyl, wherein one or more (for example up to about 5, in another example, up to about 3) hydrogen atoms are replaced by a substituent independently selected from, but not limited to: optionally substituted alkyl (e.g., fluoroalkyl), optionally substituted alkoxy, alkylenedioxy (e.g. methylenedioxy), optionally substituted amino (e.g., alkylamino and dialkylamino), optionally substituted amidino, optionally substituted aryl (e.g., phenyl), optionally substituted arylalkyl (e.g., benzyl), optionally substituted aryloxy (e.g., phenoxy), optionally substituted arylalkyloxy (e.g., benzyloxy), carboxy (—COOH), carboalkoxy (i.e., acyloxy or —OOCR), carboxyalkyl (i.e., esters or —COOR), carboxamido, aminocarbonyl, benzyloxycarbonylamino (CBZ-amino), cyano, carbonyl, halogen, hydroxy, optionally substituted heterocyclylalkyl, optionally substituted heterocyclyl, nitro, sulfanyl, sulfinyl, sulfonyl, and thio.
[0120] “Prodrug” refers to compounds that are transformed (typically rapidly) in vivo to yield the parent compound of the above formulae, for example, by hydrolysis in blood. Common examples include, but are not limited to, ester and amide forms of a compound having an active form bearing a carboxylic acid moiety. Examples of pharmaceutically acceptable esters of the compounds of this invention include, but are not limited to, alkyl esters (for example with between about 1 and about 6 carbons) wherein the alkyl group is a straight or branched chain. Acceptable esters also include cycloalkyl esters and arylalkyl esters such as, but not limited to benzyl. Examples of pharmaceutically acceptable amides of the compounds of this invention include, but are not limited to, primary amides, and secondary and tertiary alkyl amides (for example with between about 1 and about 6 carbons). Amides and esters of the compounds of the present invention may be prepared according to conventional methods. A thorough discussion of prodrugs is provided in T. Higuchi and V. Stella, “Pro-drugs as Novel Delivery Systems,” Vol 14 of the A.C.S. Symposium Series, and in Bioreversible Carriers in Drug Design, ed. Edward B. Roche, American Pharmaceutical Association and Pergamon Press, 1987, both of which are incorporated herein by reference.
[0121] “Metabolite” refers to the break-down or end product of a compound or its salt produced by metabolism or biotransformation in the animal or human body; e.g., biotransformation to a more polar molecule such as by oxidation, reduction, or hydrolysis, or to a conjugate (see Goodman and Gilman, “The Pharmacological Basis of Therapeutics” 8.sup.th Ed., Pergamon Press, Gilman et al. (eds), 1990 for a discussion of biotransformation). As used herein, the metabolite of a compound of the invention or its salt may be the biologically active form of the compound in the body. In one example, a prodrug may be synthesized such that the biologically active form, a metabolite, is released in vivo. In another example, a biologically active metabolite is discovered serendipitously, that is, no prodrug design per se was undertaken. An assay for activity of a metabolite of a compound of the present invention is known to one of skill in the art in light of the present disclosure.
[0122] In addition, the compounds of the present invention can exist in unsolvated as well as solvated forms with pharmaceutically acceptable solvents such as water, ethanol, and the like. In general, the solvated forms are considered equivalent to the unsolvated forms for the purposes of the present invention.
[0123] In addition, it is intended that the present invention cover compounds made either using standard organic synthetic techniques, including combinatorial chemistry or by biological methods, such as bacterial digestion, metabolism, enzymatic conversion, and the like.
Experimental Section
[0124] The compounds of the invention can be made in accordance with the following general description and following the teachings provided in the Example Section, below, and methods routine to those of ordinary skill in the art. The examples are merely illustrative and are not intended to be limiting.
[0125] N-Hydroxy-1,4-disubstituted piperazine-2-carboxamides of the present invention can be synthesized using the methods described below. Method A begins with the reaction of piperazine-2-(R)-carboxylic acid dihydrochloride (1), for example, with ditert-butyl dicarbonate to yield the bis-Boc protected intermediate 2, which is esterified, for example, with methyl iodide in the presence of cesium carbonate to form methyl ester 3. The Boc groups are then removed from 3 to yield piperazine dihydrochloride intermediate 4.
[0000]
[0126] In one pot, the N4 nitrogen of 4 is selectively acylated, carbamylated, sulfonylated, alkylated, and the like, followed by sulfonylation of the N1 nitrogen to form the disubstituted piperazine 5. The methyl ester group of 5 is then converted to the hydroxamate in a mixture of DMF and 50% aqueous hydroxylamine, for example, to give the corresponding N-hydroxy-1,4-disubstituted piperazine-2-(R)-carboxamide 6, in accordance with formula I.
[0127] Method B begins with the sulfonylation of the N1 nitrogen of mono-Boc protected piperazine-2-(R)-carboxylic acid 7, for example, through the use of trimethylsilyl chloride and an appropriate sulfonyl chloride (see synthesis below) to form intermediate 8. Intermediate 8 is then esterifed with TMS-diazomethane to form methyl ester 9, followed by deprotection of the Boc group with TFA to form the TFA salt of 10. Alternatively, compound 8 can be simultaneously esterified and Boc-deprotected using HCl in methanol to form the HCl salt of 10. The N4 nitrogen of 10 is acylated, carbamylated, sulfonylated, alkylated, etc. to form methyl ester 5, which is converted to the hydroxamate 6 (see structure in Method A description) using a mixture of DMF and 50% aqueous hydroxylamine as described above or, alternatively, by treatment with hydroxylamine under basic conditions (KOH in MeOH).
[0000]
[0128] Method C begins with the one pot synthesis of the disubstituted piperazine-2-(R)-carboxylic acid 8 from the dihydrochloride 1. First, under Schotten-Baumann conditions, the N4 nitrogen of 1 is selectively Boc-protected, followed by the addition of triethylamine and the appropriate sulfonyl chloride to sulfonylate the N1 nitrogen to form 8. From intermediate 8, the desired hydroxamates 6 are formed as described in Method B.
[0000]
Example Section
Example 1
N-Hydroxy-1-[4-(4-fluorophenoxy)-phenyl)]sulfonyl-4-(4-morpholinyl-carbonyl)piperazine-2-(R)-carboxamide (Method A)
Step 1
Formation of 1,4-di-tert-butoxycarbonylpiperazine-2-(R)-carboxylic acid
[0129] piperazine-2-(R)-carboxylic acid dihydrochloride (16.6 g, 82 mmol) and dioxane (120 ml) were combined and cooled in an icebath. 5N NaOH (60 ml, 300 mmol) was added, followed by (Boc) 2 O (41.8 g, 191 mmol). The reaction mixture was allowed to warm to room temperature with stirring over several hours, then concentrated in vacuo. The resulting aqueous mixture was washed with Et 2 O (3×), cooled in an icebath, acidified to pH 2-3 with concentrated HCl and extracted with EtOAc (3×). Combined EtOAc extractions were washed with water (1×), saturated NaCl (1×), dried (Na 2 SO 4 ), and concentrated in vacuo to give 1,4-di-tert-butoxycarbonylpiperazine-2-(R)-carboxylic acid as a white solid (27.0 g, 100%). LC/MS Calcd for [M−H] − 329.2. found 329.2.
Step 2
Formation of methyl 1,4-di-tert-butoxycarbonyl piperazine-2-(R)-carboxylate
[0130] 1,4-Di-tert-butoxycarbonylpiperazine-2-(R)-carboxylic acid (70 g, 212 mmol) was dissolved in acetonitrile (1.3 L). Cs 2 CO 3 (110 g, 340 mmol) was added and the mixture stirred for 30 minutes at room temperature before the addition of methyl iodide (28 ml, 450 mmol). The reaction mixture was stirred at room temperature overnight, solids were filtered and the filtrate concentrated in vacuo. The resulting oil was dissolved in EtOAc and any insoluble material filtered. The filtrate was concentrated in vacuo to give methyl 1,4-di-tert-butoxycarbonylpiperazine-2-(R)-carboxylate (69 g, 95%). LC/MS Calcd for [M+H]+ 345.2. found 145.1 (-Boc×2).
Step 3
Formation of methyl piperazine-2-(R)-carboxylate dihydrochloride
[0131] Methyl 1,4-di-tert-butoxycarbonylpiperazine-2-(R)-carboxylate (2.9 g, 8.5 mmol) was dissolved in 4M HCl in dioxane (30 ml) and stirred at room temperature for 30-60 minutes, forming a thick white precipitate. The reaction mixture was concentrated in vacuo and the resulting white solid dried under high vacuum to give methyl piperazine-2-(R)-carboxylate dihydrochloride (1.9 g, 100%). LC/MS Calcd for [M+H] + 145.1. found 145.1.
Step 4
Formation of methyl 1-[4-(4-fluorophenoxy)phenyl)]sulfonyl-4-(4-morpholinylcarbonyl)pipera-zine-2-(R)-carboxylate
[0132] Methyl piperazine-2-(R)-carboxylate dihydrochloride (676 mgs, 3.1 mmol) was dissolved in CH 2 Cl 2 (7 mls) and DIEA (2.1 mls, 12.4 mmol) and cooled in an icebath. Morpholinecarbonyl chloride (450 mgs, 3.0 mmol) dissolved in methylene chloride (2.5 mls) was added dropwise with stirring. After addition was complete, the reaction mixture was allowed to warm to room temperature and stirred for an additional 2-3 hrs. Additional DIEA (0.6 mls, 3.4 mmol) was added, followed by 4-(4-fluorophenoxy)phenylsulfonyl chloride (904 mg, 3.1 mmol) and the reaction mixture stirred at room temperature overnight. The reaction mixture was concentrated in vacuo and the resulting residue redissolved in EtOAc and washed with water (1×), 1.0N HCl (2×), dried (Na 2 SO 4 ), concentrated in vacuo and purified by flash chromatography (3:1 EtOAc:hexanes) to give methyl 1-[4-(4-fluorophenoxy)phenyl)]sulfonyl-4-(4-morpholinylcarbonyl)piperazine-2-(R)-carboxylate (1.11 g, 70%). LC/MS Calcd for [M+H] + 508.1. found 508.1.
Step 5
Formation of N-hydroxy-1-[4-(4-fluorophenoxy)phenyl)]sulfonyl-4-(4-morpholinylcarbonyl)piperazine-2-(R)carboxamide
[0133] Methyl 1-[4-(4-fluorophenoxy)phenyl)]sulfonyl-4-(4-morpholinylcarbonyl)piperazine-2-(R)-carboxylate (1.11 g, 2.2 mmol) was dissolved in DMF (17 mls) to which was added 50% aqueous NH 2 OH (20 mls) and the reaction mixture stirred at room temperature overnight. The reaction mixture was poured into cold 1.0N HCl (100-120 mls) and extracted with EtOAc (4×). The combined EtOAc extractions were washed with 10% aqueous LiCl (4×), saturated NaCl (1×), dried (Na 2 SO 4 ), and concentrated in vacuo. The crude product was purified by flash chromatography (EtOAc) and the resulting pure oil was dissolved in 1:1 acetonitrile:water and lyophilized to give N-hydroxy-1-[4-(4-fluorophenoxy)phenyl)]sulfonyl-4-(4-morpholinylcarbonyl)piperazine-2-(R)-carboxamide as a white solid (659 mg, 59%). LC/MS Calcd for [M+H]+ 509.1. found 509.1. 1 HNMR (400 MHz, CD 3 OD): δ 7.69 (d, 2H, J=9.2 Hz), 7.04 (m, 4H), 6.95 (d, 2H, J=9.2 Hz), 4.30 (m, 1H), 3.76 (m, 1H), 3.50 (m, 7H), 3.10 (m, 4H), 2.90 (dd, 1H, J=13.2, 4.4 Hz), 2.72 (m, 1H).
Example 2
N-Hydroxy-1-[4-(4-fluorophenoxy)-3,5-difluorophenyl)]sulfonyl-4-(ethoxycarbonyl)piperazine-2-(R)-carboxamide (Method B)
Step 1
[0134] Formation of 1-[4-(4-fluorophenoxy)-3,5-difluoro-phenyl)]sulfonyl-4-boc-piperazine-2-(R)-carboxylic acid 4-Boc-piperazine-2-(R)-carboxylic acid (933 mg, 4.05 mmol), CH 2 Cl 2 (12 ml), DMF (6 ml), and DIEA (2.5 ml, 14.3 mmol) were combined under N2. TMS-Cl (810 μl, 6.38 mmol) was added slowly and the mixture stirred at room temperature for approximately 2 hrs. 4-(4-fluorophenoxy)-3,5-difluorophenyl)]sulfonyl chloride (1.43 g, 4.43 mmol) dissolved in a minimum of CH 2 Cl 2 was added and the mixture stirred at room temperature for another 2 hrs. The reaction mixture was diluted with EtOAc and washed with 0.5N HCl (3×), sat'd NaCl (1×), dried (Na 2 SO 4 ), and concentrated in vacuo. The resulting crude oil was purified by flash chromatography (6:4 hexanes:EtOAc+1% AcOH) to give the desired product (1.37 g, 65%). LC/MS Calcd for [M+H] + 517.1. found 417.0 (-Boc).
Step 2
Formation of methyl 1-[4-(4-fluorophenoxy)-3,5-difluorophenyl)]sulfonyl-4-boc-piperazine-2-(R)-carboxylate
[0135] 1-[4-(4-fluorophenoxy)-3,5-difluorophenyl)]sulfonyl-4-bocpiperazine-2-(R)-carboxylic acid (1.37 g, 2.65 mmol) was dissolved in CH 2 Cl 2 (40 ml) and MeOH (10 ml). A mixture of 2M TMS-CHN 2 in hexanes (2.5 ml, 5 mmol) and CH 2 Cl 2 (10 ml) was added dropwise with stirring and the reaction followed by TLC. Upon completion of the reaction, AcOH (1.0 ml) was added dropwise with stirring. The reaction mixture was further diluted with CH 2 Cl 2 and washed with water (1×), saturated NaHCO 3 (2×), saturated NaCl (1×), dried (MgSO 4 ), and concentrated in vacuo. The crude oil was purified by flash chromatography (3:1 hexanes:EtOAc) to give the desired product (1.10 g, 78%). LC/MS Calcd for [M+H] + 531.1. found 431.0 (-Boc).
Step 3
Formation of methyl 1-[4-(4-fluorophenoxy)-3,5-difluorophenyl)]sulfonyl-piperazine-2-(R)-carboxylate TFA salt
[0136] Methyl 1-[4-(4-fluorophenoxy)-3,5-difluorophenyl)]sulfonyl-4-bocpiperazine-2-(R)-carboxylate (1.10 g, 2.07 mmol) was dissolved in a minimum of CH 2 Cl 2 to which was added neat TFA (10 ml). The mixture was stirred at room temperature for approximately 30 min, concentrated in vacuo, further dried for several hours under high vacuum and used without further purification. LC/MS Calcd for [M+H] + 431.1. found 431.0.
Step 4
Formation of methyl 1-[4-(4-fluorophenoxy)-3,5-difluorophenyl)]sulfonyl-4-(ethoxycarbonyl)piperazine-2-(R)carboxylate
[0137] To a mixture of methyl 1-[4-(4-fluorophenoxy)-3,5-difluorophenyl)]sulfonyl-piperazine-2-(R)-carboxylate TFA salt (344 mg, 0.63 mmol), CH 2 Cl 2 (10 ml), and DIEA (250 μl, 1.43 mmol) under N 2 was added ethyl chloroformate (65 ml, 0.68 mmol). The mixture was stirred under N 2 at room temperature for 1.5 hrs, then washed with 1.0N HCl (2×), saturated NaCl (1×), dried (Na 2 SO 4 ), and concentrated in vacuo. The crude residue was purified by flash chromatography (3:1 hexanes:EtOAc) to give the desired product (218 mgs, 69%). LC/MS Calcd for [M+H] + 503.1. found 503.0.
Step 5
Formation of N-hydroxy-1-[4-(4-fluorophenoxy)-3,5-difluorophenyl)]sulfonyl-4-(ethoxycarbonyl)piperazine-2-(R)-carboxamide
[0138] A 1.7M solution of NH 2 OH in MeOH was prepared by mixing a solution of KOH (2.80 g, 50.0 mmol) in MeOH (7.0 ml) with a hot solution of NH 2 OH HCl salt (2.40 g, 34.5 mmol) in MeOH (12.0 ml) and filtering the resulting solids after cooling to room temperature. Methyl 1-[4-(4-fluorophenoxy)-3,5-difluorophenyl)]-sulfonyl-4-(ethoxycarbonyl)piperazine-2-(R)-carboxylate (218 mg, 0.43 mmol) was dissloved in the 1.7M NH 2 OH in MeOH solution (4.0 ml) and stirred at room temperature for 30-45 minutes. The reaction mixture was then diluted with 1.0N HCl and extracted with EtOAc (3×). Combined EtOAc extractions were washed with saturated NaCl (1×), dried (Na 2 SO 4 ), and concentrated in vacuo. The resulting crude residue was purified by flash chromatography (1:1 EtOAc:hexanes) to give a colorless film which was lyophilized from 1:1 AcCN:H 2 O to give the desired product as a white solid (136 mg, 62%). LC/MS Calcd for [M+H] + 504.1. found 504.0. 1 HNMR (400 MHz, CD 3 OD): δ 7.58 (m, 2H), 7.03 (m, 4H), 4.27 (m, 2H), 4.07 (m, 3H), 3.75 (m, 2H), 3.30 (m, 1H), 3.06 (m, 1H), 1.22 (m, 3H).
Example 3
N-Hydroxy-1-[(4-(4-cyanophenoxy)-3-fluorophenyl)]sulfonyl-4-(2-methoxy-1-ethoxycarbonyl)piperazine-2-(R)-carboxamide
(Method C)
Step 1
Formation of 1-[4-(4-cyanophenoxy)-3-fluorophenyl)]sulfonyl-4-boc-piperazine-2-(R)-carboxylic acid
[0139] Piperazine-2-(R)-carboxylic acid dihydrochloride (1.25 g, 6.1 mmol), dioxane (15 mls) and water (6.0 mls) were combined and cooled in an icebath. 9N NaOH (2.0 mls, 18 mmol) was added slowly with stirring, followed by (Boc) 2 O (1.35 g, 6.2 mmol). The reaction mixture was allowed to warm to room temperature and stirred for an additional 3-4 hrs. Et 3 N (1.8 mls, 13 mmol) was added, followed by 4-cyanophenoxy-3-fluorophenylsulfonyl chloride (2.00 g, 6.4 mmol). The reaction mixture is stirred at room temperature for 1-2 hrs, then concentrated in vacuo. The resulting residue was partitioned between 1.0N HCl and EtOAc. Phases were separated and the aqueous phase was further extracted with EtOAc (2×). Combined EtOAc extractions were washed with 1.0N HCl (1×), saturated NaCl (1×), dried (MgSO 4 ), and concentrated in vacuo. The resulting residue is purified by flash chromatography (7:3 hexanes:EtOAc+1% AcOH) to give the desired product (1.1 g, 35%). LC/MS Calcd for [M−H] − 504.1. found 504.3.
Step 2
[0140] Methyl 1-[4-(4-cyanophenoxy)-3-fluorophenyl)]sulfonyl-4-boc-piperazine-2-(R)-carboxylate was made in the same manner as Example 2, step 2, except purification by flash chrmoatography was unnecessary. 1.10 g recovered (97%). LC/MS Calcd for [M+H] + 520.1. found 420.1 (-Boc).
Step 3
[0141] Methyl 1-[4-(4-cyanophenoxy)-3-fluorophenyl)]sulfonyl-piperazine-2-(R)-carboxylate TFA salt was made in the same manner as Example 2, step 3. LC/MS Calcd for [M+H] + 420.1. found 420.2.
Step 4
[0142] Methyl 1-[4-(4-cyanophenoxy)-3-fluorophenyl)]sulfonyl-4-(2-methoxy-1-ethoxycarbonyl)piperazine-2-(R)carboxylate was made in the same manner as Example 2, step 4. 438 mgs recovered (83%). LC/MS Calcd for [M+H] + . 522.1. found 522.2.
Step 5
[0143] N-Hydroxy-1-[4-(4-cyanophenoxy)-3-fluorophenyl)]sulfonyl-4-(2-methoxy-1-ethoxycarbonyl)piperazine-2-(R)-carboxamide was made in the same manner as Example 2, step 5. 46 mg recovered (10%). LC/MS Calcd for [M−H] − 521.1. found 521.2. 1 HNMR (400 MHz, CD 3 OD): δ 7.73 (m, 3H), 7.65 (m, 1H), 7.34 (m, 1H), 7.19 (d, 2H, J=8.4 Hz), 4.29 (m, 2H), 4.14 (m, 3H), 3.74 (m, 2H), 3.55 (m, 2H), 3.33 (s, 3H), 3.25 (m, 1H), 3.04 (m, 1H).
Example 4
Synthesis of Sulfonyl Chloride Intermediates
Example 4a
4-(4-fluorophenoxy)-3,5-difluorophenylsulfonyl chloride
Step 1
[0144] A mixture of 3,4,5-trifluoronitrobenzene (20.0 g, 113 mmol, commercially available from AsymChem of Durham, N.C.), dry DMF (100 ml), 4-fluorophenol (13.9 g, 124 mmol), and Cs 2 CO 3 (56 g, 172 mmol) was stirred under N 2 at 60-70° C. for 1-2 hrs. After cooling to room temperature, the reaction mixture was partitioned between H 2 O and EtOAc. The phases were separated and the aqueous phase was further extracted with EtOAc (2×). The EtOAc extractions were washed with sat'd NaCl (1×), dried over Na 2 SO 4 , and concentrated in vacuo to give 4-(4-fluorophenoxy)-3,5-difluoronitrobenzene (32.0 g, 105%) which was used in the next step without further purification. 1 H NMR (DMSO-d 4 ): δ 7.15 (m, 2H), 7.22 (m, 2H), 8.31 (d, 2H, J=7.6 Hz).
Step 2
[0145] A mixture of 4-(4-fluorophenoxy)-3,5-difluoronitrobenzene (30.4 g, 113 mmol), EtOAc (300 ml), 10% Pd/C (2.6 g) was stirred under an atmosphere of H 2 at room temperature and pressure for approximately 6 hrs. The reaction mixture was filtered through Celite and concentrated in vacuo to give 4-(4-fluorophenoxy)-3,5-difluoroaniline (26.5 g, 98%) which was used in the next step without further purification. 1 H NMR (CDCl 3 ): δ 3.82 (s, 2H), 6.26 (d, 2H, J=8.4 Hz), 6.88 (m, 2H), 6.93 (m, 2H).
[0000]
Step 3
[0146] A solution of NaNO 2 (8.4 g, 122 mmol) in H 2 O (20 ml) was added dropwise to a mixture of 4-(4-fluorophenoxy)-3,5-difluoroaniline (26.5 g, 111 mmol), AcOH (160 ml), and conc. HCl (160 ml) cooled in an ice/NaCl/H 2 O bath. After addition was complete, the mixture was stirred an additional 20-30 minutes before a mixture of SO 2 (74 g, 1.15 mol) in AcOH (140 ml) and CuCl 2 -2H 2 O (11.1 g, 65 mmol) in H 2 O (16 ml) was added. The reaction mixture was removed from the ice bath and stirred at room temperature for 1-2 hrs. The reaction mixture was poured into ice water and extracted with CH 2 Cl 2 (3×). The combined CH 2 Cl 2 extractions were washed with sat'd NaCl (1×), dried over Na 2 SO 4 , and concentrated in vacuo. The resulting crude oil was purified by flash chromatography (9:1 hexanes:EtOAC) to give 4-(4-fluorophenoxy)-3,5-difluorophenyl sulfonyl chloride (29.8 g, 83%). 1 H NMR (CDCl 3 ): δ 6.94 (m, 2H), 7.10 (m, 2H), 7.71 (d, 2H, J=6.4 Hz).
Example 4b
4-(4-Chlorophenoxy)-3,5-difluorophenylsulfonyl chloride
Step 1
[0147] A mixture of 3,4,5-trifluoronitrobenzene (6.6 g, 37 mmol), dry DMF (30 ml), 4-chlorophenol (5.26 g, 41 mmol), and Cs 2 CO 3 (18.8 g, 58 mmol) was stirred under N2 at 60-70 C for 1-2 hrs. After cooling to room temperature, the reaction mixture was partitioned between H 2 O and EtOAc. The phases were separated and the aqueous phase was further extracted with EtOAc (2×). The EtOAc extractions were washed with sat'd NaCl (1×), dried over Na 2 SO 4 , and concentrated in vacuo to give 4-(4-chlorophenoxy)-3,5-difluoronitrobenzene (11.3 g, 106%) which was used in the next step without further purification. 1 H NMR (CDCl 3 ): δ 6.90 (d, 2H, J=7.6 Hz), 7.28 (d, 2H, J=7.6 Hz), 7.94 (d, 2H, J=6.4 Hz). Note: K 2 CO 3 /acetonitrile can be used in lieu of Cs 2 CO 3 /DMF.
[0000]
Step 2
[0148] A mixture of 4-(4-chlorophenoxy)-3,5-difluoronitrobenzene (10.6 g, 37 mmol), toluene (150 ml), H 2 O (150 ml), iron powder (6.9 g, 124 mmol), and ammonium acetate (9.3 g, 120 mmol) was heated to reflux with stirring for 2-3 hrs. After cooling to room temperature, the reaction mixture was filtered through Celite with thorough washing with H 2 O and EtOAc. The filtrate was transferred to a separatory funnel and the phases separated. The aqueous phase was further extracted with EtOAc (2×). The combined organic phases were washed with H 2 O (1×), sat'd NaCl (1×), dried over Na 2 SO 4 , and concentrated in vacuo to give 4-(4-chlorophenoxy)-3,5-difluoroaniline (10.8 g, 113%) which was used in the next step without further purification. 1 H NMR (CDCl 3 ): δ 3.81 (s, 2H), 6.27 (d, 2H, J=9.2 Hz), 6.85 (d, 2H, J=9.2 Hz), 7.21 (d, 2H, J=9.2 Hz).
Step 3
[0149] A solution of NaNO 2 (2.8 g, 41 mmol) in H 2 O (7.0 ml) was added dropwise to a mixture of 4-(4-chlorophenoxy)-3,5-difluoroaniline (9.5 g, 37 mmol), AcOH (50 ml), and conc. HCl (50 ml) cooled in an ice/NaCl/H 2 O bath. After addition was complete, the mixture was stirred an additional 20-30 minutes before a mixture of SO 2 (25 g, 290 mmol) in AcOH (50 ml) and CuCl 2 -2H 2 O (3.8 g, 22 mmol) in H 2 O (6.0 ml) was added. The reaction mixture was removed from the ice bath and stirred at room temperature for 1-2 hrs. The reaction mixture was poured into ice water and extracted with CH 2 Cl 2 (3×). The combined CH 2 Cl 2 extractions were washed with sat'd NaCl (1×), dried over Na 2 SO 4 , and concentrated in vacuo. The resulting crude oil was purified by flash chromatography (9:1 hexanes:EtOAC) to give 4-(4-chlorophenoxy)-3,5-difluorophenylsulfonyl chloride (11.0 g, 87%). 1 H NMR (CDCl 3 ): δ 6.92 (d, 2H, J=7.2 Hz), 7.30 (d, 2H, J=7.2 Hz), 7.72 (d, 2H, J=4.8 Hz).
Example 4c
3,4,5-trifluorobenzenesulfonyl chloride
[0150] To a 2000 mL round-bottomed flask was added 800 mL distilled H 2 O and a stir bar. Upon stirring, the flask was cooled to −10° C. in an ice-acetone bath. The flask was fitted with a 500 mL addition funnel and SOCl 2 (300 mL, 4.1 mol, 10 eq.) was added dropwise over a period of 1 h. After complete addition, the solution was stirred for 4 h while warming to room temperature.
[0151] Meanwhile, in a separate 500 mL recovery flask was added 3,4,5-trifluoroaniline (61 g, 0.41 mol, 1.0 eq.), conc. HCl (150 mL), and a stir bar. The resulting suspension was stirred vigorously and cooled to −10° C. The flask was fitted with a 250 mL addition funnel and a solution of NaNO 2 (34.3 g, 0.50 mol, 1.2 eq.) in H 2 O (125 mL) was added to the suspension dropwise over a period of 10 min. The reaction mixture, now nearly homogeneous, is yellow-orange in color. The reaction mixture was stirred for an additional 30 min while carefully maintaining the temperature at −10° C.
[0000]
[0152] The flask containing the SOCl 2 /H 2 O solution is cooled again to −10° C. and a catalytic amount of Cu(I)Cl (˜50 mg) was added. The solution turns dark green in color. The flask was fitted with a 500 mL addition funnel (previously chilled to 0° C.) and the 3,4,5-trifluorodiazobenzene solution was quickly transferred to the funnel. The solution was immediately added dropwise over a period of 3 min. After addition, the reaction mixture slowly turns darker green in color, but after stirring for 5 min becomes bright, lime green. The reaction was stirred for an additional hour while warming to room temperature. The reaction mixture was transferred to a separatory funnel and extracted with CH 2 Cl 2 (3×200 mL). The organic phases are combined and dried over anhydrous Na 2 SO 4 , filtered, and concentrated to give a darkbronze oil (79.5 g, 83%).
Example 5
Enzyme Assays
[0153] mADAM-10 or hADAM-10 activity was measured as the ability to cleave a 10-residue peptide (DABCYL-Leu-Leu-Ala-Gln-Lys-*-LeuArg-Ser-Ser-Arg-EDANS). This peptide was based on the TNF-α cleavage site (Leu 62 -Arg 71 ); however, we found that replacement of Ala 76 -Val 77 with Lys-Leu resulted in a peptide with a 5-fold greater affinity for ADAM-10 than the native TNF-α peptide. Enzyme was diluted to a final active concentration of 5 nM in Buffer A (50 mM HEPES 8.0, 100 mM NaCl, 1 mM CaCl 2 and 0.01% NP-40). Serial dilutions for compounds were performed ranging from 100 μM to 0.5 nM using a Beckman Biomek 2000 in polypropylene plates (Greiner). 20 μl of enzyme solution was added to 10 μl of compound in buffer A, and allowed to incubate for 15 min in 384 well black, Greiner, microtiter plates (#781076). 20 μl of substrate (12.5 μM in Buffer A) was then added, resulting in final reaction conditions of 2 nM ADAM-10, 5 μM substrate, and compound concentrations ranging from 20 uM to 0.1 nM. The reaction was incubated for 2 hr at RT, and fluorescence was measured at Ex355, Em460 on a Wallac Victor 2 fluorescence reader. For final analysis of potent inhibitors, a similar reaction was set up with a final active ADAM-10 concentration of 0.1 nM. This reaction was incubated for 16 hr at RT and fluorescence was read using identical conditions.
[0154] One aspect of the invention is, for example, piperazinederived hydroximates according to formula I, which are selective ADAM-10 inhibitors. In one embodiment, such inhibitors comprise a bis-aryl ether substitution for —R 2 (—R 21 -L 2 -R 22 , where R 21 is phenylene, L 2 is oxygen, and R 22 is phenyl), the proximal ring (R 21 ) of which is substituted particularly with one or more halogens, more particularly with one or more flourines, even more particularly with two or more flourines. For example, by combining such groups with appropriate substitution, -L 1 -R 1 and —R 22 , inhibitors that are selective for ADAM-10 are produced.
[0155] Table 5 below shows structure activity relationship data for selected compounds of the invention when tested in vitro with various metalloproteases. Inhibition is indicated as IC 50 with the following key: A=IC 50 less than 50 nM, B=IC 50 greater than 50 nM, but less than 1000 nM, C=IC 50 greater than 1000 nM, but less than 20,000 nM, and D=IC 50 greater than 20,000 nM. Blank cells indicate lack of data only. The abbreviations in Table 5 are defined as follows: TACE stands for TNF-alpha converting enzyme (also known as ADAM-17; MMP-1 stands for Fibroblast collagenase; MMP-2 stands for 72 kDa gelatinase (gelatinase A); MMP-3 stands for Stromelysin-1; MMP-8 stands for Neutrophil collagenase; MMP-9 stands for 92 kDa gelatinase (gelatinase B); and MMP-13 stands for collagenase-3.
[0000]
TABLE 5
EN-
ADAM-
TACE
MMP-1
MMP-2
MMP-3
MMP-8
MMP-9
MMP-13
TRY
STRUCTURE
10 IC 50
IC 50
IC 50
IC 50
IC 50
IC 50
IC 50
IC 50
1
A
A
A
A
A
2
A
A
A
A
A
3
A
B
A
C
A
4
A
B
A
A
A
5
A
B
A
B
A
6
A
B
A
A
A
7
A
B
A
A
A
8
A
B
A
A
A
9
A
C
A
C
C
10
A
C
A
C
A
11
A
D
B
C
D
12
A
C
A
B
A
13
A
C
A
B
A
14
B
D
A
D
A
15
A
B
C
A
B
A
A
A
16
A
D
A
C
A
17
A
C
A
B
A
18
A
D
A
B
A
19
A
D
A
B
A
20
A
D
A
C
A
21
A
D
A
C
B
22
A
C
A
B
A
23
A
D
A
C
A
24
A
D
A
C
A
25
A
D
A
B
A
26
A
D
A
C
A
27
A
C
A
B
A
28
A
B
A
B
A
29
A
C
A
B
A
30
A
B
C
A
B
A
B
A
31
A
B
C
A
B
A
32
A
C
A
B
A
33
A
C
A
B
A
34
A
A
C
A
B
A
35
A
C
A
B
A
36
A
C
A
B
A
37
A
B
C
A
A
A
38
A
B
C
A
A
A
39
A
B
A
A
A
40
A
C
A
B
A
41
A
C
A
A
A
42
A
C
A
C
A
43
A
D
A
B
A
44
A
D
A
C
B
45
A
B
C
A
B
A
46
A
C
A
B
A
47
A
D
A
B
A
48
A
D
A
B
A
49
C
D
A
B
A
50
C
D
D
B
A
51
B
C
B
C
B
52
A
C
A
C
A
53
A
B
A
B
A
54
A
A
B
A
A
A
55
A
C
A
B
A
56
A
C
A
B
A
57
B
D
B
C
B
58
A
B
A
B
A
59
A
B
C
A
B
A
60
B
D
A
C
A
61
B
D
C
D
C
62
B
D
A
C
A
63
B
D
B
C
B
64
A
B
A
A
A
65
B
A
A
A
A
66
A
B
A
A
A
[0156] Table 6 contains physical characterization data for selected compounds of the invention. 1 H-NMR data were taken with a Varian AS400 Spectrometer (400 MHz, available from Varian GmbH, Darmstadt, Germany). The entry numbers in Table 6 correspond to those of Table 5 (and their corresponding structures).
[0000]
TABLE 6
Entry
1 H NMR Data (or MS data)
1
(CD3OD): 7.68 (d, 2H), 7.18-7.14 (m, 4H), 7.05 (d, 2H), 4.32 (m 1H), 4.23 (d, 1H),
4.15 (m, 2H), 4.00 (d, 1H), 3.68-3.64 (m, 2H), 3.55 (m, 2H), 3.35 (s, 3H), 3.2 (m, 1H), 3.00 (m,
1H) ppm.
2
(CD3OD): 7.69 (d, 2H, J = 9.2 Hz), 7.04 (m, 4H), 6.95 (d, 2H, J = 9.2 Hz), 4.30 (m, 1H),
3.76 (m, 1H), 3.50 (m, 7H), 3.10 (m, 4H), 2.90 (dd, 1H, J = 13.2, 4.4 Hz), 2.72 (m, 1H)
ppm.
3
(CD3OD): 7.68 (dd, 1H), 7.55 (dd, 1H), 7.15-7.10 (m, 4H), 7.04 (dd, 1H), 4.28-4.12 (m,
2H), 4.15-4.00 (m, 3H), 3.70-3.65 (m, 2H), 3.55-3.50 (m, 2H), 3.33 (s, 3H), 3.22 (m, 1H),
3.03 (m, 1H) ppm.
4
(CD3OD): 7.68 (dd, 1H), 7.57 (dd, 1H), 7.38 (d, 2H), 7.13 (t, 1H), 7.08 (d, 1H),
4.28-4.12 (m, 2H), 4.15-4.00 (m, 3H), 3.70-3.65 (m, 2H), 3.55-3.50 (m, 2H), 3.33 (s, 3H), 3.22 (m,
1H), 3.03 (m, 1H) ppm.
5
(CD3OD): 7.75-7.71 (m, 3H), 7.65 (dd, 1H), 7.33 (dd, 1H), 7.20 (d, 2H), 4.32-4.26 (m,
2H), 4.16-4.05 (m, 3H), 3.81-3.75 (m, 2H), 3.56 (m, 2H), 3.34 (s, 3H), 3.27 (m, 1H),
3.06 (m, 1H) ppm.
6
(CDCl3): 7.73 (d, 1H), 7.61 (d, 1H), 7.34 (d, 2H, J = 8.8 Hz), 6.99 (d, 2H, J = 8.8 Hz),
6.98 (m, 1H), 4.67 (s, 1H), 4.23 (d, 1H), 3.64 (m, 5H), 3.44 (d, 1H), 3.35 (m, 2H), 3.21 (m, 2H),
3.10 (m, 4H) ppm.
7
(CD3OD): 7.68-7.64 (m, 3H), 7.58 (d, 1H), 7.22 (t, 1H), 7.08 (d, 2H), 4.30 (m, 1H),
3.78 (d, 1H), 3.75-3.48 (m, 7H), 3.08-3.00 (m, 5H), 2.81 (m, 1H) ppm.
8
(CD3OD): 7.75 (d, 1H), 7.60 (d, 1H), 7.18-7.14 (m, 4H), 7.07 (t, 1H), 4.4 (m, 1H), 3.86 (d,
1H), 3.78-3.55 (m, 7H), 3.24-3.14 (m, 4H), 3.08 (dd, 1H), 2.87 (m, 1H) ppm.
9
(CD3OD): 7.60-7.58 (m, 2H), 7.08-7.00 (m, 4H), 4.3-4.2 (m, 2H), 4.08-4.02 (m, 1H),
3.75-3.70 (m, 2H), 3.23-3.18 (m, 1H), 3.12-2.90 (m, 1H) ppm
10
(CD3OD): 7.49 (d, 2H), 7.08-7.00 (m, 4H), 4.3-4.2 (m, 2H), 4.18-4.05 (m, 3H),
3.75-3.70 (m, 2H), 3.55-3.50 (m, 2H), 3.33 (s, 3H), 3.33-3.25 (m, 1H), 3.15-3.00 (m, 1H) ppm.
11
(CD3OD): 7.65 (d, 2H), 7.08-6.98 (m, 4H), 4.58 (d, 1H), 4.05 (dd, 1H), 3.81 (ddd, 1H),
3.63 (d, 1H), 3.46 (d, 1H), 3.35 (dd, 1H), 3.18 (ddd, 1H) ppm.
12
(CD3OD): 7.62 (m, 2H), 7.08-7.00 (m, 4H), 4.40 (s, 1H), 3.86 (d, 1H), 3.80-3.74 (m, 2H),
3.65-3.58 (m, 5H), 3.25-3.12 (m, 5H), 2.96 (m, 1H) ppm.
13
(CD3OD): 7.60-7.58 (m, 2H), 7.08-7.00 (m, 4H), 4.3-4.2 (m, 2H), 4.08-4.02 (m, 3H),
3.75-3.70 (m, 2H), 3.27 (m, 1H), 3.05 (m, 1H) ppm.
14
(CD3OD): 7.65-7.62 (m, 2H), 7.08-7.00 (m, 4H), 4.45 (s, 1H), 3.80 (d, 1H), 3.52 (t, 1H),
3.10 (d, 1H), 2.72 (d, 1H), 2.21 (s, 3), 2.16 (d, 1H), 1.96 (t, 1H) ppm.
15
(CD3OD): 7.60 (d, 2H), 7.32 (d, 2H), 7.03 (d, 2H), 4.32-4.26 (m, 2H), 4.16-4.05 (m, 3H),
3.81-3.75 (m, 2H), 3.56 (m, 2H), 3.34 (s, 3H), 3.27 (m, 1H), 3.06 (m, 1H) ppm.
16
MS: Calculated for C23H26ClF2N5O6S: 573.13; Found: 574.72 (M + 1).
17
(CD3OD): 7.60 (d, 2H, J = 7.2 Hz), 7.32 (d, 2H, J = 8.8 Hz), 6.98 (d, 2H, J = 9.2 Hz),
4.21 (m, 2H), 4.08 (m, 1H), 3.80-3.60 (m, 5H), 3.40 (m, 1H), 3.23 (m, 2H), 3.04 (m, 3H),
2.21 (m, 1H), 2.50-1.50 (m, 4H) ppm.
18
(CD3OD): 7.51 (d, 2H, J = 7.6 Hz), 7.23 (d, 2H, J = 6.4 Hz), 6.88 (d, 2H, J = 6.4 Hz),
4.19-4.11 (m, 2H), 3.98-3.94 (m, 1H), 3.73-3.67 (m, 4H), 3.59 (m, 1H), 3.50-3.14 (m, 5H),
3.03-2.91 (m, 3H), 1.99-1.88 (m, 4H) ppm.
19
(CD3OD): 7.82 (br. s, 1H), 7.69 (d, 2H), 7.38 (d, 2H), 7.05 (d, 2H), 4.58 (br s, 1H),
3.88 (m, 1H), 3.60 (td, 1H), 3.19-2.91 (m, 4H), 2.85-2.70 (m, 6H), 2.40-2.29 (m, 2H) ppm.
20
(CD3OD): 7.71 (d, 2H), 7.35 (d, 2H), 7.00 (d, 2H), 4.58 (br s, 1H), 3.80 (m, 1H),
3.40-3.33 (m, 2H), 3.30-3.20 (m, 2H), 3.05 (s, 3H), 2.96 (s, 3H), 2.81 (m, 1H), 2.40-2.30 (m,
2H) ppm.
21
DMSO-d 6 : 9.8 (br, 1H), 9.0 (br, 1H), 7.85 (m, 2H), 7.4 (m, 2H), 7.1 (m, 2H), 4.4 (m, 3H),
3.6 (m, 7H), 3.0 (m, 3H), 2.0 (m, 4H).
22
(CD3OD): 7.61 (m, 2H), 7.32 (d, 2H, J = 8.8 Hz), 6.99 (d, 2H, J = 8.8 Hz), 4.40-4.20 (m,
4H), 4.10 (m, 1H), 3.80-3.60 (m, 4H), 3.50 (m, 1H), 3.40-3.15 (m, 4H), 2.89 (d, 3H),
2.15-2.00 (m, 2H) ppm.
23
DMSO-d 6 : 10.2 (br, 1H), 9.0 (br, 1H), 7.8 (m, 2H), 7.4 (m, 2H), 7.1 (m, 2H), 4.4 (m, 4H),
4.0 (m, 7H), 3.3 (m, 8H), 1.2 (t, 3H).
24
DMSO-d 6 : 7.8 (m, 2H), 7.4 (m, 2H), 7.1 (m, 2H), 3.8 (m, 11H), 3.4 (m, 2H), 3.0 (m, 4H),
2.8 (3, 3H).
25
DMSO-d 6 : 10.2 (br, 1H), 9.0 (br, 1H), 7.8 (m, 2H), 7.45 (m, 2H), 7.2 (m, 2H), 4.4 (m, 4H),
3.8 (m, 7H), 3.4 (m, 6H).
26
DMSO-d 6 : 9.4 (br, 1H), 9.0 (br, 1H), 7.8 (m, 2H), 7.4 (m, 2H), 7.1 (m, 2H), 4.85 (m, 1H),
4.1 (m, 2H), 3.0 (m, 6H), 3.4 (m, 4H), 3.0 (m, 2H), 1.9 (m, 4H).
27
(CD3OD): 7.54 (d, 2H, J = 7.2 Hz), 7.25 (d, 2H, J = 8.8 Hz), 6.89 (d, 2H, J = 8.8 Hz),
4.15 (m, 3H), 3.90 (m, 1H), 3.78 (m, 1H), 3.60 (m, 2H), 3.40-3.20 (m, 4H), 3.05 (m, 1H),
3.00 (m, 1H), 2.80 (m, 1H), 2.70 (m, 1H), 1.80-1.60 (m, 4H), 1.40 (m, 1H) ppm.
28
(CDCl3): 9.20 (br s, 1H), 7.58 (d, 2H), 7.30 (d, 2H), 6.90 (d, 2H), 4.65 (br s, 1H), 4.19 (d,
1H), 3.95-3.60 (m, 2H), 3.33 (m, 1H), 3.15-2.80 (m, 2H), 2.88 (s, 3H) ppm.
29
(CDCl3): 7.61 (d, 2H), 7.29 (d, 2H), 6.90 (d, 2H), 4.71 (br s, 1H), 3.75 (br d, 1H),
3.60-3.48 (m, 2H), 3.42 (s, 3H), 3.20 (d, 1H), 3.09 (td, 1H), 2.88 (br d, 1H), 2.75 (m, 1H),
2.60-2.49 (m, 3H) ppm.
30
(CDCl3): 11.8 (br. S, 1H), 7.61 (d, 2H), 7.55 (br. s, 1H), 7.26 (d, 2H), 6.90 (d, 2H),
4.71 (s, 1H), 4.28 (d, 1H), 3.70-3.62 (m, 4H), 3.48 (d, 1H), 3.36-3.16 (m, 5H), 3.00 (t, 1H)
ppm.
31
(CDCl3): 11.23 (br s, 1H), 7.59 (d, 2H), 7.26 (d, 2H), 6.95 (d, 2H), 4.70 (br s, 1H),
3.40 (br d, 1H), 4.23 (d, 1H), 3.85-3.38 (m, 10H), 3.20-2.90 (m, 2H) ppm.
32
(CDCl3): 7.46 (d, 2H, J = 6.8 Hz), 7.26 (m, 4H), 6.91 (d, 2H, J = 9.2 Hz), 4.60 (s, 1H),
4.00 (m, 1H), 3.80 (m, 2H), 3.60 (m, 2H), 3.40 (m, 1H), 2.60 (m, 2H) ppm.
33
(CDCl3): 7.54 (d, 2H, J = 5.6 Hz), 7.25 (d, 2H, J = 9.2 Hz), 6.86 (d, 2H, J = 9.2 Hz), 4.60 (m,
1H), 4.40 (m, 2H), 4.05 (m, 1H), 3.75 (m, 2H), 3.45 (m, 1H), 3.0 (m, 1H), 2.93 (s, 2H)
ppm.
34
(CD3OD): 8.61 (br. s, 1H), 7.75 (m, 2H), 7.67 (d, 2H), 7.33 (d, 2H), 7.03 (d, 2H),
4.54 (m, 1H), 4.03-3.88 (m, 3H), 3.60 (m, 2H), 3.12 (m, 1H), 2.93 (m, 1H) ppm.
35
(CDCl3): 7.63 (d, 1H), 7.49 (d, 1H), 7.28 (m, 2H), 6.90 (dd, 2H), 4.51 (m, 1H), 4.42 (m,
1H), 4.14 (br d, 1H), 3.82-2.91 (m, 8H), 1.84-1.45 (m, 6H) ppm.
36
(CDCl3): 7.54 (d, 2H, J = 6.4 Hz), 7.30 (d, 2H, J = 8.8 Hz), 6.91 (d, 2H, J = 8.8 Hz), 4.70 (m,
1H), 4.10 (m, 1H), 3.90 (m, 1H), 3.60 (m, 1H), 3.40 (m, 1H), 2.83 (s, 6H), 2.80 (m, 2H)
ppm.
37
(CD3OD): 7.65 (d, 2H), 7.31 (d, 2H), 7.00 (d, 2H), 4.60 (m, 1H), 4.00 (m, 2H), 3.69 (m,
2H), 3.40-3.00 (m, 5H), 2.82 (m, 1H), 1.70-1.40 (m, 6H) ppm.
38
(CD3OD): 7.69 (d, 2H), 7.33 (d, 2H), 7.00 (d, 2H), 4.60 (br s, 1H), 3.92 (br t, 2H),
3.62-3.41 (m, 10H), 2.90 (dd, 1H), 2.70 (td, 1H) ppm.
39
(CD3OD): 7.65 (d, 2H), 7.33 (d, 2H), 7.00 (d, 2H), 4.59 (br s, 1H), 3.88 (m, 2H),
3.70-3.15 (m, 5H), 2.90-2.45 (m, 6H) ppm.
40
(CD3OD): 7.48 (d, 2H), 7.22 (dd, 2H), 6.99 (t, 1H), 6.89 (d, 2H), 4.23-4.15 (m, 2H),
4.05-3.95 (m, 3H), 3.67-3.64 (m, 2H), 3.45 (m, 2H), 3.25 (s, 3H), 3.2 (m, 1H), 3.00 (m, 1H)
ppm.
41
(CDCl3): 7.46 (d, 2H, J = 6.8 Hz), 7.26 (m, 4H), 6.91 (d, 2H, J = 9.2 Hz), 4.60 (s, 1H),
4.00 (m, 1H), 3.80 (m, 2H), 3.60 (m, 2H), 3.40 (m, 1H), 2.60 (m, 2H) ppm.
42
(CD3OD): 8.79 (br. s, 2H), 7.70 (m, 4H), 7.38 (d, 2H), 7.00 (d, 2H), 4.40 (m, 2H),
4.00-3.00 (m, 5H) ppm.
43
(CDCl3): 7.50 (d, 2H), 7.23 (m, 2H), 6.87 (d, 2H), 4.86 (d, 1H), 4.57 (d, 1H), 4.05 (m,
2H), 3.38 (m, 2H), 3.04 (m, 1H), 2.31 (t, 2H), 1.53 (s, 2H), 1.25 (s, 6H), 0.85 (t, 3H) ppm.
44
(CDCl3): 7.52 (d, 2H, J = 6.4 Hz), 7.24 (d, 2H, J = 8.8 Hz), 6.87 (d, 2H, J = 8.4 Hz), 4.97 (d,
1H), 4.71 (s, 1H), 4.05 (d, 1H), 3.80 (d, 1H), 3.37 (m, 1H), 3.26 (t, 1H), 3.05 (d, 1H),
2.62 (m, 1H), 1.54 (m, 2H), 1.80 (m, 2H), 1.18 (m, 4H), 0.85 (dt, 6H) ppm.
45
(CDCl3): 8.15 (s, 1H), 7.65 (s, 1H), 7.47 (m, 2H), 7.21 (d, 2H, J = 8.8 Hz), 6.84 (d, 2H,
J = 8.4 Hz), 6.43 (s, 1H), 4.63 (s, 1H), 3.60 (m, 3H), 2.80 (m, 3H) ppm.
46
MS: Calculated for C24H26ClF2N5O8S: 617.12; Found: LC/MS: 618.2 (M + 1).
47
(CD3OD): 8.60 (m, 2H), 8.25 (d, 1H), 7.83 (m, 1H), 7.62-7.50 (m, 2H), 7.22 (m, 2H),
6.85 (m, 2H), 4.60-4.20 (m, 2H), 4.15-3.95 (m, 2H), 3.85-3.65 (m, 2H), 3.50-3.40 (m,
2H), 3.10 (m, 1H) ppm.
48
(CD3OD): 9.60 (br s, 1H), 8.60 (m, 4H), 7.95 (t, 1H), 7.60 (d, 2H), 7.37 (d, 2H), 7.00 (d,
2H), 4.60 (br s, 1H), 4.15 (br d, 1H), 3.93 (br d, 1H), 3.71-3.42 (m, 2H), 2.80-2.50 (m,
2H) ppm.
49
(CD3OD): 8.50 (d, 1H), 7.99 (d, 1H), 7.79 (d, 1H), 7.58 (m, 2H), 7.40 (m, 4H), 7.11 (m,
3H), 4.60 (br s, 1H), 4.20 (br d, 1H), 3.85 (br d, 1H), 3.49 (m, 2H), 3.09 (s, 6H), 2.50 (dd,
1H), 2.30 (td, 1H) ppm.
50
(CD3OD): 8.09 (s, 1H), 7.80 (dd, 2H), 7.60-7.42 (m, 3H), 7.31 (m, 3H), 7.95 (m, 3H),
4.60 (br s, 1H), 4.08 (m, 1H), 3.91 (br d, 1H), 3.60 (m, 2H), 3.10 (s, 6H), 2.42 (dd, 1H),
2.22 (td, 1H) ppm.
51
(CDCl3): 7.63 (d, 2H, J = 7.6 Hz), 7.56 (d, 2H, 7.2 Hz), 7.53-7.37 (m, 6H), 7.24 (m, 3H),
6.86 (d, 2H, J = 8.8 Hz), 3.90 (s, 1H), 3.70 (m, 2H), 3.45 (m, 1H), 3.30 (m, 3H) ppm.
52
(CD3OD): 8.45 (br s, 2H), 7.78 (d, 1H), 7.58 (m, 3H), 7.38 (m, 2H), 7.00 (m, 2H),
4.80-4.05 (m, 2H), 4.00-3.77 (m, 5H), 3.45-3.05 (m, 2H) ppm.
53
(CD3OD): 7.70 (d, 2H), 7.39 (d, 2H), 7.00 (d, 2H), 4.60 (br s, 1H), 4.00 (m, 2H), 3.79 (m,
2H), 4.60-3.40 (m, 6H), 3.20-2.90 (m, 4H), 2.00-1.40 (m, 6H) ppm.
54
(CD3OD): 7.70 (d, 2H), 7.39 (d, 2H), 7.00 (d, 2H), 4.60 (br s, 1H), 4.00 (m, 2H), 3.75 (m,
2H), 4.49 (m, 4H), 3.18 (m, 2H), 2.93 (s, 6H) ppm.
55
(CD3OD): 7.66 (d, 2H), 7.35 (d, 2H), 7.03 (d, 2H), 4.58 (m, 1H), 4.03-3.92 (m, 3H),
3.71-3.68 (m, 3H), 3.27-3.25 (t, 2H), 3.15-3.13 (m, 4H), 2.97-2.93 (m, 1H), 2.88 (s, 3H),
2.86-2.82 (m, 5H) ppm
56
(CD3OD): 7.68-7.66 (d, 2H), 7.35-7.33 (d, 2H), 7.04-7.01 (d, 2H), 4.57 (m, 1H),
4.13-4.08 (q, 2H), 4.02-3.98 (m, 1H), 3.71-3.68 (m, 2H), 3.46 (m, 4H), 3.26-3.23 (t, 2H),
3.19-3.15 (dd, 1H), 2.96-2.95 (m, 1H), 2.77-2.73 (m, 2H), 2.46 (m, 4H), 1.26-1.22 (t, 3H) ppm
57
(CD3OD): 7.19 (d, 2H), 7.14 (d, 2H), 6.83 (d, 2H), 4.48 (br s, 1H), 3.95-3.92 (br d, 1H),
3.83-3.80 (br d, 1H), 3.58-3.53 (m, 6H), 3.15 (dd, 2H), 2.94 (dd, 1H), 2.75-2.74 (td, 1H),
2.63-2.60 (t, 2H), 2.40-2.39 (m, 4H) ppm
58
(CD3OD): 9.00 (d, 1H), 8.23 (d, 1H), 8.07 (d, 1H), 7.92-7.86 (m, 2H), 7.52 (m, 1H),
7.22 (m, 1H), 4.50 (m, 1H), 3.90-3.57 (m, 8H), 3.22-3.08 (m, 5H), 2.97 (m, 1H) ppm.
59
(CD3OD): 8.54 (d, 2H), 7.77 (br s, 1H), 7.57-7.50 (m, 2H), 7.44-7.42 (m, 1H),
7.27-7.22 (m, 2H), 6.95-6.92 (m, 2H), 4.40-4.20 (m, 1H), 3.85-3.60 (m, 3H), 3.57-3.18 (m, 2H),
3.10-2.95 (m, 1H) ppm
60
MS: calculate for C29H27ClF2N4O7S2: 680.10; found: 681.20 (M + 1).
61
MS: calculated for C24H20Cl3F2N3O7S2: 668.98; found: 669.90 (M + 1).
62
(CD3OD): 7.63 (d, 2H, J = 7.2 Hz), 7.25 (d, 2H, J = 9.2 Hz), 6.93 (d, 2H, J = 9.2 Hz),
5.79 (m, 1H), 5.47 (s, 1H), 5.44 (d, 1H), 4.56 (d, 1H), 4.00 (d, 1H), 3.70-3.50 (m, 4H), 3.35 (d,
1H), 2.99 (d, 1H), 2.88 (t, 1H) ppm.
63
(CD3OD): 7.66 (d, 2H, J = 7.6 Hz), 7.35 (d, 2H, J = 8.8 Hz), 6.99 (d, 2H, J = 9.2 Hz), 3.85 (d,
1H), 3.67 (s, 2H), 3.61 (d, 1H), 3.44 (m, 2H), 3.04 (d, 1H), 2.83 (dd, 1H), 2.66 (dt, 1H)
ppm.
64
(CD3OD): 8.45 (d, 1H), 8.10 (dd, 1H), 7.12 (d, 1H), 7.02 (d, 1H), 6.86-6.82 (m, 2H),
4.33-4.25 (m, 2H), 4.15-4.05 (m, 3H), 3.70-3.65 (m, 2H), 3.55 (m, 2H), 3.35 (s, 3H), 3.25 (m,
1H), 3.05 (m, 1H), 2.78 (m, 4H), 1.80 (m, 4H) ppm.
65
(CD3OD): 8.47 (d, 1H), 8.12 (dd, 1H), 7.22-7.09 (m, 5H), 4.33-4.25 (m, 2H), 4.15-4.05 (m,
3H), 3.70-3.65 (m, 2H), 3.55 (m, 2H), 3.33 (s, 3H), 3.25 (m, 1H), 3.05 (m, 1H) ppm.
66
(CD3OD): 9.96 (d, 1H), 8.20 (d, 1H), 8.14 (d, 1H), 7.90 (d, 1H), 7.86 (d, 1H), 7.50 (m,
1H), 7.21 (m, 1H), 4.40 (m, 1H), 4.28 (d, 1H), 4.12-4.05 (m, 3H), 3.75-3.70 (m, 2H),
3.52 (m, 2H), 3.30 (s, 3H), 3.25 (m, 1H), 3.06 (m, 1H) ppm.
|
The present invention provides compounds useful for inhibiting the ADAM-10 protein, with selectivity versus MMP-1. Such compounds are useful in the in vitro study of the role of ADAM-10 (and its inhibition) in biological processes. The present invention also comprises pharmaceutical compositions comprising one or more ADAM-10 inhibitors according to the invention in combination with a pharmaceutically acceptable carrier. Such compositions are useful for the treatment of cancer, arthritis, and diseases related to angiogenesis. Correspondingly, the invention also comprises methods of treating forms of cancer, arthritis, and diseases related to angiogenesis in which ADAM-10 plays a critical role.
| 2
|
CROSS-REFERENCE TO RELATED APPLICATION
This application claims priority in U.S. Provisional Patent Application No. 61/595,536, filed Feb. 6, 2012, which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to satellite communication systems and, more particularly, to such a system which communicates from a communication hub to a remote station on one band and from the remote station to the hub on another band.
2. Description of the Related Art
Modern telecommunication systems provide means for communicating vocal conversations, email, and various kinds of data from originating sources to destinations over twisted pair landlines, coaxial cables, fiber optic cables, and radio frequency communication links. Satellite communications have become an important mode of communications for large and small entities for both one-way services, such as television signals, and two-way services such as data processing services, satellite internet services, and the like. Two-way communication satellite services are typically set up as a head-end or hub station which is interfaced to a large scale communication network, such as the public switched telephone network (PSTN) infrastructure, and remote stations which communicate through a communication satellite to the hub station and through the hub station to the PSTN. The PSTN provides conventional telephone services and data communication over dedicated lines, the internet, and other links. Equipment for remote satellite stations has evolved to what is known as VSAT or very small aperture terminal satellite dishes.
The present standard for VSAT satellite communications is the use of Ku band (12 to 18 GHz) satellite technology in order to use meter or sub-meter sized satellite antennas and to avoid costly licensing and frequency coordination. The problem with Ku band satellite technology is that it is highly susceptible to local rain or weather fade due to the nature of the frequencies used. For this reason, networks have to be tolerant of frequent signal fades or outages during the presence of rain, snow, and storm clouds. This occurs in all Ku band transmissions whether it is for residential satellite television or VSATs.
Some networks attempt to mitigate the fade through the use of automatic uplink power control at the customer VSAT location. This technology gradually increases the transmit power at the remote customer location via a command from the hub location when the hub location senses that there is attenuation somewhere in the path between the remote location and the hub. This works some of the time quite well, but the same local weather anomaly that causes the problem with the inbound signal to the hub also creates a problem with the outbound power control signal to the remote site. Eventually, the control signal cannot reach the remote site electronics with sufficient strength and the remote site shuts down until it can receive a valid command.
This is very bad for reliability and, as a result, Ku band networks are generally designed to be out of service for about 50 hours per year due to weather. For government and customer applications that need to know weather and other critical information, these 50 hours of down time cannot be tolerated.
Heretofore there has not been available a dual-band satellite communications system with the features and elements of the present invention.
SUMMARY OF THE INVENTION
The present invention provides a hybrid satellite communication system in which a hub station transmits signals to remote stations through a satellite at a relatively low frequency which is unaffected by weather effects and in which the remote stations transmit signals to the hub station at a relatively higher frequency which enables the use of more economical equipment at the remote stations. The hub station senses the signal quality or strength received from each remote station and transmits power control signals to remote stations with poor signal strengths to cause such remote stations to increase their output power to overcome weather effects. The power control signals are transmitted on the lower frequency to prevent the power control signals from being masked by the weather effects.
An embodiment of the present invention provides a technique to send the outbound signals from the hub at a much lower C band (4 to 8 GHz) frequency that is virtually unaffected by weather via the same satellite that is receiving a Ku band signal from the remote site. As a consequence, the remote site never or nearly never loses its control signal and is always changing its power in response to weather effects to thereby eliminate outages. This requires judicious selection of satellite transponders, special antennas, and specially designed feeds that allow simultaneous transmission of Ku band while receiving C band.
An embodiment of the present invention provides a hybrid satellite antenna for the remote stations to enable the remote station to transmit and receive signals on different bands using a single antenna assembly.
An embodiment of the present invention employs an offset feed/clear aperture antenna dish to enable the use of a reduced size dish without causing interference effects by receiving signals from or transmitting signals to multiple satellites.
Various objects and advantages of the present invention will become apparent from the following description taken in conjunction with the accompanying drawings wherein are set forth, by way of illustration and example, certain embodiments of this invention.
BRIEF DESCRIPTION OF THE DRAWINGS
The drawings constitute a part of this specification and include exemplary embodiments of the present invention illustrating various objects and features thereof.
FIG. 1 diagrammatic view illustrating an embodiment of a hybrid C/Ku band satellite communication system.
FIG. 2 is a block diagram illustrating components of an embodiment of the present invention.
FIG. 3 is a side elevational view of an axial feed antenna dish which may be employed in an embodiment of the present invention.
FIG. 4 is a side elevational view of an offset feed, clear aperture antenna dish which may be employed in an embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
I. Introduction and Environment
As required, detailed aspects of the present invention are disclosed herein, however, it is to be understood that the disclosed aspects are merely exemplary of the invention, which may be embodied in various forms. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art how to variously employ the present invention in virtually any appropriately detailed structure.
Certain terminology will be used in the following description for convenience in reference only and will not be limiting. For example, up, down, front, back, right and left refer to the invention as orientated in the view being referred to. The words, “inwardly” and “outwardly” refer to directions toward and away from, respectively, the geometric center of the aspect being described and designated parts thereof. Forwardly and rearwardly are generally in reference to the direction of travel, if appropriate. Said terminology will include the words specifically mentioned, derivatives thereof and words of similar meaning.
II. Hybrid Dual-Band Satellite Communication System 1
Referring to the drawings in more detail, the reference numeral 1 generally designates an embodiment of a hybrid C/Ku band satellite communication system according to the present invention. The illustrated system 1 generally includes a satellite teleport facility or hub station 3 which communicates with a plurality of remote stations 5 by means of a geostationary communication satellite 7 . The hub station 3 is interfaced to a large scale communication network, such as the public switched telephone and data network (PSTN) 9 which provides telephone and data communication services. The remote stations 5 include communication devices, such as computers 12 and telephones 14 , which communicate with the PSTN 9 by way of the system 1 .
Referring to FIGS. 1 and 2 , the illustrated hub station 3 includes a hub server 17 which is a processor or computer that controls the flow of data through the hub station 3 . The hub server 17 includes network interface circuitry 19 which interfaces the hub server 17 to the PSTN 9 . The illustrated hub station 3 includes a C band transmitter 21 which receives data from the hub server 17 and transmits the data through a C band antenna 23 to the satellite 7 on a C band frequency in the range of about 3.7 to 4.2 GHz. The hub station 3 includes a Ku band receiver 25 which receives data from a Ku band antenna 27 from the satellite 7 on a Ku band frequency in the range, as illustrated, of about 14 to 14.5 GHz. The transmitter 21 and receiver 25 are interfaced to the hub server 17 .
Each remote station 5 includes a remote server 30 which is a processor or computer that controls the flow of data through the remote station 5 . The remote station 5 includes interface circuitry 32 to interface the remote server 30 to the computers 12 and telephone sets 14 communicating therewith. The illustrated remote server 30 outputs data to the satellite 7 through a Ku band transmitter 34 and a hybrid C/Ku band antenna 36 on the same Ku band frequency range as the hub receiver 25 and receives data from the satellite 7 through the hybrid antenna 36 through a C band receiver 38 on the same C band frequency range as the hub transmitter 21 . The use of the hybrid antenna 36 economizes the implementation of the remote station 5 as far as the purchase and mounting of an antenna and wiring therefor.
The illustrated satellite 7 shown in FIG. 1 carries a plurality of C band and Ku band transponders (not shown). The transmission of signals from the hub station 3 and the satellite 7 on C band frequencies assures that such signals will reach the remote station 5 , since the C band range of frequencies are virtually immune to deterioration from weather effects. The hub server 17 monitors the signal quality of the Ku band signals received from the remote stations 5 . The output power of the remote Ku band transmitter 34 can be controlled by the remote server 30 to increase or decrease as needed to provide reliable signal quality from the remote station 5 to the satellite 7 and from there to the hub station 3 . The hub server 17 can control a remote server 30 to increase the output power of its transmitter 34 by an uplink power control UPC signal to overcome deterioration or fade of the signal from the remote station 5 due to weather effects. The UPC signal is sent at the C band frequency range to assure that it is received by the remote station 5 .
A geostationary satellite 7 is a satellite which has an orbital period equal to the Earth's rotational period (one sidereal day), and thus appears motionless, at a fixed position in the sky, to ground observers. A geostationary orbit can only be achieved by locating a satellite at an altitude very close to 35,786 km (22,236 mi) above the surface of the earth and directly above the equator. Communications satellites and weather satellites are often given geostationary orbits so that the ground antennas that communicate with them do not have to move to track them, but can be pointed permanently at the position in the sky where they stay. Because of efforts to maximize the coverage of geostationary satellites, there tend to be clusters of closely spaced satellites positioned over the equator to serve national or continental areas, such as the North American continent from coast to coast. However, there is a limit to how closely satellites can be spaced to avoid interference issues when using economical sized antenna dishes on the ground. Currently, the minimum spacing is about two degrees of arc.
Smaller sized dishes tend to be more economical than larger dishes and require less rugged mounting structure. However, smaller dishes have larger beam angles than larger dishes. The larger beam angle of a small dish may receive signals from two or more adjacent satellites and transmit signals to two or more satellites. The reception of signals from multiple sources either at the satellite or ground station may be interpreted as interference and cause undesired effects.
Referring to FIG. 3 , a common type of dish for communicating with satellites is an axial feed dish 42 which has a feed assembly 44 located along the axis 46 of the dish 42 . Typically, the dish 42 is oriented to intersect the axis 46 thereof with the satellite with which it is intended to communicate. The axial feed dish 42 has no simple mechanism for avoiding transmitting to or receiving from multiple satellites if the size is reduced below a certain diameter. Thus an axial feed dish such as the dish 42 must be sized large enough to control its beam angle.
Referring to FIG. 4 , an embodiment of the system 1 employs an offset feed/clear aperture dish 50 as the hybrid antenna 36 . The dish 50 has a feed assembly 52 located at an angle which is offset from the axis 54 thereof. The illustrated dish 50 is nominally a 2.4 meter dish and is appropriate for use on both C band and Ku band frequencies. The dish 50 is referred to as a clear aperture type dish because the offset feed assembly 52 does not block energy reflected from the dish surface, as can occur with an axial feed dish 42 . The dish 50 may be implemented as a 2.4 meter Model 1244 or 1251 dish manufactured by Prodelin Corporation (www.prodelin.com). Alternatively, other types of dishes may be used, such as the 3.8 meter Model 1383, also manufactured by Prodelin. The feed assembly 52 is a dual band feed assembly which is designed to receive in a C band frequency range and transmit in a Ku band range. The feed assembly 52 may be implemented as a Prodelin Model 0800-4487-1 or the like. The illustrated feed assembly 52 is supported by struts 56 and 58 in spaced and angled relation to the surface of the dish 50 to radiate radio frequency energy toward the dish 50 or to receive energy reflected from the dish 50 .
Because the feed assembly 52 is angularly offset from the axis 54 , aiming of the dish 50 toward the satellite 7 is complicated somewhat, since the surface of the dish 50 must be angled in such a manner as to reflect the signal energy from the satellite toward the feed assembly 52 and from the feed assembly 52 toward the satellite. However, the offset feed dish 50 can be used to reduce the multiple satellite interference effect of the beamwidth thereof, such that a smaller size dish can be used than would otherwise be possible.
While the system 1 has been described using C band frequencies from the hub station 3 to the remote stations 5 and Ku band frequencies from the remote stations 5 back to the hub 3 , it is foreseen that other sets of bands could be employed, such as Ka band frequencies (26.5 to 40 GHz) from the remote stations 5 to the hub station 3 .
It is to be understood that the invention can be embodied in various forms, and is not to be limited to the examples discussed above. The range of components and configurations which can be utilized in the practice of the present invention is virtually unlimited.
|
A hybrid satellite communication system in which a hub station transmits signals to remote stations through a satellite at a relatively low frequency which is unaffected by weather effects and in which the remote stations transmit signals to the hub station at a relatively higher frequency which enables the use of more economical equipment at the remote stations. The hub station senses the signal quality or strength received from each remote station and transmits power control signals to remote stations with poor signal strengths to cause such remote stations to increase their output power to overcome weather effects. The power control signals are transmitted on the lower frequency to prevent the power control signals from being masked by the weather effects.
| 8
|
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part application of U.S. application Ser. No. 09/536,416, “Transport of Isochronous and Bursty Data on a SONET Ring,” filed on Mar. 28, 2000, which is incorporated herein by reference. This application also claims the benefit of U.S. Provisional Application Ser. Nos. 60/245,387 and 60/245,262, both filed on Nov. 2, 2000, and both of which are incorporated herein by reference.
BACKGROUND
This invention relates to transport of time-division multiplexed data traffic in a synchronous communication system.
Fixed-rate data traffic can be transported using time-division multiplexing (TDM) of synchronous data frames. The approach to multiplexing data traffic in conventional SONET/SDH (Synchronous Optical Network/Synchronous Digital Hierarchy) systems is an example of such a TDM approach. SONET/SDH standards were developed as an evolution of legacy copper based transmission equipment to serve as a next generation/broadband transport of voice traffic over fiber optic infrastructure.
The first generation of digital transmission equipment used physical layer technologies that were encompassed under three regional digital signal hierarchies. The North American hierarchy consists of DS0 (64 kb/s), DS1 (1.544 Mb/s), DS1c (3.152 Mb/s), DS2 (6.312 Mb/s), DS3 (44.736 Mb/s), DS3C (91.035 Mb/s) and DS4 (274.176 Mb/s) signals. The European hierarchy consists of E0 (64 kb/s), E1 (2.048 Mb/s), E2, E3 and E4 signals. The majority of the broadband optical fiber communications are based today on the SONET/SDH family of standards (SDH is essentially the international standard corresponding to SONET). The standards provide mechanisms to transport circuit switched traffic streams within higher speed SONET “pipes,” which are aggregated streams of multiplexed low speed traffic. A series of Bellcore and ANSI specifications define data formats of payload containers (typically referred to as virtual tributaries, or VTs) to carry legacy traffic rates (DS1, DS1C, DS2 and DS3, of what is known as the PDH, or the Plesiochronous Digital Hierarchy) in higher speed synchronous communication on the optical links.
Communication according to the SONET standard makes use of a ring architecture in which a number of communication nodes are connected by optical links to form a ring. A SONET ring typically has a number of nodes each of which includes an add/drop multiplexer (ADM). Each of the nodes is coupled to two neighboring nodes by optical paths. Communication passes around the ring in a series of synchronous fixed-length data frames formatted according to a Synchronous Transport Signal (STS) standard. Each ADM is configured to pass a portion of the communication on the ring without modifying it, to extract (“drop”) a portion of the communication destined for that node, and to “add” outbound communication leaving the node to the optical path. The granularity of adds and drops in ADMs is typically an STS-1, which carries a DS3 rate data stream. The dropped and added communication passes between the ADM and local communication equipment, such as a multiplexer, which multiplexes a number of separate traffic streams. For example, an added or dropped communication stream may be a 1.5 Mb/s (DS1) data stream on which separate 64 kb/s (DS0) telephone channels that are multiplexed. The DS1 data stream is multiplexed onto (added to) the optical path and passed between particular nodes on the SONET ring. Typically, a SONET ring is provisioned to provide fixed-rate bidirectional communication streams, also known as virtual paths, between different ADMs on the ring. The virtual paths couple the separate communication streams that enter and leave the SONET ring at the ADMs. In operation, the virtual paths coupling different communication streams, including their allocated data rates, typically remain fixed for long periods of time.
The process of multiplexing standard rate data streams into higher rate streams is a basic feature of SONET communication. Multiplexed data streams pass between nodes in a SONET ring at particular data rates. These rates form a hierarchy of standard rate streams that are defined as part of the SONET standards. At the lowest rates, a VT1.5 virtual tributary supports a 1.5 Mb/s data rate. This is the data rate of a common DS1 (T 1 ) service, and can support up to 24 separate 64 kb/s (DS0) data streams. A VT2 virtual tributary supports approximately 2 Mb/s data, and a VT6 virtual tributary approximately supports 6 Mb/s. These virtual tributaries are typically the smallest units of communication that are added or dropped at an ADM. Virtual tributaries can be combined into a virtual tributary (VT) group, which can consist of 4 VT1.5, 2 VT2 or 1 VT6 virtual tributaries, and entire VT groups can be added and dropped at an ADM.
In different configurations of SONET rings, communication on the optical links can be at different data rates and use various forms of multiplexing. In one mode, a series of synchronous STS-1 frames includes a series of Synchronous Payload Envelopes (SPEs), which can be used to carry 45 Mb/s data between the SONET nodes. The series of SPEs can carry a raw data rate of 45 Mb/s or can be used to carry seven VT groups, each of which can multiplex multiple equal-size virtual tributaries. The STS-1 frame adds control and overhead data to the SPE for transmission. The STS-1 frame can be optically encoded as an OC-1 signal for transmission over an optical link, or multiplexed as three STS-1 frames to an STS-3 frame and optically encoded as an OC-3 signal for transmission over a higher capacity optical link. An STS-3 frame can alternatively carry a concatenated STS3c payload envelope, which carries data at 150 Mb/s. The STS-3 frame can multiplexed still further, for instance four STS-3 frames to a STS-12 frame, which is in turn optically encoded as an OC-12 signal. Likewise, a SONET frame could be a concatenated STS-48c frame encoded as an OC48 optical signal, and a single payload envelope accounts for the entire OC48 payload.
SONET uses pointers in the frames to compensate for frequency and phase variations of the clocks used to transmit and receive data. Each STS-1 frame includes a pointer (H1,H2 bytes) in the transport overhead (TOH) of that frame to the offset of start of the SPE in that frame. When multiple sequences of STS-1 frames are dropped at an ADM, the ADM determines start of each of the SPEs separately based on the offsets in the respective STS-1 frame. When VTs are carried within an SPE, each VT can also include a VT payload pointer (V1,V2 bytes), which specifies the alignment of the VT within the SPE. In general, the phase of the incoming SPEs have no particular relationship to the phase of the synchronous STS frames.
Clocking in SONET networks is typically organized with a master-slave relationship with clocks of the higher-level nodes feeding the timing signals to lower-level nodes. The internal clock of a SONET node can derive its timing from an external source, such as a Building Integrated Timing Supply (BITS), in which case it serves as a master for other SONET nodes to which it is connected. At slave nodes, the internal clock is derived using “line timing” from an incoming OC-n signal. Typically, a SONET ring is configured to have one node timed to an external source, and the remaining nodes timed off the ring as slaves.
Although all nodes in a SONET ring are timed to a common source, there may nevertheless be small frequency differences (jitter/wander), which result due to several reasons, including span lengths between nodes. To accommodate these small frequency differences between an incoming signal and an outgoing signal, the SONET pointer mechanisms provides positive and negative justification opportunities. The frequency justification is particularly applicable when multiplexing lower rate signals into a higher rate synchronous signal.
Pointer processing is also used to account for differences in phase between the receive and transmit frames. When a payload is passed from the input to the output of a node, a phase adjustment between the payload is performed by adjusting the value contained in the H1-H2 bytes in the TOH of outbound STS frame. Hence, if the phase of the incoming STS frame is different from the transmitted frame, the SPE within the passed-through STS frame is multiplexed from the receive frame into the appropriate location within the transmit frame, and the H1-H2 bytes within the transmitted STS frame's TOH are adjusted to reflect the new position of the SPE. Therefore, the incoming SPE is transmitted to the outgoing SONET frame with minimum delay, even if the phase difference of the incoming and outgoing STS frames are substantially different. When the payloads of multiple STS-1 frames are multiplexed into a larger frame, traditional SONET ADMs process the pointers for each STS-1 payload within the multiplexed frame independently. For instance, in an OC-48 SONET frame in which 48 STS-1 frames are multiplexed, the ADM performs separate pointer processing on each of the 48 STS-1 frames. Note that the ADM performs pointer processing for all the STS-1 frames, not only those involved in add or drop functions at that node. Typically all the outbound STS-1 frames are synchronized to a common phase, and the H1-H2 pointers are manipulated in all outbound STS-1 frames to indicate the offsets of the SPEs in those frames.
A traditional SONET ADM breaks up a synchronous STS-n frame into channels of fixed/integral granularity, typically STS-1 or STS-3. The multiplexing/demultiplexing mechanisms are broken up into two stages. First, individual STS-n channels are added/dropped/passed-through at each node. Each of the dropped STS-n channels are broken down further to identify the particular VTs which need to be extracted. This requires either an entire STS-n channel to be added/dropped at a particular node off a ring, or additional VT cross-connect logic is necessary at the back-end of the STS cross-connect/add/drop logic to multiplex lower speed streams into an STS-n. This can cause severe fragmentation and under-utilization of a SONET frame, particularly as SONET scales to higher bandwidths.
SUMMARY
In one aspect, in general, this invention is a method for processing communication at a node in a communication system. A series of fixed-length data frames are received over the communication system at the node. Multiple data streams are multiplexed in this series of fixed-length frames. Each of the data streams originates from a corresponding source of data in the communication system. At least two of the data streams originate from a same source of data. For each of the series of fixed-length frames, multiple offsets within the fixed-length frame are identified, each of these offsets being associated with a different one of the sources of data. The data streams which are multiplexed in the series of fixed-length frames are then processed. For each of the data streams, in each of the series of fixed-length frames, that data stream is processed according to the offset identified for that frame that is associated with the source of that data stream.
The invention can include one or more of the following features:
The offsets within a fixed-length frame are identified by accessing overhead data encoded in the frame to identify offsets that each characterizes a displacement relative to the start of the frame. Each of these displacements is associated with a different one of the sources of data.
Processing the data streams further includes extracting the one or more of the data streams from the series of fixed-length frames for transmission from the communication network.
The method further includes receiving multiple data streams, and multiplexing these data streams into a second series of fixed-length data frames for transmission over the communication network. Multiplexing the data streams includes computing an offset for each of the second series of fixed-length data frames and storing data for each of the received data streams according to the computed offset.
The communication system includes a SONET network. Receiving each of the series of fixed-length data frames includes receiving a SONET synchronous payload envelope (SPE) that is transported in the series of SONET transport frames (STS-n). The received SPE can be a concatenated payload envelope.
Identifying the multiple offsets for each fixed-length data frame includes using data encoded in the SPE to identify offsets which each characterizes a displacement relative to the start of the SPE that is associated with a different one of the sources of data. Each source of data corresponds to a different node in the communication network.
Identifying an offset which characterizes a displacement relative to the start of the SPE includes identifying SONET row offsets within the SPE.
Processing the data streams includes identifying a range of SONET columns associated with each one or more of the data streams and identifying row offsets for each of these data streams according to the row offsets within the SPEs associated with the sources of the data streams.
Processing the data streams further includes extracting (“dropping”) the one or more of the data streams from the series of SPEs for transmission from the SONET network.
Processing the data streams further includes multiplexing the data streams in a second series of SPEs for transmission in a second series of transport frames, and then transmitting the second series of fixed-length frames over the communication system. Multiplexing the data streams includes storing multiple row offsets in each of the second series of SPEs. In each SPE each row offset corresponds to a different source node in the SONET network. Multiplexing the data streams further includes storing data for each data stream in the second series of SPEs to maintain a same relationship to the row offset corresponding to the source node as that data had to the row offset corresponding to the source node in the series of SPEs received over the communication network.
The method further includes identifying a column offset associated with each source of data. Multiplexing the data streams in the second series of SPEs then includes determining columns in the second series of SPEs to multiplex each data stream according to the columns used by those data streams in the received series of SPEs and the column offsets.
The method further includes receiving multiple data streams, and multiplexing (“adding”) these data streams into a second series of SPEs for transmission over the SONET network. Multiplexing the data streams includes computing a row offset for each of the second series of SPEs and storing data for each of the received data streams according to the computed row offset.
In another aspect, in general, the invention is a propagated signal embodied in a communication medium comprising a series of fixed-length data frames each of said fixed length frames including a plurality of offset values, each offset value being associated with a different one of a plurality of sources of data, and data for a plurality of data streams originating at the sources of data, wherein each offset value identifies offsets within the fixed-length frame for data streams originating at the source of data associated with said offset value.
Aspects of the invention can include one or more of the following advantages:
A system configured according to this invention does not necessarily limit the size of multiplexed channels to certain discrete rates, such as VT1.5, STS-1 etc.
The method provides a method of efficiently mapping virtual tributaries into concatenated frames.
The method scales well with increased data rates since pointer processing scales approximately according to the number of nodes in the system rather than to the number of channels being processed.
Other features and advantages of the invention are apparent from the following description, and from the claims.
DESCRIPTION OF DRAWINGS
FIG. 1 is a block diagram of a SONET ring in which TDM channels are passed from node to node over the ring;
FIG. 2 is a diagram illustrating the structure of synchronous SONET frames used to transport TDM channels;
FIG. 3 is a diagram illustrating TDM channels synchronized according to an offset pointer associated with the source of the channels;
FIG. 4 is a diagram that illustrates passing data through a node;
FIG. 5 is a diagram that illustrates adding and STS channel at a node;
FIG. 6 is a diagram that illustrates adding a virtual tributary at a node;
FIG. 7 is a block diagram of processing elements of a node;
FIG. 8 is a flowchart illustrating processing steps performed at a node; and
FIG. 9 is a diagram illustrating the structure of a SONET frame which includes both TDM channels and dynamic data.
DESCRIPTION
Referring to FIG. 1 , a SONET ring 110 that is configured according to this invention includes a number of nodes 120 coupled by high-speed optical links. In this embodiment, the optical links are standard OC-n links, in particular OC-48 links. A particular node C accepts data over the ring over OC-n link 122 from a node B 120 , and passes data over the ring over OC-n link 124 to a node D 120 . Each node 120 accepts data from other network elements (not shown) over a number of inbound TDM channels 132 , which it then passes over OC-n link 124 to other nodes 120 over ring 110 . Each node also provides data, which it accepts from other nodes 120 over OC-n link 122 , to the other network elements over a number of outbound TDM channels 136 . Inbound TDM channels 132 can include an STS-m channel 134 (m≦n) and a number of lower-rate VTs 135 . Similarly, outbound TDM channels 136 can include an STS-m channel 138 and a number of VTs 139 .
According to the invention, each node 120 receives STS-n frames on its inbound OC-n link and transmits STS-n frames on its outbound OC-n link. Node 120 processes pointers in the inbound STS-n frames and sets pointers in the outbound STS-n frames in order to pass data from the inbound to the outbound STS-n frames, and perform add/drop and multiplexing functions. Each node 120 manages an entire concatenated STS frame and processes and sets pointers within the concatenated frame.
It should be understood that in alternative embodiments, the pointer manipulation which is described below in the context of a SONET system is applicable to other synchronous communication systems, such as in systems using point-to-point and mesh arrangements of optical links, in systems in which data links use framing formats other than STS-n frames, and in systems using different link layers, such as wavelength multiplexed optical links and radio frequency links. Also, in alternative embodiments, alternative SONET architectures, for instance using bidirectional rings and redundant rings can be used.
As is apparent from the description below, there is essentially no limit on the value of n. For instance, OC-n links in the ring can be OC-48, OC-192, or OC-768. The data rate of the OC-n links of SONET ring 110 does not directly affect the overhead of pointer manipulation at a node 120 for a given number of nodes 120 in the ring and a given configuration of inbound and outbound TDM channels 132 , 136 at that node. As a result, the amount of pointer processing at a node does not scale by a factor of 4 if OC-48 links are replaced by OC-192 links.
Referring to FIG. 2 , data flowing over the OC-n links of SONET ring 110 use a standard STS-n format. Each frame is represented as 90n columns and 9 rows of bytes (810n bytes), and the rows are transmitted one after another at a rate of 125 microseconds per frame. As in standard STS-n frames in which the payload is concatenated, 3n columns are used for transport overhead 220 , and the remaining 87n columns are used for the concatenated payload. It should be noted that although in various figures ranges of columns are illustrated as being contiguous for ease of discussion, these ranges of columns may in fact be interleaved in a transmitted frame.
In each STS-n frame 210 , transport overhead 220 includes line overhead 222 and section overhead 226 . Line overhead 222 includes an offset pointer 224 to the starting byte of STS-n SPE 230 , which is the payload of STS-n frame 210 . Typically, the SPE spans part of two successive STS frames.
Each STS-n SPE 230 includes a TDM overhead 240 , in this embodiment using 5 columns of the SPE. The remaining 87n-5 columns are used to carry TDM data. In each SPE, TDM overhead 240 includes a pointer array 242 . Each entry in the array is a row offset pointer (ROP) 244 which is associated with a different one of nodes 120 on SONET ring 110 . In this embodiment, pointer array 242 has 16 entries thereby supporting rings of up to 16 nodes. A row offset pointer 244 for a node indicates the starting row for synchronizing all data streams originating at that node. As illustrated in FIG. 2 , node 1 has a ROP 244 that indicates the starting row for synchronizing data originating (added) at node 1 . The data originating at node 1 is segmented into 9-row segments, one of which is illustrated as node 1 synchronized rows (node 1 sync) 250 . ROP 244 for node 2 is illustrated as having a different row offset. Therefore, data added at node 2 is synchronized to a different phase than data added at node 1 . Note that the number of entries in pointer array 242 is related to the number of nodes in the ring and is not necessarily related to the number of data streams, such as separate STS-1 channels, that are passed between the nodes. In alternative embodiments in which more than 16 nodes 120 are present on SONET ring 110 , a larger number of row offset pointers, such as 32 pointers or 64 pointers, can be used to accommodate the larger number of nodes.
Referring to FIG. 3 , spans of node 1 synchronized rows 250 are illustrated along with framing of a representative series of STS-1 SPE 310 added at node 1 , and a representative VT 320 added at node 1 . Note that the SPE 310 is synchronized such that its starting row corresponds to the starting row of node 1 sync 250 , which is offset from the starting row of the STS-n SPE according to ROP 244 for node 1 (see FIG. 2 ) and the SPE is offset from the STS-n frame according to offset pointer 224 . VT 322 is also synchronized with node 1 sync 250 . As illustrated, the VT is a floating VT whose phase is indicated by a offset pointer 322 that is located relative to the starting row for node 1 . Therefore, the VT can have a VT frame sync 324 that differs from node 1 sync 250 .
Referring back to FIG. 1 , a representative node C 120 performs the functions of passing some data from its inbound link 122 to its outbound link 124 , adding data from inbound TDM channels 132 to outbound link 124 , and dropping data from inbound OC-n link 122 to outbound TDM channels 136 . Each of these functions involves manipulation of various pointers and offsets described above.
Referring to FIG. 4 , a series of inbound frames 410 , which are shown as a series of STS-n SPE 230 that have already been extracted from the STS-n frames 210 ( FIG. 2 ) and a series of outbound frames 420 are shown. Note that the inbound and outbound frames are synchronized, but are not typically in phase. That is, there is a time difference between the start of an inbound SPE and the start of a corresponding outbound SPE that typically exceeds the time taken to transmit one row of the frame. If data were delayed so that data in the first row of an inbound frame were transmitted in the first row of an outbound frame, then the delay introduced at the node would typically exceed the maximum allowable delay of 25 micro-seconds that is specified by the GR-253 standard that governs operation of SONET nodes.
As illustrated in FIG. 4 , a representative column 412 that originated at node B 120 is to be passed through the node for transmission without modification. Recall that as illustrated in FIG. 2 , data originating at node B is synchronized according to row offset pointer 244 associated with row B. As node C 120 passes this and other columns originating at node B, it adjusts ROP 244 for node B to correspond to the first row in the outbound frame that starts at a time after the start of the row in the inbound frame pointed to by ROP 244 for node B in the input frame. A byte, indicated by the X in FIG. 4 , in the first row from node B is transmitted in the first row from node B in the outbound frame at the same column offset. In this way, byte X incurs at most a 1-row delay as it passes through node C. A 1-row delay corresponds to less than 13.9 microseconds, thereby satisfying the GR-253 specification. Note that the row offset pointers 244 in the outbound frames, other than the pointer associated with the node passing the data, are typically all incremented (modulo 9 ) by the same amount relative to the corresponding row offset pointers in the input frames. Other columns originating at node B are also offset according to ROP 244 in inbound frames 410 and to ROP 244 in outbound frames 420 . In alternative embodiments, each entry in the offset pointer array can be a byte pointer, instead of a row offset pointer. By using a byte pointer, less than a one-byte delay can be incurred at a node rather than a less than a one-row delay that can be incurred using a row offset pointer. Other granularity of offset pointers, for example, greater than a byte and less than a row, can alternatively be used.
Referring to FIG. 5 , the procedure by which a series of STS-m SPE 510 are added at node C 120 is illustrated. Note that the STS-m SPE may be an STS-1 SPE, and STS-3c concatenated SPE, or another size of concatenated SPE. As illustrated in FIG. 5 , a single series of STS-m SPE is added at the node. In each outbound frame, the row offset pointer 244 for node C (the adding node) is set to point to the first row starting after the start of the inbound STS-m SPE that is being added. The data in each STS-m SPE 510 is then inserted into the appropriate columns of the outbound frame synchronized with the row offset pointers for node C in each frame. Note that in this way, the delay introduced in adding the stream to the outbound frame is less that 1 row, or 13.9 microseconds. When multiple STS-m channels are added at node C, they are all added at the same offset according to ROP 244 for node C.
If an inbound STS-m TDM channel 134 includes a multiplexing of multiple lower rate STS channels, for example an STS-12 which includes two STS-1 channels, the SPEs for each of the STS-1 channels are synchronized to the same row offset pointer for the node at which they are being added.
Referring to FIG. 6 , the process by which a virtual tributary is added to an outbound STS-n SPE 230 is illustrated. The inbound VT is illustrated as multiplexed in an inbound SPE, for example as part of a VT group of a standard STS-1 channel, although the VT can be equivalently received by node 120 using other framing approaches, such as over a T1 circuit. In FIG. 6 , row offset pointer 244 for node C in the outbound STS-n SPE 230 is not necessarily set according to the framing of the VT. For example, the row offset pointer may be determined by an STS-m channel that is added at that node. In the outbound VT 630 , in the first row associated with node C (the adding node) a VT offset pointer 632 indicates the start of VT frame 634 . If multiple VTs are added at the node, then VT offset pointer 632 is adjusted independently for each VT.
Dropping channels that originate at a particular node involves the reverse of the pointer processing described above. In particular, after extracting the STS-m SPE, the node dropping the channels determines the row offset for the originating node, and then extracts the appropriate columns according to the row offset for the originating node. Note that if multiple channels are extracted that have originated at a single node, they are all synchronized by the row offset for that originating node. For instance if 12 STS-1 channels are being dropped at a node, all 12 STS-1 SPEs that are being dropped are synchronized to the same starting row. Therefore the dropping node does not have to perform separate pointer manipulation for each of the dropped STS-1 channels, as would generally be the case of standard SONET techniques.
Referring to FIG. 7 , node 120 includes a number of processing modules that operate in a pipelined manner. The flowchart illustrated in FIG. 8 identifies various processing steps performed by these modules. Data is received from the ring over OC-n link 122 (step 810 ) and passed to clock recovery 710 where the receive clock is determined (step 812 ). Based on differences between the recovered clock and the system clock for the node, overhead stuff opportunities are determined in order to account for jitter and wander of the receive clock relative to the system clock (step 814 ) at frequency wander/jitter compensation 730 . The row offset pointers are adjusted for the passed through channels (step 816 ) at channel multiplexing and phase adjustment 740 , and the row offset point for the added channels is also set (step 818 ). At channel dropping 750 channels are dropped according to the row offset pointers for the originating node or nodes (step 820 ) and channels are added at channel multiplexing and phase adjustment 740 (step 822 ). Finally, the assembled frame is transmitted on outbound OC-n link 124 (step 824 ). It should be understood that these steps are performed in a pipelined manner and are not necessarily performed in the order presented in the flowchart.
Referring back to FIG. 4 , each TDM channel is assigned to a particular column or columns of the SPE. That is, a particular TDM channel that is passed through a node occupies the same column 422 in an outbound frame 420 and the column 412 in an inbound frame 410 . By default, all columns pass through a node. As a node receives instructions to add or drop columns via an out-of-band provisioning process, the node maintains a column map that establishes a correspondence between channels and column offsets.
In an alternative embodiment, a particular TDM channel does not necessarily occupy the same columns over all links that it traverses. Changes in the column map at each node are optionally used in an approach to reduce delay. In addition to adjusting the row offsets for each originating node in the ring, an overall mapping of columns is performed at each node. In this approach, data passing around the ring does not necessarily remain in the same column as it is passed through nodes according to the provisioning of the channel carrying that data. A particular TDM channel is assigned a different set of columns on each link in the ring. The columns assigned to a particular TDM channel are chosen to minimize the delay in passing data through the node. In the previous embodiment, a TDM channel could experience at most a 1-row (13.9 microsecond) delay based on using the row-offset pointers alone. By adjusting the column map, the delay for any TDM channel is reduced to a small fraction of a row delay. Each node transmits the column map to its downstream neighboring node using an out-of-band mechanism when the map changes. Note that the column map does not necessarily change very often. For example, the map can be changed when an upstream link goes down and then comes up.
In another embodiment, the approach of the above embodiments is introduced into the system described in U.S. application Ser. No. 09/536,416, “Transport of Isochronous and Bursty Data on a SONET Ring” (hereinafter the “parent application”). In the parent application, an STS-n SPE, or a fixed subset of columns of such an SPE, are reserved for both TDM and dynamic data (see FIGS. 5A-B of the parent application). Referring to FIG. 9 , such an SPE includes a TDM section 920 , a dynamic channel section 930 , and an STS path overhead 910 . In this alternative embodiment, the columns of TDM section 920 are managed using the approach described above. That is, a number of columns (e.g., 5 columns) of the TDM section are devoted to TDM overhead 922 , which the remaining columns 924 of TDM section 920 are devoted to carrying the data of the TDM channels.
In another alternative embodiment, framing on the OC-n links does not use an STS-n standard. Instead, TDM overhead 240 includes sufficient information to identify frame boundaries, and includes stuffing and frequency adjustment opportunities that are needed to compensate for clock jitter and wander between the received and transmitted clocks at a node.
In yet other embodiments, the approach described above is applied to communication systems other than SONET networks. These other communication systems include SDH systems, which make use of STM-n framing, as well as other systems in which data from multiple sources is multiplexed in fixed or variable length frames. Furthermore, in alternative embodiments, the offsets are not necessarily associated with sources of data that correspond to nodes in communication system, for example, being associated with different sources outside the system, or to individual sources at a single node.
It is to be understood that the foregoing description is intended to illustrate and not to limit the scope of the invention, which is defined by the scope of the appended claims. Other embodiments are within the scope of the following claims.
|
A method and system for processing communication at a node in a communication system makes use a series of fixed-length data frames in which multiple data streams are multiplexed. Each of the data streams originates from a corresponding source of data in the communication system, and least two of the data streams originate from a same source of data. For each of the series of fixed-length frames that are processed at a node, multiple offsets within the fixed-length frame are identified, each of these offsets being associated with a different one of the sources of data. The data streams which are multiplexed in the series of fixed-length frames are then processed. For each of the data streams, in each of the series of fixed-length frames, that data stream is processed according to the offset identified for that frame that is associated with the source of that data stream. The approach is applicable to SONET communication in which multiple data streams are multiplexed in a series of synchronous payload envelopes (SPEs), and data encoded in each SPE identifies offsets that characterize displacements, such as row offsets, in the SPE that are each associated with a different source node in the SONET network. An advantage of this approach is that pointer processing scales approximately according to the number of nodes in the system rather than to the number of channels being processed.
| 7
|
FIELD OF THE INVENTION
[0001] The field of the invention is completions and more particularly when portions of a zone are perforated, flow tested and isolated in sequence and thereafter the isolated zones are to be opened to produce through packers previously used for zone isolation.
BACKGROUND OF THE INVENTION
[0002] In some completions after the well is drilled to the zone of interest, a packer is set on a string that conveys a perforating gun and a lowermost portion of the zone of interest is perforated. The gun is removed and a plug is delivered into the first packer to isolate the lower zone after an initial flow test is conducted. The lowermost region is now isolated and the process repeats in an uphole direction as many times as is necessary. The plug that can be used is a Model F Latching Packer Plug sold by Baker Hughes Incorporated. This plug has a selectively open bypass to facilitate mechanical latching when advancing the plug against formation pressure. The bypass prevents a potential liquid lock that would otherwise impede advancement of the plug until it latched to the packer bore with the seal assembly properly positioned in a polished bore normally extending below the packer mandrel. This plug has an unloader sub that can be selected for a bypass flow configuration or the bypass can be closed with a j-slot which also allows removal of the running string so that the packer is in effect a bridge plug. At a later time this plug will need to be removed to produce from the zone that is below it. If there are no obstructions above plug, its removal simply requires acquiring the j-pin mandrel at the top with a retrieval tool and pulling the plug out of the packer mandrel. If there are other packers above the packer in question with a Model F Plug in it then the plug has to be removed by other means such as drilling it out. Because the Model F is built to accomplish many objectives such as operating as a bypass device and holding differential pressure, trying to mill out such a plug can generate lots of cuttings that then have to be captured with wellbore cleanup tools such as the VACS Tool offered by Baker Hughes. The cuttings that do not get captured can migrate to undesired locations to make subsequent operations in the wellbore more problematic. Beyond that the Model F Plug is placed in a respective packer in a separate trip after the fired guns are removed and the initial flow test is conducted. As previously stated then another packer is run in and set with a string having a perforating gun and the process repeats.
[0003] What is need is a plug design that contemplates drillout so that cuttings are minimized while a drift diameter that is made available is maximized while the drillout time is minimized. What is also needed is a way to save trips when dividing a zone into segments that each is flow tested and plugged and later produced necessitating plug removal when there are obstructions above. What is provided is a bottom hole assembly that can deliver and latch a suitable plug to a lower packer while delivering the packer above. In that instance the plug is set in the lower packer and the running tool releases from the set plug to allow the string to be manipulated to position and then set the packer above. This saves a trip in the hole compared to comparable systems used before. Those skilled in the art will more readily appreciate these and other aspects of the invention from a review of the detailed description and the associated figures while appreciating that the full scope of the invention is to be determined from the appended claims.
SUMMARY OF THE INVENTION
[0004] A plug for a seal bore in a packer mandrel has a shiftable annular member that can selectively open bypass ports to facilitate latching and then be shifted as part of a release from the plug by a running tool to close the bypass passage that go around a frangible barrier that will later be broken by impact force. The annular member has minimal structure internally to allow attachment of the running tool. The annular member drillout proceeds quickly with minimal cuttings and the frangible member is broken by impact. On an assembly with multiple packers getting plugs a trip is saved as a plug is delivered into a lower packer with a string supporting the packer above. The plug is set in the lower packer allowing release of the running string for subsequent placement and setting of the next packer in the same trip.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] FIG. 1 is a section view of a known packer having a passage therethrough and a seal bore at a lower end of the mandrel;
[0006] FIG. 2 is a schematic illustration of possible liquid lock when installing a prior design plug into a packer open to formation pressure;
[0007] FIG. 3A is a schematic illustration of the running tool attached to the shiftable plug for run in with the bypass passages open;
[0008] FIG. 3B is the view of FIG. 3A where the running tool has shifted the bypass plug to close the bypass ports while releasing from the shifted plug;
[0009] FIG. 4A is a view of the plug in the run in configuration;
[0010] FIG. 4B is the view of FIG. 4A with the plug latched and the bypass passages closed;
[0011] FIG. 5 shows a first packer set and the zone below it being perforated;
[0012] FIG. 6 is the view of FIG. 5 with a plug delivered into the lower packer as the next packer is also run into the well;
[0013] FIG. 7 is the view of FIG. 6 with the running tool released from the latched lower plug and the second packer repositioned for setting;
[0014] FIG. 8 shows a perforating gun run through the second packer and set off;
[0015] FIG. 9 shows a plug for the second packer delivered in the same trip as a third packer;
[0016] FIG. 10 shows the second packer plugged and the running string repositioned for setting the third packer;
[0017] FIG. 11 shows a perforating gun run through the third packer and shot;
[0018] FIG. 12 shows the plug from the second packer is removed allowing tandem production from the top two intervals together;
[0019] FIG. 13 shows the plug removed from the bottom packer allowing tandem production from the three illustrated intervals.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0020] By way of background, FIG. 1 represents a known packer 10 having a mandrel 12 and a polished bore extension 14 . The packer 10 has a sealing element 16 flanked by upper slips 18 and lower slips 20 . An anchor latch 22 is used to retain a plug 24 as shown in FIG. 2 . The plug 24 has a through passage 26 that is blocked by a barrier 28 . Seal assembly 30 lands in polished bore extension 14 and latch mechanism 32 lands and latches to anchor latch 22 . When flow is desired at a later time through passage 26 the barrier 28 is removed by drilling or other means. The issue with this design is when trying to latch the plug against formation pressure. Because the passage 26 is blocked by barrier 28 it will frequently require a great deal of force to essentially buck the formation pressure so that the plug 24 can sufficiently advance to allow it to latch. As previously discussed, the Baker Hughes Model F Packer Plug has an unloader feature that allows temporary bypassing of the passage barrier in the plug and then closing the bypass when a running tool is released from the plug. However, this tool is fairly complex and has a j-slot actuation mechanism and was not initially designed to be milled out in situation where there are uphole restrictions that prevent its normal removal with a fishing tool that grips a fishing neck at the tool upper end. Because of this trying to millout this plug will generate significant cuttings that need capture and take a great deal of time.
[0021] FIGS. 3A and 3B show a preferred way to provide a temporary bypass for plug latching while designing the components for rapid millout that provides a drift dimension at least as large as the mill doing the millout with minimal cuttings generation. The run in position is shown on FIG. 3A and FIG. 4A shows the entire plug 34 that has external seals 36 and an anchor latch 38 all of which operate as before when describing plug 24 . The difference is in movable plug 40 which has an annular or ring shape with spaced external seals 42 and 44 that are run in offset from bypass passage 46 to allow flow represented by arrow 48 to bypass the seal assembly 36 as the plug 34 is advanced into position to allow anchor latch 38 to anchor at 50 on the packer assembly 10 . The running tool 52 is illustrated very schematically and has a shearable member 54 attached to plug 40 at cross member 56 . Raising the running tool will raise the plug 40 until it hits shoulder 58 at which point the bypass passage 46 will be closed because seals 42 and 44 straddle its opening as shown in FIG. 3B . Further pulling up will separate 54 and 54 so that the running tool 52 can be removed. The plug passage 60 is still plugged by a barrier 62 preferably one that can shatter on mechanical contact from an object such as a ceramic disc for example. Internally to the plug 40 is a web structure of struts, schematically illustrated as 63 extending from an inner wall 64 that are configured to allow retention to the running tool 52 until the plug 34 is latched to the packer 10 . Opening 66 is not to scale and is preferably just smaller than the passage 60 to allow for the creation of the shoulder 58 . As a result when it is time to produce through a packer 10 plugged with plug 34 , a mill that is not shown is advanced through opening 66 and simply mills the very open web structure 63 . On impact of the mill with the barrier 62 the barrier shatters and the passage 60 is open for production flow or other purposes.
[0022] Those skilled in the art will appreciate that the barrier 62 can be removed in other ways such as reactively or thermally for example. The open web structure of the equalizing plug 40 when used in tandem with the barrier 62 allows fast millout with minimal cuttings to capture and a procedure that allows the millout to happen in a short time. The internal components of the structure 63 can be composites, ceramics or other non-metallics or soft metals to facilitate rapid millout.
[0023] Referring now to FIGS. 5-13 another aspect of the invention will be illustrated that relates to the feature of saving a trip in the hole by delivering a plug for one packer in the same trip as the packer that is due to be set above. In FIG. 1 a first packer 70 of a type previously described is run and set in position. A string 72 that supports a perforating gun 74 is then run through the packer 70 . When the gun 74 is properly located, the gun 74 is fired into the formation lower zone 76 . FIG. 6 shows that the gun 74 is removed and what is next run in is a first plug 78 on a running tool 52 as previously described. The assembly is delivered on a running string 80 that also supports the second packer 82 . The assembly is advanced until the first plug 78 lands in first packer 70 with the plug 40 in the FIG. 3A position so that the first plug 78 can be latched as previously described. After latching, a pickup force is applied to the string 80 to get the plug 40 to move up as previously described and to release the running tool 52 from the first plug 78 also in the manner previously described. The string 80 can then be raised to locate second packer 82 at the proper spacing from first packer 70 . It is worth noting at this point that after setting the first packer 70 a flow test can be run on the lower zone 76 before the first plug 78 is installed in the first packer 70 . Also, a portion of the running tool 52 or all of it can remain with the second packer 82 after release from the first plug 78 as shown in FIG. 7 . While illustrated schematically, those skilled in the art will appreciate that the running tool 52 has a passage therethrough to accommodate subsequent flow therethrough in either direction.
[0024] FIG. 8 shows gun 84 below the second packer 82 perforating an intermediate zone 86 while supported on string 90 . First packer 70 is plugged with plug 78 and second packer 82 is set. As previously described for FIGS. 5-7 the process is the same for FIGS. 8-10 except the action is higher up in the wellbore. As shown in FIG. 9 a string 88 delivers a third packer 92 and a second plug 94 . The assembly is advanced to land plug 94 in second packer 82 and latch to it. Again the running tool 52 shifts a plug 40 and there is a shear release from the second plug 94 . The string 88 is picked up to position the third packer 92 the desired distance from second packer 82 and the string 88 is removed. At this point in FIG. 10 the first and second packers 70 and 82 are plugged and perforation of the upper zone 96 with gun 98 can take place. As stated before, a flow test can take place after each gun firing before the packer in question is plugged. In the case of FIG. 11 , production from zone 96 can begin with plug 94 in place. As shown in FIG. 12 the plug 94 has been milled out as previously described so that tandem production from zones 96 and 86 can take place. Subsequently, when plug 78 is drilled out production from all three zones including 76 can take place in tandem.
[0025] Those skilled in the art will appreciate that the design of the packer plugs lends itself to rapid millout with minimal cuttings and in minimal time. A breakable barrier 62 in conjunction with a ring shaped plug 40 with an internal web of struts 63 or other structure that is fairly minimal allows this to happen. The structure is sufficient for attaching the running tool 52 and for a shear release that separates items 54 and 56 . In a completion with multiple zones or a sectioned single zone that takes multiple perforations separated with packers such as illustrated in FIGS. 5-13 the ability to deliver the next packer when plugging a previous packer saves rig time. The prior Model F Baker Hughes plug is delivered in a separate trip and is principally designed to be removed when whole with a fishing tool. When there is an obstruction above and a plug such as the Model F has to be milled there are delays due to the need to remove significant portions of a metallic body not designed to be milled. The present system mounts the running tool for a plug to the lower end of a subsequent packer allowing the two to be delivered in tandem and then separated for subsequent setting of the packer after latching the plug that it formerly supported. The plug structure of having an open through passage closed with a removable member with bypass passage in the plug wall allows the use of a ring shaped valve associated with the running tool that is secured to the ring shaped plug with a minimal internal structure such that a pickup force slides the plug to close the bypass and shears for release. This leaves very little structure to mill out. A retaining shoulder at the plug top acts as a travel stop for the bypass plug as the running tool is shear released. The mill is sized to fit the opening at the plug top to provide the larger drift dimension for subsequent fluid flow or tools. The plug is designed to break on impact with the mill after the mill gets through the struts in the equalizer valve that previously held the running tool before the valve was shifted and the running tool shear released from the valve. The connection between the running tool actuator and the valve 40 can be a peripheral shear ring on the inside wall of the tubular valve such as an 1 -shaped ring one side of which comes out with the running tool actuator 54 , 56 as opposed to leaving in any part of the actuator to later mill out. Doing the release this way only leaves a part of the shear ring inside the valve 40 so that there is virtually nothing to mill out and leaving the possibility open to breaking the barrier 62 with a sinker bar and without milling.
[0026] The above description is illustrative of the preferred embodiment and many modifications may be made by those skilled in the art without departing from the invention whose scope is to be determined from the literal and equivalent scope of the claims below:
|
A plug for a seal bore in a packer mandrel has a shiftable annular member that can selectively open bypass ports to facilitate latching and then be shifted as part of a release from the plug by a running tool to close the bypass passage that go around a frangible barrier that will later be broken by impact force. The annular member has minimal structure internally to allow attachment of the running tool. The annular member drillout proceeds quickly with minimal cuttings and the frangible member is broken by impact. On an assembly with multiple packers getting plugs a trip is saved as a plug is delivered into a lower packer with a string supporting the packer above. The plug is set in the lower packer allowing release of the running string for subsequent placement and setting of the next packer in the same trip.
| 4
|
BACKGROUND OF THE INVENTION
The present invention is to a process for producing ferric-aminopolycarboxylic acid chelates with improved long term stability.
In the photographic industry, the oxidation of metallic silver in photographic images or negatives to silver ion is known as bleaching. A desirable bleaching agent will react rapidly with silver and then react rapidly with air to regenerate the bleaching agent. Ferric compounds have been used for this purpose for decades. The ferric compound in the most widespread use today is ferric ammonium ethylenediaminetetraacetate because of its desirable redox properties and ease of preparation from inexpensive commercial chemicals such as, ferrosoferric oxide, ethylenediaminetetraacetic acid (EDTA) and ammonia.
Donovan and Surash, U.S. Pat. No. 3,767,689, and Svatek, et al. U.S. Pat. Nos. 4,364,871, and 4,438,040, describe the formation of ferric-aminopolycarboxylic acid chelates by the reaction of iron oxide with ammoniated EDTA in an aqueous mixture at temperatures up to 105° C. for less than three hours, followed by pH adjustment, aeration, and filtration to give a ferric ammonium EDTA solution suitable for bleaching. A more recent variation of the method, described by Thunberg, et al. (U.S. Pat. No. 5,110,965), involves the use of ferrous salts to catalyze the reaction between the iron oxide and ammoniated EDTA.
Whereas chelate solutions made by the aforementioned processes are useful for photographic bleaching, over time they deposit fine, black, particulate matter which would be detrimental to the quality of photographs prepared using said solutions. It would be desirable, therefore, to produce ferric ammonium EDTA solutions which are more stable against the formation of the dark particulates.
SUMMARY OF THE INVENTION
The present invention is to a process for producing a ferric ammonium chelate of an aminopolycarboxylic acid with improved long term stability wherein an oxide of iron is reacted with an aminopolycarboxylic acid chelant in the presence of a base, which comprises: (1) providing a mixture in water of ammonia together with the chelant in a molar ratio of ammonia to chelant of about 0.5 to about 1.8, (2) adding to the mixture the oxide of iron at less than 1 mole of iron per mole of chelant, (3) heating the mixture for a sufficient time and temperature to produce a chelate which is stable for at least 28 days against the formation of fine precipitates as measured when the final chelate is stored at 40° C., (4) cooling the mixture to a temperature below about 75° C., (5) introducing ammonia to said mixture in sufficient amount to dissolve and to maintain in solution the iron chelate so formed, (6) oxidizing any ferrous ion present in the chelate solution to the ferric ion and (7) filtering the chelate solution.
In one particular embodiment of the new process, ammoniated EDTA slurry is reacted with ferrosoferric oxide at reflux temperature (105-110° C.) for in excess of three hours, followed by the cooling, addition of ammonia and aeration steps as above.
In a second specific embodiment of the process, ferrosoferric oxide and ammoniated EDTA slurry are reacted in a closed system (e.g., an autoclave) at temperatures exceeding 115° C. for 10 to 75 minutes, followed by cooling, addition of ammonia and aeration steps as above.
The methods of the present invention promote the production of ferric ammonium EDTA solutions with significantly improved stability against dark particulate formation as compared with solutions prepared by the methods disclosed in the art.
DETAILED DESCRIPTION OF THE INVENTION
It has been found that solutions of ferric ammonium aminopolycarboxylic acids with superior stability can be prepared from ferrosoferric oxide, aminopolycarboxylic acid and ammonia under the conditions disclosed herein.
Aminopolycarboxylic acids that are useful in the present invention as the chelant moiety are those which are capable of chelating iron. Examples of such chelants include nitrilotriacetic acid (NTA); iminodiacetic acid (IDA) and N-substituted derivatives thereof; 1,3-propanediaminetetraacetic acid (1,3-PDTA); ethylenediaminetetraacetic acid; N-hydroxyethylethylenediaminetriacetic acid (HEDTA) and diethylenetriaminepentaacetic acid (DTPA). Chelants containing one or more succinic acid moieties, such as ethylenediaminedisuccinic acid, can also be used as chelants in the current process. Preferred chelants are NTA, 1,3-PDTA, HEDTA, DTPA and EDTA. More preferably the chelant is EDTA.
In one specific embodiment of the present invention, ferrosoferric oxide, EDTA, and ammonia are combined in water so that the EDTA:iron mole ratio is between about 1.0 and about 1.8. Preferably the EDTA:iron mole ratio is between about 1.0 and about 1.5. More preferably, the EDTA:iron mole ratio is between about 1.1 and about 1.4. The ammonia:EDTA mole ratio generally is initially between about 0.5 and about 1.8. Preferably the ammonia:EDTA mole ratio is initially between about 1.0 and about 1.5. More preferably the ammonia:EDTA mole ratio is initially between about 1.2 and about 1.4. The amount of water added is chosen so that the concentration of iron in the final mixture is from about 4 to about 8 percent by weight.
The mixture of ammonia, EDTA and iron is then heated to boiling (ca. 105-110° C.) and kept there for three to eight hours, preferably three to six hours. More preferably the mixture is heated at boiling for four to six hours. During this time, water is added periodically to replace evaporative losses. The resulting mixture is then cooled to 25-65° C., preferably 30-50° C. More preferably the resulting mixtures is cooled to 35-50° C. Cold aqueous ammonia is then added to give a solution of desirable pH, generally between 7 and 8. The temperature of the mixture at this stage is generally kept below 60° C. The solution is then oxidized by air sparging until there is little or no detectable amount of ferrous iron remaining. After filtration through a fine (ca. 0.5 micron) filter, the resulting solution has improved stability against the formation of dark particulates as compared to such solutions prepared by processes known in the art.
In another preferred embodiment of the invention, an autoclave is charged with ferrosoferric oxide, EDTA, ammonia, and water as above. The autoclave is sealed; and, with vigorous stirring, the temperature is raised to 115-150° C., preferably 115-140° C., and more preferably 115-125° C. The length of time of the reaction is dependent on the temperature and is generally from about 10 to about 75 minutes and preferably from about 15 to about 60 minutes. For example, a time of about one hour is appropriate for a temperature of 115° C. and about fifteen minutes for a temperature of 150° C. The autoclave is then cooled as above, and the pressure is vented. The mixture is ammoniated, aerated, and filtered as above, providing a solution with improved stability against the formation of dark particulates as compared to such solutions prepared by processes known in the art.
Increased stability against the formation of dark particulates is conveniently measured by storing the chelate solutions at 40° C. and observing the formation of precipitate with time by filtering a sample of the stored chelate solution(s) through a 0.45 micron filter.
While specific embodiments have been demonstrated using EDTA as the chelant, other aminocarboxylates may be substituted for EDTA.
Certain modifications of the embodiments above will be apparent to one skilled in the art and are not considered out of the scope of this invention. For example, the ammoniation that follows the chelation reaction can be performed using anhydrous ammonia in place of aqueous ammonia. Furthermore, any reactor capable of withstanding the pressure and temperature of the second embodiment can be used in place of the autoclave.
During the course of the reactions of the present invention, a certain amount of EDTA is destroyed. Extended heating of the reaction mixtures exacerbates this situation. Whereas it is obvious that such extended heating may be performed if greater amounts of EDTA are used, the charges and conditions described above provide chelate solutions of superior stability while minimizing EDTA losses.
The invention will be further clarified by a consideration of the following examples, which are intended to be purely exemplary of the present invention.
Stability Test:
Immediately after preparation, the product solution is stored in a high-density, polyethylene bottle in a constant-temperature oven at 40° C. At appropriate intervals (usually weekly), a 125-ml sample of the solution is diluted with 125 ml of deionized water; and the resulting solution is passed through a 0.45-micron cellulose acetate filter (25-mm diameter). Failure (loss of solution stability) is recognized when the diluted solution leaves a black residue on the filter.
EXAMPLE 1
Two 2-liter beakers were each charged with EDTA acid (747 g, 2.56 moles); deionized water (750 g); 28% aqueous ammonia (195 g, 3.21 moles); and Fe 3 O 4 (171 g, 2.22 moles Fe). With vigorous stirring, the temperature was raised to the boiling point (108° C.) over the course of 20 min. and maintained there for six hours. (Deionized water was added occasionally to replace that which was lost to evaporation.) The resulting solutions were combined in one 4-liter beaker and allowed to cool to 48° C. (over the course of one hour). Ice-cold, 28% ammonia (280 g, 4.60 moles) was added slowly, keeping the temperature of the solution below 55° C. The solution was sparged with air overnight, then filtered through a 0.45-micron nylon filter. 3258 g of filtered solution was obtained. Analytical data are given in Table 1.
EXAMPLE 2
A 2-liter, stainless-steel autoclave was charged with EDTA acid (727 g, 2.49 moles); deionized water (600 g); 28% ammonia (195 g, 3.21 moles); and Fe 3 O 4 (171 g, 2.22 moles Fe). With vigorous stirring, the mixture was heated to 120° C. over the course of 25 min. and maintained there for 45 min. (The final pressure in the autoclave was ca. 100 psig.) The mixture was cooled to 35° C. over the course of 10 min. Pressure was vented from the autoclave, which was then opened. The product mixture was transferred to a 2-liter beaker; and 28% ammonia (140 g, 2.30 moles) was added, causing a temperature rise to 49° C. The solution was sparged with air overnight, then filtered through a 0.45-micron nylon filter; 1691 g of product was obtained. Analytical data are given in Table 1.
COMPARATIVE EXAMPLE A
A 2-liter beaker was charged with deionized water (600 g); Fe 3 O 4 (171 g, 2.22 moles Fe); 28% ammonia (67.5 g, 1.11 mole); and EDTA acid (700 g, 2.40 moles). With vigorous stirring, the thick slurry was heated to 65° C. over the course of 15 min.; and FeSO 4 •7H 2 O (6.1 g, 0.022 mole) was added. After a brief exotherm to 70° C., the temperature returned to 65° C. and was kept there for six hours. The solution was then cooled to 35° C. over the course of 50 min. Ice-cold 28% ammonia (204 g, 3.35 moles) was added, causing a rise in temperature to 55° C. The solution was sparged with air overnight; and then additional 28% ammonia (21 g, 0.35 mole) was added. The resulting solution was filtered through a 0.45-micron nylon filter, giving 1738 g of product. Analytical data are given in Table 1.
COMPARATIVE EXAMPLE B
A 2-liter beaker was charged with EDTA acid (485 g, 1.66 mole); deionized water (500 g); 28% ammonia (130 g, 2.14 moles); and Fe 3 O 4 (114 g, 1.48 mole Fe). With vigorous stirring, the temperature was raised to 90° C. over the course of 30 min. and maintained there for another 30 min. The mixture was cooled to 60° C. over the course of 25 min.; and 28% ammonia (90 g, 1.48 mole) was added slowly. The solution was air-sparged for 210 min. and then filtered through a 0.45-micron nylon filter, giving 1180 g product. Analytical data are given in Table 1.
TABLE 1______________________________________Solution Assay.sup.a Days to Failure.sup.b______________________________________Example 1 49.30 53Example 2 49.16 >56Comp. Ex. A 49.04 18Comp. Ex. B 48.43 20______________________________________ .sup.a weight percent of solution as (NH.sub.4)FeEDTA.NH.sub.4 OH .sup.b days at 40° C. until the stability test showed black precipitate
Other embodiments of the invention will be apparent to those skilled in the art from a consideration of this specification or practice of the invention disclosed herein. It is intended that the specification and examples be considered as exemplary only, with the true scope and spirit of the invention being indicated by the following claims.
|
A process for producing a ferric aminopolycarboxylic acid chelate with improved long term stability is disclosed. The process involves heating a mixture of iron oxide, ammonia and aminopolycarboxylic acid chelant at an elevated temperature for a sufficient time to improve the stability of the formed chelate.
| 2
|
BACKGROUND OF THE INVENTION
For many years, those who are responsible for monitoring usage of significant amounts of alternating current power have been concerned with the quality of such power. Much of the newer equipment now in use is sensitive to transient voltages, such as spikes, power surges, and random radio frequency (r.f.) noise; but at the same time, such equipment may be creating its own transient voltages which it injects back into the power line. When switches turn off and on, reverberating impulses are created on the line. Motors that start and stop cause power impulses known as surges.
Besides random r.f. pollution, electrical machinery of various kinds may generate harmonic frequencies. All of these kinds of power pollution detract from the efficiency of, inter alia, electric motors, generators, and transformers. The waveform of the power supplied to such equipment becomes distorted resulting in the creation of eddy currents in the ferrous metal parts of such equipment, such as transformer cores and motor stators and rotors. The result is that eddy currents in a motor, for example, dissipate power as heat causing it to consume more power to perform the same tasks. The motor may become damaged, either from the effect of excessive heat or from damage to insulation, causing it to break down long before its expected life.
While much has been done to improve that quality of the power being supplied to various consumers, there has been little recognition of the power pollution produced within a single facility as a result of the operation of significant numbers of electric motors, switches, computers, and other power-consuming devices.
Fundamentally, any time an inductive load is switched off, a very high voltage reverberation rising many times higher than the normal peak value of the applied voltage flows back into the power line. A typical transient voltage is shown superimposed on a sine wave in FIG. 1 . The average industrial or commercial circuit receives many daily transients in excess of 1000 volts. These transients reverberate and trigger other oscillations within the network. These reverberations bounce back and forth until they are absorbed or have done damage within the system.
Other disturbances occur when loads are unbalanced in three-phase lines, causing undesirable phase differences between voltage and current. High harmonic neutral currents flow, reacting with transient and surge activity on the line.
From the foregoing, it will be appreciated that the internal power pollution within a network frequently may be a much more serious factor in efficiency of motors, etc., than irregularities in the power supplied from outside the facility.
It has been estimated that up to 60 percent of all electricity is now, or soon will be, passing through non-liner loads. It is such loads that are principal contributors to electric power pollution.
Considerable efficiency gain can be realized if means can be provided, which is connected to the individual power lines to such power-consuming units, which can absorb or otherwise remove such transient voltages, thereby preventing them from being injected back into the power line.
It is, therefore, an object of the present invention to provide a waveform correction filter that removes and absorbs random r.f. noise, spikes, surges, and harmonics from the alternating current power supplied to the above-described power consuming units.
It is another object of the present invention to provide a waveform correction filter in which all components are bi-directional, making the waveform correction filter bi-directional.
It is another object of the present invention to provide a waveform correction filter, which will substantially reduce maintenance costs for the associated equipment.
Other objects and advantages will appear from consideration of the following specification taken in connection with the drawings taken in connection with the drawings:
BRIEF DESCRIPTION OF THE DRAWINGS
This invention may be more clearly understood with the following detailed description and by reference to the drawings in which:
FIG. 1 is a graph showing the distortion of a sinusoidal waveform resulting from a high-frequency transient voltage being imposed on it;
FIG. 2 is a schematic diagram of a basic waveform correction filter system;
FIG. 3 is a schematic diagram of a voltage divider showing characteristics of the transient voltage suppression system;
FIG. 4 is a graph showing a typical B-H curve having the characteristics of a magnetic core in applicant's system;
FIG. 5 is a graph showing flux density vs. pulse permeability of the magnetic material of the magnetic core in applicant's system;
FIG. 6 is a simplified equivalent RLC circuit showing the characteristics of the transient voltage suppression system;
FIG. 7 is a schematic diagram of the waveform correction filter system of the invention as connected to a single-phase motor;
FIG. 8 is a schematic diagram of the waveform correction filter systems as shown in FIG. 7 connected to a three-phase Wye circuit; and
FIG. 9 is a schematic diagram of the waveform correction filter system of the invention connected in a three-phase delta circuit.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The waveform correction filter system of the invention performs in the following way. It is connected across the line (Line to Neutral, typically) as shown in FIG. 2, and acts only upon the disturbances that may exist. The unit performs three important functions:
1. It senses the rising transient voltage and clips and absorbs all energy in excess of 10% above the peak value of voltage. That is, for example, +/−190 volts, in the case of a 120 volt rms. line.
2. It shows down the rise time of the transient, so the rising transient “glides” into the level of clipping. This is done so the clipping will not represent another switching event, thereby causing further ringing.
3. It filters out and absorbs all high-ringing disturbances at a rate of 6 db per decade above 60 hertz.
These actions are depicted in the following illustration:
FIG. 2 depicts a typical line to neutral connection of the waveform correction filter of the invention.
The component items in this schematic are described functionally as follows:
10 FUSE, protective line type
12 INDUCTOR, coaxial amorphous toroid of soft magnetic material
13 VARISTOR, metal oxide
14 CAPACITOR, polypropylene ac rated
15 MAGNETIC CORE, nanocrystalline toroidal
16 RESISTOR, carbon type limiting
17 LAMP, neon
The operation of the circuit proceeds as follows:
As the transient shown in FIG. 1 begins to rise, normally in an interval of 1 microsecond, its rise time is initially slowed or extended by a selectable predetermined amount by the INDUCTOR 12, and clamped by the VARISTOR 13 at approximately {square root over (2)} times the rms. line voltage. In the case of a 120 vrms line, this would be about 190 volts. This level depends upon the surge current and line impedance at the instant of the transient rise. Before the transient occurred, the VARISTOR 13 appeared as an infinitely high resistance in the circuit. But, at the instant of clipping, it becomes a very low impedance, and at the same time a current generator. Because the voltage across the CAPACITOR 14 cannot change instantaneously at the instant of the VARISTOR 13 switching, the CAPACITOR 14 becomes virtually a short circuit and provides a path for the high current to flow. Thus, the CAPACITOR 14 begins to charge. Now, connected across the CAPACITOR 14 are the elements depicted in FIG. 2 schematic: MAGNETIC CORE 15 , the RESISTOR 16 , and the LAMP 17 . The VARISTOR 13 switches back to a high impedance, and the CAPACITOR 14 transfers its energy into the components 15 , 16 , and 17 . This energy is calculated to be: E (joules)=V (clamping voltage)×I (surge current)×time. Using a Siemens S20K130 varistor, for example, its maximum energy capacity is 44 joules and clamps between 185 and 225 volts.
The MAGNETIC CORE 15 is a soft magnetic element having relatively very high initial permeability (μ=30,000), extremely low losses, and high saturation flux density (Bsat=1.2 tesla). This means that the core is very easily magnetized and maintains this condition throughout a wide flux penetration. Thus, the energy that was impressed into the capacitor is now transferred to the “reservoir” of the highly magnetic core. This energy is then processed into the RESISTOR 16 and the equivalent resistance of the LAMP 17 , where over a longer span of time such energy is collected and absorbed.
The network, in addition to absorbing the energy of the disturbance, also effectively functions as a low-pass filter.
Now it is important to consider the details of the low-pass filter network.
The voltage clamping device, which we have referred to as the VARISTOR 13 will be simply denoted “MOV” 13 . This MOV 13 is a component having a variable impedance depending upon the current flowing through the device or the voltage across its terminals. A nonlinear impedance characteristic is exhibited and Ohm's law applies, but the equation has a variable R. The variation of the impedance is monotonic and does not contain discontinuities.
As has been stated before, the circuit is essentially unaffected by the presence of the MOV 13 before and after the appearance of the over-voltage transient for any steady-state voltage below the clamping level. The voltage clamping action results from the increased current drawn through the device as the voltage tends to rise. If this current increase is greater than the voltage rise, the impedance is nonlinear.
The apparent “clamping” of the voltage results from the increased voltage drop (IR) in the source impedance due to the increased current. The device depends on the source impedance to provide the clamping. This action is depicted as a voltage divider, as shown in FIG. 3 .
The ratio of the divider is not constant, but changes. If the source impedance is very low, then the ratio is low. The MOV 13 cannot be effective with near zero source impedance and functions best when the voltage divider action can be implemented.
If the MOV were the only component serving in the role of removing over-voltage transients, it can be readily seen that because of its nonlinear switching process, further ringing transients would be generated.
The resulting ringing frequency components of the transient are several orders of magnitude above the power line frequency of an AC circuit and, of course, a DC circuit.
Therefore, an obvious solution is to incorporate a low-pass filter between the source of the transients and the sensitive load.
The simplest form of filter is a capacitor placed across the line. The reactive impedance of the capacitor forms a voltage divider with the source impedance, resulting in attenuation of the transient at high frequencies.
This simple approach can have undesirable side effects, such as:
1. Unwanted resonances with inductive components located elsewhere in the circuit, leading to high peak voltages.
2. High inrush currents during switching, or
3. Excessive reactive load in the power system voltage.
These undesirable effects can be reduced by adding a series resistor. However, the disadvantage of the added resistance is that less effective clamping results.
To achieve maximum success in clamping, attenuating, and absorbing the over-voltage transient energy, a highly permeable magnetic core is incorporated with the above-noted capacitor and damping resistor.
By second-order tuning, a critically damped RLC low pass filter can be created. Thus, the undesirable effects noted just above can be eliminated. However, not just any inductance will function satisfactorily. The specific requirements for this MAGNETIC CORE 15 , hereafter referred to as “L”, are as follows:
1) Because the capacitor response is nonlinear with frequency, but linear with current, the response of L with respect to current and frequency must be linear. This response requirement is depicted in the hysteresis graph FIG. 4 of Flux density B versus Magnetizing force H.
2) Also, since the impinging oscillatory wave statistically will not be balanced as a pure sinusoidal wave with no DC component, it is necessary that the core be reset for each cycle of the ringing frequency. This requirement is satisfied as shown in the above graph, where it is noted that the remanence Br is essentially near zero, as well as coercivity.
3) L must remain stable with respect to frequencies ranging up beyond 1 MHz, in order to function at its predetermined level throughout all components of the impinging ringing wave derived from that transient. This requirement is satisfied in the incorporation of the particular magnetic material utilized in the waveform correction filters of the invention.
4) The pulse permeability versus flux density variation of the magnetic core L must remain in a specified range as shown in the graph FIG. 5 .
The range in permeability noted above is important because under a rather random drive from the source, the inductance value must remain at its predetermined level.
The network essentially takes the form of a series RLC circuit, as shown in FIG. 6 .
The effective homogeneous equation for this system is given as: 2 i t 2 + R L i t + i LC = 0 s 2 + R L s + ω 0 2 = 0 t = s
where d/dt=s The roots are S 1 , S 2 = - R 2 L ± ( R 2 L ) 2 - 1 LC
The critical resistance is determined as: R cr = 2 L C
And the corresponding damping ratio ζ = R R cr = R 2 C L
The natural frequency is given by ω n = 1 LC
and R L = 2 ξω n
The characteristic equation now becomes:
S 2 +2ξω n S+ξ n 2
Implementing the special properties of the nanocrystalline core material, the two important parameters, ξ and ω n , in the above characteristic equation can and do govern the performance of the filter system. The performance centers on channeling current and tuning, both based on the cutoff frequency characteristic and proper damping.
The damping ratio ξ is chosen such that the impinging ringing transient is processed and absorbed by the dissipating R in the circuit (as indicated in FIG. 2) the final frequency ω n is determined such that the roll-off at −40 dB per decade gives rise to sufficient attenuation at higher frequencies as required in a particular system.
The combination of core material and circuit configuration is the key to the operation of the filter as described above.
FIG. 7 is a schematic diagram showing two waveform correction filters of the invention connected in a single-phase line. In this example, a single-phase motor 18 is shown connected to an alternating current source through lines 19 and 20 . Connected between each of lines 19 and 20 , and a neutral line 21 , are two identical waveform correction filters 22 . A separate ground line 23 is connected between the motor housing and an earth ground.
Each such filter 22 includes a fuse 10 , a coaxial amorphous toroidal inductor 12 of soft magnetic material applied in series with the fuse, and a capacitor 14 connected between the coaxial inductor 12 and neutral line 21 . Connected in parallel with capacitor 14 are a MOV 26 and a winding with a magnetic core 28 and a resistor 16 connected in series with each other. A lamp 32 is connected in parallel with the resistor 30 . A ground line 23 is connected between the case of motor 18 and an earth ground or its equivalent.
FIG. 8 is a schematic diagram showing three of the waveform correction filters 22 connected in a three-phase Wye network to a three-phase motor 36 wherein each filter 22 is connected between one of the phase lines 40 , 42 or 44 , and a neutral line 46 . As in FIG. 1, a separate ground line 48 is connected between the case of motor 36 and earth ground. Each of the filters 22 is identical to that of FIG. 7 except that values of components will vary according to the voltages applied, etc.
FIG. 9 is a schematic diagram showing three waveform correction filters connected in a three-phase delta network to a three-phase motor 50 . In this case, the waveform correction filters 52 are connected between phase lines 54 , 56 and 58 . Each filter 52 is essentially like filters 22 except that the resistor 30 , lamp 32 , and magnetic core and winding 28 are all connected in series across capacitor 24 . This variation is a matter of design choice depending upon the effective resistance desired. A separate ground line 60 is connected between the case of motor 50 and earth ground.
The above-described embodiments of the present invention are merely descriptive of its principles and are not to be considered limiting. The scope of the present invention instead shall be determined from the scope of the following claims including their equivalents.
|
A waveform correction filter is connected into an alternating current power line to absorb and remove various forms of power pollution, including high-frequency spikes, surges and other forms of high-frequency oscillations, such as those which result from switching inductive loads on and off. The waveform correction filter of the invention includes a fuse and a coaxial amorphous toroidal inductor connected between a power line and neutral with a low-pass filter connected in series with the fuse and coaxial amorphous toroidal inductor. The filter includes a capacitor, a varistor connected in parallel with said capacitor, and a magnetic core inductor connected in series with each other and in parallel with the capacitor and said varistor. A lamp may be connected in series with the resistor and the magnetic core inductor or across the resistor. Various arrangements are shown for connecting a plurality of the waveform correction filters into single phase or three-phase Wine or delta circuits.
| 8
|
TECHNICAL FIELD
[0001] The present invention relates generally to stabilization systems and methods configured to stabilize at least a portion of the spinal column via the use of an interconnection mechanism for engaging two or more stabilization members to one another.
BACKGROUND
[0002] In the art of orthopedic surgery, and particularly spinal surgery, it has long been known to anchor one or more elongate stabilization members, such as spinal plates or rods, to a portion of the spinal column to provide stabilization and support across two or more vertebral levels. With regard to prior stabilization systems, in order to revise or add to an existing system, one or more stabilization components must be loosened and/or removed to allow for integration and attachment of additional stabilization members or devices to the system, thereby tending to increase the complexity and duration of the surgical procedure.
[0003] There remains a need for improved stabilization systems and methods. The present invention satisfies this need and provides other benefits and advantages in a novel and unobvious manner.
SUMMARY
[0004] The present invention relates generally to stabilization systems and methods configured to stabilize at least a portion of the spinal column. While the actual nature of the invention covered herein can only be determined with reference to the claims appended hereto, certain forms of the invention that are characteristic of the invention are described briefly as follows.
[0005] In one aspect of the present invention, a bone structure stabilization system is provided which is capable of stabilizing adjacent bone structures. The bone structure stabilization system includes an anchor member having an upper segment and a lower segment. The lower segment of the anchor member is structurally configured to be positioned in a respective bone segment. In one embodiment, the lower segment of the anchor member comprises an externally threaded segment that acts as a bone screw for securing the anchor member in a respective bone structure. A first stabilization member is connected to the upper segment of the anchor member. In one example, the first stabilization member comprises a rod and the upper segment of the anchor member includes a head defining a cradle portion in which a portion of the rod is positioned.
[0006] The bone structure stabilization system also includes a locking member that is engaged with the anchor member. The locking member is connected to the anchor member such that the first stabilization member is fixedly secured to the anchor member by a lower portion of the locking member. The lower portion of the locking member protrudes downwardly from a mounting segment of the locking member and includes an externally threaded segment. The anchor member includes an internally threaded segment within which the externally threaded segment of the locking member is threaded to engage the locking member with the anchor member. A lower surface of the externally threaded segment makes contact with a surface of the first stabilization member to thereby secure the first stabilization member to the anchor member.
[0007] The bone structure stabilization system also includes a second stabilization member that is connected to an upper portion of the locking member. In one example, the second stabilization member comprises a plate member having an elongated slot. The upper portion of the locking member includes an externally threaded segment about which the elongated slot is positioned. A portion of the externally threaded segment protrudes upwardly through the elongated slot and above an upper surface of the plate member. A cap is connected to the upper portion of the locking member to secure the second stabilization member to the locking member. In one embodiment, the cap includes an internally threaded segment that threads onto the externally threaded segment of the locking member that protrudes upwardly through the upper surface of the plate member to secure the plate member to the locking member.
[0008] Another aspect of the present invention is directed to a method of stabilizing adjacent bone structures. The method includes the step of inserting an anchor member into a portion of bone structure. The anchor member includes a threaded portion that is capable of threading into a portion of bone structure to fixedly secure the anchor member to the bone structure. A first stabilization member is then positioned within a cradle defined by the anchor member. The first stabilization member is secured in the cradle of the anchor member with a locking member that includes a lower mounting surface and an upper mounting surface. A threaded segment protrudes downwardly from the lower mounting surface and threads into an internally threaded segment of the anchor member. A second stabilization member is then placed on the upper mounting surface of the locking member. Once in place, the second stabilization member is secured on the upper mounting surface of the locking member with a locking cap. The cap threads onto a threaded segment protruding upwardly from the upper mounting surface.
[0009] Yet another aspect of the present invention is directed to a spinal stabilization apparatus. The spinal stabilization apparatus includes a plurality of bone anchor members positioned in respective vertebrae of a spinal column. A first stabilization member is positioned in a first set of the bone anchor members that spans from a beginning location in one vertebra to an ending location in another vertebra. A first locking member is positioned in each of the bone anchor members of the first set of bone anchor members except the bone anchor member at the ending location. The first locking member secures the first stabilization member in the first set of bone anchor members.
[0010] A dual thread locking member is positioned in the bone anchor member at the ending location. The dual thread locking member includes a mounting segment positioned between an upper externally threaded segment and a lower externally threaded segment. The lower externally threaded segment threads into an internally threaded portion of the bone anchor member at the ending location to secure the first stabilization member in the bone anchor member. A second stabilization member is positioned about the upper externally threaded segment of the dual thread locking member and a portion of the upper externally threaded segment protrudes above a surface of the second stabilization member. A locking cap is used to secure the second stabilization member to the upper externally threaded segment.
[0011] Another aspect of the present invention is directed to a method of revising an implanted spinal construct. The method includes removing a set screw from an anchor member that secures a first stabilization member to a respective bone segment. A lower portion of a locking member is then connected to the anchor member to once again secure the first stabilization member to the anchor member. A second stabilization member is then placed about an upper portion of the locking member such that a portion of a lower surface of the second stabilization member rests on an upper surface of a mounting segment of the locking member. A cap is then secured to the upper portion of the locking member to fixedly secure the second stabilization member to the upper surface of the mounting segment. This method allows constructs to be revised without requiring the removal of an existing construct, thereby reducing surgery time, recovery time, and the number of components required to perform the revision surgery.
[0012] Yet another aspect of the present invention is directed to a locking member for a bone stabilization apparatus having at least first and second stabilization members. The locking member includes a mounting segment having an upper engagement surface and a lower engagement surface. A lower threaded segment extends downwardly from the lower engagement surface of the mounting and is structurally configured to be connected with an anchor member to secure the first stabilization member within the anchor member. An upper threaded segment extends upwardly from the upper engagement surface of the mounting segment that is structurally configured to receive a second stabilization member such that a portion of the second stabilization member rests on the upper engagement surface. A locking cap having an internal threaded segment is structurally configured to thread onto the upper threaded segment to secure the second stabilization device to the upper engagement surface of the mounting segment.
[0013] It is one object of the present invention to provide stabilization systems and methods configured to stabilize at least a portion of the spinal column. Further objects, features, advantages, benefits, and aspects of the present invention will become apparent from the drawings and description contained herein.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1 illustrates a stabilization system according to one embodiment of the present invention, as engaged to a portion of the spinal column.
[0015] FIG. 2 is a top view of a stabilization member according to one embodiment of the present invention.
[0016] FIG. 3 is a side view of the stabilization member illustrated in FIG. 2 .
[0017] FIG. 4 is a side perspective view of an anchor member according to one embodiment of the present invention.
[0018] FIG. 5 illustrates a stabilization assembly according to another embodiment of the present invention including an elongate stabilization member engaged with an anchor member by a locking member.
[0019] FIG. 6 is a perspective view of the locking member illustrated in FIG. 5 .
[0020] FIG. 7 illustrates a stabilization assembly according to another embodiment of the present invention including first and second stabilization members engaged with an anchor member by a locking member.
[0021] FIG. 8 is a side perspective view of a locking cap portion of the locking member illustrated in FIG. 7 .
[0022] FIG. 9 is a side view of the locking cap portion illustrated in FIG. 8 .
DETAILED DESCRIPTION
[0023] For the purposes of promoting an understanding of the principles of the invention, reference will now be made to the embodiments illustrated in the drawings and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is hereby intended, and that alterations and further modifications to the illustrated devices and/or further applications of the principles of the invention as illustrated herein are contemplated as would normally occur to one skilled in the art to which the invention relates.
[0024] Referring to FIG. 1 , illustrated therein is a spinal stabilization system 10 according to one form of the present invention. The stabilization system 10 generally includes first supports or stabilization members 12 a , 12 b engaged to a first portion of the spinal column via a number of bone anchors 18 , which are in turn interconnected with second supports or stabilization members 14 a , 14 b engaged to a second portion of the spinal column 16 via a number of bone anchors 18 . The anchor members 18 are configured to securely anchor the stabilization members 12 a , 12 b and 14 a , 14 b to respective vertebrae 22 of the spinal column 16 . As will be set forth in greater detail below, in one embodiment of the invention, the anchor members 18 comprise bone screws, with locking members provided to engage the stabilization members to the bone screws. However, it should be understood that other types and configurations of anchor members are also contemplated as falling within the scope of the present invention including, for example, spinal hooks, staples, bolts or any other suitable bone anchor device that would occur to one of skill in the art.
[0025] Although the embodiment of the invention shown in FIG. 1 illustrates the stabilization system 10 engaged to a lateral aspect of the spinal column 16 , it should be understood that the stabilization system 10 may be engaged to other portions of the spinal column 16 , including posterior or anterior portions. Additionally, it is also contemplated that the present invention may have application in other parts of the human body including, for example, other types of joints or long bones. The particular arrangement of the stabilization members 12 a , 12 b and 14 a , 14 b is determined by the surgeon before and/or during the surgical procedure to conform the stabilization system 10 to the patient's anatomy and to provide relief for the patient's diagnosed medical condition. It should be understood, however, that the particular arrangement of the first and second stabilization members 12 a , 12 b and 14 a , 14 b is exemplary, and may be adjusted or changed to provide any desired stabilization arrangement or configuration.
[0026] In the illustrated embodiment of the invention, the first stabilization members 12 a , 12 b comprise elongate spinal rods. Although a conventional circular-shaped spinal rod is illustrated, it should be appreciated that other shapes and configurations are also contemplated, including square, rectangular, hexagonal, diamond and elliptical shaped rods, or any other suitable shape that would occur to one of skill in the art. The spinal rod 12 a , 12 b may be formed from stainless steel, titanium, polyethertherketone (PEEK), or any other suitable biocompatible material known to those of skill in the art. In the illustrated embodiment, the stabilization system 10 includes a pair of spinal rods 12 a , 12 b running substantially parallel to one another along the spinal column 16 . However, in other embodiments, a single spinal rod may be used. Additionally, it should be understood that the stabilization members 12 a , 12 b may take on other configurations including, for example, plates, wires, tethers, or any other suitable configuration known to those of skill in the art.
[0027] Referring collectively to FIGS. 2 and 3 , in one embodiment of the invention, the second stabilization members 14 a , 14 b comprise plate members. The plate members 14 a , 14 b include an elongate body 26 extending along a longitudinal axis 28 . In the illustrated embodiment, the elongate body 26 includes at least one opening in the form of an elongate slot 30 extending generally along the longitudinal axis 28 . The elongate slot 30 extends through the elongate body 26 between upper and lower surfaces 32 , 34 , thereby defining side rails 36 extending longitudinally along opposite sides of the elongate slot 30 , and a pair of end rails 38 extending transversely between the side rails 36 adjacent the ends of the elongate body 26 . The plate members 14 a , 14 b further include a flange portion 39 extending downwardly from one of the end rails 38 . As illustrated in FIG. 7 , the flange portion 39 includes a lower engagement surface 40 configured to conform to an outer surface of the spinal rods 12 a , 12 b . In the illustrated embodiment, the engagement surface 40 has a curved or concave configuration which conforms with an outer curved surface of the spinal rods 12 a , 12 b . However, other shapes and configurations are also contemplated. In the illustrated embodiment, the plate member 14 a , 14 b include a curved or angled section 42 which interconnect first and second portions of the body 26 that are offset from one another by a distance d. In other embodiments, the plate member 14 a , 14 b need not include a curved or angled section, but may instead be provided with a generally flat or planar configuration.
[0028] Although a particular configuration of the stabilization members 14 a , 14 b has been illustrated and described herein, it should be appreciated that other plate configurations are also contemplated as falling within the scope of the present invention. Additionally, it should be understood that the stabilization members 14 a , 14 b may take on other configurations including, for example, rods, wires, tethers, or any other suitable configuration known to those of skill in the art. The stabilization members 14 a , 14 b may be formed from stainless steel, titanium, polyethertherketone (PEEK), or any other suitable biocompatible material known to those of skill in the art. In the illustrated embodiment, the stabilization system 10 includes a pair of plate members 14 a , 14 b running substantially parallel to one another along the spinal column 16 . However, in other embodiments, a single plate member may be used.
[0029] The spinal rods 12 a , 12 b and the plate members 14 a , 14 b are engaged to the spinal column 16 via a plurality of anchor members 18 , which as indicated above may be configured as bone screws. Referring to FIG. 4 , shown therein is one embodiment of an anchor member 18 suitable for use in association with the present invention. The anchor member 18 extends generally along a longitudinal axis and includes a distal segment 40 , an intermediate threaded segment 42 , and a proximal fixation or connection segment 44 . The distal segment 40 may be provided with self-cutting or self-drilling capabilities, including a tip 46 defining a cutout or flute 50 providing a cutting edge 52 . The threaded segment 42 defines a helical thread 54 configured for anchoring in bone, and more particularly in cancellous bone. In the illustrated embodiment, the fixation segment 44 comprises a head 60 having a pair of generally parallel arms 62 a , 62 b that provide a cradle 68 defining a generally U-shaped channel 70 between the arms 62 a , 62 b for receiving the first stabilization member or spinal rod 12 a , 12 b . An interior surface 72 of the arms 62 a , 62 b defines inner threads 74 for receiving a set screw such as, for example, a conventional set screw 19 ( FIG. 1 ) for capturing the spinal rod 12 a , 12 b within the cradle 68 and U-shaped channel 70 of the bone anchor 18 . Although a particular configuration of a bone anchor 18 has been illustrated and described herein, it should be understood that other types and configurations are also contemplated.
[0030] Referring to FIG. 5 , shown therein is another embodiment of an anchor member 18 ′ suitable for use in association with the present invention. The anchor member 18 ′ is also configured as a bone screw and, like the bone screw 18 , includes a distal segment 40 , an intermediate threaded segment 42 defining a helical thread 54 , and a proximal fixation or connection segment 44 including a head 60 having a pair of generally parallel arms 62 a , 62 b that provide a cradle 68 defining a generally U-shaped channel 70 for receiving one of the spinal rod 12 a , 12 b . Additionally, like the bone screw 18 , the interior surfaces of the arms 62 a , 62 b define inner threads for receiving a locking member or set screw for capturing the spinal rod 12 a , 12 b within the cradle 68 and U-shaped channel 70 of the bone anchor 18 ′. However, unlike the bone screw 18 which has a single-piece configuration, the bone screw 18 ′ has a poly-axial configuration wherein the connection segment 44 is formed separately from the threaded segment 42 and is attached thereto in a manner which allows the connection segment 44 to pivot or rotate relative to the threaded segment 42 prior to being locked at a selected angular and/or rotational position. Poly-axial bone screws are well know to those of skill in the art and need not be discussed in further detail herein. Although a particular configuration of the poly-axial bone anchor 18 ′ has been illustrated and described herein, it should be understood that other types and configurations are also contemplated.
[0031] Referring collectively to FIGS. 5 and 6 , shown therein is a locking member 80 according to one embodiment of the present invention for securing one of the spinal rods 12 a , 12 b within the cradle 68 and U-shaped channel 70 of the bone anchor 18 , 18 ′, and for coupling one of the plate members 14 a , 14 b to the bone anchor 18 , 18 ′. In the illustrated embodiment, the locking member 80 comprises a dual-threaded member including a lower threaded segment 82 and an upper threaded segment 84 that are separated from one another by an intermediate contact or mounting segment 86 . The locking member 80 extends generally along an axis 87 , with the upper and lower threaded segments 82 , 84 extending axially from the mounting segment 86 in generally opposite directions.
[0032] The lower threaded segment 82 includes external threads 88 that are configured for threading engagement with the internal threads 74 formed along the arms 62 a , 62 b of the bone anchor 18 , 18 ′. The length of the lower threaded segment 82 may be sized such that a lower surface 90 of the intermediate mounting segment 86 engages an upper surfaces 66 of the arms 62 a , 62 b of the bone anchor 18 , 18 ′, while at the same time exerting sufficient force against the spinal rod 12 a , 12 b to secure the spinal rod 12 a , 12 b in position relative to the bone anchor 18 , 18 ′. The upper threaded segment 84 includes external threads 92 that are configured for threading engagement within a threaded passage formed in a locking cap or nut 110 ( FIGS. 8 and 9 ). The upper threaded segment 84 further includes a pair of opposing flat or truncated surfaces 102 that are engagable by a tool or wrench. The length of the upper threaded segment 82 is sized to extend into the elongate slot 30 defined by the plate member 14 a , 14 b , with an upper surface 100 of the intermediate mounting segment 86 engaging a lower surface 34 of the plate member 14 a , 14 b . Although the external threads 88 , 92 formed along the upper and lower threaded segments are illustrated as having a particular thread configuration, it should be understood that various thread configurations are contemplated including, for example, a buttress thread, a helical thread, a square thread, a reverse-angle thread or other thread-like structures.
[0033] Referring collectively to FIGS. 7-9 , shown therein is a locking cap or nut 110 according to one embodiment of the present invention. The locking cap 100 is generally circular in shape and extends generally along an axis 112 . In the illustrated embodiment, the locking cap 100 includes an upper portion 114 , a lower portion 116 , and an axial passage 118 extending through the upper and lower portions 114 , 116 . A first portion of the axial passage 118 extending through the upper portion 114 of the locking cap 110 has a hexagonal shape configured for engagement with a driving tool and terminates at a base or shoulder 120 . A second portion of the axial passage 118 extending through the lower portion 116 of the locking cap 110 has a circular shape and defines internal threads 122 configured for threading engagement with the external threads 92 formed along the upper threaded segment 84 of the locking member 80 . The first portion of the axial passage 118 extending through the upper portion 114 of the locking cap 110 may be provided with a series of notches or grooves 124 that provide frictional engagement with the driving tool and/or which aid in engaging or securing a lid or cover (not shown) to the locking cap 110 to close off the axial passage 118 .
[0034] As illustrated in FIG. 9 , the upper portion 114 of the locking cap 110 defines a curved or rounded upper surface 115 devoid of sharp edges or corners to avoid injury or trauma to adjacent tissue. The lower portion 116 of the locking cap 110 includes a first cylindrical portion 126 having a diameter sized somewhat smaller than the upper portion 114 of the locking cap 110 , thereby defining a lower surface or shoulder 130 . The diameter of the first cylindrical portion 126 is preferably sized in relatively close tolerance with the width of the elongate slot 30 extending through the plate members 14 a , 14 b . The lower portion 116 of the locking cap 110 further includes a second cylindrical portion 128 extending from the first cylindrical portion 126 and having a diameter sized somewhat smaller than the first cylindrical portion 126 . The end of the second cylindrical portion 128 may be provided with a tapered edge 132 . As shown in FIG. 7 , when the locking cap 110 is threaded onto the upper threaded segment 84 of the locking member 80 , the lower surface or shoulder 130 of the cap 110 engages the upper surface 32 of the plate member 14 a , 14 b , thereby forcing the plate member 14 a , 14 b into tight engagement against the upper surface 100 of the locking member 80 , and also firmly engaging the lower engagement surface 40 of the flange 39 against the outer surface of the spinal rod 12 a , 12 b . Although a particular configuration of the locking cap 110 has been illustrated and described herein, it should be understood that other configurations are also contemplated as falling within the scope of the present invention.
[0035] In one embodiment of the invention, stabilization members 12 a , 12 b may comprise a stabilization system that has previously anchored to a first portion of the spinal column 16 by a number of bone anchors 18 , 18 ′ via a prior surgical procedure. In some instances, correction or stabilization of another portion of the spinal column is required or desired. In such instances, additional stabilization members 14 a , 14 b may be engaged with the stabilization members 12 a , 12 b and anchored to another portion of the spinal column 16 by additional bone anchors 18 , 18 ′ to provide further stabilization or support to the spinal column. Such procedures are sometimes referred to as a revision procedure or technique. During a revision procedure, benefits or advantages may be realized by avoiding removal or extensive manipulation of the previously implanted stabilization system.
[0036] Referring collectively to FIGS. 1 , 5 and 7 , in one embodiment of the invention, the conventional set screws 19 may be removed from the bone anchors 18 , 18 ′ adjacent one end of the existing stabilization system. The removed set screws 19 are then replaced with locking members 80 , with the lower threaded segment 82 of each locking member 80 threadedly engaged along the internal threads 74 formed along the arms 62 a , 62 b of a respective bone anchor 18 , 18 ′ and into engagement with the spinal rod 12 a , 12 b to once again securely engage the spinal rods 12 a , 12 b to the existing bone anchors 18 , 18 ′. The plate members 14 a , 14 b are then engaged to the bone anchors 18 , 18 ′ via insertion of the upper threaded segment 84 of the locking member 80 into the elongate slot 30 , with the lower surface 34 of the plate member 14 a , 14 b resting upon the upper surface 100 of the intermediate mounting segment 86 of the locking member 80 . A locking cap 110 is then threaded onto the upper threaded segment 84 of each locking member 80 until the lower surface or shoulder 130 of the cap 110 tightly engages the upper surface 32 of the plate member 14 a , 14 b , thereby forcing the plate member 14 a , 14 b into tight engagement against the upper surface 100 of the locking member 80 , and also firmly engaging the lower engagement surface 40 of the flange 39 against the outer surface of the spinal rod 12 a , 12 b . Additional bone anchors 18 , 18 ′ are used to anchor the opposite ends of the plate members 14 a , 14 b to another portion of the spinal column. As should be appreciated, the plate members 14 a , 14 b are interconnected with the existing spinal stabilization system (including the spinal rods 12 a , 12 b and the existing bone anchors 18 , 18 ′) without extensive manipulation or removal of the components associated with the existing stabilization system.
[0037] While the invention has been illustrated and described in detail in the drawings and foregoing description, the same is to be considered as illustrative and not restrictive in character.
|
A spinal stabilization system, apparatus, and method are disclosed which include an interconnection mechanism for engaging stabilization members to one another. In one embodiment, the interconnection mechanism comprises a locking member having first and second threaded segments. An anchor member is provided having an upper segment and a lower segment, wherein the lower segment is structurally configured for engagement with a respective bone segment. A first stabilization member is connected to the upper segment of the anchor member. A locking member is engaged with the anchor member such that the first stabilization member is fixedly secured to the anchor member by a lower portion of the locking member having a first threaded segment. A second stabilization member is connected to an upper portion of the locking member by a cap that is threaded onto a second threaded segment of the locking member.
| 0
|
FIELD OF THE INVENTION
[0001] This invention relates to an anisotropic conductive sheet which is interposed between a circuit board such as a substrate and various circuit components to conductive paths and to a manufacturing method thereof.
RELATED ART
[0002] As electronic devices become smaller in size and thinner in thickness, connecting minute circuits and connecting minute portions and circuitry are more and more demanding. Connection methods thereof are based upon the solder junction technology and the use of anisotropic conductive adhesive. There is employed a method of interposing an anisotropic conductive elastomer sheet between the electronic parts (components) and the circuit board to render conductive paths.
[0003] The anisotropic conductive elastomer sheets include sheets having conductivity only in the direction of thickness or conductivity only in the direction of thickness when the sheets are compressed in the direction of thickness. They have such features as accomplishing compact electric connection without using such means as soldering or mechanical fitting, and realizing a soft connection so as to absorb mechanical shocks and distortion. Therefore, they have been extensively used as connectors for achieving electric connection relative to circuit devices such as printed circuit board, leadless chip carrier and liquid crystal panel in the fields of cell phones, electronic calculators, electronic digital clocks, electronic cameras, computers and the like.
[0004] In the electric test of the circuit devices such as printed circuit boards and semiconductor integrated circuits, further, the anisotropic elastomer sheet has heretofore been interposed between a region of electrodes of the circuit device to be tested and a region of testing electrodes of the circuit board for the test in order to achieve electric connection between the tested electrodes formed on at least one surface of the circuit device to be tested and the testing electrodes formed on the surface of the circuit board for the test.
[0005] It is known that an example of the above anisotropic conductive elastomer sheet may be obtained by cutting an anisotropic conductive block in a thin sheet such that the block that is formed integrally with thin metal wires disposed in parallel and insulating material enclosing the metal wires is cut in a direction orthogonal to the direction of the thin metal wires (JP-A-2000-340037).
[0006] In the anisotropic conductive film with thin metal wires, however, it is difficult to shorten distance between such thin metal wires and to secure anisotropic conductivity with a fine pitch as required by recent highly integrated circuit boards and electronic components. Further, it is likely that thin metal wires are to be buckled with compressive force or the like during the use thereof and easily pulled out after repetitive use so that the anisotropic conductive film may fail to keep its function to a sufficient degree.
[0007] Therefore, this invention provides an anisotropic conductive sheet having a fine pitch required by the recent highly integrated circuit boards and electronic components, the anisotropic conductive sheet yet keeping high conductivity in the direction of thickness and preventing conductive members such as metals from slipping out.
DISCLOSURE OF THE INVENTION
[0008] In the present invention, it is provided an anisotropic conductive sheet in which conductive members are scattered in a nonconductive matrix, wherein the conductive members penetrate in the direction of thickness and conductive auxiliary layers are in contact with the conductive members.
[0009] More specifically, the present invention provides the following.
[0010] (1) An anisotropic conductive sheet expanding on a first plane, wherein: when a first direction contained in said first plane is denoted as X-direction, a direction orthogonal to X-direction and contained in said first plane is denoted as Y-direction and a direction orthogonal to X-direction and Y-direction is denoted as Z-direction; and the anisotropic conductive sheet has a predetermined thickness in Z-direction and a front surface and a back surface substantially in parallel with said first plane, the anisotropic conductive sheet comprising: a nonconductive matrix expanding on said first plane; conductive pieces scattered in the nonconductive matrix; and conductive auxiliary layers in contact with the scattered conductive pieces, wherein said scattered conductive pieces extend in Z-direction so as to penetrate the anisotropic conductive sheet from the front surface to the back surface.
[0011] (2) The anisotropic conductive sheet according to (1), wherein said conductive auxiliary layers penetrate the anisotropic conductive sheet from the front surface to the back surface along the scattered conductive pieces.
[0012] (3) An anisotropic conductive sheet expanding on a first plane, wherein: when a first direction contained in said first plane is denoted as X-direction, a direction orthogonal to X-direction and contained in said first plane is denoted as Y-direction and a direction orthogonal to X-direction and Y-direction is denoted as Z-direction, and the anisotropic conductive sheet has a predetermined thickness in Z-direction and a front surface and a back surface substantially in parallel with said first plane, the anisotropic conductive sheet comprising: strip-like members of a striped pattern having a width in Y-direction and extending in X-direction and conductive pieces and nonconductive pieces alternately arranged in X-direction; and nonconductive strip-like members having a width in Y-direction and extending in X-direction, wherein the strip-like members and the nonconductive strip-like members are arranged relative to each other in Y-direction, and wherein in said strip-like members of a striped pattern, a conductive auxiliary layer is arranged between the conductive piece and the nonconductive piece while in contact with said conductive piece.
[0013] (4) The anisotropic conductive sheet according to any one from (1) to (3), wherein the conductive auxiliary layer comprises an adhesive layer and a conductive layer.
[0014] (5) The anisotropic conductive sheet according to any one from (1) to (4), wherein the adhesive layer is arranged on a conductive piece side of the conductive auxiliary layer.
[0015] (6) The anisotropic conductive sheet according to (4) or (5), wherein the adhesive layer comprises indium tin oxide.
[0016] (7) The anisotropic conductive sheet according to any one from (4) to (6), wherein the conductive layer is made of material having good conductivity.
[0017] (8) The anisotropic conductive sheet according to (1) or (2), wherein the nonconductive matrix comprises a conductive elastomer and the scattering conductive pieces comprise a conductive elastomer.
[0018] (9) The anisotropic conductive sheet according to (3), wherein the nonconductive pieces and the nonconductive strip-like members comprise a nonconductive elastomer and the conductive pieces comprise a conductive elastomer.
[0019] (10) The anisotropic conductive sheet according to any one from (1) to (9), wherein the scattered conductive pieces or the conductive pieces are protruded as compared to surroundings thereof along Z-direction.
[0020] (11) A method of manufacturing a flexible anisotropic conductive sheet having a predetermined thickness, and predetermined front and back surfaces on the front and back across the thickness, the method comprising: a step of adhering a conductive auxiliary layer on the surface of a conductive sheet (A) made of a conductive member so as to obtain a conductive sheet (A) with the conductive auxiliary layer; a step of alternately laminating the conductive sheet (A) with the conductive auxiliary layer obtained in the step of adhering the layers and a nonconductive sheet (B) so as to obtain an AB sheet laminate (C); a first step of cutting the AB sheet laminate (C) obtained in the step of obtaining the AB sheet laminate to obtain a zebra-like sheet in a predetermined thickness; a step of alternately laminating the zebra-like sheet obtained in the first cutting step and a nonconductive sheet (D) to obtain a ZD sheet laminate (E); and a second step of cutting the ZD sheet laminate (E) with a predetermined thickness, which is obtained in the step of obtaining the ZD sheet laminate.
[0021] In this invention, it is characterized in that an anisotropic conductive sheet comprises conductive members scattered in the nonconductive matrix, in which the conductive members penetrates the sheet in the thickness direction, wherein the conductive auxiliary layers are in contact with the conductive members. Here, the nonconductive matrix is a sheet member made of nonconductive material so as to insulate the scattering conductive pieces in directions contained in the plane of the sheet (directions in X-Y plane) to maintain non-conductivity in the directions contained in the plane of the whole anisotropic conductive sheet. Usually, the nonconductive matrix is all connected (being continuous) in the anisotropic conductive sheet to form an anisotropic conductive sheet. The nonconductive matrix, however, may not have to be continuous. Further, the scattered conductive pieces may refer to a condition that one or more conductive pieces made of a conductive material are spread separately from each other in directions contained in the plane of the sheet.
[0022] “The scattered conductive pieces made of a conductive material penetrate the anisotropic conductive sheet from the front surface to the back surface,” may mean that the conductive pieces penetrate the sheet in the thickness direction, may mean that the conductive pieces appear on both front and back surfaces of the anisotropic conductive sheet, or may mean that the sheet has a function for electrically connecting the front and back surfaces. “The conductive auxiliary layers are in contact with the conductive members” may mean that the conductive auxiliary layers are electrically connected to the conductive members. The conductive auxiliary layers have conductivity higher than the conductive members. When the electricity flows in parallel (as being parallel-connected), therefore, the electric conductivity of the conductive auxiliary layers become dominant in the entire conductivity. As a result, the resistance between the front and the back of the sheet becomes low when the conductive auxiliary layers are adhered, and may become equal to the resistance of the conductive auxiliary layers. Here, the conductive auxiliary layers that are made of metal material can be called metal layers. In the case of the metal layer, the metal layer as a whole may be made of metal of a single kind.
[0023] The anisotropic conductive sheet of the present invention expands on a plane, and the feature of the sheet can be described by using X-direction and Y-direction which are two directions in parallel with the plane, and Z-direction orthogonal to X-direction and Y-direction. The anisotropic conductive sheet has thickness in Z-direction, the strip-like member of the striped pattern has a width in Y-direction and extends in X-direction, and the conductive pieces made of conductive material and nonconductive pieces made of nonconductive material are alternately arranged in X-direction. Further, the nonconductive strip-like member has width in Y-direction and extends in X-direction. The strip-like members having the striped pattern and the nonconductive strip-like members are arranged in Y-direction, and are included in the anisotropic conductive sheet in this state. In the strip-like members of the striped pattern, the conductive auxiliary members are arranged among the conductive pieces and the nonconductive pieces while in contact with the conductive pieces.
[0024] Being conductive may mean that the anisotropic conductive sheet of such constitution has sufficiently high conductivity in the conduction direction. It is usually preferable that the resistance among the terminals to be connected is not larger than 100 Ω (preferably, not larger than 10 Ω and, more preferably not larger than 1 Ω ). The strip-like member of the striped pattern may be thin and elongated in X-direction such that conductive members and nonconductive members are alternately arranged along X-direction, wherein a striped pattern may appear if the conductive members and the nonconductive members have different colors. In practice, they need not appear in a striped pattern. The alternate arrangement needs not expand over the whole strip-like members in X-direction but may exist in only a portion thereof. Further, “the conductive auxiliary layers being in contact with the conductive membersΩ may stand for the electric connection in the same manner as described above.
[0025] In the anisotropic conductive sheet of the present invention, further, it may be characterized in that the conductive auxiliary layers comprise the adhesive layers and the conductive layers. Here, the adhesive layers may be those for improving the adhesion to the conductive members while the conductive auxiliary layers come in contact with the conductive members. The conductive layers of the conductive auxiliary layers have physical and chemical properties which are greatly different from the physical and chemical properties of the conductive members so that the adhesive layers have a function to improve adhesion between them as the adhesive layers have intermediate properties and bond the conductive layer and the conductive member. Therefore, it may be characterized in that the adhesive layers are arranged on the side of the conductive member being in contact with the conductive auxiliary layers comprising the adhesive layers as a constituent element. For example, it may be possible to lower or absorb distortion caused by the different thermal expansion rate.
[0026] Further, it may be characterized in that the adhesive layer is arranged on the side of the nonconductive matrix while the conductive auxiliary layer is in contact with the nonconductive matrix. Here, being in contact with the nonconductive matrix may mean that the conductive auxiliary layers are physically (mechanically) in contact with the nonconductive matrix. This is because the nonconductive matrix is insulative. Being arranged on the side of the nonconductive matrix may mean that the adhesive layer is positioned between the conductive layer and the nonconductive matrix. Here, the adhesive layer may be a layer to improve the adhesion to the nonconductive matrix while the conductive auxiliary layer is in contact with the nonconductive matrix. The conductive layer of the conductive auxiliary layer has physical and chemical properties which are greatly different from the physical and chemical properties of the conductive member so that the adhesive layer can have a function to improve the adhesion between them as the adhesive layer has intermediate properties and bonds the conductive auxiliary layer and the conductive member. Therefore, it may be characterized in that the adhesive layers are arranged on the side of the conductive members which are in contact with the conductive auxiliary layers comprising the adhesive layer as a constituent element. For example, distortion caused by different thermal expansion rate can be lowered or absorbed.
[0027] It may be characterized in that the adhesive layer comprises a metal oxide or a metal. Examples of the metal oxide include indium oxide, tin oxide, titanium oxide, a mixture thereof and a compound thereof, and examples of the metal include chromium. For example, it may be characterized in that the adhesive layer comprises indium tin oxide (or indium oxide/tin oxide). Indium tin oxide (or indium oxide/tin oxide) is a ceramic material abbreviated as ITO and has high electric conductivity. The conductive layer may be made of metal having good conductivity. If the metal has electric conductivity higher than that of the conductive members and if electricity flows in parallel therewith (in a parallel-connected manner), the electric resistance of the metal controls the entire electric resistance.
[0028] In the anisotropic conductive sheet of the present invention, further, it may be characterized in that the nonconductive matrix comprises a nonconductive elastomer, and the conductive members comprise a conductive elastomer.
[0029] The conductive elastomer stands for an elastomer having electric conductivity and is, usually, an elastomer blended with a conductive material so as to lower the volume resistivity (smaller than, for example, 1 Ω-cm). For examples, butadiene copolymers such as natural rubber, polyisoprene rubber, butadiene/styrene, butadiene/acrylonitrile, butadiene/isobutylene, conjugated diene rubber and hydrogenated compounds thereof; block copolymer rubbers such as styrene/butadiene/diene block copolymer rubber, styrene/isoprene block copolymer, and hydrogenated compounds thereof; and chloroprene copolymer, vinyl chloride/vinyl acetate copolymer, urethane rubber, polyester rubber, epichlorohydrin rubber, ethylene/propylene copolymer rubber, ethylene/propylene/diene copolymer rubber, soft liquid epoxy rubber, silicone rubber and fluorine-contained rubber may be utilized. Among them, the silicone rubber is preferably used owing to its excellent heat resistance, cold resistance, chemical resistance, aging resistance, electric insulation and safety. The elastomer may be blended with a conductive substance like a powder (flakes, small pieces, foils, etc. are allowable) of a metal such as gold, silver, copper, nickel, tungsten, platinum, palladium or any other pure metal, SUS, phosphor bronze or beryllium copper, or a nonmetallic powder (flakes, small pieces, foils, etc. can be utilized) such as carbon powder to obtain a conductive elastomer. Here, carbon may include carbon nano-tube and fullerene.
[0030] The nonconductive elastomer stands for elastomer without conductivity or having a very low conductivity, or elastomer having a sufficiently high electric resistance. By way of example, butadiene copolymers such as natural rubber, polyisoprene rubber, butadiene/styrene, butadiene/acrylonitrile, butadiene/isobutylene, conjugated diene rubber and hydrogenated compounds thereof; block copolymer rubbers such as styrene/butadiene/diene block copolymer rubber, styrene/isoprene block copolymer, and hydrogenated compounds thereof; and chloroprene copolymer, vinyl chloride/vinyl acetate copolymer, urethane rubber, polyester rubber, epichlorohydrin rubber, ethylene/propylene copolymer rubber, ethylene/propylene/diene copolymer rubber, soft liquid epoxy rubber, silicone rubber and fluorine-contained rubber may be employed. Among them, the silicone rubber is preferably used owing to its excellent heat resistance, cold resistance, chemical resistance, aging resistance, electric insulation and safety. The nonconductive elastomer usually has high volume resistivity (e.g., not smaller than 1 MΩ-cm at 100 V) and is nonconductive.
[0031] In order to chemically bond the conductive elastomer and the nonconductive elastomer, a coupling agent may be applied between them. The coupling agent is an agent for coupling these members, and may include an adhesive commercially available. By way of example, coupling agents of the types of silane, aluminum and titanate may be utilized. Among them, a silane coupling agent is favorably used.
[0032] In the anisotropic conductive sheet of the present invention, it may be characterized in that the conductive members are protruded as compared to the nonconductive matrix. “Protruding” refers to a case where the portion of the conductive member is thicker than the portion of the nonconductive matrix in the thickness direction of the anisotropic sheet, a case where the position of the upper surface of the nonconductive matrix is lower than the position of the upper surface of the conductive member when the anisotropic conductive sheet is horizontally placed, and/or a case where the position of the lower surface of the nonconductive matrix is higher than the position of the lower surface of the conductive member when the anisotropic conductive sheet is horizontally placed. Then, the electric contact becomes more reliable to the electronic parts and to the terminals of the substrate. This is because the terminals, first, come in contact with the conductive members as they approach the sheet such that a suitable degree of contact pressure is maintained due to the pushing force to the sheet.
[0033] A method of manufacturing an anisotropic conductive sheet according to the present invention comprises: a step of adhering conductive auxiliary layers on the surface of a conductive sheet (A) made of conductive material to obtain a conductive sheet (A) with the conductive auxiliary layers; a step of alternately laminating the conductive sheet (A) with the conductive auxiliary layers obtained in the step of adhering the layers and a nonconductive sheet (B) to obtain an AB sheet laminate (C); a first step of cutting the AB sheet laminate (C) obtained in the step of obtaining the AB sheet laminate to obtain a zebra-like sheet in a predetermined thickness; a step of alternately laminating the zebra-like sheet obtained in the first cutting step and a nonconductive sheet (D) to obtain a zebra-D (ZD) sheet laminate (E); and a second step of cutting the ZD sheet laminate (E) with a predetermined thickness obtained in the step of obtaining the ZD sheet laminate.
[0034] Here, the conductive sheet (A) may be a sheet member of a single kind or a collection of sheet members of different kinds. For example, the conductive sheet (A) may be a collection of sheet members of the same material but having different thicknesses. In the step of adhering the conductive auxiliary layers onto the surface of the conductive sheet member made of the conductive material, the conductive auxiliary layers may be adhered onto one surface or both surfaces of the sheet members. The conductive auxiliary layers can be adhered by any one of the vapor phase method, liquid phase method or solid phase method or by a combination thereof. Among them, the vapor phase is particularly preferred. As the vapor phase method, there can be exemplified PVD such as sputtering method and vacuum evaporation, and CVD. When the conductive auxiliary layer is constituted by the adhesive layer and the conductive layer, the respective layers may be adhered with the same method or with different methods.
[0035] The conductive sheet (A) with the conductive auxiliary layer and the nonconductive sheet (B) may be the sheet members of a single kind as described above or may be collections of sheet members of different kinds. Alternate stacking may mean that the conductive sheet (A) with the conductive auxiliary layer and the nonconductive sheet (B) are alternately stacked in any order, which, however, does not exclude interposing a third sheet, a film or any other members between the conductive sheet (A) with the conductive auxiliary layer and the nonconductive sheet (B). In the step of stacking the sheet members, further, a coupling agent may be applied among the sheets so that the sheets are coupled together. The AB sheet laminate (C) prepared by stacking may be heated in order to promote curing of the sheet members themselves for increasing the coupling among the sheets or for any other purposes.
[0036] The AB sheet laminate (C) can be cut with a blade such as a cemented carbide cutter blade or a ceramic cutter blade, with a grindstone such as a fine cutter, with a saw, or with any other cutting devices or cutting instruments (which may include a cutting device of the non-contact type, such as laser cutter). In the step of cutting, further, there may be used a cutting fluid such as a cutting oil to prevent over-heating, to obtain finely cut surfaces or for any other purpose, or a dry cutting may be employed. Further, the object (e.g., work) to be cut may be cut alone or by being rotated together with the cutting machine or instrument. It needs not be pointed out that a variety of conditions for cutting are suitably selected to meet the AB sheet laminate (C). To cut with a predetermined thickness may mean to cut the block to obtain a sheet member having a predetermined thickness. The predetermined thickness needs not be uniform but may vary depending upon the places of the sheet member.
[0037] The step of obtaining the ZD sheet laminate (E) by alternately stacking the zebra-like sheet and the nonconductive sheet (D) is the same as the step of obtaining the AB sheet laminate (C) from the conductive sheet (A) and the nonconductive sheet (B). Further, the second step of cutting the ZD sheet laminate (E) in a predetermined thickness is the same as the first step of cutting the AB sheet laminate (C).
BRIEF DESCRIPTION OF THE DRAWINGS
[0038] FIG. 1 is a perspective view with partially broken portions of an anisotropic conductive sheet according to an embodiment of the present invention, in which different patterns are shown across the broken surfaces.
[0039] FIG. 2 is an enlarged view with partially broken portions of the upper left portion of the anisotropic conductive sheet in FIG. 1 according to an embodiment of the present invention.
[0040] FIG. 3 shows a conductive sheet with a conductive auxiliary layer as being related to a method of manufacturing an anisotropic conductive sheet according to the embodiment of the present invention.
[0041] FIG. 4 shows another conductive sheet with a conductive auxiliary layer as being related to a method of manufacturing an anisotropic conductive sheet according to the embodiment of the present invention.
[0042] FIG. 5 shows a further conductive sheet with a conductive auxiliary layer as being related to a method of manufacturing an anisotropic conductive sheet according to the embodiment of the present invention.
[0043] FIG. 6 illustrates a step of laminating conductive sheets with the conductive auxiliary layer and nonconductive sheets as being related to a method of manufacturing an anisotropic conductive sheet according to the embodiment of the present invention.
[0044] FIG. 7 illustrates a step of cutting a laminate of the conductive sheets with the conductive auxiliary layer and nonconductive sheets laminated in FIG. 6 as being related to a method of manufacturing an anisotropic conductive sheet according to the embodiment of the present invention.
[0045] FIG. 8 illustrates a step of laminating the sheets cut in FIG. 7 and the nonconductive sheets as being related to, a method of manufacturing an anisotropic conductive sheet according to the embodiment of the present invention.
[0046] FIG. 9 illustrates a step of cutting the laminate obtained in FIG. 8 as being related to a method of manufacturing an anisotropic conductive sheet according to the embodiment of the present invention.
[0047] FIG. 10 is a flowchart illustrating a method of preparing an AB sheet laminate (C) and a zebra-like sheet in the method of manufacturing the anisotropic conductive sheet according to the embodiment of the present invention.
[0048] FIG. 11 is a flowchart illustrating a method of preparing an anisotropic conductive sheet from the zebra-like sheet and the like in the method of manufacturing the anisotropic conductive sheet according to the embodiment of the present invention.
[0049] FIG. 12 is a plan view of an anisotropic conductive sheet according to another embodiment of the present invention.
[0050] FIG. 13 is a sectional view along A-A of the anisotropic conductive sheet according to the embodiment of the present invention shown in FIG. 12 .
[0051] FIG. 14 is a sectional view along B-B of the anisotropic conductive sheet according to the embodiment of the present invention shown in FIG. 12 .
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0052] The present invention will now be described in further detail by way of embodiments with reference to the drawings. However, the embodiments are simply to illustrate concrete materials and numerical values as preferred examples of the present invention, but are not to limit the present invention.
[0053] FIG. 1 illustrates an anisotropic conductive sheet 10 according to an embodiment of the present invention. A Cartesian coordinate system XYZ of the anisotropic conductive sheet 10 is illustrated at a left upper part. The anisotropic conductive sheet 10 of this embodiment is a rectangular sheet member but may be a sheet member of a shape other than the rectangular shape. The anisotropic conductive sheet 10 has a constitution in which there are alternately arranged nonconductive strip-like members 12 and strip-like members 14 of a striped pattern having conductive pieces 24 , 28 and nonconductive pieces 22 , 26 that are alternately arranged. The nonconductive strip-like members 12 and the strip-like members 14 of the striped pattern adjoining each other are coupled by a coupling agent. The strip-like members 14 of the striped pattern are constituted by nonconductive pieces 22 , 26 , conductive pieces 24 , 28 , and conductive auxiliary layers 25 , 29 in contact with the conductive pieces 24 , 28 . The members made of the nonconductive material constitute the nonconductive matrix, and the members made of the conductive material constitute conductive portions. When the conductive portions are scattering, the scattering conductive portions are obtained. Therefore, the scattered conductive portions exist in the nonconductive matrix in a scattered manner. In the anisotropic conductive sheet of this embodiment, the conductive elastomer is a conductive silicone rubber manufactured by Shin-etsu Polymer Co., the nonconductive elastomer is a silicone rubber manufactured by Mitsubishi Jushi Co. or a silicone rubber manufactured by Shin-etsu Polymer Co., and the coupling agent is a silane coupling agent manufactured by Shin-etsu Polymer Co. Here, if a metal material is used as the conductive auxiliary layer, then, it may be called metal layer.
[0054] FIG. 1 illustrates, on the left lower portion thereof, the anisotropic conductive sheet according to another embodiment with the broken surface as a boundary. The constitution of this embodiment is the same as that of the above embodiment except that the conductive auxiliary layers are adhered on both sides of the conductive pieces. For instance, conductive auxiliary layers 503 and 505 are adhered on both sides of the conductive piece 504 to improve the conductivity in the direction of thickness of the sheet.
[0055] FIG. 2 is a view illustrating on an enlarged scale the left upper corner portion of FIG. 1 , i.e., illustrates the strip-like members 12 and 14 in further detail. The strip-like members 12 made of the nonconductive members of FIG. 1 correspond in FIG. 2 to strip-like members 20 , 40 , etc. As for the strip-like members 14 of the striped pattern of FIG. 1 , the strip-like member including nonconductive pieces 22 , 26 , 30 - - - , conductive pieces 24 , 28 - - - and conductive auxiliary layers 25 , 29 , - - - corresponds to the strip-like member including nonconductive pieces 42 , 46 - - - , conductive pieces 44 - - - and conductive auxiliary layers 45 - - - . Namely, the nonconductive strip-like member 20 is neighbored by a strip-like member including nonconductive pieces 22 , 26 , - - - , conductive pieces 24 , 28 , - - - and conductive auxiliary layers 25 , 29 , - - - which is further neighbored by a nonconductive strip-like member 40 , and is further neighbored by a strip-like member including nonconductive pieces 42 , 46 , - - - , conductive pieces 44 , - - - and conductive auxiliary layers 45 , - - - . In this embodiment, the strip-like members have substantially the same thickness (T). The two strip-like members which are neighboring as described above are coupled together with the coupling agent. The conductive pieces with the conductive auxiliary layers and the nonconductive pieces that are neighboring to constitute the strip-like members 14 of the striped pattern, too, are coupled with the coupling agent to constitute a piece of sheet as shown in FIG. 1 . Here, the coupling agent is nonconductive, and the sheet maintains the non-conductivity in the direction of a plane.
[0056] The conductive auxiliary layer 25 at the extreme left upper position is constituted by adhesive layers 242 , 246 having thicknesses 1 t 21-1 and 1 t 21-3 and by a conductive layer 244 having a thickness 1 t 21-2 . Similarly, other conductive auxiliary layers 29 , 45 are constituted by adhesive layers 282 , 286 , conductive layer 284 , adhesive layers 442 , 446 and conductive layer 444 . In this embodiment, the adhesive layers are arranged on both sides of the conductive layer. In other embodiments, however, the adhesive layer may be arranged on either side only. It is, however, desired that the adhesive layer is between the conductive member and the conductive layer. The adhesive layer in this embodiment is constituted by the indium tin oxide, and the conductive layer is constituted by a copper alloy. In other embodiments, however, they may be replaced by other materials. These layers are formed by sputtering as will be described later.
[0057] The nonconductive strip-like members 20 , 40 , - - - have widths t 31 , t 32 , t 33 , - - - , t 3k (k is a natural number), and the strip-like members 14 of the striped pattern have widths t 41 , - - - , t 4k (k is a natural number). In this embodiment, these widths are all the same. In other embodiments, however, the widths may be all the same or may be all different. These widths can be easily adjusted in the method of producing the anisotropic conductive sheet of the embodiment that will be described later. Further, the strip-like members 14 of the striped pattern are constituted by nonconductive pieces 22 , 26 , 30 , 34 , - - - , 42 , 46 , 50 , 54 , - - - having lengths 1 t 11 , 1 t 12 , 1 t 13 , - - - , 1 t 1m (m is a natural number); 2 t 11 , 2 t 12 , 2 t 13 , - - - , 2 t 1n (n is a natural number), conductive pieces 24 , 28 , 32 , - - - , 44 , 48 , - - - having lengths 1 t 21 , 1 t 22 , 1 t 23 , - - - , 1 t 2m (m is a natural number); 2 t 21 , 2 t 22 , 2 t 23 , - - - , 2 t 2n (n is a natural number), and conductive auxiliary layers 25 , - - - . In this embodiment, the lengths of these nonconductive pieces and conductive pieces are all the same. In other embodiments, however, the lengths may all be the same or may be all different. These lengths can be easily adjusted in the method of producing the anisotropic conductive sheet of the embodiment that will be described later. In this embodiment, the conductive pieces in the strip-like members of the striped pattern have a length of about 50 μm, the nonconductive pieces have a length of about 30 μm, the strip-like members of the striped pattern have a width of about 50 μm and the nonconductive strip-like members have a width of about 50 μm. In other embodiments, however, the lengths may be longer (or larger) or shorter (or smaller), as a matter of course.
[0058] The extreme left upper conductive auxiliary layer 25 in this embodiment is constituted by the adhesive layer 242 in contact with the conductive piece 24 , the conductive layer 244 in contact with the adhesive layer 242 , and the adhesive layer 246 in contact with the conductive layer 244 , the adhesive layer 246 being in contact with the nonconductive piece 26 . As will be described later, the conductive auxiliary layers of this embodiment are formed by sputtering. By using the conductive piece 24 as a base plate, the indium tin oxide is, first, deposited like a film, a copper alloy is deposited next like a film and, then, the indium tin oxide is deposited like a film. In this embodiment, the boundaries of the layers are emphasized relatively clearly. However, the gradient of concentration may be mildly formed in the step of sputtering.
[0059] In this embodiment, the adhesive layer 242 has a thickness of about 500 angstroms, the conductive layer 244 has a thickness of about 5000 angstroms, and the next adhesive layer 246 has a thickness of about 500 angstroms. Therefore, the conductive auxiliary layer has a thickness of about 6000 angstroms. In other embodiments, however, these thicknesses may be freely varied, as a matter of course. In the foregoing was described the extreme left upper conductive auxiliary layer 25 of the embodiment. However, the same also holds for other conductive auxiliary layers 25 , 29 , - - - .
[0060] In general, it is desired that the conductive auxiliary layer is thinner than the length (e.g., 1 t 21 ) of the conductive piece, more preferably, thinner than {fraction (1/10)} thereof and, particularly preferably, thinner than {fraction (1/50)} thereof. When the length of the conductive piece is as great as 0.1 mm or more, it is desired that the conductive auxiliary layer has a thickness of not larger than 10 μm.
[0061] In the case of this embodiment, the recurring distance is a value obtained by adding up the lengths of the two neighboring elastomers of different kinds, which is divided by 2, i.e., [( k t 1m + k t 2m )/2] or [( k t 1m + k t 2(m-1) )/2](k and m are natural numbers). Here, the thickness of the adhesive layer has not been taken into consideration. This is because the thickness is usually very small as compared to their lengths (when great, it is desired that the thickness is also taken into consideration). As for the whole anisotropic conductive sheet, an average value of these values may be used, a minimum value may be used, or a minimum value or an average value of a required place of the sheet may be used. When the average value is used, the sheet as a whole exhibits fine pitch performance. When the minimum value is used, a minimum gap between the terminals that can be guaranteed is defined. When the conductive elastomer is arranged relatively uniformly, further, the frequency of appearance of the conductive elastomer per a predetermined length may be used or the cumulative length of the conductive elastomer may be used in the strip-like members of the striped pattern. In this embodiment, the recurring distance is about 40 μm even if an average value or a minimum value is used, and the cumulative length of the conductive elastomer per a unit length is about 0.6 mm/mm.
[0062] The size of the anisotropic conductive sheet of this embodiment can be clearly indicated by adding up the widths and lengths described above. However, there is no limitation on the width or on the length and there is no limitation, either, on the thickness T. When used for connecting the circuit board to the terminals of the electronic parts, however, it is desired that the size matches with these sizes. In this case, the sizes are, usually, 0.5 to 3.0 cm×0.5 to 3.0 cm and 0.5 to 2.0 mm in thickness.
[0063] A method of manufacturing the anisotropic conductive sheet of the above embodiment will now be described with reference to FIGS. 3 to 9 . FIG. 3 , illustrates a conductive sheet 71 having a conductive auxiliary layer 250 adhered on the upper side thereof. The conductive auxiliary layer 250 can be adhered by various methods but is adhered by sputtering in this embodiment. Namely, the conductive sheet 71 is used as a base plate, a target is adjusted to meet the components of the conductive auxiliary layer to be prepared, and the conductive auxiliary layer is adhered by using a sputtering device. The conductive sheet of this embodiment is a conductive elastomer, and contrivance should be so made that the substrate temperature is not excessively elevated. For instance, there is used a magnetron or ion beam sputtering.
[0064] FIG. 4 illustrates, on the left side thereof, the conductive sheet 71 with the conductive auxiliary layer 250 adhered on the upper side thereof partly being broken away. In this embodiment, the conductive auxiliary layer is constituted by the adhesive layers 252 , 256 and the conductive layer 254 ; i.e., the adhesive layer 256 is formed on the conductive sheet 71 and, then, the conductive layer 254 is formed and, finally, the adhesive layer 252 is formed. On the right side of FIG. 4 , the conductive auxiliary layers are similarly adhered to both sides of the conductive sheet. This constitution enables the effect of the conductive auxiliary layers to be further exhibited. The above sheet member can be prepared by simultaneously adhering the conductive auxiliary layers onto both sides. Usually, however, one surface (e.g., conductive auxiliary layer 250 ) is, first, treated and is turned front side back, followed by the adhesion of the conductive auxiliary layer 290 on the other surface. The conductive auxiliary layer 290 adhered onto the other surface, too, is constituted by the adhesive layers 292 , 296 and the conductive layer 294 . The conductive auxiliary layer is to improve electric characteristics of the conductive sheet 71 and is, desirably, electrically contacted to the conductive sheet 71 . The adhesive layers 256 and 292 are not to simply improve mechanical adhesion but also work to help electrical contact to the conductive layers 254 and 294 .
[0065] FIG. 5 is a view illustrating, partly in a cut-away manner, the conductive sheet 71 to which the conductive auxiliary layers 251 and 291 are adhered without adhesive layer. The left side of FIG. 5 is an embodiment in which the conductive auxiliary layer 251 is formed on the upper side only of the conductive sheet 71 , and the right side is an embodiment in which the conductive auxiliary layers 251 and 291 are adhered to both sides of the conductive sheet 71 . In this embodiment, the structure is simpler than that of the case of FIG. 4 , and the steps of manufacturing can be decreased. The conductive auxiliary layers 251 and 291 should be made of a material used for the conductive layers.
[0066] Referring to FIG. 6 , there are provided conductive sheets (A) 70 with a conductive auxiliary layer and nonconductive sheets (B) 80 , from which the sheet members are alternately stacked to prepare an AB sheet laminate (C) 90 . On the AB sheet laminate (C) 90 being stacked, there are further stacked the nonconductive sheet (B) 82 and the conductive sheet (A) 72 with the conductive auxiliary layer further thereon. A coupling agent is applied among these sheet members so that the sheet members are coupled together. The nonconductive sheet (B) 83 is arranged at the lowest part of the AB sheet laminate (C) 90 which is being stacked. It should be noted that the thickness of this sheet member corresponds to 1 t 11 in FIGS. 1 and 2 , the thickness of the conductive sheet (A) 73 just thereon corresponds to 1 t 21 in FIG. 2 , and the thicknesses of the sheet members 84 , 74 , 85 , 75 correspond, respectively, to the lengths of the conductive pieces 24 , 28 and nonconductive pieces 22 , 26 in FIG. 2 . That is, lengths of the nonconductive piece and of the conductive piece with the conductive auxiliary layer in the strip-like member 14 of the striped pattern in FIGS. 1 and 2 can be freely varied by varying the thickness of these sheet members. Similarly, lengths of the conductive pieces and of the nonconductive pieces of the members of the strip-like member of the striped pattern sandwiched between the nonconductive strip-like members 40 , correspond to the thickesses of the corresponding nonconductive sheet (B) and the conductive sheet (A). Usually, as fine pitches, these thicknesses are not larger than about 80 μm and are, more, preferably, not larger than about 50 μm. In this embodiment, the thicknesses are so adjusted that the nonconductive pieces have a length of about 30 μm and the conductive pieces have a length of about 50 μm.
[0067] To alternately stack the conductive sheets (A) and nonconductive sheets (B), the conductive sheets (A) may be continuously stacked in two or more pieces and, then, the nonconductive sheets (B) may be stacked in one or more pieces. The present invention may further include continuously stacking two or more pieces of nonconductive sheets (B) and, then, stacking one or more pieces of conductive sheets (A) alternately.
[0068] FIG. 7 illustrates a first step of cutting the AB sheet laminate (C) 92 obtained by the step of obtaining the AB sheet laminate. The AB sheet laminate (C) 92 is cut along a cutting line 1 - 1 such that the thickness of the obtained zebra-like sheet 91 has a desired thickness t 4k (k is a natural number). This thickness t 4k corresponds to t 41 and t 42 in FIG. 2 . Thus, the widths of the strip-like members 14 of the striped pattern in FIGS. 1 and 2 can be freely adjusted, and may all have the same width of different widths. Usually, the widths are not larger than about 80 μm and, more desirably, not larger than about 50 μm. In this embodiment, the widths are about 50 μm.
[0069] FIG. 8 illustrates the preparation of the zebra-D sheet laminate (E) by alternately laminating the zebra-like sheet 93 prepared in the above step and the nonconductive sheet (D) 80 . On the zebra-D sheet laminate (E) 100 being stacked, there are further stacked the nonconductive sheet 84 and the zebra-like sheet 94 thereon. A coupling agent is applied among these sheet members so that the sheet members are coupled together. The nonconductive sheet (B) 87 is arranged at the lowest part of the zebra-D sheet laminate (E) 100 which is being stacked. It should be noted that the thickness of this sheet member corresponds to t 31 which is the width of the nonconductive strip-like member 12 in FIG. 2 , the thickness of the sheet member 97 just thereon corresponds to t 41 in FIG. 2 , and the thicknesses of the sheet members 89 , 99 correspond, respectively to t 32 . etc. in FIG. 2 . That is, widths of the two kinds of strip-like members 12 and 14 in FIGS. 1 and 2 can be freely varied by varying the thickness of these sheet members. Usually, as fine pitches, these thicknesses are not larger than about 80 μm and are, more, preferably, not larger than about 50 μm. In this embodiment, the thicknesses are so adjusted that the nonconductive strip-like members 12 have a width of about 30 μm and the strip-like members 14 of the striped pattern have a width of about 50 μm.
[0070] FIG. 9 illustrates the step of cutting the zebra-D sheet laminate (E) 102 obtained through the step of obtaining the zebra-D sheet laminate. The laminate 102 is cut along a cutting line 2 - 2 such that the obtained anisotropic conductive sheet 104 will have a desired thickness T. Therefore, this makes it easy to prepare a thin anisotropic conductive sheet and a thick anisotropic conductive sheet which are usually difficult to obtain. Though the thickness is usually about 1 mm, the thickness can be decreased to be about 100 μm (or not larger than about 50 μm when particularly desired) or can be increased to be about several millimeters. In this embodiment, the thickness is selected to be about 1 mm.
[0071] FIGS. 10 and 11 are flowcharts illustrating a method of manufacturing the above anisotropic conductive sheet. FIG. 10 illustrates steps of preparing the zebra-like sheet. First, the conductive auxiliary layer is adhered on the conductive sheet (A)(S- 01 ). In this embodiment, the conductive auxiliary layer is formed by sputtering on one surface only of the conductive sheet. The conductive sheet (A) with the conductive auxiliary layer is stocked for use in the next step (S- 02 ). Next, the nonconductive sheet (B) is placed at a predetermined position for stacking (S- 03 ). Optionally, the coupling agent is applied onto the nonconductive sheet (B)(S- 04 ). This step may be omitted, as a matter of course, since it is optional (the same holds hereinafter). The conductive sheet (A) with the conductive auxiliary layer is placed thereon (S- 05 ). Check if the thickness (or height) of the stacked AB sheet laminate (C) is reaching a desired thickness (or height)(S- 06 ). If the desired (predetermined) thickness has been reached, the routine proceeds to the first step of cutting (S- 10 ). If the desired (predetermined) thickness has not been reached, the coupling agent is optionally applied onto the conductive sheet (A)(S- 07 ). The nonconductive sheet (B) is placed thereon (S- 08 ). Check if the thickness (or height) of the stacked AB sheet laminate (C) is reaching a desired thickness (or height)(S- 09 ). If the desired (predetermined) thickness has been reached, the routine proceeds to the first step of cutting (S- 10 ). If the desired (predetermined) thickness has not been reached, the routine returns back to step S- 04 where the coupling agent is optionally applied onto the conductive sheet (A). At the step of cutting (S- 10 ), the zebra-like sheet is cut out piece by piece or in a plurality of number of pieces at one time, and the zebra-like sheets are stocked (S- 11 ).
[0072] FIG. 11 illustrates steps of preparing an anisotropic conductive sheet from the zebra-like sheet and the nonconductive sheet (D). First, the nonconductive sheet (D) is placed on a predetermined position for stacking (S- 12 ). Optionally, the coupling agent is applied onto the nonconductive sheet (D)(S- 13 ). The zebra-like sheet is placed thereon (S- 14 ). Check if the thickness (or height) of the stacked zebra-D sheet laminate (E) is reaching a desired thickness (or height)(S- 15 ). If the desired (predetermined) thickness has been reached, the routine proceeds to the second step of cutting (S- 19 ). If the desired (predetermined) thickness has not been reached, the coupling agent is optionally applied onto the zebra-like sheet (S- 16 ). The nonconductive sheet (D)is placed thereon (S- 17 ). Check if the thickness (or height) of the zebra-D sheet laminate (E) is reaching a desired thickness (or height)(S- 18 ). If the desired (predetermined) thickness has been reached, the routine proceeds to the second step of cutting (S- 19 ). If the desired (predetermined) thickness has not been reached, the routine returns back to step S- 13 where the coupling agent is optionally applied onto the nonconductive sheet (D). At the second step of cutting (S- 19 ), the anisotropic sheet is cut out piece by piece or in a plurality of number of pieces at one time.
[0073] FIGS. 12, 13 and 14 illustrate another embodiment. In this embodiment, an anisotropic conductive sheet 110 is prepared according to the above method by using conductive sheets that have been cured and nonconductive sheets that have not been cured. FIGS. 13 and 14 are sectional views of the anisotropic conductive sheet 110 along the lines A-A and B-B. As will be understood from these drawings, the conductive pieces 124 , 128 , 132 and 148 with the conductive auxiliary layer are protruded on the surface of the sheet to be higher than the nonconductive pieces 122 , 126 , 130 , 134 , 120 , 140 and 160 offering improved reliability of contact. This form is assumed since uncured rubber has contracted due to the heating. Here, the conductive elastomer has been cured and the nonconductive elastomer has not been cured. The uncured nonconductive elastomer can be adhered to the cured elastomer by heating or the like. In the above manufacturing method, therefore, the optional coupling agent needs not necessarily be added and may be omitted from the steps.
[0074] As described above, the anisotropic conductive sheet of the present invention has the effect of not only maintaining insulation in the direction of the plane while exhibiting satisfactory conductivity in the direction of thickness but also enabling the sizes such as lengths of the nonconductive pieces and conductive pieces to be freely set to easily accomplish fine pitches desired for achieving a high degree of integration. When the conductive auxiliary layer penetrating through in the direction of thickness is directly exposed on the front surface and on the back surface, it is considered that the conductivity becomes particularly high. Further, since the conductive members and nonconductive members are chemically bonded together (crosslinking of rubber), the conductive portions do not slip out which, otherwise, tend to occur when a linear metal is used as conductive portions. Besides, the conductive pieces are necessarily surrounded by the nonconductive pieces avoiding contact caused by the approach/contact of conductive particles of a metal in the direction of plane of the anisotropic conductive sheet in which conductive particles are mixed.
|
An anisotropic conductive sheet interposed between a circuit board such as a substrate and various circuit parts to render them conductive and its manufacturing method. The anisotropic conductive sheet has a fine pitch required by the recent highly integrated circuit boards and electronic parts. In the anisotropic conductive sheet in which conductive members are scattered in a nonconductive matrix, the conductive members (e.g., 24 ) penetrate through the sheet ( 10 ) in the direction of thickness and conductive auxiliary layers (e.g., 25 ) are in contact with the conductive members (e.g., 24 ).
| 8
|
CROSS-REFERENCE TO RELATED APPLICATIONS
The present application is a continuation-in-part of co-pending U.S. patent application Ser. No. 12/684,479, entitled “Wave Anchor Soil Reinforcing Connector and Method,” which was filed on Jan. 8, 2010, the contents of which are incorporated herein by reference in their entirety.
BACKGROUND OF THE DISCLOSURE
Retaining wall structures that use horizontally positioned soil inclusions to reinforce an earth mass in combination with a facing element are referred to as Mechanically Stabilized Earth (MSE) structures. MSE structures can be used for various applications including retaining walls, bridge abutments, dams, seawalls, and dikes. Basic MSE technology involves a repetitive process by which layers of backfill and several horizontally placed soil reinforcing elements are sequentially positioned one atop the other until a desired height of the earthen structure is achieved.
Illustrated in FIG. 1 is a typical soil reinforcing element 100 that can be used in the construction of an MSE structure. The soil reinforcing element 100 generally includes a welded wire grid having a pair of longitudinal wires 102 that are disposed substantially parallel to each other. The longitudinal wires 102 are joined to a plurality of transverse wires 104 in a generally perpendicular fashion by welds or other attachment means at their intersections, thus forming the welded wire grid. In some applications, there may be more that two longitudinal wires 102 . The longitudinal wires 102 may have lead ends 106 that generally converge toward one another, as illustrated, and terminate at a wall end 108 . In other applications, however, the lead ends 106 do not converge, but instead terminate substantially parallel to one another. Backfill material and a plurality of soil reinforcing elements 100 are then combined and compacted sequentially to form a solid earthen structure taking the form of a standing earthen wall.
The wall end 108 of each soil reinforcing element 100 may include several different connective means adapted to connect the soil reinforcing element 100 to a substantially vertical facing 110 , such as a wire facing, or concrete or steel facings constructed a short distance from the standing earthen wall. Once appropriately secured to the vertical facing 110 and compacted within the backfill, the soil reinforcing element 100 provides tensile strength to the vertical facing 110 that significantly reduces any outward movement and shifting thereof.
The longitudinal wires 102 of the soil reinforcing element 100 may extend several feet into the backfill before terminating at corresponding reinforcing ends 112 . Where added amounts of tensile resistance are required, longer soil reinforcing elements 100 are required, thereby disposing the reinforcing ends 112 even deeper into the backfill. Single soil reinforcing elements 100 , however, often cannot be manufactured to the lengths required to adequately reinforce the vertical facing 110 , nor could such soil reinforcing elements 100 of extended lengths be safely or feasibly transported to job sites.
What is needed, therefore, is a system and method of splicing a soil reinforcing element to extend its length.
SUMMARY OF THE DISCLOSURE
Embodiments of the disclosure may provide a splice for a soil reinforcing element. The splice may include a first wave plate defining one or more first transverse protrusions configured to receive and seat a corresponding number of transverse wires of the soil reinforcing element, and a second wave plate defining one or more second transverse protrusions configured to receive and seat a corresponding number of transverse wires of a grid-strip. The splice may further include a first perforation defined in the first wave plate and a second perforation defined in the second wave plate, and a connective device extensible through the first perforation and the second perforation to couple the first wave plate to the second wave plate, wherein a portion of longitudinal wires of the soil reinforcing element and a portion of longitudinal wires of the grid strip are interposed between the first and second wave plates and are thereby prevented from removal.
Other embodiments of the disclosure may provide a composite soil reinforcing element. The composite soil reinforcing element may include a soil reinforcing element having a first plurality of transverse wires coupled to at least two longitudinal wires, the soil reinforcing element having a wall end and a reinforcing end, a grid-strip having a second plurality of transverse wires coupled to at least two longitudinal wires, the grid-strip having a splicing end, and a splice configured to couple the reinforcing end of the soil reinforcing element to the splicing end of the grid-strip. The splice may include a first wave plate defining one or more first transverse protrusions configured to receive and seat a corresponding number of the first plurality of transverse wires of the soil reinforcing element, and a second wave plate defining one or more second transverse protrusions configured to receive and seat a corresponding number of the second plurality of transverse wires of the grid-strip. The splice for the composite soil reinforcing element may further include a first perforation defined on the first wave plate and a second perforation defined on the second wave plate, and a first connective device extensible through the first perforation and the second perforation to couple the first wave plate to the second wave plate and clamp down on the at least two longitudinal wires of the soil reinforcing element and the at least two longitudinal wires of the grid-strip.
BRIEF DESCRIPTION OF THE DRAWINGS
The present disclosure is best understood from the following detailed description when read with the accompanying Figures. It is emphasized that, in accordance with the standard practice in the industry, various features are not drawn to scale. In fact, the dimensions of the various features may be arbitrarily increased or reduced for clarity of discussion.
FIG. 1 is a plan view of a prior art soil reinforcing element.
FIG. 2A is an isometric view of an exemplary splice, according to one or more aspects of the present disclosure.
FIG. 2B is an exploded view of the exemplary splice shown in FIG. 2A .
DETAILED DESCRIPTION
It is to be understood that the following disclosure describes several exemplary embodiments for implementing different features, structures, or functions of the invention. Exemplary embodiments of components, arrangements, and configurations are described below to simplify the present disclosure; however, these exemplary embodiments are provided merely as examples and are not intended to limit the scope of the invention. Additionally, the present disclosure may repeat reference numerals and/or letters in the various exemplary embodiments and across the Figures provided herein. This repetition is for the purpose of simplicity and clarity and does not in itself dictate a relationship between the various exemplary embodiments and/or configurations discussed in the various Figures. Moreover, the formation of a first feature over or on a second feature in the description that follows may include embodiments in which the first and second features are formed in direct contact, and may also include embodiments in which additional features may be formed interposing the first and second features, such that the first and second features may not be in direct contact. Finally, the exemplary embodiments presented below may be combined in any combination of ways, i.e., any element from one exemplary embodiment may be used in any other exemplary embodiment, without departing from the scope of the disclosure.
Additionally, certain terms are used throughout the following description and claims to refer to particular components. As one skilled in the art will appreciate, various entities may refer to the same component by different names, and as such, the naming convention for the elements described herein is not intended to limit the scope of the invention, unless otherwise specifically defined herein. Further, the naming convention used herein is not intended to distinguish between components that differ in name but not function. Additionally, in the following discussion and in the claims, the terms “including” and “comprising” are used in an open-ended fashion, and thus should be interpreted to mean “including, but not limited to.” All numerical values in this disclosure may be exact or approximate values unless otherwise specifically stated. Accordingly, various embodiments of the disclosure may deviate from the numbers, values, and ranges disclosed herein without departing from the intended scope. Furthermore, as it is used in the claims or specification, the term “or” is intended to encompass both exclusive and inclusive cases, i.e., “A or B” is intended to be synonymous with “at least one of A and B,” unless otherwise expressly specified herein.
Referring to FIGS. 2A and 2B , depicted is an exemplary joint or splice 200 , according to one or more embodiments of the disclosure. The splice 200 may be employed to lengthen the extent of a soil reinforcing element 100 , such as the soil reinforcing element 100 generally described above with reference to FIG. 1 . Extending the length of the soil reinforcing element 100 may prove advantageous where the soil reinforcing element 100 is not long enough to adequately reinforce a vertical facing 110 ( FIG. 1 ) into adjacent backfill (not shown).
As will be appreciated by those skilled in the art, several designs of soil reinforcing elements 100 having numerous connective devices for attaching the soil reinforcing element 100 to a vertical facing 110 can be used without departing from the scope of the disclosure. For example, the soil reinforcing elements and their various connective devices described in co-owned U.S. Pat. Nos. 6,517,293 and 7,722,296 may be used, the contents of these patents are hereby incorporated by reference to the extent not inconsistent with the present disclosure. Other examples of soil reinforcing elements and their exemplary connective devices that may be appropriately used with the splice 200 disclosed herein include co-pending U.S. patent application Ser. Nos. 12/479,448, 12/756,898, 12/818,011, 12/837,347, and 12/861,632 filed on Jun. 5, 2009, Apr. 8, 2010, Jun. 17, 2010, Jul. 15, 2010, and Aug. 23, 2010, respectively, the contents of each application are also hereby incorporated by reference to the extent not inconsistent with the present disclosure.
To effectively extend the length of a soil reinforcing element 100 into adjacent backfill (not shown), the splice 200 may couple one or more grid-strips 202 to the soil reinforcing element 100 . The grid-strip 202 generally extends the length of the soil reinforcing element 100 to the length required for the particular MSE application. Similar to the soil reinforcing element 100 , the grid-strip 202 may include at least two longitudinal wires 204 welded or otherwise attached to a plurality of transverse wires 206 . Although only two longitudinal wires 204 are illustrated, it will be appreciated that the grid-strip 202 may include any number of longitudinal wires 204 without departing from the scope of the disclosure. Once coupled together, the combination of the soil reinforcing element 100 , splice 200 , and grid-strip 202 may be characterized or otherwise typified as a single composite soil reinforcing element, for purposes of reinforcing a vertical facing 110 ( FIG. 1 ).
In one or more embodiments, the transverse wires 206 may be equally-spaced or substantially equally-spaced along the length of the longitudinal wires 204 of the grid-strip 202 . The spacing between each transverse wire 104 of the soil reinforcing element 100 may be the same or substantially the same as the spacing between each transverse wire 206 of the grid-strip 202 . In other embodiments, however, the spacing of the transverse wires 104 , 206 may only need to be equally-spaced at or near the reinforcing end 112 of the soil reinforcing element 100 or a splicing end 214 of the grid-strip. In yet other embodiments, the spacing of the transverse wires 104 , 206 is irregular along the length of the longitudinal wires 102 , 204 , respectively.
The splice 200 may include one or more wave plates, such as a first plate 208 a and a second plate 208 b . In at least one embodiment, the first and second wave plates 208 a,b are mirror images of one another. Each wave plate 208 a,b may include one or more transverse protrusions 210 longitudinally-offset from each other. Each wave plate 208 a,b may further define one or more plate perforations, such as plate perforations 212 a , 212 b , and 212 c , as shown in FIG. 2B . Each transverse protrusion 210 may be configured to receive and/or seat either a transverse wire 104 from the soil reinforcing element 100 or a transverse wire 206 from the grid-strip 202 . Accordingly, in embodiments having two or more transverse protrusions 210 , each protrusion 210 may be spaced a predetermined distance from an adjacent protrusion 210 so as to correspond to the equally-spaced transverse wires 104 , 206 of either the soil reinforcing element 100 or the grid-strip 202 .
In one or more embodiments, one or more transverse wires 104 proximal the reinforcing end 112 of the soil reinforcing element 100 may be coupled to or otherwise seated within the first wave plate 208 a . Likewise, one or more transverse wires 206 proximal a splicing end 214 of the grid-strip 202 may be coupled to or otherwise seated within the second wave plate 208 b . As illustrated, the transverse wires 104 of the soil reinforcing element 100 may be disposed above their respective longitudinal wires 102 , and the transverse wires 206 of the grid-strip 202 may be disposed below their respective longitudinal wires 204 . In other embodiments, however, the relative disposition of the transverse wires 104 , 206 may be reversed without departing from the scope of the disclosure. Furthermore, the longitudinal wires 102 of the soil reinforcing element 100 may be laterally-offset from the longitudinal wires 204 of the grid-strip 202 .
As the plates 208 a,b are brought together, and the corresponding perforations 212 a,b,c of each plate 208 a,b are axially aligned, the transverse wire(s) 104 of the soil reinforcing element 100 may be seated or otherwise received into the transverse protrusions 210 of the first wave plate 208 a , and the transverse wire(s) 206 of the grid-strip 202 may be seated or otherwise received into the transverse protrusions 210 of the opposing second wave plate 208 b . With the corresponding perforations 212 a,b,c generally aligned, the transverse wires 104 of the soil reinforcing element 100 disposed within corresponding transverse protrusions 210 of the first wave plate 208 a may be vertically-offset from the transverse wires 206 of the grid-strip 202 disposed within corresponding transverse protrusions 210 of the second wave plate 208 b.
The splice 200 may be secured by coupling the first wave plate 208 a to the second wave plate 208 b . This can be done in several ways. In at least one embodiment, a connective device 216 , such as a threaded bolt or similar mechanism, may be extended through one or more of the perforations 212 a,b,c defined on each plate 208 . While only two connective devices 216 are shown in FIGS. 2A and 2B , it will be appreciated that any number connective devices 216 may be employed as corresponding to an equal number of perforations 212 defined in the plates 208 a,b . In one embodiment, a single connective device 216 may be employed to couple the first wave plate 208 a to the second wave plate 208 b.
Each connective device 216 may be secured against removal from the splice 200 by threading a nut 218 or similar device onto its end. Furthermore, one or more washers 220 may also be used to provide a biasing engagement with each plate 208 a,b . As can be appreciated, the nut 218 and connective device 216 configuration may be substituted with any attachment methods known in the art. For instance, rebar or any other rigid rod may be used and bent over on each end to prevent its removal from the perforations 212 a,b,c , and thereby provide an adequate coupling mechanism.
Once the splice 200 is made secure, the transverse wires 104 , 206 may be prevented from longitudinally escaping the splice 200 since they are seated in respective transverse protrusions 210 . Tightening the nut(s) 218 onto the bolt(s) 216 , or similar connection device, may clamp down on the longitudinal wires 102 , 204 of the soil reinforcing element 100 and grid-strip 202 , respectively, thereby preventing the soil reinforcing element 100 and/or grid-strip 202 from translating laterally and thereby escaping the splice 200 .
As will be appreciated, any number of splices 200 and grid-strips 202 may be used to extend the length of a single soil reinforcing element 100 and create a composite soil reinforcing element that achieves a desired reinforcing distance from the vertical facing 110 ( FIG. 1 ). For instance, if splicing a first grid-strip 202 to the reinforcing end 112 of the soil reinforcing element 100 does not extend a sufficient distance into the backfill (not shown), a second grid-strip 202 may be spliced to the end of the first grid-strip 202 , and so on until the desired distance is achieved. Accordingly, multiple splices 200 and multiple grid-strips 202 may be used to extend the length of a single soil reinforcing element 100 .
The foregoing has outlined features of several embodiments so that those skilled in the art may better understand the present disclosure. Those skilled in the art should appreciate that they may readily use the present disclosure as a basis for designing or modifying other processes and structures for carrying out the same purposes and/or achieving the same advantages of the embodiments introduced herein. Those skilled in the art should also realize that such equivalent constructions do not depart from the spirit and scope of the present disclosure, and that they may make various changes, substitutions and alterations herein without departing from the spirit and scope of the present disclosure.
|
A system and method of constructing a mechanically stabilized earth (MSE) structure. A wire facing is composed of horizontal and vertical elements. A soil reinforcing element has a plurality of transverse wires coupled to at least two longitudinal wires having lead ends that upwardly-extend. A bearing plate includes one or more longitudinal protrusions configured to receive and seat the upwardly extending lead ends and couple the soil reinforcing element to the wire facing, and in particular to the vertical element. Multiple systems can be characterized as lifts and erected one atop the other to a desired MSE structure height.
| 4
|
RELATED U.S. APPLICATIONS
This is a Continuation-in-Part Application of U.S. patent application Ser. No. 08/182,810, fried Jan. 14, 1994, pending, which is hereby incorporated by reference for all purposes as if fully set forth herein.
TECHNICAL FIELD OF THE INVENTION
The present invention relates to devices and methods that facilitate formulation of posterior palatal seals (PPS) on upper dentures and particularly, to devices and molding processes by which effective PPS may be formed.
BACKGROUND OF THE INVENTION
Millions of people throughout the world, including as many as twenty million Americans are edentulous (toothless) and rely on full dentures for function and esthetics. In fabricating dentures, it is crucial for the dentist to assure that the upper denture is well-fitted and secure. This is important not only in speech and mastication, but also in avoiding the embarrassment of a loose or falling denture.
A secure denture is usually accomplished by the denture adapting well to the gum tissue, and in the case of the upper member of dentures, through the use of a posterior palatal seal (PPS). The combination of a well-fitting denture and a well-fitting PPS will create suction or vacuum once the upper denture is seated in the mouth. A PPS is a thickened posterior portion of the upper denture border extending across the palate from the left to the right maxillary tuberosity. The increased thickness of the denture along a narrow border adds "pressure" on the tissue and maintains a vacuum seal. Without this sealing effect created by the PPS, the upper denture "leaks" (the vacuum between the denture and the roof of the mouth is reduced or lost) and the denture loosens as the wearer talks, chews or swallows.
A PPS is beneficial and considered necessary by many dentists because the border of the upper denture at the posterior palate area rests on the junction between the hard and soft palate. Unless there is additional pressure against that area of the palate, there will be loss of suction during function. Anatomically, the key effective sealing area corresponds to the junction between the hard and soft palate. Among dentists, this is also called the "Ah-Line." In locating how far a denture should extend backwards, the dentist may ask the patient to repeat the "ah" sound. In doing so, the soft palate vibrates and the hard palate does not vibrate so that the demarcation between the soft and hard palate is discernible. This is typically where the denture border will lie. The junction between the hard and soft palate where the denture border lies is neither a straight line nor of uniform consistency. It is harder in the midline and soft on both sides of the midline. A well constructed PPS, therefore, has to reflect the anatomy and features of that part of the mouth.
Presently, the most common method of fabrication of the PPS requires either a dentist or a laboratory technician to carve an indentation channel on a plaster model obtained from an impression of the toothless mouth. The impression material is typically alginate, silicon, zinc oxide-eugenol or a rubber base material. The dentist normally takes an impression of the edentulous mouth and often prepares a plaster (or dental stone) model from the impression by pouring wet plaster onto the impression. Alternatively, the impression is boxed and sent to a dental lab for preparation of a plaster or dental stone model. When the plaster has set hard, it is separated from the impression. Either a dentist or a lab technician then carves an indentation on the plaster model where the PPS will be. The depth of carvings for the PPS preferably corresponds to the anatomical qualities of the area of the palate mentioned above. That is, to be an effective seal, less must be carved away from the midline where the palate tissue is hard and more on both sides of the midline where the palate tissue is softer. The carved portion is gradually deepened as it reaches the posterior border. If all goes well, the carving results in a "Cupid's Bow" like appearance with the "string" part of the bow at the denture border and the "serpentine bow" towards the front part of the mouth. Shallowest at the "serpentine bow", it deepens going towards the "string" of the bow (at the border of the denture) with the deepest on both sides of the midline and shallower at the midline of this "bow" and also the two ends of this "bow." If the "carver" lacks skill or if short cuts are taken, a simple groove might be carved or a denture might be formed without a PPS of any kind.
Carving methods are taught in practically every dental school and various shapes of PPS are practiced by most denture technicians. The carving method for forming a good PPS is tedious, time-consuming and the results are inconsistent. Some technicians simply carve a trench instead of a bow shape or another approximation of a "Cupid's bow" shape either because it saves time, because they lack a high degree or skill, or because they do not understand oral anatomy and physiology. The method of hand carving a "Cupid's bow" continues to be described and recommended by professors at reputable dental schools and major international journal articles, as for example in Quintessence, Int., 1993; 24: 753-755.
Another less prevalent method of forming a PPS is termed a functional method or a waxing method. This method if currently more tedious and more time-consuming than the carving method. During an impression visit. the dentist applies a wax material on the impression in the poster palatal area of the impression. Again, a Cupid's bow shape provides an effective seal. A special wax is used which liquifies at mouth temperature and solidifies at room temperature. The wax is carefully shaped as by dabbing, brushing or otherwise placing it bit-by-bit and smoothing it onto the impression along the identified "Ah line." The impression is reinserted into the patient's mouth and held for several minutes to allow partial liquification and plastic deformation into and along the actual functional border between the hard and soft palate. The impression is then removed and carefully boxed to ship it to the dental lab for pouring of a plastic or a dental stone mold from which a denture will be molded. The wax must be maintained in a solidified condition during pouring so that a PPS channel will be formed in the mold. This channel in the mold will result in a raised PPS in the molded denture.
The process of forming a PPS on an existing denture has many steps and is time-consuming. The technician has to lubricate the denture; pour up a plaster model onto the denture; separate the model from the denture; carve the needed void for the PPS from the plaster model as described earlier; lubricate the model so that new denture material will not stick to the model; place new denture material into the carved void between the model and the denture; apply pressure so there is intimate contact between the new material and the denture base; wait for chemical bonding and curing of the new material; separate the denture from the model; and smooth and polish it for delivery to wearer.
SUMMARY OF THE INVENTION
The present invention uniquely provides a Preformed Posterior Palatal Seal (Preformed PPS) for use in upper dentures which can be applied onto the denture impression. Methods of applying the Preformed PPS are also provided both for new denture information. In the case of new dentures, the Preformed PPS is preferably soft, pliable and maybe even tacky. This allows the Preformed PPS to be placed on the denture impression taken from the patient's mouth. The location of placement corresponds to the denture border, generally the junction between the soft and hard palate. Immediate placement on the impression advantageously facilitates accurate "on site" location of the Preformed PPS and thus, the resulting PPS.
The shape of the Preformed PPS advantageously corresponds consistently to the quality and anatomy of the oral tissue. Preferably, the Preformed PPS is thinner toward the front of the mouth and thicker at the rear border end. It is also preferably thinner at the mid-palate as human palate tissue is thin and bony and cannot be subjected to undue pressure from too much denture thickness. Thus, the PPS can be shaped like the Cupid's bow consistently. Variations in size and proportion according to size of the roof of the mouth may be accommodated with several sizes of Preformed PPS. The vault form of the individual mouth will be naturally accommodated by the flexibility and pliability of the Preformed PPS.
The human hand used in carving a plaster mold cannot consistently equal what this inventive Preformed PPS can generate without variation. It is an object of the invention to avoid repetitive laborious work in forming a new PPS with each denture. It is another object to obtain a consistently shaped PPS to maximize sealing with every denture created. It is another object to provide a preformed PPS for use with indirect denture impressions. In a flexible form, the Preformed PPS is placed directly onto the denture impression taken from the patient's mouth. The Preformed PPS takes up the space for that part of the model which the technician would otherwise have to carve out of the plaster to create PPS, obviating the need of carvings by hand or time to sculpt a wax seal ridge and to allow it to mold itself as part of the impression, in the patient's mouth. Advantageously, a sufficient flexible preformed PPS can follow the contours of the denture impression so that a consistently uniform sealing pressure is naturally provided. Thus, even though the mouth and the resulting impression has its own contours, the seal raises proportionately in the appropriate places.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other objects, features and advantages of the invention will become more evident with reference to the drawings in which like reference numerals represent like elements and in which:
FIG. 1 is a perspective partially exploded view of an impression tray with an impression thereon for a complete denture with an embodiment of the inventive Preformed PPS shown in position for placement thereon;
FIG. 2 is a top view of the inventive Preformed PPS as used in FIG. 1;
FIG. 3a is a cross-sectional view of a Preformed PPS as in FIG. 2 taken along line 3--3 showing one alternative shape;
FIG. 3b is a cross-sectional view of a Preformed PPS as in FIG. 2 taken along line 3--3 showing another alternative shape;
FIG. 4a is a cross-sectional view of a Preformed PPS as in FIG. 2 taken along line 4--4 showing one alternative shape;
FIG. 4b is a cross-sectional view of a Preformed PPS as in FIG. 2 taken along line 4--4 showing another alternative shape;
FIG. 5a is a cross-sectional view of a Preformed PPS as in FIG. 2 taken along line 5--5 showing one alternative shape;
FIG. 5b is a cross-sectional view of a Preformed PPS as in FIG. 2 taken along line 5--5 showing another alternative shape;
FIG. 6 is a cross-sectional view of the inventive Preformed PPS placed on an impression for complete dentures taken along section line 6--6 of FIG. 1;
FIG. 7 is a cross-sectional view again taken along a center line of a denture impression with a dental stone poured onto the impression;
FIG. 8 is a bottom view of a dental stone model as in FIG. 7 after the stone model is separated from the impression where the inventive preformed PPS had been used;
FIG. 9 is a perspective view of a self-adhesive Preformed PPS which may be applied by denture wearers to temporarily correct a malformed or an otherwise inadequate PPS until a visit to a dentist can be scheduled.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 is a perspective view of a denture impression 10 showing one preferred embodiment of the Preformed PPS designated 20 in preparation to be placed thereon. Prior to taking this denture impression the dentist would fabricate an impression tray 12 which generally fits the contours and borders of the upper part of the edentulous mouth. Prior to taking this denture impression, the dentist would identify the "Ah-line", i.e., the junction between the hard and soft palate. The dentist asks the patient to repeat the sound "Ah", so that the vibration of the soft-palate thus initiated allows identification of the demarcation of the hard and soft palate. A marker generally of indelible ink is used to create a mark or line onto the patient's palate. While the impression is taken, the mark transfers onto the impression material 14. This is where the Preformed PPS 20 is placed so that the border of the Preformed PPS 20 coincides with the marker line 16 transferred thereon the impression material 14 on FIG. 1. Preferably, the Preformed PPS 20 has a body 22 which is in the shape of a "Cupid's bow," which shape has been found to provide a beneficial seal. Other known shapes for PPS could also be reproduced with the inventive Preformed PPS. However, the benefits of a "Cupid's bow" shaped PPS can be easily obtained by the dentist using the inventive Preformed PPS 20 without the additional carving and other steps previously required.
The denture impression 10 obtained with the "Ah-line" 16 identified as shown in FIG. 1 and with the inventive Preformed PPS 20 overlaid is thus made ready for pouring of a dental stone or a plaster, which will set in the dental impression 10. As mouth sizes vary with body size, various sizes of a Preformed PPS will be advantageous to conveniently allow construction of an effective PPS on any size denture. Preferably, three or four properly selected sizes corresponding to child, small, medium and large or other similar designations, as with standard denture molds or impression trays, could be used. The Preformed PPS 20 for this purpose should be of a pliable, flexible material, such as silicone or arginine, for example. A pliable flexible Preformed PPS will follow the contour of the impression so that it adds depth proportionately and a uniform pressure will result in the patient's mouth when a denture is formed using the Preformed PPS. As the impression is wet during handling, the Preformed PPS is preferably constructed to be able to adhere to or at least allow placement onto impression material which may be wet after removal from the patient's mouth. Thus, adhesives capable of adhesion under wet conditions may be used advantageously. In one embodiment, a separate adhesive material may be interposed between the Preformed PPS and the impression or a self-adhesive strip or tape material may be pre-formed or pre-applied directly onto the Preformed PPS. In a further preferred embodiment, the Preformed PPS may be provided with a removable non-stick sheet to prevent inadvertent sticking or it may be stored on a non-stick sheet until it is removed for application directly onto the denture impression.
FIG. 2 shows a "Cupid's-bow" shaped Preformed PPS 20 from top view. A preferred shape of a Preformed PPS of this embodiment corresponds to anatomical features. The body 22 is thicker where the cross-sectional line 4--4 indicates and gradually less thick, both at mid-line, indicated by section lines 5--5 and also at the peripheral ends, represented by section lines 3--3.
Furthermore, the body 22 of the Preformed PPS 20 in the embodiment of FIG. 2 is tapered on side 24 towards the front (the hard-palate side of the seal). However, a rear side 26 towards the posterior denture border (the soft-palate side) is preferably formed at a right angle as shown at 26a by cross-sectional drawings in FIGS. 3a, 4a and 5a, or slightly rounded or slightly tapered according to an alternative embodiment as shown at 26b by cross-sectional drawings in FIGS. 3b, 4b and 5b. A flat base 28 of the Preformed PPS is provided for coming into contact with denture impression 14. Preferably, this base 28 will adhere to the denture impression as described above. The exposed face represented as 30, in both alternatives "a" and "b," is the face which is in contact with dental plaster or dental stone 32 when the impression is "poured" with fluid plaster or dental stone is poured into the impression 10 to form a denture model 34.
FIG. 6 is a cross-sectional view of the Preformed PPS 20 placed onto the denture impression 10. The impression face 28 of the Preformed PPS (shown in FIGS. 3, 4 and 5) goes onto the impression 10 guided by the marker or line 16 indicating the "Ah-line", i.e., the demarcation of the hard and soft palate. The tapered side 24 of the Preformed PPS is positioned toward the front of the denture (the hard-palate side) whereas the denture border side 26 is positioned so that it lies on or near the line 16.
After the Preformed PPS 20 is properly placed and dental stone 32 poured onto the impression 10 and allowed to set, the Preformed PPS 20 takes up the volume and forms a PPS channel 36 which will be occupied by a PPS when it is ultimately incorporated in a completed denture. The denture will be molded using the poured dental stone model 34 as a mold. A hardened denture with an integrally formed PPS results. The resulting raised area of the PPS on the molded denture palate is merely polished and provides increased pressure precisely along the "Ah line", allowing a suction or vacuum to be maintained when the denture is in place in the patient's mouth. The additional thickness is ground and polished off from the bottom so that a smooth, upward transition results. The newly formed denture is thus provided with a permanent PPS, which is defined during molding without the difficulties associated with hand grinding of the dental stone.
Another object is to provide a device for producing equal pressure along the seal, particularly a flexible seal which follows the terrain of the mold so that a consistent amount of pressure results.
FIG. 7 is a cross-sectional view of full denture impression similar to 10 in FIG. 3 where the Preformed PPS 20 is placed properly guided by the marker line 16. The Preformed PPS 28 is adhered to the impression material with an adhesive 38. Preferably, adhesive 38 is of a type which displaces water and adheres to either zinc oxide eugenol impression material or rubber-based impression material, even when it is wet as when it is removed from the patient's mouth after the impression is taken. Here, dental stone 32 is poured and allowed to set.
FIG. 8 is a bottom view (i. e., corresponding to the roof of the patient's mouth) of a dental model 34 similar to the one shown being formed in FIG. 7. Once the stone model 34 is separated from the impression 10, the Preformed PPS 20 has left its impression, void or PPS channel 36 as indicated at 36. The depth and contour of the PPS impression 36 or PPS channel 36 correspond to anatomical features of the mouth as needed for a proper PPS and an effective upper denture seal.
The embodiment shown in FIG. 9 provides one or more Preformed PPS devices having a self-adhesive material applied to the base. The dentist merely removes a Preformed PPS 22 from non-stick sheet 52 and applies it to the dental impression. The body is preferably flexible or pliable so that the Preformed PPS conforms to the contours of the dental impression. Both the adhesive and the body material are water or moisture-resistant so that remaining moisture from the mouth tissues will not interfere with adhesion. The adhesive and the pliable body material are also non-toxic, such as rubber or plastic material. Each Preformed PPS may be provided with its own non-adhesive backing sheet to prevent it from becoming inadvertently adhered before intended. Alternatively, a plurality of Preformed PPS devices may be provided on an enlarged sheet having a non-adhesive or non-stick surface so that individual Preformed PPS devices may be removed and used as needed.
Other alterations and modifications of the invention will likewise become apparent to those of ordinary skill in the art upon reading the present disclosure, and it is intended that the scope of the invention disclosed herein be limited only by the broadest interpretation of the appended claims to which the inventors are legally entitled.
|
A preformed posterior palatal seal (Preformed PPS) for use in preparation of dentures includes a body preformed of a predetermined anatomically based size and shape of a posterior palatal seal (PPS) for sealing a denture at the "Ah line" of the human palate and adhesive for holding the preformed body to a denture impression prior to forming a mold from which a denture is to be formed.
| 0
|
RELATED APPLICATION
This application is a continuation-in-part of commonly-owned U.S. patent application Ser. No. 09/666,096, filed Sep. 21, 2000, now abandoned, entitled “Expandable Graphite and Method”, which in turn is a continuation-in-part of commonly-owned U.S. patent application Ser. No. 09/633,184, filed Aug. 4, 2000, now abandoned, which in turn is a continuation-in-part of commonly-owned U.S. patent application Ser. No. 09/015,590, filed Jan. 29, 1998, now U.S. Pat. No. 6,149,972.
FIELD OF THE INVENTION
This invention relates to intercalated graphite flake having increased exfoliation volume at temperatures as low as 600° C. and even lower.
BACKGROUND OF THE INVENTION
Graphite is a crystalline form of carbon comprising atoms bonded in flat layered planes with weaker bonds between the planes. By treating particles of graphite, such as natural graphite flake, with an intercalant of, e.g., a solution of sulfuric and nitric acid, the crystal structure of the graphite reacts to form a compound of graphite and the intercalant. The treated particles of graphite are hereafter referred to as intercalated graphite flake. Upon exposure to elevated temperatures the particles of intercalated graphite expand in dimension in an accordion-like fashion in the c-direction, i.e. in the direction perpendicular to the crystalline planes of the graphite.
Intercalated graphite flake has many useful applications. A common application is to exfoliate the intercalated graphite particles into vermicular-like structures which are then compressed into sheets of flexible graphite for use in the manufacture of gaskets or as packing material. Intercalated graphite flake is also used in a variety of products which take advantage of the high expansion characteristic of intercalated graphite flake when exposed to high temperature. One such example is for use in combination with polymer foams to form seat cushions and furniture upholstery in aircraft. Upon exposure to fire, the high temperature will cause the particles of intercalated graphite to exfoliate which minimizes or prevents the formation of toxic gases from the polymer foam and may, of itself, smother a fire.
Since it is important to suppress, i.e. retard a fire before it has begun to spread, it would be a substantial advantage for an intercalated graphite flake product to exhibit a very high degree of exfoliation upon exposure to temperatures as low as 600° C. and even lower.
It has been discovered in accordance with the present invention that the addition of an organic expansion aid to the intercalation solution and the treatment of intercalated graphite flake with an organic reducing agent, following intercalation of the graphite flake with an oxidizing intercalant solution, and while the graphite flake is covered with a coating of oxidizing intercalant solution, results in a material which exhibits enhanced exfoliation volumes at exfoliation temperatures as low as 600° C. and even lower.
SUMMARY OF THE INVENTION
The method of the present invention for forming particles of intercalated graphite flake having enhanced exfoliation volume at temperatures as low as 600° C. and even lower by:
(a) adding an organic expansion aid to an oxidizing intercalant solution;
(b) treating particles of graphite with the oxidizing intercalant solution containing the expansion aid to provide intercalated graphite flake with a surface film of oxidizing intercalant solution;
(c) contacting the surface film of the intercalated graphite flake with an organic reducing agent in the form of an organic compound selected from sugars, alcohols, aldehydes and esters which is reactive with the film of oxidizing intercalant solution at temperatures in the range of 25° C. to 125° C.; and
(d) subjecting the thus treated intercalated graphite flake to a temperature in the range of 25° C. to 125° C. to promote a reaction of the organic reducing agent with the surface film of oxidizing solution.
DETAILED DESCRIPTION OF THE INVENTION
Intercalated graphite flake is conventionally formed. by treating particles of natural graphite with agents that intercalate into the crystal structure of the graphite to form a compound of graphite and the intercalant capable of expansion in the c-direction, i.e. the direction perpendicular to the crystalline planes of the graphite, when heated to a high temperature of above 700° C. and preferably above 1000° C. The intercalated graphite flake is washed and dried prior to exfoliation. Exfoliated graphite particles are vermiform in appearance and are commonly referred to as “worms”.
A common conventional method for forming intercalated graphite flake (and for manufacturing sheets of flexible graphite from exfoliated graphite) is described in U.S. Pat. No. 3,404,061 the disclosure of which is incorporated herein by reference. As disclosed in the above mentioned patent natural graphite flake is intercalated by dispersing flakes in a solution containing an oxidizing agent, such as a mixture of nitric and sulfuric acid. After the flakes are intercalated excess solution is drained from the flakes. The quantity of intercalation solution retained on the flakes after draining is typically greater than 100 parts of solution by weight per 100 parts by weight of graphite flakes (pph) and more typically about 100 to 150 pph.
The intercalant of the present invention contains oxidizing intercalating agents known in the art. Examples include those containing oxidizing agents and oxidizing mixtures, such as solutions containing nitric acid, potassium chlorate, chromic acid, potassium permanganate, potassium chromate, potassium dichromate, perchloric acid, and the like, or mixtures, such as for example, concentrated nitric acid and chlorate, chromic acid and phosphoric acid, sulfuric acid and nitric acid, or mixtures of a strong organic acid, e.g. trifluoroacetic acid, and a strong oxidizing agent soluble in the organic acid.
In the preferred embodiment of the invention, the intercalant is a solution of sulfuric acid, or sulfuric acid and phosphoric acid, and an oxidizing agent, i.e. nitric acid, perchloric acid, chromic acid, potassium permanganate, iodic or periodic acids, or the like, and preferably also includes an expansion aid as described below. Although less preferred, the intercalant may contain metal halides such as ferric chloride, and ferric chloride mixed with sulfuric acid, or a halogen, such as bromine as a solution of bromine and sulfuric acid or bromine in an organic solvent.
In accordance with the present invention the particles of graphite flake treated with intercalant are contacted e.g. by blending, with a reducing organic agent selected from alcohols, sugars, aldehydes and esters which are reactive with the surface film of oxidizing intercalating solution at temperatures in the range of 25° C. and 125° C. Suitable specific organic agents include the following: hexadecanol, octadecanol, 1-octanol, 2-octanol, decylalcohol, 1, 10 decanediol, decylaldehyde, 1-propanol, 1,3 propanediol, ethyleneglycol, polypropylene glycol, dextrose, fructose, lactose, sucrose, potato starch, ethylene glycol monostearate, diethylene glycol dibenzoate, propylene glycol monostearate, propylene glycol monooleate, glycerol monostearate, glycerol monooleate, dimethyl oxylate, diethyl oxylate, methyl formate, ethyl formate and ascorbic acid.
Also effective are polyfunctional compounds, e.g., those having both surfactant qualities and more than one reducing function selected from the group consisting of alcohols, esters, aldehydes and the like. One example is lignin-derived compounds, such as sodium lignosulfate. The preferred compounds are preferably liquid at application temperature and essentially free of water. Among the suitable polyfunctional compounds in this group are surfactants derived from ethylene oxide and/or propylene oxide and a compound capable of contributing a hydrophobic group to the compound, e.g., polymers of ethylene oxide and nonylphenol available as Tergitol NP detergents, products formed by the reaction of linear secondary alcohols with ethylene oxide available as Tergitol 15-S- detergents, and various alkylaryl polyether alcohols prepared by the reaction of octylphenol with ethylene oxide as are available as Triton X detergents. Examples are presented below of materials effective as reducing organic agents that can improve both free and compressed expansion.
The amount of organic reducing agent is suitably from about 0.5 to 4% by weight of the the particles of graphite flake. The use of an expansion aid applied prior to intercalation or during intercalation can also provide improvement. Among these improvements can be reduced exfoliation temperature, and increased expanded volume (also referred to as “worm volume”).
An expansion aid in this context will be an organic material sufficiently soluble in the intercalant solution to achieve an improvement in expansion. More narrowly, organic materials of this type that contain carbon, hydrogen and oxygen, preferably exclusively, may be employed. Carboxylic acids have been found effective in this invention. A suitable carboxylic acid as the expansion aid can be selected from aromatic, aliphatic or cycloaliphatic, straight chain or branched chain, saturated and unsaturated monocarboxylic acids, dicarboxylic acids and polycarboxylic acids which have at least 1 carbon atom, and preferably up to about 10 carbon atoms, which is soluble in the aqueous intercalant solution employed according to the invention in amounts effective to provide a measurable improvement of one or more aspects of exfoliation. Preferred products are characterized by an intumescent temperature of below about 200° C. According to some observations, exfoliation can be initiated at temperatures as low as 160°. Suitable water-miscible organic solvents can be employed to improve solubility of an organic expansion aid in the intercalant solution.
Representative examples of saturated aliphatic carboxylic acids are acids such as those of the formula H(CH 2 ) n COOH wherein n is a number of from 0 to about 5, including formic, acetic, propionic, butyric, pentanoic, hexanoic, and the like. In place of the carboxylic acids, the anhydrides or reactive carboxylic acid derivatives such as alkyl esters can also be employed. Representative of alkyl esters are methyl formate and ethyl formate. Sulfuric acid, nitric acid and other known aqueous intercalants have the ability to decompose formic acid, ultimately to water and carbon dioxide. Because of this, formic acid and other sensitive expansion aids are advantageously contacted with the graphite flake prior to immersion of the flake in aqueous intercalant.
Representative of dicarboxylic acids are aliphatic dicarboxylic acids having 2-12 carbon atoms, in particular oxalic acid, fumaric acid, malonic acid, maleic acid, succinic acid, glutaric acid, adipic acid, 1,5-pentanedicarboxylic acid, 1,6-hexanedicarboxylic acid, 1,10-decanedicarboxylic acid, cyclohexane-1,4-dicarboxylic acid and aromatic dicarboxylic acids such as phthalic acid or terephthalic acid. Representative of alkyl esters are dimethyl oxylate and diethyl oxylate. Representative of cycloaliphatic acids is cyclohexane carboxylic acid and of aromatic carboxylic acids are benzoic acid, naphthoic acid, anthranilic acid, p-aminobenzoic acid, salicylic acid, o-, m- and p-tolyl acids, methoxy and ethoxybenzoic acids, acetoacetamidobenzoic acids and, acetamidobenzoic acids, phenylacetic acid and naphthoic acids. Representative of hydroxy aromatic acids are hydroxybenzoic acid, 3-hydroxy-1-naphthoic acid, 3-hydroxy-2-naphthoic acid, 4-hydroxy-2-naphthoic acid, 5-hydroxy-l-naphthoic acid, 5-hydroxy-2-naphthoic acid, 6-hydroxy-2-naphthoic acid and 7-hydroxy-2-naphthoic acid. Prominent among the polycarboxylic acids is citric acid.
The intercalant solution will be aqueous and will preferably contain an amount of expansion aid of from about 1 to 10%, the amount being effective to enhance exfoliation. In the embodiment wherein the expansion aid is contacted with the graphite flake prior to immersing in the aqueous intercalant solution, the expansion aid can be admixed with the graphite by suitable means, such as a V-blender, typically in an amount of from about 0.2% to about 10% by weight of the graphite flake. After intercalating the graphite flake with an intercalating solution, preferably containing an expansion aid, and following the blending of the intercalant coated intercalated graphite flake with the organic reducing agent, the blend is exposed to temperatures in the range of 25° to 125° C. to promote reaction of the reducing agent and intercalant coating. The heating period is up to about 20 hours, with shorter heating periods, e.g., at least about 10 minutes, for higher temperatures in the above-noted range. Times of one half hour or less, e.g., on the order of 10 to 25 minutes, can be employed at the higher temperatures.
EXAMPLE 1
Twenty-five grams of a (+50 mesh) natural graphite flake were intercalated with twenty-five grams of intercalant consisting of 86 parts by weight of 93% sulfuric acid and 14 parts by weight of 67% nitric acid. After mixing for three minutes, 1.0 grams of decanol were blended into the flakes. The flakes were then placed in a 90° C. oven for 20 minutes. The intercalated flakes were then washed with four aliquots of 200 ml of water. After each washing the flakes were filtered by vacuum through a Teflon screen. After the final wash the flakes were dried for 1 hour in a 115° C. oven.
The expansion of the intercalated flakes was measured by placing exactly 1.00 g into a 250 ml crucible. The cold crucible was placed into a 600° C. oven for 2 minutes. The volume and weight of the expanded flakes were measured after carefully funneling them into a 250 ml graduated cylinder. The expansion volume was 222 cc/g.
The expansion or exfoliation volume of the intercalated flakes was also measured by heating the intercalated graphite flakes in a 845° C. preheated metal crucible over a Bunsen burner flame, and measuring the bulk volume of the resulting exfoliated flakes. The volume and weight of the expanded flakes were measured after carefully financing them into a 250 ml graduated cylinder. The expansion volume was 566 cc/g.
Comparative Example 1 (A)
Twenty -five grams of a (+50 mesh) natural graphite flake were intercalated for 20 minutes with 25 grams of intercalant consisting of 86 parts by weight of 93% sulfuric acid and 14 parts by weight of 67% nitric acid. No reducing agent and no external heat and digestion period were applied to the intercalated flakes. The intercalated flakes were then washed with four aliquots of 200 ml of water. After each washing the flakes were filtered by vacuum through a Teflon screen. After the final wash the flakes were dried for 1 hour in a 115° C. oven.
The expansion of the intercalated flakes was measured by placing exactly 1.00 g into a 250 ml crucible. The cold crucible was placed into a 600° C. oven for 2 minutes. The volume and weight of the expanded flakes were measured after carefully funneling them into a 250 ml graduated cylinder. The expansion volume was only 32 cc,/g. The expansion was inferior to that obtained in example (1) since neither a reducing agent nor ,a high temperature digestion period was employed.
The expansion or exfoliation volume of the intercalated flakes was also measured by heating the intercalated graphite flakes in a 845° C. preheated metal crucible over a Bunsen burner flame, and measuring the bulk volume of the resulting exfoliated flakes. The volume and weight of the expanded flakes were measured after carefully funneling them into a 250 ml graduated cylinder. The expansion volume was only 110 cc/g. The expansion was inferior to that obtained in example (1) since neither a reducing agent nor a high temperature digestion period were employed.
Comparative Example 1 (B)
Twenty -five grams of a (+50 mesh) natural graphite flake were intercalated for 3 minutes with 25 grams of intercalant consisting of 86 parts, by weight of 93% sulfuric acid and 14 parts by weight of 67% nitric acid. No reducing agent was applied to the intercalated flakes. The flakes were then placed in a 100° C. oven for 20 minutes. The intercalated flakes were then washed with four aliquots of 200 ml of water. After each washing the flakes were filtered by vacuum through a Teflon screen. After the final wash the flakes were dried for 1 hour in a 115° C. oven.
The expansion of the intercalated flakes was measured by placing exactly 1.00 g into a 250 ml crucible. The cold crucible was placed into a 600° C. oven for 2 minutes. The volume and weight of the expanded flakes were measured after carefully funneling them into a 250 ml graduated cylinder. The expansion volume was only 26 cc/g. The expansion was inferior to that obtained in example (1) since no reducing agent was employed with the process.
The expansion or exfoliation volume of the intercalated flakes was also measured by heating the intercalated graphite flakes in a 845° C. preheated metal crucible over a Bunsen burner flame, and measuring the bulk volume of the resulting exfoliated flakes. The volume and weight of the expanded flakes were measured after carefully funneling them into a 250 ml graduated cylinder. The expansion volume was only 147 cc/g. The expansion was inferior to that obtained in example (1) since no reducing agent was employed with the process.
EXAMPLE 2
Twenty -five grams of a (+50 mesh) natural graphite flake were intercalated with 25 grains of intercalant consisting of 86 parts by weight of 98% sulfuric acid and 14 parts by weight of 67% nitric acid. After mixing for three minutes, 2 grams of hexadecanol were blended into the flakes. The flakes were then placed in a 90° C. oven for 20 minutes. The intercalated flakes were then washed with four aliquots of 200 ml of water. After each washing the flakes were filtered by vacuum through a Teflon screen. After the final wash the flakes were dried for 1 hour in a 115° C. oven.
The expansion of the intercalated flakes was measured by placing exactly 1.00 g into a 250 ml crucible. The cold crucible was placed into a 600° C. oven for 2 minutes. The volume and weight of the expanded flakes were measured after carefully funneling them into a 250 ml graduated cylinder. The expansion volume was 178 cc/g.
The expansion or exfoliation volume of the intercalated flakes was also measured by heating the intercalated graphite flakes in a 845° C. preheated metal crucible over a Bunsen burner flame, and measuring the bulk volume of the resulting exfoliated flakes. The volume and weight of the expanded flakes were measured after carefully funneling them into a 250 ml graduated cylinder. The expansion volume was 531 cc/g.
Comparative Example 2
Twenty -five grams of a (+50 mesh) natural graphite flake were intercalated for 20 minutes with 25 grams of intercalant consisting of 86 parts by weight of 98% sulfuric acid and 14 parts by weight of 67% nitric acid. No reducing agent and no external heat were applied to the intercalated flakes. The intercalated flakes were then washed with four aliquots of 200 ml of water. After each washing the flakes were filtered by vacuum through a Teflon screen. After the final wash the flakes were dried for 1 hour in a 115° C. oven.
The expansion of the intercalated flakes was measured by placing exactly 1.00 g into a 250 ml crucible. The cold crucible was placed into a 600° C. oven for 2 minutes. The volume and weight of the expanded flakes were measured after carefully funneling them into a 250 ml graduated cylinder. The expansion volume was only 30 cc/g. The expansion was inferior to that obtained in example (2) since no reducing agent and no external heat were applied to the intercalated flakes.
The expansion or exfoliation volume of the intercalated flakes was also measured by heating the intercalated graphite flakes in a 845° C. preheated metal crucible over a Bunsen burner flame, and measuring the bulk volume of the resulting exfoliated flakes. The volume and weight of the expanded flakes were measured after carefully funneling them into a 250 ml graduated cylinder. The expansion volume was only 142 cc/g. The expansion was inferior to that obtained in example (2) since no reducing agent and no external heat were applied to the intercalated flakes.
EXAMPLE 3
Twenty -five grams of a (+50 mesh) natural graphite flake were intercalated with 25 grams of intercalant consisting of 90 parts by weight of 93% sulfuric acid and 10 parts by weight of 67% nitric acid. After mixing for three minutes, 0.75 grams of 1-octanol were blended into the flakes. The flakes were then placed in a 100° C. oven for 20 minutes. The intercalated flakes were then washed with four aliquots of 200 ml of water. After each washing the flakes were filtered by vacuum through a Teflon screen. After the final wash the flakes were dried for 1 hour in a 115° C. oven.
The expansion of the intercalated flakes was measured by placing exactly 1.00 g into a 250 ml crucible. The cold crucible was placed into a 600° C. oven for 2 minutes. The volume and weight of the expanded flakes were measured after carefully funneling them into a 250 ml graduated cylinder. The expansion volume was 203 cc/g.
The expansion or exfoliation volume of the intercalated flakes was also measured by heating the intercalated graphite flakes in a 845° C. preheated metal crucible over a Bunsen burner flame, and measuring the bulk volume of the resulting exfoliated flakes. The volume and weight of the expanded flakes were measured after carefully funneling them into a 250 ml graduated cylinder. The expansion volume was 634 cc/g.
Comparative for Examples 3 to 8
Twenty -five grams of a (+50 mesh) natural graphite flake were intercalated for 20 minutes with 25 grams of intercalant consisting of 90 parts by weight of 93% sulfuric acid and 10 parts by weight of 67% nitric acid. No reducing agent and no external heat were applied to the intercalated flakes. The intercalated flakes were then washed with four aliquots of 200 ml of water. After each washing the flakes were filtered by vacuum through a Teflon screen. After the final wash the flakes were dried for 1 hour in a 115° C. oven.
The expansion of the intercalated flakes was measured by placing exactly 1.00 g into a 250 ml crucible. The cold crucible was placed into a 600° C. oven for 2 minutes. The volume and weight of the expanded flakes were measured after carefully funneling them into a 250 ml graduated cylinder. The expansion volume was only 29 cc/g. The expansion was inferior to that obtained in examples (3 to 8) since no reducing agent and no external heat were applied to the intercalated flakes.
The expansion or exfoliation volume of the intercalated flakes was also measured by heating the intercalated graphite flakes in a 845° C. preheated metal crucible over a Bunsen burner flame, and measuring the bulk volume of the resulting exfoliated flakes. The volume and weight of the expanded flakes were measured after carefully funneling them into a 250 ml graduated cylinder. The expansion volume was only 188 cc/g. The expansion was inferior to that obtained in examples (3 to 8) since no reducing agent and no external heat were applied to the intercalated flakes.
EXAMPLE 4
Twenty-five grams of a (+50 mesh) natural graphite flake were intercalated with 25 grams of intercalant consisting of 90 parts by weight of 93% sulfuric acid and 10 parts by weight of 67% nitric acid. After mixing for three minutes, 0.50 grams of 1-propanol were blended into the flakes. The flakes were then placed in a 100° C. oven for 20 minutes. The intercalated flakes were then washed with four aliquots of 200 ml of water. After each washing the flakes were filtered by vacuum through a Teflon screen. After the final wash the flakes were dried for 1 hour in a 115° C. oven.
The expansion of the intercalated flakes was measured by placing exactly 1.00 g into a 250 ml crucible. The cold crucible was placed into a 600° C. oven for 2 minutes. The volume and weight of the expanded flakes were measured after carefully funneling them into a 250 ml graduated cylinder. The expansion volume was 94 cc/g.
The expansion or exfoliation volume of the intercalated flakes was also measured by heating the intercalated graphite flakes in a 845° C. preheated metal crucible over a Bunsen burner flame, and measuring the bulk volume of the resulting exfoliated flakes. The volume and weight of the expanded flakes were measured after carefully funneling them into a 250 ml graduated cylinder. The expansion volume was 439 cc/g.
EXAMPLE 5
Twenty -five grams of a (+50 mesh) natural graphite flake were intercalated with 25 grams of intercalant consisting of 90 parts by weight of 93% sulfuric acid and 10 parts by weight of 67% nitric acid. After mixing for three minutes, 0.375 grams of 1,3-propanediol were blended into the flakes. The flakes were then placed in a 100° C. oven for 20 minutes. The intercalated flakes were then washed with four aliquots of 200 ml of water. After each washing the flakes were filtered by vacuum through a Teflon screen. After the final wash the flakes were dried for 1 hour in a 115° C. oven.
The expansion of the intercalated flakes was measured by placing exactly 1.00 g into a 250 ml crucible. The cold crucible was placed into a 600° C. oven for 2 minutes. The volume and weight of the expanded flakes were measured after carefully funneling them into a 250 ml graduated cylinder. The expansion volume was 83 cc/g.
The expansion or exfoliation volume of the intercalated flakes was also measured by heating the intercalated graphite flakes in a 845° C. preheated metal crucible over a Bunsen burner flame, and measuring the bulk volume of the resulting exfoliated flakes. The volume and weight of the expanded flakes were measured after carefully funneling them into a 250 ml graduated cylinder. The expansion volume was 381 cc/g.
EXAMPLE 6
Twenty-five grams of a (+50 mesh) natural graphite flake were intercalated with 25 grains of intercalant consisting of 90 parts by weight of 93% sulfuric acid and 10 parts by weight of 67% nitric acid. After mixing for three minutes, 0.500 grams of 1, 10 decanediol were blended into the flakes. The flakes were then placed in a 100° C. oven for 20 minutes. The intercalated flakes were then washed with four aliquots of 200 ml of water. After each washing the flakes were filtered by vacuum through a Teflon screen. After the final wash the flakes were dried for 1 hour in a 115° C. oven.
The expansion of the intercalated flakes was measured by placing exactly 1.00 g into a 250 ml crucible. The cold crucible was placed into a 600° C. oven for 2 minutes. The volume and weight of the expanded flakes were measured after carefully funneling them into a 250 ml graduated cylinder. The expansion volume was116 cc/g.
The expansion or exfoliation volume of the intercalated flakes was also measured by heating the intercalated graphite flakes in a 845° C. preheated metal crucible over a Bunsen burner flame, and measuring the bulk volume of the resulting exfoliated flakes. The volume and weight of the expanded flakes were measured after carefully funneling them into a 250 ml graduated cylinder. The expansion volume was 511 cc/g.
EXAMPLE 7
Twenty-five grams of a (+50 mesh) natural graphite flake were intercalated with 25 grams of intercalant consisting of 90 parts by weight of 930% sulfuric acid and 10 parts by weight of 67% nitric acid. After mixing for three minutes, 1.00 grams of decylaldehyde were blended into the flakes. The flakes were then placed in a 100° C. oven for 20 minutes. The intercalated flakes were then washed with four aliquots of 200 ml of water. After each washing the flakes were filtered by vacuum through a Teflon screen. After the final wash the flakes were dried for 1 hour in a 115° C. oven.
The expansion of the intercalated flakes was measured by placing exactly 1.00 g into a 250 ml crucible. The cold crucible was placed into a 600° C. oven for 2 minutes. The volume and weight of the expanded flakes were measured after carefully funneling them into a 250 ml graduated cylinder. The expansion volume was 156 cc/g.
The expansion or exfoliation volume of the intercalated flakes was also measured by heating the intercalated graphite flakes in a 845° C. preheated metal crucible over a Bunsen burner flame, and measuring the bulk volume of the resulting exfoliated flakes. The volume and weight of the expanded flakes were measured after carefully funneling them into a 250 ml graduated cylinder. The expansion volume was 521 cc/g.
EXAMPLE 8
Twenty-five grams of a (+50 mesh) natural graphite flake were intercalated with 25 grams of intercalant consisting of 90 parts by weight of 93% sulfuric acid and 10 parts by weight of 67% nitric acid. After mixing for three minutes, 1.0 grain of the ester, ethylene glycol monostearate, was blended into the flakes. The flakes were then stirred on a hot plate for 10 minutes temperature increasing to 90° C. to dissolve the ethylene glycol monostearate). The mixture was then placed in a 100° C. oven for 20 minutes. The intercalated flakes were then washed with four aliquots of 200 ml of water. After each washing the flakes were filtered by vacuum through a Teflon screen. After the final wash the flakes were dried for 1 hour in a 115° C. oven.
The expansion of the intercalated flakes was measured by placing exactly 1.00 g into a 250 ml crucible. The cold crucible was placed into a 600° C. oven for 2 minutes. The volume and weight of the expanded flakes were measured after carefully funneling them into a 250 ml graduated cylinder. The expansion volume was 124 cc/g.
The expansion or exfoliation volume of the intercalated flakes was also measured by heating the intercalated graphite flakes in a 845° C. preheated metal crucible over a Bunsen burner flame, and measuring the bulk volume of the resulting exfoliated flakes. The volume and weight of the expanded flakes were measured after carefully funneling them into a 250 ml graduated cylinder. The expansion volume was 379 cc/g.
EXAMPLE 9
Twenty-five grams of a (+50 mesh) natural graphite flake were intercalated with 25 grams of intercalant consisting of 90 parts by weight of 93% sulfuric acid and 10 parts by weight of 67% nitric acid. After mixing for three minutes, 0.375 grams of sucrose were blended into the flakes. The flakes were then stirred on a hot plate for 10 minutes (temperature increasing to 90° C. to dissolve the sucrose). The mixture was then placed in a 100° C. oven for 20 minutes. The intercalated flakes were then washed with four aliquots of 200 ml of water. After each washing the flakes were filtered by vacuum through a Teflon screen. After the final wash the flakes were dried for 1 hour in a 115° C. oven.
The expansion of the intercalated flakes was measured by placing exactly 1.00 g into a 250 ml crucible. The cold crucible was placed into a 600° C. oven for 2 minutes. The volume and weight of the expanded flakes were measured after carefully funneling them into a 250 ml graduated cylinder. The expansion volume was 73 cc/g.
The expansion or exfoliation volume of the intercalated flakes was also measured by heating the intercalated graphite flakes in a 845° C. preheated metal crucible over a Bunsen burner flame, and measuring the bulk volume of the resulting exfoliated flakes. The volume and weight of the expanded flakes were measured after carefully funneling them into a 250 ml graduated cylinder. The expansion volume was 342 cc/g.
Comparative for Example 9
Twenty-five grams of a (+50 mesh) natural graphite flake were intercalated with 25 grams of intercalant consisting of 90 parts by weight of 93 % sulfuric acid and 10 parts by weight of 67% nitric acid. After mixing for three minutes, 0.375 grams of sucrose were blended into the flakes. The flakes were then stirred and blended at room temperature (20°) for 20 minutes. The intercalated flakes were then washed with four aliquots of 200 ml of water. After each washing the flakes were filtered by vacuum through a Teflon screen. After the final wash the flakes were dried for 1 hour in a 115° C. oven.
The expansion of the intercalated flakes was measured by placing exactly 1.00 g into a 250 ml crucible. The cold crucible was placed into a 600° C. oven for 2 minutes. The volume and weight of the expanded flakes were measured after carefully funneling them into a 250 ml graduated cylinder. The expansion volume was only 31 cc/g. The expansion was inferior to that obtained for Example (9) since the sample was blended with sucrose at 20° C. for only 20 minutes.
The expansion or exfoliation volume of the intercalated flakes was also measured by heating the intercalated graphite flakes in a 845° C. preheated metal crucible over a Bunsen burner flame, and measuring the bulk volume of the resulting exfoliated flakes. The volume and weight of the expanded flakes were measured after carefully funneling them into a 250 ml graduated cylinder. The expansion volume was only 156 cc/g. The expansion was inferior to that obtained in example (9) since no external heat was applied to the intercalated flakes.
EXAMPLE 10
Twenty-five grams of a (+50 mesh) natural graphite flake were intercalated with 25 grams of intercalant consisting of 90 parts by weight of 93% sulfuric acid, 10 parts by weight of 67% nitric acid, and 3.5 pph of oxalic acid. After mixing for three minutes, 0.25 grams of polypropylene glycol were blended into the flakes. The flakes were then placed in a 100° C. oven for 20 minutes. The intercalated flakes were then washed with four aliquots of 200 ml of water. After each washing the flakes were filtered by vacuum through a Teflon screen. After the final wash the flakes were dried for 1 hour in a 115° C. oven.
The expansion of the intercalated flakes was measured by placing exactly 1.00 g into a 250 ml crucible. The cold crucible was placed into a 600° C. oven for 2 minutes. The volume and weight of the expanded flakes were measured after carefully funneling them into a 250 ml graduated cylinder. The expansion volume was 260 cc/g.
EXAMPLE 11
Twenty-five grams of a (+50 mesh) natural graphite flake were intercalated with 25 grams of intercalant consisting of 90 parts by weight of 93% sulfuric acid, 10 parts by weight of 67% nitric acid, and 3.5 pph of oxalic acid. After mixing for three minutes, 0.625 grams of ascorbic acid were blended into the flakes. The flakes were then placed in a 100° C. oven for 20 minutes. The intercalated flakes were then washed with four aliquots of 200 ml of water. After each washing the flakes were filtered by vacuum through a Teflon screen. After the final wash the flakes were dried for 1 hour in a 115° C. oven.
The expansion of the intercalated flakes was measured by placing exactly 1.00 g into a 250 ml crucible. The cold crucible was placed into a 600° C. oven for 2 minutes. The volume and weight of the expanded flakes were measured after carefully funneling them into a 250 ml graduated cylinder. The expansion volume was 270 cc/g.
EXAMPLE 12
Twenty-five grams of a (+50 mesh) natural graphite flake were intercalated with 25 grams of intercalant consisting of 90 parts by weight of 93% sulfuric acid, 10 parts by weight of 67% nitric acid, and 3.5 pph of oxalic acid. After mixing for three minutes, 0.50 grams of sodium lignate were blended into the flakes. The flakes were then placed in a 100° C. oven for 30 minutes. The intercalated flakes were then washed with four aliquots of 200 ml of water. After each washing the flakes were filtered by vacuum through a Teflon screen. After the final wash the flakes were dried for 1 hour in a 115° C. oven.
The expansion of the intercalated flakes was measured by placing exactly 1.00 g into a 250 ml crucible. The cold crucible was placed into a 600° C. oven for 2 minutes. The volume and weight of the expanded flakes were measured after carefully funneling them into a 250 ml graduated cylinder. The expansion volume was 290 cc/g.
EXAMPLE 13
Twenty-five grams of a (+50 mesh) natural graphite flake were intercalated with 25 grams of intercalant consisting of 90 parts by weight of 93% sulfuric acid, 10 parts by weight of 67% nitric acid, and 4.0 pph of succinic acid. After mixing for three minutes, 1.00 grams of decanol were blended into the flakes. The flakes were then placed in a 100° C. oven for 30 minutes. The intercalated flakes were then washed with four aliquots of 200 ml of water. After each washing the flakes were filtered by vacuum through a Teflon screen. After the final wash the flakes were dried for 1 hour in a 115° C. oven.
The expansion of the intercalated flakes was measured by placing exactly 1.00 g into a 250 ml crucible. The cold crucible was placed into a 600° C. oven for 2 minutes. The volume and weight of the expanded flakes were measured after carefully funneling them into a 250 ml graduated cylinder. The expansion volume was 355 cc/g.
EXAMPLE 14
A series of polyfunctional reducing agents was evaluated for their effect on both cold crucible expansion and compressed expansion. For each run, graphite flake was intercalated as in Example 12 and then subjected to expansion testing as in that example to obtain a value for cold crucible expansion. A value for compressed expansion was obtained by varying the above test by using a special test device that employs a 400 gram weight to rest upon 5 grams of the graphite flake placed in a 2.54 cm diameter cylinder and exert a pressure on the flake during heating and expansion. The results are summarized in the following table:
Cold Crucible
Compressed
Grams
Expansion at
Expansion
Reagent
Reagent
600° C., cc/g
height at 600° C., mm
Triton X-100 1
0.225
298
72.8
Tergitol NP-10 2
0.225
293
76.5
Tergitol 15-S-7 3
0.225
339
73.4
Polypropylene Glycol 4
0.25
260
60
1 Product of Union Carbide Company. The Triton “X-” products are generally described as alkylaryl polyether alcohols, prepared by the reaction of octylphenol with ethylene oxide. The products are mixtures with respect to length of the polyoxyethylene chain; the subscript “x” values represent the average number of ethylene oxide units.
2 Product of Union Carbide Company, identified as a polymer of ethylene oxide and nonylphenol, with a hydroxyl number of 86 and a molecular weight of 652.
3 Product of Union Carbide Company, identified as a polyethylene glycol ether of a secondary alcohol.
4 Molecular weight 1200.
In each of the above cases, the polyfunctional surfactant reducing additive increases both cold crucible and compressed expansion compared to a nonsurfactant polyfunctional reducing additive, polypropylene glycol.
|
Intercalated graphite flake which has enhanced exfoliation volume characteristics at relatively low exfoliation temperatures, e.g., 600° C. and even lower, is made by adding an organic expansion aid to the intercalant solution and heating a blend of intercalated particles and an organic reducing agent in the temperature range of 25° to 125° C.
| 2
|
FIELD OF THE INVENTION
The present invention is directed to a method and to a device for drawing in a web in a web-fed rotary printing press. The web has a draw-in tip which is made thicker than the rest of the web.
BACKGROUND OF THE INVENTION
A device for attaching a web of material to a carrier of a web draw-in device is known from EP 0 118 860 B1. A fastening device, that receives the end of the web of material, is loosely suspended by a loop fastened on the former from the carrier, of a draw-in element.
A draw-in device is described in G 92 15 764 U1, in which a cable, which is attached to the draw-in tip, is pushed vertically in respect to the conveying direction into the openings of carriers. The cable is maintained on the carrier, secure against slipping out opposite the conveyance direction, by the use of a headpiece of the cable.
DE 198 37 361 A1 discloses a device for drawing in a web of material to be imprinted. A free end of the draw-in tip is threaded through an opening of a carrier which is connected with the draw-in device and is made into a loop by a hook-and-loop closure.
EP0 425 741 A1 shows a device for drawing in a web and having a draw-in assembly. A positive connection opposite and transversely to the conveying direction with a carrier arranged on the draw-in assembly can be made by the use of a coupling element arranged on a draw-in tip. The coupling element, embodied in a stepped manner, and the carrier can be connected with each other, or released from each other, by a relative movement along the conveying direction.
SUMMARY OF THE INVENTION
The object of the present invention is based on providing a method and a device for drawing in a web.
In accordance with the present invention, this object is attained by providing the web to be drawn in with a thickened portion. This thickened portion is received in a carrier that is part of the web draw-in device. The thickened portion is slid into the carrier in a direction perpendicular to the web conveying direction and is then moved in the carrier in a direction parallel to the conveying direction. This second movement takes place with limited travel in the direction perpendicular to the conveying direction.
The advantages which can be realized by the present invention reside, in particular, in that the connection between the draw-in assembly or device and the draw-in tip is positive in the conveying direction, which connection is embodied in a self-securing manner in respect to releasing the connection during the operation, i.e. when drawing the web in. The danger of a spontaneous and unintentional release of the connection, such as can occur in a connection with simply designed carriers, is reduced by a travel limitation imposed on the draw-in tip on all sides of the tip, which is closed to a great extent.
The connection between the draw-in tip and the draw-in assembly or device is substantially achieved in an advantageous manner by the requirement of a two-step movement, which movement is guided to a great extent, of the draw-in tip in respect to the carrier. In an advantageous manner, the suspension and securing of the tip in the carrier takes place in two defined movement directions, which extend almost perpendicularly with respect to each other. In a first step, the suspension of the tip in the carrier takes place in a direction which is almost perpendicular in respect to the web conveying direction. In a second step, the connection is secured by a relative movement between the clamping element and the draw-in tip in which the tip moves relative to the clamping element in a direction opposite to the web conveying direction. The movement, which is guided to a great extent and which extends almost perpendicularly in respect to the conveying direction for a suspension in a narrowly bordered forward direction provides increased assurance against unintentional release of the tip from the carrier.
In a particularly advantageous embodiment, a sequence of two defined movements is required for connecting, or releasing the tip and the carrier, wherein one movement represents a rotational movement, which movement is not one typically occurring in the draw-in process, in a direction R. With this sequence of movements, the connection is not sensitive to unintentional release because of fluctuations in the web tension or in web speed during draw-in.
In at least one area in which the draw-in tip, or a thickening at the draw-in tip, and the carrier engage each other, a first movement is possible only guided along in a direction which is predetermined to a great extent.
In addition to providing a high degree of assurance that the connection will not become undone, a substantial advantage of the present invention is its rapid and simple operability. Elaborate opening or closing by the use of tools, gluing or threading into closed eyes is not required.
BRIEF DESCRIPTION OF THE DRAWINGS
Preferred embodiments of the present invention are represented in the drawings and will be described in greater detail in what follows.
Shown are in:
FIG. 1, a perspective view of a device for drawing in a web in accordance with the present invention,
FIG. 2, a side elevation view, partly in cross-section, through the device for drawing in a web, in
FIG. 3, a side elevation view of the device for drawing in a web, in
FIG. 4, a top plan view of a second preferred embodiment of the device for drawing in a web in accordance with the present invention, in
FIG. 5, a top plan view of a third preferred embodiment with an inclined suspension device, and in
FIGS. 6 a - 6 e , several preferred embodiments of a thickened or portion of the draw-in tip in accordance with the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Drawing-in of webs, for example webs of material to be imprinted in web-fed rotary printing presses, takes place, in a generally known manner, by the operation of a web draw-in device 01 , for example such as a chain 01 , a belt or a cable, as depicted somewhat schematically in FIG. 1 . As a rule, the chain 01 is located adjacent the side of the paper web to be drawn in and is conveyed through the printing press, for example on a rail, along a path provided for the paper web. A carrier 02 is arranged on the chain 01 , and on, or to which a start 03 of the paper web is fastened. The chain 01 may be embodied as a roller chain 01 with rollers 09 , for example.
In the embodiment depicted in FIG. 1, the start 03 of the paper web is configured as a draw-in tip 03 , which is connected with the paper web, and whose free end 04 can be positively connected with the carrier 02 which is supported by chain 01 to move in the conveying direction T. The draw-in tip 03 can be in the form of a foil which is connected with the paper web, a reinforced end of the paper web itself, a single- or multi-part reinforcement or extension, which is connected in a non-positive manner, in a positive manner or is incorporated into the material. In an advantageous manner, the draw-in tip 03 extends in the conveying direction T at an acute angle toward the laterally arranged chain 01 , and is embodied, at least in the area of the connection with the chain 01 , or the carrier 02 , in a manner which is substantially tear-resistant, for example as a metal or as a plastic strip. The draw-in tip 03 is flat and flexible and has a reduced thickness d 03 , as seen in FIG. 3, wherein preferably d 03 <1.5 mm, for example d 03 =0.5 mm. Draw-in tip 03 preferably extends on a conveying plane. The conveying plane is understood to be that plane whose length extends in the conveying direction T on the plane of the carrier 02 through the conveying direction T and the imagined position of the web.
On its free end 04 , the draw-in tip 03 has a thickening or an enlargement 06 formed in a direction with respect to the web and to the web draw-in tip 03 which direction is almost perpendicular with respect to the conveying direction T and which draw-in tip 03 acts together, in a positive manner, with the carrier 02 in the course of the draw-in of the web in the conveying direction T. The thickening or enlargement 06 can be a raised bump generated by forming or by embossment, as seen in FIG. 6 a , by the provision of a pin or bolt penetrating the draw-in tip 03 , as seen in FIG. 6 b , or as any other raised section, which causes an increase of the cross-section of the draw-in tip 03 in respect to a direction perpendicular with respect to the conveying direction T. The shapes of the cooperating carrier 02 and the draw-in tip thickening 06 are reciprocally provided in such a way that a suspension, which is guided to a great extent, and a connection between the carrier 02 and the draw-in tip 03 with the thickening 06 takes place, which suspension and connection is limited in at least five of the six spatial directions, and in one embodiment of the invention, in six of the six spatial directions. A movement, that is guided to a great extent, is required along part of the connective path, at least in the area in which the carrier 02 and the draw-in tip 03 , or the thickening 06 , penetrate each other. Because of the reciprocal shaping of the tip 03 and the carrier 06 , the connective movement between the two takes place within a narrow angular range. Two examples from the multitude of possible options have been taken in what follows and will be described in greater detail.
In the first example, the thickening 06 , as depicted in FIG. 6 c , is embodied as a head of a screw 07 which screw 07 is extending perpendicularly through a recess, not specifically represented, in the draw-in tip 03 with the screw head situated on one side of the draw-in tip 03 and, on the other side of the tip 03 , as a nut 08 , which is, for example, fixed against relative rotation, and which is cooperating with the screw 07 . The free end 04 of the draw-in tip 03 , as provided with the thickening 06 described above, cooperates with the carrier 02 of the chain 01 when the paper web is drawn in, as depicted in FIG. 1 .
At least at its end 11 that is trailing in the conveying direction T, as seen in FIG. 1, the carrier 02 is provided with a slit 12 extending approximately parallel with the conveying plane. In the preferred embodiment, the carrier 02 is embodied for this purpose as a two piece clamping element 02 with a first cheek or segment 13 and a second cheek or segment 14 , which two segments 13 and 14 are connected with each other by two screws 16 extending almost perpendicularly in relation to the slit 12 . To provide the slit 12 with a height h 12 , it is possible to arrange a spacer element between the segments or cheeks 13 and 14 , for example. However, the segments or cheeks 13 and 14 can also be offset from each other on their sides respectively facing each other, so that a slit 12 is created when they are brought together. A one-piece embodiment of the carrier or clamping element 02 is also possible, wherein the slit 12 is embodied as a sawn cut, for example. In the configuration of the carrier 02 shown in FIG. 3, the height h 12 of the slit 12 is defined by two bolts 23 , which connect the clamping element 02 with the chain 01 and which are arranged between the two segments 13 and 14 .
In the area of its trailing end 11 , the clamping element 02 has an elongated hole or aperture 18 that is passing, almost perpendicularly with respect to the conveying direction T, through both segments or cheeks 13 and 14 , and which aperture 18 extends at least partially along its length l 18 in the conveying direction T.
The outer lateral side 19 of the clamping element 02 has a recess 21 , for example a bore 21 , with side 19 being opposite the chain 01 . The bore 21 is arranged in such a way that it connects the outer side 19 with the elongated hole or aperture 18 at the the end of the elongated hole or aperture 18 which is remote from the draw-in tip 03 .
The bore 21 has a diameter d 21 , which corresponds at least to the largest cross section of the thickening 06 , and at least to the largest of the dimensions of the length l 06 and the maximum diameter d 06 of the thickening 06 constituted by the screw 07 and the associated nut 08 . The elongated hole or aperture 18 also has a width b 18 , as seen in FIG. 2, which corresponds at least to the maximum diameter d 06 of the thickening 06 . The length l 18 of the elongated hole or aperture 18 is greater than the diameter d 21 of the lateral bore 21 . Preferably, the length l 18 is greater than the sum of the diameter d 21 of the bore 21 and half the maximum diameter d 06 of the thickening 06 .
If the thickening 06 is embodied as a pin 06 penetrating through the draw-in tip 03 perpendicularly, as seen in FIG. 6 b , the diameter d 21 of the bore 21 is selected to be at least equal to the length l 06 of the pin 06 , and the width b 18 to be at least equal to the diameter d 06 of the pin 06 . Thus a lateral interior wall 22 , extending in the direction of the length l 18 , of the elongated hole 18 acts, together with the thickening 06 , to form a detent 22 . The width b 18 of the elongated hole 18 can also taper towards the trailing end 11 of the clamping element 02 in such a way that a frictional connection between the thickening 06 and the clamping element 06 is provided by the tensile force directed in the conveying direction T.
The height h 12 of the slit 12 , as seen in FIG. 3, is at least equal to the thickness d 03 of the draw-in tip 03 , and is less than the length or the height l 06 of the thickening 06 , so that the draw-in tip 03 can be guided into the slit 12 , at least in the area of the draw-in tip free end 04 , but that the thickening 06 , together with the slit 12 , and almost all of the entire interior wall 22 , with the exception of the bore 21 , constitutes the detent 22 .
In one embodiment of the present example, as seen in FIG. 2, the draw-in tip 03 is provided with a second thickening 17 , for example a casing of the draw-in tip 03 in the form of a woven tape. This thickening 17 on the draw-in tip 03 is spaced away from the first thickening 06 at a distance a 17 and in a direction opposite the end of the draw-in tip 03 . Advantageously, the distance a 17 is less than a distance a 21 of the recess 21 , but must at least be selected to be as large as an inner width l 18 of the longitudinal hole 18 from the side 19 of the clamping element 02 .
During operation, i.e. in the suspended state of the draw-in tip 03 in the clamping element 02 , the thickening 06 is connected together with the end 04 of the draw-in tip 03 and their travel is limited in six directions. In the preferred embodiment, the draw-in tip 03 is positively connected in all directions perpendicular in respect to the conveying direction T and is movable parallel in respect to the conveying direction T, but its travel is limited. In the embodiment with the draw-in tip 03 having the second thickening 17 , the freedom of movement of the draw-in tip 03 in the conveying direction T is additionally limited and, for releasing the connection, the draw-in tip 03 initially makes a rotation in the direction R, as seen in FIG. 2, around an axis which, in an advantageous manner, extends almost perpendicular in respect to the conveying direction T. In the tightened state in particular, for example during drawing in of the web in the conveying direction T, the thickening 06 is also positively, or at least with limited travel, connected opposite to a suspension direction E parallel in respect to the longitudinal axis E of the bore 21 , which represents the direction in which the thickening 06 is conducted into the clamping element 02 in the course of suspending the draw-in tip 03 .
The clamping element or carrier 02 is releasably fastened to the chain 01 by use of the two bolts 23 , or screws 23 . In an advantageous manner, a spacing distance a 23 between the bolts 23 in the conveying direction T, as seen in FIG. 3, is a whole number multiple of the distances between the shafts of two roller 09 of the chain 01 .
In a second preferred embodiment of the device for drawing in a web, as seen in FIG. 4 , the thickening 06 is embodied as a bead 06 on the free end 04 of the draw in tip 03 , as seen in FIG. 6 d . This bead 06 can be, for example, a small tube 24 , as shown in FIG. 6 d that is worked into the end 04 of the draw in tip 03 , or as a pin or a groove, as shown in FIG. 6 a , that is formed in the draw in tip 03 during its manufacture. The bead 06 extends in the conveying plane almost perpendicular in respect to the conveying direction T.
As in the first preferred embodiment, this bead 06 cooperates positively with an elongated hole 26 formed in the carrier 02 in a manner in which it limits travel, and in the conveying direction T. The elongated hole 26 of the second preferred embodiment, as depicted in FIG. 4, does not extend perpendicularly, in respect to the conveying plane, and to the bore 21 , through a clamping element 02 , but instead is almost parallel with the conveying plane. Over its length l 26 , the elongated hole 26 extends nearly parallel in respect to the conveying direction T. To prevent the bead 06 from slipping laterally out of the elongated hole 26 , the elongated hole 26 is discontinuous on the lateral outer side 19 of the clamping element 02 ; i.e. the side of the clamping element opposed to the chain 01 , so that a projection 27 remains on the side 19 as a detent 27 . This lateral projection 27 is located on the side of the elongated hole 26 which is closer to the trailing end 11 of the clamping element 02 and thus prevents the suspended thickening 06 of the draw-in tip 03 from sliding out of the clamping element 02 in a direction opposite to the suspension or attachment direction E. The portion of the elongated hole 26 which is continuous on the outer lateral side 19 corresponds to the recess 21 in the first preferred embodiment that is required for suspending the draw-in tip 03 . On the side facing the chain 01 , the elongated hole 26 can be continuous. As a rule, the draw-in tip 03 is prevented from sliding out of this side of the clamping element 02 by the adjoining chain 01 which thus also serves as a travel limiter.
In a preferred embodiment, the elongated hole 26 can be configured as an elongated hole 26 which conically tapers in a direction opposite the conveying direction T, and which is provided with a frictional connection by the thickening 06 , in addition to the travel limitation, when the clamping element 02 and the draw-in tip 03 are moved relatively away from each other in the conveying direction T.
The elongated hole 26 can also be arranged in the clamping element 02 in such a way that its length l 26 does not extend parallel in respect to the conveying direction T, but is inclined in relation to the conveying direction T at an angle α which is not equal to 0° against the conveying direction T. In this preferred embodiment, as indicated in FIG. 5, the inclination α between the orientation of the elongated hole 26 of the length l 26 and the conveying direction T is approximately 20°. This embodiment can be selected, for example, for assuring even more security against the thickening 06 laterally slipping out of the longitudinal hole 26 , but also, if required, to point in the direction of a resultant line for the tensile force.
In a configuration that is suitable for use with both preferred embodiments, the thickening 06 on the draw-in tip 03 is formed as a ball 06 or as a cylinder 06 which are arranged on one end of a belt 28 or cable 28 , which in turn has been incorporated into the draw-in tip 03 as seen in FIG. 6 e . In actual use, a steel cable 28 with a steel ball 06 or a steel cylinder 06 , for example a Bowden cable 06 , 28 , is preferable. When using a cylindrical thickening 06 , in the first preferred embodiment an axis of the cylindrical thickening 06 is oriented nearly perpendicularly in respect to the paper plane. In, in the second preferred embodiment this axis is oriented nearly parallel with the paper plane.
The embodiment in accordance with FIG. 6 e can be modified in an advantageous manner in that additionally a bolt 29 , or, for example, a pin 29 , is arranged on the thickening 06 , which designed as a ball 06 . This bolt or pin is shown in dashed lines in FIG. 6 e , since this is optional. In the suspended state, this pin 29 is used for securing the ball 06 in the recess 18 . The pin 29 is oriented, for this purpose, in such a way that, in the suspended end state, its longitudinal direction extends perpendicular in relation to the plane of the slit 12 . If the recess 18 , the bore 21 and the slit 12 are aligned as represented in FIG. 1, the pin 29 extends perpendicular to the paper plane, or to the plane of the draw-in tip 03 . If the arrangement is rotated by 90°, the pin correspondingly extends in the paper plane, or the plane of the draw-in tip 03 .
In this embodiment, four different movements, of which two are guided translatory movements and two are rotatory movements, are required for suspension. Initially, the ball 06 must be inserted along the suspension direction E, as seen in FIG. 2, laterally into the bore 21 in such a way that the pin 29 is guided through the slit 12 into the interior of the recess 18 . To do this, a diameter d 29 , or a thickness d 29 , of the pin 29 must be less than the height h 12 of the slit 12 . Then the ball 06 with the pin 29 must be turned by approximately 45° in the recess 18 around an axis along the insertion direction E. Thereafter, the translation opposite the conveying direction T and a rotation in the direction R around an axis which is nearly perpendicular in respect to the conveying direction and the insertion direction E can take place.
The configuration of the thickening 06 and of the cooperating bore 21 , or the recesses in the form of elongated holes 18 , 26 , or differently shaped recesses 18 , 26 in the carrier or clamping member 02 is possible in a multitude of ways in order to make possible a guided suspension in the suspension direction E of the draw-in tip 03 perpendicularly to a great extent, or with a component perpendicular to the conveying direction T, and the travel limiting securing of the draw-in tip 03 in the carrier 02 against movements in a direction perpendicular to the conveying direction T. It is advantageous that the clamping element 02 is provided with a recess 18 , or 26 , which has at least one component of the diameter, or the inner width l 18 or l 26 in the conveying direction 26 , which is greater than the corresponding component of the diameter, or the inner width d 21 of the recess 21 , which is required for the suspension and which is connected with the recess 18 or 26 . Because of the separation of the movements for suspension and for securing, a travel limitation is also provided in directions perpendicular to the conveying direction T, in particular also counter to the suspension direction E.
The mode of functioning of the device for drawing in a material to be imprinted, in accordance with the present invention is as follows:
For drawing in a web of material to be imprinted, its start is provided with a draw-in tip 03 , which has a thickening 06 on its free end 04 . This free end 04 of the draw-in tip 03 , with the thickening 06 , is pushed, in the suspension direction E, into the recess 21 . Simultaneously the end 04 of the draw-in tip 03 is slid into the slit 12 of the clamping element 02 . By a movement of the draw-in tip 03 in a direction opposite to the conveying direction T, or a movement of the clamping element 02 in the conveying direction T, the thickening 06 slides in the elongated hole 18 , or 26 , in the direction toward the trailing end 11 of the clamping element 02 . The position of the free end 04 of the draw in tip 03 is thus secured in all of the conveying direction T, or the course of the elongated hole 18 in the conveying direction, against slipping out laterally. After the web of material to be imprinted has been drawn in, the release and removal of the draw-in tip 03 takes place in the reverse order. When removing the draw-in tip 03 with a second thickening 17 at the previously mentioned distance a 17 from the thickening 06 , an additional relative rotation in a direction R between the draw-in tip 03 and the clamping element 02 is required for the suspension, or release of the draw-in tip 03 .
While preferred embodiments of method and of a device for drawing in a web, in accordance with the present invention have been set forth fully and completely hereinabove, it will be apparent to one of skill in the art that a number of changes, for example, in the type of printing press being used, the structure of the draw-in chain and the like could be made without departing from the true spirit and scope of the present invention which is accordingly to be limited only by the following claims.
|
Webs of printable materials which are fed into a printing machine are provided with a feed tip that allows the web to be rapidly and releasably connected to a the web feed device. The feed tip has a thickened section which is generally perpendicular to the direction of web transport and which cooperates with a carrier element that is fastened to the web feed device. The carrier element has an oblong cavity which extents in the direction of web transport and which cooperates with the thickened portion of the web to form a stop that is perpendicular to the direction of web transport.
| 1
|
BACKGROUND OF THE INVENTION
[0001] This application is based on and claims priority to provisional patent application No. 61/983,873 filed on Apr. 24, 2014.
FIELD OF INVENTION
[0002] The present invention relates to biomass feedstocks and, more particularly, to a computing system for developing a commodity status for biomass feedstocks.
DISCUSSION OF THE RELATED ART
[0003] Biomass refers to organic matter produced by plants and/or animals. Biomass includes trapped solar energy that can be converted to electricity, heat, or liquid fuels. Examples of biomass feedstocks include crop residues such as corn stover, sugarcane bagasse, purpose-grown grass crops, and woody materials such as chips and sawdust. Biomass feedstock is any biological material that meets specification for a technology to convert it into energy.
[0004] Biomass feedstocks are converted into energy by directly burning the feedstocks to produce steam for heat and power or by refining the feedstocks into liquid fuels and/or products. Energy generation from biomass has substantially lower environmental impacts than traditional fossil fuels. Furthermore, a general move toward environmentally-friendly energy incites many businesses to adopt “green” technologies and support environmentally friendly processes. However, because biomass feedstocks are typically bulky and costly to transport, a big challenge today is for geographically dispersed bio-refineries to obtain the required amount and quality biomass feedstock to operate the facility efficiently.
[0005] Biomass is not yet a commodity because it is highly variably, widely dispersed, and typically unquantified at a scale that translates to financial market protocols. Without means to rapidly quantify and qualify materials, it is difficult to establish meaning classifications for biomass that leads to commodity status.
SUMMARY
[0006] in one embodiment of he present invention there is provided a system for matching parties to a transaction of a biomass feedstock including at least one mobile sensory device structured and disposed for collecting biomass data for the biomass feedstock; a data storage repository configured to store seller criteria and a group of buyer criteria; and a processor of a central server configured to access the storage repository and execute software instructions stored in memory for receiving a group of buyer criteria, wherein each of the group of buyer criteria is sent from a buyer computing device used by one of a group of buyers of the biomass feedstock, wherein the group of buyers comprises a buyer, and wherein each of the group of buyer criteria comprises a purchase quantity, a buyer price, and a transaction location at which to buy the biomass feedstock; receiving seller criteria for the biomass feedstock sent from a seller computing device or the at least one mobile sensory device, wherein the seller criteria comprises a sales volume of biomass from an area of production used to produce the biomass feedstock, proposed pricing, a location or group of locations at which to procure the biomass feedstock, and the biomass data as a representation of biomass specification data; matching, within a predetermined distance to a prospective buyer after receiving the group of buyer criteria, each of the group of buyers with the seller based on determining that the volume and representation of biomass specification data is sufficient to meet the purchase parameters and the transaction location at which to buy the biomass feedstock falls within the group of locations' pre-determined distance-to-market radii; and sending the user criteria to the buyer and seller account messages to indicate potential market activity.
[0007] In another embodiment of the present invention there is provided a method for providing an information technology platform for facilitating commercial transactions for biomass feedstocks and related goods and services, including collecting, by at least one processing unit, a producer profile for each of a group of producers; collecting, by the at least one processing unit over at least one network, biomass data for the biomass associated with each of the group of producers via one or more mobile sensory devices; determining, by the at least one processing unit, a representation of biomass specification data based at least in part on the biomass data; providing, by the at least one processing unit over the at least one network, to a group of buyers access to the representation of biomass qualities; and facilitating, by the at least one processing unit, a purchase of the biomass from one or more members of the group of producers by one or more members of the group of buyers.
[0008] One method provides an electronic forum for facilitating commercial transactions for biomass feedstocks and related goods and services includes collecting a producer profile for each of a group of producers, collecting biomass data for the biomass associated with each of the group of producers, determining a representation of biomass qualities using data accumulated via remote sensing technologies, providing to a group of buyers access to the representation of biomass specification data through the electronic forum, and facilitating purchase of the biomass from one or more of the group of producers by one or more of the group of buyers.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] For a fuller understanding of the nature of the present invention, reference should be made to the following detailed description, taken in conjunction with the accompanying drawings in which:
[0010] FIG. 1 illustrates a computing device and its relevant components including an application with a producer profile that collects biomass feedstock location, contact, type, qualities, quantity and cost information;
[0011] FIG. 2 illustrates a computing device and its relevant components including an application with a buyer profile that collects biomass feedstock location, contact, type, qualities, quantity and cost information
[0012] FIG. 3 illustrates the electronic system for acilitating commercial transactions for biomass feedstocks between producers and buyers, and
[0013] FIG. 4 illustrates the transactional process of the integrated computing system for developing a commodity status for biomass of the present invention according to one embodiment and including a bid/ask platform.
[0014] Like reference numerals refer to like parts throughout the everal views of the drawings.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0015] Referring to the several views of the drawings, the biomass management and exchange system of the present invention is shown and described herein and is generally indicated as 10 .
[0016] Before any embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways.
[0017] It should also be noted that a plurality of hardware and software based devices, as well as a plurality of different structural components can be used to implement the invention. In addition, it should be understood that embodiments of the invention can include hardware, software, and electronic components or modules that, for purposes of discussion, can be illustrated and described as if the majority of the components were implemented solely in hardware. However, one of ordinary spilt in the art, and based on a reading of this detailed description, would recognize that, in at least one embodiment, the electronic based aspects of the invention can be implemented in software (e,g., stored on non-transitory computer-readable medium) executable by one or more processors. As such, it should be noted that a plurality of hardware and software based devices, as well as a plurality of different structural components can be utilized to implement the invention. Furthermore, and as described in subsequent paragraphs, the specific configurations illustrated in the drawings are intended to exemplify embodiments of the invention and that other alternative configurations are possible.
[0018] The biomass management and exchange system 10 facilitates the exchange of biomass by connecting biomass producers 12 with biomass buyers 14 . The biomass management and exchange system 10 creates two types of profiles: a producer profile 16 and a buyer profile 18 . To create a producer profile 16 , the producer 12 specifies identifying information about the producer 12 and the biomass material 20 . For example, the producer can specify the location 22 of the biomass material, provide an owner's name for a contact name) 24 , specify the type 26 of biomass material, provide measures regarding the qualities 28 of the biomass (e.g., age), provide at least an estimated quantity 30 of the biomass material, provide a cost 32 associated with the biomass material, and specify types and quantity of computing devices 102 associated with the producer profile 16 (e.g., a mobile phone, a laptop computer, a tablet computer, etc.). Similarly, to create a buyer profile 18 , the buyer 14 specifies information about the buyer and the desired biomass material. For example, the buyer can specify the location 34 of the business in need of a particular type 35 of biomass material, provide a contact name 36 , provide an estimate of the quantity 38 of biomass desired, provide at least an estimate of the price 40 the buyer is willing to pay for the biomass material, and specify types and quantity of computing devices associated with the buyer profile 18 .
[0019] The biomass management and exchange system 10 includes a data storage repository 104 , processor 106 and one or more applications 10 $, such as web-based applications, for operating and controlling related hardware and software, as part of a server 100 that stores a multitude of buyer profiles 18 and producer profiles 16 , The biomass management and exchange system 10 can be accessed through a network (i.e., the Internet) through a computing device 102 (e.g., a smartphone). In some instances, the biomass management and exchange system 10 is partly hosted in the computing device while other parts of the biomass management and exchange system 10 are accessed through a network. The biomass management and exchange system 10 connects the biomass buyers 14 with the biomass producers 12 and allows the biomass buyers and producers to negotiate with each other to buy and sell biomass feedstock 20 . Using the biomass management and exchange system 10 , a buyer 14 can locate and communicate with different producers 12 and obtain the biomass material 20 in the most efficient and cost-effective method. Similarly. by using the biomass management and exchange system 10 , biomass producers 12 can reach biomass buyers 14 who didn't know about the producers before. Thus, the biomass management and exchange system 10 increases the buying and selling options for both the biomass buyers and the biomass producers.
[0020] The biomass management and exchange system 10 also includes other information to encourage and facilitate transactions between the producers 12 and the buyers 14 . For example, the biomass management and exchange system 10 can include market data including, for example, global market price data for biomass feedstock, typical or average availability, within a specified range, of different types of biomass feedstock and other relevant information for the market of biomass material. The b omass management and exchange system 10 can also include business intelligence information, For example, the biomass management and exchange system 10 can provide information to a business leader about progression toward attaining different business goals (for example, progress made in opening a new energy generating plant), or effective biomass producing methods, and the like. The biomass management and exchange system 10 can also collect information about the biomass producers 12 and the biomass buyers 14 such as, for example, how much biomass feedstock 20 a particular producer sells and how often, how much biomass feedstock a particular buyer buys in a given amount of time, what type of biomass feedstock a particular buyer buys, from how many different producers a particular buyer obtains the biomass feedstock 20 , as well as other information of the sort. The collection of this type of information allows the biomass management and exchange system 10 to analyze the selling and buying habits of the biomass producers and the biomass sellers and provide each buyer/producer with different prediction algorithms. For example, the prediction algorithms can be related to where biomass may be needed and/or produced, an estimated price of biomass for a future period of time, and the like. This type of predictability can lead to biomass feedstock 20 becoming a commodity with increased standards and protocols being apparent via data analysis. The biomass management and exchange system 10 also includes an opportunity for relevant products and/or services to be advertised to biomass producers and buyers, for example, transportation and/or logistics companies to deliver biomass feedstock to the buyers.
[0021] The following is an illustrative example of the biomass management and exchange system 10 in use. A biomass producer 12 first produces and collects the biomass raw material 20 . The producer then creates a producer profile 16 using the biomass management and exchange system 10 through a web-based application 108 on an computing device 102 . The producer 12 specifies identifying information, such as the location of the biomass, the type of biomass, the age of the biomass, and, optionally, the computing devices 102 (e.g., smartphones, computers, tablet computers) used to access the producer profile. Using one or more sensors 50 , (e.g., a wireless, Bluetooth® humidity sensor), the producer 12 measures at least one qualitative quality of the biomass, for example the humidity of the biomass feedstock. In one embodiment, the sensor 50 is connected to, or a part of, the computing device 102 . Each sensor 50 is configured to automatically upload the qualitative information, such as the humidity reading, to the producer profile 16 , where the information is associated with a particular biomass stack (Le,, at least a portion of the biomass feedstock produced). In some instances, a conventional humidity sensor 50 is used to measure the humidity of the biomass feedstock 20 . In such instances, the humidity value may be manually updated to the producer profile 16 by the producer 12 . The biomass management and exchange system 10 can differentiate between an automatic humidity reading from a humidity sensor 50 and a manual entry of a humidity reading. In other instances, other qualities of the biomass is measured (e,g., content of a particular chemical, the particle size of the biomass) using a sensor 50 and uploaded to the producer profile 16 . The producer 12 can also upload pictures of the biomass 20 to the profile 16 . Other non-limiting information associated with the biomass can include weather data, time, and location data associated with the biomass 20 . In other instances, a near infrared sensor can be used and/or unmanned surveillance of the biomass can be performed by installing additional sensors 50 . If the producer 12 sells more than one biomass stack, the producer can associate different pictures with different biomass stacks. Once all the information regarding the biomass 20 and the location 22 of the biomass is uploaded to the producer profile 16 , the producer 12 can begin to search for potential buyers 14 and offer the producers' biomass 20 for sale at a particular price 32 .
[0022] The producer 12 can also input laboratory data 52 for validation either via uploading reports or relevant documentation, photos, videos, and the like. The laboratory data 52 can also be contributory to the specification of the biomass material 20 . The cumulative data obtained through the sensors 50 (e.g., the humidity sensor) and from laboratory data 52 is aggregated by the biomass management and exchange system 10 , The biomass management and exchange system 10 analyzes the received data from the producers 12 and, using predictive algorithms, develops predictions of future biomass production, usage, and one or more qualities. For example, the biomass management and exchange system 10 gathers the biomass data from various producers and uses the biomass data to detect patterns and predict, in one such instance, a category that a biomass harvested in the future would fall into, the probability that a given biomass feedstock 20 on the biomass management and exchange system 10 will be within predetermined specifications, and/or the probability that a given biomass feedstock will become compliant with predetermined specifications over time. The pattern detection, data collection, and data processing and analysis can help to develop reliable commodity constraints for biomass, which can facilitate and encourage transactions of biomass materials.
[0023] A biomass buyer 14 creates a buyer profile 18 in a similar manner. As provided above, the buyer 14 specifies the location 34 of the business (typically an energy generating plant), the type 35 of biomass the buyer wants, and, optionally, the computing devices 102 used to access the buyer profile 18 . The buyer 14 then searches for appropriate biomass producers 12 . The buyer 14 can search for biomass producer profiles 16 and sort them according to different categories, for example, price of biomass unit, location, date available. Since transporting biomass feedstock may be costly, it is beneficial for the buyer to search for producers within a specified geographic range or perimeter. This way, transportation costs can be minimized. To this end, the biomass management and exchange system 10 allows the buyer 14 to restrict a search to a specified geographic area.
[0024] The buyer 14 then identifies the producers 12 from which to obtain the biomass 20 . The buyer then initiates contact with the producer and offers to buy at least some biomass material. In some examples, rather than waiting for a buyer to approach a producer,, the producer can search for a buyer and initiate contact with the buyer.
[0025] After a buyer 14 and producer 12 have connected, a series of negotiations and/or between the producer 12 and the buyer 14 take place until an agreement is reached. The negotiations and/or bidding may take place on an electronic bid/ask platform 60 through the computer-based system over the server 100 or external to the computer-based system (e.g., phone conference). The agreement can include transportation parameters, delivery date, one or more qualities of the biomass, the price paid for the biomass 20 , and the like. In some embodiments, the biomass management and exchange system 10 is configured to generate one or more agreement forms that indicate the parameters of the transaction. The details, discussed above, can include transportation parameters, a delivery date, qualities of the biomass, a price paid, and the like. In some embodiments, the biomass management and exchange system 10 stores different predetermined options for each parameter of the transaction. These stored options allow a buyer or a producer to quickly and easily choose a different option for a particular parameter. In some embodiments, the buyer 14 and/or the producer 14 can also specify a new parameter and customize it accordingly. The data from the transaction is loaded to the biomass management and exchange system to improve the algorithms and to increase the business intelligence of the system. In some instances, the biomass is monitored via the biomass management and exchange system until the biomass is delivered to the buyer. The biomass can be monitored for quality assurance purposes by measuring, for example. the humidity of the biomass. In some embodiments, the humidity of the biomass is measured when the biomass leaves an originating location. Based on the measured humidity, an expected humidity (or humidity range) at a destination can be calculated. The humidity of the biomass can then be measured at the destination to ensure that the humidity is within the expected range. The biomass can also be monitored via a GPS system'to calculate an estimated time of arrival. All of this information is made available to users through the computer-based system.
[0026] Each buyer can store information about the different producers in the biomass management and exchange system. For example, the buyer can store exact locations of the biomass for a particular producer, the fastest and/or most direct route to a producer location, costs associated with a particular producer, past transactions and results associated with a particular producer. The information associated with a particular producer can be visible to all or some of the users of the biomass management and exchange system. However, in some embodiments, the identity of the buyer who posted the information remains confidential. Thus, each producer can be rated in comparison with other producers and other buyers can make more informed decisions when negotiating with a particular producer. Each producer can also store information about the different buyers, such as, for example, exact locations associated with the buyers with most direct/fastest routes, past transactions with a particular buyer, and the like. The information associated with a particular buyer can be visible to all or some of the users of the biomass management and exchange system. However, in some embodiments, the identity of the producer who posted the information remains confidential. Thus, each buyer can be rated in comparison with other buyers and other producers can make more informed decisions when negotiating with a particular buyer. In some embodiments, only select users of the biomass management and exchange system have access to historical information associated with each buyer and/or each producer.
[0027] It should be understood that the above described methods and systems can be used with biomass and other bioenergy materials, including but not limited to biodiesel, ethanol, bio-chemicals, wood, woody materials, plant material, corn stover, straws and the like.
[0028] Therefore, the biomass management and exchange system 10 connects biomass producers 12 and biomass buyers 14 such that costs are minimized and the quality of the biomass feedstock is maintained. The biomass management and exchange system 10 also offers other tools for the producers and buyers to access information associated with the biomass market (local and global) and to run their own business.
[0029] While the present invention has been shown and described in accordance with several preferred and practical embodiments, it is recognized that departures from the instant disclosure are contemplated within the spirit and scope of the present invention which are not limited except as defined in the following claims as interpreted by the Doctrine of Equivalents.
|
The present invention is directed to a system for matching parties to a transaction of a biomass feedstock including at least one mobile sensory device structured and disposed for collecting biomass data for the biomass feedstock; a data storage repository configured to store seller criteria and a group of buyer criteria; and a processor of a central server configured to access the storage repository and execute software instructions stored in memory for receiving a group of buyer criteria, wherein each of the group of buyer criteria is sent from a buyer computing device used by one of a group of buyers of the biomass feedstock; receiving seller criteria for the biomass feedstock sent from a seller computing device or the at least one mobile sensory device; and sending the user criteria to the buyer and seller account messages to indicate potential market activity.
| 6
|
BACKGROUND AND SUMMARY OF THE INVENTION
The present application claims priority under 35 U.S.C. §119 to German Patent Application No. 10 2011 101 303.6, filed May 12, 2011, the entire disclosure of which is herein expressly incorporated by reference.
Exemplary embodiments of the present invention relate to an impact protection plate for mounting on the structure of a vehicle, in particular an aircraft.
Military transport aircraft, for example, the C160 Transall, are being increasingly used for humanitarian aid and disaster relief operations in crisis areas. In carrying out these operations, landings on unpaved runways are not uncommon, since the infrastructure in the affected countries, in particular in the region of the takeoff and landing strips, is often inadequately developed. These outlandings result in increased stone chip damage to the underside of the fuselage and to the antennas and valves located there. Stone chips to the antennas often have adverse effects on flight safety since proper functionality of navigation and radio devices may no longer be ensured due to the damage. In addition, these stone chips often result in high repair costs. For flights under icy conditions, propeller aircraft are also endangered by the impact of pieces of ice which come loose from the propeller.
German Patent Publication No. DE 10 2007 038 634 B3 describes an impulse-absorbing component as part of the structure of an aircraft, having a first wave-shaped, impulse-absorbing layer and a smooth cover layer situated thereon. The material of the wave-shaped layer is selected in such a way that it has a higher elongation at break than the cover layer. If a mass impact occurs and the outer cover layer is punctured, an intercept bag forms from the wave-shaped layer to dissipate the kinetic energy of the mass.
Exemplary embodiments of the present invention provide impact protection for a vehicle, in particular an aircraft, by means of which damage by stone chips, propeller ice impact, etc. may be reliably avoided, so that in particular the operational safety is not impaired, and the maintenance and repair effort for the vehicles affected by stone chip damage may be reduced.
The forces and energies that occur with stone chips (in the case of an aircraft, in particular during takeoff and landing) or propeller ice impact may be well absorbed and elastically cushioned by use of the impact protection plate according to the invention. The cushioning effect is achieved in particular by the wave-shaped layer close to the aircraft, which also has good rigidity. The impact protection plate according to the invention thus represents a type of “crumple zone” for impacting masses.
Since the critical region for stone chips on an aircraft is located in particular on the underside of the fuselage, one or more impact protection plates is/are preferably situated in this region of the aircraft fuselage. To protect from propeller ice impact, the impact protection plate is mounted in particular on the aircraft fuselage in the region of the propeller level.
Besides transport or passenger aircraft, an aircraft may also involve so-called unmanned aerial vehicles (UAVs). In addition to use on aircraft, the impact protection plate according to the invention may be used for protection of other vehicles that are subject to impact from masses, such as all-terrain vehicles, trucks, and railroad trains.
The impact protection plate according to the invention reduces repair costs for the vehicle and decrease the down times for the vehicle. The impact protection plate has very good impact-absorbing properties, with a very low weight.
The impact protection plates according to the invention may be mounted on existing vehicles without major modifications.
The impact protection plate according to the invention has the following layer structure in particular:
First Layer Close to the Vehicle (Also Referred to as “Wave Profile” Below):
This layer is composed of a fiber-reinforced plastic, and has a wave-shaped cross section with a regular pattern of alternating elevations and depressions. The transverse tensile strength of the fiber-reinforced plastic is greater than 50 MPa. The transverse tensile strength is the tensile strength of the material in the direction perpendicular to the reinforcement fibers. This transverse tensile strength is a good measure of the quality of the fiber/matrix binding within the fiber-reinforced plastic material. The selected parameter range ensures that the integrity of the layer, and thus the sought elastic effect, of this layer is maintained even under high stress from impacts. The individual elevations and depressions may in particular have a trapezoidal shape, although other shapes are also possible. The wave structure of this layer has the additional advantage that good ventilation of the interspace between the impact protection plate and the outer skin of the vehicle is ensured, so that corrosion processes at this location are prevented or at least impeded.
Second Layer Remote from the Vehicle (Also Referred to as “Cover Layer” Below):
This second layer is provided on the first layer as a cover layer. The second layer is a smooth layer having a curvature that is preferably adapted to the curvature of the aircraft structure. The second layer likewise is composed of a fiber-reinforced plastic, the elongation at break of the reinforcement fibers being greater than 3%. As a result of the high elongation at break, failure of this cover layer under the expected stresses due to impacts may be avoided with high reliability.
In one preferred embodiment, the elongation at break of the reinforcement fibers of the second layer is higher than the elongation at break of the reinforcement fibers of the first layer.
The selection of the layer thicknesses is made according to the application. In most cases, the thickness of the wave profile is less than the thickness of the cover layer. Preferred thickness ranges are as follows:
Wave profile: between 0.4 mm and 0.8 mm
Cover layer: between 0.9 mm and 2.0 mm
For the wave profile, the following combinations of fiber and matrix may be used in a particularly advantageous manner:
E-glass/PEEK
E-glass/PPS
E-glass/epoxy
S2-glass/PEEK
S2-glass/PPS
S2-glass/epoxy
Quartz glass/PEEK
Quartz glass/PPS
Quartz glass/epoxy
For the cover layer, the following combinations of fiber and matrix are particularly suited:
S2-glass/PEEK
S2-glass/PPS
S2-glass/epoxy
Quartz glass/PEEK
Quartz glass/PPS
Quartz glass/epoxy
Aramide/PEEK
Aramide/PPS
Aramide/PE
Aramide/PP
One particularly advantageous embodiment of the impact protection plate according to the invention has S2-glass/epoxy as material for both layers.
In particular for the variants containing epoxy resin matrix, the so-called VAP resin injection process, as described in European Patent Publication No. EP 1 181 149 B1, for example, is suitable as a manufacturing method. In this process, the component space defined by the outer vacuum film is divided into two subspaces by a membrane which is permeable to air but impermeable to resin.
BRIEF DESCRIPTION OF THE DRAWING FIGURES
The invention is explained in greater detail below based on specific exemplary embodiments, with reference to the figures, which show the following:
FIG. 1 shows a cross section of an impact protection plate according to the invention,
FIG. 2 shows an impact protection plate according to the invention on the fuselage of an aircraft,
FIG. 3 shows a combination of multiple impact protection plates according to the invention,
FIGS. 4 a )- 4 c ) show an illustration of the details for fastening an additional protective cover at a recess in the impact protection plate according to the invention,
FIG. 5 shows an impact protection plate according to the invention having multiple protective covers, and
FIG. 6 shows an illustration of the details for fastening an impact protection plate according to the invention to the fuselage of an aircraft to be protected.
DETAILED DESCRIPTION
FIG. 1 shows the cross section of an impact-absorbing impact protection plate 10 according to the invention, which is provided for mounting to the underside of the fuselage of an aircraft. Apparent is the first layer 1 close to the aircraft, designed as a wave profile having regular trapezoidal wave troughs WT and wave crests WB in one direction (the designation as wave troughs and wave crests is made from the viewpoint of an observer on the aircraft side). The outer (i.e., facing toward the expected stone chips) cover layer 5 is situated on the wave profile 1 . In the example shown, the wave profile 1 has a thickness of 0.5 mm, while the cover layer 5 has a thickness of 1.0 mm. The illustrated impact protection plate has a curvature conforming to the contour of the underside of the fuselage of the aircraft to be protected. FIG. 2 shows the corresponding impact protection plate 10 on the fuselage of the aircraft AC.
FIG. 3 shows a three-dimensional illustration of multiple impact protection plates 10 that are combined into a panel. The illustrated panel forms the stone chip protection for the aircraft. The subdivision into multiple subpanels results in particular from the manufacturing process, and in principle may be arbitrarily selected. In addition, the criterion for fairly small plates for better handling during installation is important here. For aerodynamic optimization, the cover layers may overlap at the connecting regions.
The extensions (in particular antennas and valves) present on the underside of the fuselage represent obstacles for the impact protection plate according to the invention. The plate is therefore provided with recesses having protective covers 20 ( FIGS. 4 a )- c ) and 5 ) in order to cover and protect the extensions located in the recesses. The same materials that may be used for the two layers 1 and 5 , for example thermoplastic materials having glass fibers as reinforcement, are suitable as materials for the protective cover. Since these are nonconductive materials, problems with electromagnetic radiation from the antennas are avoided. FIGS. 4 a )- 4 c ) show details concerning the configuration and fastening of the protective covers. Quartz glass is particularly suited as a material for the protective covers due to its particularly good electromagnetic properties. In further advantageous embodiments, in particular the impact protection plates situated in the vicinity of antennas may be made of quartz glass, while the plates situated farther away may be made from the other mentioned matrix materials, which are usually less expensive.
To allow a protective cover 20 to be fastened to the cover layer 5 , the recess in the cover layer 5 is selected to be smaller than in the wave profile 1 (D 1 <D 2 in FIG. 4 a ). The protective cover 20 is inserted through the cover layer from the inside (on the aircraft side), and is adhesively bonded to the underside (side facing the aircraft) of the cover layer 5 , specifically, over the entire or partial area of the overlap region B ( FIG. 4 b ). The difference in diameters D 1 , D 2 prevents the protective cover from falling off the aircraft in the event that the adhesive bond fails.
As additional securing of the protective cover 20 , as illustrated in FIG. 4 c a circumferential thermoplastic weld connection 30 may be present on the outer side (side facing away from the aircraft) of the cover layer 5 along the joint between the protective cover 20 and the cover layer 5 . This thermoplastic weld connection not only ensures better load-bearing performance of the cover layer 5 /protective cover 20 connection, but at the same time also provides a seal for the joint.
In addition, screw or rivet connections, in particular made of thermoplastic material, may be used for fastening the protective covers.
FIG. 5 shows the stone chip protection for the aircraft formed from plates 10 according to the invention, having multiple (a total of 11) recesses with associated protective covers 20 for covering the antennas and valves situated therebeneath. It is also apparent that the recesses may also extend over multiple impact protection plates 10 .
FIG. 6 shows the design of the fastening via which the impact protection plate is mounted on the aircraft fuselage. For introducing the forces into the aircraft hull composed of frames and stringers (not illustrated in FIG. 6 ), additional double sheets 52 are mounted on the aircraft paneling 50 . These are sheet metal strips approximately 1 mm thick which are fastened to the outer skin of the aircraft by countersunk rivets. The double sheets extend either between two stringers or between two frames. In principle, the double sheets 52 may be mounted on the outer as well as the inner side of the paneling. In the embodiment shown in FIG. 6 , the double sheets are mounted on the outer side of the paneling 50 . In addition, elastic surface materials, for example a foam rubber layer (not illustrated in FIG. 6 ), may be situated on the double sheets to balance out unevenesses and to prevent increased friction between the double sheet 52 and the wave profile 1 . The impact protection plate is fastened by screws 54 situated in the region of a wave trough. The cover layer 5 thus also acts as protection of the screw connection from external influences. If an external impact to the screw head should nevertheless occur, this embodiment ensures that the lever arm for introduction of force into the aircraft structure is relatively short, and the introduction of force is correspondingly low (compared to the attachment of the screws at the wave crests).
The cover layer 5 must be provided with a borehole to ensure access to the screws 54 from the outside. This borehole must be large enough to allow insertion of the tool necessary for tightening the screw 54 . These boreholes are closed by rubber covers 56 after the impact protection plate is installed. Pressure-tight plate nuts 58 are used for the screw connection in order to maintain the pressure in the aircraft interior. These plate nuts ensure that the paneling is leak-tight when the impact protection plate is installed. The plate nuts are mounted in the aircraft interior, and may be fastened to the paneling using two countersunk rivets.
By using the described fastening concept, the stone chip protection plates may be mounted to the aircraft in a rapid and flexible manner and removed as needed.
The foregoing disclosure has been set forth merely to illustrate the invention and is not intended to be limiting. Since modifications of the disclosed embodiments incorporating the spirit and substance of the invention may occur to persons skilled in the art, the invention should be construed to include everything within the scope of the appended claims and equivalents thereof.
ABBREVIATIONS
PEEK: Polyether ether ketone
PPS: Polyphenylene sulfide
PE: Polyethylene
PP: Polypropylene
|
An impact protection plate is provided for mounting on the structure of an aircraft. The impact protection plate includes a first layer, close to the aircraft, made of a fiber-reinforced plastic having a wave-shaped pattern of alternating elevations and depressions, the transverse tensile strength of the fiber-reinforced plastic being greater than 50 MPa. The impact protection plate includes a second layer situated on the first layer, remote from the aircraft, and is made of a fiber-reinforced plastic, the elongation at break of the reinforcement fibers being greater than 3%.
| 1
|
FIELD OF THE INVENTION
[0001] The present invention relates to a composition and a method using an immunotoxin specific to a cell expressing folate receptor beta (FR-β) for treating a disease, in which the major pathological condition is macrophage activation, or leukemia expressing FR-β. More specifically, the present invention relates to development of therapy with an immunotoxin in which a toxin is bound to a monoclonal antibody against an FR-β antigen in treating rheumatoid arthritis, juvenile rheumatoid arthritis, macrophage activation syndrome, septic shock, and acute myeloid leukemia.
BACKGROUND ART
Monoclonal Antibodies
[0002] Monoclonal antibodies are produced using the method of Kohler and Milstein or a modified method thereof (Kohler et al. Continuous cultures of fused cells secreting antibody of predefined specificity. Nature. 1975 Aug. 7, 256(5517):495-7) (Non-patent Reference 1).
Toxins
[0003] A bacterial toxin, Pseudomonas exotoxin (PE), becomes active when its amino acid sequence is cleaved between 279 and 280 (Ogata et al. Cell-mediated cleavage of Pseudomonas exotoxin between Arg 279 and Gly 280 generates the enzymatically active fragment which translocates to the cytosol. J Biol Chem. 1992, 267(35): 25396-401 (Non-patent Reference 1).
[0004] A genetically engineered PE lacks the cell-surface binding Ia domain and consists of amino acids starting from position 280 of the amino acid sequence Further, KDEL and REDLK are added to the C-terminal site to increase the cytotoxicity (Kreitman. Chimeric fusion proteins-Pseudomonas exotoxin-based. Curr Opin Investig Drugs. 2001, 2(9):1282-93) (Non-patent Reference 3).
[0005] Further, there have been reports on preclinical studies using various different immunotoxins which including type-1 ribosome other than PE (momordin, gelonin, saporin, bryodin, and bouganin) (Pastan I. Immunotoxins containing Pseudomonas exotoxin A: a short history. Cancer Immunol Immunother. 2003, 52(5):338-41 (Non-patent Reference 4); Trail et al. Monoclonal antibody drug immunoconjugates for targeted treatment of cancer. Cancer Immunol Immunother. 2003 May, 52(5):328-37 (Non-patent Reference 5); Milenic D E. Monoclonal antibody-based therapy strategies: providing options for the cancer patient. Curr Pharm Des. 2002, 8(19):1749-64 (Non-patent Reference 6)).
Immunotoxins
[0006] To date, a number of immunotoxins which use recombinant PE have been disclosed.
[0007] U.S. Pat. No. 6,703,488 (Patent Reference 1) describes the construction of a conjugate of an anti-IL-13 receptor antibody with a toxin in claim 6 and construction of a recombinant toxin of an anti-IL-13 receptor antibody with a genetically engineered PE40 in Example 1.
[0008] U.S. Pat. No. 6,703,020 (Patent Reference 2) describes the construction of a conjugate of an anti-VEGF receptor antibody with PE in claim 16 .
[0009] U.S. Pat. No. 6,696,064 (Patent Reference 3) describes the construction of a conjugate of an anti-transferrin receptor antibody with a genetically engineered PE 38 in claim 6 .
[0010] U.S. Pat. No. 6,689,869 (Patent Reference 4) describes the construction of a conjugate of an anti-CD18 antibody with an enzyme inhibitor in claim 2 and the construction of a conjugate of an anti-CD18 antibody with PE in the specification.
[0011] U.S. Pat. No. 6,417,337 (Patent Reference 5) describes the construction of a conjugate of an anti-CEA antibody with a toxin in claim 5 and its specification describes that the toxin includes PE.
[0012] U.S. Pat. No. 6,395,276 (Patent Reference 6) describes the construction of a conjugate of an anti-CD22 antibody with a toxin in claim 1 and a survival prolongation effect of an anti-CD22 antibody-genetically engineered PE conjugate in Daudi cell-implanted SCID mice in Example 5.
[0013] U.S. Pat. No. 6,348,581 (Patent Reference 7) describes the construction of a conjugate of an anti-TAG-72 antibody with a toxin in claim 4 and its text describes that the toxin includes PE.
[0014] U.S. Pat. No. 6,346,248 (Patent Reference 8) describes the construction of a conjugate of an anti-CD86 antibody with a toxin in claim 1 and its text describes that the toxin includes PE.
[0015] U.S. Pat. No. 6,319,891 (Patent Reference 9) describes the construction of a conjugate of an anti-glutathion-S-transferase antibody with PE in claim 7 .
[0016] U.S. Pat. No. 6,312,694 (Patent Reference 10) describes the construction of a conjugate of an anti-aminophospholipid antibody with PE in claim 31 .
[0017] U.S. Pat. No. 6,287,562 (Patent Reference 11) describes the construction of a conjugate of an anti-Lewis Y antibody with PE in claim 4 and suppression of cell line growth by a conjugate of an anti-Lewis Y antibody with a genetically engineered PE38 or its recombinant single chain immunotoxin in Example 7.
[0018] U.S. Pat. No. 6,267,960 (Patent Reference 12) describes the construction of a conjugate of an anti-prostate stem cell antigen antibody with PE or a genetically engineered PE40 in claim 4 .
[0019] U.S. Pat. No. 6,074,644 (Patent Reference 13) describes in claim 1 the construction of a recombinant double chain immunotoxin by S—S bonds between a genetically engineered PE (which lacks amino acid residues 1 through 279 and half or more of domain Ib) and a protein comprising an antibody component VH or VL and a protein comprising an antibody component VL or VH, and its claim 3 describes that these antibody components comprise PE and antibody components to B1, B3, B5, e23, BR96, Tac, RFB4, and HB21.
[0020] U.S. Pat. No. 6,033,876 (Patent Reference 14) describes the construction of a conjugate of an anti-CD30 antibody with a toxin in claim 4 and its text describes that the toxin includes PE38 and PE40.
[0021] U.S. Pat. No. 5,980,895 (Patent Reference 15) describes in claim 1 the construction of a recombinant double chain immunotoxin in which a conjugate of an antibody component VH with a genetically engineered PE (which lacks amino acid residues 1 through 279 and half or more of domain Ib) is linked with a conjugate of an antibody component VL by S—S bonds and its claim 3 describes that the VH and VL of this recombinant immunotoxin are derived from B1, B3, B5, e23, BR96, Tac, RFB4, and HB21 antibodies.
[0022] U.S. Pat. No. 5,840,854 (Patent Reference 16) describes the construction of a conjugate of an anti-GA733-1 antibody with a toxin in claim 21 and its text describes that the toxin includes PE.
[0023] U.S. Pat. No. 5,817,313 (Patent Reference 17) describes the construction of a conjugate of an anti-K1(CA125) antibody with a toxin in claim 3 and the binding activity of an anti-K1(CA125) antibody-PE to OVCAR-3 cells in Table 7.
[0024] U.S. Pat. No. 5,776,427 (Patent Reference 18) describes in claim 18 the construction of a conjugate of PE with each of CD5, CD8, CD11/CD18, CD15, CD32, CD44, CD45, CD64, CD25, CD30, CD54, CD71, HMFG-2, SM-3, B72.3, PR5c5, RR402, 27, OV-TL3, Mov18, and P185(HER2) antibodies.
[0025] U.S. Pat. No. 5,759,546 (Patent Reference 19) describes the construction of a conjugate of an anti-CD4 antibody with a toxin in claim 11 and its text describes that the toxin includes PE.
[0026] U.S. Pat. No. 5,506,343 (Patent Reference 20) describes the construction of a conjugate of an anti-unglycosylated DF3 antibody with a toxin in claim 12 and its text describes that the toxin includes PE.
[0027] U.S. Pat. No. 5,045,451 (Patent Reference 21) describes the construction of a conjugate of a toxin with each of CD2, CD3, CD5, CD7, CD8, glycophorin, Thy1.1, and CD22 antibodies in claim 1 and its text describes that the toxin includes PE.
[0028] U.S. Pat. No. 4,806,494 (Patent Reference 22) describes the construction of a conjugate of an anti-ovarian cancer (OVB-3) antibody with PE in claim 2 .
[0029] U.S. Pat. No. 4,545,985 (Patent Reference 23) describes the construction of a conjugate of each of anti-TAC and anti-transferrin receptor antibodies with PE in claim 3 .
[0030] European Patent relating WO 99/64073 (Patent Reference 24) describes the construction of a conjugate of an anti-HIVGP120 antibody with a genetically engineered PE in claim 2 .
[0031] European Patent relating No. NZ336576 (Patent Reference 25) describes the construction of a conjugate of each of EGP2, MUC1, MUC2, and MUC3 antibodies with PE in its abstract.
[0032] European Patent relating No. CN1330081 (Patent Reference 26) describes the construction of a conjugate of an anti-HIV antibody with a recombinant PE in its abstract.
[0033] European Patent relating WO 97/13529 (Patent Reference 27) describes in claim 1 the preparation of a recombinant double chain immunotoxin in which a protein constructed by a PE (which lacks amino acid residues 1 through 279) gene and an antibody VH gene, and an antibody VL protein are linked via S—S bonds and its claim describes that these antibodies are E1, B3, 35, e23, BR96, Tac, and HB21.
[0034] European Patent relating WO 98/41641 (Patent Reference 28) describes a method of the construction of a recombinant double chain immunotoxin in which a protein constructed by an anti-CD22 antibody VH and PE38 gene and an anti-CD22 antibody VL protein are linked via S—S bonds in claim 37 and an antitumor effect of this recombinant double chain immunotoxin in mice implanted with CD22 expressing human B-cell tumor in Example 8.
[0035] European Patent relating WO 94/13316 (Patent Reference 29) describes in claim 21 the construction of a conjugate of an antibody with a genetically engineered PE in which a mutation is introduced into domain 1 to weaken the binding to a cell and cysteine residues are added to domains 2 and 3 for binding to the antibody.
[0036] European Patent, EP 0583794 (Patent Reference 30), describes in claim 6 the construction of a conjugate of an antibody with a genetically engineered PE in which a mutation is introduced into a cell binding site of domain 1A and most or a part of domain II is deleted.
Genetically Engineered Antibodies
[0037] Further, a recombinant single chain immunotoxin can be constructed by linking DNA of an antigen binding site of the H chain or L chain of an antibody and a toxin DNA by genetic manipulation and producing a protein in cells of E. coli (Haasan R et al. Antitumor activity of SS(dsFv)PE38 and SS1(dsFv)PE38, recombinant antimesothelin immunotoxins against human gynecologic cancers grown in organotypic culture in vitro Clin Cancer Res. 2002 November; 8(11):3520-6) (Non-patent Reference 7).
[0038] Generally, a recombinant single chain immunotoxin has an intervening sequence between the H chain and the L chain which encodes approximately 15 amino acids (Reiter et al. Recombinant Fv immunotoxins and Fv fragments as novel agents for cancer therapy and diagnosis Trends Biotechnol 1998 December; 16(12):513-20) (Non-patent Reference 8).
[0039] Further, DNA of antigen binding site in H-chain or L-chain and a toxin DNA are linked by genetic manipulation and therewith a protein is produced in E. coli cells while another protein is produced using an L chain or H chain antigen binding site DNA and then a recombinant double-chain immunotoxin is constructed by linking these proteins via S—S bonds (Brinkmann et al. A recombinant immunotoxin containing a disulfide-stabilized Fv fragment. Proc Natl Acad Sci USA. 1993; 90(16):7538-42) (Non-patent Reference 9).
Chimeric Antibodies and Humanized Antibodies
[0040] It has been reported that a chimeric antibody produced in E. coli cells by linking a mouse immunoglobulin antigen binding site (Fab part) DNA and a human-derived immunoglobulin Fc part DNA by genetic manipulation produces only a small amount of antibodies against the mouse antibody part in humans and is useful for clinical administration (Smith et al. Rituximab (monoclonal anti-CD20 antibody): mechanisms of action and resistance. Oncogene 2003; 22(47):7359-68) (Non-patent Reference 10).
[0041] Further, it has been reported that a humanized antibody in which CDR1, CDR2, and CDR3 of a human immunoglobulin is replaced by CDR1, CDR2, and CDR3 of a mouse Fab part produces only a small amount of antibodies against the mouse antibody part and is useful for clinical administration (Kipriyanov. Generation and production of engineered antibodies. Mol Biotechnol. 2004; 26(1):39-60) (Non-patent Reference 11).
Liposomes
[0042] Administration of liposomes in which a drug is encapsulated with a lipid membrane has been attempted as drug delivery system. Further, in order to deliver a drug to a specific cell, an antibody which specifically binds to the cell can also be contained in the liposome in addition to the drug (Gabizon et al. Targeting folate receptor which folate linked to extremities of poly(ethylene glycol)-rafted liposomes: in vitro studies Bioconjug Chem. 1999; 10(2):289-98) (Non-patent Reference 12).
[0043] It is assumed that a drug delivery system with folate receptor beta (FR-β) is as useful as that with folate receptor alpha (FR-α) and in vitro studies on folate liposomes have been carried out using toxins such as momordin and saporin and anti-cancer agents (Pan X Q et al. Antitumor activity of folate receptor-targeted liposomal doxorubicin in a KB oral carcinoma murine xenograft model Pharm Res 2003 March; 20(3):417-22 (Non-patent Reference 13); Sudimack et al. Targeted drug delivery via the folate receptor. Adv Drug Deliv Rev 2000 Mar. 30; 41(2):147-62 (Non-patent Reference 14)).
Rheumatoid Arthritis
[0044] The present inventors have reported that expression of folate receptor beta (FR-β) is augmented in activated macrophages and synovial macrophages from rheumatoid arthritis patients (Nakashima-Matsushita et al. Selective expression of folate receptor beta and its possible role in methotrexate transport in synovial macrophages from patients with rheumatoid arthritis. Arthritis Rheum 1999; 42(8):1609-16) (Non-patent Reference 15).
[0045] As a mechanism of action of gold agents and methotrexate which are effective in treating RA synovitis, their action of suppressing migration and activation of monocytes and macrophages has been reported (Yamashita et al. Effects of chrisotherapeutic gold compounds on prostaglandin E2 production Curr Drug Targets Inflamm Allergy 2003 September; 2(3):216-23 (Non-patent Reference 16); Bondeson J. The mechanisms of action of disease-modifying antirheumatic drugs: a review with emphasis on macrophage signal transduction and the induction of proinflammatory cytokines Gen Pharmacol 1997 August; 29(2):127-50 (Non-patent Reference 17)).
[0046] Recently, it has been reported that an anti-TNF-α antibody therapy is markedly effective on RA, and the antibody-dependent cytotoxicity via TNF-α on the surface of the macrophage cell membrane has been suggested as a mechanism of its action (Maini R N et al. How does infliximab work in rheumatoid arthritis? Arthritis Res 2002; 4 Suppl 2:S22-8, Epub 2002 Mar. 27) (Non-patent Reference 18).
[0047] Further, in experimental arthritis in rats, folate uptake into arthritic areas increases and this uptake has been suggested to be by folate receptor beta (FR-β) expressing cells (Turk et al. Folate-target imaging of activated macrophages in rats with adjuvant-induced arthritis Arthritis Rheum 2002 July; 46(7):1947-55 (Non-patent Reference 19); Paulos C M et al. Folate receptor-mediated targeting of therapeutic and imaging agents to activated macrophages in rheumatoid arthritis Adv Drug Deli Rev 2004 April; 56(8):1205-17 (Non-patent Reference 20)).
[0048] The present inventors have reported that an antifolate Ly309887 specific to folate receptor beta (FR-β) suppresses experimental arthritis in mice (Nagayoshi et al. Ly309887, antifolate via the folate receptor suppresses murine type II collagen induced arthritis Clin Exp Rheumatol. 2003 November-December; 21(6):719-25) (Non-patent Reference 21).
[0049] An example of an immunotoxin which has been administered to human subjects aiming to treat RA is IL-2 denileukin diftitox (Strand V et al. Differential patterns of response in patients with rheumatoid arthritis following administration of an anti-CD5 immunoconjugate. Clin Exp Rheumatol. 1993 Suppl 8:S161-3) (Non-patent Reference 22).
[0050] An anti-CD5 antibody ricin A has been reported (Fishwild et al. Administration of an anti-CD5 immunoconjugate to patients with rheumatoid arthritis: effect on peripheral blood mononuclear cells and in vitro immune function. J. Rheumatol. 1994; 21(4):596-604) (Non-patent Reference 23).
[0051] Further, use of an anti-CD64 antibody ricin A to damage macrophages present in articular cavities has been reported (van Roon J A et al. Selective elimination of synovial inflammatory macrophages in rheumatoid arthritis by an Fc gamma receptor I-directed immunotoxin Arthritis Rheum 2003; 48(5):1229-38) (Non-patent Reference 24).
[0052] Furthermore, U.S. Pat. No. 6,645,495 (Patent Reference 31) describes the construction of anti-CD40L antibody bouganin in claim 7 and its effect in suppressing the growth of activated T cells in Example 4.
[0053] U.S. Pat. No. 6,346,248 (Patent Reference 32) describes application of anti-CD80 antibody gelonin and anti-CD86 antibody gelonin to autoimmune diseases in claim 2 .
Macrophage Activation Syndrome
[0054] In macrophage activation syndrome, the major pathological condition is considered to be abnormal activation of macrophages (Ravelli et al. Macrophage activation syndrome. Curr Opin Rheumatol 2002 S; 14(5):548-52) (Non-patent Reference 25).
Septic Shock
[0055] Septic shock has generally been recognized as a result of gram-negative bacterial infection; however, today it is revealed that it can also be eventually caused by gram-positive microorganisms, fungi, viruses, and parasites. Microorganisms themselves, their components, or their products induce host cells, particularly macrophages, to release an inflammatory substance such as TNF-α, which triggers a cascade leading to cachexia and septic shock (Evans et al. The role of macrophages in septic shock. Immunobiology 1996 October; 195(4-5):655-9) (Non-patent Reference 26).
Acute Myeloid Leukemia
[0056] It has been reported that folate receptor beta (FR-β) is rarely expressed in normal cells but the FR-β expression is accelerated in a part of the cells in acute myeloid leukemia (Reddy et al Expression and functional characterization of the beta-isoform of the folate receptor on CD34(+) cells Blood 1999 Jun. 1; 93(11):3940-8) (Non-patent Reference 27).
[0057] European Patent relating WO 03/072091 (Patent Reference 33) describes in claim 1 FR-β expression of myeloid leukemia cells accelerated by retinoic acid and administered by a liposome which contains folate and a drug, and its specification describes that FR-β expression is observed in 70% of acute myeloid leukemia and that a composition in which a drug is added to a folate liposome suppresses the growth of myeloid leukemia cells in vitro. As an immunotoxin for the treatment of acute myeloid leukemia, humanized anti-CD33 antibody calicheamicin has been approved by FDA in 2000 and has shown a good therapeutic effect (Giles et al. Gemtuzumab ozogamicin in the treatment of acute myeloid leukemia. Cancer. 2003 Nov. 15; 98(10):2095-104) (Non-patent Reference 28).
[0058] Furthermore, anti-CD30 antibody dianthin conjugate has been reported (Bolognesi et al. Anti-CD30 immunotoxins with native and recombinant dianthin 30 Cancer Immunol Immunother. 1995; 40(2):109-14) (Non-patent Reference 29).
[0059] Anti-CD33 antibody gelonin conjugate has been reported (Xu et al. Antileukemic activity of recombinant humanized M195-gelonin immunotoxin in nude mice. Leukemia. 1996; 10(2):321-6) (Non-patent Reference 30).
[0060] Anti-CD33 ricin conjugate has been reported (Russa et al. Effects of anti-CD33 blocked ricin immunotoxin on the capacity of CD34+ human marrow cells to establish in vitro hematopoiesis in long-term marrow cultures. Exp Hematol. 1992; 20(4):442-8) (Non-patent Reference 31).
[0061] Anti-CD64 antibody PE conjugate has been reported (Tur et ah Recombinant CD64-specific single chain immunotoxin exhibits specific cytotoxicity against acute myeloid leukemia cells. Cancer Res. 2003; 63(23):8414-9) (Non-patent Reference 32).
[0062] Anti-CD64 antibody ricin conjugate has been reported (Zhong et al. Cytotoxicity of anti-CD64-ricin a chain immunotoxin against human acute myeloid leukemia cells in vitro and in SCID mice J Hematother Stem Cell Res. 2001; 10(1):95-105)(Non-patent Reference 33).
[0063] Anti-HIM6 antibody cytosine arabinoside conjugate has been reported (Wang et al. [Studies of two conjugates of monoclonal antibody (HIM6) and cytosine arabinoside] Zhongguo Yi Xue Ke Xue Yuan Xue Bao. 1993; 15(4):286-90) (Non-patent Reference 34).
[0064] GM-CSF PE conjugate has been reported (O'Brien et al. A recombinant GM-CSF-PE40 ligand toxin is functionally active but not cytotoxic to cells. Immunol Cel Biol. 1997; 75(3):289-94) (Non-patent Reference 35).
[0065] GM-CSF diphtheria toxin conjugate has been reported (Hall et al. DT388-GM-CSF, a novel fusion toxin consisting of a truncated diphtheria toxin fused to human granulocyte-macrophage colony-stimulating factor, prolongs host survival in a SCID mouse model of acute myeloid leukemia. Leukemia 1999; 13(4):629-33) (Non-patent Reference 36).
[0066] IL-3 diphtheria toxin conjugate has been reported (Black et al. Diphtheria toxin-interleukin-3 fusion protein (DT(388)IL3) prolongs disease-free survival of leukemic immunocompromised mice, Leukemia, 2003; 17(1):155-9) (Non-patent Reference 37).
[0067] IL-9 PE conjugate and its in vitro and ex vivo effects have been reported (Klimka et ah A deletion mutant of Pseudomonas exotoxin-A fused to recombinant human interleukin-9 (rhIL-9-ETA′) shows specific cytotoxicity against IL-9-receptor-expressing cell lines. Cytokines Mol Ther. 1996; 2(3):139-46) (Non-patent Reference 38).
REFERENCES
[0000]
(1) U.S. Pat. No. 6,703,488 (Patent Reference 1)
(2) U.S. Pat. No. 6,703,020 (Patent Reference 2)
(3) U.S. Pat. No. 6,696,064 (Patent Reference 3)
(4) U.S. Pat. No. 6,689,869 (Patent Reference 4)
(5) U.S. Pat. No. 6,417,337 (Patent Reference 5)
(6) U.S. Pat. No. 6,395,276 (Patent Reference 6)
(7) U.S. Pat. No. 6,348,581 (Patent Reference 7)
(8) U.S. Pat. No. 6,346,248 (Patent Reference 8)
(9) U.S. Pat. No. 6,319,891 (Patent Reference 9)
(10) U.S. Pat. No. 6,312,694 (Patent Reference 10)
(11) U.S. Pat. No. 6,287,562 (Patent Reference 11)
(12) U.S. Pat. No. 6,267,960 (Patent Reference 12)
(13) U.S. Pat. No. 6,074,644 (Patent Reference 13)
(14) U.S. Pat. No. 6,033,876 (Patent Reference 14)
(15) U.S. Pat. No. 5,980,895 (Patent Reference 15)
(16) U.S. Pat. No. 5,840,854 (Patent Reference 16)
(17) U.S. Pat. No. 5,817,313 (Patent Reference 17)
(18) U.S. Pat. No. 5,776,427 (Patent Reference 18)
(19) U.S. Pat. No. 5,759,546 (Patent Reference 19)
(20) U.S. Pat. No. 5,506,343 (Patent Reference 20)
(21) U.S. Pat. No. 5,045,451 (Patent Reference 21)
(22) U.S. Pat. No. 4,806,494 (Patent Reference 22)
(23) U.S. Pat. No. 4,545,985 (Patent Reference 23)
(24) European Patent relating WO 99/64073 (Patent Reference 24)
(25) European Patent relating No. NZ336576 (Patent Reference 25)
(26) European Patent relating No. CN1330081 (Patent Reference 26)
(27) European Patent relating WO 97/13529 (Patent Reference 27)
(28) European Patent relating WO 98/41641 (Patent Reference 28)
(29) European Patent relating WO 94/13316 (Patent Reference 29)
(30) European Patent relating EP 0583794 (Patent Reference 30)
(31) U.S. Pat. No. 6,645,495 (Patent Reference 31)
(32) U.S. Pat. No. 6,346,248 (Patent Reference 32)
(33) European Patent relating WO 03/072091 (Patent Reference 33)
(34) Kohler et al. Continuous cultures of fused cells secreting antibody of predefined specificity. Nature. 1975 Aug. 7; 256(5517):495-7 (Non-patent Reference 1)
(35) Ogata et al Cell-mediated cleavage of Pseudomonas exotoxin between Arg279 and Gly280 generates the enzymatically active fragment which translocates to the cytosol. J Biol Chem 1992; 267(35):25396-401 (Non-patent Reference 2)
(36) Kreitman. Chimeric fusion proteins— Pseudomonas exotoxin-based Curr Opin Investig Drugs 2001 2(9):1282-93 (Non-patent Reference 3)
(37) Pastan I Immunotoxins containing Pseudomonas exotoxin A: a short history. Cancer Immunol Immunother. 2003; 52(5): 338-41 (Non-patent Reference 4)
(38) Trail et al. Monoclonal antibody drug immunoconjugates for targeted treatment of cancer, Cancer Immunol Immunother. 2003 May; 52(5):328-37 (Non-patent Reference 5)
(39) Milenic D E. Monoclonal antibody-based therapy strategies: providing options for the cancer patient Curr Pharm Des. 2002; 8(19):1749-64 (Non-patent Reference 6)
(40) Haasan R et al. Antitumor activity of SS(dsFv)PE38 and SS1(dsFv)PE38 recombinant antimesothelin immunotoxins against human gynecologic cancers grown in organotypic culture in vitro. Clin Cancer Res. 2002 November; 8(11):3520-6 (Non-patent Reference 7)
(41) Reiter et al. Recombinant Fv immunotoxins and Fv fragments as novel agents for cancer therapy and diagnosis Trends Biotechnol 1998 December; 16(12):513-20 (Non-patent Reference 8)
(42) Brinkmann et al. A recombinant immunotoxin containing a disulfide-stabilized Fv fragment. Proc Natl Acad Sci USA 1993; 90(16):7538-42 (Non-patent Reference 9)
(43) Smith et al Rituximab (monoclonal anti-CD20 antibody): mechanisms of action and resistance. Oncogene. 2003; 22(47):7359-68 (Non-patent Reference 10)
(44) Kipriyanov. Generation and production of engineered antibodies. Mol Biotechnol. 2004; 26(1): 39-60 (Non-patent Reference 11)
(45) Gabizon et ah Targeting folate receptor with folate inked to extremities of poly(ethylene glycol)-grafted liposomes: in vitro studies. Bioconjug Chem. 1999; 10(2):289-98 (Non-patent Reference 12)
(46) Pan X Q et al Antitumor activity of folate receptor-targeted liposomal doxorubicin in a KB oral carcinoma murine xenograft model Pharm Res 2003 March; 20(3):417-22 (Non-patent Reference 13)
(47) Sudimack et al. Targeted drug delivery via the folate receptor Adv Drug Deliv Rev. 2000 Mar. 30; 41(2):147-62. (Non-patent Reference 14)
(48) Nakashima-Matsushita et al. Selective expression of folate receptor beta and its possible role in methotrexate transport in synovial macrophages from patients with rheumatoid arthritis Arthritis Rheum. 1999; 42(8):1609-16 (Non-patent Reference 15)
(49) Yamashita et al. Effects of chrisotherapeutic gold compounds on prostaglandin E2 production Curr Drug Targets Inflamm Allergy 2003 September; 2(3):216-23 (Non-patent Reference 16)
(50) Bondeson J. The mechanisms of action of disease-modifying antirheumatic drugs: a review with emphasis on macrophage signal transduction and the induction of proinflammatory cytokines, Gen Pharmacol, 1997 August; 29(2):127-50 (Non-patent Reference 17)
(51) Maini R N et al. How does infliximab work in rheumatoid arthritis? Arthritis Res. 2002; 4 Suppl 2:522-8 (Non-patent Reference 18)
(52) Turk et al. Folate-targeted imaging of activated macrophages in rats with adjuvant-induced arthritis. Arthritis Rheum 2002 July 46(7):1947-55 (Non-patent Reference 19)
(53) Paulos C M et al. Folate receptor-mediated targeting of therapeutic and imaging agents to activated macrophages in rheumatoid arthritis. Adv Drug Deli Rev 2004 April; 56(8):1205-17 (Non-patent Reference 20)
(54) Nagayoshi et al. Ly309887, antifolate via the folate receptor suppresses murine type II collagen induced arthritis Clin Exp Rheumatol 2003 November-December; 21(6):719-25 (Non-patent Reference 21)
(55) Strand V et al. Differential patterns of response in patients with rheumatoid arthritis following administration of an anti-CD immunoconjugate, Clin Exp Rheumatol. 1993 Suppl 8:5161-3 (Non-patent Reference 22)
(56) Fishwild et al. Administration of an anti-CD5 immunoconjugate to patients with rheumatoid arthritis: effect on peripheral blood mononuclear cells and in vitro immune function. J Rheumatol, 1994; 21(4): 596-604 (Non-patent Reference 23)
(57) van Roon J A et al. Selective elimination of synovial inflammatory macrophages in rheumatoid arthritis by an Fc gamma receptor I-directed immunotoxin. Arthritis Rheum. 2003; 48(5):1229-3 (Non-patent Reference 24)
(58) Ravelli et ah Macrophage activation syndrome. Curr Opin Rheumatol. 2002 S; 14(5):548-52 (Non-patent Reference 25)
(59) Evans. The role of macrophages in septic shock. Immunobiology 1996 October; 195(4-5):655-9 (Non-patent Reference 26)
(60) Reddy et al. Expression and functional characterization of the beta-isoform of the folate receptor on CD34(+) cells. Blood. 1999 Jun. 1, 93(11):3940-8 (Non-patent Reference 27)
(61) Giles et al. Gemtuzumab ozogamicin in the treatment of acute myeloid leukemia. Cancer. 2003 Nov. 15; 98(10):2095-104 (Non-patent Reference 28)
(62) Bolognesi et al. Anti-CD30 immunotoxins with native and recombinant dianthin 30. Cancer Immunol Immunother, 1995; 40(2):109-14 (Non-patent Reference 29)
(63) Xu et al. Antileukemic activity of recombinant humanized M195-gelonin immunotoxin in nude mice. Leukemia. 1996; 10(2):321-6 (Non-patent Reference 30)
(64) Russa et al. Effects of anti-CD33 blocked ricin immunotoxin on the capacity of CD34+ human marrow cells to establish in vitro hematopoiesis in long-term marrow cultures. Exp Hematol. 1992; 20(4):442-8 (Non-patent Reference 31)
(65) Tur et al. Recombinant CD64-specific single chain immunotoxin exhibits specific cytotoxicity against acute myeloid leukemia cells Cancer Res. 2003; 63(23):8414-9 (Non-patent Reference 32)
(66) Zhong et al. Cytotoxicity of anti-CD64-ricin a chain immunotoxin against human acute myeloid leukemia cells in vitro and in SCID mice. J Hematother Stem Cell Res 2001; 10(1):95-105 (Non-patent Reference 33)
(67) Wang et al. [Studies of two conjugates of monoclonal antibody (HIM6) and cytosine arabinoside] Zhongguo Yi Xue Ke Xue Yuan Xue Bao 1993; 15(4):286-90 (Non-patent Reference 34)
(68) O'Brien et al. A recombinant GM-CSF-PE40 ligand toxin is functionally active but not cytotoxic to cells. Immunol Cell Biol 1997; 75(3):289-94 (Non-patent Reference 35)
(69) Hall et al. GM-CSF Diphtheriatoxin (DT388-GM-CSF, a novel fusion toxin consisting of a truncated diphtheria toxin fused to human granulocyte-macrophage colony-stimulating factor, prolongs host survival in a SCID mouse model of acute myeloid leukemia. Leukemia 1999; 13(4):629-33 (Non-patent Reference 36)
(70) Black et al. Diphtheria toxin-interleukin-3 fusion protein (DT(388)IL3) prolongs disease-free survival of leukemic immunocompromised mice. Leukemia. 2003; 17(1):155-9 (Non-patent Reference 37)
(71) Klimka et al. A deletion mutant of Pseudomonas exotoxin-A fused to recombinant human interleukin-9 (rhIL-9-ETA′) shows specific cytotoxicity against IL-9-receptor-expressing cell lines. Cytokines Mol Ther. 1996; 2(3):139-46 (Non-patent Reference 38)
SUMMARY OF THE INVENTION
[0139] However, there has been no report on the construction of an IgG-type FR-β monoclonal antibody effectively applying Non-patent Reference 1. Further, there has been no report on the construction of an immunotoxin which is a conjugate of genetically engineered PE with an FR-β monoclonal antibody by effectively applying Non-patent Reference 2 and Non-patent Reference 3. Accordingly, an objective of the present invention is to construct an FR-β monoclonal antibody PE conjugate.
[0140] Further, there has been no report on the construction of an immunotoxin which is a conjugate of a toxin other than PE with an FR-β monoclonal antibody by effectively applying Non-patent Reference 4, Non-patent Reference 5 and Non-patent Reference 6 and accordingly an objective of the present invention is to construct an FR-β monoclonal antibody immunotoxin.
[0141] To date, a number of immunotoxins with use of recombinant PEs have been disclosed and their effectiveness in various diseases has been shown in vitro and in vivo. However, immunotoxins described in Patent References 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, and 30 are not immunotoxins targeting activated macrophages only and have a problem that no satisfactory effect can be obtained in treating diseases in which activated macrophage is the major pathological condition and accordingly an objective of the present invention is to construct an FR-β monoclonal antibody immunotoxin which is effective in treating diseases in which activated macrophage is the major pathological condition.
[0142] A recombinant single chain immunotoxin and a recombinant double chain immunotoxin can be constructed by linking a DNA of an antigen binding site of the H chain or L chain of an antibody with a DNA of a toxin by genetic manipulation and therewith producing a protein in E. coli cells. A recombinant immunotoxin has advantages such that it can easily enter inside cells because of its small molecular weight and that its mass purification is more possible than the chemical construction of antibody-toxin conjugates.
[0143] To date, since genetic sequences of the H chain and the L chain of an FR-β monoclonal antibody have not been elucidated, there has been no report on the construction of a FR-β monoclonal antibody recombinant single-chain immunotoxin by effectively applying Non-patent Reference 7 and Non-patent Reference 8 and the construction of a recombinant FR-β monoclonal antibody double-chain immunotoxin by effectively applying Non-patent Reference 9 and accordingly an objective of the present invention is to determine the genetic sequences of the H chain and the L chain of an FR-β monoclonal antibody for the construction of a recombinant FR-β monoclonal antibody single-chain immunotoxin and a recombinant FR-β monoclonal antibody double-chain immunotoxin.
[0144] It has been described that a chimeric antibody produces a smaller amount of antibodies against a mouse antibody part in humans and is useful in clinical administration. To date, since genetic sequences of the H chain and the L chain of an FR-β monoclonal antibody have not been elucidated, there has been no report on the construction of a chimeric antibody by effectively applying Non-patent Reference 10 and accordingly, an objective of the present invention is to determine the genetic sequences of the H chain and the L chain of an FR-β monoclonal antibody for the construction of a chimeric antibody of the FR-β monoclonal antibody.
[0145] Further, it has been described that a humanized antibody in which CDR1, CDR2, and CDR3 of a human immunoglobulin are replaced with CDR1, CDR2, and CDR3 of the mouse Fab part produces a small amount of antibodies against the mouse antibody part and is useful in clinical administration.
[0146] To date, since genetic sequences of the H chain and the L chain of an FR-β monoclonal antibody have not been elucidated, there has been no report on the construction of a humanized antibody by effectively applying Non-patent Reference 11 and accordingly an objective of the present invention is to determine genetic sequences of the H chain and the L chain of an FR-β monoclonal antibody for the construction of the humanized FR-β monoclonal antibody.
[0147] For drug delivery to a specific cell, use of an antibody, which binds to the specific cell, added into a liposome in addition to a drug is useful as a therapeutic method. However, there has been no report on the use of an FR-β monoclonal antibody for the construction of a liposome by effectively applying Non-patent Reference 12, Non-patent Reference 13, and Non-patent Reference 14 and accordingly an objective of the present invention is to construct an FR-β monoclonal antibody for the construction of a liposome containing the FR-β monoclonal antibody.
[0148] The role of activated macrophages in the pathological condition of rheumatoid arthritis is known and effectiveness of the therapies for the purpose of regulating macrophage activation has been reported in Non-patent References 15, 16, 17, and 18. However, these therapies are not with an immunotoxin and have problems in terms of capability in killing and elimination of the cells.
[0149] Further, in Non-patent Reference 19 and Non-patent Reference 20, use of a conjugate of a folate with an isotope is described but the problem thereof is that there is no mention on a therapeutic effect of this conjugate. An objective of the present invention is to suppress activated macrophages in rheumatoid arthritis by an FR-β monoclonal antibody conjugate. Further, Non-patent Reference 21 by the present inventors is a report showing that a drug binding to folate receptor beta (FR-β) is effective in arthritis mice but is not a report with use of an FR-β monoclonal antibody conjugate and accordingly an objective of the present invention is to suppress activated macrophages in rheumatoid arthritis by an FR-β monoclonal antibody conjugate.
[0150] To date, immunotoxins for the purpose of treating rheumatoid arthritis have been reported in Non-patent References 22, 23, 24, 31, and 32. However, lymphocytes and non-activated macrophages are also included as a target for the action and the suppression is not solely on activated macrophages, which disadvantageously causes various side effects. Further, toxins other than PE are used as a toxin and thus the action of PE as a toxin is not clear. An objective of the present invention is to suppress activated macrophages in rheumatoid arthritis by an FR-β monoclonal antibody immunotoxin, in particular an FR-β monoclonal antibody PE conjugate.
[0151] Non-patent Reference 25 has reported that abnormal activation of macrophages is the major pathological condition in macrophage activation syndrome and thus death or elimination of the activated macrophages is desirable. However, there is no mention about immunotoxins as a therapeutic means in Non-patent Reference 25. An objective of the present invention is to treat septic shock with an FR-β monoclonal antibody toxin conjugate.
[0152] Non-patent Reference 26 has reported that abnormal activation of macrophages is the major pathological condition in septic shock and thus death or elimination of the activated macrophages is desirable. However, there is no mention about immunotoxins as a therapeutic means in Non-patent Reference 26. An objective of the present invention is to treat septic shock with an FR-β monoclonal antibody immunotoxin.
[0153] It has been reported that the expression of folate receptor beta (FR-β) is increased in some acute myeloid leukemia, and Non-patent Reference 27 and Patent Reference 33 have reported that a liposome containing folate and a drug suppresses the growth of acute myeloid leukemia cells; however, this liposome treatment is not specific to FR-β expressing cells since folate receptors also include FR-α, which disadvantageously causes various side effects. Further, drug resistance is known to occur in leukemia cells and combined use of drugs is desirable. An objective of the present invention is to treat acute myeloid leukemia, specific to FR-β expressing acute myeloid leukemia cells, using a liposome containing an FR-β monoclonal antibody. Effects of immunotoxins in treating acute myeloid leukemia have been reported in Non-patent References 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, and 38. However, monoclonal antibodies or cytokines used as a ligand are not specifically bound to acute myeloid leukemia cells and no FR-β monoclonal antibody is used in any cases, which disadvantageously causes various side effects. Further, disappearance of surface antigens and induction of drug resistance have been known to occur in leukemia cells and combined use of drugs is desirable.
[0154] The present invention provides an FR-β monoclonal antibody, in particular an IgG-type FR-β monoclonal antibody, for the treatment of acute myeloid leukemia.
[0155] An objective of the present invention is to treat acute myeloid leukemia, specific to an FR-β, expressing acute myeloid leukemia cells, by an anti-FR-β monoclonal antibody immunotoxin conjugate.
[0156] The present invention is based on the finding that a new substance which damages activated macrophage cells and acute myeloid leukemia cells without acting on monocytes as macrophage precursor cells and non-activated macrophages is found and the present invention provides a therapeutic agent that is useful in treating diseases which cannot be satisfactorily treated with conventional therapeutic agents, utilizing a novel action mechanism of the substance and in combination with conventional therapeutic agents to further increase its therapeutic effect.
[0157] An object of the present invention is to provide a immunotoxin comprising a toxin molecule, and a monoclonal antibody which is capable of binding to a human FR-β antigen present on the cell surface of activated macrophages and leukemia cells and induces cell death by binding to the FR-β expressing cells.
[0158] Another object of the present invention is to provide a method of treating a disease in which macrophage activation is the major pathological condition, such as rheumatoid arthritis, juvenile rheumatoid arthritis, macrophage activation syndrome, and septic shock, by binding of the above-mentioned immunotoxin against an FR-β antigen, resulting in eliminating FR-β expressing cells and suppressing local inflammatory response. This method comprises administering an immunotoxin capable of binding to a human FR-β antigen on the surface of an activated macrophage cell in a therapeutically effective amount together with a pharmaceutically acceptable excipient to a patient who needs treatment.
[0159] A further object of the present invention is to provide a method of treating leukemia by binding of the above-mentioned immunotoxin against an FR-β antigen and eliminating FR-β expressing tumor cells. This method comprises administering an immunotoxin capable of binding to FR-β on the surface of a tumor cell derived from a myelocyte in a therapeutically effective amount together with a pharmaceutically acceptable excipient to a patient who needs treatment.
[0160] Yet another object of the present invention is to provide a finding on the genetic sequence of an FR-β monoclonal antibody for the construction of a recombinant immunotoxin, a chimeric antibody, and a humanized antibody of the FR-β monoclonal antibody.
[0161] The folate receptor beta (FR-β) cannot be expressed in other than myeloid cells and the expression is low in cells of healthy humans. Therefore, a therapeutic method applying an antibody against the FR-β antigen is considered to be useful; however, there has been no report on the construction of an IgG-type anti-FR-β monoclonal antibody with a high affinity to the FR-β antigen. To date, there has been no suggestion to use an FR-β monoclonal antibody for eliminating FR-β expressing activated macrophages in a disease in which macrophage activation is the major pathological condition. Further, there has been no suggestion to use the FR-β monoclonal antibody for eliminating FR-β expressing leukemia cells in leukemia.
[0162] Since folate receptor beta (FR-β) is expressed only in activated macrophages or acute myeloid leukemia cells but not in monocytes as macrophage precursor cells and non-activated macrophages, the present inventors have considered that it is an effective therapeutic method to kill or eliminate activated macrophages or acute myeloid leukemia cells by utilizing an FR-β monoclonal antibody for the treatment of a disease in which FR-β expressing cells are involved in the pathological condition. As a result of intensive research effort, the present inventors have newly constructed a monoclonal antibody against folate receptor beta (FR-β) specific to activated macrophages and thus completed the invention to accomplish the abovementioned objectives by binding this antibody to a toxin to construct an immunotoxin.
[0163] Namely, the present invention is based on the finding that a conjugate of an antibody against an FR-β antigen with a toxin (immunotoxin) effectively kills cells which express FR-β molecules. The present invention is from the thought that, FR-β monoclonal antibody immunotoxin is useful to prevent or treat diseases or symptoms which are mediated by cells expressing folate receptor beta (FR-β). Further, the present invention is based on the finding that, as effective component, an immunotoxin having an FR-β monoclonal immunotoxin, in particular, a conjugate of an IgG-type monoclonal antibody with a genetically engineered Pseudomonas aeruginosa toxin is cytotoxic to activated macrophage cells at a low concentration, and an action mechanism to inhibit the growth of folate receptor beta-expressing myeloid leukemia cells. Thus, the present invention has realized a novel therapeutic agent for the treatment of a disease wherein macrophages have a major role in its pathological condition or leukemia.
[0164] The term “antibody” as used in this specification includes polyclonal antibodies, monoclonal antibodies, humanized antibodies, single chain antibodies, fragments of these antibodies such as Fab fragments, F(ab)′ 2 fragments, and Fv fragments, and other fragments which maintain an antigen-binding capacity of the parent antibodies.
[0165] The term “monoclonal antibody” as used in this specification means an antibody group consisting of a single antibody population. This term does not intend to limit in terms of the kind or origin of the antibody and the method of the production of the antibody. This term includes complete immunoglobulins as well as Fab fragments, F(ab) 2 fragments, Fv fragments and other fragments which maintain the antigen-binding capacity of the antibodies. Mammalian and avian monoclonal antibodies can also be used in this invention.
[0166] The term “single chain antibody” used in this specification refers to an antibody which is prepared by determining a binding region (in both the H chain and the L chain) of an antibody having a binding capacity and adding a binding site so as to maintain the binding capacity. In this way, a thoroughly simplified antibody substantially having solely a variable region site necessary for binding to antigen is formed. The term “double chain antibody” used in this specification refers to an antibody which is prepared by determining a binding region (in both the H chain and the L chain) of an antibody having a binding capacity and linking the H chain or the L chain to the L chain or the H chain via s-s bonds. In this way, a thoroughly simplified antibody substantially having solely a variable region site necessary for binding to antigen is formed.
[0167] In the present invention, “immunotoxin (IT)” refers to a chimeric molecule in which a cell binding ligand is bound to a toxin or its subunit. The toxin part of the immunotoxin is derived from various origins such as plants and bacteria and a toxin derived from humans and a synthetic toxin (drug) can also be used.
[0168] Preferably, the toxin part is derived from a plant toxin such as type-1 or type-2 ribosome inactivated protein (IP). The type-2 ribosome inactivated protein includes, for example, ricin. The type-1 RIP is particularly suitable to construct an immunotoxin according to the present invention Examples of the type-1 IP include bacterial toxins such as Pseudomonas exotoxin (PE) and diphtheria toxin. Other usable toxins are bryodin, momordin, gelonin, saporin, bouganin and the like.
[0169] The ligand part of IT generally refers to a monoclonal antibody which binds to a selected target cell. The IT part to be used in the present invention is a bacterial toxin, Pseudomonas exotoxin (PE). Specifically, the toxin has an ADP-ribosylation activity and translocation activity through the cell membrane. More specifically, PE becomes an active form when its amino acid sequence is cleaved between positions 279 and 280 and can be constructed by transforming E. coli with an expression plasmid containing a DNA encoding PE which lacks a natural toxin receptor binding domain Ia.
[0170] A PE binding recombinant immunotoxin of the present invention lacks an Ia domain to bind to the cell surface, starts from position 280 of the amino acid sequence, and has an addition of KDEL and REDLK at the C-terminal site to increase its cytotoxicity. Specifically, nonspecific toxicity is markedly decreased since the toxin has no cell binding activity. More specifically, a genetically engineered PE has a lower toxicity to human or animal cells in vitro and shows a lower toxicity to the liver when administered in vivo than nonengineered PE.
[0171] Further, the term recombinant single chain immunotoxin as used in the present invention refers to a protein which is constructed by linking a DNA of an antigen binding site of the H chain or the L chain of an antibody with a DNA of a toxin by genetic manipulation and therewith producing a protein in E. coli cells. Specifically, a recombinant single chain immunotoxin generally includes a intervening sequence between the H chain and the L chain which is translated in about 15 amino acids (Reiter et al. Recombinant Fv immunotoxins and Fv fragments as novel agents for cancer therapy and diagnosis Trends Biotechnol. 1998 December; 16(12):513-20).
[0172] The term “recombinant double-chain immunotoxin” as used in the present invention refers to a protein which is constructed by linking a DNA of an antigen binding site of the H chain or the L chain of an antibody with a DNA of a toxin by genetic manipulation, producing a protein in E. coli cells, separately producing a protein using the L chain or H chain of antigen binding site DNA, and linking these two proteins via S—S bonds (Brinkmann et al. A recombinant immunotoxin containing a disulfide-stabilized Fv fragment. Proc Natl Acad Sci USA. 1993, 90(16):7538-42).
[0173] The term “chimeric antibody” as used in the present invention refers to an antibody which is constructed by linking a DNA of a mouse immunoglobulin antigen binding site (Fab part) with a DNA of a human-derived immunoglobulin Fc site by genetic manipulation and producing a protein in E. coli cells (Smith et al. Rituximab (monoclonal anti-CD20 antibody): mechanisms of action and resistance Oncogene 2003; 22(47): 7359-68).
[0174] The term “humanized antibody” as used in the present invention refers to an antibody in which CDR1, CDR2, and CDR3 of a human immunoglobulin are replaced with CDR1, CDR2, and CDR3 of a mouse Fab part (Kipriyanov Generation and production of engineered antibodies Mol Biotechnol 2004; 26(1): 39-60).
[0175] The term “liposome” as used in the present invention refers to a structure composed of a lipid membrane which encapsulates a drug as a drug delivery system. Specifically, it refers to a liposome containing an antibody which binds to a specific cell in addition to a drug in order to deliver the drug to the specific cell (Gabizon et al. Targeting folate receptor with folate linked to extremities of poly(ethylene glycol)-grafted liposomes: in vitro studies. Bioconjug Chem. 1999; 10(2): 289-98).
[0176] Examples of biologically and chemically active enzymes as used in the present invention include enzymes acting on the coagulation system, such as urokinase, plasmin, plasminogen, staphylokinase, and thrombin and proteolytic enzymes, such as metalloprotease, collagenase, gelatinase, and stromelysin.
[0177] Examples of cytokines used in the present invention include those which have antitumor activity, such as interferon, TGF-β, and TNF-α, endostatin which inhibits angiogenesis, and those which have anti-inflammatory activity, such as IL-1 receptor antagonists, IL-4, IL-10, IL-19, IL-20, IL-22, IL-24, IL-26, IL-28, and IL-29.
[0178] Examples of isotopes as used in the present invention include galium-67, galium-68, indium-111, indium-113, iodine-123, iodine-125, iodine-131, technetium-99, yttrium-90, rubidium-97, and rubidium-103.
[0179] In the present invention, “chemotherapeutic agent” refers to a molecule having a cytotoxic activity. Specific examples of the agent include metabolic antagonists such as cytosine arabinoside, fluorouracil, methotrexate, aminopterin, anthracycline, mitomycin, demecolcine, etoposide, and mithramycin; alkylating agents such as chlorambucil, melpharan, and endoxan; DNA synthesis inhibitors such as daunorubicin, doxorubicin, and adriamycin; and tubulin inhibitors such as colchicine, taxane, and vinca alkaloids including vinblastine and vincristine.
[0180] In the present invention, “folate receptor beta (FR-β)” refers to a surface antigen which is expressed in activated macrophages and acute myeloid leukemia cells and is a molecule involved in intracellular transportation of folate. In the present invention, “rheumatoid arthritis (A)” refers to a chronic inflammatory disease which has symptoms such as multiple joint swelling and pain and is characterized by joint bone destruction, in which macrophage-like cells present in the RA synovial membrane produce cytokines such as IL-1B, IL-6, IL-8, IL-10, IL-15, MCP-1, MIP-1A, TNF-A, M-CSF, GM-CSF, TGF-β, VEGF, PDGF, IL-1 receptor antagonists which antagonize with IL-1, NO, active oxygen, various cathepsins, and various metalloproteases.
[0181] In the present invention, “juvenile rheumatoid arthritis (JRA)” refers to a cause-unknown disease which occurs in youngsters of no more than 16 years old and causes chronic joint inflammation as a major symptom associated with various non-joint symptoms. More specifically, JRA is classified into three categories, i.e., systemic, polyarticular and pauciarticular types. The systemic type causes remittent fever from normal temperature to 40° C., rash, systemic lymph node swelling, liver/spleen swelling, pericarditis, pleuritis, and the like; the polyarticular type is often associated with subcutaneous nodules and causes systemic symptoms such as fever and fatigue, insufficient growth and weight loss; and the pauciarticular type causes iritis and occasionally weakening or loss of eyesight.
[0182] In the present invention, “macrophage activation syndrome” refers to a pathological condition which exhibits fever, pancytopenia, disorder of hepatic functions, disseminated intravascular coagulation, and blood cell phagocytosis in the bone marrow. Specifically, it causes hypercytokinemia, especially with a high TNF-α value and macrophage activation is its major pathological condition (Ravelli et al. Macrophage activation syndrome. Curr Opin Rheumatol. 2002 S; 14(5):548-52).
[0183] As used in the present invention, “septic shock” is generally recognized as a result of gram-negative bacterial infection; however, today it is evident that it can also be caused as a result of infection with gram-positive microorganisms and probably with fungi, viruses and parasites.
[0184] In the present invention, “acute myeloid leukemia” refers to an abnormal growth of myeloid cells and causes death from infection and bleeding in untreatable cases. Specifically, it is acute myeloid leukemia in which FR-β is expressed (Russ et al. Folate receptor type beta is a neutrophilic lineage marker and is differentially expressed in myeloid leukemia. Cancer. 1999 Jan. 15, 85(2):348-57).
[0185] A subject of the present invention is FR-β monoclonal antibodies. It includes IgG type antibodies. The FR-β monoclonal antibodies of the present invention also include antibodies produced by clone 36 cell obtained by immunizing a mouse with FR-β expressing B300-19 cell and then fusing spleen cells from the mouse with mouse myeloma cells. The FR-β monoclonal antibodies of the present invention also include antibodies produced from clone 94b cell obtained by immunizing a mouse with FR-β expressing B300-19 cell and then fusing spleen cells from the mouse with mouse myeloma cells.
[0186] A subject of the present invention is genes of the H chain and the L chain of the FR-β monoclonal antibody clone 36 and proteins encoded by these genes. Further, the present invention also includes variants which have biological activities substantially equivalent to those of these genes or proteins. The present invention also includes humanized FR-β monoclonal antibodies which are obtained by chimerization of the genes of the H chain and the L chain of clone 36.
[0187] A subject of the present invention is genes of the H chain and the L chain of FR-β monoclonal antibody clone 94b and proteins encoded by these genes. Further, the present invention also includes variants which have biological activities substantially equivalent to those of these genes or proteins. The present invention also includes humanized FR-β monoclonal antibodies which are obtained by chimerization of the genes of the H chain and the L chain of clone 94b.
[0188] An FR-β antibody immunotoxin of the present invention is a conjugate of an FR-β monoclonal antibody with a toxin. Here, the toxin includes, but is not limited to, ricin A chain, deglycosylated ricin A chain, a ribosome inactivating protein, alpha-sarcin, gelonin, aspergilin, restrictocin, ribonuclease, epipodophyliotoxin, diphtheria toxin, and Pseudomonas exotoxin.
[0189] The present invention also includes a recombinant FR-β antibody immunotoxin produced using H chain and L chain genes of the clone 36.
[0190] The present invention also includes a recombinant FR-β antibody immunotoxin produced using H chain and L chain genes of the clone 94b L chain gene.
[0191] The present invention also includes a conjugate of at least one biologically or chemically active molecule selected from the group consisting of enzymes, cytokines, isotopes, and chemotherapeutic agents with an FR-β monoclonal antibody.
[0192] The present invention also includes a liposome containing an FR-β monoclonal antibody and a chemotherapeutic agent.
[0193] The present invention also includes a pharmaceutical composition containing at least one component selected from said FR-β antibody immunotoxin, said conjugate, and said liposome as an active ingredient.
[0194] The present invention also includes a therapeutic agent for treating a disease, in which macrophages are mainly involved in its pathological condition, containing at least one component selected from said FR-β antibody immunotoxin, said conjugate, and said liposome as active ingredient.
[0195] The present invention also includes the above-mentioned therapeutic agent wherein the disease in which macrophages are mainly involved in its pathological condition is a disease selected from the group consisting of rheumatoid arthritis, juvenile rheumatoid arthritis, macrophage activation syndrome, and septic shock.
[0196] The present invention also includes a therapeutic agent for treating rheumatoid arthritis or juvenile rheumatoid arthritis, in which the administration form for the above-mentioned therapeutic agent is joint injection.
[0197] The present invention also includes a therapeutic agent for treating leukemia containing at least one component selected from said FR-β antibody immunotoxin, said conjugate, and said liposome as an active ingredient.
[0198] The present invention also includes the above-mentioned therapeutic agent in which the leukemia is acute myeloid leukemia.
[0199] The FR-β antibody immunotoxin of the present invention induces apoptosis, a form of programmed cell death, in FR-β expressing macrophages. Further, the FR-β antibody immunotoxin of the present invention acts on FR-β expressing B300-19 cells and induces apoptosis, a form of programmed cell death, in the FR-β expressing B300-19 cells.
[0200] As explained above, the present invention constructs an FR-β monoclonal antibody which acts on activated macrophages and acute myeloid leukemia cells but not on macrophage precursor cells such as monocytes and non-activated macrophages, and therewith provides a therapeutic agent that is useful in treating diseases which cannot be satisfactorily treated with conventional therapeutic agents and further increases its therapeutic effect in combination with conventional therapeutic agents.
[0201] There is provided a therapeutic agent having a specific therapeutic effect on activated macrophages and acute myeloid leukemia cells by constructing an IgG-type FR-β monoclonal antibody with a low molecular weight and a high affinity to the FR-β antigen.
[0202] Gene sequences of variable regions of the H chain and the L chain of IgG-type FR-β monoclonal antibodies clone 36 and clone 94b have been elucidated to make it possible to provide a chimeric antibody, a humanized antibody, and a recombinant antibody. Further, these conjugates provide therapeutic agents which cause only a weak allergic reaction to mouse proteins and can be produced in a large scale.
[0203] The base sequence of the gene for the H chain of the antibody clone 36 is represented by SEQ ID NO: 1 of the Sequence Listing The amino acid sequence of the protein encoded by the sequence is also shown along with the base sequence. The base sequence of the gene for the L chain of clone 36 is represented by SEQ ID NO: 2 of the Sequence Listing along with the amino acid sequence of the protein encoded by this base sequence. The gene sequence of the H chain of clone 94b is represented by SEQ ID NO: 3 of the Sequence Listing along with the amino acid sequence of the protein encoded by this gene sequence. The gene sequence of the L chain of clone 94b is represented by SEQ ID NO: 4 of the Sequence Listing along with the amino acid sequence of the protein encoded by this gene sequence.
[0204] In this specification, a gene having a base sequence which comprises partial deletions, substitutions, or additions in the base sequence shown by SEQ ID NO: 1 refers to a gene in which less than 20, preferably less than 10, more preferably less than 5 bases are substituted in the base sequence shown by SEQ ID NO: 1. Further, the base sequence of such gene has a homology of 90% or more, preferably 95% or more, more preferably 99% or more to the base sequence shown by SEQ ID NO: 1. Further, such gene and the gene having the base sequence shown by SEQ ID NO: 1 form a hybrid under stringent conditions. The same is true in modified base sequence relative to the base sequences shown by SEQ ID NO: 2, SEQ ID NO: 3, or SEQ ID NO: 4. Such genes also fall within the scope of the present invention as long as they encode a protein which has biological activities substantially equivalent to the H chain or the L chain of clone 36 or the H chain or the L chain of clone 94b.
[0205] By using genetic recombination technology, an artificial mutation can be introduced into a specific site of basic DNA without changing basic characteristics of said DNA or to improve these characteristics. Similarly, a gene having a natural base sequence or a gene having a non-natural base sequence provided by the present invention can be modified to a gene having characteristics equivalent to or improved from those of the natural gene by artificial insertions, deletions and substitutions. The present invention also includes such mutant genes.
[0206] Further, in this specification, a protein having an amino acid sequence which comprises partial deletions, substitutions, or additions in the amino acid sequence encoded by the base sequence shown by SEQ ID NO: 1 refers to a protein in which less than 20, preferably less than 10, more preferably less than 5 amino acids are substituted in the amino acid sequence encoded by the base sequence shown by SEQ ID NO: 1 (the amino acid sequence provided along with SEQ ID NO: 1). Further, the amino acid sequence of such a protein has a homology of 95% or more, preferably 97% or more, more preferably 99% or more to the amino acid sequence encoded by the base sequence shown by SEQ ID NO: 1. The same is true in modified amino acid sequence encoded by the base sequence represented by SEQ ID NO: 2, SEQ ID NO: 3, or SEQ ID NO: 4. Such proteins also fall within the scope of the present invention as long as they have biological activities substantially equivalent to the H chain or the L chain of clone 36 or the H chain or L chain of clone 94b.
[0207] In the present specification, “substantially equivalent” means that activities of the protein, such as a physiological activity to specifically bind to an FR-β antigen and a biological activity, are substantially the same. It may also includes the case of having the substantially the same quality of activities, such as a capability of specifically binding to an FR-β antigen, or being physiologically, pharmacologically or biologically the same in quality. Further, the activities are preferably the same in quantity. However, the quantity element of the activities may be different.
[0208] In the present specification, the “stringent” conditions for hybridization can be appropriately selected by those skilled in the art. Specifically, the hybridization can be carried out, for example, by the following procedure. A DNA or RNA molecule transferred onto a membrane is hybridized with a labeled probe in an appropriate hybridization buffer. The hybridization buffer contains, for example, 5×SSC, 0.1% by weight N-lauroyl sarcocine, 0.02 wt % SDS, 2 wt % blocking reagent for nucleic acid hybridization, and 50% formamide. The blocking agent for nucleic acid hybridization is prepared, for example, by dissolving a commercial blocking reagent for nucleic acid hybridization into a buffer solution containing 0.1 M maleic acid and 0.15 M sodium chloride (pH 7.5) at a concentration of 10%. The 20×SSC consists of 3 M sodium chloride and 0.3 M citric acid and SSC is preferably used at a concentration of 3× to 6×SSC, more preferably 4× to 5×SSC.
[0209] The temperature for hybridization is 40 to 80° C., preferably 50 to 70° C., more preferably 55 to 65° C. After several hours to overnight incubation, the reaction solution is washed with a washing buffer. The washing is carried out preferably at room temperature, more preferably at the temperature for hybridization. The washing buffer contains 6×SSC+0.1 wt % SDS solution, preferably 4×SSC+0.1 wt % SDS solution, more preferably 2×SSC+0.1 wt % SDS solution, furthermore preferably 1×SSC+0.1 wt % SDS solution, and most preferably 0.1×SSC+0.1 wt % SDS solution. The membrane is washed with such a washing buffer and a DNA molecule or an RNA molecule hybridized with the probe can be distinguished using the label used for the probe.
[0210] Conventional immunotoxins are not to target activated macrophages only, which causes such problems as side effects and insufficient effects in diseases in which activated macrophages are the major pathological condition. Accordingly, the present invention provides immunotoxins which are effective in diseases in which activated macrophages are the major pathological condition.
[0211] In the present invention, a conjugate of an FR-β monoclonal antibody is prepared with at least one selected from enzymes, cytokines, isotopes, and chemotherapeutic agents, which induce specific cell death or elimination of activated macrophages in diseases in which activated macrophages are the major pathological condition. Accordingly, such conjugate provides a novel therapeutic agent.
[0212] In order to deliver a drug to a specific cell, encapsulation of an antibody which specifically binds to the cell into a liposome in addition to the drug is useful as a therapeutic method; however, use of an FR-β monoclonal antibody for such purpose has not so far been reported. The present invention provides a liposome which has a novel action mechanism and causes little side effects in diseases in which activated macrophages are the major pathological condition.
[0213] According to the present invention, there is provided a therapeutic agent which has a novel action mechanism, causes little side effects and induces specific cell death or elimination of activated macrophages in rheumatoid arthritis, juvenile rheumatoid arthritis, macrophage activation syndrome, and septic shock in which activated macrophages are the major pathological condition, using a conjugate of an FR-β monoclonal antibody with at least one selected from toxins, enzymes, cytokines, isotopes, and chemotherapeutic agents or a liposome containing an FR-β monoclonal antibody.
[0214] A conjugate of an FR-β monoclonal antibody with at least one selected from toxins, enzymes, cytokines, isotopes, and chemotherapeutic agents or a liposome containing an FR-β monoclonal antibody obtained according to the present invention can be used as a local joint injection in rheumatoid arthritis and juvenile rheumatoid arthritis. Accordingly the present invention provides a novel therapeutic agent to eliminate local joint inflammation.
[0215] Since many of therapeutic agents to treat leukemia also act on normal cells, they cause various side effects. Further, it has been known that disappearance of surface antigens and drug resistance occur in leukemia cells and thus a therapeutic agent with a novel action mechanism has been desired A conjugate of an FR-β monoclonal antibody with at least one selected from toxins, enzymes, cytokines, isotopes, and chemotherapeutic agents and a liposome containing an FR-β monoclonal antibody obtained according to the present invention exhibit specific cell death or elimination of FR-β expressing leukemia cells and thus provide a novel therapeutic agent having a novel action mechanism with few side effects.
BRIEF DESCRIPTION OF THE DRAWINGS
[0216] FIG. 1 shows the reactivity of an anti-FR-β antibody of the present invention.
[0217] FIG. 2 shows the separation of an anti-FR-β antibody immunotoxin conjugate of the present invention and a toxin and the ADP-ribosylation activity of these molecules. IT represents immunotoxin. PE represents Pseudomonas exotoxin.
[0218] FIG. 3 shows that an anti-FR-β antibody immunotoxin conjugate of the present invention contains a toxin IT represents immunotoxin. mAB represents FR-β monoclonal antibody PE represents Pseudomonas exotoxin.
[0219] FIG. 4 shows cell death in B300-19 cells by an FR-β antibody immunotoxin of the present invention. In the drawing, 24 h, 36 h, and 48 h represent the cell death after 24 hours, after 36 hours, and after 48 hours, respectively.
[0220] FIG. 5 shows expression of FR-β with an adenovector in macrophages.
[0221] FIG. 6 shows cell death in FR-β expressing macrophages by an FR-β antibody immunotoxin of the present invention.
[0222] FIG. 7 shows that FR-β is expressed in rheumatoid arthritis synovial cells.
[0223] FIG. 8 shows cell death of rheumatoid arthritis synovial cells by an FR-β antibody immunotoxin of the present invention.
[0224] FIG. 9 shows an SDS-polyacrylamide electrophoresis pattern for a recombinant double chain Fv anti-FR-β PE chimeric antibody.
[0225] FIG. 10 shows cell death in FR-β expressing B300-19 cells by a recombinant double chain Fv anti-FR-β PE antibody at various concentrations.
[0226] FIG. 11 shows cell death in FR-β expressing HL-60 cells by a recombinant double chain Fv anti-FR-β PE antibody at various concentrations.
DETAILED DESCRIPTION OF THE INVENTION
[Construction of FR-β Expressing Cells]
[0227] The present inventors have constructed an FP-β expressing B300-19 cell by the following method. First, the FR-β gene is incorporated into a pEF-BOS vector. The vector is not limited to the pEF-BOS vector and any mammalian expression vector can be used. Next, the FR-β gene is transfected into a mouse B300-19 cell using the lipofectamine method. The gene transfection method can be the electropolation method. Further, the cell line can be any cell line derived from Balb/C mice.
[0228] By immunization using this cell, the present inventors have constructed an IgG-type FR-β monoclonal antibody which exhibits a high affinity to the FR-β antigen and has a low molecular weight, using the cell fusion method. The antibody and a toxin molecule are chemically conjugated by one of various known chemical methods, for example, using a crosslinker having a different divalent binding group, such as SPDP, carbodiimide, and glutaraldehyde. Methods for the production of various immunotoxins are known in the art and are described, for example, in Monoclonal Antibody-Toxin Conjugates: Aiming the Magic Bullet, Thorpe et al. Monoclonal Antibodies in Clinical Medicine, Academic Press, pp. 168-190 (1982) and Waldman, Science, 252:11657 (1991). These two literatures are incorporated herewith by reference
[Construction of FR-β Antibody Immunotoxin]
[0229] The present inventors have constructed an immunotoxin by conjugating the abovementioned antibody with a genetically engineered Pseudomonas exotoxin (PE) using succinimidyl trans-4-(maleimidylmethyl)cyclohexane 1-carboxylate (SMCC) by the method of Haasan et al. (Haasan et al. Anti-tumor activity of K1-LysPE38QQR, an immunotoxin targeting mesothelin, a cell-surface antigen overexpressed in ovarian cancer and malignant mesothelioma. J Immunother. 2000 J; 23(4):473-9). Toxins to be used in the present invention include, in addition to PE, ricin A chain, deglycosylated ricin A, ribosome inactivating proteins, α-sarcin, gelonin, aspergillin, restrictocin, ribonuclease, epipodophyllotoxin, diphtheria toxin, and Pseudomonas exotoxin.
[0230] The antibody can be fused with a toxin using recombination technology in the same manner as in a process of constructing a single chain antibody-toxin fusion protein. Genes encoding a ligand and the toxin are cloned into cDNA using a known cloning method and then they are linked directly or apart by a small peptide linker. See, for example, Sambrook et al. Molecular Cloning: A Laboratory Manual, Cold Spring Harbor Laboratory (1989).
[0231] The present inventors have demonstrated by the incorporation of propidium iodium that this immunotoxin induces cell death (apoptosis) of gene-transfected macrophages, rheumatoid arthritis synovial cells, and FR-β gene-transfected cell lines. The cell to be used for verifying this effect of the immunotoxin can be any cell as long as it is an F-β expressing cell. Further, the cell death (apoptosis) can also be verified by Annexin-V staining. Further, the action effect can be shown by protein synthesis inhibition due to a decrease in the intracellular incorporation of [ 3 H] uridine or a decrease in the production of cytokines such as TNF-α, IL-1, IL-6, and IL-8.
[Base Sequences of Genes of the H Chain and the L Chain of FR-β Antibody]
[0232] The present inventors have amplified the genes of the H chain and the L chain of an FR-β monoclonal antibody (clone 36 or clone 94b) using primers of the Ig-Prime Kit (Novagen) The present inventors incorporate the genes of the H chain and the L chain amplified by the RT-PCR method using Taq polymerase into a pCR(r)2-TOPO(r) vector by the TA cloning method. This vector is transfected into E. coli . The present inventors purify vector inserts from the E. coli and determine their gene sequences using an M13 or T7 primer present in the vector. The vector can be any vector which has T at the 5′ end and contains either the M13 or T7 primer.
[Action Effect of FR-β Antibody Immunotoxin]
[0233] The immunotoxin of the present invention is applied to various diseases in which macrophage activation is the major pathological condition and leukemia in which FR-β expressing tumor cells are involved. Since no FR-β expression is observed in macrophages, the action effect is verified using FR-β expressing macrophages with an adenovirus vector.
[0234] Further, since no FR-β expression is observed in most cell lines, FR-β expressing cell lines are constructed using a general mammalian expression vector to verify the action effect.
[0235] Since macrophages obtained from the rheumatoid arthritis synovial membrane exhibit the FR-β expression they are suitable to verify the action effect.
[Dosage and Method of Administration of FR-β Antibody Immunotoxin]
[0236] Administration is carried out at an effective concentration for the treatment of rheumatoid arthritis, juvenile rheumatoid arthritis, macrophage activation syndrome, septic shock, and acute myeloid leukemia. In order to achieve this purpose, an immunotoxin can be prepared with various excipients which are acceptable and known in this field of technology. Typically, the immunotoxin is administered by injection, intravenously or into a joint cavity. A composition of the present invention is mixed with pharmaceutically acceptable non-oral excipients to formulate into the form of unit dose injections, such as solutions, suspensions, or emulsions. Such excipients are substantially non-toxic and non-therapeutic. Examples of such excipients include physiological saline, Ringer's solution, dextrose solution, and Hank's solution. Non-aqueous excipients such as fixed oil and ethyl oleate can also be used. A preferred excipient is a 5% dextrose in physiological saline solution. Excipients may contain a small amount of additives, for examples, substances to increase isotonicity and chemical stability, including buffer solutions and preservatives.
[0237] The amount and the form of administration may vary depending on individuals. Generally, the composition is administered most preferably at a dose of 0.1 to 2 μg/kg as the immunotoxin. Preferably, it is administered by bolus injection. Continuous infusion can also be used. In specific cases, the “therapeutically effective amount” of the immunotoxin of the present invention should be determined as an amount sufficient for the treatment of a patient to cure or at least partly halt a corresponding disease or its complications. The effective amount for such use may vary depending on the severity of the disease and the systemic health condition of the patient. The single administration or multiple administrations is required depending on the amount and frequency of the administration which are necessary and tolerable to the patient.
[0238] Particularly preferred embodiments of the present invention will be described as examples as follows.
EXAMPLES
Example 1
[0239] Whole RNA (200 μg) was extracted from rheumatoid arthritis synovial cells (1×10 7 ) with trizole (Gibco B L) according to the manufacturer's instruction. An admixture of 5 μl of the whole RNA (1 μg/μl), 1 μl of 10 mM dNTP (dATP, dGTP, dCTP, and dTTP), and 1 μl of oligo (dT) 12-18 primer (0.5 μg/μl) was reacted at 65° C. for 5 minutes and then allowed to stand in ice for 1 minute.
[0240] Further, 2 μl of 10×RT buffer solution, 24 μl of 25 mM MgCl 2 , 2 μl of 0.1 M DTT, and 2 μl of RNase OUT™ were added thereto and the resulting admixture was reacted for 2 minutes. Further, 1 μl of transcriptase (Superscript™ reverse transcriptase, Invitrogen) was added thereto and the resulting admixture was reacted at 70° C. for 15 minutes and then allowed to stand in ice for 2 minutes. Further, 1 μl of RNase H was added and the resulting admixture was reacted at 37° C. for 20 minutes to complete cDNA synthesis.
[0241] After obtaining cDNA, PCR was performed using 4.5 μl of the reaction product, 40 μM each of a sense primer (AGAAAGACATGGTCTGGAAATGGATG) and an antisense primer (GACTGAACTCAGCCAAGGAGCCAGAGTT), 0.6 mM dNTP, and 50 μl of Taq DNA polymerase (1.5 units, Boehringer Mannheim Corp) in 23 cycles of 94° C. for 5 minutes, 94° C. for 45 seconds, 60° C. for 60 seconds, and 72° C. for 90 seconds, after which the folate receptor beta (FR-β) gene was amplified by the reaction at 72° C. for 10 minutes.
[0242] Since the resulting PCR product contains A at the 3 end, it was ligated with a PCR2.1-TOPO vector (Invitrogen) having T at the 5′ end. Namely, 1 μl of Solt Solution, 1.5 μl of sterile distilled water, 1 μl of pCR(r)2-TOPO(r) vector were added to 2.5 μl of the PCR product and the resulting admixture was incubated at 22° C. for 5 minutes, after which a portion (2 μl) of the incubated admixture was added to one shot E. coli TOP 10F′ cells and the resulting admixture was reacted in ice for 30 minutes, after which the reaction solution was treated for heat shock at 42° C. for 30 seconds and allowed to stand in ice for 2 to 5 minutes, then 250 μl of S.O.C medium pre-warmed to 37° C. was added and the reaction was carried out at 37° C. for 1 hour in a shaker. Meantime, an LB plate was warmed to 37° C. The sample added with 40 μl of X-gal (100 mg/ml) and 40 μl of IPTG (20 mg/ml) was admixed into 3.5 ml of LB agar medium and the resulting admixture was poured onto the LB plate and incubated at 37° C. overnight.
[0243] For cultivation of E. coli cells, a white colony taken from the plate was added to 2 ml of LB medium supplemented with 1 μl of ampicillin (50 mg/ml) and the incubation was carried out in a shaker at 37° C. overnight.
[0244] DNA purification was carried out using a Qiagen plasmid purification kit (Qiagen). An insert was confirmed by verifying a 783 bp band on an electrophoresis gel after treatment with the EcoRI restriction enzyme. A vector containing the insert was treated with EcoRI and subjected to agarose electrophoresis. The insert part was dissected and subjected to ligation using T4 ligase with the vector pEF-BOS pretreated with EcoRI and alkaline phosphatase (Mizushima et al. pEF-BOS, a powerful mammalian expression vector. Nucleic Acids Res. 1990; 18(17):5322). The ligation product was subjected to transfection into one shot E. coli TOP 10F′ cells by the heat shock method. Since the transfected E. coli cells became ampicillin resistant, they were cultured overnight on a 1% agar medium containing ampicillin and the colonies obtained were further cultured overnight in an LB medium supplemented with ampicillin. The resulting E. coli cells were collected and a vector insert was purified by the abovementioned purification method. After treating with the EcoRI restriction enzyme, the insert was confirmed by a 783 bp band on an electrophoresis gel.
[0245] Using a mixture of 20 μl of lipofectamine (Gibco BRL), 1 μg of the purified pEF vector insert, and 1 ml of a Hank's balanced salt solution, the FR-β gene was transfected into B300-19 cells which were previously prepared at 1×10 5 in 24 wells. The resulting transfected cells were cultured in a DMEM solution containing G418 (1000 μg/ml) to confirm the FR-β expression of the grown B300-19 cells with an IgM-type anti-FR-β antibody. Namely, 5×10 5 B3001-9 cells were reacted with 0.1 ml of the FR-β antibody (1 mg/ml) at 4° C. for 30 minutes. The cells were washed 3 times with PBS containing 0.1% NaN 3 and 10% fetal calf serum, after which they were reacted with a fluorescence-labeled goat anti-mouse Ig antibody (BIOSOURCE) at 4° C. for 30 minutes. Then, the cells were washed twice with PBS containing 0.1% NaN 3 and 1% fetal calf serum, after which fluorescence of the cells was assayed using EPICS Elite (Coulter). B300-19 cells which consistently express folate receptor-beta (FR-β) were obtained.
Example 2
[0246] A mixture of the FR-β-expressing B300-19 cells (1×10 7 ) with Freund's complete adjuvant was immunized into 3 places on the back and the abdominal cavity of Balb/C mice. Further, 2 weeks later a mixture of the B300-19 cells (1×10 7 ) with Freund's incomplete adjuvant was immunized into the abdominal cavity of Balb/C mice. This immunization was further repeated 2 to 4 times.
[0247] Monoclonal antibodies were prepared by the method of Kohler and Milstein (Nature (1975); 256:495-96) or its modified method. The spleen (and several large lymph nodes, if necessary) was dissected and dissociated into single cells. All the dissociated spleen cells were fused with myeloma cells and the hybridomas thus constructed were cultured in a HAT selective medium. Hybridomas which reacted with the immunogen in the culture supernatant were selected.
[0248] The hybridomas thus obtained were cultured on plates by the limited dilution method and assayed for production of antibodies which specifically bind to one surface antigen of the immunized cells of interest (not bind to unrelated antigens). Next, selected monoclonal antigen-secreting hybridomas were cultured in vitro (for example, in a tissue culture bottle or using a hollow fiber cell culture system) or in vivo (as a mouse ascites). Further, using the culture supernatant, the isotype and subclass of monoclonal antibodies were determined by a mouse immunoglobulin isotyping ELISA kit (Pharmingen) using anti-mouse immunoglobulin G (IgG) subclass antibodies and anti-mouse isoclass type antibodies.
[0249] As a result, it was revealed that clone 36 was IgG 2a and clone 94b was IgG 1 . The reactivity of antibodies was analyzed by flow cytometry as shown in Example 1. FIG. 1 shows that the obtained clones react with the FR-β gene-transfected cells but not with the KB cells. In analysis by a flow cytometer (see the specification), the X axis shows the number of cells and the Y axis shows the fluorescent intensity of cells. The IgG-type FR-β antibody (clone 36) reacted with the FR-β gene-transfected cells (a) but not with the B300-19 cells which express no FR-β (b). Further, they did not react with the KB cells (c) which express FR-α but not FR-β (d).
Example 3
[0250] The hybridoma cells (1×10 7 ) were intraperitoneally injected into mice to which 0.5 cc of pristine had been injected 2 weeks earlier into the abdominal cavity and ascites was obtained 2 to 3 weeks later. A 0.5 ml portion of the ascites was loaded onto a protein G column and then the column was washed with a 10-fold volume of phosphate buffer, after which eluate was carried out with 2.5 pH glycine buffer. The pH of the eluate was adjusted to 8.0 with Tris buffer and the eluate was subjected to dialysis with PBS for 24 hours and then concentrated. From 0.5 ml of the ascites, 1 to 2 mg of IgG was obtained.
Example 4
Preparation of Pseudomonas Exotoxin from E. coli
[0251] Plasmid pMS8-38-402 for the expression of Pseudomonas exotoxin (PE) (Onda et al. In vitro and in vivo cytotoxic activities of recombinant immunotoxin 8H9 (Fv)-PE38 against breast cancer osteosarcoma, and neuroblastoma. Cancer Res. 2004; 64(4):1419-24) and its host E. coli BL21(DE3) (Stratagene) were cultured in 5 ml of LB medium supplemented with 0.1 mg/ml ampicillin and 0.1 mg/ml chloramphenicol at 37° C. for 12 to 15 hours. After 12 to 15 hours, 2 L of LB medium was added to 5 ml of the medium and incubation was continued until the absorbance at a wavelength of 600 nm reached 0.5. When the absorbance at a wavelength of 600 nm reached 0.5, IPTG was added at a concentration of 1 mM to the LB medium and incubation was further continued for 90 minutes.
[0252] After completion of the incubation, the cells were recovered and suspended in 50 ml of a 30 mM. Tris buffer solution (pH 7.4, containing 20% sucrose and 1 mM EDTA), and the suspension was allowed to stand in ice for 15 minutes. Then, the cells were recovered by centrifugation at 2,000 g for 15 minutes and suspended in 50 ml of sterile distilled water and the suspension was allowed to stand in ice for 15 minutes. Then, centrifugation was carried out at 15,000 g for 15 minutes and the resultant supernatant was collected to obtain a starting material for purification.
Example 5
[0253] Purification of PE was achieved using a Vision Workstation liquid chromatography system (Japan Perceptive). First, the starting material for PE purification was adsorbed at a flow rate of 10 ml/min onto a strong anion exchange resin column (POROS HQ, Poros) which had previously been equilibrated with a 20 mM Tris buffer solution (pH 7.4, containing 1 mM EDTA) and then the column was washed with an excess amount of the same buffer solution. Next, a 20 mM Tris buffer solution (pH 7.4, containing 1 mM EDTA) containing 1 M NaCl was used to set an NaCl concentration gradient from 0% to 100% in 10 minutes. The eluate was fractionated in 2 ml portions from the column at a flow rate of 10 ml/min for PE purification.
[0254] The purity of the fractionated sample was confirmed by SDS electrophoresis using the Laemmli method or by assaying for ADP-ribosylation activity. The PE sample after purification was further subjected to molecular size exclusion chromatography (TSK 3000 SW, Toso) with a 100 mM phosphate buffer solution (pH 80, containing 0.15 M NaCl and 1 mM EDTA) at a flow rate of 0.35 ml/min to fractionate the eluate in 1 ml portions from the column and thus highly purified PE was obtained.
Example 6
SDS-PAGE
[0255] SDS electrophoresis was carried out according to the Laemmli method (Laemmli-UK, Nature (1970) 227:6680-685). Namely, the plate gel used was a 10% polyacrylamide gel containing 0.1% sodium dodecyl sulfate (SDS) and the running buffer solution was a 25 mM Tris buffer solution containing 130 mM glycine at a final concentration of 0.1%. Each sample solution was prepared with an equal amount of a 100 mM Tris buffer solution (pH 6.5) containing 0.2% SDS and boiled for 5 minutes. After boiling, the sample was loaded on the plate gel and electrophoresis was performed at a constant current of 30 mA. After completion of the electrophoresis, the gel was stained with a 0.05% Coomassie brilliant blue R (Nakarai Tesque) solution and then destained with 100% ethanol containing 700 acetic acid to detect proteins.
Example 7
Assay for ADP-Ribosylation Activity
[0256] The method of Carroll et al was used (Carroll et al. Active site of Pseudomonas aeruginosa exotoxin A Glutamic acid 553 is photolabeled by NAD and shows functional homology with glutamic acid 148 of diphtheria toxin. J Biol Chem 1987; 262(18):8707-11). In the assay for ADP-ribosylation activity, 5 μl of a PE solution (approximately 0.1 to 1.25 μg) was added to 45 μl of 50 mM Tris buffer (pH 8.5, 4 μl of wheat germ extract (Promega), 37 pM 14 CNAD (0.06 μCi), 40 mM DDT, 1 mM EDTA) and the admixture was reacted at 37° C. for 10 minutes. After completion of the reaction, 10 μl of trichloroacetic acid (Nakarai Tesque) was admixed and the resultant admixture was centrifuged at 15,000 g for 3 minutes to remove the supernatant. The precipitate was further washed by the addition of a 5% trichloroacetic acid solution and centrifugation. After the washing, the 14 C radioactivity of the precipitate was measured using a liquid scintillation counter to obtain an index of the ADP-ribosylation activity.
Example 8
Construction of Immunotoxin
[0257] The method of Haasan et al was generally used (Haasan et al. Anti-tumor activity of K1-LysPE38QQR, an immunotoxin targeting mesothelin, a cell-surface antigen overexpressed in ovarian cancer and malignant mesothelioma. J Immunother. 2000 J; 23(4):473-9).
[0258] The coupling of an IgG monoclonal antibody against a human FR-β antigen (clone 36) with succinimidyl trans-4-(maleimidylmethyl)cyclohexane-1-carboxylate (SMCC, Sigma-A drich) was carried out. Namely, 100 μg of SMCC was added to 1 ml of a clone 36 antibody solution which was prepared at a protein concentration of 3.0 mg/ml using a 100 mM phosphate buffer solution and the admixture was reacted at room temperature for 1 hour.
[0259] After completion of the reaction, excess SMCC was removed using a desalting chromatography column PD-10 (Amersham Pharmacia) and a 100 mM phosphate buffer solution (pH 6.5, containing 150 mM NaCl and 1 mM EDTA). The efficiency of the coupling of the clone 36 antibody with SMCC was determined by measuring absorbance at a wavelength of 412 nm using a DTNB (dithiobis, Sigma-A drich) reagent and converting the measurement using the molecular extinction coefficient of DPNB per mole, 13,600. As a result, 2.8 to 3.1 molecules of SMCC were coupled with one molecule of the clone 36 antibody.
[0260] Next, the coupling of PE and succinimidyl 3-(2-pyridyldithio)propionate (SPDP, Sigma-Aldrich) was carried out Namely, 400 μg of SPDP was added to 1 ml of a PE solution which was prepared at a protein concentration of 10 mg/ml using a 100 mM phosphate buffer solution (pH 6.5, containing 150 mM NaCl and 1 mM EDTA) and the admixture was reacted at 4° C. for 12 to 15 hours.
[0261] After completion of the reaction, excess SPDP was removed using a desalting chromatography column PD-10 (Amersham Pharmacia) and a 100 mM phosphate buffer solution (pH 65, containing 0.15 M NaCl and 1 mM EDTA). The efficiency of the coupling of PE and SPDP was determined by measuring absorbance at a wavelength of 343 nm using 2-mercaptoethanol (Sigma-Aldrich) and converting the measurement using the molecular extinction coefficient of SPDP per mole, 8,080. As a result, 1.2 to 1.5 molecules of SPDP were coupled with one molecule of PE.
[0262] The coupling of the clone 36 antibody-SMCC with PE-SPDP was carried out using 3 mg of the clone 36-SMCC and 6 mg of the PE-SPDP.
[0263] First, 100 μg of tris-2-carboxyethylphosphine (TCEP, Molecular Probes) was added to 6 mg equivalent of the PE-SPDP (in a 100 mM phosphate buffer solution (pH 6.5) containing 150 mM NaCl and 1 mM EDTA) and the admixture was reacted at room temperature for 20 minutes to activate the PE-SPDP.
[0264] After completion of the reaction, 3 mg equivalent of the clone 36 antibody (in a 100 mM phosphate buffer solution (pH 6.5) containing 150 mM NaCl and 1 mM EDTA) was admixed in a centrifuge concentrator (Centricon 10, Amicon) with a molecular weight cut-off of 10,000 and centrifuged at 4,800 g at 4° C. to make a final protein concentration of 5-7 mg/ml. After the centrifugation, the resulting protein solution was reacted at 4° C. for 15 to 18 hours.
[0265] After completion of the reaction, substitution of the protein solution was carried out using a desalting chromatography column PD-10 (Amersham Pharmacia) and a 20 mM Tris buffer solution (pH 7.4, containing 1 mM EDTA) to prepare a starting material for immunotoxin purification.
[0266] Purification of immunotoxin was carried out according to the abovementioned method for PE purification. First, the starting material for immunotoxin purification was adsorbed at a flow rate of 10 ml/min onto a strong anion exchange resin column (POROS HQ, Poros) which had been previously equilibrated with a 20 mM Tris buffer solution (pH 7.4, containing 1 mM EDTA) and then the column was washed with an excess amount of the same buffer solution. Next, a 20 mM Tris buffer solution (pH 7.4, containing 1 mM EDTA) containing 1 M NaCl was used to set an NaCl concentration gradient from 0% to 100% in 10 minutes. The eluate was fractionated from the column in 2 ml portions at a flow rate of 10 ml/min for immunotoxin purification.
[0267] The purity of the fractionated sample was confirmed using the abovementioned SDS electrophoresis by the Laemmli method and by assaying for ADP-ribosylation activity. The immunotoxin after purification was further subjected to molecular size exclusion chromatography (TSK 3000 SW, Toso) using a 50 mM phosphate buffer solution (pH 7.3/containing 150 mM NaCl) to obtain a highly purified immunotoxin. The highly purified immunotoxin was further treated with a sterilization filter and stored at −80° C. (at a final concentration of 0.1 to 0.2 mg/ml).
[0268] FIG. 2 shows the result of gel filtration chromatography of the anti-FR-β antibody immunotoxin using TSK-SW3000. The X axis shows the elution volume and the Y axis shows the protein concentration at OD 280 with the solid circle and the ADP-ribosylation activity of Pseudomonas exotoxin with the solid triangle. The first peak of the protein concentration has a higher molecular weight and is considered to be the antibody or the antibody conjugated with the toxin. The next peak has a smaller molecular weight and is considered to be the toxin. Both peaks showed the ADP-ribosylation activity.
[0269] FIG. 3 is the result of Western blotting in which the FR-β antibody immunotoxin (IT) conjugate, the FR-β antibody (mAB) and Pseudomonas exotoxin (PE) were electrophoresed using SDS-PAGE and subjected to Western blotting with an anti-PE antibody and an anti-mouse IgG antibody, Only IT showed bands reacting both antibodies from 66 kDa to 200 kDa.
Example 9
[0270] Cells used were B300-19 cells in which FR-β was consistently expressed in Example 1. Toxicity of the immunotoxin was measured by the binding of propidium iodide and DNA using a flow cytometer (Nicolletti et al. A rapid and simple method for measuring thymocyte apoptosis by propidium iodide staining and flow cytometry. Immunol Methods. 1991; 139(2):271-9). Specifically, the B300-19 cells (2×10 5 /ml) and the FR-β antibody immunotoxin at various concentrations were incubated for various times. The resulting B300-19 cells were washed once with PBS, 0.5 ml of propidium iodide (40 μg/ml) was added to the cell pellet obtained and the admixture was reacted at room temperature overnight, after which the fluorescence of the cells was measured by a flow cytometer. Cells which were stained poorly with propidium iodide were considered to be dead cells and the fluorescence was measured using a flow cytometer. The result of the measurement is shown in FIG. 4
[0271] FIG. 4 shows the rate of cell death (shown in the Y axis) 24 hours, 36 hours, and 48 hours after mixing the B300-29 cells and the FR-β antibody immunotoxin in various concentrations (shown in the X axis). In FIG. 4 , data are the average of four experiments and error bars indicate SDs.
Example 10
[0272] cDNA of the FR-β was incorporated into a pEF-BOS vector, E. coli was transfected with the resulting vector by the heat shock method and then cell colonies were grown overnight to select an ampicillin-resistant insert positive clone. The positive clone was grown on 2 ml of LB medium and cDNA was purified using a Qiagen plasmid purification kit (Qiagen).
[0273] The FR-β gene was isolated from the plasmid by treating with the restriction enzyme XbaI and after ethanol precipitation, the FR-β gene was blunted using a DNA Blunting Kit (Takara), after which the resulting gene was extracted from the gel using QIAEXII (Takara) after electrophoresis. After phenol/chloroform extraction, ethanol precipitation was carried out and the resulting precipitate was dissolved in water.
[0274] The insert and a cosmid vector pAxCAwt were ligated and subjected to ethanol precipitation The resulting mixture was cleaved with SwaI. The resulting fragments were transfected into E. coli DH5α using a Gigapack 3 Gold Packing Extract (Stratagene). The resulting E. coli cells were plated on an agar plate containing ampicillin and the grown colonies were picked up and cultured in 10 ml of an LB medium supplemented with ampicillin, after which plasmids were recovered by the alkaline solution method and subjected to the PEG precipitation.
[0275] The precipitate was dissolved in water and the direction and the structure of the insert were confirmed by electrophoresis using restriction enzymes XbaI and BamHI. Cosmids having forward and backward inserts were cultured in 2 l of LB medium supplemented with ampicillin for large scale purification using a Large Construction Kit (Qiagen).
[0276] According to an Adenovirus Expression Vector Kit (Takara), the product was subjected to cotransfection with DNA-TP, which had been treated with restriction enzymes, by the calcium phosphate method using a CellPhect Transfection Kit (Amersham Pharmacia Biotech). Briefly, 9 D of pAxCAwt (8.1 μg) and 10 μl of DNA-TPC (7 μg) were mixed with 101 l of distilled water and the mixture was transfected by the calcium phosphate method into L293 cells grown in a 3.5 ml Falcon dish at a confluence of 80%.
[0277] After 24 hours, undiluted, 10-fold diluted and 100-fold diluted suspensions of the resulting L293 cells were prepared, transferred into a 96-well plate and then cultured for about 20 days. Recombinant adenovirus in which intracellular recombination occurred was obtained in a dead cell culture supernatant. Recombinant cosmids in 10-fold dilution and 100-fold dilution wells were confirmed by treating the cells with % SDS and then with phenol/chloroform and cleaving the cosmids with restriction enzymes XbaI and BamHI to individually confirm the presence of 768 bp and 1703 bp inserts using 10% agar gel.
[0278] The culture supernatant in which the inserts were confirmed was frozen and thawed 5 times and centrifuged at 3000 rpm for 10 minutes to obtain the supernatant. The supernatant was added to a 200 ml flask in which L293 cells were grown at a confluence of 80% and after 4 days, the supernatant was obtained from dead cell wells. The same procedure was repeated to obtain a virus with a high titer.
[0279] The titer of the virus was determined using the 50% tissue culture infectious dose method (Precious B and Russel W. C (1985) in Virology: A Practical Approach ed. Mahy B. W. J (IRL Oxford), pp. 193-205).
Example 11
[0280] A blood sample was taken from the vein of a healthy individual using a 50 ml heparin-containing syringe (200) and diluted 3-fold with PBS. The diluted blood was layered over a 50 ml tube containing 15 ml of Ficoll-Hypaque and centrifuged at room temperature at 3000 g for 15 minutes to isolate nucleated cells.
[0281] The upper layer was collected, PBS was added, and the admixture was centrifuged at 2000 g for 5 minutes, after which the supernatant was discarded, the pellet was loosened, PBS was added, and the admixture was centrifuged at 1000 g for 5 minutes. The pellet was loosened and cultured at a cell concentration of 1×10 6 /ml in a Falcon dish for 30 minutes and after washing 10 times with PBS, adhered cells were scraped off using a rubber policeman. After centrifugation, the cells were prepared at 1×10 6 /ml in DMEM and adhered again in a dish to obtain adhered cells. The adhered cells were cultured for 24 hours using M-CSF and then transfected at a MOI of 100 with an adenovirus vector carrying the folate receptor beta gene or an adenovirus vector carrying the reverse folate receptor beta gene.
[0282] The transfection experiment was carried out by adding the virus supernatant and centrifuging at 37° C. at 3000 g for 1 hour. The cells were prepared at 5×10 6 /ml and cultured for 72 hours. Further, to the transfected cells, an FR-β antibody and an FITC-labeled anti-mouse immunoglobulin antibody were added in sequence and positive cells were measured by a flow cytometer.
[0283] FIG. 5 shows the FR-β expression of macrophages by the introduction of the sense FR-β adenovector.
[0284] In FIG. 5( a ), the sense FR-β gene was introduced and the reaction was carried out with the FR-β antibody and the FITC-labeled anti-mouse Ig antibody. In FIG. 5( b ), the antisense FR-β gene was introduced and the reaction was carried out with the FR-β antibody and the FITC-labeled anti-mouse Ig antibody. Fluorescence was measured by flow cytometry. The X axis represents fluorescence and the Y axis represents the number of cells.
Example 12
[0285] Macrophages adjusted to 1×10 6 /ml were cultured in a 24-well dish at 1 ml per well, the measurements of the concentration of the FR-β antibody immunotoxin and cell death were carried out in the same manner as in Example 6. FIG. 6 shows cell death of the FR-β expressing macrophages by the FR-β antibody immunotoxin.
[0286] The macrophages in which the sense FR-β gene was introduced were mixed with the FR-β antibody immunotoxin in various concentrations (shown in the X axis) and the rate of cell death was obtained after 72 hours while the macrophages in which the antisense FR-β gene was introduced were mixed with the FR-β antibody immunotoxin in various concentrations and the rate of cell death was obtained after 72 hours. In FIG. 6 , the difference of the two rates was shown in the Y axis. The cells poorly stained with propidium iodide were considered to be dead cells and fluorescence was measured using a flow cytometer. In FIG. 6 , the data are the averages obtained in the experiment using the macrophages from four healthy individuals and the error bars indicate SDs.
Example 13
[0287] Synovial cells were purified from the synovial membrane obtained from a rheumatoid arthritis patient upon knee joint replacement surgery. First, the synovial membrane was cut into about 5 mm pieces and treated with 30 ml of DMEM containing 1 mg/ml collagenase type 5 at 37° C. for 30 minutes. After removing debris with a stainless mesh, an equal volume of DMEM was added and the admixture was centrifuged at room temperature at 2000 g for 15 minutes using the Ficol-Hypaque density gradient centrifuge method, after which the upper layers were collected, a 2-fold volume of DMEM was added, and the admixture was centrifuged at 1500 g, 1000 g to obtain synovial nucleated cells.
[0288] The cells (1×10 7 ) obtained were added to a Falcon dish, cultured at 37° C. for 30 minutes, and then washed 10 times with PBS to obtain adhered cells. The adhered cells were scraped off from the dish using a rubber policeman and collected into a 50 ml tube. After repeating the cell adhesion described above, the 50 ml tube was centrifuged at 1000 g. The cells prepared at a concentration of 1×10 6 cells/ml were cultured in DMEM supplemented with 10% human serum and 10% fetal calf serum. A mixture of equal amounts of an antibody and a toxin was used a control added with immunotoxin. Apoptosis of the cells after 72 hours was measured by the method described above.
[0289] FIG. 7 shows that the rheumatoid arthritis synovial cells express FR-β. The rheumatoid arthritis synovial cells were reacted with the FR-β antibody (a), CD14 antibody (b), and DR antibody, after which they were reacted with the FITC-labeled anti-mouse Ig antibody. Fluorescence was measured using a flow cytometer. The X axis represents the number of cells and the Y axis represents fluorescence. The expression of FR-β was observed more than 40% of the rheumatoid arthritis synovial cells.
[0290] FIG. 8 shows cell death of the rheumatoid arthritis synovial cells by the FR-β antibody immunotoxin. The rheumatoid arthritis synovial cells were mixed with the FR-β antibody immunotoxin in various concentrations (shown in the X axis) and the rate of cell death was obtained after 72 hours while the rheumatoid arthritis synovial cells were mixed with a mixture of equal amounts of molecules of the FR-β antibody and the toxin and the rate of cell death was obtained after 72 hours. In FIG. 8 , the difference of the two rates is shown in the Y axis. The cells poorly stained with propidium iodide were considered to be dead cells and fluorescence was measured using a flow cytometer. In FIG. 8 , the data are the averages experimentally obtained from six rheumatoid arthritis cases and the error bars indicate SDs.
Example 14
[0291] To 5-10×10 6 hybridoma cells was added 0.75 ml of a TRIZOL(r) LS reagent solution and the admixture was allowed to stand at 15 to 30° C. for 5 minutes. Further, 0.2 ml of chloroform per 0.75 ml of the TRIZOL LS reagent solution was added and the admixture was stirred and then allowed to stand at 15 to 30° C. for 2 to 15 minutes. After centrifugation at 12000 g at 4° C. for 15 minutes, only the top transparent layer was transferred to a separate tube.
[0292] To the solution thus obtained was added 0.5 ml of isopropyl alcohol per 0.75 ml of the TRIZOL(r) LS reagent solution and the admixture was allowed to stand at 15 to 30° C. for 10 minutes. After centrifugation at 12000 g at 4° C. for 10 minutes, the supernatant was discarded, 1 ml of 75% ethanol per 0.75 ml of the TRIZOL(r) LS reagent solution was added, and after centrifugation at 7500 g at 4° C. for 5 minutes, the supernatant was discarded. This procedure was repeated and then the resulting sample was dried. Before drying was complete, 10 μl of sterile distilled water without DNase and RNase was added Sterile distilled water without DNase and RNase was added to make a total RNA concentration of 1 μg/μl. To a 5 μl portion of the admixture were added 1 μl of 10 mM dNTP mix and 1 μl of an oligo(dT) 12-18 primer (0.5 μg/μl), and the resulting admixture was incubated at 65° C. for 5 minutes and then allowed to stand in ice for 1 minutes. Further, 2 μl of a 10×RT buffer solution, 4 μl of 25 mM MgCl 2 , 2 μl of 0.1 M DTT, and 2 μl of RNase OUT™ were added and the admixture was incubated at 42° C. for 2 minutes; μl of transcriptase (SuperScript™2PRT) was added and the admixture was incubated at 70° C. for 15 minutes and then allowed to stand in ice for 2 minutes; and finally 1 μl of RNase H was added and the admixture was incubated at 37° C. for 20 minutes to obtain cDNA.
[0293] The cDNA (1 μl each) was added into 13 reaction tubes, each containing the Ig-Prime Kit (Novagen) 1 unit of Taq DNA polymerase 50 μM each of dATP, dCTP, dGTP, and dTTP, 40 mM Tris-hydrochloric acid (pH 9.0), and 215 mM MgCl 2 , and into each tube, 0.5 μl of the 5′ primer and 0.5 μl of the 3′ primer for the H chain and the L chain genes were added.
[0294] PCR was performed with 27 cycles each consisting of 94° C. for 1 minute, 50° C. for 1 minute, and 72° C. for 2 minutes, and a final extension step of 72° C. for 6 minutes. For the determination of the base sequences of clone 36 and clone 94b, the 5′ primer MuIgVH5′-B and the 3′ primer MuIgVH3′-2 were used for the H chain genes and the 5′ primer MuIgκVL5′-A and the 3′ primer MuIgκVL3′-1 were used for the L chain genes. To 2.5 μl each of the PCR products were added Salt Solution (0.5 unit of T4 DNA ligase), 1 μl of sterile distilled water, 15 μl of and 1 μl of pCR(r) 2-TOPO(r) vector, and the admixture was incubated at 22° C. for 5 minutes. A 2 μl portion of the incubated admixture was added to one shot E. coli (TOP 10F′) cells and kept in ice for 30 minutes, treated for heat shock at 42° C. for 30 seconds, and kept in ice for 2 to 5 minutes, after which 250 μl of an S.O.C medium pre-warmed to 37° C. was added and the incubation was carried out in a shaker at 37° C. for 1 hour. Meantime, an LB plate was warmed to 37° C. and a mixture of the sample with 40 μl of X-gal (100 mg/ml) and 40 μl of IPTG (20 mg/ml) was mixed with 3.5 ml of LB agar medium and the resulting admixture was poured onto the LB plate and incubated at 37° C. overnight.
[0295] A white colony taken from the plate was added into 2 ml of LB medium supplemented with 1 μl of ampicillin (50 mg/ml) and the incubation was carried out at 37° C. overnight, DNA purification was performed using a Qiagen plasmid purification kit (Qiagen).
[0296] Base sequences were determined using a Big Dye Terminator V3.1 Cycle Sequencing Kit (Applied Biosystems). Namely, to a 5.3 μl portion of the purified DNA solution (25 μl) were added 4 μl of a Ready Reaction Mix and then further 0.7 μl of an M13R primer or a T7 primer.
[0297] PCR was performed with 25 cycles each consisting of 96° C. for 10 seconds, 50° C. for 5 seconds, and 60° C. for 4 minutes, and then the reaction solution was allowed to stand at 4° C. To 10 μl of the PCR product were added 1 μl of 3 M sodium acetate and 10 μl of 100% ethanol and the admixture was allowed to stand at 20° C. for 20 minutes and then centrifuged at 15000 g at 4° C. for 10 minutes, after which the supernatant was discarded, 180 μl of 70% ethanol was added and the admixture was stirred and centrifuged at 15000 g at 4° C. for 5 minutes, after which the supernatant was discarded and DNA was dried. To the DNA was added 15 μl of a template suppression reagent solution, and the admixture was stirred, subjected to centrifuge flash, stirring and further centrifuge flash, incubated at 99° C. for 5 minutes, then placed in ice and subjected to base sequence analysis using an ABI310 sequencer.
Example 15
Introduction of Cysteine Mutation in the Variable Region of Immunoglobulin Heavy Chain
[0298] A mutation was introduced into the plasmid pCR2.1-TOPO/94bVH containing the VH gene of clone 94b obtained in Example 14, using a Quick Change Site-Directed Mutagenesis Kit (Stratagene) with primers (cagaggcctgaacagtgtctggagtggattggaag and cttccaatccactccagacactgttcaggcctctg) which were designed to cause mutation of the amino acid glycine (base sequence ggc) at position 63 of the immunoglobulin clone 94b heavy chain variable region (VH) into cysteine (base sequence tgt).
[0299] This PCR reaction was carried out with 12 cycles consisting of 95° C. for 30 seconds, 55° C. for 1 minute and 68° C. for 4 minutes, after treating the reaction solution at 95° C. for 30 seconds.
[0300] Next, the DNA after the reaction was transfected into E. coli (XL1-Blue supercompetent cell) and a transformant was selected using LB medium containing 100 μl/ml of ampicillin. The plasmid of the selected transformant was extracted using a DNA purification kit (QIAprep Spin Miniprep Kit, Qiagen). Further, its base sequence was determined by an ABI310 sequencer using an M13 reverse primer (caggaaacagctatgac) and a base sequencing kit (Big Dye Terminator V3.1 Cycle Sequencing Kit, Applied Biosystems) to confirm that glycine at position 63 (base sequence ggc) was mutated to cysteine (base sequence tgt).
Example 16
Insertion of the Immunoglobulin Heavy Chain Variable Region Gene with the Introduced Mutation into pRK79/PE38 Vector
[0301] Next, the clone 96b VH gene with the introduced mutation was inserted into a pRK79 vector having the PE38 gene (PRK79/PE38) as follows.
[0302] As annealing primers for the 5′ end (FR1) and the 3′ end (JK) of the clone 94b VH gene with the introduced mutation, taagaaggagatatacatatggaggttcagctgcagcagtc and gccctcgggacctccggaagcttttgaggagactgtgagagtgg were designed, respectively. The FR1 annealing primer contains a restriction enzyme NdeI site and protein expression is possible by cloning at this site using atg in the site as a start codon. The JK annealing primer is designed to place “a” next to the JK annealing sequence followed by a restriction enzyme Hind III site so that the clone VH gene and the PE38 gene on the vector pRK79 can be ligated in the same frame by cloning at the restriction enzyme Hind III site.
[0303] Using the combination of these primers and DNA polymerase (Pfu DNA polymerase, Stratagene), PCR was performed with the pCR2.1-TOPO/94bVH plasmid into which the mutation was introduced.
[0304] This PCR reaction was carried out after 1 cycle of 95° C. for 4 minutes, with 30 cycles consisting of 95° C. for 1 minute, 54° C. for 1 minute, and 72° C. for 1 minute, followed by 1 cycle of 72° C. for 10 minutes.
[0305] Next, the PCR product was subjected to electrophoresis and DNA having a size of interest was recovered from the gel using a QIAquick Gel Extraction Kit (Qiagen). Further, the recovered PCR product was cleaved with restriction enzymes Hind III (New England Biolabs) and NdeI (New England Biolabs). The VH gene with the introduced mutation treated with the restriction enzymes was mixed with the pRK79/PE38 treated with the same restriction enzymes and the admixture was subjected to a ligation reaction at 16° C. overnight using a Ligation High kit (Toyobo).
[0306] Next, the ligation product was transfected into E. coli (TOP 10F′, Invitrogen) and a transformant was selected using LB medium supplemented with 100 μg/ml ampicillin.
[0307] The DNA of the transformant was extracted using a DNA purification kit (QIAprep Spin Miniprep Kit, Qiagen) and the base sequence of the plasmid was determined by an ABI310 sequencer using a T7 promoter primer (taatacgactcactataggg) and a base sequencing kit (Big Dye Terminator V3.1 Cycle Sequencing Kit, Applied Biosystems) to confirm that the VH gene with the introduced mutation was ligated to the PE38 base sequence in the T7 promoter downstream region on the pRK79 vector.
Example 17
Introduction of Cysteine Mutation into the Immunoglobulin Light Chain Variable Region
[0308] The amino acid glycine at position 125 of the immunoglobulin clone 94b light chain variable region (VL) was mutated to cysteine and the VL gene with the introduced mutation was inserted into the pRK79 vector as follows. As a 5′ end annealing primer, taagaaggagatatacatatggacattgtgatgtcacaatc was designed. Since this primer contains a restriction enzyme NdeI site, protein expression is possible by cloning at this site using atg as a start codon.
[0309] As a 3′ end (JK) annealing primer, gctttgttagcagccgaattcctatttgatttccagcttggtgccacaaccgaacgt was designed. This primer was designed to mutate the glycine (gga) at position 125 into cysteine (tgt) and place a stop codon tag followed by a restriction enzyme EcoRI site. Using the combination of these primers and DNA polymerase (Pfu DNA polymerase, Stratagene), PCR was performed with the plasmid pCR2.1-TOPO/94bVL containing the clone 94b VL gene obtained in Example 14.
[0310] This PCR reaction was carried out after 1 cycle of 95° C. for 4 minutes, with 30 cycles consisting of 95° C. for 1 minute, 54° C. for 1 minute, and 72° C. for 1 minute, followed by 1 cycle of 72° C. for 10 minutes.
Example 18
Insertion of the Immunoglobulin Light Chain Variable Region Gene with the Introduced Mutation into pRK79 Vector
[0311] The PCR product was subjected to electrophoresis and DNA having a size of interest was recovered from the gel using a DNA purification kit (QIAquick Gel Extraction Kit, Qiagen).
[0312] The recovered PCR product was cleaved with the restriction enzyme EcoRI (New England Biolabs) and the restriction enzyme NdeI (New England Biolabs) and then mixed with the pRK79 plasmid cleaved with the same enzymes and the mixture was subjected to a ligation reaction at 16° C. overnight using a Ligation High kit (Toyobo). Next, the ligation product was transfected into E. coli TOP 10F′ (Invitrogen) and a transformant was selected using LB medium supplemented with 100 μg/ml ampicillin.
[0313] A plasmid was extracted from the transformant using a DNA purification kit (QIAprep Spin Miniprep Kit, Qiagen) and its base sequence was determined by an ABI310 sequencer using a T7 promoter primer (taatacgactcactataggg) and a base sequencing kit (Big Dye Terminator V31 Cycle Sequencing Kit, Applied Biosystems) to confirm that the glycine (gga) at position 125 of the VL with the introduced mutation was mutated into cysteine (tgt), that the ligation was to the T7 promoter downstream region on the pRK79 vector, and that the stop codon tag was located next to the JK sequence.
Example 19
Preparation of Recombinant Protein Inclusion Body
[0314] E. coli BL21(DE3λ) was transfected using 50 ng of the plasmid pRK79/PE38 in which the abovementioned VH gene with the introduced mutation was incorporated or the plasmid pRK79 in which the VL gene with the introduced mutation was incorporated.
[0315] Selection of the E. coli in which the gene was transfected was carried out by incubation at 37° C. for 15 to 18 hours in an LB medium supplemented with ampicillin (100 μg/ml) and chloramphenicol (20 μg/ml).
[0316] E. coli cells after completion of the incubation for selection were cultured in 500 ml of a Super Broth medium supplemented with ampicillin (100 μg/ml) and chloramphenicol (20 μg/ml) at 37° C. until the absorbance at a wavelength of 600 nm reached 0.6.
[0317] Further, 1 mM IPTG (isopropyl-beta-D-thio-galactopyranoside) was added and incubation was carried out at 37° C. for 90 minutes. E. coli cells after completion of the incubation were recovered by centrifugation and then suspended using a 50 mM Tris buffer solution (pH 7.4, containing 20 mM EDA) and the suspension was made a final volume of 20 ml with the same buffer solution and transferred into a homogenizer. Egg white lysozyme was added to 20 ml of the suspension transferred into the homogenizer at a final concentration of 0.2 mg/ml and the admixture was reacted at room temperature for 1 hour to decompose the E. coli cell component. After decomposition, 2.5 ml each of a 5M, NaCl solution and a 25% Triton-X solution were added and the admixture was homogenized and then allowed to react at room temperature for 60 minutes. After completion of the reaction, the precipitate was recovered by centrifugation at 20,000×g at 4° C.
[0318] The recovered precipitate was resuspended in 20 ml of the same Tris buffer, 2.5 ml each of a 5M NaCl solution and a 25% Triton-X solution were added and the admixture was homogenized and centrifuged at 20,000×g at 4° C. to recover the precipitate. After repeating this procedure 8 times, the precipitate was resuspended in 20 ml of the same Tris buffer solution and the suspension was homogenized and then centrifuged at 20000×g at 4° C. to recover the precipitate. This procedure was repeated 5 times and the resultant precipitate to be used as a recombinant immunotoxin inclusion body was further dissolved in a 0.1 M Tris buffer solution (pH 8.0 containing 10 mM EDTA and 6 M guanidine hydrochloride) to make a final concentration of 10 mg/ml with the same buffer solution and stored at −80° C.
Example 20
Construction of Recombinant Double Chain Fv Anti-FR-β PE Antibody
[0319] The recombinant protein inclusion body solution stored at −80° C. was thawed at room temperature and 0.5 ml of VH and 0.25 ml of VL were individually transferred into a 1.5 ml tube. Next, dithiothreitol (DTT) was added at a final concentration of 10 mg/ml to carry out reducing treatment at room temperature for 4 hours. After the reducing treatment, 0.5 of VH and 0.25 nm of VL were mixed and dissolved in 75 ml of a 0.1 M Tris buffer solution (pH 8.0, containing 0.5 M arginine, 0.9 mM oxidized glutathion, and 2 mM EDTA). This solution was allowed to stand at 10° C. for 40 hours to ligate VH and VL. After completion of the ligation, the solution was concentrated to a volume of 5 ml using a centrifuge concentrator (Centricon 10, Amicon) with a cut-off molecular weight of 10,000 and further diluted with 50 nm of distilled water. This diluted solution was used as a starting material for recombinant immunotoxin purification.
Example 21
Purification of Recombinant Double Chain Fv Anti-FR-β PE Antibody
[0320] First, the abovementioned starting material for purification was adsorbed onto a strong anion-exchange resin column (Hi-trap Q, Amersham Pharmacia) previously equilibrated with a 20 ml Tris buffer solution (pH 7.4, containing 1 mM EDTA) at a flow rate of 30 ml/hour and the column was washed with a 20 mM Tris buffer solution (pH 7.4, containing 1 mM EDTA) until the absorbance at 280 nm reached less than 0.005. Next, elution was carried out with a 20 mM Tris buffer solution (pH 7.4, containing 1 mM EDTA) containing 0.3 M NaCl. After the elution, the eluate was subjected to dialysis/desalting in a 20 mM Tris buffer solution (pH 7.4, containing 1 mM EDTA).
[0321] Next, using a perfusion chromatography system (Applied Biosystems) and a strong anion-exchange column (POROS HQ, Poros), further purification was carried out. The dialyzed material for purification was adsorbed onto the column previously equilibrated with a 20 mM Tris buffer solution (pH 7.4, containing 1 mM EDTA) at a flow rate of 10 ml/min. After the adsorption, the column was washed with the same buffer solution, and then the purification of recombinant immunotoxin was carried out using a NaCl concentration gradient (setting the concentration to reach from 0 M to 1 M in 10 minutes). The eluate from the column was fractionated in 2 ml portions and a fraction with a high degree of purity was considered as a purified recombinant immunotoxin. The degree of purity was confirmed by the Laemmli method using SDS electrophoresis as described below.
Example 22
Removal of Endotoxin
[0322] Endotoxin in the purified recombinant immunotoxin was removed using a perfusion chromatography system (Applied Biosystems) and size exclusion chromatography (TSK 3000 SW, Toso). First, the chromatography system and the size exclusion chromatography column were washed with 75% ethanol for disinfection for 48 hours and then further washed with distilled water for injection (Japanese Pharmacopoeia, Otsuka Pharmaceutical Co.). After washing with distilled water, the size exclusion chromatography column was equilibrated with physiological saline (Japanese Pharmacopoeia, Otsuka Pharmaceutical Co.). After completion of the equilibration, the recombinant immunotoxin after purification was loaded onto the size exclusion chromatography column and then the eluate from the column was fractionated at a flow rate of 0.25 ml/min. The highly purified recombinant immunotoxin after purification was further treated with a sterilizing filter, a portion of the filtered fraction was used to measure the protein concentration and the rest was stored at −80° C. In this way, 0.15 mg of a recombinant immunotoxin with a high degree of purity without endotoxin was obtained from 7.5 mg of the recombinant immunotoxin inclusion body.
Example 23
SDS-PAGE
[0323] SDS electrophoresis was carried out according to the Laemmli method. Namely, the plate gel used was a 10% polyacrylamide gel containing 0.1% sodium dodecyl sulfate (SDS) and the running buffer solution was a 25 mM Tris buffer solution containing 130 mM glycine at a final concentration of 0.1%. Each sample was prepared with an equal amount of a 100 mM Tris buffer solution (pH 6.5) containing 0.2% SDS and boiled for 5 minutes. After boiling, the sample was loaded on the plate gel and electrophoresis was performed at a constant current of 30 mA. After completion of the electrophoresis, the gel was stained with a 0.05% Coomassie brilliant blue R solution and then destained with 10% ethanol containing 70% acetic acid to detect proteins.
[0324] FIG. 9 shows the SDS-polyacrylamide electrophoresis pattern of the recombinant double chain Fv anti-FR-β PE antibody. The recombinant double chain Fv anti-FR-β PE chimeric antibody (molecular weight: 60 kDa) was decomposed into V H -PE (50 kDa) and VL (10 kDa) by reduction. Each lane from left to right shows VL protein, recombinant double chain Fv anti-FR-β PE antibody (IT), VH-PE fusion protein electrophoresed under reducing conditions, molecular weight markers (Mr), and recombinant double chain Fv anti-FR-β PE antibody (IT) under non-reducing conditions.
Example 24
Construction of FR-β Expressing HL-60 Cells
[0325] The PCR2.1-TOPO/FR-β obtained in Example 4 was treated with the restriction enzyme EcoRI and mixed with a vector pcDNA3 (Invitrogen) treated with the same restriction enzyme and the mixture was subjected to a ligation reaction Gene transfection into human acute myeloid leukemia cell line HL-60 cells was carried out in the same manner as described in Example 1 to obtain an FR-β expressing HL-60 cell line.
Example 25
Action of Recombinant Double Chain Fv Anti-FR-β PE Antibody
[0326] Measurements were carried out in the same manner as in Example 8 to find out whether the recombinant double chain Fv anti-FR-β PE antibody induces cytotoxicity to the FR-β expressing B300-19 cell line and the FR-β expressing HL-60 cell line. FIG. 10 demonstrates the rate of cell death (shown in the Y axis) 24 hours, 36 hours, and 48 hours after mixing the FR-β expressing B300-19 cells and the recombinant double chain Fv anti-FR-β PE chimeric antibody at various concentrations. In FIG. 10 , the data are the averages of 3 experiments and the error bars demonstrate SDs.
[0327] FIG. 11 demonstrates the rate of cell death (shown in the Y axis) 24 hours, 48 hours, and 72 hours after mixing the FR-β expressing HL-60 cells and the recombinant double chain Fv anti-FR-β PE antibody at various concentrations. In FIG. 11 , the data are the averages of 3 experiments and the error bars demonstrate SDs.
|
An objective of the present invention is to provide a therapeutic agent for treating rheumatoid arthritis, juvenile rheumatoid arthritis, macrophage activation syndrome, septicemia, and FR-β expressing leukemia, which induces apoptosis in activated macrophages and folate receptor beta (FR-β) expressing leukemia cells to specifically destroy these cells. An FR-β monoclonal antibody of the present invention is preferably an IgG-type monoclonal antibody which specifically reacts with a human-type FR-β antigen and is produced from a clone resulting from immunization with an FR-β expressing B300-19 cell. The FR-β monoclonal antibody of the present invention specifically reacts with the FR-β antigen of activated macrophages and FR-β expressing leukemia cells and a therapeutic agent of the present invention contains an FR-β antibody immunotoxin which causes apoptosis in activated macrophages and FR-β expressing leukemia cells, as an active ingredient. Further, suitable administration form for the therapeutic agent of the present invention includes intravenous injection as well as joint injection in the case of therapeutic agents for rheumatoid arthritis and juvenile arthritis.
| 2
|
BACKGROUND OF THE INVENTION
The present invention relates to a machine which is intended for joining together mutually crossing rods with the aid of wire-ties, and particularly for lashing or tying reinforcement rods, said machine including a wire guide device having a curved guide surface and being positioned so that the guide surface will substantially surround an intersection point of two rods on three sides thereof, means for feeding at least one wire to said device so that the wire is bent by said guide surface in a manner to form a wire-stirrup which embraces said intersection point on three sides thereof, and a rotatable twisting head by means of which the free legs of the wire-stirrup are twisted around each other on the fourth side of the rod intersection point.
The reinforcement rods or irons of tied mesh reinforcements are traditionally tied or lashed with the aid of simple, manually operated tools, and the task of tying the irons is therefore highly time-consuming, costly and laborious, and is liable to cause strain injuries to the workman involved, among other things. Such strain, or wear on the joints, is caused by the fact that when tying together the reinforcement irons of concrete slab reinforcements, floor structures or the like with the aid of present-day tools, it is necessary for the workman to remain stooped over long periods of time, therewith subjecting the spine to undue loads.
The reinforcement irons are normally tied together with the aid of pliers or "twisters" by means of which the ends of a wire-tie or stirrup positioned manually around the reinforcement rods at the various intersection points are intertwined to provide a firm and durable connection. Conventional tying of reinforcement rods is also encumbered with accident risks, particularly when working on roofs, bridges and the like, due to the stooped position in which the workman is forced to work, therewith placing the workman in danger of falling.
The present invention is based on the realization that the work of tying reinforcement rods can be made much more effective while eliminating, or substantially reducing the risk of injury, when tying can be effected with the aid of a tying machine which enables the workman to work in an upright position.
An automatic tying machine is known from DE-A1-1434519. This machine, however, is a hand-operated machine which requires the workman to stoop when tying the reinforcement bars of floor reinforcements and the like. Furthermore, the machine can only work with pre-bent wire-stirrups of standard sizes. The tying head used with this machine is also relatively complicated, and includes two parts which can be moved axially in relation to one another and which are intended to hold the legs of a wire-stirrup between said parts. This mechanism is highly susceptible to damage and to the presence of contaminants, because of the small tolerances and clearances involved, and is hardly suited for use on building sites.
WO-88/01671 describes a tying machine which enables tying to be effected in an upstanding position. The function of this machine also depends on the use of prefabricated standard-size wire-stirrups housed in a magazine.
In many instances, particularly within the building industries of different countries, tying is effected with the aid of relatively thin wire-ties which are bent to an appropriate stirrup-like shape by the workman on the working site, prior to placing the ties or stirrups over the point of intersection of, for instance, two reinforcement rods or bars.
There is at present no suitable machine which will facilitate this type of tying, in which pre-cut wire lengths are not formed into stirrup-like ties until the actual tying operation is commenced.
In an attempt to automatize tying operations with the use of relatively thin wires, there have earlier been proposed tying machines which include a spool from which wire is continuously taken and passed around the rods in conjunction with a tying operation. These machines have not been found successful in practice, probably due to their unrealibility in operation, among other things. When using such machines, it is also difficult to pass the end of the wire around the rods, in an open groove and up into a twisting head. Because of this, telescopically displaceable devices (see GB-A-2171038 and DE-A1-2223099) have been used, although these devices require a relatively large amount of free space beneath the rods that are to be tied together. These devices must also be provided with wire feed means and wire cutting means, which makes it difficult to run the machine on battery power, owing to the high energy consumption of such means. The machine described in the German patent specification also includes a wire aligning mechanism. The provision of such a mechanism is necessary owing to bending of the wire as it is taken from a spool, therewith complicating guiding of the wire. The use of a wire aligning mechanism also increases energy consumption and adds to the weight of the machine.
DE-B1-1138207 describes a machine which includes a hook-shaped device which requires a relatively large space on the underside of the rods to be tied together.
U.S. Pat. No. 3,368,590 describes a machine which, in order to ensure that the end of the wire is inserted into the twisting head, includes a chain mechanism which draws the end of the wire completely around the rods. This machine is relatively complicated and heavy and consumes a large amount of energy. CH-A-408384 teaches a machine in which the end of a wire is bent into the twisting head by means of a liftable plate. This machine is also relatively complicated, heavy and energy demanding.
SUMMARY OF THE INVENTION
The main object of the present invention is to provide a realiable tying machine which will facilitate and render more effective such tying operations as those which use straight wire-sections of given lengths, said wire-sections being bent to a stirrup-like shape in conjunction with the actual tying operation itself. Another object of the invention is to enable a tie to be made without requiring the workman to stoop.
These objects are achieved by means of a machine of the kind defined in the introductory paragraph which is characterized in that the machine further includes a feed tube for feeding cut, straight wire-sections of given lengths; in that the lower end of the tube is located above an opening in the twisting head located in line with a part of said guide surface; and in that disposed for axial movement in the tube is a device which coacts with a wire-section inserted in the tube in a manner to press down said wire-section and move said section along said guide surface so as to produce a wire-stirrup.
The use of straight wire-sections in accordance with the invention eliminates initial bending of the wires as they are drawn from a spool or drum. This eliminates the need for wire aligning and wire cutting devices, used in the earlier machines.
Because the wires are initially completely straight, the force required to feed the wires can be applied in a simpler manner than with the roller feed mechanisms previously used, these mechanisms being liable to bend the wire. In the case of one preferred embodiment, the wire is fed with the aid of a plunger which is moveable in the feed tube and which coacts with the upper end of respective wire-sections. A highly powerful and rapid feed movement can be obtained with this arrangement.
In order, among other things, to reduce the need for free space beneath the rods, which is highly desirable when tying reinforcement rods or bars, for example, it is preferred that the device provided with said curved guide surface includes two curved jaws which can be swung towards one another, and that the inner surfaces of these jaws are provided with open grooves for guiding said wire-sections.
Because it is necessary for the guide grooves to be open towards the rods, a high demand is placed on the curvature of the grooves, so that the forward end of the wire-stirrup will engage in the opening in the overlying twisting head. Accordingly, in accordance with one preferred embodiment of the present invention, the groove provided in the curved inner surface of that jaw which first receives the leading end of a wire section has a substantially circular curvature, whereas the radius of curvature of the groove in the other jaw is greater than the radius of curvature of the groove in the first jaw. This enables the end of said wire to engage the opening in the twisting head with a very high degree of accuracy, as the wire is advanced.
With the intention of further reducing the need for space beneath the rods, the jaws are preferably journalled so that when pivoted in relation to one another they are also moved axially. The jaw attachment means is preferably adjustable in an axial direction, so as to enable the machine to tie rods of mutually different diameters.
When intertwining the legs of a wire-stirrup, it is important that the legs are held securely in the twisting head. Accordingly, the twisting head will preferably include two rotatable disc-like bodies, each provided with a pair of openings for receiving the legs of a wire-stirrup, and the discs will be mounted for limited pivotal movement relative to one another so that the legs of a wire-stirrup are clamped firmly between the discs prior to intertwining said legs. In order to further ensure that the forward end of the wire will positively engage the openings in the disc-like bodies as the wire is advanced, these openings are preferably given an elongated form in the radial direction.
The twisting head is preferably mounted for axial movement in a sleeve surrounding said head, the lower end of said sleeve being intended to rest on the rods to be tied together. To this end, the bottom edge of the sleeve is preferably provided with two pairs of diametrically opposed recesses for receiving and correctly positioning the machine on the rods to be tied together. This axial movement of the twisting head thus facilitates positioning of the machine on the rods and forms a space necessary for receiving the ends of the wires in conjunction with a stirrup twisting operation.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be described now in more detail with reference to an exemplifying embodiment thereof illustrated in the accompanying drawings, in which
FIG. 1 is a perspective view of an inventive tying machine;
FIG. 2 is a part sectional view through an upper part of the machine illustrated in FIG. 1;
FIG. 3 is a sectional view of the lower part of the machine;
FIG. 3A is a sectional view taken on the line IIIA--IIIA in FIG. 3;
FIGS. 4 and 5 illustrate a wire-bending problem and the solution to this problem;
FIG. 6 is a view corresponding to FIG. 3, in which the machine has been adapted for tying reinforcement rods or bars with a bigger diameter;
FIG. 7 illustrates a machine setting mechanism;
FIGS. 8A and 8B illustrate positioning of the machine on mutually crossing reinforcement rods or bars;
FIG. 9 is a schematic perspective view of the twisting head of said machine;
FIGS. 10A and 10B illustrate the twisting head from above, when at rest and when performing a twisting operation respectively; and
FIG. 11 illustrates the result of a twisting operation.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The machine illustrated in FIG. 1 includes an elongated casing 1 which is configured at one end, its upper end, in the form a handle 2. Attached to the other end of the casing, its bottom end, is an electric motor 3, which drives a gearbox 4. The motor is driven by a battery 5, mounted on the casing 1.
Shown in chain lines are two mutually crossing reinforcement rods 6, 7 which during the application of a wire-tie on three sides of the intersection point are embraced by two lower, pivotal jaws 8 and 9 for guiding a wire-tie and bending said tie to stirrup form, as described in more detail herebelow. The jaws are operated by means of lines 10, such that the jaws are swung outwards and away from one another when pressing down an operating lever 47. Each of the jaws 8, 9 is connected to a ring 11 by means of a respective operating arm 12 and 13, and the lines 10 are connected to the ring so as to enable the annulus to be lifted in response to depression of the lever 47 and therewith swing the jaws outwards. The jaws are returned to their inward position by means of two return springs 14 and 15 respectively.
In the illustrated embodiment, straight wire-sections 16 intended to form wire-ties are fed through a slot 17 in the casing 1. As will be seen from FIG. 2, the wire-sections are fed from the slot into an internal feed tube 18, in which they are able initially to fall freely through a given distance and are then pressed down through a further distance with the aid of a plunger 20 moveable in the feed tube 18, this plunger movement being effected with the aid of a further handle 19. The plunger has a concave bottom surface and is a generally close fit with the inner wall of the tube 18, so as to avoid the risk of wire-sections jamming in the tube.
As shown in FIG. 3, and also in FIG. 9, the twisting head comprises two disc-shaped bodies 21 and 22, in which there are provided openings 23 for receiving a wire-section 16 fed down through the feed tube 18, said openings 23 being located opposite one another in the rest position of the head. Each of the bodies has a further opening 24 which lies diametrically opposite respective openings 23. As illustrated, these further openings may suitably have a wider radial extension, or a radially elongated form, in order to facilitate accommodation of the forward end of the wire-section 16.
The twisting head 21, 22 is driven by a shaft 26 which extends from the motor 3 and is connected, by means of a key 27, to an axle 28 which, in turn, is connected to the bottom disc-shaped body 22 of the twisting head. The axle 28 can move axially in a lower, sleeve-like part of the shaft 26, against the action of a spring 29. The reference numeral 30 identifies a ball which when the body 22 rotates is thrown outwardly by the centrifugal forces thus generated, so as to assist in holding the wire-section 16 firmly in the twisting head. The effect produced by the ball can be amplified with the aid of a weight 31, for example mercury. For the purpose of illustration, the ball and the weight have been shown in those positions which they adopt when the body 22 rotates rapidly. When the body is stationary, the ball and the weight will slide back into the channel 32 provided in the body 22.
As mentioned in the aforegoing, the jaws 8 and 9 can be caused to swing outwards by pulling-in the levers or rods 12 and 13, in response to the upper mounting sleeve 11 being drawn upwards with the aid of the lines 10. When the jaws swing about the journal pins 33, which when pulling respective rods 12 and 13 can be displaced in arcuate slots 34, the jaws 8 and 9 will be moved axi-ally upwards to some extent, to the positions illustrated in chain lines, while swinging outwards away from one another. This makes it possible to further reduce the space required beneath the reinforcement rods 6 and 7 for the movement of the jaws.
As will be seen from FIG. 3, the inner wire-section guide surface has the form of a substantially circular curved groove on the jaw 8. The corresponding guide surface on the opposite jaw 9, however, has a substantially larger radius of curvature. This has been found necessary in order to avoid the effect illustrated in FIG. 4, in which both of the jaws illustrated have the same radius of curvature. In this case, the wire-section 16 will not follow the guide surface on the jaw 9, but will be bent back towards the jaw 8. This renders the construction of a reliable and simple twisting head difficult, if not impossible. By giving the second jaw a flatter curvature, as illustrated in FIG. 5, the aforedescribed effect can be eliminated or at least controlled, so as not to jeopardize the functioning of the machine.
The reference numeral 25 identifies a thin plate or plastic disc which can be readily moved in the guide groove in the jaw 9, see also FIG. 3A. The presence of such a plate or disc is desirable because the forward end of the wire 16, particularly when the wire is thick and cut obliquely, has a tendency to bite into and score the bottom surface of the guide groove, which can result in the wire end fastening in the groove. This risk is eliminated by virtue of the fact that at the transition or crossover from the jaw 9, the wire-end will strike the plate 25 which is located on a lower level than said crossover point, and push the plate forwards somewhat. For the sake of simplicity, the plate 25 has been shown in its starting position in the various Figures, and will return to this position gravitationally when the jaws 8, 9 are opened. As will be understood, the plate 25 or like device can be omitted, particularly when using relatively soft wires, and also when the guide surface of respective jaws is made of a very hard material.
Thus, the machine illustrated in FIGS. 1 and 3 will function to feed-down a wire-section 16 rapidly and positively, since the wire-section on which the plunger 20 bears is completely straight. Furthermore, the aforedescribed configurations of the guide surfaces of respective jaws 8 and 9 result in positive bending of the wire-section to a predetermined stirrup form, so that the legs of the stirrup can be gripped effectively and twisted with the aid of the twisting head 21, 22.
FIG. 6 is a view corresponding to the view of FIG. 3. The machine illustrated in FIG. 6 is adapted for tying or lashing reinforcement rods 6 and 7 of larger diameter than the machine of FIG. 3. In the case of the FIG. 6 embodiment, an adjustment has been made to the position of an outer sleeve 35 on which the jaw attachment lugs 36 are mounted and along which the upper ends of the arms 12 and 13, connected to the ring 11, are slideably arranged. The position of the sleeve 35 can be adjusted in relation to an inner, stationary sleeve 37 with the aid of a spring-loaded locking pin 38, as illustrated more clearly in FIG. 7. Thus, the machine illustrated in FIG. 6 can be adapted to reinforcement rods of mutually different diameters, wherein all that is required in this regard is to move the outer sleeve 35 relative to the inwardly-lying sleeve 37 and to adjust the lengths of the lines 10 used for manipulating the jaws. This latter adjustment can be appropriately effected at the ends of the lines connected to the handle 47, see FIG. 1.
As will be seen from FIGS. 3 and 6, the inner sleeve 37, in which the twisting head 21, 22 rotates, supports the machine on the reinforcement rods 6 and 7. Accordingly, the bottom edge of the sleeve 37 is provided with two pairs of mutually opposing recesses 39 and 40, as illustrated in FIGS. 8A and 8B. Thus, when using the machine, the operator merely faces the machine on the reinforcement rods at a point of intersection, so that a pair of recesses will engage the uppermost rod, the twisting head being pressed upwards against the action of the spring 29, when required as a result of contact of the head with the reinforcement rod. In FIG. 8A the recesses 40 will therefore coact with the reinforcement rod 7, whereas in FIG. 8B the recesses 39 will coact with the reinforcement rod 6. The machine is correctly and reliably positioned in relation to the longitudinal directions of the two mutually crossing rods 6 and 7, in both instances As a result of the provision of two pairs of recesses in the sleeves 37, it is not necessary for the operator to keep on adjusting the machine in order to position the machine in accordance with which rod that lies uppermost of the two rods.
FIG. 9 illustrates the twisting head with the two disc-shaped bodies 21 and 22 in their rest positions, see also FIG. 10A. The bottom disc-shaped body 22 is provided with a dogging pin 41 which moves in a slot 42 in the upper body. The reference numeral 43 identifies a return spring for the disc-shaped body 21, and reference numeral 44 (FIG. 10A) identifies a ball which is activated by a spring 45 and which functions to affix the disc-shaped body 21 in its correct starting position and to exert a given initial resistance to initial rotation of the body, for reasons made apparent below.
When using the described and illustrated machine, a wire-section 16 is introduced into the feed tube is and is pressed down through the twisting head by the plunger 20, until the upper end of the wire-section, located in the opening 23, is substantially flush with the upper surface of the disc-shaped body 21 and the forward end of the wire-section projects up through the slot-opening 24, also substantially flush with the upper surface of the body 21. The bottom disc-shaped body 22 is then rotated in a clockwise direction by the shaft 28, as indicated by the arrow, wherewith the ends of the wire-section 16 are clamped firmly in respective openings 23 and 24 as a result of relative rotation between the disc-like bodies 21 and 22. The initial clamping force is determined by the holding force of the ball 44, and the magnitude of the relative rotation between the disc-like bodies is limited by the pin 41, which subsequent to given rotation between the bodies dogs the upper body 21 in the rotational movement of the bottom body. This prevents the wire-sections from being severed as a result of a scissor action between the disc-like bodies 21 and 22. Twisting of the stirrup legs is completed after a few turns of the disc-shaped bodies and the result is illustrated in FIG. 11.
During this twisting operation, the mutually twined wire-ends are received in the cup-shaped recess 46 in the bottom surface of the bottom disc-shaped body. If so required, the twisting head can also be pressed upwards against the action of the spring 29.
Thus, the aforedescribed machine enables a tying operation to be carried out effectively, in a very simple fashion, essentially automatically in a standing position, with the use of straight, precut wire-sections.
It will be understood that the aforedescribed and illustrated embodiments can be modified in several respects within the scope of the following claims, for instance with regard to manoeuvring of the jaws and the construction of the twisting head. For example, the jaws can be operated with the aid of lines, gearwheels or the like, instead of rods. The positioning of the electric motor, battery and the external configuration of the machine can, of course, also be varied as desired. The manner in which the wire feed is accomplished can also be changed. For example, the wires can be fed down axially through an opening in the upper part of the machine.
|
A machine for tying together mutually crossing rods with the aid of wire-ties includes a device 8, 9 having a curved wire-guide surface which is intended to be positioned so that it will surround a rod intersection point on three sides of the mutually crossing rods 6, 7. The machine also includes a mechanism 18-20 for feeding at least one wire to the device, so that the wire will be bent by the guide surfaces into a wire-stirrup which surrounds the intersection point on three sides, and a rotatable twisting head by means of which the free legs of the stirrup are twisted together on the fourth side of the intersection point. The machine also includes a feed tube 18 for feeding severed, straight wire-sections 16 of predetermined lengths, and the lower end of the feed tube is located above an opening in the twisting head positioned in line with a part of the guide surface. Mounted for axial movement in the tube is a device which functions to press wire-sections introduced into the tube in a downward direction and displace the wire-sections along the guide surface, to form a wire-stirrup.
| 4
|
RELATED APPLICATION
[0001] The present application is a continuation of copending U.S. patent application Ser. No. 11/893967, filed Aug. 17, 2007, now allowed.
BACKGROUND OF THE INVENTION
[0002] Wastebaskets have been used with a plastic bag inserted so that the waste that is put into the wastebasket can be easily removed and properly disposed. Also, most wastebaskets are constructed much like an inverted, truncated cone or pyramid with a non-circular base. That is, theft side, whether round, oval, square, or rectangular in cross-section, has an outward taper, making the bottom of the wastebasket interior smaller than the top of the wastebasket interior. Wastebaskets are now usually made of plastic and, in effect, they are large containers that are waterproof and can receive certain trash bags, also usually of plastic. There are two relatively independent problems with such typical wastebaskets that the present invention addresses. Both problems arise because of the manner of use when using trash bags, particularly plastic trash bags.
[0003] The first problem has to do with the use of oversized trash bags. Typically, the plastic trash bag used is somewhat bigger than the wastebasket itself. It is therefore inserted into the wastebasket, and because the plastic bag is larger than the wastebasket, a problem often arises. When putting a plastic trash bag into the typical wastebasket, the open bottom of the bag is inserted through the top of the basket, and the bag's top is still considerably larger than a typical open top of a wastebasket, so it is just wadded up, or is sometimes tied into knot so that it will stay reasonably tight on the rim of a wastebasket. Quite often users will use large rubber bands or bungee cords around the bag top and the wastebasket rim, holding the bag in place. This is cumbersome and time-consuming. The invention herein disclosed and claimed solves this problem.
[0004] The second problem is that, while using an overly large trash bag in any wastebasket, including the ones shown herein, often the tendency is to try to get as much trash in the trash bag as possible, at least in part because of the time and effort involved in getting the rubber band or an equivalent off when using the typical wastebasket, then tying the bag so that the contents will not spill, or having no other trash bags readily available at the moment. This often results in overstuffing the bag, pushing the waste down to compact it so that just a little more can be put in it, resulting in the bag acting much like a seal with the inner wall of the wastebasket, making it more difficult to remove the filled bag. This can also occur concurrently with the first problem, trying to put just a little more trash in, even without trying to overstuff the trash bag. Whether or not the wastebasket is tapered, when the engagement of the wastebasket side wall or was by a plastic bag that has been filled fits very tightly, particularly in the lower half of the trash bag, it likely that the lower part of the bag becomes filled with a higher concentration of heavier waste material, whether or not the material has been pushed downwardly until the bag is absolutely full, and then is pushed downwardly some more to be able to put a little more waste in it. This creates pressure in the bag, particularly the lower section of the bag that is still contained by the wastebasket side wall, and that pressure can cause a forced sealing action between the exterior of the trash bag and the interior side wall of typical wastebasket. This seal is in the form of a broad band of perhaps several inches along the outer circumference of the bag and inner circumference of the side wall and effectively seals the bottom section of the wastebasket below the seal. This sealing action leaves little or no opportunity for air to flow past the bag and into the volume of the wastebasket isolated by the seal, i.e., under the bag and around the lower portion of the bag, as the bag is being pulled out of the wastebasket. Consequently, as the bag is being pulled upwardly out of the wastebasket one finds that the resistance of that seal to let the flow of some outside air to enter and fill the increasing space causes a sub-atmospheric pressure to build in the isolated space which sub-atmospheric pressure must be overcome by more strenuously pulling the bag out or by sliding ones hand between the bag and the sidewall to release the seal. Typically, the trash bag has to be pulled as much as half way or more out of the basket before the seal created along a band area of the bag is released as the upward movement of the bag continues.
[0005] Many wastebaskets are made of a plastic material that has some give in the sidewalls, When these wastebaskets are overstuffed, this is some bulging in the mid-section of the sidewalls; however, there is no give in the stiff, continuous opening or rim of the wastebasket. Consequently, in those instances where the wastebasket does not have or has a minimal outward taper from its bottom to its rim, removal of the overstuffed bag is further compromised by the interference fit between the bag and the rim. Thus, there are several aspects to be addressed with current wastebaskets. First, currently existing wastebaskets are made or materials that are too stiff to allow for overstuffing without creating significant forces or pressures against the interior side wall and also minimize the degree to which it may be overstuffed. Second, there is difficulty in lifting the filled bag, and even greater difficulty in lifting a heavy and also over-filled bag, out of the wastebasket, due in part to the creation of the seal along the bag/interior sidewall interface which isolates the lower section or volume of the wastebasket and creates a partial vacuum as the bag is being pulled out of the wastebasket.
[0006] There have been proposals to put relief openings in the lowest part of the wastebasket or even in its bottom. Other proposals involve making a pipe as a part of the wastebasket that extends upwardly from the wastebasket bottom to its top so that outside air can be taken into the bottom space as the bag is being moved out. The relief openings weaken the bottom and lower part of the basket, and the basket can be standing in just a little water and the bag interior is immediately wetted. Worse, if the bag has liquids that leak from the bag, the liquids will spread out on the floor. The pipes are more costly to make and still must be kept clear of debris, mold, and such that there is always the problem of keeping an open air passage through the pipe.
[0007] The potential, and often real, first problem led to the invention, and then it was recognized that the wastebasket construction herein disclosed and claimed also solved the second problem.
FIELD OF THE INVENTION
[0008] The invention relates to a wastebasket that makes it extremely easy and very simple to put a plastic bag inside the wastebasket, retain the bag in the wastebasket until the now-filled plastic bag needs to be removed, then remove and dispose the waste materials that have been put into that trash bag, and easily install another trash bag.
[0009] The invention also relates to that same wastebasket that will also allow an oversized or expandable trash bag placed in it to expand beyond the normal allowed room for trash bags when packed, and without creating or allowing the formation of a large sealed air space near the bottom of a standard-type wastebasket by the filled trash bag's pressing against an uninterrupted area to form a seal between the trash bag and the wastebasket. That makes it very difficult to pull the filled or overfilled trash bag out of the wastebasket, making it much easier to remove a filled bag, and also making it easier to place an empty bag back in the wastebasket without trapping air within the wastebasket so that it is difficult to fully open the trash bag from top to bottom, and have the installed trash bag to be fully open throughout its depth for the reception of waste.
DESCRIPTION OF THE RELATED ART
[0010] There are systems for retaining plastic trash bags in wastebaskets, such as using a rubber band as noted earner, or bungee cords, or providing clasps to grip the trash bag at its open end, and arrangements where the excess part of the trash bag being installed can have some sharp plastic hooks bunt into the wastebasket over which the trash bag excess part at the bag top is hooked, often making a hole in the trash bag material in doing so, as well as sticking the hand of the installer, because such hooks have sharp ends to pierce the trash bag when their top is pushed over them. Such wastebaskets use trash bags that are larger, at least in circumference, relative to the wastebaskets.
BRIEF SUMMARY OF THE INVENTION
[0011] The invention includes a wastebasket that has one or more, but often just two, openings in the side wall of the wastebasket, These openings may be relatively narrow slots, or wider ones, that extend from the top of the wastebasket near to but still spaced from the bottom of the wastebasket. The side wall (when the wastebasket is round or made like an inverted truncated cone) or was (when the wastebasket is square or rectangular so that there are several was joined together) still retain their shape but allow for some resilient movement in a cantilever manner. The invention employs their plastic memory trait of always trying to return to their free original position when not prevented from doing so.
[0012] There are two types of movement of at least one wastebasket part, and preferably with two or more wastebasket parts, associated with the openings that this construction can accommodate. In the first, the resiliency of the side walls will be used to secure a plastic bag to the top of the wastebasket. Specifically the side wall sections will resiliently resist an inward type of movement, in a cantilever manner, so that the plastic bags whose open end is just slightly smaller in their open circumference than the outside circumference of the wastebasket at the open top of the wastebasket, whether that open top be of a round, partly round or straight-sided, oval, oblong, square, rectangular, or other-shaped multisided wastebasket formed by one or more wastebasket side walls and a bottom connected to the bottom ends of said one or more side walls. The upper ends of the side-wall sections are moved inwardly, toward each other, enough to have the trash bag's open end pulled over them and hold them within that trash bag open end. When the side wall sections are released, they return part way to their normal free positions, and are retained from moving further by the narrower circumference of the trash bag opening; thus, holding the trash bag in place.
[0013] The second type of movement relates to the holding capacity of the wastebasket. Here, the side walls have their normally free position so that they have the general appearance of the usual wastebaskets; yet, they will also yield to internal, outwardly directed pressures so as to be bent outwardly to some extent. Specifically, at times, the wastebasket may not be emptied in time, and the extra trash put into the trash bag will be somewhat relieved by some outward lateral movement of those side wall areas that are quite dose to the slots or openings,
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1 is a side elevation view of one wastebasket embodying the invention.
[0015] FIG. 2 is another elevation view of another side of the wastebasket of FIG. 1 , taken in the direction of arrows 1 - 1 of that figure.
[0016] FIG. 3 is a view of the top of the wastebasket of FIG. 1 , taken in the direction of arrows 3 - 3 of that figure.
[0017] FIG. 4 is a side elevation view of the wastebasket of FIG. 1 showing the flexible skies held inward of their normal position by a trash bag having a slightly smaller circumference than the outside circumference of the wastebasket at the opening of the wastebasket.
[0018] FIG. 5 shows the wastebasket of FIG. 4 after the skies have been released, the was returning to the extent permitted by the trash bag: the trash bag still holding the flexible sides slightly bent inward.
[0019] FIG. 6 shows a modified wastebasket which has downwardly extending openings in the side sections, the openings having parallel sides that are laterally spaced apart.
[0020] FIG. 7 is a top elevation view of the wastebasket of FIG. 6 .
[0021] FIG. 8 is an elevation view of an alternate embodiment of a wastebasket according to the present invention.
[0022] FIG. 9 is a top elevation view of the wastebasket of FIG. 8 , taken in the direction of arrows 9 - 9 of that FIGURE.
[0023] FIG. 10 is a side elevation view of the wastebasket shown in FIG. 1 with a trash bag in place, whish trash bag is usually one that has a larger circumference than the wastebasket, having been overstuffed so much with trash that the sidewall at and near the edges of the vertically extending slot or opening edges have been forced slightly outward in a lateral direction by the pressure of the overstuffed trash bag.
[0024] FIG. 11 is a side elevation view of the overstuffed trash bag and wastebasket of FIG. 10 , taken in the direction of arrows 11 - 11 of that figure.
[0025] FIG. 12 is a side elevation view of still another wastebasket embodying the invention, showing the downwardly extending slot or opening of a more decorative nature, using a serpentine shape.
[0026] FIG. 13 is a side elevation view of a wastebasket having a different opening presentation that, while extending downward, extends diagonally rather than vertically.
DETAILED DESCRIPTION OF THE INVENTION
[0027] In any configuration of the wastebasket embodying the invention, such as that shown in FIGS. 1-3 , there are two or more wastebasket side walls that are separated by the two or more slot-type openings, but more often two, in the side wall, or if more than one in at least one, but more often two, of the side walls. When there is a plurality of openings, they are preferably equally spaced apart along the wastebasket open top, extending downwardly from the wastebasket open top to a low point that is slightly above the wastebasket bottom. If there should be only one such opening, however, the invention can also be practiced, but at times the benefits thereof are not so easily attained. In any event, each such opening will have two generally downward-extending, opposing edges defining the opening so that those edges of each of the openings are parts of two or more side wall sections. There will be one such side wall section for each of the openings, with each of the two or more side wall sections having edges defined by two of the downward openings.
[0028] The side wall sections are made of a plastic that has a plastic memory-recovering characteristic that allows each of them to be sufficiently flexible to have their uppermost ends resistively pushed inwardly toward each other; thereby reducing the effective circumference of the top opening of the wastebasket so that a trash bag open end, preferably one whose open end circumference is smaller than the circumference of the wastebasket in its free position, can be folded outwardly and over the wastebaskets rim. The inwardly moved side wall sections are then released, and each of them immediately exerts an outward force on the trash bag open-end area, but does not move back to its free position because the smaller circumference of the open end of the trash bag, engaged by the upper ends of the side wall sections, successfully resists such movement. The plastic memory forces of the side wall sections are therefore unable to return to their free-position location because their upper ends are surrounded by the unyielding plastic bag's circumferential open end, and the trash bag is securely retained on the wastebasket rim.
[0029] When the trash bag is to be removed, the two side wall sections are again pressed inwardly until they no longer exert any force on the trash bag open end, and the bag is simply grasped and pulled out of the wastebasket. Because the lower ends of the slots or openings terminate shortly above the trash bottom, preferably at the same position which may be only about two inches above the bottom, air is able to enter below the bag allowing for its ease of removal. That space between the bottom and the lower ends of the openings can be varied considerably, so that any liquid that may have leaked out of the trash bag into the bottom of the wastebasket will still be retained in the bottom of the wastebasket, assuming that it is not in such an unusually large quantity that it would overflow through the openings' lower ends. Such liquids are usually just the remains of the drink in one or more drink containers that have been put into the trash bag. Generally speaking, the point at which the slots or openings terminate above the bottom of the wastebasket is that which is considered sufficient to hold a reasonable volume of such liquids so that it is not spilled out of the wastebasket bottom. If the lower end of one of the openings should be slightly closer to the wastebasket bottom than any other opening end, it will be the one opening end that defines the top of the space that can contain fluid. Additionally, the length of the slots or openings is also important for allowing the desired cantilever action in the sidewalls such that the force or resilience of those side wall sections trying to return to their unfettered positions holds the trash bag in position.
[0030] As noted above, the described configuration makes the removal of the trash bags easier because the pressure, particularly from the forcibly expanded trash bag, is easily relieved as the openings or slots allow for an outward lateral movement of the side walls, i.e., a bulging of the sidewalls about the slots or openings, whether due to the overstuffing of the trash bag or manual application of force, which will lessen the grip that the wastebasket has on the side of the trash bag, especially when the trash bag open end is no longer held by the side walls. Additionally, the slots or openings allow air to enter into the space in the lower section of the wastebasket, below the bottom of the trash bag, thereby relieving the momentary sub-atmospheric pressure created in the space between the wastebasket bottom and the bottom of the relatively full trash bag as it is being removed. Here, once the bottom of the trash bag being removed passes the lower end of the slots or openings, if not before, the space that did have some temporary sub-atmospheric air is immediately fully open to the atmosphere and thus no longer has any sub-atmospheric air pressure that resists removal of the trash bag. Furthermore, the slots or openings facilitate the overstuffing of the trash bags as the force of the trash against the sidewalls will allow an expansion of the openings and, hence expansion of the bag in the wastebasket.
[0031] The slots or openings may be of several different shapes. For example, they may be shaped with an artistic effect rather than being just straight vertical slots or openings. There may be only one such slot or opening, but it is preferred that there be two or more such slots or openings so that there are two or more side walls acting on the trash bag to hold the trash bag in place as earlier described. Likewise, when the same side walls are being forced further outward from their free position, a bag therein that is being stuffed would not very likely act on just one side of the waste basket, but probably on each side of the slot or opening. This then allows for the wastebasket to bulge a bit about the openings or slots while the others part of the wastebasket do not yield to bulging caused by the pressure when pushing the trash down to make a little more room in the wastebasket. It is also contemplated, as part of the invention, to provide stiffening at or near the edges of the wastebasket formed by the slots or openings so that the strips of wastebasket siding do not move easily outward beyond a reasonable limit. Other means may also be used to resist, or at times even prevent, much outward movements of the wastebasket strips or side walls that are between the slots or openings.
[0032] The wastebasket 10 of FIGS. 1 , 2 and 3 has a rectangular shape, as seen while looking downwardly at the top of that wastebasket, and is so shown in FIG. 2 . Wastebasket 10 has a side wall 12 , a bottom 14 , and a top opening 16 which is of the same shape as the bottom 14 but is larger so that the interior 18 of the wastebasket tapers inwardly from the top opening 16 to the bottom 14 . Wastebasket 10 is shown as having two sots or openings, one opening 20 being in the section 22 of the side wall 12 and the other opening 24 in the section 26 of the side wall 15 which is opposite to the side wall section 22 . The other sections 28 and 30 of the side was 12 and 15 have no openings. In this arrangement, the openings 20 and 24 have diverging sides 34 , with the bottom 27 of the openings being semi-circular. In the position shown, the side wall sections 28 and 30 are seen here on either side of the opening 20 , with the opening 24 being behind the opening 20 . These side walls 28 and 30 , respectively, are connected with the parts of the section 26 of side wall 12 and other parts of the section 26 of the side wall 15 , so that those side walls 28 and 30 , and their respective sections of side walls 12 and 15 are integral, and can be flexed to an adequate extent either inwardly or outwardly of their free position shown, i.e., towards or away from each other from the free position as shown in FIG. 1 . It is to be understood that the wastebaskets shown herein are all made of a relatively flexible plastic material that has a strong plastic memory to try to return to their free position when they are forced to be resiliently moved inwardly or outwardly against sufficient force urging them inwardly or outwardly.
[0033] The top opening 16 and the two openings 20 and 24 have an outwardly extending structure or rim 32 , made as a bead or a planar part, outlining them and extending outwardly from the side wall sections 22 , 26 , 28 , and 30 , and the openings 20 and 24 . The portions of structure 32 that are at the top of the side sections 28 and 30 may be extended outwardly to provide handles for lifting the wastebasket, as needed, as shown in FIG. 3 . The structure also acts as a stiffening member that resists bending and movements of the parts that would be more likely to bend and move when the wastebasket is substantially full of trash. Depending upon the flexibility of the material of which the wastebasket is made, some excess flexibility usually will require stiffening by the beaded edging all along the openings 20 , as shown. Other less flexible materials of which the wastebasket is made may dispense with some or even all of the beaded edging along the openings 20 .
[0034] FIG. 4 shows the use of the invention in making it very easy to install and remove trash bags into and out of wastebaskets. As earlier noted, the wastebasket shown is the wastebasket 10 of FIG. 1 , but the arrangement also applies to other wastebasket arrangements, including those of FIGS. 2 through 8 . The only requirement for this use is the provision of trash bags 50 that are slightly smaller in circumference, particularly at the area of their open ends 52 , than the inner circumference of the rim 32 that is located at the top opening 16 of the wastebasket 10 . Each trash bag 50 should also be somewhat longer than the depth of the wastebasket, so that its bottom 54 can engage, or be quite near to, the bottom of the wastebasket while a part of its open end area can be placed over the wastebasket rim and down its outer side, or may extend longer down the outside of the wastebasket. FIG. 5 shows the wastebasket 10 and the plastic bag 50 in position, ready to receive trash, with the bag's being secured at its top and the main part of the bag well inside the wastebasket 10 .
[0035] The wastebasket 110 of FIG. 6 also has a rectangular shape as seen while looking downwardly at the top of that wastebasket, as shown in FIG. 7 . Wastebasket 110 has a side wall 112 , a bottom 114 and a top opening 116 which is of the same shape as the bottom 114 but is larger so that the interior 118 of the wastebasket tapers downwardly and inwardly from the top opening 116 . Wastebasket 110 is shown as having two slots or openings, one opening 120 being in the section 122 of the side wall 112 and the other opening 124 in the section 129 of the side wall 112 which is opposite to the section 122 . The other sections 128 and 130 of the side wall 112 have no openings like the openings 120 and 124 . In this arrangement, the openings 120 and 124 have parallel sides 134 , with the bottom 126 of the openings being semi-circular.
[0036] The top opening 116 and the two openings 120 and 124 have an outwardly extending structure or rim 132 made as a bead or a planar part outlining them and extending outwardly from the side wall sections 122 , 128 , 129 and 130 , and the openings 120 and 124 . Portions of structure 132 that are at the top of the side sections 129 and 130 are extended outwardly and may provide handles for lifting the wastebasket, as needed. The structure also acts as a stiffening member that resists bending and movements of the parts that would be more likely to bend and move when the wastebasket is substantially full of trash.
[0037] The structure or rim 132 is somewhat eider than the structure of rim 32 of FIGS. 1 , 2 and 3 and is rolled so as to form a tubular opening 135 . Opposite ends 136 and 138 of a sliding rod 140 extend into those tubular openings across the top of the openings 120 and 124 . The rod is spring-loaded to normally have the position shown in FIGS. 6 and 7 , and may be moved sufficiently to latch it in place so that the openings 120 and 124 are not blocked, and can allow somewhat freer movements of the sections 122 and 128 than is avowed when the rod 140 is in its latched position, as shown in FIG. 6 and 7 .
[0038] The wastebasket 210 of FIGS. 8 and 9 is round in shape as seen while looking downwardly at the top of that wastebasket, as shown in FIG. 9 . Wastebasket 210 has a circular side wall 212 , a round bottom 214 and a round top opening 216 which is of the same shape as the bottom 214 but is larger so that the interior 218 of the wastebasket conically tapers downwardly from the top opening 216 . Wastebasket 210 is shown as having four slots or openings 220 , 222 , 224 and 226 . These openings are positioned in the side wall 212 at 90° intervals, as is best seen in FIG. 9 .
[0039] The top opening 216 and the four openings 220 , 222 , 224 , and 226 have an outwardly extending structure or rim 232 , made as a bead or a planar part, outlining the openings and extending outwardly from the side walls at the lower parts of the openings 220 , 222 , 224 and 226 . These structures also act as a stiffening member that resists bending and movements of the parts that would be more likely to bend and move when the wastebasket is substantially full of trash.
[0040] In one general configuration, as shown in FIGS. 1-3 , 6 , 7 , and 10 - 13 , there are two or more wastebasket side walls that are separated by the two or more slot-type openings in at least one of the side wall or walls, and when being a plurality of openings being preferably equally spaced apart at the wastebasket open top, extending downwardly from the wastebasket open top to a low point that is slightly above the wastebasket bottom. If there should be only one such opening, however, the invention can also be practiced, but not as easily. In any event, each such opening will have two generally downward-extending edges defining the opening so that those edges of each of the openings are parts of two or more side wall sections. There will be one such side wall section for each of the openings, with each of the two or more side wall sections 28 and 30 having edges defined by two of the generally downwardly extending openings. The side wall sections are made of a plastic material that has a plastic memory-recovering characteristic that allows each of them to be sufficiently flexible to have their uppermost ends resistively pushed inwardly toward each other, reducing the effective circumference of the top opening 16 , 116 , etc,, of the wastebasket and the trash bag open end 52 is just folded outwardly and over the wastebasket's rim 32 , 132 , etc. The inwardly moved side wall sections are then released and each of them immediately exerts an outward force on the trash bag open end area 52 , but do not move back to their free position because of the smaller circumference of the open end 52 of the trash bag 50 . Their plastic memory forces are therefore unable to be allowed to return to their free-position location because their upper ends are surrounded by the unyielding plastic bag's circumferential open end 52 , and the trash bag 50 is securely retained on the rim of the wastebasket. When the trash bag 50 is to be removed, the two side wall sections 28 and 30 are again pressed inwardly unto they no longer exert any force on the trash bag open end, and the bag is simply grasped and pulled out of the wastebasket.
[0041] Because the lower ends 26 , 126 , etc., of the slots or openings terminate shortly above the bottom 14 , 114 , etc. of the wastebasket, preferably only about two inches, although that can be varied considerably, any liquid that may have leaked out of the trash bag 50 into the bottom of the wastebasket will still be retained in the bottom of the wastebasket. This assumes, of course, that the quantity of liquid is not such an unusually large quantity that would overflow through the openings' lower ends and that the bottom of the trash bag has leaked. Typically, this liquid is just the remains of the drink in one or a few drink containers that have been put into the trash bag. Generally speaking, the height of the terminal ends 26 , 126 , etc., of the slots or openings is that which is considered sufficient to hold a reasonable volume of liquids so that it does not spill out of the wastebasket bottom.
[0042] FIGS. 10 and 11 show the wastebasket 310 , which is the same as the wastebasket 10 of FIG. 1 , with some trash 340 having been stuffed downwardly into a plastic bag 342 that had been earlier inserted into the wastebasket 310 . Usually, the trash bag 342 is larger that the wastebasket 310 when persons tend to try to stuff more waste material into the bag. The relatively larger bag 342 also has an excess of material defining its opening, and this excess material is just gathered up or is tied with a knot to make it fit the top opening of the wastebasket 310 . These figures show a wastebasket in which the trash had been pushed and stuffed into the plastic trash bag 342 , with the lower part of the trash bag being filled even more densely near the wastebasket bottom 314 , and still some trash 340 sticking up over the top of the wastebasket 310 .
[0043] Although the description the wastebasket 10 of FIGS. 1 , 2 , and 3 is most frequently referred to, it is to be understood that this description of FIGS. 10 and 11 generally relates to all of the wastebaskets shown in the drawings. When the plastic trash bag 342 was inserted into the top opening of wastebasket 310 , or in any of the disclosed wastebaskets 10 , 110 , or 210 , it can he moved downwardly more easily without any trapped air being under it because of the openings 20 and 24 , 120 and 124 , 220 and 224 , and 320 , 322 , 324 , and 326 . If necessary, the person putting it in can reach into at least the upper part of one of those openings and guide or pull the bottom of the trash bag 342 to be sure that it is down sufficiently and fitted at least dose to the interior wall of the sections of the basket side wall. It is also a usual practice to place both hands into an opened plastic trash hag 342 and keep them there, spread apart to keep the trash bag reasonably open. After the bag has been inserted into the wastebasket, hands spread the trash bag out so that little air is trapped under it, within the wastebasket 310 . Even then, there is still some air trapped under the trash bag. As the trash is put into the trash bag, the bag fills up, and it will begin to engage the interior surfaces of the side sections 322 , 326 , 328 , and 330 or the equivalent side sections of any of the other disclosed wastebaskets, or a standard type of wastebasket having no means provided particularly for this purpose. When the trash 340 is pushed further into the trash bag 342 , it will cause there to be some pressure on the wastebasket inner was 318 . When that pressure builds up throughout the trash bag, the portions of the sides 322 , 326 , 328 and 330 will fed the pressure.
[0044] In contrast, a wastebasket having a solid bottom and side wads has no ability to compensate for the pressure build up which only increases as more and more trash is added: here the only things that try to yield to the pressure are the trash and the trash bag that is inside the wastebasket. In that situation, the trash bag, particularly the lower part of the trash bag, becomes pressed against the wastebasket inner wall making it difficult to extract the bag from the wastebasket. In particular, lower portion of the trash bag forms and air tight band with the inner wall of the wastebasket with a high pressure or force against the inner wall of the wastebasket that strongly resists any removal of the full trash bag. Additionally, as one tries to remove the overstuffed trash hag, no air is able to bypass the trash bag such that a sub-atmospheric condition is created in the lower portion of the wastebasket beneath the trash bag, making it further difficult to extract the trash bag.
[0045] When using a wastebasket in accordance with the invention herein disclosed and claimed, that pressure can become sufficient to cause the wall sections 22 and 26 , 122 and 126 , 222 and 226 , or 322 and 326 , to move outwardly, yielding to that inside force caused by tightly stuffing trash into the trash bag and the wastebasket itself. This is shown in FIGS. 8 and 9 . This yielding action lessens the pressure of the filled trash bag against the inner wall of the wastebasket, making its removal easier. Also, because the slot allows for the inflow of air, the sub-atmospheric pressure that was in the bottom of the wastebasket is likewise release, if it forms at all. Thus, when an overstuffed trash bag is being lifted out of the wastebasket, it will have less resistance to such movement at the beginning, and as soon as even a part of the trash bag clears the lowest part of the openings and can be lifted out much more easily. This advantage can even be felt when the trash bag is fairly full but has not been overstuffed.
[0046] While the disclosures in FIGS. 1 through 11 only show openings or slots having straight sides, either diverging or parallel, it is within the purview of the invention to provide one or more openings similar to those openings at a diagonal angle to the vertical, curved, Serpentine or sinuous, or even straight but zigzagged. Alternatively, they may employ a combination of any two or more of these shapes. The shapes of such openings may include artistic effects. Some of such openings may be in combination with a scene so that it appears that a part of the scene has moved when the part of the wastebasket defining the openings moves in response to being stuffed or overstuffed with trash, as shown in FIGS. 8 and 9 . Even so, any such openings are considered to be equivalent to those shown when they function in the same manner when the wastebaskets are filled, and even more so when they function in the manner set forth when the wastebaskets are overstuffed. FIGURES 12 and 13 show two of such samples. The wastebasket 410 , shown in FIG. 12 , has an opening 412 that extends downwardly, but is sinuous or serpentine in shape. The wastebasket 510 in FIG. 13 shows an opening 512 that extends downwardly, but is diagonally positioned relative to the upper edge of the sidewall.
|
A wastebasket designed to work in combination with a trash bag insert, the wastebasket having one or more openings or slots on one or more of its sidewalls, the openings extending from the upper rim of the wastebasket to a point near the bottom of the wastebasket, so as to allow for an inward and outward motion of the sidewall sections so as to allow overstuffing of the trash bag while allowing the overstuffed bag to readily be removed from the wastebasket and/or the insertion of a trash bag whose opening circumference is smaller than the upper rim circumference of the wastebasket, whereby the trash bag is secured to the rim of the wastebasket.
| 1
|
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The field of the present invention is internal combustion engines for motor vehicles and, in particular, utilization of the heat energy normally discarded in the exhaust of internal combustion engines by converting the heat to mechanical work in a highly efficient manner, thereby increasing the overall efficiency of fuel utilization.
[0003] 2. Prior Art
[0004] The growing utilization of automobiles greatly adds to the atmospheric presence of various pollutants including oxides of nitrogen and greenhouse gases such as carbon dioxide.
[0005] Internal combustion engines create mechanical work from fuel energy by combusting the fuel over a thermodynamic cycle consisting typically of compression, ignition, expansion, and exhaust. Expansion is the process in which high pressures created by combustion are deployed against a piston, converting part of the released fuel energy to mechanical work. The efficiency of this process is determined in part by the thermodynamic efficiency of the cycle, which is determined in part by the final pressure and temperature to which the combusted mixture can be expanded while performing work on the moving piston.
[0006] Generally speaking, the lower the pressure and temperature reached at the end of the expansion stroke, the greater the amount of work that has been extracted. In conventional engine designs, expansion is limited by the fixed maximum volume of the cylinder, since there is only a finite volume available in which combusting gases may expand and still perform work on the piston. This makes it impractical to expand to anywhere near ambient temperature and pressure, and instead a large amount of energy remains and is normally discarded with the exhaust. The production of work from the initial expansion of combustion gases is commonly referred to as “topping,” while the extraction of work from once-expanded gases is referred to as a “bottoming cycle.”
[0007] Bottoming cycles are commonly employed as part of the combined cycle operation of steam power plants. “Performance Analysis or Gas Turbine Air-Bottoming Combined System,” Energy Conversion Management , vol. 37, no. 4, pp. 399-403, 1996; and “Air Bottoming Cycle: Use of Gas Turbine Waste Heat for Power Generation,” ASME Journal of Engineering for Gas Turbines and Power , vol. 118, pp. 359-368, April 1996 are representative of the state of the art in this field. Exhaust heat rejected from a primary gas turbine (the topping cycle) is used to heat water to produce steam that is expanded in a secondary steam turbine (the bottoming cycle). Although in this case the working fluid of the bottoming cycle is steam, other fluids having more favorable physical or thermodynamic properties may be used, for instance ammonia-water mixtures or even a gas.
[0008] Bottoming cycles that employ water/steam or any other recirculating medium as she working fluid must provide additional hardware for recirculation and purification. For instance, steam-based plants require a boiler, a sophisticated steam turbine, condenser, purification system to prevent mineral deposits and scaling, pumps, etc. For this reason, they are practically limited to stationary applications such as public power utilities and industrial plant use and are precluded from mobile applications such as motor vehicles.
[0009] Motor vehicles represent a large portion of total energy use in the world today. There are, of course, differences between stationary power plants and power plants of motor vehicles. First, motor vehicles usually do not employ a turbine in the topping phase and so produce a less uniform flow rate of gases in the exhaust. Second, for a motor vehicle the equipment devoted to the bottoming cycle should be low cost, relatively simple to operate and maintain, and lightweight. Third, in a motor vehicle the working fluid of the bottoming cycle should be safe and not require extensive recirculation hardware.
[0010] The use of air as a working fluid for stationary power generating applications has been investigated. In U.S. Pat. No. 4,751,814, “Air Cycle Thermodynamic Conversion System,” a gas turbine topping cycle is combined with an air turbine bottoming cycle. Air is compressed in an intercooled multi-stage compression system that maintains air temperature as low as possible. Heat from the turbine exhaust is transferred to the compressed air via a counter flow heat exchanger, and the heated compressed air is expanded through an air turbine to provide at least sufficient work to run the compressors and preferably enough to use for other purposes. This system obviates sophisticated purification and processing of the working fluid (atmospheric air) if it is recirculated at all, and dispenses with bulky steam handling equipment. However, the system depends on turbine-based topping and bottoming apparatus which is not well suited to conventional motor vehicle applications.
[0011] Piston (or other means with sealed moving surfaces) compressors and expanders provide high efficiency for the processes of compression and expansion, out exhibit friction that is generally higher than a gas turbine of the same size (i.e., operating at similar gas flow rates). However, gas turbines (especially for the smaller sizes that would be needed for road vehicles) do not provide process efficiency as high as desired because of gas leakage around the edges of the turbine blades (the moving surfaces), which are not sealed.
[0012] Further, gas turbines operate at extremely high speed (often greater than 100,000 RPM), and the speed reduction gearing necessary to provide mechanical power at speeds usable in a mobile vehicle (e.g., less than 6,000 RPM) is costly and inefficient.
SUMMARY OF THE INVENTION
[0013] Therefore, an object of this invention is to provide a power train inclusive of a bottoming cycle which is suitable for use in automobiles.
[0014] Another object of the present invention is to provide such a power train using air as a working fluid in the bottoming cycle.
[0015] Yet another object of this invention is to provide a sealed moving surface compressor and expander design that performs compression and expansion with minimal friction, so that the net efficiency is significantly greater than that achievable with gas turbines.
[0016] A further object of this invention is to provide compressor and expander designs that operate efficiently at speeds below 6,000 RPM.
[0017] Accordingly, the present invention provides an air bottoming power train which includes a source of combustion exhaust gas, e.g. the internal combustion engine (ICE) of an automobile; a compressor which receives a gaseous working fluid and compresses to an elevated pressure; a cooler for cooling the compressor to provide near isothermal compression; an expander having a plurality of cylinders, each cylinder having a piston reciprocally mounted therein and operating in a two stroke cycle including an expansion stroke and an exhaust stroke, the pistons driving an output shaft; a compressed gas line for feeding the compressed gaseous working fluid from the compressor to the expander; and an expander valve for successively admitting the compressed gaseous working fluid from the compressed gas line into individual cylinders of said expander in succession and for continuously admitting the compressed gaseous working fluid to an individual cylinder through a first portion of the expansion stroke to maintain constant pressure. A heat exchanger is located in the compressed gas line for indirect heat exchange between the compressed gaseous working fluid and the exhaust gas, and is fed the exhaust gas by an exhaust gas line running through the heat exchanger.
[0018] A preferred expander includes a cylinder barrel with a plurality of cylinders formed in a circle within the cylinder barrel, open at one end face of the cylinder barrel and closed at an opposite endface of the cylinder barrel. A valve plate seals closed the one end of the cylinder barrel. The valve plate has a compressed gas inlet and an exhaust gas outlet. The cylinder barrel and the valve plate are mounted for relative rotation therebetween, the relative rotation serving to drive an output shaft. The expander preferably has a bent-shaft configuration, and has a total displacement which changes as an angle between the cylinder barrel and the output shaft is changed. The valve plate my have an arcuate groove in a face sealing against said cylinder barrel, the arcuate groove being in communication with the exhaust gas outlet and in register with the circle.
[0019] A second preferred embodiment of the expander is a Scotch yoke piston motor including plural paired and axially aligned cylinders on opposing sides of an output shaft and pistons reciprocally mounted in the cylinders and drivably connected to the output shaft. Each cylinder is axially divided into a thermally insulated is outer portion and a cooled inner portion, the insulated outer portion being separated from the cooled inner portion by a thermal brake; and further, each piston is axially divided into a hollow outer and a cooled inner section, the cooled inner section having an exterior surface bearing oil rings sealing with the cooled inner portion of the cylinder, the hollow outer section being thermally isolated from the cooled inner section by a thermal brake.
[0020] The present invention utilizes an air bottoming cycle in conjunction with unique multi-cylinder piston compressor and expander designs that are well suited for use with the conventional automotive exhaust gas stream.
[0021] An ideal representation of the desired air bottoming thermodynamic cycle is shown in FIG. 1. The line ab represents intake of working fluid to the compressor. Line bc represents isothermal compression of the working fluid. Line cd represents absorption of heat by the working fluid at constant pressure during constant pressure expansion. Line db represents adiabatic expansion of the heated compressed gas to ambient conditions, producing the maximum possible work. Line ba represents the exhaust of the expanded air before the beginning of the next cycle.
[0022] The present invention effects an air bottoming cycle consisting of five distinct phases: (1) Compression, made relatively isothermal by cooling, of a gaseous working fluid such as air in a compressor, and optional buffering of the compressed air stream in an optional surge tank to reduce fluctuations in the heat exchanger inlet stream, (2) Addition of heat to the compressed working fluid at relatively constant pressure through a device such as a counter flow heat exchanger recovering heat from the internal combustion engine exhaust; (3) An initial, near constant pressure, expansion of the heated, compressed working fluid; (4) A final relatively adiabatic expansion of the partially expanded working fluid to as close to ambient conditions as possible, producing the maximum amount of work and; (5) Exhaust of the expanded working fluid from the expander or its conveyance to an appropriate destination such as the air intake of the internal combustion engine.
[0023] The cooled compressor performs a relatively isothermal compression of a working fluid such as air, which should be at the lowest practical temperature before entry to the heat exchanger in order to maximize the potential for recovery of heat. Near isothermal compression is achieved by one or more of the following means: cooling the compressor chamber walls using a water-based coolant, air or other fluid coolant; increasing the turbulence of the intake working fluid to increase the heat transfer coefficient and in-chamber mixing; increasing the roughness of the chamber walls to increase boundary layer turbulence and thus heat transfer coefficient and to increase heat transfer area; an oil jet spray to the bottom of each piston; and injecting a liquid into the of compressing working fluid to extract heat from compression through phase change (evaporation) of the injected liquid. One unique feature of the present invention is the option of injecting the liquid fuel (to assist in cooling the compressing air) that, being mixed with the exhausted air at the end of the bottoming cycle, will subsequently be routed to the combustion engine which supplies the hot exhaust gas to “fuel” this bottoming engine. Methanol or ethanol are particularly good fuels for this use since they both can be easily mixed with water to provide an optimum mixture.
[0024] The compressed working fluid is passed through the optional surge tank and into the counter flow heat exchanger. The working fluid experiences a temperature increase, adding energy to the already compressed gas. Relatively constant pressure is assured because the heated, compressed working fluid enters the expansion chamber at a rate equal to the propensity for the heat to raise the pressure of the gas, and thus an initial constant pressure expansion phase is achieved. After the intake valve is closed, expansion continues to the end of the expansion stroke, producing mechanical work as it expands. The near-ambient pressure air exhausted by the expander could be released to the atmosphere or optionally fed to the air intake of the internal combustion engine. Optionally, the exhausted gas from the expander can be fed to the intake of the internal combustion engine (at any boost pressure) through the “Phase Change Heat Engine” which increases the efficiency of the overall cycle and serves as an intercooler for the charge air of the internal combustion engine. The exhaust gas could also be the source of heat energy for a “Phase Change Heat Engine” incorporated into yet another integrated configuration. The “Phase Change Heat Engine” is disclosed in my copending application filed on even date herewith, the teachings of which are incorporated herein by reference.
[0025] Use of a surge tank allows the use of fewer pistons in the compressor by moderating fluctuations in the compressor outlet stream and tends to reduce temperature increase during each compression stroke.
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] In the drawings:
[0027] [0027]FIG. 1 is a graph illustrating an ideal air-bottoming thermodynamic cycle utilized in the present invention;
[0028] [0028]FIG. 2 is a schematic view of a first embodiment of a powertrain in accordance with the present invention;
[0029] [0029]FIG. 3 is an end view of a preferred embodiment of the compressor and/or expander of the first embodiment depicted in FIG. 2;
[0030] [0030]FIG. 4A is a schematic end view of the compressor and/or expander of the preferred embodiment illustrating the different phases of operation in one cycle and FIG. 4B is a side view of the embodiment shown in FIGS. 3 and 4A;
[0031] [0031]FIG. 5 is an illustration of the drive shaft connection for the compressor and the expander in the drive train of the embodiment of FIG. 2;
[0032] [0032]FIG. 6 is a schematic view of a second embodiment of the powertrain in accordance with the present invention incorporating a second preferred embodiment for the compressor and the expander; and
[0033] [0033]FIG. 7 is a schematic view of one air of opposing pistons in the preferred embodiment for the expander shown in FIG. 6.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0034] [0034]FIG. 2 shows a preferred embodiment of the invention as including a cooled, fixed or variable displacement multi-cylinder piston type compressor 1 of bent-axis design, an optional surge tank 2 , a counter flow heat exchanger 3 , and a fixed or variable displacement multi-cylinder piston type expander 4 of bent axis design. Constant pressure during the constant pressure heat addition stage of the cycle is achieved by a unique design of expander 4 .
[0035] Referring to FIG. 2, fresh air or other gaseous working fluid flows through the compressor intake 5 into the compressor 1 at either ambient pressure and temperature or at a boosted pressure level. A boosted pressure allows reduction of the size of the compressor and potentially the expander. A “plug” of compressed gas exits the compressor 1 at each compression stroke, through the compressor exhaust port 6 into the surge tank 2 , thereby maintaining a designated tank pressure. A cooling apparatus 16 may operate on the compressor 1 . The cooling apparatus of the preferred embodiment includes a water-based coolant which is circulated through a space around each cylinder and through the head and includes a means (not shown) of injecting a liquid into the compressing gas to extract heat from compression through phase change of the injected liquid. Meanwhile, hot exhaust gases from an internal combustion engine or similar device 18 flow through the heat exchanger exhaust gas intake 9 into the heat exchanger 3 and out the heat exchanger exhaust 8 . In so doing, much of the heat contained in the exhaust gas is imparted to the working fluid that has concurrently entered the heat exchanger intake 7 and is making its way to the heat exchanger working fluid exhaust port 10 . Periodically, an intake port 13 to the expander 4 opens, and the expander chamber 14 expands in volume as it enters an expansion stroke. As the expander chamber expands, working fluid flows into the increasing volume chamber (cylinder) 14 at near constant pressure until the intake port closes. The intake port closes and the gas continues expansion in the expander chamber 14 , producing mechanical work on a piston 15 transmitted to an output shaft 12 . After expansion, the near-ambient pressure air is exhausted through the expander exhaust port 11 , releasing it to the atmosphere or optionally feeding it to the air intake of the internal combustion engine.
[0036] [0036]FIGS. 3 and 4 show one embodiment of an expander of the present invention having a bent-axis motor design. The expander 4 is a cylinder barrel 401 with multiple cylinders formed therein, here 8 in number shown as 402 - 409 . Each of cylinders 402 - 409 receives a piston and the pistons drive an output shaft. For variable displacement configurations, the total displacement of the expander motor can be varied by tilting the angle of the cylinder barrel with respect to the plane of the output shaft. Minimum or zero displacement is achieved when the barrel and output shaft plane are parallel, while displacement increases as the angle becomes greater, up to some maximum displacement at some maximum angle.
[0037] An intake port 410 and exhaust port 412 communicate with piston/expansion chambers 402 - 409 at certain critical portions of each cycle, making possible the constant pressure method of operation described above. As the cylinder barrel 401 rotates, for example counter clockwise as indicated by the arrow, the pistons are also cycling between TDC and BDC and the intake and exhaust ports present themselves to each piston at the appropriate times.
[0038] The operation of the expander of the first embodiment will now be explained with reference to FIGS. 4A and 4B, which follow the progress of a representative piston/expansion chamber 402 through several critical points of one cycle. In this illustration, the cylinder barrel 401 is shown rotating counter clockwise with the valve plate 20 stationary. At position a, the piston is nearing TDC and has just cleared exhaust port 412 , sealing the chamber 402 . At this point the chamber 402 contains trapped residual working fluid at the near ambient pressure and temperature of the expander exhaust. As point b approaches, the chamber continues to shrink in volume, thereby compressing the trapped working fluid. At position b, the piston has reached TDC and the working fluid in the sealed chamber 402 has reached maximum compression. Because the chamber 402 seals just prior to TDC, the volume of gas trapped and compressed, and hence the work and crank angle required, is minimal. The crank angle between positions a and b is calculated to achieve good sealing from exhaust port 412 . At TDC the unswept volume is minimized to minimize the quantity of incoming gas from the heat exchanger required to pressurize the chamber 402 . Also at point b, the intake port 410 is about to be exposed, providing passage for the heated compressed working fluid to enter the chamber 402 . Past point b, the chamber begins increasing in volume as it travels toward BDC, accepting working fluid as work is produced. Position b′ represents a typical position in this stage where the chamber is expanding in volume and the intake port supplies heated compressed working fluid to fill it. Although the chamber 402 is increasing in volume, pressure is relatively constant because the intake port 40 is supplying pressurized working fluid. Heated compressed working fluid continues to enter until position c, when the intake port loses contact with the chamber. From position c to position d, adiabatic expansion of the plug of heated, compressed working fluid that entered between b and c (as well as the initial residual compressed gas) takes place, producing additional work. At position d, the piston reaches BDC and the gas has been reduced to near ambient pressure. At this point the exhaust port 412 makes contact with the chamber 402 , allowing the spent fluid to be exhausted as the piston begins rising again toward TDC and volume decreases. Positions d′ and d″ show example positions of the chamber near the beginning and end of the exhaust cycle. Finally, the cycle repeats itself as the piston reaches position a, once again sealing the chamber 402 and beginning the compression of the working fluid remaining in the chamber. Position a could extend as far as position b without changing the function of the expander. In an eight cylinder expander, for example, all eight pistons would perform this cycle in staged succession, producing a smooth flow of work on the expander shaft 12 .
[0039] In FIG. 4 (A), the angle (i) is the compression phase, angle (ii) is the constant Pressure intake and expansion phase, angle (iii) is the adiabatic expansion phase, and angle (iv) is the exhaust phase.
[0040] Angles (ii) and (iii) together total 180°, corresponding to the expansion stroke. Angle (ii) may vary from about 18° to about 45°. In other words the constant pressure intake and expansion phase will usually be 10% to 25% of the total expansion stroke.
[0041] Because of their bent-axis design, the expander 4 and the compressor 1 are both capable of variable displacement, allowing, in addition to independently varying the speed of the expander and compressor, ability to precisely control mass flow rate and pressure through the system, thus ensuring stable and thermodynamically efficient operation.
[0042] Variations of foregoing design of the first embodiment will be apparent to one skilled in the art and include: (1) a fixed cylinder barrel and rotating valve plate, (2) a fixed cylinder barrel and individually timed valves, (3) a swash plate or wobble plate design where the pistons act on an inclined surface through a sliding pad at the base of the piston producing torque to the plate which drives an output shaft.
[0043] [0043]FIG. 5 illustrates the integration of the bottoming cycle engine with the internal combustion engine (ICE) 18 and the drive wheels 60 of a vehicle. Ambient air is inducted into compressor 1 through port 5 . Shaft 19 from expander 4 drives compressor 1 . Compressed air is discharged from compressor 1 through port 6 to heat exchanger 3 and heated compressed air exits heat exchanger 3 and enters expander 4 through port 10 . Expander 4 expands the hot compressed air which produces power which drives compressor 1 and provides net power which is combined with the power output from ICE 18 by expander gear 62 driving ICE gear 64 . The expanded air exits the expander through port 11 . The combined power from the ICE and bottoming cycle engine flows through transmission 66 to wheels 60 .
[0044] [0044]FIGS. 6 and 7 illustrate a second preferred embodiment which uses a crank-loop or “Scotch yoke” crank mechanism design with guide bearings as the compressor and/or expander, instead of the bent axis design of the first preferred embodiment. This second embodiment allows for constant pressure operation approximated through sizing the volumes of the chambers, the number of cylinders, and valve timing to ensure sufficiently constant thruflow.
[0045] In this second embodiment, the crank-loop or “Scotch yoke” design, with guide bearings which reduce piston side forces and prevent piston “cocking,” is employed in the compressor and expander instead of a bent axis design. This design reduces side forces on the pistons by arranging the pistons in rigidly connected, 180° opposed pairs and driving crankshaft 36 , 45 through a linear bearing at the center of the pair. “Scotch Yoke” type engines are known for very low friction, which makes the “crank mechanism” well suited, in combination with added guide bearings, as the piston compressor and/or expander of the invention. In the prior art, some side forces remain but this embodiment of the invention utilizes guide bearings/bushings to eliminate side forces and piston “cocking” and to further improve performance and reduce friction. Constant pressure operation is approximated through sizing the volumes of the chambers, the number of cylinders, and valve timing to ensure sufficiently constant thruflow.
[0046] Referring to FIG. 6, fresh air or other gas working fluid flows through the compressor intake 25 into the compressor 30 at either ambient pressure and temperature or at a boosted pressure level. As in the first embodiment, a boosted pressure allows a reduction in the size of the compressor and potentially the expander. For the two-stroke cycle of compressor 30 , working fluid is received in the stroke from TDC to EDC and is compressed and exhausted in the stroke from BDC to TDC. Intake and exhaust valves of various designs (not shown) can be utilized to control the timing of the intake flow to and the exhaust flow from compressor 30 .
[0047] In this second embodiment both the compressor 30 and the expander 40 employ a crank mechanism 31 , 41 of the crank-loop or “Scotch yoke” design. These crank mechanisms 31 , 41 are further illustrated with an end view on FIG. 7. Further description can be found in the journal article The Scotch Yoke Engine as a Compact and Smooth Running Motor for Passenger Vehicles , MTZ Motortechnische Zeitschrift 58(1997)6, the teachings of which are incorporated herein by reference.
[0048] Referring again to FIG. 6, both the compressor 30 and expander 40 utilize guide bushings/bearings 32 , A 2 to insure against piston cocking or side force. Also shown is the oil supply 34 for the guide bushings/bearings 32 . Oil is also utilized to cool the pistons 33 of the compressor 30 to help approach isothermal compression, and flows from ports 35 .
[0049] A “plug” of compressed gas exits compressor 30 at each compression stroke, through the compressor exhaust port 26 into surge tank 21 . A cooling apparatus 16 may operate on compressor 30 to assist in maintaining near isothermal compression. Hot exhaust gases from an internal combustion engine or similar device 50 flow through the heat exchanger exhaust gas intake 29 into heat exchanger 23 and out the heat exchanger exhaust 28 . In so doing, much of the heat contained in the exhaust gas is imparted to the working fluid that has concurrently entered the heat exchanger intake 27 and is making its way to the heat exchanger working fluid exhaust port 22 . Periodically, an intake port 23 to the expander 40 opens, and expander chamber 44 expands in volume as it enters an expansion stroke. As the expander chamber expands, working fluid flows into the increasing volume at near approximately constant pressure until the intake port 23 closes. The intake port 23 closes and the gas continues expansion in an expander chamber 44 , producing mechanical work on a piston 43 transmitted to an output shaft 45 . After expansion, the near-ambient pressure gas is exhausted by the expander exhaust port 24 , releasing it to the atmosphere or optionally feeding it to the air intake of internal combustion engine 50 .
[0050] It is especially important to operate expander 40 as near adiabatically as possible, to maximize efficiency. Toward this end, the expander expansion chambers 44 are thermally insulated, with thermal brakes 46 separating the insulated chambers 44 from the cooled cylinders 47 where the rings of piston 43 must travel on a cooled and oil lubricated surface. Unique pistons 43 each have an upper, hot portion 48 which travels through the hot expander chamber 44 , insuring the hot expansion gases do not significantly access the cooled cylinders 47 . The piston hot portions 48 are hollow to the maximum extent feasible to minimize piston mass and reduce heat transfer to the lower, cooled portion of piston 43 . A final thermal brake 49 separates the hot, upper portion 48 from the cooled, lower portion of piston 43 . The upper portion 48 is a high temperature metal alloy, preferably with an insulating ceramic outer coating; or it may be an all ceramic component, all carbon-carbon component, or other suitable high temperature material with low heat transfer characteristics.
[0051] The thermal brakes are gaskets which may be an insulating ceramic or other conventional thermal insulator.
[0052] One modification eliminates the surge tank, and the speed of the expander is fixed at a multiple of the speed of the compressor. An alternate embodiment could include a surge tank, in which case the speed of the compressor could vary.
[0053] In another modification expanded air would be recirculated, or fed to the air intake of the ICE, rather than exhausted, optionally at a pressure providing boost to the internal combustion engine.
[0054] Other modifications using other types of sealed moving surfaces for the compressor and expander will be apparent to those skilled in the art from the foregoing description of two preferred embodiments.
[0055] The invention may be embodied in other specific forms without departing from its spirit or essential characteristics. 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 claims rather than by the foregoing description, and all changes which come within the meaning and range of the equivalents of the claims are therefore intended to be embraced therein.
|
An air bottoming powertrain, suitable for use in automobiles includes an internal combustion engine, a compressor which receives gaseous working fluid and compresses it to an elevated pressure, a cooler for operating the compressor isothermally, an expander for deriving work from the compressed gas and a heat exchanger located in the compressed gas line for indirect heat exchange between the compressed working fluid and exhaust gas from the internal combustion engine. The expander may have a cylindrical barrel with a plurality of cylinders arranged in the circle and open at one end face of the cylinder barrel, which end face is sealed closed by a valve plate. The cylinder barrel and valve plate allow relative rotation therebetween to drive an output shaft, driven by compressed gas from the compressor. An alternative expander is a Scotch Yoke piston motor which includes plural paired and axially aligned cylinders on opposing sides of an output shaft. In the Scotch Yoke-type piston motor each cylinder is axially divided by a thermal brake into a thermally insulated outer portion and cooled inner portion. Likewise, each piston is axially divided by a thermal brake into a cooled inner section and a thermally insulated outer section.
| 8
|
BACKGROUND OF THE INVENTION
It frequently is desirable to sweeten a cereal product with an artificial sweetener; the more popular current class of so-called artificial sweetener is the L-aspartic acid sweetening derivatives typical of which is the dipeptide L-aspartyl L-phenylalanine methyl ester (APM). Such esters, their salts and like derivatives have a sweetness estimated by some with the power one hundred fifty times that of a like weight of sucrose. Application of such sweeteners to a cereal base, say a ready-to-eat breakfast cereal product, such as a gun puffed product or a flake, can be occasioned by a rather non-uniform sweetening response; pinpoint "hot spots" of burning sensation in the oral regions of the tongue and mouth generally are detected; this is attributable to high concentrations in discrete locations on the comistible. The low solubility of such derivatives as APM (1% in water at room temperature) appears to contribute to the incomplete solution of such dipeptide sweeteners such that any topical application thereof to the surface of a foodstuff is accompanied by non-uniformity. A more soluble salt such as APM hydrochloride does enhance solubility properties in water but nevertheless leaves much to be desired in affording a topical application to foodstuff which is uniform insofar as a sweet-tasting response generated when product is consumed with such a sweetener as a coating.
STATEMENT OF THE INVENTION
In accordance with this invention, sweet tasting dipeptides and like L-aspartic derivatives in the group of which methyl ester of L-aspartyl L-phenylalanine (APM) is a preferred member noted hereinafter in the classification marked L-aspartic acid derivatives, are combined with a starch hydrolyzate recovered as by the acid or enzymatic hydrolysis of an amylaceous substance typically having a low dextrose equivalency and providing oligosaccharides of elemental monosaccharides, di- and tri-, tetra-, penta- and hexasaccharide which may have a varying dextrose equivalency but commonly would have a D.E. less than 30. A coating of a dried solution of such an hydrolyzate of cereal solids having a fine dispersion of the L-aspartic acid derivative has been found to smooth out the taste impact generated by any sweetening imbalance attributable to the incomplete solution of the APM or nonuniformity of its dispersion. Such a solution when applied to a cereal base such as corn flakes, puffed cereal products, baked goods such as pastry mixes and a variety of confectionary foodstuffs intended to be sweetened with the sensation of sucrose will provide a uniform distribution of sweetness such that when eaten the foodstuff has minimized localized physiological response identified as "hot spots"; the starch hydrolyzate contributes significantly to smoothing out the sweetness sensation.
DETAILED DESCRIPTION OF THE INVENTION
The dextrin "solution", so-called because the oligosaccharides are not completely dissolved but practically speaking are substantially dissolved or colloidally dispersed so as to have the gross appearance of a solution, has the L-aspartic acid derivative compound uniformly dispersed throughout. It will be practical to increase the temperature of the aqueous medium serving as a solvent for the dextrinous material and facilitate mixing to a uniform degree preparatory to having the sweetening compound dispersed therein. Homogenization or other means to finely disperse the derivative throughout the solution is preferably employed to assure a uniform dispersion and permit application of the coating solution by atomization or other spray techniques known to skilled art workers. In some applications it may be practical to wet mill the L-aspartic acid derivative in the dextrin solution to assure a substantially discrete form of finely suspended particles.
Generally, the coating solution will be maintained at a temperature below 200°F and preferably below 170°F during its preparation and application to the dry comestible, said temperature being low enough to have the sweetening derivative dispersed therein as undissolved hydrated particles. The coated comestible also will be dried at product temperatures that do not exceed 200°F in order to assure that the sweetening compound is not degraded while the coated comestible is dried to a stable moisture, say below 8% and more commonly below 6%.
The L-aspartic acid derivatives, when used at a sweetening power equivalent to that of a sucrose application for which it is substituted in the coating solution, is present in sufficient quantity to exceed the solubility of the sweetening compound; thus, the sweetening derivative is present in both the form of a solution solute and a very fine dispersion. Although the dextrinous saccharides are not as sweet per se and generally contribute little noticeable sweetness, they do appear to balance the foodstuff to which they are applied as a solution and on which they are dried as a coating.
However, it is not intended to foreclose the use of sucrose and other mono- and polysaccharides in the coating solution to supplement the sweetness of a derivative or permit economic use in reduced amounts. Thus the so-called sweetening sugars may be employed at major sweetening levels or minor sweetening levels as desired.
The invention will now be described by reference to the accompanying operative example of a typical mode thereof.
9.65 grams of hydrolyzed cereal solids (MOR-REX) having a dextrose equivalency of 10-13 and composed of the following assay of carbohydrates on a dry basis are used to prepare a solution by addition to 14 grams of water at 110°F and 1.08 grams of APM.
MOR-REX ANALYSIS______________________________________D.E. 10-13pH 4.5-5.5Carbohydrate, % d.b.Dextrose 1Di-Saccharide 4Tri-Saccharide 5Tetra-Saccharide 4Penta-Saccharide 4Hexa-Saccharide and above 82______________________________________
Preferably the dextrin solution is prepared by stirring the warm solution to eliminate any lumps and facilitate mixing and insure solution of the dextrin; the APM is added to the dextrin solution and uniformly mixed and homogenized in a bench-top homogenizer to create a uniform suspension of the APM particles which is allowed to cool to ambient room temperature, say 72°F. The solution is ready for spray application.
The solution thus produced can be sprayed on 444.5 grams of corn flakes and then dried at air temperature of 180°F for twenty-five minutes until a moisture content of approximately 2.5% is obtained. Homogenizing the mixture in water produces a very discrete finite dispersion of the APM such as would permit application thereof as a fine slurry onto the corn flakes by atomization, 24 grams of the coating being employed to uniformly coat all of the cereal flakes as aforesaid resulting in a coating of sweetening of about 0.24% by weight.
The coated cereal system had a sweetness quite comparable to that of sucrose-coated corn flakes and advantageously did not have the overly frosted appearance that many comsumers associate with an undesirable or excessive amount of sucrose; the product when tested, in packaging, will be found to be stable over a period of at least 3 months storage when tested under accelerated packaging conditions of high and low relative humidity thought to be representative of climes in the continental states of this country.
Although the invention has been described by reference to a particular best mode for practicing same, it is not to be restricted to any particular embodiment since any in the wide range of sweetening materials in the class of L-aspartic acid derivatives may be employed and in view of the varying sweetness levels thereof, and the organoleptic variations for preference, that may be found with varying foodstuffs, it is meaningless to attempt to assert criticalities. It suffices to say that the dextrinous cereal hydrolyzate is employed at least at a weight proportion greater than that of the L-aspartic acid derivative sweetening compound per se and indeed the sweetening compound customarily will be employed at less than 36% by weight of the starch hydrolyzate coating solids commonly in the neighborhood of 4% to 18% selected for the sake of definiteness only but not intended to be limiting in the present context.
The level of the use of the starch hydrolyzate itself will be dictated more by the intended appearance of the coating on the flake or more comestible rather than its functionality as such; thus, for some breakfast cereal applications, it may be desirable to use a larger amount of the hydrolyzate for purposes of achieving a gloss simulating the gloss of a sugar-sweetened cereal product having a low level of reducing saccharides therein and highly suggestive therefore of a non-crystallized sugar coating. On the other hand, other applications may call for the incorporation of substances such as fats, starches, and such which are operative to create a dull or crystalline appearance suggestive of other sweetened cereal applications ranging from a fondant frosting or topping appearance to a thin light crystallization synonymous with a surface sanding which is common to many current ready-to-eat breakfast cereal applications. It will be understood therefore, that the upper level of use of starch hydrolyzate is not a limiting factor and enough must be employed to achieve the intended functional benefits ascribed to it hereinabove, that is, the smoothing of the organoleptic contributions of the L-aspartic acid derivative per se.
The L-aspartic acid derivatives thought to be of use in accordance with this invention as appendixed are:
1. The methyl esters of L-aspartyl-2,5-Dihydro-L-phenylalanine; L-aspartyl-L-(1-cyclohex-1-en)-alanine; L-aspartyl-L-phenyl-glycine; L-aspartyl; L-2,5-dihydro-phenylglycine;
2. methyl-L-aspartyl-L-alpha phenylglycinase and its salts;
3. Lower alkyl esters of L-aspartyl-L, (Betacyclohexyl) alanine;
4. Those alkyl esters classed as alpha-L or DL-aspartyl-L or DL-substituted glycine described in Netherlands Pat. No. 7,007,176 issued May 19, 1974 preparation of aspartyl compounds and issued to Stamicarbon, NV.;
5. Those hydrogenated dipeptide ester sweeteners such as L-asparagio-O-etherfied serine methyl esters described in French Patent No. 2,105,896 issued April 28, 1972 for Dipeptide Ester Sweeteners to Takeda Chemical Industries Ltd.;
6. Those aspartic acid peptide esters having claiming the formula:
H.sub.z CC(CH.sub.2 COOH)HCONHC(R.sub.1)(R.sub.2)COOR
where R and R 1 are CH 3 or C 2 H 5 and R 2 is 4-7C alkyl having the stereo chemical form L-L, DL-L, L-DL, or DL-DL:
7. Those sweetening agents having the compound:
H N -- CH -- CONH -- CH -- COOR CH.sub.2 CH.sub.2 COOH pH
shown in British Patent 1,339,101 issued Nov. 28, 1973 to Searle and Co., G. D. wherein R is a lower alkyl such as methyl and is prepared by reacting an N-protected-L-aspartic anhydride with L-phenylalanine lower alkyl esters, and
8. Those sweetening preparations having the formula L-aspartyl-L-1,4-dimethyl-pentyl amide disclosed in German Patent No. 2,306,909 issued Aug. 23, 1973 to Proctor and Gamble.
While the invention has been described by reference to a detailed discription interpretation thereof should be had to the accompanying claims for understanding thereof, particularly in view of the wide latitude of L-aspartic acid derivatives appendixed.
|
L-aspartic acid derivative sweetening compounds are admixed in aqueous suspension with hydrolyzed amylaceous derivatives comprising predominantly oligosaccharides solids having a low dextrose equivalency and applied as a coating solution to a cereal-base comestible whereby localized "hot-spots" are ameliorated and the product has a smooth sweetness, the derivative being uniformly distributed throughout the coating and a portion thereof being present as undissolved crystals.
| 0
|
Subsets and Splits
No community queries yet
The top public SQL queries from the community will appear here once available.